O&M

Most power plants use some form of condenser performance-monitoring protocol. Some of those protocols are deficient because the proper instrumentation is not installed to collect the necessary data. Three case studies illustrate how collecting good condenser performance data enabled plant staff to troubleshoot problems and make good plant performance improvement decisions.

None of you reading this magazine needs an article—or new governmental regulations—to tell you that flash fires and explosions involving coal dust can cause catastrophic incidents, fatalities, facility damage, and financial consequences.

Coal combustion products often can be recycled into a variety of construction and building materials. However, first you must be able to retrieve the wet ash from a holding pond before the ash can be dried and sold.

Following safety rules is the foundation to eliminating injuries. Commonly, a safety presenter will say that safety rules are “written in blood.” At one time, such dramatic statements were a way to get attention and illustrated the seriousness of following safety rules. Today, more highly educated workers demand less drama and more facts.

This is the fifth in a series of predictive maintenance (PdM) articles that began in the April 2011 “Focus on O&M” in which the essentials of PdM were introduced. In the May and June 2011 issues, we explored specific PdM techniques, such as motor-current signature analysis and oil analysis. In the November 2011 issue, we introduced the value of thermographic analysis and its routine use. This installment focuses on ultrasonic and vibration analysis.

Natural gas–fired fleets comprising diverse turbine unit types are operating their units more these days because of the historic low price of natural gas. With increased operating hours, fleet owners are challenged to find the best ways to manage their SCR catalyst systems.

Confined space work is often considered to be one of the most dangerous types of work performed in power generation settings. Confined spaces may contain hazardous atmospheres, they can trap entrants, and they generally can increase the hazards associated with otherwise common tasks. When the risks are not recognized, workers all too often regard incidents as surprises, but the hazards of working in confined space can be predicted, monitored, and mitigated. These “accidents” are caused by unsafe conditions, unsafe acts, or both; all accidents are preventable.

Common fuel-handling problems in the power industry often result in production downtime, costing the owner perhaps up to $200,000 per hour. There are many areas within a coal-fired power plant where mishaps can cause stoppage of material flow. Here we discuss how to select the best switch technology to reduce the possibility of coal flow stoppages.

Optimizing combustion control is critical to reducing emissions and increasing plant operating efficiency, particularly for fluidized bed combustion (FBC) boiler plants burning biomass fuel that has unpredictable moisture content. The secret: measuring actual energy flow.

A new report released in early March by the North American Electric Reliability Corp. (NERC) found that loss of reactive power was the most likely outcome from a severe solar storm that was centered over North America. Significant losses of reactive power could lead to voltage instability, and, if not identified and managed appropriately, power system voltage collapse could occur, the report concludes.

It has been said that a picture is worth a thousand words. However, photos of the conflagrations that have resulted from ignition of minor lube oil leaks on a typical steam turbine room floor will leave you speechless. Full-scale physical simulations of oil fires by the insurance company FM Global leave no doubt that power plant fire prevention and mitigation is a judicious blend of art and science.

This unconventional technique for removing slag from solid fuel-fired boilers, used for more than two decades, has exploded in popularity. But the risks are very real, and not all blasters are created equal.

ProEnergy Services (PES) was recently contracted to install six Frame 7 DLN1.0 dual-fuel assemblies in Venezuela. The problem: The lead time to purchase the conversion hardware from the original equipment manufacturer (OEM) would not meet the customer’s schedule. The only option was for PES to convert the fuel nozzles removed from a gas-only unit to a dual-fuel configuration, a process that had never before been attempted.

Turbine inlet fogging has been in use now for 20 years in combustion turbine plants. It is an obvious choice for boosting power in hot, dry areas such as Nevada or Arizona, where plants have long used fogging, but it has also proven effective in many other climates.

The Philippine Coal Plant Users’ Group (PCPUG), the leading nonprofit organization involved in generating electricity in the Philippines, recently held a conference introducing its mission and vision.

American Electric Power’s Field Services Regional Service Organization augments resident power plant maintenance teams to provide outage support and non-outage balance-of-plant support. The augmentation approach adds significant value to the maintenance process, with the greatest benefits coming in the areas of expertise, cost, productivity, and ownership.

Well-organized operations and maintenance (O&M) and outage efforts enable power plants to reduce overall operating costs, improve equipment reliability, and increase long-term productivity. Experienced contractors can help plant staff maximize the success of their outages and O&M endeavors.

In order to ramp up the success of planned outages at its power plants and lower the risk of unexpected and costly problems, OG&E management has begun using the outage readiness index process. This method identifies and defines the scope of the work needed prior to the commencement of an outage and quantifies the amount of preparedness needed to implement the outage in the most cost-effective manner.

By thoroughly planning their outage strategies well in advance, Southern Company personnel are better able to achieve a number of important objectives, including improving unit economic performance, reducing unplanned maintenance outage hours, completing outages on time and within budget, and ensuring that outage workmanship is of the highest quality.

Piping at gas-fired plants has long been cleaned using compressed natural gas because of its easy availability. The big problem? It’s also explosive. The fatal 2010 blast at the Kleen Energy plant in Connecticut began a shift toward safer alternatives such as nitrogen and compressed air that is gathering increasing momentum.

Compressible fluid flow through control valves will inevitably cause some form of flow-induced vibration in the fluid system. Identifying the type and cause of the vibration requires detective work. Determining the design changes required in the valve and fluid system to prevent the vibration from occurring requires advanced analytical techniques.

The hazards of coal dust accumulation in power plants are familiar to coal-fired plant operators. Operators of plants that burn Powder River Basin coal are particularly aware of necessary housekeeping and fuel-handling practices, but any plant that allows excessive amounts of coal dust to accumulate is playing Russian Roulette with its staff and equipment.

Creating a landfill to hold dry boiler ash is a challenging proposition these days. There’s more to the project than you might imagine, as you’ll learn from this article about the development of a typical new ash landfill.

Rules requiring removal of combustible dust from the workplace will undoubtedly improve worker safety and health. A survey of equipment suppliers finds a variety of dust collection systems are available to meet just about every dust collection need in the power house.

POWER recently talked with Erika Jakobsson, a project manager at Volvo Technology in Gothenburg, Sweden, who is responsible for developing intelligent trucks in response to European Union (EU) directives.

In a power plant, the primary use of vacuum systems is to remove air and other noncondensable gases from the shell side of the condenser in order to maintain design heat transfer and thus design vacuum. If holding condenser vacuum is a persistent problem, one often-overlooked cause is an inadequately sized vacuum system.

Measuring the level of dust and fly ash collected in electrostatic precipitators (ESPs) is a very difficult technical problem. At one utility, level switches were so unreliable that operators could not trust their readings because failures were so frequent. When a switch did fail, the precipitator would often clog up, costing the utility up to $100,000 in downtime and repair costs.

The 2011 Marmaduke Award winner was CTG Universidad, a two-unit combustion turbine plant built in the early 1970s in Monterrey, Mexico. The award was made to the plant in recognition of its upgrade of one 14-MW unit to operate as a synchronous condenser, thus relaxing power restrictions caused by a lack of sufficient reactive power production in the north of the city. More reactive power production by this urban plant also allows delivery of more power produced by efficient combined cycle plants located outside the city, because it reduces the amount of reactive power that must be moved over transmission lines.

The technologies used to generate and distribute electricity will be radically transformed during the coming decade. Amid that change, the power industry must continue to meet customer reliability, safety, and cost-of-service expectations. Achieving the right balance among these often-conflicting goals is the primary focus of every utility. The Electric Power Research Institute is helping utilities achieve that balance with R&D programs for many new and emerging technologies.

For each of the past 10 years, nearly 1,200 U.S. construction workers have died as the result of injuries received on the job. Of these fatalities, 25% involved heavy equipment—most categorized as struck-by incidents. Remote sensing and visualization technology promises to improve worker situational awareness on congested and busy work sites.