Power Market

Coal
PowerMarkets_2

Power Market

Utility-Scale Plant & Distributed Generation Facility Performance Testing & Evaluation Services.

Plant & Facility (Contractual Acceptance or Routine Testing & Improvement).

Power Output • Heat Rate • Capacity • Efficiency • Thermal Cycle Analysis Reliability • Availability • Ramp Rate • Noise Tests • Water/Steam Consumption Cycle Leakage Studies (exterior and/or internal losses • Capability Tests • Auxiliary System Load • DCS/ Response Analysis • Control and Instrumentation Adequacy Assessment

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Additional Tests

 

  • Evaluation of the effectiveness of any performance package such as heat rate monitors (visualization of operator controllable losses)
  • Evaluation of DCS and controls installation for long-term reliability (redundant air conditioning) building access control, ability to maintain cleanliness, ergonomics.
  • Evaluation of network equipment area for environmental, security, and ergonomics.
  • Evaluation of installed reliability of the field electrical conduit and flex fittings.
  • Evaluation of equipment tagging and whether it is easily understood in an emergency
  • On-site Calibration of permanent plant instruments (pressure/temperature/flow/flue gas composition)
  • Review of adequacy and organization of technical documentation
  • Review of backlog of action items left from construction
  • Review of operation procedures provided by OEM
  • Review of recommended parts lists and parts provided
  • Review of parts handling and management
  • Review of shops and tools available on site
  • Review of hazardous waste disposal methods and management

Component Testing & Evaluation

Fired Equipment

 

  • Boiler Efficiency
  • Boiler Capacity
  • Combustion gas constituency and temperature profile analysis
  • Review of recommended testing program
  • Flame Camera (video & still) study of burner flame patterns
  • Combustion air flow distribution and flame quality analysis
  • Combustion tuning of burners (using the above services)
  • Flue Gas Pressure Drop measurement and analysis
  • Air Side Pressure Drop measurement and analysis
  • Water/Steam Pressure Drop measurement and analysis
  • Air Flow Measurement and Profile studies and in situ duct meter calibrations
  • Air and Gas Temperature Profile studies
  • Boiler Air In Leakage Assessment (IR and/or He methods) [Casing/ducts/expansion joints/seals/doors/etc.]
  • Desuperheating Spray flow capacity measurement and adequacy analysis
  • Ultrasonic Thickness Testing surveys of boiler structural materials and tubes
  • Boiler Mechanical Systems Visual Inspection with photographic documentation (mills/burners/fans/pipe supports/drums/ boiler internals, etc.)
  • Boiler Mechanical and Electrical Systems IR surveys with photographic documentation
  • Boiler Insulation Systems Visual Inspection with IR photographic documentation
  • In Situ Safety Valve Relief Capacity/Rate testing
Steam / Water Cycle Equipment

 

  • Steam Turbine Power Output
  • Steam Turbine Cycle Heat Rate
  • Steam Turbine Capacity
  • Steam Turbine Enthalpy Drop
  • Steam Turbine Internal Leakage Rate
  • Fluid Flow Measurement studies and in situ meter calibrations (using either or both permanent plant meters and strap on ultrasonic meters or pitot tubes)
  • Water treatment and chemistry review and assessment (instrument, data quality, sampling systems)
  • Pump Capacity/Efficiency Testing
Bulk Material Handling and Emission Control

 

  • SCR Effectiveness testing and tuning
  • FGD testing and tuning
  • Coal Mill Capacity/Fineness/Air & Coal Distribution testing as well as distribution balancing if plant hardware supports it.
  • Bulk Material Handling Systems Testing (fuel/sorbents/ash)
  • Code-level bulk material sampling for off-site laboratory analysis (fuel/sorbents/ash)
  • Soot Blower Effectiveness & Optimization
Heat Conversion Equipment

 

  • Air Heater Leakage quantification testing per ASME Codes
  • Air Heater Heat Transfer capacity testing per ASME Codes
  • Condenser (Cleanliness, Efficiency, Capacity)
  • Cooling Tower (Noise, Thermal, Plume, and Drift)
  • Heater and Heater Train performance (Temp Rise, TTD, DCA, Efficiency, Capacity)
  • Auxiliary Equipment
  • SCR Effectiveness testing and tuning
  • FD/PA/ID or other Fans capacity/efficiency testing per ASME Codes
  • Baseline evaluations for air removal pumps and air compressors
  • Circulation Pump
  • Feedwater Pump
  • Inlet Conditioning (Steam Heater)
  • Instrument installation evaluations for access, calibration, weather exposure, saltwater mist exposure, and maintainability
  • Flow Nozzle, Orifice, or other primary flow element evaluation and qualification
  • Dye dilution testing of water systems that have no flow elements or to establish baselines and element accuracies
Miscellaneous

 

  • Instrument piping and tubing evaluations for long term reliability (how it’s mounted and secured)
  • All classifications for instrument and electrical housings (NEMA or equal and how applied)
  • Evaluation of the effectiveness of any performance package such as heat rate monitors (visualization of operator controllable losses)
  • Evaluation of DCS and controls installation for long-term reliability (redundant air conditioning) building access control, ability to maintain cleanliness, ergonomics.
  • Evaluation of network equipment area for environmental, security, and ergonomics.
  • Evaluation of installed reliability of the field electrical conduit and flex fittings.
  • Evaluation of equipment tagging and whether it is easily understood in an emergency
  • Review of adequacy and organization of technical documentation
  • Review of backlog of action items left from construction
  • Review of operation procedures provided by OEM
  • Review of recommended parts lists and parts provided
  • Review of parts handling and management
  • Review of shops and tools available on site
  • Review of hazardous waste disposal methods and management

McHale provides performance testing for the contract procurement of coal-based plants and components. Specifically, our performance testing is designed to verify contractual guarantees at the level of confidence expected by the parties of the contractual acceptance test and to ensure the successful closure of the project.

McHale also provides benchmark status performance testing to our clients to ensure that plant performance has not degraded to unacceptable levels and to identify where program improvements can be made to improve efficiency, output, and economic performance. McHale can provide the required performance testing and evaluation services in order to verify the performance of individual units and multiple facilities to establish confident benchmarks for planning optimized coordinated plant operation and outage maintenance projects.

Technical Advisor

McHale has technical advisors that are experienced in serving as “owner’s engineers” that identify, quantify, and mitigate risks associated with plant performance for our clients. We have assisted project owners, financial institutions, and legal counsel with advising/consulting services and performance audits. McHale Advisors understand the importance of reviewing proposed designs, developing strong contractual language, construction monitoring, and witnessing key tests to ensure performance guarantees are achieved with confidence to ensure the success of a project.

Test Code Specialist

McHale is recognized throughout the power generation market as a specialized engineering group that provides superior testing and plant performance improvement services. McHale is actively involved and versed in the ASME Test codes and has extensive experience conducting tests utilizing international test codes and standards:

ASME PTC 46 – Overall Plant Performance

ASME PTC 6 – Steam Turbines

DIN-1943 – Thermal acceptance tests of steam turbines

BN EN 60953 – Rules for steam turbine thermal acceptance tests

EN 12952-15 – Water-tube boilers and auxiliary installations

ASME PTC 4 – Fired Steam Generators

DIN 1942 – Acceptance Test Code for Steam Generators

GB 10184-88 – Performance Test Code for Utility Boiler

ASME PTC 4.2- Coal Pulverizes

ASME PTC 4.3- Air Heaters

ASME PTC 11 Fans

ASME PTC 19.1 – Test Uncertainty

ASME PTC 19.22 – Data Acquisition Systems

ASME PTC 19.5 – Flow Measurement

ASME PTC 12.1 – Closed Feedwater Heaters

ASME PTC 12.2 – Steam Surface Condenser

ASME PTC 12.3 – Deaerators

PTC 25 – Pressure Relief Devices

ASME PTC 36 Measurement of Industrial Sound

CTI ATC-105 – Acceptance Test Code for Water Cooling Towers

CTI ATC-140 – Isokinetic Drift Test Code

CTI ATC-150 – Acceptance Test Procedure for Wet Dry Plume Abatement Cooling Towers

We are experienced in how to properly apply these codes and other international standards to successfully demonstrate contractual acceptance with the level of confidence for lenders, owners, OEM’s and EPC’s demand.

Qualified & Impartial Test Personnel

McHale has worked with various EPC contractors, plant owners, and manufacturers throughout the power industry. The McHale team is known for quick response time, expertise in plant and component issues, and accurate results.

Code Compliant & Calibrated Test Equipment

McHale has a complement of test equipment designed to augment the standard built-in coal-fired power plant or facility instrumentation to improve the uncertainty of performance testing necessary to meet the desired confidence for contractual acceptance and provision of information for the long-term financial projections of the assets.

  • Pressure and Differential Pressure Transmitters
  • Ambient Temperature, Humidity, and Wind Sensors
  • Three-Phase Revenue Quality Power Meters
  • Three-Phase Power Quality Monitors
  • Exhaust Gas, Combustion Air, Water, Steam, and High Temperature
  • Clamp-on Ultrasonic Flow Meters
  • Clamp-on Temperature Sensors
  • Infrared Temperature Imaging
  • Flame Imaging Cameras
  • Coal Fineness Equipment
  • Fuel/Ash Thief Probes and Isokinetic Sampling
  • High-Velocity Thermocouple (HVT) Probes
  • Emissions Analyzers
  • Steam Calorimeters
  • Dye Dilution Equipment
  • Mobile Data Loggers

Type S, 3-Hole, and 5-Hole Probe Pitot Tubes