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WHAT YOU NEED TO KNOW ABOUT CHP
the magazine of power generation
119
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February 2015 www.power-eng.com
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FEATURES 119
VOLUME
22 The Coal
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Ash Rule
Learn how the Environmental Protection

Agencys recent ruling will affect the way power
plants manage coal combustion residuals.
14
CHP Offers a Competitive Edge
Combine heat and power is a highly efficient form of generation used to power
a wide range of industries. Learn more about this emerging market from experts
who specialize in CHP.
MARKETING MANAGER Rachel Campbell

(918) 831-9576 rachelc@pennwell.com
30
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Power Engineering
Best Boiler
Cleaning Practices
Maintaining a clean boiler is important to a

plants operating efficiency. Heres a review
of some the techniques and strategies
available to power producers.
NATIONAL BRAND MANAGER Rick Huntzicker

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VICE PRESIDENT Mark C. Wilmoth
No.2, February 2015
34
Comparing Natural
Gas and Diesel
Generator Sets
Our expert offers a comparison of natural

gas and diesel generators and details the
operating realities associated with both fuels.
40
Valve Repair in the Heat

Recovery Steam Generator
Advances in gas turbine technology and efficiency have placed enormous

demands on critical valves in thermal generation systems. Learn more about the
cost of repair and replacement.
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FEEDBACK
Letter to Editor:
Your recent opinion article was on point; I have been commenting for years that industry and universities need to be working
together to educate the new crop of students about the myriad of opportunities in the electric and utility industry.
No longer is our industry one of stodginess and simple E=IR knowledge. We need skills in many areas going forward. Smart grids,
data analysis and electronic relays open the door for multiple skills. Industry and universities should begin strategizing on work
force requirements. When I graduated in the late 60s, many universities had strong programs related to the power industry. Many
of those have faded away, and a new set of programs should be developed.
Intern programs are a good way to both develop replacements for an aging work
LES ON
WABDIS
RENEDTA
CUSSI
A ROUN BLE
0 GENERATION
force and expose students to the opportunities in the power industry. Until I arrived
-GENES20
ER
POWER
POW
IN
ANI
THE BEST COMP
at my current workplace, there was not an intern program in place, but we have now
embarked on one that is a positive experience for the intern and for the company.
I have to take exception to one of your comments toward the last of the article.
Many of us who are still working at retirement age are vitally interested in pushing for
changes that can improve the industry we have invested our careers in. Quite honestly,
we can push for positive changes more easily than those just starting a career - the less
e of po
to lose concept. We are interested in the future of the industry and the exciting changes
the magazin
we see taking place that open it to motivated folks in not just engineering, but other
areas such as IT, actuarial, and marketing.
Thanks for a very timely article.
201
Jim Franklin
Engineering Manager
of
Letter to Editor:
I read with interest your opinion piece in the December 2014 issue of Power Engineering.
Here in Nova Scotia, we also see a problem with the supply of Power Engineers (stationary engineers). This affects the operation of power plants, hospitals, and manufacturing
firms, as under law, we need qualified Power Engineers to operate these facilities. You need
a ticket to perform these functions.
As people retire, there are less and less qualified personnel to fill the positions.
Add to that, there is a lot of work required to study and pass the examinations that are
mandatory to rise to a First Class Power Engineer.
I was president of Engineers Nova Scotia, the licensing body for professional engineers
back in 2008. At a seminar, the looming skills deficit was discussed even back then. I sat in on
a discussion that related to the 2006 census information here in Canada.
As the baby boomer people in the age group 55-70 started retiring in droves, we found
that the equivalent population in the 20-35 year bracket only accounted for about 50 percent
of the older bracket. So even if we employed all the young people, wed still be short on total
numbers.
Before coming to work here for CBCL Limited, I was a plant engineering person for Michelin
Tires for 28 years.
Even companies like Michelin are now struggling to replace retiring employees.
One of Michelins biggest success stories here in Nova Scotia was that people came and stayed for 30 years. Now one of its biggest
challenges is that people came and stayed for 30 years; and now they want to retire. When your turnover rate jumps from 1 percent
to maybe 12 percent in just a few years (due to retirements), how do you easily handle that?
And passing on 30 years of knowledge to a newly hired person just cant happen overnight.
Conrad LeLivre, P.Eng.
Safety Coordinator, CBCL Limited
2
www.power-eng.com
14
OPINION
Solar Inequity
BY RUSSELL RAY, CHIEF EDITOR
olar power accounted for more

than a third of new generation
built in the U.S. during the first
nine months of 2014. Whats more, the
U.S. installed more than 1,300 MW of
solar photovoltaic (PV) capacity in the
third quarter, up 41 percent compared
with the same quarter in 2013, making
it the second largest quarter for solar installations in the history of this emerging market.
In just five years, U.S.
solar capacity has grown
a whopping 993 percent to 17,500 MW. The
growth stems from subsidies for rooftop solar
panels and net metering
programs that require
utilities to purchase the
excess power produced
by homes and businesses
at a set retail rate.
Although this formula
has been very effective, it
is not sustainable at the
pace the industry is growing and should
be reconstructed to reflect the realities of
maintaining and upgrading a grid used
by rank-and-file citizens. The breakneck
growth of solar PV is pinching the bottom lines of utilities in state after state.
Battles between utilities and the manufacturers of solar panels have erupted
in several states, where utilities have requested permission to charge customers
who generate their own power monthly
fees to pay for the maintenance and upkeep of a distribution and generation system that everyone still relies on.
The rules for net metering programs
and solar incentives should be revisited
and reassessed due to vastly different
4
circumstances caused by this solar revolution. Net metering programs were

never meant to be permanent. Regulators have a responsibility to consider
the rapid growth of distributed solar
and the subsequent cost to utilities
and their customers.
The growth of distributed solar,
spawned by years of generous incentives,
is affecting utilities ability to pay for the
up-keep of distribution and generation

assets because the cost of operating and
maintaining the infrastructure is not collected from customers participating in
net metering programs.
Just last month, House and Senate lawmakers in Virginia voted to repeal that
states standard for renewable generation,
which required utilities to get 25 percent of their generation from renewable
resources by 2025. In Oklahoma, Gov.
Mary Fallin enacted a law enabling utilities, upon approval of state regulators,
to charge customers who have installed
solar panels on their home a monthly
fee. In addition, Oklahoma, Kansas and
Ohio may alter their standards for the
amount of renewable generation a utility is required to provide customers.

The battle over solar incentives, renewable standards and net metering
programs is sure to escalate this year.
A well-funded campaign against the
policies that have fueled the breakneck
penetration of solar power is being
waged by utilities and their supporters.
The consequences of these battles
will be significant for both
sides. For the solar industry, sales could plunge if
the payments consumers
receive from utilities are
eliminated or fall to a level
that doesnt justify the cost
of installation. For utilities, revenues will continue
to fall and consumer rates
could skyrocket if they are
unable to convince state
regulators to create a system that accounts for these
disruptive forces.
The current net metering
structure creates a financial burden for
customers who cant afford to install
expensive solar panels on their homes.
For those customers, the cost of electricity will get more expensive as they
pay a larger share of the cost to operate
and maintain the nations grid.
With 578,000 individual solar installations in the U.S., solar accounts
for 17,500 MW of capacity, less than 2
percent of the nations total capacity.
The debate over solar is about creating a just cost structure that is fair to
both sides. This fight is expected to
take place in more than two dozen
states. The path to common ground
will surely be turbulent.
www.power-eng.com
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INDUSTRY NEWS
KCP&L to stop burning

coal at six units
Kansas City Power & Light (KCP&L)
said it will stop burning coal at three of
its coal-fired power plants.
will be created
The project is expected to be completed
within 30 months, and upon completion, the Norte III project will be the largest combined cycle plant in Mexico.
The construction investment will be
around $700 million, which will be financed with a mix of equity and nonrecourse debt.
Dominion plans large-scale

solar project in Virginia
The utility said it will end the use of
coal at the 96-MW Lake Road 6, the 170MW Montrose 1, 164-MW Montrose 2
and the 176-MW Montrose 3; and the
48-MW Sibley 1 and 51-MW Sibley 2
units in order to comply with recent U.S.
Environmental Protection Agency emission requirements. Lake Road 6 already
has the ability to burn natural gas and
will switch to gas by 2016. Montrose 1 is
scheduled to close at the end of 2016. The
Sibley units will shut down at the end of
2019 and Montrose 2 and 3 will close at
the end of 2021.
KCP&L said it was more cost effective
to shut down the smaller units to comply
with environmental regulations instead
of retrofitting them.
Abengoa to develop
largest combined-cycle
plant in Mexico
Abengoa was chosen by Mexicos
Federal Electricity Commission to develop the Norte III Project, a 924-MW
combined-cycle power plant in Ciudad
Jurez, Mexico. The project is part of the
Mexicos National Investment Plan 20142018.
Under the $1,550 million contract,
Abengoa will handle the engineering, design and construction of the plant, as well
as the operation and maintenance for 25
years. During the peak of construction,
more than 2,000 direct and indirect jobs
Dominion Virginia Power said it filed

an application with state regulators to
build the states first large-scale solar project.
The filing outlines plans for a 20-MW
solar array on 125 acres near the Remington Power Station in Fauquier County.
The power project would contain approximately 90,000 photovoltaic panels. At peak capacity, it would generate
enough power for 5,000 homes. Its estimated in-service date is October 2016.
In a statement, Gov. Terry McAuliffe
said the project would nearly double Virginias production of solar energy.
Alabama carbon capture

pilot project begins testing
The National Carbon Capture Center(NCCC) began pilot-scale testing of
a cost-effective advanced technology for
capturing carbon dioxide (CO2) from
flue gas in Wilsonville, Alabama.
Under an agreement with the National Energy Technology Laboratory,
Linde LLC is operating a 1-MW pilot
project that is expected to capture 30
tons of CO2 per day. The project will utilize Linde-BASF CO2-capture technology
on coal-derived flue gas. The technology will absorb CO2 from the flue gas
at a low temperature in the absorption
column; the solvent will then transfer to
a stripping column where steam is added
to heat the solvent, reversing the chemical reaction and releasing high-purity
CO2 for compression and pipeline transport.

The NCCCs testing facility also
includes a post-combustion carboncapture facility from Alabama Powers
Gaston plantUnit 5, an 880-MW pulverized coal unit.
Dynegy delays power

plant acquisition
Dynegy said the Federal Energy Regulatory Commission (FERC) requested additional information to process and approve the companys acquisition of Duke
EnergysMidwest Generation assets and
retail business and EquiPower Resources
and Brayton Point Holdings assets.
The company said it plans to respond
within the 30-day period. The request is
expected to delay the transactions, which
were scheduled to close by the end of the
first quarter 2015.
Duke Energy announced that Dynegy would buy its non-regulated Midwest
Commercial Generation business for
$2.8 billion in cash on Aug. 22, 2-14. The
transaction includes ownership interests
in 11 power plants with a capacity of approximately 6,100-MW and Duke Energy
Retail Sales, the companys competitive
retail business in Ohio.
B&W to supply supercritical

coal-fred boiler to Vietnam
power plant
Babcock & Wilcox Power Generation
Group Inc. will design and manufacture a supercritical coal-fired boiler and
selective catalytic reduction system for
Vietnams Duyen Hai 3 Extensionpower
plant.
The contract was awarded by Japanese
contractor, Sumitomo Corp., which will
build the 688-MW plant for Power Generation Corp. 1, a subsidiary of Electricity
Vietnam.
This is B&Ws sixth steam generator in
Vietnam and we are pleased to contribute
www.power-eng.com
A Division of THE HILLIARD CORPORATION
INDUSTRY NEWS
to the nations energy needs, said Elias

Gedeon, senior vice president and chief
business development officer at B&W.
The plant is expected to reach commercial operations in mid-2018.
Pattern increases share in

Indiana wind farm project
Pattern Energy Group Inc. increased its
Right of First Offer (ROFO) list on a 150MW wind energy project in Indiana.
Pattern added 116 MW of owned interest in the Amazon Web Services Wind
Farm, formerly known as the Fowler
Ridge Wind Farm, to its list of identified ROFO projects from Pattern Energy
Group LP. The wind project has a 13-year
power purchase agreement to supply Amazon Web Services with the output.
Pattern Development expects to begin
construction of the project in April with
operations scheduled in late 2015 or early 2016. Pattern Development owns 100
percent of the project, and Pattern Energy
will acquire a 120-MW share.
GE to provide gas turbines

for TVAs Allen Plant
GE will supply two natural gas-fired
turbine generators to help in the replacement of a coal-fired power plant
in Tennessee.
The Tennessee Valley Authority is

replacing three coal-fired units at the
Thomas H. Allen Fossil Plantin Tennessee to reduce coal emissions under new
rules from the U.S. Environmental Protection Agency. GE will provide the two
7HA.02 gas turbines for a combined-cycle power plant that will reduce carbon
dioxide emissions by approximately 65
percent and reduce both sulfur dioxide
and nitrogen oxide emissions by over 95

percent. The Allen plant will have the capacity to generate 1,000 MW of power in
combined-cycle mode.
Mexico investing
$14 billion in wind power
Mexico will invest $14 billion to
build eight wind farms over the next
three years, with a combined generation capacity of 2,300-MW.
The investment will come on the
back of the $5 billion already injected
into the wind energy sector wind energy sector,according to Business News
Americas.
Mexico currently has 2,551-MW of
installed wind capacity and will add
732 MW this year, with six wind farms
under construction, according to the
countrys wind energy association.
Wood pellet company to

build biomass power plant
Turboden was chosen to supply a
biomass-based Organic Rankine Cycle
power plant in Maine.
Maine Woods Pellet Co. picked Turboden to develop an 8-MW plant that
would convert the heat of thermal oil
generated by wood residues for the plant.
Maine Woods Pellet secured a power
purchase agreement with Central Maine
Power to export the output to the grid.
The biomass power unit is scheduled to
begin operation in March 2016.
SheerWind installing
wind power project for
Tampa Electric
Minnesota-based SheerWind announced a pilot project that will be commissioned in Apollo Beach, Florida for
Tampa Electrics Big Bend Power Station.
Tampa Electric selected the 200-KW
INVELOX wind power generation to be
built in 2015. After sufficient data is collected and if the technology is deemed to
be viable, Tampa Electric may purchase

the INVELOX system.
According to Sheerwind, operating
and maintenance costs for the INVELOX
system are 50 percent lower than the operating and maintenance costs for traditional wind turbines.
North Carolina solar project

ready for construction
Innovative Solar Systems secured
the necessary approvals to begin construction on Innovative Solar 46, an
80-MW solar power project in Hope
Mills, North Carolina.
Construction will begin this year,
after ISS secures a final owner for the
project, according to John Green, chief
executive officer of ISS.
The company is seeking a 15-year
purchase power agreement (PPA).
Shaw Renewable
acquires wind power
project from Apex
D.E. Shaw Renewable Investments
LLC and Apex Clean Energy announced
the sale of the 300-MW Balko Wind
Project in Beaver County, Oklahoma.
Upon completion, Balko Wind will
include 162 GE 1.85-87 wind turbines.
Mortenson Construction is the projects engineering, procurement, and
construction contractor.
The DESRI-managed project has
signed power purchase agreements with
the Public Service Company of Oklahoma and Western Farmers Electric Cooperative.
The project is expected to begin commercial operation this summer.
Financing was provided by Santander Bank, N.A., KeyBank, N.A., Citi, and
Banco de Sabadell, S.A. Tax equity financing was provided by affiliates of
Bank of America Merrill Lynch, General Electric Capital Corp., Google Inc.,
and Citi.
www.power-eng.com
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ENERGY MATTERS
Slogging Through a
Million-Plus Comments
BY ROBYNN ANDRACSEK, P.E., BURNS & MCDONNELL AND CONTRIBUTING EDITOR
he comment period on the

controversial Clean Power
Plan (CPP) ended Dec. 1,
2014. EPA received more than 1.5 million comments on docket # EPA-HQOAR-2013-0602-0001. What insights
are contained within? Is each comment
a unique thought on the rule? Will EPA
make substantial changes to the proposed rule?
From ordinary citizens to executives
of major think tanks, the comments
represent a wide range of sources. They
include detailed technical critiques,
generic statements of opposition and
support, and succinct counterclaims
full of legalese.
Renewable energy, along with the
associated environmental attributes, is
regularly sold across state boundaries
The lack of clarity around interstate
crediting is creating uncertainty for buyers of renewable energy and is already
impeding the development of projects
that will send power across state lines,
said Malcolm Woolf, senior vice president of Policy and Governmental Affairs for Advanced Energy Economy, a
national trade association for advanced
energy technologies.
David Doniger, director of the Climate and Clean Air Program at the
National Resources Defense Council
(NRDC), said the CPP should contain
stronger provisions.
NRDC has presented a number of
ways to improve and strengthen the
CPP and with just three of these major
recommendations: 1) updated baseline and cost and performance data, 2)
implementation of the noticed formula
change to properly account for energy
10
efficiency and renewables, and 3) adoption of a minimum transition from

older steam generation to new natural
gas combined cycle units, we find that
EPA can significantly strengthen the
proposal at reasonable cost, said David
Doniger, Director, Climate and Clean
Air Program. Natural Resources Defense Council.
The Bipartisan Policy Center has even
conveniently organized all comments
from state and federal officials:
The proposed rule places a higher
burden on some state to achieve
the required reduction vis a vis other states, said Clifford Wilson III,
Interim Secretary, Florida Department of Environmental Protection.
Idaho believes that the EPA lacks
the legal jurisdiction to regulate
carbon emissions in the overly
broad fashion it is proposing, said
C.L. Butch Otter, Governor of
Idaho.
When EPA designs its program for
regulation of existing generating
plants, it should also allow states
and utilities to take credit for already implemented actions that
have increased the use of proven,
cost-effective energy efficiency, reduced the carbon intensity of the
states generation fleet, and reduced
CO2 emissions, said Elizabeth Jacobs, chair, Iowa Utilities Board.
Significant legal issues have been
raised, one of which concerns EPAs
authority to regulate CO2 emissions
from existing power plants under the
CPP when mercury is already regulated
under the Mercury and Air Toxics Standards (MATS). This legal conundrum
was succinctly explained in comments

by Laurence Tribe, professor of constitutional law at Harvard Law School, and
Peabody Energy Corporation:1
On its face, the Proposed Rule violates Section 111 of the Clean Air Act,
42 U.S.C. 7411, because the statute
expressly forbids the regulation of any
air pollutant emitted from a source category that EPA already regulates under
Section 112 of the Clean Air Act, 42
U.S.C. 7412Stationary power plants
are already a source category regulated
under Section 112 of the CAA. EPA
categorized power plants as part of a
source category under Section 112 in
2000. In February 2012, EPA promulgated a new national emission standard for power plants under Section
112. Earlier this year, the D.C. Circuit
upheld EPAs rule under Section 112.
Accordingly, the plain text of Section
111(d) flatly and unambiguously prohibits the Proposed Rule. As the Supreme Court opined in Am. Elec. Power Co. v. Connecticut: EPA may not
employ 7411(d) if existing stationary
sources of the pollutant in question are
regulated under the national ambient
air quality standard program, 74087410, or the hazardous air pollutants
program, 7412.
EPA had a legal deadline of Jan. 8,
2015 to finish the regulation. However,
EPA must first submit the rule to the
White House Office of Management
and Budget (OMB) for review, a process
that normally takes 30 to 90 days.
This one regulation will shape the
future of energy policy in the U.S. Lawsuits, delays, and confusion are inevitable.
www.power-eng.com
VIEW ON RENEWABLES
Mexicos Ready to
Do Business in the
Wind Sector
BY SHARRYN DOTSON, ASSOCIATE EDITOR
he Mexican government announced in late 2014 that it

is going to implement a new
energy policy that would open up
the electricity market for oil and gas.
However, the benefts of the new policy have trickled down to renewables,
most notably wind power.
The policy liberalizes all of the energy sectors and ends state-owned
power utility Federal Electricity Commissions (CFE) monopoly on power
generation and trading. The Mexican government is aiming to create a
wholesale electricity market with the
decision. According to statistics from
the U.S. Commercial Service (USCS),
installed wind power capacity in Mexico is projected to double by 2026 with
an emphasis on clean energy and natural gas.
Under the new policy, the Mexican
government has a 12-year goal for renewable energy production, and plans
were just announced for an additional
6.5 GW of installed wind capacity by
2018, totaling about 9 GW of capacity
and $14 billion in investments. Mexico
currently has 2.6 GW of wind capacity
installed from 31 wind farms in operation.
The Mexican Wind Energy Association said it expects 15 GW of wind capacity online between 2020 and 2022, and
wind could potentially provide 8 to 12
percent of the worlds electricity by 2020.
International companies have taken
note and are jumping in head frst to
do business. Iberdrola said it plans
to spend up to $5 billion in renewable and natural gas projects; Gamesa
wants to spend more than a billion
www.power-eng.com
dollars on new wind projects, supplier

development and a service center; and
Acciona says it will build three wind
farms with a potential capacity of
2,000 MW a year for $650 million.
Enrique Ochoa Reza, director of
CFE, said on Fox News Mexico has to
create a diverse energy mix in to increase energy security.
We need to use wind, water, the
sun and geothermal energy to generate
electricity, Ochoa Reza said. Mexico
has a big potential in renewable energy
and its climate and geographical location make it a privileged country.
According to the U.S. Energy Information Administration, Mexico is
a hotbed of wind development. The
Oaxaca I wind project recently came
online in 2014 and was followed by the
completion of La Venta III this year.
Those projects join the Oaxaca II, III
and IV wind projects that came online
in the frst half of 2012. The Mexican
unit of EDF completed the 164-MW Bii
Stinu Wind Project in 2014. Gamesa
in October turned over ownership of
a 74-MW wind plant to Grupo Mexico.
In Baja, the electricity from Sempra
Internationals 156-MW Energa Sierra
Juarez (ESJ) wind development will be
exported to the U.S. over a new transmission line, EIA said. The 156-MW
frst phase of ESJ was scheduled for
completion in 2014. ESJs long-term
development plan includes additional
phases, with a potential total capacity
of more than 1.2 GW.
The development of wind energy, like
many other generating sources, is dependent on fnancial backing. The ExportImport Bank of the United States has
authorized $462 million to support U.S.

exports related to power generation projects, including $198 million to support
U.S. exports in renewable energy, according to the banks 2014 annual report.
The U.S. Department of Energy recently issued a presidential permit to a subsidiary of Sempra International for construction, operation, maintenance, and
connection of a 230,000-volt transmission line across the U.S.-Mexico border.
When completed, the transmission line
will supply electricity from a Mexican
wind farm to the California market. It
looks like Mexicos probable wind boom
will help the U.S. as well!
Not only will a boost in Mexican
wind help the U.S. grid, it will beneft
U.S. manufacturers. The USCS said U.S.
equipment is considered top notch for
Mexican power generation projects.
U.S. technology is highly valued as it
represents high quality and compliance
with the standards, said Claudia Salgado, a commercial specialist with the
USCS. The price is also important in
the Mexican market, and this is the reason why competition from other countries, especially Europe and Asia, is very
strong.
Mexico is well known for its oil and
gas production, but wind and solar are
quickly climbing the ranks of installed
generating capacity in the country.
Now with the opening of the energy
market, wind installations are expected
to drastically increase within the next
decade.
While that means big business for
Mexico, even U.S. companies can fnd
some beneft to the change in the policy,
and that is good news for everyone.
11
GAS GENERATION
A Short History
of the Evolving Uses
of Natural Gas
BY TIM MISER, ASSOCIATE EDITOR
ike most people in the power

industry, we editors at Power Engineering magazine spend a lot
of time looking forward. Its required if
we are to stay ahead of new projects and
emerging technologies (never mind editorial deadlines).
Now and then, though, its instructive
to look back on the industry in an attempt to maintain a sense of perspective.
A magazine like Power Engineering, which
has been in continuous publication since
the late 1800s, has an interesting history
on its own. Both Thomas Edison and
Nikola Tesla published within these covers. Perhaps as interesting, though, is the
history of natural gas generation itself.
Long before its use in power generation, natural gas had already demonstrated its utility. Its presence was known in
ancient times. Some scholars have speculated that the Oracle at Delphi, located on
Mount Parnassus in Greece circa 1000
B.C., owed its mystical reputation to natural gas that seeped through the rocks,
mentally affecting the Pythia and her
devotees, who used it as a kind of gateway
to altered consciousness. Natural gas was
also used more deliberately. As early as
500 or 600 B.C., the Chinese were transporting natural gas through bamboo
pipelines, burning it to desalinate sea water and render it drinkable. By 100 A.D.,
the Persians of modern-day Iran were
using natural gas in their homes. Many
centuries later in 1626, French explorers
observed Native Americans in New York
deliberately igniting natural gas seeps
around Lake Erie.
The first commercial use of natural gas
occurred in England, where in 1785 it
was produced from coal and used to light
12
houses and streets. Three decades later in

1816, the residents of Baltimore, Maryland did the same, becoming the first
city in the United States to harness the resource to illuminate their thoroughfares.
While in its early incarnation natural
gas was used almost exclusively for light,
in 1885 Robert Bunsen (of Bunsen burner renown) pioneered new ways to utilize
the thermal properties of natural gas. In
1904 natural gas was first used to provide
central heating and large-scale hot water
supplies in London. Once natural gas was
in common employ heating water, it was
not so great a leap to use it beneath boilers in the creation of steam for industrial
purposes. This paved the way for the use
of natural gas in the generation of electricity, and so evolved an industry that today heats oceans of bath water and acres
of casseroles, all while lighting our cities
and powering the information age.
Electricity generated using natural gas
turbines was first produced for public
use in 1939/1940 at a plant in Neuchtel, Switzerland. The total output of the
turbine was 4 megawatts (MW). Before
this in 1937, Sun Oil had used a gas turbine to generate air and electricity for
private use at its chemical plant in Philadelphia. In 1945, a two-shaft reheat gas
turbine achieved a world record 10 MW
output, followed in 1948 by a combined
total output of 40 MW generated at the
worlds largest gas plant in Beznau, Switzerland. Clearly, Switzerland was a busy
place for emerging natural gas technologies in the 1940s.
In 1960, North America claimed its
piece of the pie when a power plant in
Port Mann, British Columbia became the
largest gas plant in the world, operating
with a 100 MW capacity. A year later in

1961, the first combined-cycle plant began operation in Korneuburg, Austria. It
generated 75 MW of electricity.
Since that time, generative capacities
have grown exponentially, and technologies have evolved dramatically. Todays
combined-cycle plants operate with
greater efficiencies and lower emissions
than any other type of fossil plant, and its
realistic to expect these numbers to continue to evolve and improve. Natural gas
plants supply more than half the energy
consumed in residential and commercial
applications, and 41 percent of the energy
used by U.S. industries, all while producing half the carbon dioxide, a third the nitrogen oxides, and one percent the sulfur
oxides of the average coal-fired plant.
Admittedly, a brief anecdotal history
such as this will probably not directly
influence the technological or business
decisions of natural gas power plants in
the modern age. But perhaps the information is valuable anyway, if for no other
reason than the sense of satisfaction it
can bring us. Natural gas formed when
organic matter from untold millions of
prehistoric plants and animals was covered over by strata, decomposed, and
submitted to unimaginable heat and
pressure across the millennia. In this
way the solar energy that living matter
once absorbed from the sun was stored
as carbon beneath the ground. Quite
literally then, we now power our most
sophisticated computer systems and
communications networks on the historical light from a single star, or at the
very least on the backs of John Deeresized lizards and Cessna-scale dragonflies. Weve come a long way baby!
www.power-eng.com
NUCLEAR REACTIONS
Safety Culture Best

Practices Largely
Ignored
BY MARY JO ROGERS, PH.D.
Author
Mary Jo Rogers,
Ph.D. is a partner
at Strategic Talent
Solutions with over
15 years working
with energy leaders.
She recently
published the book,
Nuclear Energy
Leadership: Lessons
Learned from U.S.
Operators, by
PennWell. Contact
Mary Jo at maryjo@
strattalent.com.
ifferent industries have developed their own definitions

ofand approaches to
safety culture. Rather than learn from
one another and adopt the standards
and practices that produce the best results, for the most part, industries have
evolved their own unique strategies and
tools that they are comfortable with.
This trend may very well be related to
the drastically different safety performances found across industries and
evenbetween groups within the same
industry.
Take U.S. electric utilities, for example. Safety on the transmission side of
the business has made notable progress
over the past century. However, the
transmission industry still withstands
fatalities every year. No one would say
that people in transmission are cavalier
about their work or would minimize
the frequency and level of hazards they
face regularly. It cannot be ignored,
however, that it is not unusual for transmission companies to have fatalities, in
addition to serious accidents and injuries, in any given year.
What is striking about this stubborn
trend is the apparently limited crossover
of safety culture lessons learned from
right next door. Within the same utility
companies, transmission may be fairly
isolated from nuclear power plants
when it comes to safety culture. Admittedly, there are significant differences
in their operations and regulations; as
well, there are the unique challenges of
nuclear power. While you could focus
on the differences, transmission and
nuclear generation are interconnected
literally - and if one side of the equation was accidentally killing workers
www.power-eng.com
frequently and practically never doing

so on the other side, one could be curious whether there were more learning
opportunities that could be adopted.
With their relentless focus on safety
culture and high standards for safety
behavior, U.S. nuclear power plants
consistently have the safest industrial
environments in the world. A look at
the Department of Labor accident, injury, and fatality statistics shows that
nuclear power plants are safer working environments than elementary
schools, and significantly safer than
transmission organizations and any
other industrial workplace. What has
nuclear power done to achieve and sustain these gains?
Although the nuclear power industry started making accident and injury
safety improvements many years ago,
they have increased and sustained
safety performance to stratospheric levels since it began its immersion in the
concept of nuclear safety culture. Focus
on culture came out of lessons learned
from the 2002 incident at the DavisBesse Nuclear Station.
In 2002, an NRC inspection found a
football-sized hole in the reactor containment vessel, which left only a thin
layer of stainless steel barrier. Although
it was caught before any consequences
occurred, the finding shocked the industry because inspectors had not
found the degradation in containment
until it had gotten as large as it did.
Moreover, this was at a station that had
received high ratings and was widely
considered a well-run plant.
Over the next two years, multiple
investigations and analyses revealed
issues pertaining to an organizational
culture that had an impact on safety.

The industry issued a significant operating experience report that required all
plants to conduct assessments on their
own safety cultures. Since then, safety
culture has taken on a life of its own to
the point where everyone from plant
workers to senior leaders across the
country are deeply committed to creating and maintaining a healthy safety
culture.
Prior to the Davis-Besse incident, the
industry didnt focus on nuclear safety
culture, per se, although standards
around conservative decision-making
and nuclear professionalism may have
laid the groundwork. Why and how did
nuclear power plants embrace safety
culture? Because people have seen that
it worksby building strong organizations, engagement, transparency, safety
resultsin addition to better plant performance. The how involves a significant focus on aspects of organizational
culture that ultimately impact safety.
Since the Davis-Besse incident, the
industry has institutionalized quality,
regular safety culture assessments, continuous oversight, and the reinforcement of safety culture behavior. The industry has defined safety culture as an
organizations values and behaviors as
modeled by its leaders and demonstrated by its members that serve to make
safety an over-riding priority. At nuclear power plants, people are challenged
to consistently demonstrate commitment to safety through their decisionmaking, behavior and work execution.
Commercial nuclear power has
taught us that commitment to safety
culture is a major undertaking. But if it
saves a life, it would be worth it.
13
ON-SITE POWER
CHP: Energy
Independence
Offers a
Competitive
Edge
Economic analysis and design strategies
for cogeneration increase industrial
competitiveness
BY WILLIAM B. MCPHERSON AND MIKE LARSON, DTE ENERGY SERVICES,
AND THOMAS FITZPATRICK, SSOE GROUP
arge, energy-intensive commercial and industrial businesses face steep capital costs
and business risks when
investing their resources in
green/brownfield projects, equipment
upgrades or expansions to utility infrastructure facilities.
An on-site energy solution -- combined
heat and power (CHP), also known as
cogeneration or cogen -- enables industrial facilities to achieve greater energy independence, efficiency and reliability, reduced environmental impact, and lower,
more stable energy costs. The combined
benefits can increase an industrial companys competitiveness.
CHP is more efficient because it requires less fuel to produce a given energy
output compared with traditional standalone steam generation and separate
grid electricity generation, and it avoids
transmission and distribution losses that
occur when electricity travels over utility
power lines.
The cogen plant increases reliability
14
Authors:
William B. McPherson, PE, is development engineer at DTE Energy Services.
Mike Larson is director of Business Development at DTE Energy Services. Thomas
Fitzpatrick, PE, CEA, is a Power Department manager at SSOE Group.
because it can be designed to provide highquality electricity and thermal energy
independent of the power grid, decreasing the impact of outages and improving
power quality for sensitive equipment.
In fact, CHP is the only real alternative
for most industrial production sites to
achieve N+1 reliability both for electricity
and steam. Only facilities with very large
energy demands (greater than 50 MW)
typically have the leverage required for
the utility to provide electric power service from two independent sources.
CHP can save industrial facilities considerable money on their energy bills
thanks to its high efficiency and independence from increasing retail electric
prices; that being said, the project is sensitive to the delivered price of natural gas
because of higher usage to generate both
Waste Heat Recovery
Furnace
Kiln
Oven
Stove
Exhaust
25-40%
Useful Heat
50%
Wall
Losses
10-25%
A typical industrial process only uses 50 percent of the heat from fuel.
www.power-eng.com
steam and electricity, albeit at higher efficiency.

Because less fuel is burned to produce each unit of energy output, CHP also reduces air pollution and greenhouse
gas emissions, which may free up or create environmental
emissions credits for the host to be used elsewhere or sold
to the market. As a state-of-the-art, sustainable energy alternative, cogeneration can also contribute to branding as
a green enterprise.
When job creation is an important advantage to the
community in which the plant operates, a CHP project
further differentiates the company as a good corporate citizen. Most cogeneration projects increase staff and enhance
plant operators careers because they are taking control
over their energy production rather than simply buying
from the grid. Third-party CHP projects have been successfully implemented in both closed-shop and open-shop labor environments. From an economic standpoint, job creation also enables the company to leverage investment tax
credits, production tax credits, and tax abatements.
Moreover, partnering with a third-party on-site energy
provider, who designs, builds, owns and/or provides O&M
services for a customized, private cogen plant allows the
host to reduce the capital investment and operating risks
associated with a self-build CHP project while reaping all
of these benefits.
While CHP offers many potential advantages that

add up to increase an industrial companys competitiveness, not every site is an ideal candidate. Here are
insights for effective economic analysis and decision
making, as well as fundamental design strategies to
optimize the benefits.
THE ECONOMIC ANALYSIS:

FROM 10,000 FEET
First, it is important to understand the current utility environment of a potential CHP project. It may
run counter to expectations, but most local utilities
operating in todays relatively deregulated utility market are not opposed to customers implementing CHP.
A screening assessment to analyze the value of a CHP
project can be performed with basic thermal and electric
loads and billing data, as well as a simple understanding of
current energy delivery operations.
As part of the economic analysis, a potential host company will want to compare current utility costs with project
costs after implementation of a CHP plant. Remember to
base the analysis on the appropriate tariff structure, which
may differ from the current structure; in fact, if a company
brings more power generation on site, it may be eligible for
a different rate structure, including deductions based on
www.power-eng.com
ON-SITE POWER
16
benefit both partners on a CHP project.

While there are several infrastructure
funds that have a relatively low cost of
capital, they also have a relatively narrow
risk appetite. As a result, they are attracted to investing in CHP projects, but they
prefer partnering arrangements that limit
their development, construction and operational risks.
There are opportunities in CHP projects to improve the steam balance of a

site. If, for example, the site is replacing
existing electric chillers with steam absorption chillers, then it enhances the
economic case for cogen. When electric
chillers are at the end of their useful life,
instead of replacement in kind, it may be
the time to switch to steam absorption
Fuel Cost Sensitivity
250
12
$225
$212
$201
200
10
$190
$181
$172
150
$8.40
$140
$8.87
$7.93
$7.49
$132
$6.54
$6.78
$7.04
$5.96
$5.60
100
$9.32
$166
$149
Dollars
$157
Dollars
self-generation during on-peak hours,

i.e., reduced consumption from the utility when the utility system is experiencing its highest demand. So it can prove to
be enlightening to reach out to the companys utility account representative with
questions about potential rate structures
under CHP. The answers may provide
additional economic justification for a
cogen project.
The dollar value of reliability is another key factor in the analysis. Just as an
outage can be quantified as production
dollars lost -- often, into the millions depending on the length of the outage -- the
dollar value of cost avoidance should be
part of the analysis to get a true picture
of the potential magnitude of the benefits
of cogen.
Similarly, the security of the investment in a new CHP plant -- that is, site
and product life cycle and market stability -- are of great importance in the highlevel economic analysis of a cogeneration
project, whether it is a self-build project
or a partnership with a third-party provider. Specifically, the economic analysis
must consider whether or not the operation of the site and the product life cycle
will be consistent with the project financing term, i.e. the value proposition of a
CHP plant at an industrial plant with a
ten-year life expectancy must include the
cost to pay off such a CHP plant in ten
years.
When a partnership with a third-party
provider is on the table for discussion,
the hosts and the providers risk-adjusted
costs of capital are typically very close, so
there is very little difference between selffinancing or financing through a third
party. However, the key factor is their
respective hurdle rates for discretionary
projects. Where the typical industrial
company today is looking for a two- to
three-year payback on savings from capital projects, third-party energy services
providers are looking for a six- to eightyear payback on most projects, so they
have some leverage that can financially
$5.15
4
Retail Electrical Rates
Delivered Natural Gas Price
50
2
0
2015
2017
2019
2021
2023
2025
2027
2029
2031
2033
2035
Sample utility forecasts for CHP assessment
In fact, one of the key economic decisions for each party to a self-build or
partnership project is this: what level of
risk are you willing to assume in terms of
capital cost risk, performance guarantees,
O&M costs and energy prices, and what
level of risk do you want a third-party onsite energy services provider to assume?
The spreading of that risk among the
parties is one of the crucial factors that
determines the final costs and contract
structure of a third-party provider CHP
project.
THE DEEP DIVE

If the initial high-level economic analysis of a potential CHP project is positive,
an in-depth analysis examines a number
of key issues, including the opportunities for CHP to improve the operation of
the site, hidden costs, commodity price
variability, and contractual obligations.
chillers because the plant will be generating cost-effective fuel for them.
Certain hidden costs/factors should
be included in the analysis. For example,
the costs of management oversight will
inevitably change when heat and power
are generated on site rather than being
purchased from utilities.
Other factors include:
Impact of host credit on ability to finance project
Accounting treatment of project
ownership: depreciation, etc.
Development costs, interest during
construction, and initial working
capital cost
Residual value and/or any asset retirement obligations
End of term or early termination provisions
LDs for non-performance
Scheduled or unscheduled major
www.power-eng.com
maintenance or equipment replacement

Casualty losses: insurable or noninsurable
Commodity usage and price risk
Inflation risk
Change-in-law risk
Assignment provisions
There are also many peripheral costs
that must be carefully assessed, including
the costs to bring in utility gas if there is
not currently a adequately sized gas line
to the plant.
Key cost factors also include the longevity or viability of the site and product, annual operating costs, and financing arrangements. For example, a swing
production site may be the first to go, but
on the other hand, a marginal site that
increases its operating efficiency and reduces costs may move up in the corporate
hierarchy accordingly.
Commodity price variability is also a
key consideration in the analysis. Forecast information is available from the Energy Information Administration, a part
of the Department of Energy, or from a
number of energy consulting firms.
Just as the economic analysis must
consider whether or not the operation
of the site and the product life cycle will
be consistent with the project financing
term, the analysis must also weigh the
impacts of the contractual obligations
during peak production periods and during downturns. It may not be possible to
predict when the business cycle is going
to go up or down, but it is important to
generate reasonable estimates of the sites
energy requirements at peak production
and during a period of market downturn
-- over the 10- to 15-year life-cycle of the
CHP project -- and plan for how the company will meet its contractual obligations
to the project in both scenarios.
WHERE IS THE
TIPPING POINT?
Is there a tipping point for a CHP project based on scale? For some third-party
www.power-eng.com
providers, electric power generation of

4-5MW is marginal; however, this number is trending downward as the cost of
capital drops because it does not require
quite as much throughput to pay the debt
service for that capital. Today, even projects generating 2-3MW can be attractive
for a third-party developer to partner

with a potential host.
Fundamentally, the tipping point
analysis requires that the potential host
monetize or put specific values on all of
the components above, and then determine whether CHP represents a rational
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ON-SITE POWER
18
Cogeneration Options
100
90
Cogeneration Options
80
70
Percent
economic decision under the various

market scenarios. Finally, developing a series of operating scenarios for
evaluation, whether it is a Monte Carlo
analysis or another, determines the
percentage of time that a CHP plant
will generate positive financials versus
the percentage of time that it will not
-- if it is a 90/10 proposition, then most
companies will agree that the project
has reached the tipping point.
In the process, the company can
compare the costs of capital and the
value of the risks for a self-build project versus the cost of a third-party provider. The cost of capital is not typically the deciding factor -- the deciding
factor is a comparison of the hurdle
rate for internal projects versus that for
a third-party provider.
Industrial companies tend to look at
the implied cost of capital in a thirdparty providers solution and compare
it to their own internal costs of capital
instead of comparing it to their own
internal hurdle rate.
A third-party providers hurdle rate
is always going to be higher than the
costs of capital because it has a number of risk premiums -- for construction, operating and performance risks
-- and profit built into its costs.
In fact, there are few energy projects
that will ever have a return that is high
enough to meet a discretionary hurdle
rate for an industrial plant. Maybe the
real question is What is the cost of the
status quo?
This speaks to the importance of
identifying the right metrics for the
analysis when considering a third-party provider: look at the savings rather
than internal rate of return (IRR). It
is almost automatic for a company to
calculate the IRR, especially if one has
never before partnered with a thirdparty provider. Remember that it will
be the provider that makes the capital
investment, so IRR is the providers
economic issue, not the hosts.
60
50
40
30
20
10
0
Power Only
Steam Only
Exhaust
Boiler with Reciprocating

Extraction
Engine
Steam
Combine
Cycle
Power
EQUIPMENT SELECTION:
BIG OR SMALL?
ASSESSING A
POTENTIAL PARTNER
Equipment selection becomes the

rational result of the economic analysis -- the tipping point and analysis of
long-term needs -- and then selecting
the equipment that generates the most
savings for the site. Big equipment
provides the site with a lot of reserve,
while small equipment provides high
utilization; selection must be appropriate for the character of the plant.
Moreover, it is important to choose
equipment that can be upgraded easily
and will age well with the plant.
Changes in environmental regulation or a significant change in the
customers operating system can have
an effect on the viability of CHP as a
sites energy solution. In addition to
improved energy supply economics
and operating availability, CHP projects create benefits for hosts focused
on CO2 emissions reductions due to
higher efficiency and lower overall
emissions.
With changes in environmental regulations, one of the nice features of CHP
is it creates additional value streams because of its energy efficiency.
Finally, if taking the route of a partnership with a third-party energy provider,

be certain that the partner aligns its interests with yours.
One characteristic to consider is transparency; do you want to partner with a
company that is going to offer an opensource, non-proprietary solution or do
you want a partner that will provide a
black-box solution and you wait at the
end of the pipe and wire for services?
Also, consider whether you want a
partner with a long-term ownership
perspective, or one that will be focused
on taking the front end risk and then
flip the house to an equity player.
Once the project is up and running,
make sure that a project is appropriately
managed to be technically and commercially optimized,
This includes future expansion or contraction with changing energy demands,
future operational changes due to changing market commodity pricing/availability, and incorporation of potential enhancements such as additional services,
demands, feedstocks, etc. available onsite or at neighboring facilities.
www.power-eng.com
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ec AB
ia MA
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tio
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Manufacturings
Big Issue
BY SCOTT LYNCH, PRESIDENT AND CEO, ABMA
ot unlike other man- say what words come to mind when they
ufacturing
sectors, think of manufacturing, do you expect
the boiler industry the words innovation, Made in America,
continues to struggle and cutting edge technology or dirty, old
with the lack of avail- machines and China. Unfortunately, in
able talent. From engineers to welders, many cases, you get the latter.
finding good talent is very difficult and
I have been engaged in the manufacwith the improving economy, it is not go- turing sector from almost two decades
ing to get any easier.
and at all my stops I have been amazed
Some ABMA companies have ad- at the technology and innovation in our
dressed this issue with creation of their U.S. manufacturing sector. Facilities have
own welding schools and partnering smart technology everywhere, measurewith trade schools and local community ments in microns and engineers creating
colleges. While there pockets of success, 3D CAD designs.
this continues to be a struggle for the inWe need to work on changing the perdustry as whole.
ceptions but we also need to understand
I recently heard someone working what motivates those coming into the
in the boiler industry say We need to workforce. You hear young people entermake boilers sexy. This
ing the workforce want
seems to be a ridiculous We need to work to make a difference
statement but really gets on changing the
in the world for their
to the heart of the issue.
work to have a purpose.
perceptions but
Manufacturing has a
Many manufacturing
we also need to sectors like the boiler
perception problem and
people dont discover understand what industry are pushing
the amazing jobs avail- motivates those
limits of technology
able in many sectors coming into the
and physics to conserve
until after they are alenergy and reduce enworkforce.
ready doing it. However,
vironmental
impact.
while it would be great to make boiler In some cases, the air coming out of the
industry or manufacturing sector sexy, boiler is cleaner than the air coming in.
many would just settle for just leveling
So what is ABMA doing to bring attenthe playing field.
tion to this issue? ABMA established a
If you asked the average American to Scholarship Fund that has assisted young
www.power-eng.com
Scott Lynch
people in seeking careers that will benefit the boiler industry. Since inception,
ABMA has supported dozens of students
to complete their college degree. This is
start but it is not enough.
In the coming months, ABMA will be
exploring opportunities to expand this
program and seek out new opportunities
to address this issue.
But there is something every one of
us can do. We can share the innovation
in the U.S. manufacturing sector with
young people and enlighten them about
the career possibilities at all education
levels and take them into a manufacturing facility and have the witness the opportunities firsthand.
21
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THE COAL ASH RULE:
How the EPAs

Recent Ruling Will
Affect the Way
Plants M
Manage
BY TIM MISER,
ASSOCIATE EDITOR
CCRs
ast December, the Environmental Protection Agency

(EPA) published its final
ruling for the regulation of
coal combustion residuals
(CCRs). Commonly referred to as the
coal ash rule, the new policies have
largely been met with acceptance, even
relief, with many industry representatives calling the ruling a fair compromise.
The final CCR ruling follows six years of
debate about how best to handle a potentially perilous situation.
22
THE BACKSTORY
In the early morning hours of Dec. 22,

2008, a structurally deficient dike containing an 84-acre unlined surface impoundment at the Tennessee Valley Authoritys (TVA) Kingston Fossil Plant near
Harriman, Tenn. gave way, spilling 1.1
billion gallons of coal ash slurry into the
Emory and Clinch rivers. The accident
was the largest fly ash disaster in United
States history, larger in volume than the
1989 Exxon Valdez or 2010 Deepwater
Horizon oil spills. It flooded 300 acres
of land with up to six feet of solid waste

sludge, toppling trees, damaging or destroying dozens of homes, but injuring
no one. The disaster destroyed power,
water, gas, and rail lines, and killed large
numbers of fish and other wildlife.
The cleanup effort topped $1 billion,
and the Tennessee Department of Environment and Conservation saddled the
TVA with a $11.5 million fine. The TVA
was also required to monitor wildlife
damages for 30 years following the accident. To date, the TVA has spent $40
million studying the effects of the coal
ash release on the river and surrounding
environment. Additionally, the TVA contributed $43 million to Roane County
where the disaster occurred, and bought
180 properties and 960 acres that were
devastated by the accident.
www.power-eng.com
Allen-Sherman-Hoffs Remote Submerged Chain Conveyor

transports CCR using an inclined path which harnesses
gravity to dewater the coal ash.
Photo courtesy: Allen-Sherman-Hoff
Among the many environmental advocates that became involved in the aftermath of the incident, Greenpeace called
for legal action, requesting a criminal investigation into the TVAs culpability for
the accident. Local landowners also sued
the TVA for $165 million.
In the wake of the disaster, Congress
held hearings on the accident, and the
House of Representatives passed a bill
that established minimum requirements
for coal ash handling and stripped the
EPA of its regulatory power. For its part,
The EPA proposed new rules that would
regulate coal ash and classify it as a hazardous material.
Notwithstanding the magnitude of the
event and the legal circus that ensued,
coal ash remained largely unregulated for
years following the disaster, as the EPA
delayed issuing a final ruling under intense political pressure from companies
in coal-related industries.
But all this changed in the final weeks
of last year, when in a bid to establish
safeguards against groundwater contamination and air pollution, and to protect
communities from impoundment failures, the EPA announced the first national regulations for the safe handling and
disposal of coal ash.
THE RULING
With the publication of its final rule
under subtitle D (the solid waste provision) of the Resource Conservation and
Recovery Act, the EPA has attempted
to strike a balance between polarized
arguments on both sides of the issue.
While some environmental conservation
groups argued that CCRs should be classified as hazardous materials because of
their arsenic and mercury content, many
power industry representatives countered
that coal ash has beneficial uses and
should only be regulated as solid waste
akin to household trash.
Many in the coal-fired power industry
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worried that the EPA would outlaw surface impoundments altogether or designate CCRs as hazardous waste. Ultimately though, the agency omitted to
undertake either action, opting instead
for a more measured approach.
The EPAs final ruling looks like this:
Structural Integrity
To reduce the risk of catastrophic failure, coal-fired power producers must
meet certain structural integrity requirements and design criteria for their
surface impoundments. Owners must
periodically conduct assessments that
measure structural stability, minimum
safety factors, and potential for hazards
in the event of an impoundment failure.
They must also inspect impoundments
weekly and monitor unit instrumentation monthly, in addition to developing emergency plans for impoundment
breaches.
Groundwater Purity
Power producers must also meet requirements for groundwater monitoring
and corrective actions that include the
installation of monitoring wells, analysis
of water samples for hazardous contents,
and mitigation of contamination caused
by units that do not meet established
standards.
Impoundment Location
The placement of impoundments is
disallowed below the uppermost aquifer,
in wetlands, and in seismic impact zones
or areas that are otherwise unstable. This
standard is retroactive and also applies
to existing landfills and impoundments.
If owners cannot demonstrate that their
facilities conform to these requirements,
they must shut down their impoundments.
Liner Design
To prevent CCR contaminants from
leaching into the ground, all new landfills, surface impoundments, and lateral
expansions must include a composite liner that meets prescribed design criteria.
New landfills must also utilize leachate
collection and removal systems designed
to remove excess leachate from the tops

of liners. Existing unlined landfills may
continue to operate as before.
Operating Criteria
Power producers must address the
day-to-day operations of CCR units by
establishing criteria to prevent negative
impacts on public health and the environment. These criteria must include
standards for air quality, water discharge,
flood control, windborne dust, and
leachate creation. They must also control water run-on and run-off in order
to minimize erosion and protect against
pollution of surface waters.
Record Keeping and Notifications
Plant owners must maintain operating records that demonstrate compliance
with prescribed standards. In an effort to
increase transparency and inform and
engage citizens, facilities must maintain
a publicly available website that includes
information regarding compliance with
groundwater standards, plant corrective
actions, plans for fugitive dust control,
and facility closures.
Inactive Units
To prevent structural failure, inactive
units which no longer receive waste, but
which still contain water or CCRs must
be completely dewatered and covered
within three years to avoid further regulation under the rule.
THE FUTURE OF
COAL ASH HANDLING
Though the EPAs new coal ash regulations are more moderate than some
feared, they will still prove costly for the
industry. [The ruling] will make states
and utility companies vulnerable to new
regulatory costs and expensive litigation, said Sen. Jim Inhofe, R-Okla., and
Rep. Shelley Capito, R-W.Va. in a joint
statement.
But the new ruling will also open up
market opportunities for companies
involved in the transport of CCRs from
their post-boiler origination to their
CONTINUED ON PAGE 26
23
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ash never comes into contact with any
CONTINUED FROM PAGE 23
ultimate internment and disposal in transport water. The company also offers
landfills across the country.
solutions which represent hybrid wet-dry
Though the new ruling stops short of systems. These solutions differ from their
mandating wet-to-dry conversions for fly ash counterparts in that power plants
coal ash systems, dry systems do offer can retain the option of using water as a
plants the benefit of eliminating both transport medium. After transport, the
surface impoundments and their associ- coal as is then dewatered, and the liquid
ated water quality and structural integrity is either polished in preparation for disrisks. Dry handling systems can prove charge or reused in a closed-loop, zerovery expensive, however, especially when discharge model.
they are retrofitted into existing facilities
The most common dewatering techwith comparatively shorter remaining nology used by power plants in the last
lifespans. So it is good
30 years has been
As
facilities
review
news that the EPA
the submerged flight
has given power pro- their technical
conveyor, says Kevin
ducers the option to alternatives, they
McDonough,
vice
handle their coal ash
president of sales and
have to factor risk
using either wet, dry,
marketing at United
or hybridized wet-dry management into
Conveyor. A system
systems.
like this uses a metheir decisions.
Many companies - Kevin McDonough
chanical conveyor that
are well positioned to
pulls coal ash from
service the market for newly-regulated a water-impounded hopper beneath
coal ash handling. Some of these com- the boiler, up a dewatering ramp where
panies include United Conveyor, Allen- moisture content is reduced to about 15
Sherman-Hoff, Clyde Bergemann, and to 20 percent, which is the optimal level
Beumer.
for fugitive dust control and landfill comUnited Conveyor
paction. Systems like these which are
United Conveyor has for years been installed directly beneath the boiler can
active in converting fly ash handling reduce operation and maintenance costs
systems from wet to dry. The company to one-third of their traditional levels. But
is currently in the middle of several proj- many existing plants simply do not have
ects of this type. They offer six wet-to-dry the physical space beneath their boilers
conversion alternatives to help power to implement such retrofits. Bottom ash
producers handle fly ash more efficiently. pits are generally subgrade. They may
Their systems ensure that no water is used also contain structural steel and concrete
as a transport medium for fly ash, relying at both ends, making it impossible to ininstead on a positive-negative pneumatic stall conveyors.
air stream to convey fly ash to dry silos.
As a workaround for this problem,
The company predicts that within two United Conveyor has more recently ofyears over 85 percent of domestic power fered alternatives to this under-boiler
plants will convey fly ash using entirely setup, including remotely-located subdry systems.
merged flight conveyor systems. Such
United Conveyor also offers solu- systems allow existing bottom ash sluice
tions for the conveyance of bottom ash. lines to be intercepted and redirected to
As with fly ash, they offer six wet-to-dry a remote conveyor, which dewaters the
conversion alternatives for bottom ash coal ash in preparation for landfill distransport. Three of these solutions are posal. The area beneath the boiler is not
entirely dry systems in which the bottom substantially disturbed, so plants with
26
limited room can still benefit from the

technology.
As facilities review their technical
alternatives, says McDonough, they
have to factor risk management into their
decisions. When they do this, there is a
tendency to convert facilities from wet to
dry, even though that decision may represent slightly higher capital costs. This
greatly minimizes the amount of future
risk that would otherwise exist when operating wet systems that utilize surface
impoundments, because the potential for
structural breaches and leaching can be
entirely circumvented. Removing water
from the equation increases predictability down the road.
Allen-Sherman-Hoff
Allen-Sherman-Hoff, a division of Diamond Power International, offers bottom
ash handling systems that allow power
plants to continue to transport CCRs in a
wet stream. Fly ash systems will almost
universally be converted to dry handling, says Tom Moskal, general manager. This is especially true considering
the Effluent Limitation Guidelines (ELG)
due to come out later this year. But there
will continue to be a whole host of solutions for moving bottom ash. I believe
that relatively few plants will convert to
totally dry systems, mostly because of
the expense associated with modifying
and excavating the bottom of the boiler
and its foundation. Moskal believes that
submerged chain conveyors offer a good
wet-dry solution to bottom ash handling.
Like McDonough, he sees the promise
that remote dewatering systems offer
plants who seek a retrofitted solution.
Allen-Sherman-Hoff offers its Remote
Submerged Chain Conveyor (RSCC) as
a solution that transports the vast bulk
of both large and fine particles up an inclined dewatering path which uses gravity to drain away liquid. The system results
in coal ash with a water content of 20 to
30 percent by weight, which is retained
liquid mostly captured by the capillary
action inherent in porous substances like
www.power-eng.com
bottom ash.
But this is not to imply that all CCR
systems will eliminate surface impoundments. I know of one Midwestern utility that is keeping its ponds, says Moskal.
Bergemanns activity is on the elimination of surface impoundments. Ron

Grabowski, business development manager for the company, says some plants
have already begun to retrofit existing
Beumers pipe conveyor system entirely

encloses the coal ash, preventing cross
contamination with the environment.
Photo courtesy: Beumer
But instead of serving as the gross separation device, the pond will serve only to
contain the water that has already passed
through the RSCC. The pond, then, will
not be removing the bulk of the coal ash.
Rather, it will do the final job of settling
out the very fine particles over time. This
combined approach minimizes the burden placed on the ponds. They dont fill
up as quickly as they otherwise would, so
they can be used for many more years.
Moskal is skeptical that ponds will
represent a majority solution, however.
Because of the new monitoring requirements imposed on power producers by
the EPAs ruling, my guess is that more
ponds will be closed than kept open.
Clyde Bergemann
Currently the main focus of Clyde
www.power-eng.com
bottom ash systems with newer technologies.

We supplied a client with our DRYCON state-of-the-art bottom ash handling system, which is completely dry,
says Grabowski. This system has already
saved the plant over $1 million a year in
operational costs compared to the original wet bottom ash system. We also offer
a very unique technology called ASHCON which redirects bottom ash slurry
away from ash ponds for dewatering and
storage. Systems like these help plants
meet the CCR regulations, as well as the
anticipated ELG requirements.
Beumer
Beumer considers the EPAs new ruling, as well as its allowance for surface
impoundments, to be good for the industry, but nonetheless focuses its development efforts on dry coal ash handling
and landfill disposal. The company does
not offer wet or wet-dry hybrid systems
for CCR delivery and storage. Rather, it
designs conveyor systems for everything
from airport luggage terminals to bulk
material transport systems, like those required for coal ash handling.
The companys major contribution to
the coal ash handling process is its pipe
conveyor system, says Brian Giese, vice
president of conveying and loading sales.
Our system is comprised of a conveyor
that can be rolled into a pipe shape during operation, entirely enclosing the coal
ash in order to protect the material from
the environment, and the environment
from the material. This is accomplished
by a conveyor that begins and ends as a
standard three-idler trough conveyor, but
which is rolled into its round shape while
in transit via three additional idlers. The
conveyor is rated for 1200 tons per hour,
and can make horizontal and vertical
curves to follow the terrain of a specific
site. A single run can reach greater than
six miles.
The German Beumer has also partnered with Eurosilo in the Netherlands to
build automated conveyance and storage
systems for CCR handling. This allows
plants to store their CCRs in such a way
as to desynchronize the conveyance process from the pickup and disposal process. Normally a conveyor must operate
the entire time that ash is being trucked
away. If the conveyor stops, the trucking
to landfills must also stop. The automated
storage system decouples these two processes, so that previously-conveyed ash
can be stored and automatically retrieved
at a later time, when waiting trucks can
transport it to the landfill. Trucks can
be loaded even when the conveyor belts
are not actually operating. This allows
for simpler scheduling at plants, because
it normalizes employee shifts and overtime.
27
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Zeeco, Inc. 2015
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Slag deposits on boiler tubes will act

as insulation, preventing the heat
produced by the boiler from transferring
to the water inside the tubes. Photo
courtesy: Clyde Bergemann
Best Boiler
Cleaning
Practices
or power plants burning

anything other than natural gas, boiler cleaning
is an important part of
keeping the plant working efficiently.
Over time, boilers will build up ash
that will form slag deposits on the
boiler. Slag acts as an insulation that
protects the tube from the heat of the
boiler, creating a need to use more fuel
to reach the same temperature and produce the same output as a clean boiler.
Cleaning slag deposits inside a boiler
can increase boiler efficiency between
30
1 percent and 4 percent. Clean boilers

can also reduce emissions produced by
a power plant because less fuel is required to produce the same amount of
power.
While the importance of boiler
cleaning is clear, power plant operators have many options when it comes
to techniques used to clear slag and
ash buildup. Cleaning practices vary
from offline cleaning, which requires
a planned outage, to online cleaning
that can occur while the plant is still
operating. Methods can use everything from sound waves to dynamite.
ACOUSTIC CLEANING
One option for boiler cleaning is an
acoustic cleaning system, which can
knock ash off boiler tubes or selective catalytic reduction systems with
acoustic energy without risking damage or fatigue to the units. While this
can be done by using acoustic horns
that can be retrofitted onto boilers,
Advanced Acoustic Technologies LLC
uses a technique that is engineered
specifically for a plant.
Unlike the horn suppliers, our
acoustic devices are part of an engineered, integrated system where the
frequency produced by the acoustic
device is determined by 3D element
modeling, AAT co-founder Robert
van Dam said. The process is similar
to flow modeling, except the company
looks at the acoustic aspects of how
sound waves behave in an enclosure.
The companys WaveMaster Acoustic Cleaning systems provide continuous, online, volume cleaning with soot
blowers used in a remedial role, van
Dam said. The company uses acoustic
www.power-eng.com
modeling to determine the natural

frequency of the flue gas and decide
the proper frequency for the custom
system as well as where it needs to be
placed in the boiler.
Our acoustic cleaners are designed
to be operated continuously if that is
required for the application, van Dam
said. Theres no erosion. Its online,
so its running when the boiler is running, and by being specific with the
frequency and the location we can
place the acoustic effective area where
Areas that collect dry coal ash, such as
convection passes, are best suited for
acoustic cleaning. Photo courtesy: Advanced
Accoustic Technologies
we want it. Were not just cleaning what

is directly in front of our device. Were
cleaning a volume because the acoustic
cleaner is in resonance with flue gas.
Acoustic cleaning works especially
well on dry and dusty deposits, van
Dam said. The company works with
areas where ash is below the fusion
point, such as horizontal tube banks
in a utility boiler. The technology is
not as effective in superheaters or other other areas where the ash is likely
www.power-eng.com
partially molten.
According to van Dam, the company
has seen excellent results on a wide variety of fuels, including Powder River
Basin, pet-coke, bituminous and subbituminous coals. The fully-optimized
sound field can penetrate throughout
several tube banks with the application of only one or two acoustic cleaners. Van Dam said the system is used to
clean the entire convection pass at Tennessee Valley Authoritys 1,300-MW
Cumberland plant, which is 67 rows of
tubes, with two acoustic devices.
WATER LANCES
Another method for cleaning slag
from a boiler is using high-pressure
water jets. Thompson Industrial Services uses high-volume, specialized
hydroblasting equipment, with pumps
that can send up to1,200 gallons per
minute through the hoses. The company also uses remote-controlled robotic
cleaning systems and other automated
tools to clean boilers.
Thompson
Senior
Business
Development Manager Carl Wise said

the company is able to use water lances
for both online and offline cleaning, although whether online cleaning is possible may depend on the specific boiler.
You have to do online cleaning from
strategic positions because you have to be
very careful spraying the water directly
into the boiler while its operating, he
said. Its an extremely critical process.
Whether cleaning can be done while
the boiler is online depends on the
particular boiler. Although the company routinely cleans boilers without
having to shut them
down, Wise said it may
not be possible in every
situation.
Online cleaning has
multiple advantages when
it is possible, however.
If you take a boiler
completely down, it takes
a lot of time to bring it
back up, Thompson Senior Sales Representative
Jim Walker said. It saves
the utility time and money to have that boiler up
and running when we do
our deslagging.
Because of the highvolume pumps, Wise
said the company is able
to clean farther distances with their lances and
can be more effective
because the lance can go
out more than 40 feet on either side of
the lance.
Thompson also performs many other
types of cleaning for power plants, including hot ash removal and using a process involving dry foam to remove combustible dust, which can create a safety
hazard on the external part of the boiler.
SOOT BLOWERS
Soot blowers use compressed air,
steam or water to keep slag buildup
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If slag is allowed to build up inside a boiler, it can lead not only to

efficiency problems but can also cause damage because of the
weight. Photo courtesy: Norm Harty
from occurring without the necessity

of taking the plant offline. Soot blowers have been in use for some time
now, but, like many other aspects of
power plants, are becoming more sophisticated as time goes on.
We have a basic technology, and we
have our advanced technology, which
we call SmartClean, said Tim Martin,
director of product management for the
boiler efficiency product division with
Clyde Bergemann Power Group Americas Inc.. Our basic technology does the
bare minimum itll keep the boiler
clean and keep it online and running.
Our advanced technology is where we
get into targeting the areas of boilers that lead to erosion. In addition, you may
really need to be cleaned with the proper have areas of your boiler that foul much
intensity, so we really get into monitor- more quickly and because of the way the
sequence is set up, it
ing the boiler performay not be able to hit
mance and adjusting Water is really
that area for several
the cleaning parame- scarce out west,
In those hours,
ters in real time, and
and this is another hours.
that area could really
thats where the plant
foul up significantly
can gain efficiencies reason explosives
and plug the boiler
from using the ad- are being used
and cause a clinker
vanced technology.
predominantly in
or severely restrict the
Intelligent
soot
blowing
systems the western plants. heat transfer, forcing
them to have a shuthave several advan- - Norm Harty, N.B. Harty
down.
tages over traditional General Contractor Inc.
Many
coal-fired
systems, Martin said.
The companys advanced technology boilers built in the past 10 years were
can increase the efficiency by 1 percent installed with intelligent soot blower
technology, Martin said. Clyde Bergeover basic systems.
Intelligent soot blowing systems mann is also working on retrofits for
also only clean when necessary, which power plants that werent originally
equipped with intelligent soot blower
avoids boiler tube erosion.
Basic systems are blind to whats technology.
going on inside the boiler, Martin
said. There may be areas in your boil- EXPLOSIVES
Using explosives to clean slag from
ers that are clean, but youre running
a soot blower because its time in the boilers isnt a new process, but its one still
sequence, so its blowing high pres- in use that many plant operators prefer.
The method was first used by Norm
sure steam on a bare tube, which can
32
Harty of N.B. Harty General Contractor Inc. Over the years, Harty said he
and his staff have built the procedure
into a state-of-the art technique that
can quickly clean the slag from a boiler
and have it back online.
To clean a boiler using explosives,
Harty said his company will use primer cord around tubes that are close to
avoid damage. The cord has connectors to delay the chargers, which he
said is important to avoid destroying
the wall or insulation of the boiler.
Harty said using explosives has several advantages, including speed and
convenience. With dynamite, you can
put all of it in a pickup truck and clean
any boiler, he said.
Explosives also have an advantage
in areas where plants are concerned
about water use, he added.
Water is really scarce out west, and
this is another reason explosives are
being used predominately in the western plants, he said. They cant afford
to waste a drop of water, and by using
dynamite theyre able to save their water and clean their boiler at the same
time.
www.power-eng.com
GENERATOR SETS
Comparing
NATURAL GAS
and DIESEL
Generator Sets
Do the Old Rules Still Apply?
BY RAFAEL R. ACOSTA, HIPOWER SYSTEMS
nly a few years ago, traditional logic for generator sets (gensets) held
that diesel meant reliable and inexpensive
34
but also noisy, loud and messy. Natural

gas meant expensive and temperamental but also quieter and cleaner. Today,
thanks to the development of new technologies in engines, enclosures and other
components, the differences between diesel and natural gas generators is no longer
so clearly defined.
Additionally, many firms follow conventional logic in their comparisons of
these two fuel types and fail to give sufficient weight to the operating realities of
their particular applications. In this article, well take a look at both new developments and long-standing considerations
that impact generator selection by fuel
type in the power generation industry.
THE ENGINE EQUATION

Traditionally, the viewpoint has been
that diesel engines provide response,
power and longevity, while natural
www.power-eng.com
For small power producers such as those

operating mini-grids, a new generation of
generator enclosures is increasing choice
and reducing or eliminating some of the challenges with diesel. Photo courtesy: HIPOWER
Systems
gas engines are more environmentally

friendly. Although the environmental
argument for natural gas still holds true,
diesel is no longer the clear winner in
terms of power and response. Sparkignited (natural gas) industrial engine
manufacturers can now optimize the
RPM of these engines to make their transient response similar to that of diesel.
Manufacturers are also producing natural gas units that can meet the 10-second
startup requirement for backup systems
that is traditionally associated with diesel
engines, alone.
Use of gear-on-gear powertrains or
two-pole alternators (as opposed to traditional four-pole alternators) has increased
the overall performance and power of
www.power-eng.com
natural gas engines, as well. Manufacturers have also incorporated stronger, more
resilient engine parts, such as hardened
valves and seats, to boost performance
and increase reliability.
In the area of energy density, there is
no doubt that diesel has greater peak energy density than natural gas-by a factor
of more than of three (generally 129btu
versus 37btu). Even here, there are mitigating factors that may tip the scales in
favor of natural gas.
Density is impacted by both engine
and fuel conditions. A poorly maintained
diesel engine, or one running sludgy fuel
from a fuel tank filled with particulates,
likely will outperform a natural gas engine, but it will not perform at its peak.
Even more significantly, diesel engines
have a sweet spot of 50-70% of load, with
80% being the recommended maximum
for long-term prime operation. Running
them under a lighter load for long periods
of time results in wet stacking, a condition that sends unburned fuel and soot
into the exhaust system.
Operators that run engines under light
loads often employ load banks to consume the excess energy. This approach
reduces wet stacking but can waste a
considerable amount of fuel. As an alternative, those operators could instead
choose natural-gas-powered generators,
which burn hotter than diesel engines.
These engines are less likely to experience problems with unburned fuel, even
if they are run at a lighter-than-optimal
load.
BUILT TO LAST
Regarding longevity, diesel engines
still tend to have longer lives, on average,
than natural gas engines. However, many
of the new technologies mentioned
above not only enhance performance in
natural gas engines; they also increase engine resilience and longevity.
In short, companies that plan to keep
their engines operating at peak condition
will still likely enjoy the greatest longevity
from a diesel engine. If they allow it to

fall prey to the operating challenges discussed in the previous section, longevity
will suffer-in extreme cases, potentially
cutting engine life in half.
For firms that use generators only for
backup power, a natural gas engine may
provide nearly the same effective life,
given how infrequently it is used. Other
considerations such as continuity of fuel
source also come into play, perhaps outweighing diesels benefits of performance
and engine life.
COST COMPARISON
Its a common misconception that industrial diesel engines are considerably
less expensive than comparable natural
gas models. Below 150kW, natural gas
engines are actually more cost effective,
even without factoring in the fuel differential.
For applications where more kW are
required, power producers can create parallel configurations of smaller engines to
provide them with the cumulative kW
needed for the operation. Parallel systems have the advantage of supporting
load sharing and management, making them one of the most cost-effective
and environmentally friendly options,
in terms of fuel use, for variable load
applications such as mini-grids. Add to
this savings the reliability and scalability
of parallel systems where they replace a
single, larger diesel generator (such as for
backup power) and the benefits of such a
solution are considerable.
For the past two years, natural gas
genset suppliers have also been touting
fuel prices as cost benefit. While the fall
in natural gas prices is certainly making
them a more attractive option, plummeting oil prices are having a similar effect
on diesel generator fuel. We wont make
a prediction here, because the outcome of
fuel prices is anyones guess.
SAVING THE PLANET

One of the big advantages of natural
35
GENERATOR SETS
gas, of course, is that it burns more cleanly than diesel. This comparison is exacerbated for any of the operating conditions
mentioned in the previous section, where
wasted fuel increases soot and dangerous
emissions.
In addition, shortened engine life from
wet stacking, light loads, inadequate
maintenance and other common diesel
generator issues can negatively impact
monitoring must be verified through reporting, and if operators allow engines to

fall outside acceptable ranges with poor
maintenance or fuel conditioning, steep
fines can result. The fines for not keeping
an engine in optimal running condition
can quickly eclipse the added cost of a
natural gas model. Consequently, firms
should consider all of these factors before
they make an engine choice.
needs or performance issues, or during

ongoing operation.
BI-FUEL IS NOT
BI-DIRECTIONAL
ed a detailed article on bi-fuel in June

if you would like more information.
For the purposes of this article, the
point is that bi-fuel solutions do not
work both ways, and due to differences between the fuel types and the
respective ignition systems (compression versus spark-ignited), we do not
anticipate they ever will. As a result, if
you want the option of burning diesel in any percentage, along with the
flexibility to burn a large amount of
Bi-fuel systems can save operators

up to 50 percent on fuel costs, based
upon the cost of diesel relative to
natural gas, and they make diesel engines more environmentally friendly.
Going into the details of bi-fuel solutions is beyond the scope of this article. but HIPOWER SYSTEMS post-
Bi-Fuel add-ons give diesel engines the ability to

burn natural gas, but there are no solutions that
enable natural gas engines to burn diesel. Photo
courtesy: HIPOWER Systems
emissions even more. This can be an

problem, not only for the environment,
but also for regulatory compliance with
the EPA and other agencies that protect it.
The new rules require MACT (maximum achievable control technology)
emissions controls and GACT (generally
achievable control technology) management practices for both major sources
and area sources of HAPs (hazardous air
pollutants).
Engine maintenance and condition
36
One of new technologies beginning to

really make headlines is bi-fuel. With this
technology, diesel engines can run up to
75 percent natural gas, with the gas being
introduced through the air intake.
Functionality is usually provided by an
add-on system, including a highly sensitive, intelligent controller that adjusts and
optimizes the ratio of gas to diesel during startup, to address transient response
www.power-eng.com
GENERATOR SETS
natural gas, you must purchase a diesel generator.

They can come equipped with bifuel add-ons, or operators can add
them at a later date.
FUEL SUPPLY
AND STORAGE
Fuel handling is another area
where diesel gensets and natural
gas generators are not converging.
As with other criteria, the benefit
of one over another often depend
upon the situation and need.
For example, it is widely promoted that natural gas delivered from a
pipeline can run a generator indefinitely in the case of a disaster. This
is true in most situations, but there
are caveats. Its fairly evident that
any natural disaster that disrupts
the earth, such as an earthquake,
can cause supply disruption.
Of greater surprise to many enterprises, weather-related events
such as hurricanes and tornadoes
can cause damage to buildings that
disrupts their natural gas lines.
This in turn can impact gas pressure in the surrounding area or
even force a utility to shut the gas
supply off.
Any power provider considering
a natural gas genset as a backup
power supply to keep utility offices
running in the event of storm or
for other reasons should be aware
of these possibilities.
For diesel, fuel availability is limited only by delivery frequency. If
diesel trucks can service a site, then
fuel supply is no problem.
However, in remote locations
that use generators for backup or
prime power, weather can factor
into fuel delivery, as well.
Additionally, diesel fuel can become contaminated with water,
particulates and algae over time.
(Ultra-low-sulfur diesel fuel is
38
especially prone to degradation.)

For remote locations that cannot
easily undertake routine fuel sampling and cleaning, automatic fuel
polishers, which consist of a pump
and filtration system, can be incorporated into a diesel genset.
is a sensitive issue, enclosures with

rock wool insulation can close the
gap that traditionally separates quieter natural gas generators from diesel models.
THE FINAL ANALYSIS
There are other minor factors to

consider when comparing diesel generators to natural gas gensets, such
as fire safety (advantage, diesel) and
Another traditional factor in spill risk (advantage, natural gas).
comparing natural gas to diesel has
Even here, companies on both
been the cold-sensitivity of diesel sides are taking steps to level the
fuel and engines.
playing field.
This has become less of an issue
Diesel engine makers are incorpoin the past decade or so, as fuel ad- rating 110 percent spill containment
ditives and special
catch basins into
fuel types were de- Fuel handling
their enclosed genveloped to reduce
erators, and natural
diesel gelling in is another area
gas generator mantemperatures to as where diesel
ufacturers are makoF.
low as -20
ing their enclosures
gensets and
More
recently,
more fire proof.
natural gas
the rise of enclosed
They both want
generators
with generators are not
as much generator
winter add-ons has converging.
business as posmade gelling even
sible, so both will
less of a concern for diesel engine continue striving to erase any perperformance.
ceived drawbacks.
These developments are especialWith 81.6 percent of units shipped,
ly welcome in the remote locations globally, in 2013 per research firm
common to mini-grids, wind and IHS, the diesel genset market far outsolar farms, and other small energy paces that of natural gas.
producers.
However, natural gas generator
Gelling is primarily a concern sales are running nearly 12 percent
when it enters the engine (specifi- per year, and sales of alternative
cally the fuel filter, where gelled fuel energy options, such as generators
clogs up the filter, preventing a freely that run biodiesel, are increasing,
flowing fuel supply to the engine).
as well.
Heated enclosures powered by
The impact will be enough, IHS
the generator itself, not to mention predicts, that diesels market share
fuel filter heaters and other local- will have dropped 10 points by
ized heaters, do an outstanding job 2018, to 71.1 percent.
of keeping the engine and its liquids
This battle, propelled with manat the proper operating temperature. ufacturers that continue to innoModern enclosures for diesel gen- vate on a near-monthly basis, enerators also make it easier to damp- sures the contest between diesel
en sound and vibrations.
and natural gas generators will be
In areas where noise or vibration running for quite some time.
PROTECTION FROM THE

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OPERATIONS & MAINTENANCE
Cost Benefits of
Critical Valve Repair
in the Heat Recovery
Steam Generator
BY ARVO EILAU, PENTAIR VALVES & CONTROLS
urrent global power

generation
market
conditions,
driven
by an abundance of
natural gas fuel, recent
advances in gas turbine technologies
and more efficient combined-cycle
component operation, have placed
enormous demands on critical valves
within thermal generation systems.
Seeking to align their technical and
commercial goals, market leaders are
challenging traditional mindsets by
performing new, objective analyses of
valve lifecycles and product costs to
determine the most judicious strategies for keeping their power plants operating at optimal efficiency.
Corporations that had focused solely on large-ticket critical components
turbines, generators, heat recovery
steam generators (HRSGs), boiler feed
water pumps (BFWPs), etc. are now
turning toward a more inclusive approach that takes into account generation components, such as valves,
once considered non-critical to daily
operations. In the face of ever-evolving
electrical dispatch requirements, these
components are taking on renewed
importance as they move from monthly or biannual service duty to a daily
cycle.
This article focuses on two of these
now-critical components, small bore
40
vent valves and drain valves, reporting

research findings that repairing these
valves is more prudent and economical
than replacing them.
Why focus on vent and drain valves?
Modern advance frame combinedcycle power facilities operate in a dispatch environment where cold starts,
accelerated ramp rates and low load
conditions are the norm and where
Balance of Plant (BOP) equipment accounts for more than half of all forced
outages. Analysis by Pentair Valves &
Controls revealed that valves are a significant contributing factor in forced
outages, primarily based on their application numbers and the severity of
their service applications. As we segregated the valves based on their duty
service as it relates to cycling activity,
we found that small to medium bore
equipment drain and vent valves with

higher duty cycles exhibit a critical
component profile not previously associated with these former commodity, or buy-out, valves.
Pentair proceeded to review valve
products designed for combined-cycle power facilities in these small to
medium bore drain and vent applications. Applications were selected for
their severe duty cycles (temperature
and flow), directly related to cycling of
the combustion turbine/heat recovery
steam generator, and their strict boiler
and piping code design requirements.
Our project objective, beyond continuous product improvement, was to evaluate the products overall contribution
to the customers corporate strategy
objectives as previously outlined.
This research would also compare a
Example A Repair
Tooling
Material
1
Cost
Yarway Valve Tooling P/N 5617B
Insulation
Valve Packing Set
$130.00
Applied Labor rate/hour
$100.00
X number of hours
Labor
2.5
X numbers of Workers
1
Subtotal
$250.00
Total
$380.00
Source:
www.power-eng.com
repairable product to a replacement product to determine

which offered superior benefits.
The project team comprised Pentair Valves & Controls design and manufacturing experts, independent power generation consultants and product end-users. To ensure objectivity, the team also enlisted the services of independent global
consulting firm Energy Werks Consulting, LLC, recognized
for its work in the global power generation business sector.
1.866.643.1010
ClearSpan.com/ADPWRE
THE STUDY
We selected Pentairs 1.5 1700#-4500# Yarway Welbond
High-Pressure Globe valve for evaluation. This valves design is consistent with our previous Six Sigma forced outage
research findings. It exhibits a high profile of widespread
application in the global power generation market for HRSG
drain and vent applications. It also boasts a long tradition
in power generation service applications in general, and it
is refurbishable, often fitted with an automated operator for
cyclic duty.
Our objective was to independently review and analyze
the average actual repair cycle cost associated with this
valve, operated within a specific thermal cycling duty for an
HRSG vent and drain application. In our study, these valves
were located predominantly in automated vent applications
for the HRSG, while larger bore Pentair (4-6) valves were
applied to the HRSG drain applications, primarily based on
individual HRSG module design criteria. Each of the combined-cycle units utilized in the study exceeded 250 MW in
total generation capacity, were of advance frame combustion
turbine design, were equipped with a triple-drum HRSG,
had been automated specifically for cycling duty, and were
operating in the North American power generation market.
These units see multiple fast starts and cold starts, and varying daily load-range conditions, and operate within a generation grid where renewable energy is present. As our study
progressed, it became apparent that certain valve repair and
manufacturing impact similarities among this valve design
class grouping could be identified and then extrapolated to
the larger (4-6) Pentair valves not included in our study.
This case study provides insight into the typical costs associated with the average lifecycle of a repairable Yarway
Welbond 1.5, 1700#-4500# pressure class valve operating
in standard steam service application. The specific product
utilized for this detailed cost analysis was the Yarway Welbond 1.5, F-22 material, 1700# pressure class valve, operating in the HRSG automated vent service for power generation application. Both hard and soft costs related to these
valves lifecycles will be determined. These severe service
duty valves do require periodic inspection and maintenance
as part of normal operations.
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OPERATIONS & MAINTENANCE

REPAIR VS. REPLACEMENT
COST SUMMARY
Example A reflects the hard costs
associated with a typical Yarway Welbond valve repair after routine periods
of operational service. Scope of repair
consists of the valve disassembly/reassembly, the use of Yarway specialized
tooling for the refurbishment of the
valve seat, lapping of valve disc assembly (if required) and valve stem packing
replacement.
*Yarway Welbond 1.5, 1700# pressure class valve tooling (packing and
backseat removal part #5617B) consists
of a mandrel with reusable cutters sized
specifically for the valve being refurbished. This tool can be obtained from
the OEM (suggested list price is $2,700
each). Tooling cost will be applied to
each valve refurbishment cost cycle in
the Repair vs. Replace analysis table.
*Insulation costs are not calculated
in the repair summary, since the valve
remains in position, and packing may
be accessed without disturbing the existing valve body insulation.
Typical 2.5 hours to inspect and repair using the proper valve tool kit.
Example B reflects the hard costs
of a typical Yarway Welbond valve replacement after routine operational
service. Scope of replacement consists
of insulation removal, valve removal,
valve replacement, weld procedure,
NDE procedure, and insulating the
valve body and adjacent piping.
*Equipment cost has been excluded
from this cost exercise, since it may
vary significantly by location, company and corporate accounting practices.
It should be noted that even a conservative Operations & Maintenance
(O&M) accounting of equipment costs
associated with the valve replacement
procedure example would include basic hand and power tools, and welding
equipment funding @10 percent of
project total value ($302.50) per occurrence.
42
Example B Repair
Tooling
Material
2
Cost
Equipment
Insulation
* $225.00
Vlave
$1,600.00
Applied Labor rate/hour

Labor
$100.00
X number of hours
X numbers of Workers
2
Subtotal
Total
$1200.00
$3,025.00
Source:
*Insulation costs vary significantly

based on the type of material and
overall piping configuration. Reusable
valve/piping insulating blankets,
often accounted for in piping project
capital budgets, vs. in-kind insulation
replacement, accounted for in daily
O&M budgets, highlights this cost
disparity. In each example presented
(A and B), an average cost of labor
and material for turnkey installation
methodology was utilized. The valve
replacement project cost assumptions
DO NOT include labor mobilization
and demobilization costs. It is assumed the work scope is performed on
location by craft personnel.
SOFT COSTS
ASSOCIATED WITH VALVE
REPLACEMENT
Although more difficult to quantify,
soft costs must be accounted for in the
Repair vs. Replace decision process. In
recent years, site operational responsibilities and global stewardship in the industry have increased the traditional list
of soft costs associated with performing
routine valve maintenance tasks. The
following activities impact the realized
cost of the replacement valve project
considerably, but have minimal impact
on the actual project cost.
Inventory Control: Valve manufacturer, size, material, pressure rating,
configuration, quantity, etc. all must
be updated and recorded in warehouse

inventory control and workforce management software programs each time
a valve is replaced in a process system.
Welding: Prior to the physical practice of welding the replacement valve
into the process system, you must validate and record the welders qualifications, confirm that the weld procedure
is correct for the valve and connecting
piping material, and process application. Local, regional, state and national
governing codes directly and indirectly
associated with the welding process
may translate into additional cost burdens for this activity. Individual underwriters requirements for further
historical record retention of the valve
replacement event can prove to be an
unexpected/hidden overhead cost.
Nondestructive Examination (NDE):
Minimum code requirements are visual
NDE with further escalation in NDE
work scope based on the valve material
and process application.
Environmental: Environmental activities and related costs will deviate
significantly based on project location
and governing regulations. Impact costs
may range from local industrial waste
disposal policies of the discarded valve
to the carbon footprint taxes associated
with the manufacturing process of the
replacement valve. Often these environmental impacts cannot be isolated
to single project event or maintenance
www.power-eng.com
activity, and are considered in the overall site (environmental plan).
CONCLUSIONS
This study revealed that the cost to
repair this type of critical thermal valve
is significantly lower than the cost to
replace it after every cycle. The fact that
Pentairs Yarway Welbond repairable
valves can be repaired inline is an additional benefit. Repairing is also a more
sustainable solution, as is reduces the
total process cycle.
service application. Based on manufacturer repair data for routine

valve service in steam application,
the following economy of savings
could be realized by the user.
*Tooling cost has been amortized
into each of the valves repair cycles
@$900 per occurrence based on a single valves maintenance requirements
in this standalone business case. This
significantly discounts the economy of
scale for tooling, considering an average power generation facility would
Initial Capital Cost
3
Valve $1,600.00
Insulation $225.00
Craft Labor (Welding) $1,050.00

Non Destructive Examination $150.00
Total $3,025.00
Repair Cycle 1
$380.00 Replacement Cycle 1
$3,025.00
Repair Cycle 2
$3,025.00
Repair Cycle 3
$3,025.00
*Tooling
$2,700.00
Total $3,840.00
Total $9,075.00
Source:
More detail is provided in the following points:

The first maintenance cycle of the
Yarway Welbond repairable, 1.5,
F-22 material, 1700# pressure
class valve provides the opportunity to refurbish internal valve
components vs. replacing the
valve at a direct cost reduction of
$1,745 per maintenance cycle. The
total lifecycle cost associated with
the valve is primarily determined
by the number of maintenance
refurbishment events the internal
valve components (Stellite seat)
provide. Manufacturer documentation suggests a minimum of
three valve seat refurbishments
are achievable prior to replacing
the valve body or other significant
valve components under routine
www.power-eng.com
have more than 50 valves requiring

this specific tool application.
Data generated through this study
indicate that every repairable
small bore valve functioning in
these duty cycles routinely will
provide significant savings over
their entire service lifecycle, in
comparison to a valve designed
to be discarded after each and every service cycle. Given that each
combined-cycle unit in operation
today utilizes a minimum of 50
1.5-2.0 valves within this pressure class, functioning in steam
vent, steam vent blocking and
drain applications, annual valve
savings could exceed $261,000.
In addition to the economic benefits, repairing vs. replacing valves
is consistent with corporations
commitment to environmental
stewardship. Our industry has
depended in the past, and shall
depend well into the foreseeable
future, on renewable resources at
all levels of the power generation
market spectrum. Whether we define a renewable resource at the
macro level of a source like wind
or solar electrical production, or
at the micro level of a repairable,
recyclable plant component, our
primary objectives remain the
same: industry sustainability and
profitability. All successful corporate strategies today and for future
global power generation markets
will be required to address the
question of product sustainability. Competition for everything
from raw goods in manufacturing
to end-users in developed generation markets will have a profound
impact on our daily operations.
Phrases such as going green
and environmentally friendly
have been replaced by phrases
like cost-effective manufacturing environment and long-term
fixed O&M costs. Reducing the
steps in any manufacturing or repair process cycle will ultimately
reduce the process cycle cost. The
marriage of good business processes and strong quality control
measures with consistent repair
practices will result in best-inclass methodologies. Recycling
or the refurbishment of most resources utilized in our industry
today by definition reduces the
total process cycle and is part of
a cost-effective, sustainable business model.
Repairing valves is a viable option for combined cycles or coal-fired
plants. Pentairs Yarway Welbond repairable valves are a cost-effective and
responsible solution for todays power
plant operators.
43
PRODUCTS
Flue gas analyzer
instrumentation, voltage dividers, measuring equip-
Stepless shear bolt connector
ment, electrostatic and current limiting devices.
he E4400 is a portable
The ARC1 type is a space saving planar design
for emissions monitoring and
offering users a choice of axial or radial assem-
complement the line of 600 A deadbreak connector
maintenance & tuning of com-
bly and either conformal or glass coatings. The
systems from its Cooper Power Systems business.
bustion processes. Its rugged
ARC1 series have resistors with voltage handling
With stepless bolt and
design and True NOx capa-
capability of up
friction disc technology,
bility makes the E4400 the ideal industrial analyzer
to 35kVdc and
the new shear bolt con-
for boiler, engine, furnace, and other combustion
has an operat-
nector reduces the po-
applications.
ing temperature
tential for error during in-
The analyzer includes sensors that can detect
range of -55C
stallation, and increases
oxygen, carbon monoxide, nitrogen oxide, sulfur
to +175C. The ARC2 and ARC3 are radial de-
the reliability of medium
dioxide and others.
signs with operating temperatures from -55C to
voltage collector systems without crimping, fling or
E Instruments International
Info http://powereng.hotims.com RS#: 400
+225C. The ARC2 has a maximum operating volt-
additional special tools.
Arc stud welder
age of 54 kVdc, while the ARC3 reaches 96 kVdc.

ARCOL Resistors
elson Stud Welding has introduced the frst

120-volt stud welding power source developed
stepless shear bolt connector is available to
The stepless shear bolt connectors are available with Eatons 15, 25, and 35 kV class BOL-T
and BT-TAP deadbreak connector systems, and
can be used for both aluminum and copper con-
Customized stacked SMPS
ductors. The connectors are also a part of the
VX Corp. has made several new custom-
systems tested in accordance with the Institute
form. Designated the N550c Arc Charger, the new
ization options available for its SMX Series
of Electrical and Electronics Engineers (IEEE), Std.
high-speed stud weld system can precisely weld the
Stacked SMPS MLCCs. The various customiza-
386 - 2006 standard.
full range of drawn arc studs up to 3/8 pitch (M8)
tion options, which include custom geometries,
diameter. Input energy is effciently drawn from a
packages, terminals, lead confgurations, and
Cooper Power Systems

standard 120V wall outlet, and stored in a durable,
stress relief mounting options, allow engineers to
precisely charged electrical storage system. The
achieve higher effciency, space-saving designs
Boom lifts
user can even adjust the rate of this energy draw,
with enhanced mechanical and thermal reliabil-
allowing an Arc Charger to share a single wall outlet
ity. Additional benefts available through
around Nelsons industry leading Arc Charger plat-
with other devices.
LL Aerials has added to their feet with a major

package purchase of 60 new JLG aerial lifts: a
mix of telescopic boom lifts and articulating boom
The N550c Arc Charger weighs just 86 pounds
lifts to meet increasing customer needs. Of note,
and requires no special training making weld
40 of the 60 units are in the 60- to 86-foot height
set-up quick and easy. The welder just inputs the
range, the sweet spot that is heavily in demand in
stud diameter and base material type, and a fea-
mills, processing, general industrial, and the boom-
ture on the system, the Stud Expert, automatically selects the right setting.
ing vertical construction markets.

customization include wholly eliminating solder-
The package of 60 units includes (49) JLG
The Arc Chargers versatile keypad makes setup
ing requirements by enabling direct electrical and
telescopic boom lifts and (11) JLG articulating
easy, with preset buttons provided to save favorite
mechanical connection to the circuit and eliminating
boom lifts, specifcally: (6) model 400S telescopic
settings. The alphanumeric display shows set-
the risk of thermal shock by enabling remote solder-
boom lifts and (4) model 460SJ telescopic boom
tings, actual weld results, as well as diagnostic
ing further from the ceramic capacitor case.
lifts; (14) model
error codes to help with troubleshooting. The Arc
SMX Series MLCCs exhibit high frequency per-
600S telescopic
Charger is compatible with guns, cables and other
formance and high current handling capabilities in
boom lifts and
accessories from Nelson.
addition to low ESR, ESL, and DC leakage. Available
(6) model 660SJ
Nelson Stud Welding

with voltage ratings spanning 25V to 500V, capaci-
telescopic boom
tance values up to 270F, and both C0G and X7R
lifts; (5) model
dielectrics, SMX Series MLCCs also exhibit rugged
800S telescopic
Thick-flm resistors
mechanical shock and vibration capabilities and a
boom lifts and (4) model 860SJ telescopic boom
he ARC series of versatile, high-quality, non-
wide frequency response in high pulse, high current,
lifts; (4) model 1200SJP telescopic boom lifts and
inductive, high voltage, thick flm resistors are
and high temperature applications up to +200C.
(6) model 1350SJP telescopic boom lifts; and (6)
suitable for a wide range of applications, includ-
AVX Corporation
model 600AJ articulating boom lifts and (5) mod-
ing; high voltage power supplies, high specifcation
44
ower management company Eatons latest
fue gas analyzer designed
el 800AJ articulating boom lifts.
www.power-eng.com
SAVE THE DATE

DEC. 810, 2015
LAS VEGAS CONVENTION CENTER
LAS VEGAS, NV
POWER-GEN.COM
THE WORLDS
LARGEST
POWER GENERATION EVENT
OWNED & PRODUCED BY:
PRESENTED BY:
SUPPORTED BY:
Topping off the group, the 1200SJP and
two-piece contact system, which features an inte-
an automation level, thereby confrming the pow-
1350SJP telescopic boom models feature plat-
gral latch to prevent unmating in harsh commercial
er, speed and accuracy within a reduced mechani-
form heights of more than 120 feet, horizontal out-
and
cal size that is 30 percent more rigid compared to
reach of 75 to 80 feet, and a 1,000-pound capac-
applications, the
Racer 7-1.4.
ity in the restricted working envelope (500 pounds
new bonded ca-
in the unrestricted working envelope).
ble
Comau SpA
ALL Aerials
Info http://powereng.hotims.com RS: 405
match the pitch
industrial
assemblies
of the connector,
Combustion gas analyzer
provide a cleaner appearance than discrete wires
Broadband caps
bound by cable ties, and simplify the assembly
VX Corp. introduced a new series of ultra
process by providing customers with a complete,
furnace, and other combustion applications. Pre-
broadband capacitors designed to address DC
custom, and fully tested connector solution.
calibrated and feld replaceable sensors allow for
rugged unit for boiler, burner, engine, turbine,
blocking from ~16KHz to 40GHz. Exhibiting ultra
AVXs 9159 Series two-piece plug and socket
broadband performance, extremely low insertion
connectors comprise the most extensive collec-
loss, and excel-
tion of low profle, low pin count (2p-6p), WTB solu-
It tests for oxy-
lent return loss,
tions available in the industry. Based on high reli-
gen and carbon
the new GX0S
ability, gold plated beryllium copper (BeCu) spring
monoxide and uses
Series capacitors
contacts and rated for a full 5A per contact and
Bluetooth wireless
are packaged in
operating temperatures spanning -40C to +125,
communication. It
a compact 0301
9159 Series connectors provide maximum contact
includes stack gas
case. Featuring X5R characteristics, GX0S Series
integrity and performance when bringing power
& ambient air temperature measurements, draft and
ultra broadband capacitors are ideal for semicon-
and signals onto or off of a PCB in a wide variety of
differential pressure measurements, internal memo-
ductor data communications, transmit and receive
commercial and industrial applications.
ry and a 12-inch probe with 10-foot dual hose and
optical subassemblies, transimpedance amplifers,
AVX Corp.
optional hose extensions.
and test equipment.

Series are as follows: 0.1F capacitance, 20 per-
Racer 999 robot
cent tolerance, and 6.3VDC at 85C or 4.0VDC at

125C operating temperature. Insertion loss for
the series will typically fall in the range of 0.4dB;
tures of Racer 7-1.4.
time and costly repair charges.
omau launched its Racer 999 robot, a six-axis
Compact flter systems
articulated robot that inherits all the key fea-
however, insertion loss at frequencies higher than
With a reach of under a meter in length
40GHz will be partially dependent on installation
(999mm), Racer 999 is particularly suited for
parameters.
easy diagnostics and replacements to reduce down-
Electrical specifcations for the new GX0S
riez HydroFlow manufactures an array of compact flter systems. The cutting-edge products
in this line include Gravity Filter Systems, Magnetic

Coolant Cleaners and Hydrocyclone Separators.
applications in a lim-
The Eriez HydroFlow Gravity Filter Systems prod-
ited space including
uct line refers to flters that use gravity to force
well suited for high volume solder assembly and
assembly,
handling,
dirty coolant through the fltration media. These
are available with two termination options to ex-
machine
tooling,
systems are primarily used for industrial machine
pand the range of compatible attachment pro-
packaging and more.
applications, but large fow cell type systems can
cesses: Ni/Sn terminations, which are standard, or
Designed for a payload
be offered. Gravity Paper Systems employ dispos-
Ni/Au terminations, which are wire bondable and
of 7 kg, the robot can
able roll media for fltration and are ideal for grind-
can therefore prove particularly useful in bypass
carry up to 10 kg with
ing applications. Gravity Drum Systems employ
applications. Packaged on 3 tape and reel in
a limited excursion of the axis 5 for high-speed
a permanent stainless steel or nylon mesh flter
quantities of 500, 1000, or 4000 pieces, all GX0S
Pick & Place, and is undeniably the fastest in its
media and are ideal for machining applications,
products are RoHS compliant.
category. In addition, it can be mounted in a clas-
particularly aluminum machining where foating
AVX Corp.
sic ground-mount position as well as on the wall,
chips are present. Standard units are designed
ceiling or on inclined supports.
with low coolant entry height, allowing for gravity
GX0S Series Ultra Broadband Capacitors are
Racer 999 retains the technology platform fea-
46
he E1100 Hand-Held Combustion Analyzer is a
return from the machine tool.
Cable assemblies
tured in Racer 7-1.4, which means that the control
Eriez HydroFlow Coolant Cleaners keep ma-
VX Corp. offers custom cable assemblies for its
(C5Compact), Teach Pendant (TP5), engines and
chine tools running longer and more accurately
extensive 9159 Series two-piece wire-to-board
spare parts are exactly the same. This enables
with lower costs per unit produced. As stand-alone
(WTB) connectors. Paired with the highly reliable,
economies of scale and maximum integration at
units or in conjunction with the Gravity Bed Filters,

www.power-eng.com
Magnetic Coolant Cleaners provide media free re-
Coolant recycling systems
features. Its stacked tank design is ideal for the
moval of ferrous contaminants down to 50 micron.
our HydroFlow Coolant Recycling Systems from
shop trying to conserve foor space. With its stan-
Eriez Minimize Fluid Disposal and Improve Plant
dard high-speed centrifuge, this system allows for
Productivity. A HydroFlow Coolant Recycling System
complete recycling of any metalworking coolant.
from Eriez can recycle any water-miscible fuid to its
Because the CRS 120ST uses a true high-speed
Five position mini connector
maximum potential and in doing so minimizes or
centrifuge, only one pass through the system is
nderson Power Products added a 5 Position of-
eliminates disposal, reduces usage of the fuid con-
necessary to remove tramp oils, particulate matter
fering to the Mini SPEC Pak connector family.
centrate, and improves plant proftability and pro-
and a substantial portion of the bacterial popula-
This environmentally sealed and touch safe con-
ductivity. Four systems available range in size from
tion. The CRS 300ST unit delivers an even larger
nector houses up
small to large and feature low maintenance, unat-
centrifuge for higher processing rates.
to 5 contact posi-
tended operation, and fast return on investment.
Eriez
Info http://powereng.hotimes.com RS#: 413
Eriez HydroFlow
tions in a compact
latching shell.
Power
The CRS 120SS unit has convenient side-byside tank design and is equipped with a Coalescer
han-
for removing free and mechanically mixed tramp
dling capabilities
oils. The CRS 120SS can also be ftted with a high
MCI-2012 IntegraPel is an integral waterproof-
up to 23 amps and 600 volts AC/DC per pole allow
speed centrifuge (either initially or at a later date),
ing and corrosion-inhibiting admixture designed to
more power in a smaller waterproof (IP68) shell
which removes not only the free-foating and me-
prevent or retard corrosion of steel reinforcement
than competing solutions. An easy to assemble
chanically mixed tramp oil, but also those bac-
in new concrete structures. It is a water-based
back shell design enables the 5 Position Mini PL
teria-feeding tramp oils that have been partially
organic admixture.
to accommodate up to 12 AWG (2.5 mm) wires
emulsifed into the metalworking fuids.
a two-pronged approach to protect embedded
while maintaining the compact size. Gold plated
The CRS 120ST model includes even more
Corrosion prevention
MCI-2012 IntegraPel uses
steel. It reduces the intrusion of corrosive species
contacts down to 24 AWG (0.25 mm) are suitable

for power or signal needs. Optional sequencing
capabilities are available for design fexibility.
Anderson Power Products
Tension-spring connection system
he ZST pluggable, tension-spring connection

system from Conta-Clip features modular and
fexible connection technology for quick installation and wiring safety. Using the ZST tension-spring
connection,
pluggable
wiring is possible up to a
rate current
of 24A, a
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rated voltage of 500V, and a cross section range of

0.5 mm2 to 4mm2 with the easy to operate tensionspring connection system.
The housing insulation material of the ZST
system is polyamide PA6.6 UL 94, fammability
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class V0, self-extinguishing without burning drops.

Housing insulation is free of materials such as
halogen or phosphor. It is temperature resistant to
-40C to +120C and offers creepage resistance
of CTI600.
Powered by
MAPSearch
A PennWell Company
Conta-Clip

www.power-eng.com
47
into the concrete and provides a self-replenishing
Power modules
Level transmitter
protective layer on embedded reinforcement with

Cortecs patented, time-proven migratory corro-
sion inhibitor (MCI). MCI-2012 IntegraPel differen-
new 20A all-SiC
sor modules, each connected electronically to a
tiates itself from other waterproofng admixtures by
module
ideally
single transmitter. Using a Ceraphire ceramic sen-
directly protecting the reinforcing steel, the entity
suited for 5-15 kW
sor in the pressure sensor modules, the transmit-
that plays the most important role in determining
three-phase ap-
ter calculates the differential pressure from both
the longevity of a concrete structure.
plications. Based
sensors and transmits the level, volume or mass
MCI-2012 IntegraPel is particularly suited as a
on Crees C2M SiC MOSFET and Z-Rec SiC Schottky
via 4-20 mA with HART as a standard two-wire loop-
corrosion preventative for concrete construction
diode technology, the six-pack module enables
powered device.
exposed to corrosive environments (carbonation,
designers to unlock the traditional constraints of
One sensor module
chlorides, and atmospheric attack). This product is
power density, effciency, and cost associated with
measures the hydro-
formulated to reduce porosity of the concrete and
Si-based inverters used in industrial power conver-
static pressure (HP) and
make the concrete waterproof. It also incorporates
sion systems.
the other one the head
ree Inc. has expanded the silicon carbide (SiC)

1.2 kV six-pack power module family with a
level transmitter, which uses two pressure sen-
corrosion inhibitors that protect the steel rebar
The all-SiC 1.2 kV, 20A six-pack features the
itself. MCI-2012 IntegraPel admixture is added to
industrys lowest switching losses due to the zero
sensor sends a digital
concrete prior to placement, thus inherently in-
turn-off tail current in the MOSFET and the zero
signal corresponding to
creasing the durability of the concrete/mortar. This
reverse recovery current in the Schottky diode.
temperature
economically effective liquid is recommended
When compared to similar Si IGBT modules, the
sated measured pressure to the transmitter. This
for all reinforced concrete including precast, pre-
new Cree 20A six-pack module operates at a much
electronic system eliminates issues of traditional
stressed, and post-tensioned structures.
lower junction temperature allowing designers to
differential pressure measurements by doing away
Migrating Corrosion Inhibitors

aggressively pursue new paradigms in high fre-
with impulse lines or capillaries and their related
quency and power density without compromising
issues of icing, clogging, leaks, condensation and
on effciency.
changing ambient temperatures.
Cree Power
via industry standard, color-coded twisted pair ca-
Ash-free corrosion inhibitors
ortecs newest product M-531 T is an oil- based

additive package of ash free corrosion inhibi-
pressure
(LP).
Each
compen-
The sensors connect to the transmitter module

ble and have NEMA 4X/6P (IP66/IP68) watertight
tors for petroleum or
Current switches
housings and connections. The transmitter can
synthetic oil based
K Technologies introduced ASXP-LS Current
be located away from the sensors in areas safe
lubricants such as
Switches a combination current transform-
and convenient for personnel. The system meets
rust and oxidation
er and signal conditioner designed specifcally
ATEX, IEC Ex, CSA and FM specifcations for use in
preventatives,
draulic,
hy-
for
lubricants
for industrial gear oils.

M-531 T is readily compatible and very effec-
48
ndress+Hauser introduced the Deltabar FMD71
monitoring
hazardous areas including Zones 0, 1 and 2; and
large loads. The
Division 1 and 2.
ASXP-LS Current
Endress+Hauser
Switches feature
tive in naphthenic, paraffnic, isoparaffnic, or
electromechani-
poly-alpha-olefn (P AO) based lubricants. M-531
cal relay output, external power source, simple feld
Digital product catalog
T is particularly recommended for enhancing
setpoint adjustment and easy installation. The me-
corrosion protection of industrial lubricant appli-
chanical relay contact provides a trouble-free, dura-
cations where flterability and water separability
ble alarm or interlock, improving safety and overall
catalog at www.GemsSensors.com.
are required. M-531 T is soluble in petroleum and
system reliability, while the selectable Fail Safe
synthetic lubricant base stocks and most common
operation provides protection for critical loads.
ems Sensors & Controls (Gems) launched its

fully digital living online standard product
The new Gems
digital
catalog
solvents; insoluble in water. When added at rec-
ASXP-LS Current Switches are used to moni-
ommended concentrations it does not affect water
tor large machines for over- or under-load con-
delivers accurate,
timely
separability, pour point, or viscosity, resists gelling
ditions, detect open discharge lines and sense
thousands of liq-
when contaminated with water. It is available in
clogged flters. They can also monitor generators
uid level, fow and
5-gallon (19 liter) plastic pails and 55-gallon (208
to shed non-critical loads when demand reaches
liter) metal drums.
a set level.
with each model linking to immediate online or-
Cortec
NK Technologies
dering. All new product introductions, reference
data
on
pressure switches,
specifcations and pricing are updated real-time.

www.power-eng.com
COVERING IT ALL
December 6-10, 2015

Las Vegas Convention Center / Las Vegas, NV, USA
www.powergenerationweek.com
SAVE the DATE!

Owned & Produced by:
Presented by:
Supported by:
An easy-to-navigate layout offers the same look
optimizing the combustion effciency of large boil-
Nitrile-Dipped Gloves
and feel as the traditional print version. Its added
ers and industrial furnaces.
functionality includes page-fip transitions, offine
saving, full PDF downloads, social media sharing,
922CR Cut Resistant Nitrile-Dipped DIR Gloves.
bookmarking, and the capability to both make
The new 922CR offers the same patent-pending
and save page annotations. For added customer
dorsal protection, grip, fexibility, and dexterity as
Impact-Reducing (DIR) Glove: the ProFlex
convenience, the catalog also features directly

downloadable links to individual product installa-
rgodyne offers their third knit dipped Dorsal
the popular 920 and 921 DIR gloves while also

The 6888 incorporates a calibration recom-
delivering EN Level 5 cut protection and Level 3
tion manuals.
mended diagnostic with gas-switching solenoids
puncture protection from rugged HPPE seamless
Gems Sensors & Controls

embedded within the probe electronics, making
knit construction.
automatic calibration easier than ever. The em-
The 922CR features
bedded diagnostic reduces the cost of providing
an HPPE seamless knit
Solar PV metallization pastes
and installing a separate solenoid box, and also
shell for high cut and
uPont Microcircuit Materials (DuPont) has add-
reduces the effort to wire and pipe between the
slash protection and
ed two new products to its lineup of frontside
probe and electronics, decreasing man-hour re-
superior
silver metallization pastes for crystalline silicon solar
quirements. Additionally, the calibration recom-
Sewn-on (not glued)
cells. DuPont Solamet PV18H and PV18J photovol-
mended diagnostic removes the need to conduct
TPR armor ensures lasting protection in the
taic metallization pastes offer solar cell manufactur-
calibrations on a schedule, eliminating many
harshest applications. The sandy foam nitrile-
ers improved effciency and proftability.
durability.
validations (calibrations checks) or actual calibra-
dipped palm not only provides exceptional grip
The DuPont Solamet PV18x series offers more
tions. The new analyzer also includes a plugged
in water, grease, and oil, it also absorbs and dis-
effciency with less material required. These two
diffuser/flter diagnostic for applications that
places fuids for great gripping power. This kind
newest offerings demonstrate a range of technical
have fy ash or other particulate entrained in the
of durability and protection, however, doesnt
properties to meet different customers manufac-
fue gases, which further reduces personnel time
equate to wearing an oven mitt - the 922CR is
turing process re-
and maintenance as well as helping to ensure
thin and fexible for maximum dexterity and com-
quirements. The
accuracy.
fort while working.
Solamet
PV18x
Another new feature of the 6888 is a variable
series
products
insertion option, which permits ideal placement
deliver
Ergodyne
step
of the probe into the fue gas duct. With stan-
change in the power output of solar panels by
dard length probes from 18-inch (.5m) to 12-feet
Fan blades
improving the conversion effciency of solar cells.
(3.65m) in horizontal or vertical installation, the
This is due to proprietary Tellurium technology,
probe can be adjusted at any time on-line to char-
which is only licensed and available from DuPont,
acterize stratifcation across large ducts.
mized to provide a superior combination of in-
and has been instrumental in unlocking effciency
Emerson Process Management

gains by more than 0.5 percent by allowing con-
ortons most effcient fan blade to date, the

WindShift WSE, has been computer-opticreased airfow and reduced operating noise.
tact to enhanced lightly doped emitters.

Solamet PV18H further enables excellent con-
Emissions analyzer
WSE generates greater
Instruments International launched its E5500
static pressure at slower
on mono-crystalline solar cells to maximize power
portable industrial combustion emissions ana-
speeds. The WindShift
output. Solamet PV18J demonstrates superior
lyzer. The combustion analyzer is a complete por-
adhesion performance even with thinner busbars,
table tool for emis-
Tier 4 and Stage IV agricultural, construction, in-
and improves processing with excellent solderabil-
sions monitoring for
dustrial and power generation equipment.
ity and a wide solder temperature window.
regulatory and main-
The WindShift WSE Modular Fan is available
DuPont Microcircuit Materials

tenance use in boil-
in diameters of 24 to 41 inches (610 to 1040
er, burner, engine,
mm) and 2.44- to 5.94-inch (62 to 151 mm) pitch
turbine, furnace and
widths. Other WindShift blades include WSC and
Flue gas O2 analyzer
other combustion applications. The E5500 includes
WSD, which are engineered for low-restriction
merson Process Management has enhanced
electrochemical gas sensors for oxygen, carbon
airfow applications and ft a narrower, more
the Rosemount Analytical 6888 In Situ Flue Gas
monoxide, nitrogen oxide, sulfur dioxide and others.
compact space.
O2 Analyzer with new diagnostics that help main-
widths ranging from 1.88 to 6.32 inches (48 to
tact resistance to enhanced lightly doped emitters
tain optimum oxygen levels in fue gases, thereby
50
A swept-blade design,
WSE blade is ideal for
WindShift Modular Fans are offered in pitch
www.power-eng.com
161 mm) and diameters from 24 to 52 inches
communications modules to address the chang-
Combustion turbine heap flters
(610 to 1320 mm). Fans are provided with 3 to 16
ing Smart Grid landscape, including the integra-
blades, equally spaced or staggered to modulate
tion of up to 10 Ethernet ports with multi-homing
system noise.
and VLAN tag support, allowing for the deployment
ponents that offer the
Horton Inc.
of complex IEC 61850 projects. In addition, it helps
most cost-effective solu-
simplify Supervisory Control and Data Acquisition
tion for delivery of clean,
(SCADA) operational activities for the user, in-
particulate free air to
Fluid recycling systems
cludes advanced cyber-security features such as
operators of combustion
riez HydroFlows industrial fltration and fuid re-
DNP3 Secure Authentication V5 and is instrumen-
turbines.
cycling systems are optimally suited for a wide
tal to NERC/CIP compliance.
range of applications, including machining, con-
Cooper Power Systems

ventional grinding, creep feed grinding and CBN

grinding/machining.
The complete line
neumafl combined the HEPA rated STMPE10

with high-effciency replaceable pre-flter com-
In addition to the added effciency the flter fts a wide array of turbines
from makers such as GE, Siemens, Mitsubishi,
Alstom, Pratt and Whitney and Solar Turbines.
Pneumafl matched the flters high effciency
Knit Cap and Balaclava

rgodyne has announced today the expansion
components with the industrys lowest operating
ment and recycling
of their N-Ferno Warming Products to include
resistance. The HEPA rated multi-stage flter sys-
solutions from Eriez
the N-Ferno 6820 Flame Resistant (FR) Knit Cap
tem delivers superior durability and reliability over
HydroFlow includes
and N-Ferno 6828 FR Modacrylic Blend Balaclava.
conventional HEPA rated static flter options.
Coolant
These new products are not only built to keep work-
Pneumafl
of coolant manage-
Recycling
Systems, Solids-from-Liquid Centrifuges, Liquid-
ers protected from
from-Liquid Centrifuges, Coalescers and Oil
winters
Skimmers, Sump Cleaners, Magnetic Chip
they also provide
Human Machine Interfaces
Conveyors and Magnetic Separators. This equip-
the utmost in FR
ment solves common challenges in machining,
protection.
conventional grinding, creep feed grinding, CBN
N-Ferno
wrath,
arlo Gavazzi launched their CGHMI Series of
HMIs available in 4 different sizes, constructed
6820
in one of up to three different housing bezels: eco-
Resistant
nomical plastic, durable aluminum or rugged, wash
grinding/machining and more.
Flame
Eriez HydroFlow
(FR) Knit Cap has
down resistant stainless steel.
an ATPV rating of
The CGHMI Series feature ARM processors, wide
49.5 cm/cm2, this
panels, high resolution, 65,536 colors, 128MB ROM,
Substation modernization platform
product is classifed
128/256MB RAM, WinCE operating system and im-
aton introduced its Cooper Power Systems new
as an HRC 4, our
age optimization
Substation Modernization Platform (SMP) SG-
highest HRC rating!
for
4250 Gateway. The device boasts a modular design
The 6820 FR Knit
formance.
Cap provides the
CGHMI
ultimate in FR fabric
screens are avail-
protection and extreme warmth. The modacrylic
able in four sizes
cotton blend construction (in both the shell and
(4.3, 7, 10 or 15 inches), which allow the end user
lining) delivers a toasty warm yet breathable cap
to choose the optimum size that best fts their ap-
that is stylish and excels in FR protection.
plication requirements. The HMIs can be mounted
providing data acquisition and distribution, protocol
best
perThe
Series
translation and secure remote access to substation
N-Ferno 6828 FR Modacryclic Blend Balaclava
vertically or horizontally, whatever the end users
intelligent electronic devices (IEDs) to cost effective-
is classifed as HRC2 according to NFPA 70E, as
application calls for. They can be powered by 11-
ly fulfll a range of substation automation projects.
well as meeting the EN 1149 standards for anti-
36VDC or 90-250VAC. All models also offer an SD
Featuring improved processing power and
static, the FR Balaclava is an economical option
slot and Ethernet port as standard features. Extensive
memory, the SMP SG-4250 serves as a scalable
for workers looking for superior FR protection in
connectivity is possible via Profbus-DP, ProfNet,
solution that can be customized to a utilitys exact
extreme conditions. The 6828 balaclava can be
DeviceNet, EtherNet/IP, CANopen, EtherCAT, and CC-
needs. Additionally, the SMP SG-4250 is compat-
worn comfortably under a standard hat or hardhat
Link. All models are delivered with CG Design Studio
ible with most existing IED manufacturers, includ-
and is built for cold temperatures with a single lay-
software, with the optional CG Design Studio Plus,
ing the support of more than 80 protocols.
er modacrylic blend construction and long length.
which features Symbol Factory.
Ergodyne
Carlo Gavazzi
The newest solution represents the fourth

generation of SMP gateways, offering enhanced
www.power-eng.com
51
Automatic Filters
ShowcaSe advertiSing contact Jenna hall: 918-832-9249, Jennah@pennwell.com
| SUPPLIERS SHOWCASE
Air Preheaters
Why Should You

Filter Your Water?
a brand of TerraSource Global
BOILER FEED SYSTEMS
TRUE PERFORMANCE
THE LJUNGSTRM DIVISION OF ARVOS GROUP,

FORMERLY ALSTOM POWER INC. AIR PREHEATER COMPANY, IS THE WORLDS MOST
EXPERIENCED AND ONLY SUPPLIER OF
GENUINE LJUNGSTRM AIR PREHEATERS.
Wour industry leading products and
solutions and our commitment to R&D,
you can rest assured that LJUNGSTRM
will continue to raise the bar on air preheater technology.
www.arvos-group.com
ljungstrom@arvos-group.com
phone: 585 59 2501

The Best Engineered Water

Filteration Solution Always
Costs Less

Your source for custom-designed,

ruggedly-built mechanical and pneumatic
systems for feeding of biomass and alternative fuels
directly into boilers and kilns.
High-pressure, low-pressure and vacuum
conveying components available.
+1 (864) 476-7523 info@terrasource.com
Handling a World of Materials

www.TerraSource.com/PE
TerraSource Global is a wholly-owned subsidiary of Hillenbrand, Inc.
(NYSE: HI) 2015, TerraSource Global. All rights reserved.
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http://powereng.hotims.com RS#300
Damper Drive Solutions
Emission Control
Iso Phase Bus
Crown Electric
Iso Phase Bus
SOLVAir Solutions was formed

to help customers address the
problems of SOX, HCl and other
stack emissions, as well as help
with the changing EPA regulations.
SOLVAir Solutions is the market
leader in providing sodium
sorbents for use in DSI systems.
Access our brochure on our
Library page at www.solvair.us
Contact Rosemary Dunn
ardunadv@gmail.com
713.521.7450
52
Boiler Feed Systems
Fabrication
Installation
Upgrades & Uprates
GSU Change Outs
513 539-7394 ext.

201
175 Edison Dr.
Middletown, OH 45044
www.crown-electric.com
sales@crown-electric.com
www.power-eng.com
ELIMINATE
Silos, Chimneys, & Steel Stacks
Silo and Bin

Cleaning Services
and Equipment
Valve Cavitation
x
x
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Call 800-322-6653
or visit
www.molemaster.com
For info. http://powereng.hotims.com RS# 451
Quality and Service Since 1908
Ring Granulators, Reversible Hammermills,

Double Roll Crushers, Frozen Coal Crackers
for crushing coal, limstone and slag.
1319 Macklind Ave., St. Louis, MO 63110
Ph: (314) 781-6100 / Fax: (314) 781-9209
www.ampulverizer.com / E-Mail: sales@ampulverizer.com
Get a thorough mix with:
Pugmill Systems, Inc.

P.O. Box 60
Columbia, TN 38402 USA
Ph: 931-388-0626 Fax: 931-380-0319
www.pugmillsystems.com
Classified advertising ContaCt Jenna Hall: 918-832-9249, JennaH@pennwell.Com
Eliminate valve cavitation by

placing one or more diffusers
downstream of the valve.
Noise and pipe vibration will
also be eliminated or reduced.
Valves first costs and maintenance burden
will also be
reduced.
CLASSIFIEDS |
Silo and Bin Cleaning Sevices
| CLASSIFIEDS
FOR SALE/RENT
Chemical cleaning advisory services for

boilers and balance of plant systems
20,000 - 400,000 #/Hr.
DIESEL & TURBINE GENERATORS

50 - 25,000 KW
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LARGEST INVENTORIES OF:

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Valves Tubes Controls Compressors
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FAX: 847-541-1279
visit www.wabashpower.com
wabash
POWER
EQUIPMENT CO.
RENTAL EQUIPMENT
GEORGE H. BODMAN, INC.
24 / 7 EMERGENCY SERVICE
BOILERS
ESI Boi ler R enta ls , LL C
George H. Bodman
Pres / Technical Advisor
P.O. Box 5758

Kingwood, TX 77325-5758
email: blrclgdr@aol.com
Office (281) 359-4006

1-800-286-6069
Fax (281) 359-4225

CONDENSER & HEAT EXCHANGER TOOLS
CLEANERS, PLUGS, BRUSHES
24/7 On-Call Service
John R Robinson Inc

PH # 800-726-1026
1-800-990-0374
e-mail: sales@johnrrobinsoninc.com
www.johnrrobinsoninc.com
www.rentalboilers.com
- Rental Boilers - Economizers - Deaerator Systems - Water Softener Systems -
444 Carpenter Avenue, Wheeling, IL 60090
Exothermic Engineering, LLC

Burner Management
System Logic Review
Has your Burner Management System
been reviewed for compliance with
current NFPA code?
The Code is revised approximately
every 4 yrs, and our staff of NFPA 85
experts has performed more BMS
reviews than anyone.
Our staff actively maintain seats on key
NFPA 85 technical committees,
averaging over 30 yrs of experience.
Complete BMS Services

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out services

and contract administration
We are also experts at solving ancillary
problems with flame scanners, igniters
and other BMS I/O equipment.
Begin with a conference call
No cost, No obligation.
Call Bill Smith:
Exothermic Engineering, LLC
(816) 415-8888
www.ExoEng.com
For Classified Advertising Rates & Information

Contact Jenna Hall
Phone - 918-832-9249 | Jennah@pennwell.com
CONDENSER OR GENERATOR AIR COOLER TUBE PLUGS

THE CONKLIN SHERMAN COMPANY, INC.
Easy to install, saves time and money.

ADJUSTABLE PLUGS - all rubber with brass insert.
Expand it, install it, reverse action for tight fit.
PUSH PULL PLUGS - are all rubber, simply push it in.
Sizes 0.530 O.D. to 2.035 O.D.
Tel: (203) 881-0190
Fax: (203) 881-0178
E-mail: Conklin59@aol.com www.conklin-sherman.com
Just Plugging Along
featuring
Protect-Fast

Add some
Email or call for your

FREE Power Pack
sample kit today!
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Call Jenna Hall

at 918-832-9249
Tel: +1(508)229-2000
www.devicetech.com/pg
save the date!

the center of it all.
DECEMBER 8 - 10, 2015

LAS VEGAS CONVENTION CENTER
LAS VEGAS, NEVADA USA
W W W. C OA L - G E N . C O M
WE ARE PROUD TO ANNOUNCE THAT COAL-GEN IS JOINING
Covering every aspect of the power generation industry, POWER-GEN International, NUCLEAR
POWER International, Renewable Energy World Conference & Expo North America, POWER-GEN
Financial Forum, GenForum, and COAL-GEN converge in 2015 to form Power Generation Week.
Beneft from fve days packed with pre-conference workshops, technical tours, more than 100
conference sessions, panel discussions, three exhibition days and multiple networking events.
Gain access to nearly every facet of the market all under one roof.
OWNED &
PRODUCED BY:
PRESENTED BY:
Braided
Wrap
CLASSIFIEDS |
CRITICAL EQUIPMENT
PROTECTION
SOLUTIONS
INDEX
RS# COMPANY
PG#
RS# COMPANY
PG#
C4
13 MMD Equipment
37
1421 S. Sheridan Rd., Tulsa, OK 74112

Phone: 918-835-3161, Fax: 918-831-9834
e-mail: pe@pennwell.com
19
Sr. Vice President North

American Power Group Richard Baker
Brandenburg Industrial
Service Company
www.mmdequipment.com
www.brandenburg.com
8
14 Circor Energy Products
39
www.circorenergy.com
N B Harty General
Contactor Inc
www.nbharty.com
15 Clearspan Fabric Structures 41

www.clearspan.com
17 POWER GEN
International 2015
45
www.power-gen.com
14 Coal-Gen
55
21 POWER GEN Natural Gas
www.coal-gen.com
C3
www.power-gennaturalgas.com
16 Conco Services Corporation 41

19 Power Gen Week 2015
www.concosystems.com
49
www.powergenerationweek.com
12 Fluke Corporation
33
1
www.fluke.com
ProEnergy Services LLC
C2
www.proenergyservices.com
18 Gen Hubs
47
10 Rentech Boiler Systems Inc 24
www.generationhub.com
www.rentechboilers.com
HDR
5
Rentech Boiler Systems Inc 25
www.hdrinc.com
www.rentechboilers.com
Hilliard Corporation
7
9
www.hilliardcorp.com
Volvo Penta of the Americas 20

www.volvopenta.com
John Zink Co
3
11 Zeeco Inc
www.johnzinkhamworthy.com
28-29
www.zeeco.com
Kochek Company Inc
17
www.kochek.com
Magnetrol International
www.magnetrol.com
Membrana
www.liqui-cel.com
SALES OFFICE
15
Advertisers and advertising agencies

assume liability for all contents (including text representation and illustrations)
of advertisements printed, and also assume responsibility for any claims arising therefrom made against the publisher. It is the advertisers or agencys
responsibility to obtain appropriate
releases on any items or individuals pictured in the advertisement.
Reprints Foster Printing Servive

4295 Ohio Street
Michigan City, IN 46360
Phone: 866-879-9144
e-mail: pennwellreprint@fosterprinting.com
National Marketing
Consultant Rick Huntzicker
Palladian Professional Park
3225 Shallowford Rd., Suite 800
Marietta, GA 30062
Phone: 770-578-2688, Fax: 770-578-2690
e-mail: rickh@pennwell.com
AL, AR, DC, FL, GA, KS, KY, LA, MD, MO,
MS, NC, SC, TN, TX, VA, WV
Regional Marketing Consultant Dan Idoine
806 Park Village Drive
Louisville, OH 44641
Phone: 330-875-6581, Fax: 330-875-4462
e-mail: dani@pennwell.com
CT, DE, IL, IN, MA, ME, MI, NH, NJ, NY,
OH, PA, RI, VT, Quebec, New Brunswick,
Nova Scotia, Newfoundland, Ontario
Regional Marketing Consultant Natasha Cole
1455 West Loop South, Suite 400
Houston, Texas 77027
Phone: 713.499.6311; Fax: 713.963.6284
e-mail: natashac@pennwell.com
AK, AZ,CA,CO,HI,IA,MN,MT,ND,NE,NM,NV,
OK,OR,SD,UT,WA,WI,WY,AB,BC,SK, Manitoba,
Northwest Territory, Yukon Territory
International Sales Mgr Michelle Smith
The Water Tower
Gunpowder Mills
Powdermill Lane
Waltham Abbey, Essex EN9 1BN
United Kingdom
Phone: +44 1992 656 609, Fax: +44 1992 656 700
e-mail: michelles@pennwell.com
Africa, Asia, Central America, Europe,
Middle East, South America
European Sales Asif Yusuf
The Water Tower
Gunpowder Mills
Powdermill Lane
Waltham Abbey, Essex EN9 1BN
United Kingdom
Phone: +44 1992 656 631, Fax: +44 1992 656 700
e-mail: asify@pennwell.com
Europe and Middle East
Classifieds/Literature Showcase
Account Executive Jenna Hall
1421 S. Sheridan Rd.
Tulsa, OK 74112
Phone: 918-832-9249, Fax: 918-831-9834
email: jennah@pennwell.com
56
www.power-eng.com
Brought to you by the most

formidable brands in the energy
business, POWER-GEN and the
Oil & Gas Journal.
AUGUST 18 -20, 2015

GREATER COLUMBUS CONVENTION CENTER
COLUMBUS, OHIO
power-gennaturalgas.com
Introducing POWER-GEN Natural Gas, an annual

conference and exhibition targeting gas-red
generation related to the development of natural
gas reserves in the Marcellus and Utica shales of
the Appalachian Basin. Participate in this event and
join some of the top names in the energy industry
to discuss the issues surrounding technology,
operation, construction, and maintenance of gasred power and production from unconventional
hydrocarbon resources.
Preliminary Conference Tracks to Include:

POWER:
Large Frame Gas Turbines
Operations & Maintenance
Siting & Construction
Small Gas Turbine Applications
OIL & GAS:
Natural Gas Market Developments
Marcellus and Utica Project Proles
REGISTER ONLINE TODAY!
PRESENTED BY:
OWNED & PRODUCED BY:

Powerengineering201502 DL

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We didnt build the rst Boiler.

REPAIRING CRITICAL VALVES

COMBINED HEAT & POWER

the magazine of power generation

February 2015 www.power-eng.com

For info. http://powereng.hotims.com RS#1

CORPORATE HEADQUARTERSPennWell Corp.

Power Engineering is the flagship

ON-LINE EDITOR Jennifer Van Burkleo

Learn how the Environmental Protection

CHP Offers a Competitive Edge

MARKETING MANAGER Rachel Campbell

SENIOR VICE PRESIDENT, NORTH AMERICAN

CHAIRMAN Frank T. Lauinger

CIRCULATION MANAGER Linda Thomas

Maintaining a clean boiler is important to a

NATIONAL BRAND MANAGER Rick Huntzicker

CHIEF FINANCIAL OFFICER/SENIOR

No.2, February 2015

Our expert offers a comparison of natural

Valve Repair in the Heat

Advances in gas turbine technology and efficiency have placed enormous

POWER ENGINEERING ONLINE :

Stay current on industry news,

A concise, weekly update of all

For info. http://powereng.hotims.com RS#2

olar power accounted for more

circumstances caused by this solar revolution. Net metering programs were

up-keep of distribution and generation

amount of renewable generation a utility is required to provide customers.

For info. http://powereng.hotims.com RS#3

KCP&L to stop burning

Dominion plans large-scale

Dominion Virginia Power said it filed

Alabama carbon capture

CO2 for compression and pipeline transport.

Dynegy delays power

B&W to supply supercritical

A Division of THE HILLIARD CORPORATION

For info. http://powereng.hotims.com RS#4

to the nations energy needs, said Elias

Pattern increases share in

GE to provide gas turbines

The Tennessee Valley Authority is

and nitrogen oxide emissions by over 95

Wood pellet company to

be viable, Tampa Electric may purchase

North Carolina solar project

For info. http://powereng.hotims.com RS#5

magnetrol.com 1-800-624-8765 info@magnetrol.com

2015 Magnetrol International, Incorporated

he comment period on the

efficiency and renewables, and 3) adoption of a minimum transition from

was succinctly explained in comments

he Mexican government announced in late 2014 that it

dollars on new wind projects, supplier

authorized $462 million to support U.S.

ike most people in the power

houses and streets. Three decades later in

with a 100 MW capacity. A year later in

Safety Culture Best

ifferent industries have developed their own definitions

frequently and practically never doing