·       Cleanroom Revenues to Exceed $14 Billion Next Year

·       Revenue Potential for Outsourcing of Fossil-Fired Power Plant Processes Is More than $20 Billion/yr

·       Headlines for Utility E-Alert –August 29, 2014

·       “Power Plant Pumps” is the “Hot Topic” on September 11, 2014

·       McIlvaine Hot Topic Hour Registration

Cleanroom Revenues to Exceed $14 Billion Next Year

Sales of cleanroom hardware and consumables are projected to be $14.39 billion in 2015 according to the adjusted forecasts in McIlvaine World Cleanroom Markets.  (www.mcilvainecompany.com)

Asia will dominate the market with hardware expenditures of $4.3 billion and consumables expenditures of $4.5 billion.  The Asian market has grown rapidly due to the following factors:

·       Construction of international generic drug manufacturing plants

·       New semiconductor manufacturing facilities

·       Dominance of the region in the production of flat panel displays

·       Photovoltaic manufacturing expansion

·       General industry growth in the region

Over the last several decades the suppliers of computers and the components have increasingly outsourced the manufacturing of their proprietary chips. Taiwan has become the leading supplier of chips to the component suppliers.  China is rapidly building semiconductor manufacturing plants to try to keep up with the huge demand for chips in mobile devices.

The international drug companies have been losing market share to generics manufacturers.  The strategy to compete with them is to build generic manufacturing facilities in China and India. So a number of the world’s largest pharmaceutical companies have invested heavily in the region.

Hardware includes the complete cleanrooms including the HVAC systems, walls and floors.   All of these products are uniquely designed to minimize particle release to the air.  Consumables include garments, wipes, furniture and chemicals. Top of Form

For more information on World Cleanroom Markets, click on:  http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/474-n6f-world-cleanroom-markets

Revenue Potential for Outsourcing of Fossil-Fired Power Plant Processes Is More than

$20 Billion/yr

Fossil-fired power plants around the world expend more than $400 billion to operate their facilities.  More extensive outsourcing could improve operation of these facilities with at least a 10 percent savings.  This is a multibillion dollar opportunity concludes the McIlvaine company in the latest additions to Fossil and Nuclear Power Generation: World Analysis and Forecast.  (www.mcilvainecompany.com)

There are many ways to reduce costs. They include:

·       Reduce fuel costs and increase efficiency

·       Reduce other consumables expenditures

·       Decrease labor

·       Decrease other maintenance and operating costs

·       Improve fleet operations

·       Generate additional revenue streams

The operation of power plants is becoming increasingly complex.  Fortunately, there are new tools to deal with the complexity.  These tools can be most efficiently employed by specialists.   Remotely located optimization systems can operate plants more efficiently than onsite personnel.   Maintenance tasks can be scheduled based on need rather than routine.  This is in part due to smart valves and pumps which communicate their health automatically.

Fleets which include renewable generation (wind and solar) increase the complexity of management due to energy source fluctuations.  The complexity in environmental laws which require a fine balance between opposing needs make outside expertise particularly important.  SO₂ can be decreased, but CO₂ is increased.  NO_x can be decreased, but CO is increased. The operator must continually strike the optimum balance.  Day-to-day changes in the prices of pollution allowances, fuel and other factors make it desirable to outsource decisions to a supplier who can invest in the software and infrastructure to deal with these challenges.

There is a big potential to reduce the expenditure for consumables.  For example, all the filter purchases can be outsourced.  Continuous monitoring tools such as broken bag detectors and continuous emissions monitors capable of measuring individual metals, acid gases and other pollutants allow a third party to remotely make filter inspection and replacement decisions.  A medium size power plant can have more than 15,000 filters in operation.  Savings in purchasing and inventory can be significant with the large volumes involved.

The ownership and operation of pollution control systems can be outsourced.  NIPSCO has outsourced the ownership and operation of a flue gas desulfurization system at the Bailly station since the 1990s.  Air Products and Mitsubishi formed a partnership to provide the operation and maintenance. The program was quite successful in meeting emissions goals and minimizing consumption of limestone and energy.

Another big potential is for outsourcing of a “continuing education” program for plant personnel. There are both general as well as specific needs. Many general training options are available, but outsourcing provides a unique option for supplying the specific day-to-day needs to make the important decisions.

For more information on Fossil and Nuclear Power Generation: World Analysis and Forecast, click on:  http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/113-n043

Headlines for Utility E-Alert – August 29, 2014

UTILITY E-ALERT

#1189 – August 29, 2014

Table of Contents

COAL – US

·       Minnesota Power to Operate Baghouse at Boswell 4 by 2016

·       EPA wants comments on Four Corners proposed Permit for upgrade on Two Coal-fired Units

·       Mississippi Supreme Court sides with Mississippi Power on Emissions Control Regulations

·       Consumers Energy nearing completion of $250 Million Upgrade Project at Karn/Weadock

·       Duke Energy retiring Coal Operations at W.C. Beckjord Station in Ohio

GAS/OIL - US

·       Lackawanna Energy to build 1,300 MW Power Plant in Pennsylvania

·       Calpine to acquire Fore River 809 MW Gas-fired Power Plant in Massachusetts from Exelon

·       Duke Energy will buy existing Natural Gas-fired Power Plant in Polk County, FL

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GAS/OIL - WORLD

·       Reliance Power opts out of Gas-fired Power Plant in Dadri Uttar Pradesh, India

·       Group Five wins R4 Billion Ghana deal to build a 350 MW Combined Cycle Power Plant 

·       APR Energy signs Contract for Peaking Power Plant in Australia

·       L&T to construct 225 MW Sikalbaha Gas-fired Power Plant in Bangladesh

·       Santerre Limited to develop a 200 MW Combined Cycle power plant in Ghana

·       Foster Wheeler HRSG for Kimberly Clark Facility in Mexico

CO₂

• Petra Nova Groundbreaking at the NRG W.A. Paris Plant - September 5, 2014

BUSINESS

·       Dynegy cuts exposure to Wholesale Power with Deals worth US$6.25 Billion

·       Scrubber Market veering from Hardware to Consumables

HOT TOPIC HOUR

• Lots of choices for Demineralization and Degasification of HRSG Water - Hot Topic Thursday, August 28
• Is Hot Gas Filtration the New Path for Coal Plants? – “Hot Topic” September 4, 2014
• Upcoming Hot Topic Hours

For more information on the Utility Tracking System, click on: 

http://home.mcilvainecompany.com/index.php/databases/2-uncategorised/89-42ei

“Power Plant Pumps” is the “Hot Topic” on September 11, 2014

This webinar on September 11 will be both organizational and informative.  It is all part of a whole knowledge system for gas turbine combined cycle plant operators -- Gas Turbine and Combined Cycle Decisions .   The free website and periodic webinars empower the operators to buy the best products rather than the most familiar or least expensive. 

The webinar on the 11^th will try to answer the question: What are the most important and difficult decisions you will have to make regarding pumps?

Here are some of the questions which will be addressed:

Where do you use variable speed drives? (William Livoti of WEG will lead this segment of the discussion.)

What type of boiler feedwater pump is best?

With fast start HRSGS and constant cycling, what pump innovations will counter some of the negative consequences of this operating mode?

What pump issues facing GTCC operators which are unique to this type of power generation?

What are the pump needs if zero liquid discharge technology is mandated? 

What other questions are GTCC operators asking?

Here is a list of pumps used in gas turbine combined cycle plants:

• Primary Pump Systems include:
  • Boiler Feed Pumps (primary and startup)
  • Condensate Pump
  • Cooling Water Circulation Pump
  • Cooling Water Make-up Pump
  • Heater Drain Pumps
• Boiler Feed Pumps
  • High pressure, high flow barrel type multi-stage centrifugal pumps rated ^~5000 gpm and 2400 psi for major utility power plant systems (pressures will vary for subcritical vs. supercritical).
• Condensate Pumps
  • High flow centrifugal pumps rated ^~5000 gpm to move condensate from the condenser hot well to a deaerator and back to the feed water stream ahead of the boiler.
• Once-through Systems
  • Pump surface water through cooling unit and directly back to source (lake, river or ocean).
• Loop Systems
  • Circulating Pumps
    • Large centrifugals rated 100,000 gpm or more. Total coolant flow more than 200,000 gpm for a 400 MW plant.
  • Makeup Water Pumps
    • Large centrifugals rated 5,000 gpm. Makeup is typically two percent to three percent of total flow and is required to replace water lost to windage, evaporation, and blowdown.
• Secondary Pumps include:
  • Chemical Feed Pumps
  • Chemical Transfer Pumps
  • Fuel Transfer Pumps
  • Fuel Injection Pumps
  • Slurry Pumps and De-watering Pumps (used in zero liquid discharge systems)
  • Lubrication Pumps
  • Service Water Pumps, Fire Service Pumps, others.
  • Fogging nozzles
  • Ammonia injection for NO_x control

The power plants participating in the webinar will have free access to Gas Turbine and Combined Cycle Decisions .  In order to make the webinar most valuable to these operators, it is recommended that they review the following information on the site.

VFDs can make a big difference in optimizing pump energy consumption in cooling tower makeup

William Livoti writing in “Empowering Pumps“discusses some of the potential regulations which will force recycling of cooling water. He says that power plants need to assess their pump requirements and consider variable speed drives to reduce energy consumption. He cites the advantages when handling off peak loads. A specific example is given for the VFD saving with cooling water makeup pumps.

HERE ARE SOME OF THE ARTICLES REPORTED IN CCJ

Hydro, Inc. is largest independent pump rebuilder

As the largest independent pump rebuilder, Hydro works hand-in-hand with pump users to optimize the performance and reliability of their pumping systems. Hydro’s mission was developed in 1969 when Hydro realized that as an independent pump rebuilding company, Hydro had a unique capability of analyzing and understanding various designs as well as their successes or failures in specific applications and operating environments.

3 suppliers of pumps for City of Tallahassee combined cycle addition City of Tallahassee, FL Unit 2A, A B Hopkins Generating Station

City of Tallahassee, FL Unit 2A, A B Hopkins Generating Station Size 300 MW Commercial operating date: June 2008 EPC contractor: BE&K, Inc. Owner’s engineer: Sargent & Lundy Type of plant: Combined Cycle Gas Turbine Manufacturer: GE Energy Wet Cooling Tower: Hamon-Custodis (existing) Boiler-feed pumps: Flowserve Corp Boiler-feed-pump drives: Voith Turbo, Inc. Condensate pumps: Existing Condensate booster pumps: ITT Goulds Pumps Booster-pump drives: Voith Turbo, Inc. Circulating-water pumps: Johnson Pump, an SPX brand (Existing).

Pump relocation is one best practices at the CTOTF® spring meeting

Circulating pumps for the evap cooling systems serving 7EAs located in the western desert were installed on the second level inside the inlet air house. Failure of a pump required its replacement under demanding conditions, high off the ground, and likely when the GT was in operation.  Certainly not ideal.  Plant personnel relocated the two pumps (one redundant) for each unit at ground level. There have been no pump failures or system degradation issues since the modification was made.

Tenaska Lindsay Hill Generating Station ammonia pump problem

The facility’s anhydrous-ammonia forwarding pumps did not allow for double-valve isolation during maintenance. These pumps are only required for use on very cold days. This requires additional maintenance and laying them up for periods of non-use. The system had single-valve isolation from the ammonia storage tank to the suction of the pumps, a potential safety risk for the O&M team.Solution. Plant management decided to install double-block-and-bleed capabilities to the liquid suction line from the storage tank and liquid return line to the storage tank.

OTHER ARTICLES APPEARING IN THE MCILVAINE GAS TURBINE AND COMBINED CYCLE DECISIONS UNDER THE KEYWORD “PUMPS”

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MHI and Sheyang Pump have had joint agreement since 2006 for the Chinese boiler feedwater pump market

MHI and Shenyang Pump Co., Ltd. (SPC) have agreed to establish a joint venture company (JV) in Shenyang, Liaoning Province, China to conduct sales and engineering relating to pumps. The agreement was signed on March 23 in Shenyang. With establishment of the JV, MHI aims to make a full-scale entrance into the Chinese pump market, where demand for pumps of all kinds is expected to increase vigorously. The focus is on pumps for thermal power plants. Creation of the new JV will enable MHI and SPC to build further experience in collaborative activities, as a prelude to possible establishment in the future of a manufacturing JV to serve as a local production base for a variety of pump products.

Sulzer high pressure barrel casing pump designed for boiler feedwater

The HPT is a pump specifically designed for boiler feed applications in thermal power stations. The pumps are optimized to provide high-efficiency operation over an extended period of time, thus reducing operating and maintenance costs.

MHI supplies ring section boiler feedwater pumps for combined cycle operation

MHI supplies a variety of pumps for combined cycle and coal-fired power plants. Several boiler feedwater designs are available depending on pressures and other parameters. The ring section type is used in combined cycle.

Flowserve Boiler Feedwater pumps have beneficial features

The boiler feedwater pumps must handle high pressures and fairly high flow rates and for these services between bearing multistage pumps are commonly used. For very high pressure, double case pumps are sometimes required; Flowserve models DMX and WXH are commonly used. These between bearings, multistage pumps offer the following features and benefits: Choice of axially or radically split case -- Ease of maintenance.  Choice of volute or diffuser case construction --Fluid dynamics best suited for application.  Double-suction first-stage impeller (option) ------------Minimizes NPSHR Flanged balance drum or hydraulically balanced rotating unit--------Balances hydraulic thrust and reduces vibration Finned bearing housing--- Maximizes heat dissipation.

The standardized Sulzer Pumps MD raqnge meets GTCC boiler feed requirements

Although most once-through HRSGS are subcritical, their BFPs have to provide very high pressure.  In order to increase pressure, BFPs have more stages and shafts with higher torque capacity than conventional pumps. The Sulzer MD range meets these requirements.

Mitsubhishi and BHEL team up to provide power plant pumps in India

Bharat Heavy Electricals Ltd, the country’s biggest power equipment supplier, signed an agreement with Mitsubishi Heavy Industries Ltd in 2007 under which the Japanese firm will license technologies relating to pumps used in thermal power plants.

SPX's Diffuser Type Pump

The SPX's diffuser type pump CUP-FT/FK (2 Pole), ClydeUnion Pumps, offer flows up to 4,840 m3/h, delivering up to 8,200 m, on maximum temperatures of 350°C, with operating speed up to 3,600 rpm.

GE - DHM Series Pumps

High-pressure diffuser barrel multistage DDHM pumps (API610 / ISO13709 type BB5) are designed for ultra-reliability and efficiency in the most demanding onshore and offshore water-injection applications. They are also well suited for boiler feedwater, pipeline, amine, energy recovery and CO₂ injection.  During the selection process, we can tailor the complete system to specific customer objectives in terms of CAPEX, OPEX and operability. This service includes matching of the main and booster pumps as a crucial step in optimizing performance.

Boiler feedwater pump for Dubai Fertilizer from SPX Clyde Union

This quote for a $300K BFP is not for GTCC but does provide very useful and detailed information of what is included and terms and conditions. The unique appearance of a document such as this on the internet adds to its value.

SPX offers pumps and many other components for GTCC plants

This brochure covers the complete range of SPX products for the power industry. Good diagrams on GTCC show the boiler feed pumps and other offerings.  Since SPX also offers complete cooling tower systems they can offer pumps as part of packages or separately.

Grundfos has pumps for steam boilers and district heating

Grundfos supplies the high pressure multi stage pumps for steam boilers. It is a leader in pumps for district heating. Gas turbine combined cycle plants are often replacing coal plants in district heating systems. At the same time, the distribution systems are being upgraded with new pumps.

The webinar is free to power plants.   Click here to view schedule and register

For more information on the Utility Tracking System, click on: 

http://home.mcilvainecompany.com/index.php/databases/2-uncategorised/89-42ei

McIlvaine Hot Topic Hour Registration

On Thursday at 10 a.m. Central time, McIlvaine hosts a 90 minute web meeting on important energy and pollution control subjects. Power webinars are free for subscribers to either Power Plant Air Quality Decisions or Utility Tracking System. The cost is $300.00 for non-subscribers.

See below for information on upcoming Hot Topic Hours. We welcome your input relative to suggested additions.

Click here for the Subscriber and Power Plant Owner/Operator Registration Form

Click here for the Non-Subscribers Registration Form   

Click here for the Free Hot Topic Hour Registration Form   

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You can register for our free McIlvaine Newsletters at: http://home.mcilvainecompany.com/index.php?option=com_rsform&formId=5

Bob McIlvaine
President
847 784 0012 ext 112

rmcilvaine@mcilvainecompany.com

www.mcilvainecompany.com