Monitoring and Controlling Boiler Water/Steam Cycle Chemistry is Hot Topic Hour on Thursday, February 21, 2013
Safe, reliable and efficient operation of steam generating boilers and HRSGs requires the maintenance of physical and chemical conditions throughout the water/steam circuit that minimizes corrosion and deposit formation. This is especially true in the older plants that are predominate in our electricity production network. Deposition of contaminants, scaling and corrosion are the cause of many forced outages resulting in lost power generation or product output costing billions of dollars per year. Frequent blow-downs required because of excessive contaminants in the water/steam also contribute to lost production. Inadequate cycle chemistry will cause boiler tube and turbine blade/disc failures and flow-accelerated corrosion (FAC) throughout the circuit.
The method chosen to control the water/steam chemistry depends on the boiler or HRSG type, water/steam circuit design, materials of construction, physical parameters (temperatures, pressures, heat fluxes, etc.) and the operating cycle of the plant. In all cases, it is essential to be able to measure the key parameters of the water/steam so that operators are able to properly manage and adjust the control method (typically chemical addition) to ensure that physical and chemical targets for the water are achieved.
The following speakers will discuss how to monitor and manage boiler water/steam physical and chemical properties in order to reduce unplanned outages, reduce operation and maintenance costs and improve unit economics. The speakers will describe the instruments and technology available for monitoring water/steam properties and chemistry with a discussion of capital and operating costs and their experience with the instruments or technologies. They may also describe the various control chemicals and technologies available with a discussion of which particular chemicals or technology is appropriate for specific boiler/HRSG types and water/steam circuits.
Joe Zimmerman, Director of Marketing and Power Industry Sales Manager at Chemtrac Systems, Inc., will present “Continuous Real-Time Corrosion Product Transport Monitoring using Particle Counter Instrumentation.” The adverse effects of “particulate” material in steam cycle waters are frequently seen throughout the power generation process. Steam cycle corrosion products (transient metal oxides) can lead to deposition and equipment failure. This presentation introduces basic technologies used for continuous detection of insoluble particles at very low concentrations. When such monitoring methods are utilized, real-time corrosion product transport measurement can be implemented as a potential parameter for controlling the power plant cycle.
Greg Thomas, Key Account Manager for Nuclear Power at Hach Ultra Analytics, will present a comparison of the long time standard amperometric technology to the new optical technology for measurement of low level dO2 in steam cycle water. The presentation will briefly discuss amperometric and optical technology for the measurement of low level dissolved oxygen. Performance comparison data of the two technologies in steam cycle applications will be presented. Finally, comparisons along with advantages and disadvantages will be discussed.
David M. Gray, Senior Product Manager at Mettler-Toledo Thornton, Inc., will present “New Technology for Monitoring Cycle Chemistry.” He covers online analytical measurements of conductivity, pH, dissolved oxygen, sodium and silica. Intelligent Sensor Management incorporates digital sensors with improved performance, wider rangeability and predictive diagnostics. He will discuss how these capabilities can improve cycle chemistry monitoring while reducing maintenance.
To register for the February 21, 2013 “Hot Topic Hour” at 10:00 a.m. Central time, click on:
http://www.mcilvainecompany.com/brochures/hot_topic_hour_registration.htm.
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.
DATE Non-Subscribers Cost SUBJECT Webinar Type
February 21, 2013 $125.00 Monitoring and Controlling Boiler Water and Steam Cycle Chemistry Power
February 28, 2013 $125.00 Implementation of the Utility MACT Rule Power
March 7, 2013 $125.00 HRSG Design, Operation and Maintenance Considerations Power
March 14, 2013 $125.00 Inlet Air Pretreatment for Gas Turbines Power
March 21, 2013 $125.00 Industrial Boiler MACT Impact and Control Options Power
March 28, 2013 $125.00 Mercury Measurement and Control Power
April 4, 2013 $125.00 Fabric Selection for Particulate Control Power
April 11, 2013 $125.00 Air Pollution Control for Gas Turbines Power
April 18, 2013 $125.00 Multi-pollutant Control Technology Power
April 25, 2013 $125.00 Control Technologies for Fine Particulate Matter Power
May 2, 2013 $125.00 Flyash Pond and Wastewater Treatment Issues Power
May 9, 2013 $125.00 Clean Coal Technologies Power
May 16, 2013 $125.00 Power Plant Automation and Control Power
May 23, 2013 $125.00 Cooling Towers Power
May 30, 2013 $400.00 Air Pollution Control Markets (geographic trends, regulatory developments, competition, technology developments) Market Intelligence
June 6, 2013 $125.00 Report from Power-Gen Europe (update on regulations, speaker and exhibitor highlights) Power
June 13, 2013 $125.00 Monitoring and Optimizing Fuel Feed, Metering and Combustion in Boilers Power
June 20, 2013 $125.00 Dry Sorbent Injection and Material Handling for APC Power
June 27, 2013 $400.00 Power Generation Forecast for Nuclear, Fossil and Renewables Market Intelligence
July 11, 2013 $125.00 New Developments in Power Plant Air Pollution Control Power
July 18, 2013 $125.00 Measurement and Control of HCl Power
July 25, 2013 $125.00 GHG Compliance Strategies, Reduction Technologies and Measurement Power
August 1, 2013 $125.00 Update on Coal Ash and CCP Issues and Standards Power
August 8, 2013 $125.00 Improving Power Plant Efficiency and Power Generation Power
August 15, 2013 $125.00 Control and Treatment Technology for FGD Wastewater Power
August 22, 2013 $125.00 Status of Carbon Capture and Storage Programs and Technology Power
August 29, 2013 $125.00 Pumps for Power Plant Cooling Water and Water Treatment Applications Power

To register for the Hot Topic Hour, click on:
http://www.mcilvainecompany.com/brochures/hot_topic_hour_registration.htm.

Headlines for the February 8, 2013 – Utility E-Alert
UTILITY E-ALERT
#1111– February 8, 2013

Table of Contents
COAL – US
 Consumers Energy signs $19 Million Contract for Ductwork at J.H. Campbell 3
 Wyoming OCA supports SCR Retrofit at Jim Bridger Power Plant
COAL – WORLD
 Australia unlikely to build New Coal-fired Power Stations
 TEPCO prepares for Tender for Coal-fired Power Projects
 RP Energy allowed to begin construction of 600 MW Subic Bay Power Plant
 Ncondezi Coal to build 300 MW Power Plant in Mozambique
GAS/OIL - US
 PMFG, Inc. awarded Three SCR Orders with a Combined Value of Approximately $7.5 Million
 PA Township approves Site for 900 MW Gas-fired Hickory Run Power Plant

GAS/OIL – WORLD

 Yokogawa Receives Control System Order for Shoaiba II Combined Cycle Power Plant in Saudi Arabia
 Alstom to build 850 MW Natural Gas-fired North Bangkok Power Plant in Thailand
 Uruguay 530 MW Combined Cycle Power Plant Construction Work to begin Next Month
NUCLEAR
 Duke Energy to retire Crystal River Nuclear Power Plant
 Centrica pulls out of UK Nuclear Building Program
BUSINESS
 Fuel Tech awarded Air Pollution Control Orders totaling $4.4 Million
 Clean Coal Technologies signs New EPC Agreement with SAIC for the Construction of its 2-Ton/Hour Pilot Plant
 Sales of New Precipitator Systems Will Exceed $5.6 Billion in Asia in 2013
 Instrument and Control Market for Ultrapure Water Will Exceed $468 Million This Year
HOT TOPIC HOUR
 “NOx Control for Gas Turbines” is Hot Topic Hour on Thursday, February 14, 2013
 Upcoming Hot Topic Hours
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
The U.S and Europe are Embarked on Hundreds of Projects to Automate and Control Coal-fired Power Plants
The U.S. and Europe face an unusual situation. They must utilize existing coal-fired power plants. At the same time they are embarked on reducing CO2 emissions. Some of the biggest and most immediate CO2 reductions will come from increasing the efficiency of the existing fleet. At the same time, due to the age of many of the plants, there are big savings to be made by upgrading the control systems McIlvaine is tracking the activities of these plants in Utility Environmental Upgrade Tracking System. (www.mcilvainecompany.com)
There are 2000 boiler units generating electricity in the two regions. Few new units will be added and few retired. This means that most of these units will be continually evaluating upgrade options. Regulatory requirements and cost reduction will be the two main drivers.
Investments are ranging from SCADA systems to more sophisticated optimization systems. Neuco, for example, has a suite of optimization systems which combine to lower emissions and improve efficiency.
The benefits of control have increased as the cost of compliance with environmental laws has risen. The most recent air toxic rules (MATS) are forcing U.S. utilities to utilize extensive activated carbon for mercury removal. Reagents are also required to remove HCl. Any improvement in efficiency not only reduces coal usage but the amount of reagents needed.
Controlling ammonia consumption not only reduces costs but also build-up on air preheaters. A number of companies such as Sick and Yokogawa are supplying ammonia slip measuring instruments. Fuel Tech, CISCO and others are supplying integrated systems.
Advanced Process Control is proving its merit. Yokogawa combines the Exasmoc multivariable model predictive control package and Exapilot operation efficiency improvement package to gain multiple benefits. By combining DCS, Exapilot and Exasmoc, the workload on the operators is reduced. There is also typically a reduction in the number of process alarms.
Siemens, Invensys, ABB and others are also supplying systems to make significant efficiency improvements.
For more information on: Utility Environmental Upgrade Tracking System, click on: http://home.mcilvainecompany.com/index.php?option=com_content&view=article&id=72
Improvements in Wind Technology Continue
Steady advances are being made in technology to harness the wind to generate electricity. McIlvaine reports on these advances in Renewable Energy Projects and Update.
GE Developing Wind Blades that could be the “Fabric” of Our Clean Energy Future
In a move that could put wind energy on equal economic footing with traditional fossil fuels, GE, Virginia Polytechnic Institute & State University (Virginia Tech), and the National Renewable Energy Laboratory (NREL), will begin work on a project that could fundamentally change the way wind blades are designed, manufactured and installed.
With most of the cost of electricity for wind tied up in the initial capital investments made in the wind turbines themselves, new technology advancements that reduce these costs could substantially lower the overall cost of wind energy.
“GE’s weaving an advanced wind blade that could be the fabric of our clean energy future,” said Wendy Lin, a GE Principal Engineer and leader on the U.S. Department of Energy’s Advanced Research Projects Agency (ARPA-E) project. “The fabric we’re developing will be tough, flexible, and easier to assemble and maintain. It represents a clear path to making wind even more cost competitive with fossil fuels.”
According to GE, this new blade design could reduce blade costs 25 percent-40 percent, making wind energy as economical as fossil fuels without government subsidies.
GE’s research will focus on the use of architectural fabrics, which would be wrapped around a metal spaceframe, resembling a fishbone. Fabric would be tensioned around ribs which run the length of the blade and specially designed to meet the demands of wind blade operations. Conventional wind blades are constructed out of fiberglass, which is heavier and more labor and time-intensive to manufacture.
Advancements in blade technology will help spur the development of larger, lighter turbines that can capture more wind at lower wind speeds. Current technology doesn’t easily allow for construction of turbines that have rotor diameters exceeding 120 meters because of design, manufacturing, assembly, and transportation constraints. Wider, longer wind blades are tougher to move and maneuver, and molds which form the clamshell fiberglass structure cost millions of dollars to acquire. GE’s new fabric-based technology would all but eliminate these barriers.
With this new approach to making wind blades, components could be built and assembled on site, meaning design engineers no longer have to concern themselves with manufacturing and transportation limitations. Taken together, these improvements will help reduce start-up costs and the cost of wind-generated electric in general.
It’s estimated that to achieve the national goal of 20 percent wind power in the U.S., wind blades would need to grow by 50 percent — a figure that would be virtually impossible to realize given the size constraints imposed by current technology. Lighter fabric blades could make this goal attainable.
“Developing larger wind blades is the key to expanding wind energy into areas we wouldn’t think of today as suitable for harvesting wind power. Tapping into moderate wind speed markets, in places like the Midwest, will only help grow the industry in the years to come,” Lin went on to say.
The use of fabrics to reduce weight and provide a cost-effective cover dates back to the World War I era, when it was used on airplanes. Over the years fabric has proved to be rugged and reliable and GE has already begun using this spaceframe/tension fabric design in the construction of wind towers for better aesthetics, cost, and protection.
The $5.6 million ARPA-E project will span three years. GE’s blade architecture will be built to achieve a 20 year life with no regular maintenance to tension fabrics required.
Sandia Labs Benchmark Helps Wind Industry Measure Success
Sandia National Laboratories published the second annual 2012 Wind Plant Reliability Benchmark in October, and the results should help the nation's growing wind industry benchmark its performance, understand vulnerabilities and enhance productivity.
Until now, wind farm owners and operators had no way to compare their output with the output of similar operations. To benchmark the reliability of the U.S. wind turbine fleet and identify major causes of failures and downtime, the DOE commissioned Sandia in 2010 to build the Continuous Reliability Enhancement for Wind, or CREW, database. This is the first effort to compile a comprehensive, operator-independent dataset that accurately reflects the performance of the U.S. wind fleet.
Every year, Sandia Labs surveys the database and publishes the results to help benchmark the industry. This year, the more than 800 wind turbines studied are either producing electricity or are available to produce electricity 97 percent of the time, up from 94.8 percent in 2011.
"With better understanding of how major turbine systems are performing, wind operators can focus on improving those areas that will drive increased reliability and efficiency," said Sandia researcher and CREW team lead Alistair Ogilvie.
In 2008, a DOE collaborative published "20 percent Wind Energy by 2030." The report suggests that by 2030, wind could supply 20 percent of the nation's electricity, compared to less than 1 percent in 2007 and 3 percent in 2011. The report also discussed industry-wide risks related to lower-than-expected reliability and growing costs of operations and maintenance.
Major turbine systems include a set of three blades, rotor, shaft, generator and gearbox, and all of those components might break or otherwise need maintenance. Sandia's team is working to determine which components are the most vulnerable and help industry address those concerns to prevent downtime. The costs associated with a turbine going offline add up quickly. The owner not only loses productivity, but the cost of hiring a crane for repairs can be upward of $250,000. Since only a few cranes in the nation are large enough to handle turbine heights and component weights, it may be months before the turbine is up and running again.
Four wind plant owner/operators are participating in the development phase of the CREW project: EDF Renewable Energy (formerly enXco Service Corporation), ShellWind Energy, Wind Capital Group and Xcel Energy. The CREW team taps into turbines' existing Supervisory Control and Data Acquisition (SCADA) industrial control systems, and Sandia researchers are able to collect high-resolution data from key operating parameters such as wind speed, ambient temperatures, blade angles, component temperatures and torques. Every few seconds, a wind turbine's SCADA system captures a complete picture of how the turbine and its components are performing, compared to a defined operating environment.
Each plant is providing SCADA data to Sandia through a software tool developed by Strategic Power Systems (SPS). SPS developed the automated data collection software originally to collect high-volume data from steam and gas turbines. SPS reengineered its Operational Reliability Analysis Program, or ORAP®, tool to ORAPWind®, which collects data from wind turbines and creates detailed event logs for all non-operating time, in addition to daily summaries of operating time.
Sandia's CREW database contains data for more than 800 turbines, which have generated two terabytes of raw data, about 20 percent as large as the entire print collection of the Library of Congress. Sandia's Enterprise Database Administration Team is processing this enormous dataset into a usable database that can readily support a wide range of rapid queries.
The gathered data is used for various analyses, including public benchmark reporting and DOE reports. The DOE uses its reports to guide research and development investments by identifying critical issues and strategies to improve wind technologies.
The annual public benchmark report characterizes the operations and maintenance experience of the U.S. fleet, using aggregated reliability and performance metrics that lets owner/operators compare their plant against the CREW fleet.
The CREW Database Wind Turbine Reliability Benchmark and other Sandia wind energy publications are available on Sandia's website at http://energy.sandia.gov/crewbenchmark
GL Garrad Hassan Signs MOU with Taiwanese Industrial Technology Research Institute
As part of Taiwan’s push to develop its offshore wind resources the Industrial Technology Research Institute (ITRI) has signed a Memorandum of Understanding with leading renewable energy consultancy GL Garrad Hassan. The offshore wind resource around the Taiwanese coast is considered excellent, with more than 6,000 MW potential capacity at water depths of less than 50 meters. Earlier this year the Taiwanese government announced an extensive plan to speed up the deployment of offshore wind farm and promote green energy economics. Beginning with a demonstration project in 2015, offshore installation is planned to ramp up over the coming years and reach 1000 turbines and 3000 MW by 2030.
The Memorandum of Understanding will see GL Garrad Hassan and ITRI cooperate in the fields of wind energy technological developments pertaining to industrial technology, technology strategy, and technical information and training. Both Parties will carry out joint projects, exchange technical information and expertise in the research and development of industrial technology, facilitate technical upgrading of scientists and engineers, and explore opportunities for further cooperation in any other areas of mutual interest.
For more information on Renewable Energy Projects and Update please visit
http://www.mcilvainecompany.com/brochures/Renewable_Energy_Projects_Brochure/renewable_energy_projects_brochure.htm
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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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