Innovative Penetration Boiler Seal for HRSGs
Heat Recovery Steam Generators (HRSGs) are an excellent way to capture more value from the fuel budget. But achieving the most from an HRSG requires that they be operating as efficiently as possible. To increase efficiency and reduce maintenance cost, power plants are embracing a new generation of boiler penetration seals: slider seals that can significantly lower energy loss while reducing the maintenance load and risk of unplanned outage.
One new slider seal, the PS Seal® from
Expansion Joint Systems, uses a floating ring design with patented stainless steel flow-reducing seals in contact with the penetration pipe outside diameter and lateral movement plates. The seals are compressed on assembly to provide minimal gas leakage during operation. As particulates build up in the seal and further restrict passage of gas, the gas leakage in the seal increasingly reduces over time. The stainless steel wire mesh seal can be replaced easily during shutdowns, eliminating the need to replace the entire unit. Because these seals may be disassembled and repaired without cutting metal piping or welds, there is no need for specially trained welders to install the replacements. Standard sizes, 4”to 24” nominal diameter, are currently available and will accommodate axial movement lateral movements.
F Controlled Flow Material Transfer Systems
Controlled Flow Material Transfer Systems™ (CFMTS®) from
Flexco Engineered Systems Group is designed to enhance overall conveyor system uptime and productivity. Flexco’s CFMTS are designed to control flow of material through a transfer by keeping material in a continuous stream throughout the transfer. The geometry of the system is designed to accurately control velocity and direction of the material stream contained within it, so the material stream stays together with all fines and particulates entrained in the stream. CFMTS is characterized by:
• Low angles of impact
• Low material degradation and dust generation
• Low noise levels and wear rates
• Soft and central loading on the receiving belt(s)
• Being spillage and maintenance free
• Not requiring impact beds
• Not sensitive to conveyor orientations
• Low maintenance operating costs
• Reduced associated conveyor component wear
Flexco’s bucket diverter design permits simultaneous splitting of the material stream between two discharge legs of a diverting system. Furthermore, the proportion between the legs and/or the amount of material flowing down the legs can be controlled and automated, provided there is a system for measuring the amount of flow, such as a belt scale, coupled with a PLC or similar control system.
Fly Ash Handling System
FLSmidth’s A2P™ Fly Ash Handling System reduces capital cost by up to 50%. The Airslide™ Conveyor to Fuller-Kinyon™ Pump Fly Ash Handling System offers these benefits:
• All hoppers empty, all the time
• Virtually maintenance-free
• Continuous ash removal from collection hoppers
• Only two moving pieces between collection hopper and storage
• Continuous conveying to storage
Fly ash continuously discharges from all dust collector hoppers simultaneously. Ash becomes fluidized within the Airslide Conveyor and flows rapidly down the slope via gravity. Fluidization air is heated to further ensure proper ash flow to the Fuller-Kinyon Pump. The pump acts as a “line charger,” injecting the ash into the pressurized convey pipeline while acting as an airlock between the conditions in the dust collector/Airslide conveyor and the conveying system. The Fuller-Kinyon pump conveying system uses carbon steel straight piping and hard iron sweep fittings. A simple bin vent filter is required at the destination silo to vent the conveying air.
Enhanced NOx Reduction
Fuel Tech completed the acquisition of Tackticks and FlowTack in October 2008. Volker Rummenhohl brings 23 years and 55,000 megawatts of experience in the design, evaluation and performance of SCR systems for NOx control. This enhances Fuel Tech’s process design capability of its NOxOUT CASCADE system, which is enhanced SNCR with a downsized SCR system. Services include ammonia injection grid tuning and catalyst management help optimize catalyst performance and life. FlowTack brings expertise in physical experimental models and computational fluid dynamics models. Models help clients optimize performance in flow critical equipment, such SCR systems, flue gas desulfurization scrubbers, electrostatic precipitators, exhaust stacks, and sorbent injection systems. Product offerings include flow corrective devices, such as turning vanes, static mixers and its patent pending Graduated Straightening Grid.
On January 6, 2009, Fuel Tech completed the acquisition of Advanced Combustion Technology. Product offerings include ultra low NOx burners, burner upgrades, and over-fire air systems, with experience on over 70 installations. Services include airflow testing, coal flow testing, and boiler tuning and consulting services. High Energy Reagent Technology HERT or NOxOUT® SNCR systems can be combined with burner and over-fire air systems for total NOx reductions up to 85%.
Babbitt Bearing News
Fusion Babbitting Company Inc. news includes:
• Addition of a state of the art metalizing booth to rebuild the OD fit on bearings. We now are spraying, steel, cast iron, and bronze material.
• We have increased our machining capabilities by purchasing a new 42” swing lathe, setting up a new 36”centrifugal casting machine, and hiring six new employees for our 2nd shift operation.
• Redesigned company brochure and printed for distribution
• Green participation: We installed all new plant and office energy saving lighting this year.
• In March 2008 Milan Juric joined our staff as general manager.
• We are again offering babbitt bearing educational seminars.
• We will participate in 5-6 trade shows in 2009.
GSpring-VISCODAMPER Support of Machinery
The GERB Spring-VISCODAMPER® element is a widely applied device for the elastic support of power plant equipment and piping around the world. Its elements: protect equipment and structures during seismic events, reduce stress in the machine and foundation due to differential settlement, reduce sub-foundation dimensions, and reduce vibration transmission. Applications include the spring support of turbines, condensers, boiler feed pumps, coal mills, fans, diesel gen sets, and transformers.
Established in 1908,
GERB Vibration Control Systems has unique solutions for the vibration isolation of machinery, buildings, and power infrastructure. GERB offers consulting services, design, manufacturing, and installation of vibration isolation systems consisting of compression steel spring elements and VISCODAMPER. GERB has continued to develop this technology, solving complex dynamic problems in many fields of application.
Variable-Speed Tube Cleaner
Goodway Technologies Corporation is proud to introduce the RAM-5SFVS Variable Speed Ream-A-Matic® Tube Cleaner. With a shaft feed rate of up to 3' per second, it is the machine of choice among contractors and facility managers with large tube bundles. As the cleaning tool loosens debris, the shaft casing provides a steady stream of water, flushing out debris and restoring system efficiency. While the Speed Feed gun lets you control the direction of shaft rotation as well as the flow of water, the variable speed function allows you to control both the brush rpm and the feed rate. It is ideal for removing both soft and hard deposits from smooth bore as well as internally enhanced tubes/pipes 1/4"-1" (6.4-25.4mm) I.D.
Specifications:
• Flexible shaft speed: Variable, up to 862.5 rpm
• Speed-Feed gun rate variable, up to 3' per second
• Speed-Feed gun push/pull force: 50 lbs
• Motor power: 1 HP
• Input power 12 amps, 115 V, 60 Hz AC
• Optional: 12 amps, 115 V, 50 Hz; 6 amps, 230 V, 60 Hz; or 6 amps, 230 V, 50 Hz
• Dimensions (excluding gun and guide hose): 37" high x 20" wide x 17" deep
• Weight: 75 lbs net dry
Submersible Drainage Pumps
In
Grindex’s new generation of submersible drainage pumps, wear resistance has been at least tripled by preventing abrasive particles from reaching the vulnerable parts of the pump. The newly designed hydraulics section with its closed impeller is dramatically reducing the performance drop caused by long-term wear. This makes the new pumps capable of operation in really demanding applications with maintained capacity. The new design also allows easy adjustment of the impeller to regain optimal performance. It simplifies the service and ensures both longer lifetime and stable dewatering during the whole pump life.
The new pumps have an ergonomic design that makes them easier to handle. We have introduced a new cartridge seal, simplifying service routines because it can be fitted with a simple movement. And being able to adjust the impeller with a single screw simplifies service further. The new pumps still feature the SMART Grindex electronic motor guard. These features prevent overheating, incorrect rotation, and single phasing. SMART contributes to longevity and high reliability. Another refinement is the air valve. In the event of dry running, the impeller automatically functions as a fan to cool the pump motor, bearings and seals when the air valve releases the hot air.
HEquipment Management Software
HECO, Inc. Industrial Service Groups of Kalamazoo, Michigan, has just introduced the newest generation of its “equipment management” software, uniquely named “TracRat®.” This program was developed to have identified savings through repairable asset inventory reduction and repairable asset repair cost reduction.
Originally born over 25 years ago as a combination of 1980s paperwork and computer technology, the first generation of HECO’s “Motor Management” effort served a collective group of seven automotive plants in western Michigan. The goal was to store electric motor critical spares, share electric motor inventory between plants, set electric motor inventory reduction goals, and reduce the cost of repair for the plants at a measurable pace. With the advent of the PC-based World Wide Web, HECO began to develop TracRat® as a user-friendly information technology tool that could not only perform the day-to-day motor management functions but can also be easily adapted to fit any repairable asset. For all repairable assets, TracRat® can track warranty recovery, track and report cause of failures, issue request for quotes, and generate a variety of charts to determine planning for future predictive maintenance procedures and repairs.
Advanced Energy Solutions to Reduce GHG Emissions
Honeywell’s Process Solutions business has introduced its Advanced Energy Solutions, a suite of process control, monitoring, and optimization applications designed specifically for industrial power generation facilities. The Advanced Energy Solutions suite allows industrial power and cogeneration plants to balance electricity generation demands with operational efficiencies and regulatory constraints. By implementing Advanced Energy Solutions, industrial power generation facilities will benefit from reduced heat rate and power production costs, increased effective boiler operating range, reduced greenhouse gas (GHG) emissions, optimized production capacity utilization, optimized transient states control, extended production asset life and reduced maintenance.
The solution fully integrates with the Honeywell Experion® Process Knowledge System, as well as other distributed control systems. Software applications available as part of the suite include Advanced Combustion Control, Plant Performance Optimizer, Master Pressure Control, Plant Performance Monitor and Tie-Line Control. These applications have common architecture, compatible interfaces, and can be implemented individually or as a completely integrated solution in order to maximize the process optimization benefit.
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