Gas

The new, 424-MW Castejon 2 combined-cycle plant designed and built by Alstom was recently given its provisional acceptance certificate. Alstom used its “Plant Integrator” approach to fast-track delivery of a plant just like Castejon 1, which averaged 98% availability during its first three years of operation. That kind of performance is crucial to generators operating in the Spanish merchant power market—or any market.

Hot reheat steam bypass actuators are some of the most critical, yet least understood components in a typical combined-cycle plant. If you’re using pneumatic actuators to stroke your main steam or hot reheat bypass valves in a cascading bypass system, you’re behind the times. Here’s a way to get better control of the bypass process, shorten unit start-up and train blending times, and decrease your plant’s heat rate—all at the same time.

Predicting combined-cycle system longevity and determining optimal maintenance intervals at the same time is difficult: It requires balancing repair costs against the risk of trying to squeeze that last bit of life out of some component before it fails. One solution to the problem is to extend coverage of an equivalent operating hours (EOH) preventive management program for turbines to the entire plant.

DOE scraps FutureGen / U.S. nuclear plants have record year / Westinghouse wins TVA contract / UniStar Nuclear to file for COL / AEP ranks second in U.S. construction / China moving to the driver’s seat / New solar cycle poses risks / Dutch favor power from natural gas / POWER digest / Corrections

Developing power projects has become less a technical challenge and more an exercise in developing good relationships among all the stakeholders. If a community understands the need for a new plant and is involved in its development process, the odds of a successful project increase.

FutureGen picks Mattoon, Ill./Duke applies for first greenfield COL/PPL to work with UniStar on another COL
/Areva seeks NRC certification of its reactor/Mitsubishi also in line at the NRC/PV project shines in Nevada/SunEdison commissions Colorado PV plant/Big concentrating solar plant proposed/Super Boiler celebrates first anniversary/Small fuel cell uses JP-8 jet fuel/POWER digest

All fossil fuels carry some risk with their reward of an energy density that’s sufficient for producing electricity economically. For coal and natural gas, that threat is a fire or explosion. However, the risk of an explosion isn’t limited to gas-fired plants. Gas poses a threat to any plant that uses the fuel, even in small quantities for heating. Here’s an overview of what you should be doing to keep gas pipelines from corroding and exploding.

Dominion applies for new Virginia reactor / ABB commissions world’s largest SVC / Google Earth adds air quality data / Alstom supplies integrated solar/CC project in Morocco / DOE updates coal plant database / Dam the Red Sea? / Complying with CWA Section 316

In our second annual report on the state and future of the U.S. power generation industry, we combine the considerable experience of POWER’s editorial staff with the market savvy of Industrial Info Resources Inc. (see next story) to preview the industry’s direction in 2008. We anticipate that the specter of carbon control legislation will hobble coal and make renewables the hot ticket while nukes continue to inch forward in a generation market that is basically treading water.

Industrial Info Resources’ strengths are tracking capital projects and cost projections and providing intelligence about the power generation market, among others. IIR has used its large industry databases and numerous industry contacts to develop its outlook for 2008. Here’s what you should expect and plan for this year.

TVA may revive Bellefonte / GE’s globetrotting Jenbaches / Largest PV plant taking shape / When will PV be competitive? / Siemens goes to the wall with solar / Breakthrough in metamaterials / POWER digest

Siemens ships first blade from U.S. plant; GE’s frames hit 1,000; Battery problems hit hybrid EV programs; Solar thermal rebounds in California;Peabody’s Illinois coal plant gets green light;EPA could sink 278-MW CFB unit; Longest-serving NRC commissioner dies at 58; POWER digest; Readers talk back; corrections

October 1886 In the late 19th century, efficient combustion of solid fuels was achieved more by trial and error than by a fundamental understanding of stoichiometry and staged combustion. Boiler manufacturers took many different approaches to the challenge. Some made sense; others didn’t. In which category does the design described below fall? In 1886 the […]

Constellation files partial COL / IAEA scrutinizes shaken Japanese nuke / Wave energy of the future? / New GE plant reigns in Spain / Solar house competition heats up / Oxygen-blown IGCC, at micro-scale / Turning corncobs into ethanol / Court blocks gas attack on coal project / New advanced energy initiatives / POWER digest

Bahrain began privatizing its electricity and water-supply sectors three years ago, and the Al Ezzel Power Plant represents the first fruit of that strategic shift. The 950-MW plant, powered by two identical 2 x 1 combined-cycle units that burn natural gas, went commercial in May of this year. The plant now supplies about half of the national grid’s demand. The success of this fast-track project demonstrates the advantages of free markets and the wisdom of bringing in experts to build new capacity.

This plant’s main claim to fame: It marks the commercial debut of GE’s 100-MW LMS100 gas turbine-generator. According to Basin Electric, over the unit’s first year of service it has demonstrated top-notch operating flexibility in peaking, mid-range, and baseload service, thanks to capabilities such as 10-minute cold start-ups and minimal impact on heat rate at partial loads. In addition to hosting the first LMS100, Groton Generating Station earns recognition as one of POWER’s Top Plants for the attention its design pays to reliability and resource planning.

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.

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

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.

Siemens, E.ON to test world’s largest GTG / Midwest to add 76-MW peaker in Kansas / Tapping the sun near Phoenix / Georgia Tech developing 3-D PV nanocells / Wind farms with hydrogen backup? / BNSF , union come to terms / IPL to buy 200-MW wind project / India to improve environmental monitoring / POWER digest

Gas turbine manufacturers aren’t selling as many machines today as they did in the hyperactive 1990s. But they are still continuing to refine G-Class technology. It has been about eight years since the first steam-cooled SGT6-6000G from Siemens Power Generation entered service. Take a quick tour of what must now be considered a mature gas turbine technology.

World’s largest PV plant now in Portugal; latan 2 construction may resume; Allegheny to scrub Fort Martin plant; TVA will clean up big Dutch CC plant; Connecticut blesses six fuel cell projects; DOE approves IGCC plant in Florida; FERC relicenses Osage hydro plant; A nanotech perpetual motion machine?; POWER digest

Control pollution and slagging on a shoestring / Keeping HRSGs young, cool, and clean / Natural air conditioning

The 2005 amendment to the 1978 Public Utility Regulatory Policies Act created some unique challenges for the design of cogeneration plants in general and combined-cycle cogeneration plants in particular. Because utilities are no longer obligated to buy electricity at "avoided cost" from qualifying facilities, plant owners must simultaneously balance power and thermal demand efficiently and economically. Here’s a prescription for your next plant design.

Winter storms ravage Nebraska grid / Waste-fired plant coming to Arizona / Wartsila lands jobs in Azerbaijan, Sweden / Yet another controversial LNG project / Siemens lands two-gasifier order in China / IndyCars drink nothing but ethanol / New Otto/diesel engine to debut in Russia / POWER digest / Readers talk back

With domestic reserves of natural gas declining and demand for gas rising, imported liquefied natural gas will increasingly fill the shortfall in U.S. pipeline supply. More than 40 LNG receiving/regasification terminals on three coasts are in various stages of development. Yet many questions about the operational and emissions impacts of the "hotter" LNG imports on today’s cleaner-burning gas turbines remain unanswered.