Utilization of additive manufacturing for gas turbine component design has been demonstrated to accelerate design cycle times, reduce development test times, provide increased test data and serve to reduce overall time to final component release. With advances in, and adaptation of, additive manufacturing, testing can now be economically incorporated as early as the concept or preliminary design phases to reduce risk of the final design configuration not meeting requirements.

Design of gas turbine compressor flow path components, especially in concept phases, has traditionally relied upon analysis-only methodologies to down-select the final design configuration. This final configuration is then screened for requirements validation near the end of the gated design reviews. It is not uncommon in these designs that phenomenon related to incorrect or incomplete boundary conditions, off design point conditions, and/or transient effects result in component performance, functionality, or life not meeting requirements.

This risk of redesign because of design requirements not being met could be reduced if testing during earlier design phases was economical and could be executed with relatively short turn times. This early testing would serve to validate analytical boundary conditions, understand and identify transient effects and ultimately help define the most meaningful final design down-select criteria. Adopting an additive manufacturing approach for prototype creation is the ideal solution for resolving the need for an economical and rapid development test results to support the growing need for acceleration of products to market. This article outlines the successfully application of additive manufacturing to aerodynamic development testing within the preliminary design phase for boundary condition definition of new compressor static flow path components for Siemens Energy

SGT-A05 industrial gas turbine engine product line. This article will review prototype design scaling and manufacturing, the methodology for aerodynamic boundary condition validation, and lessons learned from this development testing. This review will also provide a comparison of how additive manufacturing provides a cost effective and an accelerated timeframe compliant alternative to legacy development testing.

Background

Aerodynamic development and validation testing of gas turbine component designs are typically conducted in partial sector rigs, full scale component/sub-system rigs and/or in full engine test facilities. This approach to development testing always requires a compromise between capturing the perceived most important design features, rig/test availability, test facility capability, cost, and schedule. Depending upon the component being tested, the utilization of these various testing methods is usually determined by economics, thus requiring that testing be conducted in facilities that already exist that can be made to work. This method is obviously not ideal and, in many cases, highly limits potential design improvements and introduces significant risk to the final design.

Some components, like static compressor components, have traditionally been designed via analytical methods only, using a combination of one, two, and/or three dimensional analysis methods, in order to define the final design configuration from which test hardware is created. This analysis-only technique is used in all design phases before hardware is ever made available. The final designs are at best validated in a rotating rig for compressor mapping but most often are carried directly into full engine testing for validation to reduce development costs. This methodology obviously increases the amount of significant risk that the final design will not meet requirements; which a resultant failure could easily result in schedule increases of more than a year and costs which could easily double. Based on experience, the most frequent causes of these errors are poorly-defined boundary conditions (both aerodynamic and mechanical) and the discovery of other un-analyzed/quantified design drivers like transient dynamic effects.

Lessons-learned from past compressor design experience, coupled with the high paced advancement in additive manufacturing technologies, prompted Siemens Energy to adopt AM into early design aerodynamic testing for the next generation of compressor vanes. Because of the technical complexity of these new component designs, coupled with a lack of scalable and accurate legacy test data, the need for accurate inlet boundary conditions is mandatory.

Technical Approach

The model test section for this work was designed to characterize the influence of the internal flow passage and the exit plane flow coming from the zero-stage compressor

both with and without handling bleeds active. The flow passage is defined with a symmetric center-body, which represents a combination of rotor components and static end walls, and an asymmetric outer-body for bleed. All structural static internal components, e.g. struts used for sump services and bearing support, were included in the model. The test model was a geometrically similar 1/5th scale model of the stage 0 module of the engine. Focus for the test models was on the internal static flow path features only and, where possible, split line effects associated with the actual engine assembly were replicated. A representation of the engine configuration flow path is shown in Figure 1.

Printable models for the 1/5th scale test model were developed directly from the models and drawings for full-scale parts. The drawings were stripped of all details except the surfaces defining the internal flow path to expedite printing. This process left scale reproduction of the surfaces making up the center body, the outer housing, and the supporting struts. Features were then added to this flow model to add static pressure taps along key aerodynamic surfaces. Figure 2 shows a composite of the parts for the test section and how they were individually printed to mimic the engine assembly.

Within Figure 2 it should be noted that numerous non-functional cavities as well as instrumentation egress passages were included within the printed model. The concept behind open areas was to expedite printing/curing times and for instrumentation passages was to include reproducible features so that a common setup for comparable data capture could be generated for different test setups and configurations.

These parts were fabricated with a 3-D printer using a process based on stereolithography. After they were cured, they were fastened together using epoxy forming an airtight and spatially correct flow path. To improve the overall strength of the model, this assembly was then epoxied into an 8-inch diameter, standard-wall, black iron pipe section and then back-filled with a polyester resin. The resulting structure was remarkably strong. The use of this back-fill was adapted to minimize printing of non-featured items, e.g. non-flow path, because of improved material properties and because the cost of back filling was approximately 40 percent compared to the printer resin packs. The black iron pipe was fitted with pipe flanges that connected it to the air supply. A photograph of the test rig is shown in Figure 3.

The process of defining the flow path from the full-scale CAD drawings, fabricating the parts on the 3-D printer, mounting the assembly in the black iron pipe, and backfilling the voids required about two weeks and about thirty man-hours of work. The materials for each model cost approximately $1,000. Compared to traditional methods for building similar models, this approach for rig fabrication is approximately an order of magnitude faster, an order of magnitude reduction in required labor and overall components many times less expensive. As a result of this low cost and quick method, building models with interchangeable or articulated parts was not chosen since new models could be built to incorporate any changes which allowed multiple working setups available for the required flow path characterization. Swapping models into the flow system required about 30 minutes.

One exception to the part fabrication process being from polymer was the ring bounding the bleed region in the outer housing of the test section for handling bleed testing. Analysis of the ring suggested that if it were printed with the stereo lithography resin, the ring might fail. As a result, the ring was outsourced to a vendor for 3-D metal printing. Upon receipt, the metal ring was epoxied into the assembly and the more robust model was completed. Outsourcing the metal ring required an additional two weeks in the assembly of the model.

Additive Manufacturing

The majority of the parts for models used in this testing were fabricated using a Formlabs Form 2 SLA 3D printer. The printer is shown in Figure 4. The cost of the printer was approximately $3400. The print volume is 145à—145à—175 mm (5.7à—5.7à—6.9 in). The thickness of the printed layers can be chosen to be between 25 and 100 microns (0.001 — 0.004 in) with a resolution of 140 microns (0.005 in). The resin is shipped in Standard Resin Cartridges that cost approximately $150 and contain one liter of resin.

After curing, the material properties of the resin were higher than many plastics. The ultimate tensile strength is reported as 65 Mpa (9380 psia). The Young’s modulus is 2.8 GPa (402 ksi). The polyester resin that was used to backfill the printed parts and secure the parts in the black iron pipe had properties reported at about 30% higher than the printed resin. During testing there was no noticeable deformation observed or measured. Photographs of several printed parts prior to assembly are shown in Figures 5 and 6.

Testing The flow through the model was compressed air that transitioned from an inlet Mach number of about M=0.3 to a Mach number in the exit plane on the order of M=0.6. The mass flow rate tested was the dimensionless form for a compressible flow that was scaled to the mass flow rate of the actual engine section. The mass flow rate through the model was measured along with inlet stagnation pressure and temperature. The flow conditions scaling factor was defined to align most accurately with corrected flow, MrT/PA. Testing was conducted over differing corrected flows to capture effects of variable capacity with changes in inlet conditions. Testing over different corrected flows allowed for at least a partial assessment on aerodynamic conditions with changes in Reynolds numbers.

The operating stagnation pressure for the testing was set so the cross section Mach number immediately upstream of the mass bleed was matched to the full-scale section. The Mach number at this section was set by adjusting the upstream stagnation pressure and measuring the local static pressure. These measurements were used to calculate the section Mach number. Thirty-six static pressures were measured on the model center-body using six equally spaced rows of pressure taps downstream of the bleed section. Static pressures were also measured on the outer-body in the bleed channel, downstream of the bleed and at the exit plane.

Distortion in the exit plane was evaluated by measuring the stagnation pressure distribution. The stagnation pressures in the exit plane were measured using a rake of 30 stagnation taps located in equally spaced radial rows spanning the flow passage. The rake was also indexed radially in 15° increments to make measurements at 120 distinct locations in the exit plane annulus.

All of the data, except the pressure data, was sampled using a National Instruments Compact Remote I/O Controller containing a current input module, a temperature input module, a voltage input module, a digital module, and a current output module. The pressure data was sampled using a 16-port Scanivalve pressure scanner. Scan Rates exceeding 100 Hz were possible with the setup used with most measures being physically limited based upon fluid response times.

Testing for each test configuration could be fully setup and tested for all required data in approximately 3 hours, which included at least four compressor blow downs and total test time exceeding 10 minutes.

Results

Testing of two different model standards over 20 different inlet conditions were completed in less than 5 months of testing. Numerous repeated tests were conducted to assess data quality, reproducibility, and if transient effects are consistent. All testing indicated highly accurate and low variability of testing, even between re-installation of models within the testing arrangement.

Results from testing have demonstrated high value to the current re-design program. Not only was the data made available during the entire preliminary design phase, working between test and engineering allowed easy utilization of the data being generated. In general, this new boundary condition data has demonstrated direct benefits to the current design, which incorporates a non-axis symmetric inlet profile feeding the high pressure compressor and also has incorporated factors which mimic the noted dynamic pressure effects associated with bleed into the design.

Conclusions

AM has been successfully applied to the preliminary design phase of a new compressor vane design within the Siemens SGT-A05 gas turbine engine product line. The results of this testing have been successfully applied and have resulted in significant improvements to the current design activity. As this testing was conducted such that benefits of AM use could be defined, the results for this current testing are:

– Rig development time was improved by roughly an order of magnitude,

– Rig and test component prototype costs reduced by more than 3x,

– Technical validity of results were only slightly lower than fully instrumented engine test results but improved relative to typical component testing,

Test results showed exceptional agreement to full scale 3D CFD results driven by rig test defined boundary conditions, and

Total Cost Comparison of current versus conventional testing was four to 10 times lower and resulted in more than an order of magnitude more data.

Many modern utilities may have a diverse portfolio of generating assets which often includes aging coal fired units which are nearing or at the end of their economic operating life. Many factors can lead to the retirement of coal fired generating plant including lack of competitiveness with other forms of generation such as gas plant, environmental compliance issues and plant condition.

Where the future operating life of existing coal fired assets is under question due to competitiveness or environmental compliance, the recent EPA ruling indicating a shift of position towards the reclassification of biomass as a carbon neutral fuel may present opportunities for extending the useful life of these assets by partially or wholly converting them from coal to biomass firing.

The market in the US for biomass as an alternative fuel to coal has previously been limited due to its classification as a conventional fuel however if biomass is considered to be carbon neutral status coal to biomass conversions can offer a number of benefits ion the right circumstances including a low-cost solution to plant life extension, significant reductions in emissions and a cost-effective solution to increase a utilities renewable energy portfolio.

Due to the different regulatory landscape outside the US, particularly in Europe, there has been significant experienced gained in the conversion of coal fired generating units to fire biomass fuels. This has driven the development of biomass fuel and firing technology to its present state of maturity.

This article is intended to provide a summary of the key factors to be considered when planning a coal to biomass conversion including biomass fuel specifications, implications to plant performance and operation, scope of conversion work and timescales based on recent project experience outside the USA.

Biomass Fuels

Biomass fuels constitute a wide range of materials typically encompassing agricultural, forestry or wood wastes/residues. Some biomass fuels potentially relevant to the North American market are contrasted with a typical bituminous coal in Table 1:

Table 1 illustrates the fact that the typical energy density of agricultural biomass residues, such as Switchgrass and Corn Stover, are less than 20 percent of that of bituminous coal. This has a direct impact on the volume of fuel required, impacting transportation as well as the size of the power plant fuel storage and fuel feeding systems. Additionally, as a general rule, the on-site bulk storage of biomass materials should be minimized, and a ‘just in time’ approach adopted in order to avoid fuel degradation and biological activity. If dry biomass materials get wet, say above 15 — 20 percent, there is a tendency for them to become subject to microbial respiration.

Agricultural biomass residues do not lend themselves to long distance travel and this combined with seasonal availability, usually means their use is limited to smaller scale, localised power plants.

Over the last 10 years wood pellets have become the fuel of choice when considering co-firing in coal fired power plants or 100% biomass firing in converted coal fired power plants. During this period there have been initiatives in a number of European Union countries focusing on the replacement of coal in power plants with wood pellets. This combined with the introduction of associated International Standards for fuel specification has stimulated the market. The Global wood pellet market has shown tremendous growth of around 15 percent year on year over this period. Global pellet production is currently in excess of 20 Mt per year. The European Union region produces around 10 Mt per year of pellets, all of which are essentially consumed domestically. From a pellet production point of view on a country basis the US is the largest source by far producing around 7 Mt, although Canada’s production has seen a rapid increase recently to about 2.5 Mt. The majority of the US and Canadian production is exported. South East Asia has also commenced wood pellet manufacture on a significant scale. The largest single consumer at around 6.5 Mt per year is the UK, with a number of other European countries and South Korea also being large importers.

It is evident from Table 1 that the properties of wood materials are very different from coal. The ash content of wood materials depends largely upon the bark content of the fuel, (bark often containing 5 to 8% ash); the widely available white wood pellets generally have less than 1% ash. Volatile matter contents are very high in the 72 — 75% range. The fuel components often associated with emissions such as nitrogen, sulphur and chlorine are low compared to coal which is obviously advantageous.

Torrified pellets are becoming commercially available and may be of interest to some operators. These use a thermal pre-treatment process to upgrade the biomass to a higher quality. This is achieved by heating it to 250 – 350°C, partially devolatilising it and driving off the moisture. The net result being a product that has a higher heating value, improved water resistance and better grindability in conventional coal pulverisers.

Implications to plant performance and operation

The amount of biomass firing adopted on a boiler can be from a small figure up to 100 percent. This has implications for the extent of plant modification, relative complexity and cost. Three typical schemes are illustrated in Figure 1 which provides an indication of the equipment impacted along with the associated degree of biomass firing applicable. The three schemes shown (1a, 1b and 1c) give a general indication, but there is a spectrum of permutations and options for arranging the equipment which will be dictated by individual site circumstances.

Around 10 years ago significant operational experience, especially in Europe, was gained with direct co-firing systems based on a pre-blending approach, i.e. where the biomass and coal are pre-mixed and fired through the installed coal handling, milling and firing system. The positive operational experiences accumulated from these projects provided the confidence for the subsequent upsurge of 100 percent biomass firing conversion projects, the majority of which now utilise wood pellet fuel.

The energy density of wood pellets is significantly higher than many other biomass forms although still only 50% of that of bituminous coal. This clearly has implications for the storage and metering facilities at the power plant. Wood pellets in their ‘as-delivered’ form are not suitable for feeding directly to the furnace of a PF coal fired boiler. Size reduction either in the existing boiler coal mills or via hammer mills is necessary to produce fuel particles which will result in acceptable furnace residence times.

It should be noted that wood pellets, (and other pelletised biomass fuels) have a low bulk density and modest fines content, and it is considered unlikely that the inventory contained in a bunker or hopper above the mill will provide an adequate seal. A rotary valve is therefore usually installed in the coal feed pipe between feeder and mill.

Compared to bituminous coals, extra care in terms of good housekeeping and the avoidance of dust accumulations is necessary with biomass materials. This applies to the fuel feeding and storage areas and is also important inside the fuel preparation/pulverising equipment with explosion suppression equipment being provided at strategic locations.

Biomass materials are more sensitive to heat than are coals. When most biomass materials, including wood pellets, are heated to temperatures in excess of 350 – 400°F, there is an increasing tendency to release significant quantities of combustible volatile material. This is undesirable for safety reasons and has particular implications for pulveriser performance. Under bituminous coal operation, pulveriser inlet air temperatures are usually in the range 450 – 600°F.

For biomass operation pulveriser inlet air temperatures need to be reduced to around 320°F or less. This can be accomplished by adding cold tempering air — although this will have a small negative impact on overall efficiency – as the regenerative airheater becomes less effective. A superior technical solution is to incorporate a ‘primary air cooler’ heat exchanger. This maintains regenerative airheater effectiveness, recovering unwanted heat in the primary air stream and transferring it to the turbine feedwater heating system – leading to an efficiency improvement — refer to Figure 2.

The fact that the energy density of wood pellets is only around 50 percent that of bituminous coals means that pulveriser throughput will be negatively impacted when exclusively grinding wood pellets. Experience indicates that pulverisers can provide around 70 percent of the heat input from coal when firing wood pellets. The deficiency in boiler heat input can be rectified via a number of possible routes including; (i) utilising a standby mill, (ii) introducing an additional biomass stream (similar to the scheme shown in figure 1b), (iii) replacing the existing pulverisers with a larger size selected specifically for the biomass.

Biomass fuels with their high volatile matter content do not need to be ground to a very fine particle size distribution to combust readily in a pf fired boiler. However, particles generally need to have a maximum dimension of less than 1/8” (3.2 mm) in order to burnout effectively given the relatively short residence times available within the furnace. Coal pulverisers are not able to influence biomass particle size distribution to any great extent. While they do impart a small comminution effect the biomass particle size distribution exiting the pulveriser is largely dependent upon the size of the particles constituting the original wood pellet.

To avoid drop-out of the larger biomass particle sizes of the fuel leaving the pulverisers it is necessary to use somewhat higher velocities (than would be used for coal) in the downstream pf pipework. In some instances the existing coal burners can be used without modification for the biomass, while in other instances purpose designed biomass burners may be advantageous.

The low levels of ash in wood pellets compared to a typical bituminous coal could lead one to believe that biomass ash was benign as regards boiler slagging and fouling. However, it is important to note that biomass ashes differ from coal ashes. Coal ashes are essentially an alumina-silicate system, whereas biomass ashes comprise quartz and the simple inorganic salts of potassium, calcium, magnesium and sodium with relatively high levels of potash. These alkali and alkaline earth metals have the effect of reducing the ash fusion temperatures typically 100 – 200°C below those of bituminous coals. This introduces the possibility of increased ash deposition on both boiler furnace and convective heat exchange surfaces. However, boiler plants vary significantly in their sensitivity to ash deposition, if and where the deposits accumulate, their impact on performance and the ability of the on-line cleaning systems to control deposition to acceptable levels. Experience to date indicates that ash deposition issues with wood pellets normally fall within manageable limits.

The different ash characteristics (compared to bituminous coals) and the low sulphur content associated with biomass fuels means that the performance of flue gas dust removal equipment, principally electrostatic precipitators, should be carefully considered. Minor modifications and changes to operating practices may be appropriate.

Scope of conversion work

Thermal digital modelling of the boiler under consideration is normally the starting point in any project. This involves understanding and benchmarking the existing coal fired boiler operation by calibrating the digital model against actual plant performance. Projections can then be made as to how the boiler will behave when firing biomass. Making these projections requires specific knowledge of how the biomass fuels behave — this is something a suitably experienced contractor can undertake based on proven references.

Thermal modelling and subsequent plant operation at numerous sites has shown that boiler pressure part modifications are usually unnecessary. Conversion work therefore focuses essentially on fuel feeding, preparation, and combustion equipment alterations as mentioned previously

Details of two recent biomass conversion projects executed by Doosan are provided in Figures 3 and 4. Both of these projects represent very comprehensive coal to 100 percent biomass conversions. Lower cost and less extensive conversions are possible but are largely dependent upon the objectives/goals of each individual project.

Commercial Considerations

Biomass, particularly biomass pellets, are now a commercially traded fuel worldwide with a significant proportion of these pellets being produced in North America and exported for firing in European and worldwide power plants.

In view of the renewable energy classification of biomass and the various renewable energy subsidy regimes prevalent in Europe and other markets it is economical to import pellets from sources such as the U.S. despite the considerable logistics and transportation costs. It is likely that domestic consumers of US produced biomass pellets would benefit from reduced fuel pricing due to lower transportation costs.

Based on recent projects, typical power plant coal to biomass firing conversion costs and timescales, including boiler modifications, fuel handling and storage are summarized in Table 2.

Conclusions

The potential for classification of biomass as a carbon neutral fuel provides utilities with the opportunity to economically lowering their CO2 footprint and improving emissions compliance by re-purposing aging coal fired assets.

The conversion of coal fired plant to co-fire or to fire 100 percent biomass can be considered as a mature and proven technology which can readily be implemented while retaining fuel flexibility to meet future changes in environmental regulations and market conditions.

In Europe and in many other parts of the world biomass is already playing a significant part in the drive to utilise an ever-greater proportion of renewable energy in electricity production. It is hoped that the current direction of the EPA towards a carbon neutral classification for biomass, as evidenced by its recent ruling, is a major step towards stimulating a similar trend in the USA.

Author

Dave Wilson is operation manager for Doosan Power Services. Mark Upton is specialist engineer in boiler design+development at Doosan Babcock

By Robynn Andracsek, P.E., Burns & McDonnell and contributing editor

THE NEW SOURCE REVIEW (NSR) program of the Clean Air Act needs reform. In 2002, the Bush EPA attempted to reform the NSR program with common-sense changes such as exemptions for pollution control projects, routine maintenance, and clean unit tests.

All of these exemptions were later vacated by the courts. Likewise, several reforms from 2006 (debottlenecking, aggregation, and project netting) were withdrawn or delayed indefinitely. Ultimately, these reforms died due to EPA’s attempt to regulate through memos and policies and not through changing the Clean Air Act itself, allowing subsequent administrations to reverse the reforms.

History repeats itself with the Trump EPA’s efforts to again reform NSR, focusing on the actual-to-projected-actual applicability test, project emissions accounting, aggregation, and routine maintenance, repair and replacement (RMRR). However, by again focusing on a memo/guidance (not regulatory) methodology, these reforms are likely to be reversed by the next Democratic president.

I propose that EPA consider the following in the next Clean Air Act Amendments:

1. Define “routine” maintenance. An exception without definition hinders both industry and environmental groups. Regardless of the new regulatory meaning, the existence of a definition would add clarity and decrease risk for industry. If the WEPCO four-factor test (nature and extent, purpose, frequency, cost) is the standard, then EPA should codify it. Alternately, make the definition match the New Source Performance program.

2. Create a de minimis level for a BACT analysis. If a group of similar equipment in a project subject to PSD is below 2 tpy (or some other threshold) of each PSD pollutant, that group of equipment doesn’t have to be analyzed for BACT. For example, there is little value in analyzing storage pile fugitives if the potential to emit is 0.9 tons per year of particulate matter and there is little to no impact on air quality as shown through dispersion modeling.

3. Create a list of Best Available Control Technology (BACT) insignificant modifications and equipment, such as exists for the Title V program. The emissions would still count towards the Prevention of Significant Deterioration (PSD) applicability thresholds, but a BACT analysis would not be required. Examples include emergency diesel generators subject to NSPS limits, natural gas fired heaters and boilers under 10 million British thermal units per hour (MMBtu/hr), and cooling towers with 0.005 percent drift elimination. Another good source for equipment to consider for insignificance is the Texas Commission on Environmental Quality’s Permit by Rule (PBR) list.

“It’s time to retackle this important issue and actually help industry generate electricity while protecting our air.”

4. Codify BACT for common, simple equipment. BACT for NOx emissions from natural gas-fired heaters and boilers between 10 and 50 MMBtu/hr should be low nitrogen oxide (NOx) burners, low sulfur fuel, and good combustion practices. BACT for VOC emissions from diesel storage tanks (a low volatility material) should be submerged loading. Preparing, analyzing and defending a BACT analysis for trivial equipment wastes time and effort that could be better spent on protecting the air by driving innovation to control the larger emission units.

5. Reattempt a pollution control project PSD exclusion but write it into a Clean Air Act Amendment passed by Congress instead of a rule in the Code of Federal Regulations where it can be overturned. An equilibrium can be found that allows efficiency improvements without triggering expensive add-on controls. Encourage utilities to run the most efficient equipment instead of penalizing them for not maximizing emissions in the “past actual” period.

A PSD permit takes 9-18 months for issuance and hinders industry unnecessarily. By focusing on the significant emission units and by providing the definitions that are missing, EPA, state agencies, applicants, and intervenors can concentrate on balancing their different perspectives and safeguard our natural resources. No, it won’t be easy, but it is worth doing right.

Inertia exists in the Clean Air Act. One administration’s memos get reversed by the next administration. Likewise, regulations which get ensnared in the court system hurt, not help, utilities. How much effort has the industry wasted on the Clean Air Mercury Rule, Clean Power Plan, or Clean Air Interstate Rule (CAIR)/Cross State Air Pollution Rule (CSAPR)? The Clean Air Act was last amended in 1990. It’s time to retackle this important issue and actually help industry generate electricity while protecting our air.

Construction

Microcranes, Inc. introduces the ISO Certified M1 Global Model Microcrane®. Cited to be a leader in the emerging mini crane industry, the company focuses on developing, producing and distributing eco-friendly battery powered or electric, small, portable lifting equipment used indoors, outdoors and on roof tops. The M1 Global design fits through 36-in. doorways, narrow aisles and inside elevators, yet expands to boom up to a 22-ft. tip height.

The new M1 Global hydraulic pick & carry portable crane is rated at 2,000 lbs. (905kg) (no operator license required) and has a hook height of 20’-3” (6.1m). It is only 30 in. (762mm) wide and weighs 1,800 lbs. (816kg) with 300 lbs. of removable counterweights to reduce weight while transporting.

Microcranes, Inc.

Info http://powereng.hotims.com RS#: 401

Communications

When communication is non-existent or minimal, due to power outages or a sudden increase in mobile traffic, radio communication towers and cells on wheels provide strategic expansion of cellular networks, and effectively equipment deployment. Larson Electronics’ line of portable communication towers and cells on wheels allow operators to securely deploy equipment for many large-scale applications, such as increased cellular network coverage at large venues, disaster recovery, security deployment and more.

The strong and durable mastheads provide stable platforms for large scale coverage systems. Mounted on wheeled cart bases with 360-degree pivot, these mini antenna towers can be maneuvered smoothly over rough terrain like rocks and gravel.

Larson Electronics

Info http://powereng.hotims.com RS#: 401

Tools

AFL, a manufacturer of fiber optic cable and accessories, is expanding its rapid deployment ground tactical fiber optics solution to include the new Sidewinder Rapid Cable Deployment System. This system eases the deployment of tactical fiber optic cables by greatly reducing handling and set up time for portable deployment and retrieval in field conditions.

“The highly transportable reel system is easy to carry with built-in carrying grips. For heavier assemblies or longer transport distances, the unique tripod stand can be converted to a caddy to rapidly and easily relocate the reel,” said Michael Gauci, product development manager for AFL. “Reels can be locked together using an innovative mechanism which provides four points of contact around the circumference, stabilizing reels for storage and shipping and allowing for deployment of multiple cables simultaneously.”

AFL

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

Safety

With the completely new multifunctional “protrac®” concept, BAUR GmbH introduces a modern solution for the precise pin-pointing of cable and cable sheath faults. Faults can be pin-pointed significantly more rapidly with protrac® than with conventional systems. One particularly innovative feature of protrac® is its rapid and simple commissioning, because the control unit, ground microphone and headphones are wirelessly connected by Bluetooth® (range of up to ٤٠ m between control unit and ground microphone).

A two-stage adaptive ambient noise suppression system filters ambient noise and provides a clear signal from the fault breakdown to the headphones or the loudspeaker of the control unit. The capacitive color display with touch function guides the operator rapidly and efficiently to the fault with the aid of a three-dimensional display of the cable position.

BAUR GmbH

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

Construction

LineWise will be conducting a demonstration of its TLL-1300 Triple Line Lifter on May 31, 2018 in a location east of Cincinnati. Demonstrations will be ongoing from 9:00 a.m. to 5:00 p.m., illustrating the product’s unique abilities to simplify and shorten the process of supporting three phases of energized conductors, often doing the same job in 50-percent less time than traditional methods. The exact location of the event will be determined the week of the demo.

Attendees will get a firsthand look at many of the TLL-1300’s features in action, such as the remote-controlled hydraulic articulation and hydraulic extension and retraction of the outside phases. Using the remote control, the unit can switch from a horizontal to vertical configuration, and the spacing between insulators can be adjusted from 6.5 feet to 14.5 feet to capture the outer conductors.

LineWise

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

Transmission Lines

Laserpas is an aerial power line inspection service that provides surveillance and high-precision monitoring solutions for large power line operators worldwide.

Are Power Lines Being Inspected as Often as Needed?
The transportation of one of the world’s most essential commodities is constantly taking place right above our heads. Almost anywhere in the world, you can step outside and see power lines, but how safe are those lines?

Are they thoroughly checked often enough? As the world’s electrical needs increase so does the number of power lines required to meet those needs. In the United States alone, there are more than 5.5 million miles of local distributions lines and more than 200,000 miles of high-voltage transmission lines, according to Scientific America.

Laserpas

Info http://powereng.hotims.com RS#: 406

Utility Supplies

Platinum Tools®, a provider of solutions for the preparation, installation, hand termination and testing of wire and cable, will launch three new, high performance J-Hooks (Standard, 90 Degree, and Batwing) during InfoComm 2018, held from June 6-8 at the Las Vegas Convention Center, booth C3445.

The new cULus-Listed / Plenum-Rated J-Hooks are now shipping with available special order attachments.

“Our new HPH J-Hooks have been designed to support today’s modern high performance cable installs in the shop, home, and office, including Telcom / Voice, Network / Data, Broadband, Satellite, CCTV, Fiber, and Flexible Conduit,” explained Lee Sachs, Platinum Tools, Inc. president and general manager. “Our Standard, 90 Degree, and Batwing high performance J-Hooks are built with steel J-Hooks over-molded with polypropylene for an easy cable slide.”

Platinum Tools®

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

Safety

Charles Industries radio concealment shrouds offer aesthetically-pleasing concealment of radios at small cell, densification, and DAS remote sites. Both pole and ground mount shrouds are designed to conceal and protect high value radio assets while paving the way to municipal approval.

Various shroud solutions have been created to address different radio and deployment options. Powder-coated finishes are available in multiple colors to match local surroundings. The SHRD60 series is curved to enhance the aesthetic look and feel of the solution. All solutions are subjected to extensive thermal analysis to ensure appropriate operating temperatures are maintained for the enclosed RAN equipment.

Charles Industries

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

Cable Locator

The AEMC Cable Locator Model 6681 detects buried (in ground or in walls) telecommunications cables, electric power and other cables, and metal pipes, during modification or maintenance work on installations of category III (or lower), at voltages of 300V (or less) with respect to ground. The system can locate open circuits, shorts, track cables and locate fuses or circuit breakers. The instrument is a portable system that includes a transmitter, a receiver, and accessories. The transmitter and receiver both have a large back-lit LCD and large keys.

The transmitter applies a modulated AC to the circuit that is to be located, which creates a proportional alternating electric field. 

AEMC

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

Utility Tools

Trimble has announced the Trimble® TSC7 Controller, a new field solution for land and civil construction surveyors. The TSC7, combined with specialized software, defines the next generation of data collection and computing for mobile workers.

The Trimble TSC7 brings powerful enhancements to the field and was designed based on customer feedback. It provides a tablet experience with a physical keyboard and a sunlight readable 7-inch touchscreen that supports pinch, tap and slide gestures. Users can interact with the TSC7 intuitively, easily zooming, panning and selecting items on the large touchscreen. Front- and rear-facing cameras allow users to video conference their office from the field for on-the-job support, and capture high definition videos and images that provide valuable context to their data and clients.

Trimble®

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

Switchgear

ABB’s new Tru-Breakâ„¢ solid dielectric molded vacuum switchgear module from Elastimold®, the producer of weather-protected utility equipment from Thomas & Betts, a member of the ABB Group, offers a clear viewport so workers can safely verify the hotstick-operable circuit contacts are open before they begin work — a significant improvement in safety for solid dielectric underground or pad-mounted systems. Tru-Break can be ordered fully assembled from the factory or, due to the inherent modularity of Elastimold switchgear, can be easily retrofitted into existing Elastimold equipment.

The system’s combination of proprietary EPDM rubber insulation and solid dielectric delivers a maintenance-free design that can be used in the harshest environments — excellent for storm-hardening upgrades or for new construction. Each unit is capable of independently withstanding full 125 kV basic insulation level (BIL) impulse voltage and up to 60kV power-frequency withstand without a vacuum interrupter in series, and the 1.75-inch glass-covered viewport is equipped with a hotstick-removable dust cap to keep it clear even in wet, murky environments.

ABB

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

Electrical Tools

Heavy cables installed in long vertical raceways impose excessive strain on electrical terminations, and can often lead to disconnections with the potential for equipment damage, injuries and power outages. For that reason, the National Electric Code (NEC) calls out specific installation methods for long vertical runs in NEC 300.19 that require cable supports at the top of a raceway and often with intermediate supports installed at specified intervals.

To help electricians ensure safe connections and meet NEC requirements, Emerson offers O-Z/Gedney Cable Supports for threaded rigid conduit, IMC, EMT and wire armored cable with proven field performance to make the difference between being connected and disconnected.

National Electric Code

Info http://powereng.hotims.com RS#: 412

Voltage Tester

Megger now offers a multi-function tester that tests low voltage electrical installations to fulfill the requirements of NFPA٧٠ and the National Electrical Code. The MFT٧٠ provides all tests required to complete the necessary electrical certification for industrial, commercial and domestic fixed wiring installations.

Designed for use by electricians, equipment installers and engineers, lighting installers, testing and certification companies, as well as facilities maintenance companies and micro-generation installers, this new instrument can test for continuity, insulation resistance, ground and GFCI tripping. The battery powered MFT70 can be operated from a ladder-shelf or platform, around the neck, placed on the floor or in the hand.

Megger

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

Power Transformer

The ABB Ability Power Transformer is cited to be the world’s first integrated solution for digitally enabled power transformers, fundamentally changing the transformer paradigm. All power transformers leaving ABB factories will soon come enabled with digital capabilities, enabling remote monitoring and data analytics of its vital parameters in real time. This will enhance reliability and enable higher utilization of grid assets and power networks.

The transformer will come equipped with a digital hub that can leverage a portfolio of smart devices on a modular platform with plug-and-play capabilities. This modularity and scalability makes the system future-proof while giving users full control over their digital journey.

ABB

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

Energy Management

Vacuum Interrupters Inc. has developed a replacement for the original vacuum interrupter pole assembly used in compatible Power/Vac® circuit breakers. Our replacement vacuum interrupter pole assemblies incorporate encapsulated/embedded vacuum interrupters and have passed the applicable ANSI/IEEE C37 standard tests.*

Our new encapsulated pole assemblies will upgrade older compatible breakers to modern encapsulated/embedded pole technology. The main advantages of the embedded vacuum interrupter technology (compared to a standard open pole or assembled system) are its high dielectric strength and better protection from environmental influences. Our design is compact and rugged, resulting in a vacuum interrupter assembly that is much more reliable with excellent vibration and shock resistance and enhanced mechanical strength. Additionally, it is significantly more resistant to environmental contaminants such as dust, humidity and moisture.

Vacuum Interrupters Inc.

Info http://powereng.hotims.com RS#: 415

Test Products

Megger offers a new insulation and continuity tester designed specifically for the telecommunications and cable testing markets. The MIT485/2TC-LG2 replaces Megger’s original MIT480 range tester.

Technical Specifications
– Fixed test voltages of 50 V, 100 V, 250 V and 500 V
– Delivers accurate results up to 100 GΩ
– Gated access feature to 500 V
– Insulation test voltage is accurate to +2% – 0%
– Safety rating of CAT IV 600 V

This handheld instrument features fixed test voltages of 50 V, 100 V, 250 V and 500 V, as well as variable test voltages from 10 V to 500 V. Insulation testing can be performed up to 100 GΩ at 500 V. A gated access feature to 500 V prevents accidental application of high voltage to sensitive equipment.

Megger

Info http://powereng.hotims.com RS#: 416

Monitoring System

STANLEY Security, a leading global manufacturer and integrator of comprehensive security solutions for a wide range of industries, has broadened its alarm verification offerings with STANLEY’s Thermal Perimeter Detection, a solution that provides a reinforced layer of identification and verification protection against intrusion, theft and damage in outdoor spaces with the use of thermal sensors and intelligent analytics.

With the mounting number of high-value assets being stored outdoors for multiple industries including equipment rental, utilities, vehicle service and repair, warehouse and industrial parks, these commercial properties often do not have adequate security to safeguard against outdoor crime.

STANLEY Security

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

Utility Tools

Platinum Tools®, a provider of solutions for the preparation, installation, hand termination and testing of wire and cable, announces the new Keystone Cat6A Jacks (p/ns 751-1 shielded / 752-1 non-shielded) are now available. Platinum Tools will feature the Keystone Cat6A Jacks during InfoComm 2018, held from June 6-8 at the Las Vegas Convention Center, booth C3445.

“Our new Keystone Cat6A Jack has a tool-less design that is easy and fast to terminate and made to fit industry standard wall plates and unloaded patch panels,” explained Lee Sachs, Platinum Tools, Inc. president and general manager. “It even meets Cat6A channel shielded and non-shielded performance up to 100m. It’s a must for installers and technicians across multiple markets.”

Platinum Tools®

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

Utility Tools

Jarraff Industries’ new Mini-Jarraff Rear Lot Trimmer is specifically designed for residential and municipal tree trimming. A minimal footprint and compact profile allow the Mini-Jarraff to operate in areas where only climbing crews could go before. The patent pending self-leveling carrier allows it to travel on all types of terrain and eliminates the need for traditional outriggers.

The Mini-Jarraff can retract to 36-inch traveling width – small enough for standard gates and backyard fencing – bringing a new level of safety and productivity to rear lot and residential trimming operations. The remote controlled Mini-Jarraff offers a dynamic range of operation including a 360-degree rotation, rotating saw head for precision cutting and a 54-foot vertical reach.

Jarraff Industries

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

Testing

Sharper Shape, a provider of unmanned aerial utility inspection solutions, announced the global release of its latest product, the Heliscopeâ„¢ 2.0. This new, on-board payload system expands the company’s aerial sensing portfolio into the manned helicopter industry. The Heliscopeâ„¢ 2.0 integrates multiple sensor systems into a single, lightweight helicopter payload, capable of simultaneously collecting a range of data types required for utility maintenance and vegetation management inspections. Deployment of the Heliscopeâ„¢ 2.0 enables optimized inspection and maintenance schedules, offering potential cost savings in those operational activities by as much as 50 percent. 

The Heliscopeâ„¢ 2.0 also stands out with its flexible mounting configurations and ability to adapt for mounting on many different helicopter types.

Sharper Shape

Info http://powereng.hotims.com RS#: 420

Tools

Columbus McKinnon Corp., a designer, manufacturer and marketer of motion control products, technologies and services for material handling, has expanded its offering of the CM Hurricane 360° hand chain hoist to include new 15- and 20-ton capacity units as well as a full line of army-type, integrated trolley models. Designed for versatility and safety, the CM Hurricane 360° features a patented 360-degree rotating hand chain cover that allows operators to lift and position loads from virtually any angle.

Because of its design, the CM Hurricane is cited to be the ideal hand chain hoist when working in tight spaces, above the load, in drifting applications and when the operator needs to maintain a safe distance when handling a load.

Columbus McKinnon Corp.

Info http://powereng.hotims.com RS#: 421

Energy Management

CBS ArcSafe, a manufacturer of remote racking and switching solutions for low- and medium-voltage switchgear, offers its remote switch actuator (RSA) for the Sylvania/Zinsco QSF series of 100—600 A panelboard switches (PBSs). The lightweight, portable CBS ArcSafe RSA-103 allows technicians to remotely close or trip a Sylvania/Zinsco PBS from a safe distance of up to 300 ft., well outside the arc-flash boundary.

Installation and operation do not require any modifications to the existing electrical equipment, thanks to CBS ArcSafe’s magnetic latching system. Typical applications include switching and protection of low-voltage AC-power distribution systems. When compared to other arc-flash mitigation alternatives, the RSA-103 is a cost-effective solution for keeping operators safe when using Sylvania/Zinsco QSF series 100—600 A switches.

CBS ArcSafe

Info http://powereng.hotims.com RS#: 422

Safety

Columbus McKinnon Corporation, a designer, manufacturer and marketer of motion control products, technologies and services for material handling, introduces its new Yale® YKâ„¢ and Shaw-Box® SKâ„¢ electric wire rope hoists. Manufactured to the highest industry standards, the Yale YK and Shaw-Box SK monorail hoists are German engineered and offer reliable operation, high efficiency and long life, and are competitively priced for the U.S. market.

The Yale YK and Shaw-Box SK are designed with safety in mind, incorporating standard safety features such as a block-operated limit switch, adjustable geared limit switch, motor temperature control and overload protection.

“The new YK and SK hoists feature a modular system that allows you to easily configure and design a hoist solution to your exact application needs,” said Carlos Bassa, global product manager, wire rope hoists. “With a wide range of lifting capacities from one to 10 tons and three frame sizes, these units can be used everywhere from equipment production lines to warehousing facilities.”

Columbus McKinnon Corporation

Info http://powereng.hotims.com RS#: 423

Electrical Distribution

Marmon Utility announces the reorganization of their medium- and high-voltage product brands — Hendrix and Kerite — into one integrated organization, as Marmon Power Cable. The legacy Hendrix and Kerite brands manufacture underground cable for the utility market. Kerite, founded by Austin Goodyear Day in 1854, invented the first CV for extruding underground cable and today makes the only discharge-resistant (DR) underground cable with a lifetime warranty. Kerite specializes in DR-EPR cable from 15kV to 138kV. Hendrix, founded by Bill Hendrix in 1951, developed URD cable in the 1960s and now specializes in 15kV—46kV TRXLPE cable.

As Marmon Power Cable, Hendrix/Kerite will continue to provide a broad offering of medium- and high-voltage underground and specialty cable products, from 5kV to 138kV. Hendrix medium-voltage (MV) TRXLPE-insulated cable ranges 5kV to 46kV and is widely regarded as some of the most reliable underground distribution cable products on the market today.

Marmon Utility

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

Utility Supplies

Platinum Tools, a provider of solutions for the preparation, installation, hand termination and testing of wire and cable, announces the launch of the first bendable RJ45 connector during InfoComm 2018, held from June 6-8 at the Las Vegas Convention Center, booth C3445. Available in shielded and non-shielded versions (p/ns 106220; 106230), the new flex connector is now shipping.

“Flex Connector is the first bendable RJ45 connector and makes network cable terminations easier than ever,” said Jason Chesla, Platinum Tools marketing manager. “The unique patented design ensures top tier performance for Cat5e/6/6A cabling up to 9.0mm with 24-22 AWG conductors, providing a low cost, easy termination solution with high performance and superior connectivity options. No need for crimp tools. Set it up, close it and go.”

Platinum Tools

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

Electrical Distribution

Hubbell Power Systems manufactures many specialty products for use in medium voltage electrical distribution equipment.

Custom Built for Your Needs
At Hubbell Power Systems, Inc. (HPS), we manufacture many specialty products for use in medium voltage electrical distribution equipment. This includes epoxy molded components for switches, switchgear, instrument transformers, power transformers, distribution transformers and other electrical equipment. HPS can also custom formulate materials to suit the customer’s specific product requirements.

Hubbell Power Systems manufactures

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

Fleet Management

Verizon Connect provides dependable help for essential service providers. Makes utilities, and related companies, more reliable and productive.

Get critical information more quickly by tracking all your assets on a single screen
Monitor your workers, vehicles and equipment in near real-time with advanced command and control software from Verizon Connect. See a full fleet overview in seconds, including third-party contractors, or drill down to check an ETA on a single vehicle in the field. Check status, boom activity and routes at will. Include detailed map overlays to paint a complete picture of what’s going on, including weather, satellite imagery, traffic and custom GIS data such as power lines and poles.

Verizon Connect

Info http://powereng.hotims.com RS#: 427

Electrical Measurement

Landis+Gyr announced that JEA has signed a purchase agreement to accelerate its advanced metering deployment over the next 30 months by deploying the remaining 250,000 electric meters on its distribution system.

Landis+Gyr currently manages JEA’s advanced metering and network infrastructure under a long-term managed services contract. The contract scope has expanded over the years to include enhanced SaaS data services and infrastructure support.

“The decision to accelerate our metering deployment is based on our desire to continue improving customer support initiatives, including areas of data analytics and prepayment programs,” said Kerri Stewart, Chief Customer Officer at JEA. “The enhanced data and connectivity is also critically important in our ongoing efforts to improve the efficiency and resiliency of our severe storm restoration process during hurricane season. This technology will allow for quicker restoration with better information flowing between JEA and its customers.”

Landis+Gyr

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

Safety

The vScan utility avoidance tool has been designed to make buried utility detection a simple and cost-effective process. You don’t need to be an electronics expert to get the most out of the vScan. Main features and operational controls are in keeping with industry standards so minimal training is required.

Worksite friendly controls combined with the latest electronic hardware and software, make the vScan the premier utility avoidance tool available.

A large dot matrix display gives the vScan the ability to display signals in a clear, unique way.

ABS mouldings and rubber protection buffers, ensure the vScan continues to give reliable service even in the harshest of conditions.

vScan

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

Video

Larson Electronics offers operators a wide range of security cameras, surveillance equipment and other security and surveillance equipment and accessories. These products include a variety of different types of cameras and other equipment including analog cameras, IP cameras with infrared night vision, thermal cameras, NVR systems, DVR systems, security networking equipment and solutions, cabling and complete turnkey solutions to a variety of security applications and needs including those within hazardous environments.

With a full array of explosion proof cameras and security equipment, Larson Electronics is able to provide operators, security personnel and anyone concerned with the safety and security of a business or other location a comprehensive security solution capable of fitting just about any possible security need or requirement.

Larson Electronics

Info http://powereng.hotims.com RS#: 430

Sensors

Silicon Designs, Inc., a veteran-owned U.S. based designer and manufacturer of highly rugged MEMS capacitive accelerometer chips and modules, announced the availability of its Model 1525 Series, a family of commercial and inertial-grade MEMS capacitive accelerometers, offering industry-best-in-class low-noise performance.

Design of the Model 1525 Series incorporates Silicon Designs’ own high-performance MEMS variable capacitive sense element, along with a ±4.0V differential analog output stage, internal temperature sensor and integral sense amplifier — all housed within a miniature, nitrogen damped, hermetically sealed, surface mounted J-lead LCC-20 ceramic package (U.S. Export Classification ECCN 7A994). The 1525 Series features low-power (+5 VDC, 5 mA) operation, excellent in-run bias stability, and zero cross-coupling.

Silicon Designs, Inc.

Info http://powereng.hotims.com RS#: 431

Burners

Fives, a leader in combustion engineering excellence for nearly 100 years, has just launched its North American Tempest SE industrial burner, a direct fire, nozzle-mix burner with a new, compact design that can improve temperature uniformity, product quality and system efficiency in a variety of applications.

The North American Tempest SE offers versatile and reliable performance for process and heat treating in a wide variety of industrial applications. The burner offers the convenience of multi-fuel capability, with various nozzle options, and enables any control methodology, including pulse firing, excess air or stoichiometric.

Fives

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

Flow Meters

Process engineers responsible for on-site plant biomass combined heat and power (CHP) systems will find the rugged and reliable ST51 Series Thermal Mass Flow Meter from Fluid Components International (FCI) provides continuously accurate measurement of syngas fuel flow to the CHP engine. Biomass CHP process systems provide both heat and power in one highly efficient process. Wood chips are fed into the system similar to a regular biomass boiler, but instead of feeding it oxygen to burn the wood chips, they are heated in an environment without any oxygen to around 1300°F (700°C).

In this environment instead of burning the wood, the synthesis gases are extracted from it. The syngases are a mixed composition of N2, CO, CO2, H2, CH4 and trace O2.  After extraction, the gas is run through cooling coils and ash filters to produce a clean syngas that is then used to fuel an engine connected to a generator to provide electricity.

Biomass CHP

Info http://powereng.hotims.com RS#: 433

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.

Marathon Motors

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

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.

E8500 PLUS emissions

Info http://powereng.hotims.com RS#: 435

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.

Mil-Ram Technology

Info http://powereng.hotims.com RS#: 436

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.

MOCON, Inc.

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

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.

Schweitzer Engineering Laboratories, Inc.

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

Massa Graphic

Massa Products, technology pioneer in electroacoustic transducers and industrial non-contact ultrasonic sensors, offers Wireless MassaSonic® SonAire® M3 level transmitters for remote level monitoring. SonAire is a fully integrated sensor — transmitter module is rated for harsh environmental exposure. This high-value sensor is powered with replaceable long-life AA batteries easily obtained from your local grocery or convenience store.

Available in general purpose or FM Certified C1D1 zone 0 intrinsically safe designs; both options are housed in a rugged PVDF chemical resistant IP67 housing and come with North America or European radios. SonAire is drop-in compatible with ZigBee networks for seamless expansion of pre-existing monitoring sites.

Models are rated for measurement ranges of 4 inches (200mm) to 7 feet (2m) or 12 inches (300mm) to 13 feet (4m). SonAire Sensors are ideal for quality remote monitoring for virtually any situation. The shorter range is ideal for drums, chemical totes or generator day tanks, and the mid-range model handles larger tanks, sumps, cooling ponds and wastewater operations. For the power industry, SonAire is the reliable solution for wireless monitoring. For more than 70 years Massa continues to produce the highest quality products in America. Learn More Now.

Massa

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

Switchgear

Schneider Electric has announced CBGS-0, a gas-insulated switchgear with solid dielectric busbar for applications up to 38 kilovolts, 2,000 A and 31.5kA. Schneider Electric’s CBGS-0 is the latest addition to its portfolio of innovative medium voltage switchgear solutions.

CBGS-0 has been designed to meet the needs of indoor substations, which serve a vital purpose in the broader trend of urbanization and the growth of industry. This switchgear is meant for heavy industries: utilities, traction substations, water and wastewater facilities, mining, chemical, petrochemical, wind farms, and data centers.

With operator safety top of mind, Schneider Electric’s CBGS-0 is designed to empower customers to improve operator safety, using a new standard in safety and innovation through a unique design concept. CBGS-0 includes a grounded and shielded solid insulated bus system, installed in the top rear part of the switchgear, outside the SF6 compartment — this means no gas handling is required during installation, expansions or section replacement. Shielded Solid insulation and sealed-for-life gas tank protect the medium voltage components from aggressive atmospheres, dirt, dust and vermin. The materials used also inhibit oxidation in the busbar and circuit breaker compartments and provide for a stable gas system.

Schneider Electric

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

Monitoring System

EXFO Inc., the network test, monitoring and analytics experts, unveiled SkyRAN, a scalable remote access and monitoring solution for fiber-based fronthaul networks. Developed in collaboration with the largest wireless carriers in North America, SkyRAN provides real-time, on-demand testing and 24/7 monitoring of fiber optic networks and radio frequency (RF) spectrum.

SkyRAN combines the industry’s highest resolution RF spectrum analysis over CPRI with the most advanced fiber monitoring capabilities on the market. As SkyRAN reveals RF issues that were previously either undetectable or difficult to identify, mobile network operators (MNOs) will have the capacity to proactively identify and resolve RF interference, PIM and fiber-related issues before they could impact subscribers.

In order to continue delivering superior quality of experience, MNOs will need full visibility into their RF spectrum and fiber fronthaul networks. A solution like SkyRAN will become even more critical as the mobile industry begins to transform their networks in preparation for 5G, which will rely on highly dense networks resulting in an increase of RF interference sources.

EXFO Inc.

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

Energy Management

Landis+Gyr announced the release of Command Center 7.2, the latest version of its operating platform for the company’s Advanced Metering Infrastructure (AMI) networks.
Command Center 7.2 lays the groundwork for the next generation of IoT connectivity on the grid, building in support for new devices and management of peer-to-peer communications on the network. It also enables enhanced integration with other utility software products.
“As part of the development process, we continue to look for innovation that is useful for our customer base, and positions the product well for future technology advances,” said Lisa Washburn, Director of Product Management Solutions at Landis+Gyr. “In addition to laying the groundwork for the next generation of IoT devices, Command Center is bringing more functionality for load profile data, temperature sensing and software integration.”

Landis+Gyr

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

Monitoring

Radiflow, a provider of cybersecurity solutions for critical infrastructure,and ResilientGrid, a provider of integrated software and services to maximize human performance in critical infrastructure, today jointly announced that ResilientGrid has integrated the industrial cybersecurity capabilities from Radiflow into its ResilientGrid Map solution.

The growing threats of cybersecurity and physical attacks along with a growth in big data, automation, IoT and sensors are all leading to more systems, screens, risks and stress in critical infrastructure control rooms.

ResilientGrid Map integrates data flows from an infrastructure’s core systems into a single visualization designed to maximize situational awareness and minimize risks of human error for critical infrastructure operations. ResilientGrid Map is designed around human factors principles, scaling across normal, emergency and recovery operations. This integrated operating system is designed to fight the losses of situational awareness that consistently are seen in emergency situations. This allows these operators to improve efficiencies, reduce risks of losses and rapidly return to normal operations.

Radiflow

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

Utility Tools

Klein Tools introduces three new HVAC products, including the ET10 Magnetic Digital Pocket Thermometer, the PVC and Multilayer Tubing Cutter and the Mini Tube Cutter. The ET١٠ Magnetic Digital Pocket Thermometer’s rugged, portable design attaches to air vents effortlessly for easy-to-read measurements.

The PVC and Multilayer Tubing Cutter provides quick action on drain and vent lines while the Mini Tube Cutter’s compact size is best for cutting metal tubing in tight spaces. This line expansion was designed specifically with HVAC professionals in mind to provide handy solutions against jobsite challenges.

Klein Tools

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

Asset Management

Emerson has announced a major upgrade to its SolaHD SDN 40-24-100C 40A DIN rail power supply that doubles the number of terminals available for improved connectivity to power multiple devices, while also stepping up its heat rating to expand the number of types of hazardous environments where the power supply can be deployed.

“Our SDN-C Series is one of the broadest lines of power supplies available today, now ranging from 5A to 40A in both single-phase and three-phase designs, to help customers better manage their bulk power supply needs,” said Patrick Murphy, Product Marketing Manager for Emerson’s SolaHD brand.

First available in 2014, the best-in-class SDN 40-24-100C has been redesigned by doubling its 2 terminals to 4 terminals to enable plant managers to connect more than one load to the power supply, while maintaining its small, easier to integrate footprint. The SDN 40-24-100C is now capable of powering twice the large DC loads than its predecessor on a standard, single-phase AC circuit, allowing manufacturers to add new equipment that can be powered from an existing structure with little or no retrofitting requirements.

Emerson

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

Utility Tools

Fecon Inc. announces the new FGT Viking Axe knife tool as part of its Viking Tool Series. This patented tool includes an integral, easy to use gauge that ensures proper cutting angles are maintained.

The tool is double sided and easily flipped for a brand new cutting edge when the first side is completely worn. This doubles the tool life, in comparison to other knife tools. The thicker blade creates a more durable edge, increasing the overall life of the knife; the angle is also easier to sharpen. The knife’s pointed edge allows the knife to flow through material better in an open drum and provides self-sharpening benefits while still being able to be sharpened. Ribs behind the knife’s edge lend to increased strength and durability.

Fecon Inc.

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

Safety

Increasingly volatile and extreme weather events are significantly impacting the operations and bottom lines of utilities nationwide. Weather, obsolete grid assets, a lack of automation, heightened customer expectations, and growing regulatory scrutiny all drive the need for better intelligence. To support utilities, DTN, a provider of weather insights, has launched its new Storm Impact Analytics solution.

Storm Impact Analytics provides quantitative and customized damage and outage incident predictions to help utilities better prepare for weather-driven outages, restore power faster, and increase service reliability. By knowing the what, when, and where of each weather-related incident, utilities can achieve greater decision-making confidence and deliver a higher level of customer service. In addition, a vault of operational intelligence can be used by all levels of the organization.

Storm Impact Analytics

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

Safety

National Safety Apparel’s best-selling 40 cal arc flash hood is now available with a lift front hood with PureViewâ„¢ faceshield technology for quick access to fresh air and a clearer view.

Features:
– Product Code: H65UQUQ40LF
– Arc Rating: 40 cal/cm²
– Size(s): One size fits most
– Premium anti-fog & scratch resistant coating on faceshield
– Hard hat included
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By Editors of Power Engineering

Driven by massive declines in coal, overall fossil fuel use in electric generation fell to the lowest level since 1994, the Energy Information Administration reported.

Total petroleum, natural gas and coal use fell to 22.5 quadrillion BTUs last year.

Coal represented the majority of the decline, as its use fell to its lowest level since 1982. Though petroleum use represents a relatively small portion of power generation, its use declined even more to the lowest since at least 1949, the earliest year for that data.

Natural gas use had been increasing over the last two decades, but even it fell slightly in 2017 behind its record high set in 2016.

In energy-equivalent terms, more coal was consumed in the power sector than natural gas in 2017, at 12.7 quads and 9.5 quads, respectively. However, in terms of electricity generation, natural gas-fired power plants in the electric power sector produced more electricity than coal-fired plants, at 31 percent and 30 percent of the U.S. total, respectively, in 2017. Natural gas-fired units tend to be more energy efficient, especially since combined-cycle units became more widespread close to 20 years ago.

The EIA predicted that, by the end of 2018, natural gas combined-cycle units could surpass conventional coal-fired power plants to become the most prevalent technology for generating electricity in the United States.

As a side-effect of the decline of coal and petroleum, carbon dioxide emissions from the electric power sector fell t the lowest levels since 1987.

The savings stem from implementing Suez’s mobile water solutions with InSight.

By Editors of Power Engineering

Increasing penetrations of variable renewable energy (VRE) can affect wholesale electricity price patterns and make them meaningfully different from past price patterns.

A new study from the Lawrence Berkeley National Laboratory specifically assesses wind and solar shares of up to 40 to 5 percent in California, the Midwest, Texas and New York, and contrasts those results to a low-VRE scenario.

The study’s motivating question is whether certain electric-sector decisions that are made based on assumptions reflecting low VRE levels will still achieve their intended objective in a high VRE future.

Some of the study’s key findings include:

– High shares of wind and solar lead to several profound changes in wholesale electricity price patterns. 

– Average annual hourly wholesale energy prices decrease with more VRE penetration, by $5-$16/MWh depending on the region and mix of wind and solar.

– Perhaps the most fundamental changes relate to the timing of when electricity is cheap or expensive and the degree of regularity in those patterns.

– Diurnal price patterns change significantly, especially in scenarios with large solar shares. With high solar shares in ERCOT, for example, prices slump in the middle of the day to an average of $10/MWh and then rise in the evening to an average of $80/MWh.

– The frequency of periods with low prices (below $5/MWh) increases to between 3 percent and 19 percent of hours in the high VRE scenarios depending on the region and mix of renewables. High solar in ERCOT, with its limited interconnection capacity to neighboring regions, experiences the highest frequency of periods with near-zero prices.

– Price volatility increases with higher VRE shares, particularly in the high wind scenarios. Morning prices in the spring in CAISO can vary between $0 and $50/MWh with high wind, but fall in a much narrower range in the low VRE scenario.

Ancillary service prices rise substantially with high VRE, especially for regulation and spinning reserves. Higher ancillary service prices could attract new market entrants such as batteries or incent wind and solar to offer these services themselves.

Peak net-load hours are shifted over shorter time periods into the evening, yet are distributed over more days of the year.

Researchers then highlighted qualitatively the possible impact of these altered price patterns on various demand- and supply-side electric sector decisions, from energy efficiency and demand-response programs to electric-vehicle charging locations, to the value of generation flexibility. The study also provides a foundation for later planned quantitative evaluations of these decisions in low and high VRE futures.

The study found that high shares of variable energy resources lead to several profound changes in the characteristics of electric power systems. 

The most fundamental changes relate to the timing of when electricity is cheap or expensive and the degree of regularity in those patterns. Diurnal price patterns change significantly, especially in scenarios with large solar shares. With high solar shares in ERCOT, for example, prices slump in the middle of the day to an average of $10/MWh and then rise in the evening to an average of $80/MWh. These price dynamics may support electric-vehicle charging infrastructure at commercial sites that can be accessed during the day instead of residential charging that would occur at night–opposite of the situation with low shares of VRE.

The frequency of periods with low prices (below $5/MWh) increases to between 3 percent and 19 percent of hours in the high VRE scenarios depending on the region and mix of renewables. High solar in ERCOT, with its limited interconnection capacity to neighboring regions, experiences the highest frequency of periods with near-zero prices.

“The study found that obtaining high shares of energy from variable energy resources leads to several profound changes in the characteristics of power systems.”

Average annual hourly wholesale energy prices also decrease with more VRE penetration, by $5-$16/MWh depending on the region and mix of wind and solar. Decreases in average wholesale prices and common occurrences of periods with very low prices will affect the profitability of VRE and inflexible generators that operate in these hours, but also presents an opportunity to shift or increase demand at very low cost.

Evidence of VRE-induced Price Changes

Many of these developments can be observed through changes in the patterns of wholesale prices — although it would be wrong to attribute all price changes exclusively to VRE growth, especially in an environment with dynamic natural gas pricing or stagnant load growth. A broad body of literature has discussed these empirical effects both internationally2 and in the United States3.

For example, analyses of wholesale prices in Australia (Gilmore, Rose, Vanderwaal, & Riesz, 2015) show that the deployment of photovoltaic capacity can lead to price changes: historical capacity additions by 2013 had already eroded a mid-day peak in prices in comparison to 2009 and caused the diurnal price profile to flatten significantly. Forward-looking modeling projections for the year 2030 exhibit a further reversal in price peaks to non-solar hours in the early morning and late evening. Keay (2016) summarizes recent European developments and demonstrates a substantial flattening in German diurnal price profiles between 2000 and 2012 that coincided with strong deployment in solar capacity.

Similar developments can be found increasingly in the United States as well. Wiser et al (2017) comprehensively review wholesale electricity price data of U.S. ISOs and find evidence of changed temporal and geographic price patterns in areas with high VRE penetrations. Growth in PV in the California market drove down net-load levels during the mid-day in 2017 relative to 2012 resulting in an associated change in price patterns (U.S. Energy Information Administration (EIA), 2017). In contrast to more even prices over the course of the day in the first half of 2015, the more recent price profile resembled a “duck” in the first half of 2017. In particular, prices have a local maximum around 7am at slightly under $40/MWh followed by a mid-day price slump of about $15/MWh and an evening price peak of nearly $60/MWh at 8pm. Another example of VRE-induced price changes are low power prices at night in wind-rich areas in Texas that have caused some electricity retailers to offer “free” electricity at night.

Summary

The study found that obtaining high shares of energy from variable energy resources leads to several profound changes in the characteristics of electric power systems.

The most fundamental changes relate to the timing of when electricity is cheap or expensive and the degree of regularity in those patterns. The frequency of periods with low prices (below $5/MWh) increases from zero hours in the low VRE scenarios to between 3% and 19% of hours in the high VRE scenarios depending on the region and mix of renewables. High solar in ERCOT, with its limited interconnection capacity to neighboring regions, experiences the highest frequency of periods with near zero prices. Common occurrences of periods with very low prices will affect the profitability of VRE and inflexible generators that operate in these hours, but also presents an opportunity to shift or increase demand at very low cost.

Across all of the regions, high solar scenarios lead to the largest change in the diurnal profile of prices and the greatest overall variation in prices. High wind scenarios, on the other hand, lead to the greatest increase in irregularity of pricing patterns. As a result, electricity suppliers or various electric-sector programs may need to be more flexible and adaptable in a high wind future than in a low VRE or even a high solar future.

High VRE scenarios enable some reduction in the capacity of thermal generation, yet energy from nonVRE generators decreases more significantly, particularly for natural gas and coal. Furthermore, average annual hourly energy prices decline in high VRE scenarios relative to low VRE. For many generators, this reduction in average energy prices will increase the relative importance of ancillary service and capacity market products.

In all regions, the study found that high VRE scenarios result in higher ancillary service prices, absent the ability of VRE to provide ancillary services or the entry of new emerging providers of ancillary services, such as batteries. Capacity prices on the other hand remain relatively steady. Nonetheless, the high VRE scenarios consistently spread peak net-load hours over more days of the year and push the timing of such hours into the early evening, indicating a potential shift in the resource portfolio that can contribute to meeting resource adequacy requirements.

It is crucial to note however, that the portrayed price changes will elicit responses by other market participants which in turn will affect prices. While the capacity expansion model that researchers used has optimized the non-VRE supply portfolio by selecting among traditional generator types, it has not considered investments into demand-side assets that would change the aggregate load profiles (certain energy efficiency measures or demand-response programs) or investments into electro-chemical battery storage. Very high energy prices during scarcity hours or sustained high ancillary service prices would likely motivate investments into these technologies, which subsequently would moderate prices again.

The price results are further a consequence of our modeling assumptions: The expansion of intra-regional transmission masks price variability related to local congestion, while the assumed high VRE penetrations in neighboring regions limit price mitigation due to exports and imports. Changes in our fuel price assumptions (e.g., natural gas relative to coal) would impact the merit order curve and could lead to a different optimal generator portfolio with different flexibility and ramping characteristics. Altered load profiles (such as mass deployment of electric vehicles with price-responsive charge management) would affect our diurnal price profiles. Differences in the absolute load level forecast that do not affect the load shape (e.g., due to better energy efficiency performance or less energy-intensive economic growth) would likely have less of an impact, as the generator portfolio would adjust with the retirement of some marginal plants. Because researchers only considered a single exemplary year of 2030, inter-annual variation (that may include stronger cold-spells with high heating demands, droughts with less hydro-power availability, or heat waves with large additional cooling loads) and a further evolution of the electric system beyond 2030 are not captured by our analysis.

Despite these limitations, the study found that electric systems with large shares of VRE penetration will see profound changes in average electricity prices, diurnal price patterns, and price volatility that should be considered in decisions related to long-lasting assets. This paper qualitatively highlighted some of the possible impacts on other demand- and supply-side decisions.

While the decision-making processes and considerations may differ between regulated and de-regulated regions of the country, analysis of the marginal value of different resources can be informative in either case. As such, these simulated wholesale prices can provide a foundation for quantitative evaluations to explore how various demand- and supply-side decisions might be affected by changes in the future electricity supply mix.

By John McCormick, Vice President Fossil Operations

By J. Michael Marlett

During the Obama Administration, new guidelines were promulgated for the removal of contaminants from FGD wastewater. The contaminants addressed were selenium, arsenic, mercury and nitrates. Now, with a new administration, these limits, how to achieve the limits and the time frame for implementation of processes to achieve these limits have been put into question and uncertainty reigns within the industry. Companies who had defined a course of action are now rethinking and delaying those decisions.

The ELG’s for FGD wastewater list two primary methods of treatment. One is Biological to remove Se, Hg, As and nitrates but does not address total dissolved solids or recover water for reuse within the plant. The second method is Zero Liquid Discharge. This method also addresses Se, As, Hg, and nitrates but also removes total dissolved solids and recovers water for reuse in the process.

The Biological Treatment process is perceived as the low-cost option to FGD treatment and the Zero Liquid Discharge process is perceived to be more expensive from a CAPEX and OPEX standpoint. While this is true, the difference is not as much as has been presented within the market by various engineering firms. In addition, there are options for achieving ZLD while reducing the costs associated with this alternative.

The new Effluent Limitation Guidelines gave a delayed implementation date for those plants implementing Zero Liquid Discharge. That date was 2021 while the implementation of the Biological Treatment option was to be 2018. Many companies have been able to get relief from that date due to the testing that is required to properly design and define the operating conditions and efficacy of the Biological process. Since the ZLD process relies on physical chemical treatment and evaporation, both which are well known and well proven, testing is not required for the ZLD process.

THE BIOLOGICAL PROCESS

The biological process consists of several steps. These steps consist of Feed Pretreatment, Biological Treatment and Post Filtration. These are the major steps and can vary both in methods and conditions depending on the supplier of the process.

The Pretreatment phase consists of equalization and metals removal. This is where hardness, arsenic and mercury are removed. It can consist of pH adjustment, clarification and ion exchange. The pretreatment also conditions the feed for the biological process by adjusting hardness and suspended solids. Then the wastewater is fed to the bioreactor. That can be fixed film, membrane or another type of biological process. It normally requires a carbon source as “food” for the biomass. This is typically methanol, acetic acid or some proprietary carbon source. After reaction, the effluent is filtered to remove the biomass which contains the residual metals and the elemental selenium.

THE ZERO LIQUID DISCHARGE PROCESS

There are several options available to achieve Zero Liquid Discharge. All of them require some type of thermal evaporation step. The list below is not all of the processes available but are ones that have been applied and are proven.

– Phys/Chem Treatment/RO/Crystallizer

– Phys/Chem Treatment/RO/FO/Crystallizer

– Spray Dryer Evaporator

– Phys/Chem Treatment/Evaporation/Solids Separation

– Phys/Chem Treatment/Evaporation/Solidification

This article will be limited to the last two ZLD thermal processes.

Due to the high hardness and abundance of suspended solids in the FGD wastewater, with the exception of the Spray Dryer Evaporator, a physical/chemical treatment is required for the further treatment of the FGD wastewater whether the downstream treatment process is membrane or thermal. This physical /chemical treatment can be as simple as clarification with a solids contact clarifier to as complex as 2 stage complete softening to remove the hardness and suspended solids or somewhere in between. Removal of suspended solids is required to prevent downstream pluggage of the ZLD process equipment. Clarification only would be required for evaporation with solidification. Partial softening would be required for Evaporation with Solids Removal. Full softening would be required for any process employing Reverse Osmosis as a treatment step but could also be employed with Evaporation with Solids Removal.

The thermal processes can be divided up into two categories, small flow and large flow. For small flows, ≤30 GPM, the thermal equipment would consist of a Forced Circulation Crystallizer followed by the solids separation unit, either a filter press or centrifuge. For larger flows >60 GPM, the thermal equipment would be a Brine Concentrator followed by a Forced Circulation Evaporator and solids separation unit or possibly a Spray Dryer if the flow was small enough.

FGD WASTEWATER PRODUCTION

The volume of FGD wastewater produced is a function of the size of the power plant, MW produced, coal burnt and scrubber design. FGD blowdown is controlled to maintain the chlorides of the wastewater below the maximum concentration allowed by the scrubber supplier. This is a function of the materials used in the scrubber. Decreased allowable chloride contents result in increased FGD blowdown volumes. The composition of the coal used in the production of power also has an impact on the

amount of FGD wastewater produced. High sulfur content and high chloride content will increase the amount of FGD wastewater. The high chlorides require more blowdown to maintain chloride levels in the scrubber and sulfur content will affect the amount of gypsum produced and the amount of FGD blowdown.

Based on the factors above, expected FGD blowdown, when limiting chloride content of FGD wastewater to 10,000 PPM, for various coals and plant capacities would be as shown below:

Sub-bituminous coal, aka PRB coal, and bituminous coal makes up 95% of the coal burnt in power plants as reported in 2016 by the US Energy Information Administration.

COST COMPARISON OF BIOLOGICAL WWT TO ZERO LIQUID DISCHARGE

Studies by both CH2M (now Jacobs) and Burns & McDonnell resulted reports comparing the cost of a ZLD FGD Wastewater Treatment plant to a Biological FGD

Wastewater plant. The results of their study is shown below.

Data from “Review of Available Technologies of Removal of Selenium from Water” CH2MHILL for North American Metal Council, June 2010

Industry presentations by the Engineering Firm Burns & McDonnell have postulated that the cost of Biological Treatment plants and ZLD plants are closely competitive up to 200 GPM where the above graph from CH2M indicates the installed cost of ZLD to be three times that of Biological treatment.

The equipment costs and estimated installation costs of the ZLD system generated by Aquatech paint a much more positive depiction of the relative installed costs of ZLD compared to Biological treatment.

The graph below has the estimated costs of a ZLD thermal system imposed on the graph above. It indicates the estimates by Aquatech of the cost of thermal equipment only and the installed cost of the thermal equipment. While much lower than the CH2M estimate, it still represents a 40-percent premium compared to Biological treatment.

This can be expected for several reasons. These mostly result in a difference in the materials of construction of the various pieces of equipment, details of the equipment construction, the types of equipment provided and the level of redundancy expected.

Biological Treatment systems are specified as 1×100% where ZLD systems are typically specified as 2×60% or 3×50% capacity systems.

Historical data from actual installations of ZLD plants for treating FGD wastewater have shown the shape of the curves for both the installed costs and the equipment only costs are correct and properly represent the costs that we could expect at the time of manufacture.

The costs represented by the CH2M curves are overly inflated when compared to our costing structure and estimates. The Aquatech costs include the full pretreatment and full ZLD. These costs can be significantly impacted if full ZLD is achieved not by using a Forced Circulation Crystallizer and solids removal device but by taking the blowdown from the Brine Concentrator and using it to wet the ash prior to disposal in an approved landfill. Pretreatment would be simplified to a Solids Contact Clarifier and the Forced Circulation Crystallizer and Solids Separation Equipment would be eliminated at the expense of a pug mill and mixing equipment.

OPERATING COST OF ZLD SYSTEMS

There is another component of the cost of a ZLD system and that is the operational cost of the equipment. The values in the tables below are for a plant that is generating 750 MW, is burning bituminous coal and generating 200 GPM of FGD wastewater. They demonstrate how savings can be achieved with the choice of one ZLD method over another.

With full ZLD where a solid is generated for disposal in a landfill, the costs of disposal would be $32.82/1000 gallons.

This is a significant cost for treatment but there are methods that result in significant savings to both operating costs and capital costs. This would be going to evaporation to reduce the volume of the wastewater to manageable levels and then either using it for dust suppression or mixing it with fly ash and disposing of it in an approved landfill. Tests in our laboratory have indicated that a fly ash mixture of no less than 20% FGD wastewater to fly ash mixture would still pass the EPA paint filter test. This process option would eliminate steam and the softening chemicals reducing the OPEX to $4.37/1000 gallons from $32.82/1000 gallons.

THE CASE FOR ZLD

The studies by CH2M (Jacobs) indicated that the capital cost for ZLD when compared to Biological Treatment is extraordinarily high. Burns & McDonnell agrees that ZLD is higher but can be competitive at low flows (<200 GPM). Costing studies by Aquatech supports the Burns & McDonnell position that ZLD plants can be cost competitive in these ranges.

The operating costs of ZLD plants can be excessively high depending on the chemistry of the feed, flow and method of operation. If the plants are run at full ZLD generating a solid for disposal, the cost of operation can be as high as $32.82/1000 gallons. However, operating the plants in a mode where the discharge is reduced to match the available fly ash for mixing and disposal, a treatment facility designed to take 200 GPM feed and reduce the volume, operation savings of $2.8 million can be achieved. In addition, the capital cost can be reduced by 40-50 percent, making it very competitive with Biological treatment.

The ZLD option also has positive attributes that cannot be met with Biological Treatment.

Zero Liquid Discharge is a viable option for treatment of FGD wastewater both from an OPEX and CAPEX standpoint. While ZLD can be more costly than Biological Treatment, process arrangements are available to make it more cost effective. It is also the only process that provides water for reuse in the plant and guarantees compliance with any liquid discharge regulation that may be passed in the future since it has no liquid discharge that can be regulated.

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Author

J. Michael Marlett, PE, P Eng, is the process applications manager at Aquatech International Corporation.

References:

1. “Most coal plants in the United States were built before 1990” , Energy Information Administration, Retrieved (2017, September) from https://www.eia.gov/todayinenergy/detail.php?id=30812

2. “U.S. coal flow, 2016” , Energy Information Administration, Retrieved (2017, September) from https://www.eia.gov/totalenergy/data/monthly/pdf/flow/coal.pdf

3. Hansen, Bryan (2016), Case Study — Alternatives for Compliance with ELG Rule at Midwest Utility, International Water Conference Paper IWC 16-43

4. Scroggin, Patricia (2013), The Thermal ZLD Experience for FGD Wastewater at PSNH’s Merrimack Station, International Water Conference Paper IWC-13-47

5. Marlett, J. Michael (2012), FGD Evaporation Plant Operations International Water Conference Paper IWC-12-25