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WIND TURBINE TECHNOLOGY
IMPROVING EFFICIENCY AND REDUCING COSTS
the magazine of power generation
118
YEARS
UNDER STRESS
Rethinking Your
O&M Strategy
March 2014 www.power-eng.com
As MATS/MACT and other regs spring up

SOLVAir Solutions is in the thick of it all.
This year, not only MATS/MACT regs are looming, but many other regulations are also on the
EPAs agenda. SOLVAir Solutions independent feld tests and case studies, and expert knowledge
of Dry Sorbent Injection and other air pollution control systems can help plants today, not only
with MATS/MACT, but with other regulations as well.
Air pollution control is the business of SOLVAir Solutions, and it is our only business. Our
products, trona and sodium bicarbonate, have been used to help coal-fred power plants, utilities
and industrial boilers clean the stacks and comply with regulations for more than 25 years.
We know air pollution control.
Whatever regulations concern you, call Mike Wood at SOLVAir Solutions today for a detailed
discussion of your options. Or go to our Library at www.solvair.us for a wide range of documents,
including case studies, feld tests and product applications that can help your plant reach
compliance.
Solvay Chemicals, Inc.

1.800.SOLVAY C (800.765.8292)
www.solvair.us
Copyright 2014, Solvay Chemicals, Inc. All Rights Reserved
For info. http://powereng.hotims.com RS# 1
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FEATURES 118
Turbine
24 Gas
O&M Practices
ON-LINE EDITOR Jennifer Van Burkleo

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CONTRIBUTING EDITORBarry Cassell
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& Strategy
As the U.S. becomes more reliant on gasfired generation, utilities are reevaluating
their O&M plans. Managing Editor Russell
Ray looks at strategies for protecting these
vital power generation assets.
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30 History, Challenges
and Successes of a NOx

Reduction Project
Developers of a Selective Catalytic Reduction unit in

Wisconsin faced operational and construction challenges
installing a system in an ozone non-attainment area and
share their lessons learned from the successful project.
CHIEF FINANCIAL OFFICER/SENIOR

VICE PRESIDENT Mark C. Wilmoth
46 Advancements in Wind
CIRCULATION MANAGER Linda Thomas

PRODUCTION MANAGER Katie Noftsger
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Power Engineering
No. 3, March 2014
VOLUME
Turbine Technology
With more wind power projects being installed than ever,

turbine manufacturers are looking for new ways to increase
the efficiency, output and reliability of wind power assets.
50 Preparing for Section 316(b)

Although the EPAs 316(b) rule will not be released until April,
plant owners can still take steps to comply with the regulation
that will affect more than 670 U.S. power plants.
DEPARTMENTS
2
4
10
Opinion
Industry News
Clearing the Air
12
14
16
Gas Generation
View on Renewables
Energy Matters
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OPINION
The Evolving
Coal Plant
BY RUSSELL RAY, MANAGING EDITOR
oal-fired power plants can

and should play a starring
role in the integration of renewable power.
That was the conclusion of researchers who prepared an eye-opening report for the Department of Energys
National Renewable Energy Laboratory. The December 2013 report, Flexible
Coal: Evolution from Baseload to Peaking
Plant, showcased the transformation
of a 1970s era coal-fired plant, which
was modified to cycle on and off at low
generation levels like a peaking plant.
This study proves that coal can be
part of a power system with high levels
of renewable energy, said NRELs Jaquelin Cochran, the reports lead author.
Coal plants can be modified to respond
to the changing output of renewable energy and run at low levels when renewable electricity generation is high but
demand is low, such as at night.
The case study offers a glimpse at the
future of coal-fired generation, a world
where coal is used to offset the fluctuations in renewable power through
greater flexibility. It also provides a
road map for incentivizing and modifying similar projects.
The report summarizes the hardware and operational modifications at
an unnamed coal generating station in
North America, which was originally
built to run as a baseload plant with
an 80 percent annual capacity factor.
The plant was designed to run near full
capacity most of the year, but the addition of nuclear capacity displaced most
of the plants coal-fired generation.
Today, the plant cycles on and off as
many as four times a day, the report
2
shows. It is one of a few coal plants Key to the owners success is changworldwide to accomplish this level of ing operational practices.
flexibility.
The point is this: Power plants
The steam generator and supporting equipped with combined cycle gas
equipment boilers, rotors, condens- turbine (CCGT) technology are highly
ers, turbines and pulverizers - were efficient and flexible, but CCGT techmodified to enable frequent cycling. nology isnt the only option available
But giving the
to power proplant the abilducers and grid
ity to cycle on
managers who
and off at lower
are struggling to
output required
maintain a balfew modificaanced load amid
tions in harda growing source
ware. The most
of intermittent
extensive modielectricity. The
fications
cen- - Jaquelin Cochran, NREL
NREL
report
tered around the
shows that older
plants operational practices. In fact, baseload coal units can be reinvented
the plants owner estimated 90 per- to support the use of cleaner-burning
cent of future savings in costs came power.
from adjustments to operating proceThe NREL report serves as compeldures, according to the report.
ling evidence that the key to suppressThe plant cycled on and off as many ing climate change while preserving
as four times a day to meet peak de- this nations most abundant and relimand. The increased cycling and the able source of generation is greater
rapid changes in temperature and flexibility for coal-fired plants.
pressure led to several issues, includThe name of this column, The
ing thermal fatigue, turbine corrosion, Evolving Coal Plant, is also one of
boiler tube failures, cracked rotors and seven conference tracks being offered
wear and tear on auxiliary equipment. at COAL-GEN 2014 in Nashville,
There is a cost to this flexibility, Tenn., Aug. 20-22. This issue will be
Cochran said. But these costs can be discussed in detail during one of the
minimized with strategic modifica- sessions at COAL-GEN, where paneltions and maintenance.
ists will examine ways to improve the
Despite the wear and tear to equip- flexible generation of coal-fired plants
ment, the plant continues to operate to accommodate the integration of
profitably, thanks to increased inspec- more renewable power.
tion, monitoring and training.
If you have a question or a comThe plant owner has achieved what ment, please contact me at russellr@
few coal plant operators have been pennwell.com. Follow me on Twitter
able to do, NREL said in its report. @RussellRay1.
This study proves

that coal can be part
of a power system
with high levels of
renewable energy,
www.power-eng.com
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INDUSTRY NEWS
GE launches on-site
power, distributed
generation business
General Electric launched a distributed generation business venture that combines three product linesAeroderivative Gas Turbines, Jenbacher Gas Engines
and Waukesha Gas Engines.
GE will invest $1.4 billion
over the next four years to
o
help meet the worlds growh
iing demand for on-site poweer systems that are easier to
fnance, faster to install and
f
more effcient and reliable for customers.
GE also announced a number of agreements including:
Two memoranda of understanding
with Clean Power Indonesia and
PLN for the development and deployment of its integrated biomass
gasifcation power system in Indonesia.
Two major Southeast Asia gas engine
supply and service agreements with
distributed power project developer
Navigat Energy Pte Ltd to provide
100 new Jenbacher gas engines that
will generate a total of 330 MW in
Indonesia and Thailand.
An agreement with Malaysian company Green & Smart Sdn Bhd, to
provide a solution for waste-topower using GNS patented technology in anaerobic digestors and GEs
Jenbacher gas engine technology to
produce power and supply to the
Malaysian electricity grid.
GE Oil & Gas and GEs Distributed
Power businesses signed a memorandum of understanding with PLN
Enjiniring to develop an integrated
virtual pipeline power generation
pilot project in remote islands of Indonesia.
Vogtle on track to be
completed by 2018
Georgia Power offcials said the $15
4
billion Plant Vogtle expansion project is

on schedule to be completed by 2018.
The utility said that crews fell 19
months behind on building two new
nuclear reactors in 2013. However, the
project is still on track to be completed
by the projected date. Georgia Power said
they are making up for lost time and are
completing key stages of the second reactor ahead of schedule.
The new reactors will more than double the generating capacity of the plant.
The nuclear expansion is expected to
be operational by the end of 2017 or early
2018.
Judge rules coal-fred

plant did not violate
Clean Air Act
Luminant won a court battle over alleged Clean Air Act violations at the Big
Brown coal-fred power plant in Texas.
A judge with the U.S. District Court,
Western District of Texas (Waco) ruled
that no violations occurred at the plant
and denied all of the Sierra Clubs requested relief after a three-day nonjury trial.
Sierra Club fled the lawsuit in May
2012 alleging that Luminant violated
the law due to emissions that occurred
during maintenance, startups and
shutdowns at the plant between July
2007 and the present. The suit asked
for more than $330 million in civil
penalties and $140 million in new
emission control upgrades.
FP&L, NRC refute

St. Lucie nuclear tube
wear claims
Spokespeople with the U.S. Nuclear
Regulatory Commission and Florida
Power & Light said there are no serious
safety issues pertaining to steam generator tubes inside Unit 2 at the St. Lucie
nuclear power plant in Florida.
The Tampa Bay Times quoted a nuclear
policy lecturer who said that inspection
reports at the plant showed 1,500 times

the norm of tube wear.
However, the NRC and FP&L said
there are no steam generator safety problems nor are there tube integrity safety
concerns at the plant. If there were safety
issues, they would have been refected in
the NRCs safety oversight program, offcials said.
The NRC spokesperson also said the
severity of the wear, not the number of
wear indicators, is important, and it is unfair to compare the tube wear at St. Lucie
to what was seen inside of the San Onofre
Nuclear Generating Station in California.
The generators used at SONGS were of a
different design, type and manufacturer.
The generators will undergo a routine inspection during a planned
March outage.
Calpine completes
purchase of combinedcycle power plant
Calpine Corp. completed the purchase
of the 1,050-MW Guadalupe combinedcycle natural gas-fred
power plant in Texas
for $625 million, or
$595 per kilowatt. The
deal was announced
in December 2013.
The acquisition was funded with a
$425 million incremental Term Loan B
at Calpine Construction Finance Co. L.P.
and cash on hand. The Guadalupe Energy Center includes two 525-MW generation blocks, each consisting on two
GE 7FA combustion turbines, two heat
recovery steam generators and one GE
steam turbine.
Cape Wind gets

$600mn boost
An offshore wind energy project off
the coast of Massachusetts received a
$600 million loan from a Danish export
credit agency. Cape Wind received the
loan from EKF. It is subject to fnalization
www.power-eng.com
break through
the
NOISE
Better Signal-to-Noise Ratio Means
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4.40
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The ECLIPSE Model 706 transmitter has a
signal-to-noise ratio nearly 3 times higher
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While transmit pulse amplitude (signal size) has helped to make

guided wave radar technology the standard for accurate, reliable level
measurement, the fact is signal-to-noise ratio (SNR) represents a far
more critical indicator of level control performance. For superior SNR in
all process conditions, no other GWR device beats the Eclipse Model
706 transmitter from Magnetrol .
To learn more about the breakthrough

ECLIPSE Model 706 GWR transmitter
visit eclipse.magnetrol.com or contact
your MAGNETROL representative today.

2013 Magnetrol International, Incorporated
INDUSTRY NEWS
of due diligence and completion of documentation. The wind farm is expected to

cost at least $2 billion and will be located
in Nantucket Sound.
$6.5 billion in loan

guarantees fnalized
for Vogtle
The Department of Energy fnalized
loan guarantees totaling $6.5 billion for
two nuclear reactors under construction
at Plant Vogtle in Georgia.
Energy Secretary Ernest Moniz and
several offcials from Georgia Power and
parent company Southern Co. attended
a press conference held at Plant Vogtle
in Georgia. The
conditional loan
guarantees were
frst announced
in June 2010,
and the DOE and
plant co-owners
had been in continuous discussions since then.
Georgia Power and Oglethorpe Power
fnalized the loan guarantees for $6.5 billion. The third owner of the new reactors,
Municipal Electric Authority of Georgia
will fnalize its $1.8 billion loan guarantee at a later date. The remaining owner,
Dalton Utilities, is not part of the loan
guarantee program.
According to a release from Southern,
total guaranteed borrowings will be the
lesser of 70 percent of the companys eligible projected costs - or approximately
$3.46 billion - and will be funded by
the Federal Financing Bank. Georgia
Power received an initial draw of $1
billion and future draws may occur as
often as quarterly. The loan guarantees
apply to borrowings related to the construction of Vogtle units 3 and 4, and
any guaranteed borrowings will be full
recourse to Georgia Power and secured
by a frst priority lien on the companys
45.7 percent ownership interest in the
6
two new units.

During the announcement, Southern
Co. CEO Tom Fanning said the process
had been a positive one.
This has been a fair, tough, reasonable negotiation, Fanning said. Its a
great thing for America.
The Nuclear Energy Institute praised
the loan guarantee program.
The use of loan guarantees allows
for greater access to the capital markets resulting in lower-cost fnancing,
thereby reducing the cost of electricity to consumers, said Marvin Fertel,
president and CEO of NEI. This loan
guarantee is expected to save Georgia
Power customers $200 million on electricity costs.
Combined-cycle power
plant in the works in NC
NTE Energy plans to develop a $450
million natural gas-fred power plant
in North Carolina.
The planned 480-MW Kings Mountain Energy Center will use a Mitsubishi Hitachi Power Systems Americas
M501GAC advanced combustion turbine and steam turbine in combined
cycle confguration.
Construction is expected to create
approximately 300 industry jobs. NTE
Energy has started the permitting process and submitted its transmission interconnection request to Duke Energy
Carolinas. Construction is expected to
begin in 2015 and be fully operational
in 2018.
NTE Energy has also announced
plans to build the Pecan Creek Energy
Center in Texas and the Middletown
Energy Center in Ohio.
Pipeline approved for

FutureGen CCS project
Illinois regulators approved a 30mile underground pipeline that would
carry carbon dioxide (CO2) from the
FutureGen 2.0 clean coal project to a
storage site.
The Illinois Commerce Commission approved the 10- to 12-inch diameter pipeline that would be buried
at least four feet underground on the
way to the storage site from the plant.
If it runs under farm ground, it will be
buried fve feet deep.
The FutureGen 2.0 plant is designed
to store 1 million metric tons of carbon a year for 30 years.
The process would capture and store
90 percent of carbon emissions produced by Amerens Meredosia power
plant, which will be retroftted to capture and store the CO2.
The FutureGen plant received approval on Jan. 16 from the U.S. Department of Energy to begin construction
on the retroft project. The plant will
use an oxy-combustion system, air
quality control systems, boiler, steel
and other control systems.
Siemens wind turbines

to be used at Bison
Wind project
Minnesota Power picked Siemens to
supply 64 3-MW D3 platform wind turbines for the Bison Wind Energy Center
in North Dakota.
The turbines are scheduled for installation starting in mid-June 2014,
and commercial operation is slated for
December 2014. Siemens will provide
transportation, installation and commissioning, as well as a three-year service and maintenance agreement. The
blades will be built at Siemens manufacturing facility in Iowa, and the D3s
nacelle component will be assembled at
the Kansas manufacturing plant.
The 205-MW Bison 4 expansion
will increase the projects total output
to nearly 500 MW. The previous three
phases went into operations in 2010 and
2012. The second and third phases won
the Best Wind Project for Power Engineerings 2013 Projects of the Year Awards.
www.power-eng.com
MITSUBISHI HITACHI POWER SYSTEMS
Pulling Ahead
as ONE
The global merger of Mitsubishi Heavy Industries and

Hitachis thermal power generation businesses integrates
two leaders in world class technology creating Mitsubishi Hitachi
Power Systems.
This historic combination represents over 240 years of innovative
products, systems and services. Now, Mitsubishi Hitachi Power
Systems delivers the talent and technology of both companies as
a single source solution for existing and evolving energy needs.
Visit us online to learn more about our world class capabilities.
Mitsubishi Hitachi Power Systems Americas, Inc.

www.mhpowersystems.com
Mitsubishi Hitachi Power Systems America Energy and Environment, Ltd.

www.psa.mhps.com
CLEARING THE AIR
Rise of
the WESPs
BY K. SAMPATH KUMAR, ALBERT L. MORETTI, AND MEVILLE C. HEDGES,

BABCOCK & WILCOX POWER GENERATION GROUP
ry Electrostatic Precipitators
(ESPs) have long been the
weapon of choice for utility
and industrial particulate control needs.
But a recent trend has seen more customers, particularly in industry, move toward
the installation of wet ESPs for use as a
polishing device because of their greater
effectiveness in achieving ultra-low fine
particulate emissions, as well the added
benefits of removing acid mist and some
heavy metals.
In the U.S., wet ESPs are becoming an
important tool for complying with the
industrial boiler MACT rule, enacted in
2013.
Paper mills in the U.S. are required to
meet emissions levels as low as 0.035 lbs/
mm BTU. Many of these plants have a
wet particulate scrubber already in place
which is not suitable for fine particulate
removal or the even finer sulfuric acid
mist that can be generated when firing
high sulfur coal or oil. Since wet ESPs
are designed to operate in a saturated gas
stream, they can effectively be installed
as a polishing device after the wet particulate scrubber to easily achieve the new
emission standards.
Overseas demand for wet ESPs is growing as well, including demand for utility
applications. The Chinese government is
aggressively ratcheting down PM2.5 emissions to improve the ambient air quality.
As a result, utilities are evaluating wet
ESPs as a solution to achieve lower PM2.5
emissions from their fleet of coal fired
power plants. There are several plants in
China that are in the process of installing
wet ESPs and many others are performing feasibility studies on implementing
wet ESPs downstream from a wet flue
gas desulfurization unit in order to meet
10
Al Moretti
stricter emissions standards.

There are several configurations of
wet ESP designs now in service that are
proven in commercial practice. Wet ESP
internal configurations can use either
tubular or parallel-plate type collecting
electrodes. Whiletubular configurations
will have only vertical gas flow orientation, the plate-type designs can have either horizontal gas flow or vertical gas
flow orientation.
Wet ESPs for power plant applications
tend to be mostly of the plate type design with multiple electrical sections. It
is more common to find tubular collector bundles,often upflow or downflow,
for industrial boiler applications. The
collector tubes are circular,hexagonalor
rectangular shape. While many applications involve just a single field wet ESP,it
is more common in todays market to design wet ESPs with at least two fields in
series. These multi-field designs not only
provide additional treatment time, they
provide more reliability and performance
margin for meeting emission regulations.
The material of construction for a wet
ESP needs to be suitable for corrosive duty
because it operates in a saturated acid gas
environment. Carbon steel will not work
for this purpose. Materials such as 316 SS,
2205 or even higher grade alloys such as
6 percent Mo,or C-276 may be needed.
Several suppliers are considering FRP or
polypropylene as collector electrodes instead of the more expensive alloys. The
selection of these materials for wet ESP
application is site specific and is primarily a function of chloride content and pH
in the wet ESP section, which is, in turn,
often a function of FGD mist eliminator
performance, water quality, coal type and
other process factors.
Meville Hedges
Sam Kumar
Experience suggests that wet ESP performance is determined by the corona

power that can be received by the wet ESP.
This is typically expressed as watts/1000
acfm of gas flow. Many factors determine how much corona power can be
sustained by a given field. These include
corona discharge electrode geometry, ash
build-up potential, design of wash systems to remove tenacious ash, and the
degree of electrical sectionalizaton of the
total ESP fields.
A phenomenon known as the space
charge effect, or corona suppression can
surface during wet ESP operation. Corona
suppression is associated principally with
the presence of large amounts of ultrafine particulate. This large amount of particulate can severely suppress operating
corona current in the wet ESP which will
result in low power and an associated decrease in collection efficiency in the wet
ESP. To effectively deal with anticipated
corona suppression, proper and effective
designs of collection and discharge electrode geometries must be made.
The industry has seen its share of underperforming wet ESP units as a result
of several factors which include: a) undersized wet ESPs with insufficient treatment time, b) too few electrical sections
in series, c) insufficient wash systems for
tenacious ash build-up, d) poor design
of corona discharge electrodes that are
susceptible to corona quenching by high
degree of fine particulates, e) improper
material selection for the acidic environment, and f) flow misdistributions at the
wet ESP inlet.
An experienced designer of wet ESPs
can take all the above factors into account
and can properly deliver the needed performance and reliability.
www.power-eng.com
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Handling a World of Materials

Posimetric is a licensed trademark of GE Energy (USA) LLC.
The brands comprising TerraSource Global (Gundlach Crushers, Jeffrey Rader and
Pennsylvania Crusher) are wholly-owned subsidiaries of Hillenbrand, Inc. (NYSE: HI)
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www.terrasource.com
GAS GENERATION
Investing in
an Installed Base
BY JUSTIN MARTINO, ASSOCIATE EDITOR
ew gas-fired power plants

have many advantages for
power producers: New technology is allowing new plants to reduce
emissions, have faster starts and be
more efficient than ever before. Unfortunately, with price tags reaching hundreds of millions of dollars, new power
plants are also expensive, and companies may be uncomfortable making that
type of capital investment when it isnt
strictly necessary.
Original equipment manufacturers have recognized this market niche,
however, and are working to help power
generators improve their current equipment without making the investment
in a new plant by upgrading the equipment at an existing plant.
Upgrades for natural gas-fired power
plants can involve a few different aspects. While upgrading the hardware at
a plant will result in efficiency improvements, many upgrades focus on controls and software, especially for plants
looking to upgrade how quickly it can
start.
Controls influence a lot on how
quickly you can start the equipment,
and what weve done with our controls
is try to build a startup model that allows you to optimize your start time
without putting any undue stress on the
equipment, said Justin Eggart, general
manager of monitoring, software and
analytics, power generations services
for GE Power & Water.
Faster starts have become important
for plants as more power producers use
gas-fired plants in ways not originally
intended, whether that involves cycling
a plant to compensate for renewable
12
energy production or using a plant de- controls and analytics that are giving
signed as a peaker plant to produce real performance benefits to our cusbaseload power.
tomers without having to build a new
Although controls may help increase power plant.
efficiency and startup times, upgradGE isnt the only manufacturer to ofing plant hardware is another option fer upgrade packages, however. Among
available to power producers. Upgrad- others, Siemens and Alstom also offer
ing hardware can have multiple posi- upgrade packages for existing turbine,
tive benefits for a plant, including an with Alstom recently announcing it
increase in fuel efficiency and output, would be installing its first MXL2 upEggart said.
grade packagein the Middle East for
You can take your existing power Dubai Aluminum (DUBAL).
plant and your existing turbine, and
According to Alstom, the upgrade
by making some modifications just to will allow a 1 percent increase in comthat
hardware,
bined cycle mode
you can get more Its the investment
efficiency, propower
output were making in
duce an addiand better fuel ef- software and controls
tional 12 MW of
ficiency, he said.
gross power outand analytics that
GEs total upput, reduce CO2
grade
package are giving real
emissions
and
for gas turbine performance benefits to increase service
covers three arintervals by oneour customers without
eas:
hardware,
third at the plant.
controls and a re- having to build a new
Alstom calls
mote monitoring power plant.
the MXL2, which
system. Although
works on both
- Justin Eggart, GE
these three areas
the GT26 and
can be upgraded together, any of the GT24 turbines, an established and
three areas can be upgraded indepen- proven upgrade and said the product
dently.
will allow for people who upgrade their
Eggart said GE will continue to look components to have increased perforat ways to improve its current turbines mance, improved operational flexibilon the market.
ity and reduced maintenance costs.
GE is investing heavily in the inWith so many companies offering upstalled base that we have today to make grades for existing turbines, power genthat perform better, and were doing a erators have more options than before.
lot of that with investments in software While a new plant may give a company
and analytics and control, he said. Its the best possible results, upgrading an
not just hardware. Its not just the next existing plant can provide benefits and
generation gas turbine. Its the invest- extend the plants life without a major
ment were making in software and capital investment.
www.power-eng.com
Justin Eggart, GE
VIEW ON RENEWABLES
Realizing Hydropowers
Potential in 2014
BY CARL ATKINSON, PE, VOITH HYDRO
he year 2013 was a breakout

year for American hydropower.
Last summer, President Obama
signed two bills that will help expand hydropower production: the Hydropower
Regulatory Efficiency Act, and the Bureau
of Reclamation Small Conduit Hydropower Development and Rural Jobs Act.
Both bills take aim at the licensing process for small hydropower projects, with
the ultimate goal of providing electricity
to more homes and businesses across the
U.S. Though small first steps, the fact
that both bills passed with overwhelming bipartisan support is a sign that policymakers on Capitol Hill understand the
value of sustainable, affordable, reliable,
and clean hydropower.
2013 also saw the completion or continued progress of several major hydropower projects for which Voith was proud
to showcase its domestic and international design and manufacturing capabilities, including the PPLs Holtwood Dam
in Pennsylvania and AMPs Ohio River
projects. These projects are noteworthy
as they represent some of the first significant additions of hydropower capacity at
existing dams. After a monumental year,
whats in store for hydropower in 2014?
Though weve made progress, challenges lie ahead. New natural gas discoveries and new technologies have pushed
gas prices lower, making it attractive to
many energy developers.
While we have seen major victories on
the policy front, both the Production Tax
Credit (PTC) and Investment Tax Credit
(ITC) have expired. Though hydropower
is less reliant on these credits than other
renewables, their expiration presents another challenge in a competitive energy
landscape. The prospects for renewing
14
the PTC or ITC are unclear.

Hydropower, however, has many advantages that will help it weather an
ever-changing energy landscape. No
other form of renewable energy can meet
hydros long-term cost certainty. And
while natural gas prices may ebb and
flow, the natural forces of the hydrologic
cycle replenish hydros fuel. Hydropowers levelized costs are lower than any
form of energy.
In addition, I expect the victories
gained in hydropower policy will be
more fully realized in 2014. The Federal Energy Regulatory Commission has
started implementing the laws passed last
year, and is currently seeking low-impact
pilot projects that can be used to test a
two-year, streamlined licensing process.
The onerous process, which can take 10
years or longer, is cited as a major hindrance to further hydropower development. Elsewhere at the federal level, the
Department of Energys Water Power Program continues to assist ongoing research
and development in waterpower.
Regarding conventional hydropower,
Voith is particularly excited about the
latest innovations in the small hydro sector. While Voith has always been on the
cutting edge of turbine development, our
latest technological advancement is the
StreamDiver. This compact turbine holds
great promise for small streams and rivers
with low heads at existing weirs, flowing
through the country that currently do not
produce power; the very type of development Congress is encouraging.
Larger projects are getting attention,
too. Last year, the Obama Administration placed the Red Rock Hydroelectric
facility in Iowa on its Infrastructure Permitting Dashboard. The Voith-supplied
project is a retrofit of a US Army Corps of

Engineers (USACE) Dam, and will bring
55-MW of energy to Missouri River Energy Services customers. The elevation of
this project to the Dashboard is another
signal that hydropower will play a vital
role in our nations energy portfolio.
A recent study by the USACE gives the
industry further reason to be bullish on
its future. The study found 223 non-powered USACE sites capable of producing
over 1-MW of power. These sites could
generate up to 6,256-MW of electricity,
with 2,818-MW feasible under economic assumptions made in the report. The
USACE is also supporting its existing facilities, recently announcing a $1 billion,
20-year plan to upgrade hydroelectric facilities in the Nashville District.
Expanded hydropower has another,
very important function: job creation.
The hydropower industry employs approximately 300,000 people in the U.S.
New development or retrofitting existing facilities means more jobs for engineers, machinists, developers, plant operators, and construction workers across
the country.
For years, American hydropower was
characterized by the Hoover Dams of the
country - the iconic structures that helped
fuel Americas 20th Century prosperity.
While these dams continue to play a vital role in our energy portfolio, creatively
developing previously overlooked and
underutilized waterways represents the
future.
In 2013, Congress and the Obama
Administration took several strong steps
to spur additional hydropower development. I look forward to these steps leading to tangible results in 2014 and beyond.
www.power-eng.com
Think inside the box.

It may seem familiar, but if you look closer, its what you may not see that makes the difference.
The new Megger S1 Insulation Resistance Testers provide a higher

performance range than any other comparable tester in a smaller, lighter
package. The remote control feature allows you total control of the unit
during testing, via USB to PC, removing all direct contact with the S1 unit
for safer operation. The new S1 series comes with additional features such
as improved battery life, with a customer replaceable battery, rapid charge
and ltering. With improved 8 mA noise rejection, the new Megger
insulation resistance testers give you a cleaner, more
reliable signal. There are three models to choose
from, the 5 kV model with resistance measurement
capability of up to 15 T, and the 10 kV and 15 kV
models with resistance measurement capability of
up to 35 T.
WWW.MEGGER.COM/US
S1
Series
Insulation Resistance Tester
For more information on the newest S1 Series of insulation resistance testers

download the datasheet at www.megger.com/S1 or call us at 1-800-723-2861.
The word Megger is a registered trademark
ENERGY MATTERS
Digging Deeper
into Carbon Capture
and Storage
BY ROBYNN ANDRACSEK, P.E., AND JEFFREY BINDER, P.G., BURNS & MCDONNELL
y now most utilities have probably heard the details of EPAs

latest greenhouse gas (GHG)
proposal for New Source Performance
Standards (NSPS) from new fossil fuelfred electric generation units. The rule
depends strongly on future coal- and
gas-fred power plants controlling greenhouse gas (GHG) emissions through
carbon capture and storage (CCS). How
exactly does the storage/sequestration
element of CCS work and where can it
occur?
CCS is not a new technology. It is has
been used for over 40 years in the oil and
gas industry for enhanced oil recovery.
Expanding CCS into the power generation industry is a new application of an
old technology. There is an economic
beneft to injection CO2 into depleted oil
and gas feld, collapsed coal mines, or unminable coal beds.
The key to CCS is the right geology. By
injecting CO2 under pressure into suitable rock formations, the gas absorbs into
the pores of the rock. Picture the type of
holes and cavities found in a reef. These
are the types of spaces, on a much smaller
scale, that the CO2 flls in the rock. Over
time the pressure releases as the gas reacts
with fuids in the rock and the CO2 gas
becomes a solid precipitate. The pores fll
up and the rock is full.
The volume of gases produced and the
amount of storage capacity in the U.S.
are important to consider. If a 750 MW
supercritical pulverized coal-fred boiler
is considered to be the reference plant,
16
the annual CO2 output is around 5 million tons. Assume that this plant is ideally located over a 300-foot sandstone
formation. The 50 year output of this
plant would need a 442 square mile area
(mi2) for storage. Eight plants of this size
would require a 3,450 mi2 storage reservoir which is equivalent to a Class 18 oil
feld, of which there are only 20 in the
U.S. There are currently over 200 coalfred power plants in the U.S. of the size
of this reference plant. Therefore, there is
not enough storage capacity in the U.S.
for the CO2 output from existing plants.
The Department of Energy (DOE) and
the EPA, 1 however, would disagree. They
estimate that the storage capacity in the
U.S. is equivalent to 600 to 6,700 years
of current level emissions from large stationary sources in the United States. The
difference is that DOE and EPA are taking
into account all potential geologic settings without screening ones that meet
suitability criteria and have the highest potential for success from a practical
standpoint.
One issue is that these appropriate rock
formations are not located everywhere.
Deep sedimentary basins in North Dakota, Illinois, Louisiana, and Texas, for
example, have the right geology to make
CCS theoretically feasible. A new power
plant would ideally be sited over one of
these locations. An existing plant would
need pipeline infrastructure to move the
captured gas to a suitable formation.
Safety is often a public concern whenever CCS development is proposed. Carbon
dioxide is a low hanging gas, denser than

air. It is corrosive, odorless, and colorless.
However, when properly sited, CCS in
enhanced oil recovery (EOR) operations
has been safely operated. Intensive monitoring of the CCS injection wells and storage reservoirs will help to maintain safe
operation of these facilities to protect the
safety of the public. As in all perceived
new ventures, public perceptions as well
as a NIMBY (not in my backyard) mentality could prevent and delay proposed
large scale CCS operations.
Currently there are fve large scale CCS
projects at U.S. power plants, all in the
construction or planning stages.11 Likewise in other countries, power plant CCS
projects are not yet in full-scale operation.
At the power plant, on-site space issues
can be an issue given that the CO2 capture and injection infrastructure can have
a foot print as large as the power block.
This will become a fatal faw for many
utilities if, as expected, the proposed CCS
requirement is expanded to existing coalfred boilers.
When all of these issues are taken into
account, it is clear that the proposed GHG
NSPS was not written with the intent of
encouraging CCS as a solution to CO2
emissions from modern power plants.
Rather, the CCS requirement is meant
to serve as a deterrent to construction of
new power plants.
Given the proper geology, storage and
sequestration of CO2 might be technically feasible but it is hardly a practical
solution.
www.power-eng.com
NUCLEAR REACTIONS
High Performing Teams

Invest in Teaming
MARY JO ROGERS, PH.D.
Author
Mary Jo Rogers,
Ph.D. is a partner at
Strategic Talent Solutions with over 15
years working with
leaders in the utility
sector. She recently
published the book,
Nuclear
Energy
Leadership: Lessons
Learned from U.S.
Operators, by PennWell. Contact Mary
Jo at www.strattalent.com or maryjo@
strattalent.com.
he value of high performing leadership teams is realized across the site in safety,
reliability, and cost. One of the most
powerful antidotes to challenging
plant conditions and people hunkering
down in their functional areas is the
camaraderie, effective communication,
and decision-making quality of the
well-oiled team machine. The downsides of ineffective leadership teams are
manyinefficiency and burn-out top
the list.
When running nuclear power plants
is made even more stressful by market
economics, regulatory expansion and
aging equipment, its time for leadership teams to pull together and make
the investment in their own team capability. Unfortunately, when the going
gets tough the nukes tough it out instead of stepping back and working on
the team. Nuclear energy leaders need
to be reminded of the importance of
creating effective leadership teams that
function well under duress.
ARE WE REALLY A TEAM?

Nuclear power plants are the perfect environments for building highly
effective top leadership teams that
guide the trajectory of the plant. Site
senior leaders are true teams when
members have complementary roles,
they are committed to a common
purpose, such as plant performance,
and are held accountable for shared
results. The nuclear SLT is made up
of a cross-section of the department
leaders (e.g., operations, maintenance,
engineering, work control, radiation
protection, chemistry, licensing, training, human resources and finance). Together they are responsible for the daily
18
functioning of the plant but they also

have a significant impact on long-term
asset management. INPO has concluded and communicated many times that
the effective functioning of the SLT is
critical to the sites performance.
this, but focusing on the team in this

way can take a few hours every month
(with follow-up during the week), but it
neednt be onerous, and should instead
be energizing, solution-focused and
yield team performance improvement.
WHY INVEST IN
DEVELOPING THE TEAM?
CURRENT REALITIES
Team leaders too often assume

that good team behavior and performance will emerge naturally. They
are partly correct in that strong leadership, team stability and highly capable
individual leaders can help achieve
team results over time. However, these
conditions are not sufficient to drive
sustained team performance, nor do
most teams have the luxury of time or
team stability with a full complement
of high achievers. When faced with
the current realities of frequent movement in and out of the team combined
with pressure to perform quickly, the
investment in the development team
is well worth it.
Another reason some leaders fail
to propel their teams forward, is that
they are unclear on what good team
development actually looks like. On
the one extreme, they think that social
events one or two times a year will suffice (given that they spend all day at
the plant together). Or they fear that
teaming would require one full day
or two-day long off-sites at a ropes
course and they rightly fear wasting
that kind of time. In actuality, team
development involves regularly bringing the team together to work through
how team members are going to work
together to solve the teams problems
and challenges and achieve results together. There are many ways of doing
I have had the opportunity to work

with many nuclear site leadership
teams over the years to see how investing the right kind of time on the
team itself pays dividends. Recently
it appears that the challenges to SLTs
include multiple changes in personnel and positions while expectations
remain high and site resources limited.
To use the age-old terminology, teams
keep forming and storming and fail to
reach the performing stage. They limp
along, have inconsistent results, and
burn out good people who leave to
work in a better environment.
The teams that do well in this scenario recognize the importance of SLT
alignment in leading and guiding the
site. They take some time to solidify
their shared goals and figure out how
to get there together. They also develop excellent working relationships
and have each others back. Individual
leaders should obtain feedback on how
they are impacting the teams effectiveness and what they need to do differently. Having both individual and
team behavioral feedback has a powerful impact on the teams development.
Having good relationships speeds communication and boosts commitment.
So if you wonder whether it is worth
spending precious time team-building when there is so much to do to
fix the plant, you should ask instead
whether you can afford not to.
www.power-eng.com
Sanmen Nuclear Power Company Ltd. Used with Permission. All rights reserved.
NO COMPANY IS
MORE FOCUSED
ON ADVANCED NUCLEAR
PLANT TECHNOLOGY
Westinghouse AP1000 plant under construction in Sanmen, China
Westinghouse Electric Company LLC
www.westinghousenuclear.com
Westinghouse
Electric Company
@WECNuclear
INDUSTRY WATCH
Hitachi Sees Strong Market for

Energy Storage in North America
BY SCOTT STRAKA, SENIOR DIRECTOR, HITACHI AMERICA LTD.
Author
Janette Kessler,
Sr. VP of Business
Development and
Regulatory Affairs
with Demansys
contributed to this
article.
20
ind, solar and other

forms of intermittent energy are being rapidly deployed throughout North America as a
result of the convergence of lower costs,
state and federal tax credits, local and
state Renewable Portfolio Standards,
and increasing consumer demand for
clean energy sources. Estimates of the
percentage of penetration of these systems in North America range from 15
percent to 30 percent by 2020. As more
intermittent resources are integrated
into the electrical grid, the demand
for both customer-side and grid-side
energy storage will rise dramatically.
Advanced energy storage systems can
provide frequency regulation, spinning reserves, voltage support, ramp
rate control, load-shifting, and solar
and wind smoothing, among other
benefts. Hitachi recently announced
its intention to be a market leader in
providing these advanced storage solutions in the North American market.
In California, the Renewables Portfolio Standard established in 2002 under Senate Bill 1078, and expanded under SB107 and SB2, is one of the most
ambitious renewable energy standards
in the country. The standard requires
investor-owned utilities, electric service providers, and community choice
aggregators to increase procurement
from renewable energy resources to
33 percent by 2020. The California Independent System Operator (CAISO)
and the California Public Utilities
Commission (CPUC) have reviewed
the impact of the RPS on the electrical
grid and concluded that a signifcant
increase in storage technologies will
be needed to counteract the system impact of these renewables. One impact
will be a potential over-generation during the afternoon when solar PV and

wind generation are typically high.
That could be followed by a dramatic
ramp up in the need for traditional
generation at sundown. Storage would
be an obvious solution to both these
issues.
As a result, the CPUC recently issued
a long-term procurement decision ordering that the three investor-owned
utilities procure 1.3 GW of energy storage by 2020. This is a bold directive
based on legitimate concerns about the
stability of the electrical grid.
Hitachi storage systems currently
installed around the world provide solutions for generation, transmission,
distribution, and behind-the-meter issues including: frequency regulation,
PV and wind power stabilization, spinning reserve, ramp rate management,
voltage support, constraint relief,
back-up power, microgrid and island
grid solutions, and load shifting. The
PV and Wind hybrid system in Gansu
Province, China, and the Tappi Wind
Park in Japan are just a few examples.
The recently announced 1 MW
lithium-ion CrystEna1 battery energy
storage system package utilizes an advanced lithium-ion technology, combined with a state-of-the art energy
control system and a high-effciency
power conversion system. The storage
system has been engineered to provide
an extended lifetime of 4,000 cycles.
It was developed with an emphasis on
maximizing the benefts to customers
during long-term use.
In the frst half of 2014, Hitachi
will begin operation of demonstration projects in Somerdale, N.J. (grid
side) and Chicago (behind-the-meter).
Upon successful conclusion of the

demonstration projects, Hitachi will
make the CrystEna system available for
widespread commercial use for a variety of grid-side and behind-the-meter
customer applications.
In addition to the CrystEna system,
Hitachi plans to market its lead-acid
batteries, lithium-ion capacitors and
combined energy storage systems to
address a variety of storage needs for
both grid-side and behind-the-meter
applications.
Hitachi has provided a 170kW leadacid battery to the New York City Economic Development Corp., a participant in the Secure Interoperable Open
Smart Grid (SIOSG) Demonstration
Project. The goal of the SIOSG is to
build upon the existing infrastructure
assets via a scalable smart grid prototype that promotes cyber security.
Hitachi teamed with 6-Nines Power,
which was instrumental in helping
Hitachi develop this project with all of
the players in New York.
Hitachi is currently partnering with
a smart-grid technology frm, Demansys Energy LLC, to open up the PJM
Reliability Pricing Model in PJM to
advanced storage resources. Demansys is working to address market rule
changes that would be needed, and
recently proposed a methodology for
doing so to the PJM Planning Committee (see http://demansys.com/contactus/ for more information). Demansys
and Hitachi plan to begin operations
of a demonstration project in New
Jersey later this year. Additional demonstration projects include the NEDO
microgrid demonstration project in
Los Alamos and Albuquerque, New
Mexico.
www.power-eng.com
Uneventful is paradise.
Combined cycle stations. Nuclear reactors. Hydroelectric
power plants. In places like these, where any problem could
mean catastrophe, you want each day to be as uneventful
as the next. The insights from GE Predictivity solutions
power the future by connecting intelligent machines, data
and people. From Bently Nevada condition monitoring to
Masoneilan valves, GEs Measurement & Control business is
improving the health of industry by keeping your operations
running smoothly without incident. And that is paradise.
To learn more about our end-to-end solutions,
visit ge-mcs.com.
POWER PLANT PROFILE
Southcentral Power Project:
Effciency in
Central Anchorage
he Southcentral Power Project

may technically be an expansion of an existing power plant,
but the facility a 200-MW, natural gasfred power plant located in Anchorage
stands apart from many others because of its effciency and how it was designed to operate in a diffcult climate.
Chugach Electric Association, which
owns 70 percent of the plant, and Municipal Light and Power, which owns
the remaining 30 percent, focused on
fuel effciency when building the $359 million facility
an all-inclusive number
that includes owners costs.
Alaska produces more than
half its power from natural
gas, and insuffcient pipeline capacity can be problematic even in a state with
a large amount of natural
gas resources.
The participation of these two utilities resulted in economies of scale intended to maximize savings over the life
of the plant. The end result is a power
plant that has given the fuel savings anticipated by the company and proved to
be a better investment than upgrading
an existing plant, according to Chugach
Electric Association Senior Vice President of Power Supply Paul Risse.
addition to being older, the Beluga facility is not road accessible, and it was
necessary to fy to reach the facility
and move large equipment by barge
once or twice per year.
We did a number of assessments on
work we might have to do to extend
its life for a notable period of time
20 years, approximately and the investments required to do so, and we
weighed those against building a newer plant in town, Risse said. When
the worse, which helped the cooperative get better terms from contractors
than it might have otherwise, Risse
said. That led to the decision to use an
engineering, procurement and construction (EPC) contract to integrate
more of the work. The utility purchased the major equipment, such as
the gas turbine, the steam turbine and
the boilers, itself.
The offcial groundbreaking for the
plant was in March 2011, and construction was fnished in
The 200-MW Southcentral Power
Project is the newest and most effcient
power plant in Alaska. Photo courtesy of
Chugach Electric.
BUILDING A NEW PLANT

Risse said Chugach began looking at
the possibility of building a new plant
in Anchorage when the steam unit at
Beluga Power Plant, located on the
west side of Cook Inlet near Tyonek,
approached the 30-year-old mark. In
22
we weighed those costs and effciency

improvements, a new plant was a better decision.
The decision was helped by the timing the project began around the
time the U.S. economy took a turn for
22 months fve months ahead of its

original anticipated schedule, Risse
said. The plant was also completed under the estimated budget.
Building the plant required planning, Risse said. Large modules used
www.power-eng.com
Because of the weather in Alaska, many modules that

are typically left outdoors had to be placed in buildings,
which added to the cost of the project. Photo courtesy of
Chugach Electric.
in the plant were barged to the Port of

Anchorage and transported on special
trailers on the road. Transporting the
gas turbine across the continental U.S.
and dealing with changes in rules in
different states also posed a challenge.
Heavy OTSG modules weighing more
than 300,000 pounds posed the most
signifcant transportation challenge.
It all made it here in a timely manner, he said. Alaska just means it
takes longer. Mostly its coordination
and a lot of planning.
In the plants frst year of operations,
the SPP exceeded its projected savings. Before Chugach took control of
the plant on February 1, 2013, it was
estimated the new plant would save
the cooperatives members more than
$15 million in avoided fuel purchases
in its frst year. Though November of
2013, however, the savings had already
added up to $21.7 million.
INSIDE THE PLANT

The plant is the most effcient in
Alaska, as well as the third-largest in
the state. Parsons Brinkerhoff served
as the owners engineering frm for the
plant and assisted Chugach in the bidding process, while the EPC contract
was awarded to SNC-Lavalin.
The plant is equipped with three
GE LM6000PF turbines from General
Electric, rated at 48 MW each. The
turbines were chosen for both their
effciency and their fast start capability that allows them to reach full capacity in just 10 minutes. The plants
57.5-MW steam turbine was furnished
by Mitsubishi Power Systems America.
Once through steam generators were
purchased from Innovative Steam
Technologies, a choice which prevented the need to install bypass stacks at
www.power-eng.com
the plant for simple cycle operation.

These units can be duct fred to create a
total plant capacity of 200MW.
When building the plant, Risse said
the cooperative looked at more than 400
lessons learned from other projects.
We went to a lot of other projects
during the preliminary design phase
to identify things we wanted to do,
and that played out very well, he said.
Many of those things were integrated
into the planning and the project as it
stands today.
One of the major challenges facing
the plant was the weather in Anchorage, which has a long winter with a
great deal of snow and ice accumulation. The buildup of snow can bury
parts of the power plant that would
normally be left outdoors and make
maintenance more diffcult, leading to
the decision to place those parts inside
the building to protect them from the
conditions, Risse said.
The building is also located in the
middle of Anchorage, and Chugach
worked with the community to ensure
the plant was built with the minimum
amount of problems.
As part of the construction, we
reached out at multiple community

meetings, Risse said. We would attend and explain what we were doing.
One notable advantage for this site is
it was purchased in the early 60s, and
a power plant had been here since the
mid-60s. A lot of people didnt even
know that.
The effciency of the plants design is
likely to keep it no more noticeble than
the plant already on site. The technology used reduces carbon dioxide by 25
percent and carbon monoxide and nitrous oxide by 95 percent. In addition,
Risse said the plant is exceptionally
quiet.
FINAL RESULTS
Ahead of schedule, under budget
and with savings even greater than anticipated, the Southcentral Power Project has been a beneft for its owners
and is another example in the highlyeffcient combined cycle natural gasfred power plants that are becoming
increasingly important in the U.S.
power generation industry.
Its working out great for us, Risse
said. The decision to build a new plant
has certainly been validated.
23
Alstoms G24 MXL2 gas turbine
base load capacity were designed as

peaking plants. They werent designed
to withstand the wear and tear associated with the sustained operation of
a base load facility. Whats more, the
maintenance programs for these facilities werent developed to support the
level of sustained operational reliability required for base load generation. As
a result, power producers are revamping their maintenance plans for critical systems and components of combined cycle gas plants. Maintenance
plans that reflect the actual operation
of gas turbine generators will help the
industry avoid expensive repairs and
overhauls.
An effective O&M strategy is an integral part of a high-performing gas
power plant. Enacting a successful
strategy can lead to reduced maintenance costs and increased revenues.
projected to grow 3.1 percent a year Over time, turbines will degrade in
through 2038. At that rate, more than performance, but an effective O&M
340,000 MW of gas-fired capacity will regimen can translate to a substantial
be added to the U.S. grid by 2038. By increase in production.
then, gas-fired combined cycle power
The Tennessee Valley Authority,
plants will account
which has bought
for 50.5 percent of What the power
or built five comU.S. power producbined
cycle
gas
sector needs
tion, up from 25 perplants since 2007, is
are long-lived
cent in 2014.
devising a compreWhat the pow- assets that can
hensive
operation
er sector needs are be managed
and
maintenance
long-lived assets that
plan for its fleet of
and maintained
can be managed and
gas-fired units. Just
maintained effective- effectively.
last month, the utilly, said Revis James, - Revis James, EPRI
ity announced plans
director of Generato build a $1 billion
tion Research & Development at the combined cycle gas-fired power plant
Electric Power Research Institute. in western Kentucky to replace two
Thats a technology challenge that coal-fired plants, a trend that shows no
can be met by smarter maintenance signs of slowing.
practices.
We expect to have a comprehensive
Many of the gas plants now providing maintenance basis we can use in our
Under
Stress
Utilities Reevaluate O&M Procedures as
Capacity Factors for Gas-Fired Plants Skyrocket
BY RUSSELL RAY, MANAGING EDITOR
ow natural gas prices,

stricter
environmental regulations for coal
plants, a surge in intermittent sources of renewable power and the growth of demandresponse programs have led power
producers to run their gas-fired plants
longer and harder.
As a result, capacity factors for gasfired plants have skyrocketed, from
as little as 10 percent to more than 60
percent in some cases. This increasing
reliance on gas-fired generation has
created a need for comprehensive strategies to operate and maintain these
increasingly vital assets. Enhancing
the reliability and extending the life
of these assets is paramount as power
producers turn to gas to supply a larger
share of base load capacity.
In a new report from Black & Veatch, natural gas-fired generation is
24
www.power-eng.com
Siemens SGT6-5000F gas turbine.
work controls process to prioritize actions, so we can start making sure we

have the right preventive maintenance
tasks set up to ensure that we maintain
our high level of reliability as we continue to run facilities harder and harder, said Bill Morrison, vice president
of Generation Engineering for TVA.
O&M TECHNOLOGY
In addition to improved efficiency
and lower emission rates, combined
cycle power plants can start and stop
quickly and operate at varying levels
of output. This flexibility is a big advantage for power producers and grid
managers who must accommodate
growing amounts of wind and solar
power. The rapid response times and
variable outputs of combined cycle
plants can offset the fluctuations in renewable power.
However, frequent changes in
output can damage critical components and lead to serious and costly
downtime without an effective maintenance plan, James said.

That combined cycle system doesnt
respond as well to frequent changes in
output, James said. Weve observed
over time some material damage and
equipment issues. You can have cracking damage. These are things that
can be mitigated through operational
strategies.
Todays modern-day power systems
are operating at higher temperatures
and higher efficiencies, but further improvements can be achieved through
advanced technologies in metallurgy,
coatings, cooling and aerodynamic
turbine design, James said.
O&M PRACTICES
In this pursuit of maximum efficiency, much research is being performed
on innovative construction materials
that can handle higher temperatures,
including ceramics. To cut emissions
even further, gas turbines are now
being tested and operated to run at
ultra-cool temperatures. These aspects
of design must be considered in the installation and ongoing maintenance of
the turbine. The installation of a new
gas plant can take anywhere from 12
to 24 months, with simple cycles typically taking 12 months and combined
cycle plants closer to 24 months.
Combined cycle O&M should be
performed to tune for the optimization
Alstoms GT24 gas turbine
26
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Another key to ongowash can restore
ing maintenance of a You want to make between 2 MW and
large-frame gas tur- sure you get what
5 MW, or more, debine is keeping the
pending on the deyou pay for. Its
compressor clean. Airgree of fouling.
borne contaminants more important
Another maintecan be ingested into now than ever to
nance practice imthe turbine compresfor largeknow what the gas portant
sor, causing fouling
frame turbines is a
which could lead to quality is.
regular borescope
pitting and blade cor- - Greg Gowaski, Mitchell inspection. For this
rosion damage. Two
visual inspection,
Instruments Inc.
options for keeping the
a tiny camera is
compressor clean are an on-line water used to inspect internal components
wash and an off-line water wash. Dur- such as compressed air inlets, turbine
ing an online water wash, the unit does blades and seals. Borescope inspecnot have to shut down. But washing tion of engines can be used to prevent
unnecessary maintenance, which can

become extremely costly for large turbines.
As more power producers enter more
contracts for additional supplies of
natural gas, it is becoming increasingly
important to monitor the quality of the
gas burned for generation. Too much
condensation in the pipes can lead to
excessive moisture in the gas, which can
hurt efficiency, damage the turbine and
cause costly repairs and shutdowns. The
increased use of hydraulic fracturing in
the production of gas from shale can be
problematic for power generators.
You want to make sure you get
what you pay for, said Greg Gowaski
of Mitchell Instruments Inc. Its more
important now than ever to know what
the gas quality is. You need to be more
aware of the quality of the gas youre
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Thats why measuring and monitoring the hydrocarbon dew point in a
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Excessive hydrocarbon content can
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costs for such damage can range from
$200,000 to $4million per occurrence,
Gowaski said. Any condensation in
that natural gas or in those pipes can
cause shutdowns, he said. When
these are present, you dont always
know it. You need to monitor that.
There about four different technologies out there that are being used.
The shift to more gas-fired generation
will continue, even in the face of higher gas prices and increasing regulation
of U.S. gas production. The transition
will continue because of ever increasing regulation of coal-fired plants, a
proliferation of state standards for the
production of renewable power, and
a generous supply of natural gas from
shale. Gas-fired plants equipped with
combined cycle gas turbine (CCGT)
technology compliment wind and solar power because they can start and
stop quickly, and are thus capable of
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29
The decision to install an SCR at Edgewater Unit 5

(Edge 5) resulted from the promulgation of increasingly stringent air quality regulations. Photo courtesy of
Wisconsin Power & Light
History &
Challenges of
a Successful
NOx Reduction
Project
BY JEFFREY KNIER AND KENDALL MCFARLAND, WISCONSIN POWER AND LIGHT,
AND RYAN ESSEX AND PETER GULETSKY, HDR ENGINEERING
lliant Energy - Wisconsin

Power and Light (WPL)
recently completed installation and startup of
an SCR at its Edgewater
Generating Station Unit 5, located in Sheboygan County, WI. The SCR is the last of
several NOx emissions reduction projects
completed at this site in order to comply
with changing environmental regulations. The content of this manuscript
30
focuses solely on the SCR project and is

intended to be a project history and lessons learned resource for the power generation industry.
This manuscript will highlight the criteria taken into consideration during the
design phase of the project that allowed
for the maximum amount of operational
flexibility while still achieving NOx emission levels that would allow compliance
with regulations. The manuscript also
discusses operational and construction

challenges encountered during the execution phase of this retrofit project. Topics that are addressed in this manuscript
include:
Project summary
Milestone schedule
Discussion of design considerations
and features that were included in
the project scope to aid in assuring
preservation of current reliability
and low load operation benchmarks
Highlight specific challenges encountered during SCR design and
construction phases
Review the use of a third party start
up and commissioning program
Provide an operational update on
the current performance of the SCR
PROJECT SUMMARY
The decision to install an SCR at Edgewater Unit 5 (Edge 5) resulted from the
promulgation of increasingly stringent
air quality regulations. In 2004, the EPA
designated ten counties in Southeastern
Wisconsin, including Sheboygan County
where the Edgewater Generating Station
resides, as non-attainment areas for the
ozone National Ambient Air Quality
Standard (NAAQS). As a result, the Wisconsin Department of Natural Resources
(WDNR) promulgated NR 428, creating
new NOx emissions standards through
the adoption of Reasonably Available
Control Technology (RACT) requirements for ozone non-attainment areas in
Wisconsin. RACT specified that sources
comply in two phases, Phase I limits enforced beginning in 2009 and the more
stringent Phase II limits enforced beginning in 2013.
In anticipation of lower NOx emissions requirements, WPL began reducing NOx emissions at the Edgewater
Generating Station in 1999 through the
www.power-eng.com
implementation of the Combustion

Initiative. Prior to the installation of the
SCR, NOx emissions had already been reduced at Edgewater Units 3, 4, and 5 by
58 percent, 84 percent, and 31 percent,
respectively, using combustion controls.
Selective non-catalytic reduction and rich
reagent injection (SNCR/RRI) projects
were also installed on Edgewater Units 3
and 4, which further reduced NOx emissions on each unit by approximately 30
to 40 percent. The implementation of
the Edge 5 SCR was undertaken to reduce
NOx by an additional 60 to 70 percent
in order to meet phase II RACT requirements, which went into effect in 2013.
The Edgewater Generating Station is
located south of Sheboygan, Wisconsin, along Lake Michigan. Edge 5 began
commercial operation in 1985 with a
nameplate capacity of 380 MW. The
unit currently runs at a gross maximum
operating load of 430 MW and burns
pulverized low sulfur Powder River Basin (PRB) coal. Edge 5 has a Babcock &
Wilcox (B&W) wall-fired boiler retrofitted with Separated Overfire Air (SOFA)
technology and Low NOx Burners (LNB)
to reduce NOx emissions, followed by a
cold-side electro-static precipitator (ESP)
for particulate emissions control. Edge 5
also has a unique operating characteristic
that allows the unit to be operated across
a broad load range which is an attractive
attribute that needed to be preserved as
best as possible while achieving NOx
compliance.
In 2008, WPL, with assistance from
their Owners Engineer (HDR), began
work on the conceptual design and development of the technical and performance specifications for the retrofit of an
SCR on Edge 5 for the reduction of NOx.
In 2009-2010 separate engineering and
construction firms were selected to complete detailed engineering and design,
procurement, and construction activities
for the Edge 5 SCR.
The Edge 5 SCR was placed into service
in December of 2012.
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MILESTONE SCHEDULE
Milestone
Date
Issue Request For Proposal (RFP) for engineering and procurement
Aug 2008
Issue RFP for constructor
Oct 2009
Submit regulatory approval application

to Public Service Commission Wisconsin
Nov 2008
Award engineering and procurement contract

(limited notice to proceed)
Oct 2009
Award constructor contract (limited notice to proceed)
May 2010
Receive regulatory approval
May 2010
Begin Construction - Phase 1
July 2010
Construction - Phase 2 (full notice to proceed)
June 2011
Edge 5 SCR project in service
Dec 2012
Source:
DESIGN FEATURES FOR

RELIABILITY & LOW LOAD
OPERATION
Edge 5 operates over a wide range of
loads, nominally 50 MW 430 MW,
and has a greater unit turn down capability than is typically seen on coal
fired boilers. Therefore, the SCR system to be installed on Edge 5 needed
to be a system that could maintain
Edge 5s operational flexibility while
still reliably providing adequate NO x
reduction performance.
With these operational and performance challenges recognized, several
design features were identified and
investigated early on in the planning
and design phase of the project that
would ensure the Edge 5 SCR would

be successful in maintaining Edge 5s
operational reliability and flexibility
as well as the Edgewater Generating
Stations compliance with upcoming
2013 RACT regulations. These design
features are discussed in detail in the
following paragraphs.
SCR CATALYST SELECTION

Catalyst modules are used to accelerate the reaction between NOx and Ammonia which primarily reduces NOx
into nitrogen (N2) and water (H2O).
SCR catalyst modules come in many
different types. However the main options in selecting the catalyst are in
regard to geometry, physical makeup,
and chemical formulation.
Catalyst Geometries
Plate-Type
1
Honeycomb
Corrugated
31
Catalyst Geometry
The two most common catalyst geometries in the coal fired power plant market
are the honeycomb and plate-type. Corrugated type catalyst is also available, but
is less typical, and therefore, this discussion will focus on the comparison of honeycomb vs. plate-type catalysts.
Honeycomb catalysts offer the benefit
of greater reactive surface area per unit
volume, which can provide NOx reduction performance with a smaller volume
of catalyst and an overall smaller SCR
reactor size, and typically a lower installed cost of the system vs. an SCR utilizing plate-type catalyst. However, the
compactness of the honeycomb catalyst
results in a higher pressure drop across
the catalyst layers and a greater susceptibility to pluggage when compared to
the plate-type; which leads to higher
auxiliary power consumption and potentially higher operations and maintenance costs.
Straight and
Curved Sonic Horns
The sonic horns at Edge 5 were

insulated to minimize condensation
risk within the horns.
Retrofit Location of SCR 3
Catalyst Physical Makeup

Plate-type catalysts have a stainless
steel carrier with the active ceramic catalyst layer rolled onto the steel plates.
- The steel plates are notched along
their width in order to provide a
means of maintaining the plate separation for the flue gas flow paths.
- These notched plates provide long
open channels for flue gas flow and
flyash passage and provide a structure that is more flexible than the
rigid honeycomb structure, further
accommodating flyash passage.
Honeycomb catalyst is typically either a monolithic extruded ceramic
catalyst (homogeneous ceramic carrier and catalyst components) or it is
an extruded substrate coated with the
ceramic catalyst material.
- The coated substrate type honeycomb
catalyst offers the benefit of a lower
cost option due to the more expensive catalyst components being located only on the reactive surface of
the catalyst. However, the risk with
32
Because the SCR needed to operate

across a temperature range of
approximately 550F to 800F, the SCR
reactor was installed upstream of the
existing rotary air heaters.
this design is that once the hardened

catalyst layer wears away there is no
additional reactive layer beneath
and the overall catalyst reactivity
will decrease. Also, the substrate, in
some cases, may not possess an
equivalent level of wear resistance
as seen in the ceramic coating. Once
the ceramic catalyst coating wears
away or gets cracked, the substrate
can experience accelerated erosion.
- It is the opinion of the Edge 5 SCR
project team that homogeneous
honeycomb catalysts, while typically more expensive, offer increased
durability and reliability of long
term performance over the coated

substrate type honeycomb catalysts.
This is due to the entire thickness of
the catalyst having the same physical
and chemical characteristics. Therefore, over time as wear occurs on the
surface, the layer of catalyst below
the initial layer has the same chemical reactivity and wear resistance
and will continue to resist wear and
continue to reduce NOx.
Catalyst Chemical
Formulation
The chemical formulations of the
catalyst will depend on the type of performance that is desired of the catalyst
as well as the chemical constituents of
the flue gas. Of the numerous operating
parameters that can be specified, and to
which the catalyst can be formulated, the
below listed parameters will be discussed
in more detail in this manuscript:
- High temperature service
- Low temperature service
- NOx reduction rate (based on inlet
NOx and ammonia injection rate
and temperature range)
- Selective oxidation rate (i.e. SO2 to
SO3 conversion)
- The flue gas constituent design
parameters in which the catalyst
will reside, in order to minimize
the risk of catalyst poisoning and
deactivation.
For Edge 5, in addition to specifying
the NOx reduction performance, the
other following characteristics were required:
- A low minimum acceptable flue
gas temperature to allow Edge 5 to
maintain its turn down capability.
- Low SO2 to SO3 conversion rate was
specified to minimize ammonium
bisulfate (ABS) formation within
the catalyst, the air heater and any
downstream equipment. In the end
this also aided in lowering the acceptable minimum operating temperature of the SCR and maintaining the unit flexibility.
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Note that Edge 5 retrofitted the existing cold end air heater baskets with
ceramic coated baskets in an effort
to prepare for the potential increase
in ABS due to ammonia injection
with the SCR. These ceramic coated
baskets will provide a surface that is
less susceptible to ABS adherence as
well as providing a surface that can
more easily be cleaned in the event
ABS formation occurs. This type of
balance of plant project is something
that should be evaluated when considering installation of an SCR.
It is important to note that while identifying potential fuels and operating conditions the catalyst may experience is essential to ensure future unit operational
flexibility; this flexibility may come with
a more complex and likely higher cost
catalyst formulation. It is recommended
that catalyst formulation options be
discussed with the catalyst supplier to
ensure the most beneficial catalyst is selected for each specific SCR system.
Catalyst Selection Summary

The Edge 5 SCR is located upstream
of the existing airheater and electrostatic
precipitator (ESP) resulting in a high-dust
arrangement. Typically for this type of
SCR arrangement, a plate type catalyst is
viewed as being the more suitable catalyst
type due to its ability to resist pluggage.
However, due to the tight site constraints
and in order to reduce the structural and
foundational loading of the elevated SCR,
both plate and honeycomb catalyst were
evaluated. In the end, the honeycomb
type catalyst was evaluated to be a lower
life cycle cost option for Edge 5.
Due to Edge 5 burning PRB coal and
the inherent sticky fly ash produced, it
was recognized that this fly ash passing
through the SCR would pose an added
risk of buildup and catalyst pluggage. To
minimize the inherently higher pluggage
risk in the honeycomb catalyst, being
compounded by the fact that PRB fly ash
would be passing through, larger minimum channel pitch dimensions were
34
Air Heater Outlet Duct
The air heater outlet duct needed to be

moved in order to make room for new SCR
structural columns above the fan room.
specified (larger pitch = larger flow channel size). The minimum pitch dimensions specified provided a large enough
flow path for ash particles to pass through
with minimal pluggage potential, while
also maintaining the catalyst volume to a
reasonable size to maintain the installed
cost advantage of the honeycomb catalyst
over the plate type catalyst.
For the Edge 5 SCR, a homogeneous
ceramic catalyst was specified and installed. In addition to utilizing the more
wear resistant homogenous catalyst design, the Edge 5 SCR team obtained an
extended mechanical warranty, such
that the mechanical characteristics of
the catalyst would not adversely affect its
NOx reduction performance for a period
of 60,000 hours (typical mechanical warranties range from 20,000-40,000 hrs.).
This guarantee was obtained to ensure
one or more cleaning/ rejuvenation/ regeneration cycles of the catalyst modules
(which would restore the catalyst chemical reactivity after its typical 24,000 hour
performance guarantee period) would be
mechanically possible.
ECONOMIZER FLUE GAS BYPASS

Due to the frequent turn down experienced at Edge 5 it was vital that the SCR
be designed so as not to limit the units cycling capability. To accommodate the extent that Edge 5 is turned down on a routine basis, the Edge 5 SCR was equipped
with an economizer flue gas bypass
system (bypass duct and damper) that
is used to introduce higher temperature
flue gas into the SCR inlet ductwork flue

gas stream at lower loads.
At Edge 5, a low temperature catalyst
was selected. Therefore, the SCR system
could operate without use of the bypass
damper from the maximum unit load
of 430 MW down to approximately 185
MW. At this point the flue gas temperature reaches a point at which the bypass
damper begins to open. The bypass
damper and a downstream back pressure
damper are modulated to bypass flue gas
flow around sections of the economizer.
This flue gas temperature control is maintained down to approximately 125 MW
at which point the flue gas temperature
approaches the technical limitation of
the minimum catalyst operating temperature. The pros and cons (installed cost,
minimum operating load and its associated economics, and boiler efficiency) of
several bypass locations were considered
and utilized in selecting the final bypass
design. This evaluation is recommended
during design of the SCR to determine
whether a bypass system is needed, and
if so, the final location and design of such
a system.
SCR CATALYST
CLEANING SYSTEMS
The Edge 5 SCR was equipped with
several cleaning systems to prevent
and eliminate buildup of fly ash on the
catalyst surface and pluggage within
the catalyst.
Large Particle
Ash Screen System
Large particle ash (LPA) also known
as popcorn ash is a source of catalyst
pluggage as the ash particles are too large
to pass through the catalyst channels.
These LPA particles can get lodged in the
catalyst channels and can also serve as a
buildup point for smaller ash particles;
thus increasing the plugging risk of the
catalyst. Therefore, LPA screens were installed at the economizer outlet as well as
at the inlet to the economizer bypass duct
to filter the flue gas stream of any LPA
material. The LPA screens are installed
in a manner that allows ash build up on
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the screens to fall off due to gravity once

a certain level of buildup is reached. In
areas where the screen could not be oriented such that ash would be removed
by gravity, screen rappers were installed
to promote the removal of ash build up
from the LPA screens.
Steam Sootblowers
Steam sootblowers were installed at
the three existing layers of catalyst along
with a fourth level to accommodate the
future layer of catalyst to be added. The
steam sootblowers dislodge ash from the
surface of the catalyst by injecting superheated steam onto the catalyst surface.
The ash is then carried away from the
catalyst and out of the reactor by the flue
gas stream.
When installing a steam sootblower
system it is important to know the catalyst suppliers requirements for steam
temperature and pressure when considering the steam source.
The steam source must be selected such
that it is providing a sufficient amount of
superheat to ensure dry steam is being
blown on to the catalyst surface (typically
a minimum of 50 deg. F of superheat is
required). If moisture is blown onto the
catalyst surface there is a high risk for ash
build up and fly ash set-up on the catalyst
surface; such that a unit shut down and
mechanical means of cleaning the catalyst surface would be required.
Designing the steam system to provide
steam at the appropriate temperature is
important to ensure the catalyst surface
does not incur thermal shock due to a
large differential temperature between
the catalyst surface and the cleaning
steam. Typically steam temperature differentials within the 50-100 deg. F range
are acceptable, but each catalyst supplier
may require different criteria for steam
temperatures.
The catalyst supplier will also recommend an acceptable cleaning pressure to
prevent premature wear of the catalyst
surface.
Sonic Horn System

Sonic horns were installed at the three
36
existing layers of catalyst along with a the Edge 5 SCR catalyst surface. In adfourth level which could accommodate dition to the modified arrangement of
the addition of a future layer of catalyst to the main wall of sonic horns, the Edge
be added. Sonic horns fluff ash from the 5 project team requested two horns be
surface of the catalyst by causing particles installed opposite and perpendicular
to resonate at a frequency of about 75 Hz to the main row of horns such that they
at an output power level of 147 dBA. The were dedicated to cleaning along the wall
ash is then carried away from the cata- opposite the main row of horns. To date,
lyst and out of the reactor by the flue gas this arrangement has worked efficiently
stream.
in cleaning the entire surface area of the
When designing the sonic horn system catalyst layers.
it is important to ensure the horn layout
Another lesson learned from the refdesign is such that adequate cleaning erence site visit was to use straight sonic
power is provided to all areas of catalyst horns where space permits. The reference
surface, specifically areas that may be site had curved sonic horns installed
prone to lower flue
ID Fan Rotor Retrofit
5
gas velocities. The
SCR reactors inside
turn (nearest the
inlet duct) at the
top catalyst layer
may be of particular concern.
During a reference site visit of a
similar SCR it was
communicated to
the Edge 5 project
team that the particular sonic horn
layout provided at
the site was not opA fan foundation strength test and constructability review
confirmed that the existing fan and motor foundations could be
timal, as the sonic
reused with modifications for added mass for the proposed new,
horns were all lolarger and heavier centrifugal fans and motors.
cated on a single
wall opposite from
a low flue gas velocity region. Therefore, and they had experienced fly ash plugthe cleaning energy of the sonic horns be- gage and set-up within these horns. The
ing dissipated to a degree on the opposite curved shape and orientation of the
wall of the SCR reactor, combined with horns provided a low spot for the ash
low flue gas velocities to carry away the to settle and build up. Compounding
ash build up, resulted in an area of con- this issue was the fact that these horns
stant ash build up issues for this site.
were exposed to ambient conditions in
For the Edge 5 SCR the sonic horns a northern climate. This created a cold
were arranged such that a majority of spot and promoted condensation within
sonic horns were installed on a single the horns which in turn promoted fly ash
reactor wall; however, the horns were ar- setup within the horns.
ranged such that their cleaning energy
For the Edge 5 SCR the access platwas directed from side to side across the forms were extended, where needed, to
reactor. This arrangement provided a allow for the installation of straight sonic
horn dedicated to the low flow area of horns to eliminate low spots within the
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horns. The sonic horns at Edge 5 were insulated to minimize

condensation risk within the horns. In addition to insulating
the sonic horns, dried instrument air vs. regular compressed air
was used as the motive sounding force of the horns to further
prevent condensation risk within the horns.
Cleaning System Summary

The use of the LPA screen system, to prevent LPA from migrating to the SCR catalyst, along with the combined sonic horn
and sootblower cleaning system provided a belt and suspenders type approach to the cleaning system for the Edge 5 SCR.
However, due to recent pluggage experiences at another Alliant Energy SCR site, this conservative approach was considered
prudent to ensure the operational reliability of Edge 5.
SCR FLUE GAS AND REAGENT

DISTRIBUTION AND MIXING
Selecting the proper catalyst type and formulation, maintaining adequate flue gas temperatures, and designing and installing the appropriate cleaning system are all vital aspects of the
flexible and reliable performance of the SCR system. However,
despite successful implementation of all these design features,
improper and inadequate flue gas mixing could still greatly reduce the performance of an SCR system. Therefore, it is vital to
ensure the flue gas mixing and flow distribution devices incorporated into the design of the SCR are evaluated very carefully.
For the Edge 5 SCR an SCR OEM with a proven reagent injection and flue gas mixing and distribution system was selected.
During the design phase the SCR OEM was required to create
a physical model of the SCR system to prove the design would
meet the stringent flue gas constituent, temperature, velocity,
and injected reagent distribution requirements and variance restrictions. The physical model was tested at points that spanned
the entire expected SCR system operating range to ensure that
reliable performance could be achieved at all unit loads.
In addition to the proven static mixing system the SCR OEM
provided, they also possessed a proven reagent injection system
which included adequate turn down capability to operate reliably through the entire operating range of the SCR, which the
Edge 5 project team knew was an area of concern in other OEM
aqueous ammonia injection systems.
In summary, the project team ensured that the SCR technology selected had proven operating experience similar to the
operational conditions for each specific SCR installation. It is
recommended to prove the specific SCR design with physical
modeling c ications identified in the modeling stage will be significantly less expensive than those identified after a system is
in commercial operation.
PLANT INVOLVEMENT
Over the lifecycle of the project, the SCR project team expended a lot of effort to keep the plant operations and maintenance staff involved and informed of the SCR design criteria being selected. The plant was encouraged to provide input
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into the SCR design focusing on safe

CHALLENGE:
was installed upstream of the existing
operation and ease of maintenance of
BROWN FIELD RETROFIT
rotary air heaters. The existing flue gas
the overall system. Methods of engaging
As with all large retrofit projects, the ductwork selected for SCR tie-in was the
the plant in the project included weekly Edgewater SCR required careful planning economizer outlet duct. This ductwork
internal project team meetings and hav- and advanced engineering in order to was located approximately 100 feet in the
ing plant staff participate in key drawing design and install the SCR within an al- air, and directed flue gas from the econoreviews, design basis updates and opera- ready-congested back end flue gas stream. mizer outlet down to the air heater inlet
bility reviews. Monthly project meetings The SCR was installed upstream of the ex- (see Figure 3).
were also held at the generating station, isting rotary air heater and cold-side ESP,
This location was selected because
and often included a second day of tech- which located the SCR in the area above the SCR operating temperature could
nical working design meetings
be achieved without flue gas rethat plant staff attended.
ESP Reinforcement
6 heaters, the length of duct runs
Approximately
halfway
were minimized (reducing systhrough the SCR project, WPL
tem pressure drop and minimizdedicated a full-time plant reing required ID fan power) and
source to the project. The projopen space to the north of the
ect plant liaison was designated
stack was preserved for future
as the single point of coordinaAQCS projects. A design emphation between construction and
sis was placed on minimizing the
ongoing plant operations and
pressure drop of the SCR, both to
maintenance.
minimize auxiliary power use
The plant liaison was a valuand because the ID fan footprints
able position that not only interwere limited in size increase by
faced daily between construction
the configuration of their existand the plant, but also ensured
ing fan housings. Two access
new assets were entered into
locations to the SCR reactor were
WPLs maintenance manageprovided from the existing boiler
ment software system, made sure
room. One access point included
lock out/tag out isolation points
an access path between the SCR
were developed and clearly lareactor and an existing elevator
beled, and assisted with organizdoor to allow tool cart access to
ing and completing final punch
the SCR.
The majority of the reinforcement work consisted of adding
list items on the project.
The OEM engineer specified
69,000 lbs. of reinforcing steel to the external stiffeners on the
WPL also hired a third party to
innovative
use of micropiles to
casing, hoppers and nozzles.
conduct supplemental training
support the SCR in an extremely
for operations and maintenance
congested area. The SCR is lostaff.
the combined forced draft and primary cated directly above the forced draft and
The plant liaison was instrumental in air fan room. WPL and HDR worked primary air fan room. The OEM engineer
developing the training criteria, and di- with the OEM engineer to design the SCR used a micropile design in order to keep
rectly supervised all project training.
to fit into the constrained site. Due to the the SCR foundation support independent
SCR location, the OEM specified an in- from the existing boiler concrete slab
PROJECT CHALLENGES
novative substructure foundation design. foundation, and to allow installation in
The Edge 5 SCR project brought many In order to minimize construction issues the tight working areas of the fan room.
challenges to the project team. Through associated with the SCR retrofit design, The SCR is supported on 81 steel-casing
careful planning and a collaborative ef- WPL solicited the constructors feedback micropiles. Each 9-5/8 diameter pile is
fort of all parties involved these chal- on the constructability of the design by installed in bedrock, approximately 90
lenges were identified, evaluated and incorporating their feedback into design feet below grade. The micropiles are loresolved.
reviews prior to mobilization to the site.
cated in 14 groups of 3 to 11 micropiles,
The major challenges of the Edge 5
Because the SCR needed to operate with each group supporting a steel pile
SCR project are discussed in the follow- across a temperature range of approxi- cap pedestal, which in turn supports a
ing sections.
mately 550F to 800F, the SCR reactor structural column. The pedestals are
38
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7 FINANCING
YRS
large structural supports, weighing up to 27.9 tons.

A specialty contractor was utilized by the constructor to
perform detail design and installation of the micropiles. Installation of the micropiles was a difficult process due to the
nature of the work, performing the installation in winter, and
the obstructions of plant operating equipment in the fan room.
Some micropiles failed their structural proof tests, so WPL
hired a third party expert to review the detail design, make remediation recommendations, and review the proof test results.
WPL learned that when dealing with specialty engineering and
installation, hiring an expert to review key design points and
critical installation methods can be a worthwhile investment.
As previously mentioned WPL brought the constructor on to
the project approximately four months prior to site mobilization. At that time, the constructor performed constructability
reviews of the SCR and gave feedback to the OEM engineer.
This was a critical time to bring the constructor to the project
because engineering was not yet complete, and the input received from the constructor reduced installation time and costs.
The constructor contributed worthwhile feedback in three notable areas: the modification of existing air heater outlet duct,
the load transfer of the existing economizer outlet duct and
suggestions for additional laydown area.
The first example of constructability review involved the air
heater outlet duct, which needed to be moved in order to make
room for new SCR structural columns above the fan room. The
constructor reviewed the drawings and worked with the OEM
engineer to develop a plan to modify and move the ductwork,
shown in Figure 4, during a unit outage. The actual movement
of the existing duct went without difficulty due to proper planning beforehand.
The next example of significant constructability review occurred mid-project while planning a significant structural load
transfer. The boiler economizer outlet duct was supported by
existing steel cantilevered off the boiler room structural steel.
The support for this duct needed to be transferred to the new
SCR steel, so the existing cantilever steel could be removed.
WPL and HDR facilitated several working meetings between
the constructor and OEM engineer in order to develop a load
transfer plan. The original load transfer plan required a boiler
outage, but because the constructor and OEM engineer worked
together, a safe plan to perform the load transfer online was
developed.
The constructor also provided value by suggesting WPL develop additional laydown space for the project. The Edgewater
plant is a constrained site, as it is located in town and borders
Lake Michigan. As SCR ductwork was being fabricated, it was
apparent that the new ductwork could not all be stored on site.
A WPL-owned piece of undeveloped land existed across the
street from the plant, and the project team suggested that developing that space into a laydown yard would allow all ductwork
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to be delivered to site, and would enable

crews to inspect and prep the pieces for
erection. WPL realized that opening up
as much space as was practical for the
constructor allowed them to more efficiently execute fabrication and erection.
After proper permitting and site preparation the project team was able to open
this additional area up and use it for the
duration of construction.
CHALLENGE: BURNER
MANAGEMENT SYSTEM UPGRADE
NFPA 85 requires that the SCR ammonia isolation/block valves be forced
closed upon a master fuel trip (MFT),
which necessitates interface with modifications to the plants Burner Management System (BMS). The existing BMS
was equipment installed when the plant
was originally placed in-service in 1985
and included an outdated Bailey 762 system, which had become obsolete and for
which the plant had difficulty finding replacement parts.
As a result, the project team, in conjunction with the plant, decided to take
the opportunity presented by the extended SCR outage required for the project
to update the plants BMS. To simplify
maintenance and spare parts stocking,
minimize training on new equipment,
and simplify the interface requirements
between the existing plant DCS and the
new BMS, an Emerson Process Controls
(Emerson) Ovation system was selected.
In addition to the installation of the
Ovation-based BMS-proper, the upgrade
scope consisted of installing new redundant instrumentation, reworking some
hardwired trips within the auxiliary relay
cabinet, wiring additional signals from
switchgear and the bench board into the
BMS. Plant drawings, including schematic diagrams and wiring diagrams, also
required updating. The work was completed through collaboration between
plant staff, HDR, and Emerson. Wiring
and instrumentation changes were performed by the plant during the outage.
When completing major Air Quality Control System (AQCS) projects, it is
40
essential that potential impacts to other

existing plant systems be considered.
While changes to the existing DCS were
anticipated, the most significant impacts
upon the DCS were expected to be in the
boiler control system and any motor controls that were involved. From early conceptual engineering it was identified that
the logic for the ID fan would be brought
from auxiliary relays and the bench
board into the DCS to allow the incorporation of SCR logic impacts upon the ID
fan logic. In addition to the substantial
changes that were required with the BMS
upgrade, the plant requested an update
System, WPL and HDR performed a fan

study during the conceptual engineering
phase to evaluate the capability of the existing ID fans and motors to be upgraded
for the new draft system modifications.
In addition, the fan study evaluated alternative new fan configurations and the
impact of future AQCS retrofits for sulfur
dioxide and particulate matter control,
on the fan and draft system.
The pre-SCR fan configuration at
Edge 5 included two 50 percent capacity centrifugal ID fans with speed reducing fluid couplings to control fan speed
and boiler draft. The first phase of the
NOx Emissions (lb/mmBtu)
7
Pre-SCR
Compliance Requirement
Supplier Guarantee
Post-SCR
Pre-SCR
Compliance Level
Emission Guarantee
Post-SCR
50
100
150
200
250
300
Net Generation (MW)
to the hard-wired window-annunciator

to reflect the new equipment, instead of
relying on the DCS alone for alarming as
is often done. Ultimately, when preparing for a major AQCS retrofit project, it is
essential to have dialogue with the plant
personnel early in the project regarding
preferences and expectations on equipment to update that may not have been
considered when initially scoping the job.
This dialog also allows the team to consider the spare capacity of existing equipment, even if the impact to those systems
is only expected to be minimal, as was
the case with the BMS at Edge 5.
CHALLENGE: ID FAN UPGRADE

With the addition of the new SCR
350
400
450
study included an evaluation of operating data to determine if the fans would

be adequate as-is or could be upgraded
for the intended service with the SCR
system. In addition to the owners team
evaluating the available margins in the
existing fans with plant test data, the
fan OEM performed an independent investigation to validate the findings and
propose, if needed, potential housing or
rotor modifications (e.g., blade tipping)
to add pressure margin. This first phase
concluded that the existing fans and motors were significantly pressure and flow
limited for the expected SCR pressure
drop increase and proposed test block
conditions. Further, the OEM confirmed
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that possible modifications to the housing and rotor were insufficient for the
expected post-SCR operation. Therefore,
WPL decided that the existing ID fans
and motors would be retired and new
fans and motors were installed for the
SCR Project.
For the selection of the new fans,
motors and drives, the owners team
evaluated multiple options in terms
of feasibility, evaluated costs (net present value of capital and life cycle costs,
including auxiliary power and maintenance), space requirements, outage
impacts, flexibility for low load operation, boiler transient impacts and constructability. The fan options that were
evaluated included:
Centrifugal vs. axial fans
Existing fluid coupling drive vs.
variable frequency drives for the
centrifugal fan option
The addition of two new 50
percent capacity fans sized only

for the new SCR system (with two
future booster fans installed at a
later date) vs. two new 50 percent
capacity fans sized for both the
SCR system and future AQCS
Using preliminary fan sizing data, performance data and costs provided by the
fan OEM, the owners team determined
that the option for two 50 percent capacity centrifugal ID fans with variable
frequency drives (VFDs) had the lowest
evaluated price and the greatest certainty
of meeting the RACT compliance goals.
The addition of VFDs also met the stations goals for efficient fan operation at
all loads, improved soft start capability
for the motors and the added protection
against boiler transients with the SCR addition. A fan foundation strength test and
constructability review confirmed that
the existing fan and motor foundations
could be reused with modifications for

added mass for the proposed new, larger
and heavier centrifugal fans and motors.
Further, the team confirmed that the
construction sequence of removing the
existing fans and motors, modifying the
existing foundations, assembling and
commissioning the new fans, motors and
associated tie-in ductwork could be completed during the allotted time for the fall
2012 outage.
Based on the study findings, the centrifugal fan and VFD configuration was
procured, designed, installed and commissioned for the Edge 5 SCR Project.
Since the fall 2012 outage, the new fans,
motor and VFDs have operated reliably
and the VFDs have allowed the Edge 5
Unit to maximize the efficiency of its fan
operation despite the flow rates through
the fans being reduced significantly from
their design rating; due to air heater seal
repair and redesign and other balance of
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41
plant modifications and repairs.
CHALLENGE:
ESP REINFORCEMENT
With the addition of the SCR system to
Unit 5, the operating and transient pressure conditions through the flue gas draft
system were significantly altered, and the
potential for implosion and structural
damage to some existing equipment increased unless modifications were made.
For the Edge 5 Project, the pressure drop
across the SCR system was in the range
of 8 to 9 inches WC at the maximum
unit capacity conditions. As a result, the
equipment downstream of the SCR system would be exposed to greater negative steady-state operating pressures that
had the potential to exceed the original
equipment design pressures.
To prudently reduce these operating
risks, WPL implemented a boiler implosion mitigation program consisting of the
following steps:
NFPA 85 compliance study;
Boiler implosion and controllability
study;
Review of the structural design
ratings of the existing draft components and ductwork and comparison to the post-SCR steady state
operating pressure profile through
the system;
Engineering analysis of equipment
and ductwork structural framings
requiring reinforcement;
Final design and installation of structural reinforcement modifications.
An engineering firm specializing in
furnace draft analysis performed a review
of the stations compliance to the NFPA
85, the Boiler and Combustions Systems
Hazard Code for the post-SCR operating
condition. To ensure that the planned
post-SCR draft system modifications did
not threaten the structural integrity of the
system, a dynamic simulation of the draft
system was performed. The boiler implosion and controllability study involved
modeling the entire draft system, in its
existing state and a post-retrofit state, for
42
multiple postulated operating scenarios.

The scenarios evaluated for the Edge5
SCR retrofit included multiple credible
cases, including master fuel trips (MFTs),
forced draft and ID fan trips with and
without a MFT, and runaway ID fans,
from minimum load to maximum load.
In parallel with these activities, the original plant records and OEM data for the
air preheater, electrostatic precipitator
(ESP) and the interconnecting ductwork
were reviewed to determine the equipment minimum structural pressure ratings at design and yield. These existing
structural ratings were compared to the
new steady state draft system pressure
profile and pressure transients for the
post-SCR configuration. Based on the
findings of these studies and investigations, the following mitigation steps were
implemented:
Three additional pressure transmitters were installed ahead of each
upgraded ID fan along with an override control loop to limit pressure at
that location.
With the exception of the ESP, all
of the existing draft system was
designed adequately to withstand
the lower negative steady state and
transient pressure conditions for the
post-SCR configuration. The ESP
was originally designed for a negative pressure rating of -30 inches WC
With the SCR system in operation,
the operating pressure through the
ESP was predicted to be -37 inches
WC at the maximum unit capacity
condition. Thus, structural reinforcement of the ESP casing, hoppers and
outlet nozzles was required.
To complete the structural reinforcement, the ESP OEM was retained to
perform the engineering analysis of the
structural framing, prepare construction
drawings and supply all reinforcement
materials. The majority of the reinforcement work consisted of adding 69,000
lbs. of reinforcing steel to the external
stiffeners on the casing, hoppers and
nozzles.
Although the structural reinforcement

and other control system modifications
were successfully completed such that
future potential implosion risks were
avoided, this activity highlighted some
important lessons for future similar work
for WPL projects. The boiler implosion
mitigation program was completed over
a two-year period with the final installation during the Fall 2012 outage. Ideally,
the installation should have been completed earlier to minimize schedule risk
and avoid a congested work site during
the final Edge 5 SCR tie-in outage. Based
on these experiences, it is recommended
that boiler implosion and controllability
studies be started as early as possible after a projects Final Notice to Proceed and
that workaround plans be considered to
complete as much of the modeling work
as possible in parallel with final AQCS
engineering and procurement activities.
This approach will allow greater flexibility and efficiency in scheduling the structural reinforcement work with a utilitys
outage schedules. Also, when performing
draft system reinforcements required by
AQCS retrofits, the conceptual and detailed engineering should be performed
by qualified contractors, and preferably
OEMs, with experience in these types of
modifications.
CHALLENGE:
STARTUP & COMMISSIONING
The Edgewater SCR project included
some unique challenges while planning
and executing the startup and commissioning phase of work. Challenges included the initial commissioning scope
planning, defining roles and responsibilities, integration of the startup and
commissioning schedule into the project
schedule, coordination of the final tie-in
outage, and the boiler startup with the
SCR and new ID fans.
The SCR project was executed with two
main contractors: an OEM with the scope
of engineering and equipment procurement, and a constructor with scope of
SCR erection. The startup and commissioning scope of work was defined during
www.power-eng.com
the bid phase to be collaborative between

the OEM, constructor and owner. Because of this arrangement, the owner
took the lead in organizing the startup
and commissioning execution.
A third party was utilized to coordinate
and execute the startup and commissioning phase of the project. WPL evaluated
several companies with commissioning capabilities, and selected a reputable
company based upon previous project
experience and a strong reference project with a similar AQCS retrofit startup
and commissioning scope. The start up
and commissioning company was selected in late 2011, when engineering
was approximately 90 percent complete
and construction was approximately
35 percent complete. Their role was defined as having complete responsibility
for startup and commissioning, including schedule development, definition of
commissioning packages (the entire SCR

project was divided into 14 commissioning packages), coordination of system
turnovers (both from construction to
commissioning, and from commissioning to owner), coordination with OEM
of vendor technical startup assistance, execution of system checkout, documentation of all commissioning activities, creation of commissioning turnover books,
and startup support.
An integrated team approach to commissioning was encouraged by WPL in
order to draw upon the strengths of all
parties involved. Examples of the team
approach include the development of
the startup and commissioning schedule with significant input from both the
OEM and constructor, WPL assigning a
dedicated plant operator to the project
for commissioning support, integrated
commissioning meetings, and the use of
dedicated craft from the constructor to

assist with commissioning activities.
Because the commissioning team was
added mid-project, defining commissioning packages and integrating the
commissioning schedule with the entire project schedule was a challenge. It
would have been easier to integrate the
commissioning scope if it were done at
the same time the construction schedule
was developed. The OEM had already
developed a high-level commissioning
schedule, which was used by the start
up and commissioning company as a
guideline for sequencing activities. The
constructor was flexible in working with
the project team to commit to turnover
dates for each of the 14 commissioning
packages. In general, a project team objective was to commission as many of
the 14 commissioning packages as possible prior to the start of the tie-in outage.
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Approximately 8 of the 14 systems were

completely commissioned prior to the
tie-in outage. The remaining packages
were partially commissioned to the greatest extent possible. The commissioning
team coordinated critical checkout activities to occur when construction craft was
not in the area this included some commissioning during weekends and other
off-shift hours.
The final tie-in outage required careful
coordination by WPL. Major scopes of
work included duct demolition and installation for the SCR tie in, ID fan rotor,
motor and lube oil system replacement,
precipitator reinforcement, and plant
maintenance activities. The tie-in outage was an 8 week outage that occurred
in September-November 2012. The constructor initially expressed concerns to
WPL about the ability to attract enough
labor to complete all work within the 8
week outage period but had little problem fulfilling the positions necessary to
complete the work during this prescribed
outage window. The SCR project reached
a peak labor force of approximately 250
people. In order to coordinate outage
work, WPL dedicated an outage planning
resource to monitor the entire outage, and
integrated the SCR construction planning with the plants outage planning.
Multiple planning meetings were held
prior to the outage in order to define and
freeze scope, and integrate schedules.
Outage coordination meetings were held
3 times per week to review each scope of
work and update the outage schedule.
Receiving accurate outage schedule
updates from the contractor was challenging in the first half of the outage. It
was clear the constructor was ahead of
schedule, but the constructor would not
show this progress and early finish dates
due to fear that the finish date may move
back out if progress slowed. Understanding the constructors completion date was
critical to WPL in order to schedule ID
fan startup activities and coordinate with
generation dispatch for timing to bring
the unit back online. WPL used prior
44
outage experience with the constructor

and direct observation of the constructors progress to accurately estimate the
outage completion date.
Startup and commissioning of the SCR
system concluded with the tuning of the
ID fans and injection of ammonia. The
upgraded ID fans with VFD control required remarkably little tuning during
boiler first-fire. The VFD control of the
fans was smooth, requiring only minor
adjustment to control loop response timing. Boiler draft control logic remained
similar to pre-VFD and SCR installation,
which allowed for an easy transition to
operations. The startup and commissioning team remained on-site for the first
few days of fan operation and were then
released. First ammonia injection occurred in the second week of post-outage
operation. Tuning and balancing of the
ammonia injection system was accomplished by the OEM. Minor control loop
tuning for the ammonia control valves
also occurred at this time. WPL learned
that it would have been beneficial to have
kept some of the startup team onsite for
the first few weeks of ammonia injection,
because some startup knowledge/continuity was lost when letting the OEM take
the lead in tuning the ammonia system.
Startup representatives from the OEM remained onsite after SCR tuning until the
performance testing was completed.
POST INSTALLATION
OPERATION
After successful startup and tuning
of the SCR system, performance tests
were conducted to verify the actual
performance of the SCR met or exceeded the guarantee values. A third-party
test company was hired to conduct the
following performance tests: Outlet
NO x emission; Average ammonia slip;
SO2 to SO3 conversion; Ammonia consumption; Power consumption
Each parameter was tested with the
boiler at full load, and three tests for
each parameter were conducted. The
results were averaged and compared
to the performance guarantees using

contractual correction curves to account for actual boiler operation. In
all cases, actual test data were below
the guarantee values.
After performance testing was complete, the SCR was subjected to a 60day system availability test. During
this test, the boiler was allowed to
dispatch as needed, and the SCR system was left in auto to follow boiler
load. In order to pass the 60-day test,
the SCR system had to meet or exceed
the guaranteed NO x reduction over a
30-day rolling average. Data was collected from the Edge 5 Continuous
Emissions Monitoring System (CEMS)
to verify SCR operation. As with the
prior performance tests, the SCR system passed the 60-day availability test
with no issues.
The SCR system has been operated
continuously since it was placed in service in December, 2012. After testing
was completed, WPL has maintained
operation of the SCR in order to reduce NO x below levels required by the
phase II RACT rules. Figure 7 shows
NO x levels pre-SCR and post-SCR.
CONCLUSION
The Edgewater SCR project team
faced significant challenges in designing an SCR system that would preserve
the operational flexibility of the existing unit after the SCR was installed.
By identifying the criteria that would
preserve this flexibility during the design phase and carrying it over to the
construction phase, the project team
was successful in achieving this objective. Involvement of plant operations
during the early design phases of the
project, integrating WPLs project team
members with team members from
the OEM, Constructor and startup and
commissioning team along with the
support of the Owners Engineer were
key elements in the successful achievement of the project scope in time for
compliance and within budget.
www.power-eng.com
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Advancements in Wind
Turbine Technology:
Improving Efficiency
and Reducing Cost
ind power capacity has increased dramatically in the U.S.

recently and
accompanying that, the turbines that
produce it have become more powerful,
more efficient and more affordable for
power producers.
If you go back 10 years ago and look at
wind power and then look at where is today, its just dramatically different, said
Keith Longtin, wind products general
manager at General Electric.
Those differences come in many different areas rotors, controls, electronics
and gearboxes but the advancing technology used in wind power production
have always aimed for the same goal:
making wind power a better choice for
power generation.
CAPACITY FACTOR
While a previous focus of the industry was increasing the total nameplate
capacity of wind turbines, the focus has
shifted to the capacity factor of the turbine, which helps keeps energy cost low
by providing the most possible power.
That is really the direction were going, Longtin said. If you go back 10
years ago, the turbine was at about 25
percent capacity factor. Today, its over 50
percent. As weve improved the capacity
factors and improved the cost of energy,
46
that enables us to go into more and more

locations where the wind is lower.
One of the deciding forces so far for
increasing capacity factors has been an
increase in the size of the rotors used on
wind turbines. Longtin said GEs predominant turbine in the U.S., which has
a 1.6 MW capacity, currently comes with
a 100-meter rotor, compared to a 70-meter rotor in the past.
Increasing the size of the turbine rotors
creates new challenges for manufacturers, however. Longtin said rotors scale
poorly with size, so the cost can go up
faster than the revenue generated by the
increased capacity factor.
Turbine rotors are affected by two different forces: torque, which turns the rotors and creates energy, and thrust, which
pushes against the turbine. Dealing with
thrust can be difficult when designing a
rotor.
The thrust is equivalent to five F-18
engines just trying to pull it over, Longtin said. There are tremendous loads of
forces up there, and so it goes to great engineering technology to be able to create
these very reliable turbines.
Breakthroughs on turbine controls led
to being able to handle the additional
thrust generated by wind, Longtin said.
He compared the controls used on turbines to anti-lock braking systems on
cars, saying the way the turbine is controlled and shut down, along with how it
Alstoms ECO 100 wind uses a

122-meter rotor, which is a nearly
40 percent increase from the
100-meter rotor used on the same
turbine less than five years ago.
Photo courtesy of Alstom.
www.power-eng.com
customers. When you increase the area of

the rotor, you are able to get more energy
at lower wind speed.
RELIABILITY
Breakthroughs in control technology has allowed GE

to use a 120-meter rotor on its GE 2.5-120 turbine, the
companys largest. Photo courtesy of GE.
responds to wind gusts, allows for a bigger rotor on a turbine.

Alstom has made similar changes in
the size of rotors for its platforms. The
company took its eco100, a 3-MW turbine
with a 100 meter rotor, and upgraded it to
a 110-meter rotor in 2010. Last year, the
company increased that to a 122-meter
rotor.
We were able to increase by nearly 40
percent the area of the rotor in less than
five years, said Albert Fisas-Camanes,
Director of Innovation for Alstom Wind
North America. That lets us deliver
a more efficient wind turbine to our
www.power-eng.com
While the focus on increasing the power produced from wind turbines may be
on the capacity factor, another way is to
make sure wind turbines are operational
and available. Longtin said GE has made
major strides int hat area in the past 10
years.
The availability of wind turbines 10
years ago was about 80 to 85 percent,
he said. And the wind industry was OK
with that because before that they were
available 70 percent. We took a power
generation mindset to it and said 98 percent is what we do. Thats what gas turbines run at, thats what nuclear plants
run at, thats what steam turbines run at,
so thats what were going to do. Weve
made lots of investments to improve the
overall availability of a wind turbine so
that today we have 22,000 wind turbines
with an average production-based availability around 98 percent.
To help achieve that sort of industry reliability and to continue improving on
it Longtin said the company has worked
to improve the individual components
used in turbines, both electronics and
gearboxes.
For gearboxes, GE has combined the
manufacturing processes and design processes so theyre designing components
that can be reliably manufactured. In
addition, the company does highly accelerated lifetime testing on all its gearbox
designs to validate the design on all new
gearboxes.
Longtin said the company is looking
at the manufacturing of the parts used
in the gearbox. GE is looking at ways to
harden gears as well as different types of
bearings and bearings configuration.
Gearbox reliability is something were
incredibly focused on, he said. Theres
a lot of work that goes into trying to
maximize that reliability.

In the future, Longtin said the company will also focus on how to minimize
the downtime when a gearbox does have
a mechanical failure.
Were trying to make our gearboxes so
if a problem occurs, were able to service
that uptower as opposed to bring a crane
in and replace the whole thing, he said.
That is probably one of the best things
we can do.
CHALLENGES IN
OFFSHORE PRODUCTION
While the onshore wind turbine industry is going strong, the U.S. is looking
toward the possibility of adding offshore
wind capacity in the future. Alstom recently signed a contract with Deepwater
Wind to supply turbines for the 30-MW
Block Island Wind Farm three miles off
the coat of Rhode Island, and the company is also part of Dominion Virginia
Powers Virginia Offshore Wind Technology Advancement Project, which was one
of seven picked by the U.S. Department
of Energys advanced technology demonstration projects.
The needs of offshore wind production
require different solutions than onshore,
Fisas-Camanes said.
From the Alstom perspective, we see
two different worlds, he said. Onshore
has some contraints, and they are not the
same constraints you are going to see in
an offshore site. We are treating them as
two different animals, and we are using
different technologies for those two applications.
The use of different technologies for
onshore and offshore wind power projects is another change that has occurred
over the past 10 years. While companies
used to take the same wind turbine used
on land and installed it offshore, but Fisas-Camanes said Alstom took a different
approach with its current generation of
offshore wind turbines.
If you look at the new generation of
47
offshore wind turbines, our wind turbine,

the Haliade 150, has been designed from
the very beginning to operate in offshore
conditions, he said. This has driven different aspects of the design of the wind
turbine, with one of the main decisions
being using direct drive technology.
The Haliade 150 is a 6-MW turbine
that uses a 150-meter rotor. Fisas-Camanes said the company plans to continue developing and investing in the
improvement of the direct drive solution
48
for its offshore wind turbines, including

improving its efficiency and weight.
Companies are also looking at the
use of floating wind turbines, which use
floating structures instead of requiring
wind towers be set into a foundation under water.
Ten years ago, it was hard to imagine floating wind turbines, and this is
real now, Fisas-Camanes said. Were
in a demonstration phase right now, and
Im expecting to see the development of
floating wind farms in the next 10 years.
TOOLS TO IMPROVE
EFFICIENCY
As companies look to make more sophisticated wind turbine technology,
more sophisticated tools are required.
One of those is 3D modeling technology,
which allows companies to use computer
simulations to see how products will respond before manufacturing and testing
the product in the field.
www.power-eng.com
Alstoms Haliade 150 turbine was designed from the beginning

for use in offshore wind production, resulting in different solutions
being used than the company uses in its onshore wind turbines.
Photo courtesy of Alstom.
Maybe five or 10 years ago, people

would put a wind turbine behind a tractor trailer, drive at 60 miles per hour and
measure what the velocities would be
on it, said Ahmad Haidari of ANSYS, a
company that produces simulation software. Imagine having all that on the
computer, where you can change the angle of the attack, change the velocity and
change the yaw angle.
Computer simulation can be useful to
companies as they look to increase the
www.power-eng.com
capacity factor of turbines. The software

allows companies to help design blades
that allows for attached flow across a
range of flow velocity without having
to continuously make the rotors larger,
Haidari said.
Companies are able to use software to
create a virtual lab and set up the blade in
the lab. Designers can then vary the blade
geometry, blade twist, yaw angle, angles
of wind attack and wind velocities. The
simulations will allow designers to see
the coefficient of lift and drag across the
blade on both the top and bottom surface.
In wind turbine blades, blades could
be very thin at the end, and theres also
a little twist to it, so maintaining fluid
dynamic contact on the blade across of
range of wind velocities and different
angles of attack and different yaw is a
complex fluid mechanics problem, he
said. Once we have the rotor size as large
as we can, the next thing is, How can we
get the blade efficiencies up? That means
fluid dynamic efficiency across a range of
wind speeds.
Modeling software can be used in
more than blade design, however. Haidari said software can be used when siting
wind power projects. Buildings, hills and
even trees can change wind turbine behavior, so using software can help choose
the correct installation for a given wind
farm. Although siting may be less important in offshore wind power projects, the
software can be used to help decide the
best way to run power onshore as well
as determine on the right strategy for installing the tower into the ocean floor.
The technology can be used for a variety of other simulations, including
manufacturing components, as well as
monitoring the potential performance
of generators and components, performing structural analysis or looking at
electronic controllers.
When you look at wind blades, you
have to look at the whole system, Haidari said. Looking at the blade is part of it,
but one needs to look at the entire system
design in order to have a full understanding of the blades performance. Everything, including your washing machine,
is becoming more sophisticated. Designing these around a single component
doesnt help.
THE FUTURE FOCUS ON

INNOVATION
The technological advances made
with wind turbines have resulted in
clear bottom line: Wind power is more
efficient and affordable than it has
ever been, which has helped drive its
popularity along with power prices
and incentives such as the U.S. production tax credit. Also, Fisas-Camanes
said wind power has proven itself as a
good option for companies looking for
power that can come online quickly.
Its a fast track technology, it doesnt
need water and it doesnt pollute the
earth, so its an easy and quick energy solution for increased generation,
he said. I think there are a number
of reasons, technology being one of
them, that have helped lower the cost
for energy.
As quickly as wind technology has
developed in the past 10 years, FisasCamanes said he expects that pace to
at least continue and possibly accelerate. He said he expects many advances
in the next 10 years, including a new
generation of offshore and onshore
wind turbines that will have more value for their owners and more developments in the components and controls
of a turbine.
Its an open book, he said. If you
look at how this industry has been
evolving, its amazing. Its a very dynamic, technology-driven industry
with a focus on cost, and I think well
see a lot of interesting things in the
next 10 years.
49
Side-by-side testing of different screens was performed at Alden Research Laboratory in Worcester,
Mass. All photos courtesy of EPRI
Preparing for
Section 316(b)
BY SHARRYN DOTSON, ASSOCIATE EDITOR
hough the Clean Water

Act Section 316(b) rule
was not finalized as
scheduled on Jan. 14,
there are still steps that
plant owners and manufacturers can
take to prepare for the rules passage.
Section 316(b) of the Clean Water
Act requires that the location, design,
construction and capacity of cooling
water intake structures reflect the best
technology available for minimizing
adverse environmental impact, according to the U.S. Environmental Protection Agency (EPA)s website. Due to
the government shutdown in October,
the EPA was unable to finalize the rule
by November 4 as originally agreed.
Plant owners have eight years from
50
when the rule is finalized to be in compliance with the impingement requirement. How long it will take to comply
with the entrainment requirement will
be determined by how long the project
takes to complete.
The rule focuses on two parts: impingement and entrainment. The Electric Power Research Institute (EPRI)
is currently evaluating and developing technologies that will help lower
the amount of fish and their larvae or
eggs getting impinged by or entrained
in the cooling water intake systems.
Douglas Dixon, technical executive
and program manager EPRIs fish
protection program, says the organizations research into the rule focuses
on four areas: technology, biological
sampling methods, cost-benefit analyses and thermal discharge.

One of the key things we have
found through our research is that
the ways to reduce the impact on marine life are site-specific, Dixon said.
What you can do at one plant would
not be applicable at another.
Some of those site-specific factors
include plant location, species of fish
involved, how the plant operates, the
debris that it has to filter, the hydraulics of the location and the temperature of the water.
Dixon said research has shown
that closed-loop cooling is as close
to a broad technological fix of reducing fish and shellfish impacts as any
available technology, but it has its own
shortcomings and is not a workable solution for many power plants.
Problem is that while it works,
EPRI has done research to document
that it would be expensive and highly
disruptive of our electric power system
and the ecological benefits would be
debatable.
One of the key things

we have found through
our research is that
the ways to reduce the
impact on marine life
are site specific.
EPRIs national closed-cycle cooling
analysis estimated $100 billion to retrofit 450 power plants four years ago.
Those costs are now estimated to be at
least $50 million per plant. The system
could cost $2 billion or more per plant,
particularly for nuclear facilities, Dixon said.
www.power-eng.com
Tackling 316(b) is S.I.M.P.L.E with Ovivo!

Our proven Fish Guidance System incorporates a stimuli deterrent
method which queues on the natural response of sh to guide them
away from a cooling water intake. Each site is evaluated for the
proper frequency and/or combination of acoustics, illumination
and air curtain to alter the path of specic species.
The Fish Recovery method developed and utilized by Ovivo
incorporates the S.I.M.P.L.E (Stabilized Integrated Marine Protection
Lifting Environment) process. This combined with the advanced
features of Ovivo Traveling Water Screens greatly increase
survivability for sh and longevity for continuously operating intakes.
To learn more, call 1-801-931-3113 or visit us at ovivo.me/316b
Bilfinger Technologies contributed its fine-mesh pilot

screen for testing at the Alden Lab. It is not available
commercially in the U.S.
Other technologies include a velocity cap that can only be used by

plants located near deep water, such
as plants along the Great Lakes, the
Pacific coast, the New England coast
and in southern Florida. By moving
it offshore, you also have a reduction
in the loss of entrainable life like eggs
and larvae, Dixon said. It has a high
performance, but its limited to certain
plants.
Other technologies being researched
are variable speed water pumps, fine
mesh traveling screens and fish return
systems that work similarly to a water
slide at an amusement park.
Many companies are working with
EPRI to prepare for the rule, Dixon
said. There is going to be a high demand for technological support, but
the needed expertise may not be available, Dixon said. Theyre starting to
get their contracts together, requests
for proposals, educating their own
staff about how to comply with the
rule.
Some states are being proactive with
their permit requirements, and some
have already established what they
consider to be the best available technology. The state of California, for example, is requiring Pacific Gas & Electric to look into converting its intake
system to closed-loop cooling at the
Diablo Canyon nuclear power plant,
according to Jason Eichenberger, PE,
ENV SP, a senior civil engineer with
Burns & McDonnell. Some utilities
are leaning toward a fish handling system on the intake screen or traveling
screens.
We are working on one project
where they have permit requirements to install wedge wire screens,
52
Eichenberger said. Were putting together a compliance plan for submittal

to the state agency and were currently
proceeding down the path to do the
design based on the proposed rule.
A wedge wire screen is a cylindrical screen that is placed in the river in
front of the intake structure, Eichenberger said. Its a passive screen that
gives enough surface area so youre
in compliance with the impingement
criteria. Cooling towers could bring a
facility into compliance with the entrainment criteria, but they are costly
and can impact plant performance by
raising back pressures and creating
other issues.
Consulting companies and EPC
firms are advising clients to begin lining up suppliers before there is a rush
on the projects, and Burns & McDonnell is preparing cost-analysis studies

so clients have an idea of how much
such a future compliance project could
cost. Clients have been calling and
asking how much is it going to cost to
retrofit their intake system, Eichenberger said. With impingement, compliance strategies are relatively clear.
With entrainment, that is not the case.
It may come down to the state level
and what is required on a site-specific
basis.
Jack Tramontano, environmental
group manager and program manager
for Section 316(b) with URS Corp.,
said waiting for the rule to be finalized
has put everyone in a holding pattern.
Its been kind of a frustrating process because of the numerous delays,
www.power-eng.com
DECEMBER 10-11, 2014

Orange County Convention Center Orlando, Florida
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Owned & Produced By:
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www.powergenerationweek.com
A close up of a fine mesh screen undergoing testing.

Photo courtesy of EPRI
he said. Also, the Notices of Data

Availability (NODA) published in June
2012 indicates that EPA is considering
some significant changes to the draft
rule. Its difficult for facilities to plan
ahead with all of the uncertainty.
He echoes that many plant owners
are concerned about the costs of retrofitting or modifying their cooling water intake systems.
Finding ways of complying with
minor upgrades to current intake
technology is one way to avoid a lot
of capital costs, Tramontano said.
Otherwise, because there is so much
uncertainty, most are in a wait-and-see
attitude right now.
That uncertainty has added up to a
lot of unanswered questions on how
to comply with the rule, including
whether closed-cycle cooling will be
considered best technology available
or if additional fish protection will be
necessary.
Larger plants that have been designed with closed-cycle cooling may
still have to install modified Ristroph
54
screen with fish returns for impinge- to determine through screen velocity
ment compliance, according to draft compliance, modifying the compliance
regulations, Tramontano said. Those schedule for impingement and enwho thought that with closed-cycle trainment and modifying monitoring
cooling that they were okay or thought requirements, Tramontano said. We
that they wouldnt have to apply new have heard from secondhand sources
that EPA has adopted
technologies
may
many of these changnow have to apply Finding ways of
es in the final rule.
them. However, EPA
complying with
Tramontano said
may be creating alterthat he is advising
natives for facilities minor upgrades
with very low im- to current intake
clients to collect and
pingement levels or technology is one
organize
historic
mortality rates which
studies and other
way to avoid a lot information on their
should be applicable
to facilities with cool- of capital costs,
plants cooling waing towers. This ap- - Jack Tramontano, URS
ter intake systems.
proach will require
Many of the people
impingement sampling, but could al- we work with in the industry, who
low the facility to avoid a costly intake have the institutional knowledge of
system upgrade.
316(b) at the facility are reaching reThe finalized rule could include a tirement age or have already retired.
streamlined, or pre-approved, approach He suggests that companies do a gap
based on modified Ristroph-type trav- analysis of the information needed to
eling screens for impingement, a credit comply with the rule and know where
for protective measures already in place, that information is before that instituallowing local permitting agencies tional knowledge is lost.
www.power-eng.com
TM
AUGUST
2022, 2014 | NASHVILLE, TENNESSEE

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complete unit or as a kit that will retroft thou-
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The upper portion of the
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setup possible. The seat also
er are designed
has an anti-skid bottom, tool
for
120V-7A
incoln Electric added fve welding apparel

items with a new All-American design.
slot, is weather resistant and
use, and feature a snap-in construction for inser-
swivels 360 degrees.
tion into DD holes without rotation.
on each of the companys three Viking auto-
Heyco
darkening helmet series. The 3350, 2450 and
U-TECK
56
savwhen
eyco says its modular connector system can
The systems small patented, keyed-three
Ergo seat
than
percent
energy
white-labeling capabilities, improved utility-
ra-
The new All-American design is featured
1840 Series helmets all feature large view sizes,

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Welding guns
variable shade control, arc sensors and solar
power with lithium ion battery assist
incoln Electric has extended the Magnum

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All helmets include a switchable grind mode,
semiautomatic MIG/fux-cored guns with barrel-
extra inside and outside cover lenses, a Lincoln
style or Curve handles, dedicated self-shielded
Electric bandana and a sport-pak style helmet
fux-cored K126 guns and Magnum PRO Thru-
bag. The All American design is offered on a
Arm and External Dress torches for robotic
welders doo rag and cap made of 100% cotton.
applications.
Lincoln Electric
Sustainability
Reliability
Power
Railserve LEAF Gen-Set Locomotives do more than help you meet compliance
requirements. They work. And they work hard.
Proven in service for more than four years, the Railserve LEAF and Dual LEAF
locomotives have the pulling power to efficiently switch 60 or more loaded
cars while cutting emissions and fuel consumption.
Fabricators may select the Dual Procedure or

Dual Schedule models to enhance results when
performing a single weld that requires a change
from horizontal to vertical.
Lincoln Electric
Portable infrared analyzers
ortable infrared analyzers from Wilks

Enterprise provide on-site oil in water measurement
capa-
bility in minutes,
eliminating
Rely on the Railserve LEAF for 84% lower emissions; 50% savings on fuel;
90% savings on lubricants; and dramatic savings on greenhouse gases.
the
wait for lab results.

Wilks InfraCal
A Better Way to Switch.
T O G / T P H
Analyzers are designed for easy, on-site measurement of the oil
and grease concentration level in water in under 15 minutes. Measurement data correlates
with EPA methods 1664, 413.2, 418.1 and ASTM
Methods D7066 and D3921.
Wilks
Wind turbine flter elements
wift Filters Inc. expanded its offering of flter

elements for the wind power industry.
SwiftGreen flter elements are engineered for

wind turbine gearbox lubrication lines. They feature reusable machined aluminum bypass valve
assembly that can be used indefnitely. The flter
elements are ideal replacements for OEM flters
on GE 1.5 MW Series wind turbines, but can be
used as direct replacements for more major OEM
flter elements.
Swift Filters Inc.
Railserve, Inc. | 800-345-7245 | www.RailserveLEAF.biz
www.power-eng.com
Automatic Filters
Ball Valves
Carbon Capture Technology
Why Should You

Filter Your Water?
On the northern coast of Germany, Fluor and

E.ON designed and built the Wilhelmshaven pilot
plant to capture carbon dioxide from coal-fred
fue gas. Utilizing Fluors patented and proprietary
Econamine FG PlusSM technology, the innovative
project provides a platform to demonstrate and
advance carbon capture technology that can be
applied to power projects around the world.
For more than a century, Fluors subject matter
experts have been dedicated to our clients and
the environment, creating value and innovation in
design, driving down cost and schedule.
Viega offers press ball valves specifically designed

for lead-free press systems. Made from Viegas
unique silicon-bronze alloy, engineered for press
technology, Viega ProPress Zero Lead ball
valves are certified to ASME A112.4-2004 and
NSF-61G, available in sizes 1/2- to 2-inches with a
variety of configurations.
www.ViegaProPress.us
1-800-976-9819
$%&$' '''
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Cooling Tower Fill
Demolition/Decommissioning
Electrical Connectors
Brandenburg
SAFETY
PLUGS
Brandenburg is the premier demolition and

environmental remediation contractor for
power plant decommissioning and retrotting. Brandenburg services utility companies
throughout the U.S. by performing demolition and repurposing projects ranging from
selective removal of obsolete equipment
to complete closure of power plant facilities.
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ShowcaSe advertiSing contact Jenna hall: 918-832-9249, Jennah@pennwell.com

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FLUOR DRIVES
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Keeps NFPA 70E HRC=0
(800) 932-2869 | www.brandenburg.com
www.power-eng.com
meltric.com
800.433.7642
59
Joining Stainless Pipe
Oil Purification Equipment
Increase Steam Boiler Efficiency:

Brochure HRS 1188 describes three different types of continuous boiler blowdown
heat recovery systems manufactured by
Penn Separator Corp. All systems recover up
to 90% of the BTUs normally lost to drain.
Visit our website www.pennseparator.com
for a sales representative nearest you.
www.ViegaProPress.us
1-800-976-9819
Pollution Control
Power Systems
Silo and Bin Cleaning Sevices
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For construction of the worlds largest solar power

plant, Viega ProPress for stainless was hardspecified in the plans for process water, service
water and instrumentation air systems. Viega
ProPress for stainless saved more than 30 percent
on materials and labor combined for installing the
systems.
| SUPPLIERS SHOWCASE
Heat Recovery Systems
Call 800-322-6653
or visit
www.molemaster.com
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Silos, Chimneys, & Steel Stacks
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TIER 4 FINAL READY

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CALL NOW FOR DETAILS:

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Email: jennah@pennwell.com
Books, BooksSo Many Books

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SUPPLIERS SHOWCASE |
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61
FOR SALE/RENT
Classified advertising ContaCt Jenna Hall: 918-832-9249, JennaH@pennwell.Com
| CLASSIFIEDS
ELIMINATE
24 / 7 EMERGENCY SERVICE
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Valve Cavitation
20,000 - 400,000 #/Hr.
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Eliminate valve cavitation by

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downstream of the valve.
Noise and pipe vibration will
also be eliminated or reduced.
Valves first costs and maintenance burden
will also be
reduced.
DIESEL & TURBINE GENERATORS

50 - 25,000 KW
GEARS & TURBINES

25 - 4000 HP
Get a thorough mix with:
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Columbia, TN 38402 USA
Ph: 931-388-0626 Fax: 931-380-0319
www.pugmillsystems.com
LARGEST INVENTORIES OF:

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Pulverizers Rental Boilers & Generators
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FAX: 847-541-1279
visit www.wabashpower.com
wabash
POWER
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Got jobs?
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Quality and Service Since 1908
Ring Granulators, Reversible Hammermills,

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for crushing coal, limstone and slag.
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Ph: (314) 781-6100 / Fax: (314) 781-9209
www.ampulverizer.com / E-Mail: sales@ampulverizer.com
The PennEnergy JOBS process puts your

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Visit: www.PennEnergyJOBS.com
Call: 1-800-738-0134
WE ARE
BUYING!!!
ARE YOU SELLING?

VALVES
INSTRUMENTATION
ELECTRICAL CONTROLS
PROCESS EQUIPMENT
PROCESS CONTROLS
PLANT MACHINERY
PSA SNUBBERS, ETC.
RENTAL EQUIPMENT
E SI Boil er Rentals, L LC
VISIT
www.FerncroftManagement.com
email:vavlebuyer@ferncroftmanagement.com
T. 978-815.6185 Fax. 603-814.1031
John R Robinson Inc

PH # 800-726-1026
e-mail: jrrinc@earthlink.net
www.johnrrobinsoninc.com
Ferncroft
Management,LLC
CONDENSER & HEAT EXCHANGER TOOLS

CLEANERS, PLUGS, BRUSHES
GEORGE H. BODMAN, INC.
24/7 On-Call Service
1-800-990-0374
www.rentalboilers.com
LIMITORQUE OPERATORS WANTED
- Rental Boilers - Economizers - Deaerator Systems - Water Softener Systems -
Chemical cleaning advisory services for

boilers and balance of plant systems
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
QUALITY
INTEGRITY
CLASSIFIEDS |
SAFETY
FOR OVER 9 DECADES WE AT KIMMINS HAVE PRIDED

OURSELVES ON BUILDING AND MAINTAINING A WORK
CULTURE THAT GIVES OUR CUSTOMERS THE VERY BEST
SAFETY, QUALITY, INTEGRITY, AND SCHEDULING.
INDUSTRIAL
DEMOLITION & DISMANTLING
JZemina@Kimmins.com
813.247.0147
www.Kimmins.com
1501 E 2ND AVENUE
TAMPA, FL 33605
DEMOLITION|CIVIL SITE & UTILITY CONSTRUCTION|DESIGN-BUILD

CONDENSER OR GENERATOR AIR COOLER TUBE PLUGS
THE CONKLIN SHERMAN COMPANY, INC.
Easy to install, saves time and money.

ADJUSTABLE PLUGS - all rubber with brass insert.
Expand it, install it, reverse action for tight fit.
PUSH PULL PLUGS - are all rubber, simply push it in.
Sizes 0.530 O.D. to 2.035 O.D.
Tel: (203) 881-0190
Fax: (203) 881-0178
E-mail: Conklin59@aol.com www.conklin-sherman.com
Just Plugging Along

Tur bine Controls

Woodward, GE, MHC
Parts and Service
Obsolete Parts Inventory
Control System, Modernization
Training, Troubleshooting
TurboGen Consultants, Inc.

(610) 631-3480
www.turbogen.net
info@turbogen.net
The worlds very

best portable end
prep tools and
abrasive saws
For sale or rent
800-343-6926
www.escotool.com

Classified advertising ContaCt Jenna Hall: 918-832-9249, JennaH@pennwell.Com
INDUSTRIAL DEMOLITION | COMMERCIAL DEMOLITION

SELECTIVE DEMOLITION | EMERGENCY DEMOLITION
ENVIRONMENTAL CLEAN-UP SERVICE
DISMANTLEMENT SERVICES | ABESTOS ABATEMENT
ASSET RECOVERY ON SITE | PERTOLEUM HANDLING
SCRAP MANAGEMENT
INDEX
RS# COMPANY
PG#
RS# COMPANY
PG#
13
27 Renewable Energy World
57
Aegion
www.fibrwrap.com
www.renewableenergyworldevents.com
Areva
17
16 RES Americas Inc
www.us.areva.com
33
SALES OFFICE
1421 S. Sheridan Rd., Tulsa, OK 74112
Phone: 918-835-3161, Fax: 918-831-9834
e-mail: pe@pennwell.com
Sr. Vice President North
American Power Group Richard Baker
www.res-americas.com
CB&I
7
2
www.cbi.com
Siemens Industry
usa.siemens.com/ruggedcom
20 Clearspan Fabric Structures 39

1
www.clearspan.com
Solvay Chemicals Inc
C2
www.solvair.us
26 COAL-GEN
55
www.coal-gen.com
19 Conco Systems Inc
39
18 Structural Integrity
Associates
37
www.structint.com/power-eng
www.concosystems.com
12 Cutsforth Products
25
Terrasource Global
11
www.terrasource.com
www.cutsforth.com
11 GE
21
17 United Rentals Inc
35
www.unitedrentals.com/futures
www.ge-mcs.com
Magnetrol International
www.magnetrol.com
22 Victory Energy
Operations LLC
43
www.victoryenergy.com
13 Mechanical Dynamics
& Analysis, LLC
27
14 Volvo Penta of the Americas 28

www.volvopenta.com/industrial
www.mdaturbines.com/turboparts
15 Mee Industries Inc
29
10 Westinghouse Electric Co
19
www.westinghousenuclear.com
www.meefog.com
MEGGER INC
15
www.megger.com
Mitsubishi Power
Systems Americas Inc
8-9
21 Nord-Lock Inc
41
www.nord-lock.com
24 Ovivo
51
www.ovivo.me/316b
29 POWER-GEN International
C3
www.power-gen.com
23 Power Generation Week
45
25 POWER-GEN Financial Forum53

www.powergenfinancialforum.
com
30 ProEnergy Services LLC
C4
www.proenergyservices.com
28 Railserve, Inc.
Advertisers and advertising agencies

assume liability for all contents (including text representation and illustrations)
of advertisements printed, and also assume responsibility for any claims arising therefrom made against the publisher. It is the advertisers or agencys
responsibility to obtain appropriate
releases on any items or individuals pictured in the advertisement.
Reprints Foster Printing Servive

4295 Ohio Street
Michigan City, IN 46360
Phone: 866-879-9144
e-mail: pennwellreprint@fosterprinting.com
National Brand Manager 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
Brand Sales Manager 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
Brand Sales Manager Tina Shibley
1421 S. Sheridan Road
Tulsa, OK 74112
Phone: 918-831-9552; Fax: 918-831-9834
e-mail: tinas@pennwell.com
AK, AZ, CA, CO, HI, IA, ID, MN, MT, ND,
NE, NM, NV, OK, OR, SD UT, WA, WI, WY,
Alberta, British Columbia, Saskatchewan,
Northwest Territory, Yukon Territory,
Manitoba
International Sales Mgr Anthony Orfeo
The Water Tower
Gunpowder Mills
Powdermill Lane
Waltham Abbey, Essex EN9 1BN
United Kingdom
Phone: +44 1992 656 609, Fax: +44 1992 656 700
e-mail: anthonyo@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
58
www.railserveleaf.biz
64
www.power-eng.com
D EC E MB E R 9 11 , 2014
ORLANDO, FLO RI DA
ORANGE C OUNT Y C ONVE NT ION C E NT E R

W W W . P O W E R - G E N . C O M
FOREVER ADVANCING
REGISTER BY OCTOBER 6 AND SAVE!
Register early and take advantage of the early bird discounts! POWER-GEN International will feature
more than 1,400 exhibiting companies unveiling the latest power generation products and services.
For a full list of exhibitors at the worlds largest power generation event, visit www.power-gen.com.
5 EVENTS + 5 DAYS
OWNED & PRODUCED BY:
PRESENTED BY:
SUPPORTED BY:
IF IT TURNS OR BURNS
we can fix it.
ProEnergy is a global provider

of integrated service solutions for
the POWER GENERATION and
OIL & GAS industries.
US Corporate Office | 660.829.5100

proenergyservices.com

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Heat Recovery Steam Generators | Waste Heat Boilers | Fired Packaged Watertube Boilers | Specialty Boilers

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