The magazine for the international power industry
NORTH AMERICA’S
DRIVE TO CUT CO2
SAFETY MEASURES
FOR COAL PLANTS
TIPS FOR SELECTING
THE RIGHT DRIVE
NEW SOLUTION FOR
GRID FLEXIBILITY
November 2014
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1411PEI_C1 1
11/10/14 9:54 AM
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POWER ENGINEERING INTERNATIONAL
NOVEMBER 2014/// VOLUME 22/// ISSUE 10
Contents
4
Industry Highlights
52
Diary
51
Ad Index
Canadian CCS project offers carbon-reduction breakthrough - p12
Source: SaskPower
Features
30
6
The rise of the digital power plant
Retroftting electrostatic precipitators with a high-frequency
switch mode power supply can reduce particulate emissions
and improve performance.
How real-time analysis and simulation software is bringing
operational benefts for combined-cycle plants.
12
Driving a low-carbon path for American power
36
An engineer’s guide to selecting a drive
40
Strengthening safety in mills and silos
44
Developments in power plant fre detection
The challenges and solutions involved in fre detection for
power plant operators.
A new approach to nuclear decomissioning
Meeting the challenges of decommissioning multiple nuclear
sites with a programmized approach.
Equipment selection and operating criteria are vital for
reducing fre risk in coal storage facilities.
28
Dynamic line rating: a solution for fexibility
Dynamic line rating technology can increase the capacity of
overhead transmission lines while reducing congestion.
How to fnd the optimal motor for an application while
avoiding design errors and saving money.
24
Advances in vacuum circuit-breakers
Technology advances now allow vacuum circuit-breakers to
be used in generator switching applications.
A look at North America’s new generation of low-carbon
power generation technologies.
20
A fresh perception of ESP
46
Desuperheaters rise to new challenges
How a new generation of desuperheaters is addressing
today’s 50- and 60-Hz combined-cycle power generation.
On the cover
Increasingly fast and sophisticated real-time plant analysis software is unlocking improved predictability, reliability and fexibility for combinedcycle plant - p6. Cover image credit: Siemens
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1411PEI_1 1
Power Engineering International November 2014
1
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11/10/14 9:45 AM
Industry Highlights
ubsidies – can’t live with them, can’t live
S
“We are doing our utmost to be in line
without them: at least that’s how it often
with global trends and develop these lines of
seems in the power industry.
generation,” he said.
They often dominate debates at energy
Also speaking at Russia Day was Adnan
conferences around the world, and it was no
Amin, director of the International Renewable
different at POWER-GEN Middle East in Abu
Energy Agency
Dhabi in October.
meeting the world’s rising energy demand
“Subsidies are the biggest ailment that
afficts the Middle East power sector,” said Dr
said
that
with the current global energy mix would be
“catastrophic”.
Hisham Khatib, honorary vice-chairman of the
World Energy Council.
(IRENA), who
Mr Amin said that any move to meet
demand with fossil-fuelled technology would
Speaking at the opening ceremony of
“lock in pollution and climate change”.
POWER-GEN Middle East, Dr Khatib said that
He said what was needed was a shift to
Middle East power generation subsidies use
more renewable technologies and added
8.4 per cent of the region’s GDP and account
that this was already happening.
for half of the energy subsidies in the world.
He said the continued use of subsidies was
the key factor in the Middle East’s rocketing
“Investment in renewables is booming,”
he said. “More than 100 GW of capacity has
been added every year for the past years.”
energy demand – up to 8 per cent a year for
He said fnancing of renewable projects
the last decade, which is almost four times the
was getting cheaper because the perceived
fgure for any other country in the world.
risks associated with ‘green’ technologies were
Yet he added that “subsidies beneft the
dropping.
rich, less the poor”.
Amin added that “Russia can play a very
And while he said that there were “shy”
important role in the renewables story” and
attempts to phase out subsidies, he stressed
that the Federation has “vast potential” to
that these needed to be made a “top priority”
embrace clean technologies.
and put a price tag on this of $140 billion of
Russia plans to derive 4 per cent of its
investment in the next fve years – which rises
power from renewables by 2020, which
to $230 billion if transmission and distribution
Adnan said was “a viable target”. He added
work is included.
that if Russia – which has applied to join the
Dr Khatib was joined on the stage at the
International Renewable Energy Council – hit
opening ceremony by Russia’s deputy energy
this target, it would displace six million tonnes
minister Yury Sentyurin, who used his speech
of carbon dioxide a year.
to stress the importance of international
collaboration on energy projects.
REthinking
Energy
in
which
the
organization explores “the changes that are
becoming more dynamic yet less predictable”
transforming the way we produce and use
and that the “silver bullet” to secure energy
energy, and how they will affect governments,
supplies for countries around the world was
businesses and citizens alike”.
“politically unbiased co-operation”.
In the foreword to the report (look out for
Mr Sentyurin also later spoke at Russia Day,
our feature in next month’s PEi), Amin says that
a special event being held as part of POWER-
it is “no longer a matter of whether but of when
GEN Middle East, which returned to Abu Dhabi
a systematic switch to renewable energy
for the frst time in 12 years.
takes place – and how well we manage the
told
a
packed
audience
that
transition”.
renewables were going to play a key role in
the Russian Federation’s future energy mix.
Probably true, even if he’s talking in
decades. What is certainly true – in the Middle
He said a target had been set of having
East and every other region of the world – is his
6 GW of renewables online by 2020, which
next statement: “The power sector is changing
would account for 4 per cent of the Russian
so fast that policymakers are fnding it hard to
Federation’s energy mix.
keep up.”
4
1411PEI_4 4
Kelvin Ross, Editor, www.PowerEngineeringInt.com
IRENA has just published a new report
called
He said that “the global power markets are
He
“Power generation
subsidies account for
8.4 per cent of the
Middle East’s GDP
and make up half
of the energy subsidies
in the world.”
Power Engineering International November 2014
Follow PEi Magazine on Twitter:
@PEimagzine
Follow me: @kelvinross68
www.PowerEngineeringInt.com
11/10/14 9:45 AM
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11/10/14 9:45 AM
Intelligent analytics collect vast amounts of data
Credit: Dreamstime
Operations and maintenance
Big data unlocks
better effciency
With increasingly fast
and sophisticated
real-time plant analysis
and simulation software
comes improved
predictability, reliability
and fexibility – all of
which look certain to
bring operational benefts
for combined-cycle plant,
writes Penny Hitchin
6
1411PEI_6 6
T
oday’s rate and speed of digital
be promptly looped back into the decision
development
process.
and
rate
phenomenal,
is
The physical world is increasingly getting
mirrored in the power generation
online as objects, devices and machines
industry:
acquire
of
this
is
of
rapid
development
digital
intelligence,
while
advances in connectivity mean that objects
enabling increasingly sophisticated operation
can be wirelessly integrated into information
of combined-cycle gas turbine plant. Big data,
networks. The last few years have seen a huge
the Internet of Things, wireless mesh networks
increase in the use of wireless sensors and
and cloud computing are all making their
instruments in power plants.These observe and
mark.
monitor their environment, communicating
and
information about temperature, pressure, fow
capacity have enabled collection, analysis
and vibration from the heart of the power
and
plant back to the control centre.
storage
in
technology
more
is
Increases
information
change
of
computing
increasing
speed
volumes
of
information. New software platforms are used
Big data is generating datasets that are
to interpret data and feed back information
increasing exponentially in both complexity
enabling optimization of operations and
and volume. Analyzing, storing and applying
maintenance.As the speed and sophistication
this
of real-time analytics increase, insights can
Companies such as GE are building cloud-
Power Engineering International November 2014
data
is
a
considerable
challenge.
www.PowerEngineeringInt.com
11/10/14 9:46 AM
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11/10/14 9:46 AM
Operations and maintenance
transforming the pattern of demand, so that
combined-cycle plants are called upon to
provide fexible peak load. For an existing
power plant operating in a deregulated
competitive market, accurate prediction of
plant capacity and fuel consumption under
expected conditions for the days ahead is
essential. Weather information (notably the
likely availability of wind, hydro and solar)
should be factored in to the equation.
In order to bid into the market, plant
operators need the ability to make accurate
predictions of future operational costs. Under
a capacity market operators will be looking
to predict how best to operate in the next two
weeks, informing their bids into the market.
Petek says: “In the past, in a regulated
market, you could look back at the price of
Going forward, plant performance and asset condition will be monitored with increasing reliability
Credit: Siemens
operation to make a price. Now the historic
price of power is less signifcant: you have to
bid into the future, looking at where the market
based services with intelligent analytics to
requirements of the tender and producing the
collect and combine vast amounts of data
most competitive tariff.
to use in industries which include power
generation.
Factors will include likely demand and
The contract is for a power and water
purchase agreement for 25 years and bidders
must
around
100
weather forecast for the next two weeks.
“Based on this predictive work, you feed in
documented
your fossil generation and look at how many
Software modelling
operating points so the government can
startups do you want to use in the next two
Ambient and load conditions signifcantly
evaluate the bid in technical terms. VTU’s Dr
weeks, what will be the cost of stop-and-go
affect gas turbine and combined cycle
Josef Petek explains why the simulation plays
generation. Does it make sense to have low-
performance, thus process simulation plays a
a vital role in putting together the bid:
load parking position? Does it make sense
key role in every large project.
submit
is going, depending on the renewables.”
“There is a very strong emphasis on the
to reduce load to a minimum because
to
documentation of the technical capability
electricity price is so low that it does not pay
simulate the thermodynamics and drive the
of the plant. You are going for a long-term
to shut down the plant and you are maybe
optimization of the power plant. Experts can
relationship
paid for quickly ramping up and producing if
compile detailed models of gas turbines and
guarantees. The government owns the gas
all major components and simulate plant
and is the sole buyer of the products, electricity
In the past, effciency was the priority for
operations under the entire range of ambient
and water, so understanding the effciency
combined-cycle plant, but on networks that
and load conditions. Linking market models
and capacity of the power plant is essential.”
give priority dispatch to renewable sources
Sophisticated
software
is
used
that
includes
performance
immediate need arises?”
incorporates fnancial and environmental
Thermal power plant generation has
it is increasingly fexibility, startup time and
information so that operational costs can be
traditionally been dictated by load demand,
low load operation. Operators will rely on
projected.
but the increasing supply of intermittent
emerging predictive software to provide the
renewable energy, notably in Europe, is
answers.
Austrian software specialist VTU Energy
is currently modelling a large combined
water and power plant for a bidder for an
IWPP (Independent Water & Power Producer)
contract in the Middle East.
The developers pull together technical
information from vendors of gas turbines,
desalination units and other components
which VTU feeds into its overall plant model for
use in the bid process.
The company uses the Ebsilon Professional
heat balance software and its own Gas
Turbine Library to build an accurate plant
simulation model. This is used to fnd a
commercial optimum while meeting the
8
1411PEI_8 8
Power Engineering International November 2014
HRSG detail from Ebsilon Professional heat balance software
Credit: VTU Energy
www.PowerEngineeringInt.com
11/10/14 9:46 AM
Operations and maintenance
Big data and cloud computing
cycle power plant. Increasing the amount
Hachenski explains GE’s approach to
Number-crunching the mounting volumes of
of data from within the power plant means
making screens intuitive and user-friendly:
data from a power plant requires additional
installing smart devices and instruments. GE
“One of the things we have done is to
processing power and broadband capacity.
has done a lot in development around smart
redesign the screen ‘look and feel’ so that
The aim is to increase effciency of both
bus technology to reduce the number of
operators can easily and quickly see how
operations and asset maintenance through
terminations required to install the technology.
the plant is running. We are trying to visually
improved
Reducing wired connections saves parts,
represent what is important to the operator.
costs and time.
We do not want to burden the operator with a
understanding
of
the
plant
processes.
Eric
Kauffman,
Software
&
Analytics
product
tonne of information or with too many alarms.”
Strategy Leader at GE, says: “We have created
manager at GE, explains: “By using smart bus
Alarms alert the operator to a change, inform
a cloud-based version of our Effciency Map
technology, we dramatically reduced the
the operator of the nature of the change,
product which brings data back centrally.
installation time by decreasing the number of
and guide the operator toward a course of
This enables us to get better data by adding
wires and terminations. For instance, we have
corrective action.
a reconciliation element that would be too
reduced 3600 terminations down to 1800, a
complex to do on-site. It also enables our
50 per cent reduction in the plant.”
engineers to provide a second set of eyes for
Mark
Hachenski,
executive
GE leverages its new GE Software business
and team of user experience experts to help
Hachenski gives an example of how
make the software and experience more user-
hardware developments go hand in hand with
friendly. The interface was tested by bringing
He cites an example of the benefts:
advances in communications technology: “In
in operators to use simulated screens while
“Calculations using plant sensors might show
addition, smart bus technology can provide
observers watched them walk through various
a curve with uncertainty rate of 1–2 per cent.
higher reliability for customers.
alarms or faults in the system.
the customer.”
By using a combination of a physics model,
“In the past we used hydraulic fuel skids
Hachenski says: “Customers tell us that
a precision test and the data reconciliation
which would only annunciate four or fve
operators make mistakes as they try to
algorithm we have been able to demonstrate
analogue diagnostics. Moving into the twenty-
manually start up systems. We are looking at
overall uncertainties of below 1 per cent.
frst century, with a smart bus electronic fuel
how to automate the process so that a startup
“This gives customers better visibility to the
skid we get 60 digital health bits to come back
screen walks them through a step-by-step
existence and location of problems in the plant
into our system. This provides better visibility of
sequence. However while some customers
– and, more importantly, where the problem
what is going on for quicker actions to resolve
want operators to follow this, others don’t want
is not. It also gives a better understanding of
problems.”
operators interfering, so the software interface
plant capability so purchasers are able to buy
However sophisticated the software and
fuel more effciently and reduce the amount
remote control systems, human operators
of safety margin that traders put into their bid.
must accommodate different operators.”
are an essential part of the system. It is not
Wireless mesh networks
some
helpful to swamp them with masses of data:
The development of low-cost, fexible wireless
deregulated US markets, an improvement of 1
it is important that the information presented
networks has opened up the potential for
per cent in accuracy can be worth over half a
by the software is relevant, accessible and
additional data collection from the heart
million dollars per year in a typical combined-
comprehensible.
of the power plant, increasing real-time
Kauffman
estimates
that,
in
Load quickly
ñ safely
www.rs-seliger.de
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1411PEI_9 9
Power Engineering International November 2014
9
11/10/14 9:46 AM
Operations and maintenance
from the heart of the power plant. Intelligent
devices can be coupled to intelligent networks
and the information can be analyzed remotely,
locally or through a combination of both.
Having collected the data, the control
system’s software is able to analyze it against
historical
baseline
maintenance
data
or
other
for
predictive
performance
evaluation.
Williams says: “As we go forward, I think we
will see a merging of technologies so that
we can watch the plant in real time from the
distributed control system and use simulation
that is closely tracking that performance to
run ‘what-if’ scenarios that will enable us to
Human operators are still an essential part of the system
Credit: Emerson Process Management
make process adjustments for more effcient
operations. Synchronizing the simulation with
real-time plant operation will allow asset
understanding of the way that processes
control system. A wireless instrument can
managers to optimize plant performance,
and components operate. This also allows
collect
reduce environmental footprint and keep
for performance validation and improved
unavailable due to the impracticality and
maintenance practices, including predictive
expense of hardwiring in a diffcult-to-reach or
approaches.
harsh environment.
information
that
was
previously
consumable costs as low as possible.”
Going forward…
Traditional networks rely on a small number
The data can then be integrated through
Software specialists, plant manufacturers and
of wired access points or wireless hotspots
the wireless network and sent to the control
operators say they are always learning from
for communication. In a wireless mesh
system so that it can be analyzed and
the data. Going forward, better analytics, a
network, the network connection is spread
performance
high degree of physics models plus big data
out among numerous wireless mesh nodes
equipment. This leads to the best possible use
(smart transducers and devices acting as
of plant assets.”
adjustments
made
to
the
look certain to bring operational benefts.
Performance will be diagnosed in real
transmitters that function in the same way
In the past a small number of wireless
time, sustaining output and effciency, while
as a wireless router) and share the network
instruments may have been used around
asset condition will be monitored and
connection across a large area. Information
the plant. Williams says that they are being
predicted with increasing reliability.
travels wirelessly across the network from one
increasingly used for a range of performance
mesh node to the next.
testing and diagnostics functions.
The nodes are programmed with software
“Power generators started using wireless
and
smart
performance,
enabling plant to get online faster from a hot
validate
or cold start and despatch faster. Software
network, and dynamic routing means they
performance of new equipment, but are
can co-ordinate between the steam turbine
automatically choose the quickest and most
now fnding that the accuracy of wireless
and the gas turbine to reduce startup time
reliable path. If one node is inoperative, the
instrumentation is so good that it can be
by 50 per cent.
rest of the nodes can still communicate with
used it as a backup to wired devices and to
each other, directly or through one or more
verify plant performance. A wireless network
and
intermediate nodes. Wireless mesh networks
can support dozens of instruments used to
hardware, software and communications
can self-form and self-heal.
validate performance.”
yield increasing amounts of information
with
which
The rate of change looks set to continue
accelerate
as
developments
in
wireless
about conditions at the heart of the plant.
wired to a network connection, which then
instrumentation can be deployed compared
GE’s Hachenski says: “We are learning every
wirelessly shares its connection with all other
to hardwired devices means that many new
day. The amount of information we are
nodes in its vicinity.
data sets are becoming readily available.
getting that we didn’t have before gives us so
Effciency Solutions Manager Jeff Williams of
As Williams says, “It is easy to hang a wireless
much more visibility. We have only scratched
Emerson Process Management is enthusiastic
transmitter onto a piece of equipment for
the surface of fguring out how to take it to
about the potential of wireless mesh networks
temporary analysis – getting this information
the next step.”
to improve data collection from power plants.
is something which would have previously
“Wireless networks have been available
required the use of many portable instruments
Penny Hitchin is a journalist focusing on
as well as associated manpower.”
energy matters.
for a number of years,” he says, “but today we
ease
to
improve
instruments
The
networks
software
can
that tells them how to interact within the larger
Only one gateway needs to be physically
and
Sophisticated
instruments
see them with expanded functionality. Wireless
Wireless networks and sensors are being
area networks in power plants are being used
used to measure increasing amounts of
in parallel with the plant’s real-time distributed
temperature, pressure, vibration and fow data
10
1411PEI_10 10
Power Engineering International November 2014
i
Visit www.PowerEngineeringInt.com
for more information
www.PowerEngineeringInt.com
11/10/14 9:46 AM
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1411PEI_11 11
11/10/14 9:46 AM
Carbon abatement
Canada’s Boundary Dam is the frst commercial-scale post-combustion CCS process on a coal-fred power plant
Credit: Sask Power
Driving a
path for North
American power
A confuence of factors
is driving the North
American power sector
down a low-carbon
road. Responding to
customer demands,
OEMs are expanding the
capabilities and material
composition of their
products in order to meet
effciency demands and
develop a new generation
of technologies, fnds
David Appleyard
12
1411PEI_12 12
A
lthough the US lags behind
circumstances states will have until 2018 to
Europe’s
deliver their proposals.
policymakers
in
efforts to address carbon
Power plants account for roughly one
emissions from the power
third of all US greenhouse gas emissions and
sector, under the Obama
while there are limits in place for emissions of
administration the Environ-
pollutants such as arsenic, mercury, sulphur
mental Protection Agency (EPA) has moved to
dioxide, nitrogen oxides and particulates, until
tackle carbon dioxide output from electricity
recently the US has been largely resolute in its
generation.
rejection of constraints on carbon emissions.
In June the EPA issued a proposal for a
However, in June 2013 President Obama
so-called Clean Power Plan, under which
issued a presidential memorandum directing
guidelines will be set for states in order to
the EPA to complete greenhouse standards
address greenhouse gas emissions from
for the power sector under the auspices of the
existing fossil fuel-fred generation assets.
Clean Air Act.
Refecting that different states have different
As a result, by the time the proposed plan is
mixes of sources and opportunities, the EPA
fully implemented in 2030, the EPA aims to cut
plans to deliver state-specifc, rate-based
carbon emissions from the power sector by
goals for CO2 emissions from the power sector.
30 per cent below 2005 levels nationwide, as
Currently under consultation, a fnal ruling
well as cut particulates, nitrogen oxides and
on the plan is due in June 2015. States are now
sulphur dioxide by more than 25 per cent as a
attempting to identify a path forward using
coincidental beneft.
either current or new electricity production
This, says the EPA, will avoid up to 6600
and pollution control policies to meet the
premature deaths annually and provide up
proposed programme’s goals. These plans
to $93 billion in climate and public health
are due in June 2016, though under some
benefts. Simultaneously, the agency expects
Power Engineering International November 2014
www.PowerEngineeringInt.com
11/10/14 9:46 AM
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Carbon abatement
the measures to reduce electricity costs by
effect of such a rule would be to stop the
forces. The dynamism of the US oil and gas
roughly 8 per cent through increasing energy
construction
industry has created a great reduction
effciency.
generation capacity in the US.”
of
any
future
coal-fuelled
in power generation from coal, and the
Ravi Krishnan, founder of global marketing
This is a point echoed by Krishnan, who
generation mix has seen the biggest beneft
and strategy consultancy frm Krishnan &
says: “The US is moving away from coal and
in terms of carbon footprint and that’s driven
Associates, highlights the policy context for the
it is unlikely that any new supercritical or ultra-
just by economic forces.” As a recent example,
US, but also the challenging market structures
supercritical power plant will be built in the
Nolen cites the hub pricing for gas outside
which have existed to date, saying: “The US
future.”
New York City, where the natural gas price
market was obviously expecting some future
went to $1.70 per million BTU. “There is no way
CO2 emission norms for power plants. However,
Building on market trends
coal can compete with that; it’s due to this
there were no monetization mechanisms
The EPA’s guidelines for existing facilities build
tremendous amount of supply that’s driven
such as a national cap-and-trade system,
on trends already underway in the power
that change,” he says.
penalties, tax credits or subsidies for power
sector that are resulting in a cut in carbon
producers to avail themselves of. Therefore,
intensity, both from existing power plants and
Carbon capture and storage
unlike Europe, there are fewer pre-combustion,
across the evolving generation portfolio as a
Don Ryan, who manages the advanced
post-combustion or advanced combustion
whole.
technology group at Babcock & Wilcox
technologies being demonstrated in the USA.”
As part of the proposed measures, the EPA
Power Generation Group, explains that setting
Certainly, the nation appears to be
offered four ‘building blocks’ that it believes are
carbon emission limits for coal-fred plants
making up for lost time. Measures to address
central to state measures to achieve portfolio-
only marginally above the demonstrated
emissions from existing generating facilities
level reductions in carbon intensity. The EPA
emissions from a gas turbine combined-
follow proposals announced in September
identifes measures to make existing fossil-
cycle plant makes carbon capture and
2013 that set emissions standards for new-
fuelled plants more effcient and suggests
storage a mandatory element for new coal-
build projects, a plan also developed under
despatching lower-emission sources, such as
fred capacity in the US. “Where we see the
Obama’s Climate Action Plan.
natural gas, more often.
regulations for new units is that, even with the
Under this proposal, new large natural
In particular, the emergence of cheap
best-available, highest-effciency boiler and
gas-fred turbines are limited to 1000 pounds
and abundant shale gas has seen the
steam turbine technology, you would need
of CO2 per MWh (about 450 kg/MWh), while
marginal cost of coal-fred capacity become
partial carbon capture to get to the EPA limits,”
new coal-fred units would need to meet a limit
increasingly uncompetitive.
he says.
of 1100 lb/MWh.
Scott Nolen, Global Technical Solutions
The best coal-fred technology on the
However, the American Coal Council
Leader at GE Power & Water’s Distributed
market right now features ultra-supercritical
(ACC) said the EPA’s revised carbon pollution
Power business, highlights the impact of shale
steam
standard for new power plants sets an
gas on cutting US carbon emissions:“The most
3700–4000 psi range and steam temperatures
emissions limit for coal “that cannot be met
remarkable thing is the transformation of the
of 1110–1130oF. However, as Ryan explains:
given current technology. Thus, the practical
generation mix in the US driven by economic
“That doesn’t get you down to the CO2
conditions
with
pressures
in
the
The Petra Nova Carbon Capture Project is expected to capture 90 per cent of the CO2 in the processed fue gas from an existing unit
Credit: NRG
14
1411PEI_14 14
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11/10/14 9:46 AM
Carbon abatement
emission level of a gas turbine combined
cycle without the addition of carbon capture
to a coal-fred boiler.”
As a result, North America has seen some
recent advances in CCS technology. Indeed,
NRG’s carbon capture business recently broke
ground on a 240 MW project at Unit 8 of the
610 MW WA Parish power plant in Fort Bend
County, southwest of Houston, Texas.
The WA Parish Petra Nova Carbon Capture
Project is a commercial-scale system that
is expected to capture 90 per cent of the
carbon dioxide in the processed fue gas from
an existing unit. When complete in 2016, the
project is expected to be the world’s largest
post-combustion
carbon
capture
facility
installed at an existing coal plant.
In October, NRG announced that the
majority of the excavation needed to begin
building was complete, allowing drilling of the
approximately 800 piles that will serve as the
plant’s foundation to begin. NRG has formed
a 50/50 joint venture with JX Nippon Oil & Gas
Exploration Corp to build and operate the
Petra Nova Carbon Capture Project.
The
captured
CO2
will
increase
oil
production at the West Ranch oilfeld some
130 km away, jointly owned by Petra Nova and
Hilcorp Energy Co. Enhanced Oil Recovery
Gas-fred generation and fexible reciprocating engines are increasingly economically attractive
Credit: GE
(EOR) is expected to boost oil production
at the feld from around 500 barrels per
day (bpd) to approximately 15,000 bpd.
up to one million tonnes of carbon dioxide
This is a point echoed by B&W’s Ryan, who
A US Department of Energy grant of up to
annually. The captured CO2 will be used for
notes that the FutureGen research project on
$167 million has been awarded to the
EOR. Babcock & Wilcox Canada was engineer,
oxy-fred combustion, being developed in the
$1 billion project as part of the Clean Coal
manufacturer and constructor of the critical
US state of Illinois, has been delayed by the
Power Initiative (CCPI) programme while
components to retroft the boiler under a
challenges of raising commercial fnance.
additional funding will come from loans of
$107 million contract.
The project’s total capital cost (planning,
$250 million and equity contributions from
Saskatchewan
design and construction) is approximately
invested C$240 million in the demonstration
$1.65 billion, of which DOE will contribute
The project will be constructed under a fxed-
project. Canadian economy minister Bill Boyd
$1 billion and the private sector will contribute
price contract by a consortium composed of
noted: “This project is important because
the remainder.
Mitsubishi Heavy Industries Americas and The
it is applicable to about 95 per cent of the
Says Ryan: “There’s a piece of the funding
Industrial Company using the KM-CDR Process
world’s coal plants.” Likewise Luke Warren,
that the equipment suppliers are putting into
jointly developed by MHI and Kansai Electric
chief executive of the Carbon Capture and
it, the US DOE are putting into it and there’s a
Power Co.
Storage Association, commented: “It is hoped
piece that we needed to go out to commercial
that Boundary Dam will form part of a much-
fnancial institutions. It’s been delayed due to
needed commercial proof point that the
working out the terms with the commercial
economics make sense.”
fnancing institutions to get the last piece of
both NRG and JX Nippon.
October also saw the offcial inauguration
of
SaskPower’s
Boundary
Dam
project,
claimed as the world’s frst post-combustion
The
commercial-scale CCS process on a coalfred power plant.
government
of
However,the economics of CCS technology
funding.”
are still tenuous, as Krishnan explains: “Future
The FutureGen Industrial Alliance was
Saskatchewan,
development of CCS technology will depend
formed to partner with the DOE on the
Canada, the C$1.4 billion ($1.25 billion)
on its cost, CO2 transport and storage
FutureGen 2.0 project to retroft an existing
rebuild project at Unit 3 of the 824 MW coal-
mechanisms, natural gas prices, regulatory
plant. Construction was due to begin on both
fred power plant generates 110 MW. CCS will
factors and the monetization of CO2 emissions.
the plant and the CO2 pipeline and storage
reduce carbon emissions by 90 pe cent and,
Presently the CAPEX of CCS projects and
facility in 2014, with commercial operations
when fully optimized, the process will capture
technology solutions is extremely high.”
originally scheduled for autumn 2017.
Located
16
1411PEI_16 16
in
Estevan,
Power Engineering International November 2014
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Carbon abatement
As Ryan says: “They’re expensive projects
based at older coal-fred plants and coincide
steam temperatures. We expect that to be
and you have to build pilot and demonstration
with opportunities for EOR – the opportunities
done next year, and then another year or two
plants to get everyone comfortable that they
for carbon reduction are based on alternative
from there we will have the ability to test some
can add this technology to their plant.” He
approaches. As Krishnan explains: “Given the
of these components.”
adds: “We’ve been pleased with the DOE
early-stage development of the affordable
Michael Gradoia, Manager of Power
support.They are seeing this to be the future of
large-scale carbon capture technologies and
Generation Product Marketing for GE Power
coal-fred generation.”
associated high CAPEX of transportation and
and Water, also highlights the challenges
An alliance between commercial and
storage, I believe that the industry will focus on
of reducing carbon intensity with power
state parties is also behind Canada’s Canmet
increasing effciency by innovative equipment
generation products. He says: “Gas turbine
advanced
upgrades, best practices and switching to
effciency is primarily a function of fring
currently abundant natural gas.”
temperature
coal-fring
research
project.
Between 1993 and 1995, CanmetEnergy
and
compressor
pressure
invested over C$4 million in building the world’s
He continues: “The new EPA carbon
ratio. There is a need for materials that can
frst advanced oxy-fuel combustion pilot-scale
pollution emission guideline for stationary
withstand those higher temperatures, and
research facility. Since its commissioning in
sources will obviously result in new innovative
cooling technologies that allow you to reduce
1995, CanmetENERGY’s CO2 R&D Consortium
approaches outside of CCS to meet the
the amount of air used for cooling that is
is now in Phase 9, which is developing a CO2
proposed
therefore not used for power.”
capture and compression unit.
seriously look at increasing the effciency of
For example, GE’s latest products, the HA
fossil fuel power plants through upgrading
gas turbines, utilize single crystal alloys in the
Challenging economics
technologies. Switching to coals that will
turbine section. Illustrating the challenges,
But even with government support, the
improve the heat rate of the units and reduce
Gradoia adds: “When looking at a turbine
economics of CCS can be challenging. For
its utilization will also be employed.”
section, there are components that are
targets.
Power
producers
will
example, in late September Leucadia National
Krishnan concludes: “In recent years,
operating at about 400 degrees above
Corporation announced that it had decided
marginal or ineffcient coal-fred power plants
the melting point of the base metals, and
not to proceed with further development of
have been under tremendous pressure to
advanced coatings and cooling technologies
the greater Lake Charles project based on
lower their cost of generation to improve the
are what enable that part to do its job while
“fnal estimates of the likely ultimate cost”.
despatchability of their units.As a result, several
providing a reliable service life.”
The decision came despite a December
innovative
boiler
effciency
improvement
On improving the effciency of existing
2013 announcement from the DOE that it
technologies through retrofts, combustion
coal-fred assets, Gradoia says: “We can help
would support the project to the tune of
controls and fuel switching have been
enhance the effciency of existing units by
$261.4 million under its Industrial Carbon
incorporated. These strategies have resulted in
retroftting the steam turbines with the latest
Capture Sequestration (ICCS) programme.
some modest improvement in CO2 emissions.”
blading and sealing technology.”
The petcoke-fred gasifcation plant was to
Ryan highlights the focus on more effcient
Similarly, B&W is looking at developing
transport the CO2 to the West Hastings oil feld
combustion technologies: “About two years
technologies and techniques to enable units
for use in EOR. The estimated total cost of the
ago we were fortunate to get a contract with
to operate more effciently at reduced load.
Lake Charles CCS project was $435.6 million.
AEP to build the frst [US] ultra-supercritical
The CCS project was to include two Lurgi
unit which is in the just-under-4000 psi steam
The US low-carbon future
Rectisol Acid Gas Removal (AGR) units and
pressure range, but the steam temperatures
More than 25 US states have already set energy
was designed to capture approximately
are up to the 1100–1150 range. That gave a
effciency targets, and more than 35 have set
89 per cent of the CO2 produced.
5 per cent to 6 per cent improvement in heat
renewable energy targets. Meanwhile, it is
Nonetheless, there are efforts to further
rate over the traditional supercritical cycles.”
evident that the DOE will pursue additional
commercialize CCS technology in the US. In
He adds: “We’re involved in a consortium
constraints on carbon.
April SaskPower and Vattenfall signed a fve-
of companies here in the US to develop
Ryan says: “In terms of where we think it’s
year agreement to explore opportunities
advanced supercritical technology. That is
going at some point down the road, it’s hard
for collaboration on CCS knowledge and
pushing the steam pressures up to 5000 psi at
for me to imagine that higher levels of carbon
technologies. More recently, Shell Cansolv,
the turbine inlet.”
capture, up to and including 100 per cent,
the subsidiary of Royal Dutch Shell behind the
He points out the challenges of materials
development
steam
He concludes: “I think it’s a matter of time,
a deal with Technology Centre Mongstad
conditions, saying: “The single biggest area
we just have to keep working on development
(TCM) in Norway for further testing of the CO2
we’re working on now is to make sure we
and getting it to a commercial state.”
capture process.The testing was scheduled to
understand the properties of the material, that
start in the third quarter of this year and will last
it’s going to withstand those pressures and
David Appleyard is a freelance journalist
for approximately fve months.
temperatures, have the life expectancy that
focused on the energy, technology and
developing
utilities like to see, and be able to fabricate
process sectors.
economically viable CCS technology – it is
and repair the material in the feld. We’re in
no coincidence that the projects that have
the process of designing a small test facility to
been developed in North America to date are
actually run some components at the same
Given
18
1411PEI_18 18
the
challenges
of
Power Engineering International November 2014
in
achieving
these
aren’t going to be required.”
technology used at Boundary Dam, agreed
i
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11/10/14 9:47 AM
YOU AIN’T SEEN
NOTHING YET
The new benchmark in electric valve actuators
All will be revealed
Valve World Expo D¸sseldorf
December 2nd ñ 4th, 2014
Hall 3 Booth D36
PROFITRON
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11/10/14 9:47 AM
For use in potentially explosive environments, ATEX certifcation is an option
Credit: Deprag Schulz
Motors and drives
An engineer’s guide
to selecting a drive
Selecting a drive involves
careful consideration
when looking for the
optimal motor for a given
application.
Dagmar Dübbelde looks
at how to avoid design
errors and save money
R
ight from the initial selection of
then this will drastically reduce the torque of
a drive, a designer has to make
the motor.
careful
considerations
when
You can imagine that the developer does
looking for the optimal motor for
not necessarily have the length of hoses at
their application. Determining
the forefront of their mind when designing the
the torque and speed, selecting
machine; equally; the connectors between
a pneumatic motor from suppliers’ catalogues
the flter units and oiler are not considered to
and clarifying the size and connections
be particularly relevant. But it is exactly these
required for the machine – it sounds simple.
throttle points which ultimately determine
But unfortunately it is not that easy, and a rude
whether the machine works correctly and if
awakening may follow if, after installation, the
the motor provides the right torque.
selected pneumatic motor does not produce
the power required. Determining the problem
Steps to selecting the right motor
may take weeks; in the worst-case scenario the
So what are these steps for the selection of
entire drive may have to be redesigned and
the right motor? First of all, the drive system
purchased again. Therefore it is worthwhile to
best suited to the customer’s application must
talk to the specialists at the beginning of the
be chosen. Then the materials of which the
drive design phase.
external parts of the motor are composed are
Deprag Schulz has developed a simple
determined. After these initial decisions, the
guide with six steps to follow so that nothing
theoretically required motor power can be
is forgotten.
calculated and all performance-infuencing
The selection of a pneumatic motor is
20
1411PEI_20 20
factors can be taken into consideration.
not diffcult. But, particularly with pneumatic
The fourth step is the integration of the
systems, there are many factors which can
motor into the complete system of the
decisively infuence the power of an air motor.
machine. You have to decide how the motor
If, for example, when installing a motor it is
will be connected to the machine and
found that too short a hose has been chosen,
which gears are required. Perhaps a brake
Power Engineering International November 2014
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11/10/14 9:47 AM
Through the Alternative Energy Source Incentives
Program (Programa de Incentivo ‡s Fontes
Alternativas ñ PROINFA), a total of
wind power projects have been put into
action, spurring the still nascent industryís
development throughout Brazil.
41
Because of the program, another,
19 biomass thermal stations, powered
by rice husks and sugarcane bagasse, are in
operation with the support of ELETROBRAS.
Cutting-edge projects such as Megawatt
Solar, implemented in Brazilís South Region,
and Xapuri, in the state of Acre, employ solar
photovoltaic panel technology.
ELETROBRAS is committed to generating clean
and renewable energy. The majority of the energy
produced by the company derives from these sources.
ELETROBRAS is one of the leading producers of electric energy in Brazil. In this light, it is encouraging
to know that a substantial portion of this energy stems from clean and renewable sources. In
addition to tapping hydroelectric power, one of the cleanest known sources of energy, ELETROBRAS
Brazilís energy sources and leveraging the related industries. These initiatives have helped transform
the Brazilian energy grid into one of the industrialized worldís most renewable systems.
It is for these reasons that ELETROBRASís work stretches as far and wide as Brazil itself.
B R A Z I L I A N
G O V E R N M E N T
Ministry of
Mines and Energy
eletrobras.com
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11/10/14 9:47 AM
Motors and drives
will be necessary in order to ensure safety
of the system. Then the durability of the
machine must be guaranteed, and fnally the
purchasing and running costs of the motor
must be calculated and optimized.
Pneumatic
motors
are
available
in
diverse design options. Their application and
the intended operating time are of great
importance when selecting the right basic
principles. An air vane motor is suitable for
regular running cycles. If you wish to run it nonstop then you must consider the wear on the
vanes and the shorter maintenance intervals
this requires. In comparison, gear motors and
turbines are maintenance-free and therefore
better suited to continuous operation. In this
case the required speed must be considered.
Turbines and gear motors rotate in upper
speed ranges at approximately 140,000 rpm.
Vane motors are available which rotate at
very low speeds, e.g., 1 rpm. Oil-free operation
is also an option for all three drive principles. A
slight loss of power must be taken into account
with oil-free operation of a vane motor.
Different materials
The second step examines the motor’s
Calculation of theoretical motor power
Credit: Deprag Schulz
construction material. If operating in a dry
surrounding atmosphere and in normal
stationary production, an inexpensive air
to the air motor manufacturers in advance
torque times working speed (nominal speed)
motor made from cast iron will be suffcient.
about your application and to describe it in
divided by 9550 you can fnd the theoretically
Deprag offers a wide spectrum of low-priced
as much detail as possible.
required power in kW.
and machines there are a variety of grinding
Motor power
data is based on varied operating pressures.
motors, drilling motors and milling motors
The next step is the calculation of the
At Deprag this is 6 bar. If the application only
available which are distinguished by their low
theoretical motor power. Motors which are
has 5 bar directly at the motor then the motor
weight and compact size.
designed for use in only one rotational
loses 23 per cent of its power. If there is only 4
For use in the food industry, pneumatic
direction are more effcient than reversible
bar available then motor power is reduced by
motors must be able to withstand cleaning
motors. When determining the rotational
45 per cent. A differing operating pressure is
agents and steam.The Deprag Advanced Line
direction, the pneumatic expert looks towards
so decisive that it must be taken into account
motors with external parts made from stainless
the motor shaft from the air inlet. This is the
at the start of the design phase using the
steel are additionally sealed and lubricated
other way around for electric motors, where
adjustment table, in order to avoid nasty
with food industry standard USDA-H1 grease.
the rotational direction is specifed by looking
surprises.
Basic Line motors. For installation in robots
Pneumatic drives can even be operated
In manufacturers’catalogues,performance
at the motor spindle.
Next, the air supply volume – which is
underwater. In this case it is essential to
First the required working point of the motor
specifed by the air consumption in the
determine the water depth required. If the
is determined: which nominal torque and
manufacturers’ details – must be ensured. Every
motors must be started underwater they
speed under load do you want to reach? The
reduction in the width of the opening, whether
can be used up to a depth of 5 metres. If
most economic use of the motor (least wear
on the feed hose itself or due to connection
the motors are started on the surface and
and least air consumption) is attained by
parts, flters, oilers or the exhaust hose and
then submerged, they can be used in a
running close to the nominal speed. If you look
silencer all have an effect on the air volume.
depth of up to 20 metres without damaging
at the characteristic curve of an air motor, it
Therefore Deprag recommends an exhaust air
the motor. If the motor must be sterilizable,
shows that it reaches its maximum torque just
throttle to its customers to regulate their speed.
as requirements demand in some medical
before standstill (around twice the specifed
Using a throttle on the supply air reduces the
technology applications, then it can be
nominal torque).
speed of the motor but, at the same time, the
equipped with special vanes. There are many
At the nominal speed the air motor reaches
torque is reduced as well. Exhaust air throttles
examples here of why it is important to speak
maximum power. With the formula nominal
can reduce the speed without great loss
22
1411PEI_22 22
Power Engineering International November 2014
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11/10/14 9:47 AM
Motors and drives
of torque. The exhaust throttle means that
permissible axial and radial load on the drive
are particularly maintenance-friendly. The
customers can better utilize the wider working
spindle of the air motor.
patented vane exchange system enables
range which air motors provide.
Air motors are powerful, durable and
an air motor’s vanes to be quickly replaced
framework
in situ using a key and tweezers. Operating
an air motor is reached with lubricated running
conditions determined during the design
costs are determined by the air consumption.
(1–2 drops of oil per 1 m³ air consumption).
phase and compliance with the instruction
The right choice of motor sets the course for
Unlubricated operation can lead to a loss of
manual will ensure the longest possible life of
low running costs. The closer the motor runs to
power of around 10–20 per cent.
the drive. These conditions include adhering
nominal speed (50 per cent of the idle speed),
to the recommended air quality, lubricated
the more effciently the air is used.
The optimal lifespan and performance of
robust.
Adherence
to
the
Design integration
operation, maintenance intervals, a maximum
Deprag Schulz has been using compressed
If the right motor with the required power has
length of the feed hose of three metres and
air as a working medium for many decades.
been found, then the next step is to integrate
suffcient opening widths of the feed hose and
Deprag’s standard programme offers a wide
it into the design. Deprag provides various
connection parts.
range of options and, from this modular
spindle designs and individual fxing methods.
system, individual drive solutions for the
Considering costs
required application can be developed and
than seeking a gear solution separately.
Finally, the purchase price is the predominant
produced at an attractive price-performance
Within the Deprag range there are numerous
consideration in the acquisition of a new
ratio. Around 85 per cent of the frm’s projects
air motors with integrated planetary gears,
drive system. But the designer should also
in the feld of air motors are special solutions
spur gears and worms gears. If you require
remember running expenses and consider the
which have been quickly and simply realized
additional safety then a holding brake can
operating costs and price for maintenance
from its standard programme.
be recommended. In the manufacturer’s
and servicing. When planning and selecting
programme you can also fnd brake motors.
a new system, the question must be asked:
Dagmar Dübbelde is Product Manager, Air
For use in potentially explosive environments,
how readily available are replacement parts
Motors at Deprag Schulz
there are also options with the required ATEX
and what are their prices? Maintenance and
certifcation. Integration is concluded with
repair service quotations ensure that this is
the technical verifcation of the maximum
calculable. Deprag’s Basic Line air motors
A complete solution is often better value
i
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ONLY ONE
BOLTING SYSTEM
IMPROVES
SAFETY, QUALITY,
& SCHEDULE
FOR GAS TURBINE
MAINTENANCE
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Power Engineering International November 2014
23
11/10/14 9:47 AM
Hoosier Energy’s Merom Generating Station in Indiana, US
Credit: Ametek Land
Coal plant safety
Strengthening safety
in mills and silos
Equipment selection and operating criteria are vital for reducing the risk of fre in
coal storage silos and mills, writes Derek Stuart of Ametek
R
isks of unwanted combustion
Good operating procedures are designed
danger that any residual coal left within the
injury,
to ensure that coal is used before it has time to
mill will oxidize, and may explode as the mill
downtime
self-ignite, and many operators use a nitrogen
is restarted. To prevent a coal fre, the mills can
– occur everywhere coal is
blanket to minimize the scope for oxidation.
be made inert with a steam deluge when an
handled, processed or stored.
Even with appropriate precautions, silo fres
unexpected shutdown occurs, or when there
Safe coal handling practices
can still occur and appropriate monitoring is
is a high risk of a coal fre.
are designed to ensure that the fuel remains
needed to prevent oxidation from developing
intact throughout its journey from the mine
into a silo fre.
–
potentially
damage
causing
and/or
until the point at which it is ignited in the boiler.
The greatest risk of fre occurs when the
It takes as little as 1.4 kg of pulverized
mill is shut down under load, as this leaves a
3
Several methods are available to detect
the presence of oxidization within the mill or
silo:
l
Thermocouples are widely used to detect
coal in 28.3 m of air to form an explosive
large amount of pulverized fuel inside a hot
the heat buildup from oxidation or an early-
mixture. Since a large boiler burns 45.4 kg or
mill. The large surface area of the pulverized
stage mill fre, but they have limited sensitivity
more of coal per second, the safe burning of
coal and the high temperature inside the mill
and
pulverized coal necessitates strict adherence
lead to rapid oxidation of the coal. This results
monitoring the whole volume of the mill. It
to planned operating sequences.
discrete
sensors
have
diffculty
in further heat buildup and the potential for a
also takes time for suffcient heat to build up
All coals oxidize during storage, but sub-
fre. If the mill is restarted without frst removing
within the mill to give a detectable increase
bituminous coals are especially prone to self-
the hot coal, an explosion can occur when
in temperature. Experience shows that
ignition. The increasing use of sub-bituminous
particles are suspended and exposed to
thermocouples do not provide a reliable
coals throughout Asia has increased the risks
the air.
indication that a hazardous condition is
of silo fres.
24
1411PEI_24 24
Power Engineering International November 2014
Even in routine mill shutdowns, there is a
developing.
www.PowerEngineeringInt.com
11/10/14 9:47 AM
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1411PEI_25 25
11/10/14 9:47 AM
Coal plant safety
l
Carbon monoxide (CO) gas detection offers
a fast and sensitive means to detect the
presence of oxidizing coal, as the oxidation
inevitably produces large amounts of CO.
The most important reasons to choose CO
measurement for this application are the
availability of sensitive CO sensors able
to detect a few parts per million (ppm)
of CO, and the ability to sample a large
portion of the mill using a probe mounted
at the classifer outlet. CO monitoring is fast,
sensitive, specifc and can be calibrated to
determine alarm levels that reliably identify
a potentially hazardous condition while
minimizing the occurrence of false alarms.
•Once a fre has started, optical detectors
respond to sparks and fames within the mill.
By the time fames are visible, it is too late to
take preventative actions because the mill is
already in a very hazardous condition.
One
of
confguring
the
a
biggest
Millwatch
challenges
system
is
in
the
determination of suitable alarm levels. A
carbon monoxide concentration greater than
250 ppm can be seen during mill startup, but
in normal operation the CO concentration is
in the region of 10 ppm.
Millwatch analyzers offer two independent
Inside view of Millwatch analyzer
Credit: Ametek Land
alarm points, so alarm levels were set at
300 ppm during startup and 50 ppm in
normal operation. Although the startup alarm
l
seemed robust, there were occasional spikes
above 50 ppm CO in normal operation, so the
Rugged sample probes with automatic
power to electric distribution co-operatives
blowback to maintain a good sample fow;
in the midwestern US. At full load it uses
l
Automatic
calibration
verifes
correct
alarm level was increased several times with a
operation of the analyzers, confrming that
fnal fgure of 125 ppm. This avoided nuisance
they respond correctly to CO;
alarms, while providing good sensitivity and
l
10,000 tonnes of coal per day, with the supply
coming from mines by road and rail.
Hoosier Energy has a strong commitment
Continuous measurement of each sample
to safety and maintains a robust safety
response to abnormal operating condition
point, with no multiplexing and response
programme, endeavouring to operate with
when the mill may need to be inerted.
time less than 60 seconds.
the utmost regard for the health and safety of
This last feature is especially important as a
its employees and the public.
Monitoring in China and the US
hazardous condition can develop within a few
Each generating unit at Merom Station
HouShiPower
electricity
minutes, and a multiplexed system sampling
has three Riley Power double-ended ball tube
generating plant in China’s Fujian province,
six measurement points will typically sample
mills. The mills can each provide 65 tonnes per
operated by the Huayang Group. It supplies
each point only once every 10–15 minutes.
hour of pulverized coal to the boiler, a total of
is
a
4200
MW
electricity to the city of ZhangZhou and the
surrounding area.
The system proved its value in 2013 when
195 tonnes per hour per boiler. The boilers at
the Millwatch system showed rapidly rising CO
Merom station burn 54 kg of coal per second.
There are seven electricity generating
levels in the outlet of one of the coal mills. It
Because the ball-tube mills have outlets
units at the site, each of which is rated for
would have taken at least 15 minutes for the
at each end with a classifer on each outlet,
600 MW. In 2011, the plant operators decided
temperature and fre detection systems to
two sample points were needed on each
to add CO monitors to the fve coal mills in Unit
respond and show an indication of a problem,
mill. For enhanced reliability, a redundant
1, supplementing their existing temperature
so the Millwatch analyzers allowed corrective
confguration was chosen with two sample
and
action to be taken signifcantly earlier than
points on each classifer, giving four samples
would otherwise have been possible.
per mill. With three mills per generating unit,
fre
sensors. They
determined
that
Ametek Land’s Millwatch analyzers were best
suited to the task. The analyzers have a long
Hoosier Energy’s Merom Generating Station
a total of 12 sample points were needed
track record, with hundreds of installations
in Indiana, US, is a coal-fred baseload plant
for each unit or six twin-stream analyzers.
worldwide, and include a number of desirable
with two 535 MW generating units. It went into
Redundant
features:
commercial operation in 1982 and provides
likelihood of a nuisance alarm, as a high CO
26
1411PEI_26 26
Power Engineering International November 2014
measurements
reduce
the
www.PowerEngineeringInt.com
11/10/14 9:47 AM
Coal plant safety
measurement is unlikely to be detected on
could be kept short and the response time
dropping
one coal pipe while the others continue to
minimized. The chosen location also gave
45 minutes it was below 10 ppm. The mill
show normal readings.
easy access for maintenance. Commissioning
was restarted two hours after the high CO
took place during an outage in May 2011.
alarm was detected, and was returned to full
The initial proposal was to mount the
after
15
minutes, and
within
sample probes directly on the classifers.
In the three years since the Millwatch
Even though the inside of the classifer is
analyzers were installed at Merom Station,
The Millwatch CO analyzers detected a
a hazardous area, the sample probes are
there have been a number of high-CO
potentially dangerous condition and allowed
simple devices with no electrical connection
alarms, but no mill explosions -- an impressive
it to be dealt with quickly with no damage to
and so no special precautions were needed.
achievement for a baseload station. During
plant or personnel.
Although
a
that time, the Millwatch analyzers have proven
In conclusion, CO monitoring provides a
representative sample, the probes have an
to be reliable, requiring no more than routine
rapid and reliable method for detection of
abrasion shield which prevents the stainless
maintenance
potentially dangerous coal oxidation within a
steel flter from being damaged by the high
safety.
this
would
have
provided
and
providing
enhanced
operation in three and a half hours.
mill so that action can be taken to reduce the
concentration of coal dust. An installation
On 8 December 2013, the Millwatch
location at the classifer outlet was preferred,
analyzers demonstrated their value. With Unit
risk of a fre or explosion.
At both HouShiPower Plant and Hoosier
since this allowed the abrasion shield to face
2 running at full load, one of the mills tripped
Energy Merom Station, Millwatch analyzers
the fow of coal dust and protect the flter.
and the operators observed a rapid increase
from Ametek Land have provided good
Blowback controllers were installed close
in CO readings even though there was no
reliability and a high level of safety coverage
to the classifers, but outside the hazardous
indication of a temperature rise. Within a few
with no explosions in the mill since they were
area.
minutes, the CO level was above the alarm
installed more than three years ago.
Along with the CO monitors, an in situ
threshold, and the operators made the
oxygen probe was installed on each classifer,
decision to activate the deluge system. The
Derek Stuart is Product Manager at Ametek
to determine the oxygen concentration while
boiler continued to operate using coal from
Land, based in Pittsburgh, Pennsylvania, US
the mills are steam-inerted. The CO analyzers
the remaining mills, with output dropping to
were installed at the same level as the
60 per cent of its rated value.
classifers. This meant that the sample lines
The CO level in the affected mill started
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1411PEI_27 27
Power Engineering International November 2014
27
11/10/14 9:47 AM
The effort involved in fre detection is justifed by the need to protect valuable power assets
Credit: Dreamstime
Fire detection
Hot topic
As the UK suffers the second major blaze at a power plant in three months,
Ali Aleali of FireVu explains the fre detection challenges and solutions
facing power plant operators
C
ombustible
dust
and
materials,
debris,
and
still being calculated, the impact on the UK’s
power needs has generated much debate.
some time, impeding early detection.
Power generation environments are known
voluminous areas make
Peter Atherton, energy analyst at Liberum
for their high levels of dirt, grease, dust and oil.
fre detection for power
Capital, stated that the risk of blackouts this
This, of course, means that any fre detection
stations challenging.
winter was now far higher due to the UK’s
system needs regular maintenance.
Solutions
must
be
sensitive to danger and raise alerts early, but
“meagre capacity” to absorb unexpected
events.
must not be prone to costly false alarms. This
As
Moreover, the combustible nature of oil,
gas, coal and renewable waste makes plants
power
vulnerable, and with the debris that can be
all amounts to another serious problem the
disruption an unacceptable situation, the
developed
countries
fnd
kicked up there is the inherent danger of
power station safety offcer or facility manager
extra capacity in the system should see the
numerous false alarms. A balance needs to
has to face.
UK with the energy supply it needs over winter,
be struck between the required sensitivity and
In July of this year, the UK’s Ferrybridge
providing that other major fres and incidents
false alarms, which some fre services are now
power plant was affected by a fre widely
to power generation are avoided. But for a
demanding visual verifcation for commercial
reported in the media.When the nationally-
single power plant to make the possibility
properties before attending, while some levy
broadcast images had begun to fade from
of power shortages a reality shows the
fnes for being called out for false alarms.
memory, the cost to Ferrybridge’s owner, SSE,
importance of protecting these critical assets.
began to be calculated.
If suppressants are released, then for
voluminous areas the cost can be substantial,
The challenges
certainly well in excess of £100,000 for many
around
The sheer size of power plants makes fre
sites. The attendant environmental impact
£35 million ($56 million). SSE will also have
detection a challenge: the huge ground
such as wash-off running into water supplies
to factor in the cost of repairing the facilities
area occupied, the ceilings often as high as
also needs to be considered.
(although insurance will cover much of the
20 metres and the voluminous areas that must
losses) and the transactional costs of buying
be monitored.
RBC
a
Capital
loss
in
analysts
earnings
estimated
of
back forward-contracted power that will now
Fire detection technology
This presents diffculties in terms of the time
Visual Smoke Detection (VSD), Infra-red (IR)
it takes for smoke to reach detectors – and it
and Aspirating Smoke Detectors (ASD) are the
Just weeks ago Didcot B Power Station, also
may not reach them at all owing to smoke
principal options for power station operators.
in the UK, suffered a major fre in its cooling
stratifcation. We can also factor in the need to
Each has advantages and drawbacks.
towers. More than 25 fre appliances from
provide a system that can cover large areas
as far as 30 miles away were called to the
effectively – no easy task.
need to be sourced from elsewhere.
1360 MW gas-fred plant, which is operated by
RWE npower.
While the full costs of the damage are
28
1411PEI_28 28
VSD uses motion system technology to
identify and analyse the behaviour of smoke
Turbines also present a very industry-
patterns and fames Visual monitoring at the
specifc issue: fre is initially hard to detect as
point of fre danger is particularly suited to
the shell can obscure and contain fames for
large areas and across distances.
Power Engineering International November 2014
www.PowerEngineeringInt.com
11/10/14 9:47 AM
Fire detection
VSD operator’s dashboard: Users can segment the video to concentrate on
specifc areas of greater fre risk
Credit: FireVu
Footage can offer visual verifcation (usually done on-site) and
large area monitoring, and can direct the use of fre suppressants and
emergency services.
HIGH PERFORMANCE
Temperature sensing capabilities can be incorporated within the
system, the latter being a new innovation in the market.
Infrared converts radiant energy in the IR into a measurable form.
Detecting IR energy emitted by objects takes away reliance on visible
light, so obscured conditions should not affect its effectiveness although
thick smoke is an issue. Oil and grease can also be problematic.
IR gives much of the VSD solution, however the latter offers
accompanying video, which provides better situational awareness in
the event of a fre. It also helps determine the most appropriate action
that should be taken, triggering an overall suppression system.
ASD is a highly sensitive technology. It can detect smoke before it
is visible to the human eye, which is particularly valuable where a fre
develops in obscured or diffcult-to-access locations or environments
containing dangerous and toxic substances. Yet the sensitivity to
distinguish between smoke and dust in early-stage fres can be
problematic in some facilities, although improvements are being
introduced. Moreover, it requires that smoke hits detectors, which can
be challenging if smoke stratifcation is a possibility.
Ferrybridge and now Didcot remind us of the costs of fre in power
generation environments.
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Safety professionals must analyse their
requirements against the solutions available, be it VSD, ASD, IR or another
system. Fire detection for power stations requires planning, frequent
maintenance and continual assessment, but the effort is justifed by the
need to protect these high-value assets.
Ali Aleali is Business Development Manager at FireVu, which
works with power plants across the UK and Ireland.
www.frevu.co.uk
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1411PEI_29 29
Power Engineering International November 2014
29
11/10/14 9:47 AM
Fly ash has been collected by particulate removal technologies since the 1920s
Credit: Pittsburgh Mineral & Environmental Technology
Retroftting
A fresh perception
of ESP
Poor electrostatic
precipitator performance
can often be traced to
an underperforming high
voltage power supply.
Retroftting with a high
frequency switch mode
power supply can quickly
reduce particulate
emissions and often
improve the performance
of a downstream wet
fue gas desulphurization
system, writes Jason Horn
S
1411PEI_30 30
fue gas, providing the driving force for moving
owners have used particulate
particles to the collecting plates.
removal technologies such as
Next, plates stationed parallel and on each
cyclones, fabric flters, or dry or
side of the gas stream are grounded in order
wet
precipitators
to attract and accumulate the negatively
(ESPs) to collect fue gas particles
charged particles in cake-like layers on the
electrostatic
such as fy ash.
plate surface. Finally, the particulate matter
Today utilities expect ESPs to effciently
is removed from the plates by mechanical
remove very fne particulates (e.g., PM10) and
rappers causing the material to fall into
often rely on a wet fue gas desulphurization
collection hoppers from which it is disposed
(FGD) system to remove smaller and harder-to-
or recycled. The ESP removal effciency is
capture sub-micron particulates (e.g., PM2.5,
highly dependent on the voltage differential
mercury, and other hazardous emissions)
between the discharge electrode (Eo) and the
as a co-beneft. Experience has shown that
collection plate (Ep). The typical ESP operates
problems often occur when a FGD system is
at a voltage in the range of 30 kV and 100 kV.
added without a concurrent ESP performance
upgrade.
ESP
30
ince the 1920s, steam generator
very
plates and multiple sets of collecting plates in
straightforward. Particles to be removed from
a single ‘feld’ in the direction of gas fow. Each
the gas stream are charged by a series of
feld acts as an independent precipitator.
high-voltage electric discharge electrodes
Multiple felds may be added in series to
to produce negatively charged ions (corona
improve particle removal effciency with most
discharge) that charge the particles in the
plants using three or more felds.
Power Engineering International November 2014
operation,
The typical ESP will have multiple discharge
electrodes between each set of collecting
in
principle,
is
www.PowerEngineeringInt.com
11/10/14 9:48 AM
Retroftting
Some plants use up to 12 felds in order to achieve collection
effciencies greater than 99 per cent. In most utility applications, each feld
is also electrically divided into separate compartments or ‘lanes’ to further
optimize particulate removal effciency, primarily due to temperature
and fow rate gradients across the fue gas entering the ESP. The ESP has
been chosen as the PM removal device in over 90 per cent of utility
applications due to its low pressure drop (usually 0.5–1.0 inch water
column), which translates into less auxiliary fan power.
The particle removal effectiveness of an ESP is largely based upon
the resistivity of the particles (the ability of a particle to hold a charge),
the gas fow properties, and the quality and strength of the electric feld
produced between the electrodes and collection plates. Also, a fuel
change often changes the resistivity of the particles in the fue gas.
The recent US Mercury and Air Toxics Standards (MATS) also place
limits on mercury and acid gas limits on boilers that may require adding
FROM
ENGINEERING
ANALYSIS TO
ADVANCED NDE,
LOOK TO
STRUCTURAL
INTEGRITY
activated carbon injection for mercury removal and/or dry sorbent
injection to remove acid gases. Adding activated carbon or dry sorbent
to the gas stream may change the particle resistivity and therefore
the effciency of ESP operation. Other changes in the fue gas, such
as volumetric fow rate, moisture content, chemical composition, and
temperature can also adversely impact the particle collection effciency
of an ESP.
There are a number of upgrade alternatives available to those
needing to increase the particulate removal capacity or those
experiencing an underperforming ESP. Options available to the end
user are increase collecting surface area, improving the fow distribution
entering the ESP, and upgrading or replacing the collection plates or
discharge electrodes. Each of these options requires extensive physical
changes to each stage of the ESP and all require an extended unit
outage and signifcant cost.
The conventional power supply system for an ESP consists of the
transformer-rectifer (TR) set current-limiting reactor (CLR), and silicone
controlled rectifer (SCR) that produce the high voltage power source
for the discharge electrodes. The TR set is a high voltage transformer and
We Connect the Dots
Over the past 30
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a team of over
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dots from problem to resolution, from regulations
to compliance, from nondestructive examination,
to engineered solutions, even custom equipment.
rectifer that converts single phase AC power to single-phase DC power
with approximately 30 per cent ripple in the output voltage waveform
due to 50/60 Hz operating frequency.
The CLR provides current limiting during transient overload (sparking)
conditions. The SCR regulates the voltage into the TR set to adjust the
output voltage and current to the ESP. Separate conventional power
You can look to us for our:
• Knowledge of power plants, codes, and how
things work.
• Extensive experience and leadership.
• High quality, hard work, and responsiveness.
systems are used on each ESP stage (sometimes each lane in a feld) in
order to optimize individual feld performance.
Anatomy of the switch mode power supply
Call us today and we’ll
connect the dots for you.
Often a quicker, less intrusive and more cost-effective solution to improve
ESP performance is replacing the conventional power supply system
with a high frequency switch mode power supply (SMPS) that converts
50/60-Hz power to low ripple DC with output waveform ripple below 3
per cent.
The reduced ripple in the output voltage allows the SMPS
to produce a higher average output voltage (Eo), which in
turn produces higher collection effciency. The typical voltage
output from the SMPS – usually determined by ESP plate spacing,
discharge electrode type and particle resistivity – ranges from
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877-474-7693
(877-4SI-POWER)
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50 kV to 120 kV with improved spark handling.The SMPS also has a faster
spark and arc response time – microseconds instead of milliseconds
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1411PEI_31 31
Power Engineering International November 2014
31
11/10/14 9:48 AM
Retroftting
FGD maintenance, an untenable situation for
a baseload unit. The site was limited in size so
adding felds to the ESP wasn’t an option.
Stock Equipment Company was asked
to evaluate options for repowering the ESP in
order to reduce particulate emissions entering
the wet FGD.
The
solution
ModuPower
was
SMPS
to
systems
add
of
60
four
kW
(83 kV/1080 mA) for each lane in the second
and third felds and four 90 kW (83 kV/
1080 mA) systems for each lane in the sixth
feld. This approach allowed the original inlet
feld TR sets to perform the relatively easy chore
of removing large, friendly particles in the
front of the ESP, and to use ModuPower SMPS
systems to do more diffcult removal work in
the center of the ESP.
Figure 1: Ohio plant ESP roof with ModuPower ground switches installed on the insulator compartment
Credit: Stock Equipment Company
The ESP represented a special challenge
in that access to its roof was diffcult, and
– that reduces power dissipated in sparks
(98 per cent removal rate) to 50 mg/Nm3
there was little space available in which to
and arcs and reduces wear on power feed
(99.95 per cent removal rate). The reduced
locate the ModuPower SMPS equipment.
components and ESP internals.
emissions limits would require a unit derate in
Also, another SMPS brand previously installed
order to continue operating.
had failed to operate reliably in the high
The SMPS upgrade option has two principal
benefts that are dependent on how the unit
Norgener replaced three of the four
conventional
collection effciency when less particulate
each unit with Stock Equipment Company’s
With this in mind, Stock Equipment worked
emissions are desired. The SMPS puts more
ModuPower SMPS, which allowed Norgener to
with the customer to remote-mount the
power (increased Eo) into the ESP resulting in
increase generation to full load on each unit
ModuPower units in a pre-wired modular
higher collection effciency.
while maintaining particulate emissions below
control room that was located on the ground
the new particulate discharge limits.
at the base of the ESP. The entire system was
The second beneft for plant owners is for
power
supply
systems
on
temperature and dirty environment within the
is operated. The frst beneft is to improve ESP
ESP weather enclosure.
a unit where less ESP auxiliary power use is
A 640 MW supercritical utility boiler located
delivered as two structures, each containing
desired in order to either improve unit heat
in Ohio was reconfgured with a wet FGD
six of the 12 ModuPower units provided. The
rate or increase sellable power to the grid. With
downstream of its existing four-lane/12-feld
plant was required to only connect power to
this option, the SMPS replaces the ineffcient
ESP. It was assumed during design that the
the switchgear provided in each control room
conventional power systems used on an
new wet FGD would capture particulates not
and run high voltage cable to the roof of
ESP operating with acceptable collection
removed by the ESP, so no enhancements to
the ESP.
effciency by limiting the power output to
the ESP were made as part of the FGD retroft
that of the TR and CLR it replaces. The SMPS
project (see Figure 1).
operates at >90 per cent power effciency
However, shortly
All the installation work was completed with
the unit in operation, with only a short outage
was
required to make the fnal electrical tie-in to
compared to the TR, which generally operates
commissioned, the plant determined that
after
the
FGD
the ESP. This unique remote SMPS installation
at <60 per cent. For the same power input
excessive particulates were entering the FGD
provided by Stock Equipment enhanced the
into the ESP (and the same ESP collection
and fouling pumps, pump linings, and piping.
project’s ROI signifcantly.
effciency), SMPS can reduce auxiliary power
Also, the ash contamination reduced the
use by 30 per cent.
quality of the gypsum byproduct from the
produced an over 100% increase in power
The
ModuPower
SMPS
installation
ModuPower SMPS systems have also been
FGD, negating its market value. Instead of a
sent to the ESP, from 464 kW to 1052 kW. With
used in a variety of unique applications, as the
positive cash fow from the sale of the gypsum,
the exception of the inlet felds that are
following three case studies will illustrate.
the utility must pay the cost of landflling the
exposed to the highest dust burden, all felds
waste product.
are operating at the nameplate current limit
Case studies
During the frst year, authorities allowed
For example, at AES Gener’s 135 MW coal-fred
the plant to ‘bypass’ the FGD system when
Norgener Power Station, located in Tocopilla,
it required monthly maintenance to repair
Chile, its 1990s vintage ESP met air emissions
damage
standards when built. New regulations that
emissions from the ESP.
caused
by
excess
particulate
rating of both the ModuPower units and the
original TR sets.
More importantly, the repowered ESP has
eliminated outages caused by excessive
particulates entering the FGD and restored
went into effect this year reduced the level
However, after the frst year of operation a
the quality of the gypsum by-product. The
of permitted particulates from 211 mg/Nm3
monthly unit outage was required to perform
plant has since installed an additional 12
32
1411PEI_32 32
Power Engineering International November 2014
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1411PEI_33 33
11/10/14 9:48 AM
Retroftting
ModuPower SMPS systems on felds 1, 4, and 6
changing the kVA rating of the units. The new
of the same unit.
TR set produced higher voltage (kV) and lower
A 670 MW supercritical utility boiler located
current (mA) but produced the same primary
in West Virginia, US is confgured with a wet
current rating. This approach saved the cost
FGD after its ESP (see Figure 2). The ESP is
of changing out the CLRs, power cables
confgured as four felds deep, eight lanes
and other equipment inside the automatic
wide, with each feld using weighted wires on
voltage control cabinet. However, the new
a nine-inch gas passage spacing. Though the
TR equipment hit its secondary current limit
ESP as designed did not perform effectively,
before reaching signifcantly higher voltage
it did not experience excess particulate
levels (Eo) and fan erosion continued.
emissions because of the downstream wet
The plant eventually decided to upgrade
FGD. However, the two induced draft (ID) fans
its ESP with an SMPS, and ModuPower units
that are positioned between the ESP outlet
from Stock Equipment were selected. Eight
and the FGD inlet were suffering signifcant
90 kW (83 kV/1080 mA) units replaced the
mechanical
producing
newer 36 kW TR systems (65 kV/550 mA) on
increased vibration as a result of excess fy ash
the inlet feld of the ESP where the majority of
leaving the ESP. Quarterly fan cleaning, repair,
the particulate removal takes place.
erosion
and
and rebalancing, plus the associated cost of
The
site
arrangement
required
the
a four- to fve-day outage cost millions, and
ModuPower equipment to be installed away
easily exceeded the cost of an ESP upgrade.
from the roof of the ESP and required the
Plant management considered a number
of
permanent
repair
options
Figure 2: A 90 kW ModuPower was installed
at a West Virginia coal-fred plant
Credit: Stock Equipment Company
use of a high voltage cable to bring the DC
including
power to the ESP. In addition, the ModuPower
increased by 3114 mA, equivalent to the
expanding the ESP, but the cost was prohibitive
units were installed and commissioned one
power input produced by fve TR systems.
and the site was space-constrained. The best
at a time while the boiler and ESP remained
A year after the installation was completed
option was to upgrade the ESPs to reduce the
online, thereby avoiding one or more costly
the unit has not experienced a single FD
amount of particulate emissions entering the
plant outages. The original TR sets were
fan erosion- or vibration-related outage. The
ID fans.
disconnected but left in place as backup
utility saved over three times the cost of the
systems should the need arise.
ModuPower units in the frst year of operation.
The plant frst rebuilt all the ESP boxes to
11.5-inch spacing and retroftted the ESP
ModuPower installation raised the power
The utility has since purchased ModuPower
with rigid discharge electrodes in an effort
(kW) not only in the inlet feld but also
units for the remaining three felds on this unit,
to improve the particle removal effciency.
across the entire ESP. The improved collection
and all four felds at the other two 670 MW
However, the existing 45 kV TR sets ran out of
effciency at the inlet of the ESP allowed the
units located at this plant.
secondary voltage and fan wear worsened.
downstream conventional TR sets to perform
Upgrading the particle removal effciency
The plant next tried to replace the existing TR
at a higher effciency as well. Power provided
of existing ESPs is inevitable as new air quality
sets with a higher-power design but without
to the ESP increased 204 kW and the current
rules take effect. However, a ModuPower
upgrade can also be a good business
decision because it can minimize ID fan
erosion and improve the performance of a
downstream wet FGD, thereby reducing the
ash content in the gypsum byproduct so it
can be recycled rather than landflled. For
ESPs already meeting air quality regulations,
an SMPS upgrade can reduce auxiliary power
requirements and pay for itself in short order.
Customers and ESP OEMs around the world
are standardizing on SMPS technology for ESP
upgrades and new precipitator installations
in place of the conventional power supply
systems.
Jason Horn is director, environmental controls
for
Stock
Equipment
Company
(www.
stockequipment.com)
AES Norgener ESP with ModuPower ground switches installed on top of its ESP
Credit: AES Norgenere
34
1411PEI_34 34
Power Engineering International November 2014
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Generator circuit-breaker switchgear in combination with steam turbines were installed
at a cogeneration combined-cycle power plant in Rayong, Thailand.
Credit: Siemens
Switchgear
Proven procedure
offers a new alternative
Technological
developments now
enable maximum normal
and short-circuit currents
to be interrupted using
vacuum circuit-breakers,
writes Nils Anger
V
acuum
circuit-breakers
are used in most industrial
switchgear
with
Last but not least, the generator can
reason, since they have their
also be switched on and off in a matter of
own
strengths
milliseconds in response to the appropriate
installation,
command, enabling it to be connected to the
particular
terms
of
operation and maintenance.
grid right on target. This function will become
In the past, it was not possible to use
more and more important in future as the
the potentials of the long-proven vacuum
trend toward renewable energy sources and
technology
Smart Grids leads to decentralized power
for
generator
switching
applications. Today, however, the appropriate
technical solutions are available, which are
Generator
circuit-breakers
are
thus
assuming a wide range of functions relevant
power plants and power supply companies.
to power plant operation. At the same time,
ensures
reliable
synchronization
and
they have to be designed for high currents.
Besides
safely
breaking
short-circuit
maximum operational safety. When installed
currents, a key requirement is to immediately
between a generator and transformer, it
extinguish any short-circuit arcing in the circuit-
synchronizes parameters such as frequency,
breaker. Until about 15 years ago, there was
voltage and phase with the grid.
only one suitable technical process to deal
In the event of a short circuit in the
with this: extinguishing the switching arc using
generator or transformer, the integrated circuit-
the isolating gas sulfur hexafuoride (SF6) in a
breaker immediately cuts the fow of electricity.
chamber flled with this gas.
This protection averts consequential problems
1411PEI_36 36
plants with multiple smaller generators.
tailored to suit the special requirements of
In power plants, generator switchgear
36
entire power plant.
good
in
–
that could compromise the operation of the
Power Engineering International November 2014
This
powerful
technology
has
been
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11/10/14 9:48 AM
Switchgear
successfully used in the power industry
vacuum
until
are also independent
now.
More
recent
technological
interrupters
developments, however, enable maximum
of
normal and short-circuit currents to be
infuences.
interrupted using vacuum circuit-breakers.
least of the advantages
This means that all switching duties in
is
environmental
that
no
Not
the
oxidation
a generator switchgear can be assumed
occurs in the vacuum,
in their entirety by vacuum circuit-breakers.
which means the metal
Unlike gas-insulated circuit-breakers, vacuum
surfaces remain clean,
circuit-breakers interrupt the switching arc
ensuring a constantly low
in a high-vacuum interrupter. This is therefore
contact resistance.
Easy to install – Vacuum generator
an especially environmentally friendly and
reliable procedure for generator switching
switchgear is a factory-assembled solution
applications that is now available as an
that is tested before it leaves the factory. It can
alternative.
be immediately integrated into the power
The characteristic benefts of vacuum
switching technology are:
plant technology on site. With SF6-insulated
circuit-breakers, on the other hand, the gas is
The HB3-80 is the frst generator switchgear in the
world equipped with a vacuum generator
circuit breaker for an IEEE standard C37.013
type-tested switching capacity of 80 kA
Credit: Siemens
High reliability – The use of vacuum circuit-
extracted for transportation immediately after
breakers guarantees a high level of personal
manufacture, and the circuit-breakers are then
and operational safety. One reason is the
reflled with gas at the time of installation, using
the case of switchgear with vacuum circuit-
small number of moving parts in the arcing
a special tool. This means not only increased
breakers.
chamber. One of the circuit-breaker contacts
expenses but also a need for further testing.
is frmly attached to the housing while the
Cost-effcient – Vacuum switchgear scores
other is movable. With this setup, the metal
in terms of overall results. The installation and
bellows enables the switching stroke and
operating benefts described above keep
creates the vacuum-tight connection to the
costs comparatively low during the entire
interrupter housing. The hermetically sealed
operating time (i.e. total cost of ownership) in
Nils Anger is Director of Generator Breaker
Switchgear at Siemens
i
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for more information
HB3-80 - A WORLD FIRST
The latest addition to Siemens’ product range
with no additional engineering costs. The
and retroft projects. The centerpiece of all
is its HB3-80 generator switchgear.
fexible selection of pole-center distances
of these systems is formed by the 3AH37 and
This enclosed single-phase unit is suitable
and diameters means that existing round
3AH38 vacuum circuit-breaker for generator
for power plant blocks of up to 160 MW or 250
conductors (isolated-phase busbars, IPBs)
switching applications: The 3AH38 high
MW, depending on the type of power plant
can still be used.
current and generator circuit-breaker is
and the operating voltage.
Further switchgear types round out the
already the standard for switching normal
HB3-80 is the world’s frst generator
portfolio to provide optimized customer
currents of up to 4,000 A in many power
switchgear with generator vacuum circuit-
solutions for the demands of a constantly
supply companies worldwide.
breakers for currents of up to 10,000 A with
developing market: The compact HB1, with
As one of the frst circuit-breakers for
natural cooling and a type-tested switching
horizontal busbars, is designed for power
short-circuit currents of 63 kA and 72 kA
capacity of up to 80 kA in accordance with
plants of up to 120 MW or 170 MW.
on the world market, it was type-tested in
IEEE C37.013.
Its
fexible
connection
concept,
accordance with the criteria of generator
The switchgear is also type-tested in
comprising bus ducts, cables and solid-
circuit-breaker
accordance with IEC 62721-200 and the
insulated bars, offers a broad range of
counterpart for higher generator ratings is
Draft Dual-Code Standard IEEE/IEC 62271-
applications. The HB1 is very adaptable to
the 3AH37. A world-leading vacuum circuit-
37-13. It offers maximum operational safety
customer-specifc requirements. The modular
breaker, it can manage a constant normal
and a high level of personal safety, since the
VB1 offers even more fexibility for personalized
current of 6,300 A at up to 24 kV with natural
single-phase enclosure rules out the risk of
solutions. This property makes it especially
cooling. With forced cooling, normal currents
short circuits between the phases.
interesting for power plants operated with
as high as 8,000 A are possible. Optimizing
be
multiple generators or feeders for auxiliary
the
compatible with other products established
supply, excitation, or brake disconnectors. It
enables them to be used in phase-enclosed
on the market, from the perspective of
is suitable for the range of ratings up to 140
switchgear and in retroftting situations.
retroftting in particular. Rather like a plug-
MW and - considering the high requirements
Maximum normal currents of 12,000 A with a
and-play solution, it can be incorporated
in terms of switching capacity, space and
short-circuit breaking capacity of 80 kA and
or retroftted into the generator connections
accessibility - for use in hydropower plants
up to 6,300 A at 90 kA can be achieved.
The
38
1411PEI_38 38
HB3-80
is
constructed
to
Power Engineering International November 2014
standard
circuit-breakers
for
C37.013.
joint
Its
operation
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Transmission & distribution
Credit: Dreamstime
A new solution for
Real-time information provided by dynamic line rating technology can play a vital
role in increasing the power-carrying capacity of existing overhead
line assets and reducing congestion writes Sandy Aivaliotis
O
ncor
is
a
regulated
though during actual operation the lines
System Operator’s (ISO) Security Constrained
transmission
are seldom loaded to their limits. If Oncor
Economic Dispatch (SCED). This innovative
and distribution service
could utilize more of the latent capacity that
combination of new and existing technologies
provider
operating
exists in every line, customer costs could be
to fully automate and stream DLR allowed
1500
reduced not only through access to lower
the ISO and Oncor to utilize the actual real-
circuits serving 10 million
cost generation, but also a reduction in
time transmission line capacity to enhance
transmission charges.
asset optimization and optimize generation
electric
approximately
customers across the US state of Texas.
This grid is subjected to signifcant variability
There is an obvious requirement for a
in demand. Oil and gas developments have
fexible solution capable of meeting the
increased
prompted rapid load growth in specifc areas,
uncertainty of transmission grid need. Yet,
wide-area system awareness (WASA).
while wind and coal have created changes in
since grid topologies must adjust constantly
completely automating the process, Oncor
generation. In addition to these larger trends,
to refect load growth and changes in the
achieved this breakthrough without adding to
weather and load create daily fuctuations in
nature of generation and transmission grid
the workload of its grid operators in the system
pricing, further increasing the unpredictability
enhancements, the demand on individual
control centre.
of the load on any particular line.
transmission lines can be diffcult to anticipate.
Utilities are unable to distribute enough
It
is
possible
that
loads
can
appear
dispatch, leading to reduced congestion,
reliability
and
heightened
By
Assumption-based operation
power to meet the demand, leading to
and disappear within the planning and
Overhead conductors exhibit a certain level
congestion. A few lines suffer from congestion
construction duration of a traditional upgrade.
of ‘sag’ when strung between their supporting
over sustained periods of time, with fnancial
Smart grid technologies such as Dynamic
towers. This is determined by both the physical
implications ranging up to hundreds of
Line Rating (DLR) are required to meet the
characteristics of the conductor (related to
millions of dollars.
fast-changing line capacity requirements of
materials and design) and the conductor
today’s grids.
temperature – as a conductor carries more
Over the three-year period monitored,
approximately 200 lines would experience
sporadic
to
chronic
congestion
under
During
the
Demonstration
Project
(SGDP)
Energy,
current it heats up and sags.
with
Transmission lines must be operated so
over
that the overhead line conductor maintains a
Electric Reliability Council of Texas) dispatches
24 months Oncor operated 13 transmission
minimum clearance from the ground or other
the system to avoid contingency overloads,
lines by integrating DLR directly into its Electric
objects allowed on the right-of-way to ensure
these constraints account for approximately
Management System (EMS) and streaming
safe, reliable operation. This safe clearance
$172 million in annual congestion costs, even
the DLR information to the Independent
is determined by specifc parameters that
1411PEI_40 40
of
Grid
the
Power Engineering International November 2014
Department
Smart
contingency conditions. Since ERCOT (the
40
US
cost-sharing
www.PowerEngineeringInt.com
11/10/14 9:48 AM
Transmission & distribution
characterize the position of the conductor.
this SGDP project, we are discussing Dynamic
These parameters include:
Line Ratings (DLR) where the condition of the
l
conductor is directly monitored in real time
l
(i.e., continuously). Further, because we have
l
ambient conditions along the transmission
integrated the DLR rating automatically into
line including the ambient temperature,
system telemetry for real-time operations, we
net solar impact on the conductor and
refer to the ratings as integrated Dynamic Line
effective wind speed blowing across the
Rating (iDLR).
the conductor properties;
the line loading (in Amps); and
conductor.
Real-time DLR technology, such as Nexans’
The current fowing in the line causes it to
CAT-1 system, utilizes sensors that monitor the
heat up due to resistive heating. The sun can
key conductor parameters and calculates
further heat the conductor while the ambient
those that cannot be directly measured,
temperature can either heat or cool it. By far
providing a calibrated basis to project
the most dominant variable comes from wind
the impact of additional current on the
which, when blowing over the conductor,
conductor’s average temperature. The goal is
provides cooling.
to maximize the line rating for existing ambient
The net heat balance between these
conditions.
There is a signifcant level of unused spare
capacity that could help to address grid
congestion issues if it can be accessed.
Credit: Oncor
infuences effectively makes the conductor
DLR is intended to adjust the SLR to the
a spatial thermometer. Each conductor has
rating appropriate for the real-time ambient
The more practical solution is to obtain the
a time constant associated with its mass –
weather conditions. Ambient temperature
effective wind speed by deriving the value
meaning that the conductor temperature
and solar radiation are relatively stable over
from the conductor temperature.
does not change instantaneously in response
distance, but they have a very modest impact
Deploying the DLR system requires a
to a changing net heat balance; instead
on the ratings compared to the wind blowing
selection of monitoring locations in order
there is a lag in response. The conductor
across the conductor. However, wind exhibits
to develop the rating for each line section,
sag, tension and temperature are a uniquely
considerable spatial variability and can vary
differentiated from the next by conductor
coupled system.
almost metre by metre along the span.
size, stringing and loading design criteria,
The majority of utilities have established
Fortunately, DLR technology can capture
what is referred to as a Static Line Rating (SLR)
that spatial variability and determine the
which represents the level of current loading
average effective wind speed on the entire
If the line has long tangent sections, it
the conductor can carry while maintaining
line section. The conductor’s time constant
may be necessary to put more than one
the desired operating safety and clearance
matches well with sampling rates and the
sensor device in the line section. The SGDP
criteria.
cycle time for state estimator analysis that
project validated that a tension or conductor
uses the DLR data to minimize wide variations
position monitor can easily characterize the
in ratings due to transient parameters.
performance of 8 km of line.
The SLR is established at a designated set
of ambient weather conditions defning the
line orientation to prevailing winds and line
loading.
ambient temperature, effective wind speed
Once a line rating is determined, a
From a capacity standpoint, the data
and level of solar radiation. A very common
protocol is required to bring this information
shows that the DLR exceeds the SLR rating
set of parameters for this is 40°C, 0.61 m/s
to the operating environment so that the real-
99 per cent of the time, and exceeds it by
perpendicular wind and full solar radiation.
time rating can be applied to operate the grid
more than 110 per cent between 93 per cent
Some utilities use an Adjusted Ambient Rating
area in which the line is located.
and 97 per cent of the time.
DLR Systems
that real-time monitoring and application of
(AAR) that adjusts the rating to account for
the ambient temperature along the line.
In
effect,
the
majority
of
The results of the SGDP project illustrate
overhead
The key parameter to determining the DLR is
DLR is essential to optimal application of the
transmission lines are operated according to a
the effective wind speed along the stringing
methodology. This is because the dynamic
set of assumptions that project their operating
section.
ratings for each line vary in real time and over
temperature and therefore sag, rather than
For a Drake conductor (a common
the long term. It is not suffcient to collect data
measuring it. This lack of real-time information
transmission line conductor) using typical
for a certain length of time on a few lines to
results in lines operating at loads well below
summer climate assumptions, a decrease
characterize the dynamic rating potential of a
their actual safe limit – or, in other words, there
in effective wind speed from 0.2 m/s to
transmission line or a system of lines.
is a signifcant level of unused spare capacity
0.1 m/s results in a rating reduction of 14 per
that could help to address grid congestion
cent. Since the wind speeds of interest are
Applying the technology
issues if it can be accessed.
very low, in the range 0–2.0 m/s, there are no
The importance of DLR is to capture real-time
meteorological services that monitor these
information and then calculate the maximum
levels along the line.
current that can be carried by the entire line
Across the utility sector, some may use
“dynamic” to refer to any line ratings which
change throughout the day, such as when
Even a distributed network of anemometers
while maintaining safe operating criteria –
ratings are adjusted for ambient temperature,
would require too extensive a deployment
setting a maximum operating temperature
seasonal or day versus night. In the context of
of instrumentation by a utility to be viable.
that maintains the required ground clearance.
www.PowerEngineeringInt.com
1411PEI_41 41
Power Engineering International November 2014
41
11/10/14 9:48 AM
Transmission & distribution
when
work
available. The
load,
reduced
reduced
operator
personnel
training
requirements and consistent availability make
the iDLR stream of ratings a valuable tool in the
operating environment.
Project results
The fnal report published on the Oncor SGDP
Project highlighted several conclusions and
breakthroughs.
Oncor found that using DLR increased
capacity
by
14
per
cent
above
the
ambient temperature-adjusted ratings. The
Overhead conductors exhibit a certain level of ‘sag’ when strung between their supporting towers.
Credit: Oncor
incremental capacity was available from
83.5 per cent to 90.5 per cent of the time.
Any DLR system should be evaluated with
before passing the data to the state estimator.
respect to cybersecurity concerns relating to
These validate that the ratings returned by
5 per cent additional capacity could relieve
In
addition, the
project
found
that
data integrity and system security.
the DLR system are within an acceptable and
congestion by up to 60 per cent on the
There are two strategic ways to apply the
expected range. If the validity checks fail, the
target lines with DLR installed, while 10 per
DLR information: system operations query
system reverts to the line rating that is normally
cent additional capacity would practically
system and autonomous streaming telemetry
applied.
eliminate all congestion on the target lines.
to state estimator.
One of the concerns that many operators
Congestion on the Oncor transmission lines
The difference between the two methods
have in making the query-based decision
in 2011 and 2012 cost more than $148 million
is how system operations accesses the DLR in
when applying DLR is that they are unsure of
and $197 million respectively. Increasing
order to apply them.
what the rating may do in the near term.
capacity is useful on overhead lines where a
System operations query system: In this
If they are increasing the line capacity
application, the DLR data is made available
based on DLR ratings, they may have concerns
By providing additional capacity, DLR can
to System Operations on a control room
about how long the rating will remain elevated
be utilized in the planning process to enable
screen.
full upgrade cannot yet be justifed.
and how it could drop in the short term.
a least-regrets capital strategy, minimizing any
Oncor uses an ambient temperature-
Furthermore, each different control room shift
potential stranded investment.
adjusted rating based on the ambient
has operators with different experience with
The integrated Dynamic Line Rating (iDLR)
temperature from a weather station assigned
line performance and their decisions may be
system feeds real-time conductor ratings
to each line.
different case to case, shift to shift.
to ERCOT, the market operator, who then
This format calls for the operator to
incorporates the additional capacity into
recognize a need for additional ratings,
Continuous monitoring
recognize that the line has DLR available and
iDLR ratings have the advantage that the
process. With zero operator intervention, DLR
then decide to allow the system to operate at
operator
capacity is used to increase market effciency.
that level.
additional decisions. The real-time nature
As evidence of the extensibility of DLR
This places considerable dependence on
of iDLR also adds a component of Wide
technology, in June 2013 Oncor deployed
the operator to take additional operational
Area System Awareness (WASA) to the line
additional DLR systems in the Odessa-Midland
decisions.
operation by continuously monitoring the
region of Texas in a commercially funded
line’s state.
follow-on project.
The
SGDP
project
demonstrated
the
is
not
burdened
its Security Constrained Economic Dispatch
with
making
benefts of using DLR in an autonomous
The cycle time for monitoring the line
For other transmission owners considering
protocol that streams the data automatically
and reporting to the state estimator can
using DLR, the project authors have developed
to the system state estimator so that the
be adjusted and synchronized to the state
a guide.
dynamic rating can be applied continuously
estimator’s cycle of managing the grid, so that
While this project has focused on a US
in real-time.
the system becomes self-resolving. If the wind
application, the principles apply worldwide.
This technique provides several advantages
should die off, the conductor heats up and
And we are already seeing signifcant interest
for grid operations. The transmission grid
iDLR levels reduce, the system automatically
in Europe.
is operating closer to its true functional
adjusts the operation to maintain system and
capability, is continuously monitored and
line reliability.
managed by the most recent and relevant
The iDLR streaming protocol has proven to
data, and relieves the system operator of
be a more reliable and consistent application
additional workload.
of DLR than the operator query based system.
Within the protocol, the system has built-in
The continuous WASA aspects of iDLR provide
quality and integrity checks that are executed
system reliability as well as increased capacity
42
1411PEI_42 42
Power Engineering International November 2014
Sandy Aivaliotis is senior vice-president,
Operations,
Technology
and
Business
Development at Nexans’ The Valley Group
i
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for more information
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11/10/14 9:48 AM
Æ
Conference & Exhibition
3 - 5 March 2015
Expocentre, Moscow, Russian Federation
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INVITATION TO PARTICIPATE
PROVIDING ENERGY SOLUTIONS & INNOVATION
POWER-GEN Russia (formerly Russia Power), co-located with HydroVision Russia, provides an ideal setting
to explore business opportunities, meet new partners, suppliers and the industry’s most infuential decisionmakers. The combined 2014 event combined attracted over 5,000 attendees from over 50 countries.
Featuring a busy exhibition foor with the pre-eminent organisations from the Russian and international
energy sector, POWER-GEN Russia and HydroVision Russia offers excellent networking opportunities.
WHY YOU SHOULD EXHIBIT IN 2015
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from the industry, for the industry. For further information on exhibiting please contact your local
sales representative.
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POWER-GEN Russia and HydroVision Russia is now open for Registration! Make sure
you register, attend, learn and network with high-level executives, professionals and
other leading decision-makers in the industry.
For queries relating to the
conference, please contact:
POWER-GEN Russia:
Emily Pryor
Conference Manager
T: +44 1992 656 614
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Mathilde Sueur
Senior Conference Manager
T: +44 1992 656 634
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For information on exhibiting and
sponsorship, please contact:
POWER-GEN Russia:
Gilbert Weir Jnr
Sales Manager
T: +44 (0)1992 656 617
F: +44 (0)1992 656 700
E: gilbertw@pennwell.com
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1411PEI_43 43
11/10/14 9:48 AM
A ‘programmized’ approach to nuclear decommissioning covers safety, organizational
transformation and integrated management as well as technical innovation
Credit: Magnox Ltd
Nuclear decommissioning
A new approach
The UK’s Nuclear
Decommissioning
Authority has awarded
Cavendish Fluor
Partnership a contract for
the decommissioning of
12 UK nuclear sites.
Kenny Douglas looks
at how this joint
venture proposes to
meet the challenge to
decommission the sites
safely and to schedule
s parent body organization
A
management team to the SLC management
to the two site licence
and workforce, and stakeholder engagement
companies (SLCs) Magnox
as well as completion of initial due diligence
and RSRL, CFP has begun
on the site’s lifetime plans.
the process of implementing
The
transition
period
also
saw
its approach to manage
preparations for the necessary organizational
the decommissioning of 12 nuclear sites,
transformation, as well as ensuring that all
and deliver each to an agreed and defned
regulatory requirements were met and the
point – either interim end state or into care
highest level of safety standards implemented.
and maintenance – while providing savings
As part of the due diligence requirement,
anticipated to be over £1.5 billion ($2.4 billion)
progress on all site plans was assessed by the
against the previous site lifetime plans.
new team against the information gained
It is no small undertaking, and in taking on
and assumptions made in the bidding
this mission Cavendish Fluor Partnership, a joint
process, to identify the additional work that will
venture between British company Cavendish
be required to be undertaken.
Nuclear and US frm Fluor, will be drawing on
Equally importantly, the transition period
its extensive UK and US decommissioning
also
experience.
Cavendish Fluor Partnership to gain a better
Indeed, this experience has already been
provided
understanding
the
of
opportunity
the
processes
for
the
being
applied, in the frst instance, to conduct a
worked to, the procurement activities, supplier
successful fve-month transition programme –
contract status and existing site initiatives,
a critical phase in advance of offcial contract
while also getting to know the people and the
award and implementation of the new
12 sites.This will feed into the changes required
programme – to ensure a seamless handover
to implement CFP’s lifetime plans which will
from two PBOs to the new one, with minimal
differ in a number of ways from the existing site
impact on the existing teams and continuity
plans.
of work taking place at the 12 sites.
The transition phase was an intensive period
Following
of
transition contract, implementation of the
this
phase,
which
concluded
on
31 August, included introduction of the new
44
1411PEI_44 44
Strategic approach
and a major project in itself. Cornerstones
Power Engineering International November 2014
successful
completion
of
the
strategy for the 12 sites is now underway.
www.PowerEngineeringInt.com
11/10/14 9:51 AM
Nuclear decommissioning
This approach is characterized by a
the option to re-licence into one site licence
PBO partners are ambitious and growing
number of key features covering safety,
company being explored with the appropriate
companies with interest in the UK’s new-build
organizational transformation and integrated
regulatory authorities.
programmes (four of which are due to take
management – a ‘programmized’ approach
CFP is seeking, from the early stages, to
– and technical innovation, ensuring that the
standardize the processes and approach
With this in mind, CFP will ultimately seek
work required is undertaken safely and at
taken across all 12 sites, and to maximize
to manage, at the appropriate time in the
minimum possible cost.
learning across all locations.
future, the transition of the skilled workforce
Implementing an affordable schedule
to
undertake
the
work
and
taking
For instance, approval for a programme
place adjacent to Magnox sites).
from decommissioning into the new-build
a
gained at one site will then be replicated
programme,
‘programmized approach’ are vital facets of
across the other sites, while incorporating
workforce members to work on new projects
the strategy. The approach is based around
learning from experience at each – an
within one of the two parent companies once
ten core programmes and the organizational
approach known as ‘lead and learn’ –
the decommissioning work is complete.
structure will progressively align to these
which effectively integrates the approach
One further key aspect in the strategy to
programmes across all the sites.
and programmes across all the sites, while
deliver the requirement for the sites effciently
delivering locally.
and successfully lies in the optimization of the
Technical innovation is a further key
with
opportunities
for
the
element of the strategy, drawing and building
Another intended initiative and part of the
supply chain. This will be made up of various
on experience and proven techniques and
standardizing of processes across the sites is
facets, including taking a single approach,
technologies, both from within the nuclear
the modularized safety and environmental
category management, SME engagement
industry and the partners’ own experience in
case approach, with a safety case interface
and SLC staff development.
the UK and US, while also potentially bringing
software tool.
best practice or technologies from other
industries where this adds value.
This involves taking a generic approach
wherever
Part of the approach will be to work with
framework
possible, with
an
overarching
strategy, developing
a
safety
Implementation and delivery
In short, the Cavendish Fluor Partnership
will manage the capability and experience
the SLC teams to ensure that the appropriate
and environmental case at one site and
residing
technical approach is undertaken for each
then checking for design differences and
SLCs by agreeing the right strategy for
site. These differing approaches are being
adapting it to the next site in line with site-
decommissioning and waste management,
developed between the CFP secondees
specifc requirements, retaining procedures
turning that strategy into detailed programmes
and the SLC teams in order to optimize the
as appropriate and sharing or transferring the
with clear targets, choosing the right people to
solutions included within the bid.
learning and experience gained.
deliver,adopting robust corporate governance
One
of
the
new
programmes
that
Additionally,
long-term
employment
in
the
Magnox
and
RSRL
processes, providing incisive challenge and
will be introduced, for example, is asset
opportunities for the SLC workforce are a key
demonstrating leadership.
management in order to standardize and
facet of the CFP approach. Notably, following
delivery of the plan, while constantly seeking
right-size the maintenance programme at
CFP’s appointment as PBO, Magnox and
to reduce cost, learn from experience, and
each of the sites at the differing stages of their
RSRL employees are now part of the largest
seek to provide additional future employment
decommissioning programme.
nuclear Suitably Qualifed and Experienced
opportunities throughout the programme.
Key
to
A central tenet of the strategy is to gain
Personnel (SQEP) team in the UK. Cavendish
approval to have a single organization
Nuclear and Fluor recognize that their people
goals
running the two site licence companies, with
are theirmost important asset, while both
technical innovation, changing operating
and
delivering
CFP will ensure
target
the
cost
established
reductions
are
arrangements, streamlining the organizational
structure
and
delivering
the
detailed
decommissioning and waste management
programmes. In implementing these, CFP will
ensure that the programme is delivered safely
and securely, without environmental impact,
on time and on budget, thereby fulflling its
primary role as PBO: to ensure safe delivery
of the decommissioning programme across
all the sites, with an integrated management
plan and system, ensuring that the NDA’s
vision is supported and requirements are met.
Kenny Douglas is managing director of
Magnox and RSRL
CFP will seek to manage the transition of the skilled workforce
from decommissioning into the newbuild programme
Credit: Magnox Ltd
www.PowerEngineeringInt.com
1411PEI_45 45
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Power Engineering International November 2014
45
11/10/14 9:51 AM
Heat recovery steam generators
A laboratory image of droplet size analysis
Credit: Pentair Valves & Controls
Desuperheaters
rise to new
challenges
The new generation of desuperheaters must be able to address the complex
engineering challenges and varied operational environments of today’s modern
50- and 60-Hz combined-cycle power generation markets, writes Martin-Jan Strebe
G
lobal
in
Martin-Jan Strebe
steam
advances
and
and varied operational environment of today’s
turbine technology are
modern 50- and 60-Hz combined-cycle power
persistently pushing the
generation markets.
envelope of metallurgy
Desuperheaters control steam temperature
and steam cycle design
by injecting water into the steam fow within
effciency, resulting in more diverse operational
the boiler circuit. This direct contact between
requirements for component manufacturers.
the steam and water causes atomization and
Greater gas turbine mass fows, and ever
evaporation, resulting in a decrease in steam
increasing fnal superheated steam volumes
temperature. Due to the high temperature,
and temperature requirements, coupled with
pressure and mass density of the steam, there
multiple thermal cycles (per 24-hour plant
is substantial risk of component wear and
operational cycle) now place substantial
thermal shock damage, which increases the
demands on critical and severe service
risk of failure and impact on plant effciency.
products.
Rapid
1411PEI_46 46
varying
load
conditions
are
Precise control of steam temperature is a
typical of combined-cycle plants (CCPs)
critical element for safe and effcient plant
and place strenuous duty cycles on steam
operation.
attemperation components and downstream
The sustained emergence and
demand for even larger and more super-
apparatus.
effcient combined-cycle power generation
operating characteristics and the extent
facilities on the global market now drives the
of load changes it is subjected to, a steam
need for a new generation of heat recovery
attemperator
steam
thermal
generator
(HRSG)
attemperator
systems.These desuperheaters must be able to
46
address the complex engineering challenges
gas
Power Engineering International November 2014
Depending
can
on
the
experience
cycling. Temperature
boiler
extensive
differentials
between the steam fow and spray water,
www.PowerEngineeringInt.com
11/10/14 9:54 AM
Heat recovery steam generators
intermittent desuperheater operation and low-load boiler operation all
contribute to potential attemperator failures. This can lead to common
problems, including cracks in material welds and older spray nozzle
designs, cracks in the thermal lining (or in the attemperator steam line
within a liner that is not used) which can cause pieces to break off, and
broken spray nozzles which can become lodged in the venturi, causing
a steam fow blockage and pressure drop.
Understanding
the
necessary
desuperheater
performance
characteristics for effective steam temperature control requires
exploration of the balance between design effciency, component
fexibility and system reliability.
Atomization is key
Water droplet atomization requires a precise methodology to improve
understanding of primary and secondary atomization within the
pipeline prior to evaporation and steam cooling.This process is ultimately
predictable and measurable based on constant fuid dynamics. If
atomization of spraywater into the steam system is negatively affecting
the temperature probe’s ability to measure correct downstream steam
temperature, this could create severe overspray and underspray
conditions which result in increased thermal cycles and damage to
system components.
Primary atomization of the cooling water is caused by the nozzle
design and geometry within the desuperheater and the pressure
differential between the cooling water and the steam. Pentair Valves
& Controls has previously developed theoretical modelling of primary
atomization using computational fuid dynamics (CFD) analysis and
laboratory laser diffraction to analyze water droplet size upon discharge
from the desuperheater. This testing examined two steam attemperator
nozzle designs, spring-loaded and swirl nozzles. Results identifed that
when operating at 25 bar with a 0.05 mm lift and Kv 0.047, spring-loaded
nozzles produce droplet sizes of 87 µm. The same calculation for swirl
nozzles at 25 bar, Kv 0.043 resulted in droplet sizes of 27 µm – a factor of
two to four times smaller than spring-loaded nozzles, depending on the
operational pressure range.
Using this data, Pentair Valves & Controls analyzed the secondary
atomization characteristics which occur when the speed differential and
drag forces between the cooling water and pipeline media cause the
droplets to split into smaller sizes. This occurrence is calculated by:
We = p.D.V²
σ
(If We >14, secondary atomization occurs)
By measuring the speed differential of the two nozzle designs, Pentair
defned which nozzle achieved higher speeds and therefore faster
secondary atomization. Optimum atomization will result in frictional
forces breaking the droplet size, which results in complete mixing and
true temperature control and measurement.
These results demonstrated that swirl nozzle designs offer enhanced
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performance and maximum use of water pressure DeltaP for atomization
in the shortest possible length. Optimized spray injection angles of swirl
nozzles allow equal temperature distribution within the pipeline and
provide the highest turndown ratio due to mass fow, rather than pressure
control. No springs or moving parts within the nozzle and no pressure drop
and cavitation in the control valve maximizes the operational lifecycle of
the swirl nozzle design compared to spring-loaded nozzles. Combining
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1411PEI_47 47
Power Engineering International November 2014
47
11/10/14 9:54 AM
Heat recovery steam generators
this analysis with Pentair Valves & Controls’
10.00
100
experience in steam attemperation provided
an insight into desuperheater performance
characteristics for engineering design criteria
7.50
to support new product development.
Effective nozzle design
5.00
50
Operating at today’s higher temperatures and
cycling ratios places high thermal stresses
on critical components, and effective steam
2.50
temperature control is needed to protect this
vital equipment. Many plant operators are
looking to maintain steam temperature control
0.00
0
and the most effective ways to achieve this
2
100
10
are through the design of the shortest possible
1000
2000
evaporation length. Critical to achieving this is
uniform and consistent atomization through
Example of non-uniform and unsteady spray pattern and droplet size
distribution for a spring loaded nozzle
small droplet sizes. Robust nozzle design offers
plant operators an optimized solution that
100
delivers effective performance and maximum
10.00
component lifecycle to avoid unnecessary
plant shutdown, maintenance and product
7.50
replacement.
Optimum
desuperheater
performance
requires evaporation of the spraywater to take
50
5.00
place as quickly as possible in the shortest
length within the pipe to avoid water droplet
impingement. Low steam velocity and large
2.50
droplet sizes create water fallout inside the
pipe, creating cold spots and thermal stress
points which risk pipeline failure. In developing
the
next
generation
of
0
0.00
0.10
desuperheater
10.00
1.00
100.00
1000.00
technology to meet the evolving needs of
plant operators, Pentair Valves & Controls,
through
its
Yarway
brand,
wanted
Droplet size distribution for pressure swirl nozzle type B; ΔP=20 bar;
solid line corresponds to left axis, histogram to right axis
to
identify which nozzle type offered the best
performance in relation to water droplet size
capillary, aerodynamic and liquid viscous
and spray pattern. Documentation to support
forces. Primary break-up of the cooling water
spraywater
this product development was limited, with
typically takes place in the wake of the spray
attemperator performance, Pentair Valves &
little data to support an analysis of nozzle
nozzle during the frst 10 mm, with complete
Controls studied the functional operation of
performance.
atmomization
around
pressure swirl nozzle and spring-loaded nozzle
for
25 mm downstream of the nozzle.The pressure
designs. Both nozzles produce a hollow cone
optimized
differential between the spraywater and steam
spray with a spray angle between 80° and
steam temperature control, Pentair Valves &
is vital for both water atomization and the
120°. The hollow cone inside a swirl nozzle is
Controls embarked on a research project
rangeability between maximum and minimum
created by enforcing a natural swirling action
with the University of Eindhoven in the
water fow. Along with spraywater temperature
where the spraywater is injected through
Netherlands. The goal of this cutting-edge
and nozzle design, the maximum pressure
tangential or helical inlet ports into a swirl
research was to undertake an assessment of
differential directly affects atomization at the
chamber. This nozzle design creates strong
existing desuperheater nozzles, focusing on
smallest droplet size. Spraywater pressure
rotational and axial velocity components
spring-loaded and swirl nozzle designs. This
is ideally 150–1000 psi (10–70 bar) greater
and a thin conical sheet forms at the exit of
assessment would help to identify the design
than the steam pressure to provide optimum
the nozzle due to the large centrifugal force.
correlations of spray characteristics, which
vaporization speed and maintain controllable
In spring-loaded nozzles this hollow cone is
could then support a product development
low fow levels. While many desuperheaters are
mechanically created. When the pressure
roadmap for improved nozzle design.
capable of operating at much lower levels,
increases the valve opens with a certain lift
there is a direct correlation between pressure
and the spraywater exists via a small circular
differentials and component performance.
slit.
To
understand
desuperheaters
to
the
design
achieve
rules
In spray generation, a viscous liquid sheet
breaks up and becomes unstable due to
48
1411PEI_48 48
Power Engineering International November 2014
taking
place
at
To better understand the impact of
characteristics
on
steam
www.PowerEngineeringInt.com
11/10/14 9:54 AM
Co-located with:
EMERGING OPPORTUNITIES IN THE
WORLD’S FASTEST GROWING CONTINENT
EARLY BIRD
DELEGATE DISCOUNT
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YOU REGISTER BEFORE
17 JUNE 2015
Conference & Exhibition
15–17 July 2015
Cape Town International Convention Centre, Cape Town, Republic of South Africa
www.powergenafrica.com
Invitation to Participate
For booth bookings and
sponsorship enquiries,
please contact:
POWER-GEN Africa, co-located with DistribuTECH Africa, will once again provide comprehensive
coverage of the power needs, resources, and issues facing the electricity generation industries
across sub-Saharan Africa.
Leon Stone
Exhibition Sales
International
T: +44 (0) 1992 656 671
E: leons@pennwell.com
The event will feature a multi-track conference covering strategic, technical and renewable topics
with practical solutions and benchmark case studies and concurrent exhibition foor featuring prime
movers showcasing the very latest equipment and technologies.
Andrew Evans
Exhibition Sales
Africa
T: +27 (0) 21 930 9515
E: andrewe@pennwell.com
POWER-GEN Africa has quickly established itself as sub-Saharan Africa’s premier and leading
event dedicated to the power generation industry, focusing on the current and future trends, as well
as the needs and resources within this region of the world.
Nowhere else provides you with the opportunity to reach and meet over 3,000 high-level industry
professionals in one place, allowing networking, business and sales opportunities with key industry
buyers and infuencers from around the continent.
To register and obtain further information, visit www.powergenafrica.com
Owned and Produced by:
Host Utility:
Presented by:
Supported by:
Supporting Association:
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1411PEI_49 49
11/10/14 9:54 AM
Heat recovery steam generators
Pentair
Valves
&
Controls
and
the
University of Eindhoven defned set research
parameters for both the pressure swirl nozzle
and
spring-loaded
nozzles.
Experiments
used demineralized water in temperature
range 5°C–85°C and set pressure between
8–70 bar, with a maximum of 8x nozzles. The
characteristics measured during the tests were
spraywater pattern, drop size distribution and
spraywater velocity. A Malvern Spraytec laser
diffraction system with a 100 mm diameter
enabled measurement of spray particle and
droplet size distribution in real-time. Using a
Dantec Laser Doppler Anemometry (LDA)
optical technique, accurate measurement
of velocity and turbulence distribution could
Testing examined two steam attemperator nozzle designs: spring-loaded and swirl
Credit: Pentair Valves & Controls
be measured in order to gain a clearer
understanding of fuid mechanics of the
spraywater characteristics of both nozzle
by restrictions in the nozzle design caused by
these properties with the need for continued
types.
tolerances engineered into the nozzle, which
operation, scheduled
creates gaps and impact on the spraywater
repair. Improving the design and engineered
pattern.
performance of critical components is key
Applying research results
Many plant operators are looking to maintain
maintenance
and
to meeting the power generation industry’s
steam temperature control. The most effective
Pressure swirl nozzle
future requirements and ensuring maximum
ways to achieve this are through the design of
Under performance testing as part of Pentair
plant uptime. Investment into sound research
the shortest possible evaporation length within
Valves & Controls’ research, this nozzle design
using modern methodologies and techniques
the attemperator system, together with equal
delivered a uniform and steady spray pattern.
is one solution to delivering new, advanced
temperature distribution within the steam and
In comparison to the spring-loaded nozzle
technology to plant engineers and operators.
high turndown ratio. Combining the results
design, this nozzle delivers much smaller
In collaboration with the University of
of the computational modelling and this
droplets to achieve evaporation more quickly
Eindhoven, Pentair Valves & Controls has
latest research from Pentair Valves & Controls,
and in a shorter pipe length. The uniform,
identifed new correlations which have been
further understanding can be gained to
hollow cone spray pattern ensures even
generated for the discharge coeffcients,
achieve
desuperheater
droplet size distribution within the pipe and
sheet velocities and drop size distribution
performance, particularly in combined-cycle
minimizes impingement and water fallout.
parameters of various types of pressure swirl
and heat recovery steam generator (HRSG)
These
faster
nozzles. As the operational and functional
applications. Using this data enables the
response times and more accurate steam
design requirements of steam attemperator
effective application of theoretical models to
temperature control to help plant operators
systems continue to evolve, this engineering
identify the nozzle design and engineering
improve
research and design understanding will be
considerations for successful primary and
effciency of the boiler circuit.
secondary
more
effective
atomization, evaporation
characteristics
the
demonstrate
precision
and
operational
critical in the development of new technology
and
to meet these new challenges. Component
Higher performance solution
performance data, advanced detailed 3D
examining the results of Pentair Valves &
The research results conclude that spring-
computer
Controls’ research, it is possible to identify the
loaded nozzles deliver a spray pattern and
industry design experience are providing the
design correlations of these parameters and
water droplet distribution that is both non-
tools for this next generation of attemperator
understand how each nozzle type impacts on
uniform and unsteady. This indicates that this
systems. The work that manufacturers such
desuperheater performance.
nozzle design is best suited to less critical
as Pentair Valves & Controls undertake is an
process conditions or unit operations. The
integral step in this process, using qualifed
Spring-loaded nozzle
robust pressure swirl nozzle provides a higher
research and testing to improve product
The research results defned the spraywater
performance solution for critical and severe
design and push the industry towards higher
characteristics as not uniform and not steady,
applications, such as steam attemperation.
effciency, reliability and safety.
defned
spraywater
characteristics.
By
modelling, and
material
and
which causes potential water fallout. Uneven
The future design of higher effciency and
and inconsistent distribution of droplet size
high cycling duty CCPs will lead to higher
Martin-Jan Strebe is Global Product Manager,
affects atomization within the pipe and
steam temperatures and fows. Addressing
Control Valves at Pentair Valves & Controls
results in longer and slower evaporation,
the requirement for more effcient power
affecting precise steam temperature control.
generation
These characteristics are typically created
development and innovation and combine
50
1411PEI_50 50
Power Engineering International November 2014
will
drive
forward
material
i
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for more information
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11/10/14 9:54 AM
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Diary
December
2015
Nuclear: Powering the UK
World Future Energy Summit
DistribuTECH India
4 December
London, UK
www.niauk.org/nuclear-powering-the-uk
19–22 January 2015
Abu Dhabi, UAE
www.worldfutureenergysummit.com
7–9 May 2015
New Delhi, India
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Energy, Environment and
Sustainable Economy Summit
Nuclear Power Asia
The Asian Conference on
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5–6 December
Bangkok, Thailand
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POWER-GEN International
9–11 December
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9–11 December
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Renewable Energy World
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9–11 December
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Smart Energy UK & Europe Summit
29–30 January 2015
London, UK
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3–5 February 2015
San Diego, CA, US
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Nuclear Energy in the UK
3 March 2015
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52
1411PEI_52 52
Power Engineering International November 2014
POWER-GEN Asia
1–3 September 2015
Bangkok, Thailand
www.powergenasia.com
VGB Congress Power Plants 2015
9–10 September
Vienna Austria
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