Projects

OIL AND CHEMICAL INDUSTRY

Mosaic, Mulberry, FL
This 30 MW cogeneration system uses steam that is produced during the processing of phosphate rock into phosphate fertilizer. The 300,000 pph of 125 psig/ 750°F steam is produced entirely without using any fossil fuels. The sophisticated control system includes special features to protect it from a corrosive atmosphere.
Yanbu Export Refinery, Saudi Arabia
The Yanbu refinery is a 400,000 barrel-per-day, full-conversion refinery. This 10.5 MW controlled extraction turbine generator normally runs in parallel with utility power and is controlled by the demand for 150 psig extraction steam. Upon loss of utility power the system supplies emergency power for critical loads, either alone or in parallel with the plant’s emergency diesel generators. Due to the critical nature of this system, the controls are based on Triconex hardware.
ConocoPhillips, Billings, MT
This 1.5 MW backpressure turbine generator set is installed at a ConocoPhillips oil refinery. The TG set replaced a steam pressure reducing valve enabling power to be generated with energy which was previously wasted. The main turbine generation control panel is completely weatherized and is located outdoors in a very harsh climate.
Jubail Export Refinery, Jubail, Saudi Arabia
The Jubail project is a new state-of-the-art refinery being built by a joint venture between Saudi Aramco and Total S.A. Two, 26 MW extraction-condensing turbines will provide supplemental power during normal operation and full backup power in the event of a loss of utility power. The controls are based on Triconex controllers for triple redundancy (TMR) for the utmost in reliability. During normal operation the turbines will provide intermediate pressure steam through the controlled extraction ports. Upon loss of utility power, the controls will automatically switch to frequency control to seamlessly support all plant emergency operations without any interruption in power supply.
Pertamina, Dumai, Indonesia
The Pertamina oil refinery upgraded their facilities to include a new 14 MW extraction steam turbine generator to improve the overall efficiency of the plant. The controls utilize triple modular redundant (TMR) Triconex computers for ultra-high reliability.
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.
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.
Suncor Voyageur, Ft McMurray, Alberta, Canada
This 12 MW cogeneration system is part of a major upgrade of the Suncor facilities at the Athabasca oil sands. The double admission steam turbine is used to balance the steam system and the generator produces power in parallel with the power grid. The controls meet the all API requirements and the strict Suncor engineering standards.
Tema Oil Refinery, Tema, Ghana, Africa
Power generation controls and medium voltage switchgear 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.
Tesoro Refinery, Los Angles, CA
The 18 MW cogeneration system is part of a major upgrade of the Los Angles refinery designed to bring the plant up to the latest environmental standards and improve energy efficiency. The extraction steam turbine utilizes steam produced by the exhaust of a gas turbine, thereby creating a highly efficient combined cycle power plant with multiple parallel generators. The control system is based on aTriconex TMR controller for high reliability.

FOREST PRODUCTS

Conifex, Mackenzie, BC, Canada
High pressure steam for this 36 MW extraction condensing steam turbine generator is produced in a new biofuel boiler fired with wood-waste from a large sawmill complex in interior British Columbia. Extraction steam is used for the company’s lumber dry kilns. The turbine generator is expected to produce 230 GWh annually to power the sawmill complex with surplus power being sold to BC Hydro. The biofuel project was an important component of capital investment program that allowed the company to re-start the mill which had been idled by the previous owners. Controls include the latest rotor stress monitoring for fully automatic warm-up and start.
Fibrek, St. Felicien, QC, Canada
This new 10 MW cogeneration system adds to the NBSK pulp mill’s power production capacity enabling the mill to generate all its own power and sell surplus to Hydro Quebec. The controls include many advanced features, with all operator interface screens in both French and English.
SDS Lumber, Bingen, WA
A 1.1 MW 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.
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.
Weyerhaeuser, Grande Prairie, AL, Canada
The Weyerhaeuser Grand Prairie integrated pulp mill provides 670,000 lbs/hr of steam at 1,500 psig/ 950°F steam from its wood waste and black liquor boilers to this 49 MW extraction-condensing cogeneration steam turbine. The high reliability controls include redundant Allen-Bradley ControlLogix processors and redundant Basler excitation controls. The system also includes a skid-mounted intelligent terminal box with remote I/O to greatly reduce field wiring.

ETHANOL

Illinois River Energy, Rochelle, IL
Illinois River Energy produces 100,000 gallons of year of fuel ethanol using local corn. The plant was originally designed to accommodate a turbine generator but actual installation was delayed until it became clear that the additional efficiency gain by a 3 MW adding cogeneration was essential to the plant’s continued profitability. The system includes a highly automated control system.
Central Minnesota Ethanol Coop, Little Falls, MN
This system includes turbine generator controls and paralleling switchgear for a 1 MW cogeneration system with a backpressure turbine and 480 volt generator. Full communications with the plant's Foxboro DCS is included.
ICM Ethanol Plants
Nine near identical cogeneration systems are installed in ethanol plants around the Midwest US. 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. These cogeneration systems generate a substantial portion of the ethanol plants' electricity and the exhaust steam is used for distillation. Complete steam turbine generator control systems are provided including auxiliary control panels for monitoring and control from the main plant control center. These are among the most energy-efficient ethanol plants in the country.
Southeast Iowa Renewable Energy, Council Bluffs, IA
This ethanol plant is located about a mile from a large MidAmerican Energy coal-fired utility power plant. The ethanol plant owners installed a 6 MW cogeneration steam turbine generator at the utility power plant. Exhaust steam from the cogeneration system will be sent by pipeline to the ethanol plant. Complete generation control system enables the power plant operators to operate the cogeneration system and the ethanol plant operators to monitor it via a fiber optic communications link.

MINING

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 turbines with parallel generators which will utilize waste heat from the smelting process. System includes complete turbine generator controls.
Huludao Nonferrous Metals, Huludao, China
Power generation 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.
Yunnan Tin, Yunnan, China
Power generation controls for a 10 MW extraction/condensing steam turbine that will allow this tin refiner to operate more efficiently by utilizing waste heat from the refining process to generate electricity. System includes complete turbine generator controls.

COMBINED CYCLE POWER PLANTS

Bis Enerji, Bursa, Turkey
This merchant power plant expanded its operation to include a new 30 MW steam turbine for combined cycle operation. The steam turbine controls allow for sophisticated sliding pressure control and include rotor stress monitoring for fully automatic warm-up and start controls. ontrol system uses Triconex TMR hardware for the utmost in reliability.
Palmet, Thrace, Turkey
This 14 MW steam turbine generator is part of an independent 60 MW high efficiency combined cycle power plant built by Delta Enerji, a subsidiary of the Palmet Group to produce power for the national electricity grid. The system utilizes an air-cooled condenser to further reduce environmental impact.
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.
Palmet, Thrace, Turkey
This 14 MW steam turbine generator is part of an independent 60 MW high efficiency combined cycle power plant built by Delta Enerji, a subsidiary of the Palmet Group to produce power for the national electricity grid. The system utilizes an air-cooled condenser to further reduce environmental impact.

OTHER INDUSTRY

EnergyWorks – BioPower, Gettysburg, PA
EnergyWorks installed this 3.3 MW steam turbine to utilize heat produced by the gasification of chicken manure from the 5 million hens at this large egg production complex. The gasification process eliminates the nitrogen and phosphorus pollution from this waste that had been a significant source of water pollution to Chesapeake Bay. The process also annually produces a mineral byproduct that can be used for fertilizer without producing water pollution.
CODANA, Guayaquil, Ecuador
Power generation 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.
Dow Chemical
This 150 kW induction turbine generator is installed in a research facility to prove the feasibility of small cogeneration systems.
Engineered Materials Solutions, Attleboro, MA
EMS converted a steam turbine driven air compressor to an induction generator that produces 350 kW to offset utility power purchases. The retrofit includes a complete new control system and 480V switchgear.
J. Wray & Nephew, Nassau Valley, Jamaica
Rum has been produced at the Appleton Estate since at least 1749 and this cogeneration system is part of J. Wray & Nephew's effort to incorporate the latest green technology into their rum distilling operation. The 1.6 MW power generation control system includes controls for the steam turbine and generator.
Kim Hock Corporation, Singapore
Kim Hock is a large waste processing and recycling facility. Local utility lines were inadequate to support the requirements of the very large motor for a new metal shredder that the company is installing. As a result the company installed a new biomass boiler and a 10 MW steam turbine generator to power the shredder. Controls were specially adapted to be able to accommodate large swings in power demand.
Lockheed-Martin, Owego, NY
Turbine 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.

DISTRICT HEATING AND COOLING

Citizens Thermal, Indianapolis, IN
Citizens Thermal is second largest district energy supplier in the US and the two, 1.5 MW backpressure steam turbine generators improve plant efficiency by producing electricity with the same steam they use for heating buildings in downtown Indianapolis. The state-of-the-art generation control system includes complete machinery monitoring and ability to remotely operate and monitor the turbine generators.
Enwave, Toronto, ON, Canada
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.
Sacramento Central Utility Plant, Sacramento, CA
The Sacramento Central Utility Plant is a district heating and cooling facility. This 2.9 MW steam turbine is designed to supply supplemental power during utility brownouts or during utility blackouts when it will parallel with an emergency power diesel engine generator. System includes complete turbine generator controls.

INSTITUTIONAL

Food and Drug Administration, Silver Springs, MD
This is a 5 MW extraction-condensing turbine generator providing power to the new FDA Headquarters campus as part of a large combined heat and power (CHP) plant. High pressure steam (650 psig/ 750° F) from gas turbines is reduced to 20 psig for heating the campus while the condensing section allows significantly more power production for load balancing.
University of Massachusetts, Amherst, MA
The new Central Heating Plant is a highly efficient combined-cycle cogeneration facility that includes combustion turbines, heat recovery boilers and a backpressure steam turbine. The new steam turbine uses 625 psig/ 740°F steam from the heat recovery boilers and packaged boilers reduced to 200 psig for use in the heating plant to make 2.1 MW.
Veterans Administration
VA hospitals in White River Junction, VT, Chillicothe, OH, and Canandaigua, NY installed 250-500 kW steam turbine generators in conjunction with biomass boilers to supply Combine Heat and Power (CHP) for the hospitals. These systems met strict government specifications to assure durability and long term performance.

The Battle Creek, MI VA Hospital is an unusual application. The system includes a single stage backpressure turbine and a small multistage condensing turbine, all on a common shaft with a reduction gear and generator with a total output of about 2.2 MW. This solution was significantly more cost effective than an extraction turbine in this size range. There is a single, fully integrated control system for both turbines and the generator. The system uses steam from a biomass boiler and is capable of operating both in parallel with the local utility and in isolation during power emergencies.
Amherst College, Amherst, MA
Generator and turbine 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.
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.
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.
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.
Northern Alberta Institute of Technology, Edmonton, AB, Canada
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, Carson City, NV
A 1 MW, 12,470 V condensing turbine generator produces electricity for this correctional facility. The steam is provided by an innovative biomass boiler
Ontario Health Science Center, London, ON, Canada
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.
Oregon State University, Corvallis, OR
This steam turbine cogeneration system provides steam and 1 MW of electric power to the university campus. The generation controls are designed to be rugged, reliable and easy to use.
SCI Laurel Highlands, Somerset, PA
Power generation controls for a 500 kW induction cogeneration system at a Pennsylvania prison. Steam is used for heat and hot water. The electricity from the utility parallel generator offsets electricity purchases.
Southern Methodist University, Dallas, TX
Controls and 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.
University of Connecticut, Storrs CT
Power generation 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.
University of Cincinnati, Cincinnati, OH
This system includes controls for a 1.4 MW cogeneration system with an induction generator. Exhaust steam from the turbine is used to heat the college campus. The control system includes complete turbine controls and a 5 kV contactor.
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.
Williams College, Williamstown, MA
Generator and turbine 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.

MUNICIPAL

Barron County Waste-to-Energy Facility, Barron, WI
This is a 1,750 kW condensing turbine installed at a municipal incinerator for power generation and steam system balancing. In addition to controls for the new turbine, the project includes also upgrades to controls for an existing backpressure turbine and new service entrance switchgear.
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. Control system includes turbine generator controls, paralleling switchgear and also included the waste heat recovery boiler controls.
Klickitat Public Utility District, Roosevelt, WA
This 6 MW steam turbine generator is part of a combined cycle power plant that includes two combustion turbines and operates on landfill gas. Controls include a fully integrated control system for turbine control, generator control, vibration and temperature monitoring and full communications.
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.

ENGINE PROJECTS

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.
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.
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.
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.
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..