The document summarizes various projects completed by a thermal power plant consulting firm, including: 1) resolving coal feeding issues that caused abnormal pressure readings at a 20MWe plant; 2) coordinating the dismantling and relocation of equipment from a 90MWe plant in Texas to Chile; 3) performing reverse engineering to support the removal of a 1950s-era 10MWe steam turbine generator set. The document also describes projects involving: emission controls, heat exchangers, process/control systems, and cogeneration systems.

1. Thermal Power Plants
• Reviewed client 20MWe plant operations that had symptoms of undersized induced draft fan. Testing
determined that while the ID fan was correctly sized, coal feeding to traveling grate boiler was
stratified, resulting in asymmetrical distribution of coal on the grate. This produced a high-pressure
area which was in close proximity to the pressure transmitter that was the process variable for the ID
fan. Client installed a $250 distributor plate as recommended and problem is largely solved (it was
also recommended that client procure consistent spec coal).
• Acted as primary liaison for joint venture of several large energy corporations on the dismantling of a
90 MWe steam turbine power plant in Texas. Coordinated efforts of the boiler / structural engineering
firms and dismantlers to assure equipment selected for refurbishment / reinstall at another plant in
northern Chile was optimized. Design of new processes included hydraulic design of seawater-
cooled condenser / cooling system consisting of a pump station, located 1.5 km away and
approximately 80 meters lower than the proposed plant, a condenser cooling circuit energy recovery
turbine generation station, condenser water thermal dissipation system to comply with World Bank
Temperatire Different limits, and redesign of the steam turbine cooling system and related design
tasks.
• Provided reverse engineering / design services in support of 10 MWe steam turbine generator set
removal from a heavy equipment manufacturing facility in Iowa. Created foundation and equipment
drawings from a combination of measurements and archives of the 1950’s-era equipment. Provided
calculation and other design services in the application of the steam turbine generator with new
circulating water condenser temperature, inlet steam pressure and temperature and extraction flow
rates. In reviewing the data, it was determined that steam would start to condense several stages
before the last stage and as a result, client was able to specify a protective coating in the overhaul
process to reduce wear / erosion damage.
Emission Controls
• Investigated client issue with three Caterpillar spark-ignited engines. After reviewing a high ammonia
slip issue associated with two of the engines, it was determined that the atomizers were not
functioning properly in high exhaust temperatures and that the mixing length was not adequate for
complete pyrolysis of the aqueous urea solution. Designed an air-cooled replacement atomizer /
lance and performed computation fluid dynamic study (CFD) to analyze the pyrolysis mixing tube.
Which revealed that the unusually short mixing tube was stratified. Designed and supplied a
replacement counter-flow mixer which, in conjunction with the air-cooled atomizing lance, resulted in
ammonia slip that was within customer specifications.
• Designed and developed a demonstration unit that would allow diesel particulate filters to be
continuously regenerated on rubber-tired, container moving cranes. The successful application was
an electrically-fired exhaust heater with integrated catalyst and associated controls. Demonstration
was a success, exceeding durability expectations.
Heat Exchangers
• Client requested taking original designs and tooling for the manufacture of double-walled heat
exchangers used to cool engine-driven flood water pumps with process water and generate new
designs and processes that would enable tube sheets and baffle plates to be produced on computer
numeric control (CNC) machines. Project work was extended to include evaluation of several of the
open channel cooler designs to assess their actual effectiveness. Several CFD studies were
performed to deterine tube velocities under different conditions in a simulated channel and also to
validate the heat transfer coefficients used in the sizing tools.
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2. • Designed a cooler for spark-ignited gas engine to cool the exhaust to 600˚F to facilitate
demonstration of an Organic Rankine Cycle system. Performed computational studies to optimize
the design and verify heat transfer and pressure drop in the exhaust gas cooler.
Process / Process Control
• Designed and supplied variable frequency drive (VFD) retrofit for an existing multistage centrifugal
blower used at site to aerate incoming waste-water stream. Design included VFD panel and
reprogramming of existing controls to allow blower to take advantage of increased operating range
while avoiding surge at the low end and preventing motor overload at the high end.
• Designed and supplied supervisory control system and control equipment used in production of
pipeline-quality natural gas from landfill gas. System included five remote I/O panels, one main
control panel, interface with three compressors, two chillers and a Wonderware-based operator
interface (provided by others).
CoGeneration
• Created design to replace existing fuel treatment system and two of three containerized generator
sets with one 630 kWe generator set within a building that had space for a second 630 kWe
generator set. Under extremely limiting site constraints, created a design that provided improved
access to the new Class I, Division I fuel treatment system, a moment frame building with upper
mezzanine for jacket water and auxiliary radiator and interior mezzanine for electric switchgear and
controls. All modeling was done in Solid works including all cogeneration pipe work andunderground
conduit.
• Provided redesign of a biogas cogeneration system. After analysis of the existing system, entire
cooling / heat rejection system and supporting controls were replaced. System now operates within
engine manufacturer’s specifications and with improved reliability.
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