POWER

When a blackout shuts down a factory, the impact isn’t apparent to the public. But lose power at an international airport, and thousands of angry travelers and the people waiting for them won’t be interested in excuses. The Greater Toronto Airports Authority learned that lesson in August 2003. Ten months later, it began building a 117-MW cogeneration plant that is now capable of supplying all of its energy needs—not just electricity, but space heating and chilled water as well.

The rationale for a typical cogeneration plant is clear: Supply some power, and maybe some steam, to an industrial host and save energy dollars on both sides of the fence. But integrating a cogen plant that also produces hydrogen with a major refinery that operates 24/7 is a job best left to a company with diverse and proven technology skills. The Air Products Port Arthur II project proves that such a job can be done right. Accordingly, it is one of POWER’s natural gas–fired Top Plants of 2007.

Since going commercial this June, Port Westward Generating Plant has taken its rightful place as one of America’s most efficient power stations. It is now helping to satisfy Portland General Electric’s summer demand reliably and cost-effectively. What differentiates Port Westward is its pioneering use in the U.S. of Mitsubishi Heavy Industries’ G1 class combined-cycle combustion turbine.

Not every facility that POWER singles out as a Top Plant has a unique design. Some, like this one, may be recognized for an excellent operations record and being a good corporate citizen. At Tenaska Virginia Generating Station, a formal program to make O&M personnel aware of best industry practices—and apply them on the job—has shortened the plant’s start-up time and elevated its availability, making it much more dispatchable and profitable.

The infrequent or improper introduction of biocides into a plant cooling system may make fouling within it worse, by creating thick biofilms that can foster corrosion, reduce heat transfer, and increase water pumps’ operating costs. At the other end of the spectrum, overuse of biocides can waste expensive chemicals. Optimizing the quantity, frequency, and type of dosage can improve both the health of a cooling system and its plant’s bottom line.

Ongoing research into experience with plant- and fleet-level software reveals that these applications work side by side but do not necessarily function as an integrated “knowledge management” system. On the supplier side, the industry continues to be fragmented, with individual programs governing a narrow part of the overall plant.

September 1886 Four years after this magazine was launched, the editors reviewed the latest improvements to industrial boilers, beginning with the Backus furnace (Figure 1). 1. The Backus furnace. “This furnace is provided with a brick arch placed just back of the fire-doors, that is intended to deflect the currents of air that are admitted […]

Not long ago, most utility investors considered California’s electricity policies too iconoclastic to support. Driven by far-left environmentalists and overzealous regulators, those policies have made it nearly impossible to build new power plants in the state, despite the urgent need for them. Now, however, with growing proof that global warming is real and with Americans […]

This July, an underground steam pipe near Manhattan’s Grand Central Terminal ruptured and spewed a scalding brown geyser of steam and debris higher than the nearby 77-story Chrysler Building. The blast, which injured 30 people, created a 40-foot crater at street level that swallowed a tow truck. A similar explosion in 1989 killed three people. […]

This August, Peabody Energy’s 1,600-MW Prairie State Energy Campus project in Illinois won a major federal appeals court decision, removing the last obstacle to groundbreaking. The six-year regulatory review process ended with an unsuccessful Sierra Club challenge to the $2.9 billion project’s air permit. The decision is sure to reverberate across the nation, and I […]

Every step forward in underground U.S. mine safety in the 20th and 21st centuries has been on the backs of mangled and dead coal miners. That grisly observation is unassailable. Following the August tragedy at the Crandall Canyon mine in Utah that killed six miners and three would-be rescuers, the federal Mine Safety and Health […]

Burning Powder River Basin (PRB) coal can be a curse or a blessing, depending on your attention to the details of plant design and operations. One disadvantage of PRB coal combustion is the abundance of bottom ash and flyash generated as a by-product. Handling and properly disposing of the ash can be challenging and costly. […]

Lansing Board of Water & Light (LBW&L), which has generated electricity since 1892 and steam since 1919 in mid-Michigan, primarily serves the city of Lansing’s business district and all state government buildings in the downtown area. But one of the municipal utility’s plants, Moores Park, has an additional and very important steam customer: General Motors’ […]

Every day, while driving to his job at PacifiCorp Energy’s Dave Johnston plant near Glenrock, Wyoming, Cole Harris used to wonder as he neared the station how opaque Unit 3’s stack emissions would look. Until a few years ago, Unit 3 (Figure 3) had trouble staying at or below opacity limits set by the state. […]

Since ratification of the Clean Air Act (CAA) in 1970, U.S. utilities have made steady efforts to install pollution control equipment to curb power plant stack emissions. The CAA Amendments of 1990 raised concerns at the time about the industry’s ability to install a large number of flue gas desulfurization (FGD) systems, or scrubbers, in […]

In Part I of this two-part report ( COAL POWER, July/August 2007, p. 22), we introduced the integrated R&D effort by the U.S. Department of Energy’s National Energy Technology Laboratory (DOE/NETL) to improve understanding of the mechanisms of mercury (Hg) capture and retention in flue gas desulfurization (FGD) systems and the fate of Hg in […]

Europeans didn’t know that corn existed before Columbus "discovered" America. It had been cultivated by indigenous North Americans for thousands of years before the Italian brought home what was to become a favorite food for many. The more adventuresome even figured out how to distill corn into something more to their liking. Fast-forward five hundred […]

PG&E mounts tidal power project / GE F-class turbine breaks record / Iowa welcomes ethanol-fed hog / NYPA upgrades pumped-storage plant / Bush blesses Browns Ferry 1 restart / Shearon Harris looks to live on / Nevada bets on solar thermal / Climate models questioned / POWER digest

Reaction to reactor comment On page 34 of your April article on nuclear power, the author mischaracterized the maturity of one of the new reactors that have been submitted for NRC approval. The statement, "None of the advanced reactors that the NRC has certified (by reviewing engineering documents) has a performance record," is incorrect. GE’s […]

Stop valves from leaking money / Integrating plant and equipment models / Pricing priceless knowledge

Southern California Edison Co. (SCE) is requesting regulatory approval to recover over $50 million from ratepayers to analyze the feasibility and cost of a "commercial-scale" clean hydrogen power generation (CHPG) facility that would gasify coal to fuel a combined-cycle power plant and sequester the associated carbon emissions underground. If the study demonstrates the CHPG technology […]

MidAmerican Energy Co. and its project partners are convinced that supercritical coal-firing technology’s inherently higher efficiency and lower CO₂ emissions no longer come with a price: reduced reliability. Their Walter Scott, Jr. Energy Center Unit 4, the first major new supercritical plant in the U.S. in more than 15 years, is POWER’s 2007 Plant of the Year.

The Northern Wood Power Project permanently replaced a 50-MW coal-burning boiler at Public Service of New Hampshire’s Schiller Station with a state-of-the-art fluidized-bed wood-burning boiler of the same capacity. The project, completed in December 2006, reduced emissions and expanded the local market for low-grade wood. For planning and executing the multiyear, $75 million project at no cost to its ratepayers, PSNH wins POWER’s 2007 Marmaduke Award for excellence in O&M. The award is named for Marmaduke Surfaceblow, the fictional marine engineer/plant troubleshooter par excellence.

By design, combined HP-IP turbines have a small amount of internal leakage from the high-pressure turbine to the intermediate-pressure turbine. As turbines age, the leakage increases considerably and becomes excessive, creating a heat rate penalty and possibly a reliability problem. Last month we explored the symptoms and causes of steam leakage within GE steam turbines and how to correct the problem. In Part II, we examine the same issues for Westinghouse and Allis-Chalmers turbines from both theoretical and practical angles.

With U.S. mercury regulations pending and control technologies in the full-scale demonstration stage, accurate and reliable measurement of mercury in flue gas is becoming more important than ever. This article compares the results of field measurements of commercially available mercury monitors to approved reference methods. A key but not-so-surprising finding: Not all mercury monitors are created equal.

Several states have mandated faster and/or deeper reductions in plant mercury emissions than those called for by the Clean Air Mercury Rule. Unfortunately, differences between plants make accurate evaluation of control options difficult. In most cases, even statistically based Hg emission models don’t pass muster because they don’t account for the dynamic chemical behavior of Hg species in gas cleaning systems. This article describes one system evaluation tool that has been validated using Hg field test data from 50 full-scale flue gas cleaning systems. It is already being used by TVA and other utilities.

The intended use is the primary consideration (even fuel is secondary) when choosing an on-site energy system. Whether the need is for power alone or for heat as well, distributed generation plants have delivered lower energy costs and improved reliability to industrial and commercial customers worldwide. Following are six case studies of reciprocating engine systems that highlight their versatility.

Have you bought electrostatic or agglomeration equipment to rid your turbine oil of varnish deposits, but its varnish potential rating failed to improve? Or, after an initial drop, has the varnish potential returned to its previous level? Even worse, have you had recurring valve sticking problems after making a sizeable investment to "solve" this problem? Welcome to the world of soluble varnish caused by autodegradation. Read the unvarnished truth about varnish and how to get rid of it for good.

Steve Elonka began chronicling the exploits of Marmaduke Surfaceblow—a six-foot-four marine engineer with a steel brush mustache and a foghorn voice—in POWER in 1948, when he raised the wooden mast of the SS Asia Sun with the help of two cobras and a case of Sandpaper Gin. Marmy’s simple solutions to seemingly intractable plant problems remain timeless. This Classic Marmaduke story, originally published in 1958, illustrates that big problems often have simple, but ingenious, solutions.