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April 2014
ON THE COVER
The high-definition camera on the ELECTRABOT unmanned aircraft system enables it to
capture high-megapixel shots from a safe distance. This drone model (photographed by a
volunteer pilot during a recreational flight) was designed for inspections of external electric system components, including power lines, external ductwork, structural supports,
hangers, coal conveyors, stacks, and cooling towers. A sister model specializes in boiler
inspections. Courtesy: United Aerobotics
26
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FEATURES
WATER MANAGEMENT
62
NATURAL GAS
PLANT SAFETY
10
Consulting Editor Bob Peltier revisits catastrophic accidents that could have been
avoided if management and workers had followed basic safety practices.
DEPARTMENTS
SPEAKING OF POWER
10
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14
17
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COMMENTARY
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Uneventful is paradise.
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SPEAKING OF POWER
Supply Competitiveness
Though there was consensus about the
continued bright outlook for shale oil and
gas in North America, several speakers acknowledged that shale resources arent a
solution everywhere. Fuel competitiveness
involves cost and availability but also
surety of supply.
In developing nations, natural gas is
not cost-competitive with other options,
including renewables. As a representative
of Chinas state grid noted, if China can
get gas from the U.S. and Russia, and if
it can develop its own shale gas, then
gas may be the best option, especially for
coastal areas. Until then, China sees wind
power as a good long-term option, nuclear
as a good mid- and long-term option, with
continued use of coal, though at a lower
percentage of the total mix.
Meanwhile, as Black & Veatch (B&V)
Chairman, President, and CEO Steven
Edwards commented, growth in the U.S.
is mostly around renewables, driven by
the competitiveness of renewables in
the marketplace.
By now, readers of POWER and our GAS
POWER Direct eletter are familiar with the
mismatch between natural gas and electricity markets, but theres an even bigger
challenge. In fact, Spectra Energy President and CEO Gregory Ebel argued that
8
Workforce Competitiveness
Several speakers, including Diane McQueen, Albertas energy minister, bemoaned the difficulty of staffing energy
projects. As IHS Vice President John Larson noted, though U.S. unemployment figures suggest there are workers to fill the
labor shortages across the energy sector,
theres a skills mismatch. Diversifying
the workforce was one solution that Secretary Moniz mentioned. Workforce diversity
was also the focus of a reception hosted
by the American Petroleum Institute for
women in the energy industry.
Global Competitiveness
In his opening address to Wednesdays gas
sessions, President and CEO of Siemens
AG Joe Kaeser argued that the U.S. has
a once-in-a-lifetime chance to develop an
industrial manufacturing sector because
energy is so cheap and stable, and people in this country know how to handle
it. Thats why global companies like his
continue to invest in the U.S. Today, he
said, its all about going west. The U.S. is
once again the place to be.
That theme was carried forward by
BASFs Schwager, who noted that Germanys BASF has started to shift investment
to the U.S., including new plants. Investment in Germany is down from 60% of total investment to less than 50% for basic
chemicals, although the total amount of
investment is up. That doesnt mean the
advantage is solely Americas; Europe isnt
doing too badly, he argued, especially
given its strong infrastructure.
Ecosystem Competitiveness
The relevant competitive dimensions depend on your business ecosystem, and
cultural values are an increasingly important dimension.
As Spectras Ebel observed, public
opinion is never right or wrongit is
what it is. And Harald Schwager, member of the Board of Executive Directors
for Germanys BASF SE, the worlds largest chemical company, noted that Europeans differ from the rest of the world
in believing that energy is only good
energy if its expensive, because only
then, they believe, will people not waste
energy. Everywhere else, the belief is that
only cheap energy is good energy.
In a Thursday plenary, B&Vs Edwards
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MORE FOCUSED
ON ADVANCED NUCLEAR
PLANT TECHNOLOGY
Sanmen Nuclear Power Company Ltd. Used with Permission. All rights reserved.
NO COMPANY IS
www.westinghousenuclear.com
Westinghouse
Electric Company
@WECNuclear
1. Serial No. 1. This September 2012 image shows construction of the first of two planned
VVER-1200 reactors at the Novovoronezh II nuclear power plant, which is nearing completion
and is slated to begin operations in 2014. The second unit will come online in 2015. The VVER1200 is a first-of-its-kind third-generation reactor that has been proposed to be built at Turkeys
Akkuyu plant under a unique build, operate, and own contract. Courtesy: Rosatom.
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structure gap, and significantlythough its economic prospects are soaringit has a staggering account deficit of 6%
to 7% of gross domestic product. Turkeys regulatory infrastructure poses another hurdle: Both the Akkuyu and Sinop
reactors need construction and operating licenses from the
Turkish Atomic Energy Authority, which lacks independence
and is prone to conflicting political interests posed by the
prime ministers office.
Both Rosatoms VVER-1200 and MHI/AREVAs ATMEA1 are firstof-their-kind designs. Four VVER-1200s, an evolutionary development of the well-proven VVER-1000 design, are being built
simultaneously in Russia at Novovoronezh II (Figure 1, due to
start between 2014 and 2015) and Leningrad II (between 2016
and 2018). The ATMEA1, a three-loop pressurized water reactor
that uses the same steam generators as the EPR, was only approved in February 2012 by Frances nuclear regulator.
Other aspects, many afflicting all newcomer nuclear countries,
are that Turkey must develop a nuclear workforce and update
existing nuclear laws.
Finally, experts contend, there is bound to be staunch public
opposition to both proposed new builds, which are sited in seismically active areas, and to Turkeys position in a region of the
world that is deeply concerned with nuclear proliferation.
ELECTRIC
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CHINA
NOTABLE NUCLEAR
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Contracts signed, legal and
regulatory infrastructure is
well-developed:
27.8 GW
RUSSIA
TURKEY
SLOVAKIA
880 MW
7.1 GW
8.4 GW
LITHUANIA
UKRAINE
INDIA
1.3 GW
1.9 GW
3.9 GW
UAE
S. KOREA
2.7 GW
6.3 GW
POLAND
BELARUS
U.S.
3 GW
1.1 GW
5.6 GW
ARGENTINA
BANGLADESH
BRAZIL
717 MW
2 GW
1.2 GW
FINLAND
JAPAN
JORDAN
(on hold)
1.6 GW
1.3 GW
PAKISTAN
FRANCE
2 GW
VIETNAM
630 MW
1.6 GW
2.1 GW
KEY:
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AP1000
EPR
VVER
(Westinghouse/
Toshiba)
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POWER Digest
Second Nuclear Unit in Northeast
China Begins Operation. The second
nuclear unit at the Hongyanhe plant
(Hongyanhe-2) in northeast Chinas Liaoning Province entered commercial operation on Feb. 25. Construction of the
CPR-1000 pressurized water reactor began in 2008. The first unit, Hongyanhe-1,
began operating in June 2013 and was
the first to be built in northeast China.
The plant, which incorporates a seawater
desalination plant that produces 10,080
cubic meters of potable water a day, is
owned and operated by Liaoning Hongyanhe Nuclear Power Co., a joint venture
of China Nuclear Power Co. (45%), China
Power Investment Corp. (45%), and Dalian Municipal Construction Investment
Co. (10%). According to the International Atomic Energy Agencys Power Reactor
Information System database, China has
28 reactors under construction and 21 in
operation. Nuclear generation made up a
sparse 2.11% share of the countrys total
power production in 2013, however.
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17
FROM
ENGINEERING
ANALYSIS TO
ADVANCED NDE,
LOOK TO
STRUCTURAL
INTEGRITY
Ghana to Build 1,560 MW of New, Mostly Coal, Capacity. A Feb. 24 deal between Ghanas Ministry of Energy and
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support the operations and lifetime extension services at seven UK Advanced Gas Cooled Reactors (AGRs) owned by French
power company EDF Energy until the end of generation at the
stations. The power stations at Dungeness B, Hinkley Point B,
Hunterston B, Hartlepool, Heysham 1, Heysham 2, and Torness together generate 7,550 MW. EDF awarded the contract
to Doosan Babcock after two years of detailed planning.
World Bank Suspends Vote on Inga 3. The World Bank
in early February indefinitely postponed a board discussion
and scheduled vote to grant $73 million to the Inga 3 hydroelectric project in the Democratic Republic of Congo (DRC) on
concerns that the project would generate power for mining
companies in South Africa rather than the DRCs energy-poor
population. The 4.8-GW Inga 3 project is the first $12 billion
phase of the giant 40-GW Grand Inga project. The project
has been listed as a priority project by the Southern Africa
Development Community and the Southern African Power
Pool.
Sonal Patel is a POWER associate editor
(@POWERmagazine, @sonalcpatel)
www.powermag.com
www.burnsmcd.com/water-team
3D-Printed Turbine
Replacement Parts Could
Cut Repair Times by 90%
3D metal printing is still an experimental
process in nearly all industries, used primarily for prototypes and test products. But if
Siemens and GE have their way, it will soon
become a standard means of rapidly producing small numbers of industrial parts.
Siemens announced in December that
it would begin using 3D printingalso
known as additive manufacturingto
produce replacement burner components
for gas turbines rather than using conventional methods. It said that for certain
types of turbines, repair times can be cut
by as much as 90%.
Meanwhile, GE Aviation announced that
it would contract with Swedish company
Arcam to produce 3D-printed components
for its jet engines. Its oil and gas division plans to start pilot production of 3Dprinted gas turbine fuel nozzles later this
year. With conventional manufacturing
methods, the nozzles are assembled from
20 separate parts, but with 3D printing,
they can be created in a single piece. Rolls
Royce is also reportedly looking at adopting the technology.
3D printing is slower than casting or
molding, but far more cost effective if
only a few parts are needed. For mass production, traditional processes still rule.
1. Bright future. Lasers move over the bed of metal powder, melting it into the desired
shape. Courtesy: Siemens
20
www.powermag.com
Repairing the burner tip with conventional methods is possible but slow. Using 3D
printing enables a 90% reduction in repair
time, and repaired components can also
be upgraded to the latest burner design.
One distinct advantage of 3D printing
processes is that shapes can be produced
that would be impossible using any other
production process (Figure 2). Siemens recently introduced an advanced design burner swirl for its SGT-750 turbine that could
only be manufactured by SLM. Here, a very
complex multi-element component was
manufactured by SLM as a single piece.
There are drawbacks, however, in that
Siemens method cannot produce parts requiring high strength or ductility, such as
turbine blades. But the company hopes to
one day make that a reality.
3D-printed turbine blades could be
produced with much more intricate internal air ducts, which could improve blade
cooling, allowing higher temperatures in
the combustion chamber and increased
efficiency.
Lasers are preferred for small, delicate parts, but electron beams can also
be used. That method is better for larger
components. Arcam is using its electron
beam method to manufacture titanium alloy turbine blades for GE Aviation.
Thomas W. Overton, associate editor
(@thomas_overton, @POWERmagazine).
2. More options.
This short pipe section connects two parts of a gas turbine. The
smooth transition from round to square is
difficult to achieve using conventional production methods, but its simple with 3D printing.
Courtesy: Siemens
3D Visualization Could
Benefit Plant Inspection
Programs
Taking a cue from the petrochemical sector, power plants may be on the cusp of
applying high-fidelity 3D models of the
as-built plant environment to streamline flow-accelerated corrosion (FAC) and
other risk-based inspection programs. In
time, this technology could anchor all of a
plants digital data.
Advanced industrial and process facilities are now employing 3D visualization
software to streamline all aspects of plant
operations and maintenance. In concept,
the technology is simple. Laser scans of the
actual plant equipment are converted into
high-fidelity computer graphics for use on
engineering and operator workstations.
All of the data, diagrams, documentation, and knowledge about any component
stored in other digital or electronic databases can then be anchored to that component (Figure 1) in the context of the actual
plant in its current state and condition.
Asset virtualization is the term used in
other industries to describe this process.
Petrochemical facilities in the U.S. and
1. Integration. Converting laser scans into intelligent 3D models integrates as-built plant
environment with the digital enterprise. Courtesy: INOVx
around the world are applying 3D visualization software solutions for critical piping
and vessel inspection programs (see sidebar). In the power sector, many nuclear
power plants are early adopters of this
technology for maneuvering complex components during outages. Next step for these
plants is to move from off-line to online
www.beis.com
www.powermag.com
21
2. Color coding.
Makes
22
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PIPING SYSTEMS
FOR POWER PLANTS
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23
Margaret H. Claybour
Federal Cybersecurity
Framework Calls for
Increased Vigilance
he energy industry, already familiar with the latest iteration of the North American Electric Reliability Corp. (NERC)
Critical Infrastructure Protection (CIP) reliability standards,
should take note: Meeting those standards may not be enough
to satisfy evolving cybersecurity threats and the need to protect
cyber assets as well as personal data. As cyber crime continues to
make headlines, the energy industry may turn to the first version
of the National Institute for Standards and Technologies (NIST)
Framework for Improving Critical Infrastructure Cybersecurity, in
addition to sector specific standards, to mitigate cybersecurity
risks to critical infrastructure. Plaintiffs attorneys and government enforcement agencies may, in turn, use the framework as a
possible de facto legal standard of care for cybersecurityeven
for entities already subject to the NERC standards or the Department of Energys Electricity Subsector Cybersecurity Risk Management Process. In addition to operational cybersecurity and risk
management, the framework also highlights the need to evaluate
and manage risks to the security of personal data.
Criminals and terrorists are constantly scanning systems looking for back doors or unmonitored assets. Seeking to shore up the
defense of critical infrastructure, in early 2013, President Obama
directed NIST to create the cybersecurity framework. In doing so,
the administration identified energy systems as uniquely critical infrastructure that enables all other critical infrastructure
systems to function. The presidents designation of energy systems as uniquely critical infrastructure did not recognize any
distinction between bulk power system facilities, already subject
to NERC oversight and CIP standards for cybersecurity, and other
energy facilities that have no such oversight or mandatory standards for cybersecurity. Indeed, NERCs submission in the NIST
process developing the framework recognized both the lack of
an end-to-end cybersecurity protocol for the energy industry and
the siloed approach across industries that has resulted in variable guidelines, standards, and regulations. The framework, according to NISTs introduction, provides a common language to
address and manage cybersecurity risk, while allowing organizations flexibility in how they implement the practices.
The framework is not intended to supplant CIP standards, which
are focused on the impact on the bulk power system. The detailed
framework provides three sets of risk evaluation and management
tools that can be more broadly applied to cyber assets and personal
data. One tool provides a high-level strategic view of an organizations
existing and target activities for addressing risks. Another allows an
organization to grade its current level of risk and examine the costeffectiveness of risk reduction in light of business objectives. The third
tool helps define strategic areas for improvement, taking into account
specific risks, and the costs of mitigation measures.
Unlike NERC, NIST has no enforcement authority. The framework
is voluntary. However, as the administrations efforts to identify
and implement incentives to promote adoption of the framework
have stalled, Congress could step in to mandate compliance. Sev-
24
www.powermag.com
PLANT MAINTENANCE
Boiler inspection is tricky work that most plant staff wish they could avoid. Now they
may get their wish. Unmanned craft can provide faster access to high-quality, realtime visual inspection. The technology also has applications for inspection of other
fossil power plant systems, wind turbines, and transmission system components.
Jon S. Cavote
Industry Innovations
UDC has been in the boiler inspection and
condition assessment business since the midwww.powermag.com
1970s. Improvements in unit safety, reliability, and overall boiler efficiency have been the
companys specialty since day one.
In the 1980s, John M. Cavote, chairman
and CEO of UDC, developed the CYBER
system, a leading-edge combustion control
system designed to read control levels and
auto tune for optimal burner function. Fast
forward to the 1990s, when UDC recognized
a significant deficiency in proper boiler and
auxiliary equipment inspection documentation, coupled with a less-than-desirable approach to tracking forced outage and tube
leak events. In response, UDC introduced the
concept of a boiler tube leak-tracking system,
and shortly thereafter developed what was
known as the TRACKER system. Although
it was a little ahead of its time, TRACKER
cleared the path for modern software companies to provide systems that track tube leaks,
track material wall wastage, mine data, and
project wastage rates.
Around the same time, UDC also recognized a fleetwide problem with streamlin-
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ADVANCED
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TECHNOLOGIES
PLANT MAINTENANCE
Table 1. Comparison of unmanned aircraft system (drone) models. Source: United Aerobotics
MAGNEBOT
ELECTRABOT
Main fuction
Internal boiler inspection tool with the ability to attach onto tube
walls
Range
Within a boiler
Up to 10 miles
Inspection areas
Burner inspection
Towers
Transmission lines
Backpass inspection
Wind turbines
Construction
Camera
Flight time
Charge time
Payload
High-definition camera, flood lights, vertical landing system; fu- High-definition camera, high-zoom lens, three-axis camera-stabilizature: tube thickness measuring equipment
tion gimbal
Other features
28
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1. Ground control. This photo shows
a typical ground station for the drones, with
dual screens and dual control. Courtesy: United Aerobotics
cessing areas that are inaccessible due to safety concerns or other regulatory restriction.
Drone Models
United Aerobotics has two drone models (see
Table 1). The trademarked MAGNEBOT
v1.0 was designed for interior structure
evaluations, such as inside the boiler proper,
while the ELECTRABOT v1.0 is used outdoors and in areas experiencing drafts.
What separates MAGNEBOT and ELECTRABOT from basic remote-controlled
helicopters is live, real-time streamed footage, allowing for real-time inspections and
reporting. The MAGNEBOT also is capable
of landing vertically on a furnace waterwall
and can turn off its rotors for energy savings
while continuing to operate the camera and
lighting system within high-priority inspection areas.
Each drone also comes equipped with a
fully functional operating ground station. Although more than one ground station design
exists, they all include:
Ground stations are used by the flight technician as well as lead inspector performing
the evaluation. The station used on a given
inspection depends on the application and requirements for the flight project, access point
(door) dimensions, travel considerations, and
other factors.
The larger ground station (Figure 1) was
designed to allow for both inspection technician and flight technician to view flight footage with ease, eliminating any interference
(crossover) between them. The flight technician can be watching for flight pattern and
30
3. Evidence.
PLANT MAINTENANCE
time. The camera and lighting (Figure 5), including articulation, remain active, allowing
the inspection to continue. Once inspection is
complete in a particular region, blade rotors
can be reenergized for effective and smooth
wall departure. Then the drone can be flown
to another region for continued inspections.
MAGNEBOT also has the ability to fly
with rolling feet, allowing the drone to scroll
up and down the wall while experiencing
stability throughout the flight. The vertical landing system and roller device are interchangeable on the drone and are utilized
based on the application.
The MAGNEBOT was designed considering payload and overall capability in regards
to battery life. The MAGNEBOT v1.0 can
currently perform inspections all day with a
complete battery charge time of 5 minutes,
an average flight time of 8 minutes on a fully
charged battery, and a battery change-out
time of less than 10 seconds. Total battery
change-out time is less than 1 minute.
We can run flights all day with consistent
battery change-outs and no restriction. Typically, flight crews will lay the inspection out
in sections or blocks. They will base the sections or blocks on 5- to 10-minute time spans
to achieve the inspection needs (factoring in
battery change-outs). Once the battery swap
occurs, the drone is reenergized and returns to
inspect the next section or block of the evaluation area. This method also helps by easily
identifying which block of footage to review
for final notes and reporting. This results in a
very high duty cycle, which is the foundation
of efficiency and cost savings.
ELECTRABOT. The ELECTRABOT v1.0,
flown by six rotors, although not as currently
productive due to Federal Aviation Administration (FAA) regulations in U.S. air space,
is the flashier of the two existing models and
currently gets the lions share of attention in
the industry. Currently, the FAA restricts all
unauthorized commercial UAS use in National Air Space (see faa.gov/go/uas). Due
to current regulations, the ELECTRABOT
has only been used for limited demonstration
purposes. All exterior photos were taken by a
volunteer pilot during a recreational flight.
ELECTRABOT comes equipped with a
zoom-capable high-definition camera (Figure 6) allowing for high-megapixel still shots
(Figure 7) as well as high-definition 1080P
video capability. The camera rests in a gimbal designed to remain completely balanced
regardless of drone position.
The ELECTRABOT was designed to fly
in atmospheric conditions not conducive to
operation of its little brother, MAGNEBOT,
and can withstand wind gusts up to 35 mph.
The rotating gimbal is designed to keep the
camera stable during stability-altering flight
patterns while allowing for a clean, zoomedin shot of the inspection location.
The drone comes equipped with attitude
control, which allows autonomous control
using global positioning systems to stabilize
within a locked position when activated. The
feature becomes essential when stability is required and wind gusts are screaming through
the flight pattern. The ELECTRABOT also
has 360-degree camera swivel capability.
This model was designed for external inspections including, but not limited to, power
Flight Crew
A flight crew consists of two members: one
flight technician and one technical inspection
expert for the specified piece of equipment
being evaluated. As you can imagine, flying
these birds accurately and safely within an
enclosed structure such as a boiler furnace
W ER E E N H A N C I N G T H E
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31
PLANT MAINTENANCE
6. Zoom in. The ELECTRABOT high-definition cameras zoom capability enables the drone
to capture high-megapixel shots from a safe distance. Courtesy: United Aerobotics
Current Limitations
cavity requires a high level of skill, experience, and, believe it or not, courage.
UDC has developed and trained flight
crews that not only have the skill set to perform the flight and the inspection but also
have the ability to perform on-the-move drone
maintenance when required. Although every
project is equipped with a complete backup
drone and repair parts, it is imperative that
the crew has the ability to make repair adjustments on the spot in a timely fashion to
ensure on-schedule project completion.
an additional 24 hours). This inspection program was developed for service purposes, so
rapid response time is key.
Safe Flights
United Aerobotics was conceived with safety
at the top of its requirements. Flying UAS
devices for either recreational and/or commercial use comes with potential risks and
hazards. It is recommended that only trained
and experienced technicians perform flight
projects. United Aerobotics safety program
allows for safe and effective flights. We stress
not just flight safety but also flight crew and
customer safety.
For example, the MAGNEBOT has been
used as an effective visual aid in determining clinker location and position for safe
and timely removal. In addition, it can be
Case Studies
United Aerobotics has been in, and serviced,
16 power station units in its first year of
operation. Work has ranged from roof/pen-
7. Close-up. This shot of high-voltage power line rigging was taken by the camera on the
ELECTRABOT from a distance of about 50 feet but is clear thanks to the camera zoom and
drone stabilization features. Courtesy: United Aerobotics
www.powermag.com
PLANT MAINTENANCE
dant inspections to superheat wrapper tube
intersection inspections, waterwall blower
(IR port) inspections, burner inspections
(including tangentiallly cornerfired and
wall-fired burner systems), and bottom ash
inspections, to name a few. Following are
specifics of two inspections.
Project X. The client in Texas needed to
inspect a Combustion Engineering (CE) 800MW eight-corner furnace with a scope that
included CE furnace burners and wall blowers during a short maintenance outage, but
they didnt have the time or funds for scaffolding or buggies.
The United Aerobotics team was able to
reach the site within 8 hours and perform an
aerial inspection of all components in one
shift, using the MAGNEBOT. The inspection scope included 80 burner/air tips and 50
IR ports.
The inspector was able to identify the
deterioration of aftermarket ceramic splitter
plates in the coal buckets. Due to vibration
and overheating, pieces of plate were falling
to the slope below, causing tube failures by
puncturing the tube wall. The inspector was
also able to identify multiple cracked lance
heads in the IR ports.
Project Y. This Missouri client needed to
inspect a Babcock & Wilcox 750-MW furnace to determine the condition of previous repairs to the membrane on the roof of
the boiler as well as determine if there was
erosion on the pendants due to adjustments
on the IR ports. This project used the MAGNEBOT because its unique design allows it
to land on the roof and its small size allows
it to fit between pendants. The scope included
18 pendants and the seam on the roof line.
The inspector was able to identify missing refractory behind the membrane as well
as confirm polishing behind the wrapper tube
on all pendants.
HIGH-EFFICIENCY
FANS
www.processbarron.com | 888-663-2028
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33
NUCLEAR POWER
thority to ensure that all long-term nuclear liabilities would be managed in a unified way.
In this context, the term liability describes
the financial liability of managing a site when
there is little operating income or selling of
assets. The term legacy distinguishes the
first generation of facilities, either shut down
or operating, from the proposed new build
nuclear power stations and newer gas reactor
and pressurized water reactor fleet.
This authority, later renamed the Nuclear
Decommissioning Authority (NDA, nda.
gov.uk) began operating in 2005 and took
responsibility for providing a clear and unified approach to decommissioning the UKs
first-generation nuclear sites (1940s to 1960s).
Stage 1: Post-operational removal of bulk radioactive material. This includes removing fuel from the facility
for reprocessing, which removes about 99.9% of the radioactivity
from the site. The remaining hazards are primarily associated with
the reactor vessels and their internals and operational wastes (such
34
Stage 2: Initial dismantling and removal of contaminated parts or care and maintenance. The reactor
is left, allowing the radioactive materials to decay. Most of the
structures are removed, and the reactor building is left in a safe
state that requires minimal supervision until final site clearance.
Stage 3: Dismantling and demolition of the structure. Demolition is followed by remediation of land and water to
meet an agreed-upon end state for future use.
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Learn more at
aprenergy.com/fastpower
Day 1
Day 8
Day 24
Day 42
NUCLEAR POWER
1. Map of the UK legacy sites.
Authority
Magnox Reactors
The complexity of the proposed cleanup was
amplified because most facilities, such as the
fleet of Magnox reactors, were one-offs.
Ongoing design modifications and construction methods meant that each new station
was slightly more refined, and different from
the previous model.
Magnox is short for magnesium non-oxidizing, from the magnesium and aluminum
alloyclad reactor fuel rods. Magnox reactors are pressurized, carbon dioxidecooled,
graphite-moderated reactors that use natural
uranium as fuel and a Magnox alloy as fuel
cladding. The spent fuel could not be stored
indefinitely because of its chemical reactivity, so it had to be reprocessed.
36
To maintain transparency, the NDA is accountable to the public and the UK government.
Milestones are established to monitor progress
against clearly defined endpoints. Political, socioeconomic, and timescale options are communicated to a wide range of stakeholders that
can affect decision-making outcomes.
Magnox Optimized
Decommissioning Program
Strategic Programs
www.powermag.com
The team has researched, coordinated, and successfully governed an ASME Section III Code revision,
which will potentially generate significant reductions in nuclear construction cost. The team is active
in the industry on a number of committees and has authored and presented more than 200 technical
papers. www.fluor.com
NUCLEAR POWER
fectively apply resources addressing the same
core challenges and waste streams across the
Magnox fleet.
Fuel Element Debris (FED) Treatment.
FED mainly consists of parts of the magnesium alloy cladding that surrounds the nuclear fuel, which, at some sites, was removed
before the spent fuel was sent to Sellafield.
FED is retrieved and placed into a safe shielded storage container following treatment.
The objective of FED dissolution is to separate radioactive material from inert waste to
avoid the unnecessary permanent disposal
of the inert waste. At Dungeness A, Magnox
Ltd. has pioneered the FED dissolution approach, dissolving FED in an acid solution,
reducing the volume by more than 90%. The
remaining effluent is treated and discharged,
within permitted levels, and items of higher
activity are packaged and stored.
Fuel Storage Ponds. Handling of fuel
storage ponds involves removing used fuel
plus draining and decommissioning the
ponds, including the active effluent treatment
plants. The ponds stored used fuel elements
after they were removed from the reactors,
before being sent to Sellafield for reprocessing. Although each pond is different, a consistent six-stage approach was developed:
component removal, sludge retrieval, drain
and stabilize, contaminated concrete removal/applying sealant, ancillary plant removal,
and C&M entry configuration.
Intermediate Level Waste (ILW) Management. Approximately 6,400 cubic me-
2. Bradwell. The former Bradwell Power Station is located in southeast England, 1.5 miles
from the Essex coastline. It consists of twin Magnox reactors that were built on the edge of
a former World War II airfield and operated from 1962 until 2002. Defueling was completed in
2006. Following entry into care and maintenance status in 2015, final site clearance is expected
between 2083 and 2092. Courtesy: Magnox Ltd.
Early Gains
A C&M Hub has been implemented that will
remotely manage all Magnox sites from the
C&M preparations phase up to, but not including, the final site clearance (FSC) phase.
This includes removal of reactor vessels,
building demolition, remediating any contaminated land, and delicensing the sites. The
Plant and Structures Program, for instance, is
directly engaged with the C&M Hub director
regarding end state definitions to ensure that
any agreement with the regulator takes into
account current proposed end states and associated risks for individual sites.
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NUCLEAR POWER
condition, including waste stores and sealedup reactors that will remain in situ for several decades. The contents are expected to be
transferred to the GDF when it becomes operational. Bradwell and Trawsfynydd will be
the first to enter this C&M phase in 2015 and
2016 respectively, with the remaining sites
entering by 20272028.
Another significant benefit expected from
the Lead and Learn approach Burnett said,
is optimum safety results. By focusing on
control and management aimed at major
hazardselevated work, electrical safety,
fire safety, chemical safety, confined spaces,
and radiological safetythe SLCs average
rate for 2012/2013 was 128 per 100,000 employees. This is a significant drop from 244
for the previous financial year. As a comparison, the latest statistics from the Health and
Safety Executive (similar to the U.S. Occupational Safety and Health Administration)
showed an average UK rate of 446 incidents
per 100,000 employees.
3. Pontoon in the pond. A floating pontoon system, as used in marinas, formed a working platform on the fuel storage pond surface, dropping lower as the liquid drained. The pontoons were first introduced at Hunterston, which has the largest Magnox pondabout the size
of an Olympic swimming poolwhen workers were using ultra-high-pressure jets to remove
contamination from the pond walls. Courtesy: Magnox Ltd.
4. Sealed. A spray-on coating of Dekguard was applied to seal Bradwells fuel storage pond
walls and floors. Courtesy: Magnox Ltd.
NUCLEAR POWER
The generic design allows the ISFs to be
constructed to accommodate different numbers
of ILW packages, depending on a sites needs.
For example, the ISF will be used to house the
ductile cast-iron containers known as yellow
boxes until the GDF becomes available.
Plant and Structures. Four, 17-metertall charge machines, each weighing around
460 mt, that were used to refuel the nuclear
reactors during the sites operational phase
have been dismantled. More than 1,300 mt
of redundant equipment have been removed
from the pile caps. Meanwhile, the deplanting of boiler houses within the reactor buildings has also progressed. More than 700 mt
of recyclable wasteincluding pipework,
external boiler drums, walkways, and stairwellshave been removed.
A specially designed remote-operated vehicle (ROV) was used to jet and flush the sludge
waste from resin vault 1 into a submerged
pump system for transfer into the main sludge
vault, ready for encapsulation as ILW. The
ROV used a variety of tools to retrieve the
sludge, including a plough, high-pressure
spray, and wet vacuum system. In total, 5
cubic meters of sludge were retrieved, which
follows the recovery of all bulk resins from
resin vault 2 in 2012, leaving just the sludge to
be removed. Contractors for this phase were
enercon.com
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41
NUCLEAR POWER
5. Trawsfynydd site.
6. Waste waiting. Intermediate-level waste (ILW) packages, contained in reinforced concrete overpacks, will remain in the ILW store at the Trawsfynydd site until the UKs permanent
geological facility becomes available, later this century. The store will then be emptied and the
site demolished. These overpacks are approximately 2.7 m x 2.7 m x 2.2 m high and weigh approximately 30 metric tons. The lid is removable to enable ILW packages (a 3cubic meter box
or 3cubic meter drum) to be inserted into the overpack. Courtesy: Magnox Ltd.
It Can Be Done
The NDAs Burnett summed up the value of
the UKs approach to decommissioning by
saying, There is a collective belief that decommissioning can be expensive and can take
a long time. Although the MODP is a new program, by adopting this approach two to three
years ago, we have reduced C&M costs by
20%, about 1.5 billion. We are demonstrating to the world that we can do this, we are on
track, and very soon we can hold up this [Lead
& Learn] example that it can be done.
As in other nations, dealing with nuclear
facilities after shutdown can be done, but it is
not cheap, easy, or without unexpected challenges. Recent reports have pegged the annual cost of nuclear decommissioning in the
UKthe largest such project in Europeat
3 billion.
According to the Magnox Lifetime Plan
for 2013 that summarizes the key activities, timescales, costs, scope, and resources
required to deliver all Magnox sites to the
agreed end state, the total expected costs of
decommissioning to the point of site clearance are 1.137 billion for Bradwell in 2092
and 1.254 billion for Trawsfynydd in 2083.
The Magnox program accounts for roughly
20% of the NDAs budget, making it the
second-largest expenditure after cleanup at
the Sellafield site (where fuel reprocessing
was handled), which is expected to cost more
than 70 billion.
www.powermag.com
NUCLEAR POWER
Cybersecurity Requirements
Ramp Up
Prior to 2001, plant digital systems included basic physical and information security
requirements in specification and design
documents. In general, however, these cybersecurity requirements were not based on information security industry standards. After
Sept. 11, 2001, the U.S. Nuclear Regulatory
Commission (NRC) and the Federal Energy
Regulatory Commission (FERC) began issuing orders on the subject.
In March 2009, the NRC issued 10 CFR
73.54, which requires plants to provide assurance that the digital computer and communication systems and networks associated with
the following functions are protected against
cyber attacks: safety-related and importantto-safety functions; security functions; and
emergency preparedness functions, including
off-site communications. Support systems
and equipment that would adversely affect
these functions if compromised are also covered by this set of requirements.
Comanche Peaks cybersecurity program
also addresses cybersecurity requirements
established through a memorandum of understanding between the NRC and the North
American Electric Reliability Corp.
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NUCLEAR POWER
The second appendix shows the practical application of the procedures, using four
examples drawn directly from actual plant
modifications and reflecting real-life techniques that plant personnel would use on
their equipment. The examples encompass
a digital protective motor relay, a safetyrelated digital sequencer, a digital radiation
monitoring system, and a turbine-generator
digital controls system. The online version of
this article includes a downloadable file that
provides a portion of the completed cybersecurity controls checklist that Luminant completed for the digital protective motor relay.
EPRI also has developed a computerbased training module to train engineers
working on modifications involving digital
upgrades. Comanche Peak and several other
nuclear plants have used this module to support cybersecurity training.
Improving Clarity
10 CFR 50/52
Concept phase
Safety, security, and emergency preparedness functions, external communications, physical locations
determined
Engage cybersecurity subject matter expert (SME) and
obtain review/approval in each phase
Conceptual design document addresses security
requirements
Requirements phase
Design phase
Implementation,
integration, and test
phase
Operations and
maintenance phase
Retirement phase
addressing cybersecurity control for certain life-cycle phases. For example, some
cybersecurity controls, such as network
scanning, cannot be implemented directly
into the design but take place in the operation and maintenance (O&M) phase.
Requirements/specification references: A
brief summary of the analysis addressing
the cybersecurity control in the requirements life-cycle phase would be recorded
in this column by the digital design engineer, along with requirements document
references supporting the summary.
Design references: A brief summary of
the analysis addressing the cybersecurity
control in the design life-cycle phase is recorded in this column by the digital design
engineer, along with design document references supporting the summary.
Test references: A brief summary of the
analysis addressing the cybersecurity control in the testing or post-design life-cycle
phases is recorded in this column by the
digital design engineer, along with testing
(factory acceptance test, site acceptance
test, and so on) document references supporting the summary.
www.powermag.com
NUCLEAR POWER
1. Visualize the cybersecurity implications. Creating a simple network diagram
like this one during the conceptual phase of a digital asset modification will facilitate a conversation with the plant cybersecurity subject matter expert on required functions and cybersecurity
features for the modification. Source: EPRI
Protected
network
Micro
Card
SLC
application
configuration
SLC
firmware
Process data
(real time)
HART
communicator
Engineering tool
workstation
Engineering tool
software
(from SLC vendor)
Item to be
procured
Likely data
elements
inside SLC
Tool data
associated
with SLC
TB-1
HART capable
single-loop
controller (SLC)
1-AOV-1
Analog input
Analog output
1-FIC-1
1-FT-1
Cybersecurity Procurement
Methodology
The guidance provided in the second EPRI
document, Cyber Security Procurement
Methodology, puts suppliers and nuclear
plant owners on the same page so that both
are familiar with the procurement and supply chain cybersecurity requirements and can
avoid costly rework. In the past, differing interpretations of cybersecurity regulations often led to varying requirements for the same
products. Suppliers also often didnt know
what role the nuclear plant owners expected
them to play in providing cybersecurity.
EPRI research has shown that a standard
set of cybersecurity control requirements
with a standard set of procurement specifications is not feasible for the multitude of
equipment types, vendors, and use cases
that exist in the various types of facilities
and applications. Consequently, a procurement methodology has been developed for
determining the appropriate cybersecurity
requirements for each use case as informed
by a number of factors.
Many of the cybersecurity controls can be
implemented only by the facility. Examples
include incident response policy and proce46
The supplier will identify and map supplier component cybersecurity capabilities to the security controls identified in
the cybersecurity control table.
The supplier will identify any deviations,
exceptions, conflicts, or options.
The supplier will provide documentation
for all responses.
The supplier will describe the suppliers
development environment and how development assets are protected.
NUCLEAR POWER
ment engineers, design engineers, and the
vendors own in-house engineers.
Plenty to Gain
In short, vendors and nuclear plant owners
who understand and address cybersecurity
requirements up front will avoid costs on the
www.powermag.com
49
NUCLEAR POWER
Nuclear Shutdowns
Since October 2012, four nuclear power
plants have announced that they would close
1. Kewaunee Power Station. The 556-MW plant owned by Dominion shut down permanently in the spring of 2013. Courtesy: Dominion
50
www.powermag.com
permanently, removing almost 4.2 GW of capacity from the U.S. electrical grid. Prior to
these announcements, no nuclear plant had
been decommissioned since 1997. Although
two of the plants had extenuating circumstances leading to their demise, thin profit
margins have certainly made retiring the
units much easier to justify.
The Kewaunee Power Station (Figure 1) in
Wisconsin was the first to officially declare
its intent to close. When announced, David
Heacock, president of Dominion Nuclear and
chief nuclear officer of Dominion said, This
decision was based purely on economics.
The dedicated employees have operated the
station safely and well. On May 7, 2013, the
plant was taken offline for the last time.
Another plant struggling with the current
market situation is Vermont Yankee Nuclear
Power Station (VY, Figure 2). Entergy said
that sustained low power prices, high cost
structure, and wholesale electricity market
design flaws for the plant drove its decision
to close and decommission the facility. It
will run through its current fuel cycle and
is expected to cease operation near the end
of this year.
Not that long ago, the future seemed
bright. Both Kewaunee and VY had been
granted 20-year license extensions by the
Nuclear Regulatory Commission (NRC)
in early 2011, which would have allowed
continued operation through 2033 and 2032
respectively.
In Florida, the Crystal River Nuclear Plant
(CR3, Figure 3) last came offline in September 2009 when it shut down for a scheduled
maintenance and refueling outage. The unit
was never restarted because, while replacing
the CR3 steam generators (SGs), engineers
discovered a delamination (or separation of
concrete) within the containment building
that surrounds the reactor vessel. Although
the damage was repaired, additional delamination was later discovered, and Duke Energy determined that retiring the plant was its
best option.
The San Onofre Nuclear Generating Sta-
NUCLEAR POWER
2. Vermont Yankee Nuclear Power Station. Entergy plans to close the 605-MW
plant at the end of its current fuel cycle, expected in the fourth quarter of 2014. Courtesy:
Nuclear Regulatory Commission
tion (SONGS, Figure 4) experienced a similar fate. Southern California Edison (SCE)
had replaced the SGs in both of its operating
unitsUnits 2 and 3between September
2009 and February 2011. In January 2012,
station operators detected a leak in a Unit
3 SG tube. Further investigation revealed
unexpected tube-to-tube wear in both units
caused by fluid elastic instability (or excessive tube vibration). After nearly a year and
a half of testing and analysis, the decision
was made to permanently retire the facility
on June 7, 2013.
3. Crystal River Nuclear Plant. Issues with the reactor containment led Duke Energy to
permanently close the 860-MW unit. Courtesy: Nuclear Regulatory Commission
www.powermag.com
X"
Priority Sootblowing
Furnace Goals
X"
Goal Tracking with Reduced FEGT
Furnace
X"
Thermal Impact Monitoring
X"
Priority Sootblowing by Determining
740.687.4334
NUCLEAR POWER
54
correctly. Another worker once told me, I was here long before
you came, and I will be here long after youre gone! In the end,
I guess he was right. However, while he enjoyed the security of a
stable career, Ive enjoyed the freedom of knowing I could thrive
in a less-stable career by being flexible.
For the most part, unlike the Navy, when folks got a job at a
civilian plant in previous eras, they were likely to remain with
that company for the rest of their working life. The jobs paid
well and included excellent benefits. Once employees established themselves in their positions, it was unlikely that they
would need, or even want, to leave. The system made for a
very experienced and capable workforce. However, when business changes lead to a plant closure, workers who excelled in
one niche may need to develop new skills and habits to thrive
in a new niche.
Creating Structure
My situation changed again seven years ago, when I was hired
to be the operations and maintenance manager at a brand new
biomass plant. The transition was a great experience for me. I was
coming from the highly structured world of nuclear power, with its
detailed procedures and by the book mentality, to a facility that
was owned by a startup company beginning with virtually a blank
sheet of paper.
I arrived as the fourth employee while the plant was still under
construction. Soon after, the original plant manager resigned, and
www.powermag.com
NUCLEAR POWER
Workforce Options
Entergy claims that it is fully committed to helping employees who
arent offered positions to find new career opportunities both inside
and outside the company. The company does have other nuclear
plants in the northeastern U.S.including Pilgrim, James A. Fitzpatrick, and Indian Pointbut realistically, any employee who transfers
to one of these plants will have to relocate.
Some VY employees are retiring early, but according to Jeffrey
Wimette, business manager for the International Brotherhood of Elec-
Table 1. List of plant closings. Source: Duke Energy, Dominion, Southern California Edison, and Entergy
Operational
staffing
Date closure
announced
Last day of
operation
600
Feb. 5, 2013
Kewaunee Power
Station
600
May 7, 2013
1,500
June 7, 2013
630
TBD (estimated
Q4 2014)
Plant name
www.powermag.com
55
NUCLEAR POWER
5. Rancho Seco Nuclear Generating Station. This photo shows the facility today,
nearly 25 years after it was permanently shut down. All plant equipment has been removed, but
the structures still dot the landscape. Courtesy: Aaron Larson
Stumbling Blocks
Nuclear plant workers frequently have more
detailed procedures to follow than employees at other facilities. In most cases, safety
policies are based on Occupational Safety
and Health Administration requirements, so
they are similar whether one is working at a
nuclear plant or some other electric generation facility. In contrast, nuclear maintenance
work practices and operating procedures are
often more comprehensive and require stepby-step adherence to NRC guidelines.
It might seem as if the transition to a lessstringent work process would be easy for
56
NUCLEAR POWER
The Czech Republic in 2012 said it wanted to add units to the Temelin station and
is evaluating bids. But the government
has changed hands, and the program has
slowed. Evans said its probable that a
decision could come in 20142015, but
that may be unraveled by a lack of political will.
Poland says it wants to build four nuclear
units by 2020, to overcome that countrys
dependence on local lignite and imported
(from Russia) natural gas. But the Poles
have announced delays in the plans for
issuing a tender, in part because national
elections are this year. So Evans said he
57
NUCLEAR POWER
Driving Factors for New Nuclear Power in the U.S. and Abroad
In a conversation between Edward Kee, vice president of NERA
Economic Consulting and a long-time observer of nuclear power
issues worldwide, and POWER Contributing Editor Kennedy Maize,
Kee stressed that these are his views, and may not be the same
as the views of his NERA colleagues or clients.
58
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NUCLEAR POWER
Building on a Legacy
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our experience allows us to see the larger
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NUCLEAR POWER
CERAWeek Insights
POWER editors attended IHS Energy CERAWeek in early
March. In addition to this issues Speaking of Power column,
we covered the event in these web-only POWER exclusives:
that U.S. vendors face a tilted market. Foreign vendors, often state-owned or stateconnected, can use their alliances with their
governments to be more nimble. He and others highlighted the ability of the Russians
to use state-supplied capital to offer buildown-operate deals to foreign countries. The
customer only faces the financial risks of
buying the power under contract. The U.S.
Congress, Hoffman said, must do more to
streamline law so the U.S. companies can
compete more effectively.
Is this vendor complaint valid? According to the State Departments Stratford,
the cumbersome 123 process has not really
been an obstacle to U.S. vendors. He said
he could point to no cases where the lack
of a state-to-state agreement had derailed
an international deal. Instead, he said, it is
sometimes the case where the foreign governments policies have slowed the ability
of U.S. vendors to supply nuclear technology to non-U.S. markets.
Thats been the case in India, Stratford
said, where the Indian government has a new
law that allows the utility to seek damages
from the nuclear technology vendor in the
case of an accident. In the U.S., the PriceAnderson Act shields vendors from liability, and similar rules operate in most of the
world. But India has specifically repudiated
this approach. That has vitiated the highly
touted 2009 U.S.-India nuclear cooperation
deal. The Indian law has also stymied deals
between India and Canada.
The real problem for U.S. vendors, noted
www.powermag.com
Craig Piercy of the ANS, is the tension between the old atomic mantra of control versus the new reality of influence. The U.S. can
no longer control how the rest of the world
develops its nuclear capabilities. But many
in Congress in both parties dont quite get
it, Piercy said, so going forward is difficult,
particularly when Section 123 agreements
must go to Congress for a 90-legislative-day
review. That period, Stratford mentioned, is
a term of art. It really means something on
the order of six months or more.
At the same time, the DOE Section 810
technology transfer approvals require traveling a byzantine pathway that includes several other federal agency sign-offs and ends
up with the energy secretary himself. The
law specifies that the determination by the
secretary that the transaction does not harm
the interests of the U.S. cannot be delegated
to a lower-level agency official.
Whats ahead for U.S. nuclear technology
exports? The DOE is revising and streamlining its Section 810 rules, hoping to make
nuclear technology transfer easier and more
transparent. The State Department is moving
ahead on a large number of expiring or new
Section 123 export agreements, including
Thailand, Norway, Taiwan, Vietnam, Jordan,
Saudi Arabia, China, and South Korea.
Will Congress change the law to fast-track
nuclear commerce? Not promising. In midDecember last year, Rep. Ileana Ros-Lehtinen
(R-Fla.), chair of the House Foreign Affairs
Subommittee on Middle East and North Africa, introduced a bill (H.R. 3766) that would
make exporting U.S. nuclear technology more
difficult. Her bill is aimed at the dispute between the U.S. and Iran over uranium enrichment and the possibility of nuclear weapons
proliferation. The State Departments Stratford
said the bill would add seven new conditions
to 123 agreements, making it more difficult to
approve bilateral export agreements.
Richard Myers at the Nuclear Energy
Institute denounced the bill. If this legislation were enacted, he said, it would
further isolate the United States from the
growing international marketplacewhere
our pre-eminence in civilian nuclear technologies has long since fadedby unilaterally establishing new terms for U.S.
nuclear energy cooperation and trade that
many prospective partner countries have
already rejected. In just the past few years,
contract awards by Vietnam and Jordan for
nuclear energy facilities supplied by Russia and Japan show the folly of H.R. 3766s
paternalistic, one-size-fits-all mandate that
sovereign nations forswear uranium enrichment and reprocessing.
ITS A NU DAY
FOR A 60-YEAR OLD
INDUSTRY.
And the winner isNuScale Power. The US Department of Energy selected NuScale
Power for the second round of funding for Small Modular Reactor (SMR) development.
The five-year funding program accelerates the design and certification of the NuScale
Power Module SMR technology. This accelerates commercial availability to support
customer needs for carbon-free baseload electricity, and validates the viability of
smaller, safer, simpler, more economical nuclear power. Its a Nu day.
nuscalepower.com
@NuScale_Power
CIRCLE 30 ON READER SERVICE CARD
NuScale Power
WATER MANAGEMENT
G E N E R AT E
NEW
ideas.
NEW
connections.
NEW
opportunities.
NEW
resources.
www.electricpowerexpo.com
WATER MANAGEMENT
scale-up. In 2014, the possibility of a field
validation of a 16-MW thermosyphon cooler
module optimized for retrofit applications
will be explored.
Dew-Point Cooling Tower. Traditional
cooling towers can only approach the wetbulb temperature of ambient air for their
cold water return temperature. EPRI, in collaboration with the Gas Technology Institute,
is investigating a concept called dew-point
cooling to attempt to lower this temperature
further. This technology enhances the standard tower performance by constructing dry
channels between wet channels in the tower
fill with a thin-walled fill material and exploiting evaporative cooling on the wet side
of the fill to cool the ambient air passing over
the dry side. This precooled air is then used
for contact evaporative cooling with the condenser water (Figure 2).
Dew-point cooling offers the potential to
improve the water efficiency and productivity of steam-electric plants with conventional
wet and hybrid wet-dry cooling towers. Preliminary evaluations indicate that tower fill
replacements that allow the precooling of
ambient air could reduce evaporative losses
and makeup water requirements at existing
plants sited in arid regions while lowering
the temperature of cooled water.
Design development and proof-of-concept
modeling initiated in 2012 focused on optimizing the fill configuration to maximize the
precooling of incoming air in dry channels
and to reduce evaporative losses. In 2013,
EPRI conducted experimental proof-ofconcept studies on a test section of cooling
tower fill to quantify potential water savings.
Engineering and economic modeling for a
representative 500-MW coal-fired plant assessed water and energy impacts across a
range of ambient conditions, investigated
system integration issues, and compared cost
and performance with conventional cooling
tower fill for both retrofit and new construction applications. In 2014, a section of dewpoint cooling tower fill engineered to provide
0.1 MW of cooling will undergo testing at an
industry-certified facility.
Hybrid Dry/Wet Dephlegmator. One
of the chief disadvantages of dry cooling systems is capacity reductions and efficiency penalties during periods with hot
temperatures. EPRI is sponsoring research
at the University of Stellenbosch in South
Africa to address this issue. The research
is developing a new design for the part of
an air-cooled condenser (ACC) called the
dephlegmator (Figure 3). In ACCs, the
dephlegmator provides a secondary condenser that facilitates vapor flow through
the primary condensers, flushing them of
any noncondensable gases.
This research project proposes to develop a novel hybrid (dry/wet) dephlegmator
(HDWD), which would replace the conventional all-dry dephlegmator unit in an ACC.
The HDWD consists of two stages. A dry
first stage is an ACC with inclined finned
tubes, similar to those in a conventional Aframe configuration. The dry/wet second
stage consists of a near-horizontal, dry/wet
heat exchanger.
The operating mode of the second stage
can be controlled in response to changing
ambient conditions. During periods of low
ambient temperature, when air cooling is sufficient, the second stage is operated dry. During hotter periods, deluge water is sprayed
over the plain tubes, and the second stage is
operated as an evaporative condenser.
This technology has the potential to increase power production on the hottest days
as compared to conventional ACCs. It would
also use less makeup water than wet cooling
tower systems and less water than currently
is used by dry cooling with the aid of evaporative precooling of the inlet air.
Air
outlet
nced
Absolute humidity
on
ati
fill
Air
Dry channel
64
tur
Sa
Warm
water
Adva
Air
dh
dhA
Air
Co
lin
ll
l fi
na
tio
n
ve
Wet channels
Air
Wet channel
tDP=53F
tWB=65F
Dry bulb temperature
www.powermag.com
tDB=85F
Inlet airflow
End elevation
LAS VEGAS, NV
NOVEMBER 5 6, 2014
THE BELLAGIO HOTEL
Western electric power markets face daunting challenges that command the attention of policy makers,
power providers, and myriad stakeholders all across the WECC region. Chief among these are issues related
to transmission, renewable energy integration, carbon emission reductions, water availability, and federal land
use policies.
EPEC West addresses strategic issues at the first annual conference in Las Vegas, Nevada:
t
t
t
Replacing SONGS and the Role of Small Modular Reactors in the Wests Energy Future
t
Power Imports and Exports and Factors that Impact Cross-Border Cooperation
t
t
EPEC West is exclusively for executives and will provide an environment to discuss
challenges and explore a range of strategies that address the rapid change impacting
Western electricity providers.
WATER MANAGEMENT
4. Waste not. Membrane distillation technology cuts energy costs by using latent energy
from waste heat to drive a membrane separation process that removes salts and other total
dissolved solids (TDS) from an unconventional water type such as brackish groundwater or
seawater. Source: Sandia National Laboratory/WEN Engineering
Proposed stub
stack(s)
Condensing heat
exchanger in stub
stack(s)
Hot treated
municipal wastewater,
gas well production water,
Existing boiler
stack(s)
Flue gas
Membrane distillation
heat exchanger
High-TDS wastewater to
WWTP influent
Cooling
tower
Heat
exchanger
Hot
distillate
Existing
condenser
Cool distillate
Blowdown
reduced volume
Condensate
Warmer condensate return to boiler(s)
membranes (CNIM) could enable the generation of pure water from saline and brackish
water, as well as support the use of degraded
water sources for power plant cooling.
5. Enlisting nanotubes for advanced membranes. This drawing shows the preferred water molecule movement pathways made possible through the addition of carbon nanotubules (CNTs) to a traditional membrane distillation membrane. Source: New Jersey Institute
of Technology
Membrane
Sample
Hydrophobic effect
Liquid water
molecule
66
Carbon nanotube
(CNT)
Water vapor
molecule
www.powermag.com
with the University of California, Los Angeles (UCLA) Water Technology Research
Center to develop and demonstrate a novel
RO operational paradigm for treating cooling tower blowdown (CTB) water. Building
on a UCLA-patented membrane monitor
(MeMo), the technology could recover up to
80% of CTB for reuse.
In the electric power sector, significant interests have emerged regarding the use of RO
technologies for the treatment of CTB wastewater and reuse as cooling tower makeup
water or other beneficial uses (such as boiler
feed). Although RO is a relatively mature
technology, its application for treatment of
CTB water for on-site reuse (including cooling water makeup) remains a challenge due
to membrane mineral scaling, which leads
to water permeate flux decline and potential
membrane damage.
Direct, real-time mineral scale monitoring
using MeMo will enable RO plants to operate self-adaptively near the maximum water
recovery levels while maintaining operational reliability in mitigating mineral scaling.
In addition, automated self-cleaning via
cyclic mode of feed flow or other cleaning
methods, triggered by MeMo, can potentially
eliminate or reduce antiscalant use and thus
reduce operational costs (Figure 6).
Application of the MeMo-Feed Flow Reversal (FFR) technology in RO plants for
cooling tower water treatment would enable
RO operation at optimal water recovery levels, improve plant operational reliability and
robustness (with respect to changing feedwater quality), and thus reduce membrane
cleaning frequency and their associated
costs. In some applications, a MeMo-FFR
WATER MANAGEMENT
Adaptive Brush
Seal Solutions for
Air Preheaters
Direct,
real-time mineral scale monitoring using a UCLA-patented membrane
monitor (MeMo) will enable reverse osmosis plants to operate selfadaptively near maximum water recovery levels while maintaining operational reliability in mitigating mineral scaling. Source: UCLA Water
Technology Research Center
Permeate
Feed
Concentrate
Normal feed flow mode
Feed
Permeate
Concentrate
Reversed feed flow mode
JOIN US AT
Electric Power
BOOTH: 661
108&3
For more than 25 years, Sealeze has helped design and manufacturing
engineers design solutions.
800.787.7325
e-mail: power@sealeze.com
www.sealeze.com
ISO 9001 Certified
www.powermag.com
67
Natural gas
19%
Hydro
5.5%
Total Generation
July 2011July 2012
253.9 TWh
Brown coal
22%
68
Black coal
47%
Engine Services
Operation and Maintenance Services:
Fossil Wind Solar
Rotor Life Assessment Programs
nrgenergyservices.com
NRG is a registered servicemark of NRG Energy, Inc. The plus signs and plus clusters are servicemarks of NRG Energy, Inc. 2014 NRG Energy, Inc. All rights reserved.
www.powermag.com
69
www.powermag.com
LCOE (A$/MWh)
350
300
250
200
150
100
50
0
Nuclear
(Gen +3)
Combined
cycle gas
turbine
Wind,
onshore
Supercritical Supercritical
pulverized
pulverized
black coal
brown coal
IGCC black
coal
Photovoltaic,
Solar thermal,
nontracking
parabolic
trough
3. Down Under.
development, it says.
Curiously, the governments December
2013released Issues Paper, drafted to
prepare for its energy policysetting Energy White Paper due this September, hints
that the use of small modular reactors could
offer myriad benefits for the country. But,
though Australia has one of the worlds largest deposits of uranium and thorium, it has no
nuclear plants, and the ban on nuclear power
introduced by the Howard government has
longstanding bipartisan backing. The Industry Ministry confirms that the Coalition has
no plans to pursue nuclear energy.
However, Australia does champion carbon capture and storage (CCS) and advanced
coal technologies as means of high efficiency low-emissions intensity generation.
It has been pivotal in the establishment of the
Global CCS Institute, and through its CCS
Flagships Program, it fostered five CCS projects that are in various stages (Figure 3). But
even here there is turmoil. Industry observers
point out that while there is a general lack
of industry advocacy for CCS, likely due to
costs, the governments own position on CCS
has flip-flopped with political leadership.
One possible solution with multi-pronged
benefits that has industry patronage is to increase the uptake of electric vehicles. As well
as increasing electricity demand, electric vehicles could deliver energy efficiency across
the power sector, indirectly improve energy
security, mitigate the intermittency of renewables, and reduce carbon emissions from the
transport sector, which spews about 15% of
the countrys carbon emissions.
www.powermag.com
NATURAL GAS
Supply Constraints
Gas market regulators and observers have been
warning for several years that the rapid shift toward reliance on natural gas was creating a risk
of shortages in the event of unplanned demand
shocks. The mild winters in the early 2010s reduced demand for heating, freeing up supplies
and pipeline capacity for power generation.
1. Spiking prices. Natural gas spot prices in February jumped to levels not seen in years
on the back of severe cold and supply constraints. Futures markets also climbed on concerns of
shortages later this spring. Source: Energy Information Administration
Henry Hub Month-ahead futures
9
8
7
$/MMBtu
6
5
4
3
2
1
0
2 4 6 8 0 2 4 6 8 0 2 4 6 8 0 0 1 3 5 7 9 1 3 5 7 9
n. n. n. n. . 1 . 1 . 1 . 1 . 1 . 2 . 2 . 2 . 2 . 2 . 3 . 1 b. b. b. b. b. . 1 . 1 . 1 . 1 . 1
Ja Ja Ja Ja Jan Jan Jan Jan Jan Jan Jan Jan Jan Jan Jan Jan Fe Fe Fe Fe Fe Feb Feb Feb Feb Feb
www.powermag.com
NATURAL GAS
2. Falling stocks. Withdrawals this winter have reduced gas in storage to levels not seen in
years. (Trend for missing years folllowed years shown.) Source: Energy Information Administration
2008 2010 2012 2014
4,500
4,000
3,500
3,000
2,500
2,000
Overreliance?
1,500
1,000
500
0
n.
Ja
b.
Fe
ar.
r.
Ap
ay
n.
Ju
l.
Ju
g.
Au
p.
Se
t.
Oc
v.
No
c.
De
2014
Enhanced PDF version now available
The 2014 UDI Whos Who Directory covers more than 4,500
U.S. and Canadian generating plants. The directory provides:
Nearly 8,100 plant management and support
contact names, titles, and primary job functions.
Basic plant operating statistics for more than 1,500
power stations, including:
Generation (MWh)
Availability (%)
Heat rate
Capacity Factor (%)
Power plant design characteristics
Choose which purchase option that best suits your needs:
Hardcopy Book
Enhanced Directory PDF (CD-ROM)
Mailing List (CD-ROM), Enhanced Directory PDF & Hardcopy Book
74
www.powermag.com
NATURAL GAS
Developments in Europe
Gas-fired power in Europe continues to be moribund at best. Construction of new plants has essentially ceased in Western Europe,
and around 30 GW of gas-fired capacity is currently mothballed. IHS
CERA recently projected that a further 110 GW of currently operating capacity is at risk of being shut down, with around 25 GW likely
to be shuttered in 2014. The situation has gotten bad enough that
bottom-feeding investors are beginning to buy up idled plants that
the majors are ready to unload.
The culprits remain cheap coal, expensive gas, and depressed
wholesale electricity prices stemming from renewable subsidies
and flat demand. Rising gas prices in the U.S. are unlikely to
provide any relief to European generators. Should gas-to-coal
switching in 2014 reach meaningful levels, however, this is likely to reduce U.S. coal exports to Europe, which could ease the
current glut and create upward pressure on coal prices. (For an
overview of recent and projected coal export markets globally,
see THE BIG PICTURE: Coals Export Future in the March issue
at powermag.com.)
The continuing problem of depressed carbon prices on the European Union Emissions Trading System (ETS), which has largely
eliminated any penalty for coal-fired generation, may or may not
see improvement this year. The European Commission is proposing reforms of the ETS that are intended to boost carbon prices
and clear the current backlog of allowances.
Essentially, the new scheme would create an automated stability reserve that would withhold allowances from the market
until the amount in circulation falls below 400 million, or until
the carbon price rises to three times the previous two-year average and remains there for six months. A previous plan to simply
delay release of allowances in order to raise the pricea practice known as backloadingwas scuttled after objections from
the European Parliament and member states.
Opinions are mixed on whether the reforms will make a meaningful difference in the near and medium term. Carbon prices
have climbed slightly (from about 5 to 7 at this writing) since
the announcement, but they are still well below levels that observers see as necessary for gas to begin making a comeback.
ity Commission of Texas. The situation in the U.S. remains far better
than in Europe, where gas-fired power is still looking for the light at
the end of a very dark tunnel (see sidebar).
Effects on Production
Its unclear at the moment whether higher prices on the spot market
will lead to an increase in production this summer. Many producers
plan their output well in advance, and with significantly lower prices
last fall, may not have planned for increased drilling this year. Canadian stocks are also very low, which may limit exports to the U.S.
Analysts expect the U.S. withdrawal season to end with stocks at
around 1 Tcf, the lowest in at least 10 years. Levels below that, should
they occur, may send summer prices back over $5/MMBtu, a level
that could spur substantial gas-to-coal switching. Morgan Stanley
analysts projected in February that an average price of $4.35/MMBtu
during this summers injection season would support adequate refilling of storage because of reduced demand.
Some increase in production seems certain, given the number of
shut-in wells that were drilled but not brought into production during
the glut in 2012. Higher prices this spring are likely to bring many
of those wells online. Bentek Energy estimates a 4.5% increase in
production in 2014, though the EIA expects production growth for
2014 to be only 2.2%.
One key fact to keep in mind is that takeaway capacity in the
Marcellus region is still constrained. This means that only so much
production can be brought online without creating bottlenecks and
a regional glut that would cause a rapid price dropa situation that
producers will wish to avoid.
Switchback
The spike in gas prices has caused a rebound in coal-fired generation,
with coal plants producing around 4.5 million MWh per day this winter, the highest levels since 2011. After falling to around a 32% share
of total generation during the gas glut in early 2012, coal has returned
to around 40% this year.
The EIA projected in its February 2014 Short Term Energy Outlook that coal-fired generation will rise from 4,326 GWh/d last year
to 4,519 GWh/d in 2014, while gas-fired generation will fall slightly
from 3,050 GWh/d to 3,023 GWh/d this year.
Still, construction of new natural gas plants continues to far outstrip coal, in large part because such decisions are made outside
short-term pricing concerns. California, for example, has more than
3 GW of gas-fired capacity under construction or in active development, according to the California Energy Commission, while Texas
has around 3.5 GW under construction, according to the Public Util-
www.powermag.com
76
Reliability issues
Hard-to-procure replacement parts and accompanying services
Sharp increases in vendor support costs
Difficult-to-provide internal and thirdparty support
Major plant expansion that cant be accommodated by the existing DCS
DCS cant connect with new or existing
third-party applications
Desire to standardize automation systems
among plants
Better plant performance needed
Improved cybersecurity required
was the heat recovery steam generator, deaerator and feedwater system, gas compressor system, compressed air system, and water
treatment plant.
In the initial phases of the project, Maverick worked with Ripon to determine its goals
from a technical and business perspective, a
process that allowed the client to objectively look at the technology available to best
achieve its objectives.
Ripons goals were to take advantage of
its existing HART smart instrumentation
and to standardize on a new automation
platform that would allow for increased
productivity of its maintenance teams. The
company also wanted a system that included a central and actionable alarm system
2. Upgrade time. The existing DCS at this cogen plant needed to be replaced to improve
operations, cut downtime, and minimize maintenance. Courtesy: Maverick Technologies
to reduce required operator action by giving the operators a means to quickly react
and provide a solution to any process upset.
Another area of concern was compliance reporting and ease of access to plant operating
and performance data.
As with most power generators undertaking a major automation upgrade, Ripon was
concerned with the impact to operations due
to possible downtime, and managers wanted to
take advantage of existing field wiring and infrastructure. In addition, they wanted an open
architecture automation system that would allow
seamless interface with their critical subsystems.
Finally, they wanted a system that they could
support primarily with internal resources.
These were the reasons Ripon needed
a new automation system. Those reasons
framed the case for the DCS replacement and
indicated what type of new system should be
selectedin this case a Rockwell Automation PlantPAx.
As part of the FEL evaluation, Maverick
worked with Ripon to develop a cutover plan
that would minimize downtime and risk. Existing processor and I/O drops were replaced,
but all existing field terminations were left
intact, a course of action that greatly reduced
required new wiring and associated cost and
downtime issues (Figure 3).
The plant experienced no unscheduled outages during the migration process, and the facility started up on schedule with output ramped
up to full power on the first day of operation.
As confirmation that an upgrade was the
right decision, the plant has experienced fewer outages, due in large part to the improved
automation system. Performance has also
improved, and all of the other goals outlined
above were attained.
3. Time management. Upfront planning can reveal many ways to minimize downtime when migrating from an old DCS to a
new automation system, as with this new
system, which allowed existing field terminations to remain intact. Courtesy: Maverick
Technologies
78
www.powermag.com
replace the existing pneumatic and relaycontrolled combustion, steam, and burner
management systems on two of its units.
Each of these units uses a natural gasfired
boiler to supply steam to a turbine generator.
The capacity of each unit is in the 50-MW to
100-MW range, and the two units were commissioned decades ago.
Although the existing automation system
was not a DCS, the challenges were similar
in that the reasons for the upgrade had to be
determined to ascertain the goals, and then a
plan had to be made to perform the upgrade
and meet those goals.
The city engaged Maverick Technologies for the upgrade project, and Maverick
found that the initial challenges were to develop conceptual designs with basically no
data from the original configuration and with
minimal information on any subsequent upgrades and/or changes to the facility. The first
steps were to identify the customers goals
and develop a baseline for the project.
During that process, it was determined that
the reasons for replacing the existing automation systems were to stabilize critical control
variables (such as steam pressure, temperature,
and drum level) in order to produce power
based on varying dynamic load changes. The
utility also needed to ensure it could maintain
load during peak operating periods.
Plant operators needed an efficient operational management system that would enable
them to quickly address system upsets, and
the facility needed to generate regulatory reports from historical trend data. To achieve
these goals, it was important to design a system offering seamless control while providing operators with centrally located operator
consoles. As with most upgrades, it was also
critical to minimize downtime during system
cutover and to provide the operations staff
with an automation system that they could
Tyrone Bowman
(tyrone.bowman@mavtechglobal.com) is
industry manager, Pulp & Paper, Power
& Energy Solutions, Field Services for
Bolting solutions
ADVANTAGES:
Increases worker safety
Accurate & reusable
Reduces downtime
www.powermag.com
79
PLANT SAFETY
80
CFR
(29
CFR
CFR
1910.134)
Electrical, wiring methods, components,
and equipment (29 CFR 1910.305)
Powered industrial trucks (29 CFR
1910.178)
Ladders,
construction
(29
CFR
1926.1053)
Control of hazardous energy (lockout/
tagout) (29 CFR 1910.147)
Electrical systems design, general requirements (29 CFR 1910.303)
Machinery and machine guarding (29
CFR 1910.212)
www.powermag.com
feet long. The penstock is the conduit or tunnel that delivers the water from the reservoir
to the hydroelectric turbine-generators. The
tunnel interior diameter varies between 12
and 14 feet at this plant. Recoating of the
walls is a common maintenance requirement
to maintain structural integrity, maintain water tightness, and prevent corrosion of steel
surfaces (Figure 1).
Workers experienced problems with their
paint spray equipment shortly after beginning the epoxy application. The spraying was
stopped and the sprayer system was cleaned
using the industrial flammable solvent methyl ethyl ketone (MEK). The cleaning work
was done at the work location within the
penstock. The National Institute for Occupational Safety and Health (NIOSH) lists MEK
as a highly flammable solvent, with a flash
point below 73F.
A flash fire occurred when a static spark
ignited the solvent inside one of the two epoxy feed hoppers. The fire spread quickly
when other plastic containers of the solvent
(later determined to be approximately 16 gallons) and epoxy erupted. Four workers near
the exit were able to quickly exit the penstock
with minor injuries. Emergency response
teams were unable to reach the five workers
trapped behind the fire in the penstock before
they succumbed to smoke inhalation. The fire
occurred when the safety inspector and general foreman were away from the worksite
having lunch.
The subsequent investigation conducted
by the U.S. Chemical Safety Board (CSB)
focused on the technical and organizational
causes of the fire. The CSB investigated the
incident to determine the root and contributing causes to help other plant owners prevent
similar tragedies from occurring.
The investigation determined the technical
cause of the incident was the ignition of the
MEK that was circulated through the sprayers for purposes of cleaning. The work occurred in an open area within the penstock,
although a number of ignition sources pres-
PLANT SAFETY
1. Penetrating the penstock. A 4-foot by 6-foot opening was cut into the penstock for
contract worker access. Two wooden bulkheads were constructed to contain and remove sandblasting and grinding debris and to provide work area ventilation via flexible ducts. The result
was a confined space with only a single means of egress. Source: U.S. Chemical Safety Board
Lower outlet
(powerhouse)
Upper intake
(Mushroom)
Flame-cut
access door
Temporary
east bulkhead
Elevation:
11,065 ft
11,000 ft
ft
20
1,0
55
at
Turbines
20 ft at 90
Temporary
west bulkhead
10,200 ft
1,563 ft a
t 10
10,056 ft
10,000 ft
1,560 ft at 2
Paint sprayer at
time of incident
Epoxy components
Temporary
west bulkhead
Solvent
Two-part
epoxy paint
sprayer
Spray wands
Static mixing
block
15-ft-diameter
concrete penstock
12 ft diameter
steel-lined
penstock
MEK solvent
pump
PLANT SAFETY
were at the hydroelectric plant and immediately available for rescue on the day of the
incident. The CSB investigation determined
that the closest community rescue service
was approximately 75 minutes away. Rescue
workers talked with the trapped workers on
hand-held radios for 45 minutes before they
died from smoke inhalation. There were no
fire extinguishers located inside the tunnel.
The owner and contractor subsequently
failed to cooperate fully in the CSB investigation, particularly with providing requested
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PLANT SAFETY
3. Dangerous work environment.
way around the spool with his second pass when the pressure vessel
exploded. A portion of the reheated root pass and the second pass weld
material struck the welder in the chest, causing serious injuries, and hit
the welders helper in the face and eyes, causing what was probably a
permanent loss of vision.
These preventable injuries were caused by a series of mistakes by
the workers and plant supervision. The lessons learned from this tragedy are self-evident:
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83
PLANT SAFETY
4. Explosive opening. The explosion folded over the roof, killing the welder and severely
injuring the foreman. Source: U.S. Chemical Safety Board
ing did not consider that VF could accumulate in sufficient amounts in a tank to reach
flammable levels, although the hazard analysis did determine that loss of the compressor would double the VF vapor produced.
The cracked looped seal pipe in Tank 2
had the unfortunate effect of increasing the
amount of flammable vapor present in Tank
1. In addition, the insulation was removed
from Tank 1 during the overhaul and not yet
been replaced at the time of the incident,
which also resulted in the production of
more flammable vapor due to condensation
(colder tank metal temperatures).
www.powermag.com
PLANT SAFETY
The owner was fined for not including a process to completely isolate the tank and for
failing to install blind flanges in the overflow
line. The contractor was fined for failing to
ensure the lockout/tagout procedure was
rigidly followed and the tank was properly
isolated. OSHA fined both companies for
failing to inform employees about the explosion potential when performing hot work on
Tank 1.
The CSB subsequently issued the bulletin Seven Key Lessons to Prevent Worker
Deaths During Hot Work in and Around
Tanks in February 2010, which discusses
11 incidents in which hot work ignited flammable vapor in or near storage tanks, three
of which were violated during this incident.
The CSB report can be found at http://tinyurl.
com/mmqv7t3.
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PLANT SAFETY
Also, electrical equipment located above
the suspended ceiling was not rated for use
around combustible dust (Figure 5).
The post-incident investigation found that
employees were not trained about the hazards of combustible dust. OSHA, local fire
department, and insurance company inspectors inspected the plant, although none made
comment about the potential for a dust explosion. The CSB determined that if the company had adhered to NFPA standards for
combustible dust, the explosion could have
been prevented or minimized.
The second incident occurred in an aluminum products manufacturing plant in Indiana, where an explosion killed one worker
and injured several others. The plant recycled
scrap aluminum produced by its production
line and fed it into a melt furnace. Transporting the aluminum scrap produced aluminum
dust that was sucked into a dust collector.
The explosion occurred in an inadequately
vented and cleaned dust collector that was located too close to the scrap processing area.
The initial explosion spread through ducting, causing a large fireball to emerge from
the melt furnace. Dust was also present on
overhead beams and other structures that was
lofted as a result of the first explosion.
The proximate cause of the fire that
burned the facility to the ground was a dust
collector that was not designed or maintained to prevent dust explosions. Neither
the owner nor regulators adequately investigated earlier dust fires at the facility, nor
were any process changes made. Again, the
CSB determined that if the company had
adhered to the NFPA standard for combustible metals, the explosion could have been
prevented or minimized.
The third major eruption occurred in a
facility located in Kentucky that produced
acoustic insulation for automobiles. The explosion claimed the lives of seven workers,
injured 37, and completely destroyed the
facility. According to the CSB, the manufacturing process began by impregnating a
fiberglass mat with phenolic resin, and then
used air to draw the resin into the fiberglass
webs. On the day of the explosion, a curing
oven that had been left open because of a temperature control problem likely ignited the
combustible resin dust stirred up by workers
cleaning the area near the oven.
With the knowledge of plant managers,
dust had accumulated throughout the manufacturing facility in dangerous amounts. The
production process used compressed air for
cleaning, often blowing large amounts of resin dust into the air. Again, Kentucky OSHA,
state fire marshals, and insurance company
safety inspectors had inspected the facility,
but all failed to recognize the combustible
86
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POWER PROFESSIONALS
Opportunities in Operations and Maintenance,
Project Engineering and Project Management,
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First-line Supervision to Executive Level Positions.
Employer pays fee. Send resumes to:
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email: dwood@powerindustrycareers.com
(360) 260-0979 l (360) 253-5292
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NAES Corporation is a leading provider of
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Layup Desiccant
Dehumidification
& Filtration Units
for long term layup
of power generation
equipment. For over
35 years of drying
solutions contact:
Tom Haarala
612-202-0765
thaarala@cdims.com
Todd Bradley
810-229-7900
tbradley@cdims.com
www.cdims.com
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Turbine Controls
Woodward, GE, MHC
Parts and Service
TurboGen (610) 631-3480
info@turbogen.net
READER SERVICE NUMBER 207
PRODUCT
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Cooling Water
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BANGKOK, THAILAND
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October 2014
23646
LOGO :
ORANGE :
C0 M50 Y100 K0
DATE :
22 May 2012
BLUE :
C100 M70 Y0 K0
Advertisers Index
Enter reader service numbers on the FREE Product Information Source card in this issue.
Page
ABB
Reader
Service
Number
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 . . . . . . . 22
CIRCOR
www.winsted.com
Zachry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 . . . . . . . 29
www.hawkmeasure.com
www.westinghousenuclear.com
Winsted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 . . . . . . . 34
www.insituform.com
Kenda Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 . . . . . . . 36
www.teaminc.com
Westinghouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . . . . . . . 5
www.harcolabs.com
Insituform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . 15
www.structint.com
www.ge-mcs.com
Harco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 . . . . . . . 35
www.siemens.com/ruggedcom
Structural Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 . . . . . . . 11
www.fluor.com
General Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . 4
www.sealeze.com
Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . . . . . . . . 8
www.fibrwrap.com
Fluor Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . . . . . . . 21
www.selinc.com
Sealeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 . . . . . . . 32
www.enercon.com
www.rentechboilers.com
Schweitzer Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 . . . . . . . 38
www.diamondpower.com
Enercon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . . . . . . 23
www.rangerack.ca
Rentech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover 2 . . . . . . 1
www.cutsforth.com
Diamond Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 . . . . . . . 28
www.processbarron.com
Range Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 . . . . . . . 39
www.corrpro.com
Cutsforth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 . . . . . . . 24
www.nuscalepower.com
Process Barron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 . . . . . . . 19
www.cleaverbrooks.com
Corrpro Companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . 15
www.nrgenergy.com
NuScale Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 . . . . . . . 30
www.circorenergy.com
CleaverBrooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 . . . . . . . 25
www.superbolt.com
NRG Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 . . . . . . . 33
www.burnsmcd.com
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 . . . . . . . 26
www.mpshq.com
Nord-Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 . . . . . . . 37
www.brandenburg.com
www.mdaturbines.com
www.beis.com
Brandenburg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover 4 . . . . . 41
www.matrixservice.com
MD&A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 . . . . . . . 17
www.piping.bilfinger.com
Brand Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 . . . . . . . 13
www.martin-eng.com
Matrix Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . . . . . 7
www.baldor.com
www.gotmussels.com
Martin Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . . . . 10
www.aprenergy/fastpower
Baldor Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . . . . . . . 9
www.corzancpvc.com
Marrone Bio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 . . . . . . . 40
www.amec.com/power
APR Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . . . . . . .
www.kiewit.com
www.ajweller.com
AMEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 . . . . . . . 27
Kiewit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . 16
www.abb.com/powergeneration
A.J. Weller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . . . 3
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91
COMMENTARY
New Connections
Connections are also developing among the energy infrastructure and communications networks as well as other traditional
infrastructures such as water and wastewater systems. As we see
these connections evolve, it is causing us to rethink the traditional paradigms of energy system planning and operation with a
strong focus on how we achieve the most efficient, flexible, and
reliable energy systemone that enables planning and operations across interdependent domains (fuels, electricity, thermal,
water, communications) to provide the required energy services
to consumers at an affordable cost.
NREL is leading a worldwide conversation on how these connections will change the way we generate, deliver, and use energy. While we cant anticipate the nearly infinite number of
combinations of technologies, data, and devices that will interact in an integrated energy system, we do know that ESI is much
broader than just building a smarter grid. By focusing on the
optimization of our entire energy system, new research in ESI
can increase efficiency, reliability, and performance while reducing cost and minimizing environmental impacts.
Looking ahead, we see ESI research examining the following
interconnected and evolving elements of our energy system:
92
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