What your colleagues were telling CCJ subscribers five, 10, 15, and 20 years ago
Five years ago
The 7F Users Group and CCJ collaborated on the first virtual user-group meeting conducted as a result of the global pandemic. It was the launchpad for more than 20 online user meetings facilitated by CCJ during that challenging three-year period.
The Combined Cycle Users Group (CCUG), a core building block of the Power Users’ network of O&M conferences and online forums serving owners and operators of gas turbines, addressed the following at its annual meeting: Damage to main-steam piping and hot-reheat valves, how to identify and mitigate compressor losses, compressor cleaning alternatives, corrosion under insulation, causes of performance degradation, impacts of drain issues and how to deal with them, SCR and AIG tuning, experience with film-forming substances, and much more.
Results of a comprehensive training program dispelled the notion that coal-plant personnel can’t be transformed into multi-skilled combined-cycle operators.
Turbine Logic, EPRI, and ENMAX Energy introduced a novel combustion-dynamics monitoring algorithm and case study to demonstrate the successful detection of a gas-turbine combustor fault which otherwise might have done extensive damage to both the combustor and hot-section components.
The Power Cycle Chemistry working group of the International Association for the Properties of Water and Steam (IAPWS) announced publication of the following Technical Guidance Documents, available free of charge on the organization’s website at www.iapws.org:
- “Application of film-forming substances (FFS) in industrial steam generators.”
- “Chemistry management in generator cooling water during operation and shutdown.”
- “Application of FFS in fossil, combined cycle, and biomass powerplants.”
- “Air in-leakage in steam/water cycles.”
A combined-cycle conference specific to the needs of Saudi Arabian users was hosted by the Ali A Tamimi Co in Dhahran. The meeting was coordinated by Keck Group International LLC, headed by former GE executives Richard Keck and Bob Johnston.
Depending on your plant’s power purchase agreement, adding peak-firing capability to simple- and/or combined-cycle gas turbines can provide significant economic benefit—provided the peak-fire capability is used strategically at times of high demand to avoid unnecessary maintenance.
10 years ago
Western Turbine Users Inc, led by Riverside (Calif) Public Utilities’ Generation Manager Chuck Casey, hosted its annual conference and vendor fair in Long Beach to commemorate 25 years of dedicated service to owners and operators of GE aeros (LM2500, LM5000, LM6000, and LMS100).
There was a special tribute to Jim Hinrichs, who retired as president of WTUI in 2008, having directed the organization for 17 years, some of those requiring full body armor in dealings with the OEM. Jim passed a few months before the celebratory meeting.
Among those contributing thousands of hours to assure the organization’s success during its first quarter century (and earlier, before incorporation): Wayne Kawamoto, Mike and Charlene Raaker, Jon Kimble, Mark Axford, Sal DellaVilla, Wayne Feragen, Jack and Gae Dow, Andrew Gundershaug, Brian Hulse, Jimmie Wooten, Frank Oldread, Dave Merritt, Bill Lewis, Steve Johnson, Ed Jackson, Alvin Boyd, Jim Bloomquist, John Baker, Jason King, Perry Leslie, Don Driskill, Bryan Atkisson, and so many others. Apologies to those not mentioned.
CTOTF™ celebrated four decades of service to the industry at its 2015 conference and trade show in Coeur d’Alene, Idaho. The formal affair was a fitting send-off for Wickey and Mike Elmo, who retired after managing the organization’s meetings and administrative affairs for 20 years. Their Puritan work ethic, business sense, warmth, and generosity were constants in a prolonged period of disruptive industry change, contributing very significantly to the group’s success.
The first 7FA.05 gas turbines began commercial operation at Xcel Energy’s Cherokee Generating Station, Denver, which connects to 17 transmission lines. The combined cycle incorporating these two GTs made use of a grey-market D11 GE steam turbine owned by the utility. CCJ editors had the pleasure of visiting site during commissioning.
Allied Power Group’s Aaron Frost, a well-respected metallurgical engineer and hot-parts repairs expert, tells attendees at CTOTF’s fall 2015 meeting that commercial realities may complicate 7EA first-stage repair techniques. He warned that some repair shops may be under pricing pressure, potentially affecting repair quality, and electing to fix components multiple times rather than educate the owner and operators on previous (and often substandard) repair methods. Caveat emptor!
Wind effects on the thermal performance of air-cooled condensers and fan reliability draw increased attention worldwide, prompting testing and analysis of alternative wind-screen designs.
High-voltage electrical emerged as a top interest area among gas-turbine users. One reason: The reliability and availability of the basic engine had improved to the point where other plant equipment—such as bus duct—was at least as likely to cause an outage.
Steam-turbine warming blankets grow in popularity as operating experience proves their ability to enable faster starts, and eliminate cold starts altogether, by preventing rotor-stress and differential-expansion issues. ARNOLD Group leads the industry with its products.
GE completes its acquisition of Alstom’s power and grid businesses.
Babcock & Wilcox Co publishes the 42nd edition of “Steam/Its Generation and Use,” considered by many the world’s most authoritative reference on boilers, dating back to 1875. Structural changes to the electric-power industry likely mean there will not be a 43rd edition, at least in the near term. CCJ Consulting Editor Steve Stultz was the editor of both the 41st and 42nd editions and provided guidance on the production of the most recent book, weighing in at eight pounds (3.6 kilos).
15 years ago
Clyde Maughan, renowned authority on electric generators, penned his first article for CCJ, “Input from monitoring, inspections, tests critical for maintenance planning,” launching an information service specific to the needs of gas-turbine owner/operators that continues to this day (see “Club 99 welcomes Clyde Maughan” elsewhere in this issue).
Capital Power installed the first STIG-equipped LM6000 at EF Oxnard. Designated the LM6000-PC CDP, the machine’s HTP first-stage nozzle area, shafts, and coupling adapter are different from standard Model PC components. The modified engine can replace workhorse LM5000 STIG 120 engines as they are retired.
NV Energy and CTOTF™ conducted a special workshop to help guide the electric power industry in identifying the challenges and unknowns associated with integrating renewables into the generation mix. CTOTF Chair Bob Kirn, then a senior manager at TVA, called for a national forum of stakeholders to address the impacts of “must take” renewables on electric-system operations. Speakers and panelists were among the industry’s thought leaders.
The city of Toledo’s (Ohio) Bay View combined-cycle cogeneration facility integrated state-of-the-art landfill-, digester-, and natural-gas fuel systems to provide the city waste-management services while producing up to 10 MW of electricity.
The 7F Users Group, led by Chairman Richard Clark of SCE Energy (now with GEV) and Sam Graham of Tenaska Virginia Generating Station (now its plant manager) developed what was believed at that time the organization’s “best 7F meeting ever.” Hot compressor topics included tip cracking of R0 and R1 blades, R0 dovetail cracking, clashing; cracking of piccolo pipes for the inlet-bleed-heat system; erosion attributed to the wash system; pinning of rocking stator vanes; loose shims; blade health monitoring; plus, plus, plus.
The vendor community contributed its expertise on modeling for troubleshooting HRSGs, collector-ring fires, water cooling to improve the reliability of fuel valves, optimization of GT operation, uncooled flame scanners, varnish solutions, PAG alternative to mineral oils, control-valve repairs, etc.
In the months following the 7F Users Group, the framework for Power Users Group was developed as a support system for 7F gas turbine users and quickly grew into a broader network addressing the needs of the entire power generation community.
Over time, the group expanded to include steam turbines, combined-cycle equipment, generators, and more. Today, Power Users supports eleven user groups and hosts industry-leading forums and conferences that promote collaboration, knowledge sharing, and operational excellence across technologies and fleets.
NV Energy’s generation department, led by Kevin Geraghty, and CCJ’s editorial staff, collaborated on the launch of the Air-Cooled Condenser Users Group and conducted the new organization’s first conference at the utility’s headquarters, focusing on steam-cycle chemistry and corrosion, performance issues, design, O&M, fans and gearboxes, and inspection.
20 years ago
Bob Anderson, Competitive Power Resources, recognized worldwide for his deep knowledge of heat-recovery steam generators, conducted a special workshop to alert plant owners and operators to challenges regarding the use of P91/T91 material for headers and tubes—including post-weld heat treatment, exposure to temperatures in the inter-critical region post production, control of properties through hardness testing, etc. Today Anderson co-chairs the HRSG Forum with Barry Dooley of Structural Integrity.
7F users focused their attention on compressor tip failures, latter-stage compressor failures, compressor clearances, early flameouts on shutdown, combustion dynamics, varnish mitigation, gas-valve reliability, hydrogen seal damage, and other issues.
The operational benefits of using JASC water-cooled liquid-fuel check valves in dual-fuel gas turbines were acknowledged based on experience at Valero Energy Corp’s Delaware City refinery.
Challenges in the 501F community with TXP controls came across loud and clear.
The dormant Frame 6 Users Group made a positive comeback with financial support from Foster Wheeler Martinez and technical leadership provided by Larry Flashberg of Saguaro Power and Jeff Gillis of ExxonMobil. Wickey and Mike Elmo organized the technical meetings and vendor fair.
The first 100,000-hr major inspections of V84.2 gas turbines conducted onsite by plant staff (with OEM oversite) were completed successfully at the Brooklyn Navy Yard cogen facility. Plant Manager Mike Brown shared the details of this landmark project with the industry.
Gas-side corrosion problems in HRSGs, borescope inspections, inspection and maintenance of air-cooled condensers, varnish issues, life management of GT parts, and gear maintenance were other hot topics at this time. CCJ
