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YEARS

119

DEMAND RESPONSE WHAT’S DRIVING THE MARKET?

HRSG WASTEWATER TREATMENT METHODS

VALVES & ACTUATORS UNDERSTANDING YOUR OPTIONS

Advanced Class Gas Turbines

August 2015 • www.power-eng.com

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DEPARTMENTS

2 Opinion

4 Gas Generation

6 View on Renewables

8 Energy Matters

10 Nuclear Reactions

48 Ad Index

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12 The Fall of the F-Class Turbine

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1508pe_1 1 8/7/15 10:54 AM

2

OPINION

www.power-eng.com

prices dropping 48 percent by 2040.

Talk about a tipping point. These

new economic dynamics, along with

other technology and cost advances

particularly in energy storage, are why

states, cities, corporations, and nations

can now set once-unthinkable targets

for generation from renewables without

breaking the bank. In more news from

the month of June, Hawaii (100 percent

by 2045) and Vermont (75 percent by

2032) both signed unprecedented

renewable portfolio standards into

law. And in California, the state senate

passed Gov. Jerry Brown’s goal of 50

percent renewables generation by 2030.

It now awaits expected approval by the

state assembly.

Policy drivers like these will

continue to be critical to drive the

growth of renewables. In one piece of

bad news on the policy front at the end

of June, the U.S. Supreme Court issued

a key ruling against EPA regulation of

mercury emissions from coal-fred

power plants. It’s certainly not a good

development for the environment, but

unlike what I’ve read in various media

accounts, it does not directly affect

CO2 regulation such as the EPA’s Clean

Power Plan.

The court’s ruling does not change

the fundamental economics of energy:

coal is simply no longer a cost-effective

choice for new generation in the U.S.

and increasingly, overseas as well.

Compared to the much larger trends

in fnance and policy that are driving

the momentum of renewables, many

of which came to the fore in June, I

predict that this SCOTUS decision will

be a blip on the radar.

Last month, we Americans cel-

ebrated our nation’s birthday,

capped off perfectly by the USA

women’s soccer team’s sensational

5-2 victory in the World Cup final. As

we hit the halfway point of 2015, the

clean-energy industry also has much

to celebrate, much of it in the month of

June alone and much of it financial.

Consider all of these recent

developments:

• The White House announced $4

billion in clean-energy funding

commitments, including $1.1 bil-

lion from five large institutional

investors such as the University of

California and TIAA-CREF, with

the balance from major founda-

tions and nonprofits.

• Bill Gates quite literally doubled

down on financing innovative

renewables technologies. The

software mogul-turned-clean en-

ergy investor told the  Financial

Times he would add an additional

$1 billion over the next five years

to his $1 billion already invested

in clean-tech companies and the

venture capital firms that back

them.

• Another tech mogul, Masayoshi

Son of Japanese telecom giant

Softbank, went even further. Al-

ready a major funder of large solar

energy projects in Japan, Softbank

committed $20 billion for solar in

India — aiming to help grow that

market to 100 GW in 2022 from 3

GW today.

• Sixty percent of large investment

firms plan to invest in solar pow-

er projects for the first time in the

next five years (including 32 per-

cent in the next year), according to

a survey released in June by solar

PPA market maker Wiser Capital.

Eighty percent said they want to

“support a clean-energy future”

and more than 60 percent are con-

fident in the chances of high ROI.

At the end of June, China upped its

commitment to reduce greenhouse

gas emissions by 60-65 percent from

2005 levels by 2030, including a goal

to receive 20 percent of its primary

energy from non-fossil fuels by 2030.

The announcement was part of a slew

of new GHG cut commitments from

the U.S., Brazil, and South Korea, in

advance of the United Nations climate

talks in Paris later this year.

A great driver of all of this recent

momentum is the rapidly changing

economics of clean energy. Headlines

about record-low prices for solar and

wind power in a myriad of regions

appear almost daily. To cite just two

examples, Michigan utility DTE

Electricity has asked regulators to

approve a rate cut because of falling

wind prices in the state, while Austin

Energy, seeking to procure 600 MW of

solar in Texas, received developer bids

at less than 4 cents per kilowatt-hour.

Those are just two examples of a

broad-based global trend that shows

no signs of slowing down. A June

report from Bloomberg New Energy

Finance predicts that wind power will

become “the least-cost option almost

universally” within 10 years, with

prices falling 32 percent by 2040. And

solar will join wind as cheaper than

fossil fuel-fred energy by 2030, with

Fireworks, a World Cup, and Clean Energy MomentumBY CLINT WILDER, CLEAN EDGE

Author

Clint Wilder is

senior editor at

clean-tech research

and advisory frm

Clean Edge and

the coauthor of

two books: “Clean

Tech Nation: How

the U.S. Can Lead

in the New Global

Economy” and

“The Clean Tech

Revolution.”

1508pe_2 2 8/7/15 10:54 AM

For info. http://powereng.hotims.com RS#2

1508pe_3 3 8/7/15 10:54 AM

4

GAS GENERATION

www.power-eng.com

I was surprised to learn that an ul-

tra-complex bit of precision engineering,

with a final price tag that can reach many

millions of dollars, would ultimately de-

pend on good old-fashioned air to keep

itself from melting down onto the boots

of the engineers.

“The air-cooled version of the turbine

is just much simpler and more cost-effec-

tive,” Abate told me. “The steam-cooled

turbine was technical-

ly elegant, but it was

expensive to operate.

Air cooling makes

the turbine cheaper

to maintain because

there are no steam

circuits to tear down

before accessing key

components. That adds up to lower life

cycle costs.”

In fact, air-cooled turbines are very

common in the industry. While air-

cooled designs do require hot air to be

extracted from the gas turbine to cool

hot-path components, and the theft of

this heat can compromise their overall

efficiency, they can still be preferable to

steam-cooled designs which do not incur

such performance penalties, if only for

their simplicity and lower operation and

maintenance costs.

So what’s old is new. It turns out GE’s

turbines are far from the only ones in

the industry to rely on such tried-and-

true engineering; Siemens and Alstom

(among others) also produce air-cooled

gas turbines, and it’s safe to bet that other

companies are right now putting new air-

cooled designs through the paces in R&D

labs across the world. I guess sometimes

simpler really is better.

When I was a teenager, I dat-

ed a girl whose parents

wouldn’t let her dress grun-

ge. Having grown up in another era, her

mom couldn’t understand the movement

I suppose, and she flatly outlawed such

foolishness in the house. Did people real-

ly wear plaid flannel and cut holes in their

jeans intentionally?

The whole episode became a major

problem for us. (Actually, it created an

existential crisis worthy of Kierkegaard’s

storied prose.) Admittedly, it was the

mid-nineties, and Nirvana had been over

and done with for a couple years. But

fashion moves more slowly in a little farm

town, and grunge was still very much in

vogue where we lived.

Not to worry though. This was no av-

erage girl, and she quickly found an en-

terprising solution to her problem. If she

couldn’t dress grunge, she would find an-

other counter-cultural fashion statement

that her mom could relate to, and drag it

kicking and screaming into the modern

era. She would dress like a hippy. This

girl was committed. We’re talking full-on

Haite and Ashbury here. It was a circus!

But come on, dressing like an anachro-

nistic hippy? That’s so amateurish, and we

were better than that. Enter the mid-60s

Volkswagen Beetle.

Yes, as it happened, the neighbor up

the road was selling his pitiful little bug

for a pittance, so my girlfriend paid the

few hundred dollars he was asking and

drove it home that weekend. It was baby

blue, and that afternoon she sent away

for the mandatory flower decals to stick

on the hood. She let me drive it a time

or two. You had to stand on the clutch

to shift into reverse, but other than that

it handled like a dream—a fever-fueled,

hallucinogenic nightmare of a dream.

We drove that thing up and down the

back roads all over the county. It was awe-

some…and terrifying.

Here’s a hint though. If you’re going to

park your cranky geriatric bug at the local

drive-in burger place, shut the engine off.

Turns out vintage Beetles were air-cooled,

and idling one in a stationary position

long enough to eat a

double quarter-pound-

er with cheese will ren-

der it hotter than an

Oklahoma July. Can I

really be the only per-

son in the world who

didn’t already know

this? Next someone

will try to convince me that VW put the

trunk in the front of the blasted thing.

A few years ago I learned Volkswagen

would be ending the manufacture of their

original air-cooled masterpiece. Sure, the

company had already come out with a re-

placement—the “new” Beetle—but it was

thoroughly modern and water-cooled, so

it wasn’t the same. Yes, it seems the evolu-

tion of internal combustion engines has

unfailingly included an upgrade from air-

cooled to fluid-cooled systems. But not so

with natural gas-fired turbines, it seems.

Last year, I had the pleasure of speaking

with Victor Abate, president and CEO of

power generation products at GE Power

& Water. We were talking about GE’s HA

turbines, which are among the largest and

most efficient in the world. Unlike GE’s

previous H-class turbines which utilized

steam cooling, GE’s new HA turbines rely

on air for temperature regulation. (The

“A” stands for air, in fact.)

Economy from Thin AirBY TIM MISER, ASSOCIATE EDITOR

Air cooling makes

the turbine cheaper

to maintain because

there are no steam

circuits to tear down.

- Victor Abate, GE

1508pe_4 4 8/7/15 10:54 AM

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6

VIEW ON RENEWABLES

www.power-eng.com

capacity limits and are struggling with

T&D networks critically in need of up-

grades.

The world may not be entirely ready

to change the way it sources electricity. It

will need to get ready because the conven-

tional energy status quo needs to adjust

rapidly in order to realize true energy in-

dependence for all.

True energy indepen-

dence will not rely 100

percent on the electricity

grid and it will look a lot

more like off grid solar.

The current focus on mi-

cro grids, under the defi-

nition that micro grids

include storage, is the off

grid model. True inde-

pendence will encourage

electricity conservation and include edu-

cating electricity users about the photo-

voltaic/storage systems that allow them

to decouple from the utility grid when

necessary.

The slow, messy changing of the elec-

tricity guard will also include altering the

antiquated concept of what utilities are

and what utilities should provide. De-

ployment of PV is often antithetical to the

utility model – simply put, it cuts into the

utility revenue model.

The slow messy changing of the

electricity guard will force electricity

users to become responsible for their

electricity future and this is not a bad

thing. All industrial and technological

changes cause seismic ruptures in the

status quo and this one will be no dif-

ferent. The results of this change will

be a seismic correction.

Conventional energy technolo-

gies and investors in big oil, nat-

ural gas and coal are highly resis-

tant to letting insurgent renewable energy

technologies such as solar and wind take

the lead. No matter, squint your eyes and

the energy future with renewable energy

as the dominant technology is visible over

the horizon – hazy and still a bit far off,

but visible. Currently, renewable ener-

gy’s share of global energy production is

a fraction of conventional energy’s share

but change is slowly taking hold despite

well-funded resistance to it.

The global photovoltaic industry has a

leading role to play in this messy chang-

ing of the energy guard. It’s been playing

a role for decades, though it has seldom

been easy and rarely highly profitable.

Viewed simply through the lens that

growth is always good, decades of neg-

ative or low margins could be written

off as the price of gaining share, though

it should be remembered that PV has

a very small share of global electricity

production.

There is another perspective with

which to view decades of PV industry

behavior, that of courageous persever-

ance in the face of well-funded (con-

ventional energy) competition. This

perspective is also true. Photovoltaic

industry participants have persevered

through slap dash and unreliable in-

centives, drastic, abrupt and some-

times retroactive changes to incentives,

end users waiting for the technology to

mature and many others miss or poor

understandings of the technology and

industry.

In truth, the global photovoltaic

industry has persevered through decades

of double digit growth and decades of fi-

nancial struggle.

The availability of government legis-

lated incentives is a fragile and unreliable

thread on which to hang the hopes and

dreams of an entire industry. Sudden

and retroactive changes have broken the

hearts and bank balances of many a PV

industry participant. Yet,

deployment often contin-

ues despite the cessation

of an incentive primarily

because, simply, it must.

It would be more fiscally

devastating than many

realize if deployment

ceased abruptly. There is

significant inventory on

demand and supply sides

of the solar industry and if deployment

ceased, it would become even more of

a burden. Jobs would be lost. Research

and development would stall. Continued

deployment, however, is different from

profitability.

Incentives are expensive to support,

and when governments in Europe be-

gan pulling the incentive-rug out from

under the PV industry this, along with

fallout from pricing set below cost,

stimulated an industry-wide consol-

idation that included the failure of

many well-known and industry lead-

ing companies.

Currently with deployment of renew-

ables (and PV) encouraged by govern-

ments and end user interest at a high lev-

el, utilities are pushing back on continued

accelerated deployment while globally,

utility grids have been pushed to their

The Slow, Messy Changing of the Electricity GuardBY PAULA MINTS, SPV MARKET RESEARCH

“True energy independence will not rely 100 percent on the electricity grid and it will look a lot more like off grid solar.”

1508pe_6 6 8/7/15 4:30 PM

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8

ENERGY MATTERS

www.power-eng.com

design that has tripped up many owners

during permitting. Air permits include

separate limits when operating with and

without duct firing. Typically the max-

imum amount of duct firing is set by

either the desired amount of peak plant

output or the maximum practical design

limit. Often, preliminary engineering is

completed to estimate the amount of duct

firing that is required to achieve one of

these limits. Emissions produced during

duct firing are calculated based on this

heat input. However, the actual required

amount of duct firing is determined by fi-

nal major equipment OEM selection and

thermal cycle design optimization. The fi-

nalization of these two decisions is often

completed after air permit issuance. This

may result in limitations on duct firing

capability. In this case, it is important that

the design engineers determining cycle

design and the permitting engineers de-

veloping emissions estimates understand

and consider the impact various major

equipment OEMs and variations in cycle

design may have on heat input and asso-

ciated permit limitations.

Gas turbine technology is evolving at a

rapid pace. In the past three years, most of

the major gas turbine OEMs have released

several performance improvements.

Many owners, especially those with proj-

ect delays or longer permit approvals,

have been caught with air permit require-

ments restricting the ability to implement

the latest gas turbine technology platform

without revising the air permit. The is-

sues described above can be mitigated or

eliminated when the permitting and the

design engineers communicate.

Coordination up front can save time

and money in the end.

The battle for a good permit be-

gins well before the application

is submitted, with the initial

Front End Engineering Design (FEED)

and development of conceptual engineer-

ing information used as inputs to permit

modeling and development.

A lack of communication between per-

mitting and design engineers can lead to

big problems for a facility, as each group

has its own perspective, language, drivers,

and needs. Ultimately however, align-

ment between permitting and design en-

gineers will best serve the long term inter-

ests of the facility.

Particulate emission limits are a fre-

quent source of permitting/design discon-

nect. A major contributor to condensable

particulate matter (PM) is the amount of

sulfur in the fuel gas and the amount of

oxidation of sulfur dioxide (SO2) that oc-

curs through the gas turbine combustion

process. This occurs throughout the heat

recovery steam generator (HRSG) in the

selective catalytic reduction (SCR) sys-

tem, carbon monoxide (CO) catalyst, and

duct burner. The maximum amount of

sulfur in the gas may not be easy to define

over the life of the plant. Conservatively

using the sulfur tariff for the gas pipeline

is often too high an assumption and can

lead to serious impacts during dispersion

modeling, especially considering that the

actual gas sulfur content is typically sig-

nificantly lower than tariff value. How-

ever, owners are often hesitant to rely on

past gas supply sulfur levels as a reliable

prediction of long term levels, as several

shales predict a potential for increasing

sulfur content as production areas shift.

The type and location of SCR and oxi-

dation catalyst impacts the conversion

of SO2 to sulfur trioxide (SO

3) through-

out the gas turbine/HRSG train, and the

amount of ammonia injection and slip

impacts the amount of SO3 in the ex-

haust gas that is converted to ammonium

bisulfate. Because conversion of SO2 to

SO3 is not widely understood, most own-

ers are prudent to assume 100 percent

conversion of sulfur to particulate when

establishing their plant PM limit.

Start-up emissions are another area of

concern. Actual hot, warm, and cold start-

up emission rates are highly dependent

on the gas turbine manufacturers (OEM)

and starting package selection, the HRSG

and steam turbine generator design, OEM

selections, the overall steam cycle design,

and balance of plant equipment design.

“Conventional” start-up times are based

on holding the gas turbine at select, low

operating loads to allow the HRSG ma-

terials to gradually warm. These hold

points also provide time for cycle water

quality to be brought within specifica-

tion before steam can be admitted to

the steam turbine. This typically results

in the gas turbine operating outside of

emissions compliance load during start-

up with NOx, CO, and VOC emissions at

orders of magnitude higher than during

normal steady state operation. An alter-

native is to remove the gas turbine low

load hold points and reduce the overall

startup emissions. It is also important

to understand how to appropriately esti-

mate start-up emissions for the final plant

configuration. Calculation of start-up

emissions is not easy. Regardless of major

equipment selection, start-up emissions

are highly dependent on, and influenced

by, the overall cycle design.

Duct firing is another element of plant

FEEDing the Permitting BeastBY MEGAN PARSONS, BURNS & MCDONNELL, AND ROBYNN ANDRACSEK, P.E., BURNS & MCDONNELL AND CONTRIBUTING EDITOR Megan ParsonsRobynn Andracsek

1508pe_8 8 8/7/15 4:39 PM

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10

NUCLEAR REACTIONS

www.power-eng.com

so future leaders can see what may be

available to them and how.

Line leaders’ routines need to include

succession planning, development and

coaching in addition to the routines

they use to run the plant.

Leaders must serve as role models in

the time they spend developing their

own succession candidates as well as

coaching and mentoring others.

Leadership development and train-

ing programs must be seen as effective

by participants and sponsors.

Leadership roles at the site need to

be viewed as desirable opportunities by

potential succession candidates. If not,

site leaders need to figure out why.

Line leader and HR roles and respon-

sibilities should be documented, under-

stood clearly and executed accordingly.

HR personnel assigned to talent

management and leadership develop-

ment roles must be highly capable and

viewed as effective by line leaders.

Assessments of succession candidates

and potential leaders need to be con-

ducted by trained professionals who

understand what nuclear power de-

mands from talent to be successful.

Decisions about leadership changes

and promotions should be made me-

thodically, with adequate input from

all appropriate parties.

Overall program effectiveness re-

views need to be conducted regularly,

focusing on process, behavior and re-

sults.

Although these requirements may

appear demanding, the more successful

utilities are following them and have

made strategic decisions to invest in the

leadership capabilities necessary to run

nuclear plants effectively.

The cover story in the June issue

of Power Engineering magazine

highlighted the challenges

facing the energy, utility and manufac-

turing sectors in finding skilled labor

as baby boomers retire in greater num-

bers. These same challenges are being

seen in the supervisor and manager

ranks at nuclear power plants across

the country. Engineering—more than

any other department—appears to be

the canary in the coal mine. Engineer-

ing organizations are feeling the loss

of knowledge and the impact of too

many open engineering positions and

leadership roles filled by much less ex-

perienced engineering supervisors and

managers. As U.S. nuclear power plants

and their systems age and license exten-

sions go into effect, the need for highly

capable engineering leadership will in-

crease, if anything.

Operations departments are not feel-

ing as much pain as engineering be-

cause sites have been more diligent and

proactive in feeding the licensed opera-

tor and non-licensed operator pipelines

or face being out of compliance with

their legal commitments for operating

the reactor. Maintenance, work man-

agement and training organizations are

right behind engineering in struggling

to fill open positions with qualified

professionals and capable supervisors.

As nuclear operating companies

make short- and long-term asset man-

agement decisions about what equip-

ment to replace, fix, or maintain, they

need to be making strategic decisions

about investing in the talent they need

to effectively run organizations as com-

plicated as nuclear power plants. On the

surface, most nuclear utilities across the

U.S. appear to be doing so, in that they

have recruiting, assessment, and lead-

ership development programs in place

conceivably to grow talent and increase

leadership effectiveness. But scratch

below the surface, and many programs

fail to reach a large portion of nuclear

power leaders and potential leaders.

Leadership training programs may be

limited in their effectiveness and/or not

available to a large portion of the pop-

ulation. Succession planning, critical to

focusing developmental activities, too

often consist of lists of names repeated

too often and discussions concentrated

on personality and historical personal

references, good and bad. Instead, suc-

cession planning discussions need to

be regular meetings, supported by the

highest levels of leadership, and cen-

tered on leadership attributes necessary

to be effective. Candidates’ level of read-

iness should be based on independent

assessments of these attributes, which

also serve as a basis for future leaders’

development.

Some companies are applying the

necessary discipline and rigor to talent

development in order to close gaps and

grow their own talent, forestalling lead-

ership shortages. In my book, Nuclear

Energy Leadership: Lessons Learned

from U.S. Operators (2013), I offered

a checklist that nuclear sites can use

to identify where they need to work to

improve their talent development capa-

bilities:

The site must have documented pro-

cesses for succession planning, talent

management and leadership develop-

ment. Leaders need to follow these pro-

cesses and communicate about them

with the broader management team

Strategic Investment in TalentBY MARY JO ROGERS, PH.D.

Author

Mary Jo Rogers,

Ph.D. is a partner

at Strategic

Talent Solutions.

She recently

published the book,

“Nuclear Energy

Leadership: Lessons

Learned from U.S.

Operators,” by

PennWell. maryjo@

strattalent.com.

1508pe_10 10 8/7/15 11:04 AM

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��������&��&���&���&������� &$&

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1508pe_11 11 8/7/15 11:04 AM

12 www.power-eng.com

The Fall of the F-Class Turbine

Advanced class turbines such as the M501J

are overtaking F-Class turbine technology

as the preferred choice for new gas-fired

projects. Photo courtesy: Mitsubishi Hitachi

Power Systems Americas.

BY MICHAEL J. DUCKER

temperatures and pressure ratio. As

advances were made in materials and

cooling technologies, gas turbines were

able to fire hotter, resulting in better

efficiencies and higher outputs. Design

changes in the compressor and tur-

bine section were commonly needed,

and thus when a manufacturer made

improvements significant enough to

increase output and efficiency, a new

turbine class was born. Although at

It seems oil prices are not the

only phenomenon experienc-

ing a sudden, and seemingly

unexpected, decline from the

status quo. For the first time

since F-Class turbine technology came

to dominate the market over 20 years

ago, the technology is no longer the

leader in North America 60 Hz heavy

duty gas turbine (HDGT) sales. Ad-

vanced class turbine (typically defined

as G-, H-, and J- class technologies)

sales have seen greater than 50 per-

cent year-on-year growth in the past

five years and are the reason for this

unseating. The recent gas turbine OEM

emphasis on these advanced technolo-

gies confirms the trend is here to stay.

DEFINING THE CLASSES

Historically, gas turbine frame

types were defined by output, firing

For the first time in over 20 years, F-Class turbine technology no longer commands majority share in the North America 60 Hz heavy duty gas turbine market

Author

Michael Ducker is the manager of Mar-

ket Research at Mitsubishi Hitachi Power

Systems Americas. In this role, Michael

is responsible for strategic analysis of

energy markets.

GAS TURBINES

1508pe_12 12 8/7/15 4:32 PM

For info. http://powereng.hotims.com RS#7

1508pe_13 13 8/7/15 4:32 PM

14 www.power-eng.com

HDGT Market Share

North Amreica Market Share Evolution between D/E-Class, F-Class, and G/H/J-Class Turbines.

1

D/E Class

% o

f G

T s

ale

s b

etw

een

cla

sses

100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

0%

GT Sale Year

1980 1985 1990 1995 2000 2005 2010

Actual

Trend

G/H/J Class

FClass

Source: 2014 McCoy Power Report

off, marking the beginning of the tran-

sition away from F-class technology

and into the new era where efficiency,

not a turbine class or flexibility, is now

king.

WHY NOW?

Just a few years ago, many gas turbine

OEMs hyper-focused their marketing

on the flexibility of F-class turbines.

With increasing penetration of renew-

ables – some studies even suggesting

upwards of 80 percent renewables in

the U.S. as technically achievable – it

seemed as though F-class turbines

would dominate the market and would

help transition the U.S. to a new wave

of renewable energy technologies. Yet

in this same time frame, several events

occurred helping to promote the up-

ward trajectory of advanced class tur-

bines.

First, EPA regulations combined

with low gas prices facilitated the clo-

sure of thousands of megawatts of

coal-fired generation. While this result

was not at all unexpected, what was

somewhat unexpected was how these

units were replaced. Many early retire-

ment forecasts pegged coal units with

primarily the only large HDGT prod-

ucts on the market. Yet in 1987, we see

the introduction of F-class technology

and a rapid rise of market shares as it

simultaneously erodes D/E-class tur-

bine sales. By 1996, F-class becomes

the relative market leader and enjoyed

nearly 20 years of sustained majori-

ty market share. Yet in the late 1990s

and early 2000s, the introduction of

advanced class turbines begins to take

times the nomenclature became murk-

ier, as evidenced by technologies called

“F-class” that featured firing tempera-

ture, output, efficiency, and design in

line with advanced technology, today’s

HDGT classes can be broadly catego-

rized into three areas based on OEM

gas turbine product names, size, and

efficiency. Focusing on size, D- and

E- class engines are typically in the

75 – 110 MW range. Products include

GE’s 7E.03, Siemens SGT6-2000E, and

Mitsubishi Hitachi’s H-100. F-class tur-

bines are typically in the 170-230 MW

range. Products include GE’s 7F.03-.05

models, Siemen’s SGT6-5000F, and

Mitsubishi Hitachi’s M501F. Lastly,

the advanced class turbines (G-, H-,

and J- frames) are typically in the 275

– 350 MW range. These include Mit-

subishi Hitachi’s M501J and M501G

machines, Siemens SGT6-8000H, and

GE’s 7HA.01 and .02 models.

A HISTORY LESSON

Before considering where the mar-

ket may be heading, it is worth taking

a look at where we have been. Figure

1 shows a historical evolution of mar-

ket shares between the HDGTs. Prior

to 1987, D- and E-class engines were

GAS TURBINES

Past 5-Year Reliability/Availability Data(January 2010 - December 2014)

Third Party Verifed Reliability and Availability Data

Source: Source: ORAP®—All rights reserved.

2

100%

98%

96%

94%

92%

90%

88%

86%

M501G F-Class

-1.36%

- 0.69%

Reliability

Availability

Re

liab

ility

/A

va

ilab

ility

%

99.05% 91.78% 97.69% 91.09%

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16 www.power-eng.com

Yet the regulatory permitting issue is

unfortunate with the number of own-

ers and developers who, in prior years,

based air permits, certificates of public

need, transmission interconnect studies,

and the like on a smaller F-class tech-

nology but viewed changing permits to

advanced class turbines as too costly or,

more importantly, a potential regulato-

ry delay. When a permit is in hand, not

many developers are eager to risk opening

their projects to public or governmental

change of hearts even if the economics

make better sense. As more permits are

initially filed to include advanced class

technologies, it is likely this portion of

the F-class market share will continue to

deteriorate over time.

Of course there are other strategic

reasons a developer may choose F-class

over advanced class turbines – such as

parts pooling, desire for multi-unit

configurations, mitigating regional re-

quirements for loss-of-load contingen-

cies, and other reasons not considered

beyond maximum capacity needs or

permitting issues. Still, the economics

and competitiveness of advanced class

turbines over F-class technologies are

difficult to negate.

THE DRIVE TOWARDS

EFFICIENCY

In 2011, Mitsubishi Hitachi Power Sys-

tems (MHPS) demonstrated the J-class

technology at its “T-Point” test facility in

Takasago, Japan. 2,900°F turbine inlet

temperature was achieved, translating

into a combined cycle efficiency of 61.5

percent. Today, MHPS is poised to release

additional improvements to its advanced

class technologies capable of achieving

>63 percent efficiency. General Electric

markets its 7HA.02 capable of achiev-

ing >61 percent efficiency and Siemens,

though quiet recently, still maintains

their SGT6-8000H at 60 percent efficien-

cy. With natural gas prices continuing at

record lows, will these major gains on

efficiency still be realized in the market?

order until system load is met. Therefore,

competitiveness in deregulated power

markets translates into being “1st on, last

off” – meaning the most efficient units

will be the first ones to power on (and be-

gin earning profits) and the last ones to

turn off (maximizing profits throughout

operation). From the value chain of these

markets, advanced class turbines are the

clear winner and, subsequently, sales in

these markets have reflected that.

WHY F-CLASS STILL SELLS

Some still consider F-class as the

“proven” technology (i.e. less risky

from a reliability standpoint) even

though the new F-class engines of to-

day have less operating hours than

the G-class engines

that have been run-

ning since the late

1990s. Additional-

ly, 3rd party gener-

ator reliability and

availability data

clearly shows some

of these advanced

engines featuring steam cooling are ac-

tually more reliable than their F-class

counterparts (see Figure 2).

Still, other themes emerge outside

of the “proven” technology view-

point. Primarily, two rational reasons

come to light for a developer to choose

F-class over advanced class technolo-

gies: transmission issues that would

require system upgrades to incorporate

a larger unit, or the tragedy of regula-

tory permits. Not much can or likely

will change with the former. There will

continue to be a market for D/E-class

and F-class turbines to meet the needs

of developers who have finite capacity

needs. These include building a gas tur-

bine in a region that does not require

>500 MW capacity due to demand or

building at a brownfield/other site that

would require significant – and costly

– transmission upgrades to enable the

larger unit.

low utilization rates as the most at risk

to retire, and thus a 1:1 capacity re-

placement would be unlikely. Yet what

materialized are a number of the large

advanced class turbines replacing these

coal units that had minimal operating

hours. Long-term resource planning

hinges on having an adequate installed

base to meet peak demand, and this

motivated many owners to replace old-

er under-utilized capacity with new,

highly efficient baseload NGCC capac-

ity that simultaneously displaced more

costly generation on their system.

Moreover, continued expansion of de-

regulated energy markets and consolida-

tion of balancing authorities in the US

and Canada helps to improve region-wide

load balancing. As a

result, a highly inte-

grated grid capable

of pooling many re-

sources with minor

flexibility require-

ments reduces the

needs to procure

sources with major

flexibility capabilities. For instance, as

PJM has grown, the entire regional trans-

mission organization (RTO) now only

typically procures 2,000 MW of primary

reserve requirements for a market that

sees peak loads in excess of 150,000 MW

(<2 percent of total demand). These an-

cillary services are pooled across the RTO

and within regional subsets, not just via

a few highly flexible units. Undoubtedly

some markets need greater flexibility, but

advanced class turbines are continuing to

push the envelope in this area. Minimum

emissions compliant loads and start

times are now nearly equivalent between

F-class and advanced class units.

And thus if flexibility attributes

between the gas turbine classes is es-

sentially equivalent, what is valued in

these markets? At their core, deregu-

lated energy markets thrive on the eco-

nomic dispatch principal whereby units

are cost-effectively dispatched in merit

GAS TURBINES

“The economics and competitiveness of advanced class turbines over F-class technologies are diffcult to negate.”

1508pe_16 16 8/7/15 4:33 PM

ADVANCED CLASS

TURBINES WILL

CONTINUE TO LEAD

Moving forward, there are many

questions regarding centralized power

generation and the role it will play in a

future considered ripe for demand re-

sponse, energy efficiency, and distrib-

uted generation. Yet at least within the

bulk power category, advanced class

turbines are in a position to succeed

and recent market events certainly sup-

port this fact. The way any successful

developer operates is simply to hedge

risks against potential market out-

comes.

When one stacks up the potential

and likely future market needs for cen-

tralized power, it is hard to see F-class

technology being a better hedge over

the advanced class turbines.

Meanwhile, President Obama’s

proposed CO2 new source (NSPS) and

existing source performance standards

(ESPS) will no doubt have a profound

effect on the drive towards better

efficiency. The NSPS rules themselves

are essentially an efficiency standard,

whereby the more efficient the unit is

the lower the lb-CO2/MWh emissions

rates will be. The ESPS rules may

further exacerbate coal retirements

and give way to newer, more efficient

advanced class gas turbines. Just

the threat of CO2 taxes or a formal

carbon trading scheme, even if

assumed 10-15 years away, can still

make a dent in a project’s proforma.

While the regulations themselves

will be contested, the general trends

are driving towards a low-carbon

regulatory and policy landscape.

In North America, the future

certainly seems promising for high

efficiency gas turbines. Deregulated

markets continue to expand, and

with recent and new environmental

regulations continuing to push coal

out of the market, baseload gas

generation is a nice fit. This trend is

not unique just to the United States

and Canada; Mexico’s recent market

reforms are bolstering the need for

more efficient and environmentally

friendly gas-fired generation in lieu

of existing coal assets. Additionally,

as markets continue to move towards

greater dependencies on gas-fired

generation, gas units will evermore

be competing amongst themselves to

be the lowest cost energy producer.

Efficiency will drive who outperforms

who in the markets.

1508pe_17 17 8/7/15 4:33 PM

18 www.power-eng.com

MARKET ANALYSIS

A New Era of Demand Response

Demand Response (DR)

capability in North

America has grown

considerably in the past

five years, both at utili-

ties and within competitive markets such

as PJM. However, DR technologies and

policies have generally relegated DR to a

minor role as a last-called resource. DR

has typically been slower to respond than

combustion turbines, and the load relief

it provides has been difficult to assess pre-

cisely (if at all) in the real-time operating

environment in which control center staff

operate. Furthermore, regulatory policies

in support of DR have generally focused

on the magnitude of megawatts achieved

at the expense of the quality and useful-

ness of those megawatts. Slowly, but sure-

ly, this is changing.

The use of DR in grid planning and

operations has solidified as utilities in-

creasingly rely on DR to meet installed

capacity requirements and sometimes

even operating reserve requirements. Fur-

thermore, independent system operators

(ISOs) led by PJM have incorporated DR

into procurement mechanisms for capaci-

ty, energy, and ancillary services. Industry

acceptance of DR as an integral part of the

future grid continues to grow, with states

like California and New York rolling out

major regulatory initiatives and Hawaiian

Electric issuing a request for proposals to

Authors

Stuart Schare is a Managing Director of

Energy at Navigant Consulting Inc. Brett

Feldman serves as Senior Research An-

alyst at Navigant Consulting.

Blurring the Lines between Generation and Demand-Side ResourcesBY STUART SCHARE AND BRETT FELDMAN

1508pe_18 18 8/7/15 4:33 PM

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MARKET ANALYSIS

in electricity usage by end-use customers

from their normal consumption patterns.

What makes these consumption changes

“demand response” is that they are in re-

sponse to changes in the price of electrici-

ty or to direct incentives, typically at times

of high wholesale market prices or when

system reliability is jeopardized.

Common examples of DR include

direct load control of residential air con-

ditioning, curtailment of commercial

cooling and lighting loads by building op-

erators participating in utility programs,

and shutdown or deferral of industrial/

manufacturing processes. An important

distinction for DR is that it must be dis-

patchable by a utility or system operator,

or be initiated by a customer in response

to a non-fixed price signal. Thus, static

time-of-use rates and scheduled thermal

energy storage are not typically consid-

ered to be DR; but critical peak pricing—

where the highest price tier is only in ef-

fect periodically as called by the utility or

operator—is characterized as DR.

UTILITY PROGRAM

OR GRID RESOURCE?

DR has matured from manual response

to inflexible, interruptible industrial rates

of a generation ago to the much more

automated and customizable programs

and products being offered today—with

plenty of everything in between account-

ing for the bulk of current DR capacity in

North America. An important distinction

in characterizing DR activity is whether

the curtailment capacity is part of a verti-

cally integrated utility program or within

a market defined by an independent sys-

tem operator (ISO).

Utility programs are typically based on

a regulator-approved tariff, and offer a

fixed incentive, or set of participation and

incentive options, to eligible customers

who voluntarily enroll in the programs.

While voluntary, many programs have

non-performance penalties or provisions

for withholding incentives or removing

customers from the programs.

One of the most frequently used and

long-standing programs is Florida Power

& Light’s (FPL) On Call Savings Program

with more than 800,000 participants

and well over 1,000 MW of central air

conditioning curtailment capability. Xcel

Energy in Minnesota and Colorado has a

similar participation rate of over 20 per-

cent of eligible customers. Other non-ISO

utilities with significant residential DR

programs include Duke Energy Caroli-

nas, NV Energy, and PacifiCorp. Most

investor-owned utilities also offer one or

more rates or programs for commercial/

industrial DR.

DR programs tend to be more lim-

ited in ability than generators in that

they are often only available when

cooling loads are prominent, and they

are commonly restricted to perhaps

a dozen events per year of four to six

hours in duration, often within a nar-

row window of eligible hours.

DR IN ISO MARKETS

In the United States and Canada, there

are nine major Regional Transmission Or-

ganizations (RTO) and ISOs responsible

for running wholesale electricity markets

DR aggregators for the provision of “grid

services,” including ancillary services,

from demand-side resources. So which

technologies and policies will drive DR

into the future as a more integrated and

valued resource?

This article describes the current DR

landscape in North America, including

state and regional activities that uniquely

affect how much DR is in place and how it

is utilized. It covers some of the emerging

DR technologies that are allowing DR to

be viewed more on par with generators,

and it reviews new applications of DR that

are raising its prominence as a valued re-

source alternative for utilities and system

operators. Looking ahead, emerging state

policies and utility initiatives are driv-

ing DR to a heightened prominence that

would have been difficult to envision just

five years ago.

DR IN NORTH AMERICA

Demand response is a term that can

mean many different things to many dif-

ferent people. A common definition that

traces back at least to a U.S. Department of

Energy report nearly 10 years ago charac-

terizes DR as changes (usually reductions)

North America RTO and ISO Map and Associated DR Capacity

1

ISONew England

New York ISO

Electric ReliabilityCouncil of Texas

CaliforniaISO

SouthwestPower Pool

MidcontinentISO

AlbertaElectricSystem

Operator OntarioIndependent

Electricity SystemOperator

PJMInterconnection

500MW

1000MW

1000MW

3000MW

2000MW

10,000MW

1508pe_20 20 8/7/15 4:33 PM

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Reforming the Energy Vision (REV), the

initiative’s goal is to transform the cur-

rent utility model into a distribution sys-

tem platform (DSP). The role of the DSP

would be to lay the groundwork required

for energy service providers on both the

grid side and the customer side of the

meter to provide products and services

2014 Polar Vortex, most DR bid into PJM

was only required to be available for ten

six-hour events during summer months.

Within the New York ISO footprint, the

New York Public Service Commission is

undertaking perhaps the most ambitious

plan to date from a state looking to mod-

ernize its electric utility sector. Called

and managing a large transmission grid

with high voltages. Some of these orga-

nizations have crafted DR programs or

integrated DR into their market designs,

thereby encouraging customer load par-

ticipation. DR has matured in the elec-

tricity market and has been afforded the

opportunity to bid directly against gen-

eration in these markets—commonly for

capacity, but also for energy and ancillary

services in some regions.

Currently, there are approximately

30,000 MW of DR in North America,

according to Navigant Research’s recent

Demand Response report, with a bit over

half coming from the RTOs/ISOs. This is

made up of about 8 million residential

and commercial & industrial (C&I) cus-

tomers. This market size equates to ap-

proximately $1.5 billion in DR revenues

for DR providers and customers.

PJM manages the largest DR market in

the world, at approximately 10,000 MW.

In some zones within the ISO, DR makes

up more than 10 percent of the capacity

resource base. PJM has also been a leader

in making it possible for DR to participate

and submit bids for reductions in the syn-

chronized reserves and frequency regu-

lation markets. However, there are some

headwinds that may challenge the contin-

ued growth of DR in PJM markets, such as

regulatory/legal challenges and increased

operational requirements that limit com-

pensation for DR that is not available 24

hours a day, year round. Until recently,

punctuated by the grid demands of the

“Looking Ahead, emerging state policies and utility initiatives are driving DR to a heightened prominence that would have been diffcult to envision just fve years ago.”

1508pe_21 21 8/7/15 4:33 PM

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MARKET ANALYSIS

to enhance the distribution system’s ef-

ficiency. Examples of these products and

services include network sensors, dis-

tribution automation, DR, distributed

generation, and microgrids. As part of

the proceeding, utilities are required to

develop their own DR programs as a sup-

plement to or replacement of the NYISO

DR programs.

In California, the ISO (CAISO) is one

of several bodies contributing to a “bifur-

cation” plan to split

DR into supply-side

and “load-modifying”

resources. Essential-

ly, this means is that

price-based programs

intended to shape

loads will remain with

the utilities, while

programs focused on

reliability, flexibility,

and ancillary services

will reside with CAI-

SO. Furthermore, a

stakeholder process is underway where

all types of DR would be identified, as

well as how they could play a part in

California’s electrical grid and what ben-

efits they could provide. State policy is

directing utilities to consider DR, not

just generation, as a partner in planning

how to balance and ensure reliability for

the electric grid. Further, the California

PUC is leading a process to value different

types of DR for its ability to contribute to

reliability, as well as to support the state’s

goals for reducing greenhouse gas (GHG)

emissions.

DR VENDORS AND

SERVICE PROVIDERS

As DR offerings and technologies

have matured, an ecosystem of vendors

has emerged with continually advanc-

ing hardware, controls, and head-end

communications systems. Similarly,

load curtailment “aggregators” have

formed to recruit and enable custom-

ers to collectively deliver to utilities

and ISOs DR capacity measured in the

tens or hundreds of megawatts—or

even more in some ISO markets.

The DR market can be segmented from

a vendor/aggregator perspective. On the

C&I side, companies such as EnerNOC,

CPower, and Johnson Controls special-

ize in one or more DR-related services

including recruiting customers, automat-

ing rapid and reliable load response, and

providing granular building usage data

and performance diag-

nostics.

The bulk of the

mass-market segment

includes single-fami-

ly homes with central

air conditioning and/

or electric water heat-

ing, as well as small

businesses with pack-

aged units of 20 tons

or less. As load control

switches are nearly a

commodity, and com-

municating “smart” thermostats are fast

becoming the specialty domain of Nest

and a variety of established and start-up

companies, players in the mass market

segment such as Comverge and Eaton

(formerly Cooper Power Systems) special-

ize in one or more of the following: mar-

keting/customer acquisition, head-end

control systems, and communications be-

tween the customer and the service pro-

vider/utility (for example, Eaton offers a

two-way mesh network dedicated to load

control).

A few vendors attempt to service all

markets in the DR space. Honeywell is

probably the best established, leveraging

its experience in commercial building

management as well as its thermostat

hardware business and its 2010 acquisi-

tion of Akuacom, an early developer of

open source Auto-DR software on the

OpenADR platform. Other major players

include Schneider Electric and Siemens,

global companies attempting to develop

differentiated services and acquire market

“State policies provide one indication of the future of DR, and these suggest a more integrated role for DR in resource planning and grid management.”

1508pe_22 22 8/7/15 4:33 PM

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DR AS A GRID

MANAGEMENT RESOURCE

If DR is now well-established as a ca-

pacity resource that can provide emer-

gency relief for reliability purposes, it has

only recently begun making a name for

itself as an operating resource to be used

on a more regular basis for providing

10-minute operating reserves and other

more precise ancillary services.

Many of the core attributes describ-

ing combustion turbines and other

generators have analogs for DR re-

sources. For example, both generators

and DR can be characterized by their

megawatts of capacity and by the time

it takes to bring those megawatts onto

the grid.

The real question is whether the per-

formance of DR is comparable to gen-

eration—or at least whether DR can

perform well enough compete and to

provide a portion of the services re-

quired by grid operators.

DR has been active in the synchro-

nous reserves market in PJM for several

years, providing up to 25% of the re-

quirement at times. However, chang-

es to the transmission system in 2013

dramatically lowered prices in this

market and made it uneconomic for a

lot of the DR to participate.

These conditions may change in the

future, so the technical capability is

ready to jump in when prices warrant it.

The frequency regulation market has

shown signs of growth, particularly

since PJM implemented FERC

Order 755 which affords greater

compensation to faster-responding

resources. Several alternative resource

providers, including batteries and DR,

have begun bidding into the market

and showing their ability to compete.

A major driver for DR is the increasing

penetration of intermittent renewable

energy due to both regulatory mandates

1508pe_23 23 8/7/15 4:33 PM

24 www.power-eng.com

MARKET ANALYSIS

of the generation portfolio. The state

will experience steeply declining net

loads (customer demand minus cus-

tomer-sited renewable generation) in

the mid-to-late morning as solar pro-

duction picks up, and even more dra-

matic increases in net load growth in

the late afternoon as solar production

drops off concurrent with an increase

in residential loads.

The new load shape provides op-

portunities for DR (as well as storage),

especially in the late afternoons when

load curtailment could slow—or at

least help manage—the sharp ramp

up. Alternatively, DR could be used

to shave off some of the new evening

peak. In the mornings when net load is

in decline, DR can also help to balance

the grid by soaking up excess supply as

generators struggle to ramp down. Re-

call that DR is defined as “changes” in

usage by end-use customers, but these

changes don’t always have to be reduc-

tions.

An increase in demand—in response

to an incentive or price signal—is also

demand response. Some of the ap-

plications and technologies for DR

as a down-ramping resource include

over-cooling cold storage facilities and

refrigerated warehouses, within ac-

ceptable limits of course.

Essentially, the customers are using

existing facilities and technologies for

on-demand thermal storage. In this

case, the benefit may be the ability to

draw power from the grid, as well as

the ability to tap into the stored energy

at a later time to reduce demand from

the grid.A newer and more innovative

application of customer-sited thermal

storage is grid-interactive water heat-

ing (GIWH). GIWH is the emerging

consensus term for describing electric

water heaters controlled by real-time,

two-way communication with the util-

ity, grid operator, or load aggregator.

When equipped with grid-interac-

tive controls, an electric water heater

and improving economic and regulatory

treatment of renewables.

Resources like solar and wind pow-

er rely on natural elements that can

sometimes be unpredictable and re-

quire backup power resources to re-

spond quickly if clouds roll in or the

wind stops blowing.

Traditionally, this has been accom-

plished by having fossil power plants

on standby or generating at below op-

timal levels.

As the penetration of intermittent

renewables increases, however, build-

ing generation just for this purpose

may kill the business case for the re-

newable energy, so cheaper, more flex-

ible backup alternatives must be con-

sidered. DR can help fill this void.

California is perhaps the poster

child for renewable energy inputs un-

settling a grid. In 2013, CAISO con-

structed the now famous “duck chart,”

which shows the anticipated future

load shape for the state in the shoulder

seasons as solar becomes a larger part

Source:

Attribute DR Resources Generation Resources

Resource SizeNumber and size of customers;curtailable share of total load

MW unit size

Responsiveness Advanced notifcation requirements Start-up/ramp-up times

ReliabilityCommunications reliability & variance in customer load response

Availability of fuel supply & transmission capacity

LimitationsConstraints on number and duration of events

Emissions limits

Temperature Dependency

Temperature-dependent loads;hourly/seasonal variations

Temperature-dependent heat rates and capacity

Resource Diversifcation

Diversity of self-generation, customer sectors, and participating end-uses

Fuel diversity and baseload vs. peaking

Analogous Attributes between DR and Generation Resources

California’s Future Load Shapeand Opportunities for DR

2

Increase in load could allowgenerators time to ramp down

Overgeneration risk Reductions in load could allowgenerators time to ramp up orshave off the new evening peak

2012(actual)

2013 (actual)

Ramp need~13,000 MWin three hours

28,000

26,000

24,000

22,000

20,000

18,000

16,000

14,000

12,000

10,000

0

Meg

awat

ts

Hour

Net load – March 31

12am 3am 6am 9am 12pm 3pm 6pm 9pm

201420152016

2017

2020

20182019

1508pe_24 24 8/7/15 4:33 PM

25 www.power-eng.comFor info. http://powereng.hotims.com RS#14

can respond to near real-time input by enabling fast

up and down regulation and frequency control for the

purpose of providing ancillary services and renewable

storage to the utility or grid-operator.

In addition to two way communication, GIHWs

can measure and transmit information on water tem-

perature, so grid operators know how much energy

storage potential the fleet of GIWHs have at any given

time; and based on customer usage patterns, they also

can judge how much load curtailment, or regulation

down service, the fleet can provide while still meeting

customers’ needs.

Through the use of high-storage capacity, highly in-

sulated water heater tanks, GIWH can provide even

greater storage and operational capacity/flexibility

than traditional water heaters that are simply retrofit-

ted with interactive controls.

THE FUTURE OF DR

IN NORTH AMERICA

If DR is on a decades-long evolutionary path, will it

continue to mature into an even more valuable grid re-

source on par with generation? Or will energy storage and

the increasing demands for grid management in a world

of high renewables penetrations squeeze DR out of the

picture?

State policies provide one indication of the future

of DR, and these suggest a more integrated role for DR

in resource planning and grid management—but with

stricter requirements on how DR must perform. The days

of rarely called interruptible rates and monthly capacity

payments for the occasional 3-hour event may be in the

past. The advent of grid modernization is tied to the new

resiliency view on how the grid should be designed.

States like California, Illinois, Maryland, New York,

Massachusetts, and Hawaii have begun grid moderniza-

tion proceedings to investigate how the future grid should

look in terms of issues including metering and dynamic

rates, distributed generation, and the associated implica-

tions transmission and distribution infrastructure.

This modernization approach goes beyond siloed

hearings on the individual aspects of utility operations to

create a holistic structure for grid planning and payment

formulas. DR may finally be able to compete on a level

playing field, which could eliminate some current forms

of DR while encouraging development of others.

At the national level, a current FERC Supreme Court

case has much bearing on the ability of DR to partici-

pate in wholesale markets in the United States. In ear-

ly 2011, the FERC issued Order 745, which required

1508pe_25 25 8/7/15 4:33 PM

26 www.power-eng.com

MARKET ANALYSIS

This change encompasses a diverse

suite of technologies that includes en-

ergy storage, energy efficiency, DR, and

the advanced software and hardware

that enable greater control and interop-

erability across heterogeneous grid ele-

ments. These are all key components of

the emerging energy cloud that is be-

ing accelerated by evolving regulation

of carbon emissions, a more proactive

consumer or pro-

sumer, and the con-

tinuously improving

financial viability of

distributed resources

compared to tradi-

tional generation.

Navigant projects

that there will be

about 70,000 MW of

DR in North America by 2023, an 11

percent annual growth rate. One indi-

cation of the growing prominence of

DR and the vendors/service providers

supporting it is the growth in

membership of the leading

DR trade association.

The Peak Load Manage-

ment Alliance (PLMA) has

been in existence since 1999,

yet just in the past three

years had more than dou-

bled in membership from

less than 40 members to

nearly 90 today.

The recent setbacks and

regulatory uncertainty in

PJM—while interrupting

DR’s long-term trajectory—

are an indication that the

industry demands more re-

sponsiveness and account-

ability from DR resources.

This will push the continued

evolution to more fully auto-

mated, fast-responding, and controlla-

ble DR resources that are able to play

an increasing role in integrating inter-

mittent renewable energy and in man-

aging real-time grid operations.

wholesale energy markets to pay the

same for DR as they do for electricity

generation. Energy supplier and gen-

eration groups challenged the order in

federal courts as unjust and unreason-

able compensation.

In May 2014, a panel of the U.S.

Court of Appeals overturned the or-

der by a 2-1 vote, potentially reverting

things to how they were before—or

making them worse, depending on

interpretation. The majority opinion

went even further and found that DR

in the wholesale energy market is a re-

tail transaction, which is outside of the

FERC’s jurisdiction.

In December 2014, FERC asked the

U.S. Supreme Court to review the case,

which was granted, setting the stage

for a hearing likely in early 2016. If the

worst-case scenario plays out and DR is

disallowed from all wholesale markets,

states and utilities will have to fill the

void. Depending on their status and

disposition, this could take months to

several years to enact. The short-term

momentum of DR would be halted, but

in the long term, if states and utilities

assign higher value to DR than do the

wholesale markets, it could lead to in-

creased opportunities for DR.

DR IN THE

ENERGY CLOUD

Aside from government policy, the

power sector is undergoing a fundamen-

tal transformation that could lead to an

increase in DR capacity or how widely DR

is used.

Led by rooftop so-

lar, encouraged by

the prospect of cheap

storage, and with the

possibility of massive

amounts of electric

vehicles on the grid,

the industry is slowly

shifting away from a

centralized hub-and-

spoke grid architecture based on large

centralized generation assets like fossil

fuel, hydro, or nuclear power plants.

The new paradigm—dubbed the En-

ergy Cloud in a 2015 Navigant white

paper—envisions an increasingly de-

centralized electrical grid that makes

greater use of distributed energy re-

sources, including DR.

“Navigant projects that there will be about 70,000 MW of DR in North America by 2023, an 11 percent annual growth rate.”

“Smart” thermostats are fast becoming the specialty domain of several established startup companies, as demand response (DR) becomes a major resource for power producers. In some places, DR developers are granted the opportunity to bid directly against generation.

1508pe_26 26 8/7/15 4:33 PM

For info. http://powereng.hotims.com RS#15

1508pe_27 27 8/7/15 4:33 PM

28 www.power-eng.com

A large Hyundai shovel operates on the surface of cured dense slurry at the

Matra power facility’s impoundment in Hungary, attesting to the compressional

strength and environmental stability of the end-product. The shovel excavates

cured slurry from around the perimeter for use in building up the levee of the

15-tiered, 150-foot-high impoundment. Photo courtesy: NAES

ENVIRONMENTAL REGULATION

1508pe_28 28 8/7/15 4:33 PM

29 www.power-eng.com

BY DALE TIMMONS

The Environmental Protec-

tion Agency’s (EPA) newly

enacted Coal Combustion

Residuals (CCR) rules and

proposed Effluent Limita-

tions Guidelines (ELG) will significantly

impact waste management practices in

the coal-fired power industry. The new

rules will regulate fly ash settling ponds

out of existence; regulate the location, de-

sign, operation, and closure requirements

for impoundments; and impose new re-

quirements for wastewater.

Traditional “dry ash” management

techniques satisfy the rules’ proposed re-

quirements, but they suffer from inherent

technical deficiencies and pose prohibi-

tive costs.

The Circumix™ Dense Slurry System

(DSS) technology, developed by GEA

EGI Ltd. of Hungary and represented ex-

clusively by NAES Corporation in North

America, mixes wastewater with CCRs to

produce a stable product with near-stoi-

chiometric use of water. Once cured, the

slurry exhibits low hydraulic conduc-

tivity, high compressional strength, no

discharge of fly ash transport water, little

or no fugitive emissions, and enhanced

metals sequestration, thereby achieving

the goals of the CCR and ELG rules.

The EPA has also imposed stricter stan-

dards for air emissions with the Mercury

and Air Toxics Standards (MATS). As with

the proposed CCR and ELG rules, the vast

majority of toxic metals targeted by MATS

originate from coal-fired power plants.

The EPA recognized that many processes

designed to remove metals from gaseous

emissions result in a transfer of the metals

to other effluents, which is one reason it

Author

Dale Timmons is a egistered geologist

and Business Development Program

Manager with NAES Corporation.

Dense Slurry Coal Ash Management: Full Compliance, Lower Cost, Less Risk

1508pe_29 29 8/7/15 4:33 PM

Electron Microprobe Image of a No-Lime Sample 1

Source: NAES Corporation

30 www.power-eng.com

fly ash transport water discharge, little

or no fugitive dust, and enhanced se-

questration of contained metals. These

properties meet the performance re-

quirements specified in the new CCR

rule and the proposed ELG.

DSS is currently used at eight power

plants – seven of them in Europe and

one in the U.S. Two more plants are

being built or commissioned – one in

Europe and one in India – that will use

the technology. Circumix DSS systems

have processed over 60 million cubic

yards of dense slurry into environmen-

tally stable end products, primarily

using flue gas desulfurization (FGD)

water and other plant wastewater as the

stabilizing medium.

In addition to achieving compliance

with the new ELG and CCR rules, DSS

offers numerous additional advantages:

• Combined stabilization of ash and

wastewater

• Reduction of water use by 80 to 90

percent compared to traditional

practice

• Zero discharge of transport water

• Significant reduction of plant-wide

wastewater

of trucks and heavy equipment signifi-

cantly increases safety risks.

DENSE SLURRY SYSTEM ASH

MANAGEMENT

A dense slurry system (DSS) offers a

safer, less expensive alternative to dry ash

management while producing a product

with improved environmental perfor-

mance. DSS is a high-intensity mixing

process that combines plant wastewater

with CCRs to produce dense slurry that

is easily pumped to an impoundment or

landfill. The process maximizes the avail-

ability of reactive ions in the ash and opti-

mizes the use of wastewater.

Dense slurry produced by the DSS

process displays a consistency of 50 to 60

percent solids by weight with a density

of about 1.3 g/cm3, which is maintained

to within 1 percent. This is thick enough

to minimize free water but thin enough

to allow pumping to a distance of over 6

miles using centrifugal pumps.

Once discharged, the slurry hard-

ens in 24 to 72 hours and substantial-

ly cures in about a month. The cured

product exhibits low hydraulic conduc-

tivity, high compressional strength, no

proposed the ELG rule.

Suffice it to say, the CCR, MATS, and

proposed ELG rules are requiring own-

ers and operators of coal-fired power

plants in the U.S. to make pivotal de-

cisions regarding future operations at

these plants and how best to address

the regulatory changes.

DRY ASH MANAGEMENT

Power plants face a number of chal-

lenges when converting to an alterna-

tive ash management system because

few options are available. Conventional

practice is commonly called “dry ash”

management, which is misleading. So-

called dry ash management for transport

and disposal to an impoundment or

landfill typically involves the addition of

20 to 25 percent water to suppress dust.

Once the wetted ash is transported and

disposed of, it is typically spread and

compacted using heavy equipment. Ad-

ditional water is often added using sprin-

klers or water trucks to control dust and

improve compaction.

Traditional dry ash management typ-

ically involves handling and moving the

ash multiple times, with each transfer

adding more risk of dust release. To ad-

dress this, the new CCR rules impose

stringent controls on fugitive dust at im-

poundments. Even after ash is spread and

compacted, it can easily be mobilized

by wind if allowed to dry. It also exhib-

its relatively high hydraulic conductivity,

which translates into high rates of leach-

ate production.

Traditional dry ash management also

poses a major expense. The costs of

transferring the ash to ash/water mixing

facilities, together with the capital and

operating costs of the facilities them-

selves, are high. Truck transport, road

construction and maintenance, fuel

management, heavy equipment opera-

tion and maintenance, continual dust

suppression, lighting and security at the

disposal site, plus associated labor fur-

ther reduce the appeal of dry ash han-

dling. Lastly, the continual operation

ENVIRONMENTAL REGULATION

1508pe_30 30 8/7/15 4:33 PM

Electron Microprobe Image of a Lime-Added Sample 2

Source: NAES Corporation

31 www.power-eng.com

concrete contains about 25 percent

bound water.)

Although DSS has been used extensive-

ly in Europe and at one plant in the United

States for decades, plant-specific testing is

still required to establish the proper blend

of solid waste products and wastewater

for optimal environmental performance.

While performance-enhancing additives

are available, all of the DSS facilities cur-

rently in operation process ash that is suf-

ficiently reactive on its own.

The ash produced by some power

plants in the United States, however, ex-

hibits little or no reactivity. Where this

is the case, additives may be used to in-

crease compressional strength and reduce

hydraulic conductivity. Typically, 2 to 3

percent active lime is enough to achieve

adequate solidification.

CASE STUDY:

PRB COAL ASH

For example, NAES tested samples

of Powder River Basin (PRB) coal ash to

determine their performance relative to

DSS. The samples contained over 20 per-

cent CaO, but only 0.14 percent of it was

chemically active.

Figure 1 shows an electron microprobe

image of cured slurry product made using

60 percent PRB fly ash and 40 percent

water. (Note the regions where ettringite

crystals have formed.) After six weeks of

curing, the low reactivity of the ash result-

ed in very little cementation. The cured

product exhibits a porosity of about

50 percent, as evidenced by the dark

regions of empty space in the image.

After curing, the sample showed com-

pressional strength of 48,263 Nm-2 (7

psi) and the hydraulic conductivity

measured 3 x 10-5 cm/sec.

To find out how the PRB slurry per-

formance could be improved, NAES pre-

pared another sample – this time using

50 percent fly ash, 2.5 percent active lime,

and 47.5 percent water by weight – and

allowed it to cure for six weeks. In figure

2, the cured product shows a significant

reduction in porosity compared to the

variations in the amount of water used

to make the slurry can impact process-

ing parameters of that slurry. It has also

demonstrated that small quantities of ad-

ditives, where indicated, can dramatically

improve product performance.

The compressional strength and hy-

draulic conductivity of cured DSS prod-

ucts depend largely on the chemical

reactivity of the fly ash contained in the

slurry. This reactivity in turn depends on

several variables: type of fuel, emission

controls used, type of boiler, and combus-

tion temperature, among others.

As dense slurry cures, hydrated mineral

crystals grow in the spaces between ash

particles, including the following:

Ettringite 60% Bound Water

Allite 32% Bound Water

This interstitial crystal growth se-

questers water, entrains small parti-

cles, and inhibits fluid flow. In addi-

tion, the crystals act as an adhesive that

binds ash particles together, resulting

in greater compressional strength.

This process – the same that occurs

in the curing of concrete – is a desired

outcome of DSS. (For reference, most

• Low hydraulic conductivity (10-6 to

10-10 cm/sec)

• High compressional strength

• Enhanced metals sequestration

• No risk of liquefaction or spills asso-

ciated with liquefaction

• Significant reduction of leachate vol-

ume

• Significant reduction of fugitive dust

emissions

• Enhanced land-use efficiencies from

elevated disposal facilities

• Reduced energy consumption

Several variables contribute to low hy-

draulic conductivities in the cured prod-

uct, including particle size distribution,

particle shape, water chemistry, and ash

chemistry. The mixing process results in

close packing of the ash particles upon

discharge. The chemistry of the ash

and water determine the type of crystal

growth that takes place in the interstitial

spaces between ash particles upon curing.

PERFORMANCE

ENHANCEMENT OF SLURRY

PRODUCTS

NAES has found in recent testing that

1508pe_31 31 8/7/15 4:33 PM

Hydration Curves Showing Sequestration

of Water Over Time3

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 5 10 15 20 25 30 35 40 45 50

0% CaO

2,5% CaO

5% CaO

10% CaO

Free water

(kg free water/kg total process water)

Number of days of curing

Free

wa

ter

per

cen

tag

e

32 www.power-eng.com

by progressively reducing hydraulic

conductivity and increasing compres-

sional strength.

In active impoundments and land-

fills that receive dense slurry, evapo-

ration removes significant quantities

of water before it can infiltrate the im-

poundment. The hydration reactions

that occur during curing, coupled with

evaporation, result in zero discharge of

fly ash transport water.

A COMMERCIALLY

OPERATING DSS

IMPOUNDMENT IN

HUNGARY

The active ash disposal impoundment

at the Matra Plant, which began opera-

tion in 1998, consists of 15 tiers, each 10

feet thick, of solidified Type F ash that has

been pumped to the impoundment from

the plant as dense slurry. The 150-foot

high impoundment covers an area of 314

acres at its base and 122 acres at the top.

The established tiers have been planted

with fruit trees.

The top of the impoundment is di-

vided into six smaller enclosures sep-

arated by dikes. When an enclosure

is full, discharge is transferred to an

adjacent enclosure. Cured dense slur-

ry from the perimeter of the full im-

poundment is then excavated and used

to construct the dike for the next tier.

To prevent interruptions in plant

operations caused by lack of dispos-

al space, at least two of the multiple

smaller impoundments at the top of

the facility are always made available

to receive dense slurry. The impound-

ment poses no risk of liquefaction of

ash products or catastrophic failure

(e.g., inundation of the surrounding

community) because the compres-

sional strength of the contents ranges

from 5,000 to 11,000 lbs/ft2. Hence,

there have been no slope failures or

other incidents requiring remedi-

al action since operations began. All

leachate is returned to the plant for

use in DSS processing, making this a

amount of water sequestered with the

concentration of lime.

The samples were molded into

4-inch plastic tubes wrapped with geo-

textile fabric at the base to allow leach-

ate to drain out of the slurry. The cap-

tured leachate was periodically poured

back through the curing product. The

samples and drained water were main-

tained in a closed system to prevent

evaporation of water.

As shown in the hydration curves for

the four mixes (Figure 3), water is rap-

idly sequestered during curing. The mix

with 2.5 percent active lime sequestered

90 percent of the free water in 15 days.

Samples with higher active-lime concen-

trations sequestered the same amount of

water in five days or less.

NAES also found that as the thick-

ness of accumulated slurry product in-

creases in an impoundment or landfill,

so does the amount of water seques-

tered. As dense slurry impoundments

accumulate more slurry, the amount of

leachate produced thus declines over

time because the water that infiltrates

has more time to react as it percolates

through the curing product. These con-

tinuing reactions enhance the perfor-

mance of the impoundment over time

no-lime sample – about 6 percent po-

rosity in the lime-added product versus

50 percent in the no-lime product. The

reduction in hydraulic conductivity of

the lime-added sample – 3.4 x 10-6 – rep-

resents about one order of magnitude.

The compressional strength increased by

97 percent to 1,296,214 Nm-2 (188 psi).

SEQUESTRATION

OF WATER

Mineral growth that takes place during

curing sequesters significant quantities of

water. This is important because the EPA’s

preferred options under the proposed

ELG prohibits discharge of fly ash trans-

port water under any circumstance. Dis-

posal facilities that use the DSS process

have achieved zero discharge of transport

water by reprocessing leachate to produce

more dense slurry.

To assess how much water is seques-

tered in the DSS curing process, NAES

tested ash samples from the Matra Pow-

er Plant near Budapest, Hungary, the

‘flagship’ of DSS facilities. Using a slur-

ry of 60 percent fly ash and 40 percent

water by weight, NAES prepared sam-

ples with 2.5, 5, and 10 percent active

lime added, as well as a control sample

without added lime, to correlate the

ENVIRONMENTAL REGULATION

1508pe_32 32 8/7/15 4:33 PM

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‘recipe’ for stabilizing CCRs. NAES

conducted testing at numerous loca-

tions using a pilot-scale dense slurry

processing system.

Prior to the pilot test, samples of

combustion products and wastewater

are analyzed to determine their chem-

istry and particle size distribution.

zero-discharge facility for both trans-

port water and leachate.

DSS TESTING

The physical and chemical proper-

ties of ash and water vary from plant

to plant, so these materials must be

tested at each site to determine the best

The tiered and elevated DSS impoundment at Matra

Power Plant in Hungary is planted with fruit trees. Inset:

The cured dense slurry from the impoundment perimeter

is used to construct a dike for newly discharged slurry on

the top level. Photo courtesy: NAES

The pilot-scale system is then used to

process a range of promising ‘recipes.’

Each recipe is allowed to cure for 90

days before the samples are collected

for testing.

Data collected during slurry pro-

cessing includes rheology parameters

(yield stress and rigidity), water con-

tent/flow dynamics, energy consump-

tion, mix ratios, and water stoichiome-

try. Cured samples may be analyzed for

the following:

• Compressional strength

• Porosity and hydraulic conductivity

• Bulk chemistry

• Moisture and density

• Electron microprobe analysis

• Leach performance

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produce the dense slurry

• Zero discharge of transport water

• Zero discharge of leachate if re-

used for dense slurry production

• Enhanced sequestration of con-

tained metals

• Reduced risk of groundwater con-

tamination

• Reduced or eliminated risk of dust

generation

• High compressional strength

In addition, the tiered, elevated

disposal facilities typically used with

DSS enable more efficient use of dis-

posal space. Piping the slurry to these

impoundments reduces or eliminates

the use of heavy equipment and its

attendant safety and environmental

risks. More to the point, DSS process-

ing eliminates ash sludge liquefaction,

and with it the risk of dike failure and

catastrophic releases.

The data collected, along with plant

information, are used to determine

system capacity, slurry pumping re-

quirements, and impoundment/land-

fill design. They are also used to esti-

mate probable leachate production and

environmental performance of the sta-

bilized product.

ENVIRONMENTAL

PERFORMANCE

The CCR and ELG rules are closely

related and interdependent. Design

changes at coal-fired power plants that

affect the quantity and chemistry of

generated wastewater also affect the

transportation, management, com-

position, beneficial reuse options,

and disposal of combustion products.

These changes in turn affect the design,

operations, monitoring, and closure

requirements for impoundments into

which CCRs are deposited. They also

influence decisions regarding the man-

agement and fate of CCRs in existing

impoundments.

In terms of environmental protec-

tion, operational safety, and financial

risk, DSS has proven itself altogether

superior to “dry ash” management.

It not only meets the requirements of

CCR and ELG but yields a product with

outstanding environmental perfor-

mance:

• Hydraulic conductivity that is sub-

stantially lower than that resulting

from traditional “dry ash” man-

agement as described in the pro-

posed ELG

• 80-90 percent less consumption of

water compared to traditional ash

sluicing

• Stabilization of wastewater (in-

cluding FGD water) used to

ENVIRONMENTAL REGULATION

1508pe_34 34 8/7/15 4:33 PM

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36 www.power-eng.com

Valves & ActuatorsBY RUSSELL RAY, CHIEF EDITOR

unchanged, innovative applications

and design modifications are being

developed to withstand these demand-

ing environments. In addition, these

improvements can reduce costs by sup-

porting the control valve’s ability to

throttle accurately, thereby providing

better performance for high-pressure

steam bypass, turbine bypass and oth-

er critical power plant operations.

Actuators regulate mass and energy

flows by adjusting valves, flaps and

cocks.

The actuator and valve create a single

unit — the control valve. Actuators

perform different motion sequences,

including linear, pivoting and rotating

motions, and they are powered by

pneumatic, hydraulic or electrical

energy.

Actuators receive a control signal

from automation systems. The signal

is converted into a motion so that the

A single power plant uses

hundreds of valves to

control almost every as-

pect of its operation.

Valves, in conjunction with a con-

trolling actuator, are used for pollu-

tion control, feed water, cooling water,

chemical treatment, bottom ash and

steam turbine control systems.

They work in harsh environments

and are exposed to a variety of chem-

icals, abrasive materials and high

temperatures. They are critical in

optimizing efficiency, and they are

often the final control element in the

operation of a power plant.

What’s more, additional demands

are being placed on valves and actu-

ators as power plants are forced to be

more flexible to accommodate the

growth of intermittent sources of re-

newable power and mandates to curb

carbon emissions. As a result, valves

and actuators must operate at higher

pressures, temperatures and frequency.

Although the basic technology for

most valves and actuators has remained

Cycle Isolation testing utilizes acoustic monitor-

ing instruments to help customers monitor valve

performance. Photo courtesy: ValvTechnologies

OPERATIONS & MAINTENANCE

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38 www.power-eng.com

acts as a piston to create linear force to

close and open the valve. Power plants

have traditionally used pneumatic

actuators to drive the many control

valves throughout their facilities.

However, major improvements in

control element of the actuating el-

ement assumes a corresponding po-

sition. With control valves, this is a

stroke motion. With flaps, ball cocks

or rotary plug valves, this is a pivoting

motion.

VALVE-ACTUATOR TYPES

There are three common types of

actuators: Electric, pneumatic, and hy-

draulic.

Pneumatic valve actuators are pow-

ered with air or gas. The air pressure

The Rotork CVA offers an accurate and responsive method of

automating control valves without the complexity and cost of a

pneumatic supply. Photo courtesy: Rotork

OPERATIONS & MAINTENANCE

1508pe_38 38 8/7/15 4:39 PM

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position transmitter is greater than

300:1 position turndown.

The valve body is coupled to an actu-

ator assembly that contains a fail-safe

spring to quickly close the valve, halt-

ing fuel flow in the event of a power

failure or turbine trip condition.  When

electric control-valve actuator technol-

ogy are helping power producers lower

costs and boost efficiency. Valve actua-

tors powered by an electric motor can

withstand the demands of continuous

movement. In addition, they work ef-

fectively in harsh environments, and

provide superior performance in a

wide range of applications. The bene-

fits include better efficiency, less main-

tenance and enhanced performance

of the control valves. What’s more,

electric actuators do not require recali-

bration over time. Once calibrated, the

electric control valve actuator can op-

erate for months, even years, without

adjustment.

Hydraulic actuators, which use pres-

surized hydraulic fluid to open and

close valves, are increasingly popular

because of their ability to achieve high

torque. Hydraulic actuators are de-

signed to carry out linear movement of

all kinds. When a large amount of force

is required to operate a valve, hydraulic

actuators are normally used. The most

common type of hydraulic actuator

uses pistons that slide up and down

within a cylinder containing hydraulic

oil and a spring.

Young & Franklin offers electrome-

chanically actuated (EMA) gas control

valves designed specifically for the

challenging operating conditions of in-

dustrial gas turbines.

Industrial gas turbines require pre-

cise control of the combustion process

to drive efficiency, reduce emissions,

and maximize availability. According

to Young & Franklin, the company’s

EMA valves offer substantial advan-

tages over their hydraulically actuated

counterparts.

Young & Franklin 3010 Series

Choked flow valves are electromechan-

ically actuated (EMA), single seat pre-

cision fuel control valves. These sonic

flow valves are available in a range of

sizes suitable for industrial or power

turbines of any size.

The Y&F 3010 EMA gas control valve

(GCV) is a modern, high precision

control valve with excellent speed and

valve position accuracy at low open-

ings. This GCV electronically re-ze-

ros its closed position reference every

time the power is cycled and the valve

1508pe_39 39 8/7/15 4:39 PM

COAL ASH MANAGEMENT & STORAGEORIGINALLY AIRED JUNE 30, 2015

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of the effects of valve leakage, this adds

substantial costs to operations and the

capability is limited. Recent client ex-

perience includes mitigating cycle wa-

ter losses on a new

generating plant in

which cumulative

valve leakage rates

exceeded the make-

up water system ca-

pacity. This forced

the plant to curtail

operations to allow

the make-up system

to catch up demon-

strating how cycle isolation can directly

impact plant reliability and availability.

The cornerstone to capturing these

benefits is diagnostics. A systematic

approach to accurately measuring valve

leakage eliminates uncertainties that

the valve and EMA are coupled to the

Y&F series 1100 Digital Motor Con-

troller, the complete system provides

precise fuel flow delivery with reliable

operation.

VALVE LEAKAGE

Leaking isolation valves are found

everywhere in the steam generation

industry and equally widespread is the

detriment to P&L statements world-

wide. How can a simple worn, damaged

or improperly specified isolation valve

have such far reaching effects?

Like all thermal engines, steam plants

are powered by energy differences and

the greater this difference, the greater

the fuel efficiency. Valves maintain the

separation by isolating the high energy

processes from the low energy process-

es. When valves leak, they are acting in

direct opposition to the forces that drive

the plant by allowing energy to leave

the high energy processes and enter the

low.

Another key

characteristic of the

steam cycle is that

production (or kilo-

watt-hours) is gov-

erned by the steam

rate or mass flow

through the cycle

processes. Steam or

energy that is bled

out of the process-

es via leaking valves is not being put to

beneficial use and thus may be propor-

tionately reducing the amount of elec-

tricity or revenue being produced.

While plants are designed with ancil-

lary equipment to compensate for some

OPERATIONS & MAINTENANCE

“Additional demands are being placed on valves and actuators as power plants are forced to be more fexible to accommodate more renewable power.”

1508pe_40 40 8/7/15 4:39 PM

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manifest as unnecessary added costs. Improvements

to valve leakage diagnostic programs quickly result in

plant performance improvements as well as sustained

reductions to valve O&M costs.

ADVANCEMENTS

IN TECHNOLOGY

Power plants are complex in that there are many

different sub systems required to deliver electricity.

These plants were an early adopter of distributed control

systems to monitor and control the facilities. Due to the

arduous nature of the environment, certain practices

were adopted to allow for reliability and maintenance.

Motor operated valves in particular are key to plant

performance. Until 20 years ago motor operated valves

tended to have motor control centers remote from the

valve. This did not allow for the benefit of technology

advances in electric actuators.

The early 1990s saw a trend towards smart actuators

with integral data logging capabilities. These actuators

could also be networked to provide the control system

to receive data that had occurred in the actuator. Power

plant designers started to take advantage of this in the

past 10 to 15 years.

Today, there has been a major change in the

availability of better information from the motor

operated valves. Instead of being alerted after the fact,

the electric actuators are now monitoring the systems

and providing data ahead of potential failures in the

equipment.

As an example, early actuators had torque switches

which tripped after the valve had an internal failure

which caused it to require more force than originally

designed for. The more recent smart actuators have an

internal data logger inside which has had the ability to

monitor torque output.

The most recent electric actuator has these two features

plus more. The newest feature is to have a monitoring

set point above the baseline torque and below the over

torque setting to alert the plant operator that there is an

impending issue that needs to be addressed.

Miscellaneous trip alarms are also included to

monitor things like starts per hour to insure the internal

contactors are not being overused, perhaps due to an

actuator that is hunting because of a faulty process

signal. There are also maintenance interval settings that

can be adjusted by the plant operator.

These newer actuators also have expanded screens at

the unit to allow for better operator local diagnostics.

These are just a few of the upgrades available today.

1508pe_41 41 8/7/15 4:39 PM

42 www.power-eng.com

After decades of advancing clean-air reg-

ulations, the U.S. Environmental Protection

Agency plans to put a higher priority on new

water rules for power producers. 

Water’s Journey

The Threads Between Power Plant Makeup Water, Cooling Water, and Wastewater Selection and Treatment BY BRAD BUECKER

More so than at any

other time in the

power plant era, wa-

ter from the begin-

ning of its journey

through a plant to its discharge must be

viewed holistically. This is as true for com-

bined-cycle power plants as it is for the re-

maining coal units in the U.S.

This article examines combined-cycle

plants and their attendant heat recovery

steam generators (HRSGs), where increas-

ingly stringent wastewater regulations are

forcing plant personnel to consider com-

plex treatment methods to ensure that

liquid discharge complies with regulatory

guidelines.

In some cases, zero liquid discharge

(ZLD) may be the only option. These is-

sues in turn are influencing other water

treatment processes, most notably cool-

ing water treatment. At plants with cool-

ing towers, personnel may need to look

beyond what have been the mainstream

treatment programs. In part, increased

wastewater treatment complexity has

influenced some developers to select air-

cooled condensers in place of the steam

surface type. Finally, by choice or often

mandate, many plant designers are se-

lecting less-than-pristine water supplies,

such as treated municipal wastewater,

for makeup. These supplies often contain

unwelcome contaminants, including am-

monia, phosphorus, organics, and sus-

pended solids, which in turn can affect

downstream processes including cooling

and wastewater treatment.

EVOLVING DISCHARGE

REGULATIONS

While this article primarily spotlights

combined-cycle power issues, a trip back

in time helps to illustrate how plant dis-

charge regulations are evolving.

When I began my utility career at City

Water, Light & Power (CWLP) in the ear-

ly 1980s, the plant’s National Pollutant

Discharge Elimination System (NPDES)

guidelines consisted of the following.

The streams to which these limits

applied were cooling water discharge

(many plants including CWLP had once-

through systems), coal pile runoff, and

ash pond discharge. These were indeed

simple times, but now additional constit-

uents are appearing in coal plant effluent

limitation guidelines (ELG), and especial-

ly at those plants with wet flue gas desul-

furization (FGD).

But what about combined-cycle pow-

er plants, which obviously burn a much

cleaner fuel and do not exhibit the en-

vironmental complexity of coal plants?

First, consider changes with regard to

turbine exhaust steam cooling. Where-

as many large plants in the last centu-

ry were equipped with once-through

cooling, this is not the case for new

plants. 316a (thermal discharge) and

316b (impingement and entrainment

of aquatic creatures at plant intakes)

regulations have generated a paradigm

shift from once-through cooling to so-

called closed systems. Cooling towers,

and to a lesser but growing extent air-

cooled condensers, have become the

popular choices now. At the many

1508pe_42 42 8/7/15 4:39 PM

43 www.power-eng.com

and when released to open bodies of

water can often initiate and propagate

algae blooms. In like manner ammo-

nia is an impurity of concern. Large

ammonia releases have been known

to cause massive fish kills, but in the

quantities that might exist in plant dis-

charge, will serve as a nutrient in a re-

ceiving body of water.

We will continue to explore water

discharge issues during and following

discussion of cooling and makeup wa-

ter treatment, as control methods for

impurities may need to be implement-

ed throughout the process.

CAUGHT BETWEEN A

ROCK AND A HARD PLACE

Cooling system operation is vital for

plant performance and reliability. At a

plant with a reclaim water makeup sup-

ply, the nutrients for explosive microbi-

ological growth, organics, phosphorus,

and ammonia, can be directly introduced

to the cooling water system. But, wastewa-

ter discharge issues may also significantly

affect cooling water treatment.

Adding to the complexity is that the

most common cooling tower treatment

program for over three decades has

been based upon inorganic and organ-

ic phosphate chemistry for both scale

and corrosion protection. These pro-

grams are typically supplemented with

an accompanying polymer for calcium

phosphate scale control and perhaps a

small zinc residual for additional corro-

sion protection. So, at plants impacted

by phosphorus discharge regulations,

chemistry, as sulfuric acid feed to cool-

ing tower makeup has been a common

method to remove bicarbonate alkalinity

and thus minimize calcium carbonate

(CaCO3) scaling potential in the condens-

er and cooling system.

H2SO

4 + Ca(HCO

3)

2→CaSO

4 + 2H

2O +

2CO2 ↑

Tighter regulations on sulfate in the

discharge stream may curtail or elimi-

nate this straightforward method of scale

control at some plants. On a related note,

I have heard rumblings that chloride and

bromide may be added to future regulato-

ry lists. Limits on chloride could have the

same effect as those on TDS.

As has been noted, zinc and chro-

mium limits have been placed in the

proposed national

ELG. State regula-

tions may be more

restrictive. For the

plant mentioned

above, the expec-

tations are that

copper discharge

will, in a few years,

be limited to less

than 30 parts-per-billion (ppb). Even

tighter restrictions have already been

placed on copper discharge in the

Great Lakes area. At these very low lim-

its, copper discharge can potentially be

a problem from units equipped with

copper-alloy condenser tubes. Howev-

er, another copper source, from older

wooden cooling towers, comes from

copper compounds utilized as a wood

preservative. These preservatives may

also contain arsenic and chromium.

Although wood preservative treatment

methods were designed to minimize

leaching of the preservatives, some ac-

cumulation of impurities may occur in

the cooling water, particularly if the

tower sits idle for extended periods.

Phosphorus is another constituent

under scrutiny. Many bodies of wa-

ter in the U.S. have been designated

“phosphorus impaired,” as phosphorus

serves as a nutrient for plant growth

plants with cooling towers, cooling

tower blowdown typically represents

the largest wastewater stream, but the

discharge often includes some or all

of the following – RO reject, evapora-

tive cooler blowdown, quenched boiler

blowdown, and plant drains.

One might be tempted to think that

these seemingly benign streams would

not be much more heavily regulated than

the example of Table 1. Such may not be

the case. First on a national level, the EPA

has proposed limits of 0.2 ppm for chro-

mium and 1.0 ppm for zinc in cooling

tower blowdown per the pending ELG.

This is far from the end of the story, how-

ever. Individual states are allowed to de-

velop their own discharge guidelines, as

long as the regulations are as stringent as

those of the EPA. In some cases, states are

promulgating tight regulations that place

limits on some or all of the following

additional constituents in cooling tower

blowdown:

• Total dissolved solids (TDS)

• Sulfate

• Zinc

• Copper

• Chromium

• Phosphorus

• Ammonia

• Quantity of discharge

As an example of state influence,

consider the new guidelines at a com-

bined-cycle power plant with a cooling

tower in one of our southern states. Prior

to 2013, the plant’s NPDES permit was

similar to that shown in Table 1. The new

discharge permit now imposes an average

monthly limit of 1,200 mg/l TDS. Given

that the makeup water TDS concentration

sometimes reaches 400 mg/l TDS, the

tower cycles of concentration (COC) may

be limited to three under the new regu-

lations, whereas previously the tower had

operated at a significantly higher COC. As

Figure 1 indicates, this can have signifi-

cant consequences on blowdown volume.

Another impurity receiving more

scrutiny is sulfate (SO4). This issue can

be problematic with regard to process

Author

Brad Buecker serves as a process specialist in the Process Engineering and Permitting group of Kiewit Engineering and Design Company.

Source:

ConstituentMonthly Average (Limit or Range)

Free Available Chlorine 0.2 mg/l

O&G 15 mg/l

pH (range) 6.0 – 9.0

TSS 30 mg/l

A Long-Ago NPDES Example 1

1508pe_43 43 8/7/15 4:39 PM

Extreme algae growth in a cooling tower. 2

Cooling Tower Blowdown vs. Cycles of Concentration 1

Recirculating fow = 100,000 gpm

Range = 25 degrees F

Evaporation factor = 0.75

2000.0

1800.0

1600.0

1400.0

1200.0

1000.0

800.0

600.0

400.0

200.0

0.0

COC

BD

Ra

tes In

Ga

llo

ns P

er

Min

ute

1 2 3 4 5 6 7 8 9 10 11 12 13 14

44 www.power-eng.com

removed by clarification with an iron

or aluminum-based coagulant feed, but

this process may be lacking for treatment

of other contaminants like ammonia. A

technology that is becoming increasing-

ly popular for reclaim water treatment is

biological processing of the plant intake.

Bioreactors and membrane bioreactors

are two technologies in this regard.

Via microbes that are seeded and al-

lowed to grow on internal devices with-

in the reactors, the incoming organics

and nutrients are consumed. The final

step which may be external or internal

is filtration to minimize TSS discharge.

With membrane bioreactors, where the

membranes are of the micro- or ultrafilter

variety, effluent turbidities may be be-

low 0.1 NTU (nephelometric turbidity

units). This is quite satisfactory for gen-

eral plant makeup, and even is suitable

for feed to reverse osmosis units that

produce high-purity makeup for the

steam generator.

At any plant with a cooling tower, and

especially if extra nutrients arrive with the

makeup water, microbiological control

is of utmost importance. Common for

many towers in the past has been bleach

feed, as bleach is safer than gaseous chlo-

rine. However, ammonia and organics in

incoming makeup will consume chlorine,

potentially destroying the residual that is

needed to keep cooling systems clean.

Also, the chemistry may form halogenat-

ed organics, which are also unwelcome.

Alternative treatments may be needed.

One such possibility is chlorine dioxide

(ClO2), where generation methods have

been greatly improved from the former

sodium chlorite (NaClO2)-chlorine reac-

tion, and in which large quantities of haz-

ardous sodium chlorite had to be stored

on site. One of the new processes utilizes

a compact generator that combines sodi-

um chlorate (NaClO3) with a pre-mixed

blend of sulfuric acid (H2SO4) and hy-

drogen peroxide (H2O2) to induce the

following reaction.

an alternative non-phosphorus pro-

gram may be necessary.

The major water treatment companies

are diligently developing non-P technolo-

gies, which are based on polymer chemis-

try. Co- and ter-polymers containing the

active groups shown below are the out-

come of these efforts.

The polymers serve as crystal modifiers

and sequestering agents to inhibit scale

formation. There is also evidence that the

polymers form a thin coating on metal

surfaces to inhibit corrosion. A common

dosage concentration is 2 to 10 ppm ac-

tive in the cooling water. In some cases,

an all-P program may be less expensive

than an equivalent phosphate/phospho-

nate program, although every potential

application must be carefully evaluated.

At this point the reader may be wonder-

ing about those cooling systems, whose

number is increasing, that take municipal

wastewater plant discharge as makeup.

Without any treatment, the impurities in

this makeup will enormously increase the

potential for microbiological fouling.

The extra phosphorus can negative-

ly impact towers that are still on phos-

phate/phosphonate programs, and can

be problematic for those on non-phos-

phorus programs, too. Also, if phospho-

rus, ammonia, and/or TSS are limited in

the plant’s NPDES guidelines, a switch to

reclaim water may cause immediate dif-

ficulties in this regard.

It is now time to examine the most

popular conventional and emerging

treatment technologies for makeup water,

cooling water, and wastewater to provide

some guidance for plant personnel faced

with process and regulatory issues.

MAKEUP AND COOLING

WATER TREATMENT

TECHNIQUES

At plants with or planning to accept

reclaim water as makeup, we have seen

that a number of impurities may be in

this water, which would be negligible in

fresh water supplies. Such contaminants

as phosphorus and TSS can be readily

1508pe_44 44 8/7/15 4:39 PM

Cutaway view of a microfilter pressure vessel with outside-in membranes.

3

Photo courtesy: Pall Corp.

45 www.power-eng.com

EFFLUENT TREATMENT

Depending upon the method of waste-

water treatment allowed or available, this

issue can range from straightforward to

exceedingly complex. Some plants are

permitted to discharge spent water to a

local municipal wastewater treatment

plant, provided the industrial water does

not contain excessive concentrations of

harmful impurities such as heavy metals.

At plants in arid regions of the country,

evaporation ponds may serve the pur-

pose. However, these ponds must be per-

mitted and installed in a proper manner.

Lined ponds are de rigueur in today’s stri-

dent environmental climate.

If none of the above options are avail-

able, mechanical-thermal evaporation of

the waste stream may be the only choice.

Accurate determination of influent water

chemistry is vital for design and selection

of such systems, as hardness, alkalinity,

and silica can cause severe scaling prob-

lems in evaporator/crystallizers. In this

regard, at one of our members’ plants, the

cooling tower blowdown is first treated in

a softening clarifier to reduce hardness.

This stream is then processed in a brine

concentrator/crystallizer. The primary

constituent of the solids produced by the

system is sodium sulfate, which forms

messy deposits but not hard scale. For

other crystallizers, crystal seeding is

employed. A common seed crystal is

gypsum, which provides a more ther-

modynamically stable site for precipi-

tation of such minerals as calcium sul-

fate and silicates.

Energy requirements for convention-

al evaporators are quite large. In large

measure this is due to the fact that during

evaporation the dissolved solids concen-

tration increases, which then increases

the boiling point. The boiling point rise

requires additional energy. A modifica-

tion to the process that has been success-

fully applied in the salt production indus-

try is evaporation-crystallization with a

mechanical vacuum applied to the evap-

oration chamber. This greatly lowers the

temperature at which the liquid boils, and

water-cooled condensers, obvious-

ly due to the much lower density

of air as compared to water.

• ACCs will only cool the turbine

exhaust steam to a temperature

approaching dry bulb. Cooling

tower temperatures approach wet

bulb. In warm climates this can

represent a significant efficiency

penalty. As an example, consider

a wet tower operating on a sum-

mer day at 90oF with 30 percent

relative humidity. The dry bulb

temperature is obviously 90oF,

but the wet bulb temperature is

66o F. So a cooling tower that pro-

vides an approach within 10o of

the wet bulb allows significantly

better efficiency than an ACC.

• Typically, finned tubes are the choice

for ACCs to improve heat trans-

fer. The fin spaces clog with debris

blown through the tower by the fans.

The material is difficult to remove.

• ACCs often suffer from two-phase

flow-accelerated corrosion (FAC),

which not only reduces tube life

but introduces many iron oxide

particulates to the condensate. A

virtual must for any steam gen-

erator equipped with an ACC is

a condensate particulate filter to

prevent transport of the iron ox-

ides to the boiler.

NaClO3 + ½H

2O

2 + ½H

2SO

4 ClO

2 + ½O

2

+ ½Na2SO

4 +H

2O

Chlorine dioxide does not react with

ammonia, nor does it react with organics

to form halogenated organic compounds.

Also, and unlike hypochlorite, chlorine

dioxide is not affected by pH. This can be

an important advantage in those towers

(the majority) whose chemistry programs

operate in an alkaline pH range.

Some plant personnel have had good

success with on-line hypochlorite-gener-

ating systems such as the MIOX process,

which via brine electrolysis produces a

hypochlorite solution that also contains

residual hydrogen peroxide. An advan-

tage of this technology is that the oxidant

is produced on an as-needed basis rather

than being stored in large tanks where it

can degrade and lose strength.

Another technology that is high-

ly recommended for cooling towers is

sidestream filtration. Very often I see re-

quests-for-proposals (RFP) that call for

makeup water filtration. Developers and

owner’s engineers often do not recognize

the fact that cooling towers are superb air

scrubbers, and that many particulates are

introduced to cooling water by the scrub-

bing action. Makeup filtration does noth-

ing to control these particulates. A wide

variety of technologies is available for

sidestream filtration, ranging from con-

ventional multi-media filters to automat-

ic backwash systems with metal screens.

SOME THOUGHTS ON

AIR-COOLED CONDENSERS

At the most recent International Wa-

ter Conference, more than one present-

er seemed to somewhat lightly suggest

that if plant personnel are worried

about cooling tower issues, air-cooled

condensers (ACC) are an easy cure.

Yes, ACCs may be the only choice

where water is scarce, but a number

of factors must be considered before

choosing ACC over a cooling tower.

These factors include:

• ACCs are enormously large,

especially in comparison to

1508pe_45 45 8/7/15 4:39 PM

46 www.power-eng.com

of multiple, parallel flow modules each

containing thousands of spaghetti-like,

hollow-fiber membranes.

The membranes must be regularly

backwashed every 10 to 20 minutes

or thereabouts to remove particulates.

The backwash flow path is the reverse

of the normal flow path. In this par-

ticular case, conversion of the mem-

branes from inside-out to outside-in

normal flow path greatly improved the

backwash efficiency.

Another interesting initial difficul-

ty was noted with the UF backwash

process. Typically with these systems

a small portion of the permeate is col-

lected in a separate tank at the begin-

ning of each process cycle for use in

backwash. So far, so good. But most

modern MF and UF units are now

equipped with automatic chemical-

ly-enhanced backwash (CEB) systems.

After a certain number of cycles, a

CEB backwash kicks in where first the

membranes are cleaned with a dilute

caustic/bleach solution to remove or-

ganics and microbiological organisms,

followed by rinsing and then a dilute

citric acid wash to remove iron partic-

ulates. When this UF was first com-

missioned and CEB backwashes com-

menced, the membranes developed a

layer of calcium silicate during the CEB

caustic stage. The driving force was

the higher pH generated by the caus-

tic, which in turn greatly reduced the

silicate solubility. The solution to this

problem was a switch to softened water

for the backwash supply.

CONCLUSION

This article hopefully illustrated many

of the threads between the water treat-

ment processes at new power plants.

Complex scenarios may arise due to wa-

ter chemistry issues and discharge reg-

ulations. Processes must be viewed and

designed in a holistic manner and not

piecemeal. Accurate and historical water

quality data is an absolute must for de-

signing reliable systems.

feed and a degasifier to lower bi-

carbonate alkalinity.

Under proper conditions, the RO

recovery rate may reach 90 percent.

The RO permeate recycles to the plant

high-purity makeup water system or oth-

er locations. However, while the process

appears straightforward, a number of

lessons-learned have emerged regarding

this technology in actual application.

The following lessons are taken from a

HERO system operating at a power plant

near the Pacific Northwest. One of the

most notable examples for any of these

systems is that some standard water

treatment chemicals may foul the UF

membranes. Operating experience indi-

cates that the membrane manufacturer

and type greatly influence this phenom-

enon. Fouling is induced because mem-

branes typically carry a negative surface

charge while often cationic polymers

are employed for coagulation or floc-

culation. Residual cationic polymer is

strongly attracted to the membranes. A

very similar phenomenon has been ob-

served with MF or UF systems installed

in makeup water systems downstream of

a clarifier. Inexperienced designers and/

or plant personnel have not always rec-

ognized that MF or UF should generally

serve as a replacement for clarification,

not a polishing process for the clarifier.

A straightforward solution that has

significantly improved the reliability of

this particular system is conversion of

the ultrafilter from an inside-out nor-

mal flow path to outside-in. Typical

micro- and ultrafilter systems consist

helps to overcome the boiling point rise

that occurs in conventional units as the

dissolved solids concentration increases.

Considerable energy savings appear pos-

sible with the vacuum systems.

Becoming popular are treatment meth-

ods to reduce the volume of the plant

waste stream before final treatment. Most

notable is high-recovery reverse osmosis.

This schematic outlines the HERO pro-

cess, which is licensed by such firms as

Aquatech, GE, and U.S. Water, while Veo-

lia supplies their Opus technology, which

may also include high-rate softening/clar-

ification as a unit operation. Keys to the

process are:

• Microfiltration (MF) or ultrafiltra-

tion (UF) to remove suspended sol-

ids in the waste stream. This is a

critical process to prevent suspended

solids from fouling reverse osmosis

(RO) membranes.

• Sodium bisulfite (NaHSO3) feed

to remove residual oxidizing bio-

cides. This is also critical to remove

oxidizers that would degrade soft-

ener resin and RO membranes.

• A sodium softener to remove cal-

cium and magnesium. Otherwise

the downstream equipment would

suffer from calcium carbonate and

magnesium silicate scaling.

• Sodium hydroxide injection to ele-

vate the pH above 10. (The combi-

nation of hardness removal and pH

elevation keeps silica in solution.)

• Two-pass reverse osmosis (RO)

treatment.

• Some systems may include acid

Source:

Pollutant Maximum for any 1 dayAverage of dailyvalues for 30 consecutive days shall not exceed

Arsenic, total (µg/L) 8 6

Mercury, total (ng/L) 242 119

Selenium, total (µg/L) 16 10

Nitrite/nitrate (mg/L) 0.17 0.13

Proposed ELG for FGD WastewaterBest Technology Available [1] 2

1508pe_46 46 8/7/15 4:39 PM

©2015 Cleaver-Brooks, Inc.

Visit Stand L24 at the 2015 Power-Gen Asia Show.

For info. http://powereng.hotims.com RS#24

1508pe_47 47 8/7/15 4:39 PM

48 www.power-eng.com

PRODUCTS

a proof-of-concept 50kW string solar inverter that

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Info http://powereng.hotims.com RS#: 403

Data integration software

Cogent Real-Time Systems Inc. released the

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Cogent Real-Time Systems Inc.

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Gateway modules

WAGO Corp.’s new 750-658 I/O module eas-

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Wind power cable seals

UK based Roxtec targets power and wind-farm

sectors with innovative new cable seal.

Roxtec has extended its range of cable seals

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serving structures

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turbines. The new

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Roxtec

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Conveyor belt cleaner

A new conveyor belt cleaner has been engi-

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Martin Engineering

Info http://powereng.hotims.com RS#: 401

Corrosion inhibitor

CorrBlock is a time-release, biodegradable cor-

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tries. It is designed for open loop recirculating cool-

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water systems.

The block is formu-

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phase Corrosion Inhibitor (VpCI) technology. The

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Cortec Corporation

Info http://powereng.hotims.com RS#: 402

Diode technologies reduce solar inverter size

Cree Inc. (Nasdaq: CREE) has demonstrated

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1508pe_48 48 8/7/15 4:39 PM

49 www.power-eng.com

applications, such as shipboard engine monitoring

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Wago

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Digital genset controller

Basler Electric announces the newly enhanced

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Industrial and adaptable PC

Daisy Data Displays Inc. unveiled its highly

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Suspended platform

Power Climber, a division of SafeWorks LLC, has

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Power supplies

W AGO expands its growing portfolio of pow-

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Pressure transmitter

T he SITRANS LH100 series pressure transmitter

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Siemens

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Power resistors

Stackpole announces the expansion of the TR

Series of TO-220 and TO-247 style power re-

sistors. The TR Series value

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liohms and goes up to 20K

ohms for most sizes (the

TR30 value range extends up

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Stackpole

Info http://powereng.hotims.com RS#: 411

Resistant coating solution

Cortec Corp. introduced VpCI-386 HT Black - a

high heat resistant water-based acrylic silicone

primer/topcoat that provides protection in harsh,

outdoor unsheltered applications.

1508pe_49 49 8/7/15 4:39 PM

50 www.power-eng.com

Working” diagnostics. A unique, high-speed safe-

ty relay output is incorporated for local alarm or

emergency shutdown. Discrete outputs deliver

diagnostics and relay status voting logic input to

the safety PLC to determine appropriate action.

The transmitter is certifed for use in SIL 2 safety

instrumented systems, and is capable of SIL 3 per

IEC 61508. It has confgurable self-diagnostics and

achieves a safe failure fraction of 98.5 percent.

Instrument response time is <100 milliseconds.

United Electric Controls

Info http://powereng.hotims.com RS#: 414

Pressure transmitters

Schneider Electric introduced the Foxboro Field

Devices’ pressure transmitter “S” series models

IDP10S, IGP10S and IAP10S. These intelligent, two-

wire pressure transmitters feature patented FoxCal

technology.

The Foxboro S series models IDP10S, IGP10S and

IAP10S transmit a 4 to 20 mA signal with a superim-

posed HART® smart instrumen-

tation digital signal for remote

confguration and monitoring.

All the Foxboro S series

two-wire pressure transmitters

feature two “time-in-service”

clocks. Foxboro’s S series

boosts accuracy while enabling

customers to track time-in-ser-

vice fawlessly. The time-in-service feature enables

advanced diagnostics monitoring. In addition, the

user days value can be reset to zero using a HART

communicator, a PC-based confgurator, or the

optional local indicator. (Note: The lifetime service

parameter cannot be reset.)

Schneider Electric

Info http://powereng.hotims.com RS#: 415

Semiconductor materials

Morgan Advanced Materials announces ad-

vances in their range of materials grown us-

ing chemical vapor deposition (CVD) processes.

Morgan’s CVD Silicon Carbide (SiC) and Pyrolytic

Boron Nitride (PBN) materials are ideal for use in

semiconductor applications, including rapid ther-

mal processing and plasma etch process chamber

components, as well as metalorganic CVD tools for

high-brightness white LED manufacturing using the

indium gallium nitride process.

The protective coating signifcantly delays the

reaction of metal ionization and water permeation,

which protects against corrosive electrolyte and

aggressive environments, thus preventing cor-

rosion. VpCI-386 HT Black provides a fast-drying

thixotropic coating that is resistant to sagging or

running. This unique coating offers extended

protection for sheltered, unsheltered, outdoor, or

indoor conditions. Thermally stable when dried

from -150°F to 500°F (-78° to 260°C), the coating

is ultraviolet resistant and gives optimal outdoor

performance without cracking or chipping upon

prolonged exposure to sunlight.

VpCI-386 HT Black is available in 5 gallon (19

liter), 55 gallon (208 liter), liquid totes, and bulk.

Keep product from freezing. Avoid temperatures

higher than 75°F (24°C) while in storage.

Cortec Corporation

Info http://powereng.hotims.com RS#: 411

Customized vanes, rotors and end plates

Metallized Carbon Corp. announces the avail-

ability of custom vanes, rotors, and end plates

for use in rotary vane pumps pumping both liquids

and gases. The carbon-graphite components pro-

vide superior lubrication in most environments, and

are ideal for pumping liquids with poor lubricating

qualities, strong chemicals that attack metals, and

to pump air, vacuum, combustion products and

gasoline vapors.

Metallized Carbon supplies the carbon-graph-

ite vanes, rotor, and end plates to rotary pump

and compressor manufacture and rebuilders. The

materials are chemically resistant and have a low

wear rate running in both gas atmospheres and

low viscosity liquids.

Carbon graphite vanes can withstand the rub-

bing of the vane tip against the housing bore and

the rubbing of the side of the vane against the slots

in the rotor. Lightweight carbon graphite rotors

save energy and withstand the rubbing against

the vane and the end plates. Carbon graphite end

plates are pressure tight and dimensionally stable

so that they can make a close clearance seal with

the rotor and vanes. They also withstand the rub-

bing of both the vanes and rotor.

Metallized Carbon Corp.

Info http://powereng.hotims.com RS#: 412

Siemens safety relays

The Sirius 3SK2 safety relay from Siemens offers

multiple safety functions in the smallest of spac-

es. Thanks to the user-friendly drag & drop param-

eterization interface,

it is simple to create

safety functions that

can be optionally

expanded to include

test and diagnostics

functions.

Sirius 3SK2 safety relays come in two different

variants – the 22.5-millimeter-wide device, which

comes with up to four safety functions, is slimmer

than any other software-parameterizable safety

relay currently available on the market, while the

45-millimeter-wide device, which offers up to six

safety functions, comes equipped with a diagnos-

tics display. The functions of the 3SK2 fail-safe out-

puts can be assigned independently of each other.

Typical applications for Sirius 3SK2 devices

include emergency stop push buttons, protective

doors with tumblers, or material feeder systems

with light barrier sensor technology. The fail-safe

outputs can be supplemented in a modular fashion

as required – even without additional wiring. Just

like devices in the Sirius 3SK1 series, Sirius 3SK2

units are simple to combine with conventional

industrial controls, for example, devices from the

Sirius 3RM1 motor starter range can be simply inte-

grated using device connectors.

Siemens

Info http://powereng.hotims.com RS#: 413

Safety system transmitter

United Electric Controls has introduced the One

Series Safety Transmitter, the frst SIL 2-certi-

fed transmitter designed solely for safety system

applications.

The One Series transmitter provides 4-20 mA

NAMUR standard output with exclusive “I Am

1508pe_50 50 8/7/15 4:39 PM

51 www.power-eng.com

Tachometer generator

Marsh Bellofram Corp. announced the global

market introduction of its WESTCON 758-

9910001 industrial AC tachometer generator.

These highly rugged, explosion-proof devices can

effectively support the demanding predictive mainte-

nance requirements of oil and gas drilling, industrial

mud pumps, and waste and wastewater pumps and

systems, with complete and effcient 24/7 rotational

speed monitoring. The tachometer is especially ben-

efcial for rotary table RPM and mud pump SPM, two

of the primary parameters for achieving maximum

drilling effciencies.

WESTCON 758-9910001 AC tachometer gener-

ators are designed to convert rotational shaft speed

inputs into a linear

analog voltage output,

even in the harshest

of environments. The

tachometers feature a standard 3 4² drive shaft, with

only a 3 oz-in starting torque. Their components are

housed within a explosion-proof case that is ATEX

certifed for Class 1, Division 1, Class 1, Group D and

Class 2, Groups F and G. Series units are also UL list-

ed. In addition, their rugged, bearing-free and brush-

free design requires absolutely no maintenance for

increased reliability and minimal downtime.

Marsh Bellofram Corp.

Info http://powereng.hotims.com RS#: 420

Input temperature detectors

New additions to the WAGO I/O system expands

the functionality of the 750 series. 750-450

4-Channel and 750-451 8-channel RTD Analog

Input Modules directly connect to Pt and Ni resis-

tance sensors, providing highly accurate reading of

sensor data.

Benefts of the

modules include con-

fgurable for multiple

sensor types or po-

tentiometers, red sta-

tus LED that indicates

sensor errors, such as short circuit, wire break, or

out of measurement range, and a compact 12mm

profle saving cabinet space.

The 750-450/451 is ideal for a wide range of

temperature data collection tasks in factory auto-

mation, motor and process control applications.

WAGO

Info http://powereng.hotims.com RS#: 421

Morgan’s improved CVD SiC growth capabil-

ity enables the manufacture of 300+ millimeter

diameter components with thicknesses of more

than 10mm at production volumes for recently de-

veloped plasma etch applications. With access to

world class ultrasonic machining capability, Morgan

offers high tolerance CNC machining and precision

hard grinding, as well as the patented Rmax process

for producing focus CVD SiC ring shapes.

Morgan’s high purity (99.999 percent+) SiC ma-

terial has high thermal conductivity, is resistant to

chemical erosion, and features minimal particulate

generation, making it ideal for use in chlorine and

fuorine plasma etch processes. The material is

ideally suited for use in producing GDMs (gas dis-

tribution plates) where the material’s erosion resis-

tance can lead to long life and extended tool PM

schedules. Ultrasonic drilling can provide holes with

diameters as small as 0.5mm, ideal for custom etch

applications.

Morgan Advanced Materials

Info http://powereng.hotims.com RS#: 416

Slurry knife gate valves

DeZurik’s new KSL Slurry Knife Gate Valves are

designed for on-off (isolation) service for appli-

cations consisting of abrasive, high solids content,

wet or dry media.

The KSL-LA Slurry Valve features sleeves of natu-

ral rubber or other elastomers that are compressed

by sleeve retainers. The sleeves have an encapsu-

lated supporting ring for long service life, and the

valve’s sleeve compression design eliminates the

cavity where solids can collect.

The sleeve design of the KSL Slurry Valve pro-

vides bi-directional, drip tight shutoff up the valve¹s

100 psi (690 kPa) pressure rating. The valve has a

full port, which reduces turbulence and pressure

drop across the valve. In addition, the gate fully

retracts out of the fow path in the open position.

The KSL Slurry Valve is available in sizes 2-24²

(50-600mm) with larger sizes and higher pressure

ratings available on application.

DeZurik

Info http://powereng.hotims.com RS#: 417

Compact solid state relay

Carlo Gavazzi launched their new RF1 Series

Compact Solid State Relay. The RF1 Series

provides compact solid state switching suited for

applications with con-

fned space. The RF1

Series is ideally suited

for applications where

trouble free operation

is required for a large number of cycles and where

space is limited. The RF1 Series occupies only 30

percent of the panel space typically required for a

typical panel mounted (hockey puck) solid state re-

lays, it’s merely 36 x 21 x 24mm.

The RF1 Series is designed for control of resistive

loads. The zero switching type (RF1A), switches ON

when the voltage crosses the AC sine wave’s zero

crossover point. The instant-ON type (RF1B), switch-

es on at the instant when control voltage is ap-

plied. Integrated transils provide protection against

over-voltage. A green LED indicates the presence of

control voltage. Fast-on terminals for the input and

output voltage enable fast and secure installation.

Carlo Gavazzi

http://powereng.hotims.com RS: 418

Wrist, elbow and knee supports and wraps

Ergodyne refreshed and enhanced their ProFlex

Supports Line. The updates are coming to

ProFlex Wrist Supports, ProFlex Wrist Wraps, ProFlex

Knee Sleeves, as well as ProFlex Elbow Support and

Sleeves and will complete the full line overhaul that

was kicked off by Back

Supports in 2013.

A number of chang-

es to the models were

made, including: new

material colors, improved fabrics, new logo treat-

ments, lower profle buckles (on the 4020 Wrist

Support and 650 Knee Sleeve), larger thumb loops

(on the 4020 Wrist Support), new binding and pre-

curve design (on all sleeves), improved fabrics, pull

tabs for easy on/off (on all straps), and more… All

in an effort to improve the performance, comfort,

breathability, shape, and design.

The supports are ideal for workers with minor

sprains, strains, or exposure to repetitive motion on

the job.

Ergodyne

Info http://powereng.hotims.com RS#: 419

1508pe_51 51 8/7/15 4:39 PM

52 www.power-eng.com

largest provider of PPE, said Sach Sankpal, presi-

dent, Honeywell Safety Products.

New online tools from Miller Fall Protection

that make it easier for engineers and architects

to design, specify, and select fall protection

systems for different projects. The new inter-

active tools include engineering specifcations

and Computer Aided Drawings (CAD), system

comparison charts, a fall clearance calculator,

a ShockFusion kit selection guide, and “Ask the

Expert” and additional resources.

Uvex Instinct: High-performance protection

with a sleek design and a variety of adjustability

features for a customized ft. Uvex Instinct pro-

vides high-performance protection with a sleek

design and lightweight frame, featuring a variety

of adjustability features for a comfortable, cus-

tomized ft. The soft, fexible fngers on the nose-

piece help to minimize slippage, while the slim,

curved temples provide a secure ft with minimal

tension around the ears.

Uvex Tirade: Sealed Eyewear features closed

cell foam, removable temples and adjustable

headband for a comfortable, gap-free ft. Uvex

Tirade sealed eyewear protects workers in high

particulate environments where dust, dirt and de-

bris present the risk of eye injury. The large uni-

lens design provides a wide feld of unobstructed

peripheral vision, with a soft foam subframe to

ensure a comfortable gap-free ft.

Honeywell Solutions

Info http://powereng.hotims.com RS#: 424

(HEMTs), VisIC’s products accelerate the semi-

conductor industry’s push to extend GaN-based

technology from communications subsystems

into power conversion subsystems. Meeting the

highly demanding requirements of power switch-

ing with GaN has been the Holy Grail for power

conversion research in the last decade.

VisIC Technologies

Info http://powereng.hotims.com RS#: 423

Turbine linear actuator

The Voith SelCon was primarily designed as

a linear actuator with safety function for the

valve controls of gas and steam turbines.

The hydraulics provides high force density and

dynamics, the electromechanical side contrib-

utes simple, cost-effective system integration.

Large effective forces up to 500 kN and ATEX

certifcation allow it to be used on turbines under

virtually all conceivable ambient conditions.

The hydraulic system of the SelCon is self-con-

tained. An external hydraulic power pack with oil

tank, control block and pipework is completely

unnecessary. This reduces procurement costs

by up to 35 percent compared to a conventional

solution. External hydraulic disturbances such as

pressure fuctuations, mismatched pipe diame-

ters or negative pressure in the tank line are out

of the question.

The fail-safe function is implemented using an

internal return spring. The trip time for the valve

controls is typically less than 300 ms. This reduc-

es the danger of direct and consequential dam-

age considerably.

Voith Turbo

Info http://powereng.hotims.com RS#: 423

Worker safety productsThe new personal protective equipment prod-

ucts introduced today by Honeywell (NYSE: HON)

at ASSE Safety 2014 represent a ³fervent dedica-

tion to innovation² in worker safety by the world¹s

Temporary power connector

Cliff Electronics announces its Quicktest QT3,

a compact, robust 3-Phase power connec-

tor designed for temporary, safe and effcient

connection of unterminated cables to 440VAC,

3-Phase power supplies. The QT3 has a maximum

power rating of 16 amps per phase.

The Cliff QT3 is designed for use in applica-

tions including manufacturing, test and repair,

calibration, measurement and burn-in where fast,

safe and non-permanent connection to 3-Phase

power supply is required.

The colour-coded piano key cable clamps are

also marked L1, L2, L3, N and E to prevent any

confusion. Each phase is protected by an individ-

ual 16 amp fuse as standard and each phase is

ftted with an individual neon indicator lamp to

indicate when the phase is live and connected to

the supply.

Cliff’s Quicktest QT3 is designed for use either

free standing or mounted to a bench or test fxture

and it measures a very compact 49mm x 100mm

x 160mm.

Cliff Electronics

Info http://powereng.hotims.com RS#: 422

Power transistor switches

VisIC Technologies, a developer of Gallium

Nitride (GaN) power semiconductors an-

nounced the world’s lowest-resistance, fast GaN

transistor in their power conversion switch.

VisIC’s 650V, 50A GaN transistor achieves

a remarkable 12mohm Rdson. Based on a new

design for GaN High Electron Mobility Transistors

1508pe_52 52 8/7/15 4:39 PM

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www.power-eng.com 53

Why Should You

Filter Your Water?

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The Best Engineered Water Filteration Solution Always Costs Less

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Automatic Filters

SOLVAir Solutions was formed

to help customers address the

problems of SOX, HCl and other

stack emissions, as well as help

with the changing EPA regulations.

SOLVAir Solutions is the market

leader in providing sodium

sorbents for use in DSI systems.

Access our brochure on our

Library page at www.solvair.us

Contact Rosemary Dunn

ardunadv@gmail.com

713.521.7450

Emission Control

24/7/365

HIGH VOLTAGE EQUIPMENT& SERVICE

Call or Email for a quick quote

and fast track delivery of

660.596.7727

hvsales@energy-parts.com

www.energy-parts.com

High Voltage Equipment

http://powereng.hotims.com RS#300 http://powereng.hotims.com RS#302

Crown Electric

Iso Phase Bus

FabricationInstallation

Upgrades & UpratesGSU Change Outs

175 Edison Dr.

Middletown, OH 45044

www.crown-electric.com

sales@crown-electric.com

ext.

201513 539-7394

Iso Phase Bus

3

NuScale Power has attained the Triple

Crown for Nuclear Plant Safety™. With

NO operator action, NO AC or DC

power, and NO added water, the

NuScale Power Module™ will achieve

safe, self-cooled shutdown, and

maintain it indefinitely.

Safety: the Element of Nu.™

nuscalepower.com

© 2015 NuScale Power, LLC. All Rights Reserved.

Safe Nuclear Power

http://powereng.hotims.com RS#304

Silo and Bin

Cleaning Services and Equipment

Call 800-322-6653

or visit

www.molemaster.com

Silo and Bin Cleaning Sevices

http://powereng.hotims.com RS#305

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www.power-eng.com 53

http://powereng.hotims.com RS#303

http://powereng.hotims.com RS#301

1508pe_53 53 8/7/15 10:54 AM

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LASSIF

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REACH YOUR AUDIENCE

ADVERTISE your career opportunities, equipment, services,

and training programs in Power Engineering’s Classif ed Section.

GET RESULTS

Put your message in front of North

America’s most qualif ed circulation

with Power Engineering’s classif eds.

CALL NOW FOR DETAILS: JENNA HALL

Phone: 918.832.9249 | Email: jennah@pennwell.com

1319 Macklind Ave., St. Louis, MO 63110 Ph: (314) 781-6100 / Fax: (314) 781-9209

www.ampulverizer.com / E-Mail: sales@ampulverizer.com

Quality and Service Since 1908

Ring Granulators, Reversible Hammermills,

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for crushing coal, limstone and slag.

For info. http://powereng.hotims.com RS# 453

Get a thorough mix with:

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boilers and balance of plant systems

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For info. http://powereng.hotims.com RS# 451

For info. http://powereng.hotims.com RS# 452

For info. http://powereng.hotims.com RS# 450

1508pe_54 54 8/7/15 10:54 AM

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For Classifed Advertising Rates & Information

Contact Jenna Hall

Phone - 918-832-9249, Jennah@pennwell.com

CONDENSER & HEAT EXCHANGER TOOLS

CLEANERS, PLUGS, BRUSHES

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For info. http://powereng.hotims.com RS# 455

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1508pe_55 55 8/7/15 10:54 AM

www.power-eng.com56

INDEX

RS# COMPANY PG# SALES OFFICERS# COMPANY PG#

1421 S. Sheridan Rd., Tulsa, OK 74112 Phone: 918-835-3161, Fax: 918-831-9834 e-mail: pe@pennwell.com

Sr. Vice President North American Power Group Richard Baker

Reprints Foster Printing Servive 4295 Ohio Street, Michigan City, IN 46360 Phone: 866-879-9144 e-mail: pennwellreprint@fosterprinting.com

National Marketing Consultant Rick Huntzicker Palladian Professional Park 3225 Shallowford Rd., Suite 800 Marietta, GA 30062 Phone: 770-578-2688, Fax: 770-578-2690 e-mail: rickh@pennwell.com AL, AR, DC, FL, GA, KS, KY, LA, MD, MO, MS, NC, SC, TN, TX, VA, WV

Regional Marketing Consultant Dan Idoine 806 Park Village Drive, Louisville, OH 44641 Phone: 330-875-6581, Fax: 330-875-4462 e-mail: dani@pennwell.com CT, DE, IL, IN, MA, ME, MI, NH, NJ, NY, OH, PA, RI, VT, Quebec, New Brunswick, Nova Scotia, Newfoundland, Ontario

Regional Marketing Consultant Natasha Cole 1455 West Loop South, Suite 400 Houston, Texas 77027 Phone: 713.499.6311; Fax: 713.963.6284 e-mail: natashac@pennwell.com AK, AZ,CA,CO,HI,IA,MN,MT,ND,NE,NM,NV,OK,OR,SD,UT,WA,WI,WY,AB,BC,SK, Manitoba, Northwest Territory, Yukon Territory

International Sales Mgr Tom Marler The Water Tower Gunpowder Mills Powdermill Lane Waltham Abbey, Essex EN9 1BN United Kingdom Phone: +44 1992 656 608, Fax: +44 1992 656 700 email: tomm@pennwell.com Belgium, Czech Republic, Denmark, Finland, France, Germany, Hungary, Norway, Poland, Portugal, Slovenia, Spain, Slovakia, Sweden

International Sales Mgr Roy Morris The Water Tower Gunpowder Mills Powdermill Lane Waltham Abbey, Essex EN9 1BN United Kingdom Phone: +44 1992 656 613, Fax: +44 1992 656 700 email: rmorris@pennwell.com UK, Austria, Africa, Holland, India, Italy, Ireland, Israel, Russia, Australia & New Zealand, Singapore, Scotland, Switzerland, Turkey, Greece, UAE/SAUDI and Iran

Classifieds/Literature Showcase Account Executive Jenna Hall 1421 S. Sheridan Rd., Tulsa, OK 74112 Phone: 918-832-9249, Fax: 918-831-9834 email: jennah@pennwell.com

13 Nord-Lock Inc 23 www.bolted.com/subscribe

9 Orion Instruments 19 www.orioninstruments.com

21 PENNWELL CORPORATION 40 www.power-eng.com/webcasts

17 PENNWELL CORPORATION 34 www.power-eng.com/webcasts

25 Power Generation Week C3 www.powergenerationweek.com

15 Power-Gen 27 International 2015

www.power-gen.com

RENTECH BOILER SYSTEMS INC. DIGITAL EDITION-COVER

www.rentechboilers/facilities

6 Rotork Controls Inc 11 www.rotork.com

3 Siemens AG 5 www.siemens.com/sppa-t3000

8 Terrasource Global 15 www.terrasource.com/pe

23 Valve and Gate Group 41 www.vag-group.com

5 Victory Energy 9 Operations LLC

www.victoryenergy.com

18 Young & Franklin Inc 35 www.yf.com

Advertisers and advertising agen-

cies assume liability for all contents

(including text representation and il-

lustrations) of advertisements print-

ed, and also assume responsibil-

ity for any claims arising therefrom

made against the publisher. It is the

advertiser’s or agency’s responsibil-

ity to obtain appropriate releases on

any items or individuals pictured in

the advertisement.

AREVA DIGITAL BELLYBAND www.areva.com

Brandenburg Industrial C4 Service Company

www.brandenburg.com

16 Busch USA 33 www.buschusa.com

4 CB&I 7 www.CBI.com

20 CD-adapco 39 www.cd-adapco.com

22 Clearspan 41 Fabric Structures

www.ClearSpan.com/ADPWRE

24 Cleaver-Brooks Inc 47 www.cleaverbrooks.com/chemical

2 Conbraco Industries Inc 3 www.apollovalves.com

11 Flexim Americas Corp 22 www.flexim.com

12 Goodway 23 Technologies Corp

www.goodway.com

Hytorc Industrial Tools 17 www.hytorc.com

1 Kiewit Power C2 www.kiewit.com

10 Lapeyreb Stair 21 www.lapeyrestair.com

19 Magnetrol International 37 www.magnetrol.com

14 Membrana 25 www.Liqui-Cel.com

7 Mitsubishi Power 13 Systems Americas Inc

www.mhpowersystems.com

1508pe_56 56 8/7/15 11:06 AM

COVERING IT ALLDecember 6-10, 2015

Las Vegas Convention Center / Las Vegas, NV, USA

www.powergenerationweek.com

SAVE the DATE!

Owned & Produced by: Supported by:Presented by:

For info. http://powereng.hotims.com RS# 25

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