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NUCLEAR ROUNDTABLE
EXECUTIVES DISCUSS THE FUTURE OF NUCLEAR POWER
THE 316(B) RULE

TECHNICAL CHALLENGES
OPERATION & MAINTENANCE
TECHNIQUES TO IMPROVE YOUR HEAT RATE
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MATS Compliance: The Countdown to 2015
Hydro-Optic UV Technology for

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Range and Applicability of Heat Rate Improvements

Remote Vibration Monitoring Keeps
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in Unconventional Oil and Gas Exploration
124 Using Predictive Analytics to Minimize
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No.11, November 2014
VOLUME
132 On-Site Power Conversion: University Rebuilds
On-Site Power Plant, Switching from Coal to Gas
140 Battle Ready, Built Right: Air Force Seeks Partnerships

to Develop Reliable and Sustainable Energy Sources
150 Under Attack: How to Protect Your Power
Generation Project Against Environmental

Group Opposition Under the Clean Air Act
156 The Continuing Evolution of
Cooling Tower Water Treatment
164 Energy-Pipeline Operator Upgrades to
Open-Architecture Reciprocating Engines Control
DEPARTMENTS
2
4
6
8
Opinion
Clearing the Air
Gas Generation
View on Renewables
10
12
14
172
Energy Matters
Nuclear Reactions
Power Plant Profile
What Works
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OPINION
Clean Power Plan

is a Glorious Mess
BY RUSSELL RAY, CHIEF EDITOR
e have learned a lot about

the effects of the Environmental
Protection
Agencys controversial Clean Power
Plan since it was first introduced back
in June.
State regulators in Virginia say the
plan will cost Dominion Virginia Power up to $6 billion to comply. Another
study places the cost of compliance at
$366 billion nationwide.
Whats more, the plan depends largely on the displacement of coal in favor
of natural gas to meet state targets for
carbon dioxide (CO2) emissions, a fact
that power producers are deeply concerned about, especially after last years
polar vortex, which sapped Americas
gas supplies as they were re-routed for
home heating. Power producers are
rightfully worried the plan could accelerate the shutdown of coal-fired generation in the U.S., putting reliable and
affordable power at risk by becoming
too reliant on natural gas and its insufficient infrastructure.
Under the proposed rule, each states
CO2 reduction target is based on four
building blocks: 1) Heat rate improvements; 2) dispatch changes among affected units; 3) increased use of renewable energy; 4) and demand-side energy
efficiency.
Some power producers have expressed concern that the plan does not
provide enough flexibility to comply.
For some states, building block 2 is the
only option for meeting the reduction
targets. Power producers have questioned the feasibility of the plan, pointing to deficient gas pipeline capacity and
the value created by major investments
2
in much of the nations coal-fired generation. Under the proposed rule, the
benchmark year would be 2012, which
means any improvements completed at
coal-fired plants during that year or before will not be recognized.
The feedback has led the EPA to issue a request for more input about the
methodology being used to meet the
plans CO2 emission targets.
The EPAs request for more information is a frank admission that the plan
is a glorious mess forcing the agency to
deploy procedural belts and suspenders to hold it together, said National
Mining Association President and CEO
Hal Quinn. With enormous costs and
unmeasurable benefits, the only option
EPA should consider is withdrawal of
this symbolic but expensive gesture on
climate change.
According to Standard & Poors, up
to 75,000 MW of coal-fired generation
may be shuttered by 2020 due to a host
of new regulations targeting coal-fired
plants. We are really in for a wild
ride for five to six years because of the
amount of coal shutting down in such
a short amount of time and the transformation toward more gas being used
to generate electricity, Philip Moeller,
a member of the Federal Energy Regulatory Commission, told Bloomberg.
The Clean Power Plan would require existing power plants to reduce
carbon dioxide emissions 30 percent
below 2005 levels by 2030. Although
the national average would be 30 percent below 2005 levels by 2030, the
specific reduction target for each state
varies. EPA is expected to issue a final
rule by June 2015. States would have
until June 2016 to file their compliance

plans, with one- and- two-year extensions available to qualifying states.
Ive heard some states arent going
to do it. Theyre going to say give us a
federal plan, said Jacob Hollinger, former Clean Air Act attorney for EPA Region 2. Im not sure thats a good idea.
If the state doesnt submit a plan, EPA
is going to impose a federal plan. If
you end up with a federal plan, youre
going to have more burdens on EGUs
than you are under a state plan.
In addition to concerns about the
plans impact on reliability, many
states contend the EPA proposal is unlawful. The staff of the Virginia State
Corporation Commission said the
proposal would impose substantially
more stringent emission requirements
for affected, existing generating units
in Virginia than the standard for new
units, yet to be built.
Jeff Holmstead, former assistant administrator of the EPA and one of the
nations leading climate change lawyers, said the rule will likely be overturned by the courts.
The idea that this somehow gives
the EPA authority to require all states
to fundamentally change the way electricity is produced and consumed in
their state is a real stretch, Holmstead
said. This is something that wont
withstand judicial scrutiny.
The Clean Power Plan will be the topic
of a Mega-Session entitled Potential Impact of GHG Regulation on the Future of
the Power Industry at POWER-GEN International 2014. The session begins at 10
a.m. Dec. 11 at the Orange County Convention Center in Orlando, Florida.
www.power-eng.com
Sanmen Nuclear Power Company Ltd. Used with Permission. All rights reserved.
BUILDING A
NEW GENERATION
OF NUCLEAR ENERGY
Westinghouse AP1000 plant under construction in Sanmen, China
Westinghouse Electric Company LLC
www.westinghousenuclear.com
Westinghouse
Electric Company
@WECNuclear
CLEARING THE AIR
Bagging Two Birds

with One Economizer
BY DENIS OSOWSKI, BABCOCK & WILCOX POWER GENERATION GROUP
ometimes power industry professionals get lucky when a solution developed for one complex challenge provides coincidental
benefit for an unforeseen issue that
arises in the future.
Such is the case with a process originally developed to reduce acid gas formation when operating a selective catalytic reduction system (SCR) during
turndown on coal-fired boilers which
led to an unplanned (but very welcome, in todays regulatory climate!)
improvement in heat rate, and a corresponding reduction in greenhouse gas
emissions.
When SCRs were introduced in the
early 2000s, it was recognized that
the equipments minimum operating
temperature posed a limitation on
unit turndown. Turndown limits were
reached when boiler load was reduced
and economizer exit gas fell below the
minimum SCR inlet temperature. In
many cases this limitation was so severe that units could essentially only
run at full load.
Back when coal units were base loaded, this was not a serious restraint. But
as the economics of the power market
changed, units without turndown capability became liabilities. Multiple solutions were implemented to address this,
including economizer gas bypasses,
economizer water bypasses, variable
temperature economizers and even duct
burners. All these devices were intended to maximize economizer exit temperature at low loads and return some
of that valuable turndown back.
But with the rollout of U.S. EPAs
MATS rules, limiting acid gas emissions
became the hot topic of the day - and all

that hot gas going to the SCR was found
to unwittingly enable the production of
acid gas through the conversion of SO2
to SO3. To some, the solution for acid
gas control was to add a dry sorbent injection system and reduce SO2 entering
the SCR. But for some plant operators,
relying on DSI would create an undesirable increase in operating cost. It was
clear that not only was low temperature
at low loads an issue for SCR operation, but high temperature at high loads
needed to be controlled as well. Its decidedly cheaper for an operator to control the conditions that cause the acid
gas production in the first place, rather
than spend money on reagent for acid
gas control.
The solution to economizer exit gas
temperature control was an over-surfaced economizer with water bypass
or water flow bias control. The same
systems used to modify the amount of
water fed to the economizer to maintain higher temperature at low load can
be used in conjunction with an oversurfaced economizer to control economizer exit gas temperature nearly to a
setpoint from full load down to about
50 percent load. This number could be a
little lower or a little higher, depending
on the boiler design.
The additional economizer surface
installed to knock down full load temperature has been successfully added to
existing economizer spaces by redesigning the surface geometry, adding fins or
extended surface, moving equipment
(i.e., sootblowers) to make room for additional surface, or even adding a new
standalone horizontal economizer in
the downstream flue work. Through

the application of flow biasing within
a specially designed economizer or water bypassing of an entire economizer
or both used together operators can
gain great flexibility to control exit gas
temperature to maximize SCR performance, while minimizing SO2 to SO3
conversion and dry sorbent reagent cost.
Then came a pleasant surprise. Since
adding surface to an economizer also
provides a significant improvement in
heat rate by capturing additional energy
in the final heat trap of the boiler, we
find we have to combust less fuel for the
same load, thus producing less CO2.
This heat rate improvement offers a significant head start toward a compliance
strategy w for the currently contemplated EPA CO2 rules for existing sources
and, in this case, the heat rate improvement building block in the EPAs plan.
Depending on the existing full load
economizer exit gas temperature, the
extra heat absorbed by the additional
economizer surface can provide for an
improvement in full load heat rate of up
to 1%, meaning less fuel burned, and an
associated reduction in CO2 emissions.
Such a reduction in CO2 emissions represents a significant piece of the 6-percent heat rate improvement target that
the proposed existing source CO2 rule
describes as one of the four primary
building blocks to achieving the Agencys greenhouse gas reduction targets.
In a world where emissions control
technologies are seen as parasitic, this
tool for acid gas control contributes to a
healthier bottom line today and a possible aid to regulatory compliance tomorrow.
www.power-eng.com
GAS GENERATION
Generating Power to
Increase Efficiency
BY SHERIF YOUSSEF, P.E., PHILADELPHIA GAS WORKS
ombined heat and power

(CHP), also known as co-generation, is the simultaneous
production of useful thermal energy
and electric power. The technology is
receiving increased consideration by
consulting engineers and architects as
a viable option for customers who want
to generate their own electricity. Generally, a CHP integrated mechanical system refers to a power generation process
in which thermal heat is recovered and
used to drive heating, hot water, or cooling through an absorber. CHP involves
a facilitys entire energy delivery system.
This useful thermal energy is essential
for the success of the application.
Modular designs for CHP systems allow for easy expansion. Onsite generation can be equipped with dual-fuel capabilities of natural gas and/or oil. This
helps increase the reliability of the system
and reduces its operating costs. To qualify
for a discounted or interruptible rate, an
alternate fuel should be used as a backup
in case of interruption. Oil, propane, and
electricity have all been used as backups
for engines or turbines. Turbine efficiencies are in the range of 30 percent, and
overall thermal efficiency can reach 70 to
80 percent when heat recovery is added to
the equation.
The power consumption requirement
for a commercial customer is always
greater in the summer than in the winter. Because electricity cannot be stored,
utilities build generating capacity to supply the maximum summer load requirements. To recoup this investment, a utility must charge for the excess capacity it
generates to meet summer requirements.
Through CHP, customers can avoid the
6
need for excess capacity and have a flat

electric demand all year long. CHP can
also help the customer become more energy independent, reduce the end of system load levels, reduce system losses, and
improve voltage.
CHP begins with a power generation
process in which thermal heat is recovered and used to drive cooling and/or
heating equipment. Various technologies
are available to generate onsite electricity.
These include internal combustion (IC)
engines, gas turbines, microturbines,
steam turbines, and fuel cells. Facilities
or businesses must develop feasibility
studies which are unique to their energy
demands and can identify technologies
that are appropriate for their needs. Possible technologies include:
IC engines The reciprocating engine market is growing robustly, averaging 27 percent annual growth in
sales over the last 10 years. Dual-fuel
engines used in co-generation applications can be run on natural gas,
and light fuel oil engines represent a
reliable technology that is easily serviced and maintained with relatively
low capital costs.
Gas turbines Gas turbines can
be operated in several different configurations. They can be combined
with a heat recovery steam generator
(HRSG) to form a system in which
both gas and steam turbines are
used in a combined cycle. Gas turbines are relatively inexpensive to
own and operate.
Microturbines If noise level and
avoidance of oil is a concern, microturbines can be an attractive option. Some products offer flexible
modular systems, but microturbines

are generally more expensive than
IC engines.
Steam turbines Steam turbines
provide fuel flexibility and come in
multiple configurations. They can
be used alone or in conjunction with
gas turbines in a combined cycle
system. The primary energy of the
new steam is used in the turbine to
generate electric power and is subsequently used to generate process
heat or steam.
Customers should evaluate the feasibility of a co-generation project for their facilities. Examples of facilities that might
be good candidates for co-generation
include universities, hospitals, hotels,
nursing homes, prisons, large apartment
complexes, and industrial manufacturers
that have thermal needs such as drying,
melting, or sealing.
There are several factors to consider
when exploring the suitability of co-generation for a facilitys needs. These factors
include average costs of electricity, heating fuel costs, fuel flexibility, operation
and maintenance costs, and potential impacts of regulatory emissions. Facilities
should determine whether or not they
need substantial amounts of thermal energy. Other factors such as the number
of hours of operation and the location of
the facility may impact decisions about a
project.
In the last couple years, reliability has
driven additional interest in CHP systems. CHP systems can be a potential
solution for organizations wanting to diversify energy options and reduce costs. It
can also help customers meet their longterm energy and power goals.
www.power-eng.com
We introduced H-class.
So its only natural that
we take it to the next level.
A decade ago, GE built the industrys first H-class gas turbine. Since then, our H-class gas turbines
have logged more than 200,000 hours of operation and data monitoring. This experience, and
data-driven insights, have led to performance improvements and smart innovation. Today, our
7HA and 9HA gas turbines lead the industry in total lifecycle value through strategic service
solutions that enable our customers to adapt their operations and assets for cleaner, more reliable
and cost-effective conversion of fuel to electricity.
Come see us at POWER-GEN International booth #2221.
Follow GE Power & Water
efficiency.gepower.com
2014 GE Power & Water, a division of General Electric Company.
@ge_powergen | @HArriet_GE
VIEW ON RENEWABLES
U.S. Schools Saving

Money, Helping Environment
by Going Solar
BY RHONE RESCH, PRESIDENT AND CEO, SOLAR ENERGY INDUSTRIES ASSOCIATION
he report card is in and thousands of U.S. schools are bringing home straight As.
In a comprehensive, first-of-its-kind
new study, Americas K-12 schools have
shown explosive growth in their use
of solar energy over the last decade,
soaring from 303 kilowatts (kW) of installed capacity to 457,000 kW, while
reducing carbon emissions by 442,799
metric tons annually the equivalent
of saving 50 million gallons of gasoline
a year or taking nearly 100,000 cars off
U.S. highways.
Brighter Future: A Study on Solar in
U.S. Schools was prepared by The Solar Foundation (TSF) with data and
analysis support from the Solar Energy
Industries Association (SEIA) and
funded through a grant provided by the
U.S. Department of Energys SunShot
program.
The Solar Foundations report is the
first nationwide assessment of how solar energy helps to power schools in
communities across America. Most importantly, the report shows that thousands of schools are already cutting
their utility bills by choosing solar, using the savings to pay for teacher salaries and textbooks. Whats more, the
report estimates that more than 70,000
additional schools would benefit by doing the same.
Here are the reports key findings:
There are 3,752 K-12 schools in the
United States with solar installations, benefitting nearly 3 million
students.
Today, Americas K-12 schools
have a combined capacity of
490 MW, generating 642,000
megawatt-hours (MWh) of electricity each year.

Of the 125,000 schools in the
country, as many as 72,000 could
go solar cost-effectively.
If you think thats good news, then
get a load of this: An analysis performed
for this report found that 450 individual school districts could each save
more than $1,000,000 over 30 years by
installing a solar photovoltaic (PV) system. New York City alone, according to
the report, could save $209 million.
In a time of tight budgets and rising costs, solar can be the difference
between hiring new teachers or laying
them off. Just as importantly, solar is
also helping to fight pollution.
The new report also found:
More than 3,000 of the 3,752 systems were installed in the last six
years. Between 2008 and 2012,
solar installations on U.S. schools
experienced a compound annual
growth rate of 110 percent.
Nearly half of the systems currently
installed are larger than 50 kW and
55 schools have systems that are 1
MW or larger. About a quarter of
the PV systems at schools are smaller than 5 kW.
As schools system sizes increase,
so too does the incidence of thirdparty ownership.
Excluding small demonstration
systems, the median system size of
K-12 school PV systems was found
to be 89 kW (approximately equal
to 18 average residential solar PV
systems).
As is the case with the solar industry at large, the report found that more
schools are going solar as installation

costs decrease. According to the SEIA/
GTM Research U.S. Solar Market Insight
report, national blended average system
prices have dropped 53 percent since
2010.
The movement of schools to go solar
is certainly part of a larger trend. According to industry forecasts, the United
States is expected to install an estimated
7.4 gigawatts (GW) of solar this year a
42 percent increase over 2013 making it the best year ever for solar installations in America. Whats more, solar
accounted for a record 53 percent of
all new electric generation capacity installed in the first half of 2014, pushing
solar to the front as the fastest-growing
source of renewable energy in America.
Today, the U.S. solar market segments
include utility scale PV (48 percent);
utility scale concentrating solar power,
also known as CSP (9 percent); nonresidential PV (26 percent); and residential PV (17 percent). All totaled, there
are an estimated 650,000 installed solar energy systems in the United States,
including systems on more than half a
million homes.
To put that into some perspective, the
U.S. now has an estimated 20.2 GW of
installed solar capacity, enough to effectively power nearly 4 million homes in
the country or every single home in a
state the size of Massachusetts or New
Jersey with another 20 GW under contract for 2015-16.
So anyway you look at it from saving money to helping the environment
more and more U.S. schools, businesses and homes are seeing the benefits of
going solar.
www.power-eng.com
ENERGY MATTERS
A Tailor-Made Fit
BY ROBYNN ANDRACSEK, P.E., BURNS & MCDONNELL AND CONTRIBUTING EDITOR
n June 2014, the Supreme Court

ruled on EPAs Tailoring Rule, resulting in partial victories for all
sides. EPAs authority to regulate greenhouse gases (GHG) was upheld, while
industry got a small, but important,
concession.
Writing for the majority, Justice Scalia
chastised the EPA, saying, the EPA, was
mistaken in thinking the Act compelled a
greenhouse-gas-inclusive interpretation
of the PSD and Title V triggers, and that
its greenhouse-gas-inclusive interpretation of the PSD and Title V triggers was
impermissible. The Court ruled that a
federal agency like the EPA has no power to tailor legislation to bureaucratic
policy goals by rewriting unambiguous
statutory terms. Therefore, EPA could
not defend the Tailoring Rule as an exercise of the agencys enforcement discretion. Agencies can only exercise discretion where there is statutory silence
or ambiguity, the Court said. But when
the statute is unambiguous, the agency
must give effect to the expressed intent
of Congress.
In perhaps his most scathing comments, Justice Scalia wrote that EPAs
Tailoring Rule attempted to assert
newfound authority to regulate millions of small sources, such as retail
stores, offces, apartment buildings,
shopping centers, schools, and churches, and to decide, on an-ongoing basis
(without regard for the thresholds prescribed by Congress) which of those
sources to regulate. We are not willing
to stand on the dock and wave goodbye
as EPA embarks on this multiyear voyage of discovery, said Scalia.
Numerically, EPA was granted license
to regulate 83% of stationary-source
greenhouse gas emissions, versus the
10
86% of sources included in the original

rule. But those 3% of sources granted a
reprieve are an important concession.
In Step 1 of the original Tailoring
Rule, EPA wanted to regulate emissions
from 83% of stationary GHG sources.
These were known as anyway sources,
since they were already subject to major
source Prevention of Signifcant Deterioration (PSD) construction permitting and major source Title V operation
permitting because of emission from
another pollutant, such as nitrogen oxides (NOx) or sulfur dioxide (SO2). Step
1 was upheld by the Court; it was Step 2
that the Court struck down.
Step 2 sources were subject to PSD and
Title V solely because of their GHG emissions. Both PSD and Title V are complex regulatory programs best entered
into cautiously. Classifcation as a PSD
major source means that future expansion is either limited or subject to Best
Available Control Technology (BACT)
add-on control devices and dispersion
modeling. PSD permits take on average 12-18 months to be issued, delaying
construction and increasing costs. Title
V is a permit for the on-going operating
of a major facility that requires extensive recordkeeping and reporting. Fines
for even paperwork violations of Title
V requirements start in the $10,000$100,000 range. Both programs should
be avoided if at all possible.
Two very important types of power
plants fell into Step 2: simple-cycle
peaking plants and reciprocating engine
plants. These plants are of increasing
value in light of EPAs proposed Clean
Power Plan, which shifts generation to
renewables and natural-gas fred assets.
Many simple-cycle gas turbines
were constructed with limits to avoid
classifcation as a PSD major source.

Due to their limited operation, it was
relatively easy to keep emissions below
the major source threshold of 250 tons
per year (tpy) of a criteria pollutant. But
under Step 2, the major source threshold for GHG was 100,000 tpy, which although a large number, is trivial given
the order of magnitude of GHG emissions. Suddenly, these peaking plants
were PSD major sources, with future
plant expansions tripping PSD at 40 tpy
NOx instead of 249 tpy NOx.
Reciprocating engine plants have become an important growth industry in
the countrys evolving power mix. Recip
plants are quick to construct, much less
expensive than turbine plants, and can
go from zero to full load in under 10
minutes, making them ideal to balance
out wind generation. With individual
engines rated at 9-18 MW, building
blocks of engines allows great fexibility in meeting power demands. Under
Step 2, just 30 MW of recips tripped major PSD permitting, but with the Court
ruling, 120 MW can realistically be permitting as a PSD minor source.
But what if your plant was already
issued a PSD or Title V permit based
solely on GHG emissions? EPA has yet
to issue guidance on how to rescind or
revise these now unnecessary permits.
However, it seems logical to assume
that there are suffcient grounds for
repermitting as a minor source and for
the removal of some emission and operating limits.
You could get whiplash trying to determine your plants applicability under
the EPAs Tailoring Rule. But with the
Supreme Court partially striking down
the rule, the power industry caught a
break, albeit a small one.
www.power-eng.com
NUCLEAR REACTIONS
Setting the Bar

at Watts Bar
BY BRIAN SCHIMMOLLER, CONTRIBUTING EDITOR
ob Williams, TVAs Watts Bar Fukushima project manager, was in

a tight spot in August 2012 when
the U.S. Nuclear Regulatory Commission
issued its orders concerning nuclear plant
modifications in response to the Fukushima Daiichi accident. Construction of
TVAs new nuclear plant, Watts Bar Unit
2, was well underway when Fukushima
happened. The NRC order required operating plants to be in compliance within
two operating cycles, but required construction permit plants like Watts Bar 2
to be in compliance before receiving an
operating license. So while the existing
Watts Bar Unit 1 would need to be in
compliance by October 2015, Unit 2 had
to get there by early Fall 2014.
The original plan was to do Unit 2
first because of the schedule requirement, said Williams. However, as the
mitigating strategies were developed and
designs were initiated, we discovered that
approximately 70 percent of the connection points were common (shared)
between the two units. With a small
amount of additional work in the Unit
1 refueling outage, we could bring both
units into compliance at once. This solved
an operational issue with operators in a
common control room having to operate
common equipment to two different sets
of procedures. It also allowed us to touch
procedures, instructions, drawings, training once instead of twice.
Because of the compressed schedule
imposed by the order, Watts Bar had
to begin design and procurement activities before any of the regulatory and
industry guidance around flexible coping (FLEX) was finalized. TVA had to
make some conservative assumptions as
to what would be required. Basically,
because of the timing and the unknown
12
requirements, our design is more robust

than the minimum requirements, said
Williams. We also have less reliance
on the Regional Response Centers than
many utilities will have.
The FLEX equipment at Watts Bar
is truly robust. A new Flexible Equipment Storage Building (FESB) has been
constructed to house the FLEX equipment, which includes: three Triton diesel
pumps, three diesel Dominator pumps,
two 3 MW diesel generators, two tow vehicles, a compact track loader for debris
removal, two diesel intermediate-pressure pumps, two diesel transfer pumps,
hose trailers, portable light stands, small
portable diesel generators, and disaster
kits. The FESB building has been constructed above the probable maximum
flood level and is designed to remain
functional at two times the site safe shutdown earthquake. For coping with spring
and summer storms, the FESB is designed
to withstand a design basis 360 mph
tornado (rotational plus translational
speed). Williams noted that the monster
tornado that swept through Tuscaloosa,
Alabama, in 2012 had total speeds in the
high 200-mph range.
To ensure rapid emergency response,
225 KVA diesel generator connections
are provided to the vital battery chargers, and the 480V shutdown boards;
and 3-MW diesel generator connections
are provided for the 6900V shutdown
boards. The site was originally designed
for a fifth diesel generator, which enabled
us to use some existing switchgear for
our FLEX strategy, said Williams. Prior
to the modifications, we only had four
paths by which to get power to the plant;
now we have nine.
Although water (too much of it) initiated many of the troubles at Fukushima, it
was the lack of water (and an inability to

get it where it was needed) that ultimately
contributed to the subsequent core meltdowns. Water should not be a problem at
Watts Bar. The new auxiliary feedwater
supply tank has a capacity of 500,000
gallons, and meets the same design basis criteria and seismic basis as the FESB.
The tank will provide 15 hours of clean
water to both units, or about 30 hours
to one unit. Maintenance procedures are
in place to periodically test the isolation
valve, and as a passive system, the tank
can supply water on either loss of power
or control air.
TVA also has installed connections to
the refueling water storage tank, the boric
acid tank, the demineralized water storage tank, the primary water storage tank,
and the tritium water storage tank if additional sources of clean or borated water
are needed. And although theyd obviously rather not use it, TVA has access to a
nearby water source, Watts Bar Lake.
Because it was designed ahead of the
industry guidance related to Fukushima,
the FLEX equipment at Watts Bar duplicates some of the equipment provided by
the Regional Response Centers. Equipment from the Regional Response Centers can then be used as replacement
equipment for a failed piece of equipment or to prevent multiple moves of site
equipment as events proceed.
TVA is developing preventive maintenance procedures for all of the FLEX
equipment. We are contracting with
the equipment manufacturers to conduct maintenance on some of the larger
pumps and diesel generators, said Williams. FLEX equipment similar to existing plant equipment such as breakers and
valves are being added to existing maintenance procedures.
www.power-eng.com
POWER PLANT PROFILE
Pandas New
Power Plant Up and
Running in Texas
n late September, Panda Power

Funds dedicated its Panda Temple
combined-cycle power plant at an
inaugural celebration and ribbon cutting ceremony in Temple, Texas. The
event concluded a 30-month long, $1
billion construction projectthe biggest in Central Texas to dateto build
the much-needed natural gas-fired facility. The complex was completed two
weeks ahead of schedule, and with better performance statistics than guaranteed. It is now completely operational
and serving the Central Texas region.
EFFICIENCY AND
ENVIRONMENT
Built on a 250-acre former sunflower
field, the 758-MW facility is the first Flex
Plant in Texas. As one of the cleanest
natural gas-fired plants in the U.S. fleet,
the facility operates at 57.5 percent overall
14
efficiency and can synchronize to the grid

in ten minutes, reach an emissions-compliant 60-percent baseload in 20 minutes,
and arrive at full power in an hour.
The plant utilizes the latest and most
advanced emissions-control technologyDry Lox-NOx Burners + SCRto
minimize its environmental impact, and
it recycles treated municipal waste water
from the city of Temple for its cooling.
The plant is permitted as a zero-liquiddischarge site and uses evaporation ponds
to avoid introducing liquid pollution into
the surrounding area. Flex Plant technology allows the facility to avoid holding the
gas turbine at a low load during startup.
This means the plant can ramp up directly
to a low-emissions point, resulting in 84
percent less carbon monoxide (CO) per
start cycle, and 89 percent less Nitrogen
Oxide (NOx). Carbon monoxide emissions total less than 10 parts-per-million
(ppm), and NOx emissions total less than

2.0 ppm.
CONSTRUCTION
AND EQUIPMENT
The facility was delivered as a turnkey
system in a project that brought together
the efforts of EPC giant Bechtel and global OEM Siemens. Designed as a power
island, all major components of the plants
power block including turbines, boilers,
and generators were supplied by Siemens,
thereby providing for a composite installation that is highly integrated.
The 2x2x1combined-cycle plant relies
on two Siemens SGT6-5000F turbines
with shaping power, followed by newly
designed Benson heavy duct-fired horizontal heat recovery steam generators
(HRSG) manufactured by NEM, which
can utilize all but 185 degrees of the turbines waste heat to generate secondary
www.power-eng.com
energy completely emissions-free.

Shaping power allows each turbine to
increase overall electricity production by
20 percent, effectively providing built-in
peaking capacity that can be called upon
during hot conditions or other high-demand times. When combined with newly
designed boiler technologies that allow the
plant to start more quickly, these innovations make the facility highly responsive
to grid demand and market opportunities.
The Temple plant is only the third Flex
Plant in operation in the United States. It
features innovative design features that
enable the fast-start facility to ramp up
and down very quickly, across a large
operating window, from low plant turndown to high plant output. This functionality allows the plant to meet the challenges of an increasingly diversified power
generation landscape in which facilities
are called upon to supplement intermittent renewable energies at a moments
Population in the Texas Triangle

Total Estimated Population of Texas (by
County) Showing the Texas Triangle that
Includes Dallas, Houston, Austin, and San
AntonioFour of the Fastest Growing
Cities in the Country
Source: Texas State Demographer, August 5, 2014 Presentation

to Texas Electric Cooperatives Annual Meeting
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notice. Located as it is in Texas, a state

with vast amounts of wind generation,
the plants fast-start capabilities offer a
highly-attractive feature that will greatly
benefit the region. Speaking about these
benefits, Martin Tartibi, Senior Executive
Vice President at Siemens Energy Solutions Americas said, Siemens fast and
efficient Flex-Plant technology is a perfect fit in balancing intermittent renewable resources.
Bechtel depended on the services of
more than 1,000 workers for construction
of the plant. Of these, about 70 percent of
the projects contractors, and 80 percent
of its craft workers were locally sourced in
Texas. The Temple project also represented the inauguration of a program in which
discharged military veterans from Fort
Hood in Killeen, Texas were trained and
put to work as carpenters, ironworkers,
electricians, pipefitters, and millwrights.
Bechtel was well-suited to such a large- pounds for the steam turbine generator
scale project. With 116 years experience the entirety of the project was completed
and 53,000 employees
safely across two milglobally, the company Siemens fast
lion man-hours, withhas been the number and efficient Flexout any lost-time accione power industry Plant technology
dents. Panda Temple
engineer and construcrepresents a tremenis a perfect fit
tor for 16 consecutive
dous team effort, inyears. To date, the in balancing
cluding our partners
company has com- intermittent
Siemens and Panda,
pleted more than 125
all of whom worked
renewable
combined-cycle
gas
seamlessly to bring
turbine power projects resources.
the plant online early,
with a total generat- - Martin Tartibi, Sr. Exec.VP, which was important
ing capacity of 54,000
for both our customer
Siemens Energy Solutions
MW.
and the community,
The Temple project was managed by said Mary McLaughlin, president of
Michael Robinson, who was responsible Bechtels thermal power business line.
for engineering, procurement, and exThe plant required 24,000 cubic yards
ecution of plant construction. Despite of concrete, 80,000 cubic yards of excathe heavy industrial workthe project vated dirt, 1,086 tons of steel, 125,000 linrequired a construction lift of 750,000 ear feet of installed pipe, and 1.5 million
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linear feet of electrical cable. At

baseload, it has the equivalent of
approximately 1.1 million horsepower, or about nine 747 jet aircraft.
In addition to its primary Fclass turbines, the plant also
includes one SST6-5000 steam
turbine, two SGen6-1000A
generators, one SGen6-2000H
generator, and an SPPA-T3000
instrumentation and control system, all manufactured by Siemens at its production facility in
Charlotte, North Carolina. The
combustion turbines were proactively designed to be upgraded as needed across their useful
service life, allowing the plant to
keep pace with advancements in
electric generation technologies
20
Panda Power Funds 758-MW Combined-Cycle Power Plant in Temple,

Texas. Photo courtesy: Siemens
to be realized in the coming

decades.
Located in the Texas Triangle that includes Dallas,
Houston, Austin, and San
Antonio four of the fastest growing cities in the
countrythe Temple plant
is well-positioned to provide electricity to an area of
the state that needs it badly.
Speaking about the future of
energy in Texas, Todd Carter,
Senior Partner and President
of Panda Power Funds said,
One thousand new residents move to Texas every
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day, and this increase in population has

the potential to outpace the states generation capacity. To solve this problem,
the grid must grow in proportion to the
states growth. The Temple facility will
provide enough energy to power 750,000
homes in a 60,000 square mile area, and
contribute up to 1.6 billion dollars to the
Central Texas economy, as verified by
economic analysis conducted by Impact
Data Source in Austin.
Looking up outside the plant, Jacki Engel, marketing manager for Siemens 60
Hz product line said, Im very proud of
this project. I know youre not supposed
to think a power plant is beautiful, but I
cant help but see beauty in this facilitys
clean functionality.
An identical plantTemple IIis now
being constructed adjacent to the current
facility. When it becomes operational in
2015, it will double the facilitys capacity.
ABOUT PANDA
POWER FUNDS
Formed in 2010 and headquartered in
Dallas, Panda Power Funds grew out of
Panda Energy International. Run by former senior management from Panda Energy, Panda Power is comprised of executives who have financed, developed, built,
and operated 9,000 MW of generating capacity in projects totaling about $6 billion.
The company employs 59 people.
Past projects include two of the largest natural gas-fueled power plants in the
countrya 2,250-MW plant in Gila Bend,
Arizona, and a 2,250-MW plant in Eldorado, Arkansaswhich required the combined efforts of more than 40 banks for
financing.
The 2012 financing of the Panda Temple
plant is regarded as a breakthrough for the
U.S. project-finance market, and represents
the first time in six years that institutional
ACTIVE IN THE
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a Ceco Environmental company
investors have financed a capital-intensive

construction project in the U.S. using a
term loan.
Panda Power focuses on domestic,
greenfield power development, and brownfield acquisition and expansion. The company currently has multiple power projects
in various stages of development or construction, including a 758-MW plant in
Sherman, Texas of similar size to the new
facility in Temple, a second sister plant
called Panda Temple II located immediately adjacent to the current Temple facility,
the Panda Stonewall project in Leesburg,
Virginia, and two 829-MW plants called
Liberty and Patriot in Pennsylvania. The
Fund also develops solar and other energy
projects. In 2011, it developed and constructed one of the Northeasts largest solar farms in Pilesgrove, New Jersey. The
20-MW facility was a joint project between
Panda Power and ConEdison.
10
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24
www.power-eng.com
The Future
of the U.S. Nuclear
Industry Depends
on Collaboration
BY SHARRYN DOTSON, ASSOCIATE EDITOR
uclear power projects are emerging

from the ground in
the U.S. and other
countries, including
India, Iran and Saudi Arabia. Four new
builds in Georgia and South Carolina,
the restarted nuclear project in Tennessee
and the recent development of new and
advanced reactor technologies are a sign
of the progress for an industry once considered stagnate.
Nuclear Power International talked with
Rita Bowser, vice president of New Build
Project Advancement, Westinghouse
Electric Co. LLC; David Sledzik, vice
president of Product Management and
International Nuclear Plants, GE Hitachi
Nuclear Energy; Mike Twomey, vice president of External Affairs, Entergy Wholesale Commodities; and Mike McGough,
chief commercial officer, NuScale Power
LLC. The discussion centered on the future of the U.S. nuclear industry and how
social media has helped vendors and utilities educate the masses on this complex
subject.
Power Engineering: Can we expect more construction of new U.S.
nuclear in the next 10-15 years?
Mike McGough: I do believe that
we can expect to see more construction
of U.S. nuclear plants in the next 1015 years. Obviously, with the AP1000
www.power-eng.com
projects being constructed now and the

Watts Bar project almost completed, as
an industry, we need those projects to be
successful and were confident that they
will. In the advent of some of the new
pressures of carbon-generating baseload,
combined with some of the new technologies that are being developed, like
the NuScale small modular reactor, we
believe that provides an excellent opportunity for new baseload to be
considered. We are engaged with a
group of utilities in our Western Initiative for Nuclear, which plans to develop
a nuclear project in Idaho for a 580-MW
NuScale installation for commercial operation by the end of 2023, so we have a
line of sight to several additional projects
that we expect in the next 10 to 15 years
will become operational.
David Sledzik: I agree with Mike.
We will definitely see new nuclear construction in the next 10 to 15 years. We
recently received our ESBWR (Economic
Simplified Boiling-Water Reactor) certification from the NRC (Nuclear Regulatory
Commission) to positive votes last week.
We started a development agreement
with Dominion for North Anna 3 about
a year-and-a-half ago, and that projects
underway. We also have DTE Energy in
Michigan who is the lead COLA utility
for the ESBWR, and theyre targeting their
COL approval in the first quarter of 2015,
25
David Sledzik
Mike Twomey
so thats another exciting advancement

for our technology.
Mike Twomey: I agree with the previous two speakers; there are some very
exciting projects that are going to move
forward. I do think, however, where you
will see new nuclear construction will
depend on the regulatory framework in
place. For vertically integrated regulated
utilities that have the opportunity to create a long-term diverse portfolio with the
partnership of regulators and the support
of a customer base, you have the opportunity to build these large-scale projects.
In parts of the country where you have a
wholesale unregulated market, it will be
a challenge to see new large-scale nuclear
construction due to low natural gas prices and the market pricing mechanisms
that dont reflect the attributes of nuclear
power. In New England and the Northeast in general, as well as the West Coast,
it seems to be more difficult to get a project of that nature moving forward.
Rita Bowser: I want to just add to what
the other speakers already said. Were
currently building four AP1000 reactors
in the U.S., and we expect that there will
be more. New nuclear has to be part of
the future energy mix. We all talk about
the clean energy and thats an important
feature of nuclear energy. Also, addressing the security in energy supply, we have
seen the fluctuations of gas prices in the
past and the uncertainties that result; we
want to avoid another economic downturn and energy security is necessary
to do so. We believe you will see more
AP1000 nuclear power plants in the mix
26
Mike McGough
as we go forward.
I know the question is about the U.S.,
but, the world is increasing its nuclear
fleet substantially and as we go forward,
I think that will motivate the U.S. The
world nuclear fleet has more than 430
nuclear reactors, with 70 more in some
phase of project development and construction currently. Clearly, theres a
reason for that; a diverse energy mix, security of supply and clean energy are all
important components.
Power Engineering: The NRC recently finalized a used storRita Bowser
age rule and lifted the suspension of licensing activities. Do
you think companies and utilities will removal of the suspension of power
have even more incentive now to plant licensing activities was sort of a
build a new nuclear plant?
momentary pause, although there were
Bowser: As we know, Ive been in- not what I would call frenetic activities
volved in used fuel storage for a very long in new plant licensing. It certainly does
part of my career. As a supplier, now that remove a roadblock. But, I dont think it
licensing activities can resume with the changes the incentive that a utility may or
finalization of the used storage rule, its may not have to develop a nuclear plant.
important for us, because offering the As we talked about in the first question,
AP1000 nuclear power plant with its there are some significant driving forces
strong licensing pedigree, particularly that will provide any utility incentives to
with the U.S. as country of origin for have non-carbon generating baseload as
that licensing basis, has been important. a part of their mix that will be immune
Weve undergone reviews in many coun- to price fluctuations that Rita mentioned,
tries, by independent, technically rigor- associated with commodity fuels like
ous transparent regulators, but the U.S. natural gas.
licensing really remains an important
standard for the rest of the globe. So, I
Power Engineering: Is there a growthink this is a good step for Westinghouse ing trend of U.S. companies that are
and the rest of the industry as we look for- looking to work overseas with estabward in the marketplace.
lished and emerging countries lookMcGough: I can just add that the ing to build nuclear?
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Sledzik: There is definitely a renewed

interest and interest hasnt really gone
away for nuclear power outside of the
U.S. Weve been working a lot with some
of the countries that currently have nuclear. They have the establishment in place;
the regulatory agency and how to deal
with the regulatory issues that come up
as well as the back end of storage, so those

countries are definitely well ahead of the
pack. Weve been working in Finland, the
UK is coming on really strong with Horizon, NuGen and EDF; and now with the
latest EU announcement we saw in the
press yesterday allowing for some kind of
a strike price that will move it (Hinkley
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Point C nuclear project) even faster. The

UK is an exciting market. Even the emerging countries want U.S. technology, they
want that backing and knowledge of the
U.S. and what we have done in new nuclear. I think there is a trend that really
hasnt gone away, its always been there,
and were focusing a lot of efforts overseas
in addition to the U.S., but we think there
are huge opportunities out there.
Bowser: I agree with Dave, absolutely.
The countries outside of the U.S. have
substantially significant growing energy
needs, and as part of satisfying those
needs, they really are looking for energy diversity and clean energy as a part
of their mix. We see it in our projects in
China, where we have four units currently under construction with more potentially on the horizon, as well as globally. Westinghouse has significant project
opportunities in the United Kingdom,
Vietnam, Poland, India, Brazil, Bulgaria
I could literally go across the globe
and name about a third of the countries
on the planet. Everybody is interested in
finding that right balance of sustainable
energy that allows them to move forward
in a way to meet demand in those marketplaces. Its still an exciting time to be
in this industry and I think its only going
to get better.
Power Engineering: Another hot
topic in the nuclear industry is the
market conditions, particularly those
working adversely against single-unit
power plants such as Vermont Yankee and Kewaunee. How can this issue be dealt with before more units
are forced to shut down?
Twomey: Entergy is the operator
of Vermont Yankee and we did make
the difficult decision to shut that facility down. There are a few factors that are
conspiring against the nuclear facilities
in merchant situations. Low natural gas
prices are a main concern because they
affect the prices that everyone in the market can get. But, there are policy decisions
that the independent system operators,
follow us:
www.power-eng.com
with input from the states that are in the

areas, can take to improve the outcomes.
Capacity prices today that these nuclear
facilities receive do not appropriately reflect the attributes that the nuclear plants
provide. That is, fuel on-site, lack of carbon emissions, reliability, and price stability. Right now, capacity prices generally treat each kilowatt-hour the same in
the market, regardless of what attributes
those particular generators bring to the
table. By contrast, policymakers have
made exceptions for long-term contracts
for things like the Cape Wind project off
the coast of Massachusetts. Because of
those attributes, regulators are willing
to sign above market, high priced, longterm contracts that really affect the ability
of other market participants to continue
to be viable.
The other issue, aside from capacity
prices, is energy prices. The problem in
some areas, including New York and New
England, is that the energy market prices
dont currently reflect the true cost of providing the last kilowatt-hour of energy
in a day. There are complicated formulas
for establishing energy prices. But the
bottom line is that uplift payments for
some generators and other structures in
place today artificially suppress prices for
other generators. So, all generators participating in the market are not getting
the appropriate price for the energy they
provide. If you look at the flaws in the energy market and the flaws in the capacity
market, all together, the picture that gets
painted is that these nuclear facilities are
there, theyre baseload -- generally speaking, 24-7 -- they have a terrific environmental portfolio attribute for them, and
they provide reliable and price stable energy into the marketplace, but theyre really not being compensated appropriately
for the value they provide. Were engaged
in conversations with policymakers to
try to effect change, and were trying to
drive the message that the importance of
a diverse energy portfolio cannot be understated. We saw that last winter in New
England when natural gas prices were
pushed to a very high level as a result of
inadequate transportation and natural
gas availability. Were gaining traction
with some of these policymakers, but
theres a lot of other noise out there in the
marketplace, so we continue to focus on
the changes that are needed to keep these
units open.
Bowser: The only thing I wanted to
add, and I think that [Mike Toomeys response] was a really helpful explanation,
is that its about all of us. The utilities are
doing a great job in educating policymakers and the communities they serve and
the suppliers have a role in that as well. A
piece of that is being able to answer those
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think theres a role for all of us in supporting that dialogue

as we go forward.
Sledzik: I agree with that. NEI plays a role and it helps
utilities and vendors bring a common voice in their Nuclear Matters campaign in trying to help the public and
policymakers understand, so NEI does a pretty good job of
pulling us all together with one common front. So, thats
part of the vendors responsibility as well as the utility to
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Power Engineering: Besides market conditions,

the opinions of the public and lawmakers play a
big part into whether a plant can continue to operate or even be built, much like were seeing with
Indian Point. How is your company working with the
public and lawmakers to show them the positives of
nuclear?
Twomey: Indian Point is another one of our facilities.
We have been involved in a robust campaign regarding
Indian Point since we filed the application for license renewal in 2007. That application is still pending in front of
the NRC and there are related proceedings going on at the
state level. Your question really does hit the various points.
We are working not only with lawmakers, but with the
public. We are participating in all the administrative proceedings to drive the message, and there are a handful of
key messages. One is that nuclear power is safe. It has an
excellent track record. Weve made significant investments
in Indian Point, as I know other operators have done in
their own facilities. That message is important. Another
message is that nuclear power is essential to a diverse energy portfolio. The low natural gas prices that we see today
are likely not going to be there 10 years from now. Anyone
can look at the last 30 or 40 years of energy markets in the
U.S. to see that there are cycles where natural gas or other
energy prices will go up and then come back down and
then go up again. We spend a lot of time working through
the administrative legal process, but also directly with the
public, whether its paid media, social media, stakeholder
outreach or direct meetings with individuals to try to drive
awareness that youve got a safe, reliable, clean, price-stable
resource in nuclear facilities. Right now, our focus in the
Northeast is keeping these existing facilities open, but that
is fully consistent with and supportive of efforts in other
parts of the country to build new nuclear. This message
campaign cant be heard often enough, whether its at the
local level or the national level in D.C. Rita mentioned
that it is not just an effort by the utilities and operators
of these facilities and shes right. The vendors play a key
role in driving that message because its not enough to just
hear it from the operator who owns the facility. Lawmakers and the public need to hear a wider voice from other
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credible sources about the importance of

these facilities.
Bowser: Mike, youre right about that.
We talked about the increased public
awareness, and we changed our approach
to that and increased our commitment
to it. In the past, we had a tendency to
focus our messages on our products
and technologies. Today, thats simply
not enough. We have had to expand our
messages and even our delivery model.
We talked about social media, where we
talk about clean air, sustainability and
safety really early in our messages. We
have far more than just a product-driven
message. One of the things we recently
did, and this was different for us and
was generally very well-received, was
using social media as a promotion tool
for Pandoras Promise. Our employees
were engaged in that very personally and
individually. We used different means
of promoting this, like our media relations and television commercials and
these messages have made a difference.

It was about thinking outside of the box,
and thinking about who needs more information to be better informed and to
make better choices about the energy
mix. Another example of a newer message approach thats a little more global
for us was a different sort of campaign
on the Ex-Im Bank. That campaign was
more targeted at the political influence
of it and pointing out the impact of not
having the Ex-Im Bank would have.
There were people in power positions
who were surprised to hear what some
of the effects of that would be. I just
want to reinforce the fact that we need
to keep that increased commitment to
the public, and continually look for
ways to do that, which matches todays
communications media.
Twomey: One of the big challenges
is informing policy makers of the facts
of public support. Because we do polling, we keep pretty close tabs on public
support for the facilities. We find we have

very strong public support for the operation of each of our facilities. Indian Point
is a good example of a facility that has
very solid public support from those who
are living and working near the facility as
well as those in the general New York City
area. We do have critics, we do have those
who would prefer not to see the plant
continue to operate, and they tend to
be very loud in their expression of criticisms, but we need to be focused on
delivering the facts to the policymakers so that they understand that these
facilities, including Indian Point, enjoy very strong public support. Thats a
message we drive home every time we
have the opportunity to do that.
McGough: From the perspective of a
new technology developer, with respect
to small modular reactors, obviously we
have to build on the success and stand on
the shoulders of the existing outstanding record of the operating nuclear fleet
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in the country and the rest of the world.

As we contemplate building new technologies, the NuScale small modular
reactor design has some unique features
that are very attractive to prospective customers and to the public. From a safety
standpoint, the NuScale design has resolved one of the most vexing challenges
in the nuclear industry, and that is how
do you cope with a Fukushima-like station blackout event? In that situation, the
NuScale plant is designed and has been
tested and proven that it will shut itself
down and cool itself indefinitely that is,
forever - with no operator action, with
no source of power, either AC or DC,
and with no additional water other than
what is in inventory on-site. So these are
some relatively new types of innovations
that require an education to the public.
With the consumers (e.g. electric utilities) in our marketplace, our prospective
customers are very eager to have us help
them communicate this message to their
consuming electricity users. When they

consider the size of the plant being quite
small compared to the larger units, they
can be built more quickly and scaled for
incremental baseload additions at a price
point that is below the costs associated
with large nuclear plants. Rita mentioned
Pandoras Promise, and in that film,
our small modular reactor design was
featured as one of the prospects for the future. So were working very hard to help
educate the public about the differences
between some of the new technologies
that were proposing
Sledzik: From our side, we do social
media outreach, even locally in the public, a lot of our engineers are involved
with the local schools to help educate.
One of the things we recently did in the
last couple of years with our Global Laser Enrichment - which is not a nuclear
plant but its related to it - is a lot of public outreach to neighborhoods around
the plant to educate them on what were
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doing, how much impact it would have

on the roads with trucks coming in and
out. Theres a lot of support locally for
what we do here at the plant, as well as
with nuclear power, since we do have a
reactor just down the road in Brunswick.
We do a lot of this and, again, support
NEI. Weve also done things overseas. In
Poland, we have supported some of their
students there, and they have an atomic
bus that they drive around the country
and educate different cities and schools
on nuclear energy. We have supported
that the last few years.
Twomey: Let me add, a coordinated
and consistent effort across the industry
is very important for the future of these
facilities. From our perspective, the continued operation of the existing nuclear
fleet is important for the new builds as
well. Its important for the new small
modular reactor technologies. From the
publics perspective, nuclear is nuclear,
and the more challenges that are brought
against existing nuclear facilities, the bigger the challenge is for the industry as a
whole. Indian Point is a good example
of where the whole industry needs to
get behind the effort and recognize that
that facility, which provides excellent reliability to the NYC area, is one of the top
performing plants in the country. We just
had our last annual assessment from the
NRC and got consistent green ratings,
which is consistent with how its been
over the last eight or nine years. The major criticism of that facility is that its near
a large population center. That cant possibly be the litmus test for continuing to
operate these facilities, because there are
large nuclear facilities near Washington
D.C., Boston, Baltimore, Chicago, Cleveland, Detroit, Miami, New Orleans, and
other major cities. As we move forward
with this challenge against some of these
facilities, the industry as a whole has to
recognize that we need to win these battles, because these facilities are critical to
the nations energy infrastructure for a
whole host of reasons. Theyre an important asset from an economic standpoint,
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an environmental standpoint, and a reliability standpoint. We need to put forth

the appropriate effort to make sure we
keep these facilities in place.
Power Engineering: We have seen
all of your companies on Twitter, a
few on Google Plus, some, if not all
of you, also have a Facebook page.
Can you speak about how much
social media has helped you reach
out to the public in general?
McGough: Ive been in this industry
for 35 years. When I started my career
with Westinghouse where I spent 14
years, we used to have a program called
Campus America, which was designed
to take relatively young engineers out
into the public domain and speak about
nuclear things. We, as a nuclear community, tend to forget that what we all know
and have lived for so long is not a simple
topic, and its not easy for the public to
understand. The advent of Twitter with
140 characters where you have to get your

message across, I think has forced many
of us to realize that weve got to make it
simple. Weve got to make it digestible,
and weve got to make it in somewhat
soundbite fashion for todays world
where people expect things relatively succinct and in a fashion that is easy to understand. Nuclear energy is not a simple
topic. But breaking it down into simple
to digest components, with help from
people like the Nuclear Energy Institute,
we have worked very hard on making
some very short video clips available on
our website to help educate people. Our
customers, the Utah Associated Power
Systems, put together three, three-minute
videos that educate their entire constituents. Its been a really interesting development and its forced us to think differently about how we break down and parse
our communications.
Twomey: Ill echo that 100 percent. We have a Facebook page for each
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individual operating plant that we have

in the Northeast, not just the nuclear
side. Weve got one for Indian Point, one
for Vermont Yankee, etc. Weve also got a
separate Twitter feed for each of the facilities. We find its such an enormously important communication tool, not just to
younger people, but to anyone who is following the industry. You asked have we
found it to be important and the answer
is yes; Ill give you one example. During
Hurricane Sandy, we were communicating with reporters about the status of Indian Point as the storm was approaching
and coming ashore in New Jersey. There
was some misinformation that was generated by some parties that suggested that
Indian Point was having difficulty, and
we were able through Twitter to, within
about 40 minutes, correct the misinformation by having the facts delivered
directly to reporters in real time with
credible messaging that was able to show
that we really didnt have any issues. That
essentially was, from my perspective, a
watershed moment for understanding
that reporters and other media are using
these social media tools. Its not enough
to have an answer the following day to
an inquiry. You have to be able to answer
immediately. These tools have been very
helpful to us in keeping people on the
right course with respect to what is actually going on at each of the facilities.
Bowser: We use diverse social media
methodologies and platforms as well
with dual sites one each for Westinghouse Electric Company and one specifically for our AP1000 plant news on
Facebook, Twitter and YouTube. The
biggest thing we see is that need to use
various tools for our communications
and to fill a desire for quick information,
often in real time, from either the public
or various stakeholders. That seems to
be what makes the biggest difference in
peoples willingness to use social media
for various news sources that we provide
to them. Having participated in some of
those events, I feel that it is really exciting
from a nuclear vendor perspective as well
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McGough: I think its critically important when were faced with those
who may not necessarily be supporters of nuclear energy. I tell them you
are entitled to your own opinions, but
youre not entitled to your own facts.
Having the facts available in the fashion that Mike described is really admirable and its something that will really
serve us all well.
Sledzik: I agree with everybodys
comments. This is one of the things
we have learned, and the older generation of us who have been around for a
while are starting to learn. The young
gens society that we support fully and
I think all the other guys do as well in
the U.S. and around the world, have really brought social media into nuclear.
Thats their world that they live in now,
so we use them as a sounding board
40
on things that we do and learn from

them on how to get the word out. Our
representatives of the young gens are a
big support and help our PR campaigns
and our social media.
Power Engineering: DOE Secretary
Ernest Moniz and President Obama
have both publicly backed nuclear
as a generating source of the future,
but high upfront costs are still a detriment to some. What can the government do to help push more new
builds?
Bowser: Clearly, Westinghouse has
strong feelings on this. On the U.S. side,
the biggest single message is that we need
to level the playing field. Within the U.S.,
the subsidies across electricity production have really varied, and that has put
nuclear energy, among other clean energy providers, at a real disadvantage. Thats
what I mean by leveling the playing field.
We need to make sure that the advantages

of nuclear are weighted as heavily as other generating sources. Speaking globally,
there is a different kind of leveling of the
playing field. Were competing with companies that are financially backed by their
governments, and tools such as the Ex-Im
Bank, which I mentioned earlier, are vital if we want to remain competitive in
the global market and, frankly, to retain
U.S. and global jobs. That said, Secretary
Moniz and the President have been absolutely stellar in supporting nuclear energy
and we need to continue that push for the
foreseeable future.
McGough: I would say Secretary
Moniz and President Obama have exhibited excellent leadership in their interest
in developing a small modular reactor
program. NuScale was the recipient recently of a DOE SMR development grant,
which is very similar to the DOE grant
that funded the development of the ESBWR and the AP1000. With that grant
money, were very appreciative of the opportunity to be the lead small modular
reactor developer in the United States.
We understand that with a grant like that
from the DOE, a responsibility comes
with it to use our U.S. taxpayer dollars
properly, and we take that responsibility
very seriously. We are working hard to
meet the administrations expectations
as we move quickly toward commercialization of a product that can be built in
a factory and exported internationally to
help re-establish U.S. leadership in commercial nuclear.
Sledzik: Loan guarantees are huge for
the U.S. market, and the DOE grants and
the DOE advanced reactor cost-share opportunities that come out annually are
huge. Those help us move new technology forward so that we can stay ahead of
our competition, stay ahead in nuclear
technology across the globe. Rita, your
comment on Ex-Im financing is huge.
Weve been out there pounding the pavement on this as well. This keeps Westinghouse and GE-Hitachi competitive
against those big global players that are
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really backed by their country and can

bring that backing with them. Without
Ex-Im financing, theres an imbalance in
opportunities for both of us.
Power Engineering: Yucca Mountain will probably not be built. Is there
even more of a need for technologies such as breeder reactors in
the U.S., or will interim storage be
enough at power plants?
Sledzik: The nuclear industry and even
the government needs to look forward
and past long-term storage into how
can we recycle and use what we have as
a power source. Our PRISM technology,
which DOE helped fund the development for the last forty years, is an advanced solution to recycle the fuel that we
would store in Yucca Mountain and use
whats there as a fuel source. Instead of
having our nuclear used fuel as a liability,
well use it as an asset and create energy
from it. Weve been trying to move this
technology forward, and we eventually
gained some ground in the UK with their
long-term storage of commercial-grade
plutonium, and were helping them, as
a solution, to potentially use PRISM to
burn the plutonium and generate electricity. There are opportunities in the
advanced generation of technology that
were on the forefront.
Twomey: I agree that not having Yucca
Mountain move forward is not an ideal
situation.
But, it is worth noting and repeating,
particularly from the governments perspective, that the existing storage of spent
nuclear fuel at facilities across the United
States is safe, and not allow the critics to
create a false issue where none should be
present.
We do need to continue to work toward
long-term storage or to consider utilizing
the spent fuel again for energy production.
In the meantime, it is incumbent upon
the industry and policymakers to assure
the public that the existing configuration,
although not ideal, is safe.
42
Power Engineering: Tell us about

your advanced technologies and
why your company developed
them?
McGough: The NuScale design began about 15 years ago when Dr. Jose
Reyes (Chief Technology Officer and
co-founder of NuScale) was working on
developing design certification testing for
the AP1000, and he had the idea that he
could develop a plant that could be immune to a station blackout condition.
This was long before we had experienced
the Fukushima events. The desire to continue development of our technology,
which provides a new level of safety, significant simplicity of the operating systems, and provides different economics
because of the ability to quickly deploy
the plants from a factory manufactured
platform, provides some different paradigms to new nuclear. That is the reason
we are developing the plant. Probably
the most important reason for us is the
significant urging that we have from our
customer base, which is comprised of a
24-member utility advisory board.
Bowser: Were deploying the AP1000
plants as we speak. We made some
choices when we decided to go forward
with that, and its nice to see that others
are benefitting from the philosophy we
developed. Clearly, developing a standardized modular passive safety power
plant literally a couple of decades ago
was important, and we pursued a collaborative approach as well with utilities to
incorporate their hands-on plant experience. I think thats invaluable, because
by leveraging both the manufacturers
and operators experiences, we were
able to design in improvements that will
serve us all well in the long term. This
is the same kind of approach that were
taking forward into our SMR and other
products as well. Standardization makes
for safer operations, quicker licensing, lower operations and maintenance
costs, even lower back-end costs for
waste management and decontamination and decommissioning costs. There
are a lot of advantages to that, and to the

more modern modularity of construction. Those techniques, again, keep us
current with the market and also bring
significant cost savings every time. By
way of philosophy, these are the kinds
of things that we are trying to embed
as sound principles and it seems like
we are on our way to doing that within
the marketplace, with primary focus on
that hand-in-glove relationship with the
utilities to address and incorporate into
the design.
Sledzik: Weve got three technologies
in our new plant portfolio. Weve got the
ABWR, which has been constructed and
operated in Japan, so we have history behind that and have operated and have a
good knowledge base behind that and
how its constructed and how to bring a
plant online, on time and on budget. The
evolution of that is the ESBWR. That is
the Economic Simplified Boiling-Water
Reactor. We just received our license last
week from the NRC. It is a passive GenIII+ design that we started developing in
the early 1990s with a lot of support from
customers, to bring their knowledge of
how to make the operation of a reactor
simpler, less operation and maintenance
costs, as well as enhance the safety of
that technology. Through those interactions with utilities, we have come up with
the ESBWR. If you look at core damage
frequency, it is the safest light water reactor on the market today using the true
passive safety systems. The third reactor
I talked about earlier is PRISM. Thats a
sodium fast-cooled reactor. Its not set
up as a breeder, its set up as what I call
an eater. Were moving forward on
this technology. The UK has deemed the
PRISM technology as one of the credible
options for plutonium disposition. That
happened earlier this year in January. We
are supporting the UK in how to potentially use this technology for their plutonium disposition and storage issues. So,
weve got three technologies that are out
there, tried and true, and were working
forward on those.
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Authors:
Douglas A. Dixon is a Technical Executive and Program Manager of EPRIs Fish
Protection Research.
316(b)
Technical
Challenges
BY DOUGLAS A DIXON AND DAVID E. BAILEY,
BAILEY
Y, ELECTRIC
ELE
LECTRIC
E
POWER RESEARCH
H IINSTITUTE
Editors note: This is the second

of a two-part series on the U.S. Environmental Protection Agencys
316(b) rule, which will affect more
than 500 power plants in the U.S.
here are numerous
technical and schedule
challenges associated
with implementation
of 316(b). The following
are a few of those challenges, particularly those on the immediate horizon:
Many facilities with actual intake
flows > 125 MGD will need to begin entrainment characterization
studies in 2015. Collecting and
identifying early life stages of fish
and shellfish are technically challenging. Demand for qualified
consulting services may exceed
existing capacity. The rule also requires identification of species to
the lowest taxon possible. (e.g.
the lowest plant or animal classification grouping) It is unclear
how that will be implemented
since it is not uncommon to see
as many as 50% of entrainment
samples characterized as unidentified. The new method of DNA
bar-coding can identify species to
the lowest taxon possible, however the technique is new, relatively expensive and those with
the requisite skills are limited. It
44
is unclear if EPA considered DNA

bar-coding relative to identifying
eggs and larvae to the lowest taxon possible.
Two
streamlined
approaches
(compliance alternative 5 using
modified traveling water screens
and 6 using an integrated system
of technologies) require conducting a 2-year optimization study
with sampling occurring at least
monthly. The rule is suggestive
of possible approaches for optimizing traveling water screens
and fish return systems, however
approaches for optimizing an in-tegrated system of technologiess
are absent. Implicit in the ideaa
of optimization studies is the notion that impingement is chronic,
however impingement characterization studies have consistently
demonstrated that impingement
is episodic, occurring at irregular intervals. For many months
of the year impingement can be
zero. When it does occur it is typically dominated by fragile species
(e.g., Gizzard Shad, Alewife, Bay
Anchovy) and numbers of nonfragile species can be very low
(maybe 5, 10 or 25 fish per day of
a certain species). It would be difficult to detect significant differences in an operational parameter
David E. Bailey is a Senior Technical

Leader managing EPRIs closed cycle
cooling retrofit research and 316(b)
compliance support.
(e.g., screen rotation speed, pressure wash) with very small sample
sizes. Water quality (e.g., temperature, suspended solids, dissolved
oxygen) and the health of fish may
also factor into the optimization
assessment. While not mentioned
in the rule, conversations with
EPA have indicated that they do
not see any problem in addressing
this issue by using hatchery fish in
an experimental design that could
serve as a proxy for actual field
monitoring. The challenge for applicants will be to develop a creative experimental design, such as
using hatchery fish, and Directors
will need to be understanding and
flexible in their review and acceptance of optimization studies and
results in order to get meaningful assessments. In addition to
these experimental challenges,
traveling water screen and fish
return system components will
be costly and/or difficult to
change post installation.
While EPA relaxed the
implementation schedule
from the one in the proposed rule and tied information
submittals
to the NPDES permit
cycle, completion of
all the requisite studies, particularly for
those facilities also in-scope for

entrainment compliance, will be
extremely challenging and taxing
of the qualified existing in-house
staff and available consulting services.
Economic social cost analysis
(the r10 study for entrainment
compliance) is a complex issue and those with the requisite
skills to complete the studies are
very limited. Compliance costs
to industry are not social costs.
Social costs include the cost of
environmental impacts caused

by a potential BTA (e.g., noise, air
pollution, habitat loss, salt drift,
increased carbon emissions, and
water consumption associated
with closed cycle re-circulating
systems) and the increased cost
of electricity to the consumer as
a result of the compliance cost.
Downtime associated with a potential retrofit of a closed cycle
system and its impact on energy
reliability is an additional complexity that will challenge benefit
analysis. It is also unclear how
non-use benefits will be assessed
or quantified. EPA did not use its
willingness-to-pay (WTP) survey results to support quantifying the rules benefits, however
EPA intends to consult with
its Science Advisory Board
on how the results can be
used in the future. It is possible

the WTP results could return in
some form in the future. The rule
also does not require the Director to require a facility owner or
operator to conduct or submit a
stated preference survey to assess
benefits. Whether such a study is
conducted is left to their discretion, and it remains to be seen
how this would be used.
EPAs requirement for peer review
of the three entrainment-related
r studies (r10 through r12) was
included to reduce the report review burden on Directors. The requirements or qualified peer-reviewers should probably include
an understanding of how power
plants operate, how fish and
shellfish eggs and larvae are spatially and temporally distributed
and develop, how fish protection
technologies work and perform,
and how economic benefits are
calculated. The pool of potential
reviewers who possess this knowledge and can also be an independent and un-biased is not large.
Most of the industry is expected
to select the streamlined fish protection-modified traveling water
screen compliance option (i.e.,
option 5) for impingement control. The fine-mesh form of these
screens may also be the predominant technology identified as BTA
for entrainment control where
Directors determine control of entrainment mortality is required.
EPA estimates that 93 percent of
the electric power industry and
73 percent of the manufacturing industry in-scope of the rule
A turnkey installation of a refurbished thru-flow traveling water

screen at a coal-fired power plant. The screen was removed
from the well and shipped to Atlas Manufacturing for a complete
restoration and returned and installed with a new screen warranty
applied. Photo courtesy: Atlas Manufacturing Company Inc.
45
currently use traveling water

screens. EPA further estimates
that 29 percent of the industry
will select this streamlined compliance approach. When installed
and optimized (a challenging
study in itself), these screens will
need to be operated continuously
and monitored carefully for debris
clogging basically a significantly
heightened level of O&M. Practical industry experience indicates
that these modified screens can
be effectively maintained, including fine mesh (there are two U.S.
nuclear plants with fine mesh
1.0 mm operating since the late
1980s and another 10 to 12 fossil plants with screen mesh 2.0
mm). Fine mesh screens are also
common in Europe. There are
still concerns about the long-term
viability of these screens when

operated continuously as well as
concerns about the debris handling ability of fine mesh. While
a challenge for developing new
O&M best practices, practical experience suggests the challenge
can be met.
While the EPA dropped requirements to protect entrapped fish,
they still require they be counted
as mortality as part of Compliance Options 5, 6 and 7. It is unclear how someone can count entrapped fish. While they may not
be able to escape, entrapped fish
and shellfish can lead a sustainable life for many years including
spawning. Theoretically, tag and
release studies, acoustic cameras,
sonic devices, remotely operated cameras and scuba divers

46
can be used to estimate the size

of entrapped fish and shellfish
populations, but it would be very
difficult to use these methods in
some intake configurations such
as the header pipe for velocity
caps. An absolute count can also
be made by using rotenone to kill
and count entrapped populations.
While this method seems counterproductive, the EPA already considers entrapped fish as 100 percent mortality.
These are some of the known challenges, and many more are likely to develop as compliance is implemented.
The challenges will not be limited to
power plants and other manufacturers. Permit Directors will be similarly
challenged in understanding the application information, managing the peer
review results, making BTA decisions,
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48
EPA does not plan to issue any formal guidance to

support the rules implementation, however it does
plan to respond to frequently asked questions
(FAQs) and post the responses to its website (see introduction for link). They have also indicated they
may have conferEPA does not
ence calls with Permit Directors and
plan to issue
they plan, assumany formal
ing travel budgets
guidance to
are available and
suppor the rules management apimplementation, proval is received,
to attend technihowever it does
cal
conferences
to make presentaplan to respond
tions and engage
to FAQs.
in attendee dialog.
. Many required studies in the rule, such as the de
minimus waiver for impingement compliance and
the two-year Screen and Technology Integration Optimization studies for compliance options 5 and 6,
lack procedural or content information. In lieu of
guidance for such key required studies, permit applicants will need to develop approaches on their own
and seek approval from their Permit Director.
The window for filing litigation starts following
the rules official publication in the Federal Register.
The rules promulgation date is 14 days after it
appears in the Register, then litigants have 10
days to file appeals which will go into a lottery for
selection of the court that will hear the litigation.
Final petitions are due 120 days after promulgation.
Environmental groups who oppose the lack of a
national uniform BTA standard and a requirement
for retrofit of closed cycle re-circulating systems have
publically stated their intent to litigate. The rules
provisions remain in force until litigation is decided,
unless a stay is issued. Relative to the 2004 Final
Phase II rule for existing facilities, litigation was
decided in 2007 and that rule was remanded shortly
thereafter and replaced by permit decisions based on
Permit Directors BPJ. That approach is replaced by
this EPA regulatory action.
www.power-eng.com
HOD UV technology installed during full-scale trial at

Plant Bowen Water Research Center. Photo courtesy:
Southern Research Institute
HYDRO-OPTIC
UV Technology for
Boiler Feed Water
Dechlorination
BY BEHRANG PAKZADEH, PH.D., SOUTHERN RESEARCH INSTITUTE;
TRACY UNDERWOOD, GEORGIA POWER; AND MORGAN FRENCH,
SOUTHERN COMPANY GENERATION
oal-fired steam generation power applications typically use

reverse osmosis (RO)
technology to provide
high purity feed water for the boiler
and steam cycle. As an oxidizer in
aqueous solutions, free chlorine generating solutions are commonly injected
into the feed lines of the water treatment process at power plants to reduce
the microbial load. However, RO membrane elements are easily damaged by
strong oxidants and membrane performance warranty terms usually include
specification for the allowable level of
50
free chlorine not to exceed a concentration of 0.1 ppm in feed water to the
membrane unit. In a typical power
plant dechlorination application, the
water treatment facility aims to produce water with undetectable levels of
free chlorine.
RO membrane elements must be
protected from biological fouling
and oxidation in order to minimize
frequent membrane and micronfilter maintenance and replacement.
Therefore, a dechlorination process is
undertaken to remove free chlorine
compounds from the feed water in order for the RO technology and other
chlorine-sensitive equipment to operate properly. Without dechlorination,

the operational impacts of biofouling
on RO technology would include more
frequent membrane element replacement and associated costs, increased
cleaning in place, production loss, increased energy costs and product quality being compromised.
Dechlorination can be achieved
through chemical and non-chemical
treatment approaches. Passing feed
water through activated carbon filters (GAC) is a typical non-chemical
dechlorination approach; however,
it is not a common practice used in
power plant applications. Chemical
neutralization, through the injection
of a sodium bisulfite (SBS) or sodium
metabisulfite (SMBS) solution into
the feed water, is common practice in
power applications. The difficulty of
SBS/SMBS neutralization is that it is a
chemically based approach attempting to balance the chemical feed with
the ever-changing chlorine demand.
Thus, this approach requires additional handling, storage and operational requirements. As an alternative
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All trademarks used herein are trademarks or registered trademarks of Exxon Mobil Corporation or one of its subsidiaries unless otherwise noted.
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Supported by
to conventional methods, ultraviolet

(UV) treatment can be used as a chemical-free dechlorination approach in
boiler feed water applications.
Plant Bowen, a 3,160-megawatt
coal-fired power station, in Cartersville, Georgia faced frequent membrane and micron-filter maintenance
and replacement as a result of bio and
solids-fouling despite their use of a
SMBS dechlorination process. In an effort to address their concerns, the Plant
Bowen Water Research Center (Plant
Bowen WRC) decided to evaluate a dechlorination treatment alternative that
would enable them to replace the use
of sodium metabisulfite, reduce the
usage of chlorination, and achieve a
chemical-free dechlorination process.
During a three-month period, 4
March through 30 May 2014, the Plant
Bowen WRC evaluated the performance of a Hydro-Optic (HOD) UV
water treatment technology, manufactured by Atlantium Technologies, Inc.,
for use as a chemical-free dechlorination approach to improve the overall
quality of RO feed water at the Plant.
UV TECHNOLOGY
UV is a physical process for disinfection that exposes bacteria, viruses and
protozoa to germicidal wavelengths
of UV light, measured as nanometers
(nm), to render them incapable of reproducing or further infecting a water
system. Through UV oxidation, UV
light can also destroy chemical contaminants.
Medium pressure (MP) UV lamps
provide polychromatic UV light (200
- 415nm), while low pressure (LP)
lamps provide monochromatic light
(254nm). The polychromatic nature of
MP lamp technology enables the production of a high-density broad-spectrum UV light that inactivates a greater
number of microorganisms as compared to LP lamp based UV systems.
Additionally, MP lamps can more easily pick up free chlorine; making it the
plastocor,
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53
A Furukawa Company
Your Optical Fiber Solutions Partner
Georgia Powers Plant Bowen location near Cartersville, Ga., is home to a state-of-the-art water
research center dedicated to improving water quality and increasing water efficiency during the
power generation process. As a partnership between Georgia Power, the Electric Power Research
Institute (EPRI) and Southern Research Institute and other companies aligned with the power
generation industry, the water research center tests and explores water-dependent technologies
associated with power generation. Photo courtesy: Plant Bowen Water Research Center
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ideal UV treatment for dechlorination

applications.
The Hydro-Optic UV technology
uses a proprietary MP lamp and effectively recycles a required UV dose
throughout the reaction chamber using a patented internal reflection technology similar to fiber optic science.
The core of the HOD technology is its
water disinfection chamber made of
high-quality quartz surrounded by an
air block instead of traditional stainless steel. This configuration uses fiber optic principles to trap the UV light
photons and recycle their light energy. The photons repeatedly bounce
through the quartz surface back into
the chamber, effectively lengthening
their paths and their opportunities to
inactivate microbes.
Maintaining a correct UV dose
with any UV system is dependent
on three parameters: UV intensity,
water UV transmittance and water
flowrate. Since these parameters are
dynamic and fluctuate, continuous
measurement is required. The HOD

UV system measures these critical data
points in real time to determine the actual UV power produced by each of the
UV lamps and the amount of UV light
available for dechlorination.
Proprietary software enables the
reactor to self-adjust and manage a
safety zone so the HOD unit continuously provides the minimum dose
or registers and reports off-spec status
when any of the critical parameters affecting UV dose fluctuate outside of
the safety zone.
EVALUATION STUDY
Atlantium Technologies, Inc. provided three RZ300-13 HOD UV systems to the Plant Bowen WRC for
the full-scale demonstration study to
achieve dechlorination on feed water with a free chlorine concentration
of 0.5 ppm. The units accommodated
a flowrate varying from 340 to 680
gpm (77 to 154 m 3/hr) with 95 percent
UV transmittance. The UV units were

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installed in series on existing stainless steel piping after

the media filters and before the micro and the RO train.
Operational parameters as well as dechlorination and
bacteria removal efficiencies of the HOD UV technology
were evaluated. To evaluate the effectiveness of HOD UV
technology at removing chlorine, free and total chlorine
levels were monitored at four sampling points. Oxidation
reduction potential (ORP) values of the RO feed water
were continuously monitored during the trial as well.
Generally, positive ORP values indicate oxidizing conditions while negative ORP values indicate reducing conditions.
During the study, HOD UV operational parameters
continuously monitored included:
The water flow in the pipegpm (m3/h) through a signal received from a flow meter.
The actual UV output of each lamp as measured by
the UV units sensor, one per lamp.
The UV Transmittance (UVT- percent) of the water
as measured by the UV units embedded UVT sensor
(two per unit).
The UV units delivered dose (mJ/cm2) as calculated
by the units controller (colored display touch screen)
based water flowrate, the actual output of each lamp
and the UVT of the water.
The water temperature (F or C) as measured from
the UV dedicated temperature sensor.
During the study several operational modes were also
tested and included 100 percent power of all three systems, 90 percent power of all three systems and 90 percent power of two systems with no power to the third.
STUDY RESULTS
The HOD UV systems yielded a Post-UV total chlorine
ranging between non-detectable and 0.11 ppm and free
chlorine was non-detectable (<0.05 ppm) when processing boiler feed water with an average inlet value of 0.3
ppm total chlorine and 0.2 ppm free chlorine. These values indicate the HOD UV technology effectively removed
chlorine. The Post-UV ORP values fluctuated between
277 mV and 368 mV with an average value of 316 mV. The
Pre-RO ORP values varied between 197 mV and 444 mV
with an average value of 326 mV, which was acceptable for
plant operations.
At equipment startup, the SMBS feed was reduced from
5 gpd (19 Liter per day) on 4 March 2014 to 0 gpd (0 Liter
per day) on 20 March 2014. After reducing the SMBS feed
rate to zero (or near zero) the water was strictly dechlorinated by HOD UV and the results were comparable, or
better in certain instances, than chemical dechlorination.
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The HOD UV technology was also effective at controlling bacteria growth.

The Post-UV heterotrophic plate
counts were comparable with those in
Pre-UV chlorinated waters.
Results from the full-scale demonstration testing of the Atlantium UV
system confirm the efficacy of UV as
a treatment technology option suitable for dechlorination. Whats unique

about the Hydro-Optic treatment approach is its ability to disinfect and
dechlorinate in a single, chemical-free
process, said Richard Breckenridge,
EPRI Water Management Technology
Program Manager.
At the conclusion of the evaluation

period, results showed the HOD UV
system to consistently meet or exceed
treatment objectives. The HOD UV
technology effectively removed free
and total chlorine from boiler feed
water to undetectable levels from inlet
free and total chlorine levels above 1
ppm. Bacteria levels were also reduced
to low acceptable levels.
CONCLUSION
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Following the successful full-scale

demonstration of the HOD UV technology, the Plant Bowen WRC is finalizing the justification necessary to
incorporate the system into full-scale
operations at the plant. Based on the
savings in chemical elimination, benefits of reduced CIP, extended life of
the membranes, and reduced organic
loading leading to fewer regeneration
cycles of the demineralizers, the HOD
UV technology will be a favorable addition to dechlorination treatment efforts at Plant Bowen WRC.
The HOD system decomposes the
free chlorine oxidant in process water
to protect RO membranes. Additionally, the HOD technology provides
disinfection to reduce the membrane
biofouling potential by eliminating anaerobic and aerobic bacterial
growth.
Power plant applications looking
to replace the use of SBS/SMBS and
achieve a chemical-free dechlorination
process may benefit from a physical
process such as the HOD UV technology. UV treatment allows for a dechlorination treatment approach with the
potential to eliminate the handling,
storage and operational requirements
of chemical disinfection solutions.
The efficacy of the HOD UV technology, coupled with its specific operating principles and ease of use, allows
for a unique chemical-free approach to
dechlorinate and disinfect boiler feed
water.
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Author:
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distribution and standalone powergeneration equipment in the U.S. and
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HIPOWER SYSTEMS
Custom Natural Gas
Generator.
Whats Fueling
the Fire?
The Growing Market for

Natural Gas Generators and Engines
BY RAFAEL R. ACOSTA, HIPOWER SYSTEMS
he growing popularity of
natural gas as a fuel source
is no secret to most power
industry
professionals,
given that natural gas has
at least partially replaced oil and coal in
power plants across the nation. However,
natural gas is becoming an increasingly
popular fuel for industrial and commercial generators (gensets) as well. A 2013
report from Pike Research asserts that the
market for natural gas generators will rise
to nearly $10 billion by 2018.
Rising diesel costs, coupled with a corresponding drop in natural gas prices, are
often cited as a reason for the increased
interest in natural gas engines and
gensets. As is often the case with market
changes, the growth of the natural gas
engine and genset markets is far more
complex than that. Myriad factors, from
regulatory and environmental compliance pressures to new developments in
genset and engine features, are driving
60
demand and compelling commercial and

industrial facilities to power their generators with natural gas.
A QUICK HISTORY
It seems logical that growth in the natural gas generator market would be paralleled by growth in the market for natural
gas. Statistics from the U.S. Energy Information Administration (EIA) appear to
support this assumption. Petroleum is
still king in the United States, but since
2006 its use has been in decline. As of
2012, natural gas constitutes 27 percent
of total U.S. energy consumption.
However, according to the EIA much
of this consumption occurs in only a few
industriesespecially chemical production. The need for feedstock in this industry, specifically in ammonia-based fertilizer and methanol plants, is the key driver
of industrial natural gas consumption.
(Natural gas liquids are steam-cracked
in chemical production. These plants are
the most natural-gas-intensive industrial

end users.) Furthermore, the EIA has predicted that natural gas consumption in
the residential and commercial sectors
may drop between now and 2015 before
rising again. Yet, natural gas generators
will continue to explode in popularity.
This creates an interesting conundrum. Given that the primary use of gas
in chemical plants isnt to power gensets,
and that commercial customers arent
using as much gas, what is behind the
expansion of the natural gas generator
market? A deeper dive into the current
environment will demonstrate what is
fueling this growth.
BYPRODUCT GAS FINDS

A HOME ON THE RANGE
One of the primary areas showing substantial interest in natural gas gensets is
oil drilling, where natural gas is a byproduct of oil production. This gas has traditionally been flared off, a process once
recognized as the more environmentally
friendly option, compared to emitting
the gas unburned.
However, with pressure mounting
from state and local regulatory agencies
to reduce CO2 emissions at exploration
and drilling sites, petroleum sector companies are seeking better alternatives. In
North Dakota for example, new flaring
standards require that drillers must capture 90 percent of all byproduct gas by
2020. To reach this figure, requirements
are being phased in beginning immediately. As of October 2014, the required
capture percentage has risen to 74 percent.
Capturing rather than flaring gas
makes economic sense, even with natural gas prices so low. In the Bakken alone,
drillers burn off more than 350 million
cubic feet of natural gas each day, more
than $100 million worth each month.
Not only are environmentalists upset
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GS6
50Hz
Output
O
utput
(kW)
RPM
(min-1)

CHP
CHP
315
60Hz
300
GS6R-PTK
GS6
50Hz
320
60Hz
305
KU30GSI
KU30GS
KU3
0GSII Series
Series
Seri
es
GS12R-PTK
GS 2R-PTK
GS1
GS16R-PTK
GS 6RGS1
6 PTK
50Hz
60Hz
60Hz
50Hz
GS16R2-PTK
GS 6R2
GS1
6 -PTK
50Hz
60Hz
12KU30GSI
60Hz
700
610
930
815
1500
1000
12000
1000 1200 1500 1200 1500
1200
1500 1200
1500
1200
12000

75.4
75 4 78.0
78 0 75.3
75 3 76.0
76 0 74.5
74 5 76.5
76 5 74.1
74 1 76.0
76 0 74.4
74 4

74.8
74 8

75.1
75 1
50Hz
60Hz
14KU30GSI
50Hz
16KU30GSI
60Hz
50Hz
60Hz
18KU30GSI
60Hz
50Hz
Output
3800 3650 4450 4250 5100 4900 5750 55000
(kW)
(kW)
RPM
RPM
750
720
750
720
750
720
750
7200
(min
(m
min-1)

min. 8855 min
min.
min.. 8855 min.
min. 8855 min
min.. 8855 min.
min. 8855 min
min.. 85
85 min.
min. 85
85 min
min.. 85
85
CHP
HP
Two Pierce Place 11th Floor

Itasca, IL 60143
630-268-0750
salesinfo@Mitsubishi-engine.com
about this, but mineral rights holders

arent pleased either. Most oil producers
are ramping up to sell this gas, but processing and transportation beyond a local
market can make such a solution complicated and expensive to implement.
Savvy producers are exploring every
possible avenue for using this gas efficiently, with one logical solution being
to replace older, inefficient diesel generators with natural gas units. These gensets
can burn properly treated byproduct (e.g.
well-head) gas to drive oil well pump
jacks, power man-camps and other buildings, and meet additional electrical needs
close to the well site. In making these upgrades, producers gain productive use of
more byproduct fuel locally, and acquire
more efficient, feature-laden generators at
the same time.
Of course, well head gas must be
analyzed and cleaned before it can be
burned safely in a generator, and this
can present an additional complication.
62
Satellite Image of
Flaring in North Dakota
This usually happens in a multi-stage

process of conditioning (removing impurities) and polishing (removing water
and condensate). However, a handful
of manufacturers, including HIPOWER
SYSTEMS, make generators that can
burn raw gas directly out of the wellhead. Gensets such as these provide
natural gas producers with even better
value from their natural gas generator
purchases.
MANAGING THE
GREENHOUSE
Another factor driving the market for
natural gas gensets and engines is the
intense focus on reducing greenhouse
gas emissions. The most well-publicized
benefit in this area relates to the use of
natural gas as a replacement for coal and
petroleum, especially in power plants.
In 2011, total U.S. CO2 emissions were
down by nearly nine percent from peak
www.power-eng.com
levels of 6,020 million metric tons in

2007, an improvement largely attributed
to the substitution of natural gas for coal
and petroleum in power plants.
However, the lower environmental
price tag of natural gas is also spurring
sales of gensets and engines that burn
this fuel. In a fitting twist of fate, natural
gas gensets are becoming key players in
the success of alternative power producers such as wind farms. Not only do generators often power some of the equipment on remote wind farms, but they
also provide power-supply continuity for
these intermittent power sources.
In another area, natural gas engines are
playing a role in expanding the feasibility
of combined heat and power (CHP) systems. These cogeneration systems, which
produce energy not only from the power
source itself but also from the heat which
that source emits, are expected to be a
major contributor to the reduction of
CO2 emissions in the United States. CHP
systems can operate at efficiency levels
as high as 80 percent, a marked improvement over conventional power supplies,
which operate at only about 45 percent.
Per a joint report from the U.S.
Department of Energy and the Environmental Protection Agency, CHP
systems are poised to cost-effectively
satisfy a significant portion of the
growing U.S. electricity requirements
while continuing to meet the countrys
thermal demands. Currently, CHP
makes up about eight percent (82 GW)
of total U.S. generating capacity, but
the Obama administration has set an
official goal of upping that capacity to
122 GW (a 40 GW increase) by 2020.
One of the keys to achieving this goal
is broader adoption of CHP systems, especially in commercial and industrial
buildings, as opposed to their current
use predominantly in power plants.
New developments in the latest generation of natural gas reciprocating engines
are making these systems cost effective
down to 50 KW, which analysts expect to
be a major driver of increased adoption.
www.power-eng.com
THE LITTLE ENGINE

THAT COULD
Another dynamic accelerating the
popularity of natural gas generators
is the extraordinary amount of function and technology that can now fit
into a fairly small and portable package. Thanks to miniaturization and
more efficient designs for engines,
components, and enclosures, it is now
possible to find fully self-contained,
enclosed natural gas generators, complete with built-in transformers and

power distribution panels, with working power ratings of several MW.
Some of these units are stationary and
must be lifted by crane to be transported
from one location to another. However,
using a truck-type chassis, it is possible to
manufacture units that can be towed by a
sufficiently powerful vehicle. These units
can have working power ratings of more
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Annual Share of Fossil-Fired Electric

Power Generation, 1950-2012*
Less coal,
more petroleum
Less petroleum,
more natural gas
Less coal, more

natural gas
90
80
70
Coal
60
50
40
30
Natural gas
20
10
Petroleum
0
1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010
Low oil prices during 1960s, combined
with smog concerns, spur new additions
to petroleum-fred capacity.
POWER ON DEMAND
Between the increase in disruptive
weather events and the vulnerability of
the power grid (with projected upgrade
costs reaching $2 trillion), there has
also been a measurable increase in sales
of permanent standby generators; the
choice of fuel for these generators is often natural gas. In many cases, these are
Less petroleum,
more coal
100
Percent
than 2 MW.
Even more impressive is the size of
these self-contained packages. Excluding
the wheeled chassis, an enclosed generator in the 350KW size range might measure no more than 13 by seven feet, yet
be equipped with 110-percent spill containment, exterior power distribution
panels with receptacles and Cam-Loks,
and other popular features. Sub-base fuel
tanks can make the entire power generation package even more compact. In urban environments, when delivery down
narrow roads is a factor, or in any situation where space is at a premium, having
so much power in such a small package
is a benefit.
Rapidly-rising oil prices lead many

generators to switch oil-fred peaking
capacity to natural gas.
Oil price shocks during 1970s lead

to increased utilization of coal-fred
capacity for baseload generation.
Historically low natural gas prices lead

to increased utilization of combined-cycle
plants at expense of coal units.
*2012 refects Jan to Apr data

Source: EIA
not small units previously popular for

powering emergency exit lights and other
limited power needs. Rather, industrial
and commercial enterprises in all locations are opting for units that can power
their entire operations for hours or even
64
www.power-eng.com
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Annual Awards Gala

Youre invited
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MONDAY, DEC. 8, 2014
Honoring excellence in design, contraction and engineering of power generation facilities worldwide.
2014Projects of the Year winners will be announced at the Annual Awards Gala during Power Generation
Week 2014 in Orlando, Florida. Register for your seat at this exclusive awards gala, Monday, December 8.
Register online at www.power-gen.com.
Awards will be given in the following categories:
Best Coal-fred Project

Best Gas-fred Project
Best Nuclear Project
Owned &
Produced by:
Best Renewable Project

Cleanest Coal Projects
Presented by:
Papers of the Year

Woman of the Year
Sponsored by:
days. Choosing natural gas units not only

makes greater economic sense than ever
before, it also enables urban purchasers
to more easily meet regulatory and other
requirements when applicable, and to
take advantage of existing pipeline supply channels.
HIPOWER SYSTEMS noticed that
Hurricane Katrina generated some interest in these units, but Superstorm Sandy
was really the wake-up call. If a city as
modern and well-run as New York can
be significantly impacted by storm-related power outages, everyone is at risk.
Natural gas generators became particularly enticing after this event, because the
damage and flooding were so widespread

that tankers and trucks could not deliver
diesel fuel to locations with standby generators. Had the owners of those generators installed natural gas units instead,
their pipeline supply would likely not
have been affected.
Furthermore, both industrial and commercial companies are becoming much
more cognizant of the demand-based
benefitsincluding peak shaving
of standby generators. Today, net-zero
power generation is a possibility in many
areas, and using inexpensive natural gas
as the fuel source increases the financial
benefit all the more.
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Diesel generators and engines are

not going away anytime soon. For
many industries and applications, they
are still a practical solution. However,
theres no doubt that natural gas generators and engines are more appealing
than ever. The supply of domesticallyproduced natural gas is steadily increasing, and prices are dropping correspondingly. This is due in part to the
exploration of unconventional sources
of gas like coal beds, tight sandstone,
and shale formations. Because of this,
natural-gas powered generators hold a
lot of promise for many applications.
Furthermore, companies in all sectors are seeking ways to improve their
environmental record for public relations reasons, if not regulatory ones.
According to a March 2012 Nielsen report, The Global, Socially Conscious
Consumer, 64 percent of North American customers say they prefer to buy
products and services from firms that
give back to society. Among the socially conscious solutions they wanted
their companies to embrace, environmental improvements were the number one choice. When organizations
use natural gas engines and gensets to
meet their distributed power needs,
they can rightly claim that they are
cleaning up their acts.
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Author:
Michael Corvese is director of Business
Development for Environmental and
Process Monitoring at Thermo Fisher
Scientific.
A wide variety of monitoring technologies exist that help

EGUs comply with the Mercury Air and Toxics Standard
(MATS). Facilities working toward MATS compliance will need
several different monitoring instruments in operation by
April 2015. Typically, it is necessary to install one monitoring
instrument for each regulated element or compound emitted.
Photo courtesy: Thermo Fisher Scientific
MATS Compliance:
The Countdown
to 2015
BY MICHAEL CORVESE,
THERMO FISHER SCIENTIFIC
he U.S. Environmental Protection Agencys

(EPA) Mercury and Air
Toxic Standards (MATS)
rule has been in place for
new coal-fired electric generating units
(EGUs) since 2012, but the regulation has
yet to take effect for existing units. Existing EGUs and their management teams
were allotted additional time (including
an option to apply for an extension with
their state agency if necessary) to define
their strategy and decide whether retrofitting or retiring existing facilities would
make the most business sense for them.
We are only five months from the April
2015 deadline for MATS compliance
and while many EGUs already have comprehensive plans in place, a surprising
amount do not.
68
Meeting the compliance deadline takes

significant planning and preparation; the
closer EGUs get to April 2015, the more
difficult (and costly) it becomes to have
all the necessary pieces in order on time.
This is especially true if the decision is
made to retrofit an existing facility, as the
EGU must then begin managing outside
vendors and ensuring that all equipment
is in place to meet the new requirements.
April 2015 is rapidly approaching, and
that puts EGUs under significant pressure
to develop and begin executing a compliance plan.
Vendor schedules will continue to fill
up as the deadline approaches, and that
means more and more options will become unavailable. The later the decision
to upgrade an EGU is made, the more
limited and hasty the decision-making
process becomes. While this isnt necessarily problematic, it is generally true that
decisions made under pressure deliver
worse outcomes than those planned well
in advance. Making compliance decisions
early gives plants the opportunity to
thoroughly explore all options available
to them and formulate a knowledgeable,
achievable plan.
Every EGU is different, so the decision
to upgrade or retire a facility in response
to MATS must incorporate all relevant
factors. Decision-makers must consider
state-level regulations, taxes, the condition of the facility and more. While MATS
will certainly make operating older coalfired EGUs more difficult at least in the
short term it is important that plant
operators understand that technology
exists that can help limit the disruption
caused by this additional regulatory burden. Without fully understanding existing MATS compliance technologies,
coal-fired EGU operators cannot make
well informed retrofitting or retiring decisions.
EGUs that are considering upgrading
and continuing operation under MATS
should have that MATS technology review completed at this point. If the decision is made to upgrade, the EGU will
need to have a comprehensive plan for
achieving compliance by the April 2015
deadline. For facilities that have yet to formulate their own compliance plan, these
five steps can serve as a broad outline for
developing one.
STEP 1:
RULE INTERPRETATION
MATS will affect every EGU in a
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slightly different way depending on the

configuration of the plant. Some facilities will already have certain monitoring equipment installed, while others
will have to start from a more rudimentary stage. Most EGUs will need a combination of both emissions control and
emissions monitoring technologies to
meet the MATS requirements. Emissions
control equipment may include flue gas
desulfurization (FGD), activated carbon
injection (ACI), and dry sorbent injection
(DSI); necessary emissions monitoring
technologies for MATS compliance include mercury (Hg) monitors, hydrogen
chloride (HCl) monitors, sulfur dioxide
(SO2) analyzers and particulate matter
(PM) monitors.
Some EGUs will already have some of
this equipment installed for another reason, such as compliance with an existing
state-level regulation. Facilities preparing
to achieve MATS compliance should take
a comprehensive audit of their existing

emissions control and monitoring equipment in order to identify how and where
new technology is most needed. This will
also provide a useful starting point for
discussions with instrument manufacturers; most of them will have significant
experience helping EGUs achieve MATS
compliance, and additional information
on a facilitys unique compliance challenges will help them formulate more effective recommendations. This increases
efficiency and improves results for both
parties.
STEP 2:
INSTRUMENT SELECTION
& DAHS INTEGRATION
A wide variety of monitoring technologies exist that help EGUs comply with
MATS. Facilities working toward MATS
compliance will need several different
monitoring instruments in operation by
April 2015. Typically, it is necessary to install one monitoring instrument for each
regulated element or compound emitted.
Mercury (Hg)
Many facilities already have existing
mercury monitoring systems, most of
which were installed in response to the
Clean Air Mercury Rule (CAMR). After
CAMR was vacated in 2009, a number
of these EGUs continued to operate their
systems to meet the requirements of state
and local agencies.
EGUs that do not already have a mercury monitoring system have many elements to consider. One example is the
instruments ability to measure different
types of mercury. An instrument being
used to achieve MATS compliance should
be able to measure elemental, ionic and
total mercury output. One technology
that offers this capability is Cold Vapor
Atomic Fluorescence (CVAF).
CVAF systems work by bombarding
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ON DEMAND
NEW METHODS FOR BOLTING SAFETY
gases leaving the stack with ultraviolet

light and measuring the response of the
mercury within the gas. While older systems were hobbled by their need for expensive carrier gases (such as argon), gold
amalgam traps and a source of distilled
water, modern CVAF systems use direct
measurement methods to capture mercury from the ambient air for analysis. In
addition to reducing the need for expensive equipment and consumables, direct
measurement also offer more reliable and
continuous measurement.
Hydrogen Chloride (HCl) and/or
sulfur dioxide (SO2)
The levels of these two compounds
have a fixed ratio in most facilities, which
means that the vast majority of coal-fired
EGUs will not need to measure both of
them to achieve MATS compliance instead, they can simply use the level of one
to determine the level of the other. This
means that deciding which compound
to measure is a critical part of any MATS

compliance plan.
Facilities that decide to monitor HCl
have a number of options available. One
of the most reliable techniques for this
application is Fourier transform infrared
(FTIR), which uses infrared light to measure the molecular contents of stack gas.
FTIR continuous emissions monitoring
systems (CEMS) are capable of measuring up to 10 stack emission components
including HCl simultaneously.
EGUs that choose to measure SO2 also
have several different options. One of
the most highly recommended is pulsed
fluorescence technology, which measures
SO2 content in stack gas using pluses of
ultraviolet light. This technique can accurately measure concentrations of SO2 as
low as 50 parts per trillion (ppt).
Particulate Matter (PM)
MATS also requires facilities to measure and report their PM output. For
existing EGUs complying with MATS,

PM measurements act as a surrogate for
all toxic metal emissions. In some cases,
certain subcategories of EGUs can use
alternative measurements to PM, such as
total non-mercury metal air toxics. However, the vast majority of facilities will
find that PM measurement is the most
effective option for MATS compliance.
EGUs that believe that they may have
other applicable measurement options
should fully explore them during the
Rule Interpretation step.
The most common PM monitoring
technologies include light-scattering,
beta attenuation, light extinction (essentially a measurement of opacity) and inertial microbalance. Because beta attenuation uses emissions from radioactive
materials to measure the contents of a
stack, it is typically only recommended in
cases where no other analysis techniques
are possible. Introducing radioactive
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materials adds an additional level of regulatory complication that is rarely worthwhile for this application.
One of the best solutions is to combine both light-scattering and inertial
microbalance into one measurement
instrument. Light-scattering is a precise
continuous monitoring technique, but it
is also prone to decalibration over time.
Inertial microbalance is a much less driftprone technique, but it cannot perform
continuous measurement like light-scattering can.
DAHS Integration
Once all the necessary monitoring instruments have been chosen, work must
be done to ensure that the collected compliance data is compatible with all existing plant systems. Most importantly, all
instruments must be integrated with
the plants existing data acquisition and
handling system (DAHS). Successful
integration usually requires bringing in
the plants DAHS provider to manage
the process and confirm that the newly

modified system is able to meet all statespecific DAHS requirements. Starting the
process early allows EGUs to give themselves the necessary time to deal with any
unexpected issues that may come up in
the DAHS integration process. This extra
time is especially critical when several
new instruments are being brought online for MATS compliance, as each one
must be fully integrated and functioning
reliably before the compliance deadline.
STEP 3:
SITE PREPARATION
MATS compliance requires significant investment in new instrumentation, and installing all that new
equipment can be disruptive to plant
operations if it isnt planned around.
A rushed compliance process increases
the chances that these disruptions will
occur. Problems with MATS compliance preparations can lead to cost and
time overruns which, if they are severe

enough, can derail the entire process.
To avoid these complications, EGUs
must create a detailed site preparation
and equipment installation plan. This
plan should include at least four months
for instrument delivery and installation.
Additionally, time should be budgeted
for required physical plant upgrades,
which can include everything from new
communications and electrical lines to
construction of equipment shelters and
changes to plant air systems.
Installation operations get even more
complicated the farther up the stack they
go. Instrumentation being installed in
the stacks annular space can cause additional logistical challenges. Because of
space limitations, existing instruments in
the annular space may have to be moved
to accommodate new measurement
equipment. Ensuring that instruments
high up the stack get the proper voltage and amperage needed for safe and
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reliable operation can also be a challenge.

Planning for RATA
Site preparation plans should also include some basic preparations for the
facilitys first MATS relative accuracy test
audit (RATA). All EGUs subject to MATS
will have to undergo at least one RATA
per fiscal year for each installed monitoring instrument. Mercury monitors, for
example, must demonstrate performance
accuracy within 20 percent of the reference instruments reading to pass a MATS
RATA. If the monitor fails, all data from
the system are considered invalid by the
EPA until the problem is fixed.
Preparing for a RATA is stressful, as is
scheduling one. The U.S. currently has
a limited number of stack testers, so appointments must be scheduled far in advance. EGUs that plan ahead for MATS
compliance will have an easier time setting a meeting with a RATA tester, and
can even have time to perform some internal testing before their first RATA.
STEP 4:
SERVICE, SERVICE, SERVICE
Coal-fired EGUs have very strict data

availability requirements under MATS,
so it is critical to ensure that everything
is ready to go by April. This includes
maintenance schedules; calibration and
planned maintenance do count against
a facilitys data availability statistics, so
limiting unplanned maintenance and
other downtime also reduces blank spots
on the monitoring record. All monitoring
instruments require regular servicing,
including diagnostic checks, calibrations
and adjustments; the more this service
can be preplanned the better.
In addition to onsite maintenance,
some instruments are also capable of
being remotely serviced by their manufacturer. To facilitate this process,
EGUs should also plan to have a data
link set up during installation. Setting up remote access with the manufacturer in advance of the compliance
deadline can save significant time, effort and cost down the road.
STEP 5:
PRODUCTIVE, COMPLIANT
EGU
Achieving compliance with MATS is
not the easiest or most pleasant part of
operating an EGU. However, it will soon
be necessary for all facilities, old and new:
April 2015 is only a half-year away. In six
months, retrofitted old facilities will have
to comply with MATS.
Demonstrating MATS compliance is
a burden on businesses, but it only becomes more difficult when a facility is not
adequately prepared.
Beginning the compliance process as
early as possible makes meeting the deadline much easier. The countdown to April
2015 is already well underway, and EGUs
that dont already have a formal compliance plan in place should start formulating one now.
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Author
S. Korellis is a Project Manager at EPRI.
The Jeffrey Energy Center, a 1,857-MW coal-fired

power plant in St. Marys, Kansas. For coal-fired
power plants, fuel is the largest expense. A 1-percent heat-rate reduction will save about $700,000
in annual fuel costs, according to the Electric Power
Research Institute.
Range And
Applicability
Of Heat Rate
Improvements
BY S. KORELLIS, ELECTRIC POWER RESEARCH INSTITUTE
power plants heat rate

measures the input of
heat energy into the plant,
relative to the output of
electrical energy from
that plant.
More specifically, heat rate compares
the amount of heat in Btus required to
generate 1 kilowatt-hour (kWh) of electricity. Accordingly, typical units for heat
74
rate are Btu/kWh. Heat rate is also the inverse of plant efficiency. As such, a lower
heat rate is better than a higher one.
A power plants heat rate depends on
its design, its operating conditions, and
its level of electric power output. For existing coal-fired power plants, heat rates
are typically in the range of 9,00011,000
Btu/kWh. A plant with the industry average heat rate of 10,300 Btu/kwh will
operate with an overall plant efficiency

of about 33 percent.
BENEFITS OF
LOWERING HEAT RATE
For a coal-fired plant, fuel is by far
the largest expense item, amounting
to about 55 to 75 percent of total plant
costs. Coal costs $1.50 2.00 per million Btu, or about $30 a ton, and a typical coal plant consumes about 6,000
tons per day. The heat content of coal
ranges from of 8,000 to 12,000 Btu/lb.
Accordingly, reducing a power plants
heat rate can significantly lower fuel
consumption and expense. At a typical
500 megawatt (MW) plant operating
at 80 percent capacity factor and firing
$2.00/MBtu bituminous coal, a 1-percent heat rate reduction will save about
$700,000 in annual fuel costs.
Improvements in heat rate are also
the first step in reducing carbon dioxide (CO2) and other emissions.
Heat rate reductions are commercially
proven to be the most cost-effective
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HISTORICAL HEAT RATES

Since the mid-1960s, the average heat rates of fossil-fueled electric
power plants in the United States have
gradually increased. Several factors
have contributed to this slow degradation in unit performance. First was
the introduction of nuclear generating
units to provide an increasing share
of baseload generation, along with
the anticipation of a large expanding
nuclear construction program into the
future. With these low-cost generating
units forecast to provide a large fraction of the baseload capacity, utilities
devoted less attention to the maintenance and upkeep of their older fossil
stations in anticipation of their retirements in the 1970s and 1980s.
This trend was exacerbated as nuclear construction costs escalated, reducing the funds available for maintaining fossil station performance, as well
as diverting the attention of utility upper management from the operation of
these stations. For those utilities that
brought nuclear units online, many
of the fossil plants that formerly comprised their systems baseload capacity were changed to cycling duty. The
thermal inefficiencies associated with
start-ups, shut-downs, and swings in
76
load, as well as extended periods of retrofitting air emission control equipoperation at less than full power, re- ment, and the normal degradation assulted in increased heat rates for these sociated with aging units. This latter
units. Generating units are designed concern continues today, as units are
and built to achieve their best heat operated with more rigorous emission
rates when operated in steady state at controls, beyond their expected opfull load.
erating lifetimes, and on increasingly
Additionally, environmental regula- flexible schedules.
tions were enacted that forced many
With all these elements working
utilities to retrofit energy-consuming, against heat rate improvements, curpollution-control
1
Plant Heat Rate Changes
equipment such
as Flue Gas De400
sulfurization
300
(FGD) systems.
200
The addition of
100
such controls had
0
many deleterious
-100
effects,
includ-200
ing increase in
-300
auxiliary power
-400
consumption and
-500
decrease in boiler
-600
efficiency.
This
A
B
C
D
E
adverse
trend
PLANT
started with the
required addition
of electro-static precipitators (ESPs) rent estimates suggest efficiencies at
to remove particulate matter from the many existing coal-fired power plants
flue gas prior to exhausting it out the have dropped by several percentage
stack. These new ESPs increased the points. Some of this efficiency might
consumption of auxiliary power and be recoverable, provided that the corcreated a pressure drop, forcing fans to rect processes, procedures, and rework harder.
sources are applied and maintained.
Simultaneously, the use of fuels like
Powder River Basin (PRB) with higher CAPITAL AND
moisture contents contributed to a re- MAINTENANCE PROJECTS
duction in unit performance.
In 2008-2009, EPRI developed a
Most recently, the proliferation of re- methodology to assess the costs and
newable and gas generation has, along benefits of potential maintenance imwith economic factors, resulted in a provements to coal-fired power plants,
need for more flexible operation of the and refined this methodology to asexisting coal-fired fleet, necessitating sess the net annual benefit of potential
more frequent cycling and lower turn- capital improvements to these plants.
down, which has a substantial negaThe assessment methodologies were
tive effect on plant heat rates.
then applied to a hypothetical 500The challenge of improving fos- MW plant to calculate the potential
sil plant heat rates in the 1980s was benefits of capital improvements and
made more difficult by declining coal maintenance projects, including heat
quality, the penalties associated with rate reduction benefits, reductions
Btu/kWh
and immediate process for controlling

CO2. A 1 percent heat rate reduction
corresponds to a 1 percent reduction
in CO2 emissionsabout 40,000 tons/
yearwhich could amount to significant savings if new regulations permit
trading of CO2 credits or impose fees
on CO2 emissions.
Heat rate reductions will also result
in decreases in other emissions, such
as nitrogen oxides (NOx), sulfur dioxide (SO2), particulates, and mercury.
These reductions can help plants meet
other compliance requirements, and
in some cases, the benefit of emissions
reduction may exceed the value of fuel
savings.
www.power-eng.com
in auxiliary load, capacity increases,

equivalent forced outage rate (EFOR)
improvements, and emissions benefits. The calculations were captured
in two spreadsheetsone for capital
projects and the other for maintenance
projects. Inputs could be modified
according to plant-specific circumstances, thus making it possible for
individual utilities to use the methodology for scoping studies.

The
magnitude of the actual heat rate improvements are site specific, as are the
drivers and economic benefits.
METHODOLOGIES
The assessment methodologies followed a six-step approach that divided
the effort into logical steps designed

to ensure a reasonably comprehensive
and technically accurate analysis.
1. Identify major systems in a typical plant.
2. Identify typical or potential projects for each system.
3. Obtain input data and values (e.g.
costs and heat rate improvement).
4. Characterize typical or potential
projects for each system.
5. Summarize uncertainty and potential findings.
6. Conduct a reasonability check of
results and input data.
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The report contained spreadsheets

listing 32 capital projects. For each
project, the spreadsheets identify the
estimated capital cost, added O&M
cost per year, heat rate reduction (percent and Btu/kWh), estimated auxiliary
load benefit, capacity increase, EFOR
improvement benefit, heat rate benefit,
emissions benefit, added power sales
benefits, and net annual benefit. At the
time the project was completed and the
report written, the emissions benefit
related only to NOx and SO2, but the
equations could easily be adapted to include CO2 and mercury.
The report could benefit multiple
projects including: turbine steam seal
upgrades, turbine section replacements, intelligent soot-blowing systems, automated boiler drains, coaldrying systems, air heater baskets, and
combustion optimization. The results
represent a wide range. Not all projects
generated net benefits with a positive
payback. Heat rate reductions ranged
from 0.10 to 2.50 percent. The spreadsheets can be used by plant engineers
and planners to develop realistic cases
for making specific capital investments.
MAINTENANCE PROJECTS
The report also contained spreadsheets listing 25 maintenance projects and practices. For each entry, the
spreadsheets identify the estimated
www.power-eng.com

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initial maintenance cost, additional with estimated improvements.

O&M costs per year, heat rate reducThe plant participants were not altion (percent and Btu/kWh), estimated ways able to implement all recomauxiliary load benefit, capacity in- mendations and often had their own
crease, EFOR improvement benefit, initiatives for outage work that reheat rate benefit, emissions benefit, sulted in decreased heat rate. Perforadded power sales benefits, mainte- mance improvements were significant
nance annual benefit-cost ratio, useful and ranged from 3 to 5 percent. This
life, and payback in years.
level represents an equal percentage
Example projects included: replac- of each plants annual fuel bill and
ing feed pump turbine steam seals, re- demonstrates that making heat rate an
pairing steam and water leaks, boiler integral part of maintenance and opchemical cleaning, repairing boiler air erations activities can yield real and
in-leakage, cleaning air preheater coils, lasting financial savings, as well as a
repairing condensate pumps, and re- significant reduction in CO2 and other
pairing flue gas desulfurization (FGD) emissions.
systems. The results were wide-rangThe five coal-fired units had net caing. Heat rate reductions
Typical Fuel Savings for 5-Percent
spanned from 0.03 to 1.50
percent.
Heat Rate Improvement
HEAT RATE
IMPROVEMENTS
AT FIVE SITES
$1.50 / MMBtu
$2.00 / MMBtu
The
EPRI
Produc6
tion Cost Optimization
5
(PCO) project assisted
4
participating members in
implementing or enhanc3
ing heat rate optimiza2
tion programs to reduce
1
production costs through
sustainable performance
0
improvements.
The PCO assessment
process consisted of benchmarking
plant thermal performance using historical plant data to identify potential
areas for performance improvement.
In some instances a significant heat
rate improvement was achieved with a
recommitment to best operating practices, and without the need for capital
expenditures on new technology.
Unit heat rate improved at four of the
five plants in the time between their
initial and follow-up assessments.
While most plants had estimates of the
improvement expected with the actions taken, it was not always possible
to reconcile observed improvements
$2.50 / MMBtu
Millions of Dollars
Driven by
300 MW
500 MW
800 MW
pacities ranging from 95 to 650 MW.

The service ages of the plants ranged
from 30 to 55 years. The units represented the variation in design, configuration, fuel supply, and vendors
observed in plants throughout the US.
COMMON ISSUES
In the five plants that completed
analyses and reports, the common issues included:
Combustion problems and high air
heater/stack exit gas temperatures
Limited heat rate information
availability
Need for training to raise heat rate
www.power-eng.com
awareness, including understanding controllable losses

Need for unit and equipment performance testing
Feedwater heater train performance problems
Need for sootblowing optimization
COMMON
RECOMMENDATIONS
The
following
recommendations were common to the
five units covered by follow-up
analyses:
Provide heat rate awareness
training to operations staff that
is focused on the basics of heat rate,
the cost of heat rate deviations, and
actionable heat rate information for
operations.
Make heat rate information
readily available to more plant
personnel. Sharing heat rate-related information with a broader segment of plant personnel can result in
earlier identification and resolution
of heat rate problems. Incorporating
thinking about heat rate into dayto-day operational decisions can reduce overall plant heat rate.
Improve utilization of controllable losses information by
operations staff. Incentivize operations staff to monitor and minimize controllable losses. Keep targets achievable within constraints
of equipment and operating conditions. This may require sites to
enhance, upgrade, or initiate realtime controllable losses displays.
Optimize sootblower operation.
This can help to improve steam
temperature control, normalize
heat absorption patterns, and improve precipitator performance.
Additional benefits include reduced air heater/stack exit gas temperatures, decline in circumferential cracking of boiler tubes, and
reduced NOx emissions.
Initiate a routine testing program.
www.power-eng.com
500
2.5
Cost per ton
400
2.0
Projects with a negative cost
per ton of CO2 (blue line is
below the red line) may be
justifed without credit for CO2
1.5
Cumulative tons removed
300
200
1.0
100
0.5
Cost per Ton of CO2 Reduced by Each Project (Blue Line)
Millions of Cumulative Tons of CO2 Removed per Year by All Projects

(Green Bars)
Cumulative CO2 Reduction and Cost per Ton of CO2 Reduced (UE: 10-YR Economic Life)
-100
0.0
1
11
21
31
41
51
61
71 81
Project #
91
101
111 121 131 141 151 161 171
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A periodic testing program should

be established to aid in early detection of changes in equipment performance and/or unit operation to
improve maintenance scheduling
efforts and reduce unscheduled
outages. By utilizing station instrumentation, a reliable and repeatable
trend of unit performance can be
developed.
Increase Feedwater Heater
Performance Monitoring. Heater levels and performance parameters should be monitored on a
daily basis to maintain best performance. The Drain Cooler Approach (DCA) should be checked
to ensure that steam is not entering the drain cooler. If this happens for an extended period of
time, the heater will be damaged,
resulting in tube leaks, off-design

operation, increased maintenance, and higher unit heat rate.
QUANTIFIED BENEFITS
OF IMPLEMENTING
RECOMMENDATIONS
Plant heat rates were trended for onemonth periods during the original PCO
assessment, and then again during the
follow-up assessment. The time elapsed
between the original and follow-up assessments ranged from 20 to 24 months.
Some plants reported expected heat
rate improvements from actions they
had taken, which ranged from 200 to
400 Btu/kWh, or approximately 2 to 4
percent. While it was difficult to correlate specific improvements with measured data, it was clear from the assessments that plant efficiencies improved
significantly at four of the five plants that

completed follow-up assessments. The
magnitude of the heat rate improvements
ranged from 279 to 557 Btu/kWh at or
near fullload operation, as shown in Figure 1. This represents an improvement in
heat rate of approximately 3 to 5 percent.
The results of this project are site specific
and are not universally applicable to all
coal-fired power plants.
FUEL SAVINGS
AND CO2 BENEFITS
With heat rate improvements ranging
from 3 to 5 percent, the results of the
PCO follow-up studies clearly demonstrate that plant heat rate can be favorably
affected by operational and maintenance
activities undertaken by plant owners.
Figure 2 shows the range of equivalent
fuel savings for a 5 percent reduction in
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heat rate at generating units of three different sizes, and factoring for different
levels of fuel costs. The figure demonstrates that these savings are significant.
A five percent improvement in the heat
rate of a 500-MW (net) power plant can
amount to $3.5 million in annual fuel
savings. It can also reduce CO2 emissions
over 180,000 tons annually.
FLEETWIDE ASSESSMENT
AND CASE STUDY
In 2010, EPRI conducted a study with a
member utility to identify power plant efficiency improvements that could reduce
carbon dioxide (CO2) emissions in all 12
coal-fired plants in the fleet.

The project was undertaken to show
how improvements in coal plant energy
efficiency could be used to reduce carbon
dioxide (CO2) emissions. The utility established an internal team to explore its
options for improving coal plant efficiency. The results focused on the amount of
CO2 reduced, as well as on the cost per
ton of that CO2. The estimated cost per
ton of reduced CO2 can be used to determine which projects are viable based on
the price of CO2 credits.
During the study, the project team applied a standardized methodology previously developed for evaluating efficiency
improving projects in a single power
plant.
In this project, the team compiled a
list of feasible efficiency improvement
options and conducted analyses to determine project-specific net annual benefits
in relation to reduction of CO2 emissions. Team members compiled information from various internal sources and
then added more projects from the EPRI
capital projects report. All projects were
listed in a spreadsheet and normalized
to match each unit within their current
operating system.
The study covered only projects for
existing coal-fired power plants. The assumption was made that net plant output remained constant. If the proposed
project happened to increase capacity
along with efficiency, the fuel burn was
reduced to hold net output constant. The
plant could then calculate and summarize the CO2 emissions that were reduced
or avoided.
The following steps were used to evaluate potential energy efficiency improvement projects for the fleet:
Assemble a team of experts within the utility that have collective
knowledge covering all the units being investigated, and all the projects
being considered.
Identify potential projects.
Identify coal-fired units to be
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included in the analysis.

Screen projects for feasibility of
application to each unit in the
fleet.
Determine project attributes for
each application.
Evaluate applicable projects for
each unit.
Develop project rankings based
on the cost-benefit analysis for
each application.
Prepare Pareto curves to provide
management with a decisionmaking tool to prepare for any future carbon-related charges.
ISSUE FLEET-SPECIFIC
REPORTS.
The technology feasibility screening
process identified more than 40 candidate projects, organized by six major
plant systems, as listed in Table 1.
Using this list, the project team conducted a fatal-flaw analysis to determine the feasibility of the efficiency
projects on a unit-by-unit basis. Because of their configurations, some
plants did not qualify for particular
projects. Numerous efficiency projects
had already been completed in advance of the study.
TOP PROJECTS
Over 490 potential projects were
identified and screened for feasibility.
Of these, 174 projects were identified
as feasible.
Analysis determined that several
projects were justified, independent
of the projects economic life. The following projects were justified without
any CO2 credits:
Boiler drain automation (12 units)
Air heater seals (8 units)
Station air systems (2 units)

Circulating water strainers (8
units)
Air heater baskets (4 units)
Condenser ball cleaning systems
(8 units)
KEY OBSERVATIONS
Many projects can improve plant efficiencies and reduce CO2 emissions.
Analysis provides a tool that can be
used to evaluate and rank potential
projects by their projected benefits.
Based on a 30-year economic life, analysis estimated that, if all 174 projects
were implemented, the upper limit for
fleet-wide coal plant CO2 reductions
would be about two million tons per
year (an approximate 5.3 percent reduction of current operating fleet CO2
emissions), at an estimated capital cost
of over $800 million. However, initial
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evaluations indicated that some projects should be investigated further,

regardless of the value of CO2, thus
yielding about one million tons a year
in reduction of CO2 emissions (an approximate 2.7 percent reduction in the
fleets CO2 emissions).
The Pareto-type curve in Figure 3
shows cumulative CO2 reduction, as
well as the cost per ton of that CO2. The
x-axis represents projects ranked in order of cost per ton of CO2 from Project
Numbers 1-174. The y-axis represent
the cumulative tons of CO2 reduced
per year by all projects (green bars), as
well as the cost per ton of CO2 reduced
by each project (blue line). The red line
separates projects that may be justified
with a net annual benefit that is $0/
ton of CO2. Projects with a negative
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cost per ton of CO2 may be justified

without credit for CO2.
FLEXIBLE OPERATION
Flexible operation refers to a plants
ability to operate in part-load, load-following, and cycling modes. This is often
done in response to economic conditions
and increased utilization of non-coalbased generation. Operating plants in
flexible modes can result in reductions
in plant efficiency and increased degradation of components due to constant
swings in operating temperature and
pressure.
A 2010 EPRI study identified cost-effective capital modifications and adjustments to plant operating procedures that
would improve heat rates during cycling
operations. The study identified 10 upgrade options:
Automated pulverizer supervisory
controls
Boiler draft system control schemes
and operating philosophy
Cooling system optimization
Feedwater heater drain system modifications
Minimization of flow, pressure, and
temperature oscillations
Optimum partial load operation of
air quality control systems
Performance monitoring
Reduction of warm-up flow for idle
boiler feed pumps
Sliding pressure operation
Variable-speed drives
CYCLE ALIGNMENT
PUMPS
HEAT EXCHANGERS
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Cycle alignment, also known as

cycle isolation, refers to alignments
in valves that reduce the high-energy
fluid leakage from the steam cycle at
a power plant. Certain leaking valves
will cause a direct loss in generation,
or an increase in fuel costs.
When used as part of an overall
plant performance improvement program, cycle alignment programs have
provided large gains at low costs. With
improved cycle alignment, heat rate
www.power-eng.com
improvements in the range of 50 Btu/ cases, the heat rate improvements were
kWh (about 0.5 percent) are common. significant and well surpassed the inUnits with problematic valves or no cremental costs for monitoring heat
history of cycle-alignment mainte- rate in addition to reliability. Heat rate
nance may experience a large one-time improvements in the range of 2.5 to 4
heat rate improvement upon the im- percent have been reported as attributplementation of such a program.
able to actions of these remote moniVarious methods have been used to en- toring centers.
sure proper cycle alignment, but an applications success and costs vary depending STEAM TURBINE STEAM
upon the specific valves and unit designs PATH MODIFICATIONS
involved. In an effort to help power comOver the past 20 years, an increased
panies optimize the application of cycle number of nuclear and fossil power
alignments, a 2011
plants have underEPRI project assessed By improving the
taken modifications
cycle alignment acto increase the power
performance of
tivities and identified
rating and/or immultiple
integrated
their costs and benprove the heat rate of
efits. The study identi- systems within
selected units. Many
fied field methods to a power plant,
of these actions have
estimate the leakage
resulted from physiheat
rates
can
rates in valves and
cal upgrades to steam
used several real-life be improved and
turbine generators, as
examples to illustrate facilities rendered
well as enhancements
how cycle alignment
to auxiliary compomore
efficient.
programs have been
nents.
implemented.
EPRI conducted a survey to compile the current results of performance.
REMOTE MONITORING
Commonly reported heat rate improveCENTERS
ments attributed to turbine modificaRemote monitoring centers (RMCs) tions were in the range of 2 to 4 percent.
have been used for many years to track
and improve equipment reliability. In HEAT RATE IMPROVEMENT
many cases, these same RMCs have PROGRAM GUIDELINES
thermal performance software inPower plant facilities with heat rate
stalled for monitoring heat rate. The improvement programs perform better
value of finding and fixing reliabil- than those without such programs. A
ity issues can often be quantified, but heat rate improvement program typiplacing a value on heat rate monitoring cally provides sufficient information
is not so easy.
for decision making with respect to
The project team visited RMCs at timely maintenance actions, operathree power generating companies. tional adjustments, and physical modThe main priority of these RMCs was ifications.
to improve reliability, but they also
Monitoring the performance of any
monitored for heat rate improvements. power plant component includes the
In addition to improvement in equip- trending of parameters that also dement reliability, all of the visited com- scribe the performance of other plant
panies were able to verify heat rate components, providing insight and
improvements based on the activities information on improving their opof the monitoring centers. In many eration as a whole. A performance
92
program creates a culture that is centered on improving plant performance.

Sharing performance data with plant
staff strengthens their understanding
of how each individual may contribute, ultimately making heat rate improvement a team effort.
STEAM TURBINE
PERFORMANCE
ENGINEERS GUIDE
The steam turbine is the workhorse
of most power plants. Its performance
and reliability relate directly to the
performance and reliability of the
power plant it serves. The actions of
the turbine performance engineer are
crucial to the turbines high level of
performance.
The primary role of a steam turbine
performance engineer is to improve
and maintain the efficiency and power
output of the steam turbine cycle. One
of the measurements of success is improved turbine heat rate.
CONCLUSIONS
Power plants are designed for an
optimal heat rate. While that heat rate
may not be the lowest achievable at a
given point in time, trade-offs occur
with respect to capital and O&M costs,
siting, and fuel. The average coal-fired
power plant is now 40 years old. Over
the course of four decades, these plants
have been subject to physical modifications and repairs, and have suffered
age-related degradation. Many of these
modifications have included the addition of emissions controls, which
typically have an adverse effect on
heat rate. Since initial startup, many
units have changed their fuel supplies,
reduced staffing sizes, and been called
on for flexible operations that create
adverse effects on heat rates. By improving the performance of multiple
integrated systems within a power
plant, heat rates can be improved and
facilities rendered more efficient.
www.power-eng.com
Author
Deane Horn is product manager of Online Machinery Monitoring at Emerson
Process Management.
Remote Vibration
Monitoring Keeps
Power Plants Running
at Full Capacity
BY DEANE HORN, EMERSON
ou can get the monitoring and analysis

you need without requiring your equipment specialist to
be on-site at the plant. In fact, you
could send your equipment specialist to a conference across the country
knowing that when he goes, he will
carry with him the power to monitor
the condition of rotating machinery
at your power plant. With only a cell
phone, he can provide graphical evidence of unusual vibration activity to
an OEM expert anywhere in the world
for a second opinion. If necessary, the
equipment specialist can even take action to protect equipment thousands
of miles away, improve safety for plant
personnel, and prevent a disruption in
service to your plants customers all
without leaving the conference. Thats
exactly how a power plant in North
America uses this capability.
WHAT MAKES UP THE

REMOTE MONITORING
NETWORK?
Three components make this possible: a monitor that provides continuous protection and prediction,
software that provides predictive machinery health displays and analysis
tools, and a network that feeds the
website.
Using the website, the equipment
94
specialist keeps track of the condition

of rotating equipment in three widely
separated power generating stations
without having a vibration specialist
in each plant to monitor every developing situation.
If a turbine blade were to crack due
to a coiler upset at one of the power
generating stations, the equipment
specialist will learn about it and keep
that machine under close surveillance
no matter where
he might be.
Figure 1 (pg. 98)
is a system diagram demonstrating the data collection points and the
transmission network. The generating station on the
right side of Figure
1 shows Emersons CSI 6500 Machinery Health Monitors wired directly to
an AMS Suite: Machinery Health Manager predictive maintenance server.
The left side of the figure shows how
data is also transmitted wirelessly
from monitors in remote locations.
The data acquired from each online
monitor are stored on a hard drive in
the server, buffered, and presented on
a screen in high-definition plots that
depict what is happening in a given
machine.
The result is a comprehensive view
of each monitored machine for accurate diagnoses when changes in a

machines condition are discovered.
In addition, AMS Machinery Manager provides analytical tools that help
trained personnel diagnose problems
and generate a prognosis on the health
of the machine.
Power plants can monitor every rotating machine in the plant continuously with the CSI 6500 for critical
machines and periodically with the
portable CSI 2140
Machinery Health
Analyzer for less
critical machines.
The CSI 2140 is
used by the walk
around
analyst
where he can safely approach machines and when machine failure has
no derate consequence. The portable
analyzer uploads data to the predictive
maintenance software where information can be accessed from anywhere in
the world.
The plants corporate WAN connects
the server in each generating station to
AMS Machinery Manager in the headquarters.
Data residing at each site is accessible via a web-based platform by remote personal computers or smart
phones like the one the equipment
Power plants
can monitor every
rotating maching
in the plant
continuously with
the CSI 6500 for
critical machines.
www.power-eng.com
See Us at POWER-GEN Intl, Booth # 1427
specialist uses from any location. The

specialist in our example has accessed
the network to do remote diagnostics
at locations ranging from Fort Myers
Beach, Florida to Anchorage, Alaska.
Experts from Emerson, GE, Siemens,
and ABM Technical Services have accessed the network as well.
The network is used for critical
equipment for each operating unit.
This equipment is monitored for vibration characteristics, exceptions
are captured, and time-based historical data are saved weekly, at the userdetermined optimal interval for that
machine.
If vibration exceeds a pre-determined alarm, the signature and waveform data are immediately saved for
analysis. When this happens, it triggers a yellow or red indication on the
AMS Machinery Manager screen to

signify specific points and parameters
in alarm.
The equipment specialist reviews
this equipment list daily for alarming or trending of vibration plots, and
machines showing signs of trouble are
watched very closely.
WHY REMOTE
MONITORING WORKS
Remote monitoring enables the facility to maintain critical equipment
for maximum availability while keeping their expensive machinery running as long as possible.
The frequent scans pick up anything
unusual and provide ample warning of a potential failure. The equipment specialist analyzes the scans and
identifies the fault, tracking it until it
becomes obvious that repairs will be

necessary.
The result is greater plant reliability,
improved safety, and more uptime,
which means more income, especially
during peak periods.
Using this technology, the power
plants resources are able to efficiently
monitor and maintain critical assets
including turbine/generator sets, boiler ID and FD fans, boiler feed pumps,
condensate pumps, circulating water
pumps, etc.
Safety has increased for plant personnel by eliminating the need for
taking frequent vibration readings
with handheld analyzers on difficultto reach machinery such as icy cooling
tower fans.
At this power plant, the practice
had been to derate the plant while a
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96
www.power-eng.com
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AUMA Generation.2
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valuable, user friendly features. AC controls are the perfect
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functions, data logging and congurable user interface or if
the automated valve is to be implemented into a plant asset
management system by advanced diagnostic functions.
AUMA valve actuators are capable of providing multi-turn,
quarter-turn and linear output to a valve or other controlled
device.
Multi-turn capabilities include thrust acceptance up to
900,000 lbs (4,000 kN) and torque output from 7 to
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Quarter-turn actuators are available with output torque
from 74 to 498,000 ft lbs (100 to 675,000 Nm).
Linear actuators have a range of 900 to 48,825 lbs (4 to
217 kN).
AUMA damper drives are widely used on guillotine, diverter,
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output speeds and closing times are available.

SIPOS 5 HiMod
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Bluetooth connectivity wireless parameterization
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!

Vibration Monitoring Network
Corporate AMS Suite Machinery Manager Server
POWER COMPANY Corporate WAN

AMS Suite Machinery Manager
Online Server
Generating Station #1
You have
the POWER,
WE
Wireless Network, 2.4 GHz,

802.11b, 11Mbps
Prosoft and D-Link
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AMS Suite Machinery Manager

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Generating Station #2
Yagi
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Sample House
Crusher House
Cooling Towers Cooling Towers Cooling Towers
- Hammer Mills - Coal Conveyors -Gearbox, motor -Gearbox, motor -Gearbox, motor
- Coal Conveyors
- Pump
- Pump
- Pump
TOMCO2 Systems
Fire Systems Division
7619 Hamilton Avenue
Cincinnati, Ohio 45231 USA
Tel: 1.513.729.3473
Email: Fire@TOMCOSystems.com
www.TOMCOsystems.com
Basement
Boiler Feed
Pumps
Crusher House
- Coal Conveyors
FD and ID Fans
Wired
Circ Water
Pumps
Wireless
A system diagram demonstrating the data collection points

and the transmission network.
www.power-eng.com
potentially crippling condition was

being analyzed and a course of action
was being determined.
With the introduction of online
monitoring, production doesnt have
to be compromised
while the plant
waits for an expert
to come out and
analyze the issue.
Instead, real-time
plots are sent to a
Level IV vibration
specialist or OEM
expert; they can see
the problem without being physically on-site. The expert analyzes the problem, determines
root cause and recommends a course
of action more quickly and with less
expense. This approach allows plant
personnel to be more productive,
tapping experts only as needed.

In one facility, using data from online monitoring, the internal expert
identified a fault in the turbine blade.
He monitored the vibration; it wasnt
catastrophic but it
was getting higher
by the day.
In fact, it was on
track for reaching
shutdown levels in
five days. He sent
the plots to remote
turbine
services
for analysis. Since
they knew it was
a cracked blade, they got the right
people and parts onsite, scheduled
the shutdown for the weekend when
demand would be lower, made the repair over the weekend and were back
online very quickly.
Production
doesnt have to
be compromised
while the plant
waits for an expert
to come out and
analyze the issue.
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As reflected in the example above,

mechanical equipment seldom fails
without giving signals well in advance.
Breakdowns can often be predicted
by watching for the warning signs.
Vibration monitoring and the analysis of the resulting data are proven
ways to identify changes in machine
behavior.
The advance knowledge provided by
online monitoring enables the power
plant staff to address the problem as
part of a planned outage.
For the power plant in our case
study, using online remote monitoring
has yielded savings in time and dollars.
With the decreased number of derating periods and the delay of repairs
until planned outages, online remote
monitoring has paid for itself many
times since the first online vibration
Snapshot of Turbine Driven Feed Pumps Vibration
2
monitors were installed in the power
plant nearly ten years ago.
5174 RPM
5126 RPM
<HIGHEST VIBRATION@ 5127
Amplitude (Mixed Units)
5164 RPM
5200.
5120.
5125 RPM
16-May-04
16-May-04
U14 - #14 W Turbine Driven BFP

14W02PB 0 -PIH Pump Inboard Horiz
TROUBLE ON A SUNDAY
Speed
RPM
Total Energy
In/Sec
.72
.36
< VIBRATION ACCEPTABLE BETWEEN >
Over a Period of Nine Hours

A snapshot from a nine-hour trend study of the CSI 6500. The upper line shows the pump speed in
revolutions per minute, and the lower line shows total vibration energy in inches per second.
Operators identified an abnormality

in a turbine driven boiler feed pumps
operation, and they brought it to the
specialists attention on a Sunday.
The CSI 6500 works like a black box
on aircraft; when the pump so much
as hiccups, the data can be retrieved
and played back as if watching it live.
Figure 2 is a snapshot from a nine-hour
trend study of this machine. The upper
line shows the pump speed in revolutions per minute, and the lower line
shows total vibration energy in inches
per second.
As illustrated in the figure, the vibration increases rapidly from 0.4 in/
sec at 5164 RPM to 0.65 in/sec at 5125
RPM and drops back to an acceptable
WEBCAST
ON DEMAND
MODERNIZATION SOLUTIONS IMPROVE POWER SYSTEM

RELIABILITY AND LOWER LIFE-CYCLE COSTS
PERFORMANCE
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level as the speed increases to 5174

RPM. This trend continued throughout the nine-hour
period.
Based on the
historical
vibration data and the
allowable limits
for operation, the
equipment
specialist was certain
that a bearing
was going bad
and needed to be
replaced. He was
able to make this diagnosis remotely,
so he didnt even have to go in to the
plant on Sunday.
No immediate operational adjustments were needed for the pump, so

production continued
without
disruption.
The
necessary part was
ordered and the
repair was managed as part of a
planned outage.
The advance
knowledge
provided by online
monitoring enables
the power plant
staff to address the
problem as part of
a planned outage.
Online
vibration monitoring of
critical equipment
has achieved a number of positive results for this power plant, including:
Improved plant reliability and
104
SUMMARY
uptime, resulting in more revenue

during peak operations
Decreased safety risk for plant personnel
Closely monitored assets without
increasing resources
Saved time and money by diagnosing problems remotely
Reduced need to derate units
while waiting for analysis
The power companys goal is to keep
these plants up and running without
risk to the machinery or personnel.
At the same time, they strive to get
the most out of the equipment. With
online vibration monitoring, the company has the ability to achieve both of
those goals.
www.power-eng.com
Author:
Carrie S. Penman is the Chief Compliance Officer and Senior Vice President
of Advisory Services at NAVEX Global
WHISTLEBLOWING:
What Industry Leaders Need

to Know and Do
BY CARRIE S. PENMAN, NAVEX GLOBAL
tories about whistleblowing

and retaliation are front page
news these days. The SEC has
recently given multi-million
dollar rewards to whistleblowers and levied fines and penalties
on organizations that have engaged in
retaliation against employees who raise
concerns. The power and utility industry has been aware of these issues for
decades. For too long, corporate cultures
of accountability have been scuttled, and
with negative results.
Nearly 20 years ago it was a utility industry whistleblower, George Galatis,
who was featured on the March 4, 1996
cover of Time magazine. He had reported
nuclear safety issues at a power plant in
Connecticut that would eventually lead
to the plants shut down. This shutdown,
however, did not occur before his employer had retaliated against him, reinforcing
a culture of submission and compliance
in the face of mounting problems. At the
time, Westinghouse Electric Corporation
offered assistance to the utility, who was
also its customer.
Today, more and more employees,
including those within the utilities and
power engineering industry, are using
formal internal reporting programs, a
key component of an effective ethics
and compliance program. Research using the NAVEX Global database, which
represents about 2 million hotline reports received by clients during the past
five years, shows a 33 percent increase in
reporting rates to company hotlines. The
concerns shared through these internal
channels are also being substantiated at a
106
significantly higher rate than ever before

now at 40 percent, up from 29 percent
five years ago.
Executives and business leaders can
no longer complain that internal whistleblowers are simply malcontents. Nor
can it be said that anonymous reports
should be taken any less seriously. The
data shows that 36 percent of anonymous
reports received in 2013 were substantiated. Overall, employees are providing
high quality, actionable reports, and
companies must ensure that they have
effective programs and processes to investigate and address these concerns in a
timely and professional way.
In addition, the spread of information outside traditional channels moves
quickly within the 24/7 news cycle. Social media that is accessible to any employee, contractor, or customer can amplify this information exponentially. A
problem that might have remained contained at a far-off outpost, or in the hands
of a third party vendor or contractor, can
now move quickly. This means quick internal responses to reports of problems
are imperative.
KEY METRICS TO WATCH

In the past, the power and utility industry has been slow to respond to whistleblowers or concerned employees. Five
years ago, when an employee reported a
problem, statistics show it took industry
companies nearly 90 days to close a case.
Now best practice organizations close
cases in an average of 30 days. The power
industry has made good progress.
The median time it now takes to close
a case in the power industry is 46 days

which is still higher than the current
36-day median of all industries, but
nonetheless a significant improvement.
Substantial delays in case closures can
have negative results, including loss of
employee confidence in the reporting
program and belief that management
does not regard their employees seriously. When employees lose confidence in a
program, they look to other channels like
outside entities and government agencies
to listen to their reports. Worse, they may
stop reporting at all, thereby allowing potential problems to grow worse.
In another dramatic change, the number of repeat reporters to company hotlines has doubled in five years, and these
reporters continue to provide high quality information. In 2013, issues reported
by repeat callers were substantiated at a
higher rate than those reported by firsttime callers. This shows that organizations should take matters provided by
these reporters seriously.
The data is not good when it comes to
issues of retaliation. Very few reports of
retaliation come directly into company
hotlines. Less than 1 percent of the total
hotline reports are primary allegations
of retaliation, and these reports are substantiated at a significantly lower rate
(12 percent) than all other
types of reports (40 percent). Noting that 40
percent of complaints
filed with the EEOC last
year involved allegations
of retaliation, it is evident
that employees who have raised
www.power-eng.com
issues and later experienced retaliation

are not willing to give their organizations
a chance to perpetrate further abuse. Instead, they are more likely to take their issues outside the company.
A CALL TO ACTION
Forces outside the power industry
may add urgency to the task of upgrading internal reporting processes within
the industry. In recent weeks, the SEC
announced its first whistleblower award
to an audit and compliance professional.
The $300,000 award announcement noted that the recipient had reported concerns to appropriate personnel within
the company, including a supervisor,
but after 120 days,had gone to the SEC
when he believed the company failed to
take action. A clear message is sent to the
workforce when an audit or compliance
professional feels there is no choice but
to report a problem outside the company.
Bigger than this was a second SEC announcement in September of an award
on the scale of a lottery win. The $30 million award given outside the U.S. will be
registered by whistleblowers everywhere,
and underscores the importance of global
action. Given that most power and utility
industry companies are publicly traded
corporations, the proactive enforcement
stance of the SEC needs to be considered
www.power-eng.com
in ensuring effective formalized reporting processes.

Finally, the 2010 rupture and explosion of a natural gas pipe that killed
eight people and destroyed 38 homes
demonstrates that work in this area is
never done, and that fostering a culture in which employee concerns are
encouraged and appreciated can save
lives. In the long investigation that followed the accident, it was discovered
that engineers had raised concerns
about inaccuracies in the companys
data concerning line locations.
The power industry has taken enormous strides toward accountability, but
more must be done. The current media
attention on whistleblowing outside organizations should serve as a strong reminder to the power and utility industry
that constant care and feeding are necessary to support a culture in which concerns are encouraged and truly accepted.
NEXT STEPS AND BEST

PRACTICE RESPONSES
So what can industry leadership do to
support and further the great progress
it has made in ensuring that employees
have multiple safe and responsive reporting channels available to them?
Assure employees with both words and
actions that the company will follow up
on their concerns and will enforce a policy of no tolerance for retaliation. Publish
sanitized cases of issues addressed to

help demonstrate actions taken.
Establish processes and systems that
ensure reports older than 30 days are
flagged, reviewed, and escalated to ensure
appropriate and timely action. Closely
monitor progress. Ensure that there are
sufficient and properly trained resources
available to manage the increasing volume of reports expected in the coming
year. Develop formal case management
systems to manage reports and identify
areas of concern for leadership.
Keep the lines of communication
open with the internal reporter during
the course of an investigation. Communicate throughout the process to inform
the reporter that the company is working
on the issue and that it will let him know
when the matter has been addressed.
Train supervisors on how to respond.
Keep in mind that hotline reports represent only about 1 percent of issues raised
by a companys employees. Remember
that employees regularly identify issues
to other recognized resources like human
resources and their immediate managers. Ensure that all local line management (including supervisors within the
plant, as well as those out in the field) are
trained and equipped to handle issues
raised directly to them. Use case management systems to track all resources that
receive reports in order to gain a broader
view of the issues that are raised.
Ensure that there is a robust communication plan in place to explain
and demystify all the reporting processes available to employees. Send
periodic reminders about these plans
and include this information in all relevant training sessions.
Ensuring that a company has a
strong ethics and compliance program will not only improve
that companys corporate
culture, it will also
help protect its people, reputation, and
bottom line.
107
Author
Chris Nagle is the general manager for
engines and small gas turbines in North
America at Dresser-Rand.
Swine Waste
A fully remote controlled Guascor SFGLD 480 genset provided by Dresser-Rand produces 600kW of
power. Biogas from Storms Hog Farm is combusted
in the engine/generator to produce enough power
for nearly 300 average North Carolina homes. The
new power plant has been operating at full capacity
since June 2014. Photo courtesy: Dresser-Rand
Generates Electricity
in North Carolina
BY CHRIS NAGLE, DRESSER-RAND
ladenboro is a small
town in Southeastern
North Carolina with just
under 2,000 residents.
Originally known for its
timber and turpentine, it is now in the
heart of hog country.
Some 10 million pigs can be found
in the southeastern region just east of
Interstate 95, making North Carolina
the second leading hog producer in the
United States.
108
Many of the residents in Bladenboro

can thank the nearly 30,000 hogs that
live at Storms Hog Farm for power
that is now generated from North
Carolinas largest swine waste-toenergy systemthe 600-kW Storms
Hog Power Plant.
Manure collected daily from the
hogs is biologically decomposed in
an oxygen-free, 1.2-million gallon
reinforced concrete vessel, or tank,
known as an anaerobic digester. The
bacteria in the digester metabolically

break down the waste and generate
biogas, while destroying nearly all of
the pathogens and odor.
The biogas is combusted in an
engine/generator, sending enough
clean renewable electricity to the
local utility to offset the electricity
consumption of nearly 300 averagesize homes in the area. The new
power plant has been operating at full
capacity since June 2014.
www.power-eng.com
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The bacteria in the digester metabolically breaks down the

waste and generate biogas, while destroying nearly all of
the pathogens and odor. Photo courtesy: Dresser-Rand
HISTORY OF HOG
WASTE MANAGEMENT
Southeastern North Carolinas hog
farms historically stored more than
350,000 gallons of manure produced
each week in open-air lagoons and
mixed with off-site agricultural wastes,
which were previously either landapplied or destined for a landfill.
When designed correctly, the sewage
in a lagoon quickly decomposes
through exposure to sunlight and
oxygen. The challenges that can arise
from such an arrangement include
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A NEW DIRECTION
The concept for the waste-to-energy
project evolved from a grant for four
swine farm renewable energy pilot
projects administered by the North
Carolina Department of Energy. These
grants were applied for in May 2010 by
Storms Hog Farm.
The farm ultimately hired AgPower
Partners LLC to develop the project,
which in turn enlisted DVO, Inc.
for its anaerobic digester experience
and Martin Machinery/GenTec for
its biogas engine/generator turn-key
services.
Some of the preliminary plans to
generate energy at the farm started with
biogas boilers that operated through
the anaerobic digesters and ultimately
flared gas. Known for his interest in
renewable energy, William R. Storms,
the farm owner and operator, initially

had a desire for the power plant to
produce 1,200 kW of electricity.
Ultimately it was determined that a
600kW power plant
would be the best
path to take because of the incentives that come by
developing a wasteto-power
plant
through the Power
Purchase
Agreement with North
Carolina.
The team decided
to reduce the size
of the power plant to 600kW because
they wanted to be sure it would work
on a smaller scale before ultimately expanding later to a 1,200kW plant.
LIGHTS OUT, PRESSURES ON:
DVO installed its patented TwoStage Mixed Plug Flow anaerobic digester and Martin Machinery/GenTec
highly recommended the installation
of a fully remote
controlled Guascor
SFGLD 480 gen-set
provided by Dresser-Rand to produce
the 600kW output.
The new power
plant was designed
to collect manure
from the hog barns
and then transport
the waste by truck
then conveyor belt,
into the digester which holds 1.2 million gallons of wastewater. Inside the
enclosure, bacteria decompose the
manure, producing methane thats
The concept
for the waste to
energy project
evolved from a
grant for four swine
farm renewable
energy pilot
projects.
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112
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collected to combust the electric generator.

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The SFGLD engine was chosen primarily for its long history of performance and reliability. There are over
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The outstanding performance and reliability of the Guascor
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farm. It was also chosen with a possible expansion in mind. If the unit was
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Other benefits
from the power
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consumption
for power
generation.
then another unit would later be installed at the facility, doubling the size
to a 1,200 kW plant.
The new anaerobic digester and
renewable energy-generating system,
along with an enhanced animal waste
extraction and collection systems
that uses scrapers instead of flush
water to remove manure from the
houses, greatly reduced the negative
environmental impacts of the lagoon
and manure management systems.
The result is cost-effective generation
of renewable energy.
The digester produces wastewater
that is free of pathogens and odors and
the power plants new nutrient recovery
technologies allow for the practical
removal of additional phosphorus and
ammonia nitrogen. Some excess gas is
flared at the site.
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Biogas from Storms Hog Farm is piped to the utility building housing the generator set used to produce 600 kW of
power. Photo courtesy: Dresser-Rand
Storms Hog Power now sells its

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Author:
Forrest March is Business Development
Manager for Oil & Gas at Aggreko North
America.
As unconventional oil and gas operations that

require sophisticated temporary power solutions
for water management continue to grow, the
need for highly credible power providers will
become more crucial. Photo courtesy: Aggreko
Temporary Power
Solutions for Water
Management in
Unconventional
Oil & Gas Exploration
BY FORREST MARSH, AGGREKO
nconventional
oil
and gas field exploration and production
in the United States is
anything but typical.
New shale field discoveries are promising
record amounts of production, leading
to an exponential increase in the number of stages of hydraulic fracturing to
access previously inaccessible resources.
With this increase of shale activity comes
a critical component that oil and gas operators need to consider strategic water management in shale gas plays and
how temporary power solutions aid the
118
process. Water is the key component and

managing its use, complex.
A significant increase in the need for
water to support hydraulic fracturing is
growing, resulting in higher than expected volumes of produced and flowback water, thereby creating a demand
for better water management practices.
Water management decisions within
shale gas production fall into two primary categories: water use for hydraulic fracturing and the disposal process
from drilling and production. According to the North Dakota Department
of Mineral Resources, it is estimated
a Bakken well requires 1 million to 5

million gallons of water for hydraulic
fracturing and 20 million to 30 million gallons of water a dayequating
to 7.3 billion to 11 billion gallons of
water needed over the next few decades. Because of this demand, growing volumes of flowback and produced
water from shale gas plays are creating
a compelling market opportunity for
water technology and service providers that can aid in the water management process.
As a result of market opportunity,
many operators are leveraging temporary power generation solutions to support various components of onsite water
management needs including: managing
power for water handling and related processes, including: disposal and/or treatment of produced water; energizing low
and high pressure pumps allowing for
the delivery of fresh water from holding
tanks to assist fracking operations; and,
powering the filtration process needed
to sweeten or clean the gas supply of hydrogen sulfide.
CONSIDER THE
POWER SOURCE
Before implementing a temporary
power solution to meet a projects
unique water management needs, operators must weigh and measure potential
power challenges and constraints. If
these issues are not properly addressed
early, the operator can expect to face increased downtime of their process and
unnecessary additional costs.
First, a qualified temporary power
provider should be knowledgeable of the
required water volume needed for operations as well as its effect on power requirements and associated power generation
load sizing. Every project requires a different power solution to achieve production efficiencies. The power management
company should be able to determine
www.power-eng.com
requirements and help identify engineered solutions

that match the operations
power needs through the full
lifecycle of a water management support project.
They must be proficient
in determining what power
systems or configurations are
most optimal for a sites water management needs. If the
volume of water (pumped,
disposed or processed) is
expected to fluctuate over
the course of the operation,
a scalable solution may be
required. In remote locations
lacking power, temporary
power generation equipment
ranging from 150 kW to 10
MW can be deployed quickly
and set in parallel to operate
as one system. This will also
serve well during periods
of service or maintenance,
when redundant or back-up
power has been built in to
keep operations running and
production at optimal uptime levels.
Second, a reputable provider should identify cost efficiencies
while also meeting base load delivery in
fracturing operations when water volumes are the greatest. Per the scalability
needs of the temporary power package,
determine what makes the most logical
sense for the load characteristics of the
project. Can it be reconfigured on an ongoing basis to meet project objectives? A
static power solution versus a scalable option implemented for purposes of water
management can affect reliability and
delay or stop operations, resulting in increased operating expenses or unnecessary capital expenditure commitments.
Third, temporary power providers
must have a thorough understanding of
all relevant operational and environmental regulations for power generation pertaining to onsite water management that
120
Many operators in unconventional oil and gas

production are also leveraging temporary power
generation solutions to match their onsite water
management requirements. Photo courtesy:
Aggrekoa
supports drilling activity. It is important

the provider understand the unique environmental landscape in which an operator is working and that it meets all emissions requirements. Regulations vary
from basin to basin and state to state, and
the power solutions must meet local, state
and federal environmental regulations
specific to onsite water management.
Fourth, an operator should consider a
temporary power providers engineering
capabilities, experience, and ethics during the selection process. Partnering with
an established provider who has a proven
track record will provide operators with
added assurance that they will offer consulting and assistance through the full
lifecycle of the project. Temporary power
providers with a been there, done that
record are valuable partners to add to any
team. Beware of companies

promoting new power solutions and lower costs without a verifiable track record,
comparable project examples
or in-house engineering support.
Finally, select a temporary power provider with an
established safety program.
With oil and gas operations
in North America continuing to ramp up production,
producers and service providers are running 24/7 to
ensure the highest levels of
productivity. However, in an
urgency to meet production
and revenue goals, jobsite
safety can often times be
deprioritized or sometimes
completely
overlooked.
A strong safety culture or
Health, Safety and Environment (HSE) program must
be evident with a strict adherence policy by the temporary power provider and their employees during on- and
off-site operations. This is essential to not
only guarantee a successful outcome, but
also to ensure the overall well-being of all
participants operating onsite.
PROVEN FIELD RESULTS

A recently purchased and remote oil
and gas development site in North America needed enough power for water flooding, which involved injecting a combination of water and CO2 into an older,
existing reservoir. However, the present
power grid was not designed for the anticipated load and required an update
to the substation and additional power
lines to begin operations. With insufficient access to full-capacity grid power,
the operator faced the critical questions
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of whether to wait for the upgrade or

find a scalable, temporary option that
would also fall within environmental
requirements set by the state.
To address the customers concerns,
temporary power provider, Aggreko,
assembled a project team to help the
customer improve their processes and
operations, enhance bottom-line performance and address environmental
concerns. The team assessed utility demands, which included one 1018 horse
power electric submersible pump. At
1283 amperage, this was a considerable
amount that the grid would not be able
to supply for at least 10 months. The
providers objective was to design an
equipment package comparable to the
grid while meeting the Best Available
Control Technology (BACT) requirement for emissions as regulated by the
State. The final design needed to incorporate a scalable option to quickly

ramp up or down with changing power
requirements while allowing for 100
percent uptime.
The engineered system included
seven low-emission Tier 4 power generators set up in parallel, with six units
planned for full operation and one of
the units dedicated to serve as a redundant back-up solution during maintenance. The configuration was also set
up to allow the customer to achieve
maximum operational and cost-saving
efficiencies. For example, if only five
generators were required to maintain
load, the sixth unit would be shut
down to conserve costs.
Using an engineered temporary power
management system allowed the customer to begin the flooding process 10
months sooner than anticipated while

providing the versatility to scale back
without losing time between equipment
setup configurations. Further, the paralleling option allowed the pump to function at full capacity while operating within low emission requirements.
CONCLUSION
As unconventional oil and gas operations that require sophisticated temporary power solutions for water management continue to grow, the need for
highly credible power providers will
become more crucial. Partnering with
the right provider helps to ensure that
projects of any size and complexity are
designed, installed and operated safely
and cost-effectivefrom start up to
shut down to meet short - and longterm needs of water management.
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122
www.power-eng.com
Author:
Mike Reed is the Manager of Analytical
Services at InStep Software, a leading
global provider of eDNA real-time performance management and PRiSM predictive asset analytics software.
Using Predictive
Analytics to Minimize
Risk Associated with
Aging Assets
BY MIKE REED, INSTEP SOFTWARE
ts no secret that an aging asset infrastructure is of major

concern to power generation
companies. In fact, 74 percent
of all coal-fired capacity in the
United States was 30 years old or older
by the end of 2012, according to the U.S.
Energy Information Association. That
infrastructure is further stressed by the
growing populations and urbanization
trends that demand increased generation capacity. Additionally, most utilities
face pressure to keep electricity costs low
while delivering reliable power, which
can lead to challenging budget constraints. As a result, operators, engineers,
and plant managers continually strive to
make every plants operation and maintenance dollar stretch as far as possible.
While running assets for as long as
possible can be cost effective and efficient,
the practice can have quite the opposite
outcome without proper preparations.
Aging equipment can contribute to
outages, failures, downtime, higher costs,
decreased efficiency, and a number of
other associated problems. Aging assets
can also cause regulatory, environmental
compliance, and safety issues. To ensure
that these assets continue to provide
value to the plant and organization,
engineers and operators are tasked with
determining the criticality of specific
124
Alarm Management
Home
Rating 1
Asset Status
2
Name
Alarms
Annunciator Panel
Explorer
5
Rating
Critically
U1 Steam Turbine Mech
U6 Mill 6B Performance
U4 Mill 4B Performance
U5 Mill 5C Performance
US Mill 5A Performance
U6 Mill 6A Performance
U6 Mill 6ETemp
U1 Mill 1D Performance
U1 Mill 1E Performance
U1 Mill 1D Temp
U2 Mill 2A Performance
U1 Mill 1F Performance
U1 Mill 1C Performance
U2 Mill 2B Temp
U1 Steam Turbine Performance
U2 Mill 2A Temp
U2 Mill 2D Performance
Current Status
Early warning indications can be grouped in many ways. In this case, they are in order of current
status (alarms in priority) and criticality. A thorough issue management system is key to a
successful predictive analytics program.
www.power-eng.com
assets and assessing their risk. Such an

assessment examines the probability
of failure and the consequences of
that failure. A number of factors are
considered as well, including added costs
for items like unplanned maintenance,
impact on resources, environmental
effects, safety issues, and public
reputation, among others.
In an ideal world, budgets would be
unlimited and utilities could always
replace equipment long before any signs
of declining asset performance became
apparent. While that is unfortunately
not the case, there are a number of steps
that can be taken to mitigate the risks
and sometimes-costly consequences
associated with aging assets. Equipment
reliability processes and systems can
prevent failures of both new and
aging assets. That being said, ensuring
equipment reliability is key when
operating these aging assets.
MAINTENANCE
FOR OLDER ASSETS
Effective maintenance is critical to
ensuring that assets, plants, and entire
fleets continue to operate reliably for
long periods of time. Because older assets
have a higher propensity for failure, they
usually require more frequent maintenance. Engineers and operators employ a
combination of maintenance techniques
depending on the criticality of each asset. Organizations that do not have a
comprehensive maintenance strategy in
place are putting the operation at risk.
On one extreme, if a potential asset
failure has little to no immediate effect
on the safe and reliable generation of
electricity, an engineer may choose to
run that asset to failure and then simply
replace it. However, when used to manage assets that significantly impact generation, such a run-to-failure strategy can
prove inefficient and possibly dangerous.
Typically, a preventative or conditionbased approach will be used to ensure
that an asset does not reach a point
of failure. These techniques rely on
126
calendars, intervals, and condition monitoring of the asset to determine when

maintenance is performed. However, if a
potential asset failure could result in significant damage, safety issues, or power
outages, the risk is obviously much higher, and a more proactive maintenance approach is required.
One such proactive approach is Predictive Maintenance (PdM). PdM involves
continuously monitoring the health of
equipment and comparing its state to a
model that defines normal operation.
This is done to detect subtle early warning signs of potential failure in equipment. The practice of collecting, storing
and trending data on an assets performance and health is ideal for determining if that older asset is heading toward
the end of its life, or if it is likely to continue running as needed for months or
years. This information allows for smarter maintenance decisions and avoids
the sometimes arbitrary shortening or
lengthening of maintenance intervals
based on little performance evidence.
PREDICTIVE ANALYTICS
PdM strategies are most beneficial
with the implementation of proper online condition monitoring and analytics software. Typically, predictive analytics software analyzes information
from an enterprise historian, ensuring
that all historical and real-time data
is included in the analysis and model
building.
It is not possible to manually analyze the real-time data streaming
from thousands of sensors which are
simultaneously transmitting equipment health and performance-related
information. There is simply no way
to derive real-time insights under the
crush of so much information. As a
result, data can quickly become contaminated through human error, and
equipment issues can arise before an
engineer has time to even analyze the
data. Predictive analytics software solutions are much more efficient when
it comes to detecting potential failures

or possibly disastrous problems with
critical assets.
When used for asset performance
management, predictive analytics
software continuously monitors equipment through sensor data and uses
various prediction engines and algorithms to provide advanced warnings
for equipment problems and failures.
One predictive analytic technique frequently used is Advanced Pattern-Recognition (APR). APR derives predictions from empirical models generated
by learning from an assets unique
operating history during all ambient
and process conditions. The model effectively becomes the baseline to determine the normal operational profile for a piece of equipment or system.
Depending on the software selected,
the modeling process can require varying skill levels and time commitments.
The technology can compare an assets unique operational profile with
real-time operating data to detect subtle changes in system behavior, which
are often the early warning signs of
impending equipment failure or performance problems. Engineers and
operators are alerted well before the
abnormal conditions reach standard
alarm levels, creating more time for
analysis and planning any corrective
action. Thus, engineers and operators
are able to better prioritize maintenance needs and reduce costs due to
better planning efforts.
After an issue has been identified,
predictive analytics solutions can provide root-cause analysis and fault diagnostics to help plant engineers understand why an issue occurred. That
information can then be used to deter
similar issues in the future. In addition, diagnostic technology reduces
the likelihood that an engineer will attribute abnormal operating conditions
to the wrong variable.
Organizations that implement predictive analytics software to monitor
www.power-eng.com
Wherever light is lacking,

our technology is delivering
Please visit our booth #2001 at Power Gen International
critical assets can feel comfortable

knowing that they will receive early
warning notifications of incipient
issues. Rather than spending time
searching for issues, or worse, waiting
for an important piece of equipment
to fail, they will be notified via an
alert that an asset is not operating as
expected. Depending on the software
selected, alerts can be customizable
and emailed immediately to the appropriate personnel. The insights from
of a vibration step change via an email

notification sent from the plants predictive analytics solution. The appropriate personnel are able to verify that
a proximity probe and casing vibration
have both changed. Further analysis
indicates a likely loss of mass in the
turbine blade path. Based on the units
history, site personnel immediately
suspect shroud material has been lost.
It is determined that the unit can continue to run at a reduced output, under
positive outcome, resulting in a potential savings of millions of dollars in

lost revenue and increased repair costs,
in addition to the safety of the operating engineers.
The inclusion of a predictive maintenance plan in a comprehensive
strategy creates benefits that are both
immediate and long-term. Predictive
maintenance allows plants to keep
running aging assets even longer, with
the ability to proactively manage and
Signal and Deviation Trend

Two methods of depicting signal deviations are overlaid on one graph. The red line represents the actual value of the signal. The blue line represents
the predicted value and is measured against the scale on the left. The second graph (measured on the scale to the right) represents the deviation
(the Actual vs. Predicted Value). This value is compared to the Alarm & Warning Thresholds depicted on the graph, with notifcations when persistent
(the tan & pink shading, for warnings & alarms, respectively).
50
120
Deg C
30
100
Deviation Absolute - High Alarm
10
Deviation Absolute - High Warning
80
10
Deviation Absolute - Low Warning
60
Deviation Absolute - Low Alarm
Deg C (Deviation Absolute)
+/-
Mill D Class Out Temp
30
14:00:00 15:00:00 16:00:00 17:00:00 18:00:00 19:00:00 20:00:00 21:00:00 22:00:00 23:00:00 00:00:00 1:00:00 2:00:00 3:00:00 4:00:00 5:00:00 6:00:00 7:00:00 8:00:00
Warnings: 1 Alarms: 1
03-12-2014
03-13-14
Actual (PRiSM History)
a predictive analytics solution will

help engineers and plant operators
better determine when an aging asset
can continue running as is, should be
serviced, or needs to be replaced.
ROI
A predictive analytics solution used
to monitor and improve the reliability
of aging assets will pay for itself in a
short time. Consider the probability
that an older piece of equipment is
likely to fail and think about the financial impact it would have on operations and resources.
For example, a hypothetical situation might look like this: an aging
steam turbine has been operating normally until site personnel are alerted
128
Time
Deviation Absolute
Predicted
increased observation, until a more

convenient and strategic time is found
to take the unit offline. Once the unit
is brought offline, a borescope inspection verifies missing shroud material
and several other segments that are
close to liberating.
Had this issue not been identified
through APR vibration modeling,
it could have caused immediate unplanned downtime, loss of generation,
possible catastrophic failure, and danger to personnel. The vibration step
change was not significant enough to
alert the operations staff of this impending condition via normal monitoring practices; it was the predictive
analytics software and PdM protocols in place that brought about this
act on potential problems. Plants can

effectively move from unexpected and
immediate maintenance to planned,
strategic maintenance.
When applying predictive maintenance strategies, power generation organizations are able to make
smarter decisions about when and
where maintenance should be performed. These decisions are based on
the criticality of the asset, the assets
performance history, and the goals of
the plant managers. Predictive analytics solutions allow decision makers to extend maintenance windows
by delaying maintenance that may
not be immediately necessary. Rather
than completing maintenance exactly
as suggested by the original equipment
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manufacturer, the maintenance can be

performed during a more convenient
and cost-effective time. Additionally,
maintenance duration can be reduced
because plants receive early warning of
an issue, thus allowing efficient use of
resources. Both of these benefits reduce
overall maintenance expenditures while
continuing to esnure that older assets are
performing well.
Predictive analytics software can also
identify underperforming assets, which
can be a problem with older equipment.
This knowledge can help personnel understand what factors are contributing
to that underperformance. In the same
manner, predictive analytics technology
can prevent equipment failures by providing early warning of subtle changes
that may have otherwise gone unnoticed.
The technology can sometimes identify
problems months before they happen,
allowing plants to be more proactive.
Not only do organizations benefit by

further extending the life of their equipment, thereby lengthening maintenance
windows, increasing asset efficiency, and
increasing availability; other savings are
also realized when potential costs are
averted, including downtime, replacement equipment, lost productivity, and
additional man hours.
MOVING FORWARD
The entire power industry is continuing to advance with new technologies,
becoming smarter every day. The transition from traditional maintenance approaches to a comprehensive strategy involving predictive techniques is allowing
organizations to safely run their equipment for as long as possible. As the power
generation infrastructure in the United
States continues to age, its more important than ever to understand how and
why an asset is performing the way it is in
order to avoid costly failures.

Plant engineers, operators, and managers can utilize predictive analytics solutions to help them work more effectively
and efficiently by equipping them with
the information needed to make proactive and well-informed decisions. Aging
assets will continue to present challenges
and raise warranted concerns for utilities.
This issue is not unique to power generation; rather it runs the gamut from
generation to transmission and distribution, from coal- and gas-fired plants to
nuclear facilities. However, the amount
of data available to engineers and plant
personnel also continues to grow, creating opportunities to further improve
plant reliability and efficiency. Through
predictive analytics solutions, this information is now being used to monitor the
health and performance of equipment
and can be used to circumvent the failure
of older assets.
AUGUST 18 -20, 2015

GREATER COLUMBUS CONVENTION CENTER
COLUMBUS, OHIO
power-gennaturalgas.com
CALL FOR ABSTRACTS

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Please visit www.power-gennaturalgas.com
for more information.
#PGNG2015
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On-Site Power
Conversion
Author:
Jay Ehrfurth is director of project development, power and industrial for
The Boldt Company. He is a registered
professional engineer with more than
three decades of experience in project
management, project engineering, supervision and training, operations and
maintenance, air permitting and quality
assurance.
University rebuilds on-site power plant,

switching from coal to gas
BY JAY EHRFURTH, THE BOLDT COMPANY
hat do billions of dollars worth of

research, football
games,
government shutdowns, police escorts
and dry ice have to do with a universitys heating plant? As it turns out, everything.
A wide range of challenges must be
overcome during power projects. Some
involve emissions issues or crowded
urban sitesothers have tight schedules or are hit with adverse weather
conditions.
The Charter Street Heating Plant
rebuild project that The Boldt Company and project joint-venture partner
AMEC recently completed at the University of WisconsinMadison faced
them all and more.
The Charter Street plant is a true
tri-generation plant; steam produced
by the plant (at 1.2 million pounds
per hour) generates 10 MW of electricity, runs through campus to heat the
universitys facilities and drives compressors to create chilled water (with
a capacity of 26,000 tons). Sitting on
a postage stamp-size, brownfield site
surrounded by a bustling urban area,
the large on-site Charter Street plant
is just one of two power plants run by
the university to serve its more than
43,000 students and 330-plus buildings, a task so critical that the plant
can never afford to go offline for any
extended
A prolonged outage could result in
132
devastating scenarios. Freezers

housing delicate research materials shut down and a professor
loses his lifes work. A doctor
cant proceed with a life-saving
operation when her facilitys
power is cut. Student services
cease.
That means taking the plant
offline for a massive rebuild
project is simply out of the
question, which is one of the
many challenges the Boldt
and AMEC team faced when
the university selected it as
eng ineer-proc urement- construction (EPC) contractor to
convert the then coal-powered
Charter Street plant to run on
natural gas, expand the facility
and update the plants equipment and controls.
The massive rebuild and
conversion project features the
addition of four 225,000-lb./hr. natural gas/fuel oil package boilers and a
70,000-sq.-ft. plant expansion to accommodate the new boilers and additional equipment.
Other elements of the project include:
Water treatment equipment installation
Upgrades to feed water and condensate collection systems
New air compressors
Upgrade to digital controls for
both campus heating/cooling
plants
Electrical system upgrades and additions

New 13.8-KV switchyard
Fire protection for the existing
plant and expansion
New six-cell, 50,000-GPM cooling
tower
Construction of a new control
room
POWERING THROUGH
CHALLENGES
The set of challenges facing the project team were both unique and diverse.
One of the main project challenges
www.power-eng.com
The University of Wisconsin Madison Charter Street Heating Plant is near

student housing, urban development, sporting venues and a rail line.The
plant was recently rebuilt, converted to run on natural gas instead of coal
and expanded. Photo courtesy:The Boldt Company
for the owner, UWMadison and state

of Wisconsin Department of State Facilities (DSF), was simply the sheer
size of the undertaking.
The $250 million project budget was
the largest in the owners history and
the project contract was the first to be
delivered on for the owner through the
EPC process.
Since the rebuild of the plant is
meant to last 50-plus years, the EPC
process was chosen to allow flexibility within the project to select work
and equipment bids based on cost and
value, instead of just cost alone, as is
www.power-eng.com
normally the case under the states

standard design-bid-build contracts.
As the EPC contractor, the Boldt and
AMEC team was responsible for procurement, which allowed the team to
receive bids and then discuss different options with the owner and assess
them for value. This allowed the owner
to spend money on the best project options in terms of value, not low bid
alone, to reach the highest level of
quality possible for the project within
its budget.
The owner also didnt have the available staff resources that were needed
to manage the project from an internal

standpoint, so it hired P3M as its owners engineer. (P3M is a joint venture
created for this project and made up of
Power Engineers Collaborative, Pyry,
Middough and Potter Lawson.) With
Boldt leading the project planning and
delivery effort, its project joint-venture
partner AMEC doing the engineering
work and P3M producing conceptual
drawings and schematics, the owner
was able to successfully navigate the
EPC process and manage the project
with just a few of its own staff members.
133
Boldt employees oversee the rotation of one of the plants new

boilers prior to its installation, which was part of converting the
plant to run on natural gas instead of coal. Photo courtesy:The
Boldt Company
DETAILED PLANNING
KEY TO SUCCESS
High-quality preconstruction planning and scheduling are important
for any project, but the unique characteristics of the Charter Street plant
rebuild required an especially rigorous
level of precision and detail:
Since the plant is vital to supporting
the campus, the project needed to be
completed without shutting down the
facility. There was also a main utility
high-pressure gas line and high-voltage lines that ran directly through the
main construction zone.
The project would run through all
of Wisconsins seasonsmeaning the
project team had to plan for both sweltering heat and frigid cold. Temperatures during the course of the project
ranged from more than 100 degrees
Fahrenheit to less than minus 15 degrees Fahrenheit.
The project schedule was aggressive
and deadlines had to be met to meet
campus steam and chilled water needs.
The 3.3-acre project site is surrounded by urban development, student
housing, a main artery into campus, a
main rail line and sporting venues the
Kohl Center and Camp Randall.
134
An intricate plan of 20-plus phases

was used to ensure the plant remained
operational throughout the project.
Each phase was linked through the
building of one new component so
that one existing component could be
replaced and torn down without impacting the plants operations. In addition, the main high-pressure gas line
and overhead high voltage lines that
ran directly through the site were relocated before the project began.
The main weather challenges involved removing existing boilers during summer and tearing down and
building a cooling tower during the
winter. The boiler work was planned
for summer, when demand for steam is
lowest and likewise, the cooling tower
work was scheduled for winter, when
there is little need for chilled water services.
In addition to making safety the
number one priority as always, a number of unique solutions were employed
to deal with the congested project site,
including:
The project site is bisected by one of
the main streets on campus, so it could
almost never be closed for construction because of its use by emergency
vehicles, public transportation vehicles and students. To work around

that busy passage, a transfer bridge
was built over the street that could be
used for project foot traffic, storage
and as a laydown area. It also provided
a safe space over the road for cranes
to traverse picks over. The bridge was
removed when the project was completed.
Because of limited lay-down space,
just-in-time deliveries were central
to keeping the project on schedule. Using this scheduling tool, every material delivery was planned for precisely
the time at which each material would
be needed. This requires a very coordinated execution of the project schedule, but keeps lay-down areas open
and reduces costs and waste due to lost
time waiting for materials or waiting
for space to open up for materials.
The height of the projects crane
tower was made high enough to allow it to clear a large chimney on the
site (which was eventually removed).
There is also a rail line on the site,
above which cranes are not allowed
to operate, so the cranes swing radius
was locked in order to avoid that area.
Every sports game or other event
that would impact the project was meticulously built into the schedule and
planned for by the project team. For
example, the project team made sure
roads were open for sporting event
traffic and did not schedule overtime
work on Saturdays when there were
home UW Badgers football games.
Extensive planning was conducted
for crane picks. For example, a detailed
pick plan was created for the installation of a new deaerator. The large deaerator had to be installed in the existing boiler plant, which is located more
than 80 feet past the facilitys faade.
www.power-eng.com
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A new deaerator is lifted as part of a complex pick and installation plan at the University of Wisconsin Madison Charter
Street Heating Plant. Photo courtesy:The Boldt Company
Putting the 84-ft., 134,000-lb. component into position was akin to picking up a submarine and sliding it into
place over ones head. To accomplish
the installation, an extensive scaffolding system was built next to the facility,
which the deaerator was placed on by a
crane. A rail system and steel supports
replaced an existing coal bunker next
to the scaffolding and inside the building; the rail system was used to slide
the deaerator from the scaffolding into
its final position in the building. Execution of the plan resulted in the safe,
effective installation of the deaerator
and minimized the pick time and disruption to local traffic.
GOVERNMENT
SHUTDOWN AND
MIDNIGHT DELIVERIES
It wasnt just the construction site
itself that dealt with tight spaces and
complex schedules during the project though. The four massive boilers
needed for the project were delivered
from Nebraska and were each built as
one piece. With each trailer (carrying
one boiler apiece) measuring 214 ft.
in length and each boilers dry weight
tipping the scales at 240,000 pounds,
delivery of the boilers was no simple
task.
Due to road weight and other restrictions, the boilers took a circuitous
route through five states. Additionally, shoring work had to be done on
some of the culverts along the boilers
journey and inspections needed to be
performed both before and after the
boilers crossed some of the roads and
bridges on the route.
Outside of Nebraska, the boilers
progress was impeded in Iowa due
to road weight restrictions caused by
136
significant flooding in the state. Nearing their destination, the boilers were
again delayed, this time for seven days
in Minnesota when the states government shutdown in the summer of
2011the boilers were stuck because
Minnesota state police were working
on an emergency-only basis during the
shutdown and were not available to
support oversized-load escorts. When
the Minnesota government started
churning again, so did the boilers
journey toward their Wisconsin destination.
As planned, the boilersthen
joined by police escortarrived in
Madison in the middle of the night
in order to minimize traffic disruption; the vehicles carrying the boilers
took up most of the road and turning
corners were lengthy affairs, as the vehicles and boilers cleared traffic lights
and other municipal features by mere
inches.
EFFICIENCY, EXECUTION
AND THE ENVIRONMENT
Much of what made this rebuild a
success was the elimination of waste
throughout the project. Using innovative Lean processes, that idea manifested itself through the prevention
of both physical waste and wasted
timeespecially important with Boldt
personnel alone putting in more than
475,000 hours of work on the project.
The project team repurposed as
many materials as it could in order to
add in additional value to the project
without additional cost. For example,
a large amount of grating was removed
when the plants existing boilers were
taken out, but instead of throwing the
grating out, it was repurposed and installed throughout the plant to add a
significant amount of extra storage
area.
The new boilers that were installed
greatly boosted the plants efficiency.
The previous four boilers generated
500,000 pounds of steam, versus the
900,000 pounds of steam produced
by the four new, somewhat larger and
more efficient boilers.
Efficiency in communication was
also very important throughout the
rebuild. The projects complex and aggressive schedule required efficient
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The Charter Street power plant conversion was completed in

December 2013. Photo courtesy:The Boldt Company
communication
between
Boldt,
AMEC, owner UWMadison and state
of Wisconsin DSF, P3M and others involved on the project. Six-week lookaheads were one tool used to achieve
that. Everyone involved in the project
gathered to coordinate work detailed
in each look-ahead to ensure that the
execution effort was well defined and
understood before any work began.
This reduced the need for any rework
and also helped keep the project on
schedule and on budget. Effective
communication lines were also invaluable during the commissioning, startup and turnover phases of the project,
which all required close coordination
between each of the parties involved.
Environmental topics were another
significant focus area of the project. Aside from changing the plants
fuel source from coal to natural gas,
the project also diverted waste from
landfills by recycling at a rate of 86.8
percent, dealt with environmental remediation issues, reduced the plants
emissions, increased its energy efficiency and set up the facility to meet
new maximum achievable control
technology industry regulations.
The Charter Street Heating Plant
had been operating as a coal-fueled
plant since the late 1950s before its
conversion to natural gas. Over the
years, chemicals had contaminated
soil on the site and coal dust coated
the entire facility. In addition, many
of plants old control valves operated
with mercury switches and the facility contained significant amounts of
lead paint and materials containing asbestos. Identifying the environmental
hazards and implementing appropriate related procedures early was key to
successfully dealing with the projects
environmental issues.
Since it can be flammable and unhealthy to inhale if disturbed, the coal
138
dust presented a safety concern to workers on the site. Dry ice blasting and large
vacuum systems were used to physically
remove the coal dusta more effective
method than sandblasting. In addition,
extra fire blankets and fire extinguishers
on site, as well as fire watches, were used
to mitigate the fire hazard. Additional
personal protective equipment, such as
respirators and Tyvek suits, were also
used to keep everyone on the project
safe and healthy.
As for the other contaminant issues, an environmental remediation
company removed contaminated soil,
the old mercury control valves were

identified and safely removed before
any work began and another company
completed asbestos abatement and the
removal of lead paint.
Those and other environmental
aspects of the project have led to the
project seeking Leadership in Energy
and Environmental Design (LEED)
certification from the U.S. Green
Building Council. The project is currently aiming for the gold level of
LEED certification and would be one
of the only university power plants in
the U.S. to achieve it.
www.power-eng.com
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President Barack Obama, Col. Dave Belote,

former 99th Air Base Wing commander, and
Sen. Harry Reid, D-Nev., tour the Nellis Air Force
Base, Nevada photovoltaic array less than two
years after it commissioned into operation. With
more than 72,000 solar panels spread across
140 acres of base property, the 15-megawatt
generating operation saves the base more than
$1 million a year in energy costs. (U.S. Air Force
photo by Senior Airman Nadine Y. Barclay).
140
www.power-eng.com
Author
Joe Sciabica is the Director for the Air
Force Civil Engineer Center
Battle Ready, Built Right:
Air Force Seeks

Partnerships to Develop
Reliable and Sustainable
Energy Sources
SOLAR IN THE SOUTHWEST
BY JOE SCIABICA, AIR FORCE CIVIL ENGINEER CENTER
n the Nevada desert near Las Vegas, 140 acres of neatly arranged
photovoltaic solar panels quietly
track the sun across the sky and
create enough clean, renewable
energy to power 2,800 homes. At Joint
Base Cape Cod in Massachusetts, three
400-foot wind turbines tower over surrounding forests, their revolving blades
capturing some of the peninsulas ample
wind resources and converting it into
enough electricity to power massive
groundwater cleanup and other installation systems. In Alaska, five 1.4-MW generators hum along, fueled by methane
from a nearby landfill.
These are just a few examples of more
than 250 renewable energy projects created, developed, and managed by the Air
Force Civil Engineer Center (AFCEC).
Many of the projects were accomplished
through third-party financing.
The Air Force is the largest consumer
of energy in the armed forces. Energy is
a part of every training event, every job,
and every mission. The need for energy
will not change, but the methods, efficiency, and funding used to generate and
harness it are changing.
As mandated by Congress, federal government agencies must reduce their energy intensity by 30 percent by 2015, based
on a 2009 baseline. The Department of
Defense (DOD) also requires that by
2025, all military installations either
procure or produce at least 25 percent of
www.power-eng.com
their total energy consumption in renewable energy.

To meet these goals, AFCEC has established multifaceted public and private
partnerships with industry and embraced the latest power engineering technologies. These relationships leverage
both third-party financing opportunities
and technical know-how of private industry on the cutting edge. By partnering
with industry professionals, the Air Force
reaps the benefit of clean, fixed-cost energy, while avoiding additional operating
expenses all without an extra dime of
taxpayer money.
As of 2013, 261 operational renewable
projects across 96 sites make use of solar,
wind, landfill gas, and waste-to-energy
technologies. Ten of these have a capacity
greater than one megawatt.
The projects alone have a combined
production capacity of over 82 MW,
enough energy to power 14,000 homes.
Another 65 projects are currently in development that will add 610 MW of capacity and save the Air Force $13.6 million annually.
The projects span from coast to coast
and save the Air Force millions of dollars
in annual energy costs while enhancing
security and reliability. For developers,
these projects can generate a consistent
source of revenue. For example, power
purchase agreements with the Air Force
are on track to reach $100 million annually.
One of the first large-scale Air Force

renewable projects, a photovoltaic array at Nellis Air Force Base in Nevada,
went into operation in 2007. The array of
72,000 solar panels covers 140 acres and
has a production capacity of more than
14 MW, making it one of the largest arrays in the United States. The project produces some 31 million kWh of renewable
power annually, saving Nellis more than
$1 million per year in electricity costs. It
also reduces carbon dioxide emissions
by 24,000 tons a year, the equivalent
of planting 260,000 trees or removing
185,000 cars from the road.
The Nellis array is an example of the
innovative partnerships the Air Force
forges with private industry to implement
renewable projects without passing costs
to taxpayers. By entering into a power
purchase agreement with developer SunPower, the Air Force avoided up-front
financing and operating costs associated
with the solar array.
The agreement stipulated that SunPowers business partner, MMA Renewable Ventures, finance the construction
and operation of the $100 million solar
power plant on Air Force property. In
return, electricity is sold to Nellis at a
guaranteed fixed rate for 20 years, providing predictable cost avoidance for the
Air Force as energy rates rise. In addition
to Air Force cost-avoidance, a power purchase agreement also shifts the maintenance and operation costs of the plant to
the managing developer.
Though the project has since changed
hands to a new developer, SunEdison
141
LLC, the deal secured the managing developer a high-consuming energy population for the next two decades. And as a
net-metering state, NV Energy is purchasing renewable energy credits generated by
the array.
Seven years after the first solar array
powered up on Nellis, a second solar
project is underway. In 2013, the Nevada
Legislature passed a senate bill requiring
NV Energy to permanently cut 800 MW
of coal-fired generation in southern Ne-
mission-critical redundant power source

for the base.
The 19-MW array should be operational by December 2015. Once complete, the
renewable energy from both solar arrays
is expected to provide 42 percent of the
energy needed to power the base.
WIND POWER
At Joint Base Cape Cod in Massachusetts, five white wind turbines whip
through the air, generating power to
aquifer is remedied. The groundwater

cleanup site consists of over 100 extraction and reinjection wells and nine treatment plants of varying size. Over 12
million gallons per day of contaminated
water is being cleaned. The equipment
requires tremendous amounts of energy
that, at its peak, amounted to a $2.5 million annual power bill for the Air Force.
Today, three wind turbines on the site
generate enough electricity to provide
100 percent of the power needed for the
Air Force Renewable Energy Projects

Projects in Operation (> 1MW)
1
2
3
4
8
16
11
13
14 23
5
3
24
7
8
9
10
9
4
1
12
15
11
12
21
13
19
17
22
14
18
19
15
16
17
20
18
19
20
10
21
22
23
24
LANDFILL
GAS
vada by 2019. In their pursuit to acquire

more solar capacity, NV Energy signed a
deal with the Air Force to lease property
for the second array at Nellis.
Instead of arranging a reduced-rate
deal similar to the first array, Nellis will
purchase power at the existing NV Energy
tariff rate. In return for the 31-year land
lease, NV Energy will provide a secondary substation and a transmission line
as in-kind consideration that provides a
142
WIND
SOLAR
WASTE TO
ENERGY
Megawatts
1 Nellis AFB, NV (14.2 PPA, .5 Government)

2 Davis Monthan AFB, AZ (PPA)
3 JB Cape Cod, MA (Government)
4 USAFA, CO (6 PPA, .5 Government)
5 Edwards AFB, CA (PPA)
6 FE Warren AFB, WY (Government)
7 Hill AFB, UT (Government)
8 Burlington ANGB, VT (Government)
9 Buckley AFB , CO (Government)
10 JBER, AK (UP)
Projects in Development (> 1MW)
11 JB Cape Cod, MA (PPA)
12 Nellis AFB, NV (PPA)
13 Vandenberg AFB, CA (PPA)
14 JB McGuire-Dix-Lakehurst, NJ (PPA)
15 Laughlin AFB, TX (PPA)
16 Hanscom AFB, MA (PPA)
17 Holloman AFB, NM (PPA)
18 Dyess AFB, TX (PPA)
19 Sheppard/Goodfellow AFBs, TX (PPA)
20 JB San Antonio, TX (EUL)
21 Luke AFB, AZ (EUL)
22 Robins AFB, GA (EUL)
23 JB McGuire-Dix-Lakehurst, NJ (EUL)
24 JB McGuire-Dix-Lakehurst, NJ (EUL)
14.7
16.4
7.9
6.5
3.0
3.3
2.2
1.5
1.0
7.0
Megawatts
6.0
19.0
20.0
10.0
10.0
10.0
3.1
5.4
6.0
4.5
10.0
10.0
30.0
18.0
PPA = Power Purchase Agreement

EUL = Extended Use Lease
UP = Utilities Privatization
clean contamination from nearly a century of military activity at the base, while
also powering a vital radar system.
Home to four military commands,
Joint Base Cape Cod is a full-scale, jointuse base. Since 1996, AFCEC has managed the cleanup of soil and groundwater contamination there. On upper Cape
Cod, the Air Force converted more than
1,100 homes from a private well to a municipal water supply while the sole-source
water cleanup effort. The other two windmills generate sufficient energy to offset
usage of the 6th Space Wing Squadrons
PAVE PAWS radar system, saving the Air
Force about $600,000 annually.
ONE MANS TRASH

With installations spread throughout
the continental United States, what works
at one installation might not be feasible
at another, meaning military engineers
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Wind turbines built on Joint Base Cape Cod to offset electrical costs for powering
numerous groundwater cleanup systems at the reservation. The turbines also
power the Air Forces electric needs for groundwater remediation at the base, saving more than $1.5 million per year. Power generated by the turbines also cut the
installations energy cost by 50 percent and aligns with the Air Forces goal of using 25 percent renewable energy by 2025 (U.S. Air Force photo/Scott DeHainaut)
must be well-versed in various energy

technologies. Although wind energy
was a viable opportunity at Cape Cod,
large, rotating wind turbines are often
incompatible with many flight and other
specialized military missions, and solar
arrays like those at Nellis AFB are not always practical.
At Joint Base Elmendorf-Richardson in
Alaska, engineers worked with the Municipality of Anchorage and Doyon Utilities for a cutting edge waste-to-energy
project that generates more than a quarter of the installations electricity needs.
In 2013, through a utilities privatization arrangement, the base banded together with other agencies to build the
Joint Base Elmendorf-Richardson Landfill Gas Waste-to-Energy Plant. Prior to
the arrangement, the municipality flared
the gas in accordance with EPA regulations. The costly burn operation exceeded
$60,000 a year. Today, methane from the
87-acre landfill is piped into a processing
skid at the plant where five 1.4-MW GE
Jebaucher gas generators convert it into
electricity.
IMPROVING PERFORMANCE
AFCEC has also used third-party financing to refit existing facilities with
high-efficiency technologies. At Tinker
Air Force Base in Oklahoma, four decades-old central steam plants formerly
used to heat 71 buildings on the base
are now decommissioned. In their place,
each building is now equipped with its
own modern natural gas boiler.
The upgrade saves Tinker $6.4 million
a year in electric, natural gas, water, and
operation and maintenance costs, with
an overall natural gas consumption reduction of 30 percent.
The project was executed through an
Energy Savings Performance Contract,
144
an arrangement in which the Air Force

partners with an energy services company (ESCO). The ESCO conducts a comprehensive energy audit of facilities and
identifies improvement opportunities
to save energy. After consulting with the
Air Force, the ESCO arranges necessary
financing and designs and constructs a
project that meets Air Force needs.
The Air Force pays the ESCO back from
cost savings created through improved
efficiency resulting in reduced utility expenses. For the Tinker project, the performance contract will be paid back over a
21-year performance period.
ENHANCING ENERGY
OPPORTUNITIES
In a state where 100,000 square feet of
solar panel surface area could generate
enough electricity to power more than
1,500 homes on average, its no surprise
that Arizona is home to the Air Forces

first signed energy Enhanced Use Lease
(EUL).
Initially planned as a power purchase
agreement, the proposal by Arizona
Power Service for a solar array at Luke
Air Force Base ultimately changed course
after market fluctuations no longer supported the favorable fixed-price power
rates that Arizona Power initially planned
to offer the base. Still a viable project opportunity, Luke and APS chose to go the
route of an EUL. Similar to a power purchase agreement, EULs are fully owned,
maintained, and operated by private industry; however, the land is leased and
the power generated is not necessarily
used by the host base.
Under U.S. Code, defense agencies
have authority to lease non-excess
property for commercial use. In the
face of shrinking budgets, a number of
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installation leaders find financial opportunity in the ability to leverage real

property assets in exchange for cash or
in-kind return from a lessee at or above
fair market value. EUL opportunities
are not limited to the energy market,
but with the capacity to generate both
revenue and renewable energy, installations often consider energy production as a way to put non-excess property to its highest and best potential use.
The deal between Luke and APS was
finalized in June 2014, and a new solar power plant will be constructed
on 100 acres of base property late this
fall. The production facility, which will
commission and power up by spring
2015, is expected to generate 10 MW of
renewable energy and earn more than
$5 million in base revenue through the
duration of the 30-year lease.
Once in operation, the solar plant
will generate enough energy to power
2,500 Arizona homes and will prevent
the emission of 12,000-15,000 tons of
greenhouse gases annually.
The project will also benefit the
community. APS estimates construction activities alone could add 200
new jobs locally. For the developer,
leasing Air Force land eliminates the
need to secure additional funds up
front to purchase property and, unlike
many private property owners, the Air
Force maintains longstanding records
and deeds associated with its property.
Although the project is still several
months away from powering up, the
installation has already collected revenue that base engineers plan to use
for improvements to dormitory rooms
and outside pavilion areas.
DISTRIBUTED
GENERATION IN GEORGIA
In an effort to spur economic growth
and increase reliability within the solar
community in Georgia, Southern Company-owned utility provider Georgia
Power enacted an advanced solar initiative in 2012, seeking contracts for at least
146
45 MW of solar capacity in 2014. In December 2013, Georgia Power announced

the execution of four power purchase
agreements totaling 50 MW, 10 of which
will be purchased from a generation facility built on Robins Air Force Base by global developer New Generation Power Inc.
Though a final contract price has not
been set, the civil engineer team at Robins
expects the 20-year lease to sustain several follow-on energy conservation projects. In addition to the monetary return,
energy generated from the facility will
count toward the DODs 2025 renewable
energy goal. The renewable energy credits
will remain with New Generation Power.
With final lease negotiations nearly
complete, the Chicago-based developer
expects a fully operational facility by
summer 2015.
NEGOTIATIONS
IN NEW JERSEY
New Jersey is another contender in the
proactive adoption of solar energy, a feat
that is related not to high solar resources
but to legislative support and high demand.
It was a chain of socioeconomic events
and a natural disaster that ultimately
brought industry and Air Force leaders together at the gates of Joint Base McGuireDix-Lakehurst.
The Air Force was already assessing
various energy technology opportunities at the base when news broke that
one of four licensed nuclear power reactors in the state, Oyster Creek Nuclear
Generating Station, would shut down
10 years earlier than expected. Prior to
the December 2010 announcement, the
636 MW facility was licensed to operate
through 2029.
Plagued by Tritium leaks and recurrent shut downs, Oyster Creeks
reactor was already offline when Hurricane Sandy struck the East Coast.
Amid the massive flooding and wind
damage, relief efforts were hindered by
widespread power outages.
In New Jersey, Federal Emergency
Management Agency (FEMA) workers established a central mobilization and staging site on Joint Base McGuire-Dix-Lakehurst. Because of its proximity to major
cities, large amount of available space,
and built-in security, the base served as
the hub for equipment, supplies, and relief response for the next several weeks.
The base didnt receive full power restoration until six days after the storm struck
the coast, which slowed response efforts.
The delay hindered the bases full mission
capability, an observation that did not go
unnoticed by state and military leaders.
Following Sandy, state support for the
base escalated. In a speech to the Commission on the Force Structure of the
Air Force, Jon Runyan, New Jersey Third
District representative, called the base
essential to national security, homeland
defense, disaster response, and the military services.
Governor Chris Christie also pledged
his support by creating a task force to issue recommendations to preserve, enhance, and strengthen New Jerseys military installations.
With the desire to simultaneously
improve both the infrastructure and energy sources for Joint Base McGuire-DixLakehurst, AFCEC ultimately ramped up
the EUL discussion and issued a formal
solicitation for business proposals in December 2012.
In November 2013, the Air Force selected the Starwood Siemens development
team for the project. Alongside partners
Energy Management Inc. and CB&I, the
Starwood Siemens team plans to create the largest clean energy park built
on Air Force property. The project could
ultimately produce more than 550 MW
of combined solar, biomass, and clean
natural gas power generation developed
in three phases over the next five years.
Phase one includes two photovoltaic
solar arrays that would generate 30 MW
of renewable energy. Phase two calls for
15-20 MW of additional renewable energy currently planned as a biomass plant.
Phase three, a combined cycle gas turbine
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plant, would supply the public grid with

more than 500 MW of clean energy.
Negotiations on the lease and final
project details are currently underway,
but the return to the Air Force and developers could be substantial. With an
EUL, the Air Force has the option to take
lease payments or receive in-kind consideration, which can be of benefit to
the installation in many ways including:
energy storage, on-site power generation, smart grid and micro grid integration, and black start capability. With the
ability to restore power without relying
on the external electric grid, black start
would give Joint Base McGuire-DixLakehurst quick recovery capability in
another Sandy-like event.
POWERING AHEAD
For the Starwood Siemens team,
partnering with the Air Force provides

an added level of support. With more
than just the developers interests on
the table, the mutually beneficial arrangement will ultimately be carried
through to completion by an entire
team of supporters. The benefits of a
successful EUL in New Jersey extend
far beyond the gates of the joint base.
It means more jobs in the local community, improved energy reliability
and service for the entire region, and
investments in state energy infrastructure. The project is a pilot for combining programs like EULs and power
purchase agreements, while integrating multiple energy technologies. If
successful, the project will significantly contribute to the Air Forces energy
security and independence goals.
The AFCEC has a motto: Battle Ready
Built Right. It means that the organization has the ability to deliver
warfighter needs by implementing enterprise solutions; foster collaborative
and integrative approaches to problem
solving; and find opportunities for
partnerships with sister services, communities, and industry.
To meet the challenges facing the nation and the Air Force, AFCEC is turning to private industry for innovation
and creativity. Through partnership
with industry, AFCEC can develop
the solutions the nation needs to meet
those challenges for both Airmen and
the country. Thats what drives the
organization today, and its what will
drive it tomorrow.
For more information about the
Air Force Energy Program, please visit
http://www.afcec.af.mil/.
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149
Under Attack
How to Protect Your Power Generation Project
Against Environmental Group Opposition
Authors:
Richard Alonso is a partner at Bracewell
& Giuliani where he advises manufacturers and energy companies on environmental, permitting, compliance, and
enforcement issues. Sandra Y. Snyder is
an attorney at Bracewell & Giuliani, representing energy companies, industry
trade associations, and manufacturers
in environmental litigation. Tim Wilkins
is the head of Bracewell & Giulianis
firm-wide Environmental and Natural
Resources practice group.
BY RICHARD ALONSO, SANDRA Y. SNYDER, AND TIM WILKINS,

BRACEWELL & GIULIANI
ower plants, pipelines, policy and regulatory objectives. Clirefineries, and even mate change has provided a new batgolf courses regardless tleground for challenging large power
of the type of project projects that have significant greenyou plan to construct, house gas emissions. Over time, the
there is always a risk that someone, arguments raised by these groups have
somewhere will oppose your idea evolved to become much more technior how you plan to construct it. The cally advanced and far more difficult
most potent tool for blocking many to defend against.
industrial projects is a challenge to their
preconstruction Clean Air Act permits. THE PSD PROGRAM
The tool that national environmenProject opposition is not reserved for
controversial or headline news projects tal groups seem to favor in opposing
like the Keystone XL pipeline. In fact, major projects in the United States is
such challenges can be a major threat the Prevention of Significant Deterioto nearly any type of project even if ration (PSD) program under the Clean
they are ultimately unsuccessful as Air Act. The PSD program is a pre-conthey can derail project financing and struction permitting program, which
delay construction for many months means that a facility cannot start construction without first receiving a final
or even years.
Project challenges today have moved permit, most often issued by state regupast the simple Not in My Back Yard lators under authority from the U.S. Enor NIMBY challenges, where neighbor- vironmental Protection Agency. Most
ing residents voiced concerns about PSD permits are subject to challenge in
nuisances or how
lengthy adminisa proposed proj- The most potent tool
trative proceedings
ect could person- for blocking many
and do not become
ally impact them,
final until after the
industrial projects
the value of their
conclusion of adhomes, or their lo- is a challenge to
ministrative and
cal communities. their preconstruction
remand proceedChallenges
are
Clean Air Act permits. ings. These adminnow commonly
istrative
appeals
led by well-organized and well-funded can last many months or even several
environmental groups that have be- years and they are often even subject to
come much more sophisticated and subsequent judicial review. Financing a
now often oppose projects based on project can be extremely difficult until
concerns about national and global a final, wholly non-appealable permit
impacts or in furtherance of major is in hand.
150
One leading example of such organized opposition arose in 2002, when

the Sierra Club launched a campaign
responding to a Bush administration
initiative aiming to construct 150 new
coal-fired power plants in the United
States. Sierra Clubs campaign, known
as the Beyond Coal campaign, utilized grass roots recruiting efforts to
drum up interest at universities and
with neighborhood activist groups
across the country. The goal of this
campaign was to preempt what the Sierra Club perceived to be a coal rush,
or a boom in both supply and demand
for coal. The mission of the campaign
was to retire one-third of the nations
www.power-eng.com
coal plants by 2020 and replace them

with clean energy solutions. The
Beyond Coal campaign has claimed
numerous victories across the country
with 178 coal-fired power plants shuttering or halting construction. Sierra
Club used the PSD permitting process
to introduce uncertainty in the development process, thereby preventing
many projects from being timely financed.
While not all of the decisions to
forego construction of coal-fired
power plants should be directly
attributed to Sierra Clubs efforts,
such efforts need to be considered
seriously during discussions about
www.power-eng.com
whether or how to construct any new

power project. Regardless of the type
of project you intend to construct, it
is important to take note of and learn
from these campaigns because over
time, the target often evolves. And
that is exactly what Sierra Club did
after winning the war against coal:
Sierra Club launched a brand new
campaign against natural gas in 2012.
Sierra Club did this despite accepting
over $25 million in donations from
2007 to 2010 from natural gas interests
to help fund its anti-coal efforts. This
new campaign seeks to halt projects
that either consume large quantities of
natural gas or that Sierra Club perceives
as encouraging additional production

of natural gas in the U.S. This new
campaign, aptly named the Beyond
Natural Gas campaign, was modeled
after Sierra Clubs earlier success with
its Beyond Coal campaign. The goal of
this campaign is to end the use of fossil
fuels for electric power in the United
States by 2050. After coal, the largest
source of industrial greenhouse gas
emissions is natural gas electric and
steam generation. The organization
realizes that if new natural gas plants
are built today, they will still be in
their operational prime in 2050, which
would likely frustrate one of Sierra
Clubs fundamental policy missions.
151
The Beyond Natural Gas campaign

has several goals. But its key objectives
are reducing the use of natural gas in
the United States and halting the
practice of hydraulic fracturing which
has made natural gas cheaper and
more plentiful. By trying to reduce
natural gas use in electric generation,
Sierra hopes to reduce greenhouse gas
emissions and also to keep gas prices
low to better ensure that cheaper
coal does not regain popularity. If
natural gas prices rise substantially,
environmental groups are concerned
that coal may be revived as the favored
fuel for electric generation because
it is inexpensive and quite reliable.
The environmental organizations
hope to achieve the goal of reducing
natural gas demand by opposing
liquefied natural gas (LNG) exports,
encouraging the development of
more renewable energy alternatives
such as solar and wind, and adopting
tougher energy efficiency standards.
As a result, many different types of
projects LNG export facilities, new
natural gas-fired electric plants, gas
processing and transportation, and
chemical plants that use natural gas
as feedstocks are all potential targets
for the Beyond Natural Gas campaign.
REDUCING IMPACT OF
PROJECT OPPOSITION
In order to best defend against
potential attacks from environmental
groups, project proponents need
to be mindful of the risk of project
opposition beginning at the very
initial stages of the project. Efforts
to avoid project delay should not
start when litigation or a permit
challenge is filed. Rather, this process
should start the moment you begin
to develop a PSD permit application.
In many jurisdictions, once a permit
is challenged it is difficult or legally
impermissible to introduce new
information into the permit record.
The reviewing body usually limits its
152
The tool that national environmental groups seem to favor in

opposing major projects in the U.S. is the Prevention of Significant Deterioration (PSD) program under the Clean Air Act.
evaluation of the permits adequacy to

the information in the administrative
record supporting the permit.
In
other words, in many circumstances,
neither the approving agency nor
the project proponent will be given
an opportunity to provide further
evidence or testimony to support
the agencys decision.
Therefore,
establishing a robust and legally
defensible administrative record is
fundamental in any PSD permitting
process and this effort should start
from day one of the permitting process.
It is not sufficient to simply obtain a
permit from the State environmental
regulatory staff; to withstand likely
challenges, the permit that is issued
must be legally defensible. Project
proponents and their consultants, in
coordination with experienced legal
counsel, should try to make sure the
administrative record contains all of
the information that will be necessary
to support the agencys final decision
even in the face of sophisticated legal
and technical arguments.

Project proponents cannot and
should not assume that the agency
issuing the permit or granting the
approval will create an adequately
robust record that will support the
agencys decision.
Although the
agency issuing the permit or approval
has an interest in seeing its decision
be upheld, the risk to the agency from
a successful permit challenge is far
less than that faced by the permittee.
The project proponent may lose its
financing, default on contracts for
services or equipment that have been
purchased, incur significant penalties
for construction delays, or even find
itself having to lay off employees.
Thus, the project proponent should
pursue its permits with a defensive
mindset even before the project
officially comes under attack. Project
proponents can begin by playing
devils advocate, hypothesizing
potential
arguments,
comments,
or criticisms that might be filed by
www.power-eng.com
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the public or environmental groups early in the BACT analysis process.

regarding any of the permits or This includes a full analysis, includapprovals that must be obtained for the ing a detailed cost analysis, of carbon
project. Identifying these arguments capture and sequestration technology,
before a draft permit is opened for even though such technology is curpublic comment can help identify rently infeasible on natural gas electric
potential weaknesses that might generating plants from both a technootherwise exist in the administrative logical and economical perspective.
record. Weaknesses identified during One needs to accept that many aspects
this process represent opportunities of PSD permitting are unnecessarily
for the project proponent to bolster burdensome and often do not make
the record with
sense, but one must
additional
legal Climate change
still take great care
and
technical has provided a new to meet all appliinformation
that
cable PSD requirebattleground for
will be responsive
ments to ensure the
to these anticipated challenging large
issuance of a defenconcerns.
power projects that sible permit. ThinkFor example, if a
ing defensively, the
have significant
company wishes to
project proponent
build a new natu- greenhouse gas
might want to conral gas-fired power emissions.
sider expanding the
plant, there is a
list of design options
high likelihood that local or even na- considered to include a discussion of
tional environmental groups will be any alternatives that might possibly be
closely watching the project. Some is- raised in the public comment period.
sues that the project developer might As part of the cost-effectiveness porwant to consider are whether to build a tion of the BACT analysis, the project
simple cycle plant or a combined cycle developer would be well-served to
plant. If a simple cycle plant is cho- thoroughly explain and document the
sen, the administrative record should basis for all of its assumptions to avoid
clarify why the company made this de- criticisms during the public notice and
cision and did not elect to construct a comment period. Simply by thinkcombined cycle plant that is generally ing defensively, a project proponent
considered to be more efficient with may find that an initial cost analysis
respect to its greenhouse gas emis- was too back-of-the-envelope, that
sions. Similarly, if the project requires it overlooked certain costs or tax benPSD authorization for significant efits, or that certain assumptions may
greenhouse gas emissions, the permit- not be fully defensible for the particutee will need to be sure to provide a lar project.
robust and defensible Best Available
Control Technology (BACT) analysis THE LA PALOMA
fully justifying the technologies em- SUCCESS STORY
ployed to control greenhouse gas emisOne success story in this regard is
sions (e.g., efficiency improvements the PSD greenhouse gas permit issued
to turbines). Among other things, a to the La Paloma Energy Center. La
robust BACT analysis should include Paloma is a merchant power provider
a thorough discussion of all available with plans to construct a new combined
control options and should be care- cycle natural gas-fired power plant in
ful not to disregard those options too Texas. Sierra Club filed a petition with
154
EPAs Environmental Appeals Board

(EAB) in December 2013 challenging
EPAs decision to issue a PSD permit
to La Paloma for its greenhouse gas
emissions. On March 14, 2014, the
EAB issued an order denying review
of this petition, which was the first
petition seeking EAB review of a Texas
greenhouse gas PSD permit.
Although this case raised issues
of first impression, the EAB issued
a decision upholding the permit a
mere 98 days after Sierra Club filed its
petition for review. This is the shortest
timeframe in which the EAB has acted
on a substantive challenge to a PSD
permit in recent history. The La Paloma
case reflects that a permits validity
will ultimately be determined on the
strength of the administrative record.
As this case demonstrates, to have such
success, project developers should work
closely at an early stage with counsel
and consultants that understand PSD
legal challenges to better ensure that
their permit records are fully developed
to help minimize the risks associated
with a permit appeal.
SUMMARY
By anticipating challenges and
taking a proactive strategy to a
permits administrative record, project
proponents can take affirmative steps
to make their permits as defensible as
possible. Doing so can be beneficial
for a number of reasons: (i) a strong
record may dissuade the environmental
groups from challenging your project
in the first instance and (ii) a strong
record will help uphold your permit or
the agencys approval in the event of a
legal challenge. While such a strategy
may involve more up-front work
and expense, in the long run, it can
make the difference between starting
construction of your project on time
instead of suffering years of vastly
costly litigation and potentially years
of project delays.
www.power-eng.com
Author:
Brad Buecker is a Process Specialist in
the Environmental Services group with
Kiewit Power Engineers, Lenexa, Kansas.
THE PHOSPHORUS TWIST
Microfilter pressure vessel

showing the thousands of
hollow-fiber membranes.
Flow is outside-in for this
configuration. Photo courtesy: Pall Corp.
The Continuing
Evolution
of Cooling
Tower Water
Treatment
BY BRAD BUECKER, CONTRIBUTING EDITOR, KIEWIT POWER ENGINEERS
he many new combinedcycle power plants being

constructed in the U.S.
are being equipped with
either cooling towers or
air-cooled condensers for steam condensation. Once-through cooling systems
are out. For plants with cooling towers,
the days of relatively straightforward
chemical treatment have reached an end,
156
although in large measure that ended

three decades ago when chromate treatment was banned. Plant operators and
technical personnel, many of whom are
new to this industry, are facing significant challenges when it comes to keeping
cooling towers reliable and efficient. This
article outlines a number of important
details regarding modern cooling water
treatment methods.
Since the outlawing of chromate-based

chemistry programs, the treatment method employed for many cooling towers
has utilized a blend of organic and inorganic phosphates for primary scale and
corrosion control along with an organic
polymer for calcium phosphate scale
control, and perhaps a small dosage of
zinc for additional corrosion protection.
These programs can be effective, but they
require very close monitoring and control
to prevent chemistry upsets. Accordingly,
the major water treatment chemical companies developed sophisticated chemical
feed and control systems for this methodology. One problem with phosphorus-based programs, which is becoming
critically important, that the cooling
tower blowdown obviously discharges
the phosphorus, mostly, of course, in the
form of phosphate (PO4). Phosphorus is
a primary nutrient for aquatic organisms,
including toxic algae and cyanobacteria.
Many receiving bodies of water are now
considered to be phosphorus-impaired,
which means that discharges from new
plants may be severely limited when it
comes to phosphorus concentration (and
sometimes other impurities as we will
see). So, essentially two choices are available, treat the plant wastewater, perhaps
even to zero liquid discharge, to remove
impurities, or employ an alternative cooling tower treatment program.
Lets discuss alternative treatment first.
Researchers are working diligently to perfect non-phosphate programs, and some
results have been very successful in fullscale applications. The new programs
are based on polymer chemistry, where
the polymer chains contain carboxyl (RCOO-), sulfonate (R-SO32-), and amide
(R-CONH2) sites, among others. (R
represents the organic substrate. Polymers of course can be manufactured
in an infinite variety of chain lengths.)
The polymers and their active groups
www.power-eng.com
Powering
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sequester the scale forming cations calcium, magnesium, iron, and others to prevent them from reacting with anions such
as bicarbonate alkalinity (HCO3-) and
silicate (HSiO3-) to form scale. Research
also shows that some of the polymers can
provide effective anodic corrosion protection. One potential drawback is cost, as
it appears that the polymer concentration may, depending upon the makeup
water quality and cooling tower cycles of
concentration, need to be maintained at
several hundred parts-per-million (ppm).
Wastewater Treatment
Besides phosphorus, other compounds
are beginning to appear on plant discharge guidelines. These regulations
fall under the auspices of the National
Discharge Pollutant Elimination System
(NPDES), but in some cases individual
states are imposing restrictions above and
beyond the national guidelines. New
proposed national regulations will impose restrictions on chromium and zinc
(0.2 ppm and 1 ppm, respecitively), but
other constituents that are appearing on
new state-influenced guidelines include
ammonia, copper, sulfate, and total dissolved solids (TDS). Rumors have flitted
around that bromide and chloride may
be added to the list, with other possibilities in the future.
These issues raise a number of concerns.
For example, a common treatment method to reduce scaling potential in cooling
towers is feed of sulfuric acid (H2SO4),
which reacts with bicarbonate alkalinity
and converts it to carbon dioxide. This reduces the potential for calcium carbonate
scale formation. Obviously though, any
limits on sulfate discharge can potentially affect this straightforward treatment
method. TDS limits offer an interesting
and at times potentially very frustrating
paradox. In some states, with California
being a notable example, restrictions are
being placed on the quantity of plant
discharge, of which cooling tower blowdown is often the major component. But,
the method to reduce blowdown is to increase the cycles of concentration (COC).
158
Now, however, the blowdown may run

afoul of TDS limitations. In yet another
example, a combined-cycle plant with an
existing cooling tower of wood construction is facing difficulties with regard to
proposed new copper discharge limits.
The wood was fabricated with a preservative containing copper, and leaching of
this preservative, especially during times
when the unit is down, may cause violations in future discharge limits.
if plant personnel would wish to incorporate this process in plant design, permission is not granted.
At plants in arid locations with a large
land area, evaporation ponds may be
sufficient to handle the wastewater discharge. However, these ponds must be
properly lined to prevent seepage of the
wastewater with its impurities into the
underlying soil. Permitting may or may
not be granted for evaporation ponds.
Outline of An Emerging Wastewater

Treatment Technology
NaHSO3
CT Blowdown
Permeate
Return To
Process
Sodium
Softener
High pH
RO Unit
UF or MF
NaOH
Sometimes the only recourse may be

blowdown treatment, and the author has
been involved in a number of recent projects in this regard. But, the stream can be
rather complex, with the need to potentially remove phosphate, heavy metals,
and other compounds such as sulfate and
chloride. For these reasons some experts
recommend selection of ZLD up front so
that plant owners and operators do not
have to worry about discharge regulations and future restrictions.
Perhaps the most straightforward ZLD
technique, but with large caveats, is deep
well injection. Such wells are usually several thousand feet deep to avoid any discharge into shallow groundwater used for
domestic purposes. While this concept
sounds simple, experience has shown
that some wastewaters can generate scale
within the well shaft, particularly as
the water warms further underground.
High-pressure is generally required for
this process, and if scale formation occurs, capacity may decrease. Often, even
Reject To
Pond or
E/C
Alternatively, at sites strategically located,

it may be possible to have the wastewater
trucked off-site to a waste disposal company.
If none of the above options are available, thermal evaporation of the waste
stream may be the only choice. At a recent visit to a plant in the southwestern
U.S., the author observed a brine concentrator/crystallizer system that treats the
entire cooling tower discharge. While the
system operates well, the inlet flow rate
at full load is nearly 1000 gpm. Thus, energy requirements are quite large, as are
the regular maintenance costs to remove
accumulated solids from the equipment.
Per the above-mentioned reasons,
becoming more popular are treatment
methods to reduce the volume of the
plant waste stream before final treatment. A notable example is high-recovery
reverse osmosis, as outlined generically
below.
Keys to the process are:
Microfiltration (MF) or ultrafiltration
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(UF) to remove suspended solids in

the waste stream. This is a critical
process to prevent the solids from
fouling reverse osmosis (RO) membranes.
Sodium bisulfite (NaHSO3) feed to
remove residual oxidizing biocides.
This is also critical to remove oxidizers that would degrade softener resin
and RO membranes.
A sodium softener to remove calcium and magnesium. Otherwise
the downstream equipment would
suffer from calcium carbonate and
magnesium/calcium silicate scaling.
Sodium hydroxide injection to elevate the pH above 10. (The combination of hardness removal and pH
elevation keeps silica in solution.)
Two-pass reverse osmosis (RO) treatment.
Under proper conditions, the RO recovery efficiency may reach 90 percent.
The RO permeate recycles to the plant
high-purity makeup water system or other 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 system
operating at a power plant near the Pacific Northwest. One of the most notable
is that some standard water treatment
chemicals may foul the UF membranes.
Operating experience indicates that the
membrane manufacturer and type influence this phenomenon. Fouling is often
caused by the fact that many membranes
carry a negative surface charge while cationic polymers are commonly employed
for coagulation and flocculation. Residual polymer will coat the membranes. (A
very similar phenomenon has been observed with MF or UF systems installed
in makeup water systems downstream of
a clarifier. Inexperienced designers and/
or plant personnel have not always recognized that MF or UF should generally
serve as a replacement for clarification,
not a polishing process for the clarifier.)
A straightforward solution that has
160
significantly improved the reliability of

this particular system is conversion of
the ultrafilter from an inside-out normal flow path to outside-in. Typical
micro- and ultrafilter systems consist of
multiple, parallel flow modules containing thousands of spaghetti-like, hollowfiber 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
case, conversion of the membranes from
inside-out to outside-in normal flow path
improved the backwash efficiency.
Another interesting initial difficulty
occurred during the original UF backwash process. Typically with these systems, a small portion of the permeate
is collected in a separate tank at the beginning of each process cycle for use in
backwash. No issues during standard
When this particular UF was first commissioned, the membranes developed a

layer of calcium silicate scale during the
CEB caustic stage. The driving force was
the higher pH generated by the caustic,
which in turn greatly reduced the silicate
solubility. The solution to this problem
was a switch to softened water for the
backwash supply.
THE RAW WATER

CONUNDRUM
Now we come to an issue that can influence all of the above processes; the
quality of cooling tower makeup supply. As fresh water sources become more
scarce, cooling tower makeup at an increasing number of plants, either by
mandate or choice, is being taken from
less-than-pristine sources. A perfect example is treated municipal wastewater
effluent. While this water undergoes
Extreme algae growth in

a cooling tower. Photo
courtesy: Ray Post, ChemTreat
backwashes. But most modern MF and

UF units are now equipped with automatic chemically-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
organics and microbiological organisms,
followed by rinsing and then a dilute citric acid wash to remove iron particulates.
significant treatment to convert it from a

raw sewage-laden inlet to a pathogen-free
effluent, the discharge still often contains
significant concentrations of ammonia,
phosphorus, organic compounds, and
suspended solids. When used for power
plant makeup, the stream may require
upfront treatment such as clarification/
filtration to prevent detrimental influences in the cooling tower and on blowdown
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quality. Well recognized is that microbiological fouling is the issue of a greatest concern in a cooling water system. A
makeup stream containing phosphorus,
ammonia, and organic compounds is
the perfect bug food. The three types
of microorganisms that most affect cooling towers and cooling water systems are
algae, fungi, and bacteria. Algae require
sunlight to grow, and these organisms
most commonly foul cooling tower spray
decks and other locations exposed to the
sun, as the figure from a top expert below
illustrates. The growth then can degrade
performance and cause unsafe working
conditions.
Fungi proliferate within cooling tower
internals that remain moist. The organisms are particularly troublesome in
wooden cooling towers, as they can cause
rot of wood components, which in turn
greatly weakens the structure.
Bacteria are separated into the following three categories,
Aerobic: Utilize oxygen in the metabolic process.
Anaerobic: Live in oxygen-free environments and use other sources, i.e.,
sulfates,
nitrates, or other donors for their energy supply.
Facultative: Can live in aerobic or
anaerobic environments.
A problem with microbes, particularly
many bacteria, is that once they settle on
a surface the organisms secrete a polysaccharide layer (slime) for protection. The
slime layer is an excellent insulator, and
even a small film will significantly inhibit heat transfer. The slime will also gather
silt from the water, growing even thicker
and further reducing heat transfer. And,
even though the bacteria at the surface
of a colony may be aerobic, the secretion
layer allows anaerobic bacteria underneath to flourish. These bugs in turn can
generate acids and other harmful compounds that directly attack the condenser
and heat exchanger tubes. Also, microbial deposits establish concentration cells,
where the lack of oxygen underneath the
162
deposits causes the locations to become processes.

anodic to other areas of exposed metal.
Of additional benefit is use of bioPitting is often a result. So, poor control penetrant in any chemical formulation.
of microbiological fouling can lead to As has been previously noted, some
conditions that will cause:
microbes secrete a protective layer to
Serious efficiency loss in condensers shield the organisms from poisons. This
and auxiliary heat exchangers
layer is very effective at deactivating
Condenser tube corrosion and fail- oxidizing biocides. A bio-penetrant or
ure
bio-dispersant as it is often also called,
Restricted flow and severe loss of acts as its name applies and helps the
heat transfer in the cooling tower
biocide to penetrate the slime layer and
Partial cooling tower collapse due to attack the organisms underneath.
increased weight of structural comAnother important point to consider
ponents
regarding biocide treatment is feed duEstablished microbiological colonies ration. A typical requirement for onceinduce growth of higher organisms, through cooling systems is a two-hour
which in turn can lead to growth of le- feed per unit per day. This regulation
gionella bacteria. For
was designed to prothose unfamiliar with A makeup
tect aquatic creatures
legionella, these or- stream containing
at the cooling water
ganisms can cause illdischarge. However,
phosphorus,
ness (and sometimes
this means that each
ammonia,
death in weak individcondenser and any
uals) if inhaled.
auxiliary heat exand organic
So, feed of an oxichangers go untreatcompounds is the ed for 22 hours per
dizing biocide is still
very important, as it perfect bug food. day. If microbes sethas always been. But
tle and form a slime
makeup containing significant concen- layer, they are then protected from
trations of ammonia and organics will the next dose of biocide. Many coolquickly consume the standard treat- ing towers have been placed under the
ment chemical, chlorine. While bromine same restrictions, [2] but one has to ask
chemistry has been successfully used in why? Any oxidizing biocide residual in
many applications, an increasingly popu- the blowdown whether it be chlorine,
lar alternative is chlorine dioxide (ClO2). bromine, or chlorine dioxide, can be
ClO2, which must be generated on-site, neutralized with a reducing agent such
is a powerful oxidizer that does not re- as sodium bisulfite (NaHSO3). Thereact with ammonia or form halogenated fore, it seems very worthwhile to neorganics. In the past, the most common gotiate this point with environmental
technique for ClO2 generation was reac- regulators to allow more frequent or
tion of sodium chlorite (NaClO2) with ei- perhaps even continuous biocide feed
ther chlorine gas or bleach in an educator to the tower, provided the blowdown
or other blend system. This required stor- is treated to remove residual oxidant.
age of large quantities of hazardous mate- The cost of biocide chemicals can be rerials and was rather more expensive than paid many times over in reliable tower
either chlorine or even bromine chem- performance and heat transfer. Also,
istry. Now, modular systems that utilize continuous biocide feed, particularly at
sodium chlorate (NaClO3), activated certain times of the year, can control inby acid and hydrogen peroxide (H2O2) festations of macro-fouling organisms,
to produce ClO2, are available, and are including zebra mussels and Asiatic
much more safe and efficient than older clams.
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CenterPoint Energy Mississippi River
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BY CONNIE OSLICA, CENTERPOINT ENERGY
lectricity and natural-gas

delivery company CenterPoint Energy Mississippi River Transmission
LLC (CNP-MRT) owns
and operates 8,200 miles of transmission pipeline that carried 1.6 trillion
cubic feet of gas throughout a ninestate, mid-continent region during
2012. Transmission-business success
depends on meeting complex, capitalintensive and data-critical infrastructure challenges, and moving large
volumes of natural gas reliably, over
long distances to 22 gas-fired power
plants.
Competing for utility customers
against other transmission companies
and alternate forms of energy requires
CNP-MRT to leverage technology that
minimizes operating, maintenance
and downtime costs. This allows them
to achieve price and service levels that
win and retain utility customers.
164
opportunities to reduce infrastructure

maintenance costs, minimize downtime and leverage real-time diagnostics
are significant. But so is the potential
capital investment and resource allocation attached to deploying upgraded
control technology across almost 70
transmission-line compressor units.
Transmission profitability is complicated further because the throughput-dependent segment also must
accommodate variables, such as de- CHALLENGE
mand-reducing mild weather, fluctuEach compression station located
ating gas prices and regulatory-com- 40- to 100-mile intervals along a pipepliance overhead.
line route utilizes two to 10 compresEfficiently, reliably and intelligently sors in the 2,000-horsepower range.
controlling, automating and monitor- Aging systems typical in the energying the performance
delivery space are
of reciprocating en- Transmission
built to last. Even
gine
compressors business success
equipment that went
represents one of
online in the 1960s
depends on
the most significant
can have another 20
challenges in mov- meeting complex,
years of life. At the
ing the highest quan- capital intensive
same time, the detity of natural gas at
cades-old machines
and data critical
the lowest cost. The
are not as efficient as
school bus-sized en- challenges.
current technology.
gines maintain a pressurized flow (up As a result, control systems tend to unto 1,500 psi) to reduce gas volume up derperform current standards.
to 600 times and propel it through a
Upgrading control systems across
pipeline.
the sizeable Midwest compressor
Control
and
automation fleet represents an enormous capital
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undertaking particularly under a traditional outsourcing model that contracts control design and implementation to multiple engineering firms and
system integrators. Over time that approach created a mix of control products and solutions at CNP-MRT often
based on black-box proprietary logic.
Because this scenario tends to keep
management and station operators at
arms length, overreliance on external
vendors limits in-house ability and
significantly increases the cost to
configure, integrate, expand and upgrade control.
The CNP-MRT control and automation group saw the companys Horseshoe Lake compressor station as a test
case for designing and deploying an
internally executed station upgrade.

The four-compressor facility in Grant
City, Ill. is on the CenterPoint Mississippi River Transmission (MRT) pipeline that transports the bulk of natural
gas moving state to state in the Missouri, Arkansas and Illinois region.
The company inherited Horseshoe
Lake from another entity that specified and built the facility before turning it over to CNP-MRT to operate. The
seven-year-old station was relatively
new, but at the time of construction
the original, economically minded
systems integrator opted for proprietary architecture and PLCs already
nearing the end of their life span.
Relative to the potential of todays open architecture, the result
was an antiquated control system programmed in a very antiquated way,

said Steve Starkey, the CNP-MRT instrumentation and electronics specialist overseeing the companys Northern
pipelines. In addition, CNP-MRT uses
Rockwell Automation exclusively and
doesnt support the platform that was
in use at that facility. So we couldnt
work on the control system ourselves
without investing a significant amount
of time and money in training.
Simply adding another step in an engine startup sequence, for example, required a control vendor to reprogram it
at an additional cost for each improvement. Troubleshooting a problem or
obstacle, particularly in the middle
of the night or on a weekend, opens
The PlantPAx system provides a window on compression by incorporating performance metrics

and the situational display of production information at engine, station and pipeline system levels.
Photo courtesy: Rockwell Automation
166
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Each compression station located at 40- to 100-mile

intervals along a pipeline route utilizes two to 10
compressors in the 2,000-horsepower range. Photo
courtesy: Rockwell Automation
cant replace things individually when you need to

integrate and expand.
Finally, CNP-MRT needed significant improvement in the information
solution, from data access,
collection and sharing, to
real-time remote monitoring and alarming. Major
expense variables for large
compressors include engine maintenance to optimize operating efficiency
and performance, as well
as the cost to repair failures
that should be avoidable.
An engine that goes
down or fails means an
energy company does not
make money. With contracts based on high standards for delivery reliability including fines for not
moving gas as promised a
lack of data-driven visibility prevents being proactive
on maintenance, reacting
quickly with adjustments,
and efficiently expanding
or scaling up.
SOLUTION
compressor operations to downtime

risk.
Its often said that there are not
many ways to troubleshoot a black-box
problem, said Starkey. CNP-MRT
168
doesnt believe that. We wanted something that we can manage directly, so

we can be in control of the troubleshooting. In addition, a proprietary
system typically is not modular. You
CNP-MRT used the

Horseshoe Lake station
to create and prove a potential model to cost-efficiently develop, manage
and implement a major
control upgrade relying heavily on inhouse resources.
Partnering with oil and gas specialists from the Global Solutions team at
Rockwell Automation, CNP-MRT set
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out to design a solution that was spe- on compression by incorporating percific to Horseshoe Lake, but that could formance metrics and the situational
serve as the standard, or template, for display of production information at
upgrading the rest of its Midwest re- engine, station and pipeline system
gions compressor fleet.
levels. Accurate reporting of real-time
TM
CNP-MRT selected a PlantPAx pro- engine events, along with analysis
cess automation system from Rockwell tools and management dashboards,
Automation that indeliver
contextual,
tegrates control and
localized, role-based
Were trying to
information, using
information for betan open architecture optimize every
ter decision making.
to combine the capa- operational aspect,
Anything that we
bilities of a DCS sys- in real time, that
need to do in the protem with pervasive
cess world, Rockwell
contributes to
access to engine opAutomation has done
eration data. Vastly improved uptime,
it, Starkey said. Havimproved asset vis- efficiency and
ing access to that doibility and producmain expertise helps
profitability.
tion
information
us, as an operations
gives station opera- - Steve Starkey, CNP-MRT
group, to turn out an
tors the data neceseffective control solusary to respond faster on maintenance, tion. Its very full-function, which makes
operation and flow-control issues.
application development and improveThe trend in compressor opera- ment easer. If you can dream it, you can
tions is collecting, integrating and us- do it.
ing higher amounts of data, Starkey
said. Were trying to optimize every RESULTS
CNP-MRT summarizes the upgrade
operational aspect, in real time, that
contributes to improved uptime, effi- returns in four key areas.
1. Cost of ownership Design
ciency and profitability. That includes
monitoring for unit performance, through installation and delivery of the
emissions and even the safety of en- new system at Horseshoe Lake came in
well below previous systems. Based on
gines that pump gas and run on gas.
The Horseshoe Lake upgrade en- experience with previous systems, Starables station operators to more easily key estimated the capital investment at
manage speed and load control. The approximately 20 percent of the total
control system also determines which for control projects equal in scale.
compressor units should start based
2. Simplified HMI configuration
on engine hours and the number of Not having to learn every HMI appliengines the system controls.
cation from scratch cuts training time
In the past, when you turned on considerably. With a baseline to work
engines individually, Starkey noted, from, even if a station is different,
you started No. 1, then No. 2, and so the in-house control group can make
on. As a result, those units always had modifications to fi t nearly every type
more hours. Now, the PlantPAx sys- of engine, which reduces integration
tem knows to start the engine with the time significantly.
lowest amount of hours, and takes the
3. Improved operability The
highest-hour engines offline first.
Horseshoe Lake experience indicates
The visualization capabilities within that operators, who are responsible
the PlantPAx system provide a window for their respective stations, can be
170
confident in most anything they will

be asked to do.
Previously, there were many gray
areas; too many instances where
operators didnt have control or the
necessary insight, Starkey said. The
approach is different now. Operators
themselves helped build really good
HMI and PAC programs. Its their
control system.
4. Reduced downtime The
PlantPAx system has reduced station
downtime and the capital outlay for repairs. Previously, there were no alarms
other than shutdown. Today, with
alarms programmed to catch engine
issues before failure, operators initiate repairs ahead of engine failure. By
watching the data remotely, staff can
make an engine the least available until they resolve an issue.
Horseshoe Lake represents the first
time that CNP-MRT has undertaken
an entire compressor control station
using in-house resources. There was
understandable skepticism on the part
of top management.
We had to demonstrate that the new
system was substantially easier for our
team to manage than previous systems,
Starkey said. It had to be more scalable,
more efficient, and more reliable than
anything purchased previously.
With Rockwell Automation supporting the project through goal setting,
engineering advice, guidance and energy-specific best practices, the PlantPAx solution is the consensus control
and automation model for the entire
compressor fleet. From the faceplates
to the look and feel of how the control
system operates, the design and implementation is the CNP-MRT standard
for upgrading other compressor stations in the future.
The PlantPAx system has outperformed on every metric, from reliability to scalability and integration of
most anything we can think of, Starkey said.
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UTILIMAP CORPOR ATION
WHAT WORKS
Projects Illustrate
Strategies for
Comprehensive
Design Tools
BY ZACH PLATSIS AND TOM FITZPATRICK, SSOE GROUP
hen renewable energy is

part of the total energy
equationforanindustrial
plantorutility,afeasibilitystudyprovides invaluable cost-beneft information for decision makers. Performed
duringtheplanningphaseofaproject,
afeasibilitystudyisanevenbettervalue when engineers can generate realisticpotentialoutcomesquickly,easily
andcosteffectively.
tosolar.Intheend,thearraywasdesigned,built,andisownedbyalocal
solardeveloper.
As industrial manufacturing facilities go, the plant is a very energy-in-
Authors:
Zach Platsis is an Energy Consultant for
SSOE Group.
Thomas Fitzpatrick is a Power Department Manager at SSOE Group.
Building group: project capital

costorpaybackorboth
Operations:annualoperationand
maintenancecost
Sustainability: total energy productionandLEED-creditvalue
Environment: regulations and
permitting
Marketing:corporatebranding
Althoughsuchgroupsmayinitially
appear as obstacles to project managers, they can offer insights into unforeseen costs, as well as cost-saving
For the solar facility project, engineers used the
modeling tool for a cost-effective analysis of 18
initial permutations of project parameters.
COMPREHENSIVE
RENEWABLE ENERGY STUDY
AND PRELIMINARY DESIGN
Aleadingcarandtruckmanufacturingplantinthesouthisaninstructive
example of the beneft of such a feasibility study. In the planning phase,
SSOE performed a comprehensive renewable energy study that forecasted
cost-beneft information for various
design alternatives. Specifcally, the
engineers used the companys solarfeld computer modeling program
to develop a preliminary design that
optimized energy production on the
proposed site. The study presented
options for responding to two major
constraints associated with the solar
feld:ahighexpectationforrenewable
energyuseandasitethatconsistedof
noncontiguousareas.Thesolaraspect
was only a small part of the overall
renewable energy study and initially
was not chosen. Instead, Landfll Gas
(LFG)Energywaschosen.Onlyafter
themanufacturingplantwascompleted did the manufacturer change back
172
tensivesite.Becauseitwasaimingfor
LEED certifcation, the project set a
hightargetforrenewableenergy.
A comprehensive planning process
isaboutmorethaninformationmodeling; it is also about bringing all the
keyplayerstotheplanningtable.Balancing their interests, needs and valuesand measuring these accurately-can be one of the most challenging
parts of the planning process. It can
alsobeoneofthemostproductivein
terms of a projects success. Consider
thefollowingstakeholders:
opportunities. The operations group,

forexample,willidentifycostsassociated with O&M costs that could be
addressedbyrefningthedesign.
Managingprojectcostsrequiresthe
design to maximize the area of the
existing site while minimizing construction costs, such as the need to
level a hilly site. The locations of the
central or distributed inverter system
and the array medium voltage transformersalsoaffectprojectcapitalcost,
to which engineers must assign dollaramounts.Theymustalsofactorin
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additional costs associated with the

interests of internal groups and third
parties such as regulators and federal,
state, and local governments. Using a
modeling tool, these costs can quickly
be calculated to refne the design and
generate cost-beneft data.
USTATION TOOL
An innovative design tool was developed for use at the Bentley MicroStation, an information modeling
environment for architecture, engineering, construction and operation
of infrastructure, including utility systems. The software tools let engineers
optimize solar arrangements quickly,
easily, and cost effectively, especially
for large, utility-scale felds. Engineers
used software to determine the optimal arrangement of solar panels and
to ensure that the confguration would
ft within the site.
The tool works in four phases. First,
the engineer enters a digital survey
drawing, map, or aerial photograph
into the modeling tool and traces the
perimeter. Second, he specifes potential parameters of the installation, including panel type, panel angle, and
arrangement. Third, the tool automatically flls the feld and computes the
total number of panels that will ft in
the space. Finally, the tool is used to
compare alternatives based on varying arrangements and panel angles,
which enables the engineer to discover
the optimal design of the solar feld to
generate maximum power.
OHIO SOLAR FACILITY

A second application of modeling
tools is demonstrated by the solar facility in Ohio, a 3.54-MW AC facility
with more than 17,000 crystalline silicon panels.
The client opted for a cost-effective, customized solution rather than
a third-party developer for a standard turnkey system. Engineers were
hired to handle the following tasks:
174
determine the solar capacity of the cost-effective analysis of 18 initial persite; provide basic layouts of the arrays; mutations of project parameters. This
simulate solar production from mul- included three module technologies
tiple layouts and module technologies; of varying initial costs and effciencomplete a full-cost pro forma for the cies, three panel angles, and the space
fnal arrangement; and, lastly, develop available on the 20-acre site based on
specifcations for general and electrical various confgurations of land usage.
construction of the power island.
The engineers ran through various perTo assess the feasibility of the proj- mutations. For example, they moved
ect, the engineers analyzed 18 initial or removed a row of solar panels to
permutations of project parameters. provide shading clearance or road acThese included module technology, cess. They flled more of the angles in
panel angle, and space available on the the perimeters of the land units. They
20-acre site based
compared
energy
on various confgu- A feasibility study
production at panel
rations of land usprovides invaluable angles of 10, 20, and
age. They used their
30 degrees. By makcompanys solar-feld cost-beneft
ing fne adjustments
information
for
computer modeling
and avoiding blocked
program to develop a decision makers
access to infrastrucpreliminary design.
ture, they optimized
The Ohio site is comprised of several panel angles and maximized the total
parcels of land with varying dimen- number of panels that could be ft into
sions and shapes, including one unit the space.
with an acute angular perimeter. AlFor each confguration, engineers
lowing for roads, fencing, and shad- ran a simulation to generate the aning clearances, the site confguration nual estimated energy output over 25
created several challenges. The frst years. They then associated a cost for
was simply to maximize the number that system based on the type and toof panels required to generate approxi- tal number of panels. Factoring in site
mately 4 MW of power. The second costs, engineers generated an estimatwas to deploy the system in a heavily ed cost pro-forma for each scenario. As
wooded site. The third was a require- a result, they determined that crystalment for one section to be maintained line silicon technology was the most
as green space. Lastly, one section was cost-effective technology for this projoff limits because of its wetland desig- ect.
nation.
By making the design decisions deEngineers analyzed three module scribed in this overview, and by using
technologies and weighed the advan- proprietary software simulation tools
tages and disadvantages of each. The to model multiple panel and technolfrst optioncrystalline siliconhis- ogy arrangements, SSOE maximized
torically had the highest initial cost production and minimized risk for the
but has since achieved cost parity; initial development project. Detailed
it was also the most effcient of the fnancial modeling and iterations opthree. Cadmium telluride, the second timized the clients investment return.
option, was the lowest in initial cost As the project demonstrates, owners
and effciency. The third technology can develop customized utility-scale
amorphous siliconwas a mid-range solar facilities cost effectively and in
solution in initial cost and effciency.
a short time period by relying on conFor the solar facility project, engi- sulting engineers with the right tools
neers used the modeling tool for a and expertise.
www.power-eng.com
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Author:
Chris Wacker is executive vice president
at Laserfche, a provider of electronic records management and enterprise content management software solutions.
Going Paperless
Improves Performance
at Texas Power Plant
BY CHRIS WACKER, LASERFICHE
472-MW power plant depends

just as much on the fow of
information to workers as the
fow of fuel to its generators, particularly when that information includes
the maintenance manuals and repair
records for thousands of pieces of
equipment.
TMPA runs a 32-year-old coal-fred

power plant comprised largely of
components it cannot operate without. Some of those components, like
the turbines, date back to the plants
construction and have maintenance
histories hundreds of pages long. Most
of those components also have manu-
The Texas Municipal Power Agency provides power via the coal-fred Gibbons Creek Steam Electric Station to
four municipalities in central Texas with a total population of about 500,000. Photo courtesy: Laserfche
So it was with those records that Texas Municipal Power Agency (TMPA) IT
Director Jeff Keys undertook an ambitious project two years ago that is now
turning piles of paperwork throughout
the facility into a seamless fow of information emanating from a centralized electronic records repository accessible through the PCs, tablets and
smartphones of the plant staff who
depend on them.
176
facturer-issued maintenance manuals

that are frequently updated and reprinted. Add on the records involved
in complying with six different federal
agencies and legislative acts regulating
public power companies, and you begin to appreciate the paperwork problems TMPA faced.
Along with the equipment maintenance manuals and repair records,
TMPA had personnel fles, certifcation
reports, inspection reports, and technical drawings flling fle cabinets and
computer hard drives throughout the
dozens of buildings comprising the
plant. Employees tended to collect
their own copies of documents and
keep them in cubbies within their departments for fear of not being able to
fnd those records when needed. As a result, vital records
were being used throughout
the plant without knowing if
they were the most up-to-date
and accurate.
Several years ago TMPA had
a records management system,
but it was better suited to a
small offce rather than a large
enterprise like a power plant.
Keys wanted to get a high capacity records management
system, particularly one that
would allow its engineers to access the maintenance manuals
and the repair records through
one source. He also wanted
a system that would allow
TMPA to expand over time to
meet the records management
needs of other departments. It also had
to work with AutoCAD documents in
a way that allowed staff to easily make
changes to those documents. With
the help of a recommendation from
one of TMPAs client cities Bryan, TX,
Keys opted for a Laserfche enterprise
content management system to be the
foundation of a new records management system he is building at TMPA.
Job one for the new system was getting the plant equipment maintenance
manuals into the new records system
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and then tying those manuals back to manual, scans it in, and if Workfow
the equipment maintenance histories matches that manual with fve other
stored in the plants computerized as- identical turbines, the staffer will be
set management program. Some of assigned 50 points. Points earn staffers
the equipment is unique, and there bragging rights and recognition from
may only be one or two in the entire management.
plant. With other plant equipment,
While everyone enjoyed the friendly
like the pumps, there may be many competition, it is the improvements to
of the same models in use. For those operational effciency making the greatpieces of equipment there may be est impression on plant staff. That is makmany more copies of the same main- ing it much easier for the IT department
tenance manual in use. The challenge to approach other departments to get
was fnding the latinvolved in Keys
est version of those Its hard to put
project. Expanding
manuals and scanthe new repository
a value on the
ning them into the
to include the Acnew records system improvement in
counts Payable dewhile eliminating operational effciency partment provided
the duplicates and TMPA is seeing with
TMPA with perhaps
older versions.
the greatest benits new records
Every time a
eft realized since
management
staff member loundertaking
this
cates a plant equip- system.
project: automated
ment fle in the
indexing.
asset management program which
In the process of scanning the equiphas no manual associated with it in ment maintenance manuals into the
the new records system, the staffer lo- new records repository it became clear
cates the manual, verifes it, and then that if TMPA was going to expand the
scans it in. A software module within system substantially, properly indexing
Laserfche called Workfow automati- the records would be vital to easily fndcally matches that manual to any other ing them at a later date, particularly as
identical equipment in the asset man- the size of the repository grew. Indexing
agement program fles.
involves pulling identifying bits of inforMost plant equipment fles in the mation from each record as it is scanned
asset management program now also in and then using those bits of informahave documentation available in La- tion to more easily locate that record at a
serfche, but there are still some with- later date.
out manuals. To encourage staff to
Working with the staff in AP, the
take time out of their regular jobs to IT department decided which idenlocate and scan those manuals into tifying bits of information are most
the new records management system, useful for indexing records specifc to
TMPA designed a special competition. that department, and Laserfche now
Every time a staff member locates an automatically pulls those pieces of inequipment fle in the asset manage- formation from each document as it is
ment program and associates it with a scanned in. TMPA is now able to store
verifed manual, he is assigned a cer- and automatically index all shapes
tain number of points. So if a staffer and sizes of documents including Aufnds an equipment fle in the asset toCAD drawings, voluminous regumanagement program with no as- latory reports, vendor invoices, dissociated manual he fnds the correct bursement records, and construction
178
project turnover packages. Whereas

such previously existed in numerous
locations, they are now in a central,
easily searched repository that yields
far greater user accessibility.
When TMPA is being audited, providing the documents is just a matter
of anyone with proper authorization
searching for the record type requested
using the indexing information selected. The more indexing information
used, the easier it is to fnd a particular
record, but even without indexing, any
document can be retrieved from Laserfche using words or numerals contained
in it. The indexing just helps narrow the
search. Previously the worker in charge
of the records being searched needed
to be tracked down and, on those occasions when that person could not be
tracked down, it was diffcult to locate
requested records. Utilities are heavily
regulated facilities which are frequently
asked for historic documents. The inability to produce these documents can
translate into fnes.
Its hard to put a value on the improvement in operational effciency
TMPA is seeing with its new records
management system, but the anecdotes are everywhere. In AP, cash coding,vouchers, and journal entries were
all done manually by an accounting
temp who worked 20 hours a week with
an input error rate of four to ten percent.Todaythat whole process has been
automated and catches errors before
documents are committed to the repository. By consistently naming and fling
documents through automated indexing, it gives TMPA staff confdence that
they can easily recall important documents at a moments notice.
As TMPA continues to deploy automated indexing and build more workfows, it improves the fow of information to an ever-expanding network of
offces and departments. That insures
the fow of electricity to the ever-expanding network of customers.
www.power-eng.com
Make Fuel Flexibility Your New

Standard Operating Procedure.
Fact is natural gas is the new standard to meet emissions regulations.
Let Zeeco take the anxiety out of switching to or adding natural
gas to your power facilitys fuel sources.
Zeecos 35-year history of combustion and environmental successes
makes us the logical choice to convert coal-red power to natural
gas, or add gas-red capability to existing burners that meet all
emissions and efciency targets. In a combined cycle facility, ZEECO
low-NOx duct burners also assist in meeting clean-air standards.
Its time you introduced the fuel exibility that keeps power and steam
generating for years to come.
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Meet the Zeeco team at PowerGen, booth #5165
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PRODUCTS
MEMS Accelerometers
workspace or around the world. This optional kit
Stainless steel cable clamps
he single-axis SDI Model 2220 is a higher-
includes a laptop computer, remote viewer, wire-
performance version of the companys Model
less router, network cable and a choice of a hard
case or backpack for easy portability.
Clamps.
2210, combining an integrated low-noise, nitrogen-damped, fully-calibrated MEMS VC acceler-
The confgurable digital solution is outftted
ometer chip with high-drive, low-impedance buff-
with a specially designed adapter for quick, on-
ering, each contained in an epoxy-sealed rugged
site user installation. To set up, the feld techni-
anodized aluminum housing that mounts via two
cian simply connects the camera assembly to the
M3 screws. This design is ideal for measuring ac-
optical instrument, and plugs the USB cable into
celeration within industrial and commercial envi-
the camera and the computer.
ronments, where low mass (10 g) and small size
Brunson Instrument Co.
(1 inch by 0.5 inch by 0.44 inch) help to minimize
Info http://powereng.hotims.com RS#: 401
mass loading effects. Available in seven unique
eyco Products Inc. announced availability of their new Heyco Stainless Steel Cable
Ideal for clamping cable or tubing securely

into place, the clamps are available in two types:
models, with measurement ranges from 2 g to
Flexible belt encoders
standard corrosion resistant 304 stainless steel
200 and a wide frequency response, the SDI
DMag has made available fex encoders from
and insulated LDPE coated 304 stainless steel.
Model 2220 series responds to both DC and AC
Baumer that include fexible magnetic belts
Both the standard and LDPE coated clamps fea-
acceleration, with either two analog 4 V (dif-
for mounting and accurate measuring under harsh
ture smooth coined clamp edges to prevent
ferential); or 0.5 to 4.5 V (single-ended) outputs
conditions on large shafts such as those in gen-
damage to cable insulation, and are designed for
that vary with acceleration. At zero acceleration,
erators, large drive units, hoists and cranes, wind
.203 (5,2 mm) mounting hold diameters. Both
output differential voltage is nominally 0 VDC
turbines, hydroelectric plants and others.
clamps are suited for use in harsh environments,
(DC response). Differential sensitivity ranges are
and the LDPE clamp is coated with polyolefn, a
from 2000 mV/g for the 2 g module; to 20 mV/g
thermoplastic co-polymer that provides a durable
for the 2000 g module, with typical 1 percent
non-toxic, odorless coating that has very good
cross-axis sensitivity. Onboard voltage regulation
low temperature fexibility and excellent electri-
also minimizes supply voltage variation effects.
cal properties. This coating also has FDA food
SDI Model 2220 series modules can withstand
contact approval.
shock inputs of up to 2000 g and can reliably
Heyco Products Inc.
operate over a temperature range of 55C to
Info http://powereng.hotims.com RS# 403
+125C. Each module is serialized for traceability

and is fully calibrated.
180
Available for shaft diameters from 300 millime-
Nuclear cask handling
Silicon Designs Inc.
ters (11.8 inches) to more than 3 meters (9.8 feet),
the fexible magnetic belt can be buckled around
the shaft using only two included screws by a
is founded on solid experience gained over de-
Alignment solution
single operator in mere minutes. That means that
cades of machine design, feld installations and
runson Instrument Co. today announced
the HDMag fex encoders can be installed in ex-
service support.
onecranes offers the Supersafe crane. The

third generation single failure-proof design
the release of their next-gen AlignCam sys-
isting machinery without removing any parts. The
The cranes are designed to greatly reduce
tem for Brunsons current line of alignment tele-
non-contact, magnetic sensing principle ensures
the risk of accidental load drop, and can safely
scopes, levels and transits.
maximum resistance to shock, vibration, dust, dirt,
lower a load in the event of total loss of power.
The Brunson AlignCam solution includes a
liquids and condensation. HDMag fex magnetic
Multiple redundant features and fail safe opera-
digital camera and high quality CCD sensor with
belt encoders are available either as incremental
tor controls are also added. The Supersafe crane
Brunsons TeleView software and an instrument
with HTL, TTL/RS422, or 1 Vpp SinCos outputs and
adapter. Technicians can leverage this digital
up to 131072 lines per revolution, or as quasi-
toolset to troubleshoot precision alignment prob-
absolute with SSI data and additional incremental
lems, increase productivity, archive and docu-
output signals. With IP 67 protection class, 30 g
ment results, and more.
vibration, and 300 g shock ratings, these encod-
The innovative AlignCam system provides a
ers are suitable for the harshest applications from
live image and continuous feedback on sight
-40F to +185F. The operational speed rating is up
lines, so a feld technician can make adjustments
to 1850 rpm, making the HDMag fex series ideal
to achieve precision alignments. The AlignCams
for any large shaft application.
mobile option allows a single operator to view
HDMag
the image on a mobile device anywhere in the

www.power-eng.com
JASC Fuel System Reliability Upgrade

Performance results after 5+ years of
field operation*
300+ successful fuel transfers with less than 4 check
valve related trips over a 5 year period
Only 1 forced outage due to a major fuel system
component failure over a 5 year period
Liquid fuel system recommended maintenance at major
turbine service intervals is refurbishment of liquid fuel,
purge air and water injection check valves
Annual gas to liquid transfer success rates typically
100%
*JASC installed turbine base includes the U.S., Middle East, Africa and Asia.
New JASC Tees

Featuring Integral HighTemperature
Metal-to-Metal Seal Technology
SAE J1926 compatible for purge air, liquid fuel check
valves and nozzle connections
Adjustable orientation for easy connection interface to
existing piping
Engineered for continuous service at 750F ambient
and 2000 psi
Tube adapter Tee
for standard fuel nozzle
Positional Tee
for DLN fuel nozzle
Eliminates leaks associated with high temperature

O-ring degradation
Multiple make-and-break capability provides years of
leak free service
New F-Class Water Injection Check Valve

HighTemperature Metal-to-Metal
Internal Seat
Dash 12 and 16 SAE with Crush Seal Gasket
eliminates O-rings
Exceeds ANSI Class VI seal rating
Crack Pressure: 15 PSID Nominal
Flow Range: 0-20 GPM
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Tel: +1 602.438.4400 Fax: +1 602.438.4420
sales@jasc-controls.com
and cask transporters meet all standards of the
Windows application software provides compre-
U.S. Nuclear Regulatory Commission.
hensive sensor confguration capabilities, fle
Konecranes
management and real-time analysis and evalu-
ation, displaying the measured values as bar

graphs (for absolute values) or pie-charts (for
Coil current
relative value). The sensor is supplied with the
measurement products
software, mounting hardware, interface cables,
AGO Corp.s Rogowski coil current mea-
1230 VDC power supply, and an I/O board with
needed. They effectively maximize life of cutting
surement products offer fast and con-
status indicators.
tools, grinding wheels, pumps and coolant fuids.
venient installation, even in existing systems.
EMX Industries Inc.
Eriez HydroFlow Coolant Cleaners are easy to
Simply wrap the coil around the conductor or bus
bar and snap together, no mounting required.
install in restricted spaces and can be used on

new or existing machines. With their low initial
Substation computing platform
price and virtually no maintenance costs, they
atons Cooper Power Systems division is of-
fexible confguration. The 857-552 JUMPFLEX
are a very economical choice.
fering end users the ability to run many types
module converts the Rogowski coil to standard
of substation application software programs with
analog signal types (i.e. 0-10V, 4-20mA). The
its new SMP Local Computing Platform (LCP).
Fluid recycling equipment
750-495/000-002
power
This substation-hardened computer allows us-
measurement module directly accepts the output
ers to maximize uptime, and it serves as an ideal
WAGOs new Rogowski coils offer direct interfacing to WAGOs I/O System and JUMPFLEX with
WAGO-I/O-SYSTEM
riez HydroFlow offers a vast product line of fuid

recycling equipment that brings a 40 percent
of a Rogowski coil. For extended distances, the
to 80 percent reduction in fuid purchases and
789 Series Rowgoski coil interface module can
a corresponding
be added.
decrease in dis-
WAGO Corp.
posal costs.
Eriez
CRS
Fluid Recycling
Color light measurement sensor
Systems
are
MX Industries Inc. is supplying its LEX-1000
platform for running Cooper Power Systems
self- contained
color light measurement sensor. The LEX-
Yukon Visual T&D Substation Human-Machine
coolant
1000 is used within industrial automation and
Interface (HMI). The SMP LCP is also designed
fuid
manage-
factory assembly related applications.
to withstand harsh environments while providing
ment
systems
increased reliability over other alternatives.
designed to recycle any water-miscible fuid to its
and
The new SMP LCP is a robust, secure and fex-
maximum potential. These systems can include
ible computing platform that allows end users to
separate dirty and clean tanks, automatic pro-
run very demanding utility substation automation
portioner mixers, oil removal devices, coalesc-
applications. It combines the Yukon Visual T&D
ers, liquid-from-liquid centrifuges and pure water
and Yukon IED Manager Suite enterprise software
sources.
solutions with the SMP 16, SMP 4/DP, SMP/IO and
Eriez HydroFlow
now the LCP, to offer utilities the most compre-
hensive and evolved smart grid substation automation solution for security, event retrieval and
Current measurement products
equipment confguration management.
that measure the light refected from a target, the
Eaton Cooper Power Systems
LEX-1000 proprietary optics focus the light emit-
surement product line. Unlike traditional current
In contrast to traditional optical color sensors
ted by the product onto a sensitive red, green,
182
AGO Corp. added the 855 Series Current

Measurement products to its power mea-
transformers, the 855 Series offers CAGE CLAMP
blue (RGB) photodiode, where it is then read and
Coolant cleaners
connection technology and quick mount kits for
analyzed for its respective RGB composition. The

RGB reading is then automatically compared to
the primary conductor or bus bar.
Earth Coolant Cleaners are designed for use
Available from 50 to 1,000 amps with 1 or 5
preprogrammed parameters. If readings of all
with surface grinders, gear grinders, honing and
amp secondary currents, WAGOs new current
three colors fall within these parameters, the LEX-
lapping machines, broaches, milling and drilling
transformers feature continuous overload of 120
1000 sensor issues a discrete signal to indicate a
machines, face grinders, oil reclaiming machines
percent of primary current. A unique wire tie ac-
color proper match. Supplied PC-based ColorMax
and essentially anywhere else clean coolant is
cessory for securing the wire enables quick and
riez HydroFlow Permanent Magnetic and Rare
www.power-eng.com
www.brush.eu
ENERGY SOLUTIONS FOR THE GLOBAL POWER INDUSTRY

FOR FURTHER INFORMATION CONTACT US: CALL +44 1509 611 511 OR EMAIL SALESUK@BRUSH.EU
easy installation. Flexible mounting options,
data rate adjustment (auto-negotiation) and au-
GRP alternatives. They are designed for installa-
including DIN-rail or panel mounting, are an
tomatic transmit/receive cable detection (Auto-
tion in harsh industrial environments such as the
added beneft of the 855 Series. The new current
MDIX). Up to 2,000 devices can be managed via
water industry, oil and gas plants, utilities, mining
measurement products can be connected via
the MAC address list. Full-duplex communication
conveyor belt controls and process control ap-
WAGOs 2007 Series current transformer terminal
complies with IEEE 802.3x at permissible operat-
plications. One of the key benefts of the range
blocks to the
ing temperatures ranging from 0 to 60 degrees
is the three-point heavy-duty handle mechanism
750
Series
Celsius. The front-panel LEDs permit quick on-
with padlock, which gives excellent sealing with
I / O - S y s t e ms
site diagnostics, increasing visibility and acces-
minimum effort in opening and closing the door.
3-phase power
sibility. Power supply ranges between 18-30 V DC
The enclosures are suitable for housing both
measure-
and integrated overvoltage protection provides
electrical equipment and electronic systems.
ment
additional safety.
Hammond Manufacturing
Wago Corp.
mod-
ule. The 855

Series can also be used in conjunction with
Gauging probe
WAGOs JUMPFLEX current signal conditioner.

Applications include power measurement and
Film chip resistors
energy monitoring.
WAGO Corp.
electrode material and features precision toler-
OA Speer Electronics offers the anti-sulfur
RK73H-RT that is made with a sulfur-proof
mensional gauging probes, or pencil probes, for
.G. Schaevitz LLC, Alliance Sensors Group,

released a line of spring-extend AC-LVDT di-
QC metrology and X-Y tables.
ances of 0.5 percent and 1 percent and a resis-
DC power supplies
tance range of 10 to 10M.
PSITRON ECO power supplies are 24V DC
KOA Speers RK73H-RT chip resistor has a pow-
power supplies with all three Ex approvals
er rating from 1/16W up to 1W and TCR values of
(UL Class 1, Div.2, ATEX and IECEx). Available
100 and 200ppm/C. With an operating tem-
in 2.5, 5 or 10 Amps, the 787 Series accepts a
perature of -55C to 155C, the RK73H-RT uses a
wide input range of 85-264V AC input and 24V
thick metal glaze flm to provide excellent heat re-
DC output.
sistance and weather resistance, making it a high
The power
supplies
stability and high reliability triple layer structure.
The sensors have three ranges available from
fea-
The RK73H-RT chip resistor is available in sizes
stock featuring submicron resolution and repeat-
ture compact
ranging from 0402 up to 2512, and is ideal for
ability, an operating temperature range of -10
DIN rail mount
industrial, power supplies, factory automation,
degrees Celsius to 65 degrees Celsius. Alliance
metal housing
oil-rich environments and outdoor environments
Sensors Group also offers the SC-100 LVDT signal
and offer quick
such as welding and mining.
conditioner module for use with the DGP probes.
monitoring
KOA Speer Electronics
The SC-100 is push button calibrated and has
with two LEDs for easy status indication. CAGE
the proper excitation voltage and frequency to
CLAMP wiring technology enables fast, simple
use the DGP probes as they were designed and
and maintenance-free wiring.
Wall mount enclosures
calibrated.
WAGO Corp.
he HWSSHK 304 and 316L stainless steel
Alliance Sensors Group
wall mount enclosures from Hammond
Info. http://powereng.hotims.com RS# 415
Manufacturing are available in a market-leading
Gigabit Eco Switch
184
30 sizes, ranging from 24-inches x 20-inches x
Film chip resistors
ago Corp.s new ETHERNET Eco Switch
6-inches to 60-inches x
helps small- and mid-sized data networks
36-inches x 16-inches.
by eliminating preconfguration. The plug-and-
They offer excellence
electrode material and features precision toler-
play 852-1111 connects up to fve network de-
corrosion
ances of 0.5 percent and 1 percent and a resis-
vices to an ETHERNET network. Data transmission
that does not degrade
occurs at rates of 10, 100 or 1,000 Mbit/s.
after
resistance
scratching
OA Speer Electronics offers the anti-sulfur

RK73H-RT that is made with a sulfur-proof
tance range of 10 to 10M.
or
KOA Speers RK73H-RT chip resistor has a pow-
Designed for compact control cabinets, the
other surface damage
er rating from 1/16W up to 1W and TCR values of
Eco Switchs DIN-rail mount, IP30-rated metal
with high resistance
100 and 200ppm/C. With an operating tem-
housing is just 74 x 110 x 24 mm. While small in
to
attack.
perature of -55C to 155C, the RK73H-RT uses a
size, the Eco Switch features all standard func-
Sealed to NEMA 4X (IP66), the units are UV resis-
thick metal glaze flm to provide excellent heat re-
tions of a network switch, including automatic
tant and are stronger and more vandal-proof than
sistance and weather resistance, making it a high
chemical
www.power-eng.com
Chromalloy extends engine life like no other company can, by providing the industrys most complete independent

advanced independent castings facility. These unrivaled in-house capabilities represent over 60 years of
innovationand they can make an impact today.
Long live your engine.
chromalloy.com
stability and high reliability triple layer structure.
values. With an extended temperature range of
durable alternative to standard halogen remote
The RK73H-RT chip resistor is available in sizes
-25 degrees C to 70 degrees C and safe and re-
control Golights.
ranging from 0402 up to 2512, and is ideal for
liable operation, the 857-450 JUMPFLEX can be
Stryker features magnetic mounting, motor-
industrial, power supplies, factory automation,
used for electrical isolation of active I/O modules
ized remote control, weatherproof construction,
oil-rich environments and outdoor environments
from the feldbus level.
and the power and effciency of LED lighting
such as welding and mining.
WAGO Corp.
technology.
KOA Speer Electronics
The GL-30855 LED Golight
The GL-30855 LED Golight Stryker motorized

remote control spotlight is designed for durabil-
Transponder coils
ity and high performance and provides operators

with a versatile and powerful LED spotlight capa-
TW Linx is supplying its SurgeGate CAT6 RJ45
OA Speer Electronics introduces the KT11835

and KTZ1030, part of the KT series of receiv-
ble of throwing a beam reaching over 900 feet in
4-Pair surge protector. The SurgeGate CAT6
ing transponder coils for low frequency antennas.
length. A 16-foot cord with cigarette plug adapter
RJ45 4-Pair protector provides superior protec-
They feature precision tolerances of 2 percent,
makes installation even simpler and allows users
tion for technologies using 10 G Base T Ethernet
3 percent or 5 percent, inductance at 125kHz
to quickly and easily move the unit from one vehi-
connections. The SurgeGate CAT6 RJ45 4-Pair
between 1mH~12mH (KT11835) or 1mH~7.6mH
cle to another as needed. This LED hunting spot-
protector fea-
(KTZ1030), and an operating temperature range
light also features a single wireless dash mount
tures patented
between -40 degrees C to 125 degrees C. Both
remote control and a handheld remote control,
circuitry allow-
the KT11835 and KTZ1030 products meet EU
both with 100 feet of range and the ability to con-
ing the protec-
RoHS requirements and are AEC-Q200 qualifed.
trol on/off, up/down, and side to side movement.
tor to provide
Lead time is 10 weeks, please contact KOA Speer
This remote control capability is ideal for utility
for more information.
workers who frequently require illumination while
Surge protector
response
time to capacitance ratio superior to any product
away from their vehicle and allows them to direct
available in the market today.
light wherever it is needed without having to re-
The SurgeGate CAT6 RJ45 4-Pair protector
turn to the vehicle to make adjustments.
is available in three different clamping voltage
Larson Electronics
levels and is available with both wall mounted
and rackmount housing options. ITW Linx surge

protectors are UL listed. They meet or exceed the
Power measurement modules
UL 497 standard are are RoHS compliant. The

SurgeGate CAT6 RJ45 4-Pair protector is avail-
able in-stock from Graybar. ITW Linx can provide
Modules provide energy consumption and
The KT series transponder coils showcase a
power quality analysis in an I/O module form-
expert technology integration support.
unique construction that arranges the electrode
factor, eliminating stand-alone power measure-
ITW Linx
in the long side of the body, which is then cov-
ment equipment. The
ered with molding resin. Because neither the
12mm wide 750-494
electrode nor the land pattern disturb the coil
and 24mm 750-495
Jumpfex signal conditioners
fux, KT111835 and KTZ1030 transponder coils
capture and analyze
AGO expanded its JUMPFLEX line of signal
feature excellent sensitivity up to 75mV/T in low
reactive,
conditioners and relays to include a loop-
frequency around 125 kHz.
and effective power,
apparent
powered signal conditioner offering conversion,
KOAs KT11835 and KTZ1030 construction also
power factor, phase
isolation and transmission of a variety of signal
features four metal plate electrode terminals,
angle, frequency and
types. The new 857-
which help ensure a strong PC board fxation, in
over/under
450 features power
addition to a strong resistance to vibration, shock
These modules also
supplied
by
voltage.
the
and the substrate bend test. KT series transpon-
identify heat-generating harmonic distortions
output signal loop
der coils also offer excellent resistance to impact
from non-linear loads that can result in machine
so no separate 24V
from dropping.
failure.
DC power supply is
KOA Speer
required.
The
compact
WAGO-I/O-CHECK software simplifes parameterization and energy analysis via a four-quadrant

display that shows if a load is inductive or capaci-
signal conditioner ensures safe electrical isola-
LED remote control spotlight
tive, and whether its producing or consuming.
tion of circuits at 2.5kV with less than 0.1 per-
arson Electronics released an LED Golight
I/O-CHECK also offers an easy-to-view energy
designed to provide a powerful and more
dashboard, 3-phase and single phase energy
cent transmission error enabling precise signal
186
AGO Corps 3-Phase Power Measurement
www.power-eng.com

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To learn more about PIC Group and its services, visit us at www.picworld.com.
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detail, harmonic display to the 41st harmonic and
dimension of 4 inches x 7 inches x 2 inches includ-
InGaAs detectors. On an optional basis versions
simple confguration.
ing the protective cover, the lightweight diagnostic
up to 2600 nm will be available, too. The inte-
WAGO Corp.
meter operates on a rechargeable 3.7-volt lithium
grated M12 thread facilitates the integration of
ion battery.
the module.
Parker Hannifn Corp.
The DPDS modules have broad capabilities:
Portable inspection lamp
LED remote
temperature protocol. Communication is car-
intricate detail of the specimen under surveil-
control spotlight
ried out through an RS-232 interface. Use of the
lance. Simply unlatch the upper handle assembly
arson Electronics released an LED Golight de-
modules is extremely easy; they have an intuitive
from the battery retainer and move the magnify-
signed to provide a powerful and more dura-
user interface. Thus, all parameters can be easily
ing assembly freely within the proximity of the ob-
ble alternative to standard halogen remote con-
adjusted.
trol Golights. The GL-30855 LED Golight Stryker
Laser Components
features magnetic mounting, motorized remote
he Onguard portable inspection fuorescent

lamp provides enough light to reveal the most
they are equipped with an automatic amplifcation adjustment, averaging, time stamp, and
control, weatherproof construction, and the

power and effciency of LED lighting technology.
Plant monitoring software
remote control spotlight is designed for durabil-
ity and high performance and provides operators
tinuously measure, monitor and alert operations
with a versatile and powerful LED spotlight capa-
and management to process safety risks. The
ject to view. The upper lamp assembly attaches
ble of throwing a beam reaching over 900 feet in
software also delivers contingency plans that
to the battery pack via a 24-inch (610 mm) power
length. A 16-foot cord with cigarette plug adapter
can be executed immediately to address issues
cord. Unplug the cord from the lamp assembly
makes installation even simpler and allows users
and reduce risk. By presenting real-time risk infor-
and plug the car cigarette lighter adapter into the
to quickly and easily move the unit from one vehi-
mation and expert knowledge to make effective
lamp to provide remote 12V DC power. The lamp
cle to another as needed. This LED hunting spot-
operational decisions, SafeGuard Sentinel helps
can be placed on its side for fxed inspections.
light also features a single wireless dash mount
prevent safety incidents, environmental infrac-
Extremely versatile for inspecting any type of
remote control and a handheld remote control,
tions and downtime.
product or device in the feld or at a plant.
both with 100 feet of range and the ability to con-
Allestec Corp.
trol on/off, up/down, and side to side movement.
This remote control capability is ideal for utility
The GL-30855 LED Golight Stryker motorized
CM Facility Safety releases SafeGuard

Sentinel safety monitoring software to con-
workers who frequently require illumination while
Handheld meter
arker
Hannifn
away from their vehicle and allows them to direct

Corp.
supplies
the
SensoControl Diagnostic Serviceman Plus,
light wherever it is needed without having to return to the vehicle to make adjustments.
a handheld meter that provides portable main-
Larson Electronics
tenance and diagnostic data for hydraulics and
pneumatics.
SafeGuard Sentinel runs on a Windows-based

Other features of
Parkers Serviceman
Plus include a ro-
188
Digital photodiode sensors
server in a plant network, and can be accessed
aser Components announces the frst digital
by any device capable of running a browser, in-
photodiode sensors, DPDS.
cluding DCS workstations, operator terminals,
bust design with an
The MAJOR series will be available in two
tablets and smartphones. The server connects
oil-resistant rubber
versions: For the
through OPC and ODBC, allowing it to gather
protective cover for
wavelength range
information from a variety of systems including
use in harsh or chal-
from 500 - 1700
DCSes, PLCs and PACs from all major control sys-
lenging conditions;
nm the products
tem suppliers. Other sources of data typically in-
IP67-rated protection in extreme conditions; large
will be equipped
clude safety systems, historians, SCADA systems,
back-lit display for easy, quick readings in low light;
with InGaAs detec-
maintenance systems, operator logbooks and
rear panel integrated support for free-standing op-
tors, for the range
workfow tracking systems.
eration; intuitive operation; and MIN/MAX memory
from 700 - 2200
ACM Facility Safety
and differential measurements.
nm with extended
With a small
www.power-eng.com
Power inductors
the series is rated for 0.1H to 8.2H inductance,
failure or extraordinary energy usage.
VX Corp. has introduced the new LMIP Series
up to 3.0MHz frequency, and up to 60A saturation
WAGO Corp.
SMD power inductors. Featuring a homo-
current. Operating temperatures for the series
geneous pressed iron powder core construc-
range from -40 degrees C to +125 degrees C.
tion, LMIP Series inductors exhibit low loss and
AVX Corp.
Pressure regulators
reduced inductance drop due to applied current,
Power measurement products
acting, self-operating, spring-loaded, adjustable
AGO Corp.s power measurement fam-
pressure regulators for use in applications where
ily features components for industrial
pressure reduction is required.
he BelGAS division of Marsh Bellofram has

introduced the P200P series manual, direct-
and building applications. The new product
Designed for maximum durability, Marsh
line includes the 750 Series - 3-Phase Power
Bellofram BelGAS P200P regulators are offered
Measurement Modules, 855 Series - Rogowski
with cast iron or WCB steel bodies, with alumi-
coils and CTs and 857/798 Series - Signal
num bonnets and with a durable powder-coated
Conditioners.
WAGOs new power measurement modules
enabling higher saturation current ratings in
can be integrated into a WAGO-I/O-SYSTEM node
smaller, lower profle packages. Available in six
with other standard digital/analog input and out-
miniature case sizes, the new LMIP Series induc-
put signals. This system can also be networked
tors are ideal for applications including: LED light-
to an existing control platform. If an integrated
ing, portable electronics, power inverters, power
solution is not required, WAGO signal condition-
supplies, reverse battery protection, and DC/DC,
ers can convert standard 1A or 5A current trans-
AC/DC, and point of load (POL) converters.
former or Rogowski coil signals into a standard
epoxy exterior fnish. Units offer an internal relief
Magnetically shielded, lead-free compat-
PLC analog signal type. A full range of measuring
valve for overpressure protection, and minimize
ible, and RoHS compliant, the new LMIP Series
devices, current transformers and Rogowski coils
sudden downstream load changes, reducing
SMD power inductors feature tin plated termina-
round out both applications. Power measurement
the risk of safety equipment shutting an opera-
tions and reliable, low loss SMT construction.
products can be used to measure and collect mo-
tion down. The regulators are available in a wide
Available in six case sizes, two tolerances, and
tor current data to detect instant or cumulative
range of available fow capacities and spring
with thicknesses ranging from 1 mm to 6 mm,
loading to protect an installation from potential
ranges. These features make the P200P ideal for

www.power-eng.com
189
use in other types of industrial monitoring appli-
overlap. Recessed doorjambs, polymer seals,
GridAdvisor smart sensor
cations, such as pressure regulation of compres-
water management systems and drains have all
sors, gas engines, and service regulators.
been redesigned for optimal performance. The
Marsh Bellofram
doors are constructed of A60 galvannealed steel
division has launched the GridAdvisor Series II
with 50 percent greater corrosion-inhibiting prop-
smart sensor, improving outage management
ower management company Eaton announced that its Cooper Power Systems
erties than most service body doors. The tough,
and
Circuit automater
5/16-inch, stainless steel, piano-style door
bank monitoring
ower management company Eaton an-
hinges are 25 percent beefer than the industry
while
nounced that its Cooper Power Systems
standard and are intentionally left unpainted to
real-time
division has launched a new SPEAR recloser
prevent chipping paint from migrating from the
system
solution. This newest single-phase reliability
hinges to the body and causing corrosion.
tion not previously
product provides the industry with a dependable,
Warner Bodies
available in the
cost-effective Smart Grid device to automate single-
marketplace.
Guided wave radar
sophisticated device improves overall effcien-
he modular design of the four basic versions:
cies in distribution systems by identifying direc-
Sitrans LG240, Sitrans LG250, Sitrans LG260
tional fault targeting, detecting capacitor bank
control package
and Sitrans LG270, with numerous confguration
fuse failure and providing real-time line moni-
boasts full sys-
options, allows for level measurement in the oil
toring at nearly any location via the Distributed
tem protection,
and gas and other industries. The modular radar
Network Protocol 3 (DNP3).
automation, me-
transmitter covers a broad application spectrum
Cooper Power Systems
tering and data
for the measurement of liquids and interfaces,
acquisition, mak-
from aggressive materials to hygienic conditions
ing it an ideal
and complies with SIL2 safety standard.
phase circuits up to 38 kV and meet critical power

requirements.
This intelligent
recloser
and
capacitor
providing
critical
informa-
The simple, yet
Molding capabilities
comprehensive, user-friendly ProView NXG software
platform, the SPEAR control hosts protection func-
macromelt low-pressure moldings.
solution for multiple grid applications. Utilizing the
tandex-Meder Electronics offers high-quality thermoset, thermoplastic insert, and
tionality and time-current curves fexibility to maxi-
Total molding solutions are available -- from
mize system coordination and reduce customer
design and testing to manufacturing and delivery
outages.
of end-products. The companys engineers will
Another signifcant beneft of the SPEAR recloser
work directly with customers to fnd the best solu-
is its increased application fexibility. Complete with
tions for their applications. Specially engineered
a separate regulated power supply, the control is
plastics to provide heat dissipation and transfer
automation-ready for the end-users choice of ra-
can be used; plastics can also be custom blend-
dio. The digital communications performance can

also be tailored with the user-confgurable mapping
ed to meet exact specifcations. Additionally,

Sitrans LG240 was specifcally designed for hy-
Standex-Meders facility can mold materials to
of protocol Distributed Network Protocol 3 (DNP3).
gienic applications in the pharmaceutical or food
serve as connectors, strain relief, and/or seal
Cooper Power Systems
and beverage industries and has the required
EHEDG, FDA and 3A certifcates. The Sitrans

LG250 is ideal for the wide range of liquid level
Service body doors
measurement such as those in water treatment
arner Bodies, a manufacturer of service
applications. The Sitrans LG260 version accu-
bodies, crane trucks, haulers, fre/rescue
rately measures levels of solids, granulates and
trucks, brush trucks and custom vehicles, intro-
powders even with extreme dust. In particularly
duced its Select II service body. The Select II fea-
harsh environments with high temperatures up
protection from elements like heat, water, and
tures Warners new FlushFinish door system. The
to 450 degrees Celsius (842 degrees F) or high
dust. Stamping capabilities provide custom ter-
rugged doors look and function unlike anything
pressures up to 400 bar (5800 psig) the Sitrans
minals that can be over-molded if required for the
else in the marketplace.
LG270 is the best choice.
application.
Siemens
Standex-Meder Electronics
When closed, the doors on the new Select II

are entirely fush with the body panels and dont
190
www.power-eng.com
Synthetic lubricants
that minimizes the amount of fnishing required.
Soot analyzer
ltrachem has developed a new line of high-
Wall Colmonoy
performance synthetic lubricants the
Chemlube Plus Series designed to be used in a
he InfraCal Soot Meter from Wilks provides

users with a rapid, on-site ASTM Method
D7686 for measuring soot concentration levels in
wide variety of rotary screw and rotary vane com-
Tethered tools system
diesel engine oils. Soot levels as high as 12 per-
pressors. True universal lubricants, the Chemlube
roto says its tethered tools system will help
cent to 15 per-
Plus Series is fully compatible with most OEM
technicians and contractors in the oil, gas,
cent are mea-
Rotary Screw compressor oils and can be used to
energy and construction industries comply with
sured in just
top off and replace existing fuids.
fall protection regulation.
30 seconds.
The Chemlube Plus Series lubricants are made

with a very thermally and oxidatively stable polyol
The new Proto Tethered Tools system includes
This compact,
11 types of lanyards, depending on need and use
pushbutton
case. The system also includes eight sizes of tool
analyzer pro-
collars and seven different looped heat shrinks
vides
for retroftting existing tools. Protos tether ready
readout of the percent of suspended carbon
tools include 130 different sockets, 80 wrenches,
(soot) in the diesel engine lubricating oil without
32 screwdrivers and hex keys, 22 striking and
sample preparation, dilution, or solvents and
struck tools, and 27 pliers and specialty tools.
messy transmission cells to clean.
direct
All of these accessories work within the PROTO
Since the InfraCal Soot Meter was specifcally
SkyHook system, or with traditional elastic lan-
designed for easy, on-site testing, it represents a
yards. The looped heat shrink comes in seven
major time savings from the widely-used and ac-
different sizes for cariable sized tools.
cepted thermogravimetric analysis (TGA) and FT-
IR methods that are impractical as feld analysis
ester (POE) blend. These oils were designed to

take advantage of superior lubricating properties inherent in polyol esters, and yet be economical, by combining them with less expensive
synthetics.
Typical
industrial
applications
for
the
Chemlube Plus Series include: rotary screw compressors, rotary vane compressors, centrifugal
compressors, and vacuum pumps.
Ultrachem Inc.
Surfacing powders
and wire alloys
all Colmonoys range of surfacing powders

and wire alloys are used for the protection
and renovation of critical industrial components,

including drill stabilizers, drill strings and drill bits
in the oil & gas industry, and boiler tubes and
panels in the waste-to-energy industry.
Powders for Laser processes must have careful control over particle size distribution and composition, while laser cladding offers an extremely
precise method of applying a clad overlay with
the lowest possible dilution of any conventional
welding process. This means high frst pass hardnesses are possible. Sound welds with virtually
zero porosity can be made with precision control
www.power-eng.com
191
methods. A rugged, no-moving parts design en-
with raised tactile plug alignment indicator and
sures years of virtually maintenance-free opera-
a secure cable clamp design. A highly reliable
tion with the InfraCal Soot Meter. Weighing less
crimp contact ensures a safe and secure connec-
than 5 lbs., it operates off 12 volt DC power and is
tion, and termination can be accomplished with
ideal for use along side diesel engines for on-site,
a commercially-available crimp tool.
feld measurements in power generation stations
and used oil/engine testing laboratory. It is ideal
Database Systems
for use on all types of diesel lubricating oils and

Wilks Enterprise
SkyPower system that delivers power to the man
basket through an integrated power cable. This
leased version 6.0 of its eXtremeDB In-Memory
engines.
All of the machines are equipped with the JLG
cObject, developer of innovative database

system software, announced it has re-
is ideal when using power tools or hand tools for
Database System (IMDS) and related product
Thermal imagers
such jobs as welding and cutting steel. For extra
family. The upgrade adds support for distributed
esto Thermal Imaging launched their next
reliability, all of the machines have foam-flled
query processing, which improves database
generation thermal imagers, the Testo 870
tires, eliminating fats.
speed and scalability by leveraging the pro-
series. The 870 series is built around the widest
cessing power, memory and bandwidth of mul-
lens (34 degrees by 26 degrees) in a point and
tiple hardware nodes in carrying out queries.
Power Connectors
Additional improvements in version 6.0 beneft
irose, a leader in the development of innova-
developers and end-users in areas including per-
els, which is upgradeable
tive connector solutions, has strengthened
formance, ease of development and operating
to 320 x 240, or 76,800
its circular power connector product offering with
system support.
pixels
Testo
the development of the HR41 Series weather-
With distributed query processing, eXtremeDB
option.
resistant connector. The IP68-rated, waterproof
partitions a database and distributes query pro-
The thermal images are
connector is designed specifcally for outdoor
cessing across multiple servers, CPUs and/or
displayed in real time on a
use in applications such as lighting (LED lighting,
CPU cores. Performance is accelerated dra-
large 3.5 LCD view screen
street lamps, tunnel lighting, marine/boating,
matically, in some cases via parallel execution
which is 36 percent larger
agriculture and construction site lighting), base
of database operations and by harnessing the
than some imagers avail-
station transceiver systems (BTS) and electronic
capabilities of many host computers rather than
able today. Critical center
toll collection (ETC) systems.
just one.
shoot imager and the FPA operates at a 160 x 120

resolution, or 19,200 pix-
with
the
SuperResolution
temperature and automatic hot & cold spot de-
When in the mated condition, the unique wa-
tection is a valuable standard feature of Testo
terproof gasket design prohibits water intrusion
imagers, which can be displayed directly on the
while submerged in up to 2m water depth for
Epoxies
view screen as well. Detailed image analyses
14 days. Featuring a lightweight and corrosion-
and reports can be performed easily and reliably
resistant plastic body, the HR41 Series connec-
on any windows PC using the IRSoft analysis soft-
tor incorporates high lightning surge protection
sion, all common chemicals, thermal shock and
pecially formulated Resbond S5H13 has excellent high temperature resistance to corro-
ware supplied with every imager.
electricity. Its the ideal epoxy for bonding dis-
Testo Thermal Imaging
similar materials in any high temperature, high
performance adhesive application up to 500 degrees Fahrenheit.
Boom Lifts
Resbond
LL Aerials, a standalone division of the ALL
S5H13
Family of Companies, has added to their
heavy plastic to
feet with a major package purchase of 60 new
192
bonds
stainless
steel,
JLG aerial lifts: a mix of telescopic boom lifts and
(15 kV), salt spray resistance (no corrosion after
seals and insulates
articulating boom lifts to meet increasing cus-
1500 hours of salt spray) and high withstanding
Bi-Polar,
tomer needs. Of note, 40 of the 60 units are in the
voltage ratings.
Cauterizers
and
withstands
thou-
Electro-
60- to 86-foot height range, the sweet spot that
The HR41 Series is designed with sequential
is heavily in demand in mills, processing, general
contact mating and sacrifcial contact points for
sands of success-
industrial, and the booming vertical construction
hot swap capability. Optimized for feld assembly,
ful steam steriliza-
markets.
the HR41 Series has a user-friendly bayonet lock
tion cycles at 375

www.power-eng.com
AUGUST 18-20, 2015

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CENTER
COLUMBUS, OHIO
EXHIBIT AND SPONSORSHIP

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by Power Engineering and Oil & Gas Journal in
conjunction with POWER-GEN, ofers vendors,
suppliers and operators the opportunity to get
their equipment and services before a distinct
audience of key decision-makers in the power
and natural gas sectors.
Reserve your space today for the best available
position. Sales are strong and growing, so book
your space today!
For info on exhibiting, visit
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For info on sponsorship opportunities, visit
power-gennaturalgas.com/sponsor.
PRESENTED BY:
OWNED & PRODUCED BY:
degrees Fahrenheit.
crops, transport mud, distill seawater, support
Applications include high performance bond-
carwashes, and more.

ing, potting, sealing and coating in instrumentation, medical devices, critical aerospace, automotive and electronics. Resbond S5H13 has
Filtration
excellent adhesion to metals, plastics, high performance composites, glass, ceramics and cures
at room temperature.
nounced the introduction of its new packaged
water treatment system, the Pall Aria FIT water
all Corporation , a global leader in fltration, separation and purifcation, today an-
treatment system. Extending the Pall Aria AP
Callibrators
and a motorized Z-axis model, each with a variety
platforms long history of producing consistent
GE Measurement & Control announced new
of stage options. Designed for highly effcient in-
and reliable high-quality water for both mu-
high performance temperature calibrators from
spection and enhanced productivity, the STM7s
nicipalities and industry, the Pall Aria FIT system
the GE Druck family of products. The calibrators
large square stage (up to 300mm x 300mm) can
offers a fexible, confgurable platform which
provide high accuracy, stable temperature refer-
accommodate a number of variously shaped
enables the system to suit even the most chal-
ence to help achieve optimum operation of tem-
samples at the same time. The STM7 makes it
lenging space requirements.
perature sensors and instrumentation.
possible to measure large samples such as print-
Pall Aria FIT water treatment systems are de-
ed circuit boards or semiconductor wafers with
signed to produce drinking water that meets
no shift in orientation.
todays strict purity standards around the world,
and also provide clean process and waste water
The high performance
calibrators
are the latest additions to GEs inte-
for many industries. The systems use proprietary
Pumps
fltration modules to remove a wide range of con-
taminants from surface and ground water sources.
of pumps, valves, and service, offers one
Customers want and deserve a membrane
and are designed for
of the most fexible multistage pumps on the
system that doesnt require modifcation or
use throughout the
market: the Multitec high-pressure pump in ring-
compromise because of their needs, said Dave
process, industrial,
section design. From ski resorts making snow to
Lamphere, global water portfolio manager, Pall
oil and gas, power generation, pharmaceutical,
Caribbean enterprises looking to distill seawater/
Process Systems. Pall is happy to provide exactly
food and beverage and general engineering
brackish waters, this pump is a great ft for nearly
that. End-users beneft from the ability to cus-
sectors. When used in conjunction with a multi-
limitless applications. Best of all, the Multitecs
tom-design a system to their unique specifca-
function calibrator, such as GEs Genii, an instru-
low-maintenance design and long-lasting reli-
tions, and consulting engineers and contractors
ment technician can cover more than 80 percent
ability make it cost effective in any setting.
will appreciate the Pall Aria FIT systems simple
grated
calibration
and communication
solutions
platform
SB, the worlds most experienced supplier
of all calibration tasks, including those relating to
Multitec is one of the most fexible multi-
HART and Fieldbus devices, with just two portable
stage pumps out there, says Douglas Pereira,
system start-up and commissioning.
instruments.The new series includes four, easy-
KSBs Regional Manager of the Energy, Industry
to-use temperature calibrators: two Dry Blocks;
& Desalination Division. Its impressive versatility
and two Liquid Baths.
is due in part to the great number of available
Software
options for customization.
Microscopes
VEVA recently announced the launch of its

latest software solution: AVEVA Control of
Work. This advanced suite of products enables
lympus Corporation recently announced the
the highest levels of safety and effciency to be
launch of the new STM7 measuring micro-
achieved when planning and performing both
scope, an industrial microscope system designed
routine maintenance and in-plant engineering
for highly accurate measurement of machined
operations in potentially hazardous plant envi-
parts, semiconductors, electronic components,
ronments. It comprises best-in-class applications
and other processed industrial materials.
194
water and electrical hookups, which ensure rapid
for Risk Assessment, Work Permit Management,
A measuring microscope series that combines
This fexibility allows Multitec pumps to pro-
high-performance Olympus optics with todays
cess just about anything imaginable. Users can
Work Activity Plotting, Isolation Planning, Safe
most advanced measurement capabilities, the
supply water or drinking water (ACS), heat water,
Jan Edvin Pedersen, Vice President of Enterprise
STM7 is available as both a manual Z-axis model
flter water, fght fres, run wash plants, irrigate
Asset Management, AVEVA, explained some of the
Job Analysis and Lessons Learned Reporting.
www.power-eng.com
advantages of using this new technology: One
easier-to-use Model 455 Micro-Spray Valve. It
material compatibility.
The pneumatic pinch
of AVEVA Control of Works major benefts is its in-
features an inert, 100 percent disposable fuid
valve, outftted with a stainless steel spray nozzle
teroperability with a wide range of Enterprise Asset
path which carries materials from the material
and spray regulator assembly, utilizes tube over-
Management solutions, such as SAP, IBM Maximo
reservoir to the spray nozzle in a sealed path. This
pinch, a feature that extends tube life, enhances
and AVEVA WorkMate. This open approach provides
prevents materials from coming in contact with
repeatability, and offers precise control over ma-
access to the asset information necessary for effec-
the valves inner components and ensures a con-
terial fow.
tive planning and execution of all types of in-service
taminate-free dispensing process. The fuid path
The spray nozzle is an external air-mix type
engineering tasks. Not only can this make such tasks
is easy to replace and requires minimum clean-
which utilizes a standard luer-lock design allow-
safer, it can also enable better use of resources and
up,
allowing
ing different gauge tips to be exchanged to adjust
downtime, offering excellent return on investment. It
for rapid ma-
fow rate needs. The combination of tip variation
is quick and easy to implement which together with
terial change-
and integrated pneumatic controls allows control
its market-leading 2D and 3D visualisation, make it
over.
The
over the amount of air relative to the amount of
an unrivaled solution for asset operations.
valve can be
fuid. The controls feature a built-in delay system
supplied with
that atomizes the tiny droplet that would normally
fuid paths of
remain on the nozzle when the valve is shut off.
varying mate-
This enhances repeatability and guarantees drip-
rials and sizes
free operation.
for
Valves
ymax
Corporation
Dymax
Corporation
has released a more precise, fexible, and
optimum
WEBCAST
ON DEMAND
THE TOTAL CONDENSER PERFORMANCE WORKSHOP:

TUBE CLEANING
www.power-eng.com
195
Hand Pumps
ciated pipeline infrastructure including valve
company whose management has a combined
assemblies.
experience of over 50 years in the sensor indus-
cant advantages in reliability, maintenance,
All of these installations need rapid installa-
try. A trained staff can help you select the ideal
durability and price/quality. However the extras
tion and effcient maintenance requiring fast dis-
sensors for your application. Our core product
like the oil level glass, the Push & Unlock pump
assembly and reassembly for work to be carried
offering includes Exhaust Gas Thermocouples
handle lock, the integrated oil funnel and pres-
out with maximum speed and precision, reducing
(EGT) Probes, Thermocouples, RTDs, Linear
sure gauge adapter on the pump block, make
workers exposure time to potential hazards and
Position sensors, Rotary Position sensors,
the new hand pumps extremely user friendly.
reducing downtime that no company can afford
Pressure sensors and switches.
Holmatro has set a new standard in innovation
as it steps up production to combat falling com-
and quality with its new hand pump range for
modity prices.
he new Holmatro hand pumps offer signif-
industrial use.
A solution to the problem is offered by
Power Modules
Industries, which produces the expanding glob-
ally successful EziTite family of hydraulic nuts
module family with a new 20A all-SiC module ide-
and bolts used on many high temperature ap-
ally suited for 5-15 kW three-phase applications.
plications worldwide where speed, safety and
Based on Crees C2M SiC MOSFET and Z-Rec
accuracy are critical. The Technofast product
SiC Schottky diode technology, the six-pack mod-
family includes the CamNut systems used on
ule enables designers to unlock the traditional
steam turbines and extreme temperature appli-
constraints of power density, effciency, and cost
All products are developed, produced and ex-
cations from 40C to 650C and the EziTite TR
associated with Si-based inverters used in indus-
haustively tested in-house. The result: true Dutch
Hydraulic Nuts designed especially for high tem-
trial power conversion systems.
quality and robustness. Moreover, our products
perature applications up to 550C and higher in
have an extremely long life span that can also
some instances.
be extended with an extensive service program.
Australian joint security innovator Technofast
ree Inc. has expanded the award-winning

silicon carbide (SiC) 1.2 kV six-pack power
There are no less than eight models available in order to provide for the requirements of
Instrumentation
discerning professionals with diverse areas of

application.
line of measurement and control instrumentation
he Sensor Connection, a divison of Harold G.

Schaevitz Industries LLC, has expanded its
Cummins, Inc., a global power leader in
Nuts and Bolts
electrical power generation systems, has tested
ome of the most potentially hazardous bolt-
and confrmed the capabilities of Crees all-SiC
ing tasks in the mining, energy and materials
1.2kVsix-pack power module family in their invert-
handling sectors involve mission-critical and high
er platform. Furthermore,engineers at Cummins
heat
are working to integrate and exploit these capa-
ment.
equipThis
bilities with their next generation, high effciency
can
include
with the addition of the model TCA-MS-K-8-A4.
high
pres-
This 8 Channel Type K Thermocouple Amplifer
Crees new 1.2kV all-SiC six-pack module
sure mineral
Module converts the low output voltage signal
family will allow us to increase the power rating
and materials
from 8 Type K thermocouple probes to 8 indepen-
of our class-leading inverter by 40 percent while
processing
dent linearized 0 to 5 VDC output voltages. This
reducing power losses by 50 percent to increase
equipment,
196
products.
output is ideal for interfacing to instrumentation
effciency by 5 percent, said Brad Palmer, power
generators,
equipment including data loggers, temperature
electronics product line architect, Cummins, Inc.
steam
tur-
indicators, chart recorders, and controllers. A
This new power module is a signifcant techno-
bines,
heat
unique feature of this product is the addition of
logical advancement, capable of outperforming
exc h an g er s,
an onboard single-axis +/- 4g capacitive accel-
Si IGBT modules with four times the current rat-
autoclaves,
erometer for monitoring vibration or shock to the
ing. We are delighted to have had the opportunity
boilers, pres-
module.
to be an early tester of this technology and look
sure
vessels
The Sensor Connection, a division of Harold
and
asso-
G. Schaevitz Industries LLC, is an American
forward to incorporating it in our products.

www.power-eng.com
Terminal Protector
terminals allows for potentials to be distributed to
ower management company Eaton has re-
adjacent fused terminals from the FSIK series. For
cently introduced its new ground terminal
multiplying the potentials, CONTA-CLIP offers the
wildlife guard, an expanded product offering of
FQI standard connection system, available with 2
the Wildlife Protection System from its Cooper
to 10 poles. Using VBS connection sleeves, two or
Power Systems business. In addition to the ex-
three extraction levers can be coupled and operat-
isting terminal wildlife guards, the latest offering
ed simultaneously. FSIK 4 housings are made from
reduces service interruption from animal interfer-
polyamide 6.6 UL 94 V-0.
ence while maintaining the reliability and perfor-
mance of distribution arresters.
Flow Meters
Interference from wildlife is one of the lead-
Features include: Contactless operation pre-
ing causes of service interruptions for our utility
vents wearout from dither or cycling; 6 Ranges
customers. It can result in costly outages, reduc-
from 25 to 200 mm (1 to 8 inches); Excellent
tion in reliability and harm to wildlife, said Chris
stroke-to-length ratio; 19 mm (0.75 inch) diam-
the line will fnd the new FPI-X Dual Sensor
Decker, product line manager, Eatons Cooper
eter anodized aluminum housing sealed to IP-67;
Electromagnetic Flow Meter from McCrometer
Power Systems division. Both line and ground
Radial cable exit version comes with swivel rod
delivers accurate and repeatable measurement
terminal wildlife guards are designed to address
eye ends; Axial termination versions with either
under extreme fow conditions unachievable with
these potential challenges by providing the high-
M-12 connector or cable.
other technologies.
est level of protection with low maintenance
Operating from a variety of DC voltages, the
costs. At the same time, they are engineered to
LR-19 series offer a choice of four analog outputs
reduce utility exposure and more readily ensure
and all include ASGs proprietary SenSet feld
the safety of wildlife.
recalibration feature.
Ideal for traditional heavy-duty and riser pole
The LR series also includes a larger body ver-
applications, the ground terminal protector has
sion, the LR-27, for those applications needing
a universal ft that can be quickly added to any
a heavier duty unit. Technical data sheets and
standard distribution arrester. It has the ability
additional information can be found at www.al-
to protect against fashovers between live and
liancesensors.com.
ground terminals and provides electrical insu-
lation through a compact, inexpensive and ef-
rocess and plant engineers contending

with swirl and other fow disturbances in
The McCrometer FPI-X fow meter reliably

achieves 0.5% accuracy under the most severe
swirling fows. Designed for use in close proximity
fective system. Because it can reduce the time
Connections Systems
to cascading or multiple pump arrays, this meter
required for a lineman to identify fault locations
delivers the advantage of accurate measure-
in the feld, the ground terminal wildlife guard can
SIK 4-type fuse disconnect terminals from

CONTA-CLIP feature a folding extraction lever
ment where no fow meter previously could serve.
also contribute to saving time and money for util-
that locks into its end position and provides space
Whether installed near pumps, valves, elbows,
ity customers.
for a spare fuse. Alternatively, CONTA-CLIP also sup-
headers, or any other equipment that makes it
plies the fuse
impossible to create a symmetrical velocity fow
disconnect terminals with an integrated LED sta-
profle in the pipe, the FPI-X will outperform tradi-
Sensors
tus display. The pressure spring connection system
.G. Schaevitz LLC Alliance Sensors Group
allows fast and safe contacting of the wires. A cross-
The FPI-X mag meter provides measurement in
has expanded its sensor product offering
connection channel within the fuse disconnect
diffcult sites that otherwise require multiple me-
tional mag meters.
by adding a line of LR-19 Series Inductive Linear
ters in various locations, saving customers both
Position Sensors; contactless devices designed
money and installation time. The FPI-X also elimi-
for factory automation and a variety of industrial
nates the expensive fow conditioners and piping
or commercial applications such as motor sport
modifcations necessary with other meters.
vehicles, automotive testing, solar cell position-
ers, wind turbine prop pitch and brake position,

and packaging equipment. With their compact
Communications
design, superior performance, and excellent

stroke-to-length ratio, LR-19 sensors are ideal
for both industrial testing laboratories and OEM
municate simultaneously just like on a regular
applications.
telephone. These revolutionary headsets are
www.power-eng.com
omSTAR is a new generation of full duplex

wireless that allow up to eight users to com-
197
was Can you reduce the set up and calibration

time?
Solution: S1A and SC-100 LVDT Signal
Conditioners offer smart and fast LVDT setup
with built-in null indication and simple front
panel pushbuttons to set zero and full scale.
Calibration time is now reduced from at least 20
minutes per channel to just a minute or two.
to calibrate with traditional signal conditioners
Testing
because they required an operator to adjust trim-
AKOR Technologies, Inc., a recognized leader
mer pots and/or set jumpers. With an Alliance
transmitting. They enhance industrial job site pro-
in the implementation of instrumentation prod-
Sensors SC-100 AC-LVDT Signal Conditioner, an
ductivity and safety by providing instantaneous,
ucts for dynamometer testing, said its AccuDyne
internal microprocessor eliminates the need to
hands free voice communications within an
AC Dynamometer system for wind power testing
calculate jumper settings for gain, range, etc.
not voice activated and there is no delay when
800 yard range.
applications
The XTreme is a specialty hard hat compat-
now
is
ible ComSTAR headset that features miniatur-
The system can
Volatage Conversion
ized wireless circuitry and antenna installed right
be used by mul-
inside the ear cup. This streamlined All in One
tiple
design is a breakthrough, eliminating the need
ing groups to
platform which increases throughput power for
test and verify designs, as well as for quality control
Pulses planar SMT transformers by 50 percent
for cables and belt pack transceivers.

ComSTAR operates within the DECT, 1920
engineer-
ulse Electronics Corp., a provider of electronic components, launches a new planar
over transformers
testing after manufacturing.
of
comparable
1930 MHz band allocated by the FCC for voice
Ideal for testing both active and passive wind
communications only. No FCC licensing required.
power driveline components, the AccuDyne dy-
size to deliver up
namometer system can be used to test turbines
to 800 watts of
and their associated blade pitch control motors,
power capability.
Sensors
generators and wind-sensing devices and motors,
These
he S1A and SC-100 DIN-rail-mounted, push-
and transmissions. The system can also be used
ers are used for
button-calibrated LVDT signal conditioners
for testing water coolant pumps and other ancil-
isolation and voltage conversion for switched
lary components.
mode power supplies in datacom and intermedi-
were developed by listening to customers and
transform-
LVDT manufacturers comments and wish list.
In addition to independent component test-
This has allowed Alliance Sensors Group to de-
ing, the system can also be used to test groups of
Pulse Electronics PH9278NL planar transform-
sign and build signal conditioners that work with
components simultaneously to see how they work
er is built on Pulses new ER25+ platform and can
all different types of LVDTs, LVRTs, GE buck-
together.
be customized depending on the application. The
boost LVDTs for gas turbines, half-bridge pencil
platform measures 33.5 x 26.8 x 18.3mm and de-
gaging probes, and RVDTs, rather than only satis-
ate bus converter applications.
livers 50% greater power than transformers built
fying markets
Sensors
on an ER28 platform which measures 35.5 x 30.5
where
lliance Sensors Group introduces the SC-100
x 12.6mm. The increased power is achieved by
DIN-rail mountable AC-LVDT Signal Conditioner
increasing the effective cross-sectional area of
and not ad-
module that offers smart and fast LVDT setup with
the core by 40 percent. This results in lower core
dressing the
built-in null indication and simple front panel push-
losses for a given number of winding turns.
concerns of
buttons to set zero and full scale. The SC-100 is
LVDT
users
engineered to work with the widest range of AC-
with
other
operated LVDTs, RVDTs, and inductive half-bridge
Pilot Regulators
position sensors and was specifcally designed to

be compatible with both Marposs and Solartron
analog pencil gaging probes.
Group of Companies, has introduced its PL82,
are
they
strong
applications.
The number one ques-
198
available.
elGas, a division of the Marsh Bellofram

Corporation and a member of the Bellofram
tion from the
In the past, AC-operated LVDT linear and
PL82B and PL83 Series pilot regulators, each de-
marketplace
RVDT rotary position sensors were fairly diffcult
signed to provide high-reliability gas back pressure

www.power-eng.com
relief within a variety of oil and gas applications.
ranges up to 480 VAC with ABC phase sequence.
pressure gauge installation. The port can also be
Although most main gas pressure regulators
Models are available in choice of several enclo-
used as an additional full fow outlet. The Type
are modifed to accept pilot regulators from the
sure styles, as well as with selection of fxed, lock
T60 air regulator is offered with a unique and
same manufacturer, BelGAS pilot regulators may
shaft, or screwdriver adjustment. Series models
easily removable self-cleaning nylon 40 micron
be used along
are available with either SPDT (enclosure styles
mesh flter. When preset to 30 psig, these tam-
with other indus-
A and N) or DPDR (style E) output. An on-
per resistant regulators also meet OSHA require-
try models. The
board LED illuminates when all conditions are at
ments for air supplied to handheld air guns.
pilot
operated
normal, for a quick and clear visual reference
BelGAS PL82 and
of system conditions. Most units also feature au-
PL83
tomatic reset (manual option available with E
Pressure Transducers
signed for seam-
are
de-
style enclosure).
less compatibility
P:50 Corporation has introduced its Model

188/288/388 miniature fush diaphragm
with the companys P1808 and F289 back pres-
pressure transducer series.
sure relief regulators. They feature aluminum
Air Pressure Regulators
body material and choice of PSIG or WC range.

Their robust design allows them to vent continu-
ously when the main valve is either repositioned
Type T60 air pressure regulators.
The unique fush diaphragm design of the
arsh Bellofram Corporation today an-
GP:50 Model 188/288/388 now makes pos-
nounced the global market launch of its
sible accurate pressure measurements of highviscosity
fuids,
or in relieving mode. They will not bleed or relieve
Marsh Bellofram Type T60 industrial air pres-
even within high
when pressure values fall below set pressure. The
sure regulators are preset, fxed units for instru-
shock and vibra-
PL82B is designed for more general purpose back
mentation and general purpose use. Test data
tion environments,
pressure relief. As a low bleed pilot, the regula-
for these regu-
without port plug-
tor will only bleed when the valve is repositioned.
lators
ging and clogging.
The PL83 is a high-bleed restriction pilot and
their
lower pressure unit. Options for low, medium
performance
series
and high gain allow for the lowest buildups and
as compared to
useful for the sup-
fastest response speeds (i.e., high gain is high-
other
industrial
port of aerospace
est speed) and are determined according to the
pressure regula-
and automotive test
needs of each application. Please consult the
tors on the mar-
stands;
factory for details.
ket. In particular,
and
their
cal
Monitoring Relays
shows
excellent
regulated
This
makes
the
particularly
chemical
pharmaceutiprocessing,
pressure vs. fow
plastics extrusion; and adhesive, sealant and
metric, forward-
paint systems.
TC Diversifed, a division of the Marsh
to-reverse fow offset, supply pressure sensitiv-
The GP:50 Model 188/288/388 series features
Bellofram Group of Companies, today an-
ity, repeatability, and stability specifcations all
an all-welded stainless steel construction and
nounced the global market introduction of its SLA
exceed typical industry performance.
incorporates a 7/16-20 UNF pressure port that
Series, a family of high-reliability three-phase

monitoring relays.
Units are ruggedly designed with die cast alu-
eliminates any zero installation effect. Standard
minum housings. The housings are also fnished
wetted parts are made from stainless steel, with
The series offers
with a special scratch- and weather-resistant vi-
optional substitution of Inconel or Hastelloy. The
cost-effective pro-
nyl paint. Each air regulator is fully pressure and
standard operating temperature range for the
tection from phase
leak tested prior to factory shipment. Through a
Model 188/288/388 is -65F to +250F (-54C to
loss, under voltage,
combination of careful design engineering and
+121C), with an optional high-temperature ver-
and phase reversal
the incorporation of quality materials, Type T60
sion to +350F (+177C).
conditions that can
regulators offer trouble-free operation over an
Model 188 is the smallest transducer of the
contribute to pre-
extended useful service life, even in the most
family, with an overall length of just 1.35 in. (34
mature equipment
diffcult of industrial environments. A rubberized,
mm). It can measure fast events due to its high-
failure and down-
soft-seat valve stem provides positive shut-off
frequency response, typically less than 3 kHz.
time within motor
and forgives dirt or other foreign matter. An
Model 188 operates over a standard range of
control centers, critical motors and pumps, and
aspirator maintains downstream pressure and
300 PSI to 20k PSI (21 to 1,379 BAR), with total
other Delta and Wye systems.
compensates for droop when high fow occurs.
accuracy to 0.25% RSS.
The integral gauge port is also convenient for
The SLA Series can effectively monitor current

www.power-eng.com
199
STATEMENT OF OWNERSHIP, MANAGEMENT,

AND CIRCULATION
1. Publication title: Power Engineering. 2. Publication number:
440-980 3. Filing date: October 1, 2014. 4. Issue frequency:
Monthly. 5. Number of issues published annually: 12. 6.
Annual subscription price: $106.00. 7. Complete mailing
address of known office of publication: PennWell Corporation
1421 South Sheridan Road, Tulsa, OK 74112, Tulsa County. 7a.
Contact person: Traci Huntsman. 7b. Telephone: 918-8319435. 8. Complete mailing address of headquarters or
general business office of publisher: PennWell Corporation
1421 S. Sheridan Road, Tulsa, OK 74112. 9. Full names and
complete mailing addresses of Publisher, Editor and Managing Editor: Publisher: Richard Baker 1421 S. Sheridan Road,
Tulsa, OK 74112. Editor: Russell Ray, 1421 S. Sheridan Road,
Tulsa, OK 74112. Managing Editor: Russell Ray, 1421 S. Sheridan Road, Tulsa, OK 74112. 10. Owner: PennWell Corporation,
1421 So. Sheridan Rd, Tulsa, OK 74112, Tulsa County; Sucessors
to the Estate of Helen B. Lauinger, 1421 So. Sheridan Rd, Tulsa,
OK 74112, Tulsa County. 11. Known Bondholders, Mortgages,
and Other Security Holders Owning or Holding 1 Percent or
More of Total Amount of Bonds, Mortgages, or Other Securities: None. 12. N/A. 13. Publication Title: Power Engineering.
14. Issue Date for Circulation Data: September, 2014.
Solenoid Valves
in the pressure transmitter, and a plastic lock out de-
ems Sensors & Controls (Gems) has reintro-
vice is clipped over the electrical termination. With
duced its BL Series of general purpose latch-
the sensors available in many cable lengths, sen-
ing solenoid valves.
sor materials and connection options, users have
The Gems BL Series is designed to support de-
more fexibility to
manding fuid control requirements, such as those
reduce the time
common to natural gas separation, natural gas
to install or per-
plunger lifts, gas chromatography equipment, ir-
form
rigation systems, pneumatic pipelines, and others.
maintenance.
a. Total number of copies

45670
b. Legitimate paid and/or requested distribution
1. Outside county paid/requested
42190
mail subscriptions stated
on PS form 3541
2. In-county paid/requested mail
0
subscriptions stated on PS form 3541
3. Sales through dealers and
723
carriers, street vendors, counter
sales, and other paid or requested
distribution outside USPS
4. Requested copies distributed
0
by other mail classes
through the USPS
c. Total paid and/or
42913
requested circulation
d. Non-requested distribution
1. Outside county nonrequested
343
copies stated on PS form 3541
2. In-county nonrequested copies
0
stated on PS form 3541
3. Nonreqeusted copies distributed
0
through the USPS by other
classes of mail
4. Nonrequested copies distributed
1851
outside the mail
e. Total nonrequested distribution
2194
f. Total Distribution
45107
g. Copies not Distributed
563
h. Total
45670
i. Percent Paid/Requested Circulation
95.14%
No. copies of
single issue
published
nearest to
filing date:
45837
44025
0
539
Offered with
The AST4300
choice of either
series is avail-
2-way or 3-way
able with gauge
design, the BL
and compound ranges from -14.7 to 20,000 PSI
Series
allows
while the AST43LP pressure transmitter can mea-
a user to pulse
sure low pressure and bi-directional pressures from
the valve itself. This facilitates its change of state
1 to 15 PSIG. With its rugged construction and best
into a closed or open position, depending upon
price-to-performance ratio, the AST43LP is the solu-
requirement, with fast response times. The series
tion for low pressure measurement for a variety of
does not require continuous voltage in order to
applications in process instrumentation, oil & gas
hold its designated state. The term latching sole-
equipment, process control and gas compression
noid valve refers to the Gems BL Series in its open
and storage.
state condition, during which supply pressure
15. Extent and Nature of Circulation:

Average No.
copies each
issue during
preceding
12 months:
goes to the external valve. The unlatched solenoid

valve refers to its closed state condition, during
Software
which supply pressure is cutoff and the external
valve is exhausted to ambient.

44564
385
0
0
376
761
45325
512
45837
98.32%
16. Electronic Copy Circulation

a. Requested and Paid Electronic Copies
0
0
b. Total requested and paid print copies 42913
44564
+ requested/paid electronic copies
c. Total requested copy distribution + 45107
45325
requested/paid electronic copies
d. Percent Paid and/or requested
95.14%
98.32%
circulation
x I certify that 50% of all my distributed copies (electronic and print)
o
are legitimate requests or paid copies.
17. Publication of Statement of Ownership: Will be printed

in the November 2014 issue of this publication.
18. Signature and title of Editor, Publisher, Business
Manager, or Owner: Traci Huntsman, Manager Corporate Assets
and Postal Compliance. Date: 10/01/2014.
I certify that all information furnished on this form is true
and complete. I understand that anyone who furnishes false
or misleading information on this form or who omits material or information requested on the form may be subject to
criminal sanctions (including fines and imprisonment) and/
or civil sanctions (including civil penalties).
VEVA recently announced the launch of its latest

software solution: AVEVA Control of Work.
The Gems BL Series is ideal for larger pneu-
This advanced suite of products enables
matic valve control applications, particularly
the highest levels of safety and effciency to be
those with external power source limitations;
achieved when planning and performing both
undesirable coil heating; or where the tempera-
routine maintenance and in-plant engineering
ture of fowing media must remain unaffected as
operations in potentially hazardous plant envi-
it travels through a valve. Customers who incor-
ronments. It comprises best-in-class applications
porate the BL Series into larger pneumatic valve
for Risk Assessment, Work Permit Management,
applications can further enhance the opening
Work Activity Plotting, Isolation Planning, Safe
and closing functionality of larger pipes. Optional
Job Analysis and Lessons Learned Reporting.
dual diode system protection is also available.

Jan Edvin Pedersen, Vice President of Enterprise

Asset Management, AVEVA, explained some of the
advantages of using this new technology: One
Pressure Sensors
of AVEVA Control of Works major benefts is its in-
merican Sensor Technologies offers its
teroperability with a wide range of Enterprise Asset
AST4300 and AST43LP Class I Division 2
Management solutions, such as SAP, IBM Maximo
Non-Incendive Pressure Transmitters with a
and AVEVA WorkMate. This open approach provides
Turck Mini-Fast electrical connection, eliminating
access to the asset information necessary for effec-
conduit requirements from installation. With a
tive planning and execution of all types of in-service
Mini-Fast electrical connection integrated into its
engineering tasks. Not only can this make such tasks
housing, the Pressure Sensors also make instal-
safer, it can also enable better use of resources and
lation fast and simple.
downtime, offering excellent return on investment. It
The sensor design confguration eliminates
is quick and easy to implement which together with
the need for conduit material or conjunction
its market-leading 2D and 3D visualisation, make it
boxes. The pressure transmitter is installed in the
an unrivaled solution for asset operations.
process, the mating cable assembly is installed
200
routine

www.power-eng.com
Automatic Filters
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SOLVAir Solutions was formed

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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
http://powereng.hotims.com RS#300
Engineering Environmental EPCM
EPC FIRM
Hoists
J O I N T H E R E VO L U T I O N
Recognized as a market leader and innovator in
the hoist and crane industry, Harrington Hoists,
Inc. provides a wide variety of lifting solutions
for many industrial applications. Our top quality
products include:
Electric Chain Hoists

Air Chain Hoists
Lever Hoists
Electric Wire Rope Hoists
Manual Hand Chain Hoists
Push and Geared Trolleys
ShowcaSe advertiSing contact Jenna hall: 918-832-9249, Jennah@pennwell.com

DuPont Krytox Fluorinated Oils and

Greases offer the following advantages:
Chemically inert. Widetemperature range
(-103F to 800F). Compatible with plastics,
rubber, ceramics, & metals. Nonflammable.
Insoluable in common solvents. No silicones
or hydrocarbons. Krytox is applied to gearboxes, dampers, ductwork valves, steam
valves, gaskets, seals, compressors, bearings (including trunnion bearings), boilers,
pumps, and Turbine Auxiliary systems.
SUPPLIERS SHOWCASE |
Why Should You

Filter Your Water?
Overhead Cranes
Crane Components
Crane Accessories
Beam Clamps
A full line of replacement parts
For more information:
Call: 800-233-3010
Visit: www.harringtonhoists.com
www.power-eng.com
201
| SUPPLIERS SHOWCASE
Insulation: High Temperature
Iso Phase Bus
Manifolds/Water
Crown Electric
High Volume
Manifolds
Iso Phase Bus
The global language of insulation

is now written in stone.
Introducing ProRox and SeaRox

The new Global assortment for
Performance Driven Solutions
Fabrication
Installation
Upgrades & Uprates
GSU Change Outs
Kochek manifolds allow immediate, multiple access to

discharge valves which maximize water flow. Used with
Kochek's LDH (large-diameter hose), manifolds are lightweight, durable, and easy to position. Units are configured
to users' specifications with discharge valves, pressure
gauges, drain bleeder valves, and caps with cables.
Encased in aluminum welded frames, they come standard
with large diameter inlets, pressure relief valves, and
folding handles. Call Kochek for custom solutions.
513 539-7394 ext.

201
Unlock the future of insulation at:
www.roxul.com | 800.265.6878
175 Edison Dr.

Middletown, OH 45044
www.crown-electric.com
sales@crown-electric.com
Material Handling Systems
Media Blasting Services
Polymer Mortar Pipe
Media Blasting Services
Kochek Company Inc.

800.420.4673 ~ www.KOCHEK.com

From Dry Ice to
Walnut Shells,

Abrasive Blasting

www.molemaster.com
202
www.power-eng.com
Silos, Chimneys, & Steel Stacks
Design-Build Storage Solutions with

ClearSpan Fabric Structures
ClearSpan Fabric Structures are a fast, economical solution for equipment and material storage,
warehousing, manufacturing and more. ClearSpan
buildings feature exceptional height and wideopen spaces with ample clearance for access and
ease of movement. Constructed in the USA from
the highest quality steel and fabric, these buildings
can be built to any length and up to 300 wide.
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ADPWRE or call 1.866.643.1010 to speak with
one of our ClearSpan specialists.
Quality and Service Since 1908
Tube Cleaning & Maintenance
Ring Granulators, Reversible Hammermills,

Double Roll Crushers, Frozen Coal Crackers
for crushing coal, limstone and slag.
1319 Macklind Ave., St. Louis, MO 63110
Ph: (314) 781-6100 / Fax: (314) 781-9209
www.ampulverizer.com / E-Mail: sales@ampulverizer.com
For info. http://powereng.hotims.com RS# 450
REACH YOUR
AUDIENCE
CONDENSER TUBE CLEANING & MAINTENANCE
Concos 2014 Catalog showcases our

complete line of products and services for
the Power Generation Industry, highlighting
our unique and exclusive technologies for
Condenser Tube Cleaning, Non-destructive
Testing and Leak Detection Services. Call today to request a catalog 1-800-345-3476 or
visit us online at www.concosystems.com.
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For hundreds of years navigation was

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SUPPLIERS SHOWCASE |
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Making fundamentals fun

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719 651-7383
Nschroeder48@aol.com
203
Classified advertising ContaCt Jenna Hall: 918-832-9249, JennaH@pennwell.Com
| CLASSIFIEDS
ELIMINATE
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Eliminate valve cavitation by

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540-265-0004
Get a thorough mix with:
Pugmill Systems, Inc.

P.O. Box 60
Columbia, TN 38402 USA
Ph: 931-388-0626 Fax: 931-380-0319
www.pugmillsystems.com

ARE YOU SELLING?
Ferncroft
Management,LLC
VISIT
www.FerncroftManagement.com
email:vavlebuyer@ferncroftmanagement.com
20,000 - 400,000 #/Hr.
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visit www.wabashpower.com
wabash
POWER
EQUIPMENT CO.
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24/7 On-Call Service
1-800-990-0374
www.rentalboilers.com
- Rental Boilers - Economizers - Deaerator Systems - Water Softener Systems -
T. 978-815.6185 Fax. 603-814.1031
LIMITORQUE OPERATORS WANTED
Exothermic Engineering, LLC

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Has your Burner Management System
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The Code is revised approximately
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We are also experts at solving ancillary
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Begin with a conference call

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Call Bill Smith:
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(816) 415-8888
www.ExoEng.com

GEORGE H. BODMAN, INC.
CONDENSER OR GENERATOR AIR COOLER TUBE PLUGS

THE CONKLIN SHERMAN COMPANY, INC.
Chemical cleaning advisory services for

boilers and balance of plant systems
Easy to install, saves time and money.
George H. Bodman
Pres / Technical Advisor
P.O. Box 5758

Kingwood, TX 77325-5758
email: blrclgdr@aol.com
Office (281) 359-4006

1-800-286-6069
Fax (281) 359-4225
ADJUSTABLE PLUGS - all rubber with brass insert.

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Sizes 0.530 O.D. to 2.035 O.D.
Tel: (203) 881-0190
Fax: (203) 881-0178
E-mail: Conklin59@aol.com www.conklin-sherman.com
Just Plugging Along
CONDENSER & HEAT EXCHANGER TOOLS

CLEANERS, PLUGS, BRUSHES
John R Robinson Inc
PH # 800-726-1026
e-mail: sales@johnrrobinsoninc.com
www.johnrrobinsoninc.com
See Us At Power-Gen
Booth 3340
VALVES
INSTRUMENTATION
ELECTRICAL CONTROLS
PROCESS EQUIPMENT
PROCESS CONTROLS
PLANT MACHINERY
PSA SNUBBERS, ETC.
FOR SALE/RENT
24 / 7 EMERGENCY SERVICE
BOILERS
CLASSIFIEDS |
WE ARE
BUYING!!!
| CLASSIFIEDS
POWER PROFESSIONALS
Opportunities in Operations and Maintenance,
Project Engineering and Project Management.
Business and Project Development.
First-line Supervision to Executive Level Positions.
Employer pays fee. Send resumes to:
P.O. BOX 87875,
VANCOUVER, WA 98687-7875
email: dwood@staffing.net
(360) 260-0979 (360) 253-5292
www.powerindustrycareers.com

PRAIRIE STATE GENERATING COMPANY IS HIRING!

Prairie State Generating Company is looking for the
Experienced Power Plant Professionals to work in our
state-of-the-art, 1,600 megawatt power plant. Prairie State
provides low-cost electricity to 2.5 million families across 8 states.
Prairie States adjacent coal mine supplies its the power plant,
insulating Prairie State from the ups and downs of the coal marketplace
for the next several decades. Positions we are hiring for include:

!

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#

$ %!
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" &

Dedicated to building a great team, we offer:

o 160 hours PTO per year
o Medical, Dental, Vision
o 8 paid holidays
o 75% company-funded HSA
o 401K
o Life insurance

"! '

www.prairiestateenergycampus.com
for more information or to apply online!
The Prairie State Generating Company is the project manager
of the Prairie State Energy Campus project facilities
www.prairiestateenergycampus.com.

! !

(
Females and minorities are encouraged to apply.
Add some
COLOR!
Call Jenna Hall

at 918-832-9249
CRITICAL EQUIPMENT
PROTECTION
SOLUTIONS
Seal-Fast Edge Seal
Protect-Fast
Braided Sleeving
Visit us at Booth #950 at

PowerGen 2014 Dec 9-11
Tel: +1(508)229-2000
www.devicetech.com/pg
INDEX
RS# COMPANY
PG#
15
Aarding Thermal
Acoustics BV
www. aading.com
22
92
Acromag
www.acromag.com/powerio
112
74
Aegion
www.corrpro.com
91
Amec E&C Serv

www.amec.com/power
11
49
Annual Awards Gala

www.power-gen.com
65
AREVA INC
us.areva.com
13
78
Auma Actuators Inc

www.auma-usa.com
97
111 Baldor Electric

www.baldor.com
145
51
Basler Electric Co
www.basler.com/BE/11PEPGS
67
13
Belt Tech Industrial

www.belttech1.com
20
34
Braden Manufacturing
www.braden.com
48
67
BRAND ENERGY AND

INFRASTRUCTURE SERVICES
www.beis.com
85
Brandenburg Industrial
Service Company
www.brandenburg.com
C4
131 Brush TurboGenerators

www.brush.eu
10
RS# COMPANY
PG#
169
29
Hughley & Phillips

www.hughleyandphillips.com
40
82
CMI Energy
www.cmigroupe.com/energy
101
11
Hurst Boiler & Welding Co Inc

www.hurstboiler.com
17
56
Combustion Technologies Corporation73

www.combustiontc.com
101 HX Holding GMBH

www.power.gea-hx.com
123
122 Comrent International LLC

www.comrent.com
165
40
Hydrolox
www.hydrolox.com
55
18
CONBRACO INDUSTRIES INC

apollovalves.com
29
71
Hydrothrift Corp
www.hydrothrift.com
88
63
Conco Systems Inc

www.concosystems.com
82
41
Cormetech Inc
www.cormetech.com
56
64
IMI Sensors
www.imi-sensors.com
82
116 Cummins Generator Technologies

www.gridcodegenerators.com
153
76
Indeck Power Equipment

www.indeck.com
95
Daewoo Shipbuilding
& Marine Engineering
www.dsme.co.kr
15
126 Integrated Power Services

www.ips.us/megaseal
173
Delta Measurement
and Combustion Controls
www.deltameasurement.com
71
123 Invensys Systems

www.foxboro.com/foxboroevo
167
54
181
DNV Energy
www.dnvgl.com/energy
43
130 JASC Jansens Aircraft

Systems Controls Inc
www.jasc-controls.com
72
89
31
127
108 Elster
www.elster-instromet.com
137
183
107 Enercon Services Inc

www.enercon.com
135
Buckman
www.buckman.com
16
98
ETHOSENERGY
www.ethosenergygroup.com
119
62
Burkhalter Rigging
81
35
Evoqua Water Technology LLC

www.evoqua.com
49
48
Busch LLC
www.buschusa.com
64
47
Fairbanks Morse Engine

www.fairbanksmorse.com
63
96
Caldwell Tanks
www.caldwelltanks.com
116
117 Fisher Tank Company

www.fishertank.com
155
21
Camfil Farr Group

www.camfil.com/ps
32
26
Fluor Corp
www.fluor.com
37
43
Carver Pump Company

www.carverpump.com
58
25
FMP Coatings
fmpcoatings.com
36
20
CB&I
www.cbi.com
31
GE Power & Water

7
www.powergen.gepower.com/flexefficiency
73
CD-adapco
www.cd-adapco.com
90
GE Power & Water

9
www.powergen.gepower.com/flexefficiency
132 Chromalloy
www.chromalloy.com
185
115 Glaunach GMBH

www.flowandcontrol.com
149
97
117
86
104
109 Circor Energy Products

www.circorenergy.com
139
128 Haldor Topsoe Inc

www.topsoe.com
177
69
CLARCOR
www.clearcurrentpro.com
87
121 HDR
www.hdrinc.com
163
90
Clark-Reliance Corporation
www.clark-reliance.com
111
32
HILLIARD CORPORATION
hilliardcorp.com
46
28
Cleaver Brooks Inc/Nebraska Boiler 39

www.cleaverbrooks.com/papermill
135 Houston Dynamic Service Inc.

www.houstondynamic.com
191
www.power-eng.com
PG#
124 Clyde Bergemann Power Group
103 Doosan Heavy Industries

& Construction
Chromalox
www.chromalox.com
RS# COMPANY
Graphite Metallizing Corp

www.graphalloy.com
HYTORC Industrial Bolting Systems 18
John Zink Co
www.johnzinkhamworthy.com
118 Kiewit Power Inc

www.kiewit.com
157
17
Kochek Company Inc

www.kochek.com
28
77
Kral Ag
www.kral-usa.com
96
84
LJUNGSTROM DIVISION
OF ARVOS GROUP
www.arvos-group.com
103
88
Man Diesel & Turbo

www.mandieselturbo.com
109
12
Martech Training Services

www.martechtrainingservices.com
19
55
MARYLAND DEPT. OF
BUSINESS & ECONOMIC DEV.
www.choosemaryland.org
72
44
Mechanical Dynamics
& Analysis, LLC
www.mdaturbines.com
59
110 Metso Power AB

www.valmet.com
143
87
Mistras Group
www.power.mistrasgroup.com
105
45
MITSUBISHI ENGINE
NORTH AMERICA INC.
61
57
MITSUBISHI HITACHI POWER

SYSTEMS AMERICA ENERGY
AND ENVIRONMENT, LTD
www.psa.mhps.com
75
24
Mitsubishi Power Systems

Americas Inc
www.psa.mhps.com
35
58
MMD Equipment
www.mmdequipment.com
77
207
INDEX
RS# COMPANY
36
RS# COMPANY
PG#
SALES OFFICE
51
60
ROTORK CONTROLS INC

www.rotork.com
79
127 Nem Energy B.V.

www.nemusacorp.com
175
16
Roxul Inc
www.roxul.com
27
1421 S. Sheridan Rd., Tulsa, OK 74112

Phone: 918-835-3161, Fax: 918-831-9834
e-mail: pe@pennwell.com
93
Nooter Eriksen
www.ne.com
113
119 SEALEZE, A UNIT OF JASON, INC.

www.sealeze.com
159
Sr. Vice President North

American Power Group Richard Baker
94
Nord-Lock Inc
www.superbolt.com
114
46
SEI Group
www.southernenvironmental.com
62
52
Nuscale Power Inc

www.nuscalepower.com
69
91
Selkirk Corp
www.selkirkcommercial.com
112
39
OFS Specialty Photonics Division

www.ofsoptics.com
54
102 Siemens Ag
www.siemens.com/energy
125
95
Orion Instruments
www.orioninstruments.com
115
104 SPX
www.spx.com
129
33
Ovivo
www.ovivowater.com/power
47
81
Stanley Consultants, Inc.

www.stanleyconsultants.com
100
27
PCORE Electric &

Electro Composites
www.hubbellpowersystems.com
38
Stantec Inc
www.stantec.com
14
195
SULZER TURBO SERVICES

www.sulzer.com
21
137 PennWell Webcast Conco

power-eng.com/webcasts
PennWell Webcast Hytorc
70
Terrasource Global
www.terrasource.com/pe
23
53
59
PennWell Webcast Schneider Electric102

Testo Inc.
www.testo350.com
78
83
50
Philadelphia Gear Corporation

www.philagear.com/boring/pe
THE SOCIETY FOR

PROTECTIVE COATINGS
sspc.org
66
42
57
133 PIC Group Inc

www.picworld.com
187
100 Tianjin Valvo Co
122
38
PLASTOCOR, INC
plastocor.com/wordpress
53
61
TMEIC
www.tmeic.com
80
37
POWER-GEN Week
www.powergenerationweek.com
52
79
Tomco Fire Systems

www.tomcosystems.com
98
19
Power Systems Mfg LLC

www.psm.com
30
85
TPC Wire & Cable

www.tpcwire.com
104
113 POWER-GEN 200

power-eng.com/power-gen200
148
66
Tri Tool Inc

www.tritool.com/RBLG2
84
105 Power-Gen Natural Gas

130
106 United Rentals Inc

www.unitedrentals.com/urcontrol
136 Power-Gen Natural Gas

193
89
23
Process Barron
www.processbarron.com
34
22
ProEnergy Services LLC

www.proenergyservices.com
33
Proton Onsite
www.protononsite.com
88
70
120 PW Power Systems

www.pwps.com
161
125 Quanta Services

www.quantaservices.com
171
Rentech Boiler Systems

www.rentechboilers.com
C2
114 Ring Power Corporation

www.plastocor.com/wordpress
149
30
208
Mobil Industrial Lubricants

www.mobilindustrial.com
PG#
Robinson Fans
www.robinsonfans.com
41
134 Roeslein & Associates, Inc.

www.roeslein.com
189
131
UNIVERSAL ACOUSTIC
110
& EMISSION TECHNOLOGIES
www.universalAET.com/power-generation/
112 Valvtechnologies, Inc
147
138 Victory Energy Operations LLC

www.victoryenergy.com
C3
65
Volvo Penta of the Americas

www.volvopenta.com/industrial
83
75
Vooner Flogard Corporation

www.vooner.com
93
99
Weg Electric Motors

www.weg.net/us
121
Westinghouse Electric Co
www.westinghousenuclear.com
68
Winsted Corporation
www.winstedcustom.com
86
80
Young & Franklin Inc

www.yf.com
99
129 Zeeco Inc

www.zeeco.com
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 Michelle Smith
The Water Tower
Gunpowder Mills
Powdermill Lane
Waltham Abbey, Essex EN9 1BN
United Kingdom
Phone: +44 1992 656 609, Fax: +44 1992 656 700
e-mail: michelles@pennwell.com
Africa, Asia, Central America, Europe,
Middle East, South America
European Sales Asif Yusuf
The Water Tower
Gunpowder Mills
Powdermill Lane
Waltham Abbey, Essex EN9 1BN
United Kingdom
Phone: +44 1992 656 631, Fax: +44 1992 656 700
e-mail: asify@pennwell.com
Europe and Middle East
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
179
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We didnt build the rst Boiler.

EXECUTIVES DISCUSS THE FUTURE OF NUCLEAR POWER

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108 Swine Waste Generates Electricity in North Carolina

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