More Than 11,000 Control System Projects at Fossil-fired Power Plants Next Year
Existing coal-fired power plants are upgrading to become more cost competitive
and reduce emissions of pollutants and greenhouse gases. They will account for
more than half the 11,250 controls projects which are planned for completion
next year at fossil-fired power plants. These are the findings in two McIlvaine
publications. Utility Environmental Upgrade Tracking System and Chinese Utility
Plans. (www.mcilvainecompany.com)
Classification |
2014 MW |
Units |
Controls Projects |
Existing Gas Turbines |
1,126,000 |
13,000 |
4,000 |
New Gas Turbines |
73,000 |
1,000 |
1,000 |
Existing Coal-fired |
2,142,839 |
3,000 |
6,000 |
New Coal-fired |
123,999 |
250 |
250 |
Total |
|
|
11,250 |
The controls projects vary in scope. There are quite a few modifications to
existing systems to incorporate monitoring of new emissions control equipment.
Other systems involve safety and security. The largest investments are in major
modernization programs.
ABB has won an order from
Enel, Italy’s largest power company, to supply its Symphony®
Plus automation and control system to serve one of the major units at the Grazia
Deledda Sulcis power plant on the island of Sardinia. Grazia Deledda Sulcis is a
590 MW
coal-fired power plant with two units. The existing control systems
will be replaced with a total plant automation solution to enhance the unit’s
efficiency and improve its environmental performance. The new Symphony Plus
solution includes the recently introduced high-performance controller, burner
management and flue gas desulfurization systems, instrumentation, a new control
room and operator stations.
EDF, the world’s leading nuclear utility, is also counting on coal. It has
selected ABB to supply Symphony Plus total plant automation systems and
long-term service support for three 600 MW units at the Le Havre and Cordomais
coal-fired power plants in France. Recently, EDF initiated an extensive program
to modernize Le Havre 4 and Cordomais 4 and 5 units to extend their operating
life by 20 years to 2035. These three units are the largest coal-fired units in
the EDF fleet.
Korea Midland Power has awarded Emerson Process Management a contract to replace
the existing controls on two coal-fired units at the Boryeong plant with its
PlantWeb digital plant architecture. Previously, the two units each utilized
multiple control systems—analogue Toshiba turbine controls and a Bailey820
analogue system that controlled each unit’s Babcock & Wilcox boiler and balance
of plant processes. Boryeong is the biggest thermal power station complex in
Korea. With a generating capacity of 4800 MW, it accounts for 7.4 percent of
Korea’s total electrical output.
India-based Instrumentation Ltd has signed a deal with Metso, to upgrade an
automation system at the 890 MW Parichha thermal power plant located in the
Indian state of Uttar Pradesh. The generating station in Jhansi will be able to
improve process efficiency and ensure safer process operation as a result of the
upgrade.
Yokogawa Electric., Ltd. has an order from Doosan Heavy Industries &
Construction Co., Ltd. in South Korea to supply control systems for the Mong
Duong 2 coal-fired power plant, which is being constructed in Quang Ninh
Province in Vietnam. The Mong Duong 2 coal-fired power plant, one of the largest
power plants in Vietnam with a total output of 1,200 MW (two 600 MW units), is
scheduled to start operation in August 2014. This order includes the CENTUM®
VP integrated production control system for the power plant's boilers, turbines,
and auxiliary facilities and the ProSafe®-RS safety instrumentation
system.
An owner of a large fleet of combinedcycle power plants in the U.S. has awarded
Wood Group GTS a contract to install 15 ECOMAX® systems, an automated
combustion tuning technology. Twelve units have already been installed and the
remaining units are scheduled to be installed later this year. The independent
power producer granted the contract to Wood Group GTS following assessment of a
pilot project at one of its facilities operating two GE Frame 7FA turbines. One
year after installation the ECOMAX tuning technology demonstrated more than 0.75
percent power increase and more than a 0.15 percent decrease in heat rate.
Wood Group GTS has completed an upgrade of the controls system on a
GE
LM6000 natural gas-fired turbine at Jonesboro, Arkansas, City Water and Light
(CWL)’s northwest combustion turbine site. Wood Group replaced the original
controls system with an open-architecture system that will enable CWL to access
and configure the turbine to meet fluctuating demands. It also provides CWL with
the ability to perform maintenance in-house.
For more information on Utility Environmental Upgrade Tracking System
click on:
http://home.mcilvainecompany.com/index.php?option=com_content&view=article&id=72
For more information on Chinese Utility Plans click on:
http://www.mcilvainecompany.com/brochures/energy.html
How to Cope with Retirement of Experienced Power Plant Environmental Engineers
There is great concern about the large numbers of power plant environmental
engineers who will retire in the next few years. The concern is that much of
their knowledge will be lost and it will be difficult to maintain or improve the
quality of environmental decision making. McIlvaine Company says that the answer
to this question is the use of digital technology and organization to provide
the successors with knowledge which would otherwise be lost. Power
Plant Air Quality Decisions, published by the McIlvaine Company, is a way to
capture and make this knowledge easily available. (www.mcilvainecompany.com)
Three percent of the engineers at power plants who focus on environmental issues
retire each year. The percentage of expert knowledge which is retiring is closer
to 10 percent. The reason is that the average career in the environmental
specialty is 20 years. The individual usually spends a portion of his career in
other technologies before becoming specialized. From this much smaller pool, the
most knowledgeable are usually the ones closest to retirement.
The challenge is to make sure that the younger engineers assimilate the
knowledge of those who will retire and to ensure that there is a minimal loss of
accumulated knowledge. To do this the following steps must be taken:
·
Make sure that knowledge gathered is knowledge maintained
·
Organize a system for retrieval of this information
·
Create methods to convert information into knowledge and knowledge into wisdom.
The digital tools which are available are powerful and invaluable but need to be
structured. Google tends to declassify, whereas what is most valuable is
decisive classification of options. YouTube and recorded webinars are
invaluable. The adage that a picture is worth a thousand words is even more
relevant when process flow diagrams and sequential displays provide easily
understood visuals. The challenge is to generate the comprehensive coverage of
the environmental subjects and to keep the data current.
Another valuable effort is to encourage the retiring engineers to become niche
experts in a narrow specialty. Many retirees welcome the opportunity to
provide advice. Focus on a narrow subject allows them to retain or become as
knowledgeable as anyone in the world in a specific niche.
Power Plant Air Quality Decisions
provides the organized systems and the use of the latest digital technology to
compensate for the loss of the retiring environmental engineers. For more
information on this service, click on:
http://home.mcilvainecompany.com/index.php/component/content/article?id=48#n44i.
Using McIlvaine Recorded Webinars for Permanent Training Program
Weekly McIlvaine webinars typically have four speakers. Their presentations are
recorded and available as shown below. These recordings along with the Power
Plant Air Quality Decisions service can provide the foundation of an ongoing
training program. Subscribers to the service have continuous access to all
the recordings online. You can design your own training program or we can
assist you to do so. The advantage we offer is the ability to tailor the
training to the individual and to the knowledge which is most needed.
The webinars in the last six months are displayed below. However, all the
recordings are available for the past few years. The speakers have been
selected for their expertise and knowledge. The subjects covered are those
important to decision making.
April 11, 2013 |
Mercury Measurement and Control
- Part 2
86 minutes
|
April 4, 2013 |
Industrial Boiler MACT Impact
and Control Options Part 2
68 minutes
|
March 28, 2013 |
Mercury Measurement and Control
- Part 1
115 minutes
|
March 21, 2013 |
Industrial Boiler Mact Impact
and Control Options Part 1
64 minutes
|
March 14, 2013 |
Inlet Air Pretreatment for Gas
Turbines
114 minutes
|
March 7, 2013 |
HRSG Design, Operation and
Maintenance Considerations
115 minutes
|
February 28, 2013 |
Implementation of the Utility
MACT Rule
124 minutes
|
February 21, 2013 |
Monitoring and Controlling
Boiler Water and Steam Cycle
Chemistry
84 minutes
|
February 14, 2013 |
NOx Control for Gas Turbines
130 minutes
|
February 7, 2013 |
Valves for Power Plants, Boilers
and Water Treatment Facilities
48 minutes
|
January 24, 2013 |
Gypsum Dewatering
76 minutes
|
January 17, 2013 |
Production of Fertilizer and
Sulfuric Acid at Coal-fired
Power Plants
75 minutes
|
January 10, 2013 |
Update on Oxy-Fuel Combustion
132 minutes |
December 13, 2012 |
Co-firing Sewage Sludge Biomass
and Muncipal Waste
156 minutes |
December 6, 2012 |
Boiler Feed and Cooling Water
Treatment
142 minutes |
November 29, 2012 |
Catalyst Selection For NOx and
Other Gases
113 minutes |
November 8, 2012 |
FGD Scrubber Components
85 minutes |
November 1, 2012 |
Cooling Towers and Cooling Water
Issues
83 minutes |
Marine Market for Flow Control and Treatment is Growing at Double-Digit
Rates
Marine vessels are purchasing air and liquid flow control and treatment
equipment at an accelerating rate due to new limits on both emissions to the
atmosphere and to the water. This is the conclusion reached in the
McIlvaine report Air/Gas/Water/Fluid Treatment and Control: World Markets.
(www.mcilvainecompany.com)
The U.S. EPA set standards for ballast water discharge in March of 2013. The
compliance date is 2016. This rule is just one of a number passed by various
different governmental bodies around the world. These rules will impact nearly
70,000 ships which use international ports. The average cost of treatment
systems to kill invasive organisms will range from as little as $300,000 to more
than $3 million.
A number of companies are generating substantial revenues already in this
market. Alfa Laval just announced a $50 million SEK order from a Korean ship
builder. Severn Trent has now sold 18 systems. Calgon Carbon has emerged
as a major participant in this market. More than 50 companies are selling
treatment systems.
This market is now the largest for the self-cleaning or automatic backwash type
filters which use disks or screens to achieve particle reduction to 50 microns.
Calgon Carbon has signed a long-term agreement with Amiad to supply them with
the Arkal type disc filters. These self-cleaning filters are used in irrigation,
municipal water treatment and even the purification of chocolate.
Another fast growing segment is the treatment of the stack gases from fuel
burning. Wartsila and others are selling scrubber systems which remove both
particulate and SO2. NOx control systems are also
being purchased for some vessels.
Cruise ships are opting for advanced treatment of sewage. Several membrane
bio reactor (MBR) suppliers such as GE and Hamworthy (Wartsila) have been
selling systems for ships since 2002. The market includes new ships but also
retrofits. Hamworthy replaced an older sewage treatment system with an MBR on
the Star Princess.
Pumps and valves are integral to the ballast water and sewage treatment. They
are also needed for the stack gas scrubbing systems, engine lubrication and for
cargo transport on tankers. A fast growing segment for pumps and valves is the
Floating Production, Storage and Offloading (FPSO) vessels. Two hundred
vessels are already in use for sub-sea oil and gas extraction. The movement of
the industry to deeper waters has accelerated the demand for a floating unit
rather than one anchored to the seabed.
The market growth for controls and instrumentation for these processes is
growing even faster than the hardware. There is a move toward smart
valves. Metso has supplied its latest generation stainless steel valve
controllers to the Norwegian Goliat Floating Production Storage and Offloading
(FPSO) plant in the Barents Sea. The intelligent controllers are used on all
pneumatic actuated control, on/off and ESD valves at the plant and help to
monitor and report on valve performance for asset management purposes.
Suppliers are providing advanced control systems for all the flow processes.
For the BP Angola FPSO, Yokogawa supplied an integrated control and safety
system (ICSS). The ICSS provided control and safety functions for
the sub-sea, marine, hull and topside facilities of the FPSO vessel along with a
single interface allowing operators to start, control and monitor all facilities
from a central control room.
For more information on Air/Gas/Water/Fluid Treatment and Control: World
Markets, click on:
http://home.mcilvainecompany.com/index.php?option=com_content&view=article&id=71
“Particulate and Condensable Removal” is the Subject
of the Hot Topic Hour on April 25, 2013
As you know on December 21, 2012, the EPA released the final
Mercury and Air Toxics Standard (MATS or historically referred to as the Utility
MACT) establishing mercury and air toxics standards
for coal- and oil-fired electric generating units larger than 25 MW. The rule
establishes particulate matter as a surrogate for non-mercury metallic toxics
and sets new challenging limits for particulate emissions. Although legal
challenges to the rule are ongoing, the courts have not stayed the rule, so
operators of the affected EGUs will now need to move the compliance process into
high gear. All existing EGUs will have three years to comply with the standards
although the rule allows states to grant specific units an additional year for
equipment installation.
The MATS, along with the newly revised NAAQS and Regional Haze regulations, will
require operators of coal- and oil-fired EGUs to significantly reduce
particulate emissions. Some good news is that MATS compliance is measured with
only filterable PM so that some power plants can comply with less expensive
upgrades or even existing controls. Others may still need to address the
condensable issue. To achieve compliance, plants with existing ESPs may need to
upgrade them and/or add a fabric filter.
However, control of condensable PM cannot be neglected.
The Cross State Air Pollution (transport) Rule (CSAPR) that was issued last year
and the NAAQS may well force control and reduction of condensable particulate
emissions. The states are now in the process of finalizing and beginning
implementation of their SIPs required to meet the NAAQS standards. The
NAAQS regulations establish standards for CO, lead, NO2, ozone,
particulate matter and SO2, all of which (except perhaps CO and lead)
can have a significant impact on current EGUs combusting coal or oil.
The bad news is that the MATS 30 day rolling average limits include start up and
shut down emissions. Since some control equipment, particularly ESPs, may not
operate during start up and shut down, power plants will either need to really
reduce PM emissions during normal operations or add additional controls just for
start up and shut down.
The following speakers will discuss the impact of MATS, CASPR and NAAQS on coal-
and oil-fueled EGU operators relative to filterable and condensable PM, such as
the key issues to be considered when developing a strategy to achieve
compliance, available control technologies and equipment that can be utilized to
achieve the emissions limits as well as the
advantages and disadvantages of the various control technologies and criteria
for selecting specific technologies – existing facility configuration, existing
control equipment installed, fuel type and others.
Jim Griffen,
Sales Manager at Donaldson Membranes, will discuss “Particulate and Condensable
Removal with Membrane Filters.” This presentation will discuss MATS
applicable to coal-fired utility boilers. MATS applies to all existing coal- and
oil-fired electric generating units larger than 25 MW and they must comply prior
to April 16, 2015.
Andy Olds,
Project Manager at Envitech, Inc, will discuss “WESP
Technology for Particulate and Condensable Removal.” The biggest issue for EGUs
is determining if they will have to control for condensable particulate matter
(PM) and metals and what technologies are available for meeting these
requirements. This presentation will provide an overview of this topic,
discuss how Envitech’s WESP technology has achieved low condensable PM and metal
removal in large industrial processes and how this technology can be applied to
existing utilities.
Kevin Crosby,
Technical Director at The Avogadro Group, will present “Can your unit pass an
emission compliance test?” The measurement of emissions of filterable and
condensable PM is defined not by the control systems used but by the testing
methods used. You might control actual emissions well, yet be stymied by
biased PM test results. The biases and limitations in the test methods
should be considered when determining how your control strategy will fit with
the test results and when choosing the best testing approach, so that you may
ultimately prove compliance with the emission standards. This presentation will
include brief descriptions of how the test methods work and their biases and
limitations for measuring emissions from different sources. Case studies
will be used to illustrate problems and potential solutions for proper
measurement to prove compliance.
Tom Anderson,
Vice-President Pleated Products at TDC Filter
Manufacturing, Inc., Midwesco Filter Resources Company
To register for “Particulate and Condensable
Removal” on April 25, 2013 at 10:00 a.m. (DST), click on:
http://www.mcilvainecompany.com/brochures/hot_topic_hour_registration.htm.
Headlines for the April 12, 2013 – Utility E-Alert
UTILITY E-ALERT
#1120 – April 12, 2013
Table of Contents
COAL – US
COAL – WORLD
COMBUSTION TECHNOLOGIES/BOILER EFFICIENCY
§
Wood Group installing ECOMAX® Systems on Combined Cycle Power Plants
in US
§
ABB to supply Symphony®Plus System for One Unit at 590 MW Grazia
Deledda Sulcis in Italy
§
Metso Modernizing Automation System at Parichha Power Plant in Uttar Pradesh,
India
§
EDF selects Symphony Plus for Le Havre and Cordemais
§
Metso Automation for Huadian Jurong Xiashu Power Plant in China
GAS/OIL - US
GAS/OIL – WORLD
GASIFICATION
NUCLEAR
BUSINESS
HOT TOPIC HOUR
For more information on the Utility Environmental Upgrade Tracking System,
click on:
http://home.mcilvainecompany.com/index.php?option=com_content&view=article&id=72
McIlvaine Hot Topic Hour Registration
On Thursday at 10:00 a.m. Central time, McIlvaine
hosts a 90 minute web meeting on important energy and pollution control
subjects. Power webinars are free for subscribers to either
Power Plant Air Quality Decisions or Utility Environmental Upgrade
Tracking System. The cost is $125.00
for non-subscribers.
Market Intelligence
webinars are free to McIlvaine market report subscribers and are $400.00
for non-subscribers.
|
2013 |
|
Date |
Subject |
|
April 25 |
Particulate and Condensable
Removal |
Power |
May 2 |
Flyash Pond and Wastewater
Treatment Issues |
Power |
May 9 |
Clean Coal Technologies
|
Power |
May 16 |
Power Plant Automation and
Control
|
Power |
May 23 |
Cooling Towers |
Power |
May 30 |
Air Pollution Control Markets
(geographic trends, regulatory
developments, competition,
technology developments)
|
Market Intelligence |
June 6 |
Report from Power-Gen Europe
(update on regulations, speaker
and exhibitor highlights) |
Power |
June 13 |
Monitoring and Optimizing Fuel
Feed, Metering and Combustion in
Boilers |
Power |
June 20 |
Dry Sorbent Injection and
Material Handling for APC
|
Power |
June 27 |
Power Generation Forecast for
Nuclear, Fossil and Renewables |
Market Intelligence |
July 11 |
New Developments in Power Plant
Air Pollution Control |
Power |
July 18 |
Measurement and Control of HCl |
Power |
July 25 |
GHG Compliance Strategies,
Reduction Technologies and
Measurement |
Power |
August 1 |
Update on Coal Ash and CCP
Issues and Standards |
Power |
August 8 |
Improving Power Plant Efficiency
and Power Generation |
Power |
August 15 |
Control and Treatment Technology
for FGD Wastewater |
Power |
August 22 |
Status of Carbon Capture and
Storage Programs and Technology |
Power |
August 29 |
Pumps for Power Plant Cooling
Water and Water Treatment
Applications |
Power |
Sept. 5
|
Fabric Selection for Particulate
Control
|
Power |
Sept. 19 |
Air Pollution Control for Gas
Turbines |
Power |
Sept. 26 |
Multi-Pollutant Control
Technology
|
Power |
To register for the “Hot Topic Hour’, click on:
http://www.mcilvainecompany.com/brochures/hot_topic_hour_registration.htm.
----------
You can register for our free McIlvaine Newsletters at:
http://www.mcilvainecompany.com/brochures/Free_Newsletter_Registration_Form.htm.
Bob McIlvaine
President
847-784-0012 ext 112
rmcilvaine@mcilvainecompany.com
www.mcilvainecompany.com
191 Waukegan Road Suite 208 | Northfield | IL 60093
Ph: 847-784-0012 | Fax: 847-784-0061
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