The combed-teeth structure of Siemens’ new low-noise DinoTail aerodynamic blade add-on mimics an owl wing’s trailing edge fringe. For comparison, an un-combed blade is shown on the left.

Following years of research and development, Siemens recently announced a breakthrough in low-noise wind turbine blade design. The new DinoTail technology is an aeroacoustic noise augmentation tool patterned after the trailing fringe of an owl’s wing during flight. It can be added to existing blades.

Silent operation of onshore wind projects is important for facilities located near populations that might be disturbed by noisier turbine blades. To combat this problem, Siemens patterned new technology after the wings of owls, who are silent hunters, flying without noise to better hunt their prey. A serrated, fringed structure at the back edge of the wing, along with small combs at the front edge of the wing, is believed to mitigate the noise of airflow via the creation of small vortices.

In addition to vortex generators on the blade surface, Siemens now equips trailing edges with a combination of serrations and combs. These combed teeth create fine vortices at the point where the fast air stream from above the blade meets the slower flow from below. As a result, the aerodynamic noise from the trailing edge of the blade is reduced significantly.

“In our wind tunnel measurements and field tests, the combed teeth showed a substantial reduction in wind turbine noise at all wind speeds,” reports Stefan Oerlemans, Key Expert, Aeroacoustics, at the technology department of Siemens Wind Power.

The new combed-teeth blade add-on will largely replace Siemens’ first-generation DinoTail for onshore wind turbines. Serial manufacturing will begin as soon as part of the low-noise equipment of the new Siemens wind turbine SWT-3.3-130LN. The new DinoTail technology will also be applied to subsequent turbine models.

The new design does not compromise blade performance or annual energy production, says Siemens.

A123’s new 26650 cylindrical cell is the next generation that brings greater power and energy density and lower impedance. This versatile lithium-ion cell is suitable for a wide variety of applications and systems designs.

Proven performance in the toughest conditions, combining durability, reliability, and safety, the 26650 cylindrical cell offers an excellent combination of price-performance.

The cylindrical cell’s primary applications are for use as portable, high-power devices and as stationary battery backup systems.

A123 Systems
Info http://powereng.hotims.com RS#: 400

Data Acquisition System

Endress+Hauser releases the Memograph M RSG45 Data Manager, a compact device that can serve as a data acquisition system for small process control applications. The RSG45 acquires up to 14 discrete and 20 universal/HART analog inputs from process sensors, displays sensor data on its 7-inch multicolor TFT screen, records the data internally, performs math calculations and alarm checks, and transmits the data to a PC or any control system via Ethernet, RS232/485, Modbus, Profibus DP or PROFINET digital communication links. Data can also be stored to a device plugged into the USB or the SD port.

Inputs to the RSG45 include 4-20mA, 4-20mA with HART, voltage, RTD, thermocouple, pulse, frequency and current. The base unit can accommodate up to 14 discrete inputs, 2 analog outputs and 12 relay outputs. Up to five I/O cards can be added to the base unit, allowing up to 20 universal/HART analog inputs. Data is stored in tamper-proof internal memory, on an SD card or on a USB stick-all of which fulfill the security requirements of FDA 21 CFR part 11. An integrated web server allows browser-based access to the unit via laptops, PCs, smartphones, tablets, handheld maintenance devices and remote systems.

Batch management software allows users to reliably record and visualize process data. User-definable or externally controlled analysis intervals can be configured for up to four batches simultaneously. Batches are assigned batch-specific values and the measured data, start, end and duration of every batch, along with the current batch status, are displayed on the device. At the end of the batch, a batch print-out is automatically sent to the device’s USB or network printer, or can be printed out on a connected PC.

The energy package allows users to calculate the mass and energy flow in water and steam applications on the basis of the flow, pressure, temperature or temperature difference input variables. Other energy calculations are also possible for glycol-based refrigerant media.

Endress+Hauser
Info http://powereng.hotims.com RS#: 401

Combustion Gas and Emissions Analyzer

E Instruments introduces its E6000 hand-held industrial combustion gas and emissions analyzer.

The E6000 analyzer can measure up to six gases simultaneously: O2, CO, NO, NO2, SO₂, CxHy (HC) and H2S. It also includes a dilution pump for CO auto-range measurements up to 50,000 ppm. The analyzer has a built-in printer, full color graphic display, and temperature and pressure measurements. The internal data memory can save up to 2,000 tests automatically. The software package comes with a USB and Bluetooth.

E Instruments
Info http://powereng.hotims.com RS#: 402

Electrical Housing Enclosures

The HWHK Series from Hammond Manufacturing is a family of easy to open, yet secure, wall mount enclosures designed to house electrical and/or electronic equipment in harsh industrial environments. Available as standard in 30 sizes in six heights from 24 to 60 inches, five widths from 16 to 36 inches and five depths from 6 to 16 inches, the range is specifically engineered for use in heavy industrial plants, utility, outdoor municipal or other locations where the enclosure sits in harsh conditions and is frequently opened for internal equipment access.

Access is via a durable zinc die-cast handle with padlock provision, which operates a smooth action three-point roller latch locking system that gives excellent sealing with minimum effort in opening and closing the door. The rugged full height stainless steel piano hinge enables 180° door opening, and the removable hinge pin allows the door to be demounted if required.

Manufactured from 14-gauge mild steel, finished with a recoatable smooth ANSI 61 gray powder coating to both the interior and exterior, the HWHK features ground smooth continuously welded seams, a formed lip to exclude flowing liquids and contaminants and a seamless poured-in place gasket. It meets the requirements of UL 508 Type 3R, 4 and 12, CSA Type 3R, 4 and 12, NEMA 3R, 4, 12 and 13 and IP66 to IEC 60529.

Hammond Manufacturing
Info http://powereng.hotims.com RS#: 403

Gigabit Managed Switches

Antaira Technologies is proud to announce its expansion in the industrial networking infrastructure family with the LMP-0800G series.

Antaira Technologies’ LMP-0800G series is a cost effective 8-port industrial gigabit PoE+ managed Ethernet switch line with a 48~55VDC power input. Each unit is designed with eight 10/100/1000Tx gigabit ports that are IEEE 802.3at/af compliant (PoE+/PoE) with a PoE power output up to 30W per port. With a 16 Gigabit backplane speed, the LMP-0800G supports Jumbo Frames and wide bandwidth for huge Ethernet data packet transmission for edge level connectivity solutions. The product series provides high EFT, surge (2,000VDC) and ESD (6,000VDC) protection; and built with dual power input design with reverse polarity protection. There is also a built-in relay warning function to alert maintainers when power failures occur. This makes it ideal for applications requiring high reliability and distance extension.

This product series is pre-loaded with “Layer 2” network management software that supports an ease of use Web Console or Telnet through the serial console by CLI configuration. All Antaira managed switches provide the ring network redundancy function with STP/RSTP/MSTP and the ITU-T G.8032 (ERPS – Ethernet Ring Protection Switch) protocol which supports a <50ms network recovery time, eliminating the compatibility issue for any existing network concerns. The advanced network filtering and security functions, IGMP, VLAN, QoS, SNMP, Port lock, RMON, Modbus TCP and 802.1X/HTTPS/SSH/SSL increase determinism and improve network management for remote SCADA systems or control networks. Plus, the advanced PoE ping alarm software function allows users to recycle power on any remote powered device (PD) through PoE ports. The external USB2.0 port allows users to export and save all the configuration settings. Lastly, the flexible “custom label” feature allows networking planners to name each connection port. By naming each port, the networking planners can easily manage remote field devices.

Antaira Technologies
Info http://powereng.hotims.com RS#: 404

Hydro Network Modeling

Power Costs Inc. has updated its optimization algorithms to include sophisticated hydro network modeling. Optimizing thermal generation, hydro generation and/or pumping resources, reservoirs, and fuel constraints, ancillary services simultaneously is a highly complex process. Adding cascading hydro network, elevation and head-dependent efficiency parameters to the problem is even more challenging. The latest version of PCI GenTrader is deploying the most advanced algorithms to solve these challenges and is taking hydro-thermal and network optimization to the next level. Four key model elements distinguish PCI GenTrader’s enhanced hydro network model:

Complex Topology Users may define a complex hydrological network with reservoirs and ponds and then connect them through waterways. Multiple hydro-electric generators can be fed by reservoirs via penstocks. Pumps can be configured to move water between two reservoirs. Each water path can be constrained with minimum and maximum flow rates expressed in cubic feet per second (cfs). Local inflows (e.g., rainfall) and outflows (leakage and evaporation) can be specified as well. Water level, flow rates, and even spillways can be controlled to achieve desired water management objectives.

Water Measurement

Reservoir elevation is expressed in feet, storage in acre-feet and flows in cubic feet per second. During the optimization process, PCI GenTrader performs the necessary internal conversions as described in the next section.

Non-linear Conversions

A key to incorporating detailed hydro characteristics in any optimization is the inclusion of non-linear conversion curves that define the relationship of water to electrical energy. GenTrader uses such curves for:

Tailrace Representation

In order to accurately capture the efficiency effects of varying head levels, GenTrader explicitly calculates upper reservoir level and tailrace level. Since tailrace elevation can vary significantly with discharge rate, GenTrader includes this calculation to obtain a precise head level.

PCI
Info http://powereng.hotims.com RS#: 405

LVDTs

Alliance Sensors Group is offering a system for drop-in mounting their PGHD series LVDTs for use on GE steam turbines that currently utilize GE’s inductive valve position sensors. These mounting kits utilize the same hole spacing and produce the same center height as the existing GE sensors. They are available for mounting a either a single PGHD LVDT or a dual-redundant stacked pair of PGHD LVDTs. These kits make it unnecessary to design new mounting schemes or to fabricate new hardware when replacing the old GE sensors. The picture below shows how the GEDS kit makes mounting a pair of PGHD LVDTs for dual redundant operation a simple undertaking.

Features of the Alliance sensors PG LVDTs and mounting hardware:

1. Mounting hardware meets the same hole spacing as the GE mounting blocks and produces the same center height

2. Mounting hardware is available in single and dual redundant configurations

3. Dual kit includes tie bar assembly

Alliance Sensors Group
Info http://powereng.hotims.com RS#: 406

Linear Position Sensors

LVDT Linear Position Sensors can be repackaged with modern materials to address conditions associated with thorium-based nuclear power and high sulfidation processes associated with heavy oil, process control and bio-chemicals.

Macro Sensors’ HSAR Hermetically Sealed Sensors are constructed entirely of stainless steel along with coil windings sealed against hostile environments to IEC standard IP-68. The conduit exit of these AC-operated sensors ensures a hermetic seal from the operating environment.

For harsher environments, the HLR 750 Series LVDT Linear Position Sensors for Hazardous Locations meet UL and ATEX requirements for Class I Division 1 & 2, Zones 1 & 2. Macro Sensors offers Teflon-free, half bridge versions of these AC-operated linear position sensors that are popular in steam turbine applications in radiation environments.

As passive sensors, the HSTAR, HSAR and HLR sensors can operate in more robust applications, offering a high mean time between failures. LVDT electronics that power these sensors, like Macro Sensors’ EAZY-CAL LVC-4000 LVDT Signal Conditioner, can be partitioned from harsh environments, enabling the Nuclear LVDT sensors to operate under more extreme conditions than is viable with DC-operated sensors having internal electronics.

Macro Sensors
Info http://powereng.hotims.com RS#: 407

Proportional Valve Module

WAGO Corp.’s new Proportional Valve Module significantly simplifies the connection of hydraulic or pneumatic valves to the WAGO-I/O-SYSTEM 750. Just 12 mm wide, the compact 750-632 Proportional Valve Module offers a high-performance solution with flexible valve control operation modes.

Two single-coil valves or one dual-coil valve can be controlled either uni- or bi-directionally. For each channel or coil, the output current is 2A in 1-channel operation and 1.6A in 2-channel operation. In connection with a lower set point/actual value deviation, both small and large valves can be controlled reliably and with high repeatability.

The 750-632 features two current-controlled pulse-width modulation outputs (24V) with adjustable dither. Discrete dither frequency setting minimizes the motion, which is adjusted to the valve around the rest position, allowing the set point to be defined without considering static friction. This also prevents the valve from being stuck due to medium residues. Set point definition can be adjusted to the application via both scaling and configurable up/down ramps.

The Proportional Valve Module can operate via any popular fieldbus (e.g., MODBUS TCP, EtherNet I/P, CAN or PROFIBUS) and offers reliable CAGE CLAMP connection technology. Ideal for heavy equipment that uses high-pressure pneumatic or hydraulic valves, the 750-632 can be utilized across a variety of industries, including mining, oil and gas, heavy mobile equipment and metal forming.

WAGO Corp.
Info http://powereng.hotims.com RS#: 408

Siemens Industrial Notebooks

Siemens has equipped the latest generation of its rugged, ready-to-run industrial notebooks with a multitude of practical functions for mobile engineering. The Simatic Field PG m5 programming device has been designed with pre-installed Simatic TIA Portal (Totally Integrated Automation) engineering software for fast and efficient configuration, commissioning, service and maintenance, as well as for engineering work in technical bureaus. There are two versions of the new notebook with robust hardware for mobile use in industrial plants: The Comfort version is equipped with an Intel Core i5 processor, the Advanced version with a more powerful Intel Core i7 processor. The Advanced device can also be configured with the interfaces of the previous Simatic S5 controller generation.

Simatic memory cards can be programmed directly on the industrial notebook through the Simatic Card Reader interface. The Simatic Field PG m5 is delivered ready-to-run with pre-installed Simatic engineering software. It has also been optimized for engineering with the TIA Portal – for the current and previous generations of Simatic controllers and HMI (Human Machine Interface) devices.

The Simatic Field PG m5 is equipped with a fast DDR4 work memory of up to 32 GB and an impact-resistant, fast, exchangeable, solid-state technology mass storage device of up to 1 terabyte. The space-saving, three-pole power supply unit is supplemented by a powerful accumulator with sophisticated accumulator management and a smartphone charging concept: In off-mode, the Field PG can be used as a power bank. Integrated TPM (Trusted Platform Module) data security functions and WoL (Wake on LAN) and iAMT (Intel’s Active Management Technology) increase the level of security when using the hard disk and simplify remote administration in the company network.

Siemens
Info http://powereng.hotims.com RS#: 409

Signal Conditioners

Alliance Sensors Group’s S1A and SC-100 DIN-rail-mounted, push-button-calibrated LVDT signal conditioners were developed by listening to customers and LVDT manufacturers’ comments and wish list. This has allowed Alliance Sensors Group to design and build signal conditioners that work with all different types of LVDTs, LVRTs, GE “buck-boost” LVDTs for gas turbines, half-bridge pencil gaging probes, and RVDTs, rather than only satisfying markets where they are strong and not addressing the concerns of LVDT users with other applications.

Solution: S1A and SC-100 LVDT Signal Conditioners offer smart and fast LVDT setup with built-in null indication and simple front panel pushbuttons to set zero and full scale. Calibration time is now reduced from at least 20 minutes per channel to just a minute or two.

The S1A and SC-100 each offer the user:

– Power inputs from 15-30 V DC or ±15 V DC.

– Choice of 4 LVDT excitation frequencies

– Choice of 6 voltage and 2 current loop analog DC outputs

– Unique auto-mastering for master/slave operation – even if a master were to fail, the S1A and SC-100 can eliminate beat frequency effects in remaining units

– RS-485 digital communications link with an available GUI and hot swapability

– Built-in diagnostics for LVDT winding failures or cable disconnection.

Alliance Sensors Group
Info http://powereng.hotims.com RS#: 410

Nuclear Electronic Monitoring Units

CMR Group has launched a new series of electronic monitoring units for the nuclear power industry.

The S-Unit range has been specifically designed by CMR for the simple and effective condition monitoring of safety backup diesel genset systems used in nuclear power plants. Designed to be compliant with nuclear energy industry standards and ensure that backup diesel gensets continue to operate at optimum performance, the units provide advance warning of potential problems and serious damage, improving the scheduling of maintenance programs.

The next generation S128 and S129 units comprise easily configurable 32 channel analogue inputs for the accurate condition monitoring of key engine characteristics. These include measurement of exhaust gas temperature, bearings temperature, water temperature, stator winding temperature, pressure, lubrication oil temperature and other features.

Designed to withstand harsh and demanding operational environments, the robust units have two operational modes, providing a permanent display of the last channel manually scanned or the automatic display of all sensor channels.

A user friendly interface and front panel keyboard enables configuration changes to be made easily, allowing individual output relay settings to be modified and alarm groups and set points to be fixed.

CMR Group
Info http://powereng.hotims.com RS#: 410

Distributed Plant Monitoring

Siemens has extended its Sinema Remote Connect software for the efficient maintenance of distributed plants and machines to include a number of new security and virtualization functions. Alongside OpenVPN, Version 1.2 of the management platform now also features IPsec encryption, allowing a wide range of various machines with different security protocols to be flexibly connected. The new version is also capable of running in a virtualized environment. This not only increases the flexibility and availability of the platform but also the efficiency of maintenance and support services. The management platform is particularly suited for series and special-purpose machine building.

The Sinema Remote Connect management platform is a server application, allowing users to conveniently and securely maintain widely distributed plants or machines by means of remote access. Depending on the supported security protocols, machines can now be flexibly connected, either by OpenVPN or IPsec. This facility means that Sinema Remote Connect can communicate securely over routers with the majority of connected machines. Siemens also offers a complete solution for virtualization (Simatic Virtualization as a Service): The solution encompasses set-up of the Sinema Remote Connect Server, the configuration of virtual machines and their network structure, the installation and configuration of the operating system and ready-to-use installation of the Simatic software. To support the virtualized systems over their entire life cycle, Siemens offers a number of inter-coordinated services, including Simatic Remote Services for remote access by means of a cRSP (common Remote Service Platform), and Managed Support Services, which encompass all support activities surrounding the virtualized host system.

Siemens
Info http://powereng.hotims.com RS#: 411

Alarm Horns and Strobe Warning Lights

E2S Warning Signals launched the new ‘D1x’ range of alarm horns, PA loudspeakers and integrated alarm horn/Xenon strobe warning units employ the latest electronic technology and acoustic engineering in robust, marine grade, Lm⁶ aluminum enclosures. Designed to create the most effective warning signals available for use in Class I/II Division 1, Zone 1 & Zone 20 environments, the UL/cULs approved alarm horns and combined units are available with traditional directional flare horns or omni-directional radial horns that generate a uniform 360° sound dispersion.

The company also showcases its new ‘GNEx’ GRP Xenon strobe beacons, which add visual signaling to the explosion proof and corrosion resistant GNEx family. Suitable for all Zone 1, 2, 21 & 22 hazardous location applications the ‘GNEx’ beacons have extended temperature range with IECEx and ATEX approvals. For applications with high levels of ambient light the GNExB2 beacon is available in 10, 15 and 21 Joule variants producing up to 902cd – a very high output Xenon strobe. The GNExB1 offers a 5 Joule Xenon strobe in a compact lightweight enclosure. Complementing the family is the GNExJ2 Ex d junction box, which, having multiple cable entries and terminal configurations is suitable for a large variety of applications. All ‘GNEx’ beacons can be supplied as plate mounted assemblies configured with and without an alarm horn sounder or junction box. These new Xenon strobe beacon visual signals broaden the ‘GNEx’ family which includes alarm horn sounders, PA loudspeakers and manual call points for activation of fire alarms, gas detection and emergency shutdown systems.

E2S Warning Signals
Info http://powereng.hotims.com RS#:412

Training Simulation Software

Siemens is launching Version 9 of Simit, marking a new generation of its acclaimed virtual commissioning and plant operator training simulation software. The new software generation is based on a standardized simulation platform. Using Simit 9, automation functions can be comprehensively tested for development or functional faults and optimized prior to actual plant commissioning using real time simulation and emulation. By adopting existing planning, engineering and automation data as well as libraries containing functionally capable components over interfaces to Comos and Simatic PCS 7, the new Simit generation helps real commissioning processes to be carried out more quickly, more economically and with fewer risks.

Simit 9 allows testing and optimization of the automation solution within the simulation and emulation environment on a completely virtual basis using a totally integrated virtual controller. The virtual plant test can be performed directly at the workplace without available plant equipment and without the need for in-depth simulation expertise.

The new Simit generation also offers scope for safe, efficient training of plant operating personnel. Different plant operating scenarios can be simulated using realistic training environments. Operators can be familiarized with the plant using original operator panel screens and automation programs in advance of actual commissioning. Using Simit as a training system not only reduces the use of actual resources, it also allows possible hazards for operating staff in running operation to be minimized or even avoided altogether.

Siemens
Info http://powereng.hotims.com RS#: 413

DC Power Converter

The Sinamics DCP DC power converter from Siemens extends the scalable power range achievable with a parallel connection up to 480 kilowatts. The high switching frequency enables smaller nuclear reactors to be used, giving the unit very space-saving dimensions. The integrated voltage control allows the DC/DC power converter also to be used as a high-power 0 to 800 V DC voltage source.

The Sinamics DCP is suitable for industrial and multi-generator applications in the renewable energy sector. As a buck-boost converter with scalable power, the device can work in either motor or generator mode. The unit can connect two DC voltage levels, irrespective of these levels, on both the input and output side. This makes the Sinamics DCP ideal for charging and discharging batteries and supercapacitors. Internal protective measures ensure that the connected devices are neither overcharged nor completely discharged. The high internal switching frequency makes the compact design and low weight possible. The overload capability of up to 150 percent of the rated current allows it to be used in even highly dynamic applications.

The Sinamics DCP DC/DC power converter can be used in a range of applications. These include its use as a hybrid system with energy storage in photovoltaic and wind power plants, or for covering peak loads in press applications. It can also be used in diesel-powered gantry cranes and storage and retrieval systems, as well as in rapid charging stations for electric cars, and as a voltage source for test rig equipment in the automotive industry. Stationary battery storage systems can also be implemented with Sinamics DCP.

Siemens
Info http://powereng.hotims.com RS#: 414

Solar PV String Inverter

Ideal Power Inc. introduced its new SunDial solar photovoltaic (PV) string inverter which includes an optional bi-directional 3rd port for direct integration of solar with energy storage during initial installation or any time in the future. The SunDial is a compact, efficient, and fully isolated PV string inverter with an integrated PV combiner, disconnects, and a built-in Maximum Power Point Tracker (MPPT). It also features an optional, low cost “plug and play” bi-directional DC port kit. This new “solar first, storage ready” design is the only commercial string inverter available with a field-upgradable, bi-directional energy storage port, making the system market ready today for the solar + storage market.

The initial SunDial product is a 30kW system (Model 30PV+S) based on Ideal Power’s patented and award winning Power Packet Switching Architecture with 1000V max PV DC input and 480V, 3-phase output. It is the first in a planned family of field-upgradable SunDial PV string inverters. An important new feature of the SunDial system will be a newly designed AC link providing true galvanic isolation from the AC to the DC ports, enabling PV installations to be either grounded or true floating. The new SunDial inverter is comparable in size and cost to today’s widely used transformerless PV string inverters, but is fully isolated and offers the additional value of an optional, upgradable fully isolated bi-directional port for direct storage integration. The SunDial can be applied to both new PV installations and PV system retrofits where there is a desire to add energy storage to an existing array.

Ideal Power Inc.
Info http://powereng.hotims.com RS#:0415

High Pressure Bellows Seal

Senior Operations LLC Metal Bellows has developed a high pressure bellows seal, the DELTA P, for use in injection valve applications. The DELTA P is capable of withstanding high external system pressures, while maintaining low differential pressure across the edge welded bellows. This low differential pressure feature enables the bellows to be designed with thinner material, which increases the stroking and cycle life capability. This bellows seal is ideal for use in gas lift valve applications. Senior has applied for a patent on this new technology.

The following are the main features and benefits of the DELTA P:

– Dome pressure: 1,000 to 15,000PSIG

– Injection pressure: 1,000 to 15,000PSIG

– 20,000 cycles minimum

– Inconel 718/625 bellows

– Incaloy 945/945X housing

Senior Operations LLC
Info http://powereng.hotims.com RS#: 416

Updated Wireless Network Module

The WNM Wireless Network Module from Moore Industries has been redesigned with a new, sleeker housing and now incorporates both Serial and Ethernet communications in one model. The WNM, originally released in 2011, has been an accurate and reliable solution for sending process signals between remote field sites. The WNM provides a low-cost wireless communications link between field sites that are in rugged or impassable terrain, with a single unit transmitting for up to 30 miles and the ability to act as a repeater for a virtually unlimited transmission range.

The bi-directional WNM employs Spread Spectrum Frequency Hopping technology to avoid interference problems caused by crowded radio spectrums. This technology allows multiple radio networks to use the same band while in close proximity. Operating at standard operating frequencies of 902-928MHz or 2.4-2.4835GHz, the WNM does not require a regulatory license and can typically be installed without performing costly RF site surveys.

The WNM is ideal for use with the Moore Industries NCS NET Concentrator System®, as well as other SCADA and distributed I/O systems. As a result of its redesign, the WNM now supports data communications networks that use Ethernet and serial (RS-485) communications in one model. In each WNM network, one module is set as a Master. This can be set to communicate with a single WNM remote unit in a Point-to-Point architecture or multiple WNM remote units in a Point-to-Multipoint architecture.

Moore Industries
Info http://powereng.hotims.com RS#: 417

Energy Management Monitoring Systems

Carlo Gavazzi Inc. launched a new line of modular monitoring systems for energy management. VMU-C EM is a data logger system for small to medium projects, VMUC-Y EM is a hardware data aggregator for medium to larger projects and Em2 Server is a software solution for large projects. They are designed to complement the extensive line of Carlo Gavazzi energy maters and current transformers.

The VMU-C EM is a combination of hardware modules, whose primary function is to collect data from a network of energy meters and environmental sensors and then make this data available to end users utilizing industry standard methods, such as integrated web server, FTP, HTTP and Modbus/TCP data transfers. In addition to data management, the VMU-C EM platform can provide a relay output, SMS or email alarms and scalable pulse rate inputs. The VMU-C EM can function as a standalone data logging solution for applications with up to 32 meters or as a data gateway for larger installations.

The VMU-Y EM is a data aggregator that is built upon the VMU-C EM hardware platform, with a primary function of aggregating data from a network of VMU-C EM data loggers in applications where support for more than 32 energy meters is required. The VMU-Y EM relies on VMU-C EM data loggers to collect the data from energy meters and environmental sensors, but it is also responsible for the management of collected data and web server function. Up to 10 VMU-C EM / 320 meters can be managed by single VMU-Y EM.

The Em2 Server is a software solution provided as a Virtual Machine software appliance to be hosted either in a customer’s facility or remote server. Similar to the VMU-Y EM, the Em2 Server relies on the VMU-C EM for communication with energy meters. It aggregates data in large applications with up to 100 VMU-C EM loggers / 3,200 energy meters and provides web server function.

Carlo Gavazzi
Info http://powereng.hotims.com RS#: 418

Shielding Products

WAGO offers a wide variety of shielding products to assist in eliminating unwanted electrical noise. Used with WAGO’s new shield clamp that features an exclusive latching spring, 790 Series adjustable busbars provide excellent shield contact and performance. The adjustable carriers are available with heights from 70 to 80 mm. Busbars can be cut to any desired length.

– Busbars are pre-connected to the DIN rail adapter – cutting installation time

– Adjustable T-connectors allow the busbar to be positioned horizontally and vertically

– Flexible mounting options with carrier on one or both sides and varying heights and orientations

Adjustable busbar carriers are also compatible with other WAGO shield accessories offering a one-stop solution that makes any installation quick and easy.

WAGO Corp.
Info http://powereng.hotims.com RS#: 419

Particle Measurement Lasers

Laser Components Flexpoint laser module series now includes dot and line lasers with 488 nm. Therefore, in addition to 405 nm and 450 nm, a third wavelength is available in the blue spectral range.

Depending on the beam profile, the output power amounts to up to 40 mW. Due to the narrow-banded emission of 488 nm ±2 nm, these laser modules are optimally suited for fluorescence applications, spectroscopic applications, and particle measurements.

In addition to standard modules, customized laser modules can be developed and produced at attractive prices.

Laser Components USA
Info http://powereng.hotims.com RS#: 420

High-Pressure Regulator

AURA Controls has introduced a self-relieving, high-pressure regulator designed to provide primary pressure control of non-corrosive gas or liquid for delivery pressures up to 4500 psig. The new EXH regulator is suited for applications including test benches, high-pressure cylinder control, hydraulics and more.

The EXH ensures accurate control and stable downstream pressure in a durable, compact design. Ideal for applications requiring variable delivery pressures, it vents excess downstream pressure to the atmosphere through the bonnet as the regulator set-point is reduced. Its high-load marginal spring provides consistent delivery pressures even at high-flow rates while its non-rising stem design minimizes the equipment’s footprint.

Fully configurable to meet end-user specifications, the EXH is available in PTFE, PCTFE, and PEEK seat materials along with orifice sizes up to 0.2 to accommodate application-specific process conditions. Standard threaded bonnets and screw holes allow the regulator to be flush or panel-mounted for ease of installation.

Combined with multiple porting configurations and an extensive range of delivery pressures, the EXH is the precise and reliable choice for high-pressure applications. Each regulator is 100 percent helium leak-checked and fully flow- and function-tested to ensure the highest levels of durability and performance available.

Aura Gas Controls
Info http://powereng.hotims.com RS#: 421

Field Force Automation Program

Doble Engineering Co., a subsidiary of ESCO Technologies Inc., released its Field Force Automation program, a customizable platform that helps power companies meet requirements of new NERC CIP regulations by standardizing diagnostic testing and data collection programs through a combination of rugged controllers, testing software, custom engineering and data management processes.

Using Field Force Automation, companies are able to consolidate field test data and automatically save and sync it from the jobsite to the office. By automating as many as seven manual steps in traditional testing workflows, companies can greatly reduce the risk of human error and expedite the data collection process. Supervisors and managers are able to immediately access the data the moment it is synced, review it in real time and remotely access the controllers to collaborate with their field engineers and verify test results before leaving the job site. Rather than having test data stored in disparate forms and various locations, Field Force Automation centralizes the data and drastically improves its security, ultimately providing the right people with access to reliable, comprehensive data.

One of the ways Doble’s Field Force Automation program helps companies meet the new NERC CIP Version 6 standards is through its rugged controllers which are configured as “locked-down” devices to ensure they are only able to execute necessary, work-related tasks and to limit its communication capabilities for security purposes.

The program also makes it easy for Doble to generate government-facing reports for clients to demonstrate compliance and adherence to testing and data management processes. These reports can show who has used the program, what system they accessed it from, its geographical location, the software version and the specific work that was done. Providing this level of specificity ultimately helps utility companies to successfully complete audits.

Doble Engineering Co.
Info http://powereng.hotims.com RS#: 422

Linear Position Sensors

H. G. Schaevitz LLC, Alliance Sensors Group is proud to release its LA-25-A series LVDT linear position sensors, designed to handle extreme industrial environments. Available in ranges from 3 inches (75 mm) to 15 inches (375 mm), the LA-25-A is ideal for roller gap positioning, process valve displacement, head box and actuator position feedback with the durability to withstand the harsh environments found in steam and hydro power plants; paper, steel, and aluminum mills; die and stamping presses; building and bridge monitoring; and industrial automation and fluid power systems. It can operate in hostile factory environments such as lubricant and chemical mists, airborne grit and dust, and typical industrial wash downs.

The robust LA-25-A LVDT linear sensor has a sturdy one-inch (25.4 mm) diameter heavy wall housing of aluminum or stainless steel, two double-contact shaft seals that keep fluids and solid contaminants out of its bore, and offers a choice of axial connectors or a cable in a metal cord grip.

The LA-25-A series permits a variety of mountings, including standard saddle-type clamps, a two-hole flange that screws onto its front bushing, and a single hole mount through a bulkhead up to 1/8 inch thick. The LA-25-A’s core is enclosed in a core extension rod assembly from which it can never break loose, while offering a sturdy male thread for easy mechanical connection. When mated with ASG’s SC-100 industrial LVDT DIN-rail-mountable signal conditioner, an LA-25-A LVDT becomes an ideal solution for heavy duty industrial applications for position sensing.

Alliance Sensors Group
Info http://powereng.hotims.com RS#: 423

Underground Cable Entry Seals

Roxtec UG solutions have been developed to meet the demanding requirements specifically in underground applications. Part of the Roxtec underground product family, the UG knock-out sleeve is designed to be cast directly into the foundation structure, and is easily attached to the casting mold prior to casting. A knock-out plate is located inside the sleeve to ensure a tight seal prior to routing cables.

The UG product can be installed below ground to seal cables entering through the foundation of electrical substations and shelters, as proven by UG test standards. These reliable underground solutions have been documented to provide optimal performance, especially when it comes to withstanding constant pressure.

Roxtec uses innovation to design the most reliable solutions that better meet the demands of challenging conditions in underground applications. UG seals are made of high-elastic EPDM rubber, developed specifically to resist a low constant water pressure.

The UG knock-out sleeve is designed to fit Roxtec UG seals and frames, and is available in three different standard industry sizes to provide customized protection for a variety of underground applications.

Roxtec
Info http://powereng.hotims.com RS#: 424

Continuous Gas Analyzer

Emerson released the Rosemount CT5100 continuous gas analyzer, a hybrid analyzer that combines Tunable Diode Laser (TDL) and Quantum Cascade Laser (QCL) measurement technologies for process gas analysis and emissions monitoring. The CT5100 can detect down to sub ppm level for a range of components, while simplifying operation and significantly reducing costs. Unlike traditional continuous gas analyzers, the CT5100 can measure up to 12 critical component gases and potential pollutants simultaneously within a single system – meeting local, state, national, and international regulatory requirements.

The CT5100 operates reliably with no consumables, no in-field enclosure, and a simplified sampling system that does not require any gas conditioning to remove moisture. The new gas analyzer is ideally suited for process gas analysis, continuous emissions monitoring, and ammonia slip applications.

The CT5100 is a unique combination of advanced technology, high reliability, and rugged design. Its “laser chirp” technique expands gas analysis in both the near- and mid-infrared range, enhancing process insight, improving overall gas analysis sensitivity and selectivity, removing cross interference, and reducing response time. The laser chirp technique produces sharp, well-defined peaks from high resolution spectroscopy that enable specificity of identified components with minimum interference and without filtration, reference cells, or chemometric manipulations.

Emerson
Info http://powereng.hotims.com RS#: 425

Thermal Inspection Camera

FLIR Systems, Inc. released the T1K series of premium HD thermal inspection cameras. Creating a new performance point at the top of FLIR’s uncooled thermal camera value ladder, the T1K series sets a new industry standard with an HD infrared detector delivering outstanding image clarity, exceptional measurement performance, and an intuitive yet simple hybrid-touch user interface. The new cameras allow users to find problem areas quickly, measure them precisely, and document and report findings for corrective action.

T1K series cameras feature a rich set of new hardware, software, and optical designs each tailored to take advantage of the new 1024 X 768 HD-IR detector. High fidelity images are created utilizing FLIR’s OSX Precision HDIR optics which feature a precision ultrasonic autofocus capability. The combination of the higher resolution detector and the variety of OSX lenses available allow users to view problems from longer distances and with greater accuracy, promoting better safety and more efficient workflow.

Advanced real-time image processing is done utilizing the integrated on-board FLIR Vision Processor, which combines FLIR’s patented MSX multi-spectral dynamic imaging with a series of other proprietary image enhancement algorithms to deliver highly detailed thermal and visual images to users while in the field. The advanced image processing features provide the highest quality images available in a compact uncooled system. Additionally, built-in audio and on-screen text/sketch annotation features support in-field documentation while the included FLIR Tools reporting software allows users to generate instant reports on a variety of mobile and desktop platforms.

The FLIR T1K series is available now through select channel partners and directly from FLIR.

FLIR Systems
Info http://powereng.hotims.com RS#: 426

EMAX4 Fans

Multi-Wing introduces the EMAX4 Fans, which provide up to 77 percent total efficiency.

EMAX4 has a computer-optimized blade design for maximum performance. Customized for your requirements, EMAX4 decreases noise by 2 to 3 dB and reduces energy consumption in air-cooled condensers, chillers, cooling towers, evaporators and more.

A modular design, EMAX4 is available with 5, 6, 7, 9 or 12 blades in diameters from 22 to 36 inches (559 to 914 mm). Pitch angles include 20 degrees to 48.5 degrees in 3.5-degree increments. EMAX4 blades are constructed of glass-reinforced polyamide (PAG), and the hub is made from pressure die cast silicon aluminum alloy.

Multi-Wing
Info http://powereng.hotims.com RS#: 427

Profibus-to-Fiber Converters

Moxa, Inc. is helping connect PROFIBUS devices with its ICF-1180I and ICF-1280I PROFIBUS-to-Fiber converters, which now feature Class 1 Div 2, IEC Ex, and ATEX certification for deployment in hazardous locations including upstream and downstream petrochemical processing, chemical plants, and other areas where explosive vapors are present.

PROFIBUS is the world’s most widely used fieldbus and especially common in the oil and gas industry. With the newly certified ICF-1180I and ICF-1280I, oil and gas users can now use optical fiber to connect their PROFIBUS devices and controllers in remote or hazardous locations. The industrial-hardened units offer 2 kV isolation protection for the PROFIBUS system and dual power inputs to ensure non-stop communications.

Rated for operation in environments ranging from -40 to 75°C, both units are capable of distances up to 4 km (2.5 miles) on multi-mode fiber, or up to 45 km (28 miles) on single-mode fiber in both ordinary and hazardous applications, a first for the industry. The ICF-1180I extends connections over a single optical fiber port, whereas the ICF-1280I extends connections over two optical fiber ports that can be arranged in a redundant ring for extremely high communications reliability.

In addition to hazardous area certification, the ICF-1180I and ICF-1280I offer protection from bus faults. The ICF-1180I and ICF-1280I work transparently to detect and recognize bus faults. If the bus fails on one side, the issue will not propagate through the ICF units and affect additional bus segments. In addition, the ICF units will also trigger an alarm notification to the field engineer on the location of the failure so that it can be quickly replaced with minimal downtime.

Moxa Inc.
Info http://powereng.hotims.com RS#: 428

Wireless Headsets

ComSTAR offers full duplex wireless that allow up to eight users to communicate simultaneously just like on a regular telephone. These revolutionary headsets are not voice activated and there is no delay when transmitting. They enhance industrial job site productivity and safety by providing instantaneous, “hands free” voice communications within an 800-yard range.

The XTreme is a specialty hard hat compatible ComSTAR headset that features miniaturized wireless circuitry and antenna installed right inside the ear cup. This streamlined “All in One” design is a breakthrough, eliminating the need for cables and belt pack transceivers.

ComSTAR operates within the DECT, 1920 – 1930 MHz band allocated by the FCC for voice communications only. No FCC licensing required.

ComSTAR
Info http://powereng.hotims.com RS#: 429

Emergency Lighting Inverter

Staco Energy Products released a new Three Phase, On-Line Double Conversion Emergency Lighting Inverter called the FirstLine P 924.

General Highlights on the FirstLine P 924:

– 58.5-225 Kw, Three Phase, On-Line Double Conversion, UL924 Central Lighting Inverter

– Features IGBT and digital signal processing (DSP)

– Emergency power provides FULL LIGHT OUTPUT from all lamps and fixtures for the entire runtime

Staco Energy Products
Info http://powereng.hotims.com RS#: 430

Expanded Linear Position Sensors Line

Alliance Sensors Group a div of H.G. Schaevitz LLC has expanded its sensor product offering by adding to its line the LR-27 and LRL-27 Series Inductive Linear Position Sensors. These are contactless devices designed for factory automation and a variety of heavy duty industrial or commercial applications such as solar cell positioners, wind turbine prop pitch and brakes, chute or gate positioners on off-road or agri-vehicles, robotic arm position feedback, and packaging equipment. With their compact yet robust design, superior performance, and excellent stroke-to-length ratio, LR-27 and LRL-27 sensors are ideal for both industrial and OEM position sensing applications.

Operating from a variety of DC voltages, the LR-27 and LRL-27 series offer a choice of four analog outputs, and all units include ASG’s proprietary SenSetâ„¢ field scalability feature.

The LR series also includes the LR-19 series for applications where a shorter length and smaller diameter body is required and the spring loaded LRS-18 for applications where the probe cannot be hard fixed to the measurand.

Alliance Sensors Group
Info http://powereng.hotims.com RS#: 431

Communications

Antaira Technologies is a global leading developer and manufacturer of industrial device networking and communication product solutions for harsh environment applications and is proud to announce its expansion in the industrial networking infrastructure family with the LMX-1202G-SFP series.

Antaira’s new LMX-1202G-SFP industrial gigabit managed Ethernet switch series has been designed to fulfill applications in harsh or outdoor environments. Some applications where the LMX-1202G-SFP switch works well includes: power/utility, solar grids, windmills, mining infrastructures, factory/process control automation, ITS – roadway traffic control/monitoring, building facility outdoor infrastructures or security surveillance and access control systems.

Antaira Technologies’ LMX-1202G-SFP series is a cost effective 12-port industrial gigabit managed Ethernet switch line that supports a 12~48VDC power input range. Each unit is designed with ten 10/100/1000Tx Fast Ethernet RJ45 ports and two 100/1000 dual rate SFP slots for fiber. With a 24 Gigabit backplane speed, the LMX-1202G-SFP supports jumbo frames and wide bandwidth for large Ethernet data packet transmissions. These switches are also made with high density port counts for edge-level connectivity solutions. The LMX-1202G-SFP product series provides high EFT, surge (2,000VDC) and ESD (6,000VDC) protection. These units are built to have a dual power input design with reverse polarity protection, and there is also a built-in relay warning function to alert maintainers when any ports break or power failures occur. This makes it ideal for applications requiring high reliability and distance extension.

This product series is pre-loaded with “Layer 2” network management software that supports an ease of use Web Console or Telnet through the serial console by CLI configuration. The LMX-1202G-SFP series is backed by a five year warranty and the units are IP30 rated, compact, fanless, DIN-Rail and wall mountable.

Info http://powereng.hotims.com RS#: 432

Gel Sealant

Just dispense and apply Resbond 907TSG Thread-Locker Gel for high temperature thermally stable, electrically insulating and chemically resistant seals up to 2100 degrees F. Ideal for screws, nuts, bolts, pipe threads, fittings, fasteners, set screws, bearings, studs, bolts, etc. Available in three strengths: Blue Standard for general purpose, Red High Strength for vibrating applications and Gold High Strength to fill large gap widths.

Resbond 907TSG Thread-Locker Gel goes exactly where you apply it. Eliminate the running, dripping and messy globs that are usually caused from standard thread-lockers. Resbond Gel is easy to apply and cures at room temperature to form thermally stable, electrically insulating, and chemically and corrosion resistant seals.

Packaged in economical easy-to-use, 4-ounce applicator bottles. One bottle provides up to 2000 applications. One-ounce trial kits available. All materials are manufactured according to Military Specification Mil-I-45208.

Cotronics Corp.
Info http://powereng.hotims.com RS#: X433

Data Management and Simulation

By enabling the seamless exchange of data between Comos and the simulation platform Simit, Siemens is driving forward its digitalization strategy. A whole host of improvements in the Comos platform make for enhanced software performance, increasing the speed and efficiency of project completion. New developments and extended functions help improve the efficiency of data management across a plant’s entire life cycle, while also enhancing convenience and simplifying decision-making processes for users.

New and improved interfaces for even faster data exchange with external applications underpin the continued expansion of the Comos interoperability strategy. These include the interface to eCl@ss Advanced 9.0 to facilitate the comparison of device data from different suppliers and to allow it to be imported directly into the CAE system Comos, including the relevant documentation. Also improved: interfaces to Proteus 3.6.0, formerly XMpLant scheme, or the Siemens PLM Software Teamcenter.

Version Comos 10.2 comes with a variety of new functional features and useful wizards designed to make the daily work of users both simpler and more efficient. New symbols in object libraries and additional color coding of objects on P&ID’s make for greater manageability. Electrical engineering has been significantly simplified by the new Marshalling Designer and the Brownfield Loop Wizard. New PERT diagrams make it possible to more clearly visualize maintenance work sequences.

With the 3D virtual reality viewer Comos Walkinside, color coding and the isolation of individual elements, allows project and status checks to be performed directly in the 3D model. This focusing capability means that all those involved in a project are able to more easily gain a uniform understanding of the current status of a plant or project. And the technology provided by the state-of-the-art Oculus Rift virtual reality headset enables realistic training scenarios to be generated.

Siemens
Info http://powereng.hotims.com RS#: 434

Planar SMT Transformers

Pulse Electronics Corp. offers a planar platform which increases throughput power for Pulse’s planar SMT transformers by 50 percent over transformers of comparable size to deliver up to 800 watts of power capability. These transformers are used for isolation and voltage conversion for switched mode power supplies in datacom and intermediate bus converter applications.

Pulse Electronic’s PH9278NL planar transformer is built on Pulse’s new ER25+ platform and can be customized depending on the application. The platform measures 33.5 x 26.8 x 18.3mm and delivers 50 percent greater power than transformers built on an ER28 platform which measures 35.5 x 30.5 x 12.6mm.

Pulse’s planar transformers are RoHS compliant and meet standard EIA481 requirements. They are available in tape-and-reel packaging.

Pulse Electronics Corp.
Info http://powereng.hotims.com RS#: 435

Solar Energy Storage System

The POWERSTATION 247 is a complete and fully integrated scalable solar energy storage system with built-in battery storage.

The system comes in three sizes, 5 kW, 10 kW, or 15 kW; all have the same battery storage capacity of 17,28 kWh. Its free standing cabinet is easy to install and easy to use. The system integrates up to 3 hybrid inverters, solar MPP-trackers, charge controller and lithium-ion batteries, all necessary field wiring terminals and disconnect switches. It is completely “plug and play”, and can be installed on and off grid.

The POWERSTATION 247 is the first fully integrated system that is UL certified. Concept by US has complete IP ownership and the comprehensive ability to build all its components, except the lithium-iron batteries. The POWERSTATION 247 has a battery storage capacity of 17.28 kWh.

Energy generated by solar panels can be directly used, stored or fed into the public grid.

Concept by US
Info http://powereng.hotims.com RS#: 436

Reversible Liquid Vacuum

Eriez HydroFlow Reversible Liquid Vacuums offer a simple, speedy solution to the usually time consuming and bothersome task of removing spent coolants, waste fluids and oils from machine sumps, reservoirs and storage tanks. These units will also discharge fluids out of the drum into a separate container, if desired, with just the turn of a knob.

High quality, compact Eriez HydroFlow Reversible Liquid Vacuums operate quietly, efficiently and reliably. They are incredibly durable and small enough to fit in the palm of the user¹s hand.

Reversible Liquid Vacuums operate on shop air and attach to the small bung on a standard drum. With only one moving part, they require no maintenance.

Every kit includes a venturi unit, 1+ inch x 10-foot (38mm. X 3 m L) suction hose, drum standpipe adapter, quick disconnect fittings, air control valve, safety shut-off valve and aluminum wand.

Eriez
Info http://powereng.hotims.com RS: 437

LED Warning Lights

Larson Electronics announced the release of a new dual colored hazardous location LED warning light equipped with two 10 watt LED lamps.

The HAL-TL-2X10W-C-OXM chemical resistant LED warning light from Larson Electronics is a Class 1 Division 2 oxygen level warning light that is approved for use in hazardous environments where explosive and flammable gases, vapors, and dusts stand the potential to exist. This hazardous light is designed for use in industrial environments where oxygen levels are monitored within the atmosphere and have the potential to fall below the OSHA recommended oxygen concentration within the work environment.

This signal light is equipped with two 10 watt LED lamps that produce a green and blue light output. Each lamp is equipped with a warning sign to indicate the status of oxygen levels within the environment. A green LED lamp illuminates the “OK” sign to indicate that the oxygen levels are satisfactory. A blue LED lamp illuminates the “LOW O2” sign to indicate that oxygen levels have reached an unsatisfactory level. This indicator light works in conjunction with existing oxygen level monitoring systems and is used to provide a visual indication of levels. These lights can be configured to operate on a steady burn, a strobe or a steady burn and strobe combination and each LED lamp offers an exceptional 1,050 lumen output.

The LED lamps are housed within a waterproof, corrosion and chemical resistant body that is equipped with Pyrex globes and a polycarbonate globe guard. This unit is weatherproof, dust-proof, and marine rated for wet environments. Power for this unit is provided by a shared neutral and ground, with separate hot wires for each lamp. This warning light can be configured to work on 120 volts or 240 volts AC for use with standard line voltages or 12/24 volts DC for low voltage operation. Mounting is provided by a heavy gauge aluminum base with predrilled holes designed to be bolted to walls and flat surfaces for permanent and secure attachment. This hazardous area LED warning sign light is configured for green and blue output, offers exceptional lumen output, and a 50,000-hour life span.

Larson Electronics
Info http://powereng.hotims.com RS#: 438

Cooling Tower Motors

Marathon Motors recently introduced a new line of totally-enclosed air-over (TEAO) cooling tower motors with BCP – Bearing Current Protection using AEGIS® Shaft Grounding Rings. These NEMA Premium Severe-Duty motors feature BlueChip quality 100 percent cast iron construction for rigidity and reduced vibration. With internal and external epoxy paint, sealed bearings, T-drains in both endshields for effective drainage, drive-end bearing isolators with shaft slingers, and fully gasketed conduit boxes (with lead separators), they are IP56 rated and built to withstand the harsh environments of cooling towers.

Designed for 10:1 VT or 20:1 CT operation with a variable frequency drive, motors have MAX GUARD Class F insulation and are equipped with AEGIS Bearing Protection Rings installed internally. AEGIS Rings channel VFD-induced shaft currents away from motor bearings and safely to ground, protecting bearings from electrical damage including EDM pitting, frosting, fluting, and premature failure. Internal installation of the rings protects them from the extreme temperatures and moisture found in cooling tower applications and other severe environments.

Suitable for angle mounting, the motors are available in models from 3-250 HP. They meet or exceed NEMA Premium efficiencies; are UL Recognized, CSA Certified, and F1/F2 capable; and come with a

3-year warranty. They are ideal for use in cooling tower fans and blowers, pumps, compressors, condensers, and evaporators, as well as a variety of severe-duty processing applications.

Info http://powereng.hotims.com RS#: 439

Portable Emissions Analyzer

The new E8500 PLUS emissions analyzer is a complete portable tool for EPA compliance level emissions monitoring and testing. This model has been upgraded to measure up to 50 percent CO₂ using an NDIR sensor. The E8500 PLUS is ideal for regulatory & maintenance use in boiler, burner, engine, turbine, furnace, and other combustion applications.

Info http://powereng.hotims.com RS#: 440

Gas Detectors

Mil-Ram Technology’s Next Generation smarter gas detector with Large Graphics Display-TA-2100 – provides user-friendly data, bar graph, instructions, advanced diagnostics-continuous on-board systems monitoring, and eliminates short-hand, coded messages. Programmable Calibration Reminder. Toxic, LEL, Oxygen, hydrocarbons, VOC: hundreds of different gases and vapors utilizing several sensor technologies: electrochemical, catalytic LEL, infrared, photoionization (PID), solid-state and more. Continuous advanced diagnostics to meet SIL 2 compliance. For use in many industrial applications such as Oil/Gas Exploration/Refining; Chemicals/Plastics; Water/Wastewater Treatment; Food Processing/Refrigeration; Mud Logging Drilling/Exploration; Pulp/Paper Mills; Steel Mills, and many more.

Info http://powereng.hotims.com RS#: 441

Environmental Monitoring

The U.S. Environmental Protection Agency (EPA) recently toughened air pollution standards to further control toxic air emissions emitted by petroleum refineries. The new rules now enact fenceline monitoring to better protect local communities from exposure to toxic air pollutants, such as benzene and other volatile organic compounds (VOCs).

The MOCON, Inc. – Baseline Series 9100 on-line GC delivers direct, continuous, real-time measurement of benzene, toluene, ethylbenzene and xylenes (BTEX), 1,3-butadiene, volatile organic compounds (VOCs), and other hazardous air pollutants released at industrial sites.

The Series 9100 GC provides fast, reliable, accurate detection using one of two MOCON – Baseline’s available photoionization detector (PID) options. The first, a standard PID with a minimum detectable quantity (MDQ) for benzene of < 1 ppb without preconcentration. The second, a high-sensitivity PID with an MDQ for benzene of < 0.05 ppb without preconcentration. The elimination of preconcentration reduces analysis time, cost, complexity, maintenance, and efficiency issues.

Info http://powereng.hotims.com RS#: 442

Wireless Communications

Schweitzer Engineering Laboratories, Inc. (SEL) announced that the SEL-3031 Serial Radio Transceiver has attained U.S. Department of Defense (DoD) JF-12 certification. With this certification, the SEL-3031 can provide wireless communications in U.S. military incident command system (ICS) applications in the continental United States and several U.S. territories.

“The SEL-3031 Radio not only meets the DoD FIPS and JF-12 requirements, it is unique in providing a solution designed for reliable, low-latency SCADA control system applications,” said Dennis Gammel, SEL engineering director for Cybersecurity.

JF-12 certification is a typical requirement for all radios prior to DoD procurement. This certification adds the SEL-3031 to a select group of industrial-grade radios certified for use in the ICS environment. The radio is also FIPS 140 Level 2-compliant.

The SEL-3031 is designed for low-latency, performance-based applications, including high-speed control, reliable teleprotection and communications for fast automation. The radio performs exceptionally well in SCADA and critical-industrial communications, operating in the 900 MHz license-free ISM band and with a line-of-sight range of up to 20 miles. For longer distances and non-line-of-sight applications, the SEL-3031 uses SEL Hop-Syncâ„¢ technology for reliable communications.

Info http://powereng.hotims.com RS#: 443

Corrosion Prevention

Controlled bolting equipment manufacturer HTL Worldwide Ltd have released a specialist coating to extend the life of any structure or assembly; HTL Pro-Tect.

Offering complete joint preservation and corrosion prevention, HTL Pro-Tect is suitable for any mechanical and electrical application which is subject to climatic corrosion in any industry sector. With easy application and a life span of up to 25 years, the product will protect all mechanically exposed assemblies in the harshest environmental conditions including subsea.

The high strength nature of the product comes from its silicone base which forms a strong, resilient, and rubberised coating; averting moisture, debris, and water or oxygen ingress, therefore resulting in the workpiece being kept in its “as installed” condition. Non-marine pollutant, or toxic to the environment, HTL Pro-Tect is 100 percent recyclable.

The external part of any mechanical joint is highly vulnerable to the ingress of debris and moisture which can result in the degradation of bolted joints as well as corrosion damage. Excessive corrosion is hazardous and repair could mean unscheduled downtime for machining, failure and potentially replacement of damaged flanges, gaskets and fasteners.

Supplied as a complete kit with everything needed for application, this product promotes best practice engineering and is a major contribution towards maintaining critical joint integrity.

Easily removed by cutting and peeling back, HTL Pro-Tect is applied and removed as desired. Complete or partial reinstation is a simple secondary application.

Info http://powereng.hotims.com RS#: 444

Pillow Blocks

Graphite Metallizing Corporation announces GRAPHALLOY Type 163 Pillow Block Assemblies for high temperature and submerged environments that do not require the use of grease or oil.

GRAPHALLOY Type 163 Pillow Block is a rugged, easy-to-install design for moderate speed applications that will operate successfully under high or low load conditions. This heavy-duty unit is available in cast iron or stainless steel. A cast iron split-angle housing is also available.

Pillow Block Type163 is suitable for high temperature applications such as ovens, drag-line conveyors and dampers. This pillow block also performs well in wet applications such as wash downs and submerged applications like plating tanks and industrial washers.

All GRAPHALLOY pillow blocks have a low coefficient of friction, can withstand submerged conditions and are chemically resistant and non-galling. Since the self lubricating properties of GRAPHALLOY are constant throughout the material, these pillow block assemblies will provide long life and reliable operation. Graphite Metallizing has other pillow block models that meet a variety of speed and load conditions. They are available in a wide range of sizes and housing types, in two and four bolt arrangements as well as in solid, split and self-aligning configurations. Flange and custom models are also offered.

Info http://powereng.hotims.com RS#: 445

Bulk Handling

Building upon the standard crowned roller, the Martin® Roller Trackerâ„¢ from Martin Engineering uses a unique ribbed lagging made of durable polyurethane to increase performance and wear life. The roller does not come in contact with the belt edge, which means no fraying and excellent tracking for single-direction or reversing belts. The result is more centered cargo loading, less spillage and increased safety from the hazards of belt wander, leading to higher productivity and a lower cost of operation.

Used for lower tension belts from 500-1500 mm (20-60 in.) in width, running at a speed of up to 5 m/s (984 fpm), crowned roller trackers have a slightly larger diameter at the center than at the edges. Realignment is based on the basic principle of the belt contacting the raised portion of the raised portion of the roller first (the crown) first.

When the belt wanders off-center, the assembly tilts to the opposing side and steers it back toward the normal position. By retaining a consistent path on the return side, the belt passes over the tail pulley and enters the loading zone centered, delivering equal cargo distribution and reducing spillage.

Previous designs had lagging made out of a single smooth piece of rubber or soft gripping material, to retain a hold on the belt and train it back into position. Being in constant contact across the entire surface of the belt caused the material to wear quickly, requiring frequent and expensive replacement. The Martin Roller Tracker improves upon this technology with ribbed lagging made from thick, rugged polyurethane. Covering the entire belt width using less surface contact, the ribbed design reduces lagging wear and improves resistance to better train the belt back to center. This design is also very cost-effective to manufacture, contributing to a reduced purchase price.

Info http://powereng.hotims.com RS#: 446

Industrial Lighting

Larson Electronics, a company that specializes in industrial lighting equipment, has announced the release of a 150 watt explosion proof LED light mounted atop a telescoping aluminum pole.

The EPL-APM-150LED-RT explosion proof LED work light produces 17,500 lumens of light capable of illuminating an area 9,500 square feet in size. The telescoping pole mount is designed for permanent mounting operations while offering five foot to 12 foot adjustability. The LED light head on this unit produces a wide flood beam of light that is ideal for illuminating large workspaces and job sites. The light head on this unit contains 12 LEDs arranged in rows and paired with high purity optics producing a 60 degree flood beam. The light fixture carries an IP67 waterproof rating, is dust-proof, and protected against high pressure jets.

This telescoping LED work light is comprised of a removable LED light head mounted atop an anodized aluminum adjustable pole fabricated with 2.5 inch by 2.5 inch tubing for the first stage, two inch by two inch tubing for the second stage, and one inch by one inch tubing for the third stage. The tower is anodized and the brackets are powder coated for durability and rust resistance. The EPL-APM-150LED-RT is equipped with a powder coated flat mounting bracket that is easily attached to any flat surface. This hazardous location LED work light is equipped with 50 feet of 16/3 SOOW oil and chemical resistant cord that is terminated in an optional explosion proof cord cap. The light is universal voltage capable and can be operated with 100 to 277 volts AC.

Info http://powereng.hotims.com RS#: 447

Monitoring

Brà¼el & Kjà¦r announced the release of its new Vibration Monitoring Terminal Type 3680.

The device enables users to effectively:

– Protect against structural damage risks in construction and mining

-Assess human response to ground-borne vibration from road and rail traffic

– Monitor background vibration to ensure sensitive equipment operates correctly

The robust unit provides uninterrupted, tri-axial, real-time ground vibration measurement to help avoid harming buildings. It automatically delivers alerts to avoid breeching set limits and provides reports proving regulatory compliance.

The Vibration Monitoring Terminal also reliably assesses vibration impact from traffic. It enables users to efficiently conduct background surveys prior to new construction, as well as receive accurate data to evaluate vibration mitigation techniques.

In addition, the system monitors background vibration for organisations such as hospitals, semiconductor manufacturing plants and museums. It helps ensure patient comfort at medical facilities, trusted monitoring of delicate equipment to avoid costly errors and reduced risk of artefact damage.

The Vibration Monitoring Terminal operates stand-alone or with Sentinel for comprehensive, multi-location, vibration compliance monitoring.

Standalone devices come with a smartphone app enabling setup, remote display and operation from anywhere and data transfer to standard post-processing applications.

Info http://powereng.hotims.com RS#: 448

Sensors

SignalFire Wireless Telemetry introduces the Pressure Scout, an intrinsically safe wireless pressure sensor that supports pressure monitoring and alarm reporting as part of the SignalFire Remote Sensing System. The first in a line of wireless integrated sensors, the Pressure Scout consists of a pressure sensor integrated with a wireless node and internal battery. The Pressure Scout is a low-cost alternative to conduit-wired or other wireless pressure monitoring solutions. Ideal applications for the Pressure Scout include well tubing and casing pressure monitoring, tank level monitoring and compressor station status monitoring.

As part of a wireless remote monitoring and control network, the Pressure Scout provides a robust, long-range (up to ½ mile) transmission to the Signal Fire Gateway where pressure data becomes available via a Modbus RTU or TCP interface. Available in standard pressure ranges, the Pressure Scout performs rapid (5 sec) pressure sampling with configurable alarm reporting (report by exception). Units offer local pushbutton zeroing. Operable in temperature ranges from -40°C (104°F) to 80°C (176°F), the Pressure Scout operates in challenging outdoor environments, sustaining signal strength through terrain, structures, or weather. Class 1, Division 1 certification is pending.

Operating on extremely low power, the Pressure Scout utilizes an internal battery that powers the integrated pressure sensor and radio for up to 10 years. For example, an application requiring a five second pressure sample interval for alarming, with a one minute reporting interval will last for 6.5 years. Extremely compact, units are both easy to install and maintain.

Info http://powereng.hotims.com RS#: 449

Emissions Monitoring

AMETEK Land, the leading industrial combustion efficiency and environmental pollution emissions monitoring specialist, announces a number of enhancements to its Lancom 4 Portable Gas Analyser to improve usability and provide attractive features as standard.

Now available as a free download, Lancom 4’s innovative data acquisition software, Insight, is a powerful tool that allows users to interface their analyser with a PC for remote control and data logging. Insight offers graphing and analysis tools for data visualisation and reporting purposes, providing even easier access to data. Communications between Insight and the user’s PC requires a USB-RS232 interface converter, which is now supplied with every Lancom 4 for quick and easy set up.

In addition, Lancom 4 now includes Wake and Sleep functions, allowing measurements and data logs to be recorded over an extended period, and a rugged Carry Case, ensuring that the instrument is protected at all times when in use. All are now supplied as standard at no extra charge.

Upgrading to Lancom 4 also has been made much easier. Hardware items, such as external printers or analogue output modules, can be simply plugged in, with no firmware configuration needed. This means that these items can be fitted in the field, avoiding the need to return the instrument to the factory.

Lancom 4 is renowned as the world’s most versatile and accurate portable flue gas analyser for checking or testing a boiler system or pollutant process. It has the capability to monitor up to 9 different gases, a total of 17 measurement parameters with one instrument as well as the ability to data log up to 250,000 records.

Info http://powereng.hotims.com RS#: 450

Sensors

Schaevitz LLC Alliance Sensors introduced its GHS-19 series of spring-loaded LVIT (Linear Variable Inductive Transducer) gaging sensors. They are contactless devices designed for dimensional gaging and position measurements in factory automation and in various industrial and commercial applications such as automotive testing, mil/aero test stands, robotic arms, and packaging equipment, where the sensing element cannot be attached to the object being measured. Using LVIT technology with its simple coil design, the GHS-19 series offer excellent stroke-to-length ratios.

GHS-19 Features:

– Low cost drop-in replacement for spring-loaded LVDTs, with same connector and pinouts

– 0.75 inch (19 mm) diameter aluminum or stainless steel body with1/2-20 mounting thread

– EXCELLENT stroke-to-length ratio means much shorter housings

– Full scale ranges from 0.5 to 4.0 inches (13 to 100 mm)

– 1 pound (0.45 kgf) maximum tip force

– Contactless operation prevents sensor wearout from dithering or rapid cycling

GHS-19 sensors have a 0.75 inch (19 mm) diameter aluminum or stainless steel body with a 1/2-20 UNF-2A threaded nose 1.5 inches (38 mm) long and two 0.75 inch (19 mm) hex jam nuts for drop-in installation in place of spring-loaded DC-LVDT gage heads. The sensors’ 0.25 dia. probes are equipped with a No. 9 contact tip, producing a maximum tip force of 1 pound (0.45 kgf). They are offered with a PT02-10-6P. Operating from a variety of DC voltages, these sensors are available with a choice of one of four analog outputs, and they all include ASG’s proprietary SenSet field calibration feature.

Info http://powereng.hotims.com RS#: 451

Internet of Things

As Machine to Machine (m2M), Internet of Things (IoT), and the Industrial Internet of Things (IIoT) continue to make the transition from technology magazines to corporate strategic initiatives, companies are recognizing a significant opportunity to enhance productivity, efficiency, and profitability through Wireless Sensor Networks, according to OleumTech Corporation, a global leader in m2M communications and industrial automation solutions.

Wireless Sensor Networks (WSNs) have emerged as a key technology for oil and gas exploration and production companies looking to gain a competitive advantage. Since initially introducing WSNs, manufacturers like OleumTech have enhanced product offerings to operate in the most inhospitable of environments while fortifying the technology with more robust communications architectures, hardening security, increasing reliability, and driving down power consumption. Through the entire oil and gas value chain (upstream, midstream, and downstream) as well as other industrial markets including electric power, water/waste water, and manufacturing, wireless sensor networks are increasingly being deployed where hardwiring was the de facto standard.

“For many industrial applications, it has been well documented that wirelessly connected assets are up to 10 times less expensive than wired alternatives,” said Brent E. McAdams, Vice President, OEM & Strategic Initiatives at OleumTech. “Driven by substantial and measurable cost savings in engineering, installation, and logistics as well as dramatic improvements in the frequency and reliability of data, wireless sensor networks offer much faster startups, and accelerated profits.”

Info http://powereng.hotims.com RS#: 452

Clamps

The New POWER CAGE CLAMP is now available for up to 350 kcmil conductors and offers direct panel mounting, expanding application options.

This versatile version still provides all of the original WAGO design advantages, such as being maintenance-free, vibration-proof, and enabling fast, hands-free wiring. Unique to WAGO, separate side entry jumper slots leave wire entry-way unhindered and able to accommodate the maximum wire size possible. In addition, the POWER CAGE CLAMP block accepts either the WMB markers or WAGO’s multi-line continuous strip that can conveniently be printed on site from WAGO’s new smartPRINTER. Other important features include:

– 1/0 to 350 kcmil wire size

– 310 amps up to 1,000 volts

– UL recognized (CSA and hazardous location approvals pending)

The POWER CAGE CLAMP with panel mounting is a reliable, user-friendly product that embodies WAGO’s mission to supply you with quality, innovative products that succeed in a myriad of applications.

Info http://powereng.hotims.com RS#: 453

Sensors

CMR GROUP, the engine control technology and instrumentation specialist, has combined its high performance temperature sensors and electronic monitoring unit series into an integrated solutions package for applications in the nuclear power industry.

The move will meet the requirement for instrumentation in the nuclear sector where technology can add value throughout the engineering supply chain and ensure compliance with domestic nuclear safety authorities, who provide regulation and technical approval.

Incorporating four different sensor series, CMR’s newly combined offering features the K3 or K3ad performance temperature sensors, which are environmentally compliant for the ambient temperature monitoring of fluid, gas and bearing temperatures in the nuclear industry.

The AN sensor series is designed for the temperature measurement of high pressure fluids and aggressive gaseous fluids used in nuclear power generation, although they can also be used effectively with non-pressurised fluids. The AMB sensor series is recommended for the conventional measurement of ambient temperatures to very low or sub-zero levels in damp or refrigerated atmospheres, and ventilation ducts.

For temperature measurements associated with alternators, pumps, steam and gas turbine bearings and other rotary machine bearings, the BS6 nuclear sensor with an insulated platinum resistance temperature detector (RTD) for use in harsh environments is available together with a BCI6 type K thermocouple sensor for bearing temperature measurement on rotating/reciprocating machines.

Info http://powereng.hotims.com RS#: 454

Instrumentation

Image: Single Channel Type K Thermocouple…

The Sensor Connection a division of Harold G. Schaevitz Industries LLC, has expanded its line of measurement and control instrumentation with the addition of the model TCA-MS-K-1. This Single Channel Type K Thermocouple Amplifier Module converts the low output voltage signal from a Type K thermocouple probe to a single independent linearized 0 to 5 VDC output voltage. This output is ideal for interfacing to instrumentation equipment including data loggers, temperature indicators, chart recorders, and controllers. A unique feature of this product is the fast dynamic response of 1 mS.

The Sensor Connection a division of Harold G. Schaevitz Industries LLC is an American company whose management has a combined experience of over 50 years in the sensor industry. We have a technically trained staff to help you select the ideal sensors for your application. Our core product offering includes Exhaust Gas Thermocouples (EGT) Probes, Thermocouples, RTDs, Linear Position sensors, Rotary Position sensors, Pressure sensors and switches. In addition to our standard products, we have capabilities to design and build custom products to suit your specific application. Major markets served include Motorsports, Marine, Heavy Vehicle, R&D Test labs, Power Generation, Military, and Industrial Manufacturing Assembly & Test.

Info http://powereng.hotims.com RS#: 455

Sensors

Alliance Sensors Group has expanded its sensor product offering by adding to its line the LRL-27 Series of long-stroke LVIT position sensors. These are contactless devices designed for factory automation systems and a variety of heavy duty industrial or commercial applications such as solar cell positioners, wind turbine prop pitch and brakes, material chute or gate positioners on off-road or agri-vehicles, robotic arm position feedback, and packaging equipment.

Operating from a variety of DC voltages, the LRL-27 series offer a choice of four analog outputs, and all units include ASG’s proprietary SenSet field scalability feature. With their compact yet robust design, superior performance, and excellent stroke-to-length ratio, LRL-27 sensors are ideal for industrial and OEM position sensing applications.

LRL-27 Features:

– LVIT Technology (Linear Variable Inductance Transducer)

– Contactless operation prevents wearout from dither or cycling

– 5 Nominal ranges from 250 to 450 mm (10 to 18 inches)

– Excellent stroke-to-length ratio

– 27 mm (1.05 inch) diameter anodized aluminum housing sealed to IP-67

– Radial cable exit version comes with swivel rod eye ends

– Axial termination versions with either M-12 connector or 1-m cable

The LR series also includes the LR-27 for shorter stroke applications, LR-19 series for applications where a short length and smaller diameter body is required, and the spring loaded LRS-18 series. Technical data sheets and additional information can be found at www.alliancesensors.com.

Info http://powereng.hotims.com RS#: 456

Cables

CDM Electronics announced the availability of custom overmolded cable assemblies designed to withstand demanding environmental conditions in a wide range of industries including commercial, industrial, medical, military, and agricultural. The overmolding process provides a seamless seal of the junction between a connector and cable to ensure the utmost protection against liquids, dust, heat and impact. Overmolding additionally enhances strain and flex relief, as well as maintains the integrity of connections in applications requiring repeated mating/unmating cycles.

Designed for long life and reliable performance, CDM’s overmolded cable assemblies improve performance and reduce total cost in an extensive variety of applications in which harsh environments, abrasion and EMI/RFI are factors. As these assemblies are usually custom, they may be engineered for a broad array of applications including intermediate and light-duty power cable assemblies for industrial usage, RF coaxial assemblies, military/tactical assemblies, D-subminiature and mini assemblies. Overmolded assemblies are equally suitable for wire harnesses, telecommunications and medical assemblies.

CDM’s overmolded cable assemblies offer 360-degree strain relief and EMI/RFI shielding, optimized pull strength, and flexible support at the cable exit. They are provided with an unlimited variety of interconnects, cables, and thermoplastic materials in a range of colors to provide unparalleled design flexibility and aesthetics. Common materials include polypropylene (PP), Santropeneâ„¢ (TPV), Polyvinyl chloride (PVC), polyethylene (PE), acrylonitrile butadiene styrene (ABS) and thermoplastic polyurethane (TPU).

Info http://powereng.hotims.com RS#: 457

Watershed events such as the Fukushima-Daiichi accident threaten to shake public confidence and it is up to the regulators and industry worldwide to provide transparency, education and appropriate improvements to maintain and improve safety margin against safety goals.

Most operating nuclear power plants were designed for an operating life of 30 or 40 years after which the units would be permanently decommissioned. The global nuclear energy industry has seen marginal growth in recent years with approximately 67 new plants under construction as of July 2015, in comparison to 438 operating nuclear reactors, according to numbers from the Nuclear Energy Institute. With many operating plants reaching their end of life in the coming decade, major refurbishments and life extension projects will play a critical role in the stability of nuclear power generation.

Continued operation beyond original design operating life presents a number of technical and regulatory challenges. Plant refurbishments require replacement and/or rehabilitation of major components, including steam generators, turbine generators, instrumentation and control or process computers and reactor components. Obsolescence is a continuous problem and replacement of components often requires significant design changes to accommodate current production models. Qualified components with a finite service life must be replaced, sometimes with great difficulty and cost. However, these types of replacements are required for the maintenance of nuclear safety and efficient operation with minimal downtime due to forced outages. Despite these significant investments in plant life extension, maintenance of nuclear safety margin from the initial plant design and licensing may not be sufficient for extended operation.

Regulator Interface

The regulatory regimes worldwide are adapting to the concept of life extension and longer operating lives. In the United States, plants are initially licenced to operate for 40 years. Current rules allow for life extensions of an additional 20 years and guidance is under development for operating licences of up to 80 years. In Canada, licence renewals for periods up to 10 years have been granted. However, approval of life extensions require that the power plants are deemed to be safe to operate during this period in compliance with modern standards and safety goals.

Plant Design, the Design Basis and Beyond

Modern new build plants have the benefit of the lessons learned from the existing fleet. Next generation and advanced reactor designs include safety designs that provide emergency core cooling and containment features to deal with beyond design basis accidents (BDBAs) and severe accidents, particularly those involving a total loss of on-site electrical power. Existing plants must rely on inherent design safety features and may require modifications to improve robustness in order to meet modern standards and safety goals.

The initial licensing of nuclear power plants worldwide considered design basis accidents which ultimately define the range of analyzed accident conditions; these are considered to be the more probable accident sequences. These accidents consisted of initiating events, coupled with a failure of a safety system that resulted in an accident with its associated consequences (i.e., possible radioactive release). While BDBAs, including severe accidents, were considered in some jurisdictions prior to the Fukushima-Daiichi accident in Japan, following the accident, utilities and regulators worldwide endeavoured to provide increased capability to deal with such events. Utilities and regulators conducted assessments and analysis to analyze the capability of plants to cope with these severe events. Examples include the use of Review Level Conditions in Canada and the European Union Stress Tests. Nuclear safety practitioners have been challenged to identify those sequences that are outside the plant design basis but represent those events that could occur due to initiating events or failures not postulated through conventional deterministic safety analysis. While some of these sequences can be defined, such as more challenging seismic events or floods, others cannot be easily defined. Most utilities have adopted a combination of plant modifications and dedicated portable equipment that provide additional mitigation options for defined beyond design basis accidents, and even for more extreme events whose progression cannot be predicted in advance.

Portable equipment, often called FLEX equipment or Emergency Mitigating Equipment (EME) can be highly effective to mitigate BDBAs, particularly extreme natural disaster events. Portable pumps, generators and uninterruptible power supplies can be stored on-site, but remote from other emergency water and power supplies, or may also be stored in a centralized location. The physical separation of and independence of EME/FLEX from the plant and its structures, systems, and components provides added confidence that an event which disables all mitigating capability (i.e., similar to the Fukushima event) would not occur. Centralized FLEX storage sites have been established in the U.S. to provide the ability to deploy resources to a number of plants within a geographic area. This minimizes costs for individual plants and maximizes the availability of equipment for use should the need arise. Similarly in Canada, support agreements have been reached between utilities and within utility fleets to share their equipment if the need arose. FLEX or EME provides a highly beneficial set of options and helps to bridge the gap between installed accident mitigation capability for DBAs at existing plants and the modern approach to accident management.

Procedural changes have also been made to better address BDBAs. Operating procedures have been extended to provide instructions relevant to these types of events. Symptom-based procedures provide valuable diagnostic capability and flexible accident mitigation actions to cater to such events.

Other modifications have been incorporated worldwide to cater to BDBAs. These events present unique challenges for multi-unit containment designs such as those at the Ontario Power Generation and Bruce Power CANDU stations in Ontario, Canada. At these plants, new systems have been developed and installed for hydrogen control (for example, Passive Autocatalytic Recombiners). Dedicated Containment Filtered Venting Systems for BDBAs have also been installed at certain plants and new techniques for depressurizing containment have been developed. Events that may occur from a shutdown or low power state, or events affecting multiple units or multiple stations are now considered in accident management guidance and emergency procedures.

The Fukushima event also taught the nuclear industry that attention must be given to irradiated fuel bays during extended periods without power for cooling and water makeup. The effects of hydrogen accumulation and bay boil off are severe and although events tend to develop slower than reactor events, mitigation actions can also be very challenging.

While the concepts of BDBA and Severe Accident mitigation represent a new evolution in accident management, the overall principles remain consistent with longstanding nuclear safety principles. Controlling reactively, cooling the fuel, and containing the radioactivity remain fundamental. Enhancements that provide robust capability for fuel cooling without reliance on in-plant supplies (e.g., EME/FLEX) and containing the radioactivity (e.g., procedural enhancements, containment venting systems, hydrogen control measures) help to maintain these safety principles for BDBAs and serve to mitigate the consequences of such events.

Safety Improvement Opportunities and Prioritization

Compliance with modern codes and standards, as well as meeting more stringent safety goals is likely to require significant capital investment by operators of most plants. Environmental requirements also play a significant role for continued operation. Generally, environmental and safety considerations have a strong correlation; an improvement in one often improves aspects of the other. Safety improvements and upgrades form a large portion of capital investment for plant life extensions and should be carefully strategized in order to maximize return on investment. Utilities typically employ cost-benefit analysis (CBA) tools to assist with this strategy and the prioritization of improvements. The CBA process provides for a structured and systematic approach for evaluating alternatives and ensures that the costs of implementing proposed alternatives are commensurate with the benefits gained.

There are many established methodologies for quantifying and ranking safety improvements; most utilities will employ plant Probabilistic Safety Analysis (PSA) models to provide key insights, typically at least a Level 1 and Level 2 PSA will have been conducted. A Level 1 PSA is intended to estimate the frequency of core damage and models all safety functions and postulated failures; whereas a Level 2 PSA is intended to estimate the radioactive release magnitude and timing by analyzing accident progression phenomenology. Some plants may also develop a Level 3 PSA for which the effect of the postulated release and plant damage is assessed. These consequences are monetized and consider injuries and economic losses as well mitigating and aggravating factors such as atmospheric dispersion. By interrogating the plant Level 1 PSA to identify risk-dominant sequences, high-value opportunities can be determined. Utilizing the Level 3 PSA where available, these “offsets” of plant risk can be directly correlated to economic benefit. Utilizing the results of these interrogations and potential risk benefit, conceptual options can be quantitatively evaluated and ranked, providing a valuable tool to utilities when prioritizing capital investments in their plants.

The benefits realized from a safety improvement opportunity (SIO) are typically estimated by calculating the monetary value of the consequences averted by reducing the frequencies of the Fuel Damage Categories (FDCs) and Release Categories (RCs) impacted by the SIO. FDCs and RCs are categories of consequences dictated by the Level 1 and Level 2 PSAs, respectively; certain jurisdictions may use other terminology for these quantities but the intent is the same. The benefits are compared against the costs associated with implementing the change to determine the acceptability of the SIO based on acceptance criteria such as a benefit-cost ratio greater than one. It is possible to help increase the benefit-cost ratio by considering non-safety aspects such as improved economic risk. Any modification which may reduce the forced loss rate, increase generator output, decreased maintenance or operator burden, or minimize outage duration can be highly beneficial and provides added justification for gaining even a modest safety improvement. The CBA is usually expressed in terms of total estimated benefits, total estimated costs, net present value of the SIO and the overall benefit-cost ratio. A good CBA considers the entire life cycle of the SIO, including any associated ongoing deltas in maintenance or decommissioning. Favourable options are then progressed for further development, funding approval, design and implementation as appropriate.

Conclusions

The nuclear power industry is faced with an appropriately high degree of public and regulator scrutiny. Continued safety improvements are key to maintaining public trust and reduce the likelihood and severity of possible accidents. Watershed events such as the Fukushima-Daiichi accident threaten to shake public confidence and it is up to the regulators and industry worldwide to provide transparency, education and appropriate improvements to maintain and improve safety margin against safety goals. Life extensions provide a unique opportunity to examine risk significance and develop appropriate safety improvements to better attain and surpass safety goals. Effective assessment of options and planning of safety improvements is critical to the success of any nuclear plant life extension and long term economic viability.

Author

Sean Donnelly is manager of Station Operations and Licensing for Amec Foster Wheeler’s Nuclear Canada.

A technological revolution is underway in the energy industry. We are already seeing the results of that revolution in the surge of oil and gas production in the United States. But even more profound changes are happening in nuclear power – changes that have the potential to transform electricity production in the United States and around the world for decades to come.

Dozens of innovative start-up companies and other industry stakeholders are pioneering new advanced reactor designs that could be as revolutionary to nuclear energy as the iPhone was to the telephone. They promise cheaper and easier deployment, lower operating costs, and increased safety. Despite the American talent for developing advanced reactor technologies, the transition from design to commercialization and deployment – both in the United States and globally – has been slow.

A new report from the Nuclear Innovation Alliance (NIA) looked at the key initial obstacle to getting new advanced plants built: a nuclear regulatory structure in urgent need of updating. Currently, there is no efficient, cost-effective, predictable process for licensing advanced reactor technology in the United States. The report’s authors consulted with nuclear innovators, safety experts, former staff and commissioners from the U.S. Nuclear Regulatory Commission (NRC), members of the financial community, and other nuclear industry stakeholders. They also examined nuclear reactor licensing systems in the United Kingdom and Canada, and looked at how the U.S. Federal Aviation Administration and Food and Drug Administration regulate their respective industries.

An overhead view of the Unit 4 containment vessel at Plant Vogtle, which is under construction in Georgia. Photo courtesy: Southern Company.

The result was a detailed series of recommendations for updating America’s system for certifying and licensing nuclear plants that differ from the traditional light water reactor model.

The NIA believes that updating the regulatory process is urgent. The world will double or triple its energy demand in the next 30 years, driven by an emerging middle class in the developing world and the need to bring electricity to 1.4 billion people who lack it today. At the same time, many analyses point to the pressing need to reduce global carbon emissions by 80 percent or more over roughly the same timeframe to avoid the worst impacts of climate change. New safe, efficient, low-cost, proliferation-resistant nuclear generating technologies should play a central role in reconciling these two apparently contradictory challenges – they can provide the large volume of baseload electricity generation needed to meet surging demand without emitting greenhouse gases into the atmosphere.

The NIA report identified how current NRC regulation presents the licensing of advanced technologies with two major challenges. First, NRC design certification or approval calls for enormous front-loaded investment during a protracted development and licensing phase – without a staged structure to provide applicants with clear, early feedback on an agreed schedule. Second, current regulation is structured to oversee traditional light water reactors, but advanced reactors have different features and performance characteristics, and use substantially different fuels, cooling systems, and safety and operating strategies.

To overcome these challenges, the NIA recommends regulatory changes that the NRC should consider, as well as U.S. government policy changes requiring congressional action, and actions the nuclear industry should undertake to help facilitate needed changes.

The NIA’s recommendations for the NRC include developing a licensing project plan, as well as a statement of licensing feasibility process, that enable applicants to approach the process in standard stages, clarifying expectations, establishing clear milestones and facilitating communications between applicants and regulators throughout the licensing process. At the same time, the NRC can adapt current light water-centric regulations to be more technology inclusive through the development and use of risk-informed and performance-based evaluation techniques and guidance.

To facilitate the commercialization of innovative designs, the NIA recommends developing a staged approach to licensing advanced reactors that will better align with typical development and investment stages in new technologies. Several mechanisms for staging are recommended as starting points, principally the use of topical reports and the standard design approval process.

The NRC could also develop an optional statement of licensing feasibility process to standardize a limited review of early design information. This would provide early feedback to applicants, allow timely alterations in approach to better meet regulatory obligations and provide useful structure to pre-application engagement. The Canadian Nuclear Safety Commission’s vendor design review process offers a useful model for this approach.

Figure 1 depicts the elements that could be used to support the staged licensing of an advanced reactor and structured via a licensing project plan.

Licensing Project Plan – Figure 1

Congress can support these efforts by changing the NRC’s budget structure so license applicants only pay for activities related to their regulation, rather than funding nearly all of the NRC’s activities. It should also appropriate funds to help the NRC prepare for advanced reactor licensing and for the Department of Energy (DOE) to provide financial support for early-stage regulatory costs for promising advanced reactor designs.

Congress has already taken action with the Nuclear Energy Innovation and Modernization Act (S. 2795) and the Advanced Nuclear Technology Development Act (H.R. 4979), which have recently been reported out of committee. Both call on the NRC to enhance their regulatory framework for advanced reactors. S. 2795 also establishes a DOE cost-share grant program to assist with some early licensing costs for advanced reactors. The bills will need to be signed into law and funds appropriated, but the NRC and industry are also moving forward in parallel to meet the challenges identified in the NIA report and to ready the regulator and the prospective applicants for the review of advanced reactors.

The industry also has a role to play by providing crucial information and communications support to the NRC, the DOE and other stakeholders, and by spearheading efforts to develop codes, standards and conventions for advanced nuclear power.

Taking the new generation of advanced nuclear reactor technologies from the drawing board to deployment is vital for meeting the world’s growing demand for electricity without damaging the environment. The NIA’s recommendations outline a path forward that will dismantle some of the barriers to world-changing American innovation.

Author

Dr. Ashley Finan is the policy director of the Nuclear Innovation Alliance and project director at the Clean Air Task Force.

An increasing number of corporations are directly buying (or building) their own clean electricity. For decades most Fortune 1000 companies did little more than try to manage costs as they bought electricity and fuel from the existing marketplace. This model of simply relying on the existing marketplace to meet energy needs has, however, suddenly become outdated. More and more companies are realizing the strategic advantages of sourcing renewable power. Companies that fail to adapt will face serious competitive disadvantages as this trend accelerates.

There are several reasons for this explosion in interest in direct purchases of clean energy. Reasons range from pure cost per kwh purchased, to market and regulatory certainty, to the brand value of reducing reliance on fossil fuels, to concerns over the future of specific markets in the face of a changing climate. Consistent in every one of theses reasons is an underlying economic case – replacing electricity generated from burning fossil fuels with electricity from wind and solar is a good business strategy.

Over the past few years electricity from wind and solar has become cheap – in many cases it is less expensive to build new generating capacity from wind or solar than to build a new gas or coal plant. Buying renewable electricity removes fuel price volatility so prices are much more stable. Wal-Mart has been aggressively buying renewable power for years, primarily for the cost saving the company realizes. Ikea constantly touts immediate costs savings as the primary driver for its massive clean energy purchasing. Oil refining giant Valero uses wind power to drive refining operations in Texas because wind power was cheaper and the price was more stable than what was otherwise available in the market.

Renewable electricity is clean, and an increasing number of companies are setting aggressive clean energy and greenhouse gas emission reduction targets. Companies across the business spectrum – from Apple to General Motors, which both publicly announced goals for 100% renewable power for their global operations are using clean energy investments to gain competitive brand advantage, companies ranging from Bank of America to Dow have built advertising plans around their clean and sustainable investments. Consumers, both individuals and businesses, place real value in their buying choices based on the energy and climate footprint of brands. Forward thinking companies are committing to buying clean power in an effort to build a competitive advantage with these consumers.

Corporate interest in renewables is also being driven by anticipation of significant climate-policy changes, which could materially disrupt the market and existing cost structure of fossil fuel-based electricity. Several countries have put serious carbon pricing regimes in place as part of their efforts to meet the goals laid out in the Paris Climate Accord, and the two largest global markets, China and the U.S. have both formally joined the pact. In the U.S., EPA’s Clean Power Plan is still being contested, and the effect of specific implementation remain uncertain, but a material impact on power markets and electricity customers remains virtually certain. Around the globe many other countries are working through the implementation of new laws to reduce greenhouse gas emissions, all of which shifts value towards renewable electricity generating sources.

Many large corporations are not only trying to calculate the effects of these regulatory shifts, but are directly supporting these climate change driven policy changes. Amazon, Apple, Google, Microsoft, Mars, Ikea, Blue Cross and Blue Shield, and Adobe all submitted briefs supporting the Clean Power Plan in its appeal before the DC Circuit Court of Appeals. While there was a diverse set of reasons for each of these companies’ support for the Clean Power Plan, from getting regulatory certainty on the future of power markets, to mitigating the negative health effects (and costs) to a belief it will support longer term global economic stability, each was rooted firmly in the conviction that the Clean Power Plan would lead to long-term valuation creation for these companies. As more corporations see the value of aligning their business with mitigating and managing climate change, the pace of clean energy acquisition by corporations will only increase, growing a market worth hundreds of billions of dollars for new solar and wind projects.

Forward thinking companies are committing to buying clean power to build a competitive advantage with consumers. Corporate interest in renewables is also being driven by significant climate-policy changes, which could disrupt the market and existing cost structure of fossil fuel-based electricity.

The potential for this new market, worth hundreds of billions of dollars, has grabbed the attention of clean energy developers and investors. While the renewable energy market has grown rapidly over the past few years, developers and investors have become frustrated by many utilities are reducing the amount of wind and solar generated electricity that they are willing to buy under long-term contracts. These long-term commitments to buy the electricity generated from a wind or solar facility are typically necessary for an investor or lender to put money into the construction or purchase of a new wind or solar farm. Without these long-term agreements billions of available dollars are not being committed to projects.

New corporate buyers will be a vital and growing segment of the solar and wind markets. Developers and investors are actively looking for ways to gain access and market share in this new segment. The Renewable Energy Buyers Alliance (REBA), which was created by the Rocky Mountain Institute, the World Resources Institute, the World Wildlife Federation and BSR, has attracted more than one hundred of the largest corporate buyers to join its membership, as well as dozens of leading renewable energy developers, private equity fund managers, and banks to REBA events.

The combination of these two dynamics – developers and investors looking for new long-term commitments to buy power, while businesses are looking to lock in long-term supplies of clean and inexpensive solar and wind power – is driving a fundamental shift in the electricity market. In 2012 500 MWs of renewables were directly contracted for using corporate power purchase agreement, by 2015 more that 3400 MWs of capacity was contracted for by corporate buyers and the Rocky Mountain Institute projects this market to be more than 60,000 MWs by 2025.

In addition to shifting corporate strategy and a matching demand for long-term buyers, changes in the electric regulatory structure and innovations in the deal structures used to sell and finance electricity have helped open this new market for buyers to contract directly with power plants many miles away. Additionally, an explosion in available data about usage as well as new tools to manage energy consumption are making the intermittent nature of solar and wind power easier and cheaper to manage, further supporting the economic case for shifting corporate energy consumption to renewable power.

Developers and investors must reconcile this huge new segment of the market for power as part of their respective strategies. Effective, forward-thinking energy planning will be an important part of future competitive advantage across most businesses – and the companies that get this transition right will be rewarded. It will be vital for corporations to learn the power contracting and delivery process at a level of detail that only a select few strategic-thinking super-users of energy have ever considered. Finding the experience and talent to succeed in this dynamic new market will be increasingly challenging. Early adopters are building a critical advantage by being ahead of this market, and building a solid foundation for either the buying or selling of renewable power directly to corporations will be a barometer of success for businesses of all types.

Author

Elias B. Hinckley is a strategic advisor on energy finance and energy policy to investors, energy companies and governments. He is an energy and tax partner with the law firm Sullivan and Worcester.

Gas engines show advantages in their single cycle efficiency value (figure 2) and a very fast startup performance. Photo courtesy: MAN Diesel & Turbo

The transforming energy market shifts focus to reducing power plant environmental impacts, where financial and technical benefits improve competitiveness. This leads to an increased share of renewable power generation and also a focus on highly efficient, flexible and cleaner conventional power plants. Consumer perception and recent regulations have led to some coal and oil fired power plants to be shut down, depending on changing weather conditions, are not consistent and require very fast power generation capacity response to ensure a stable grid.

Power plant operators and investors looking to operate on natural gas have the choice between gas turbines and pure gas or pilot oil fueled engines, the latter technologies enjoying a recent and significant development. Engine power outputs now exceed 20 MW and benefit from increasing efficiency. Combined cycle engine based power plants emerge in the market place. Exceeding 200 MW becomes more common.

This article presents specific decision criteria that highlight key differences between applications and site performance of both technologies in gas-fired power plants.

Some obvious criteria that follow allude to the paper’s content: Single cycle efficiency, an expedient fats startup performance (within 3 minutes), and reduces load operation (below 25 percent) benefit the support of fluctuating renewable power generation. Low gas pressure requirements benefit distributed power projects. A project’s heat energy and electricity balance will favor a specific technology and site specific conditions and will also influence the decision process.

Power plant projects below 400MW require modernized decision criteria when it comes to selecting engines and/or turbines. This article offers guidance in a more objective choice between both technologies.

Technical Parameters Comparison

In any power plant technology comparison the list of parameters needing appropriate consideration includes at a minimum:

• Power plant load profile/start up time
• Start-up time
• Plant life cycle cost
• Project site ambient air temperature
• Plant altitude
• Agine/maintenance over operating time
• Reliability/availability
• Efficiency
• Power to heat ratio
• Dual Fuel requirements/capabilities
• Overall plant footprint

Most of these parameters impose severe impact when considering technical concepts or commercial feasibility and therefore are discussed in more detail.

Startup Time Comparison – 1

Electrical Efficiency Comparison at MCR for Single Units – 2

Power Plant Load Profile/Start-Up Time

The traditional load scenarios are:

• Base Load – with dominant constant load phases and basically continuous operation
• Intermediate – with more fluctuating load phases needed across a significant amount of operating hours
• Peak Load – with quick need of extra power at fast ramp-up rates

With an increased amount of fluctuating renewable power generation being fed to the grids sometimes during the day the demand may possibly be generated from renewable sources. However, depending on weather conditions on other days or at other times during the day, generation from such sources often remains insufficient. Sub sequentially required back-up, or reserve-means of power generation, therefore are a factual necessity. Many existing thermal plants, however, were designed for more or less continuous high loads. Presuming renewable power generation being prioritized when feeding the grid, the existing thermal plants can no longer do what they were intended to, but have to consider a stand-by position with decreasing annual operating hours at highly fluctuating load requirements. As a consequence, intermediate and peak load scenarios with the need of frequent fast equipment start for limited operating times of few hours only become a common requirement.

Gas engines show advantages in their single cycle efficiency value (figure 2) and a very fast startup performance. Multiple equipment starts per day are possible and reduced load operation at 25 percent or even lower are common features of modern engines. One hundred percent of output can be achieved under five minutes, starting from warm standby condition, compared to 30 minutes for a turbine under the same conditions. Such technological features are tentatively better suited to match the modern industry and energy market demands as described above.

Figure 1 shows a typical comparison of a gas engine plant start-up versus gas turbine combined cycle, both from warm conditions i.e. prior shut down of more than eight hours.

Gas Turbines, however, demonstrate superior performance under a relatively continuous stable load regime.

Tentative Plant Life Cycle Cost

While life cycle costs of any thermal power plant are vastly dependent on fuel cost, appropriate reflection of the expected load profile need to be incorporated into any comparison of various technological concepts. The number of full load hours and especially the increasing amount of part load hours need to be forecasted as precise as possible, however strictly individually. Conversion to full load equivalent hours tentatively includes the risk of ignoring the efficiency losses factually occurring under part load operation. Whenever limited overall operating hours and part load phases or even multiple starts and stops dominate the load profile, a GT and/or combined cycle option may disqualify. Gas engine maintenance costs often turn out to be lower than those for turbines, depending on actual project parameters.

Project Site Ambient Air Temperature

For gas turbines, maximum power is often defined by maximum component temperature in the turbine, permissible forces to the shaft, or the generator frame size. For gas engines, maximum cooling water temperature often is the limiting factor. The gas engine output is hardly affected by increases in ambient air temperature and stays at 100 percent up to around 38OC. When running a gas turbine, however, power output continuously decreases.

Plant Altitude over Sea Level

Figure 3 compares the plant altitude effects on the performance of gas engines versus gas turbines. Again, the diagram duly takes into account the different “regular” ISO conditions for gas engines as shown in the diagrams legend. The equipment behavior differs dramatically. While engines offer full load output at any altitude up to 1,000 meter above sea level, the industrial gas turbine’s output decreases by 10 percent.

Effect of Altitude Comparison – 3

Aging/Maintenance over Operating Time

The aging behavior of the different technologies can be seen by examining the “heat rate” evolution as a continuously increasing factor in between maintenance periods as compared in Figure 4. Furthermore, and “peaking” demand vs. a regular baseload operation has additional effects on gas turbines because every gas turbine start accounts for some extra operating hours being added to the counter. Operating hours counting of gas engines is not affected by multiple starts. Subsequently peaking operation with gas turbines will exaggerate gas turbine maintenance costs with overhaul activities appearing earlier.

Plant Efficiency

Comparing both technologies under the same plant load, in single or combined cycle, helps to understand the superior efficiency of the gas engines over operating time.

If we add the particular consideration of part load efficiencies for a single machine, we can clearly see the efficiency difference between the competing technologies where the gas engines are significantly less affected by reduced load demands.

Power Plant Footprint & Civil Works

Gas Engines are now available in up to 20.2MWe where a power plant of 100MW requires an area of around 60mx60m. A gas turbine power plant can achieve ~100MW output by installing 2x50MW units, which will install with a more compact foot print at subsequently reduced civil works cost.

Aging Effect Comparison – 4

In general, with gas turbines, the total installed masses are smaller. This is an advantage for transportation into remote areas and installation. A gas turbine power plant requires fewer auxiliary systems, as well as no, or fewer, additional exhaust devices. Pure machine weight-related issues should be considered as well where gas turbines benefit from much lower equipment weight than gas engines.

Summary

Many technical and commercial parameters need due consideration when selecting the proper gas power plant technology in accordane with the actual project parameters. Such parameters and other required data will be presented and further discussed as part of the convention’s presentation.

In general, the reciprocating four-stroke gas engines show advantages in single cycle efficiency, high efficient part load operation and a very fast startup performance. Reduced load operation at 25 percent or lower is also possible if needed. This makes gas engines ideally suited to compensate for the fluctuating renewable power generation.

Low gas admission pressure requirements for engines (6 bars comparing to around 21 – 40 bar for turbines) reduces infrastructure costs and risks and allows placing of such generators close to the consumers. Therefore engine based power generation also supports the decentralized power generation concepts, as well as reducing CAPEX and OPEX by eliminating the need of fuel gas compression.

In case thermal energy can be utilized, an overall plant efficiency beyond 90% can be achieved.

The engine technology is furthermore less sensitive to hot ambient temperatures and altitude in comparison to gas turbines. Base load gas turbine combined cycle power plants of >400 MW can provide full load efficiency of >60 percent. When running many thousand full load hours annually, such big plants clearly outperform any gas engine configuration as a function of reduced fuel spending. Gas turbine plants typically also benefit from a smaller footprint compared to engine based power plants.

Finally, gas turbine combined cycle plants may also take advantage from any location being incorporated in industrial areas by selling steam to neighbor industries. However, the same logic applies to a potential gas engine plant in CHP configuration. Thermal energy provision to neighbor industries or any district heating provider with heat being provided by means of hot water efficiently generated from advanced heat recovery systems can create extra profitability.

In the power range up to ~200-300 MW we see an interesting field in which both technologies can be fairly considered.

Author

At the time this article was written, Ralf Grosshauser was the senior vice president of MAN Diesel & Turbo SE. Grosshauser now serves as CEO of Thermamax GmbH…

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Decarbonization, Optimizing Plant Performance, the Future of Electricity, the New Energy Mix (CHP, microgrids) and Trends in Conventional Power are all tracks planned for POWERGEN International happening Jan. 26-28 in Dallas. The POWERGEN Call for Speakers is now open and seeking session ideas around projects and case studies.

The equipment associated with the Instrument air system as used in the industry, generally consists of an air compressor, air dryer and an air receiver fitted with a liquid drain trap. The instrument air system is utilized by various plant instrumentation, some of which may have a critical role in plant operation and safety. Therefore, the equipment should be properly sized and capable of producing the required air quality.

This article provides an overview of some of the key points and calculations associated with the instrument air system, which can assist the design engineer in his task.

Air Quality Specification:

The Specification for Instrument air quality is governed by ANSI/ISA-7.0.01 “Quality Standard for Instrument Air”. This specification stipulates the following:

1. Pressure Dew Point: “The pressure dew point as measured at the dryer outlet shall be at least 10C (18F) below the minimum temperature to which any part of the instrument air system is exposed. The pressure dew point shall not exceed 4C (39F) at line pressure”.
2. Particle Size: “A maximum 40 micrometer particle size in the instrument air system is acceptable for a majority of pneumatic devices”.
3. Lubricant Content: “The lubricant content should be as close to zero as possible and under no circumstances shall it exceed one ppm w/w or v/v.”
4. Contaminants: “Instrument air should be free of corrosive contaminants and hazardous gases which could be drawn into the instrument air supply”.

Calculation of Pressure Dew Point:

Note that the pressure dew point is the dew point at line pressure (example, -40F dew point at 100 psig.) As line pressure increases the dew point increases. Traditionally, regenerative desiccant air dryers for instrument air systems are capable of providing high level of moisture removal (usually -40F dew point but as low as -100F) over a wide range of air flow rates used in the industry.

Consider ambient conditions of 14.7 psia, 68F and 40 percent Relative Humidity. The dew point can be calculated as follows:

Sat. vapor pressure at 68F= 0.3389 psia (from steam tables)

Therefore moisture vapor pressure at 40% RH= 0.3389 x0.4=0.135 psia

From steam tables 0.135 psia is the saturation vapor pressure at 43F, therefore normal dew point is 43F

Now consider the same case when dew point (that is, pressure dew point) is evaluated at a higher pressure of 114.7 psia. In this case, the moisture vapor pressure evaluated above at 0.135 psia is multiplied by the pressure ratio, giving 0.135 x 114.7/14.7= 1.053 psia. From steam tables, this is the saturation pressure at approximately 104F.

Therefore the pressure dew point is 104F compared to normal dew point of 43F.

Regenerative Desiccant Air Dryers:

There are various types of air dryers such as the regenerative desiccant type, refrigerated type, deliquescent type, membrane type and point-of-use type dryer. Each type of dryer has its own limit on the air outlet dew point. Regenerative desiccant air dryers are commonly used in the process industry and are the most expensive.

The dryers work by adsorbing moisture on desiccant material such as alumina, silica gel molecular sieves. The desiccant material is contained in two packed towers which are alternately in service or being regenerated. The regeneration can be achieved by different methods, such as, using a purge of dry air from the operating tower or by using internal heaters or by an external heat source. Use of purge of dry air is a simple process with the discharge air purged to the atmosphere. However, use of purge air consumes about 15 to 20 percent of the compressed air capacity and is best utilized when there is sufficient excess air capacity.

The capacity of air dryers as provided by the vendor is generally in terms of “inlet scfm” at a service pressure of 100 psig and service temperature of 100F. At different service conditions, the inlet flow to the dryer needs to be corrected by multiplying by the pressure correction factor and the temperature correction factor.

If service pressure is higher than 100 psig (say 120 psig) the flow capacity of the dryer increases by the pressure ratio (120+14.7)/(100+14.7)=1.17. On the other hand, if service temperature is higher than 100F (say 115F), the flow capacity of the dryer decreases by the ratio of moisture saturation vapor pressure ratio at 100F and 115F (that is, 0.9492 psia/1.4711 psia=0.64).

Based on above, the corrected flow to a dryer rated for inlet of 100 scfm (at 100 psig/100F) and operating at 120 psig/115F, would be =100 x 1.17 x 0.64 = 75 scfm. Note that this is 25% less than the rated value of 100 scfm.

Desiccant Type Air Dryer Schematic – 1

Possibility of Mismatch between Compressed Air Supply and Demand:

The term “standard cubic feet per minute – scfm” should be used with caution due to variation in values used to represent standard pressure and standard temperature. In the compressed gas industry, standard conditions are taken as 14.5 psia, 68F and 0 percent relative humidity. Other variations for standard pressure/temperature conditions are 14.7 psia and 32F. As such, these variations can cause confusion and result in a mis-match between the compressed air supply and compressed air demand.

For example, consider an end-user demanding 10 scfm of air with the understanding that standard conditions are at 14.7 psia and 32F. Air density (ρ) at these condition of pressure and temperature is ρ=p/RT= 0.808 lbs/cu. ft. In other words the air demand is for 10 ft3/min *0.808 lbs/ft3= 8.08 lbs/min.

Now consider a reciprocating compressor supplying 10 scfm air at standard conditions of 14.5 psia, 68F. Air density (ρ) at these condition of pressure and temperature is ρ=p/RT= 0.742 lbs/cu. ft. In other words the air supply is providing 10 ft3/min *0.742 lbs/ft3= 7.42 lbs/min of air. This quantity of air is only 92% of the air demand of 8.08 lbs/min and therefore does not meet the requirement of the end user.

In case of a centrifugal compressor, the lower ambient pressure and higher ambient temperature at suction conditions leads to lower discharge pressure.

Note that in some cases, compressor capacity is stated in terms of Free Air Delivery (FAD) which is merely the discharge volumetric flow converted back to inlet conditions of the compressor.

Effect of Relative Humidity on Compressor Inlet Conditions:

As mentioned earlier, the compressed gas industry uses 14.5 psia, 68F and 0 percent relative humidity as the standard conditions. Now consider actual site conditions at 14.5 psia, 68F and 100% relative humidity. The moisture saturation vapor pressure at 68F is 0.339 psia, therefore the dry air pressure is reduced from 14.5 psia to 14.161 psia (14.5 psia-0.339 psia= 14.161 psia). In turn, this reduced pressure value at compressor suction decreases the mass flow capability of the reciprocating compressor (or decreases the discharge pressure in case of a centrifugal compressor).

Air receiver with Liquid Drain Trap and Balance Line – 2

Volume of the Air Receiver Tank:

The air receiver provides a storage volume of compressed air to be used when the compressor is off-line or when the air demand temporarily exceeds the compressor output. If the users require 100 psig in the air receiver and the compressor is set to provide 100 psig air to the receiver, then there is no hold-up or buffer. For the air receiver to be effective, it must therefore operate within a pressure band.

For example, assume that the demand for compressed air requires 100 psig pressure in the air receiver and the compressor is set to operate in a pressure band to load at 120 psig and unload at 130 psig. This means that in case the compressor is off-line, or if air demand increases, a storage volume corresponding to air receiver pressure ranging from 120 psig to 100 psig is always available. The air receiver volume can be calculated from the following equation which shows the time taken for the air receiver to drop from the higher pressure point to the lower pressure point within the operating pressure band:

t=V(p1-p2)/C*pa

Where,

t= time, mins

V= volume of air receiver, cu ft

p1= upper limit of air receiver operating band, psia

p2= lower limit of air receiver operating band, psia

C= net air consumption (scfm)

pa= atmospheric pressure (psia)

If air is supplied to the air receiver during the time interval being evaluated, then the value of C must be reduced by the rate of air supplied.

Air Compressor:

There are three types of air compressors generally used in the industry. These are as follows:

1. Centrifugal Compressors
2. Reciprocating Compressors
3. Rotary Screw Compressors

Centrifugal compressors are cost effective in large sizes only, can provide oil-free air delivery and have the characteristic pressure curve with pressure decreasing as capacity increases.

The reciprocating compressors have effective multistep capacity control but has a high first cost with special foundations for vibrations and needs routine maintenance.

The rotary screw compressor is popular in instrument air service since it is a compact package at a relatively low first cost and provides oil-free air.

Compressor Control Strategy and Air Receiver Volume:

The rotary screw compressor capacity can be controlled by a variable speed drive. However for oil free compressors speed turndown is limited to about 50% of maximum speed depending upon adequacy of bearing lubrication at low speed and on compressor discharge temperature. Therefore during periods of low air consumption, the compressor will need to be unloaded with the discharge-to-suction bypass open (and if an over-run timer is fitted, it can stop the compressor in case it runs in unloaded condition for a pre-set period of time). With a large sized air receiver, the compressor will be unloaded for a longer period of time thus minimizing wear and tear associated with the compressor’s load/unload frequency or start/stop frequency. Therefore the air receiver should be sized accordingly keeping in view the associated wear/tear effect on the compressor and motor.

Moisture Drainage from Air Receivers:

The atmospheric humidity entering the air compressor ends up in the air receiver which is usually at a temperature below the dew point of the compressed air. Note that the pressure dew point is higher than the atmospheric dew point resulting in water accumulation at the bottom of the air receiver. This water is usually drained out through a liquid drain trap which drains the water while preventing escape of compressed air.

The balance line allows air which has entered the trap to be discharged back to the receiver. Without the balance line, air binding can occur in the liquid trap.

The size of the liquid trap depends on the differential pressure across the trap and the required discharge flow rate. The required discharge flow rate can be computed as follows:

Assume ambient air is at 14.5 psia, 70F and 70% relative humidity:

Saturation vapor pressure at 70F = 0.363 psia (from steam tables)

Vapor pressure at 70% Relative Humidity = 0.363 x 0.7 = 0.25 psia

Vapor pressure of dry air=14.5-0.25 = 14.25 psia

Mol fraction of water vapor=0.25/14.5=0.017

Assuming compressor inlet capacity of 500 scfm= 500/379.5=1.317 moles/min

Water vapor in compressor inlet= 1.315 x 0.017 =0.022 moles/min

Now (0.022 moles/min) x 18 x (60/8.338) = 2.89 gallons per hour. This is the amount of water to be discharged from the liquid trap at the bottom of the air receiver.

Conclusion:

The demand for compressed air may vary significantly at the plant. Therefore, the compressed air system must be designed such that that all components in the system (compressor, air dryer, air receiver and drain) are able to cope with the variation in demand. In this context, the design tips provided in this paper may help the system designer.

Author

S. Zaheer Akhtar, P.E. is Principal Engineer at Bechtel Corporation.

Water treatment technologies for a coal power plant.

Increasing demand, evolving energy sources and environmental drivers are shifting the global power landscape. With growing populations in emerging markets, like Asia and Pacific, comes growing demand for power and new installations. The shifting global energy landscape means the global water landscape is also shifting, as water is used to propel the turbines that run the generators that produce power for communities around the world. The power generation industry relies on quality water to complete the processes necessary to generate electricity. Thermal cycle plants also require large amounts of water for steam, cooling and condensing. In the U.S. alone, the National Renewable Energy Lab notes that electricity production from fossil fuels and nuclear energy requires 190,000 million gallons of water per day, accounting for 39 percent of all freshwater withdrawals. These demands for water are shaping the shift in water treatment in power generation from freshwater sourcing to wastewater treatment and reuse. For example, strong environmental drivers in China and the U.S. are increasing flue gas desulphurization (FGD) and minimum liquid discharge (MLD) applications. Typically the upgrades to advanced water treatment are done in phases, starting with the lower hanging fruits such as increasing the cooling tower cycles or treating the cooling tower blowdown for a reuse.

Powering the Water-Energy Nexus

In order to meet the demand for power generation across markets, and also meet increasingly stringent environmental regulations, operators can use treatments to protect assets and improve plant operating efficiency. Reducing energy usage, chemical costs and water footprints, while increasing reclamation of non-conventional water sources like wastewater, are key industry focal points. Nuclear power plants worldwide face the added challenge of reducing their radioactive waste sustainably and cost effectively. The water-energy nexus, the concept that water and energy are interconnected – energy is needed to create power and power is needed to create water, has become a major driver of innovation in the industry, as high water quality is of paramount importance to protect investments and ensure equipment runs efficiently and reliably. Effective water treatment technologies on the market today including ultrafiltration (UF), reverse osmosis (RO) and nanofiltration (NF) and ion exchange (IX), help ensure reliable, efficient, more sustainable operations in a range of power plants.

UF: Reducing the impact of poor water on boiler and cooling system management

Ultrafiltration reduces colloids, particles and bacteria in a continuous system to deliver higher reliability and lower maintenance with a smaller footprint. Used as a pretreatment for downstream units like RO, UF helps reduce the impact of poor or variable make-up water on boiler and cooling system management.

UF in Action: Northern China is home to one of the largest fossil power plant in Asia. The plant’s source water is a combination of cooling tower blowdown wastewater with high levels of salts and alkalinity, and pretreated water from the Huanghe River, which has high levels of mud, sand and suspended solids. This highly-variable source water requires a treatment technology that functions effectively across various temperatures and pressures. These demanding operational requirements can lead to increased fouling, a contaminant build-up on the filter, corrosion and equipment malfunction. When operators expanded the plant’s system to reclaim additional cooling tower blowdown through two additional generators, they also upgraded the treatment system to include conventional filtration and outside-in UF technology.

RO and NF: Removing contaminants reliably

RO and NF provide a balance between efficient contaminant removal, demineralization and reliability. RO and NF elements can cost-effectively remove a broad range of molecules and ions that can cause scaling and fouling. By using RO and NF technologies, operators can increase the number of cooling tower cycles and facilitate the use of alternative water sources to address local water scarcity challenges.

UF and RO: Reusing Difficult Waters

The Gaojing Power Plant in Northern China is an excellent example of how large, mature facilities can retrofit their water footprint to comply with stricter environmental standards. This 40 year old power plant was first upgraded to reuse cooling tower blowdown as feed water to boilers. Dual membrane technology (UF and RO) together with pretreatment and chemical dosing, helped Gaojing Power Plant to achieve reuse of cooling tower blowdown of more than 70 percent. Followed by a change in cooling tower water source from surface water to secondary effluent from the nearby municipal wastewater treatment plant, the Gaojing Power Plant was able to realize a double reuse of water. This project provided a true test of UF and RO enabling the reuse of difficult waters. Cooling tower blowdown is highly turbid and has high hardness. An extreme challenge for many technologies but reliably handled here. As a result of a successful first phase retrofit/expansion, additional phase expansions with UF and RO were developed.

RO in Action: A captive power station for a major brewer in North America turned to Dow Water & Process Solutions to help combat challenging local source water. By upgrading the system with a next-generation configuration using DOW FILMTECâ„¢ ECO RO elements, the brewery has increased uninterrupted beer production and reduced the energy required to treat feed make-up water. The brewery is also meeting its electrical energy and process steam requirements. The new water treatment system has reduced the power station’s energy consumption by 10-20 percent and improved peak flow performance.

IX: Efficiently removing ionic impurities

By removing ionic impurities, ion exchange resins produce softened, partially or fully demineralized water reaching to ultrapure water quality. IX resins can be highly specialized to remove a narrow or wide range of contaminants and tailored for specific fossil and nuclear power applications to soften, demineralize and polish make-up water, or enable FGD. IX resins are also the technology of choice for condensate polishing applications designed to protect multi-million dollar assets such as boilers, steam generators, turbines and nuclear reactors. IX resins also can help improve the quality and clarity of reactor water, fuel pool water, and re-use or discharged water.

IX in Action: Conemaugh Station in Pennsylvania required treatment of FGD wastewater to meet discharge limits for boron. Dow’s boron selective IX resin was installed in 2012 and has successfully allowed Conemaugh Station to meet discharge limits. As the first installation of boron selective resin in FGD wastewater treatment, it has seen highly variable feed water and many other challenges. Through all of these difficulties, the system has continued to meet discharge limits. It proves to be an effective, reliable technology in removing boron from FGD waste water.

A Cohesive System

UF, RO, NF and IX work cohesively throughout a power plant to optimize operations and minimize unscheduled outages. For example, make-up water may need pretreatment (UF), demineralization (RO) and polishing (IX) to help reduce corrosion, scale, fouling and other asset-limiting factors. IX in deep bed or powdered resin beds serve as the backbone of condensate polishing for boilers, steam generators and turbines to help remove dissolved purities like chloride, sulfate, silica, and sodium along with particulate iron and copper corrosion products. Treating strator cooling water with an IX mixed bed polisher will help remove soluble contaminants to prevent generator failure. To help minimize corrosion and reduce ionic hideout, blowdown water can be treated with ion exchange for reuse or discharge. The shifts in water treatment needs for the power industry also drive the innovations in water treatment technologies at individual component level as well as in integrated systems.

Enhancing Sustainability

Environmental regulations have driven many fossil-fueled power plants to install FGD systems, requiring the treatment of FGD blowdown water prior to discharge. Highly selective ion exchange resins are helping operators meet discharge regulations by removing trace contaminants, like arsenic and mercury.

As freshwater sources grow increase scarce across the globe, many industries, including power, are moving away from a “take, make, dispose” approach to a circular strategy where raw materials, including water, are reduced, reused and reclaimed. A circular economy model employs advanced water technologies that help enable facilities to reduce their intake of freshwater by sourcing reclaimed water for operations and increasing the number of cycles for which the water is used. The water can then be treated and upgraded before discharge for alternate use.

Operators are feeling pressure from environmental regulations, sustainability trends and the rising price of water and discharge mitigation costs to reduce their impact on the environment. Sustainability has become a boardroom issue, with many recognizing the need to improve their water footprint. Minimum liquid discharge (MLD) is enabling up to 95 percent liquid discharge recovery at a fraction of the cost of solutions aiming for zero liquid discharge (ZLD). While the term MLD might be new, the processes on which it is based rely on advanced UF, RO, NF and IX filtration technologies. MLD can help plants make solid, substantial gains in minimizing liquid discharge while also minimizing their capital and operating costs, since achieving the final 3 to 5 percent liquid elimination for ZLD can be very costly. Since the greatest challenges to ZLD are economic because ZLD systems require higher capital and operating expenditures and have greater technical challenges, it can nearly double a user’s costs.

MLD shows we can achieve significant gains in sustainable water management at a lower cost than ZLD. MLD solutions can be tailored for individual needs. For example, MLD can be used in the wet wastewater stream of FGD or for cooling tower blowdown.

MLD in Action: More strict discharge requirements and water scarcity in China over the past few years have fueled the consideration of zero-liquid discharge to manage flue gas desulfurization wastewater. Because thermal ZLD processes are both capital and energy intensive, membrane based minimal liquid discharge technology was applied to reduce the volume of water undergoing thermal processing and thus reduce costs. In close partnership with an original equipment manufacturer in China, DOW completed 6 months of membrane piloting and demonstrated a membrane application capable of reliably reaching high water recovery despite the challenging FGD wastewater. The cascading treatment process from selective ion separation membrane followed by brine concentration using high pressure membranes were the key membrane treatment strategy successfully employed. The proven performance during piloting provided the OEM confidence to design and build a full scale system which is currently in commissioning stage at a power plant operated by one of China’s largest national power groups.

The Future of Power

Power operators are being squeezed on both ends in terms of water sourcing and water discharge, which has elevated water to a business factor, and, on a broader scale, an economic development factor. Despite the huge market, the belief persists that investing in advanced water treatment technologies is too costly. But for the power industry, it is costly to not invest in advanced water treatment technologies. Power providers are seeing the impact the cost of water and the cost of interrupted supply and operations can have on continuous power generation. In most stringent cases whether or not to invest on advanced water treatment becomes a question of having the license to continue operation. From ensuring optimal operating efficiency and protecting assets, like generators and cooling towers, and lowering the cost of water and energy through reuse, advanced water treatment technology is ensuring we can keep the lights on and the economy humming.

Authors

Katariina Majamaa is a global strategic marketing manager at Dow Water & Process Solutions. Steve Rosenberg is a research fellow for Dow Water & Process Solutions. Bill Carlin is a senior technical service engineer for Dow Water & Process Solutions.

Combined cycle power plants have become in large measure the de facto replacement for the many coal plants that are being retired. A particular aspect of these new plants is that they are often minimally staffed with few if any personnel who are well trained in water/steam chemistry. Yet, failures due to inadequate water treatment and chemistry control, whether they be in the steam generator or cooling system, can cost a plant huge amounts in lost revenue and equipment repair if they cause failures and forced outages. With respect to cooling, no longer are plants being built with once-through cooling systems but rather the choice is either a cooling tower or air-cooled condenser. This article focuses on the former. Cooling system treatment programs have evolved substantially over the last several decades, and this evolution continues, but with increasing complexity.

Basic Cooling Tower Flow Path – 1

Cooling Tower Heat Transfer Basics

The figure below illustrates the fundamental flow path of a cooling tower, and indicates one set, of an obviously vast number, of conditions that are possible with regard to temperature and moisture content of the process streams. The data are included to outline important concepts of a cooling tower.

Note the large change not only in the temperature of the air moving through the tower but the relative humidity (RH). Typically, 65 to 85 percent of the cooling in a tower comes from evaporation of a small portion of return water to the tower. The remainder is by sensible heat transfer. While rather detailed mathematics and engineering are required to properly select the size and air-to-water flow ratio (more commonly known as the liquid-to-gas [l/g] ratio) of a cooling tower, several common equations are very functional for determining operating aspects of a system. Consider the example above, where we will select an evaporation ratio of 75 percent, which in the following equation is converted to decimal format as an evaporation factor (Æ’).

E = (R * Æ’ * Range)/1000, where

E = Evaporation (gpm)

R = Circulating water rate (in this example, 150,000 gpm)

Æ’ = Evaporation factor (in this example, 0.75)

Range = Temperature difference between hot return water and cold discharge (27oF)

So, the evaporation rate in this example is 3,037 gpm, which is approximately 2 percent of the circulating water rate.

As water evaporates in a cooling tower, dissolved solids (and suspended solids) remain behind. These solids concentrate and increase the scaling, corrosion, and fouling potential of the water. Chemical treatment programs are based on controlling all three of these mechanisms, which we will soon examine after first considering additional fundamental flow calculations.

Even with the best chemical treatment program, impurities in the cooling tower can only be allowed to accumulate to a certain level before the scaling potential overwhelms the chemical treatment. The amount to which the impurities are allowed to concentrate over those in the cooling system makeup water is known as the cycles of concentration (COC). The COC is controlled by periodic blowdown of a fraction of the cooling water, whose volume is replenished with makeup water. The relationship of blowdown to evaporation and COC is shown by the following equation.

BD = E/(COC – 1)

Blowdown Rate vs. COC – 2

A very small amount of water, often negligible with regard to these calculations, leaves the tower fan exhaust in the form of water droplets. This loss is known as drift (D), and can be considered as a very minor continuous blowdown. So, adding this factor to the equations above, the total makeup (MU) to a cooling tower is represented by the following equation.

MU = E + BD + D

In cooling towers with well-engineered mist eliminators, a common design drift rate is 0.0005% of the circulating water flow rate. So, for our example drift would amount to approximately 1 gpm, which is indeed negligible.

An important issue with regard to blowdown is that as COC increases the blowdown volume decreases inversely, as is shown in the following chart.

Fig. 2. Blowdown rate vs. COC for the example outlined above.

As is evident, the “law of diminishing returns” applies as the COC increases. A common COC range is 4 to 8. But if the tower is located in an arid environment or blowdown quantity is restricted, a higher COC may be mandated. However, this comes at a cost, as the higher COC means a greater concentration of dissolved solids in the cooling water, which increases the scaling and corrosion potential.

Modern Chemistry Control

In towers supplied by fresh water, and in the absence of any treatment, almost always the first scale to form would be calcium carbonate (CaCO3). Calcium ions (Ca2+) love to combine with bicarbonate ions (HCO3-), especially as temperatures rise in condensers and other heat exchangers.

Ca2+ + 2HCO3- + heat → CaCO3↓ + CO₂↑ + H₂O

So, in the middle of the last century a very common treatment program was utilized, which addressed both scaling and corrosion via a two-chemical process. The first step was feed of sulfuric acid to maintain a cooling water pH within a range of about 6.5 to 7.0. Acid converts bicarbonate to carbon dioxide, which of course escapes as a gas. This was coupled with feed of sodium dichromate to the water. Chromium forms a surface layer on carbon steel and gives it stainless steel-like qualities. In common vernacular, this program was almost a “no-brainer,” although upsets in acid feed could and did cause serious corrosion.

Two Common Phosphonates – 3

Unfortunately, chromate-based treatment can generate hexavalent chromium (Cr6+), which is toxic. The method essentially disappeared for all cooling systems, whether open or closed. The popular replacement until recently has been alkaline-based treatment, primarily relying on inorganic and organic phosphates (phosphonates), with a supplemental polymer to sequester and modify non-carbonate scale-formers, and perhaps a low dosage of a zinc salt.

At the typical pH range of these programs, low- to upper-8 range, corrosion is reduced, but also the various chemicals inhibit the corrosion reactions that occur at anodic and cathodic sites in metal.

Fig. 4. The effect of inhibitors on corrosion. Source: Reference 1.

The Effect of Inhibitors on Corrosion – 4

Common Polymer Building Blocks and Functional Groups – 5

Fouled Cooling Tower Film Fill – 6

The chemistry minimizes calcium carbonate formation, but unfortunately can induce calcium phosphate scaling without careful control. Prevention of this scale is a primary reason why a polymer is usually part of the chemical blend.

The major water treatment chemical companies have developed sophisticated monitoring and feed programs for the phosphate/phosphonate programs, but a new problem has arisen. Many receiving bodies of water in the country are now considered phosphorus-impaired due to the influence of phosphorus on the generation of toxic algae blooms. Thus, new plants may not be allowed to discharge any phosphorus-containing streams to these water bodies. Emerging are all-polymer programs, in which the polymer blends act as crystal modifiers and sequestering agents to keep scale-forming ions and crystals in suspension. The figure below illustrates the active sites on many of these polymers.

When choosing a cooling water treatment program, modeling software can be of great benefit. French Creek Software is a leader in this technology, and many of the major water treatment chemical vendors utilize the software for their programs.

Control of Microbiological Fouling

While scaling and corrosion are very important concerns in cooling systems, microbiological fouling often by far causes the most problems.

Cooling systems provide an ideal environment, warm and wet, for microbes to grow and establish colonies. Bacteria will grow in condensers and cooling tower fill, fungi on and in cooling tower wood, and algae on wetted cooling tower components exposed to sunlight. Biocide treatment is absolutely essential to maintain cooling system performance and integrity.

Bacteria are separated into the following three categories,

• Aerobic: Utilize oxygen in the metabolic process.
• Anaerobic: Live in oxygen-free environments and use other sources, i.e., sulfates, nitrates, or other donors for their energy supply.
• Facultative: Can live in aerobic or anaerobic environments.

Dissociation of HOCl as a Function of pH – 7

A problem with microbes, particularly bacteria, is that once they settle on a surface the organisms secrete a polysaccharide layer for protection. This film then will collect silt from the water, thus growing even thicker and further reducing heat transfer. Even though the bacteria at the surface may be aerobic, the secretion layer allows anaerobic bacteria underneath to flourish. These bugs in turn can generate acids and other harmful compounds that directly attack the metal. Microbial deposits also establish concentration cells, where the lack of oxygen underneath the deposit causes the locations to become anodic to other areas of exposed metal. Pitting is often a result, which can cause tube failure well before the expected lifetime of the material.

Fungi will attack cooling tower wood in an irreversible manner, which can eventually lead to structural failure. Algae will foul cooling tower spray decks, potentially leading to reduced performance and unsafe working locations.

The core of most microbiological treatment programs is feed of an oxidizing biocide to kill organisms before they can settle on condenser tube walls, cooling tower fill, and other locations. Chlorine was the workhorse for many years, where when gaseous chlorine is added to water the following reaction occurs.

Cl2 + H₂O ⇔ HOCl + HCl

HOCl, hypochlorous acid, is the killing agent. The functionality and killing power of this compound are greatly affected by pH due to the equilibrium nature of HOCl in water.

HOCl ⇔ H+ + OCl-

OCl- is a much weaker biocide than HOCl, probably due to the fact that the charge on the OCl- ion does not allow it to penetrate cell walls. The killing efficiency of chlorine dramatically declines as the pH goes above 7.5. Thus, for the common alkaline scale/corrosion treatment programs, chlorine chemistry may not be efficient.

Chlorine demand is further affected by ammonia or amines in the water, which react irreversibly to form the much less potent chloramines. Due to safety concerns, liquid bleach (NaOCl) feed has replaced gaseous chlorine at many facilities.

A common alternative is bromine chemistry, where a chlorine oxidizer and a bromide salt, typically sodium bromide (NaBr), are blended in a makeup water stream and injected into the cooling water. The chemistry produces hypobromous acid (HOBr), which has similar killing powers to HOCl, but functions more effectively at alkaline pH.

Chlorine dioxide (ClO2) is becoming more popular for several reasons. Its killing power is not affected by pH, the chemical does not react with ammonia, and it does not form halogenated organic compounds. Also, chlorine dioxide is more effective in attacking established bio-deposits.

ClO2 is unstable and must be generated on-site. In the past, a common method was reaction of sodium chlorite (NaClO2) and chlorine in a slipstream fed to the cooling water.

2NaClO2 + Cl2 ® 2ClO2 + 2NaCl

However, this technique required storage of large quantities of hazardous chemicals, and was several times more expensive than bleach or even bromine treatment. Much improved technology is now available, with one design based on the following chemistry.

NaClO3 + 1/2 H₂O2 + 1/2 H2SO4 → ClO2 + 1/2 O2 + 1/2 Na2SO4 + H₂O

Sodium chlorate (NaClO3) is the core chemical rather than sodium chlorite.

A method to help control microbes is a supplemental feed of a non-oxidizing biocide. Typically, feed is needed on a temporary but regular basis, perhaps once per week. Table 1 outlines some of the properties of the most common non-oxidizers.

Careful evaluation of the microbial species in the cooling water is necessary to determine the most effective biocides. None of these chemicals should be used or even tested without approval from the appropriate regulating agency. They must fit in with the plant’s National Pollutant Discharge Elimination System (NPDES) guidelines.

As with all chemicals, safety is an absolutely critical issue when handling the non-oxidizers. Adherence to all handling guidelines and use of proper personal protective equipment is a must. Many of these chemicals will attack human cells as well as those of microbes.

Author

Brad Buecker is a process specialist in the Process Engineering and Permitting group of Kiewit Engineering and Design Company.

Many utility companies are turning to mobile power generation to ensure continuous service to customers during planned and unplanned outages. Photo courtesy: Aggreko

Today’s utilities face many more challenges than just a handful of years ago. Aging infrastructure compounded by peak season demands or natural disasters have placed an enormous strain on grids worldwide, thus increasing the risk for potential power outages. Further, a host of new, less traditional challenges are taking center stage which could impact grid stability: rising cybersecurity threats; more demanding consumers; an influx of unpredictable renewable sources; and, with the shift toward distributed generation, an increasing number of innovative competitors and the growing popularity of “behind the meter” (BTM) on-site generation sources.

Many utility companies are turning to mobile power generation to ensure continuous service to customers during planned and unplanned outages.

Power generation providers can get equipment into place very quickly to meet a utilities load requirements. These engineered solutions help utilities improve customer service by keeping customers energized while planned work is performed or restoring power more quickly during an unplanned outage.

Electric utility companies measure the reliability of their service in a commonly used metric called, Customer Average Interruption Duration Index (CAIDI), which quantifies the average outage duration that any given customer would experience.

When considering a mobile power generation solution, it is important that the temporary power system to be interconnected to the grid matches the specific requirements of the project.

Each temporary generation project is unique and has different needs so there is no such thing as one-size fits all. Therefore, it is critical to work with a third-party generation provider that has in-house technical expertise, such as electrical engineers, that understand how to design a power system that can seamlessly tie into each utility’s infrastructure and adhere to unique grid interconnection processes.

Utility companies worldwide are benefitting from the many advantages mobile power generation provides, from capital avoidance to improved customer service and emergency response plans.

The paragraphs below highlight just a few examples of why these solutions are commonly deployed in the utility industry.

1. Meet shifting demands quickly with operating budgets Installing permanent infrastructure to meet seasonal demand can be impractical, time-consuming and costly. The right solution – for example a 50 MW plant – can quickly resolve capacity issues without requests for capital expenditure approval. Mobile reciprocating generators can be placed on-site in a matter of weeks, not years, and can be ramped up in only one to two minutes. This option also provides flexibility, where the demand is for a finite period. Finally, mobile generators can be applied to alleviate bottlenecks where transmission and distribution is constrained due to insufficient conductive capacity.
2. Manage aging infrastructure repairs cost-effectively The massive T&D infrastructure in North America is aging and breaking down in many areas. Capital infusion to upgrade T&D infrastructure is forthcoming, but due to the scale of T&D investment needed, the necessary improvements will span over a couple of decades, rather than a couple of years. The modular design of mobile power generation units allow for rapid mobilization and demobilization, making them ideal for temporary projects where T&D infrastructure is being repaired, replaced, or upgraded. In addition, these temporary power projects can be designed to ensure electric service to customers is uninterrupted while the maintenance work is performed.
3. Improve emissions and environmental compliance As restrictions on solid fuel plants increase in favor of renewable energy development, emissions controls are being set at ever-higher levels. Power generators using natural gas can provide a much cleaner and more cost-effective option than other alternatives – including diesel units – to reach compliance. They can also provide immediate power in support of green projects, such as wind farms when the wind is not blowing. When used for long-term, continuous operation, natural gas units have been shown to offer total cost savings of 40-45 percent compared to diesel units, primarily due to savings in fuel. Natural gas also burns approximately 85 percent cleaner than diesel.

Rent vs. Buy: Total Cost of Ownership Affects Choice

Once the decision is made to employ mobile power generation as a cost-effective solution, the next question becomes “is it better to rent or own generators?”

While ownership is often assumed to be the better choice, cost analyses consistently show that rented power generation equipment produces a better return on investment.

Because each situation addressed by mobile power varies greatly, and therefore requires different engineered solutions and equipment, utility plant owners’ inventoried generators rarely meet every need.

All too often, purchased equipment is deployed once, stored and then found either unsuitable for the next need or is long-forgotten in a warehouse, producing no long-term value to the purchaser.

Additionally, seldom-used owner equipment typically does not receive the appropriate maintenance or safety and emissions testing that rental fleets routinely undergo.

Because fleet management is a core competency of a power generation rental company, technician training, parts management, fleet availability and highly responsive service crews add significant value to the rental alternative when the true cost of ownership is calculated.

Continuous Power during Infrastructure Changes: A Case Study

Some electric utility companies prefer to outsource the majority of their mobile generator needs, preferring to focus on the T&D work and avoid the hassles (and costs) associated with regular maintenance of diesel driven gensets that is critical to ensuring reliable operation.

In the last couple years, Pacific Gas & Electric (PG&E) used Aggreko’s mobile generation solution to keep customers energized while they perform maintenance and/or upgrades to their grid infrastructure and substation equipment.

One such project took place when 10.5 MW of Aggreko’s power generation equipment energized more than 1,500 PG&E customers in San Luis Obispo County for 13 hours while upgrades were completed at the Cholame substation.

Sixty year-old 12kV distribution lines needed to be upgraded because they were too small to meet new demand. Without the use of these generators, customers in the area would have experienced a “planned” outage for several hours while this work was being performed.

In many cases, the customer is taken offline for incremental periods until the project is completed, increasing the utility company’s CAIDI.

However, whether the end-user is industrial, commercial, residential (or a combination), new types of electrical consumption (e.g., urban medical center) make any planned or unplanned offline incident unacceptable, even for short increments, regardless as to how much notification time is provided by the utility.

For these constraints, temporary power can be delivered without interrupting the customer’s service, such as with the planned Cholame substation outage, one of several dozen substation-level temporary generation projects that have been performed, confirming PG&E’s ability to utilize portable generation systems for both large- and small-scale projects.

Other PG&E projects have focused on improving the restoration time of electric service when an unplanned outage occurs on their T&D system. PG&E serves a large area where unplanned events such as earthquakes, landslides, and wild fires can’t be predicated, but power can nonetheless be restored more rapidly with portable generator units.

Whether the need is for 1 MW or 20 MW, the projects validate that mobile distributed power can deliver repeatable and scalable solutions. PG&E utilized outside expertise to resolve the challenges associated with modernizing a 120-year-old grid while minimizing impact to customers, and building a better proficiency for emergency deployment of distribution-level temporary power generation.

Upgrading a constrained section of the grid no longer means that thousands of customers must be taken offline for hours or even a few minutes. With temporary power solutions, generators can be synchronized so that the electric demand is transferred to the generators without interruption to customers.

In addition to planned upgrades and maintenance, numerous utilities are calling on temporary generators to restore power more quickly in response to unplanned outages. Whatever the application, temporary power solutions are utilized nationwide to help electric utilities provide reliable service to their customers.

Author

Frank Pizzileo is business development manager for Aggreko.