Markets Energy

Utilities & Power Generation

Orbital offers a wide range of Engineering, Risk Mitigation, and Project Delivery services to the Utility & Power Generation industry. Our staff possesses decades of collective evaluation, engineering, and design experience in the area of power generation, including new coal and natural gas fired (simple and combined cycle) plant design, fuel conversion and repowering projects, major environmental retrofit work, and cogeneration/combined heat & power applications – both domestic and international. We aim to be the number one source for all of your Utility & Power Generation needs.

The following lists a few specialty areas in which Orbital Engineering possesses proven expertise:

Coal Combustion Residuals (CCR's)

The EPA in 2014 issued final regulations dealing with coal combustion residuals (CCRs). Focused on leakage and structural integrity of landfills and impoundments, it also pulls in alternative beneficial use, source recycling and reporting requirements. Orbital Engineering, Inc. ® has the expertise to assess your plant to this new regulation.
 

Landfills and Impoundments

Landfills and Impoundments

If you continue to use your landfills and impoundments, requirements for structural integrity, leakage and monitoring may apply.

Inactive facilities are not exempt. Existing sites may be required to be stabilized.

Third party landfill sites are not exempt.

 
Recycling Options

Recycling Options

If de-watering silos are used, excess water can be recycled back through filters and RO systems to meet water quality specifications for boiler make-up water, chemical injection dilution systems or back to the wet bottom ash system.

Recycling may necessitate the need for storage tanks to provide a source of water supply to the ash pumps.

 
Dry bottom Ash Stystems

Dry bottom Ash Stystems

Retrofitting with a dry bottom ash system can minimize the use of water and produce a dry end product for other uses. This includes:

  • Retention Berms
  • Road Base Material
  • Snow and Ice Traction Control
  • Concrete Based Materials
 

   CCR CHECKLIST

  • Dry Bottom Ash Systems
  • Piping Condition Assessments
  • Fugitive Dust Plans
  • Integrity Inspections
  • Record Keeping
  • Emergency Action Plans
  • Coal Pile Runoff Management
  • Water Management Study
  • FGD Water Treatment Systems
  • Concept Models
  • TIC Estimates
  • Project Development
  • Execution Engineering
  • Berm Integrity Assessment
  • Groundwater Extraction Wells
  • Groundwater Monitoring Wells
  • Closure Plans & Post Closure
  • Water and Mass Balance
  • De-Watering Silos and Systems
  • Off-site Trucking Logistics
  • Re-cycled Water Storage Tanks
  • Re-cycled Water Filtration Systems
  • Raw Water Settling Tanks
  • Reverse Osmosis Systems

 

Natural Gas Conversion

So what is holding back converting your smaller sized coal fire units to natural gas? Will low NOx burners be needed? Do the furnace controls need updating? Where is a suitable natural gas pipeline? Do you need a pressure reducing station? Will this pull-in any new regulations? Orbital Engineering, Inc. ® has the expertise to answer these questions.
 

Low No'x Burners

Low NOx Burners

Low NOx burners are used to burn the natural gas. Burner controls may need updating.

Air Pollution Control (APC) systems will need to be adjusted for the new fuel.

Furnace design should be checked since energy absorption will be different with natural gas. There will be minimal slag.

 
Where's the Pipeline

Where's The Pipline?

If the natural gas pipeline main is too far away or if there are environmental issues to work through, the economics may not work.

Suitable pipeline locations should be assessed and connection costs included in the project economics.

 
Pressure Reducing Station

Pressure Reducing Station

If your natural gas pressure is too high, a pressure reducing station may be necessary.

As shown to the right, these systems can be skid mounted to ease installation.

 

   NG CONVERSION CHECKLIST

  • Location of NG Main
  • Economics of NG Pipeline to the Plant
  • Environmental New Source Review
  • Gas Regulation Review
  • NFPA Regulation Review
  • Area Re-classification
  • Boiler Controls
  • Furnace Design
  • APC System Adjustments
  • Low NOx Burners
  • Gas Pressure Reducing Station
  • Inplant Gas Distribution Piping
  • Dual Fuel Capability
  • Conversion Economics
  • Concept Models
  • TIC Estimates
  • Project Development
  • Execution Engineering

 

Effluent Limitation Guidelines

So you thought CCRs was the end and now ELGs come along. It’s a one-two punch. Effective January of 2016, 40 CFR Part 423 are final rules dealing with pollutants discharged to surface waters. Focused on establishing limits on specific chemicals, it also pulls in limits on suspended solids. Are there exclusions, new technologies or other options? Orbital Engineering, Inc. ® has the expertise to assess your plant to this new regulation.
 

Landfills and Impoundments

Landfills and Impoundments

If your landfill or impoundment overflows to surface waters, you may now have more stringent limits on specific chemicals and TSS.

Monitoring wells may be required and more frequent condition assessments.

There are plant size exclusions and fuel type adjustments.

 
Effluent Processing

Effluent Processing

Fly and bottom ash water could be processed through settling tanks, filters and RO systems (see photo to the right) to meet re-cycle water quality specifications.

Processing systems may necessitate the need for grey water storage tanks.

Sludge disposal would be treated as a solid waste.

 
FGD Waste Biological Treatment

FGD Waste Biological Treatment

The new rules require that FGD streams be treated to the new effluent guidelines. This includes systems for mercury control.

The system shown to the right employs chemical precipitation and biological treatment technologies.

 

   ELG CHECKLIST

  • Berm Integrity Assessment
  • Groundwater Extraction Wells
  • Groundwater Monitoring Wells
  • Closure Plans & Post Closure
  • Water and Mass Balance
  • De-Watering Silos and Systems
  • Off-site Trucking Logistics
  • Grey Water Storage Tanks
  • Grey Water Filtration Systems
  • Grey Water Settling Tanks
  • Reverse Osmosis Systems
  • Dry Fly Ash Handling Systems
  • Equipment Sizing Verifications
  • Dry Bottom Ash Systems
  • FGD Effluent Treatment
  • Piping Condition Assessments
  • Concept Models
  • TIC Estimates
  • Project Development
  • Execution Engineering

 

Grid Reliability Starts At The Plant

Grid reliability has been the focus of many organizations such as PJM, et al. Recent weather events have shown that many power plants cannot sustain generation exposing large areas of the US vulnerable to a loss of power. New PJM guidelines have been suggested to increase plant reliability during these events. Orbital Engineering, Inc. ® has the expertise to assess your plant to these new guidelines.
 

Fuel Oil Storage

Fuel Oil Storage

Whether fuel oil is your primary fuel source or is your selected secondary fuel source, storage tank condition, capacity and delivery system need to be assessed.

On demand switchover to fuel oil may require a circulation system to a local day tank or back to the main storage tank.

Fuel oil delivery pump reliability and capacity should be verified.

 
Natural Gas Transition Vessel

Natural Gas Transition Vessel

Loss of natural gas as the primary fuel will most likely cause a unit or plant shutdown. Providing a transition natural gas storage vessel can assist in delaying the shutdown and additional time for bringing online the secondary fuel source.

 
Demineralized Water Storage

Demineralized Water Storage

For stand-alone operation, plant raw water supply may be at risk due to the same weather event.

Additional on-site storage of demineralized water may be needed for extended stand-alone operation. Demineralized water will be needed for CGT water injection, chemical dilution systems and steam plant make-up water.

 

   RELIABILITY CHECKLIST

  • Primary Fuel Dependencies
  • Secondary Fuel Selection
  • On-site Storage Assessment
  • Primary to Secondary Fuel Switchover
  • Fuel Oil Logistics
  • Railcar Unloading System
  • Site Flood Control
  • Demineralized Water Assessment
  • Condition Assessment Inspections
  • Fuel Oil Storage Tank Inspection
  • Natural Gas Transition Storage Vessels
  • Raw Water Reliability
  • Dual Fuel Capability
  • On Demand Fuel Oil Switching
  • Back-up Ash Disposal Methods
  • Stand-alone Operation Constraints
  • Safety Instrumented Systems
  • Environmental Controls Exemptions
  • Third Party Supplier Reliability Assessments
  • CGT Water Injection
  • Concept Models
  • TIC Estimates
  • Project Development
  • Execution Engineering

 

Planning For A Unit Retirement

Retiring an older coal fired unit is an economic decision. The cost to operate, maintain and update to changing environmental regulations exceed the projected profit. So what needs to be done? Are there risks? Should older systems be disconnect from the rest of the plant? Should retired equipment be removed or retired in-place? Orbital Engineering, Inc.® has the expertise to assess your plant to these questions.
 

Stacks

Stacks

Older stacks may be constructed of bolted connections and more brittle material. These stacks pose a risk to failure.

Should stack heaters be installed or should the stack be removed to a safe height.

What is the condition of the stack, supports and supporting structure?

 
Plant Freeze Protection

Plant Freeze Protection

Loss of heat from a boiler may expose areas of the plant to freezing temperatures.

Should an auxiliary boiler be installed or continue to operate the boiler is plant heating mode? Or, install an auxiliary boiler, unit heaters or heat tracing. Can the affected piping be removed and drained?

 
Material Handling

Material Handling

Many times the material handling flow of the plant needs revision to account for the unit being retired.

Tripper tailings, as an example, can build-up in coal bunkers that are retired. Moving the tripper end point to the correct location solves this issue.

 

   UNIT RETIREMENT CHECKLIST

  • Stack Condition Assessment
  • Stack Removal
  • Stack Heaters
  • Auxiliary Boilers
  • Piping Isolation
  • Electric Unit Heaters
  • Switchgear Isolation
  • Electrical Isolation
  • Control System Modifications
  • Selected Equipment Demolition
  • Boiler Natural Gas Re-firing
  • Coal Handling Modifications
  • Tripper Relocation
  • Dust Control Systems
  • Fire Protection Systems
  • Retire In-place Option Analysis
  • Electric Heat Tracing
  • Concept Models
  • TIC Estimates
  • Project Development
  • Execution Engineering

 


Other areas of service include wastewater treatment, air pollution control, structural inspections, storage tank, piping, and pressure vessel inspections, arc flash studies, fall protection solutions, bulk material handling and conveying, construction management and support, as well as project management and scheduling. Orbital's expanding inspection services include high-end data collection and analysis utilizing drones.

Our overall project design portfolio includes:
 
  • Coal Barge Unloading Facility
  • Coal Yard Retrofit for Sub-Bituminous Coal
  • New Control System and Tripper Automation
  • Gas Pipeline Design
  • Fuel Flexibility and Fuel Supply Certainty Studies
  • Boiler Pilot Burner Fuel System Upgrade
  • Boiler Feed Water System Upgrade
  • Boiler Air Heater Replacement Rigging
 
 
  • Steam Chest Replacement
  • Soot Blower Installation and Steam Supply Piping Design
  • High Pressure Service Water Upgrade
  • CCR and ELG Compliance Projects
  • Scrubber Upgrade Project & Construction Management
  • FGD Waste Settling Basin Design
  • Ash Pond Pump, Pit & Piping Design
  • Plant-Wide Lift Beam Analysis


Services

Orbital Engineering provides the full-service Engineering, Risk Mitigation, and Project Delivery experience and expertise of a large company - but with the flexibility, responsiveness, economy, and personal attention of a local entity.

Engineering
Risk Mitigation
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