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Installing one of the largest combustion turbine inlet air chilling systems in the US

Duke Energy is one of the largest electric power holding companies in the United States, supplying and delivering electricity to approximately 7.4 million U.S. customers.

The 1847 MW Hines Plant, located in Bartow, Florida has four 2x1 combined-cycle blocks. The Hines Chiller Uprate Project allowed Duke Energy to boost plant output.

During the proposal phase, Amec Foster Wheeler worked closely with the main OEM vendor to propose a solution that optimised the current plant layout. The optimised plant layout saved in installation costs.

In order to boost power production at the Duke Energy Hines plant during the hot summer months, a Turbine Inlet Air Cooling (TIAC) system was installed. This system boosts plant capacity by over 200 MW net during hot and humid ambient conditions when power demand is at its peak by cooling the air entering eight existing gas turbines. This is accomplished using a chiller plant and Thermal Energy Storage (TES) tank capable of providing chilled water to newly installed cooling coils in the turbine inlet ductwork. The TES, one of the largest in North America, stores over 17million gallons of chilled water.

The project increases the summer capacity of the existing Hines Complex without requiring the installation of new units. This further solidifies the Hines plant as a leading power producer for Duke Energy in Florida. The project was completed under strict environmental restrictions, with a focus put on minimal water and chemical spills to meet a commitment made by Duke Energy to the state of Florida. A condensate recovery system was also included to reduce the amount of chemical treatment required onsite for the cooling tower.

Amec Foster Wheeler utilised past experience with TIAC systems to collaborate with the selected vendor, and delivered an optimised chiller plant layout. The original design was modified to provide a much more open floor plant allowing access for future maintenance activities. Additionally, our design team worked with Duke Energy and a third-party testing contractor to develop and implement a first-of-its-kind performance testing procedure.

Despite several challenges, the project finished successfully and met all performance guarantees. Amec Foster Wheeler is currently providing engineering services to add a new mode of operation for the system (direct chilling).

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Location:Florida, USA
Client:Duke Energy
Value:US$110 million
Scope:EPC services
Date:2015 - 2017