O&M

Spurred on by a recent audit showing widespread utility noncompliance with voluntary recommendations meant to protect the grid from cyber attacks, key lawmakers have unveiled plans to give the Federal Energy Regulatory Commission (FERC) broad powers to enact new mandatory measures to close vulnerabilities in the U.S. bulk power system to potentially devastating computer-launched assaults.

News reports tell us that rapidly growing economies, such as China’s, are importing more oil and raw materials each year, thereby pushing up commodity prices on the world market. One of the side effects of rising commodity prices is considerable increases in the cost of water treatment chemicals. Don’t be tempted to skimp on chemicals to save a buck but risk catastrophic damage. In the words of NASA’s former flight director, Gene Kranz: “Failure is not an option.”

Proper attention to dissolved oxygen levels in feedwater is fundamental for long-term equipment reliability, especially in a combined-cycle plant. When equipment approaches its design life, proper use of new analytic tools and technical expertise can identify impending corrosion and erosion problems and provide you with an estimate of remaining equipment life.

Tackling substandard water sources / Control abrasive wear in scrubber piping / Sensors and final control elements

Assess your cooling tower’s condition / Proper technique for vertical-up stick welding / Move material with a sonic horn

Many of today’s advanced steam generators favor either an all-volatile treatment or oxygenated treatment chemistry program, both of which require strict maintenance of an ultra-pure boiler feedwater or condensate system. Those requirements are many times at odds with the lower-quality water sources, such as graywater, available for plant makeup and cooling water. Adding a condensate polisher can be a simple, cost-effective solution.

Over time, turbine compressors and other driven compressors suffer from corrosion, oxidation, and, in many cases, severe fouling, which in turn can cause in-service breakdown and premature overhaul. Today’s innovative protective coatings can be applied on-site to rotors and individual components to replicate the surface finish, corrosion resistance, and antifouling properties of new components.

Measuring the level of flyash in your silos is not an easy task, in part because the flyash collected at one plant can be remarkably different from that collected at another plant, even if both fire the same coal. Such variability means that selecting the right instrument for your application is important.

Protection against arc flash more important than ever; Laramie River Station uses new coating technology; Protecting power plant pipes: Basics you must know

Power plant training: New techniques required

Boiler water wall leaks have been a major cause of steam plant forced outages. But conventional nondestructive evaluation techniques have a poor track record of detecting corrosion fatigue cracking on the inside surface of the cold side of waterwall tubing. EPRI is performing field trials of a prototype direct-digital radiographic system that promises to be a game changer.

Burning spot market fuels can reduce plant fuel costs, but it can also introduce unexpected operational problems throughout the boiler island. Orlando Utilities Commission’s Stanton Energy Center optimized its Unit 2 combustion system and improved O&M practices as part of a project to increase the unit’s fuel flexibility without degrading reliability or heat rate. OUC’s attitude: If you can measure it, you can manage it.

TRENDS: Retail competition

Tag-teamed seawater cleanup; New cooling towers to improve river’s health; Back to school

Leaders in the utilities sector talk a lot these days about talent. On one hand, they express concern about facing a shortage of knowledgeable staff as 76 million baby boomers exit the workforce. On the other, they worry about where they’ll find enough qualified people to remain competitive in light of the fierce battle for engineering talent that globalization has created. The antidote to these worries lies in reconfiguring HR practices.

New CIP standards leave questions unanswered/Solving common analyzer problems/Qualifying rebuild shops

Even comedian Rodney Dangerfield got more respect than many plant water sample panels do. But power plants ignore sample panels at their peril. Those sample panels, and readings of the on-line analyzers they support, identify when multi-million-dollar systems have a problem that demands immediate attention.

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

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

Survey captures industry’s carbon concerns; Sequestering coal plant emissions; Comparing mercury measurement methods

Shawnee’s new 1,093-day long-run record is a testament to the plant’s highly qualified and trained staff, excellent operations and maintenance processes, and the quality leadership required to keep all the moving parts pointed in the right direction. If running a power plant is a team sport, then the staff of Shawnee are in a league of their own.

The Fossil Productivity Committee of the EUCG conducts an annual analysis of its member plants’ operating results and selects the Best Performer in the categories of small and large coal plants. For 2007, Alliant Energy’s Lansing and Edgewater Generating Stations took the top spots—the first time in recent history that a single utility claimed both awards.

POWER has reported on several EUCG benchmarking studies over the past several years. This month we examine the maintenance staffing of 45 coal plants reported by 13 EUCG member utilities. If you benchmark your plants or fleet, as you should, some of the study’s results challenge what is considered conventional wisdom.

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

Nobody expected driveline vibration to occur after a flawless retrofit of a 200-MW steam turbine. But when it did, Mitsubishi Power Systems and Exelon vibration specialists identified the symptoms and rapidly narrowed the list of possible causes. Confounding factors made the root cause difficult to identify, but the experts pinpointed the problem, made necessary hardware modifications, and placed the turbine back in service in a week.

Immunity from voltage sags is vital for reliable operation of our ever-more-sophisticated electronic controls and equipment. Every electrical product should be able to ride through typical voltage sags, but in many cases the first sag test occurs after equipment is installed and in operation. Select the appropriate sag immunity specification and equipment compliance testing, and you’ll be glad you did.

Single-window control of CHP plant’s energy converters / Safety stuffers entertain as they inform / Doubling up for a heavy load

A federal appeals court has rejected a National Mining Association (NMA) suit seeking to throw out new regulations issued by the Mine Safety and Health Administration (MSHA). The rules were to improve protection for miners in the wake of accidents at two West Virginia coal mines in January 2006 that killed 15. (See COAL POWER […]

Condition monitoring (CM) has become an increasingly important aspect of power plant maintenance philosophy. Today many utilities are using a variety of predictive maintenance (PM) techniques like CM to lower their operation and maintenance expenses. Over the years, gencos have developed a diverse collection of CM programs of various breadth, depth, and formality. All are […]

Employees of Alabama Power, a Southern Company subsidiary, routinely work near energized wires, intense heat, nuclear fuel, heavy equipment, moving vehicles, and pressurized equipment, as well as under other conditions that require exceptional safety attitudes and measures. Though it is vitally important to provide electricity to customers, neither company believes that doing so is worth […]