Pwer Engineering October 2013

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SPECIAL REPORT
A DISCUSSION ABOUT THE FUTURE OF NUCLEAR POWER
IVANPAH
THE WORLDS LARGEST SOLAR PROJECT
REPOWERING
UNDERSTANDING THE RISKS AND REWARDS
the magazine of power generation
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DEPARTMENTS
2 Opinion
4 Clearing the Air
6 Industry Watch
8 Nuclear Reactions
10 Energy Matters
FEATURES
No. 10, October 2013
26
SPECIAL REPORT
Nuclear Executive Roundtable
1
1
7
VOLUME
38 Converting Once-Through Cooling
to Closed-Loop
60 Executing the Complete Power Generation Project
68 Lessons Learned: Ivanpah Solar Facility
78 Developing a Low-Cost MATS
Rule Compliance Strategy
100 Protecting Wind Turbines
in Extreme Temperatures
108 How Regulations will Drive Innovations
in Water Management Systems
116 Plant Performance Improvements
by Enhanced Combustion Optimization
126 EPC Agreements for Re-Powering Projects
140 Synopsis and Impact
of the Industrial Boiler MACT
152 Preparing the Grid for Renewable Resources
160 A Conversation on Alliance Contracts
with Day & Zimmerman and TVA
168 Improving Performance with
Biogas-to-Energy Project
174 Evaluating Bids for Air Quality Control Systems
184 Grand Coulee Dams Third Power
Plant Undergoes Refurbishment
12 View on Renewables
16 Gas Generation
18 Demand Response
20 Power Plant Profile:
Stanton Energy Center
188 Generator Spotlight:
NV Energy
196 What Works
211 Ad Index
1310pe_1 1 10/16/13 5:28 PM
www.power-eng.com
2
OPINION
well below the average CO
2
emission rate
for coal plants 1,700 pounds per MWh.
The standard for gas plants remained at
1,000 pounds per MWh.
The revised rule is a halfhearted at-
tempt at pragmatism. During her con-
firmation, EPA Administrator Gina
McCarthy was hailed as a great prag-
matist who could reach a good-faith
compromise with the power sector.
The revised rule is a clear sign this as-
sumption was wrong. The new rule sig-
nifies her commitment to a calculated
strategy to advance the Obama admin-
istrations anti-coal agenda.
THE BEST TECHNOLOGY?
Under the Clean Air Act, any CO
2

standard for new plants must be based
on the best system of emission reduc-
tion that has been adequately dem-
onstrated. This is where the battle will
be fought.
EPA based the CO
2
limit for coal plants
1,100 pounds per MWh on Carbon
Capture and Storage (CCS) technology.
Astonishingly, EPA found that CCS tech-
nology has been adequately demonstrat-
ed and is available. The logic is confound-
ing. The problem is the technology has
never been used or demonstrated on a
commercial-scale power plant in the U.S.
EPA pointed to a handful of CCS proj-
ects that are still under development,
including a 582-MW coal gasification
plant in Kemper County, Miss. The plant,
which is designed to capture 65 percent
I
f you dont think the War on Coal is
real, the revised greenhouse gas rule
for new power plants should leave
no doubt that U.S. regulators are fully
engaged in a campaign against the most
important segment of the power genera-
tion industry.
The industry was hoping for a bal-
anced, common-sense approach that
would lower CO
2
emissions without tak-
ing coal out of the mix. Instead, the En-
vironmental Protection Agency issued an
impractical proposal based on conjecture
about a technology that is not used any-
where in the U.S.
It is yet another example of the EPA
drafting a rule without the data or evi-
dence to support it.
The industry was hoping for a pro-
posal that would keep coal in the mix
by allowing utilities to build innovative
coal plants such as the ultra-supercritical
coal-fired John W. Turk Plant, the most
efficient coal-fired power plant ever built,
and the Virginia City Hybrid Energy Cen-
ter, one of the cleanest coal-fired plants in
the country. These kinds of projects, how-
ever, could not be built under the revised
GHG rule because they would not be able
to meet the rules draconian limits for
CO
2
emissions.
The revised New Source Performance
Standard for CO
2
is essentially no differ-
ent than the original proposal, which es-
tablished one CO
2
limit 1,000 pounds
per megawatt-hour for all new power
plants. The re-proposed rule corrected
this fundamental legal flaw in the origi-
nal proposal by establishing separate
standards for coal- and gas-fired plants.
But the re-proposed rule failed to provide
a meaningful difference in the standard
for new coal plants. The new standard
is 1,100 pounds per MWh, only slightly
higher than the first proposal and still
of its carbon output, should begin gener-
ating power next year.
The question is this: Can the EPA im-
pose a technology based on projects still
under development or in planning, or
should CCS be demonstrated on a work-
ing power plant? This question will no
doubt be answered by the courts.
Forces within the federal govern-
ment dont agree about the availabil-
ity of CCS technology. While the EPA
claims CCS technology is ready and
available, officials within the Depart-
ment of Energy will tell you, privately,
the technology is not yet feasible for
commercial applications.
EPA also concludes that strict emission
limits on CO
2
would foster the develop-
ment of CCS research and technology.
The truth is no one will build another
coal-fired plant in the U.S. because the
standard for coal is unachievable with
current technology. With no incentive
to build, there will be no incentive to ad-
vance CCS technology.
By stopping the development of
new coal plants, the EPA is halting
the development of carbon capture
and storage technologies, said Robert
Duncan, CEO of the American Coali-
tion for Clean Coal Electricity.
The industry has not abandoned coal.
Without the Obama administrations
draconian rules for power generators, the
industry would be pursuing clean coal
projects to mitigate the risk associated
with the unruly price of natural gas.
It is a misguided rule that eliminates
coal as an option and endangers the re-
liability and affordability of Americas
power supplies.
If you have a question or a com-
ment, please contact me at russellr@
pennwell.com. Follow me on Twitter
@RussellRay1.
A Disappointing and
Dangerous Rulemaking
BY RUSSELL RAY, MANAGING EDITOR
1310pe_2 2 10/16/13 5:28 PM
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4
CLEARING THE AIR
cesium, hafnium, and scandium.
These elements have RE factors of
>1 and are typically enriched in
bottom ash.
t Category II includes elements that
volatilize during combustion, such
as arsenic, nickel and lead. These el-
ements show RE factors of <0.7 and
are redistributed into both the bot-
tom and fly ashes. They are removed
as bottom ash and in electrostatic
precipitator or fabric filter as fly ash.
t Category III consists of highly vola-
tile elements, such as mercury and
selenium. They are almost entirely
volatilized and emitted from the
stack, except for the portion that is
condensed and enriched in fine fly
ash particles and captured in partic-
ulate-collecting devices such as ESP
or fabric filter and in a downstream
flue gas desulfurization (FGD) sys-
tem. These elements have very low
RE factors in the range of 0.4 or less.
If collected in FGD, they are removed
with gypsum or other byproducts
from FGD and also as suspended
and dissolved solids in the bleed to
the FGD waste water treatment sys-
tem (WWTS).
The distribution of trace elements in
various streams leaving the plant have
been estimated with some success. Fin-
gerprinting these estimates with actual
measurements of a few key elements
that are easy to analyze can enhance
accuracy. Despite recent advancements,
more data gathering and analyses are
needed to permit reliable predictions
of trace element emissions and their
distribution among the various power
plant waste streams.
C
oal consists of both organic and
inorganic substances. The or-
ganic substances are metamor-
phosed from dead vegetation over thou-
sands of years under various temperature
and pressure conditions. The degree of
metamorphism increases with time and
temperature and determines the coal
rank; increasing amounts of carbon result
in peat, brown coal, lignite, sub-bitumi-
nous coal, bituminous coal, anthracite
and diamond, which is pure carbon.
The inorganic substances are essen-
tially impurities in coal, incorporated
into the coal matrix from the surround-
ings during the coalification process.
Collectively known as ash, the trace
elements in coal are not typically pres-
ent in the organic substances and result
mainly from these inorganic impuri-
ties. With a few exceptions, the coal
rank, which depends on time, tempera-
ture and pressure of the metamorphism
process, has relatively little influence
on trace element content in coal.
During combustion the trace elements
are first released as elemental metals,
which subsequently may react with oxy-
gen or other chemicals released during
the combustion to form chemical com-
pounds. Combustion in most boilers
cyclone, tangential-fired (T-fired), or
wall-fired occurs in the temperature
range of 2800F to 3200F. Because the
boiler combustion temperatures are
about the same, the trace element forma-
tions, the related reaction chemistries
and the emissions also are relatively simi-
lar among various boilers.
The relative independence of coal rank
and boiler type provides the basis to jus-
tify using data from different types of
boilers burning different types of coal
to characterize emissions and develop
emission factors for the trace elements.
In practice, however, the actual emissions
and the predicted estimates based on
these emission factors can vary because
of (1) uncertainty and difficulty in mea-
suring the emissions; (2) differences in
fuels and fuel properties, especially the
ash characteristics and co-firing of other
fuels such as oil/gas/biomass during the
tests; and (3) differences and difficulty in
defining the boiler operating parameters
during measurements.
The International Energy Agency, De-
partment of Energy and Electric Power
Research Institute have sponsored com-
prehensive programs to measure and
characterize trace element emissions.
Data that encompass different types of
boilers burning various coals have been
gathered from several operating plants.
These programs provide a valuable da-
tabase used to develop emission factors
for a number of trace elements. Much
of the data were found to follow log-
normal distributions for most elements.
The resulting correlations and geometric
mean values provide reasonable median
emission factors. The elements analyzed
include antimony, arsenic, barium, beryl-
lium, cadmium, chromium, cobalt, cop-
per, manganese, mercury, molybdenum,
lead, nickel, selenium, silver, thallium,
vanadium and zinc.
Trace element distribution in power
plant ashes can be broadly classified into
three categories by using the Enrichment
Index (RE), a function of elemental con-
centration in ash, elemental concentra-
tion in coal and percent of ash in coal.
t Category I includes the non-vola-
tile elements and consists of major
and rare earth elements, as well as
Characterizing Trace
Elements Emissions
BY NAT SEKHAR, P.E., CH2M HILL
1310pe_4 4 10/16/13 5:28 PM
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6
INDUSTRY WATCH
that FERC is considering taking short-
term steps to address what it views as
a pressing reliability concern.
Soon after issuing the data re-
quests, FERC issued an order direct-
ing ISO-NE to revise its tariff to afford
generators that are dispatched to ad-
dress reliability needs with additional
opportunities to recover their fuel
costs.
FERC directed these changes after a
generator was unable to recover a ma-
jority of the additional fuel costs that
it incurred when ISO-NE directed it
to run beyond its day-ahead schedule
after a snowfall resulted in the genera-
tor being the only resource capable of
providing needed reliability services.
Because the generator only learned
that it would be required to run be-
yond its day-ahead schedule after the
deadline for nominating natural gas
deliveries had passed and after it al-
ready had submitted an offer into the
day-ahead market, the generator was
required to purchase the fuel neces-
sary to comply with ISO-NEs in-
struction at high spot market prices,
but was unable to recover approxi-
mately $2 million of these costs. Even
though ISO-NE objected, suggest-
ing that FERC should allow existing
stakeholder discussions concerning
long-term solutions to address these
issues to run their course, FERC di-
rected ISO-NE to implement market
rule changes by winter 2013-2014
that would allow generators that are
dispatched beyond their day-ahead
schedules to make a FERC filing to
recover such costs.
T
he Federal Energy Regula-
tory Commission has set
its sights on the coordina-
tion between natural gas and electric
markets as a priority agenda topic in
recent years. In its most recent salvo,
FERC on June 4 posed data requests
to each of the countrys Independent
System Operators and Regional Trans-
mission Organizations to explore im-
provements to the coordination of the
natural gas and electric markets.
In recent years, the increasing reli-
ance of electric generators on natural
gas as their fuel of choice has high-
lighted the importance of the avail-
ability of natural gas in ensuring
electric reliability and meeting the
nations energy needs. FERC, in par-
ticular, became increasingly focused
on the issue after a cold snap in the
southwest in February 2011 resulted
in rolling blackouts at the same time
that a decline in natural gas produc-
tion resulted in curtailments of natu-
ral gas supplies. A joint FERC and
North American Electric Reliabil-
ity Corporation task force report con-
cluded that while the primary cause
of the blackouts and the decline in
production was the extreme weather
conditions, inadequate fuel supplies
did play a role in generator outages.
In light of these issues, in February
2012, FERC instituted a general pro-
ceeding in Docket No. AD12-12-000
to explore and seek comment on the
need for greater gas-electric coordina-
tion. At the urging of commenters,
FERC commenced a series of techni-
cal conferences to explore whether
greater harmonization of the gas
and electric industries is needed,
and, on May 16, held a special meet-
ing at which representatives from
the various ISOs and RTOs detailed
their experiences and described the
progress each region has made in
promoting coordination between
these industries. The data requests
asked each region by July 5 to pro-
vide a response detailing:
t Steps that can be taken in the
short-term to enhance gas-elec-
tric coordination;
t Whether the region is consid-
ering changes to align its day-
ahead scheduling practices with
the markets for natural gas simi-
lar to ISO-NEs recent decision
to change the deadlines for the
participation and commitment
of resources in its day-ahead
electric market to reflect trading
patterns in natural gas markets;
t Whether the region has any spe-
cific concerns regarding the com-
ing winter;
t Whether shifting the start of the
gas operating day ahead of the
increased demand for electricity
in the morning could improve
coordination in the region;
t If gas system contingencies are
taken into account in system
planning; and
t What steps the region is taking
to improve its awareness of local
conditions.
FERCs issuance of the data requests
is one of a number of recent signals
FERCs Latest Market
Convergence Agenda:
Gas and Electric
Coordination
BY SANDRA E. RIZZO AND STEPHEN J. HUG, BRACEWELL & GIULIANI LLP
Authors
Sandra E. Rizzo is the
head of Bracewell &
Giuliani LLPs Energy
Regulatory Group. Ste-
phen J. Hug represents
clients in matters relat-
ed to federal regulatory
policies, regulations
and rules applicable to
the power generation
industry.
1310pe_6 6 10/16/13 5:28 PM
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8
NUCLEAR REACTIONS
electricity prices, nuclear plant own-
ers have relied on these studies to cut
costs by reducing staff. While efficiency
and worker productivity are appropri-
ate goals, time in the plant reveals daily
breakdowns in the model when critical
staff are sick, on vacation, or re-distribut-
ed to special teams.
Communications from INPO and
the NRC about future reductions in low
value-added programs and processes are
welcome signs. These efforts may sig-
nificantly improve the efficiency of the
plants operation. Or a significant para-
digm shift may be necessary.
Perhaps the industry desperately needs
truly new thinking that finally strips
away excess work so people can focus
on running the plant and supervising
people. Perhaps the industry needs an ap-
proach that builds on and leverages safety
culture but avoids babysitting processes
and overblown data collection. To do so,
you need a leadership team and a culture
to lead and guide the organization. Such
a leadership team would be truly cross-
functional, high performing and market
savvy. They would be intentional about
fine-tuning safety culture. The plants ap-
proach to cost management must then
reflect a new balance between unit gen-
eration and rationalizing the asset. Such
a business-minded nuclear organization
would also need a scorecard that reflects
real economic and market pressure and
success. In all, this approach would
achieve business results for the plant.
Such an approach may be too radi-
cal, not radical enough, or the timing
may be off. Or it just may be that nu-
clear power plants need this approach
to remain relevant.
N
uclear power in the U.S. is
facing unprecedented eco-
nomic challenges at the same
time regulatory burdens on the indus-
try continue to increase, as highlighted
by looming Fukushima modifications.
Early hopes that relief would eventually
come from rising gas prices have faded.
Environmental regulations (real and pro-
posed) have only managed to dampen
the coal power business with no percepti-
ble detriment to natural gas. Meanwhile,
natural gas reserves appear endless while
fracking and horizontal drilling continue
unabated. In short, prices for electricity
and natural gas have remained low.
Despite an occasional nod from the
President and his administration on the
importance of nuclear power leadership
in the U.S. and internationally, relief
from the current conditions which
have led to the shuttering of four reactors
so far this year has not been forthcom-
ing. Merchant nuclear power plant own-
ers with the tightest margins have been
forced to plan for more shutdowns and
regulated utilities continue to squeeze
their operations.
This challenging environment has led
to calls for the industry to re-invent itself
and make innovative changes to become
more competitive and resilient. Some
people have pointed to the successes of
the post-deregulation period where the
industry as a whole made large gains in
reliability and safety. The Institute for
Nuclear Power Operations (INPO) and
the industry should be proud of such im-
provements, which were made through
relentless attention to operational fo-
cus and nuclear safety culture. Unlike
now, however, the turn of the century
operators had much more cash and much
less sustained pressure from electricity
prices. The need for a new approach is
even more urgent.
What industry leaders have begun to
recognize is that these unit reliability and
system performance gains have come
with a great deal of baggage, in terms
of a multitude of large and small pro-
grams and processes. INPO has openly
acknowledged that some of the addi-
tional burden that has accumulated over
the years may be low value-added, and
groups have been formed to see if there
are changes that can be made, starting
with corrective action, work control, and
human performance programs. The NRC
has stated that it is looking at the cumu-
lative impact of regulation to determine
if there is anything that can be done to
moderate such a trend.
From the perspective of plant workers
and supervisors, it is a struggle to feed
the information-hungry programs and
processes. For years, nuclear first-line
supervisors have complained of admin-
istrative burden preventing them from
spending more time in the field with
their people and the work. Although
these types of complaints have gotten
louder, the companys typical response
is that time spent on the computer and
dealing with documentation is part of the
job, because extensive corrective action
and work control processes are the way
the plants must be run. Supervisors just
need to be more efficient and demanding
of workers.
At the same time, staffing levels have
been steadily reduced based on bench-
marking studies of other departments
in other plants. With sustained low
U.S. Nuclear
Power Survival
BY MARY JO ROGERS, PH.D., PARTNER, STRATEGIC TALENT SOLUTIONS
1310pe_8 8 10/16/13 5:28 PM
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10
ENERGY MATTERS
C
simple-cycle should be considered since
combined-cycle often has a lower rate of
CO
2
on a megawatt hour basis. However,
in the case of the Pio Pico Energy Center
in Otay Mesa, CA, the EAB ruled that
EPA does not need to consider lower-
emitting combined-cycle plants in deter-
mining the best available control tech-
nology for greenhouse gases. The EAB
held that because the BACT analysis is
a site-specifc determination that must
be appropriate for the particular facil-
ity, such technology can be scratched
from consideration. The EAB went on
to say that the Sierra Club and other pe-
titioners have not demonstrated that
the region clearly erred in eliminating
combined-cycle gas turbines in step
2 of its BACT analysis for greenhouse
gases, or that the issue otherwise war-
rants review or remand. In view of the
role the Pio Pico facility would serve,
combined-cycle gas turbines had been
eliminated as a potential candidate for
BACT by the EAB and deemed techni-
cally infeasible. The EAB noted that un-
like simple-cycle turbines, which can be
dispatched from cold iron to 300 MW
in less than 30 minutes, combined cy-
cles, even those with fast-start technol-
ogy, take signifcantly longer to start-up.
This precedent setting ruling should be
referenced in future simple-cycle permit
applications.
The reality is that absent Congres-
sional action, we have to live with the
Clean Air Act as written, warts and all.
It may be illogical to some, confusing
and outdated to others, but by keeping
apprised of new court interpretations,
we can make it work for us as much as
possible.
W
hile reading about legal
cases is certainly not very
interesting to non-lawyers,
it is one of the few ways utilities are giv-
en insight as to what the Clean Air Act
(CAA) actually means (or at least how
the laws are being applied and interpret-
ed by the courts). To this end, it would
be useful to understand three recent
decisions that affect the mechanics and
economics of power generation.
First, does a utility need to worry
about CAA enforcement as well as nui-
sance lawsuits? In Bell v. Cheswick Gen-
erating Station, 1,500 property owners
fled a class action lawsuit against Ge-
nOn complaining that fy ash from a
570-MW coal-fred power plant settled
on and damaged their property. Briefy,
while such citizen suits are expressly
allowed under the Clean Air Act, state
tort law also might apply. The trial court
agreed with GenOn that state claims
were preempted by the CAA, but the
Appeals court disagreed and reversed
that decision, holding that if Congress
intended to preempt state tort claims,
it would have said so in the CAA. The
short of the matter is that not only do
utilities need to comply with their CAA
permits, they are subject to enforcement
by both CAA citizen suits and also nui-
sance claims under state law. The appel-
late court sent the case back for a trial,
which leaves the utility vulnerable to
uncertainty.
Second, one of the largest monetary
risks in operating a coal-fred utility is
retroactive New Source Review (NSR)
enforcement. Twenty years ago, when
you replaced some boiler tubes and an
economizer, should you have gotten a
construction permit? In the last 13 years,
EPAs coal-fred power plant enforcement
initiative has resulted in 27 settlements
covering 91 plants and 262 boilers, with
an average total settlement cost per boil-
er (including controls) of $72,800,000.
These settlements have some root in the
CAA legal maximum penalty of $32,500
per violation per day. A series of recent
court cases (in both the 8
th
and 11
th
Cir-
cuits) has established that not obtaining
a construction permit is not a continu-
ing violation. As held in a July 2013 Fed-
eral case, Todays emissions cannot be
called unlawful just because of acts that
occurred more than fve years before the
suit began. In other words, the fve-year
statute of limitations under the CAA
begins to run when the facility opera-
tor fails to obtain a construction permit
under the CAA, and each day the plant
operates without the permit does not
constitute a fresh violation of the Act.
As the Court stated, Once the statute
of limitations expired,[the plant owner]
was entitled to proceed as if it possessed
all required construction permits. This
should be good news for utilities trying
to manage risk and fnancial exposure.
Finally, and in another bit of good
news, EPAs Environmental Appeals
Board has issued a ruling relevant to any-
one trying to build a new simple-cycle
plant. The decision on whether to build
a simple-cycle or combined-cycle plant
is based on economics and dispatch pre-
dictions; it should not be held hostage to
only environmental concerns. The Sierra
Club argued that when evaluating Best
Available Control Technology (BACT)
for simple-cycle turbines, building a
combined-cycle confguration instead of
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VIEW ON RENEWABLES
addition, the buildings, turbines, gen-
erators, feedwater and cooling systems
are being reused.
In the communities where the sta-
tions are located, the switch to bio-
mass will help preserve or restore jobs
and ensure a continued stream of lo-
cal property tax revenue. An ancillary
benefit will be the many jobs created
to supply the waste wood from lo-
cal timbering operations that will be
needed to fuel the stations.
Dominion had experience with bio-
mass when it made the decision to
convert the three stations. The compa-
nys 83-MW Pittsylvania Power Station
in Pittsylvania County, Va., just across
the Roanoke River from the Altavista
station, is one of the largest wood-
waste stations in the nation. Also, our
new Virginia City Hybrid Energy Cen-
ter in Wise County, Va. is designed to
co-fire with coal and biomass.
Dominion Virginia Power needs the
electricity that the converted power
stations will produce. Based on the
projections from PJM, our regional
transmission operator, the need for
electric generation in Virginia is ex-
pected to grow by thousands of mega-
watts during the next decade. PJM has
identified a gap of 4,000 MW by 2023
that our company is working to close.
The converted stations will provide
much needed baseload electricity.
So when it comes to biomass, natu-
ral gas or any other form of power gen-
eration, we believe that our approach
is the right one balanced fuel diver-
sity that leads to reasonable rates and
economic development.
D
ominion Virginia Power has
long recognized the virtues
of fuel diversity in power
generation and, in recent years, has
turned to biomass as well as other re-
newables to achieve a desired balance
of generation sources. Fuel diversity
not placing all bets on any single gen-
eration source leads to reasonable
rates that best serve the needs and in-
terests of customers and shareholders.
In mid-summer, we completed the
conversion of our Altavista Power Sta-
tion in Altavista, Va. from coal to bio-
mass and placed the station into com-
mercial operation. Altavista is the first
of three former coal-fired stations of
similar size and design that will begin
operating on biomass before the end of
2013. The other two are the Hopewell
Power Station in Hopewell, Va. and the
Southampton Power Station in South-
ampton County, Va.
These coal-to-biomass conversions
will benefit our customers, the envi-
ronment and the Commonwealth of
Virginia. They will provide low-cost
baseload energy, promote Virginias re-
newable goals, provide economic ben-
efits and, of course, improve our fuel
diversity.
When the decision was made to
convert the stations two years ago, the
reasons for moving forward with the
conversions were many:
t Existing generation facilities that
were little used could be modi-
fied to enhance their value to our
customers, creating significant
customer savings over their antici-
pated 25-year lifetimes.
t Although the net output of each of
the three stations would fall from
63 MW on coal to 51 MW on bio-
mass, the three are expected to run
92 percent of the time as baseload
units after conversion, compared to
an estimated 18 percent if they were
to continue on coal. The three units
had been peakers, supplying elec-
tricity mostly during times of peak
demand such as hot and cold days.
t Benefits to the environment would
include reductions in nitrogen ox-
ides, sulfur dioxide, particulate mat-
ter and mercury.
t Customers would gain the benefit
of production tax credits available
to renewable projects as well as
the benefit of renewable energy
certificates flowing from biomass
generation.
The three stations had become less
economical to operate on coal over
the last decade, running at a combined
capacity factor of only 26 percent in
2009-2010. Altavista was not running
at all after 2010 as it was placed in cold
reserve that year.
The cost of converting the three
coal stations $166 million is a
fraction of the cost of building a new
150-MW biomass station from scratch.
Although major modifications are be-
ing made to fuel handling equipment,
boilers and bag houses, much of the
equipment in the coal stations is be-
ing reused. For example, the coal units
already had the majority of the emis-
sions controls necessary to manage
NOx, SO
2
and particulate matter. In
Dominion Turns
To Biomass To Grow
Fuel Diversity
BY PAUL RUPPERT, SENIOR VICE PRESIDENT, BUSINESS DEVELOPMENT AND GENERATION CONSTRUCTION, DOMINION
1310pe_12 12 10/16/13 5:28 PM
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14
VIEW ON RENEWABLES
under the radar. Georgia Power has an-
nounced a 525 MW program, up from
almost nothing two years ago, though its
structure is still under discussion. Third-
party ownership in this regulated state
remains a hot-button issue. Florida has a
large solar resource but opportunities for
solar energy remain limited, with many
market barriers to third-party owned so-
lar and a lack of supportive policies.
Texas, a longtime leader in wind en-
ergy, is starting to awaken to its solar
energy potential, given its vast land and
solar resources and high electricity load
and rates. What its lacking now is policy
support as was put toward wind energy.
In the West, California remains a lead-
er in solar energy, and just passed several
pieces of legislation addressing rate de-
sign, net metering, and RPS targets. After
seeing significant growth during the past
couple of years, Arizona is a big question
mark with uncertainty around net meter-
ing and its RPS. Clarification and resolu-
tion is hoped for in coming months, giv-
ing this market more certainty going into
2014. Nevada recently passed legislation
that could create more opportunities for
large-scale and distributed generation so-
lar. NV Energy has committed to replace
553 MW worth of coal plants with a mix
of renewable energy and natural gas, and
its pending acquisition by MidAmerican
offers further optimism for more renew-
able energy development..
The aforementioned top-12 states,
and the issues theyre wrestling with,
will help shape the future of solar
energy in the U.S. Learning from
their successes, and their challenges,
will ensure the industrys continued
growth along the path toward a future
of sustainable domestic energy.
A
recent report from the Environ-
ment America Research & Policy
Center identified the top U.S.
states for solar energy, ranked by criteria
ranging from new and cumulative in-
stalled capacity to electrical generation to
solar-friendly policies.
The top states in order of ranking are:
Arizona, Nevada, Hawaii, New Jersey,
New Mexico, California, Delaware, Col-
orado, Vermont, Massachusetts, North
Carolina, and Maryland. They share
some important characteristics, includ-
ing renewable electricity standards with
carve-outs for solar, strong statewide in-
terconnection and net metering policies,
and accommodations for creative financ-
ing options such as third-party owner-
ship and property assessed clean energy
(PACE) financing.
Many of these states also share some
challenges, which are described in the So-
lar Energy Industries Associations (SEIA)
second-quarter report:
- Net metering. Utilities and grid
operators continue to struggle to under-
stand and embrace increasing amounts
of behind the meter power generation,
fairly valuing distributed generation and
ensuring grid reliability. Earlier this year,
a report found that solar net metering in
Vermont is a net-positive for the state, fol-
lowing similar conclusions in California,
New York, and Texas. Californias just-
passed AB 327 includes some amend-
ments to address concerns about net me-
tering caps. Net metering also is a central
issue in Arizona, causing uncertainty in a
state thats seen soaring solar growth the
past few years. In Colorado, a proposal
filed this summer by Xcel evaluating dis-
tributed generation has raised some eye-
brows, notes Carrie Hitt, SEIAs senior
VP for state affairs. Other states, includ-
ing Louisiana and Texas, are exploring
the issue, and will likely take some cues
from the aforementioned states.
- Market growth for non-residential
solar. While residential solar PV and
third-party ownership have taken off,
growth in commercial solar has lagged,
shrinking 11 percent in the first half of
this year compared with the same period
a year ago, according to SEIA. The group
suggests New York and California will
need to take the lead on growth in this
sector in the coming months.
Meanwhile, utility-scale solar, large-
ly centered in California and Arizona,
has seen a slowdown in utility pro-
curements, SEIA said. Current PPAs
were driven largely by state RPS re-
quirements, which are already in sight,
Future PPAs need to emphasize cost-
competitiveness, and well see to what
extent utilities will step up to embrace
centralized utility-scale solar.
Looking ahead, what does the state-
wide landscape look like for solar energy?
SEIAs Hitt offers some highlights:
In the East, Massachusetts has hiked
its solar goals (1600 MW by 2020) and
currently is figuring out the framework
structure to support that growth. New
York had exhausted most of the funds for
its current program, though longer-term
the state shows promise.
In the Midwest, Ohio is still a market
of opportunity for solar energy, despite
recent efforts to revisit the states RPS.
Michigan remains well under the radar
for solar energy, in part because of Detroit
Energys plans to reduce solar incentives.
Smaller markets such as Minnesota and
Missouri show growth promise.
The Southeast U.S. region still is largely
Whats Driving States
to Adopt Solar Energy?
BY JAMES MONTGOMERY, ASSOCIATE EDITOR, RENEWABLEENERGYWORLD.COM
1310pe_14 14 10/16/13 5:28 PM
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16
GAS GENERATION
in capital spares or keep the existing in-
surance policies in place and repair or
replace equipment when the events hap-
pened. In order to do that, we needed to
calculate reliability rates to fulfll our in-
formation requirements.
The Electric Power Research Institute
(EPRI) is working with its members to
use experience and best practices from
coal and nuclear power plants to devel-
op a comprehensive maintenance basis
for critical systems and components in
combined-cycle plants. A comprehen-
sive maintenance basis provides a ratio-
nale to determine critical components
and identify the most effective tasks to
address reliability and operational chal-
lenges. It also helps ensure overhauls are
scheduled and that unanticipated break-
downs do not occur, making generation
assets more reliable and cost-effective.
The EPRI project is identifying the
components important to long-term
generation reliability; determining what
types of failure modes exist; and detail-
ing the most effective tasks with a focus
on condition-based maintenance (CBM).
The results can be used to assemble a
plant maintenance basis that refects the
actual operational mission for the station
instead of a more generic maintenance
strategy that could lead to excessive over-
hauls of equipment with limited wear.
When we started asking ourselves
what we can do to start putting the right
preventive maintenance frequencies in
place we recognized that theres al-
ready been a signifcant amount of work
done by EPRI for both the nuclear and
fossil assets, Morrison said. To a large
extent, our combined-cycle feet is very
similar to a nuclear or a fossil plant, with
C
urrent gas prices and expand-
ing emissions regulations on
coal-fred plants are resulting in
increased capacity factors at combustion
turbine combined-cycle (CTCC) plants
in some cases, from as little as 10 percent
to more than 60 percent. The increasing
reliance on these assets to provide basel-
oad generation drives the need for com-
prehensive new operations and mainte-
nance strategies.
We realized that our gas plants were
starting to run considerably more than
our annual projections due to lower gas
prices and other factors throughout our
service territory, said Bill Morrison, Vice
President of Generation Engineering for
the Tennessee Valley Authority (TVA).
And we recognized that the plants were
not designed to run the way that they
were being run. Most of our plants were
built to be peaking, and we were starting
to run them more and more as a baseload
facility, and we knew the maintenance
and predictive maintenance programs
were not in place that would give us the
abilities to support that level of sustained
operational reliability.
Paulo Jorge Domingues dos San-
tos, Subdirector Servicios Tecnicos for
Endesa Generacion, S.A. had similar
maintenance program needs, but for a
different reason. We didnt have much
reliability information organized in the
way that EPRIs Preventive Maintenance
(PM) Basis is organized to support our
reliability-centered maintenance and
reliability-centered spares programs,
Domingues dos Santos noted. My team
was performing an analysis for our insur-
ance policies. We needed to calculate if it
would be worth it to invest more money
the exception of the prime moverits a
jet engine instead of a boiler or a reactor.
To us, it only made sense to use EPRI as
a starting point for going after the addi-
tional gaps that existed within its Pre-
ventive Maintenance (PM) Basis that had
already been developed in other areas.
Our approach is to utilize the existing
maintenance bases to put the right PM
programs in place.
We expect to have a comprehensive
maintenance basis we can use in our
work controls process to prioritize ac-
tions, so we can start making sure we
have the right PM tasks set up to ensure
that we maintain our high level of reli-
ability as we continue to run facilities
harder and harder, Morrison said. For-
tunately, the assets are running well now,
but thats because theyre new, and typi-
cally around the 8- to 10-year time frame
is when you start to see signifcant reduc-
tions in the level of performance. The
time is right to do this now; otherwise
youll be digging out of a hole for years
to come.
We have information about steam
turbines, generators, transformers,
pumps, etc. from EPRIs PM Basis,
Domingues dos Santos said. But the
majority of our gas turbines are rela-
tively new. The oldest ones are only 10
to 11 years old, so we didnt have a large
operational history to use in building a
reliability table for the majority of our
combustion turbines. I can tell you that,
because of implementing the proper set
of maintenance processes on our coal
side of the house, weve seen in the $10
to $20 millions worth of value annually,
and I would expect our gas feet will see
the same type of benefts.
Maintaining natural-gas
fred baseload plants
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1310pe_16 16 10/16/13 5:28 PM
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18
DEMAND RESPONSE
in response to power requirements po-
tentially eliminating or stalling the need
for additional generating requirements
and providing more predictable energy
market purchases.
The widespread implementation of
demand response systems could signifi-
cantly reduce usage by educating users on
their current consumption patterns.
In 2011, the U.S. Green Building
Council granted LEED (Leadership in
Energy and Environmental Design) rat-
ing credits to companies that implement
DR programs into their buildings. LEED
certified buildings have official verifica-
tion of energy efficiency and therefore
often provide healthier environments for
residents or tenants. As concerns about
environmental sustainability continue to
take root among Americans, so does the
appeal and ultimately, necessity for LEED
accreditation.
DR programs can sense imminent
demand load problems and reduce
electricity usage in high-consumption
places, removing the chance of over-
load and resulting power failures.
According to the U.S. Green Build-
ing Council, commercial and indus-
trial buildings with a peak demand load
greater than 200 kW (kilowatt) have a
significant impact on energy demand
and electricity grid stability in general, es-
pecially in urban and business areas with
many commercial buildings or industrial
operations.
As the worlds population continues to
grow, so does the need for energy. With
Energy Awareness Month upon us, there
is no time like the present for utilities and
consumers to take control of their elec-
tricity usage.
E
nergy Awareness Month in Octo-
ber is a national effort to promote
smart energy choices that literal-
ly puts power in the hands of consumers.
Yes, simple actions such as turning off
the lights or adjusting the thermostat can
significantly lower energy bills and en-
vironmental strain, but what if consum-
ers had more information about their
energy usage would they make more
intelligent decisions?
There are many vehicles used by utili-
ties to promote energy awareness and
conservation to their customers. Fly-
ers stuffed into mailed monthly bills,
energy audit opportunities and top ten
conservation tips on utility websites are
common.
As technology has evolved, so have
the approaches that utilities can use to
encourage, or in some cases, enable con-
servation through Demand Response
(DR) systems.
Demand Response systems for electric
grids promote sustainable energy usage
among both utility companies and their
customers, while also allowing utilities
to control energy demand. DR technolo-
gies also help utility personnel commu-
nicate directly to customers. Through DR
systems for electric grids, customers can
use smart thermostats, consumer portals
on their home computer or mobile ap-
plication, and in-home display devices
to monitor and better understand their
electricity usage. All of this has been
made possible through the deployment
of AMI that provides real-time usage data
at a finer granularity than ever possible.
Demand Response systems send us-
age information to both utilities and
their customers via Home Area Network
(HAN) devices such as smart thermo-
stats and in-home display devices com-
municating directly to the electric meters
via ZigBee or through the internet over
home computer and mobile applica-
tions fed from the head end of the AMI
system. This allows consumers to person-
ally monitor their energy usage via online
portals and better understand how much
electricity they are regularly consuming.
Consider how much energy an individ-
ual uses on a daily basis. Everyday tasks
such as keeping a home at a cool tempera-
ture and lighting several rooms at a time
may seem harmless in the moment, but
over time, the costs add up. By opting to
remain unaware of energy usage habits
and exact consumption data, consumers
are wasting money and resources. With
DR technology, utility customers can
make more intelligent energy decisions,
as well as receive greater control over their
electricity purchases.
Once consumers start reducing the
amount of electricity they use, power
companies will be able to reallocate
the electricity they produce, and be
able to factor the effectiveness of their
DR programs into their decision mak-
ing process for developing new genera-
tion, using renewable, or offering even
more DR programs.
DR programs are also a powerful tool
when blackouts occur during times of
peak demand, particularly during ex-
treme weather conditions. Without DR
systems in place, utility companies are of-
ten faced with operating power plants at
full capacity when demand for electricity
spikes, and paying more for peak energy
on the spot market. DR technology allows
electricity users to reduce consumption
Raising Energy
Awareness through Demand
Response Technology
BY GREG MYERS, VICE PRESIDENT, SENSUS
1310pe_18 18 10/16/13 5:29 PM
1310pe_19 19 10/16/13 5:29 PM
www.power-eng.com
20
POWER PLANT PROFILE
Duke Energy partnered with Regenesis
in the construction. After construction,
Duke purchased the project, which is
currently operated under a two-year op-
eration and maintenance contract with
Regenesis that expires in December.
Building the solar project came with
some challenges, according to Michael
Butler, Duke Energy Renewables Solar
Manager East. Florida does not provide
incentives for solar power plants, so mak-
ing the economics work is diffcult. In ad-
dition, the site was a wetlands area identi-
fed as a water retention area, meaning it
needs to hold water than letting it run off.
Florida weather and the potential of
hurricanes also played a factor into the
design of the solar facility. The system
has a weather-stow feature that puts the
panels into stow position if it detects sus-
tained winds of 40 mph or greater for 10
seconds.
Despite the diffculties, though, Butler
said the project has multiple advantages.
There is a reuse of land that was once
landfll area, so really land that could
not be developed into anything else,
he said. Using it for a solar ft was a re-
ally good ft.
W
hile many utilities talk
about maintaining feet
diversity, not many power
plants are as diverse as the Orlando Utili-
ties Commissions Stanton Energy Cen-
ter. The facility uses a range of fuel sourc-
es and includes a 5.91-MW solar farm.
The Stanton Energy Center has two
460-MW coal-fred units, a 300 MW nat-
ural gas-fred combined cycle unit, a 633-
MW combined-cycle unit and a 5.91-MW
solar array. In addition, the coal-fred
units can burn natural gas and landfll
gas. The units are also equpped to burn
two different types of coal.
It really makes your operators have to
be on their A game all the time to make
sure the combustion processes are opti-
mized, OUC Director of Power Produc-
tion Wade Gillingham said. If theyre
not, you can have some serious boiler op-
eration and maintenance problems, and
so far weve been successful.
The two coal-fred burners are oper-
ated by OUC, which also owns 70 per-
cent of the units. The units burn a blend
of Illinois Basin and Central Appalachian
(CAPP) coal and have secondary aug-
mentation igniters that use natural gas.
Thats usually to start the coal fame,
but we also use it to supplement coal if its
more economical, Gillingham said. If
we have pricing signals that gas is cheaper
than coal, we burn as much of the gas as
we can.
The units also burn landfll gas from
a facility owned by OUC. The utility has
been burning landfll gas since 1998.
Although the initial landfll gas process-
ing facility and the wells it used have ex-
hausted itself, Gillingham said OUC has
owndership of another process faiclity in
the same landfll.
OUC also owns 100 percent of the
300-MW combined cycle unit on site
and 28 percent of the 633-MW combined
cycle unit. Southern Power operates the
larger unit and is majority owner with 65
percent ownership.
Gillingham said the site was originally
designed to have four coal-fred units.
After building two, the utility decided
to diversify its portfolio with combined
cycle technology and entered a partner-
ship with Southern Company for the
larger combined cycle unit. After that was
built, OUC began working with South-
ern Company on a coal gasifcation unit,
but the project was upscaled and moved
to the Kemper County energy facility.
OUC then built the 300-MW combined
cycle unit.
If we didnt build (the coal gasifcation
unit), we still needed generation, so we
landed a combined cycle unit, Gilling-
ham said. That decision has paid divi-
dends by taking advantage of the natural
gas market and not having to run a coal
unit in the shoulder months when its not
as economical and demand is down.
The solar power project was added in
2010 after OUC issued a request for pro-
posals. Regenesis won the proposal, and
Diversity, Zero Liquid
Discharge and Dedication
BY JUSTIN MARTINO, ASSOCIATE EDITOR
The Stanton Energy Center has two coal-fred
cofring units, two natural gas-fred combined
cycle units and a 5.91-MW solar array at the
same site. Photo courtesy of Orlando Utilities
Commission.
1310pe_20 20 10/16/13 5:29 PM
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catalytic reduction technology that was
the frst SCR on a pulverized coal-fred
unit of more than 200 MW in the U.S.
and has 70 percent plus removal.
We run it as hard we need to meet
our emissions allowances, Gillingham
said.
The site is also a zero liquid discharge
site, which means any water used on
site or that comes in contact with the
process areas of the site has be routed
back to holding ponds and reused.
Orange Countys Eastern Wastewater
Treatment Facility provides reclaimed
water to the site for cooling, and all rain
runoff on the site is diverted to holding
ponds for reuse.
A zero liquid discharge facility is
good for the environment but it comes
with many challenges.
The primary mechanism for man-
aging the pond level is evaporation
through the scrubber process. When
In addition, building a utility-scale
solar project on the grounds of an
existing plant made it much easier to
connect it to the power grid, although
Butler said that was a fairly unique
opportunity and does not expect an
increase of solar projects at existing
power plants.
The majority of the power produced
at the Stanton Energy Center is still fos-
sil fuel-based, and OUC has multiple
processes to deal with with emissions.
Both coal-fred units have scrubbers
with 90-percent-plus removal and
electrostatic precipitators with 99.995
percent removal. Unit 2 has selective
Workers at the Stanton Energy Center face many
challenges, including using a mix of fuels and
operating a zero liquid discharge facility in a climate
with heavy rainfall. Photo courtesy of Orlando
Utilities Commission.
1310pe_22 22 10/16/13 5:29 PM
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When coal was the most economical
source of electricty, you may have your
problems during hurricanes and highly
inclement weather, but the 85 to 90 per-
cent capacity factor (in the coal-fred
units) made it easier to manage ponds,
Gillingham said. It wasnt easy, but it
was easier.
Quite honestly, sometimes our wa-
ter challenges are quite a bit more chal-
lenging than our air quality challenges.
A lot of the air quality challenges in the
past can typically be solved through
capital investments, operating tech-
niques and/or production effciencies.
Despite the challenges of running
a plant with high fuel diversity and a
zero liquid discharge system in a cli-
mate known for 52 to 54 of annual
rainfall, the plant has a low rate of
forced outages. Gillingham said the
fve-year average for forced outage rate
is 0.6 percent on Unit 2 and 1.3 percent
on Unit 1, both well below the nation-
al average.
So while the Stanton Energy Center
may stand out because of its unique
blend of power generation sources on
one site as well as its high levels of
emission control, both in air and wa-
ter quality, for Gillingham what stands
out the most is the quality of people
who run the facility.
Im very proud of the facility and
the people who work here, he said.
We have a forced outage rate that
would rival most anybody. We take a
very reliable approach to plant opera-
tions while trying to balance the eco-
nomics and budget.
the plant is burning less coal and us-
ing the scrubbers less, the plant is able
to evaporate less water. The combined
cycle units do not have evaporative
equipment, but their cooling towers
contribute to the ponds, making them
a producer of wastewater and a poten-
tial challenge to ZLD design. If one of
the coal-fred units is inactive four to
six months a year, the plant loses half
its evaporative ability, Gilling-
ham said.
Floridas rainfall also contrib-
utes to the issue. six to seven
inches of rain equates to around
an additional two feet of water
level in the recycle pond.
The coal-fred units at Stanton Energy Center
burn a blend of Illinois Basin and Central
Appalachian pulverized coal. Photo courtesy
of Orland Utilities Commission.
1310pe_24 24 10/16/13 5:29 PM
1310pe_25 25 10/16/13 5:29 PM
www.power-eng.com
26
theres obvious technical challenges
with renewables. Theyre becoming
more cost-effective, but still very ex-
pensive and they have the limitations
of intermittency, which creates prob-
lems for the quality of service, at least
in the United States, that everybodys
accustomed to. When you turn the
switch on, the power is there whenever
you need it. For us, its not just simply
an economic consideration, its also a
diversity and long-term consideration
as Marv was alluding to.
Mike Rencheck: Theres some oth-
er aspects when you look at the opera-
tion of a grid where nuclear isnt fully
compensated for its entire support of
the grid. In other words, a lot of volt-
age control and frequency control
comes from these very large machines
that you simply cant get from a natural
gas plant or a renewables offering right
now, and if you would, you would have
to add other components into the sys-
tem, making it much more expensive.
When you couple that with the ability
of uranium as a fuel being only 5 to
15 percent of the cost of operating a
unit, you can see that over time, theres
relatively very little volatility due to
swings in fuel pricing.
Bill Johnson: I think I am the cus-
tomer representative in the group, or
at least the person who is in charge of
L
ow natural gas prices,
an increase in the use of
renewable energy and
the high upfront costs of
nuclear have dominated
the headlines, but many in the nuclear
industry believe these are just tempo-
rary setbacks. Power Engineering sat
down with several nuclear industry
executives about the current state of
nuclear and its future. The participants
were: Bill Johnson, CEO of the Tennes-
see Valley Authority; Mike Rencheck,
CEO of AREVA Inc. North America;
Marvin Fertel, CEO of the Nuclear En-
ergy Institute; Neil Wilmshurst, Vice
President of Nuclear, Electric Power
Research Institute; and Joe Zwetolitz,
President of Nuclear Energy, Babcock
& Wilcox. What follows is a transcript ,
edited for style and length, of that dis-
cussion.
PE: With the price of gas so low
and the price of solar panels
dropping, and the cost of a new
nuclear power plant running in the
billions, like we see at Vogtle and
Summer, what is the financial ar-
gument for nuclear?
Marvin Fertel: You mention Vogtle
and Summer. Vogtle and Summer are
obligated to, on a continuous basis
almost, to inform their public utility
BY SHARRYN DOTSON, ASSOCIATE EDITOR
commission of the economic value of
Vogtle and Summer to their ratepayers
and customers in Georgia and South
Carolina. Up through the last review
that they did, they continue to find
that, over the life of the plant, its go-
ing to save their customers at Vogtle at
least $4 billion over the next best al-
ternative, which is natural gas. I think
part of the reason for that is youre
looking at a 60-year asset and youre
projecting out not only gas prices, but
youre projecting out the performance
of the nuclear plant. I think part of the
challenge is the upfront capital costs,
but if you look at customers over the
long term, nuclear probably fares pret-
ty well, we just dont think long-term
enough.
Joe Zwetolitz: Marvin, youre the
right person to respond to this from
an overall industry perspective and I
agree completely. For us, its about not
putting all your eggs in one basket. Gas
is cheap today, but weve seen the price
go up and down in the past. Bill can
probably talk about this, hes probably
seen it. As the price is low, its very at-
tractive to build gas but you have to
maintain your options in the future,
and if everybody were to go to gas
today, theyd probably suffer some of
the same problems as in the past. Not
just with gas, if you look at renewables,
Nuclear Execut
Roundtable
1310pe_26 26 10/16/13 5:29 PM
www.power-eng.com
27
residential customers, it had gone up
into the 46 or 47 cents per kilowatt-
hour range and that was unaccept-
able. They were basically telling her to,
I think, junk the experiment and get
back to making sure they had a reliable
grid at lower prices.
PE: In light of the recent court
decision ordering the NRC to finish
looking into Yucca Mountain as a
nuclear waste storage site, where
do we stand with respect to waste
storage? How big of an impact
does the waste storage issue have
on the nuclear industrys ability to
be competitive?
Fertel: First of all, on the court deci-
sion, we think that the NRC will even-
tually tell everybody if they are going
to go forward. We think that theyll
be able to finish the safety evaluation
report, which we expect will demon-
strate that Yucca Mountain, at least
competitive around the world. I have
also read stories recently about the ex-
periment in Germany where they de-
cided to get out of nuclear and replace
almost entirely with renewables, and
theres a lot of cracks starting to be seen
in that strategy. The business commu-
nity in Germany is really starting to
complain about the electricity rates go-
ing up. I think itll be interesting to see
how Germany does with their experi-
ment. I think if anybody can do it and
make it work, they probably can, but
theyre going to have some struggles
and its going to be a challenge to be
able to get there.
Fertel: To Joes point, The Journal
had an article this weekend where the
business community apparently sent a
letter to (German Chancellor Angela)
Merkel just before the election empha-
sizing the fact that costs in the busi-
ness community had doubled from
about 12 or 13 cents to 25 cents. For
running a power system, and I would
agree with all those comments. A
couple of things we think about with
nuclear, obviously, is the fuel diversity.
You dont want to put all your eggs in
one basket. The environmental ben-
efits over a 60-year period of the clean-
est technology we have. Mike Ren-
check makes an excellent point in the
importance of large rotating masses in
the frequency control - which is a fine
point of physics - turns out to be really
important in making sure the trans-
mission system is stable. So for us, this
comes down to power density trans-
mission support, low price when you
spread it over 60-80 years of the assets.
General concept of balance of the port-
folio. I think theres still a strong case
to be made for nuclear going forward.
Zwetolitz: I do want to make one
other point. Just looking at gas around
the world, were obviously the lowest,
and so nuclear becomes a lot more
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1310pe_27 27 10/16/13 5:29 PM
www.power-eng.com
28
like Vietnam and Turkey, were saying
Were being advised by IEA to con-
sider the whole fuel cycle, and actually
consider disposal before we build a
program. What is the U.S. doing about
it? People are looking at us as an ex-
ample, like Well, you guys havent fig-
ured it out yet, why should we figure it
out before we start?
PE: What is the status of the
mPower small modular reactors
and the SMR project at the Clinch
River plant site?
Zwetolitz: Weve been in the design
phase for the SMR for a number of
years. We are looking
for a goal of next year
to have our design
certification applica-
tion being submitted
to the NRC some-
time in the late part
of 2014. And then in
2015, working with
TVA, we hope to have
a construction per-
mit application sub-
mitted at that time. It
will take a number of
years going through the NRC process
to support that, so design is going on
to support the DCA, we have detailed
design going to continue after that. All
that converging around 2018 or 2019
to have design certification document
in hand and all of that in support of
a goal of having two SMR mPower
units running at Clinch River in the
2021 timeframe. We have the agree-
ment with the Department of Energy
in terms of the funding opportunity,
which we were awarded, so thats al-
ready underway. We had a recent in-
crease in the amount that has been
provided under that agreement. We
look at this as an excellent opportuni-
ty to work with the federal government
to develop U.S. technology thats going
to be a game changer in the nuclear
from the staff standpoint, is safe. Were
not sure theyll get money to do very
much more because of Senator (Har-
ry) Reid, so Im not sure how much
movement well see on that. From the
waste standpoint, part of the blessing
and the curse for us is we manage the
waste so safely and securely at our sites
that quote, unquote, theres no cri-
ses, and thats why the government
can steal $30 billion and not fulfill
its obligation. And there wont be any
crisis because we will continue to do
that. To your question of how does it
hurt us competitively, it hurts us a lit-
tle bit because were paying for it, but
thats only part of the issue. The issue
is everybody else should be paying for
what they should be paying for. So, we
would like to see all costs fairly inter-
nalized for everybody, and we would
like to see our waste program go for-
ward. But, fundamentally, were in it
for the long haul.
Rencheck: Just to comment on
the waste statement. Really, 96 per-
cent of a fuel assembly is reusable. So,
the amount of waste produced is very
small, in essence, because you can
recycle the fuel assemblies. Its done
with techs today and if we spend more
R&D efforts on it, then Im sure we
can continue to improve on those pro-
cesses, either through new reactors or
recycling technologies.
Neil Wilmshurst: Obviously, the
waste confidence discussion going
forward is important. The number of
efforts going on which were involved
in, the demonstration of high burn-up,
long-term storage and the longterm
viability of the existing dry cask stor-
age facilities. So, I think theres a lot
of work going on in the background
to keep the confidence for the safe
storage of the waste. I was in Vienna
last week at the IEA General Confer-
ence, and a number of the new entry
countries were observing, countries
industry.
Johnson: Let me talk a little about
whats going on at Clinch River. Prep
work is going on at the site, so things
like core boring, drilling, geographi-
cal assessments, meteorological data,
those kinds of things are going on. The
latest action from us is preparation of
a Notice of Intent to submit a Supple-
mental Environmental Impact State-
ment on construction, and then have
a public meeting sometime in Octo-
ber, probably in Oak Ridge, to discuss
these things. As Joe said, theres a lot
of work going on in the design and
development of applications to the
NRC. This is going to
come down to, is it a
commercially viable
technology. I dont
think anyone has
any doubts about the
technology itself. Its
application has been
longstanding in vari-
ous forms. The oper-
ational construct for
SMRs is going to be
different than weve
been doing with the
large reactors for a long time. The NRC
is going to have an important role to
play here in sorting through the dif-
ferences and see how this is going to
come to fruition.
PE: Entergy recently said that
the power market was partially to
blame for the closing of the Ver-
mont Yankee plant. Do you feel
that the markets are having a neg-
ative impact on U.S. nuclear? What
can be done to change that?
Fertel: First I would say yes, its hav-
ing a negative impact. Its not clear yet
what the right solution may be, even
though theres a lot of them out there.
Ill quote from The Market Monitor
in ISO New England, and this was in
his 2012 State of the Market Report.
We manage the
waste so safely
and securely ...
and thats why the
government can
steal $30 billion
and not fulfill its
obligation.
- Marvin Fertel
1310pe_28 28 10/16/13 5:29 PM
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www.power-eng.com
30
Fertel: Just to Bills last statement,
for both VY and Kewaunee, VY was
just about $50 per megawatt-hour and
Kewaunee was, like, $52, which is not
outrageous as far as the price of elec-
tricity.
PE: A new and vitally important
security frontier is cybersecurity.
What is your company doing in
their own business to protect them-
selves, and what protections are
you offering to your customers?
Rencheck: We build digital control
systems. We have taken cybersecurity
very seriously, and I think the industry
has as well. In March
of 2009, the NRC is-
sued a new cyberse-
curity rule outlining
how the protection
of digital computer
and communications
systems should be
done. NEI then fol-
lowed suit for the
industry, working
with all the different
players in the indus-
try to come up with a document called
NEI 08-09, that would be used to assist
utilities and folks like us in looking at
our stations and figuring out what as-
sets need protecting and how best to
go about protecting them. I think that
process is being implemented very ef-
fectively at the plant sites now, and one
of the products that AREVA offers is we
have a cybersecurity offering where we
have teamed up with Northrup Grum-
man, who, over the years, has provided
a number of different tools for the De-
partment of Defense, Homeland Secu-
rity and other national assets to be able
to apply a product, but then look at the
nuclear power plants assets and then
be able to provide monitoring systems
and protection systems for those units.
We think were being very proactive in
He said it is unlikely that significant
generation investment will occur until
capacity clearing prices increase signif-
icantly. Basically, if youre not paying
people correctly for the capacity that
they have there, and this was true in
Wisconsin with Kewaunee, youre ba-
sically going to lose some units and
youre not going to be replacing them
very easily. So, for instance, both the
VY case and the Kewaunee case, if nat-
ural gas is up around $4.50, which is
certainly not outrageous for where it
is today and where people think it will
go, both of those plants would have
been in the money. Right now, with
the way the market treats them for the
capacity thats there all the time - and
its clean capacity, doesnt emit any
greenhouse gases - it makes it hard for
single units to survive, so there are dys-
functions in the market.
Rencheck: I would also add that
baseload nuclear is also not being paid
for all of the ancillary services it pro-
vides, like frequency support, for the
grid. Thats also something that maybe
should be looked at with the intermit-
tency of renewables now entering the
market and not having to bear those
costs.
Johnson: I dont have any experi-
ence in operating in those markets. An
observation from afar is I think there
may be an inadequate price signal on
the capacity piece here, agreeing with
Marv and Mike. When you have an
existing asset that is baseload and is
providing ancillary services, it doesnt
clear the market because of short-term
economic or supply dynamics. I think
a little longer view here would proba-
bly have been helpful. I dont know the
actual internal workings of the plants
or the economics of it, but I would say
there is a significant problem here if
we are going to retire assets in a mar-
ket that doesnt give a capacity signal
to build new ones.
cybersecurity space. We recognize it as
a challenge that we think were up for
the challenge as an industry, and were
able to keep our plants safe and operat-
ing well.
Wilmshurst: The Department of En-
ergy, who several years ago was fully
aware of the need for worker and cy-
bersecurity, worked with us and es-
tablished an organization called NE-
SCOR, the National Electric System
Cybersecurity Organization Resource,
which EPRI is providing as part of its
partnership with DOE for the entire
electric infrastructure, including nu-
clear. NESCOR works collaboratively
with the DOE, and
the federal agencies
on enhancing cyber-
security, assessing se-
curity features, look-
ing at R&D priorities
and disseminating
those best practic-
es. So, were really
deeply engaged and
involved in the entire
spectrum of the cy-
bersecurity effort.
Johnson: From the operating sys-
tems side, this obviously is a topic that
has gotten a lot of interest from the
Congress, from various agencies, from
the military. So we are heavily engaged
in this every day. We follow the NEI
standard, the NERC Critical Infra-
structure Protection Standards. Theres
a whole frame of these standards that
require, obviously, information sys-
tems protection, physical security. We
have a very strong awareness program
internally and externally. The problem
with this topic is the threat evolves,
so its hard to get ahead of the strong
thinking of the bad guys here. So, no
matter what you do, theyre always try-
ing to get ahead of you and this is one
of the harder issues that Ive seen in my
long time in the business.
Baseload nuclear
is also not being
paid for all of the
ancillary services
it provides, like
frequency support
for the grid.
- Mike Rencheck
1310pe_30 30 10/16/13 5:29 PM
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32
world, but creating significant barriers
for individuals when theyre traveling
with their accessed information and
protection of information on all of
their devices, and so on. Its a signifi-
cant issue, and we have to continue to
be on our toes because, as Bill says, the
threats are going to continue to evolve
and we have to be ready for them.
Fertel: As Joe and Bill just said, this
is a threat thats very significant for
our country, not just for our nuclear
plants or our electricity system. I think
that everybody has summarized a
lot of things that are being done. The
only thing I would add is right now,
as were talking, our security working
group is actually in town today meet-
ing with NRC on issues like cyber and
what do we need to do that maybe we
havent. We have a number of what we
Zwetolitz: Yeah, I agree with that.
For my company, B&W, we have two
category 1 fuel cycle facilities where
we handle strategic nuclear material.
And we have a tremendous challenge
fortifying those operations against cy-
ber attacks. We had an event recently
where we had to respond to a rather
aggressive attack. Weve instituted very
strong and very fortified IT defenses,
and it carries throughout our work-
force, because we have such a variety
of activities within our company, the
presence of those two cat 1 facilities
has created a level of security that has
to necessarily vary across the company,
but maintains a minimum threshold
for everybody, so its a real challenge
in our mobile work environment. We
defend the facilities quite well, essen-
tially isolating them from the outside
designated as critical digital assets in
our plants. Most of them have no con-
sequence from a safety standpoint,
they do have a consequence from a
reliability and operations standpoint.
We dont have that many that really
have safety consequences if you lost it,
but those are certainly being protect-
ed. EEI is now the Secretariat for the
Electric Sector Coordinating Council.
We actually have a meeting with about
20 CEOs from across the industry
and the associations that involves us,
American Public Power Association
and the National Rural Electric Coop-
erative Association, this Friday with
DOE, DHS, FBI and every other acro-
nym you can think of, for quarterly
meetings that we have with them to go
over cyber issues as well as a briefing
that they will be giving. So, theres a
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33
Wilmshurst: Im just back from Ja-
pan. I was fortunate to be a participant
in a trip by all the U.S. CNOs to Fu-
kushima organized by INPO. We got
to see up close and personal the Fuku-
shima event. Really, just echo whats
been said about the work of INPO and
NEI. NEI has done a great job since the
Fukushima event with really commu-
nicating whats happened and whats
been going on. I think the visit from all
the U.S. CNOs to the
plant and the com-
munications thats
starting to come out
from the videos, the
websites of various
utilities, are going
to go a long way to
communicate the
magnitude of what
happened and show
the genuine kind of
response and the serious reflection
within the U.S. industry.
PE: Over the course of the next
decade well need to bridge
a rather large generation gap
among workers in the nuclear in-
dustry. What is being done to ad-
dress the vacancies that will be
left when as much as 40 percent
of the nuclear workforce will reach
retirement age by the middle of
the decade?
Rencheck: Were doing a lot in the
area of STEM outreach in the com-
munities in which were present to
be able to go into the various school
systems starting in the elementary
schools, and working our way through
the community colleges and the uni-
versities. We think STEM outreach is
not only important for the nuclear in-
dustry, but its also important for the
country. When you look at the number
of jobs that the nuclear industry has to
offer, these are good-paying jobs. Jobs
tremendous amount of high-level and
working-level energy going into pro-
tecting our grid and our plants from
a cyber standpoint. The challenge, I
think Bill articulated it very well, is the
bad guys try to keep thinking of new
things they can do, and I think the
good guys are thinking about that, too.
Everybodys doing what they need to.
PE: The Fukushima Daiichi nu-
clear plant has been back in the
news for several large leaks of
radioactive water. Do you think
the latest headlines will influence
public opinion in the U.S. against
nuclear power? How does the in-
dustry combat that?
Fertel: This is coincidence, but we
do a couple of surveys a year on pub-
lic opinion. We actually had one in the
field Sept. 5th through the 15
th
, which
was right at the height of a lot of the
Fukushima information on their wa-
ter leaks in the tanks and other places.
Our folks, I was told, were concerned
that would influence the outcome of
the opinion survey and, if it did, that
would be good input for us. It actu-
ally didnt. The favorability towards
nuclear was 69 percent, which is basi-
cally what it was before the Fukushima
accident. It dropped to 46 percent im-
mediately after the accident and recov-
ered up to 65 or 66, its now at 69 per-
cent. All the other key things that we
looked at were really good. 84 percent
of the public thought that you ought
to go forward with license renewal; 70
percent of the public said if you need-
ed more electricity and you wanted to
build a new nuclear power plant site
where one exists, they supported it, it
was acceptable; 77 percent of the pub-
lic said that they believed plants in
the U.S. were safe, thats up from 73
percent in our earlier survey in Febru-
ary. Also, they did ask a question very
relevant to yours. They asked have you
heard anything about nuclear in the
news recently, and 60 percent said yes.
So, the Fukushima issues didnt really
seem to influence their opinions.
Johnson: Just an observation on
the public perception in the U.S., Marv
is right that public support continues
to be strong. I think one reason is that
the public generally trusts us, has con-
fidence in us and believes that we will
protect them. Thats a good, but sober-
ing, reminder of our
responsibility every-
day.
Fertel: Youre right
on. One of the ques-
tions that they ask
was Do you think
that we learned from
what happened to
make plants safer?
And 83 percent of the
public said yes, so
Bill is right on with that.
Zwetolitz: I think the key to keep-
ing the support in the public is infor-
mation. The public is generally more
informed and its reflected in those
survey results. A lot of the schools, be-
cause I still have children in schools,
the curriculums, especially in science,
are including pretty in-depth discus-
sions on nuclear energy. So, the educa-
tion is out there in the general public
and even starting with young folks. So
theres some greater familiarity that
comes with a level of trust.
Rencheck: I think in the U.S., we
are fortunate to have a regulator in
the Nuclear Regulatory Commission
that is transparent and open with the
public and also, through the Institute
of Nuclear Power Operations (INPO),
where the industry is self regulating
and uses peer pressure and peer re-
views to establish best practices, have
gone a long way to ensuring the pub-
lic confidence has been maintained
throughout the events at Fukushima.
The public
generally trusts us,
has confidence
in us and believes
that we will protect
them.
- Bill Johnson
1310pe_33 33 10/16/13 5:29 PM
www.power-eng.com
that are truly middle class or higher
that you can have a career and raise
a family with. I think the opportuni-
ties are there whether you want to be a
craft worker, a welder, an electrician, a
mechanic, or if you want to go into the
engineering ranks, taking a STEM
Science, Technology, Engineering and
Math education is very important.
The reason I say that is because when
you look at this, in the ninth grade,
theres about 4 million students who
typically enter the ninth grade. By the
time they graduate from college, were
at about 167,000 with a STEM degree.
When you look at our industry need-
ing to replace about 50,000 jobs by
2016, the opportunities will be there
for jobs and for well-paying jobs, and
I think that will attract as were seeing,
people back into the STEM programs
at various universities.
Zwetolitz: I agree with Mike. We,
like many in the industry, have been
involved in partnerships with the local
schools and community colleges and
universities, and its starting to pay off.
Mike and Bill and Marv were talking
before about how old were getting and
were reminded by that when we walk
around our organizations and see the
many young faces that are out there.
What Im amazed about is the fact that
these efforts are starting to pay off with
the quality. Not only are they young,
but theyre coming out with the right
skills and the right backgrounds to be
able to do this kind of work. And thats,
for me, showing significant payoff.
Were also doing a lot of work to retrain
the existing workforce, so as people
have been in this industry and have
the background, theyre training for
new roles and different roles within the
nuclear industry, and thats also paying
off as well, so were having those kinds
of programs bearing some fruit.
Johnson: I have a little different
view, I suppose, given the operational
nature of our business. We are doing
all the usual things in outreach in the
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community colleges with the young
nuclear, the typical things. Im really
not as concerned about finding the
workforce as I am about the loss of ex-
perience in the current workforce. I do
agree with Joe that the people we see
today are generally
better educated, bet-
ter trained and ready
to go to work. But if
you think about the
history of the indus-
try, in the 80s, our
capacity factor was
in the mid-50s. To-
day, theyre in the
mid-90s, and one of
the ways that we got
there was we made
every mistake possible and figured
out how to do it right. In our current
workforce, which is aging, there is a
tremendous amount of operational
engineering and other knowledge that
is more experienced-based than edu-
cation-based. So, I think our biggest
challenge here is knowledge transfer,
some efficient way of experienced
transfer so that when these new work-
ers show up, we can train them up not
just with qualifications but with the
experience of the past generation.
Zwetolitz: I agree with Bill. I dont
think we realize how much we are
leaning on those experienced folks.
Its going to be an eye opener, perhaps.
Wilmshurst: Just following on from
Bills comment, the new generation
of workers, they learn differently. So,
were in the process now of working
with a number of utilities to deploy
electronic work packages. You see
maintenance techs out there with
iPads with all their procedures.
Delivering knowledge through apps,
using videos and gaming technology,
developing web-based training
packages, which are being shared
through INPO, and other things, just
to help people maybe learn faster and
learn quicker and learn differently. I
think thats going to be key as well to
bring on the new generation quicker.
Fertel: The only
thing that I would
add is that you
should have the
impression that we
are taking the issue
very seriously on
both sides of the
issue. Its attracting
the right people and
its the knowledge
transfer because of
the loss of the people
we currently have. And as Neil just
said, its the recognition that the new
people coming in may actually behave
a lot differently in how they learn and
how they work. I wish I had as much
confidence in the non-commercial
part of the nuclear industry, the
weapons side, the regulatory side, that
they are giving the same amount of
attention to these very challenges that
our industry has. Not that were there
yet, but we at least recognize it.
Rencheck: Id like to add one
comment. I agree with all of that,
but we were talking a little about the
1980s before the call. One thing that
was prevalent in the 1980s was that
when you were a young engineer
starting, you really didnt have
anybody to ask questions to, because
the whole industry was in an infancy
state. The younger folks coming in,
when they have a question, they can
actually stop, ask somebody and get
an answer. That will make a difference
in these folks getting up to speed a lot
quicker then, potentially, the folks of
our generation did.
I dont think we
realize how much
we are leaning on
those experienced
folks. Its going to
be an eye opener,
perhaps.
- Joe Zwetolitz
1310pe_37 37 10/16/13 5:29 PM
www.power-eng.com
38
fish back to the environment, however,
some of the fish will die in the process.
As typical mesh size of intake screens is
on the order of 3/8, very small fish, fish
larvae and fish eggs will pass through
the screens and will get chopped up as
they pass through the impellers of the
circulating water (CW) pumps. Organ-
isms that survive the pumps chopping
action may die from the thermal shock
as they pass through the power plant
condensers that heat the water on the
order of 20F.
To satisfy the requirements of Section
316(b) of the Clean Water Act, many
power plants designed for once-through
cooling are performing studies evaluat-
ing alternatives that will reduce IM&E
impacts. One of the options to reduce
IM&E is conversion of the once-through
cooling system into a closed-loop system
utilizing cooling towers. Evaporative,
wet cooling towers are the preferred op-
tion as they produce colder water tem-
peratures and require smaller footprint
than dry cooling towers. Air cooled
condensers are usually eliminated from
the start as they have a large footprint
and require installation of large steam
duct from the turbine exhaust to the air
cooled condenser, which is impractical,
if not impossible, to retrofit in an existing
plant. Thus the discussion in this paper
will be limited to the wet cooling tow-
ers. Wet cooling towers will reduce wa-
ter withdrawal by about 90 percent. The
remaining water withdrawal includes
the cooling tower makeup and in some
cases auxiliary cooling. Cooling tower
makeup replaces tower evaporation and
tower blowdown, which is required to
maintain tower water chemistry.
CLOSED-LOOP
CONVERSION CHALLENGES
Converting a once-through system to
closed loop presents many challenges.
Finding a Suitable Site
Cooling tower footprints are large
and finding a suitable site can be a chal-
lenge. In-line towers should be located
nearly parallel to the summer prevailing
winds to minimize plume recirculation.
Plume recirculation increases tower inlet
wet bulb temperature, which results in
higher cold water temperature, higher
condenser pressure and lower steam tur-
bine output.
Fogging and icing on adjacent struc-
tures, switch yards, roads and nearby
residential areas needs to be considered
when selecting the site for the tower and
its relationship to the prevailing wind.
Available areas often contain wetlands
and may be a habitat for threatened and
S
ection 316(b) of the EPA
Clean Water Act requires
that the location, design,
construction and capac-
ity of cooling water intake
structures reflect the best technology
available for minimizing adverse envi-
ronmental impact. These impacts in-
clude Impingement Mortality and En-
trainment (IM&E) of fish, fish larvae,
and fish eggs.
Power plants with once-through cool-
ing systems utilize intake structures with
rotating screens to prevent debris from
entering the system. However, together
with the debris, larger fish get trapped on
the screens. Most screens are equipped
with fish collection systems that return
Converting
Once-Through
Cooling to
Closed-Loop
BY MO MASSOUDI AND MIRO CERHA, URS
Cooling towers at a power
plant in Pennsylvania
Authors
Mo Massoudi is director of the Power
Group at URS. Miro Cerha serves as
a performance engineer in the Power
Group at URS.
1310pe_38 38 10/16/13 5:29 PM
Industrial Insulation Shaped by Experts
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1310pe_39 39 10/16/13 5:29 PM
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40
EXCAVATION REQUIRED FOR CIRCULATING WATER PIPES 1
Grade
Not To Scale
~36
~18
~72
~9 ID, 11 OD
~4
~6
Typical excavation required for two 9-foot internal diameter pipes is shown.
Permitting challenges
Permitting challenges associated with
plume impacts, visual impacts and noise
can be enormous and in some cases in-
surmountable, particularly for plants
located near residential areas. Under cer-
tain atmospheric condition, particularly
on cool humid days, the whole plant and
adjacent residential areas can be put in
fog by the plume discharged from low
profile mechanical draft cooling towers.
Plume abated towers are available at a
higher cost. Noise is being generated by
the splashing water in the tower basin
and by the cooling tower fans. The noise
becomes an issue particularly at night.
To mitigate noise levels, sound barri-
ers in form of walls around the cooling
towers may have to be constructed. Care
must be taken not to obstruct the air in-
let to the towers.
Plant Net Output Reduction
Plant net output is reduced due to
higher condenser pressure particularly in
summer months, when cold water tem-
peratures from the tower are the highest,
and due to auxiliary load associated with
CW pumps and cooling tower fans.
High capital cost
Capital cost associated with the instal-
lation of tower(s), new CW pumps, CW
piping, etc. is high. The cost of the tower
itself is often relatively small compared
to the total conversion cost.
Lay-down Area for Construction
Large equipment lay-down area for
construction will be required in the near
vicinity of the plant, which, depending
on plant location, often results in de-
forestation, encroachment on wet-lands,
traffic congestion, noise, etc.
ADDITIONAL, LESS
OBVIOUS, CHALLENGES
AND ISSUES
The challenges and issues discussed
above are relatively well known and ap-
parent at the first glance. However, there
are less obvious issues that will be spe-
cific to a particular plant, depending on
the plant topography and design, which
need careful consideration. Some of
these issues are discussed below.
Existing Condenser Design
Condensers designed for once-
through operation, particularly in colder
endangered species. Locating towers in
these areas will present permitting chal-
lenges.
Large Diameter
Circulating Water Lines
New circulating water (CW) lines
need to be installed between the cool-
ing tower and the existing condenser.
Depending on the plant size, these lines
can be very large. For a typical 1,000 MW
plant you will need about 600,000 gpm
of circulating water. To maintain a typi-
cal velocity of 10 ft/s in the pipe, the pipe
internal diameter would be about 13 feet
(ID = sqrt (0.408 * GPM / velocity) = sqrt
(0.408*600,000/10)=~156 = ~13). The
largest commercially available concrete
pipe internal diameter is 12 feet. For the
1,000 MW plant, in order to maintain
10 ft/s velocity, you will need two CW
lines, each about 9-foot internal diam-
eter. Typical excavation required for two
9-foot internal diameter pipes is shown
in Figure 1. Running these large lines
through the congested areas of an exist-
ing power plant is not an easy task, par-
ticularly since many underground utili-
ties may be encountered along the way.
1310pe_40 40 10/16/13 5:29 PM
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1.5 2 2.5 3 3.5
Cond Pressure, Hga
4 4.5 5
Steam Turbine Output Versus
Condenser Pressure
even start to decrease with further re-
duction in condenser pressure (Figure 2).
Operation at condenser pressures lower
than the pressures at which the STG out-
put peaks is therefore not desirable. To
minimize condenser and circulating wa-
ter system costs, and to avoid operation
at these very low exhaust
pressures, the condensers de-
signed for operation in once-
through systems are often
designed with higher TTDs
than condensers designed for
operation in closed-loop sys-
tems with cooling towers. So
while you may see 7F TTD
for a condenser designed for
a cooling tower operation,
you may see a TTD of 20F
and larger for a once-through
cooled condenser. This pres-
ents challenges for a conver-
sion to a closed-loop cooling
with cooling towers, as the
resulting condenser pressures (steam
turbine backpressures) may approach or
reach the existing steam turbine back-
pressure alarm point during hot sum-
mer months. Prolonged operation at or
above the alarm point is not desirable, as
the turbine last stage blades may become
climates, are often designed
with a high terminal tempera-
ture difference (TTD). Con-
denser TTD is the difference
between the steam side satura-
tion temperature and the tem-
perature of the hot circulating
water leaving the condenser.
The higher the condenser
TTD, the higher the condenser
pressure. The reason for the
higher TTD for condensers de-
signed for operation in a once-
through system is as follows:
once-through systems operate
at low circulating water tem-
peratures and can develop rel-
atively low condenser pressures particu-
larly in winter. As the condenser inlet
water temperature and consequently the
condenser pressure decreases, the steam
turbine generator (STG) output increas-
es. However, at some low condenser
pressure, the STG output peaks and may
1310pe_42 42 10/16/13 5:30 PM
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3 Cooling System Analysis
Q Ws W
Lg
Pc
Qc
Tw Th
Tc Condenser
GPM
R = Th Tc
Thermal
Cycle
Cooling Tower
unstable and are subject to
vibration and possible dam-
age. For this reason, operation
near the alarm point is not
desirable. Sufficient margin
should be allowed to avoid ex-
ceeding alarm pressures dur-
ing and after upset conditions,
such as after a trip of one CW
pump.
When condenser pressures
resulting from conversion to
cooling towers are near the
steam turbine backpressure
alarm point during high sum-
mer temperatures, the follow-
ing remedies may be applied: Reduce
load or increase condenser surface area
(re-tubing) in order to reduce condenser
pressure. Replace steam turbine last stage
blades with blades designed for higher
turbine exhaust pressure.
Conversion of a single-pass condens-
er to a two-pass condenser has been
suggested by some, but that is not a vi-
able option. Here is why: In a single-pass
condenser the cold water enters on one
side of the condenser and hot water ex-
ists on the other side. In a two-pass
condenser, both the cold water and hot
water enter and exit on the same side of
the condenser; the partially heated water
making a U-turn on the op-
posite side of the condenser.
As the water enters and exists
on the same side, the circu-
lating water flow would have
to be significantly reduced
since now only half of the
condenser tube-sheet area
would be available for the en-
tering cold water. This would
result in condenser pressure
increase, not decrease. For the
two-pass condenser to work,
the condenser dimensions
would have to be increased,
which in an existing plant
may prove impractical, as it would in-
volve construction challenges including
excavation around the condenser and
possibly structural changes to the steam
turbine exhaust hood. Additionally, the
condenser inlet water box would have to
be replaced with a new water box with
a partition that would separate the cold
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Cooling System Analysis 4
Cooling Tower
Stand Pipe
Condenser
LCV
Gate
Booster
Pump
Motor
water from the hot water and would have
additional outlet nozzles for the hot wa-
ter. Additional piping would have to be
installed to bring the hot water from the
front of the condenser to the back of the
condenser for tie-in into the existing dis-
charge piping. All of this is nearly impos-
sible to accomplish within the available
space around the existing condenser.
New Condenser Pressure
with Cooling Tower
To correctly estimate the condenser
pressures resulting from the conver-
sion to closed-loop cooling, the follow-
ing performance models need to be
developed: (1) Condenser model using
Heat Exchange Institute (HEI) standard
methodology and original condenser
vendor data sheets; (2) Steam turbine
performance model based on the steam
turbine vendor Thermal Kit; and (3)
Cooling tower model based on cooling
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tower vendor performance correction curves. The condenser
pressures at any ambient wet bulb temperature are then cal-
culated by an iterative process between these models. The
variables involved are depicted in Figure 3.
For a given unit load and ambient conditions the Thermal
Cycle Heat Input (Q), the Circulating Water Flow (GPM),
and the Cooling Tower Inlet Wet Bulb Temperature (Tw) are
known values. As all the other variables are a function of the
condenser pressure, an iterative solution for the condenser
pressure is required.
Tower on a Hill
At sites where the only available space for the new cool-
ing tower is at higher elevations than the plant elevation,
the arrangement similar to that shown in Figure 4 may be
employed. The water from the tower would be directed into
the existing intake structure, which would be isolated from
the river intake by a gate or stop logs. Water level in the in-
take structure would be controlled by a level control valve.
To take advantage of the energy in the water flowing from
the cooling tower, a hydraulic turbine could be installed in
the cold water line to help drive the new booster pump. Cool
tower water is then pumped through the condenser using
the original CW pumps. To assure that the condenser water
box is not exposed to higher pressure than its design pres-
sure, a stand pipe would be installed downstream of the con-
denser as shown. This stand pipe would prevent excessive
condenser waterside pressure for all postulated transients.
Finally a booster pump provides the head required to drive
the hot circulating water flow back to the cooling tower.
Control of the three active elements of this system (hy-
draulic turbine, original circulating pump, and booster
pump) must be adjusted to assure balanced operation.
The use of a hydraulic turbine and stand pipe depends on
plant specifics, plants with a tower basin elevation which is
only several feet above the original intake level would gener-
ally not use a hydraulic turbine, while plants with a tower
elevation that exceeds the resultant potential design pressure
of the condenser waterbox would often have both the stand-
pipe and hydraulic turbine.
Multi-mode Capability
Multi-mode capability of a retrofit closed-loop cooling wa-
ter system refers to the capability of the system to revert back
to the original once-through operation at times when the
impact on marine life is minimal. This is usually in winter
time, so this arrangement also eliminates the plume fogging,
shadowing, and icing issues in winter. There is also increased
output benefit in winter, though it may not make up for the
loss of output in summer. Typical multi-mode arrangement
is shown in Figure 5.
There as some disadvantages to the multimode arrange-
ment. Switchover from one mode to the other involves
1310pe_48 48 10/16/13 5:30 PM
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Renewables, Alternate Technologies,
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and Operations & Maintenance.
1310pe_49 49 10/16/13 5:30 PM
www.power-eng.com
50
A Global Power Company
Braden Systems for
Gas Turbines
For over 45 years, Braden has designed, engineered
and manufactured hundreds of GT auxiliary systems
as the preferred supplier for turbine OEMs.
Comprehensive Retrofit Solutions
Bradens full array of engineers (structural, mechanical,
electrical and acoustical) scrutinize every aspect of
your retrofit design. Braden also installs complete
intake and exhaust systems.
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Air Filtration
Inlet Cooling/Heating
Silencing
Exhaust & Inlet
Ductwork
Diverter Dampers
Expansion Joints
Bypass Stacks
Diffusers and Plenums
Installation
Inspection and
Reporting Services
SCR & CO Catalyst
Systems
Filter House
Exhaust Bypass
Inlet
SCR & CO Catalyst Systems
Diverter Damper
Exhaust Stacks
starting and stopping large volume CW pumps with a po-
tential of water hammer. Proper control schemes need to be
developed to assure smooth switchover. During the once-
through mode there will be stagnant water in the system. As
much of the stagnant water as possible should be drained;
the remaining water must be treated. Cooling tower layup
for winter may include maintenance activities such chang-
ing oil in fan drive gear boxes and motor bearing housings,
cleaning electric motor air passages and lubricating bearings.
Space heaters should be used for motors in humid climates.
Temporary motor covers for motors may be required to pre-
vent moisture exposure. During the shutdown period motors
should be operated for about 20 minutes each month. Oil
levels should be checked in gear boxes and bearing housings
and oil added if necessary.
Impact on Auxiliary Cooling Water System
Cooling water is required not only to cool the main con-
denser, but also to cool various heat exchangers in the plant,
such as the main generator coolers, generator stator coolers,
compressor intercoolers, various pump and fan bearing oil
coolers, HVAC chillers, etc.
In some fossil plants, the auxiliary cooling pumps take
suction from the CW pump discharge (Figure 6A). When this
arrangement is converted to a closed-loop system, the auxil-
iary cooling water system will receive warmer cold water tem-
perature than the temperature it was originally designed for.
Therefore, the auxiliary cooling system has to be evaluated to
see if sufficient margin exists to account for higher cooling
water temperatures, or if modifications such as upgrades or
replacements of heat exchangers are required. If this proves
too difficult, or impossible, the auxiliary cooling system may
have to be converted to the once-through mode (Figure 6B).
This is costly, as new auxiliary cooling pumps, with approxi-
mately the same head as the CW pumps, would have to be in-
stalled to take suction from the river (lake, ocean). If there is
no room in the existing intake structure, a new intake struc-
ture would have to be constructed for the new auxiliary cool-
ing pumps. The water discharged from the auxiliary cooling
system could be used as the new cooling tower makeup. This
would reduce the size of or eliminate the need for the new
cooling tower makeup water system. The makeup flow will
be hotter than makeup from the river (lake, ocean) and will
add a small increase in cooling tower heat duty.
In some plants the auxiliary cooling pumps are separate
from the CW pumps. The advantage of this arrangement is
that during plant shutdown, the high power consuming CW
pumps can be shutdown, while the low power consuming
auxiliary cooling pumps provide cooling required for residu-
al heat removal and/or miscellaneous cooling duties during
shutdown. In this case the auxiliary system flow may be used
as cooling tower makeup. However, a partition needs to be
1310pe_50 50 10/16/13 5:30 PM
1310pe_51 51 10/16/13 5:30 PM
A PROUD HISTORY OF
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Multi-mode Arrangement 5
Existing
New
Condenser
CW Pumps Screens
CW CW
Gate
Gate
Gravity Line
CW Booster
Pumps
CW Discharge
Tunnel
Intake
Structure
installed in the existing intake structure
to separate the CW pumps from the aux-
iliary cooling pumps.
If this is not possible, the existing CW
pumps may have to be relocated to the
cooling tower basin, provided their head
is sufficient for the new duty, or new
pumps may have to be installed in the
cooling tower basin. In this case the ex-
isting intake structure will only serve the
auxiliary cooling water system.
Alternatively new intake may have to
be constructed for the auxiliary cooling
pumps.
Also, the existing CW pumps may
have to be relocated to the cooling tower
basin or new pumps installed there if the
gravity feed from the tower to the exist-
ing intake structure is not practical due
to insufficient elevation difference, long
distance or difficulty to bring the large
amount of water into the existing struc-
ture without affecting the operation of
the existing CW pumps.
1310pe_52 52 10/16/13 5:30 PM
1310pe_53 53 10/16/13 5:30 PM
www.power-eng.com
54
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Auxiliary Cooling Pumps Take Suction From CW Pump Discharge 6
Existing
New
Existing
New
A. Aux Cooling Included In Closed-Loop Conversion B. Aux Cooling Converted To Cooling Tower Makeup
CW Booster Pumps CW Booster Pumps
CW Pumps
Gravity
Line
Gravity
Line
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Aux
Cooling
Pumps
Aux
Cooling
Pumps
1310pe_54 54 10/16/13 5:30 PM
Follow the maze to the end.
When it comes to a facilitys maintenance schedule there
is no end. Planned maintenance is integral in any asset
management program to ensure safe operations and to
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365 days a year. Call TEAM today: 1-800-662-8326
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www.power-eng.com
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available makeup water is the salty sea
water. In rare occasions, water from a
local municipal waste water treatment
plant may be available.
With salt water makeup, the water in
the entire circulating water system, be-
comes concentrated, with typical salt
concentration increasing to between
1.5 to 2 times that of the sea water, or
higher. Sea water salinity is about 35
grams solids per 1,000 grams of sea
water, or 35,000 ppm.
Major issues arising with use of salt
water in cooling towers include:
t Effect on construction materials.
Salt water towers require many
provisions to accommodate the
corrosive salt atmosphere.
t Effect on thermal performance.
Sea water is a less effective coolant
for the system.
t Environmental impacts associated
with salt deposition
Metal components in contact with salt
water must be of corrosion resistant ma-
terials.
Special concrete mix and epoxy coat-
ing of all reinforcing bars is required for
concrete structures in contact with salt
water to prevent corrosion of reinforce-
ment steel.
The lower specific heat of salt water
results in reduced thermal performance
of the cooling system. The heat removed
from the condenser is approximated by
the following equation:
Q = 500 GPM dT cp sg
where: GPM = circulating water flow
dT = circulating water temperature
rise
cp = circulating water specific heat
Since the auxiliary cooling system
provides water for the ultimate heat sink
for removal of heat from safety-related
components during plant postulated ac-
cidents and shutdown, the auxiliary sys-
tem is safety related and must remain in
the once-through configuration, separate
from the non-safety related circulating
water system. The auxiliary cooling water
can be used as cooling tower makeup.
Final solution will depend on the
auxiliary cooling water system design
margins and arrangement in the par-
ticular plant.
Salt Water Towers
Cooling towers require makeup
water to replenish water lost to atmo-
sphere as evaporation and drift and to
replenish blowdown.
Blowdown is required to maintain
tower water chemistry. For plants lo-
cated by the sea shore, often the only
1310pe_56 56 10/16/13 5:30 PM
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sg = circulating water specific

gravity
For example, salt water at two cycles
of concentration (concentration is twice
that of normal sea water), at 60F wa-
ter temperature, the specific heat cp =
~ 0.92 and specific gravity sg = ~ 1.05.
The product of cp and sg is about 0.97.
For fresh water this product is equal
to 1.0. Thus, for the same temperature
rise, about 3 percent more circulating
water flow is required to remove the
same heat from the condenser with
the salt water tower as compared to the
same condenser operating with fresh
water tower.
In addition, the higher density salt
water requires more pumping power.
If the circulating water flow rate is kept
the same as original, the temperature
rise would increase by about 3 per-
cent, resulting in condenser pressure
increase.
Beyond the flow issues with salt wa-
ter, the thermal transport character of
salt water within the cooling tower fill
degrades the tower performance some-
what when compared to a fresh water
tower.
Environmental concerns with salt
water tower are primarily cooling tower
drift and blowdown.
The drift and blowdown contain the
same concentration of total dissolved
solids as that of the circulating water.
Under certain weather conditions, the
salt content in the drift will deposit
on adjacent structures and cause cor-
rosion of metallic components. With
typical 1.5 to 2 cycles of concentra-
tions, the blowdown discharged back
to the ocean should cause no problems,
provided no toxic materials have been
added to the circulating water as part of
the water treatment, and sufficient dilu-
tion of the blowdown is provided.
CONCLUSION
Installation of cooling towers offers
one of the most effective options to re-
duce IM&E of marine life, as it reduces
water intake by about 90 percent.
The goal of this paper was to iden-
tify some of the less obvious issues that
arise from the conversion of an open-
loop cooling system to a closed-loop
cooling system and suggest possible
solutions. These issues with their asso-
ciated impacts and the final solutions
will vary from site to site and require
careful analysis considering all site spe-
cific conditions.
1310pe_58 58 10/16/13 5:30 PM
1310pe_59 59 10/16/13 5:30 PM
www.power-eng.com
60
STEPS 1 AND 2
Site and Technology Selection
Many variables must be clarified/de-
termined during this phase of project de-
velopment. These items include:
t Targets for plant performance
t Fuel source and availability
t Fuel constituents and chemistry
t Technology assessment
t Project schedule
t Geotechnical conditions
t Makeup water source, chemistry,
and treatment selection
t Exhaust steam cooling
- Cooling tower
- Air-cooled condenser
t Wastewater treatment selection
t Interconnection logistics
t Noise constraints
Some of these variables are easier to
identify than others, but all need to be
addressed very early in the project de-
velopment cycle. The lack of timely deci-
sions can significantly impact the overall
project schedule. Owners today are being
challenged with permitting and intercon-
nection agreements that may take in ex-
cess of 12 months to complete. Lead times
for major equipment acquisition are an-
other schedule driver and will become a
greater challenge as the global market for
these products continues to grow. To help
minimize the impact of equipment ac-
quisition, a limited engineering release is
necessary to begin procurement and pre-
liminary design. Developers need a thor-
ough understanding of the selected site
prior to acquiring bids from engineering
and construction firms, as this will great-
ly influence the final cost of the project.
While much data exists in the public do-
main regarding subsurface conditions for
many states and counties across the coun-
try, the data is often not specific enough
to finalize costs and schedules. Often, a
site investigation with only a handful of
borings can give much insight, but a de-
tailed study should be completed before
design commencement or site activities.
With regard to equipment selection,
a number of reputable and experienced
vendors are available both nationally and
globally to supply the major equipment
plus the auxiliaries. Of course, the key
selections include the combustion tur-
bines, HRSGs, and steam turbine. How-
ever, auxiliary systems should not be
overlooked by excessive focus on the ma-
jor equipment. Important auxiliaries in-
clude transformers, makeup and cooling
water equipment, auxiliary boilers, and
instrumentation and control systems, to
name several.
As the decision is made regarding the
primary technology, thereupon comes
development of heat and water balances.
I
n todays climate of advanced
environmental regulations and
greater public awareness (or
sometimes fear) of energy issues,
the evaluation, planning, and
permitting of new power plants are criti-
cal issues.
For a developer today to be success-
ful, they must select the best technology
and site, receive the required permits and
construct the plant in a timely and cost-
effective manner.
This article examines the most impor-
tant issues of this process, with a particu-
lar focus on the most popular installa-
tions in the U.S., combined-cycle power
generation plants. However, many of the
topics apply to other methods of power
generation including coal, stand-alone
combustion turbines, biomass plants and
others.
Executing the
Complete Power
Generation
Project
BY BRAD BUECKER AND TONY JAIME, KIEWIT POWER ENGINEERS
Construction of the John Sevier Combined Cycle
Project, which was fully commissioned in April 2012,
was overseen by Kiewit Construction.
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water flow rates and usage can easily be
calculated for any variety of conditions.
Once equipment selection has been
finalized, the focus shifts to equipment
layout. Some sites offer plenty of space
for combustion turbine and auxiliary
systems placement, but others may be
very tightly constrained. One of the most
significant factors for overall plant cost is
quantities of commodities. Regardless of
the space available, proper effort is need-
ed to optimize the plant layout and in
turn accurately calculate quantities and
simplify construction. Factors that im-
pact quantities include: piping and wir-
ing locations and run lengths, steam tur-
bine location, switchyard location, water
treatment building placement, cooling
tower location and many others.
It is important as a developer or utility
to write the RFP in a manner that gives
the EPC contractor flexibility regarding
the plant layout. This is possible while
still maintaining pre-established emis-
sion points included in air permit appli-
cations. As the equipment is being laid
out two-dimensionally, designers also
construct the model in 3D, which al-
lows a much better analysis of pipe rack,
cable tray and other overhead equipment
locations. Development of the equip-
ment arrangement expediently and with
precision is also important for planning
of of underground piping and electrical
supplies. These need to be installed ac-
curately upon the first attempt, as other-
wise considerable time and effort may be
expended in rerouting piping and cables
after the fact.
All of these decisions factor into final
technology selection. Besides power re-
quirements, important aspects of com-
bustion turbine selection include:
t Fast start requirements
t Planned startup/shutdown
frequency
Modern programs incorporate specific
data from the equipment chosen and
will produce accurate calculations for
many parameters including combustion
turbine output, heat rate, steam produc-
tion in the HRSGs, cooling tower perfor-
mance and circulating water flow rate,
among others. This data in turn allows
refined calculations of water balances.
Precision is paramount, as the water bal-
ance determines the required capacity of
makeup water, and at times cooling wa-
ter, treatment equipment. Undersizing of
such equipment can lead to severe oper-
ating problems at and after startup, while
oversizing adds significant cost to the
system and may also result in poor per-
formance. Another factor of importance
is that a poor water balance can lead to
installation of piping that is either too
small or large for the application. Excel or
a similar spreadsheet program is an excel-
lent tool for preparing water balances, as
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www.power-eng.com
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aeroderivative or frame units. The former
offer very fast startups, but the heat rate is
not as good as for frame units.
Of course, for a combined-cycle plant
the complexity increases. Additional
equipment selection issues include:
t HRSG details
- Quantity
- Width (2 bay vs. 3 bay)
- Single- or multi-pressure
t Steam turbine manufacturer
t Makeup water treatment
t Steam condensation technology
- Cooling tower
- Air-cooled condenser
- Wet-surface air coolers
t Wastewater discharge control
The bulleted items above include ref-
erence to a critical aspect of power plant
design, water/wastewater equipment se-
lection and treatment. Author Buecker
has covered many of these issues in re-
cent issues of Power Engineering, but addi-
tional commentary regarding impending
wastewater issues is provided in the sec-
tion below.
STEP 3
Permitting
As even many homeowners know,
construction of simple buildings often
requires one or more permits. The issue is
vastly more complicated for power plant
construction. Critical to the start of any
project are air and water discharge per-
mits, for if these are not requested early
and contain very accurate information,
the project will inevitably be delayed.
As time passes, air permits continue to
become more and more complex. In the
past, permits were consistent regarding
the pollutants to be regulated, and they
were relatively specific and straightfor-
ward on reporting requirements. Permits
today include strict limitations on startup
and shutdown activities and may now
include limitations on CO
2
emissions. If
permitting requirements are not clearly
defined and matched to plant design, the
owner could face operating limitations
that significantly impact the profitability
of the plant.
Regarding water discharge, the guide-
lines are also becoming more complex.
The EPA is preparing new National Pol-
lutant Discharge Elimination System
(NPDES) regulations. For many years,
the primary impurities regulated by NP-
DES guidelines were pH, total suspended
t Emissions control
- SCR system
- CO catalyst
t Possible water requirements
- Compressor intercoolers
- Water injection for NO
x
control
These factors drive the choice of
combustion turbine(s), including
1310pe_64 64 10/16/13 5:30 PM
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66
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requires careful thought when it comes
to deciding on selection of makeup and
cooling water treatment, well ahead of
equipment selection. Some experts now
recommend zero liquid discharge in-
stallation for nearly every new project to
avoid difficulties with additional regula-
tions that most likely will occur in the
future. But, ZLD is easier said than done.
A final stream always remains from the
primary process, and careful analysis, in-
cluding additional permitting, is needed
to determine whether the final product
can be disposed in evaporation ponds,
deep well injection, by off-site means, or
by thermal evaporation. The upshot is
that it is important to begin the permit-
ting process very early on in a project, for
final approval may take well over a year.
STEP 4
- Construction
Many projects we perform are of the
engineer-procure-construct (EPC) type.
Two critical items are important for start-
ing a project correctly and taking it to a
successful conclusion. These are:
t Safety
t Close contact with the owner
throughout the project
Bringing in the EPC contractor early in
the development process helps with plan-
ning and constructability of the project.
The engineering and construction team
can identify potential safety risks related
to construction or operations/maintain-
ability of the plant.
STEP 5
Startup and Performance Testing
As construction reaches completion,
the startup and performance testing ac-
tivities commence. These activities can
be performed by the owner, the EPC con-
tractor or a third party. In any event, it is
critical to involve the startup and testing
teams early such that coordination of the
tests and testing equipment may be incor-
porated in the design and construction.
Kiewit Power Engineers has been in-
volved with countless project develop-
ment and EPC projects. The time and
effort owners put into making a project
shovel ready is quite significant. By
getting a jump on permitting and in-
volving an EPC Contractor early, owners
have a better chance of seeing the project
up and running in the most expeditious
amount of time.
solids (TSS), oil & grease (O&G) and
residual halogen (most typically chlo-
rine or bromine). But now other items
are appearing on the list, and not only
from the USEPA but often from local or
regional regulators. We are seeing limits
for copper, zinc, ammonia, phosphate,
sulfate and total dissolved solids (TDS).
Undoubtedly, others will appear. This
1310pe_66 66 10/16/13 5:30 PM
BP PM 2012 Dec
CIVIL
GOVERNMENT SERVICES
MINING & METALS
OIL, GAS & CHEMICALS
POWER
Bechtel is among the most respected engineering,
project management, and construction companies in
the world. Bechtel operates through _ive global
business units that specialize in power generation;
civil infrastructure; mining and metals; oil, gas and
chemicals; and government services.
Since its founding in 1898, Bechtel has worked on
more than 22,000 projects in 140 countries on all
seven continents. Today, our 53,000 employees team
with customers, partners and suppliers on diverse
projects in nearly 50 countries. We stand apart for our
ability to get the job done rightno matter how big,
how complex, or how remote.
Building the Worlds
Energy Future
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68
Authors:
Andy Gillespie, Bechtel project manager
of the Ivanpah Solar Electric Generating
System, along with members of the
Bechtel/Ivanpah Six Sigma team,
Mark Wagner, Kimberly Johnson, Terry
Copeland, and Kathi Kirschenheiter,
contributed to this article.
on existing rolling terrain to avoid and
minimize the need to grade or level
at the project site, further adding to
B
uilding the worlds largest
concentrating solar facility
and one that is the first of
its kind requires nothing
less than innovation at ev-
ery step. While the 377 MW Ivanpah So-
lar Electric Generating System (ISEGS)
falls squarely into a sweet spot of com-
plexity and scale, one can never overlook
the processes and tools needed to man-
age a project of this kind.
From building a first of a kind auto-
mated assembly line to erecting three
450-foot power towers, Bechtel had the
opportunity to apply its expertise to
what has become a unique facility. De-
veloped by Solar Partners NRG Energy,
Google and BrightSource Energy the
ISEGS is a concentrating solar power
(CSP) facility built in the Mojave Des-
ert that will nearly double the amount
of commercial solar thermal electricity
produced in the U.S.
To ensure customer satisfaction and
predictability of outcome throughout
this multi-year project, Bechtel turned to
Six Sigma. Six Sigma is Bechtels chosen
methodology for improving quality and
performance.
Bechtel is one of the few engineering,
procurement, and construction (EPC)
companies that use Six Sigma to deliver
big projects to its customers. The com-
pany has been using it for over a decade
and has trained thousands of technical
Bechtel Uses Six Sigma
to Drive Performance
at Ivanpah Solar Facility
BY MEMBERS OF THE BECHTEL PROJECT MANAGEMENT AND SIX SIGMA TEAM
and professional employees on Six Sig-
ma tools. Those who have completed the
most robust training achieve advanced
level certifications.
DEVELOPING A BUSINESS
CASE FOR IVANPAH
Six Sigma works best on projects
that have a lot of repetition or first of
a kind elements. Ivanpah is an ideal
candidate. Consider that the project
includes assembling and installing
software-controlled heliostats or mir-
rors 173,500 of them. The heliostats,
each the size of a garage door, consist
of two mirrors mounted on a post that
tracks the sun throughout the day to di-
rect sunlight to boilers or solar receiver
steam generators (SRSG). The sunlight
heats water inside the boilers to create
superheated steam, which then gener-
ates electricity. There are three boilers
on the project, each weighing 2,200
tons. Each boiler sits on top of a 339-
foot power tower for a total height of
450 feet thats one and a half times
taller than the Statue of Liberty.
There was no standard template for
the Ivanpah project. Heliostats had
been installed at one of BrightSources
pilot projects, but nothing at this scale.
All the processes of assembly, trans-
porting and installing the heliostats
had to be developed from scratch. To
boot, the heliostats had to be installed
One of three 459-foot tall towers at the Ivanpah
Solar Electric Generating System. Photo Courtesy of
Bechtel Corp.
1310pe_68 68 10/16/13 5:31 PM
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69
Bechtels challenges.
The kind of complexity embedded in
the Ivanpah project was a good fit for
the Six Sigma approach. By using Six
Sigma to address design, procurement,
and construction challenges, Bechtel
was able to develop new processes that
helped us meet performance goals and
execute successfully, while simultane-
ously building trust and credibility
with our customer.
WORKING WITH THE
CUSTOMER TO DEFINE
PROCESS IMPROVEMENTS
Bechtels engineering and construc-
tion teams joined with engineering and
construction experts from BrightSource
to form a Six Sigma team. Keeping in
mind the needs of the customer in ad-
dition to cost and schedule, the team
identified five areas that needed process
Power Engineering and Bechtel will be hosting an
#Ivanpahchat on Twitter Nov. 5 from 10a-11a Central
(11a-12p Eastern).
Be sure to follow @pwrengineering
for more details!
Ti me- l apse vi deo
(www.power- eng.com)
1310pe_69 69 10/16/13 5:31 PM
www.power-eng.com
70
on a solar site. But Ivanpahs HAB was
state-of-the-art and featured robotics
designed by BrightSource to lift the
mirrors from a stack to the pad bond-
ing area, where special pads were put
on the backs of the mirrors in prepara-
tion for installation. Visiting the HAB
was like looking inside a watch; parts
moved in place, one after another,
perfectly timed and in sequence. The
beauty of its efficiency was in the sim-
plicity of the design. But, it wasnt al-
ways planned that way.
The original design of the HAB con-
sisted of one building that contained
both the pad bonding equipment and
the assembly line equipment and only
one exit area at one end of the build-
ing. This design posed significant risk
of congestion.
The Six Sigma team got an inside
view of a mock-up assembly testing
improvements: material handling; he-
liostat assembly; field transportation;
solar field installation; and power tow-
er erection. In each of these areas, the
team found new or more efficient ways
that drove better performance and bet-
ter results.
As one might imagine, managing
materials for a project this size is quite
complicated. Bechtel was tasked with
handling 42 million total heliostat
components, including 22 million
rivets, more than 7,500 tons of steel;
2,000 kilometers of cable; and more
than 36,000 cubic yards of concrete.
The original plan called for a 19-acre
area to hold heliostats, pylons and oth-
er solar field equipment, in addition
to the erection and operation of the
assembly equipment. When the area
was reduced from 19 to 14 acres in an
effort to reduce the project footprint,
the team had to use modeling tools to
make sure all the materials came in
and out without any hiccups.
The team developed models to map
how heliostat containers were moved
throughout the site. With the data from
the models and feedback from traffic
and logistics stakeholders, the team
redesigned the area to allow for stack-
ing of the heliostat containers. Choos-
ing specialized yard equipment meant
containers could be moved more easily
in the smaller space provided.
HELIOSTAT
ASSEMBLY BUILDING
Outside of the solar fields and power
towers, Ivanpahs Heliostat Assembly
Building (HAB) has been a main site
attraction. While one might find an
assembly line at a manufacturing fa-
cility, chances are you wont see one
1310pe_70 70 10/16/13 5:31 PM
1310pe_71 71 10/16/13 5:31 PM
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and a larger building for heliostat as-
sembly that had multiple exits. The
separation of the buildings with addi-
tional exits meant less congestion and
maximum efficiency.
HELIOSTAT
TRANSPORTATION
In order for 173,500 heliostats to
be installed on schedule, 500 of them
would need to be transported to the
solar field every day for two years.
Based on the scale of the project, this
equaled roughly 35,000 miles of travel
required to move the heliostats.
To solve the puzzle, the Six Sigma
team analyzed various transportation
models to uncover the most efficient
routes from the time the heliostats
left the HAB to the time they reached
the point of installation. The team de-
signed a transportation management
system with a number of crane, trac-
tor and trailer combinations needed to
sustain the required installation rate.
The processes were then institutional-
ized within the execution plan for the
solar field.
HELIOSTAT AND SOLAR
FIELD INSTALLATION
Once the team figured out the best
way to transport materials and assem-
ble the heliostats, they needed to evalu-
ate the solar field installation. This pro-
cess involved analyzing how holes were
augured to pylon insertion, and finally,
to heliostat installation.
When working on a project this size
and the company has strong relation-
ships with vendors, Bechtel had the
flexibility of redesigning installation
equipment to best suit the needs of the
project and customer. For example, the
team contacted a vendor to redesign ex-
cavators so that auguring and pylon in-
sertions could be done without chang-
ing attachments on the machinery. The
team also chose leading edge excavator
machines that were fuel efficient and
had the ability to reach 25 feet to auger
facility where they could conduct time
and motion studies. The results of the
studies enabled them to redesign the
building using efficiencies that would
enable craft to assemble 500 heliostats
per day, or 1.7 a minute.
The redesign included separating the
facility into two distinct areas: One set
of smaller buildings for pad bonding
While you might find
an assembly line at a
manufacturing facility,
chances are, you
wont see one on
a solar site.
- Bechtel
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74
CRAFT PARTICIPATION IN
THE SIX SIGMA PROCESS
The success of the Six Sigma team
also depended on craft input. The craft
provided the team with invaluable
feedback with regards to work flow,
cycle times, equipment functional-
ity and challenges with pylon instal-
lation. By being a part of the process,
the craft became more invested in the
success of the project and the desire to
continuously improve the process.
The Six Sigma philosophy of con-
tinuous improvement also carried
over into their daily work. Craft would
have competitions to see which teams
could insert the most pylons or build
and install the most heliostats in a day
according to project specifications.
These competitions created a tremen-
dous sense of team spirit and pride in
their work. Craft participation in the
Six Sigma process was critical and led
to discretionary effort that strength-
ened customer satisfaction throughout
the build. The same enthusiasm, effort,
and can-do attitude they displayed at
the beginning of construction contin-
ues on the project today.
POWER TOWER ERECTION
AND BOILER LIFT
Another first-of-a-kind challenge on
Ivanpah was the erection of the 339-
foot steel power towers and the lift of
holes and install pylons. By changing
the design of the equipment, craft were
able to better protect the Mojave Desert
landscape during installation by reduc-
ing impact to the desert environment.
The efficiencies created in the helio-
stat and solar field installation process
enabled craft to reach and exceed the
500 heliostat-a-day goal. At peak, craft
installed heliostats at a rate of 600-750
per day. Additionally, a GPS system
was utilized on each auger and pylon
excavator that reduced the required
survey manpower and provided quick
and accurate installations to the re-
quired tolerances.
The team helped
craft exceed its
goal of inserting 500
heliostats per day and
developed installation
processes that were
low impact on the
surrounding desert
environment.
- Bechtel
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76
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your parnter in handling success
maximizing productivity. After the
team successfully erected the first tow-
er, they improved the processes and in-
stitutionalized lessons learned for the
other two, which are complete.
three 2,200-ton boilers. Construction
experts recommended building the
tower and lifting the boilers in pieces.
The team created multiple assembly
areas around the tower foundation
where craft could begin work on the
next section immediately after finish-
ing the first.
The lower portion of the tower was
built on the tower foundation, while
the upper portion was preassembled
on the ground and lifted into place.
Building pieces on the ground was
safer for the craft, and the repetition
of the modular approach enabled the
workers to perfect the process, saving
time along the way.
With the tremendous weight of the
boilers and their original size of 50 feet
x 50 feet x 120 feet, craft built ten 90-
ton structures in a common area and
then lifted the sections with a special
450-foot tower crane. Only 22 of these
cranes existed in the world, and Ivan-
pah had three of them. By making
lifts at maximum weight, the number
of lifts was reduced, saving time and
One of the towers and heliostats of the
Ivanpah project. Courtesy: Bechtel.
1310pe_76 76 10/16/13 5:31 PM
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1310pe_77 77 10/16/13 5:31 PM
www.power-eng.com
78
EGUs includes emission limits for: mer-
cury (Hg), hydrochloric acid (HCl), and
particulate matter (PM).
The MATS Rule also establishes alter-
native standards for HCl (via SO
2
control)
and an alternative standard for non-mer-
cury metallic hazardous air pollutants
(HAPs) via a filterable particulate matter
(FPM) limit.
SUMMARY OF MATS
RULE REQUIREMENTS
The main emissions criteria estab-
lished by EPA as part of the MATS Rule
applicable to NIPSCOs stations are sum-
marized in Table 1.
In addition to the emission limits sum-
marized above, the MATSRule contains
a work practice standard for organic HAP
emissions, including emissions of dioxins
and furans (D/F), non-D/F organic com-
pounds, and hazardous volatile organic
compounds (VOCs). The work practice
standard requires maintaining and in-
specting the burners and associated
combustion controls, tuning the specific
burner type to optimize combustion, and
obtaining and recording carbon monox-
ide (CO) and nitrogen oxides (NO
X
) val-
ues before and after burner adjustment.
This paper summarizes operating his-
tory of the NIPSCO coal-fired EGUs af-
fected by the MATS Rule, and presents
the evolution of the strategy developed
for the units to assess the implications
of the proposed MACT Rule regulations
through the continuing assessment of
the finalized MATS Rule regulations.
This strategy has been an evolutionary
process reflecting events through the
proposed and finalized versions of the
legislation and the assessment and de-
velopment of initial unit performance
baseline data, followed by updated data
resulting from additional testing. The
process has been iterative. What may be
believed at the beginning of the process
may change throughout the development
of the strategy. The strategy is an attempt
to utilize and leverage NIPSCOs existing
environmental assets to support the de-
velopment of a cost-effective, yet flexible,
response to the MATSRule legislation.
NIPSCO COAL-FIRED EGUS
NIPSCO operates seven EGUs that
are affected by the MATS Rule regula-
tions. A summary-level description of
the coal-fired EGUs included in the strat-
egy development and the environmental
equipment that is currently installed or
that is planned to be installed prior to the
O
n March 16, 2011, U.S.
Environmental Pro-
tection Agency (EPA)
issued a proposed rule
that included stan-
dards for the Utility Maximum Achiev-
able Control Technology (MACT) Rule
standards for coal- and oil-fired electric
generating units (EGUs). NIPSCO en-
gaged Sargent & Lundy, L.L.C. (S&L) to
assist in assessing the implications of the
proposed MACTRule regulations on the
coal-fired EGUs within NIPSCOs fleet.
On February 16, 2012, the EPA pub-
lished in the Federal Register the fi-
nal Mercury and Air Toxics Standards
(MATS Rule), which effectively replaced
the proposed MACT Rule regulations.
The MATSRule for the existing coal-fired
Developing a
Low-Cost MATS
Rule Compliance
Strategy
BY WILL BOWARD AND DANIELLE FLAGG, SARGENT & LUNDY,
AND KURT SANGSTER AND WILLIAM CAIN, NIPSCO
The Mercury Air and Toxics Standard (MATS), which
was finalized by the Environmental Protection Agency
last year, established emission limits for mercury and
hazardous air pollutants, including lead, arsenic, hy-
drogen chloride, hydrogen fluoride and dioxins/furans.
Power generators have until April 2015 to comply.
1310pe_78 78 10/16/13 5:31 PM
1310pe_79 79 10/16/13 5:31 PM
www.power-eng.com
80
low-sulfur Powder River Basin (PRB) and
15% bituminous fuels. Unit 12 is cur-
rently equipped with the following con-
trol technologies:
t OFA and SCR technology for NO
X

control
t ESP with a SO
3
flue gas conditioning
system for particulate control
There is currently no FGD technol-
ogy installed on Unit 12; however,
NIPSCO had plans to install a dry
FGD in 2018. These plans were devel-
oped prior to the promulgation of the
MATSRule regulations.
R.M. Schahfer Generating Station
(RMSGS) Units14,15,17, and18
RMSGS is located on approximately
a 2,900-acre site two miles south of the
Kankakee River in Jasper County, near
Wheatfield, Indiana, and is the largest of
NIPSCOs generating stations. The SGS
four base load and two peaking units
came on line over an 11-year period, end-
ing in 1986.
Unit14 is a 1976 B&W cyclone boiler
with a net full-load output of 431 MW.
The unit currently burns a blend of Il-
linois bituminous and low-sulfur PRB
fuels; in the future, Unit 14 may burn
up to 100% bituminous fuel. The unit
is equipped with the following air pollu-
tion control equipment:
t OFA and SCR technology for NO
X

control
t ESP for particulate control
t Currently being retrofit with wet
FGD technology for SO2 control
and sorbent injection for SO3 con-
trol (will be in operation by the end
of 2013)
Unit 15 is a 1979 Foster Wheeler op-
posed-firing pulverized coal (PC) boiler
Unit 15 was designed for PRB fuel and
currently burns a blend comprising
of 90% PRB and 10% Illinois bitumi-
nous; in the future, the unit may burn
up to 25% bituminous fuel. Unit 15 is
equipped with the following air pollu-
tion control equipment:
t Low-NO
X
burner (LNB) and OFA
technology for NOX control
t Currently being retrofit with wet
FGD technology for SO2 control
and sorbent injection for SO3 con-
trol (in conjunction with Unit 14
installation; will be in operation by
the end of 2015)
Unit17 is a 1983 CE tangential firing
PC boiler with a net full-load output of
361 MW, and currently burns Illinois
bituminous fuel. Unit 17 is currently
equipped with the following air pollu-
tion control technologies:
MATSRule implementation date follows.
Bailly Generating Station (BGS)
Units7 and8
BGS is located on a 100-acre site on the
shores of Lake Michigan in Porter Coun-
ty, Indiana. The BGS two base load units
and one peaking unit came on line over a
six-year period, ending in 1968.
Unit 7 is a 1962 B&W cyclone boiler
BGS Unit8 is a B&W cyclone boiler with a
net full-load output of 320MW installed
in 1968. Both of the boilers at BGS cur-
rently burn Illinois bituminous (Illinois
Basin) fuels. The station has also burned
Indiana (Illinois Basin)-sourced fuels
that are lower in chloride content.
Unit 7 is currently equipped with
the following air pollution control
equipment:
t OFA and selective catalytic reduction
(SCR) technology for NO
X
control
t Electrostatic precipitator (ESP) for
particulate control
t Limestone wet FGD for SO
2
control
t Sodium Bi-Carbonate (SBC) injec-
tion for SO3 control
Unit 8 is currently equipped with
the following air pollution control
equipment:
t OFA and selective catalytic reduction
(SCR) technology for NO
X
control
t Limestone wet FGD for SO
2
control
t SBC injection for SO
3
control
BGS Units7 and8 share a common
FGD system and have a common stack,
and their emissions will be evaluated
together.
Michigan City Generating Station
(MCGS) Unit12
MCGS is located on a 134-acre site on
the shores of Lake Michigan in Michigan
City, Indiana, and comprises one base
load coal-fired steam unit.
Unit12 is a 1974 B&W cyclone boiler
Unit 12 currently burns a blend of 85%
Source:
Existing
Coal-Fired
EGUs
Non-Mercury
Metals(5)
Acid Gases Mercury
Existing
coal-fired unit
designed for
coal 8,300
Btu/lb
(bituminous-
and sub-
bituminous-fired
boilers)
Filterable PM
(1)
0.030 lb/MMBtu
or
Total non-mercury
HAP Metals
(2)
0.000040 lb/MMBtu
or
Individual HAP
Metals
(3)
HCl
0.0020 lb/MMBtu
[~2 ppmvd @ 3% O
2
]
or
SO2
(4)
0.20 lb/MMBtu
Mercury
1.2 lb/TBtu
(0.008 lb/GWh)
Summary of EPA MATS Rule Emissions Criteria 1
1310pe_80 80 10/16/13 5:31 PM
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82
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- LNB[OFA cclnoIogy foi NO
X
con-
ioI
- ESP foi paiicuIac conioI
- Limcsonc wc FCD foi SO2 conioI
Unil8 is an idcnicaI, sisci o Unil7,
insaIIcd in l986. Uni l8 las lc samc
conioI cclnoIogics insaIIcd as Unil7.
MACT RULE
CONSIDERATIONS
AII of NIPSCO's unis aic in compIi-
ancc wil lcii pcimicd cmission ic-
quiicmcns. Duc o lc vaiious conioI
cclnoIogics cquippcd on cacl uni and
lc ovciaII agc of lc unis and cquip-
mcn, lc unis lavc a widc iangc of cmis-
sions. 1lc fiis scp in lc pioccss was o
considci lc icquiicmcns of lc MAC1
and MA1SRuIcs wil icspcc o cuiicn
uni pcifoimancc. Oncc lc unis' hasc-
Iinc cmissions wcic csahIislcd, wil
icspcc o lc pioposcd and finaI icguIa-
ions, lc pocniaI conioI cclnoIogics
foi cacl poIIuan wcic idcnificd and
cvaIuacd. 1lis scp was icvisicd scvciaI
imcs liouglou lc piojcc wlcn lc
finaI MA1S RuIc was issucd and wlcn
addiionaI cmission cs daa hccamc
avaiIahIc. 1lc foIIowing summaiizcs lc
iniiaI siacgy in icIaion o lc majoi ic-
quiicmcns of lc MA1SRuIc.
Acid Gas Removal Requirement
Bol lc pioposcd MAC1 RuIc and
lc finaI MA1SRuIc icguIaions aIIowcd
lc usc of a suiiogac SO
2
icmovaI Iimi
of u.2u IhsSO
2
[MMBu o slow compIi-
ancc wil lc acid gas piovisions. Foi
NIPSCO's syscm, lis was lc simpIcs
cmission Iimi wil wlicl o compIy. AII
of NIPSCO's coaI-fiicd ECUs cilci lavc
cxising wc FCD cclnoIogy insaIIcd oi
wiII lavc wc FCD cclnoIogy insaIIcd,
capahIc of icducing lc SO
2
IcvcIs hc-
Iow lc u.2u Ihs SO
2
[MMBu Iimi. 1lc
cxccpion is MCCS Unil2. Foi a num-
hci of icasons la aic cxpIaincd undci
lc olci icguIacd poIIuans poiion
of lis papci, i was dccidcd la impIc-
mcnaion of lc pIanncd MCCS Unil2
diy FCD syscm, oiiginaIIy sclcduIcd in
1310pe_82 82 10/16/13 5:31 PM
1310pe_83 83 10/16/13 5:31 PM

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NIPSCO units, six either already have
wet FGD installed or are in the process of
having it installed. NIPSCO instituted a
testing program to characterize the units
Hg emissions. As was expected, based on
the fuel analyses, those units burning Il-
linois basin bituminous fuels with rela-
tively high chloride content were shown
to have stack and sorbent trap emissions
for many of the point tests lower than the
MATSRule Hg limit.
Under these conditions it appeared
that the existing FGD units were capable
of controlling Hg emissions below the
MATSRule limit. As the majority of emis-
sions data to date are from individual
stack tests, some uncertainty regarding
whether the units can comply with the
MATS Rule limits on a continuous 30-
day rolling average basis exists. NIPSCO
has recently installed Hg continuous
emission monitoring systems (CEMS)
on all units and particulate (CEMS) on
selected units. Some of NIPSCO units
burn a blend of PRB and bituminous fu-
els; these units typically have higher Hg
emissions than the MATSRule emission
limit.
The preliminary compliance strategy
was to use fuel additives, which are de-
signed to oxidize Hg to a form that is more
readily captured in the FGD systems. This
would be the most cost-effective manner
of reducing the Hg emissions; however,
the use of fuel additives was contingent
upon a successful demonstration test. An
alternative strategy, especially for units
that burn primarily PRB fuels, includes
activated carbon injection (ACI) and
halogenated powdered activated carbon
(PAC).
Non-Mercury Metal Hazardous Air
Pollutants Removal Requirements
The final MATS Rule allows utili-
ties to comply with requirements for
non-mercury metal (NMM) HAPS by
2018, would be accelerated in order for
the system to be operational in time for
compliance with the MATSRule acid gas
requirement.
Other options were considered, includ-
ing installation of a baghouse along with
dry sorbent for HCl removal to operate
between the MATSRule compliance date
and the dry FGD installation in 2018.
The economics favored early installation
of the dry FGD. With that decision, NIP-
SCO will have operational FGD systems
on all units capable of complying with
the 0.20lbsSO
2
/MMBtu requirement pri-
or to the MATS Rule deadline. The acid
gas removal requirement will be met by
using existing or planned FGD systems.
Mercury Removal Requirement
The original MACT Rule require-
ments for Hg included an outlet emis-
sion rate below 1.0 lbs Hg/TBtu. The fi-
nalized MATSRule has a requirement of
1.2 lbs Hg/Btu. Of the seven applicable
1310pe_84 84 10/16/13 5:31 PM
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OPTIONS CONSIDERED
FOR MATSRULE
COMPLIANCE
FPM Particulate Control
The assessment of the particulate re-
moval capability was begun by review-
ing the biennial stack testing data that
NIPSCO had accumulated. A number
of the NIPSCO existing ESPs showed
removals within the compliance levels
of MATSRule, even though none of the
original performance guarantees were for
a continuous 0.030lb/MMBtu outlet. The
particulate results varied widely from test
to test, with test results above and below
the MATSRule limit. The only major ex-
ception to this was MCGS Unit12, which
was consistently above the limit. How-
ever, since the decision has been made to
install dry FGD to comply with the acid
gas provisions of MATS Rule, the exist-
ing ESP at MCGS Unit 12 will be replaced
with a baghouse, bringing this unit into
compliance; although, the baghouse
would need to be installed prior to the
MATSRule compliance date.
As discussed above, the main issue for
the NIPSCO system once the decision
was made to install dry FGD at MCGS
Unit 12 for MATS Rule compliance was
how to ensure compliance with the par-
ticulate requirements. This is complicated
by the likely need for ACI to control Hg
emissions below the MATS Rule limit.
The decision to accelerate the installation
of the dry FGD system in time for the
MATS Rule compliance date was final-
ized, as this would provide compliance
with both the acid gas and NMM require-
ments for MCGS Unit12.
In reviewing the design specifica-
tions for NIPSCOs existing ESPs, it was
noticed that the designs included boxes
that appeared to be conservatively sized.
One parameter used to evaluate the po-
tential for ESPs to readily collect FPM is
specific collecting area (SCA). The ESPs
have substantial SCAs, with the excep-
tion of MCGS Unit12, which has an SCA
of ~ 177 ft
2
/1,000 acfm. The other ESPs
range from a low SCA of 312, up to 495
controlling filterable particulate mat-
ter (FPM). Judging compliance perfor-
mance for this requirement was not as
straightforward as for the acid gas re-
quirements.
The proposed MACT Rule required
compliance with a total particulate
matter (TPM) limit, which included
both FPM and condensable particulate
matter (CPM), rather than just FPM.
The TPM emission limit under the
proposed MACT Rule was 0.030 lb/
MMBtu. Very little data existed to eval-
uate the condensable contribution to
the TPM.
Although NIPSCO conducted stack
testing historically at least every two
years on all their units, the particulate
regulations they were required to meet
prior to the proposed MACT Rule did
not encompass CPM; therefore, it was
not measured.
NIPSCO instituted a testing program
to develop TPM data on their units. The
final MATS Rule eliminated the CPM
component of the limit and identifies
a FPM limit for NMM compliance. The
final MATSRule FPM limit is 0.030lb/
MMBtu.
The inclusion of CPM in the limit
when the MACTRule regulations were
first proposed put the units firing pri-
marily bituminous fuels at risk. There
could potentially be sufficient SO
3
in
the flue gas that would appear as CPM,
resulting in a TPM emission above the
0.03 lb/MMBtu MACT Rule limit. The
changes in the final MATS Rule made
the NMM removal requirements more
straightforward to obtain.
Upon the initial assessment, it be-
came clear that the greatest risk in-
volved with the NMM removal require-
ments was the condition of the existing
ESPs and their ability to control FPM
below the MATS Rule limits. In addi-
tion, future increases in particulate
loading to the ESPs due to the poten-
tial addition of halogenated activated
carbon for Hg control could pose further
complications.
1310pe_87 87 10/16/13 5:31 PM
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ESPs. The potential ESP upgrades include:
t Install high-frequency transformer-
rectifier (TR) sets
t Upgrade collector and emitting elec-
trode rapping systems
t Replace the ESP internals
t Add an additional field or additional
plate area to the ESP
t Convert part of the ESP to a baghouse
(COHPACII)
1
t Convert existing ESP into baghouse
After reviewing the basic size of NIP-
SCOs ESPs, it was decided, based on S&L
judgment, that upgrades under consider-
ation would include wider plate spacing,
improved rapping systems, rigid elec-
trodes, and high-frequency TR sets. As
it is S&Ls opinion that each of the ESPs
(with the exception of MCGS Unit 12)
can be upgraded to provide reduced FPM
emissions, more capital-intensive op-
tions, such as the COHPACII or conver-
sion of the ESP into a baghouse, were not
evaluated further.
Implementation of Baghouse for
Particulate Compliance
The underlying reason to upgrade the
existing ESPs was that the sizes of the pre-
cipitators (normally described by SCA)
are quite large. With upgraded capability,
we would expect sufficiently low particu-
late emissions that should allow NIPSCO
to continue to produce outlet FPM emis-
sions in compliance with MATS Rule
limitations in the future.
A baghouse addition to the units
would also represent a means to comply
with the particulate requirements of the
MATSRule. A number of utilities that do
not have large ESPs may utilize this op-
tion.
The following is a high-level analysis
of the cost difference to install baghouse
technology as compared to ESP upgrades.
S&L did not perform walkdowns for the
implementation of baghouse technology
at the NIPSCO units other than MCGS
Unit 12. Such walkdowns are necessary
to more accurately predict baghouse ar-
rangements and installation costs. How-
ever, S&L has been involved in a number
of baghouse retrofit projects over the re-
cent years and believes an analogous cost
based on the units size may prove illus-
trative. The vast majority of the costs for
baghouses scale with the volume of flue
gas being treated. The flue gas volume
is proportional to the heat input of the
unit, which is directly proportional to the
megawatts produced by the unit.
for RMSGS Units17 and18. These gener-
ous SCAs served as the impetus to inves-
tigate whether there might be benefit in
upgrading the installed ESPs to achieve
the MATSRule level particulate removal.
ESP Upgrade Options
There are several available ESP upgrade
options that may be capable of reduc-
ing the FPM emissions from the existing
1310pe_88 88 10/16/13 5:32 PM
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Exhaust Diffuser / Exhaust Plenum
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Table 2 shows the analogous capital
cost differences between the ESP up-
grades (which were scaled from bud-
getary quotes on similarly sized units
in June 2011 costs) and the baghouse
installation.
These costs do not include demoli-
tion costs of the existing ESPs once the
baghouse is operational. In addition to
capital cost, the baghouse option will
require an additional flue gas pressure
drop of roughly 4 to 6 inches w.g. This
will increase parasitic auxiliary power
and may require new induced draft
(ID) fans and re-enforcement of por-
tions of the flue gas path.
It is important to note that since de-
tailed assessments have not been made
on each unit, the costs for some NIPSCO
units may be less than the analogous
costs. Some ESP boxes may be candidates
for gutting and stuffing with baghouse
technology. This may provide some cost
savings over the values in Table 2. How-
ever, this may require longer outages to
install this option and would be highly
dependent on detailed condition assess-
ment of the current condition of ESP and
Without taking into account the site-
specific constraints of the individual
units, such as potentially longer duct-
work on some units due to where the bag-
house would have to be built, whether ID
fans would have to be replaced to provide
the additional pressure drop, whether
foundations would be more costly due to
unusual soil conditions, and so forth, the
costs for units similar in size to NIPSCOs
range from $150/kw to $200/kw. These
costs do not include AFUDC, taxes, own-
ers cost, or escalation, and are expressed
as 2011 dollars.
Source:
Station/Unit BGS 7 BGS 8 MCGS 12 RMSGS 14 RMSGS 15 RMSGS 17 RMSGS 18 Total
MW 160 320 470 430 470 360 360
ESP Upgrades $14.7M $29.3M N/A $46.3M $38.0M $41.8M $41.8M $212M
Baghouse Cost
($200/kW)
$32.0M $64.0M N/A $86.0M $94.0M $72.0M $72.0M $420M
Differential Cost $208M
Cost Comparison of ESP and Baghouses 2
1310pe_90 90 10/16/13 5:32 PM
H W MANY
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1310pe_91 91 10/16/13 5:32 PM
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92
Avoid water wash
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Solution: turboweb-media.com
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Meet us at Power-Gen International: Booth 51-73
- Inspccing 1Rs and cIcciicaI com-
poncns
- Inspccing loppcis wlcic possihIc
1liougl lc condiion asscssmcns,
wc wcic ahIc o ascciain a icasonahIc
dcciminaion as o lc sac of lc ESPs,
as wcII as lc numhci and ypc of icpaiis
la wouId hc ncccssaiy o csahIisl an
opciaing hasc moving foiwaid. In gcn-
ciaI, lc inspccions indicacd la lc
ESPs wcic in hcci condiion lan migl
olciwisc hc cxpcccd hascd siicIy on
lcii agc and opciaing lisoiy on IaigcIy
hiuminous fucIs and hIcnds.
More Particulate Testing Results
NIPSCO's csing piogiam cncom-
passcd aII of lcii coaI-fiicd unis in 2ull,
accoiding o lc FPM pioocoI caIIcd foi
hy lc MA1SRuIc IcgisIaion. WliIc mos
of lc NIPSCO uni sack cs icsuIs aic
cuiicnIy hcIow lc FPM Iimi foi lc
MA1S RuIc, i is impoian o noc la
nonc of lcsc unis lavc dcmonsiacd
compIiancc wil lc MA1S RuIc Iimi
on a coninuous 3u-day ioIIing-avciagc
hasis using paiicuIac CEMS, wlicl is
lc mclod of compIiancc monioiing
NIPSCO las closcn in icsponsc o lc
MA1S RuIc. Sack csing icsuIs fiom
RMSCS Unil4 foi 2ull, wcic onIy mai-
ginaIIy hcIow lc MA1S RuIc Iimi foi
FPM. Emissions fiom MCCS Unil2 aic
significanIy liglci lan lc MA1SRuIc
Iimi foi FPM.
Comhining lc icsuIs fiom lc condi-
ion asscssmcns, lc Iacs cmission cs-
ing, and lc ouagc sclcduIc hcfoic lc
MA1S RuIc compIiancc dac, a sciics of
upgiadcs and ichuiIds of lc ESPs wiII hc
dcvcIopcd on a uni-hy-uni hasis.
MERCURY CONTROL
Wlcn coaI is comhuscd in a hoiIci,
lc Hg conaincd in lc coaI is icIcascd
picdominanIy in licc foims: paiicu-
Iac-hound mcicuiy (Hg
p
), ionic mcicuiy
(Hg+
2
), and cIcmcnaI mcicuiy (Hg
u
).
ducwoik incinaIs, and lcii ahiIiy o
copc wil lc incicascd picssuic icquiic-
mcns of lc iciofi haglouscs.
Foi lcsc icasons, S&L las iccom-
mcndcd compIiancc liougl a piogiam
of upgiading lc ESPs liouglou NIP-
SCO's fIcc (wil lc cxccpion of MCCS
Uni l2, wlicl is oo smaII o hc cffcc-
ivcIy upgiadcd).
ESP Condition Assessment
Mos of lc suhjcc ESPs lad hccn in
scivicc foi 2u o 3u ycais. In oidci o dc-
ciminc lc cuiicn sac of icpaii of lc
ESPs, a condiion asscssmcn cvaIuaion
on cacl ESP was undciakcn. Piccipia-
ois wcic inspcccd hascd on sloi-ou-
agc oppoiuniy. Inspccions incIudcd:
- Asscssing coiiosion oi maciiaI lin-
ning in kcy aicas
- Mapping misaIigncd and coiiodcd
pIacs and cmiing cIcciodcs
- Inspccing incinaI suppoi siuc-
uics and cIcciicaI insuIaois
- Inspccing iappci syscms
1310pe_92 92 10/16/13 5:32 PM
Founded in 1988, PIC has been a leader in the
power generation industry for over 20 years. We
are experts at managing multi-faceted projects
including start-up and commissioning, operations
and maintenance, installation, turbine outages,
mechanical services and technical services.
Combine these capabilities with our responsive
approach and global resources, and its easy to
see why those who know choose PIC.

25
The Best Of The Best

www.picworld.com
YEARS EXPERIENCE
READY TO MANAGE
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POWER PROJECT.

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Visit us at POWER-GEN International in booth 2321.
1310pe_93 93 10/16/13 5:32 PM
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involve converting elemental mercury to
water-soluble, ionic mercury, for capture
in a downstream FGD. Others involve
adsorption of mercury on activated car-
bon by injection of carbon in the flue gas.
Units with wet FGD may also require ad-
ditives to retain captured mercury in the
FGD byproduct if re-emission is evident.
NIPSCOs units have not shown evidence
of re-emission under testing performed
to date.
The speciation of the mercury plays a
significant role in the ease of its capture.
The conversion of elemental mercury to
oxidized (ionic) mercury depends upon
several factors:
t Cooling rate of the gas
t Presence of halogens or SO
3
in the
flue gas
t Amount and composition of fly ash
t Presence of unburned carbon
The strategy first developed to address
Hg emissions used a layered approach.
As stated previously, all the subject
units will have FGD installed prior to
the MATS Rule compliance date. Early
data for the units firing bituminous fuel
showed that the 30-day rolling aver-
age for Hg emissions was below the
MATS Rule compliance limit. It was be-
lieved that with slight fuel variations, fuel
additives represented a cost-effective op-
tion to increase the amount of oxidized
mercury that would be collected by the
FGD system and, therefore, lower the
outlet Hg emissions. This was especially
true for RMSGS Units14 and 15, which
are in the process of installing wet FGD
systems and fire a high percentage of
western PRB fuels. The PRB fuels do not
have sufficient halogen content to ensure
that a large majority of the mercury ends
up in the oxidized form, which is readily
collected in a wet FGD system. Because of
the fuel mix of the subject units, it is also
planned to install ACI systems to trim the
Hg emissions, if needed.
The amount of each form of mercury that
develops during combustion depends on
a number of factors, including other con-
stituents of the coal itself, such as the hal-
ogen content. The various types of mer-
cury formed are referred to as speciation.
Particulate-bound mercury exists in
solid form, is typically a small fraction of
the mercury present, and is removed to a
significant degree by conventional par-
ticulate control equipment.
Elemental mercury is insoluble in wa-
ter and is not removed to a great extent
in normal particulate control devices or
in an FGD system. In contrast to elemen-
tal mercury, oxidized mercury is highly
water-soluble. Downstream FGD systems
readily capture oxidized mercury. The
formation of oxidized mercury is directly
related to the halogen (chlorides, bro-
mides, fluorides) level in the coal. NIPS-
COs FGD units collect oxidized mercury
present in the flue gas.
Some mercury removal technologies
1310pe_94 94 10/16/13 5:32 PM
1310pe_95 95 10/16/13 5:32 PM
www.power-eng.com
96 For info. http://powereng.hotims.com RS# 71
Advanced
CORMETECH
Technology
S
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olutions
*N=xtG=N Hi-ACTive
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catalyst
for superior NOx ControI
*N=xtG=N COMET
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catalyst
Hg Oxidation soIution
*N=xtG=N SDA
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for UItra-high NOx
removal and low NH
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Slip
*N=xtG=N Advanced ModuIe
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pressure drop solution
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919-620-3000
www.cormetech.com [email protected]
CORMETECH offers a full
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of your SCR System
C
L
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A
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G
H

I
N
N
O
V
A
T
I
O
N
Testing of Fuel Additives
Fuel additive testing was undertaken by NIPSCO to con-
firm that the fuel additives adequately oxidized the Hg and
that the FGD system collected sufficient mercury to main-
tain the Hg emissions below the 1.2lbs/TBtu MATSRule
compliance limit. The results of the testing were mixed.
Section 45 Tax Credit Additives
Section45 of the U.S. tax code was designed to stimu-
late early NO
X
and Hg reductions utilizing coal treatment.
RMSGS Unit14 was the only NIPSCO unit to run a dem-
onstration test with tax credit additives. The main focus
of this demonstration was to evaluate whether additives
could be used to meet the requirements of the Section45
tax credit. In order to qualify for the Section45 tax credit, a
fuel additive has to concurrently reduce NOX and mercury
emissions from the unit. The preliminary results of this
test show that the demonstration was successful, which
suggests that mercury-oxidizing fuel additives would ef-
fectively oxidize the mercury present in the flue gas.
Commercial Fuel Additives
NIPSCO also began commercial fuel additive testing in
2012. Fuel additives were tested on BGS Units7and8 in
June of 2012; the results of this testing showed that while
additional mercury was converted to the oxidized form,
additional mercury removal may be required to meet
the MATS Rule requirement. Recent fuel additive testing
on RMSGS Units 17 and 18 has shown higher mercury
emissions (particularly at higher loads) than the histori-
cal CEMS data would indicate. Analyses are pending and
no root cause for the differences has as of yet been deter-
mined. At the time of this paper, it is believed that addi-
tional mercury control technologies will be required for
NIPSCOs units to comply with the MATSRule.
Meeting Mercury Emissions Limit
The mercury MATS Rule emissions limit will be
achieved through a multi-faceted strategy. Existing ESPs
and the planned future upgrades to the ESPs will remove
a portion of the particulate-bound mercury. (In addition,
depending on the unburned carbon level of the fly ash,
some of the oxidized mercury may also be collected in the
ESP.) A significant component of oxidized mercury remov-
al will occur in the existing pollution controls and planned
FGD systems. The availability of oxidized mercury will be
improved with the utilization of fuel additives, which are
designed to increase the amount of oxidized mercury in
the flue gas. Finally, an ACI storage and injection system
will be installed to complete the mercury emission reduc-
tion strategy. The mercury reduction system will be de-
signed to achieve continuous compliance of the mercury
emission standard via ACI, along with mercury oxidation
and removal in existing and new pollution controls, while
managing operations and maintenance costs by selecting
1310pe_96 96 10/16/13 5:32 PM
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1310pe_97 97 10/16/13 5:32 PM
www.power-eng.com
98
FESSENHEIM - Feedwater Heater
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be accomplished by the addition of ACI
upstream of the ESPs. The goal of the cur-
rent strategy is to minimize the amount
of ACI needed (optimize ACI usage). For
units that burn either high-sulfur bitu-
minous fuels or a significant bituminous
portion of their coal mix, SO
3
control to
acceptable levels through the use of re-
agent injection, may be needed, to ensure
the ACI usage is effective. (SO
3
competes
with mercury for active sites on the ACI.)
The design of the ACI injection systems
will be based on equipment sized to re-
move all the required mercury to meet
the MATS Rule requirements without
any removal by the FGD system. Due to
the cost of compliance via activated car-
bon alone, the system will be designed
to optimize (minimize) the amount of
ACI added, while removing as much Hg
as possible in the FGD and other emis-
sion equipment. To this end, S&L has
reviewed the impact that ACI and dry
sorbent injection (DSI) will have on
particulate emission levels. Based on the
size of the existing ESPs and their per-
formance testing completed to date, the
additional particulate loading should be
accommodated without problems. Spe-
cific loadings will be incorporated into
the ESP design upgrades and will be fac-
tored into project-specific guarantees and
warranties.
SUMMARY
By utilizing existing emissions control
systems to the greatest extent practical,
NIPSCO can leverage its previous envi-
ronmental investment for future emis-
sion reductions. This strategy is being
achieved through an iterative process of
utilizing existing emissions data to devel-
op a flexible compliance strategy, while a
parallel path is forged for obtaining ad-
ditional emissions data and testing por-
tions of the strategy in a timely manner to
allow the maximum amount of schedule
flexibility.
the mix of options that meets the mercu-
ry limits and minimizes cost. S&L recom-
mends that ACI testing on selected units
be incorporated into the schedule in an
appropriate time frame to allow for con-
firmation of ACI effectiveness in mercury
removal.
The specific mercury compliance strat-
egy selected for each unit will include a
combination of these options, and will
account for unit-specific operating con-
ditions (e.g., fuel composition, tempera-
tures, etc.). The strategy will attempt to
first utilize any naturally occurring mer-
cury oxidation due to the halogen con-
tent in the fuel and the ability of the ESP
and FGD collection to reduce mercury
emissions. Secondarily, fuel additives,
where shown to be effective, will be uti-
lized to achieve incremental oxidation,
which should lead to additional mercury
removal in the existing systems. Finally,
if further mercury removal is required to
meet the MATSRule requirements, it will
1310pe_98 98 10/16/13 5:32 PM
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1310pe_99 99 10/16/13 5:32 PM
100
www.power-eng.com
Wind farm developers must consider the environment in which
their turbines will operate and make wise decisions about
how their selected technology will function in all expected and
unexpected weather conditions. Photo courtesy of Alstom.
1310pe_100 100 10/16/13 5:32 PM
101
www.power-eng.com
A
s renewable energy sources continue to
gain momentum and drive the electri-
cal grid to a more intelligent and reliable
source of power, integrating the right
components and peripheral systems
is essential to reliability. As most renewable systems
are located in outdoor and potentially harsh environ-
ments, critical attention must be paid to the suitability
and robustness of the equipment to be installed in these
environments. Since this equipment is only as reliable
as its power source, backup power is often required in
addition to the utility power source.
As an example, wind turbine control systems are
essential to their operation and safety. The function
of these systems provides vital control of the turbine
and incorporates power-sensitive state-of-the-art elec-
tronics that demand absolute reliability. Yet they are
installed in locations subject to every form of weather
conditions from the extreme lows of the Arctic to the
excessive heat of the desert.
The most essential function of a wind turbine con-
trol system is the continuous control of wind turbine
blade speed and braking.
In most new turbines, the pitch of the blades con-
trols the output frequency of the AC power being gen-
erated in addition to bringing the blades to a complete
stop in high wind conditions. An electronically con-
trolled braking system assures the blades are locked
in stopped state. Should the brakes be applied before
Protecting
Wind Turbines

in
EXTREME
Temperatures
BY MICHAEL A. STOUT, FALCON ELECTRIC
the rotor speed is below allowed braking speed, the brakes
would be damaged. Without these vital controls, the wind
turbine blade rotational speed could reach a runaway
condition, causing the complete destruction of the entire
turbine.
Adjacent property damage and loss of life could also re-
sult. A power backup system is demanded to assure these
vital control systems remain viable in the event of the loss
of the primary utility power source.
To achieve the full functionality of the wind turbine
there are a large number of electrical and electronic equip-
ment elements required to ensure the safe, reliable genera-
tion of power. These include:
t Main control computer, I/O modules, relays and
components for monitoring and control of the wind
turbine
t Equipment dedicated to the continuous remote mon-
itoring of wind turbine operation
t The hub computer to control pitching of blades
t Frequency converter, yaw motor protection systems
t Power converter (full or dual-fed), filters, phase com-
pensation electronics
t UL Listed, wide-temperature range online uninter-
ruptible power supplies (UPS)
t Communications computer, network and SCADA-
monitoring and control equipment
t High voltage, medium voltage and low voltage distri-
bution control equipment
As stated prior, due to the wind turbine locations they
1310pe_101 101 10/16/13 5:32 PM
102
For info. http://powereng.hotims.com RS# 75 For info. http://powereng.hotims.com RS# 76
Duke Energy Florida is seeking proposals to supply approximately
1,640 megawatts (MW) of power generation beginning in 2018.
The request for proposal (RFP) will be issued on Oct. 8, 2013.
Interested bidders must obtain the RFP to participate and will be
required to get initial RFP information from the Web site at duke-
energy.ccm/NcridaRFP.
Proposals must be received by 3 p.m. EDT on Dec. 9, 2013.
Proposals will compete with Duke Energys self-build option consisting
of a 1,640 MW (net summer) combined-cycle natural gas unit to be
located in Citrus County, Fla. The proposal will have an in-service date
in 2018 consisting of a minimum of 820 MW capacity available by
May 1, 2018, and the balance in service no later than Dec. 1, 2018.
An RFP pre-release meeting is planned for Oct. 2, 2013,
and a meeting for interested bidders will be held on
Oct. 18, 2013. Both meetings will take place from 1-3
p.m. at the Marriott Westshore, 1001 N. Westshore Bld. in
Tampa, Fla.
Upon completion of screenings and evaluations, a short list of
proposals will be announced in March 2014. Finalists are expected
to be named by May 2014 and the award announcement is planned
for August 2014.
Beginning Sept. 24, 2013, additional information about the RFP will
be available to prospective bidders on the Duke Energy RFP Web site
at duke-energy.ccm/NcridaRFP.
All inquiries about the RFP must be directed in writing to:
Duke Energy Florida reserves the right to revise the schedule at any time, at the
companys sole discretion, and the company may shorten or lengthen the schedule
and revise the dates associated with the schedule.
Independent Monitor/Evaluator
Sedway Consulting Inc.
821 15th St.
Boulder, CO 80302
303.581.4172
[email protected]
DEF RFP Contact
Ben Borsch
Duke Energy Florida (DEF16)
299 1st Ave. North
St. Petersburg, FL 33701
727.820.4781
[email protected]
BATTERIES -
THE WEAKEST LINK
A standard off-the-shelf UPS is de-
signed for 0C to 40C office or computer
room environments, and therefore its re-
liability and ability to survive in a high-
humidity environment is suspect. Batter-
ies in these standard systems are typically
not rated for the higher temperatures that
are often encountered. At these high tem-
peratures, battery life can be reduced by
as much as 90 percent.
The majority of UPS products rated
under 10kVA use valve regulated lead-
acid (VRLA) batteries to provide backup
energy. Due to identical battery chemis-
tries and like construction, most battery
manufacturers specifications are very
similar. Battery manufacturers rate their
projected battery service life with the bat-
tery operating in a 25C environment.
are subjected to extreme temperatures
swings, typically from -30C (-22F) to
55C (131F). All of the electronic equip-
ment and circuits installed in the turbine
must be designed to operate reliably over
the entire temperature range.
As a source of backup power is essen-
tial, the online uninterruptable power
supply (UPS) designed
into the system must be
rated for these harsh tem-
perature environments.
Further, due to its key
function, it must have been
specifically designed to pro-
vide years of operation while
operating over the entire tem-
perature range.
As the UPS is located in the nacelle
at the top of the turbine tower with the
rest of the equipment, humidity and con-
densation can be another factor affecting
reliability.
The conformal coating of circuit
boards is required to protect circuitry on
the board from becoming shorted out by
moisture condensing on the board. These
environmental factors demand the use of
a special UPS.
The wind turbine control system handles several
essential functions, inlcuding the continuous
control of wind turbine blade speed and braking.
Photo courtesy of Falcon Electric.
1310pe_102 102 10/16/13 5:32 PM
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To meet the demand for wide tem-
perature range UPS and power conver-
sion products, a few manufacturers are
designing products that not only sur-
vive in these difficult environments,
but offer superior performance. For
these new products, the cost of owner-
ship is reduced through robust design
and by reducing the number of battery
replacements over the UPSs typical
12-to-15-year service life. Robust indus-
trial-grade, wider-temperature range
products may be found in standalone
UPS units or in prepackaged turnkey
NEMA rated enclosure systems.
Direct from the manufacturer, these
systems are ready for immediate instal-
lation and operation.
WORD TO THE WISE
WIND FARM DEVELOPER
Never use a UPS that is not rated for
the temperatures to be encountered in
the installed environment. If you require
a UPS that will be used in an extreme
operating temperature environment and
are confused by some manufacturers
specifications, verify the UPS has a UL
Listing stating the wide temperature
range desired. Using a UPS outside the
stated UL Listed temperature range can
invalidate the UL Listing status. This can
lead to reliability, code enforcement and
product liability problems.
However, newer technology VRLA
batteries can now yield a four-year life at
50C and up to 12 years at a 25C room
temperature per the battery manufactur-
ers stated service life projections.
Higher temperatures cause the acid-
based battery chemistry to become more
active, accelerating destructive factors
inside each battery cell. However, very
low temperatures slow down the chemi-
cal reactions and impair the batteries
ability to deliver current. This results in a
substantially shortened UPS battery run-
time when compared with the stated bat-
tery runtimes, which are typically stated
with the UPS operating at 25C.
Falcons UL, cUL and CE-Listed SSG Series UPS in a
NEMA enclosure. Photo courtesy of Falcon Electric.
1310pe_104 104 10/16/13 5:32 PM
1310pe_105 105 10/16/13 5:32 PM
www.power-eng.com
106
helped drive these changes, including
plant design improvements, required
upgrades to water management sys-
tems, and innovations to supporting
purification technology.
DESIGN EXTREMES
China and the U.S. represent the
two extremes of power plant designs.
China is the largest producer and
consumer of coal in the world and ac-
counts for nearly half of the worlds
coal consumption, according to the
Energy Information Administration
(EIA); it stands to reason that China is
investing predominantly in coal-fired
plants. In addition, owing to electricity
demand growth, nuclear power also is
receiving notable investment in China.
On the other end, the U.S., with more
moderate electricity demand growth,
is investing primarily in natural gas to
reduce its coal dependence while still
reticent to adopt a notable nuclear
power plant investment strategy.
Coal has been the largest source of
electricity generation for more than 60
years, but its annual share of genera-
tion declined from 49 percent in 2007
to 42 percent in 2011. Some power pro-
ducers switched to lower-priced and
more environmentally friendly natu-
ral gas that has about half the carbon
dioxide emissions of coal, according to
EIA data.
The Environmental Protection
Agency (EPA) in 2012 proposed the
first Carbon Pollution Standard for
New Power Plants. This new stan-
dard would set national limits on the
W
hile industri-
alization and
p o p u l a t i o n
growth create
an ever-greater
need for electricity, power-generating
technologies continue to drive in-
creased fuel efficiency, flexibility and
reduced air and water emission. To
achieve this, water must be optimized
in power generation to enhance effi-
ciency of operations and minimize the
environmental impact.
Each goal has influenced plant de-
sign and subsequently plant water
management and the supporting tech-
nologies.
This water vs. energy nexus is a ma-
jor driver of innovation in the power
industry. Many recent advances have
COOLING TOWERS:
How Regulations will Drive
Innovations in Plant Design,
Water Management Systems
BY STEVE ROSENBERG, THE DOW CHEMICAL CO.
In many parts of China and other select
regions of the world with poor water
availability, air cooling is being adopted in
place of water cooling.
Author
Steven Rosenberg is a Research Fellow
for Dow Water and Process Solutions
with more than 28 years of industrial
experience in the development of ad-
vanced materials. His main focus is on
developing breakthrough innovations for
water treatment technologies.
1310pe_106 106 10/17/13 9:05 AM
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1310pe_107 107 10/17/13 9:05 AM
www.power-eng.com
108
Source: Energy Information Administration International Energy Statistics.
1
Chinas Electricity Generation by
Fuel Type, 2000-2010 Conventional Thermal = Coal
4,500
4,000
3,500
3,000
2,500
2,000
1,500
1,000
500
0
T
e
r
a
w
a
t
t

H
o
u
r
s
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Year
Conventional Thermal
Hydroelectric
Nuclear
Other Renewables
of cooling systems.
During the past 40 years, improved
fuel efficiency has driven fossil de-
signs with ultrasupercritical steam and
increased steam pressures and tem-
peratures. Fuel flexibility has facili-
tated the development of combined-
cycle designs that lower water usage.
This new development has been par-
ticularly helpful in regions with water
scarcity. These regions have been at
the forefront to drive early adoption
of recirculation water
cooling towers and
the use of air cooling
instead of water.
A major design
trend that affects
steam generation for
fossil fuels is the use
of supercritical steam
generators. By operating at higher pres-
sures and temperatures, fossil plants
become more efficient and require
less fuel consumption, having both
cost and environmental emissions
benefits. To achieve such designs, the
required water quality has increased
dramatically. In older nonsupercritical
designs, water is boiled, the steam sep-
arates and is then sent to spin steam
turbines. Minerals dissolved in water
will not boil, and the water reservoir
(drum system) can be bled periodical-
ly to remove unwanted contaminants.
Supercritical designs send 100 per-
cent of the feed water to the turbines
without an intermediate water reser-
voir. As a result, all minerals dissolved
in the water will end up in the steam
and can form scale on the turbines and
hurt system operation and damage ex-
pensive equipment. The result is a high
dependency in supercritical designs on
very high-purity water. Ion exchange
resins are the predominant condensate
polishing technology, and there has
been continuous innovation in these
systems to meet the higher water-qual-
ity demand.
A second design trend that affects
steam generation is the adoption of
combined-cycle plants where natural
gas is the fuel. The combustion prod-
ucts are gases that directly turn the
gas-powered turbines while they pro-
vide heat to create steam for a steam
turbine, hence the name combined
amount of carbon pollution power
plants can emit, which applies only
to new fossil fuel-fired electric utility
generating units. This will help current
progress continue toward a cleaner,
safer and more modern power sector,
according to the EPA.
There are four generally recognized
ways to reduce carbon emission via the
choice of fuel source:
1. More efficient boiler designs that
use less coal per unit of electricity;
2. se of natural gas, which has half
the CO
2
emissions of coal;
3. Use of biomass fuels, which are
treated as having zero emissions
because they are renewable; and
4. Use of alternative technologies
with low to zero emissions, such
as hydroelectric, geothermal, so-
lar, wind and nuclear power.
Nuclear power is the most mature
fuel source and generates 16 percent of
all world electricity.
DESIGN TRENDS FOR
FOSSIL PLANTS
With two-thirds of the planets elec-
tricity coming from burning fossil fu-
els, some of the greatest changes are
on fossil power plant designs. Fossil
plants typically have multiple water
treatment systems:
a demineralization
system to provide
water for steam gen-
eration; a condensate
polishing system to
repurify condensed
steam for reuse in
the steam system; a
cooling tower to cool steam and a flue
gas desulphurization system to pre-
vent toxic volatile emissions. The need
for higher efficiency of operation and
lowered environmental emissions has
led to design changes in each subsys-
tem with the greatest changes in the
method of steam generation and type
A major design
trend that affects
steam generation
for fossil fuels is the
use of supercritical
steam generators.
1310pe_108 108 10/17/13 9:05 AM
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Announcing the
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performed only when necessary, reducing wear.
Pinpoints the failure of any module or peripheral
in the system to simplify repair.
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Source: Energy Information Administration.:
2 Net Generation for All US Sectors, Monthly
US Conventional Thermal = Migration to Natural Gas
500,000
400,000
300,000
200,000
100,000
0
T
h
o
u
s
a
n
d

M
W
h
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
Year
Conventional Hydroelectric Nuclear Natural Gas Coal All Fuels
1310pe_110 110 10/17/13 9:05 AM
1310pe_111 111 10/17/13 9:05 AM
112
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cycle for the different types of tur-
bines used. This reduces water demand
for power generation because steam is
not required for all the turbines. This is
a strong design trend in the U.S. where
retired coal fired plants are being re-
placed wherever possible by natural
gas and other renewable sources of
fuels.
Cooling system design has under-
gone major changes where there is se-
vere water shortage. Cooling the steam
back to condensate is essential to drive
the pressure gradient that spins the
turbine. Typically, water is cooled to
less than 55 C. Where practical, such
as near large rivers or the ocean, water
can be sent through a cooling tower
in a single pass. This consumes large
quantities of water and is only practi-
cal if the power plant does not disturb
the natural environment or compete Source: U.S. Geological Survey Circular No. 1268, 2000.
3
Total Withdrawals
Trends in Total Water Withdrawals by Water-use
Category, 1950-2000 (Total withdrawals for rural domestic
and livestock and for other industrial use are not available for 2000.)
300
250
200
150
100
50
0
500
450
400
350
300
250
200
150
100
50
0
W
i
t
h
d
r
a
w
a
l
s
,

i
n

B
i
l
l
i
o
n

G
a
l
l
o
n
s

p
e
r

D
a
y
T
o
t
a
l

W
i
t
h
d
r
a
w
a
l
s
,

i
n

B
i
l
l
i
o
n

G
a
l
l
o
n
s

p
e
r

D
a
y
1
9
5
0
1
9
5
5
1
9
6
0
1
9
6
5
1
9
7
0
1
9
7
5
1
9
8
0
1
9
8
5
1
9
9
0
1
9
9
5
2
0
0
0
Year
Public Supply
Rural Domestic and Livestock
Irrigation
Thermoelectric Power
Other Industrial Use
1310pe_112 112 10/17/13 9:05 AM
Dont get
caught with
your plants
down
Reduce risk and accelerate protability with Invensys.
Despite aging assets, uctuating fuel prices and mounting market pressures, you must still
keep your plant online meeting demand. Consider ultra-reliable Invensys technology to
deliver the operational integrity, insight, and agility you need to amplify the contributions
of every individual in your plant. Be compliant, competitive and protable.
See how at PowerGen booth #3121, or visit
www.invensys.com
Copyright 2013. All rights reserved. Invensys, the Invensys logo, Foxboro, Triconex, SimSci, Wonderware, and Avantis are trademarks of Invensys plc,
its subsidiaries or afliates. All other brands and product names may be trademarks of their respective owners.
1310pe_113 113 10/17/13 9:05 AM
of cooling water. Recycling results in
salinity increases in the cooling tower
owing to evaporation. It is possible
to occasionally blow down or bleed
off mineral-enriched water, but that
water must be treated
further.
This has created
the need for brine
concentration sys-
tems to reduce dis-
posal and recover as
much water as practi-
cal. Reverse osmosis
has been the technology of choice for
the primary concentration stage.
WATER STRESS, CO
2

EMISSIONS DRIVING
DESIGN
Because fossil power generates one-
third of the worlds CO
2
emissions,
more countries are implementing
strict environmental standards. Where
coal will be used, supercritical designs
are the standard; however, wherever
possible, natural gas and renewable
energy sources are being adopted.
Water shortages worldwide will
continue to drive innovation in fossil
plant design and accelerate the adop-
tion of alternative power generation
technologies. Using the U.S. as an ex-
ample, industrialization has driven
a change in water usage. During the
1950s, agricultural consumption used
the most water, but now it is electric-
ity generation. As more countries in-
dustrialize, they will undergo similar
trends as industry competes with hu-
mans for water access. This already is
playing out in China as seen by the
trend to air-cooled vs. water-cooled
towers in power plants.
for water usage with the needs of hu-
man consumption.
In many parts of China and other
select regions of the world with poor
water availability, air cooling is being
adopted in place of
water cooling. Con-
densate temperatures
often exceed 60 C on
air-cooled systems.
This places severe de-
mands on traditional
ion exchange resins
used to purify the
condensed steam before cycling back
to the steam generation system, which
typically are unstable at these elevated
temperatures. Manufacturers of ion ex-
change resins continue to innovate to
meet these challenges.
An alternative to air cooling for
water-starved regions is the recycling
During the 1950s,
agricultural
consumption used
the most water, but
now its electric
generation.
1310pe_114 114 10/17/13 9:05 AM
Potential is limitless.
An idea has no momentum until talented people start
chasing it. Its then that one begins to glimpse whats
possible, and the future begins to take shape. Today,
we are thousands of people sharing ideas, dedicated to
nding new ways to meet the needs of an ever-demanding
Power sector. Which is why, when it comes to nuclear,
natural gas, coal, renewables, hydroelectric and electric
delivery systems, more people are turning to us to get it
done. We are URS.
For more information, please contact 609.720.2000.
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1310pe_115 115 10/17/13 9:05 AM
www.power-eng.com
116
fuel flexibility. Advancements in todays
optimization technologies are allowing
plant operators to achieve their changing
objectives while also strategically control-
ling plant emissions and overall operat-
ing efficiency.
IMPROVING THE
TECHNOLOGY
Since optimization technology was in-
troduced nearly 15 years ago, there have
been misconceptions among some that
combustion optimization systems are
perhaps an outdated approach to increas-
ing plant efficiency and improving plant
availability. Currently, these misconcep-
tions are being dispelled due to improved
technology generating new and better re-
sults. Researchers and engineers at energy
supply companies across the globe are
discovering that they now have the abil-
ity to strategically assess operational
data and functionality at each individual
plant before the optimization process be-
gins. This allows operators to determine
the best optimization approach based on
the plants goals.
A goal of operating at the most profit-
able level demands a high degree of flex-
ibility, high efficiency, high availability
and low emissions. One of the most cost-
effective and common ways to improve
boiler efficiency is to apply primary mea-
sures based on optimized combustion
adjustments. However, this optimization
approach is usually restricted by the pow-
er plant operators limited knowledge of
actual combustion conditions. These un-
certainties about the actual combustion
process lead to situations where opera-
tors keep most boiler settings constant,
although considerable variations occur
with respect to fuel properties, fuel flow
I
n todays power generation
market, steam power plants are
focused on identifying ways to
operate more efficiently and ef-
fectively to reduce losses, maxi-
mize reliability and boost revenue. Due
to continually changing demands by en-
vironmental and governmental authori-
ties as well as consumers, plant operators
and engineers are continuously seeking
more effective and sophisticated technol-
ogies to support this focus and gain an
edge in meeting todays complex electric-
ity generation market.
Intelligent combustion optimization is
one method proven to accomplish plant
performance improvements such as in-
creased efficiencies, reduction in emis-
sions, improved availability and greater
Plant Performance
Improvements by
Enhanced Combustion
Optimization
BY DR. SUDHA THAVAMANI, SIEMENS ENERGY, INSTRUMENTATION,
CONTROLS & ELECTRICAL, AND JIM STEWART, LACYGNE STATION,
KANSAS CITY POWER & LIGHT CO.
Kansas City Power & Light installed Siemens combustion
optimization technology at its LaCygne Unit 2 Power Plant
and achieved significant NOx reductions while improving
the overall combustion and unit heat rate.
1310pe_116 116 10/17/13 9:05 AM
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To find a flexible solution for your power plant,
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1310pe_117 117 10/17/13 9:05 AM
www.power-eng.com
118
straightforward when it comes to op-
erations and maintenance training. Each
system is comprised of measurement sys-
tems and combustion optimization con-
trols. Some companies, such as Siemens
Energy, use modules for laser-based mea-
suring technology, distribution calcula-
tion based on computer-aided tomogra-
phy (CAT) procedure and combustion
optimization controls based on both
mathematical modeling and neural net-
works.
But the tools are only part of the trade.
The key factor in promoting cleaner,
more efficient power plant operations
while still leaving space for more flexible
operation is to truly take into account the
appropriate recipe of data and control to
properly determine the best optimization
approach.
Major strides have been made in this
realm. Offering qualitative and quantita-
tive audits of system controls at the onset
of the problem was discovered to be the
best way to ensure plants are producing
the correct data to determine the best ap-
plication for the use of technology. For
instance: if a plant operator is aware of a
very specific operational problem such
as slagging, derates or heat rate gain and
has data that can pinpoint it, he or she
can rely on classic optimization controls
to alleviate the issue.
However, immediate availability of
such precise data is rarely the case. When
little can be directly measured on a plant
operation, more advanced solutions are
needed to help solve what is a far more
complicated problem. In this situation,
laser-based or even hybrid measurement
systems in unison with the appropriate
closed-loop combustion optimization
solutions will produce the maximum
achievable benefits.
APPLICATIONS IN ACTION
In recent years, a growing number
of modernized combustion optimiza-
tion success stories have been surfacing
around the world, delivering renewed
and warranted faith in the technology.
From the U.S. to Germany and to China,
plant operators are realizing the benefits
of using intelligent combustion optimiza-
tion technology to fix specific problems
or even to ensure their plant is running
more cleanly and efficiently.
Application 1: Lowering Coal-Fired
NOx with Robus Hybrid Optimization
In 2011, operators at Kansas City Power
& Lights (KCP&L) LaCygne Unit 2 Power
Plant were looking for a way to reduce
stack emissions of NOx. This 30-plus-
year-old 720-MW balanced draft, Caro-
lina-type, B&W wall-fired unit has seven
MPS-89 pulverizers, each having eight
coal outlets that make up an individual
row of burners. The burners are second-
generation, dual-register, low-NOx burn-
ers. There are seven rows of burners, each
with a compartmental wind box that has
two controllable dampers. The unit did
not have an overfire air (OFA) system.
LaCygne operators turned to Siemens
to address their concerns. In this in-
stance, the optimization process used a
hybrid structure of closed loop controls
with neural network optimization tech-
nology, integrated with a laser-base com-
bustion measurement system.
The integration process began first
with the installation of the laser measure-
ment grids inside the combustion cham-
ber. Next, parametric testing was done on
the conditions of the boiler followed by
deduction and analysis of spatial distri-
butions to determine the required con-
trolled variables for the closed loop con-
trols engineering. Finally, the Siemens
combustion optimization control system
was integrated into LaCygnes existing
plant DCS System.
Model Based Controls Target Emis-
sion Reductions under Strict Opera-
tional Restraints
The laser-based measurement system
maps the concentration of in-furnace
CO, O2, H2O and temperature simulta-
neously in real time and directly in the
furnace. Laser transmitters and receivers
rate imbalances, load range or air flow
disturbances.
In general, insufficient monitoring
and control means that the operation
of the boiler is based on the use of cer-
tain combinations of global or indirect
variables, derived either from the recom-
mendations of the boiler manufacturer or
from the accumulated experience of the
operators of the specific plant. Combus-
tion optimizer technology was designed
to give operators a better understanding
of the plants data and how to prioritize
it to increase overall efficiency, but its
the proper application of that data that
makes or breaks the optimization pro-
cess. Today, more sophisticated technolo-
gies exist that allow software providers to
work with operators at the onset of the
problem, looking at data differently to
produce better, faster and smarter result
to combustion variables.
VARIABLES
IN APPLICATION
Though initially well received, early
optimizers began exhibiting systematic
issues and operators began turning them
off. Today, the importance of these tools
is being realized and efforts are under-
way to improve the older technology and
provide engineers and plant operators a
reason to trust the systems once more to
improve heat rate, lower emissions and
improve availability. Newer optimizer
systems feature more advanced controls,
control more data and are more adapt-
able to changing conditions. Simply
stated, newer upgrades feature a carefully
constructed recipe emphasizing only
the most relevant data and minimizing
the rest.
Modern combustion optimization
technologies provide closed-loop opti-
mization of fuel and air mixing by ma-
nipulating fuel and air levels to balance
combustion in the furnace. They are
software-based solutions that require no
more than minor modifications to me-
chanical equipment and are relatively
1310pe_118 118 10/17/13 9:05 AM
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up to 5000 psig (345 bar).
Full-penetration chamber welds meet ASME Section IX and
B31 construction and inspection requirements.
The stainless steel enclosing tube completely isolates the
switch magnet from the process environment, preventing
interference with the magnet, while allowing reliable
magnetic coupling with the attraction sleeve.
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Stainless steel
enclosing tube
(cutaway)
Magnet
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are arranged outside the boiler resulting
in a grid of laser beams crisscrossing the
furnace. Each path measures an average
value for temperature, O
2
, H
2
O and CO
simultaneously, and together the paths
are used to create a tomographic image
of this plane in the boiler that is also
displayed to the operators directly in the
control room.
Temperature and concentration distri-
butions are calculated from the measured
path averages with the aid of the CAT
procedure. CAT algorithm was used for
calculating certain characteristic distri-
bution data, e.g. values at different grid
points, averages, minimum and maxi-
mum values for different paths in the dis-
tribution, skewness, etc.
The laser measurement system is in-
tegrated into the Siemens Optimization
System Server, which is in turn connected
to the ABB Infi90 Plant DCS. These con-
nections permit access to measured data
from the existing DCS, such as coal and
airflows or CO and NOx in the flue gas,
by the combustion optimization process
and also facilitated the optimization of
process signals back to the DCS.
A watchdog signal allows communica-
tion verification between the optimizer
and the DCS. The process measurements
from the DCS along with the laser mea-
surements data from the boiler are used
to calculate the optimized values within
the Siemens optimizer. These values are
integrated into the plant DCS as biases to
the existing setpoints in the DCS, which
are transferred to the basic underlying
controls and to the field.
Safety measures are followed in se-
quence for incoming setpoint biases be-
fore they are used in control and boiler
processes. The operator can smoothly
switch the optimizer controls with the
ON/OFF switch. If the optimizer loses
connection to the DCS, the control inter-
face design automatically transfers con-
trol back to the plant DCS and control
room operators without introducing a
transient condition.
Distributing air properly is a critical
step in combustion optimization. The
objective behind CO balancing is to
uniformly spread the CO distribution
across the boiler. In wall-fired units, the
countermeasures involved in lowering
NOx include air and fuel staging. This
methodology reduces stoichiometry
during combustion and minimizes the
formation of both unburned fuel and
thermal NOx, improving the completion
of the combustion process in the boiler.
Hence the staged combustion helps in
better completion of the combustion pro-
cess in the boiler. At LaCygne, the staged
combustion technique for NOx control
involved the re-distribution of secondary
air (staged air) from the main combus-
tion zone to the top levels while reducing
air in the bottom levels of the furnace.
This moves the compartment air to the
air-starved regions in the furnace, and
improves the air/fuel mix within all re-
gions.
Neural Networks Control Multiple
Variables
Neural network technology can be
viewed as a multivariate nonlinear non-
parametric estimation tool. It shares a
descriptive term from biology in that
they are represented as networks of sim-
ple neuron-like processors. This highly
adaptive technology uses a unique com-
bination of neural network and complex
systems algorithms to learn the complex
interactions of process variables from his-
torical data.
The manipulated variables for the neu-
ral model used at LaCygne Unit 2 were
secondary air north/south damper posi-
tions, compartment airflow setpoint and
feeder speeds. Some of the input variables
comprise of laser measurement readings
of temperature, O
2
and CO profiles, and
unspecified basic conditions such as
load. The output variables include the
stack CO measurement. The primary tar-
get value for LaCygne was the Stack NOx.
With the help of the neural network,
the optimum manipulated variables for
the specified target of NOx reduction are
determined with due consideration of
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122
- Bcci ccniaIizaion of lc fiichaII
- Sagcd comhusion aclicvcd cmis-
sion icducions
1lcsc impiovcmcns wcic aiihucd
IaigcIy o lc comhusion haIancing con-
ioIs, fucI[aii saging conioIs and O
2
ic-
ducion conioIs. CoaI and aiifIow sag-
ing conioI soIuions foi conioIIing lc
disiihuion of aii and puIvciizcd coaI
fIow o individuaI hoiIci IcvcI icsuIcd in
Iowci cmissions. O
2
scpoin icducions
piovcd o hoos lc hcncfis of sagcd
comhusion pioducing cvcn Iowci NOx
cmissions.
Application 2: Enhanced Plant
Performance with Combustion Opti-
mization
A SPPA-P3uuu Comhusion Opimi-
zaion Syscm was aIso insaIIcd aImos
idcnicaIIy in 2ull a Uni 4 of Huancng
Rizlao Powci PIan, P. R. Clina and las
aIicady hoascd significan pcifoimancc
impiovcmcns. 1lis uni is a 66u-MW
angcniaIIy-fiicd, supciciiicaI hoiIci us-
ing sof-coaI fucI. 1o haIancc lc comhus-
ion, a cIoscd-Ioop opimizaion is dcIiv-
cicd hy manipuIaing fucI and aii IcvcIs
wil lc lcIp of Iasci mcasuicmcns,
wlicl piovidc lc kcy comhusion com-
poncns O
2
, CO, H
2
O and cmpciauic
simuIancousIy, diiccIy in lc fuinacc.
Paiamciic 1csing Lcads o Impiovc-
mcns in BoiIci Bclavioi
Duiing lc paiamciic csing plasc,
lc hclavioi of lc Rizlao hoiIci was
ohscivcd hy clanging and adjusing in-
dividuaI sccondaiy aii, sccondaiy auxiI-
iaiy aii, and SOFA dampcis. 1lc csing
and comhusion anaIysis slowcd la lc
uni's fiichaII was ofcn no in lc ccnci
of lc hoiIci wlcic i hcIongcd, cica-
ing an unhaIanccd lca iansfci o waci
waII and lcacis. 1lis aIso incicascd lc
pioducion of sIagging foi pais of lc
waci waII. 1csing aIso confiimcd la
lc non-lomogcncous disiihuion of
cxccss aii in lc hoiIci Icd o cfficicncy
Ioss in icgions wil oo mucl aii and had
comhusion in icgions of saivcd of aii.
1lc comhusion opimizaion conioIs
a Rizlao aIIowcd foi a numhci of siu-
aionaI impiovcmcns in lc hoiIci o
impiovc cfficicncy. Sccondaiy auxiIiaiy
aii dampcis lcIpcd o ccnci lc hoiIci's
fiichaII foi impiovcd lca iansfci and
icduccd sIagging. Impiovcd conioI of
SOFA dampcis faciIiacd a piopci O
2

haIancc foi moic unifoimcd disiihuion,
icduccd O
2
and Iowci cmissions. Sccond-
aiy houndaiy aii dampcis cicacd an im-
piovcd aii-o-fucI iaio foi moic unifoim
comhusion.
1lc fiichaII ccnciing, O
2
disiihuion
and comhusion haIancing conioIs cacl
lcIpcd o aIIow lc icducion of lc cxccss
O
2
foi incicascd hoiIci cfficicncy ovciaII.
1lis addiionaI Iogic using CO conccnia-
ion was impIcmcncd o dcciminc lc
O
2
scpoin coiiccion dcpcndan on lc
acuaI comhusion siuaion in lc hoiIci.
1lc CO vaIucs in lc fuinacc mcasuicd
consiains. 1lc consiains wcic icIacd
o maximum aIIowahIc sack CO and
opaciy. 1lc olci modcIing consiains
wcic o kccp lc oaI aii and lc sum of
fccdci spccds consan, a a givcn Ioad
condiion.
Optimized Results
Wil lc usc of lc SPPA-P3uuu
Comhusion Opimizaion cclnoIogy,
LaCygnc saw significan NOx icducions
wliIc impioving lc ovciaII comhusion
and uni lca iac.
AddiionaI hcncfis of using Comhus-
ion Opimizci a LaCygnc Uni 2 Powci
PIan incIudcd:
- Enlanccd and haIanccd comhusion
- Significan impiovcmcns in hoiIci
sIagging
- Bcci CO disiihuion in hoiIci
- SuppIcmcnaiy O2 icducion hascd
on lc haIanccd comhusion
- Impiovcd uni lca iac
1310pe_122 122 10/17/13 9:05 AM
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were reduced by 14.4 percent as a result
of lower excess O
2
while the CO and LOI
did not materially change.
REVALIDATING THE NEED
FOR OPTIMIZATION
The experiences at Unit 2 in LaCygne
and Unit 4 in Rizhao have shown that
the appropriate use of real-time com-
bustion optimization technology in
a coal-fired plant can definitively im-
prove combustion and heat rate while
reducing emissions and the potential
for lost generation. Both plants experi-
enced documented, improved efficiency
through optimizing their combustion. If
the technology is properly designed and
applied, plant operators and engineers
can make appropriate adjustments to
improve unit performance with mini-
mal training and eliminating the need
for costly mechanical changes. Improve-
ments to combustion optimization
through the years have validated a sec-
ond look at the software-based tools as a
means of improving plant efficiency and
lowering emissions.
References
1. Boiler Efficiency Calculation via
ASME PTC 4.1 Method
2. GB 10184-88 Performance Test
Code for Utility Boiler
TPRI conducted a boiler efficiency test
using GB 10184-88 standard method-
ology at full load and at partial load to
compare the boiler efficiency with com-
bustion optimizer OFF and ON. Per-
formance improvements attributed to
combustion balancing but not included
in the TPRI boiler efficiency calculation
such as lower auxiliary power require-
ments (from induced, forced and pri-
mary air fan loads) and increased steam
enthalpy were also calculated using TPRI
test data and ASME 4.1 standards.
The combustion optimizer improved
the performance by a total of 0.57 per-
cent at full load. A more balanced com-
bustion was achieved permitting the
excess O
2
to be reduced by 0.93 percent
based on the DCS setpoints. This result-
ed in the decrease of fan loads (induced/
forced draft and primary air), which
further diminished the auxiliary power
requirements by 293 KW/hr, or 0.05 per-
cent of the load. This reduction in aux-
iliary power led to the increase in the
amount of electricity available for sale by
the plant.
Also, at full load the steam enthalpy
increased as superheater and reheater
steam temperatures were enhanced as
a result of better combustion which in-
creased the steam turbine output by 0.07
percent overall. In addition, NOx levels
by the laser measurements, and the CO
after boiler from the DCS, were used to
determine the rated CO concentration.
The CO setpoint to the integral control
was determined as a function of the unit
load. The optimization controller was re-
stricted by the lower limit for O
2
reduc-
tion, which was based on the function of
unit load and had an absolute lower limit
from the O
2
setpoint characteristics from
the DCS. A reduction in O
2
was achieved
when the optimizer was switched ON.
An Improvement in Overall Efficiency
The combustion optimizer was tested
for different plant conditions like that of
different unit loads, different coal etc.
Additional results of using this opti-
mizer were clearly discovered:
t Better centralization of the fireball
t Better O2 distribution in boiler
t More O2 reduction based on the bal-
anced combustion, normally the O2
reduction is 0.7~1.1
t Reduced auxiliary power, reduced
coal consumption and increased
boiler efficiency
At the request of the management at
the Rizhao Power Plant, a third-party
evaluation of boiler efficiency improve-
ment achieved by Combustion Optimiz-
er was administered by Xian Thermal
Power Research Institute Co, Ltd. (TPRI).
1310pe_124 124 10/17/13 9:05 AM
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AUMA valve actuators are capable of providing multi-turn,
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Multi-turn capabilities include thrust acceptance up to
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1310pe_125 125 10/17/13 9:05 AM
www.power-eng.com
126
one might be tempted to assume that
re-powering an existing plant would
be a relatively simple contractual mat-
ter, when compared to the full con-
struction of a new greenfield project.
To the contrary, there are several
unique aspects of re-powering proj-
ects that create material risks beyond
those encountered in a typical green-
field EPC project. These additional
risks complicate the overall EPC con-
tracting approach for such projects,
and can present serious challenges to
D
riven by low natural
gas prices, permit-
ting efficiencies, and
political and eco-
nomic headwinds
against coal-fired generation, many
U.S. power companies are working to
increase the capacity of their existing
fossil-fuel facilities by re-powering
them as combined-cycle gas-fired facil-
ities. When considering the contracts
for the engineering, procurement and
construction (EPC) of these projects,
Author
Richard E. Chip Thompson II is the co-
founder of Mercer Thompson LLC, a bou-
tique law firm focused on serving com-
panies in the energy industry. For over 18
years, Thompson has represented energy
companies in the development, acquisition
and sale, and ownership and operation of
power projects.
A steam turbine being reassembled.
Photo courtesy of Sargent & Lundy
EPC Agreements
for

RE-POWERING
Projects
BY RICHARD E. THOMPSON II,
MERCER THOMPSON LLC
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www.power-eng.com
128
approach, where the Owner enters
into various engineering, equipment
supply, and construction contracts,
taking on the responsibility and risk
of managing the costs and schedule
of the overall project. At the opposite
end of the spectrum lies the turnkey
EPC contract between the Owner and
a single EPC contractor who takes sole
responsibility for delivering the entire
project on time and on budget. Be-
tween these poles are various alterna-
tives, and where a given Owner will
land between the two will depend
upon several inter-related factors.
These factors may include the breadth
of the Owners experience in major
project management, the depth of its
internal resources and capabilities,
the Owners risk appetite, the current
markets for major equipment and/or
turnkey EPC services, and limita-
tions of the projects economics.
This contract structuring issue is
certainly not unique to re-powering
projects. However, various aspects
of a re-powering project may further
complicate the Owners decision-mak-
ing process for solving the issue. For
example, if modifications or upgrades
will be required on the Existing STG
to prepare it for the envisioned com-
bined-cycle operation, there may be
good reason for the Owner to retain
the original equipment manufacturer
(OEM) of the unit to perform such
work. Perhaps the Owner views the
OEM as being more familiar with the
unit and thus more qualified for the
job. Or perhaps the OEM has patented
technology that only it can implement
into the unit as part of a necessary up-
grade. It could also be the case that
the OEM is willing to guaranty the
post-modification performance of the
Existing STG, a guaranty that might
not be forthcoming from a non-OEM
provider. Without such a guaranty,
there would be a considerable hole in
the overall power island performance
the classic turnkey risk allocation
model frequently pursued by facility
Owners, and favored by their lenders.
Contracts for these projects will fre-
quently require complex, customized
provisions that identify and allocate
responsibility for these risks, render-
ing any standard form greenfield EPC
contract inadequate. This article ex-
amines, from the Owners perspective,
several of the unique aspects and risks
presented by re-powering projects, and
suggests certain contractual strategies
for allocating or mitigating the same.
For the sake of illustration, this
article assumes the hypothetical re-
powering of an existing steam turbine-
generator (the Existing STG) into a
2x1 combined-cycle configuration,
by adding two heat recovery steam
generators (the HRSGs), and two,
new large-frame gas-fired turbines (the
New Units). It further assumes that
the project is to be undertaken at the
site of an existing power-generation
facility where other units are in opera-
tion, and that there will be multiple
points of interface between the new
project and the facilitys existing wa-
ter, steam, gas, electrical, control and/
or other critical equipment, systems,
instrumentation and infrastructure on
the site (the Existing Systems). De-
spite this assumed scenario, much of
this articles insights will also apply to
projects that involve the wholesale re-
placement of existing coal-fired units
with a new combined-cycle power
island, where Existing Systems will
remain in place to support the new
power island.
OVERALL
PROJECT DELIVERY
Contracting Structure
Any Owner considering an EPC
project must first decide which con-
tracting structure is appropriate for
overall project delivery. At one end of
the spectrum lies the multi-prime
guarantees, increasing the projects
risk.
Similar issues arise when the Owner
seeks to procure the New Units and
the HRSGs. Should one contract di-
rectly for those items? Or should one
retain a competent EPC contractor to
procure them, along with balance of
plant equipment? As a variation on
this theme, the Owner might contract
directly for these items with the inten-
tion of assigning these contracts to an
EPC contractor for management, if not
for a full turnkey wrap of schedule and
performance. Perhaps the New Units
OEM would be willing to provide (via
its own subcontract) the HRSGs as
well? In this event, the New Units
OEM might be willing to provide a
performance guarantee that covers
combined performance of the New
Units and the HRSGs one step away
from a full power-island performance
guarantee. If the New Units OEM is
also the OEM of the Existing STG, then
perhaps that full guarantee is within
reach. However, what if the Existing
STG OEM is a competitor of the New
Units OEM? Trouble in paradise?
Installation and Balance of Plant
Considerations
These are but a few of the several
considerations that an Owner can face
in the context of modifying or procur-
ing the major equipment components
for a re-powering project. However,
there is also much to consider beyond
the major equipment. For example,
an Owner must evaluate the merits of
various approaches for the engineer-
ing and design of the overall project.
This is no minor or risk-free task. The
engineering and design work will drive
decisions as to the specifications (and
thus potential sources) of the New
Units and HRSGs in the first place.
Such engineering and design must also
include the integration of the opera-
tions of the Existing Systems of the fa-
cility with the New Units and HRSGs,
1310pe_128 128 10/17/13 9:06 AM
1310pe_129 129 10/17/13 9:06 AM
www.power-eng.com
130
in a multi-prime contracting approach,
the Owner will want to be very careful
to address potential gaps between the
contracts, including as relate to con-
tractor responsibilities for work scope,
schedule delays and performance and
reliability guarantees.
INTERFACING WITH
EXISTING SYSTEMS
Many of the unique risks and issues
presented by re-powering projects re-
sult from the fact that key aspects of
the work involve physical interface
with existing systems, instrumenta-
tion and infrastructure on the site.
Examples may include cooling wa-
ter systems, compressed gas systems,
steam systems, condenser systems,
chemical feed systems, instrument air
systems, demineralization systems,
reheat systems and waste water treat-
ment systems. With reference to the
hypothetical re-powering project de-
scribed above, such Existing Systems
may be in place in support of the prior
operation of the Existing STG or other
major equipment at the facility. In ei-
ther case, modifications to the Existing
Systems will likely be required to inte-
grate the New Units and HRSGs into
the overall facility and to support the
future operation of the combined-cycle
power island. Even if the re-powering
specifying any required new civil, me-
chanical or electrical works, and modi-
fications to Existing Systems, as neces-
sary to support such operation. Thus,
the Owner must decide who will per-
form this complex and important work
and plan the stages of its performance.
Might the Owners in-house staff or an
outside engineering firm perform pre-
liminary engineering work in order to
establish initial parameters for scoping
the project and its costs? Or perhaps
the work would better be outsourced
to a preferred EPC contractors engi-
neering team, with the intention that
it would serve to underwrite certain
performance guarantees from such
contractor, were they to be selected for
the construction and installation of
the project?
Such construction and installation
work presents yet another area for
Owner analysis and planning. De-
pending on its internal resources, risk
appetite and other factors, an Owner
may elect to retain and manage some
or all of the required construction and
other trade labor on its own, while
other Owners would not hesitate to
outsource this work. The installation
work for the New Units and HRSGs
will require particular expertise and
focus, given the heightened risks of
project delays due to the complexity of
such installation and the risk of void-
ing OEM warranties if such work in
not properly performed.
Thus, these types of factors will
drive an Owners decision-making
process as regards contract structur-
ing for overall project delivery. Like
assembling a jigsaw puzzle without
the box-top picture as a guide, only by
gathering all of the pieces and consid-
ering the various possibilities for fit-
ting them together will an Owner be
able to develop a view as to the optimal
contractual structure for the project.
In instances where this analysis results
project involves the wholesale replace-
ment of existing generating units, in-
terface with and modifications to Ex-
isting Systems will often comprise a
key consideration for the project.
Existing System Operational Details
Such required interface gives rise to
several issues. As an initial matter, the
appropriate contractor(s) will need to
engineer the required interfaces with
the Existing Systems. In many in-
stances, such engineering will include
necessary modifications to the Exist-
ing Systems, as well as new equipment
additions, as necessary to support the
operation of the project (along with
continued operation of any other ex-
isting generating units at the site). To
perform all of this work correctly, the
contractor will require accurate data
concerning each Existing Systems
present location, configuration, condi-
tion and operational capabilities. This
may not always be a simple request.
Especially in older facilities, an Owner
may not have complete as-built draw-
ings depicting the location and con-
figuration of such systems, or if such
drawings exist, may not have complete
confidence in their current accuracy.
Further difficulties will arise to the
extent that such systems are enclosed
or underground, and thus not imme-
diately available for visual inspection.
The physical condition and/or opera-
tional capabilities of such systems may
also be in doubt, especially insofar as
their ability to support operation of
the combined-cycle power island with-
out negatively impacting other facility
operations.
Thus, to the extent that complete and
accurate data regarding the Existing
Systems is unavailable, the contractor
will face significant challenges in scop-
ing and performing the interface engi-
neering work. The contractor will also
have difficulty providing fixed pricing
for such engineering work, a difficulty
Many unique risks and
issues presented by
re-powering projects
result from the fact
that key aspects
of the work involve
physical interface
with existing systems,
instrumentation and
infrastructure.
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132
to the inclusion of excessive float time
in the project schedule.
One potential solution to these is-
sues is for the Owner and contractor
to develop together a detailed descrip-
tion of the assumed (as applicable) lo-
cation, configuration, condition and
operational capabilities of each of the
Existing Systems. The work to develop
this information may precede the exe-
cution of the primary EPC contract(s),
or may be included as part of a lim-
ited notice to proceed workscope that
precedes the commencement of full
work on the project.
The contractor can then more readily
establish fixed pricing and a more real-
istic project schedule, based upon the
express statement that the information
is presumed to be accurate. The con-
tract would further provide for change
that will also arise in providing pric-
ing for equipment procurements and
in-field construction work relating to
Existing System modifications. Own-
ers and their lenders often prefer fixed
pricing or other pricing limits as a mat-
ter of budget control. However, any
pressure to provide such fixed pricing
would basically require the contrac-
tor to develop its own estimates and
assumptions regarding the Existing
Systems, undoubtedly including con-
tingency fees designed to mitigate the
risk that their assumptions are proven
to be incorrect. In this case, the Owner
ends up paying the fees whether the as-
sumptions were correct or not. Such
risk issues are not limited to pricing.
Lack of accurate data regarding the Ex-
isting Systems can also create schedul-
ing uncertainties, potentially leading
order relief to the extent an Existing
System is not located or configured
as presumed, or, once accessed, is dis-
covered to require upgrades or proves
to be unable to operate in accordance
with its presumed operational capabil-
ities. To be clear, this approach does
ultimately cause the Owner to bear the
risk of unknown aspects of the Exist-
ing Systems. However, the Owner has
the opportunity to mitigate this risk
through data gathering and diligence
as would underlie its detailing of the
original assumptions.
At the same time, this approach
avoids the Owners paying unneces-
sary contingency fees and being sad-
dled with an extended project sched-
ule, as would otherwise likely be the
case were the risk to be entirely borne
by the contractor.
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1310pe_132 132 10/17/13 9:06 AM
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134
Existing System in a condition of being
demonstrably operable at that baseline
level of performance.
WARNING: OPERATING
FACILITY AHEAD
Property Damage
Beyond the issues created by inter-
faces with Existing Systems, there are a
number of risks inherent in a contrac-
tors performing work at an operating
generating facility. Near the top of
the list is the risk that the contractors
personnel will accidentally damage or
destroy existing systems or property
while working at the site. This risk
is of course present for any construc-
tion project, but is heightened when
the work involves workers, machinery,
heavy equipment and even cranes op-
erating in close proximity to operat-
ing power generation equipment. In a
typical greenfield project, the risk al-
location for property damage is fairly
straightforward. The contractor is
given care, custody and control of the
project, and will typically bear most
of the risk of property damage, at all
times until the project is turned over
to the Owner. Backstopping this risk
is a builders all risk insurance pol-
icy that will cover the costs of repairs.
Contrast that with a re-powering proj-
ect, where care, custody and control
of all or part of the existing facility
(including the Existing Systems) may
Ongoing and Future Operations of
Existing Systems
As a contractor proceeds to perform
interface and modification work on Ex-
isting Systems, additional risks arise.
One area of risk involves the ongoing
operation of the Existing Systems. In
order for work to be performed on an
Existing System, the Owner will need
to remove it from operation and turn
it over to the contractor. Especially if
other units at the facility are depen-
dent upon the operation of such an Ex-
isting System, this will require highly
coordinated scheduling, and presents
the risk that delays in the contractors
work will result in delays to the return
of other facility units to operation.
In some instances, specific schedule
deadlines and delay liquidated dam-
ages for extended system downtime
may be an appropriate contractual
means of causing the contractor to
bear such risk. Also, if the output of
the facilitys other units (as rely upon
the Existing Systems) are the subject of
an offtake agreement, it will be critical
to understand what liability risk might
be borne by the Owner in the event
such units cannot operate due to an
Existing Systems becoming inopera-
ble for an extended period. An Owner
should consider whether this risk can
be transferred to the contractor, if it is
the cause of the inoperability.
Of equal concern is the risk that the
contractors work on an Existing Sys-
tem, while perhaps not rendering it
wholly inoperable, negatively impacts
such systems operations such that it
can no longer support the ongoing re-
liable operation of other facility units.
In this context, it may be advisable for
a contract to expressly document each
such systems pre-turnover operational
capabilities, so as to provide a base-
line for allocating this risk. With such
clarity, an Owner may contractually
obligate the contractor to return each
only be held by the contractor tempo-
rarily, if at all, and where the Owner
will already have property insurance
in place to cover damage to the exist-
ing facility. At the same time, such
property insurance will typically not
cover new equipment brought to the
site by the contractor for the project,
especially when such equipment is un-
der the care, custody and control of the
contractor.
These two inter-related components
of a re-powering project existing fa-
cilities and new equipment - create
complex considerations for assigning
the risk of loss or damage to the proj-
ect and allocating responsibilities for
insurance coverage. For example, de-
pending on the project, it may be ap-
propriate for the Owner to establish a
period during which care, custody and
control of certain Existing Systems
will expressly transfer to the contrac-
tor. During that period, the contractor
would bear the risk of damage to the
systems on a strict liability basis (i.e.,
without regard to negligence or fault).
An alternative approach would forego
a formal passing of care, custody and
control, and simply have the contrac-
tor bear the risk of damage to any the
existing facility (including Existing
Systems), but only to the extent the
damage is caused by its or its subcon-
tractors negligence.
In either case, if the contractors work
damages the existing facility, there
will be a question as to which partys
insurance will cover that damage. The
Owner will have its existing property
policy in place, but the contractor will
also typically carry its own commercial
general liability (CGL) policy, which
would respond in the event of damage
caused by contractor negligence. Thus,
the contractor will want the Owners
policy to be primary in responding
to a loss claim and will typically ask
to be listed as an additional insured
Beyond the issues
created by interfaces
with existing systems,
there are a number
of risks inherent
in a contractors
performing work at an
operating generating
facility.
1310pe_134 134 10/17/13 9:06 AM
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policy as will normally be in place for
the new construction work. Thus, a
well-advised Owner will weigh these
various options under the circum-
stances.
As regards the risk of damage to
the New Units, the HRSGs and other
new equipment, these items will typi-
cally remain under the contractors
care, custody and control until project
turnover, which usually coincides with
the power island entering commercial
operation. It is not uncommon for the
contractor to bear the risk of loss of
these items during this period, and for
one of the parties to maintain a build-
ers all risk policy in place to provide
funds for repairs. In this context, the
Owner will want to consider the extent
to which it can, through delayed start-
up coverage under such policy, recover
lost revenues if a damage event delays
under that policy, so that it may make
claims directly under it. Owners will
frequently accept this approach, pro-
vided that the Contractor bears the risk
of the deductible or self-insured reten-
tion (in the context of risk of loss as
discussed above). However, this does
create the risk of increased premiums
being imposed upon the Owner after a
contractor-caused event. Other Own-
ers may consider pushing to have the
contractors CGL policy serve as the
primary policy in the event of con-
tractor negligence, with the Owners
policy responding only once such CGL
has reached its limits; however, Con-
tractor will resist having such expo-
sure to their basic CGL policies (which
typically apply to risks beyond one
project). Another solution may lie in
obtaining adjacent property damage
coverage under the builders all-risk
the units commercial operation.
Demolition Activities
Another area of risk inherent in a
contractors performing work at an
operating generating facility relates
to demolition activities. Frequently,
a re-powering project will involve the
demolition and removal of unneces-
sary or abandoned equipment. Un-
like a greenfield EPC contract, a re-
powering EPC contract must consider
and address the risks involved with
such work. For example, as a matter
of scope, risk and pricing, the con-
tract may need to clarify exactly which
items of existing equipment are to be
abandoned in place, and which ones
are to be demolished and/or removed.
To the extent that the removal involves
handling any hazardous material (in-
cluding asbestos abatement and sub-
surface soil work), the contract must
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are nearly doubled when the new fa-
cilities comprise a re-powering project.
They are perhaps doubled again if the
project adjoins a facility with ongoing
operations. Thus, as companies across
the country proceed with re-powering
projects, they would be well advised to
remember the one size does not fit all
adage. One should not assume that a
contain provisions addressing the
unique risks involved in these activi-
ties, including appropriate indemni-
ties, risks allocation clauses. In this
regard, Owners will want to consider
requiring such a contractor to have
pollution liability insurance in place.
This insurance can provide funding
for remediation costs stemming from
pollution incidents resulting from the
contractors operations.
A COMPLEX STEP BEYOND
THE GREENFIELD
The engineering, procurement and
construction of new power facilities
present several complex and challeng-
ing contracting issues for any company
and their legal counsel. Due to the
types of considerations as described
above (which only touch upon the tip
of the proverbial iceberg), these issues
simple (or even modified) form of
greenfield EPC contract will suffice
to cover the applicable legal, techni-
cal and commercial issues as will be
presented by a re-powering project.
While such a contract may provide an
appropriate starting point, there will
be much to consider beyond its origi-
nal four corners. Such considerations
must necessarily focus on the unique
physical, technical and commercial
aspects of the particular project, with
experienced technical, commercial,
insurance and legal advisors combin-
ing their skills to uncover, identify and
address the projects unique issues.
Based upon this work, qualified legal
counsel can then customize an over-
all documentation structure, and fine
tune contract provisions, so as to help
ensure that risks are prudently identi-
fied and appropriately allocated.
One should not
assume that a simple
form of greenfield EPC
contract will suffice to
cover the applicable
legal, technical and
commercial issues as
will be presented by a
repowering project.
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1310pe_138 138 10/17/13 9:06 AM
1310pe_139 139 10/17/13 9:06 AM
www.power-eng.com
140
oils), and light liquids (distillate oil,
biodiesel and vegetable oil). As men-
tioned earlier, although boilers/heaters
at major HAP sources burning any one
of these fuels will be subject to rule re-
quirements, the focus of this paper will
be existing coal-fired units. These ex-
isting sources currently have less than
3 years to determine methods of com-
pliance, and potentially design, procure
and install costly air pollution controls.
Significant time can be needed for im-
plementation of a compliance program
due to the design and procurement
phases of the project. Therefore, exist-
ing coal fired units should begin work
on this program as soon as possible.
EMISSION LIMITS
Table 1 shows emission limitations
for a variety of existing coal-fired boil-
ers or process heaters with a heat input
capacity of greater than 10 MMBtu/
hour. These emission limits must be
met at all times excluding startup and
shutdown conditions. As shown in the
table, applicable units have the option
to comply with emis-
sion limitations that
are defined by either
a heat input basis or
steam output basis.
In addition to
demonstrating com-
pliance, affected fa-
cilities are required to
operate and maintain
any affected emission source, including
associated air pollution control equip-
ment and monitoring equipment, in
a manner consistent with safety and
good air pollution control practices for
minimizing emissions.
WORK PRACTICE
STANDARDS
Facilities which are subject to the
emission limitations in Table 1 are also
required to comply with work practice
standards. Work practice standards
T
he Clean Air Act
Amendments of 1990
(CAAA) brought sig-
nificant change to the
regulation of air pol-
lutant emissions in the United States.
Reduction of toxic or hazardous air
pollutants (HAPs) from specific indus-
trial categories was a key focus, and the
United States Environmental Protec-
tion Agency (USEPA) laid out a plan to
develop national emission standards
for HAP emissions.
Included in the targeted source cat-
egories were Industrial/Commercial/
Institutional Boilers and Process Heat-
ers. Boilers can burn a variety of fuels,
including natural gas, fuel oil, coal,
biomass (e.g., wood), refinery gas, or
other process gas to produce steam. The
steam is used for multiple processes in-
cluding heating, cooling and electrical
generation. Process heaters heat raw or
intermediate materials during an in-
dustrial process. Based on EPA defini-
tions, these combustion sources, can be
a significant or major source of HAPs
such as mercury (Hg), metals (in par-
ticulate form), organic compounds (as
CO) and hydrogen chloride (HCl).
The MACT Standards are contained
in 40 CFR 63, Subpart DDDDD and
became effective on April 1, 2013. They
will impact major source boilers/heat-
ers at refineries, chemical plants, man-
ufacturing facilities and commercial/
institutional facilities. Existing sources
must be in compliance with the regula-
tions by January 31, 2016.
The regulatory synopsis which fol-
lows will outline requirements for
Industrial
Boiler MACT
Synopsis and Impacts
on the Regulated Community
BY JOE RUBINO, STANLEY CONSULTANTS INC.
various categories of boilers burning
different fuels; however the majority
of the discussion will focus on existing
coal-fired units which are expected to
bear the brunt of regulatory impacts.
REGULATORY SYNOPSIS
Subpart DDDDD establishes emis-
sion limitations, operational limits,
and work practice standards for HAPs
emitted from industrial, commercial,
and institutional boilers and process
heaters located at major sources of HAP.
A facility is considered a major source
of HAPs if it emits or has the potential
to emit 10 tons of a single hazardous
air pollutant or 25 tons of combined
HAPs. Subpart DDDDD also estab-
lishes requirements
to demonstrate ini-
tial and continuous
compliance with the
emission limitations
and work practice
standards.
Your facility is
subject to Subpart
DDDDD if you own
or operate an industrial, commercial,
or institutional boiler or process heater
that is located at, or is part of, a major
source of HAPs.
Subpart DDDDD establishes emis-
sion limitations, work practice stan-
dards and operating limits for both new
and existing units which burn a variety
of fuels. These fuels include coal (an-
thracite, bituminous, sub-bituminous,
lignite), biomass (wood products, ani-
mal manure, agricultural materials and
food products), heavy liquids (residual
The MACT
Standards are
contained in 40
CFR 63, Subpart
DDDDD and
became effective
on April 1, 2013.
1310pe_140 140 10/17/13 9:08 AM
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141
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1310pe_141 141 10/17/13 9:08 AM
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142
Oxygen or carbon dioxide concentra-
tions (Method 3A or B); and,
Moisture content (Method 4).
Specific methods for measuring pol-
lutant concentrations are given in Table
2.
Once emission concentrations are
determined, they are converted to lb/
MMBtu emission rates using the Meth-
od 19 F factor methodology contained
within 40 CFR 60. In advance of ex-
ecuting performance tests, a test proto-
col must be prepared and submitted to
your local state agency for review and
approval. Additional information on
the contents of this protocol will be dis-
cussed in a later section.
Fuel Analysis
Fuel analyses can only be used for
TSM, HCl and Hg as long as the calcu-
lated emissions using specific formulas
contained in the rule are less than the
applicable emission limit. Very specific
procedures for the collection and analy-
sis of composite fuel samples must be
followed. These procedures include
the analysis of fuel heat and moisture
contents. Similar to the performance
testing requirements, concentrations
of TSM, HCl and Hg are converted
from an emission concentration to a lb/
existing unit with a heat input capacity
of 10 million Btu per hour or greater
is equipped with a continuous oxygen
trim system the tune-up frequency is
reduced to every 5 years.
ADDITIONAL
REQUIREMENTS
Subpart DDDDD stipulates specific
testing, monitoring and operating
limit requirements dependent on the
method of compliance chosen for each
applicable unit. In general, compli-
ance with an applicable emission limit
can be achieved through performance
stack testing and continuous monitor-
ing system (CMS) or fuel analyses. If
compliance is demonstrated through
stack testing, control device parameters
must be set during the test and then
monitored continuously. A discussion
of each of these areas follows below:
Performance Testing
Requirements associated with
performance testing are specified by
methods in 40 CFR Part 60 for the fol-
lowing parameters:
Selection of sampling locations
(Method 1);
Velocity and volumetric flow rate of
exhaust gases (Method 2, 2F, or 2G);
for an existing boiler or process heater
located at a major source facility, not
including a limited use unit include a
one-time energy assessment performed
by a qualified energy assessor. Several
options to comply with this require-
ment include:
1. An energy assessment completed
on or after January 1, 2008, that meets
or is amended to meet the energy as-
sessment requirements of this rule; or
2. A facility that operates under an
energy management program compat-
ible with ISO 50001 that includes the
affected units.
In addition to the energy assessment,
existing boilers or process heaters with-
out a continuous oxygen trim system
having a heat input capacity of 10 mil-
lion Btu per hour or greater are required
to conduct an annual tune up. Oxygen
trim systems are a system of monitors
used to maintain excess air at the de-
sired level in a combustion device. The
tune up includes inspections of the
burner, flame pattern, and system con-
trolling air to fuel ratio. Adjustments
should be made to optimize the flame
pattern and CO emissions. Cleaning
or replacing any burner components
should also be done at this time. If an
Notes: 1) CO limits are based on a 3-run average of 1 hour samples. 2) CEMS limits for CPO are based on a 30-day rolling average.
FUELS/POLLUTANTS HEAT INPUT BASIS ALT. STEAM OUTPUT BASIS
SUBCATEGORY POLLUTANT LIMIT UNITS LIMIT UNITS LIMIT UNITS
Coal/Solid Fuel Hg 5.7E-06 lb/MMBtu 6.4E-06 lb/MMBtu OR 7.3E-05 lb/MWh
Coal/Solid Fuel HCI 2.2E-02 lb/MMBtu 2.5E-02 lb/MMBtu OR 0.27 lb/MWh
Coal/Solid Fuel
Filterable PM
(or TSM)
4.0E-02
(or 5.3E-05)
lb/MMBtu
4.2E-02
(or 5.6E-05)
lb/MMBtu OR
4.9E-01
(or 6.5E-04)
lb/MWh
Pulverized Coal
CO
(or CEMS)
130
(or 320)
ppmvd @ 3% 02 0.11 lb/MMBtu OR 1.4 lb/MWh
Stoker Coal
CO
(or CEMS)
160
(or 340)
FB Coal CO (or CEMS)
130
(or 230)
FBHE Coal CO (or CEMS)
140
(or 150)
ppmvd @ 3% 02 1.3E-01 lb/MMBtu OR 1.5 lb/MWh
Emission Limits for Existing Coal-Fired Boilers and Process Heaters 1
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144
provided below -
If your boiler or process heater is sub-
ject to a CO emission limit in Table 1,
you must install, operate, and maintain
an oxygen analyzer system or install,
MMBtu emission rate. If an applicable
unit uses a wide array of coals or coal
blends having different chemical com-
positions and thermal properties, this
method may prove burdensome given
the volume of sampling and fuel spe-
cific calculations which are required.
Continuous Monitoring System
The CMS can include a continuous
emission monitoring system (CEMS),
continuous opacity monitoring system
(COMS), continuous parameter moni-
toring system (CPMS) or a particulate
matter CPMS. Reliance on a CMS will
require development of a site-specific
monitoring plan. The monitoring plan
will address design, data collection and
quality control elements.
Certain applicable units are required
to install CMS to demonstrate compli-
ance. A description of these sources is
Source:
Pollutant 40 CFR 60 Test Requirements
Filterable PM Method 5 or 17
TSM Method 29
Hydrogen chloride (HCI) Method 26 or 26A
Mercury (Hg)
Method 29, 30A, or 30B; Method 101A (40CFR Part 61);
or ASTM Method D6784.
CO Method 10
Performance Testing Requirements 2
N
Compliance Method Type Specified Operating Limit
Wet PM scrubber control
a boiler not using a PM CPMS
Maintain the 30-day rolling average pressure drop and the 30-day average liquid flow rate
at or above the lowest one-hour average liquid flow rate, respectively, measured during the
most recent performance test.
Wet acid gas (HCI) scubber
control on a boiler not using
a HCI CEMS
Maintain the 30-day rolling average effluent pH at or above the lowest one-hour average
pH and the 30-day rolling average liquid flow rate at or above the lowest one-hour average
liquid flow rate measured during the most recent performance test
Fabric filter control on units not
using a PM CPMS
a. Maintain opacity to less than or equal to 10 percent opacity (daily block average); or
b. Install and operate a bag leak detection system and operate the fabric filter such that the
bag leak detection system alert is not activated more than 5 percent of the operating time
during each 6-month period.
Electrostatic precipitator control
on units not using a PM CPMS
a. This option is for boilers and process heaters that operate dry control systems (i.e., ESP
without a wet scrubber). Existing boilers and process heaters must maintain opacity to less
than or equal to 10 percent opacity (daily block average); or
b. Maintain the 30-day rolling average total secondary electric power input of the ESP at or
above the operating limits established during the performance test.
Dry scrubber or carbon injection
control on a boiler not using a
mercury CEMS
Maintain the minimum sorbent or carbon injection rate.
Any other add-on air pollution
control type (dry systems) on
units not using a PM CPMS
Existing boilers and process heaters must maintain opacity to less than or equal to 10
percent opacity (daily block average).
Fuel analysis
Maintain the fuel type or fuel mixture such that the applicable emission rates calculated ar
less than the applicable emission limits.
Oxygen analyzer system
For boilers and process heaters subject to a CO emission limit that demonstrate compliance
with an O2analyzer system, maintain the 30-day rolling average oxygen content at or above
the lowest hourly average operating load recorded during the most recent performance test.
SO2 CEMS
For boilers or process heaters subject to an HCI emission limit that demonstrate
compliance with an SO2 CEMS, maintain the 30-day rolling average SO2 emission rate at
or below the highest hourly average SO2 concentration measured during the most recent
HCI performance test.
Operating Limits for Boilers and Process Heaters 3
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146
you may choose to conduct perfor-
mance tests for the pollutant every
third year.
NOTIFICATIONS
Existing sources will need to submit
a Notification of Intent and Notifica-
tion of Compliance Status. The Notifi-
cation of Intent is required to conduct
a performance test and must be sub-
mitted at least 60 days before the test
is scheduled to begin. The Notifica-
tion of Compliance Status follows the
initial compliance demonstration for
each boiler or process heater.
This notification would include
all performance test results and fuel
analyses and must be submitted before
the close of business on the 60th day
following the completion of all initial
compliance demonstrations for appli-
cable emission sources at the facility.
certify, operate and maintain CEMS for
CO and oxygen.
If your boiler or process heater is
in coal/solid fossil fuel subcategory
and has an average annual heat input
rate greater than 250 MMBtu per hour
and you demonstrate compliance with
the PM limit instead of the alternative
TSM limit, you must certify and main-
tain a PM CPMS. As an alternative,
compliance with the PM limit can be
demonstrated with a PM CEMS which
must also be certified and maintained.
For other boilers or process heaters,
you may elect to use a PM CPMS or
PM CEMS in lieu of using other CMS
for monitoring PM compliance, such
as bag leak detectors, ESP secondary
power, or scrubber pressure. Owners of
boilers and process heaters who elect to
comply with the alternative TSM limit
are not required to install a PM CPMS.
Subpart DDDDD also establishes
operating limits for boilers and process
heaters. These limits are dependent on
the type of compliance method em-
ployed and in some cases are based on
the results of a specific performance
test. Table 3 defines the operating limit
for the field of possible compliance
methods.
INITIAL COMPLIANCE
Existing boilers or process heat-
ers are required to complete perfor-
mance tests and/or fuel analyses (if
applicable), establish operating lim-
its and conduct CMS performance
evaluations no later than 180
days after the compliance date of
January 31, 2016 (i.e., July 29, 2016).
Both the initial tune-up and one time
energy assessment should be complet-
ed by January 31, 2016.
As discussed earlier, prior to con-
ducting any performance tests, a site-
specific stack test plan must be pre-
pared and submitted to your state air
permitting authority for review and
approval. Since the performance tests
would be used to establish operating
limits for future compliance, the plan
should identify operating data and
how it will be collected to establish
these operating limits. Table 4 sum-
marizes which parameters should be
used to establish operating limits as a
function of pollutant and control type.
Following the initial compliance
demonstration, all applicable perfor-
mance tests are required on an annual
basis and must be completed no more
than 13 months after the previous per-
formance test. If your performance
tests for a given pollutant for at least 2
consecutive years show that your emis-
sions are at or below 75 percent of the
emission limit for the pollutant, and
if there are no changes in the opera-
tion of the individual boiler or process
heater or air pollution control equip-
ment that could increase emissions,
Source:
Pollutant Control Type Operating Limit Parameters
PM, TSM, or Mercury Wet scrubber Minimum scrubber pressure drop
and minimum flow rate
PM, TSM, or Mercury Electrostatic
precipitator with wet
scrubber
Minimum total secondary electric
power input
HCI Wet scrubber
Dry scrubber
SO2 CEMS
Minimum pressure drop, effluent
pH, and flow rate
Minimum sorbent injection rate.
If different acid gas sorbents are
used during the HCI performance
test, the average value for each
sorbent becomes the site-specific
operating limit for that sorbent.
Alternate maximum SO2
emission rate
Mercury Activated carbon
injection
Minimum activated carbon
injection rate
Carbon monoxide Oxygen analyzer
system
Minimum oxygen level
Any pollutant for
which compliance
is demonstrated by
a performance test
Boiler or process
heater operating load
Maximum operating load
Establishing Operating Limits 4
1310pe_146 146 10/17/13 9:08 AM
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148
silos, and material handling activities.
Although this additional equipment or
operations may require minor source
construction permits, the overall proj-
ect should still be able to avoid a major
Prevention of Significant Deteriora-
tion (PSD) review. A minimum of six
months should be allowed to develop
an air permitting strategy, meet with
state permit engineers, prepare/sub-
mit the necessary permit applications
which could include dispersion mod-
eling analyses, and obtain a valid con-
struction permit.
Modifying a facility to accommo-
date cogeneration will look very dif-
ferent from an emissions perspective
compared to control equipment instal-
lations. Natural gas-fired combustion
turbines and HRSGs with supplemen-
tal natural gas firing are much more
likely to show a net emission increase,
triggering a PSD review which would
require a longer permit timeframe of
up to 12 months. Under PSD review,
facilities are subject to a Best Available
Control Technology demonstration
and dispersion modeling analyses to
demonstrate compliance with appli-
cable pollutant standards.
CONTROL, REPOWER
OR RETIRE
One of the largest impacts to exist-
ing coal-fired boilers or process heaters
will be whether add-on pollution con-
trol equipment needs to be installed to
comply with emission limits. Table 5
summarizes control devices that can
be used on a pollutant specific basis.
As an alternative to control equip-
ment installations, affected facilities
can also consider boiler/burner con-
versions to natural gas or cogeneration
utilizing heat recovery steam genera-
tors (HRSGs). Utility systems that are
the most efficient, such as cogenera-
tion, often command an economic ad-
vantage. Therefore, facilities should
not limit their options to the genera-
tion side of utilities only. Conversion
of steam distribution systems to hot
water may produce significant opera-
tional cost savings and long term sys-
tem benefits.
If control equipment or unit repow-
ering are not attractive, affected facili-
ties can also consider retiring dated,
less efficient, high-maintenance coal-
fired units and replacing them with
natural-gas fired package boilers or
HRSGs. Steam needs can also be met
through power purchase agreements
with a co-located utility. Finally, if
feasible, facilities can eliminate steam
entirely and convert plant HVAC to
direct-fired natural gas.
In addition to evaluating whether
certain control options or a redesign
of operations is needed for continued
steam generation, time should be tak-
en to consider environmental conse-
quences for each viable option. Once
a clear path to compliance is defined,
project sponsors will need to develop
detailed schedules for environmental
permitting, detailed engineering de-
sign, procurement and construction.
AIR PERMITTING
In general, installation of add-on
pollution controls will serve to de-
crease actual emissions from a boiler
or process heater. However an exist-
ing Major PSD facility will still need to
compare current to future actual emis-
sions to demonstrate that a net decrease
will be occurring. A small portion of
the overall decrease in emissions may
be offset by increases associated with
ancillary equipment, such as storage
Source:
Pollutant Control Type Advantages Disadvantages
PM, TSM, or Mercury Fabric Filter High control efficiencies for filterable
PM (98-99%); Can be sized for
upstream equipment loading.
Limited operating temperature
rangees typically less than400F.
PM, TSM, or Mercury Wet Scrubber or Wet ESP High control efficiencies for
condensable PM.
Requires significant water usage
HCI Dry scrubber Most common method is dry sorbent
injection with hydrated lime, baking
soda or trona; provides SO2 and
(minimal) NO
X
control; typically 80-
90% HCI removal.
Requires silo or bulk bag
system. Additional loading on
downstream controls.
Mercury Activated carbon injection Effective for Hg, Dioxins/Furans, and
VOC; Typically 90-95% Hg removal.
Requires silo or bulk bag
system. Additional loading on
downstream controls.
Carbon monoxide Good combustion
practices
Low cost; enhanced by proper bumer
maintenance and oxygen control
packages.
Achieve balance with low
thermal NOX production.
Control Equipment Summary 5
1310pe_148 148 10/17/13 9:08 AM
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Finally, if the chosen plan to comply with Boiler
MACT involves retirement of existing assets and re-
placing these units with new natural gas-fired boilers
or heaters, triggering a PSD review will be dependent
on the size of the new units. Facilities may be able to
offset emission increases from new equipment with
decreases from retired units. However applicable
decreases will be dictated by how much the retired
equipment operated in recent years. Similar to the
permitting scenario discussed above for installing
control equipment, a minimum of 6 months should
be planned for air permitting.
CONCLUSIONS
Existing coal-fired boilers and process heaters
need to be in compliance with the Boiler MACT
emission standards by January 31, 2016. Proactive
planning and implementation of a compliance
program is critical to operating units achieving this
goal. Stringent emission limits for Hg, HCl and
PM will likely require installation of air pollution
control systems. In addition to determining
appropriate types of emission control, a long term
schedule will have to include project engineering
and design, procurement, environmental permitting
and installation.
It is recommended that facilities in the early
planning stages of this program should identify
both internal and external resources needed and
take appropriate steps to ensure a successful rollout
of their Boiler MACT initiative.
Joe Rubino, a Principal Scientist and Senior Proj-
ect Manager at Stanley Consultants, has 26 years of
technical experience in government agencies, envi-
ronmental consulting, and private industry.
As a senior project manager, Joes experience in-
cludes environmental planning and permitting; and
management of air permitting projects for a variety
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plants, building products, oil refineries, and medical
facilities.
Rubino has led successful partnerships with regu-
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ting projects and obtain critical preconstruction
permits for industrial facilities. This experience in-
cludes environmental assessments, compliance au-
diting, development of environmental management
systems, wastewater/storm water issues; and waste
management.
1310pe_151 151 10/17/13 9:08 AM
www.power-eng.com
152
SDG&E will purchase 315 MW of output from
the Ocotillo Wind Energy Facility under a 20-year
power purchase agreement. Photos courtesy:
Pattern Energy
1310pe_152 152 10/17/13 9:08 AM
www.power-eng.com
153
variability of distribution circuits?
2. What are the potential risks to our
system and what additions may be
required in order to maintain com-
pliance with the NERC/WECC/
and regional California ISO (CAI-
SO) planning standards?
A CAISO report issued at about the
same time predicted that overall, cur-
rent and planned renewable sources in
the long-range plans regional grid ex-
pansion portfolio would be adequate
to accommodate the 33 percent RPS.
SDG&E, however, wanted to take a clos-
er look at how their system would hold
up with a higher percentage of intermit-
tent resources supplying energy to their
service territory.
CAUSE FOR CONCERN
Distribution systems the size of
SDG&Es represent a multi-billion dollar
capital investment over a period of sev-
eral decades, with the original design be-
ing highly reliable when operated in the
intended fashion. The addition of new,
intermittent sources of generation at var-
ious locations creates potential reliabili-
ty impacts which the original system de-
signs were not intended to address. As is
fairly standard, across SDG&Es system,
12 KV distribution lines are arrayed in a
Preparing
the
GRID
for
RENEWABLE
Resources
BY GAIL FREDDO, SDG&E
TRANSMISSION PLANNING
C
alifornias Renewable
Portfolio Standard
(RPS) requiring inves-
tor-owned utilities,
electric service provid-
ers and community choice aggregators
to increase procurement from eligible re-
newable energy resources to 33 percent
of total procurement by 2020 is the most
aggressive in the nation, compelling
providers to meet the challenge head on.
Large-scale integration of distributed
energy resources such as wind and solar
with electric power systems presents op-
erational and planning challenges that
all regulated utilities will eventually face
in the years ahead as more renewable ca-
pacity comes on line.
No stranger to innovation, San Di-
ego Gas & Electric (SDG&E), a Sempra
Energy utility, wanted to get ahead of
the renewables curve by commission-
ing a study in late 2010 examining
how intermittent wind and solar proj-
ects planned for Southern Californias
Imperial Valley would affect its trans-
mission and distribution systems. The
obvious questions were:
1. How do we predict system perfor-
mance issues that may arise as pow-
er sources shift to accommodate the
variable output levels of renewable
generation and increased loading
San Diego Gas & Electric tries to model the impact
of intermittency in 2020, today
tapered format, where the wires are of a
higher gauge at substations and become
progressively smaller with more numer-
ous branches as they fan out to various
loads. Because photovoltaics, or PV,
could be connected anywhere along this
complex distribution infrastructure, the
reliability of previously well-balanced
sections can get called into question. As
a typical example, there was reasonable
concern about interference due to the in-
termittency from, say, a 2-MW project at
the extreme end of a circuit and how it
would impact reliability.
Presently, the only renewable energy
project in SDG&Es service territory is a
50 MW wind project that came on line
in 2005 at the extreme periphery of their
69 KV system. This interconnection has
caused many issues with voltage swings
(signatures) at the point of interconnec-
tion. That in itself is not extreme but
grid stability gets called into question
when you multiply that by a factor of
10. Given utility focus on reliability of
service, the potential impacts have to be
considered so as to determine when and
where the matter can become more seri-
ous. Similar conditions with larger proj-
ects at other utilities have shown this to
be true.
Equally important was the matter of
voltage regulation and accommodating
1310pe_153 153 10/17/13 9:08 AM
www.power-eng.com
154
of total renewable energy served over
a years time means that, on any given
day, there could be a wide range of actu-
al associated renewable capacity being
utilized at any particular time, given the
fluctuations in output involved from
these power sources. The steadiness
of a power source is an important ben-
efit cost-wise, with the more unpredict-
able and volatile sources creating added
costs for the system planner. An initial
hypothesis held that even with an aver-
age of a certain level such as 33 percent
for renewable injection, the quality of
that energy would in all likelihood not
be of the same quality as conventional
generation because it didnt have that
same system inertia.
The investigation performed with
renewables output as a must take
source as power is being produced, thus
taking priority over conventional sourc-
es. This requires having enough spin-
ning reserves available in the intercon-
nection across the system to continue
output in case a wind farm and or a PV
project goes out of service (ie. a cloud
passes overhead or the wind suddenly
drops off). Cost accounting methods
are designed to account for things that
are common to any generation source,
as well as the very real additional cost
impacts associated with addressing the
higher unpredictability of wind and solar
sources (e.g. there is an absolute require-
ment that a certain percentage of stand-
by generating capacity be on line in or-
der to maintain system reliability in the
case of unforeseen
contingencies.).
The Generator
I nt er connec t i on
Group at SDG&E
routinely studies the
cumulative impact
of all generation
resources as part
of the CAISO Gen-
erator Interconnec-
tion Process (GIP).
These impact studies are very specific in
scope and require that all generators in
the interconnection queue be modeled.
SDG&E, however, was looking ahead
several years to the 2015-2018 time-
frame when contemplating its research
criteria as a number of projects were
slated for completion in that window
and they had to forecast power purchase
agreements for roughly the same period
of time. Regionally, SDG&E is expecting
at least 150 MW of power from a pro-
posed wind farm and an additional 150
MW of rooftop solar.
Along with needing to address reli-
ability impacts, renewables programs
need to address financial impacts, en-
suring long-term viability (see box).
Achieving an average of 33 percent
The Ocotillo Wind Energy Facility reached
commercial operation in December 2012.
Source:
Like any regulated utility, SDG&E is constrained to operate within certain financial limitations in order to stay strong as
a business, with the competing pressures of its regulators on the one hand, and the financial community on the other.
To take two extreme cases, hypothetically, if electric rates for an investor-owned utility were accidentally set much
higher than fairness would dictate, in the long term it would be unsustainable for the local economy and the utility
itself, even though in the short term its financial performance would look wonderful. Regulators ensure that will not
happen. But on the other hand, if regulators made the price of electricity ridiculously low, eventually the utility would
go bankrupt, and along the way, the financial community would respond to this risk with lower stock prices and an
unfavorable bond rating, both of which would raise the utilitys weighted average cost of capital. In both casesoverly
high or overly low ratesthere would be a reduction in investments in projects that help increase the utilization of
renewables.
Long term Viability of Investments 1
1310pe_154 154 10/17/13 9:08 AM
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156
frequency and interface data from CAI-
SO that was also entered. For the pur-
poses of the study, SDG&E and DNV
KEMA later decided for a slightly coarser
sampling to speed up the process.
RISK MITIGATION
Characteristics of renewable re-
source behavior in a time domain of
high intermittency can dramatically
affect the control functions and ancil-
lary services required in the system
to operate reliably and in compliance
with NERC standards (e.g., frequen-
cy response/droop, regulation/AGC,
spinning reserves and balancing ser-
vices). The time domain modeling fea-
tures of KERMIT are closely correlated
with these critical power system per-
formance requirements.
Results of the KERMIT simulations
shown in Fig. 2, where the renewable
event is defined and the response pro-
vided. To study the worst impact, out-
ages of the San Onofre Nuclear Gen-
erating Station (SONGS) operated by
Southern California Edison are con-
sidered as an additional contingency.
This plant provides the bulk of base
load to the region. A description of the
renewable event is indicated as:
t The Disturbance starts at 11:15:18
am
t Solar power drops 1053 MW in 1-sec
t Wind power drops 493 MW in 5-sec
DNV KEMA was a non-standard study
to divine, with a relatively high degree
of granularity. Assessing the reliability of
the grid while interacting with accumu-
lated intermittent sources proved to be a
challenge.
MODELING
GRID BEHAVIOR
The study was conducted over nine
months using commercially available
software tools GridView from ABB,
GEs PSLF (Positive Sequence Load
Flow), and combin-
ing their data with
DNV KEMAs own
proprietary model-
ing software, KER-
MIT.
GridView per-
forms regional
energy market
simulation and
analysis for mod-
eling of large-scale
transmission net-
works by factoring
in network topol-
ogy, hourly load profiles, transmission
constraints and generator data (heat
rate curves etc.). It was used in this
exercise to measure generator dispatch
values and branch flows over a period
of time. PSLF provided snapshots of
time during simulations of dispatch-
ing large blocks of power across the
transmission grid.
What interested SDG&E was that
DNV KEMAs KERMIT tool could incor-
porate the economic day-ahead studies
and power flow data gathered from the
other systems. With GridView and PSLF
calculating intermittency of renewable
plants, KERMIT could show the results
of any mitigating actions taken to cope
with intermittency. Such initiatives to
better integrate renewables into the grid
included the need to analyze the ben-
efits of energy storage, optimal capaci-
tor placement, integration of demand
reduction programs, and requirements
for new transmission capacity, to name
a few. The solution was then employed
to extrapolate the data to reflect system
behavior in the year 2020.
The study began by analyzing a years
worth of data from GridView to identify
eight sample days throughout 2010 with
data mined from SDG&E OSIsoft Pi his-
torian (Table 1). These eight days were
selected based on the level of renew-
able generation penetration, the SDG&E
load and generation dispatch so that
any drop in voltage may have the worst
possible impact. Within this grouping,
KERMIT simulations isolated April 26
th

(referred to as 2020 Off Peak case)
and September 4
th
(referred to as 2020
Peak case) as the two days with the larg-
est frequency deviation. April 26
th
was
selected over January 18
th
because it had
more renewable generation dispatched.
Expunging this data was the most
time consuming portion of the nine-
month study, as DNV KEMA required
two- to four-second interval data over a
calendar year. This translated into many
gigabytes of data transferred out of the
historian and then feeding it into KER-
MIT. Fifty-six Pi tags were necessary
to acquire all of the aggregated data of
information requested. On a two- or
four- second interval, this protocol en-
tailed utilization of a great deal of data,
even though it did not yet include the
Source:
Date Description Biggest Impact Frequency Deviation Min/Max Frequency
1/18 Solar power drop 1000MW Under 59.92 Hz
3/29 Morning wind gust 500MW
No obvious
frequency deviation
N/A
4/12 Delayed morning solar 1100MW Over 60.07Hz
4/26 Wind unit trip + Solar power drop 1500MW (two steps) Under 59.92 Hz
5/27 Wind power drop 1000MW Under 59.94 Hz
7/14 Excessive solar 800MW Over 60.05 Hz
Results Of Kermit Simulations For Days Of Interest TABLE 1
1310pe_156 156 10/17/13 9:08 AM
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158
study also tested mitigating actions to
address system disruptions from inter-
mittency.
Energy storage can reduce the extent
of frequency decay, but to be effective,
the size of energy storage must be suf-
ficient to cover the supply deficit that
arises due to a drop-off in renewable
power. It is best to view the role of
storage as a very fast-acting generator
providing short-term energy injection
onto the grid. For example, if there
was a drop-off in wind resulting in an
870 MW deficit for five minutes, a con-
ventional plant takes time to ramp up
in order to respond to this disturbance
while energy storage can respond al-
most instantly. The main barrier to
energy storage, however, is the current
cost. Prices will have to drop substan-
tially for it to be competitive.
Demand reduction is an option but
it would have to exceed more than 10
percent of load to be effective as a so-
lution. More detailed investigation is
necessary on demand reduction pa-
rameters such as ramp and dispatch
rates. Fig. 3 shows the settle down fre-
quency (Hz) between having no load
reduction to 10 percent.
Other solutions considered in the
study included capacitor placement,
dropping load, line upgrades, genera-
tor re-dispatch and reconfiguring ex-
isting protection schemes.
More work needs to be done on
specific renewable resource behavior
impacting the SDG&E grid, but the
information from this initial study
achieved through a credible simula-
tion created valuable insight on a very
complex issue. The risk depends on
system conditions including network
topology, available reserves, loading
and the penetration level of intermit-
tent generating resources. It will be
interesting indeed to actually see the
penetration numbers in 2020, but cur-
rent tools are most assuredly providing
a reasonably accurate landscape.
In this case, only 13 conventional
SDG&E power units are in service and
the total load is 2,580 MW. The SONGS
contingency is applied one second af-
ter the renewable event has ended and
the system frequency is at its lowest
(at time stamp 11:15:24). The system
frequency is at its lowest value, 59.56
Hz, at 11:15:30, six seconds after the
SONGS contingency. The frequency
recovers in two stages. The first recov-
ery is seen at 11:16:06 due to governor
action. The second recovery is seen at
11:20:00 when the real time balancing
market kicks in. The time instant cor-
responding to Point Z is 11:20:16.
In addition to uncovering system
behavior during a renewable event, the
00:00:00 04:48:00 07:12:00 09:36:00 12:00:00
Hours
14:24:00 16:48:00 19:12:00 21:36:00 00:00:00
Total Wind Power
Total Solar Power
02:24:00
1800
M
W
1600
1400
1200
1000
800
600
400
200
0
200
4-26-2020 Disturbance In Renewable Generation 2
DR=0%
59.70
59.75
59.80
59.85
59.90
Event=Renewable Disturbance + SONGS units trip
DR=1% DR=5%
2020 Off-peak
S
e
t
t
l
e
d

F
r
e
q
u
e
n
c
y

(
H
z
)
2020 Peak
DR=10% DR=0% DR=1% DR=5% DR=10%
SUMMARY: Impact of Demand Response
(DR) on Freqency Response.
3
1310pe_158 158 10/17/13 9:08 AM
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160
maintained a strategic partnership with
the Tennessee Valley Authority and in
2009 began to oversee modification,
outage, and maintenance work on the
TVAs Browns Ferry, Sequoyah, and
Watts Bar nuclear plants.Nuclear Power
International caught up with Preston
Swafford, Executive Vice President and
Chief Nuclear Officer at TVA, and Mike
McMahon, President of Day & Zimmer-
mann ECM, to discuss the ins and outs
of alliance contracts.
Power Engineering: Considering
the economic environment and
current outlook for power produc-
ers. What are the advantages of an
alliance contract?
Preston Swafford: The intent of
having the alliance is to start to build a
relationship with a single partner. We
did receive the lowest competitive bid
of qualified corporations from Day &
Zimmermann. So once that part was
behind us, we built this alliance to
really start improving our safety per-
formance at the sites. Having one ven-
dor operate with one hard hat at all
three of our sites gives a tremendous
amount of continuity. So if you learn
a lesson from one of the sites you can
quickly take it and transport it to all
three sites, thus saving us from hav-
ing the same event happen at multiple
times. We also, by this alliance, get a
return of people. Every time you bring
in a new team, they dont know your
procedures, they dont know your pro-
cesses theres a lot of upstart cost. And
in the end all of that ends up being a
fairly costly model with a fair number
of human performance mistakes that
get tied to it because they just dont
know our systems. So the flexibility is
also another key part of the alliance.
Theyre in all three of our sites, they
can move resources from one to anoth-
er as needs arise, theyre going to know
our processing rules, etc., so their up
time to get going is fairly short. And
finally, the whole part of the team.
Outages are successful when teamwork
comes into play, and in order to be a
teammate they have to understand our
programs our processes, they have to
understand our facilities, they have
to understand our people. Weve seen
over the years now a continual growth
on Day & Zimmermanns part of
learning all the ins and outs of doing
P
ower producers across the
industry are under pres-
sure from flat electricity
usage growth rates and
the need to comply with
environmental regulations. The nuclear
industry in particular has to contend
with the high cost of new build and safe-
ty regulation compliance. In the search
for cost savings, some power produc-
ers have turned to outsourcing main-
tenance and outage services to third
parties. These long-term agreements,
known as alliance contracts, can yield
substantial savings with added benefits
like workforce flexibility and the shared
knowledge that comes with a long-term
partnership.
Since 1995, Day & Zimmermann has
A Seat at the
Table and Skin
in the Game
BY DENVER NICKS
SPECIAL REPORT: A conversation on alliance
contracts with Day & Zimmermann and TVA
Mike McMahon, President, Day & Zimmermann ECM
Preston Swafford, Executive Vice President
and Chief Nuclear Officer for TVA.
1310pe_160 160 10/17/13 9:08 AM
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1310pe_161 161 10/17/13 9:08 AM
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162
able to go up and down in head count it
is a cost effective model for these short
duration outages where I need a large
number of contractors for a short period
of time. Weve seen human performance
errors and mistakes made by the ven-
dor come way down,
so the benefit of the
alliance is getting to
have a real teammate
at the table and learn-
ing from outage to
outage to keep getting
better. We are starting
to see those types of
benefits, which was
the genesis of this alli-
ance agreement in the
first place, to build that repetitive assur-
ance of a team thats going to be able to
execute per your procedures and plans
and not cost you a lot of downtime due
to human performance errors.
NPI: What should a utility consider
before getting into an alliance con-
tract?
Swafford: One, youve got to craft
this thing out to get skin in the game
by the vendor, because first of all what
youre kind of signaling is we dont
have to keep putting RFQs together and
they dont have to keep responding out-
age and to outage, which is overhead in
administrative. But on the other hand
youre kind of sending a signal that
this is their work and should they ex-
ecute they will continue to get the work.
Theres plusses in that but obviously if
there arent some checks and balances
from runaway costs and other hidden
type issues there can be, Im going to say,
not malicious, but there can be gaming
or other things that come out, So when
you up front build your Ts and Cs you
want them to share in the outcome. Part
of the alliance is that its ok to have the
vendor make a profit. You cant sit there
trying to be just a chisel because youre
in it for the long haul.
What you got to do is recognize that
they need to make money but they need
to make it by the success in the total,
if you will, by getting them skin in the
game, sharing in the outcomes, both
penalties and rewards. Another attribute
that you want to build in is your execu-
tive alignment and oversight built into
this we purposely took this away from
the plants and brought it to corporate
centrally so that the emotion of an event
or something at a plant doesnt carry
into an emotional decision. And in or-
der to make sure that all works right the
executive alignment around this is criti-
cal. Mike and myself meet frequently.
His staff underneath him, his regional
VPs and senior VPs, have been down
and talk quite regularly, so I always have
a pulse and they give me weekly reports
of the performance of their crew. And if
you read between the lines theyre do-
ing a pretty good job of telling us where
were kind of hosing them.
NPI: Mike, can you describe the
scope of the alliance agreement?
McMahon: Were contracted to do
full scope maintenance and modifica-
tions work at all six of the TVA units
and its a pay per performance con-
tract. We make our profit based on a
detailed report scorecard, which has
got some similarities at every outage
or every location, flexible to attack the
individual needs of a particular scope
of work or particular outages concerns
or things of that nature. Human per-
formance, cost versus quality, schedule
adherence, safety are always parts of
the detailed report cards, but depend-
ing on the complexities of a particular
project there might be other report
card additions in there and thats how
we make our fee. We drive towards
continuous improvement in the per-
formance of our people and we drive
towards reduced costs in the repetitive
nature of some of these tasks that go
from outage to outage.
Thats how a contract drives our team
work together, drives our success together
business with TVA and theyre be-
coming a bigger partner at the table.
Our outage performance is not where
it needs to be but weve had a huge
amount of recovery work in all three of
our plants, its been a primary focus for
four years, and weve
done just an awful
lot of work and Day
& Zimmermann has
had a seat at the table
with us. Were about
to enter into another
chapter where were
going to shave days
off the outage dura-
tion and things like
that. And the role of
Day & Zimmermann in that arena for
us, from an alliance standpoint, is crit-
ical. They start showing up at the table
and making suggestions to meet those
new sets of goals.
Mike McMahon: It just wraps
around flexibility and cost effective-
ness. Were a variable resource that
comes in and is managed with the TVA
team and with the performance, safety
and process and procedure knowledge,
the teaming arrangement - lets avoid
having our first mistake and if we have
one lets never repeat it. It allows TVA
to have less overhead than they would
have if they had multiple contractors
or new contractors each time, and it
allows them to have better and more
intrusive contractor oversight.
NPI: How does the cost of O&M
compare to the cost you would
have incurred had you done the
work yourselves?
Swafford: Good question. If we could
do the work ourselves we would, by
definition. What were really saying is we
have short periods of time, like refuel-
ing outages, where my steady state staff
cannot execute that much work. If they
could frankly I would not give it to a con-
tractor, Id keep all work in house, but be-
cause its a flexible work force and were
The benefit of the
alliance is getting
to have a real
teammate at the
table and learning
from outage to
outage.
- Preston Swafford, TVA
1310pe_162 162 10/17/13 9:08 AM
1310pe_163 163 10/17/13 9:08 AM
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indicators arent greenthey may be
redthen we wouldnt pay those per-
formance awards and if theres a dis-
pute where Day & Zimmermann be-
lieve we should and my staff believes
we shouldnt, that rolls up to the ex-
ecutive committee, where we will meet
and talk through it.
I typically see my role as to make
sure I take a high road behavior on it
all. Im not into chiseling Day & Zim-
mermann.
I want them to be successful but I re-
ally need them to be successful as Im
successful.
So far in four years I think only one
or two minor events had to come up
for dispute resolution. I think there is a
vehicle if it is severe enough where you
can get through he executive commit-
tee and get to some kind of mediation
process.
To date weve not had to exercise
that, but theres been a few, Im going
to say, performance issues where
there were significant haircuts made,
but with Day & Zimmermann on it
they recognized it like we did and
for the most part it was agreed and
appropriate.
Power Engineering: Are there
any drawbacks or particular chal-
lenges unique to an alliance
agreement.
Swafford: The Ts and Cs are really
critical. The overall alignment and
agreement in the spirit that we put this
together under, Im very happy with,
I believe its right. But there are some
things where for example our process
or procedures may cause inefficiencies
that they have to comply with. What
Im hoping to get to is where theres
enough skin in the game and enough
teamwork built up where these types
of inefficiencies are really being called
and allows the contractor to, to use Pres-
tons, words, have skin in the game, where
we make profit on performance and we
lose when we do not perform.
Power Engineering: Preston, how
does TVA evaluate D&Zs perfor-
mance?
Swafford: I have a vice president who
is responsible for outages and under him
he has several players that are kind of
contract administrators.
Theyre kind of a key focal point with
Day & Zimmermann, so Mikes staff will
interface with these personnel and they
then, in concert with the site, build a key
report card to handle the performance
fee that Mike just mentioned.
Power Engineering: What proce-
dures are in place to help manage
conflict?
Swafford: If goals arent met, where
1310pe_164 164 10/17/13 9:08 AM
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typical outage execution, and theres a
different set of values, or added value,
that a contractor can bring. Were
one of the two largest maintenance
and modifications contractors in the
nuclear business.
We work at a lot of other facilities
and we see challenged practices and we
see better practices, and its incumbent
upon us to have a seat at the table with
TVA and be a purifier, to push back
on procedures that weve seen that are
more effective at other locations, and
try to drive these outages to shorter
durations and better efficiencies. So,
as Preston said, well have to readjust
the score card to drive the behaviors
that are needed for the future model
versus the model weve been dealing
with in the past.
out by Day & Zimmermann and
theyre pushing as hard as I am to fix
them and for a total result outcome
being even more dominant in their
fee, as opposed to just execution of the
agreed upon activities.
I think that the next chapter for the
alliance is to really look at the total,
not just that piece Day & Zimmermann
does, to ask, are we gaining where we
want to there? and well see.
Its the next chapter of innovation
on it, but you spend enough time with
each other, build enough teamwork
with each other and theyre as apt
to see the opportunities as our own
people are.
Thats when we can get into our
corrective action programs and really
get them addressed. Just in the Ts and
Cs to make sure that its there: real skin
in the game.
Power Engineering: Mike,
anything youd like to add?
McMahon: The last four years
weve been, to use Prestons words,
recovering the plant, upgrading the
equipment and so on and so forth and
now were going to get into a period of
Well have to readjust
the score card to
drive the behaviors
that are needed for
the future model.
- Mike McMahon, Day &
Zimmermann ECM
1310pe_166 166 10/17/13 9:09 AM
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168
are installing anaerobic digesters and
gas-powered generator sets to convert
animal and food waste into renewable
electricity to generate power and profit.
Biogas from cow manure presents a vi-
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gas electricity, as well as competing re-
newable technologies, because biogas
can be produced on a continuous basis,
ensuring reliable, continuous power
generation. The U.S. Environmental
Protection Agency estimates that 8,200
of the nations existing dairy and swine
operations could support biogas recov-
ery systems with the potential to gener-
ate more than 13 million MWh per year
and displace about 1,670 MW of fossil-
fuel generation. In addition to the gen-
eration of renewable electricity, these
systems offer numerous side benefits
for farm owners.
Bettencourt Dairies, one of the
R
enewable and green
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BY NICK KELSCH, CATERPILLAR ELECTRIC POWER
Methane gas is collected from Rock Creek Dairy and
piped into two CAT 3520C gas generator sets that
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Idaho Power Co. for distribution to the main power grid.
Photo courtesy of Caterpillar Electric Power
1310pe_168 168 10/17/13 9:09 AM
CAT, CATERPILLAR, their respective logos, ACERT, Caterpillar Yellow, the Power Edge trade dress, as well as corporate and product
identity used herein, are trademarks of Caterpillar and may not be used without permission. 2013 Caterpillar. All Rights Reserved.
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170
of fuel with lower methane concentra-
tions (typically 35-to-50% methane)
versus a natural gas system (>95%
methane). The engines electronic con-
trol module automatically adjusts the
air-to-fuel ratio based on real-time fuel
monitoring from a gas chromatograph.
This allows the system to compensate
for methane content variations typical
of a waste source biogas, such as cow
manure. Further, individual cylinders
are monitored with
accelerometers to
sense any abnormal
combustion or deto-
nation that is a result
of a sudden change
in fuel composi-
tion. The G3520C
generator set utilizes
a 20-cylinder, elec-
tronically controlled,
lean-burn biogas
engine coupled with a two-bearing
synchronous generator. The biogas en-
gines used at Rock Creek Dairy include
stainless steel aftercooler cores, exhaust
valves, and rear gear train bearings that
remove all bright metals that may come
into contact with the gaseous fuel ele-
ments that contain hydrogen sulfide.
This is especially important because hy-
drogen sulfide, which is typical in bio-
gas production, reacts to corrode bright
metals.
The biogas cooling system is de-
signed to operate at higher jacket wa-
ter temperatures of 230 F (110 C)
versus the typical natural gas system
at 210 F (99 C). This is achieved to
prevent condensation of sulfuric acids
on internal engine components, which
can form when hydrogen sulfide gas
combines with water vapor in the air-
fuel mixture. The elevated jacket water
temperature in combination with posi-
tive crankcase ventilation also limits
acidic deposits into the engines lube
oil, further protecting components and
largest dairy farm operations in Idaho
with 60,000 cows and 13 facilities, had
a significant issue at one of its dairies
with odor from the manure produced
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year period. With each cow producing
about 100 pounds of manure each day,
the dairy has to manage about 900,000
pounds of manure on a daily basis,
while mitigating the noxious effect on
the surrounding environment. Every-
one at the Department of Agriculture
knew about the odor problem, said
Rick Onaindia, CFO for Bettencourt
Dairies. We knew we had to do some-
thing to address the issue.
TECHNOLOGY SOLUTION
Bettencourt Dairies discovered a so-
lution that would not only enable it to
solve the odor and methane emissions
issues, but would also generate power
from its dairy operations. Six one-mil-
lion-gallon anaerobic digesters were
installed at Rock Creek Dairy to pro-
cess manure, mitigate odors and extract
methane to convert to electric power.
Approximately 200,000 gallons of cow
manure are collected daily, pumped
through a nearly mile-long pipeline to
the anaerobic digesters, and processed
into clean compost used for animal
bedding. It is the largest facility of its
kind in the western United States.
As the manure is processed, the re-
sulting methane gas is collected from
the digesters and piped into an adja-
cent powerhouse containing two Cat

G3520C gas generator sets that con-
vert the gas to electricity. The gener-
ated power is then sold to Idaho Power
Company for distribution to the main
grid.
Rated at 1600 ekW at 1200 rpm, the
fuel system of each G3520C generator
set is sized to handle higher volumes
Everyone knew
about the odor
problem. We
knew we had to
do something to
address the issue.
- Rick Onaindia,
Bettencourt Dairies
helping to extend oil-change intervals.
In addition, the G3520C is optimized
for efficiency for use in parallel-to-grid
applications. At Rock Creek Dairy, one
of the generators runs continuously
while the other unit runs variable hours
following the available biogas produc-
tion. Both generators feed power to
a utility-grade paralleling switchgear
before being sent to voltage step-up
transformers and the local utility distri-
bution network. Ul-
timately, it is the in-
terface with the local
electric utility that
drives economies of
scale for many bio-
gas-to-energy project
developers in North
America.
The interconnec-
tion with the utility
was expensive, and
thats where you need consolidation of
the larger dairies, says Jay Kesting of
New Energy One, the project developer
and plant operator, and subsidiary of
local Cat Dealer Western States Equip-
ment Company. Its one of the things
that holds these projects up if you dont
receive the optimal rate for the power
and you are paying a lot for the inter-
connection. So, if you can bring dairies
together in a community concept with
one interconnection, you can improve
your return.
The Rock Creek Dairy system is high-
ly efficient. In addition to converting
biogas into electricity, the plant utilizes
waste engine heat to keep the anaerobic
digesters running at the optimal tem-
perature. Substituting engine heat for
heat generated in a boiler is yet another
way for the dairy to reduce its energy
costs while boosting biogas production.
A third byproduct from the anaerobic
digesters is a dry, odorless compost that
can be used as a soil conditioner or for
animal bedding.
1310pe_170 170 10/17/13 9:09 AM
1310pe_171 171 10/17/13 9:09 AM
www.power-eng.com
172
us survive as a dairy, said dairy owner,
Louis Bettencourt. There is less odor
from the dairy, which is good for our
neighbors, and the harmful greenhouse
gases are no longer escaping into the at-
mosphere.
RESULTS
Since August 2012, Rock Creek Dairy
has been steadily ramping up biogas pro-
duction, providing more than 2MW of
power for distribution to the grid as part
of a power purchase agreement with the
local utility. Once the operation reaches
full-tilt, Rock Creek Dairys generation
capacity will double to 4 MW of power.
New Energy One supplies Idaho Power
with enough power to provide electricity
to thousands of Idaho homes.
New Energy One and Western States
are evaluating other uses for the heat
With lessons learned from five hun-
dred G3520C biogas generator sets in-
stalled since 2005, Caterpillar has been
able to optimize the design of the genera-
tor set such that repair and maintenance
schedules make feasible 10-to-20 year
operating contracts on biogas fuels. This
generator set is designed to enable highly
efficient and reliable operation on digest-
er gas, delivering electricity at extremely
competitive cost per kWh, said Michael
Devine, gas product & marketing man-
ager at Caterpillars Electric Power Divi-
sion. At Rock Creek Dairy, the recovered
heat is providing significant cost savings
by avoiding the cost of a traditional heat
source for a digester operation, while the
sale of power is a revenue stream that off-
sets the costs to operate the system.
On the environmental side, this tech-
nology is something that I think will help
from the generators, including heating
greenhouses at Rock Creek Dairy. While
dairies in Idaho are not currently man-
dated to reduce methane gas emissions,
the anaerobic digester system at Rock
Creek Dairy will prevent 40,000 tons of
methane from being released into the at-
mosphere every year.
Converting waste into energy mini-
mizes our environmental impact and
provides a consistent source of renew-
able energy that can be distributed to
our surrounding communities, said
Onaindia. The true value of this proj-
ect is its ability to serve as a model for
the Idaho dairy industry for long-term
sustainability, from both the environ-
mental and business perspectives. We
want to be here for the long term, and
we view this project and this technol-
ogy as important to our future.
Bettencourt Dairies installed six one-million-gallon
anaerobic digesters on site to process manure at Rock
Creek Dairy. Photo courtesy of Caterpillar Electric Power
1310pe_172 172 10/17/13 9:09 AM
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174
The Graf-Wulff Process
Makeup
water
Water
tank
Flue gas
Lime
Venturi
section
Particulate collector
Recirculation lim
e
Byproduct
bleed
To stack
Byproduct
silo
A
b
s
o
r
b
e
r
As can be seen, hot flue gas enters
an absorber below the venturi section,
where the gas contacts fresh hydrated
lime and recycled ash / byproduct. Fresh
water is sprayed into the absorber to
enhance chemical reactions, but wa-
ter injection is controlled to maintain
temperature above the saturation level.
The scrubbing action removes prior-
ity pollutants, including SO
2
, SO
3
, HCl
and mercury. The cooled flue gas enters
a particulate collector, normally a pulse
jet fabric filter, to remove flyash and re-
action byproducts. Clean flue gas from
N
umerous methods
of evaluating air
quality control sys-
tems are used by
various companies.
The innovative procedure of soliciting
and evaluating bids discussed in this pa-
per has been used successfully to fairly
evaluate bids from engineering, pro-
curement and construction (EPC) con-
tractors and original equipment manu-
facturers (OEM) for dry and semi-dry
flue gas desulfurization systems.
This method gives the bidders a
spreadsheet tool to optimize bids based
on life cycle costs and uses this same
spreadsheet to evaluate the bids. The fol-
lowing technique can be used both for
high level and detailed evaluations. A
discussion of important considerations
is given to avoid making poor selections;
for example, selecting the lowest initial
capital cost but neglecting operating and
maintenance costs can result in large life-
cycle costs. It is also necessary to compare
technologies and bids on an equal basis,
which is a process that can be challenging
for significantly different technologies.
EXAMPLE
Figure 1 shows a typical dry scrubber
that is in the mix of choices: the circu-
lating dry scrubber (CDS) as represented
by the Graf-Wulff process.
Evaluating
Bids for Air
Quality Control
Systems
BY MITCHELL KRASNOPOLER, MANAGER
OF AIR QUALITY AND RAY ZBACNIK,
AQCS PROCESS ENGINEER, KIEWIT
POWER ENGINEERS
Source:
Variable Inputs
(Input Cells are Yellow Highlight, Red Text. Values Shown are for Example only.)
PARAMETER VARIABLE SDA CDS SDA
Auxiliary Electric Power, kW Power 1.00 1.00 1.00
Hydrated Lime consumption, lb/hr HLime 1.00 1.00 1.00
Quicklime consumption, lb/hr QLime
Halogenated PAC consumption, lb/hr HPAC 1.00 1.00 1.00
Equivalent Hydrated Lime Consumption, lb/hr EqHLime 0 0 0
FGD Byproduct to Landfill, lb/hr Byproduct 0 0 0
FGD Byproduct to Landfill, lb/hr (Bidder's Input) Byproduct
Total EPC Contract Price Price $1 $1 $1
Operating labor number of personnel hired OLabor 6.0 4.5 4.5
Maintenance labor number of personnel hired MLabor 1.5 1.0 1.3
Variable Inputs, Outputs, Constants
and 20-Year NPV Unit Costs
1
1310pe_174 174 10/17/13 9:09 AM
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1310pe_175 175 10/17/13 9:09 AM
www.power-eng.com
176
spreadsheet helps the bidder select the
proper technology.
INITIAL REVIEW OF BID
Even though lowest capital cost
and meeting the required guarantees
are important, the process and equip-
ment design must be proven. Table 5
provides a summary checklist of major
items in the bids that are reviewed.
It is important to evaluate the bids to
be certain that the complete RFB scope
is included. The RFB should clearly
identify the major and auxiliary equip-
ment. If the RFB is not detailed, OEMs
can take shortcuts and may propose
systems that differ from standard prov-
en designs.
For example, for a CDS sometimes
an OEM will suggest lowering the
the particulate collector is sent to a dry
stack. Flyash / byproduct is recycled and
has a purge or waste stream feeding a by-
product silo.
Other, similar technologies are
available, including the Enhanced All-
Dry (EAD) and NID dry scrubbers as
well as the more traditional spray dry-
er absorber (SDA).
INITIATING THE BID
EVALUATION PROCESS
The bid evaluation process begins
with the Request for Bid (RFB) in which
bidders are provided information rel-
evant to the project and instructed in
how the bids will be evaluated. For
some projects, the owner prefers to fo-
cus on price and guarantees with only
minimal technical analysis of the of-
fering. Factors that affect pricing in-
clude low capital cost, low operating
cost and life-cycle cost.
The method starts with a spread-
sheet, similar to that shown below in
Tables 1,2,3 and 4. This spreadsheet is
included in the RFB and allows bid-
ders to determine the best offering in
terms in lowest life-cycle cost.
For bidders that offer both spray dry
absorbers (SDA) and CDS or can use
eitehr quicklime or hydrated lime, the
Source:
Output
PARAMETER FORMULA SDA CDS NID / EAD
Auxiliary Electric Power evaluation factor NPV = Power x PowerCost $2,225 $2,225 $2,225
Hydrated Lime consumption evaluation factor NPV = HLime x HLimeCost $8,900 $8,900 $8,900
Quicklime consumption evaluation factor NPV = QLime x QLimeCost $0 $0 $0
Halogenated PAC consumption
evaluation factor NPV
= HPAC x HPACCost $111,200 $111,200 $111,200
Operating labor evaluation factor NPV = OLabor x OLaborCost $9,906,000 $7,429,500 $7,429,500
Maintenance labor evaluation factor NPV = MLabor x MLaborCost $2,476,500 $1,651,000 $2,063,750
Repair/Maintenance evaluation factor NPV = Price x RepairCost / 10,000 $12,510,185 $0 $0
Landfill evaluation factor NPV
= (HLime + QLime) x
LandfillCost
$5,360 $5,360 $5,360
Total Economic Evaluation factor NPV = sum of NPVs $12,510,185 $9,208,185 $9,620,935
Maintenance labor number of personnel hired MLabor 1.5 1.0 1.3
Output for Bidders 2
Source:
Constants
PARAMETER VALUE
Operating Hours per Year 7,008 hr/yr
Escalation Factor 3.00%/yr
Discount Rate 5.00%/yr
Operating and Maintenance Labor Rate $50/hr
Electric Power Cost $20/MW-hr
Hydrated Lime Cost $159.00/ton
Quick Lime Cost $159.00/ton
Halogenated PAC Cost $1.00/lb
Annual Repair/Maintenance 1.5% of Total EPC Contract Price
Landfill Cost, Including Transportation $58.40/ton
NPV Base Year 2012
Number of Years in NPV Evaluation 20 years
Start of NPV Evaluation Time Period 11/1/2014
End of NPV Evaluation Time Period 10/31/2034
Constants for Bidders 3
1310pe_176 176 10/17/13 9:09 AM
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178
stoichiometry (amount of hydrated
lime feed) by dramatically increasing
the ash / byproduct recycle rate or by
lowering the approach to saturation of
the flue gas entering the pulse jet fabric
filter. A high recycle rate can result in
a very high particulate loading on the
fabric filter, which may push the bag-
house to its limits with regard to regula-
tions compliance. If the approach tem-
perature is too close to saturation, there
is a chance of wetting the vessel walls,
which would initiate corrosion, and of
damaging the bags and internals of the
fabric filter.
Sometimes personnel access and
maintenance requirements for envi-
ronmental equipment are overlooked.
Often these inadequacies lead to seri-
ous maintenance issues.
ECONOMIC ANALYSIS
After the bidders complete the
spreadsheets outlined earlier and in-
sert pricing, a total economic evalua-
tion factor is necessary. Lowest initial
capital cost due to budget constraints
was often a major deciding factor in
the past; however, it is more important
to consider life cycle costs. The evalu-
ation is therefore not subjective: the
bidder with the lowest life cycle cost,
and who meets the RFB requirements,
will be awarded the work. The follow-
ing economic review and analysis is
recommended, with an example pro-
vided.
The input table considers:
t Total EPC contract price
t Operating power requirement
t Lime, PAC and byproduct landfill
requirements
t Operating and maintenance costs
The output table considers 20-year
NPV evaluation factors for power,
lime, PAC, byproduct landfill, oper-
ating & maintenance, payments and
payment schedule.
Many factors can influence the
choice. For example, the price of
PAC has a major impact on the total
Source:
20-Year NPV Unit Costs (generated from above constants)
PARAMETER VARIABLE 20-YEAR NPV COST PER UNIT
Auxiliary Electric
Power evaluation rate
PowerCost $2,225 per kW
Hydrated Lime consumption
evaluation rate
HLimeCost $8,840 per lb/hr
Quicklime consumption
evaluation rate
QLimeCost $8,840 per lb/hr
Halogenated PAC
consumption evaluation rate
HPACCost $111,200 per lb/hr
Operating labor evaluation rate OLaborCost $1,651,000
per person
hired @ $50/hr
Maintenance
labor evaluation rate
MLaborCost $1,651,000
per person
hired @ $50/hr
Repair/Maintenance
evaluation rate
RepairCost $2,381
per $10,000 of
EPC Contract Price
Landfill evaluation rate LandfillCost $3,248 per lb/hr
Maintenance labor
number of personnel hired
MLabor 1.5 1.0
20 YR NPV for Bidders 4
economic evaluation factor. If the
PAC rate has high margin, it dramati-
cally increases the total economic
evaluation factor. For the example
provided in Table 6, Brand X is the
choice.
Source:
1 Conformance to the RFB requirements (major exceptions and clarifications)
2 Completeness of scope
3 Interfaces with plant and limits of supply
4 Required number of operating and maintenance personnel
5 Schedule requirements
6 Company experience and financial position
7 Number of units operating with similar process requirements
8 Equipment List
9 Piping and instrumentation diagrams
10 Instrumentation and control system
11 Compliance with the requested guarantees
12 Evaluation of the bidder-provided guarantees
13 Operations and maintenance requirements
14 Technical services and training
15 Performance guarantees
16 Open issues
17 Options
Summary Checklist for Bid Review 5
1310pe_178 178 10/17/13 9:09 AM
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EPC Contract Evaluation Factors
Input Table
1 EPC Bidder Company Name Brand X Brand Y Brand Z
2 Type of AQCS System (SDA, CDS or NID / EAD) SDA CDS SDA
3 Auxiliary Electric Power, kW (Power) 3,100 2,600 2,200
4 Hydrated Lime consumption, lb/hr (Variable Name: HLime) 0.00 1800 0.00
5 Quicklime consumption, lb/hr (Variable Name: QLime) 1,500 0.00 1,500
6 Halogenated PAC consumption, lb/hr (Variable Name: HPAC) 45 43 35
7
Equivalent Hydrated Lime Consumption, lb/hr (Variable Name:
EqHLime)
1,900 1,800 1,900
8 FGD Byproduct to Landfill, lb/hr (Variable Name: Byproduct) 3,100 3,100 3000
9 Total EPC Contract Price (Variable Name: Price) $43,800,000 $52,400,000 $57,100,000
10
Operating labor number of personnel hired
(Variable Name: OLabor)
6.00 4.50 6.00
11
Maintenance labor number of personnel hired
(Variable Name: MLabor)
1.50 1.00 1.50
Input and Output for Total Economic Evaluation for Sample Project 6
TABLE CONTINUED ON PAGE 183
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The output table with embedded calcu-
lations is provided with the input tables to
the OEMs in the RFB, allowing them to put
in their own in-house numbers and deter-
mine the best design to provide.
For some utilities, a major concern is the
impact of operation and maintenance per-
sonnel costs on the 20-year NPV for each
system. To distinguish between each tech-
nology, the following number of personnel
has been predicted:
1. 7.5 personnel full time average for
SDA,
CDS,
NID/EAD.
CONCLUSION
The process outlined in this article rep-
resents an objective method to evaluate
air pollution control technologies, where
a number of processes are possible for re-
moval of sulfur dioxide and other acid gas-
es from flue gas streams. Given the variety
of technologies that exist today, such a tool
is very much needed to select the best pro-
cess at each plant.
References
Buecker, B. and L. Hovey, Circulating Dry
Scrubbers: A New Wave in FGD?, Power Engi-
neering, November 2011.
R. Rhudy, Flue Gas Desulfurization Bid Prepa-
ration and Proposal Review Guideline, Final Re-
port 2003.
EPC Contract Evaluation Factors
Output Table
12 EPC Bidder Company Name Brand X Brand Y Brand Z
13
Type of AQCS System (SDA, CDS or
NID / EAD)
SDA CDS SDA
14
Auxiliary Electric Power evaluation
factor NPV = Power x PowerCost
$6,700,000 $5,700,000 $4,700,000
15
Hydrated Lime consumption
evaluation factor NPV = HLime x
HLimeCost
$0 $15,700,000 $0
16
Quicklime consumption evaluation
factor NPV = QLime x QLimeCost
$12,900,000 $0 $12,600,000
17
Halogenated PAC consumption
evaluation factor NPV = HPAC x
HPACCost
$4,800,000 $4,800,000 $3,900,000
18
Operating labor evaluation factor
NPV = OLabor x OLaborCost
$9,900,000 $7,500,000 $9,900,000
19
Maintenance labor evaluation
factor NPV = MLabor x MLaborCost
$2,500,000 $1,700,000 $2,500,000
20
Repair/Maintenance evaluation
factor NPV = (Price / 10,000) x
RepairCost
$10,400,000 $12,500,000 $13,600,000
21
Landfill evaluation factor NPV =
Byproduct x LandfillCost
$9,900,000 $9,900,000 $9,700,000
22
NPV of payments per one dollar
of contract price =
NPVperPaymentDollar
$0.937 $0.951 $0.947
23
Payment Schedule NPV = Price x
NPVperPaymentDollar
$41,000,000 $49,800,000 $54,100,000
24
Total Economic Evaluation Factor
NPV = sum of NPVs
$98,000,000 $105,400,000 $110,900,000
Input and Output for Total Economic
Evaluation for Sample Project
7
TABLE CONTINUED FROM PAGE 180
Source:
1310pe_183 183 10/17/13 9:09 AM
www.power-eng.com
184
and supplies an average annual energy
output of some 2,300 megawatts, which
is enough power to continuously supply
Seattle and Boston.
THE GRAND
COULEE LANDSCAPE
The dams infrastructure comprises
three power plants, a pump-gener-
ating plant, and three switchyards.
There is a power plant on both the left
and right sides of the spillway on the
downstream face of the dam. There is
pumping generation plant on the left
abutment of the dam, an 11.95/115-ki-
lovolt switchyard, a 230-kilovolt con-
solidated switchyard, and a 525-kilo-
volt Third Power Plant cable-spreading
yard and switchyard are located high
on the hills west of Grand Coulee
Dam. Today much of the reclama-
tions focus is on the Third Power Plant
because the refurbishment project that
is underway has begun with this plant
located on the downstream face of the
fore bay dam.
The first powerhouse comprises
three station service generators rated at
10,000 kW and nine generators rated at
125,000 kW. The second houses nine
generators rated at 125,000 kW. The
Third Power Plant, which is getting
all the attention as the refurbishment
project kicks off, comprises six genera-
tors (three generators nameplate rated
at 600,000 kW but able to operate up
to 690,000 kW, and three generators
rated at 805,000 kW). The pump-gen-
erating plant contains six pump-gen-
erators. Individual penstocks supply
each of the generators. The Third Pow-
er plant has the largest penstock that is
approximately 40 feet in diameter and
carrying up to 35,000 cubic feet per
second of water. One switchyard has
11.95 kilovolt distribution and four
115 kilovolt transmission lines; one
switchyard has 230 kilovolt generation
(from eighteen 125,000 kW units) and
eleven transmission lines; the third
switchyard has 525 kilovolt genera-
tion and six transmission lines. There
are electrical connections through
transformers between the 115 and 230
kilovolt switchyards and the 230 and
525 kilovolt switchyards. The main
dam contains 11 drum gates, each 135
feet long and 40 outlet tubes with 102-
inch ring seal gates for spilling water.
The dam complexs three switchyards
transmit electricity into the regional
power grid.
USING ADVANCED
MATERIALS, AUTOMATION
AND TECHNOLOGY
The Grand Coulee Dam is the largest
G
rand Coulee Dam on
the Columbia River
in the state of Wash-
ington produces hy-
droelectric power and
provides irrigation. The Dam is im-
mense. To put it in perspective, it
was built with enough concrete to
build a four lane highway stretching
from Los Angeles to New York (over
3,000 miles long).
The U.S. Department of the Interiors
Bureau of Reclamation (BOR) is cur-
rently in the midst of a sizable refurbish-
ment project that will take years to com-
plete because of its size and importance
as the Reclamations Columbia Basin
Project in central Washington. It is not
only providing flood control, irrigation,
recreation, stream flows, and fish and
wildlife benefits, its total hydropower
production capacity is 6,809 megawatts
Grand Coulee
Dams Third Power
Plant Undergoes
Refurbishment
The Bureau of Reclamation Commences
Major Rehab of Hydropower Project
BY ERIC MARKS, PRICEWATERHOUSECOOPERS
Grand Coulee Dam is the largest hydropower project
in North America with a capacity of 6,809 MW.
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186
advanced synthetic polymer alloy,
which requires a unique manufactur-
ing process to make in order to deliver
the high concentration of PTFE in the
sliding area while maintaining sub-
stantial compressive strength.
Since the PTFE layer is several mil-
limeters thick, it makes the material
highly tolerant and wont wear out.
The Orkot also maintains its low fric-
tion properties throughout the service
life of the bearing,
which is another key
factor for a project of
this size and require-
ment for advanced,
long lasting materi-
als.
The Grand Cou-
lees Third Power
Plant is in process
of being refurbished
and the advanced
Orkot TXMM Hydro
was chosen for this
retrofit project es-
pecially for its dry running capabili-
ties and tolerance to edge loading and
misalignment even with the heaviest
loads.
The hydro bearings are well suited
to freeze fitting without the danger
of shattering, which is a key factor for
dam conditions.
In addition, materials to be used in
this refurbishment have to not only
deliver the highest wear resistance pos-
sible but also be dimensionally stable
and not swell in water. Trelleborgs
materials were credited through lots of
testing by Powertech Labs and received
approval by the US Army Corps of
Engineers, which further established
confidence in the use of Orkot hydro
bearings.
BACK TO THE SOURCE:
HYDROPOWER
Hydropower makes up almost 80
percent of Grand Coulees authorized
purposes. However irrigation and
flood control make up the additional
20 percent. It is of interest to note that
the publics desire for irrigation was
a key driving force behind the dams
construction.
Having already invested several
years in planning for this refurbish-
ment project, all eyes are on the Third
Power Plant of the 6,809-MW Grand
Coulee project.
The Rehabilitation will start with
the retrofit of all six generators, of
which three will be uprated. The BOR
wants to ensure continued reliable op-
eration of this gravity dam, especially
since it is the largest hydroelectric fa-
cility in the US.
The state has proclaimed that the
6,809-MW Grand Coulee project on
the Columbia River in Washington is
a critical component for power gen-
eration in the region. The Third Power
Plant, which began operating in 1975,
has six units that need substantial re-
habilitation simply because they have
become antiquated.
The Bureau of Reclamation, the
plant owner and operator, has set
high expectations and have followed
through with years of careful planning
for this rehab.
This past March, the overhaul on
three of the six units has started and
is not expected to be completed until
September 2017.
The Reclamation will then access the
three completed units and work on the
remaining three units is then expected
to start in January 2018 and will not be
finished until December 2022.
The expectation that was set in us-
ing state of the art materials and in
leveraging the newest in technology
advancements whether for polymers,
remote monitoring and data acquisi-
tion, power generation equipment,
etc. to ensure the plant will operate re-
liably, efficiently and safely for at least
another 40 years.
hydropower plant in North America.
The Bureau of Reclamations engineers
prudently monitor and control any
power supplied to the grid to ensure
it is safe and fault tolerant from any
possible power anomalies (spikes or
dropouts). The current retrofit of the
control system for the BOR is in co-
operation with the Bonneville Power
Administration (BPA), the U.S. Army
Corps of Engineers Hydroelectric De-
sign Center (HDC),
the projects system
integrator, and RTI
Data Distribution
Service to ensure a
SCADA solution is
deployed to be able
to remotely monitor
and control power
operations.
Data acquisition
is being conducted
with the monitoring
of some 40,000 I/O
points. The SCADA
monitors and controls 30 generators
and the transmission switchyard. RTIs
SCADA will communicate with about
55 Linux-based Programmable Logic
Controllers (PLCs) on the central con-
trol network. Operators will monitor
via a Windows-based Human-Ma-
chine Interface (HMI) that will display
data from other various databases and
redundant servers. Based on standard,
commercial computing hardware, the
system is robust and secure. The plan
is to use this same SCADA configura-
tion for twelve dams in total with the
Federal Columbia River Power System.
Trelleborg Sealing Solutions is the
supplier of hydro bearing material
called Orkot TXMM to be used in mul-
tiple applications such as the control
gate link bushings, operating rings
and wicket gate bushings. Progress
has already started with three of Grand
Coulees Third Power Plant units. The
Orkot material was selected for its
The third power
plant, which began
operating in 1975,
has six units that
need substantial
rehabilitation
simply because
they have become
antiquated.
1310pe_186 186 10/17/13 9:09 AM
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188
GENERATOR SPOTLIGHT
Currently, NV Energy has a capacity of
around 6,000 MW. Around 2,800 MW
of that capacity been added since 2006,
mainly in four different plants: the Clark
plant, the Chuck Lenzie Generating Sta-
tion, the Harry Allen Generating Station
and Frank A. Tracey Generating Station.
All four plants are natural gas facilities.
Despite the major increase in power
generation, NV Energy has not had a ma-
jor increase in its generation staffng. That
is not only a cost-saving measure, but also
prevents the utility from initiating layoffs
if a plant is taken offine during times of
low power demand.
We are very proud of our effort to
avoid any layoffs or increase staffng and
be forced to reduce it when the plants are
not utilized, Rekowski said. We are al-
ways very careful of planning our work-
force utilization.
Keeping staffng levels at the same rate
has required some fexibility. Rekowski
said the utility is transitioning workers
and training them to work in new types
of power plants. In addition, there is an
W
hen NV Energy Genera-
tion Executive Dariusz
Rekowski gets excited
about something, his voice tends to
speed up and when talking about
NV Energys project at the Edward W.
Clark Generating Station in Las Vegas,
his words come as fast as the tempera-
ture drops on a desert night.
We doubled the generation of the
facility from 600 to 1100 MW, and we
cut emissions by half, he said. In 10
minutes, it can put 600 MW on the
system. That is a great story for us, so
were proud of it.
Rekowski, who was plant director
of the facility during the project, is
passionate about his work and the
improvements made at the facility.
The peaking plant sits inside Las Vegas
and is surrounded by communities.
The utility kept that in mind during
construction, choosing to forego
explosives during demolition of the
old plant to avoid noise pollutions and
bringing in 24 turbines in 12 blocks
without major traffc interruptions
or complaints from its neighbors.
The project also included replacing
the standard combustion system
on existing units with a low-NOx
combustion system to help with
additional emissions reduction.
The Clark Generating Station is more
than just one isolated project for NV
Energy, however. The improvements are
part of a trend of a utility adapting to the
changing face of providing electricity in
the U.S. and committing to doing more
with less and accomplishing its goals
effciently and cost-effectively.
RECENT GROWTH
NV Energy can trace its origins back
more than 150 years under various com-
pany names. In 1999, Nevada Power Co.
merged with the Sierra Pacifc Power Co.,
and the two companies began consolidat-
ing many functions to reduce operating
costs. In 2008, the company announced
it would do business under the name of
NV Energy.
The utility serves most customers in
the state, and has a customer base of
around 2.5 million Nevadans. In addi-
tion, Rekowski said it serves around 40
million tourists visiting the state annu-
ally. Not surprisingly, growth demand is
one of the biggest areas NV Energy has
dealt with in recent years.
What were proud of is responding to
growth demand, he said. Weve dou-
bled our energy capacity in the last six or
seven years, but weve still kept our gen-
eration staff at the same level. We are very
sensitive to the cost of power generation
and energy to our customers. We always
make big efforts to keep the cost as low
as possible.
NV ENERGY: Planning for
a New Energy Frontier
BY JUSTIN MARTINO, ASSOCIATE EDITOR
NV Energy recently installed new units at its natural gas-fred Clark
facility in Las Vegas, cutting emissions in half while doubling the
generation capacity of the station. Photo courtesy of NV Energy.
1310pe_188 188 10/17/13 9:09 AM
1310pe_189 189 10/17/13 9:09 AM
www.power-eng.com
190
utilities do not have available. Nevada,
however, has one of the best geothermal
profles in the U.S, which gives the utility
some advantages when it comes to plan-
ning its renewable resources.
Geothermal isnt intermittent the
way wind and solar are, so it delivers en-
ergy around the clock around the year,
he said. You dont have to worry about
it dropping to zero at any point in time.
Its a dispatchable resource you can call
upon. Its not always the same number of
megawatt-hours coming out of it, but its
always something and you can plan for.
The company is also looking at ex-
panding its solar energy profle, but it is
expanding its search beyond standard
photovoltaic solar power projects. Next
year through a power purchase agree-
ment, the company will help bring 110
MW of solar thermal energy online that
can provide fve or more hours of ad-
ditional energy through a molten salt
storage sysem. Hollis said there is a lot of
solar development taking place, and the
company is exploring all its options.
The company also uses the Hoover
Dam to produce hydropower, has power
purchase agreements with four biomass
plants and owns the Goodsprings Ener-
gy Recovery Station, a waste heat power
plant near the California border.
Its defnitely carrying on a very recent
tradition of incorporating every viable
technology into our portfolio that ben-
efts our customers, Hollis said. It was
overlap in duties so that workers may
have multiple skills that can be used
One example of this type of fexibility
is the utilitys Arrow Canyon complex
of three new plants located in the same
vicinity. Previously, those three plants
were operated by separate crews, but now
those workers are treated as one crew.
If we have an outage at one facility,
people at other plants in the complex can
come support it, Rekowski said. So that
gives us the desired fexibility, and thats
the program we keep expanding across
generation.
A FRAMEWORK
FOR THE FUTURE
Although an increased demand for
power has helped drive the new generat-
ing capacity in NV Energys portfolio, the
utility is looking to retire older assets
specifcally, coal-fred power generation
units that are being targeted by U.S. En-
vironmental Protection Agency rules and
regulations.
To that end, the company worked with
the Nevada Legislature on Senate Bill
123, known as the NVision law, which
was signed into law this year. The bill
guides NV Energy in moving its generat-
ing portfolio away from coal-fred sourc-
es and toward cleaner energy sources.
The utility recognized there are some
limitations to operating coal long-term,
and we really wanted to have a frame-
work from the policy makers at the state
level as to what direction they wanted
us to move in and what the timeframe
would look like for that, NV Energy Re-
newable Energy Executive Bobby Hollis
said. It contemplates early retirement
of the coal facilities over the next fve or
six years, and it also contemplates adding
350 MW of renewable energy through
construction and RFPs (Request for Pro-
posals) that will be issued over the next
three years.
The utility is planning to close three
of the four units at the 557-MW Reid
Gardner Generating Station by the end
of 2014, and the fnal unit by the end of
2017. Overall, the law provides for NV
Energy to divest 800 MW of coal-fred
power generation by 2019.
The utility will build and own 50
MW of new renewable energy resources,
and the other 300 MW will be acquired
through competitive solicitations, us-
ing what works best with the companys
portfolio including power purchase
agreements.
Although the move away from coal-
fred generation is a common theme with
many utilities these days, Hollis said the
decision to move toward cleaner fuels
and renewable energy is not a new one
for NV Energy.
The one thing that is a bit of a misun-
derstanding overall is that this is a U-turn
we made recently, he said. It really goes
back almost a decade. For the last fve
or six years the company has really been
taking to heart the renewable portfolio
standard in this state, recognizing theres
a lot of federal movement toward clean-
er fuel sources and away from fuels like
coal. In 2012, we really started seeing the
successful results of that focus.
USING RENEWABLES
NV Energy has a portfolio of more
than 1,000 MW of renewable energy
under contract and delivering already
or very soon, Hollis said, with most of
that capacity coming from geothermal
power plants.
Geothermal power is a very plentiful
regional resource and an option many
NV Energys 1,102-MW natural gas-fred Lenzie
facility provides a large percentage of the 2,800 MW
of capacity the utility has added since 2006. Photo
courtesy of NV Energy.
1310pe_190 190 10/17/13 9:09 AM
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has learned to work with the drawbacks
of the system, however, to preserve water,
which is especially important in the des-
ert climate.
The utilitys plans to retire its coal-fred
generation units will help the company
reduce its water usage even more, Rekows-
ki said, and keeps the company poised to
not only preserve water resources but stay
ahead of EPA regulations regarding water
usage and emissions.
The coal retirements will eliminate
a lot of water issues, and the new plants
meet all the new regulations, he said.
We probably have the most dry cooling
of any company in the nation, and we
preserve our water were reusing water
within the facility. I think at meeting EPA
regulations, we are one of the best in the
nation.
MOVING FORWARD
NV Energys view on the environ-
ment is one aspect of the companys
our generation group that really pushed
for the idea of how NVision needs to look
at planning in the future. The value of
energy diversity is widely recognized at
NV Energy and will be important mov-
ing forward.
PRESERVING
A PRECIOUS RESOURCE
The renewable resources provide the
beneft of lower air emissions, but NV
Energy also looks at all aspects of the
environmental impacts of its plants. Be-
ing in a desert climate, water usage has
been a concern of the utilities
for some time, and the com-
panys new facilities are zero
liquid discharge plants. One of
the plants, the natural gas-fred
530-MW Walter M. Higgins
Generating Station, uses grey
water produced from the showers and
laundries at nearby casinos.
Rekowski said the utility is also using
dry cooling, which uses about 7 percent
as much water as a traditional cooling
system. The system has some drawbacks,
however. Huge fans are required to create
the draft of air to provide cooling, which
produces a signifcant parasitic load of up
to 20 or 30 MW.
Dry cooling also causes a higher pres-
sure at the exhaust of the turbine, mean-
ing not as many MW of power can be ex-
tracted from the facilities. The company
NV Energys newest plants are all zero liquid discharge facilities and
have installed air cooling systems that use 7 percent as much water
as traditional systems. Photo courtesy of NV Energy.
1310pe_192 192 10/17/13 9:09 AM
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Energy planned the Clark project to avoid disturbing its neigh-
bors, using no explosives when demolishing the old units and
avoiding traffc disruptions when bringing in the new turbines.
Photo courtesy of NV Energy.
remain headquartered in Las Vegas.
This is a great ft for Berkshire Hatha-
way, and we are pleased to make a long-
term investment in Nevadas economy,
Berkshire Hathaway chairman Warren
Buffett stated in a release at the time of
the announcement. Through MidAm-
erican, we have found in NV Energy a
great company with similar values, out-
standing assets and a superb manage-
ment team.
NV Energy shareholders recently ap-
proved the agreement, which still needs
to clear several customary closing condi-
tions, including approvals from the Fed-
eral Energy Regulatory Commission and
the Public Utilities Commission of Ne-
vada. The transaction is expected to close
in the frst quarter of 2014.
Hollis said that once that occurs, the
companies will see what opportunities
exist between the two. Although the
shared expertise may be useful, how-
ever, NV Energy has already charted its
own path.
Were always looking to the next 20
to 30 years to fgure out what we have to
do to provide that reliable, low-cost elec-
tricity customers expect, especially when
its 105 degrees outside, he said. Were
moving into a new energy frontier in Ne-
vada with the changes that came from the
2013 legislative session.
For Rekowski, managing the genera-
tion assets of an entire state is just a larger
version of the process that resulted in
the Clark station project: Be effcient, do
more with less and be a good neighbor in
the community.
I think we as a company are always
looking into positioning ourselves for
the future and considering our alterna-
tives, he said. Thats what we can be
proud of.
operations which made it an attractive
ft to MidAmerican Energy Holdings
Co., a subsidiary of Berkshire Hatha-
way, which announced it would be ac-
quiring the utility last May. Under the
agreement, NV Energy will continue to
operate as a separate corporate subsid-
iary of MidAmerican Energy and will
1310pe_194 194 10/17/13 9:10 AM
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196
WHAT WORKS
and forth until they fall onto one of two
conveyor systems. Conveyor speeds are
adjusted to fuel load requirements with
variable speed drives.
Sawdust and chips smaller than 2
in diameter are sorted onto a conveyor,
driven by motors, couplings and gear-
boxes, which takes them to the airlock
separator. A second conveyor takes the
larger sized fuel to a mechanical chip-
per and the material is shredded to the
proper size.
Next, the chips are conveyed to an air-
lock separator. Powered by a motor and
vacuum pumps, air pressure within the
airlock separator is maintained lower
than outside the chamber ensuring prop-
er input to the gasifcation chamber.
Four large augers, each with a gear-
box and couplings, move the chips to
the gasifcation chamber where they are
superheated in a low oxygen chamber.
As the chips smolder and emit wood-
gas, oxygen is then introduced on the
backside of the boiler causing the gas to
ignite, producing heat at temperatures
of over 1100 F and producing steam at
H
eres how to win a project.
Show a plant developer how
to cut $3.5 million from $85
million in upfront capital costs, or 4.1
percent of the entire project cost. To top
it off, improve the annual proft margin
from 11.5 percent to 14.41 percent by
delivering labor, operational and mainte-
nance effciencies.
A Midwestern U.S. biomass gasifca-
tion power plant recently achieved this
through Integrated Drive Systems.
Siemens Renewable Power Generation
Sales Manager David Jackson, with the
companys Drive Technologies Division,
says the plant has the costs typically as-
sociated with a biomass plant.
However, Jackson says the Siemens
proposal whacked 10 percent from la-
bor costs, 30 percent from operational
costs and two percent from routine and
major maintenance costs, thus provid-
ing the customer with an advantage in
the workplace.
The developers gave us the bill of ma-
terial for this plant that included multiple
vendors, Jackson says. I reviewed the
design and showed the customer where
we would shake costs out of the project
with an integrated system.
In some cases, Jackson says it was a
matter of resizing pumps for improved ef-
fciencies. In other instances, the recom-
mendations called for variable frequency
drives to power large fans.
We were proactive with the customer and
worked in their best interest to lower costs and
increase their margin, Jackson says. Our ex-
perience, equipment effciency, environmen-
tal sustainability and superior economics en-
abled the customer to trust us with the order.
BIOMASS
GASIFICATION SIMPLIFIED
The biomass gasifcation plant receives
saw dust from a nearby lumber mill ad-
jacent to the facility and chipped wood
waste from up to 75 miles away. These
materials are loaded into a chip bunker.
A large mechanical wedge, equipped
with a gearbox, moves the chips back
Integrated Drive
Systems cut
$
3.5 million from
capital costs
Labor, operational and maintenance
effciencies increase margin nearly 3 percent
BY JASON HOOVER, DIRECTOR OF BUSINESS DEVELOPMENT, SIEMENS
This biomass gasifcation power plant in the
Midwestern U.S. receives saw dust from a
nearby lumber mill adjacent to the facility
and chipped wood waste from up to 75 miles
away. Photo courtesy of Siemens
1310pe_196 196 10/17/13 9:10 AM
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ST. LOUIS, MISSOURI 63026
tel: 636.651.1000 [email protected]
ne.com
NOOTER/ERIKSEN, SRL MILAN, ITALY
VIA VOLTA, 50
CARDANO AL CAMPOS (VA), 21013
tel: 39(331)232500 [email protected]
1310pe_197 197 10/17/13 9:10 AM
www.power-eng.com
198
process, the plant has found some
unique process improvements and
revenue sources other than steam. For
example, ash from the process falls
out of the bottom of the boiler and is
carried by conveyor to an ash storage
box where it is collected and sold as
fertilizer supplement to local farmers.
Also, as exhaust from the gasifer
circulates through a cyclone separator
large particles drop away. The exhaust
then enters the bag house where
it passes through a series of flters
to remove fne particulate matter.
Controlled by fan motors and VFDs,
the fltration system removes 99.7
percent of particulates before it leaves
the smoke stack as water vapor.
Further energy effciency measures
include using the gasifcation exhaust
to preheat the water entering the boiler
and using the steam to turn turbines
to cogenerate electricity before being
distributed to the lumber mill.
and some require a substantial invest-
ment.
Today, you can spend up to
$100,000 on a winding analyzer,
says Mark Peden, president of Alliance
Pump and Mechanical Service (Inde-
pendence, MO), but at the same time
you could fnd a very robust model at a
much lower price.
Peden, whose company services
utilities including water and
wastewater treatment plants, as well as
municipal, commercial and industrial
pumping equipment, elected to do the
latter, investing in a powerful portable
winding analyzer and motor tester. Not
only was the price in the lower range,
but also the system is user-friendly
and is easy enough to use that highly
trained specialists are not required to
operate it.
LIVING UP TO
CUSTOMER GUARANTEES
Were a motor shop, which means
approximately 200 K per hour.
Jackson recalls that the original
plants design specifcations for the
boiler and gasifcation system were
connected to a constant speed motor,
which was to be mechanically con-
trolled and operated continuously at
100 percent regardless of the actual
load requirement.
The effciency of fans delivering air
for combustion was greatly increased.
Jackson said. The variable frequency
drives (VFDs) save approximately 30
percent of the energy used by constant
speed motors for the conveyors, gasif-
cation system and augers.
Additionally, by having one drive
system throughout the plant, rather
than a variety of pumps, motors, valves,
and mechanical drives, training and
maintenance costs where both reduced
by two percent.
Just as important, the plant has only
one company to call and needs to train
employees on only one system.
T
he electronic devices used to
test and analyze electric mo-
tors and other equipment have
become much more powerful than in
the past. Yet, in many instances these
sophisticated devices have also intro-
duced a high degree of complexity for
users, requiring that highly trained
Drives vertically integrated with pro-
cess control
Siemens SIMATIC PCS 7 process con-
trol system is vertically integrated with
the drives system and ensures that the
boiler and gasifcation system operates
at optimum effciencies. Communicat-
ing to the drives with remote I/O via the
PROFIBUS network, the control system
is a cost-lowering nerve center at the
plant, according to Jackson.
We have reduced their labor costs by
10 percent because alarms can be trans-
mitted to the operators in the control
room via the network, Jackson says.
All operations, including fuel supply,
auger operation and boiler control are
controlled by the system. Employees
dont have to be on the plant foor eye-
balling gauge and meters and valves.
They do all that in the control room.
ADDED INCOME
FROM WASTE RECOVERY
At different stages of the gasifcation
and experienced personnel perform
the testing.
Many of todays devices are feature
rich and capable of measuring and an-
alyzing many factors, including surge
comparisons, resistance, impedance
and more. Unfortunately, not all of
these potent systems are user friendly,
Power Plants
Diagnose Motor
Problems without
Highly Trained
Personnel
Motor diagnostics now can be
performed at the push of a button.
BY CARLO CHATMAN, FREELANCE WRITER
1310pe_198 198 10/17/13 9:10 AM
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1310pe_199 199 10/17/13 9:10 AM
www.power-eng.com
200
several years at the coal-fred power
generation plant.
The Electrom testers use high-fre-
quency 60Hz surge pulses eliminating
ionization dissipation and thus better
simulating what motors are subject to
during operation.
This is really the only testing and
analyzing device we use for checking
motors, Myers says. We also use it on
the back of switchgear to ensure proper
protection of the motor and the line.
Typically this testing is done during a
scheduled outage.
Myers, a 35-year veteran of power
plant construction and operation, adds
that the iTIG is quite user friendly, and
does not require engineering expertise
or extensive training to operate it suc-
cessfully.
Im not what you would call an ex-
pert as far as instrumentation is con-
cerned, he says. This particular instru-
ment is pretty straightforward. Basically,
the company just showed us how to use
the device, and ever since it has been
pretty much second nature.
The iTIG II gives users the ability to perform a variety
of tests from the most simple low resistance tests to
Megohm, Hipot and advanced Surge testing. Photo
courtesy of Electrom Instruments
we clean motors and install or service
windings, Peden explains. We use an
electronic analyzer to test the integrity
of the motor windings, to ensure that
they are going to provide our custom-
ers with dependable
performance.
The motors Alli-
ance Pump and Me-
chanical service have
sometimes been sub-
jected to harsh con-
ditions, including
excessive heat, de-
bris, or occasional lightning strikes, all
of which mean that windings have to
be replaced. When a damaged or sim-
ply worn out pump and motor assem-
bly arrives at the shop, Alliance tech-
nicians disassemble and thoroughly
inspect the motor. The windings are
then cleaned, baked and surge tested
to make sure they are good.
We have to be certain that the
windings are good or six months later
a motor could fail, and due to the com-
prehensive warranty we provide, wed
end up eating the cost of repairing the
unit, Peden explains.
Peden says it takes a good analyzer to
do a thorough test on the windings to
make sure that the integrity of the mo-
tor windings is good.
I looked at several
different models, and
decided that the iTIG
II looked like a pretty
user-friendly unit
that performed all of
the tests and reports
that we needed.
The iTIG II is a winding analyzer and
motor tester from Electrom Instruments
(Longmont, CO) that comes with vary-
ing options and output ranges from 4kV
to 12kV. By adding Power Packs one can
go to even higher voltages.
POWER PLANT
APPLICATIONS
Clark Myers, an electrician at Twin
Oaks Power, L.P. (Bremond, TX) a di-
vision of Optim Energy LLC, has been
using Electrom winding analyzers for
The iTIG II looked
like a pretty user
friendly unit that
performed all
of the tests and
reports.
1310pe_200 200 10/17/13 9:10 AM
BE1-11t Transformer Protection System
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1310pe_201 201 10/17/13 9:10 AM
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1310pe_202 202 10/17/13 9:10 AM
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203
Mobil SHC Pegasus
Mobil SHC Pegasus

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natural gas engine component reliability,
deliver exceptional engine cleanliness,
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2013 Exxon Mobil Corporation.
All trademarks used herein are trademarks or registered
trademarks of Exxon Mobil Corporation or one of its subsidiaries.
Engine Oil, Synthetic
FLUOR, WE ARE
PROBLEM SOLVERS
With worldwide energy consumption
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1310pe_203 203 10/17/13 9:10 AM
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204
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Brochure HRS 1188 describes three differ-
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(888) TRI TOOL (916) 288-6100 tritool.com
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2013 Babcock & Wilcox Power Generation Group, Inc.
All rights reserved.
Secure remote access to air quality data through
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1310pe_205 205 10/17/13 9:10 AM
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the Energy Industry at PennEnergy.com
The School of Engineering and its Institute of Electrical
Engineering invites applications for a tenure track assis-
tant professor position in the area of Power Electronics.
A senior hire may be considered in exceptional cases.
A strong expertise is requested in the broad fields of devic-
es and circuits for power switching and energy conversion,
including demonstration of experience in device technology,
circuit design and experimentation. Specific research areas
of interest include, but are not limited to: (a) advanced power
semiconductor devices in emerging technologies (e.g., GaN,
SiC, ), (b) power interfaces to low and medium voltage grid
systems, (c) applications to vehicular control (automotive and
train) as well as to renewable energy systems.
The successful candidate is expected to initiate independent,
creative research programs and to be committed to excellence
in undergraduate and graduate teaching. Significant start-up
resources and state-of-the-art research infrastructure will be
available. Salaries and benefits are internationally competitive.
Applications should include a cover letter with a statement
of motivation, curriculum vitae, list of publications and pat-
ents, concise statement of research and teaching interests,
and the names and addresses of 5 references. Applications
must be uploaded in PDF format to the web site:
power-electronics.epfl.ch
Candidate evaluation will begin on 15 December 2013.
Enquiries may be addressed to:
Prof. Giovanni De Micheli
Search Committee Chair
For additional information on EPFL, please consult the web
sites www.epfl.ch, sti.epfl.ch and iel.epfl.ch.
EPFL is committed to increasing the diversity of its faculty,
and strongly encourages women to apply.
Faculty Position in Power Electronics
at the Ecole polytechnique fdrale de Lausanne (EPFL)
usa.siemens.com/searchjobs
Don
t follow the leader.

Join their team.

If youre in sales and want to work for a leading supplier of
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1310pe_207 207 10/17/13 9:10 AM
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211
INDEX
RS# COMPANY PG# RS# COMPANY PG# RS# COMPANY PG#
70 A J Weller Corporation 95
www.ajweller.com
65 Aarding Thermal Acoustics BV 90
www.aarding.com
114 Amec E&C Serv 157
www.amec.com/power
26 AP & M 45
www.apm4parts.com
85 Apex Engineering Products 112
www.apexengineeringproducts.com
25 API Heat Transfer 44
52 Areva 75
www.us.areva.com
119 Atlas Copco 165
www.atlascopco.us
96 Auma Actuators Inc 125
www.auma-usa.com
43 Babcock & Wilcox Co 63
www.babcock.com
15 Babcock & Wilcox Co 19
www.generationmpower.com
33 Babcock Power Inc. 52
www.babcockpower.com
80 Baldor Electric 107
www.baldor.com
143 BASLER ELECTRIC CO 201
www.basler.com
Bechtel 67
31 Braden Manufacturing 50
www.braden.com
18 Brand Energy and
Infrastructure Services 35
www.beis.com
BRANDENBURG
INDUSTRIAL SERVICE CO. C4
www.brandenburg.com
9 Brush Turbogenerators 21
www.brush.eu
104 Buckman 138
www.buckman.com
117 Capstone Turbine Corp. 163
www.capstoneturbine.com
46 Carver Pump Company 66
www.carverpump.com
122 Caterpillar Inc 169
www.catgaspower.com
55 CB&I 79
www.cbi.com
135 Ch2m Hill 189
www.ch2mhill.com
35 Check All Valve Mfg Company 54
www.checkall.com
8 Chromalloy 31
www.chromalloy.com
130 Chromalox 181
www.chromalox.com
108 Circor Energy Products 147
www.circorpowerprocess.com
81 Clark Reliance Corporation 109
www.clark-reliance.com
112 Clearspan Fabric Structures 151
www.clearspan.com/adpwre
113 Cleaver Brooks Inc/Nebraska Boiler 155
www.cleaverbrooks.com
45 Clyde Bergemann Power Group 65
www.cbpg.com
103 Coal Gen 2014 137
www.coal-gen.com
66 Colfax Fluid Handling 91
www.colfaxcorp.com/power-generation
105 Conbraco Industries Inc 139
www.apollovalves.com
71 Cormetech Inc 96
www.cormetech.com
132 Corrpro 183
www.corrpro.com
24 Cummins Generator Technologies 43
www.stamford-avk.com/applications
50 Doosan Heavy Industries
& Construction 73
www.doosanheavy.com
129 Dresser-Rand 180
www.dresser-rand.com/products/gimpel
75 Duke Energy 102
www.duke-energy.com
61 Elster 86
www.elster-instromet.com
142 Enercon Services Inc 199
www.enercon.com
23 Entegra GMBH 42
www.primtech.com
20 Fibrwrap 37
www.fibrwrap.com
123 Fisher Tank Company 171
www.fishertank.com
128 Fluid Energy Controls 180
www.fecintl.com
30 Fluor Corp 49
www.fluor.com
10 FLUOR CORP 22
www.fluor.com
57 Frontier Water Systems 82
www.frontierwater.com
109 GE 149
www.ge-flexibility.com
64 GE 89
www.adapt.ge.mcs.com
22 GE Water & Process Technologies 41
www.geimagination.com/CMS/Power
94 GEA HEAT EXCHANGERS GMBH 123
www.gea.com
60 Geda USA, LLC 85
www.gedausa.com
7 Generac Power Systems 17
www.generac.com/industrial
63 Gorman Rupp Company 88
www.grpumps.com
56 Gundlach Crushers/
Pennsylvania Crusher 81
www.terrasource.com
124 Haldor Topsoe AS 173
www.topsoe.com
51 Harco 74
www.harcolabs.com
127 HDR 179
www.hdrinc.com/power
79 Hilliard Corporation 105
www.hilliardcorp.com
47 Hipower Systems 70
www.hipowersystems.com
76 Houston Dynamic Service Inc. 102
www.houstondynamic.com
78 Hydrolox 104
www.hydrolox.com
Hytorc 15
www.hytorc.com
Hytorc 13
www.hytorc.com
98 IEA LLC 129
www.iea.net
83 Ingersoll Rand 111
www.ingersollrandproducts.com/c800
89 Innovative Steam Technologies 117
www.otsg.com
62 Insituform 87
www.insituform.com
6 Integrated Power Services 11
www.ips.us/rewind-technologies
86 Invensys Systems 113
www.invensys.com
49 Jasc 72
www.jasc-controls.com
13 Kiewit Power Inc 25
www.kiewit.com/power
120 Kral Ag 166
www.kral-usa.com
40 Larsen& Toubro Limited 59
www.lntvalves.com
90 Magnetrol International 119
www.magnetrol.com
97 Man Diesel SE 127
www.man-bluefire.com
106 Marrone Bio Innovations 143
www.gotmussels.com
126 Matrix PDM Engineering 177
www.matrixpdm.com
87 Mee Industries Inc 114
www.meefog.com
111 Metso Automation Usa Inc 151
www.metso.com
41 Michigan Seamless Tube 61
www.mstube.com
5 Mitsubishi Power Systems, Inc. 9
www.mpshq.com
77 Mobil Industrial Lubricants 103
www.mobilindustrial.com
19 Multi-Contact USA 36
www.multi-contact-usa.com
16 NEM BV 32
www.nemusacorp.com
93 Nexus Engineering 122
www.nexus-tech.com
53 Nol-Tec Systems Inc 76
www.nol-tec.com
1310pe_211 211 10/17/13 9:10 AM
www.power-eng.com
212
INDEX
RS# COMPANY PG# SALES OFFICE RS# COMPANY PG#
1421 S. Sheridan Rd., Tulsa, OK 74112
Phone: 918-835-3161, Fax: 918-831-9834
Sr. Vice President North
American Power Group

Richard Baker
Reprints

Foster Printing Servive
4295 Ohio Street
Michigan City, IN 46360
Phone: 866-879-9144
National Brand Manager

Rick Huntzicker
Palladian Professional Park
3225 Shallowford Rd., Suite 800
Marietta, GA 30062
Phone: 770-578-2688, Fax: 770-578-2690
AL, AR, DC, FL, GA, KS, KY, LA, MD, MO,
MS, NC, SC, TN, TX, VA, WV
Brand Sales Manager

Dan Idoine
806 Park Village Drive
Louisville, OH 44641
Phone: 330-875-6581, Fax: 330-875-4462
CT, DE, IL, IN, MA, ME, MI, NH, NJ, NY,
OH, PA, RI, VT, Quebec, New Brunswick,
Nova Scotia, Newfoundland, Ontario
Brand Sales Manager

Tina Shibley
1421 S. Sheridan Road
Tulsa, OK 74112
Phone: 918-831-9552; Fax: 918-831-9834
AK, AZ, CA, CO, HI, IA, ID, MN, MT, ND,
NE, NM, NV, OK, OR, SD UT, WA, WI, WY,
Alberta, British Columbia, Saskatchewan,
Northwest Territory, Yukon Territory,
Manitoba
International Sales Mgr

Anthony Orfeo
The Water Tower
Gunpowder Mills
Powdermill Lane
Waltham Abbey, Essex EN9 1BN
United Kingdom
Phone: +44 1992 656 609, Fax: +44 1992 656 700
Africa, Asia, Central America, Europe,
Middle East, South America
European Sales

Asif Yusuf
The Water Tower
Gunpowder Mills
Powdermill Lane
Waltham Abbey, Essex EN9 1BN
United Kingdom
Phone: +44 1992 656 631, Fax: +44 1992 656 700
Europe and Middle East
Classifieds/Literature Showcase

Account Executive

Paige Rogers
1421 S. Sheridan Rd.
Tulsa, OK 74112
Phone: 918-831-9441, Fax: 918-831-9834
email: [email protected]
37 Stanley Consultants Inc 56
www.stanleyconsultants.com
73 STF Spa 98
www.stf.it
12 Structural Integrity Associates 24
www.structint.com/power-eng
121 Super Radiator Coils 167
www.customaircoolers.com
67 TDC Filter 92
www.turboweb-media.com
36 Team Industrial Services 55
74 Testo Inc. 99
www.testo350.com
44 The Society for Protective Coatings 64
www.sspc.org
11 TIC/Kiewit 23
www.ticus.com
91 TMEIC 120
www.tmeic.com
32 Topline Energy Systems Inc 51
www.topline-energy.com
17 Tranter Radiator Products Inc. 34
www.tranter.com
138 Tri Tool, Inc 193
www.tritool.com
118 Turbo Parts LLC 164
www.mdaturbines.com/turbo-parts
133 United Rentals Inc 185
www.unitedrentals.com
102 Universal Aet 136
www.universalaet.com/enclosures
88 URS Corporation 115
www.urs.com
100 Valvtechnologies, Inc 133
www.valv.com
144 Victory Energy Operations LLC C3
www.victoryenergy.com
39 Victory Energy Operations LLC 58
www.victoryenergy.com
69 Volvo Penta of the Americas 94
www.volvopenta.com/industrial
42 Wanzek Construction Inc 62
www.wanzek.com
140 Wartsila Corp 195
www.smartpowergeneration.com
72 Weg Electric Motors 97
www.weg.net/us
14 Westinghouse Electric Co 29
34 Wood Group Gas Turbine Services 53
www.woodgroupgts.com
134 Zeeco Inc 187
www.zeeco.com
Advertisers and advertising agencies assume lia-
bility for all contents (including text representation
and illustrations) of advertisements printed, and
also assume responsibility for any claims arising
therefrom made against the publisher. It is the
advertisers or agencys responsibility to obtain
appropriate releases on any items or individuals
pictured in the advertisement.
141 Nooter Eriksen 197
www.ne.com
137 Nord-Lock\Superbolt 192
www.nord-lock.com
3 Norit Americas Inc 5
www.norit-americas.com/extra
95 OFS Specialty Photonics Division 124
www.specialtyphotonics.com
92 Orion Instruments 121
www.orioninstruments.com
99 Parker Hannifin Corporation 131
www.parkerpowergen.com
58 PCC Energy Group 83
www.pccforgingahead.com
139 PENNWELL CORPORATION 194
www.power-eng.com/webcasts
125 PHG Energy 175
www.phgenergy.com
68 PIC Group Inc 93
www.picworld.com
110 POWER-GEN International 150
www.power-gen.com
136 POWER-GEN International 191
www.powergenfinancialforum.com
29 Powerbarge Corporation 48
82 Process Barron 110
www.processbarron.com
4 ProEnergy Services LLC 7
www.proenergyservices.com
107 PW Power Systems 145
www.pwps.com
115 Rajysan Inc 159
www.mmdequipment.com
48 Reliable Turbine Services 71
www.reliableturbineservices.com
1 Rentech Boiler Systems C2
www.rentechboilers.com
131 REW North America 182
www.renewableenergyworld-events.com
101 Rexnord Corporation 135
www.vag-group.com
54 Robinson Fans 77
www.robinsonfans.com
38 Rolls Royce Energy Systems 57
www.rolls-royce.com
21 Roxul Inc 39
www.roxul.com
59 Schmidt & Clemens
GmbH & Co. KG 84
www.schmidt-clemens.com
27 Scottish Development International 46
www.sdi.co.uk/energy
28 Siemens Ag 47
www.siemens.com/energy
2 Siemens Industry 3
www.usa.siemens.com/ruggedcom
84 Southwire Company 112
www.southwire.com/apps
116 SPX 161
www.spx.com
1310pe_212 212 10/17/13 9:10 AM
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1310pe_C3 3 10/17/13 10:31 AM
1310pe_C4 4 10/17/13 10:31 AM

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