Recent Projects

STEAM TURBINE GENERATOR CONTROLS

ICM Ethanol Plants

Nine near identical systems are installed in ethanol plants around the Midwest. The systems include controls and 4160 V utility paralleling switchgear for 2 MW backpressure steam turbines. Some of the plants also include a second high pressure turbine generator. This cogeneration systems generate a substantial portion of this ethanol plant's electricity and the exhaust steam is used for distillation. Control system includes an auxiliary control panel for monitoring and control that is located in the main plant control center. These are among the most energy-efficient ethanol plants in the country.

Simpson Tacoma Kraft, Tacoma, WA

This is a 65 MW double extraction turbine generator that uses 825,000 lbs/hr of 875 psig/825°F steam for cogeneration generation at a large pulp and paper mill. The boilers are fueled with waste wood and black liquor. Nearly all of the steam is used at one of the three extraction pressures for operating the paper making process. Because of the size, complexity and critical nature of this system the controls include both redundant PLCs and governor CPUs and extensive machinery monitoring, communications and integration with the customer's DCS. Controls include provisions for turbine governing, machinery monitoring, generator control and protection and synchronizing.

Salaha Methanol, Oman

Salaha Methanol is a large methanol plant on the Persian gulf. The plant produces all of its electric power with three paralleled 7 MW extraction turbine generators. Because of the critical nature and exceptional reliability required of the control system, the controls are based on Triconex triple redundant computers. Control system includes load sharing control, extraction pressure control, machinery monitoring, generator protection, synchronizing and extensive redundant communications.

Praxair, Richmond, CA

This 15 MW extraction/condensing turbine generator set uses steam produced by Praxair at a hydrogen plant connect with a ChevronTexaco refinery. This is a highly engineered control system that includes remote startup and control from the plant DCS and redundant PLC processors.

Huludao Nonferrous Metals, Huludao, China

Controls for a 10 MW extraction/condensing steam turbine that will allow this zinc and copper refiner to operate more efficiently by utilizing waste heat from the refining process to generate electricity. System includes complete turbine generator controls.

Olmstead County, MN

Controls for a 4.1 MW extraction/condensing turbine generator at a county municipal waste incinerator. Controls include a fully integrated control system for turbine control, generator control, vibration and temperature monitoring and full communications.

Erdenet Mine, Mongolia

Erdenet Mine is the largest copper mine in Asia. Sufficient electricity to operate the mine is not available so the mine installed two 2.5 MW condensing turbine generators which will utilize waste heat from the smelting process. System includes complete turbine generator controls.

ConocoPhillips, Billings, MT

This 1500 kW backpressure turbine generator set is installed at an oil refinery. The TG set replaced a steam pressure reducing valve enabling power to be generated with energy which was previously wasted. The main control panel is completely weatherized and is located outdoors in a very harsh climate.

City of New Haven, CT

This project is for a 750 kW condensing turbine generator set at a municipal sewerage incinerator. The project will enable the facility to utilize waste heat to generate electricity for the facility. Controls turbine generator controls, paralleling switchgear and also included the waste heat recovery boiler controls.

Ontario Health Science Center, London, ONT

Controls for a 2 MW, 13.8 kV steam turbine generator at a large teaching hospital. Machine control and monitoring information is passed to the plant DCS with a data communications link.

Enwave, Toronto, ONT

Two 5 MW condensing turbine generators to provide emergency power for the district cooling system pumps. Enwave supplies high reliability district heating and cooling for the city of Toronto and needed a way to assure that the chilled water pumps would continue to operate in the event of a utility power outage. The generators can also operate in parallel with the utility for peak shaving. Controls allow unattended remote startup and permit either turbine to operate alone or in parallel with the other turbine or with the utility.

Williams College, Williamstown, MA

Controls for a 4160 V utility paralleled 3 MW steam turbine, a future 2 MW engine driven emergency generator and a complete emergency power control system. Controls include using the steam turbine generator for campus-wide power factor control and utility import power control. Emergency power controls included auto-adaptive load shedding, load control for the emergency generator, emergency parallel operation of the steam turbine and diesel generator and automatic re-synchronization with utility power.

University of Connecticut, Storrs CT

Controls for 5 MW steam turbine which is part of a new combined cycle power plant for the campus. System operates in parallel with the utility and is also paralleled with the gas turbine generators during a utility outage. Controls are fully integrated into plant data communications network.

Amherst College, Amherst, MA

Controls for a 500 kW synchronous generator for this college heating plant. This is a combined cycle cogeneration plant and steam from a gas turbine waste heat recovery boiler passes through the steam turbine for heating the campus. Controls include full turbine generator controls with utility paralleling synchronizing.

Tema Oil Refinery, Tema, Ghana, Africa

Switchgear and controls for this 6.5 MW cogeneration system in Ghana's only crude oil refinery. This turbine generator system improves plant efficiency and reduces the demand for utility power. Exhaust steam is used in the oil refining process.

Lockheed-Martin, Owego, NY

Controls for a 668 kW turbine generator with an induction generator at 480 volts. Exhaust steam is used for building heat at this large manufacturing and data center.

Abener Baja California Sur, Mexico

Switchgear and controls for a 2 MW steam turbine generator which is part of a combined cycle power plant operated by the Mexican central utility, Comisión Federal de Electricidad (CFE). Switchgear includes a 4000 amp, 480 V circuit breaker and complete paralleling controls.

CODANA, Guayaquil, Ecuador

Controls for a 700 kW steam turbine cogeneration system at a cooperative alcohol distillery. Exhaust steam is used in the distillation process. The distillery makes high quality pure alcohol for beverage and industrial use.

Greensburg Thermal, Greensburg, PA

Controls and switchgear for an innovative cogeneration power plant that includes a 500 kW backpressure synchronous turbine generator and a 260 kW induction condensing unit. This facility provides steam and electricity to a large prison using waste coal as fuel. Controls are connected to the central control room using Windows OPC.

Central Minnesota Ethanol Coop, Little Falls, MN

This system includes turbine generator controls and paralleling switchgear for this 1 MW cogeneration system with a backpressure turbine and 480 volt generator. Full communications with the plant's Foxboro DCS is included.

Southern Methodist University, Dallas, TX

Controls and 480 V utility paralleling switchgear for a 530 kW backpressure steam turbine. Exhaust steam is used for campus heating. Control system includes an auxiliary control panel for monitoring and control that is located in the main plant control center.

Idaho State University, Pocatello, ID

Controls and switchgear for a 120 kW backpressure steam turbine. This system was originally designed to power the central heating plant in isolation form the utility and was subsequently retro-fitted to allow utility parallel operation. Exhaust steam is used for campus heating. It includes automatic synchronizing controls for bumpless transfer between generator and utility power.

Clinton Correctional Facility, Dannemora, NY

Two 1500 kW cogeneration steam turbine generators provide electricity and steam to the prison. The TG sets operate in parallel with a large diesel engine to power an emergency bus. Loads are switched to the emergency bus even when utility power is present in order to reduce costs. Exhaust steam from the turbines is used to provide heat and hot water.

Northern Alberta Institute of Technology, Edmonton, Alberta

Controls for a very small turbine generator set to be used for training. The system included a complete, modern control system to replace an out dated TG set.

Northern Nevada Correctional Center

A 1000 kW, 12,470 V condensing turbine generator produces electricity for this correctional facility. The steam is provided by an innovative biomass boiler

Vassar College, Poughkeepsie, NY

The college originally installed a TG set in 1984 and recently installed a second induction generator set to bring their total capacity to 1000 kW. The new control system and switchgear controls both TG sets including sequencing controls to take maximum advantage of varying steam flows. The controls also include a provision for varying the exhaust pressure in response to ambient temperature changes.

SDS Lumber, Bingen, WA

A 1,100 kW steam turbine cogeneration system was installed to supplement this forest products company's existing electric generating capability. High pressure steam is produced in a biomass boiler and turbine exhaust steam is use for lumber drying.

Victorville Municipal Utility, Victorville, CA

Controls for a 5 MW, 4160 volt condensing steam turbine generator which is part of a combined cycle cogeneration plant. Steam is produced with waste heat from gas turbines. The system is designed to operate both in isolation from the grid and in parallel. Controls feature dual, redundant processors and full communications.

OTHER PROJECTS

Massachusetts Water Resources Authority, Boston, MA

Controls for the emergency flood water pumps for Boston. These seven diesel engine driven pumps must work in the event of a major storm or the city will flood. This is a highly engineered project that required very high reliability and security.

Hartford Fire Insurance Co., Hartford, CT

Engine generator controls and 4160 V switchgear. Controls and switchgear permit the 750 kW natural gas engine to independently power central chillers or, during a utility outage, function as an emergency power generator. System includes an engine room panel and a main engine and switchgear control panel linked by data communications.

United Illuminating, Sheldon CT

This is a continuing project building custom controls for this electric utility's substation upgrades.

Westfield Gas and Electric, Westfield, MA

Two, 300 kW utility parallel engine generators running on landfill gas. The facility is unattended and is run by fiber-optic communications link to a remote central control facility. Controls include the ability to automatically modulate engine output based on methane content of the gas or in power output control mode with a natural gas blend..

Massachusetts Department of Corrections

Natural gas fired engine generators for cogeneration at two Massachusetts prisons: Norfolk and Cedar Junction. The 600 kW generators operate in parallel with the utility and provide steam for the prisons for space heating and hot water.

Ecotarium, Worcester, MA

New engine controls and 480 V switchgear for an off-the-grid natural history museum. The museum generates all its own power with two 350 kW natural gas engines and recovers engine and exhaust heat for plant heating and cooling. Project involved new engine controls and main switchgear for the museum. The entire system can be monitored and controlled via the campus computer network or remotely via the internet.