Remember California? Deregulation of the Power Generation industry forced California's investor-owned utilities to sell most of their power-generating plants to unregulated private companies called independent power producers or IPPs. As a result, the utilities had to buy their power from IPPs and through energy traders (such as Enron) on the volatile wholesale market. Prices can fluctuate daily and as demand grew, prices rose quickly. However, price controls prevented the utilities from passing the rising costs of power on to customers. As a result many utilities went bankrupt or teetered on the brink.

The foodservice equipment industry felt a great deal of anxiety, as restaurants are large consumers of electric power. There are many pieces of high temperature equipment (ovens, warming cabinets, etc.) in every restaurant. Watlow's involvement in the development of the NAFEM protocol is one way Watlow is contributing to energy efficiencies. Connecting equipment online will help optimize energy usage.

Southern California's injection molding companies saw their electric bills quadruple. As a result, injection molders are doing what they can to become more energy efficient and make intelligent decisions about where to buy energy and how it is used. Some California-based injection molders have signed with energy brokers who can provide energy at a lower cost and reduce the volatility. In addition, the use of Watlow's MI band heaters and thick film nozzle heaters can help molders increase energy efficiencies.

Semiconductor fabricators were one of the most highly affected industries. Power – "it's like the roads," said one Silicon Valley CEO. The industry uses backup generators and multiple-supply contracts to help during times of crisis. Many of those backup generators use efficient Watlow engine heaters to ensure that power can be delivered within seconds of generator start up.

Watlow temperature sensors, especially high performance thermocouples, are perfect matches for mini and micro-turbines used in primary, stand by and distributed power applications as well as aero-derivative and large frame gas turbines. Sensors range from high temperature thermocouple sensors for turbine inlet and outlet temperatures to RTD-based sensor probes for the cooler inlet air and compressor sections.

Watlow custom engineers and manufacturers adjustable temperature setting, tank and circulation-style heaters. The company's specialty is in frame-mounted heaters, however, a frame-mounted version is also available. The all-steel, welded construction and vibration dampening mounting system are built for rugged environments, unlike plastic or aluminum-body engine preheaters.

Process Heating Systems for Balance of Plant Applications
Increasing the efficiency, power output and service life of gas turbine power systems (both small and large) as well as intervals between maintenance shut downs is of prime importance to power system OEMs and their customers. Designing in the right process heating solutions for balance of plant applications helps achieve these goals.

Using these Watlow process heating systems ensure clean, dry gas for better combustion, reduced turbine component wear and NOx emissions.

Turbine Support Systems
Lube oil systems ensure the proper operating temperature of the lube oil in both gas and steam turbines and provide filtration and conditioning too. Turbine wash skids supply heated water-based cleaning solutions used for cleaning of turbine compressor sections. They usually employ solution tanks, heaters, valves, pumps and in some cases protective housings to protect the system. Another product Watlow supplies frequently are CO₂ vaporizers used for Flame Suppression Systems. This prevents flame flash backs during fuel change overs (i.e.. gas to fuel oil).

Freeze Protection
In colder climates, oil gets difficult to pump and water may freeze. Watlow provides solutions here as well. Fuel oil is preheated by “suction” heating systems. These are essentially circulation type heaters that heat the fuel oil as a down stream pump pumps the fuel oil to the turbine. Another method is heating of the fuel oil storage tank using “bayonet-like” heaters inserted into tank. The entire contents of the storage tank are then heated. Finally, water and de-ionized water storage tanks use immersion heater systems to maintain water above freezing.

Emissions Control
Selective Catalytic Reduction (SCR) technology uses various forms of ammonia injected into exhaust gas streams to remove nitrogen oxide (NOx) pollutants. Watlow heaters and heater systems are used in vaporizer applications as well as for air heating and air/NH₃-mixing systems. SCR systems have historically been used in coal-fired plants, but are increasingly being used for gas turbine power system applications.

Summary
Power is an integral part of everyday life but remains a volatile entity on an open market. To keep costs under control and maintain a delicate balance between supply and demand, industries and consumers must work to find ways to maximize energy efficiencies.

Watlow is continuing to refine current products and develop new products to help companies achieve energy efficiencies and meet the growing needs of companies involved in power generation to help them continue to stay competitive in this unpredictable industry.

Oil temperature sensor

Micro turbine inlet air sensor

Temperature sensor for large commercial aviation (left)
EGT sensor for private aircraft jet engine (right)

Engine compartment sensor

Tapered tip EGT subassembly for engine harness

Dual element staggered junction design for EGT harness