CGTA’s years of experience have given them extensive knowledge of mechanical and electrical equipment operation in the power and utility industry. This experience has been invaluable and is evidenced with the long standing and continuous relationships that CGTA maintains with its clients.

CGTA’s consulting engineering services includes front end studies, detailed engineering, major and minor equipment procurement, construction designs and specifications, construction supervision assistance and commissioning and ongoing operations support. The following highlights recent projects:

Full consulting engineering service to Power and Utility Plants

• Behind-the-meter 8 MW GTG Cogeneration Project. The project received OPA PSUI financial assistance and was completed in the 1st quarter of 2017. Highlights include:
  • Preparation of mechanical, piping, civil, structural, electrical, instrumentation and control specification and drawing packages.
  • Highly fired 140,000 lb/hr HRSG.
  • Auto-islanding.
  • Auto-islanding.
• Behind-the-meter rental natural gensets for peak shaving. Highlights include:
  • Preparation of mechanical, piping, civil, structural, electrical, instrumentation and control specification and drawing packages.
  • Rental modular NG gensets complete with individual selective catalytic reduction (SCR) units and urea/compressed air injection systems.
  • IESO and Hydro One submission.
  • Automatic minimum import controls.
  • Commissioning and testing.
• Behind-the-meter self-generation power plant, preparation of detailed statement of work specifications and Lead Owner’s Engineer during project execution phases.
  • Study included simple cycle, cogeneration and combined cycle configurations for natural gas reciprocating engines rated between 4 and 12 MW each and gas turbine generators between 8 to 40 MW each and with combined power plant outputs between 12 MW and 110 MW.
  • Study led to implementation of behind the meter power plant with CGTA providing preparation of detailed Statement of Work Specifications as part of the Turn-key EPC Specifications and Lead Owner’s Engineer during the project execution phases.
• Full service detailed engineering, procurement, construction designs and specifications, construction supervision and commissioning of a behind-the-meter 8 MW Cogeneration Project. The project received OPA PSUI financial assistance and was completed in the Summer of 2014.

Front-end studies:

• Front-end study and preparation of a turn-key specification for a modular 2 MW and 2.5 MW natural gas Genset Plant to supply behind-the-meter station power when the power plant is on.
• Front end study and preparation of a turn-key specification for a modular 20 MW natural gas Genset Plant to supply standby power and peak shaving for three mine sites in northern Ontario.
• Front end study and first phase engineering for an 8MW, 15MW and 40 MW cogeneration plant utilizing a GTG or a combination of natural gas Gensets.

Detail Design:

• Preparation of design basis document for a 40 MW enhanced wood waste burning power plant consisting of HRSG’s recovering waste heat from gas turbine driven line compressors, 250,000 lb/hr wood fired boiler, wood handling system, condensing steam turbine, water cooling system, water treatment system, auxiliaries, transformers and HV transmission system. Review and approval of cycle design, procurement contracts, bid analysis and process design.
• Preliminary cycle design, layout and cost estimate for a 1000 MW cogeneration plant retrofit at a thermal generating station.
• Designed a temporary 300 MW plant consisting of twelve trailer mounted TM 2500 GTG, gas compressors, demineralized water treatment plant for NOx control, liquid fuel, oil pumping and storage system, 75 MVA,13.8/122 kV transformers, switchyard, breakers and disconnect switches.

CGTA’s years of experience have given them extensive knowledge in the power and utility industry that has been invaluable and is evidenced with the long standing and continuous relationships that CGTA maintains with its clients. CGTA’s extensive experience in engineering investigations, reports and power and utility design is highlighted in the following recent projects:

• Engineering Investigations:
  • Investigated the siting of an 850 MW cogeneration plant to be installed on the site of a demolished coal firing plant. Prepared heat balance calculations and power output for various types and combinations of gas turbine generators/HRSG/Steam turbine generators using analyzing program G.T. Pro and Peace for cost estimates.
  • Investigated performance of HP Superheaters and Reheat Superheater for conversion of boilers from PF coal to natural gas at a Coal Fired Plant: 2 x Boilers rated 5,500,000 lb/hr 1050/1000˚F.
  • Completed cogeneration plant feasibility studies on behalf of clients.
  • Conducted cogeneration plant, thermal plant and air compressor plant energy audits.
  • Investigated cooling water system requirements for a 75 MW steam turbine generator. Engineered new circulating water pumps, intake screens, modifications to existing 72” diametre piping system and H.V. electrical system. Engineered new fuel system for existing 600,000 lbs/hr, 1500 PSIG/90oF boiler including new combustion control system and burner management system.
  • Owner’s Engineer for site investigations, managing of Thermoflow & Steam Master Pro thermal modelling, heat rate determination and technical integration of a 30 MW biomass fired cogeneration proposal for a Southern Ontario plant utilizing agricultural biomass.
  • Conducted due diligence investigation and operations review on behalf of CGTA clients.
  • Investigated problems experienced with buried steam and condensate systems consisting of 2500 ft of 20” steam pipe and 6” condensate pipe. Engineered new above ground steam and condensate piping system to replace the failed buried system.
  • Investigated cracks on primary and secondary superheaters of an HRSG. Inspected the various sections of the HRSG including economizer and deaerator. Prepared a report on findings with recommendations regarding changes and repairs.
  • Investigated the cause of a boiler furnace explosion of a 100,000 lb/hr boiler at a South Western Ontario cogeneration plant. Prepared new design of the combustion control system for Low NOx burner.
  • Conducted investigations of boilers, steam turbine and gas turbine failures. Examples include investigation of boiler explosions, tube failures, furnace header cracks, superheater failures and gas turbine coupling.
• Designs:
  • Provided design, field supervision and commissioning of a district hot water system operating at 250 oF @ 100 P.S.I.G. to replace an existing system which had failed.
  • Conducted heat rate tests on a 34.5 MW steam turbine generator. Investigated loss of performance. Performed a risk analysis life extension study to operate the steam turbine for an extended period of time without a shutdown of the steam turbine generator.
  • Designed thermal fluid/vapour and high temperature hot water systems, plant auxiliaries and distribution systems.
  • Lead engineer for a heat recovery power plant, GT Pro modelling and follow-up plant expansion and NOx reduction studies for client. Plant consists of a high pressure superheated heat recovery steam generator and nominal 50 MW condensing steam turbine generator. Study led to the following projects engineered by CGTA:
    • Supplemental burner upgrade for an additional 7 MW of STG power.
    • Retrofit of natural gas co-firing of a reform gas (hydrogen) burner into the reactor hot duct providing an additional 5 MW.
    • Expansion of the HRSG baghouse.
    • 1st Phase SCR system process design and cost estimate.
  • Developed a high energy piping integrity program for client for all ASME Covered Piping Systems and developed a detailed scope of work for the recommended condition assessment to be performed in accordance with EPRI requirements. The SOW included the development of the HEP Integrity Plan, Site Specific EPRI Level 1 Review and Risk Assessment, and an EPRI Level II Site Inspection Specification. A site specific P91 high temperature/high pressure QA/QC program was developed for the overall facility.
  • Provided engineering overview for carbon black furnaces exhausting into an HRSG/steam turbine generator. HRSG provided with a register type burner. Investigated failure of steam turbine bearings. Reviewed burner performance for increase in power output. Revised DCS, burner management system and commissioned the burner for an increase of 13 MW output steam turbine generator.

CGTA has provided project management and commissioning to its clients with the following outlining recent projects:

• Plant operations support including development of plant and boiler performance tests, and major plant equipment inspection services.
• Field experience includes inspection of piping systems during construction. Commissioning of high energy piping (HEP), steam and compressed air systems and boilers. Inspection of steam blowing of main steam turbine piping at cogeneration plants. Inspection of retubing of power boilers and tubular air heaters.
• Inspection, repairs and overhauls of steam turbine driven boiler feedwater and steam turbine generators.
• Managed the overhaul of a 500 MW STG and condenser retubing project.
• Project Manager for the waste heat recovery power plant GT Pro modelling at client’s power plant. Plant consists of a high pressure superheated heat recovery steam generator and nominal 50 MW condensing steam turbine generator. Study led to a supplemental burner upgrade for an additional 7 MW of STG power and retrofit of natural gas firing to the reform gas (hydrogen) burner into the reactor hot duct to provide an additional 5 MW of power output.
• Provided mechanical and electrical project engineering services including review of all EPCM contractors’ engineering, procurement, designs, procedures, commissioning and testing for a 850 MW Cogeneration Plant.
• Reporting to OPA as owner’s engineer on the readiness of OPA Cogeneration Plants for the export of electrical power on the contract date. Inspection of mechanical and electrical equipment and systems, code compliance procedures, testing procedures and performance testing.
• Provided mechanical and electrical engineering support for review of EPCM contractors engineering, procurement, construction, designs, and procedures. Supervised start up, commissioning and testing. Designed burner management modifications to HRSG exhaust by-pass duct.
• Engineering review and commissioning assistance of two 200,000 lb/hr, 940 psig/920 oF OTSG's.
• Senior Consultant for the acquisition of a 1,000 MW combined cycle power plant. Lead technical mechanical and electrical team for review of plant design basis, operations and maintenance planning and scheduling CAPEX/OPEX review, site inspection, efficiency and availability calculations, and implementation of maintenance and repair best practices.
• Senior Consultant engaged to investigate and provide solutions for a SAGD 10,000 kPag Once Through Steam Generator internal tubes corrosion issue. Scope included the inspection of the corroded tubes, apply knowledge based on the original code of construction and design basis to determine the corrosion mechanism including water treatment aspects of the feedwater. Applied current water treatment application knowledge and understanding of two-phase flow design aspects of wet steam generators to determine failure mechanism and issued recommendations for updated design and OTSG specifications for tube materials.

CGTA’s front-end engineering and detail design support to its clients have gained trust and confidence that has led to ongoing engineering support to operational staff. The following highlights recent projects:

• Project engineering duties include design, plant operations support, development of plant and boiler performance tests, and major plant equipment inspection services.
• Field experience includes inspection of piping systems during construction, commissioning of high energy piping (HEP), steam and compressed air systems, commissioning of boilers, steam blowing of main steam turbine piping at cogeneration plants, retubing of power boilers and tubular air heaters. Steam turbine driven boiler feedwater and steam turbine generator inspections, repairs and overhauls.
• Managed the overhaul of a 250 MW steam turbine generator and generator repairs for client.
• Provided engineering support and maintenance engineering review for acquisitions of a 70 MW hog fired boiler and STG power plant for client. Reviewed cracking experienced on furnace side wall heads. Recommended type of repair and supervised repair procedures.
• Provided mechanical and electrical engineering to review EPCM contractor’s engineering, procurement, construction, design and procedures for client. Supervised start up, testing, commissioning and on-going operation support. Provided arc flash study for the cogeneration facility.
• Responsible for inspection and maintenance of HRSG’s, and the investigation and outage management of a triple pressure three casing steam turbine generator (237 MW). The steam turbine is integrated into a fired triple pressure reheat combined cycle facility.
• Lead Engineer responsible for on-site shop QA/QC surveillance, monitoring and reporting for warranty repairs to the clients site’s Mitsubishi Hitachi Power Systems (MHPS) America Tandem compound double exhaust condensing reheat steam turbine low pressure (LP) rotor. The LP rotor was shipped, inspected, repaired and tested at Mitsubishi Hitachi MHPS America Savannah Machinery Works located in Savannah, Georgia. Highlights include:
  • High speed balancing (HSB) prior to and after the completion of repairs.
  • Mid-point snubber and integrated shroud tip contact pressure sensitive paper testing prior to and after the completion of repairs.
  • Blue Light scanning of existing and replacement L-0 blades.
• Project and Lead engineer and on-going, on-site support for numerous projects for client including various main steam hot reheat steam, HRSG drains, HRSG inlet expansion joints, electrical underground vault sump pump investigations, repairs and upgrade projects.
• Senior Consultant for remediation efforts to reinstate an extensive run of a large diameter hot-reheat F-technology CTG/HRSG steam turbine bypass to condenser line damaged due to condensate hammer events. Performed on-site post event evaluation. Performed steam line stress analysis, site coordination for contractor non-destructive testing for condition assessment and repair, and coordination of structural support rework for line support.
• Senior Engineer for the development and implementation of control strategies to maintain stability of multiple header pressure levels, and maintain steam delivery to multiple steam hosts with electrical power generation influences and optimization of overall plant efficiency
• Senior Consultant for the development of a high energy piping integrity program for all ASME Covered Piping Systems and developed a detailed scope of work for the recommended condition assessment to be performed in accordance with EPRI requirements. The SOW included the development of the HEP Integrity Plan, Site Specific EPRI Level 1 Review and Risk Assessment, and an EPRI Level II Site Inspection Specification. A site specific P91 high temperature/high pressure QA/QC program was developed for the overall facility.
• Senior Consultant acting as an Independent Engineer for a 900MW GS 2x1 combined cycle power plant. Scope included development of performance test procedures for Contract Capacity and Four-Hour Capacity Test protocols and procedures, Ramp Rate test procedure, confirmation of Meter Service Provider monitoring, inspection and review of the plant design to ensure installation is compliant with all applicable agreements, certificates of authorization, environmental requirements, laws and regulations of Ontario.