Gas

How does your company prepare and share fossil plant performance data? What data are important, and how much effort is required to collect and report the data? What are the most important statistics for reporting key fossil plant operations? The latest EUCG benchmarking survey reveals the favored fossil performance metrics at several of the largest utilities in eight key categories.

A common concern for gas turbine power plants is treating exhaust gases to comply with laws restricting pollutants present in the gases that are emitted into the ambient atmosphere. The challenge for designers is to control the exhaust gas operating temperature within a range that maximizes performance of the oxidation and reduction catalysts.

European carbon trading is gradually pushing down coal-fired capacity factors, and operating costs are rising. The U.S. may not have a carbon market, but increasing regulatory requirements are having the same effect on coal-fired generation capacity factors and operating costs. In the meantime, gas-fired assets are enjoying increased usage and lower unit costs.

Though electricity generation has entered a key period of transition—as investment shifts to low-carbon technologies—world electricity demand is set to grow faster than any other “final form of energy,” the International Energy Agency (IEA) says in its latest annual World Energy Outlook.

Mitsubishi Heavy Industries (MHI) has begun converting a combined-cycle plant in Japan to prepare for verification testing of its long-anticipated J-Series gas turbine in February 2011—a system that the company claims has the most power generation capacity and highest thermal efficiency in the 1,600C turbine inlet temperature class (Figure 3). The work being carried out at the Takasago Machinery Works facility in Hyogo Prefecture (where the company’s G-Series gas turbines were tested) includes installation of the J-Series turbine, and it marks another major milestone in the technology’s development.

TransCanada Corp. on Oct. 28 officially opened its C$700 million Halton Hills Generating Station. The 683-MW 2 x 1 combined-cycle plant on a greenfield site in Ontario (Figure 5) will operate under a 20-year power purchase agreement with the Ontario Power Authority (OPA). Construction of the peaker plant started in December 2007 and was completed on time and on budget, TransCanada said.

If Hollywood were scripting the power industry story for 2011, it would be a sequel to 2010—more of the same, but just not quite as good. Natural gas gets top billing and the accolades, wind power drops to a supporting role, and new nuclear answers the casting call but has yet to get a speaking part. Coal is like Mel Gibson—a talented Oscar winner unlikely to get another leading role. In this, our fifth annual industry forecast report, the story may be familiar, but the price of admission is going way up.

Turkey, a country that has seen rapid economic growth since the 1980s, largely spurred by a shift in governmental strategy to open up markets and increase private participation, has been actively overhauling its power infrastructure to meet soaring electricity consumption. According to grid operator Turkish Electricity Transmission Co., national consumption increased to 17 billion kWh this September—an 11% increase over the 15.3 billion kWh consumed in September 2009.

A 9.5-MW gas engine unveiled by GE this October for decentralized, independent power producers in remote, hot, or high-altitude regions features a 48.7% electrical efficiency and promises to reduce lifecycle costs by lowering fuel consumption.

The CSB has made urgent recommendations to the NFPA and the International Code Council to prohibit indoor purging and require companies and installers to purge flammable fuel gases to safe locations outdoors, away from workers and ignition sources.

The University of California, San Diego has been accumulating awards for its savvy use of a constellation of power generation and energy-saving technologies. The campus already controls a fully functioning microgrid—including a cogeneration plant—and, as befits a research institution, is constantly looking for new ways to make its energy system smarter. This “living laboratory,” as campus leaders like to call it, demonstrates what it takes to build a smarter grid and why the effort is worth it.

Microturbine technology has evolved from early systems of 30 kW to 70 kW to today’s systems, which can have individual ratings of 200 kW to 250 kW. Packages up to 1 MW are now available that can be assembled into multipac units for projects of 5 MW to 10 MW. These modern units are packaged with integrated digital protection, synchronization, and controls; they produce high combined heat and power efficiencies; and they are capable of using multiple fuels.

At the Ras Laffan Power Co. facility, the 756-MW net combined-cycle plant and the integrated 40 million gallons per day desalination plant are working in tandem to provide abundant, reliable electricity and desalinated water to residents of the State of Qatar, the most prosperous nation in the Middle East.

There’s nothing slow about the fast-track operations at the new 870-MW Sloe Centrale Power Plant. The combined-cycle plant is designed for 250 starts per year and is capable of supplying power to the grid within a mere 30 to 40 minutes. In addition to its impressive rapid load response, the gas-fired plant produces low CO₂ and NO_x emissions by using the latest technology. It also attains an efficiency of 59%.

Now that the 412-MW Timelkam Power Plant has replaced a 47-year-old coal-fired power plant located in the Vöcklabruck District, northern Austrians can bid auf wiedersehen (goodbye) to high levels of air pollution. Compared to its predecessor, the new gas-fired combined-cycle plant has dramatically cut CO₂ and NO_x emissions and produces seven times more energy.

The 3,600-MW West County Energy Center, with two recently commissioned power blocks and a third just entering start-up, is the first “greenfield” combined-cycle plant constructed by FPL since the 1970s. Thanks to FPL’s long history with repowering projects, the project team commissioned Unit 2 seven months early, with no operator errors during start-up. At just over $600/kW, the cost of the plant was a bargain.

Renewable electricity generation has many environmental advantages, but adding large amounts of far-flung renewable resources to a grid requires increased operating flexibility from dispatchable generators when the wind doesn’t blow or the sun doesn’t shine. One promising option: A combined-cycle plant based on Alstom’s GT24/GT26 combustion turbine can be “parked” at approximately 20% plant load while producing emissions comparable to those during baseload operation—with little loss in thermal efficiency. When demand returns, the combined cycle can return to baseload within minutes.

In 2010, U.S. wind power development has slowed, coal-fired power development remained stalled, and the much-awaited renaissance of nuclear power took a few tentative steps forward. That left natural gas power development as the last man standing.

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GE launched what it is calling the world’s first two-stage turbocharged gas engine this June.

We first reported on combined-cycle plant reliability concerns due to erosive wear and flow accelerated corrosion (FAC) in heat-recovery steam generator (HRSG) pressure parts at the 1999 EPRI Maintenance Conference. More than 10 years later, these damage mechanisms remain significant contributors to forced outages, pressure part repairs, and major component replacement.

The UK grid, focused on adding valuable renewable generation, will rely on natural gas–fired generation for many years to come. One of the most recent additions is the Langage Power Plant, designed for quick response and low load “parking” at night while remaining below air emissions limits. With an extraordinary architectural design that blends into the natural surroundings, Langage is now a local landmark.

The Panoche Energy Center is a 400-MW simple-cycle power plant using four of General Electric’s GE LMS100s with fast-start capability. Dispatched by Pacific Gas & Electric to meet regional power and grid stabilization needs, the project entered commercial service two months earlier than planned. Panoche is the largest LMS100 peaking facility in the U.S.

This May, following two years of construction, Siemens Energy put into operation Irsching 5, an 847-MW advanced combined-cycle power plant near Ingolstadt, Germany. The plant’s owner, Gemeinschaftskraftwerke Irsching GmbH—a joint venture of E.ON, Mainova, and HEAG Südhessische Energie—features two SGT5-4000F gas turbines, one SST5-5000 steam turbine, three hydrogen-cooled generators, electrical systems, and Siemens’ SPPA-T3000 instrumentation and control system.

When heat exchanger tubes—sometimes numbering a thousand or more per unit—begin to crack or wear, the effects can lead to a cascade of subsequent failures in adjacent tubes. If too many tubes are plugged, heat exchanger effectiveness is compromised, and power generation may be curtailed. If conventional mechanical plugs are used, they can break loose, leak, and fail. At that point, the replacement of a very costly heat exchanger is imminent.

Power plant operators, especially those located in countries with enforceable carbon emissions standards, are concerned about their CO₂ emissions. But for Helsingin Energia—which provides power, heating, and cooling for Helsinki, Finland’s 300,000 residents—the main concern is local warming, not global warming. In Helsinki, temperatures on midsummer afternoons only reach an average 21C, and for half the year daytime temperatures are below 10C.

Stacks at power generating stations may be low maintenance, but they are not no maintenance. The cost of preventing corrosion may be as little as $10,000, but the cost of repair or replacement could be many times that or even put your plant out of commission until the stack problem is corrected.

Luminant used remnants of the ill-fated Twin Oaks and Forest Grove plants (which were mothballed more than 30 years ago) to build the new two-unit 1,600-MW Oak Grove Plant. Though outfitted with equipment from those old plants, Oak Grove also sports an array of modern air quality control equipment and is the nation’s first 100% lignite-fired plant to adopt selective catalytic reduction for NO_x control and activated carbon sorbent injection technology to remove mercury. For melding two different steam generators into a single project, adopting a unique and efficient “push-pull” fuel delivery system, assembling a tightly integrated team that completed the project on time and within budget, and for completing what was started almost four decades ago, Oak Grove Power Plant is awarded POWER magazine’s 2010 Plant of the Year award.

Eliminate waste in coal, gas, or nuclear power plant construction through a holistic application of lean principles.

The gas-rich emirate of Qatar, holder the world’s third-largest gas reserves, inaugurated another massive 2,000-MW gas power plant in the industrial city of Mesaieed, south of the capital Doha this May.