HRSG Design, Operation and Maintenance Considerations
is Hot Topic Hour on March 7, 2013
Heat Recovery Steam Generators (HRSGs) are a tool to improve the efficiency of
any combustion process in any industry and, consequently, reduce pollutant and
GHG emissions per unit of energy produced. HRSGs use the waste heat in the
exhaust to produce additional steam to drive a steam turbine for power
generation, provide heat for facilities, provide steam or heat for industrial
processes and even produce water by desalinization. HRSGs are available from
many manufacturers in a wide variety of shapes, designs, configurations,
arrangements and capacities to suit every application. Available types include,
but are not limited to, vertical or horizontal gas flow, single, dual and triple
pressure with reheat, fired and unfired, modular or packaged. The question for
every operator of a combustion process who is considering adding a HRSG and for
the purchaser or designer of a new combustion plant is- Which HRSG design is
best for my plant and what are the key criteria I need to consider when
specifying a HRSG?
HRSGs can pose unique operational challenges based on the application. For
example, when used with gas turbine exhaust in combined cycle operations, rapid
startup requirements and subsequent thermal stresses can cause more frequent
tube failures; when used with heavy oil-fired engines or boilers, the carbon in
the exhaust can cause fouling or coating of the tubes; plastics in waste
incinerators can also cause fouling; and when used with coal-fired boilers, the
contaminants in the exhaust gases as well as the particulate load can cause
problems. In addition, the challenges or potential problems can change when
operating conditions such as load on a power generator, heating demand, fuel
used in the primary combustion process or even ambient conditions change. Since
it is difficult for plant owners and operators to predict future operating
requirements and conditions, a HRSG that can accommodate a wide variety of
conditions while maintaining efficient, cost-effective operation can be
valuable.
The following speakers will address the issues related to the design,
installation, operation and maintenance of HRSGs for various applications,
provide suggestions for reducing acquisition, installation, operation and
maintenance costs while improving efficiency and update us on new technology or
designs under development to improve the performance and reliability of HRSGs.
John DiVitto,
Business Development Manager and Melvin J. Albrecht, Technical
Fellow at Babcock & Wilcox Power Generation Group, Inc., will discuss key issues
in the design of HRSGs. Many new combined cycle projects being developed will
require the plant to respond quickly to load demands. This includes the need for
fast start-up and fast load changes. During this Hot Topic Hour, we will
discuss key considerations in the design of the heat recovery steam generator
(HRSG) required to minimize long-term damage to the pressure part resulting from
these difficult operating conditions.
Ati Manay,
PMP, P.E. Product Manager, SMART Clean at Clyde Bergemann, Inc./ Power Group
Americas
Landon Tessmer,
Senior Sales and Proposal Engineer at IST, will present "Once-Through HRSG
Design, Operation, and Maintenance Considerations for Flexible Operation and
Long Life." The Once-Through Steam Generator (OTSG) is a drumless HRSG
that is smaller, more flexible, and simpler than a traditional HRSG. The unit is
designed with high-nickel alloy tubes that allow the OTSG to operate dry without
the use of a bypass stack. With zero blowdown, OTSG water treatment is the
primary operational concern to ensure the highest reliability and longest life.
Jake Holvey, Manager of Field Services at Vogt Power
International Inc.
To register for the March 7, 2013 “Hot Topic Hour” at 10:00 a.m. Central time,
click on:
http://www.mcilvainecompany.com/brochures/hot_topic_hour_registration.htm.
McIlvaine Hot Topic Hour Registration
On Thursday at 10:00 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 Environmental Upgrade
Tracking System. The cost is $125.00
for non-subscribers.
Market Intelligence
webinars are free to McIlvaine market report subscribers and are $400.00
for non-subscribers.
DATE |
Non-Subscribers Cost |
SUBJECT |
Webinar Type |
March 7,
2013 |
$125.00 |
HRSG Design, Operation and
Maintenance Considerations |
Power |
March 14, 2013 |
$125.00 |
Inlet Air Pretreatment for Gas
Turbines |
Power |
March 21, 2013 |
$125.00 |
Industrial Boiler MACT Impact
and Control Options |
Power |
March 28, 2013 |
$125.00 |
Mercury Measurement and Control |
Power |
April 4, 2013 |
$125.00 |
Fabric Selection for Particulate
Control |
Power |
April 11, 2013 |
$125.00 |
Air Pollution Control for Gas
Turbines |
Power |
April 18, 2013 |
$125.00 |
Multi-pollutant Control
Technology |
Power |
April 25, 2013 |
$125.00 |
Control Technologies for Fine
Particulate Matter
|
Power |
May 2, 2013 |
$125.00 |
Flyash Pond and Wastewater
Treatment Issues
|
Power |
May 9, 2013 |
$125.00 |
Clean Coal Technologies |
Power |
May 16, 2013 |
$125.00 |
Power Plant Automation and
Control |
Power |
May 23, 2013 |
$125.00 |
Cooling Towers |
Power |
May 30, 2013 |
$400.00 |
Air Pollution Control Markets
(geographic trends, regulatory
developments, competition,
technology developments) |
Market
Intelligence |
June 6, 2013 |
$125.00 |
Report from Power-Gen Europe
(update on regulations, speaker
and exhibitor highlights) |
Power |
June 13, 2013 |
$125.00 |
Monitoring and Optimizing Fuel
Feed, Metering and Combustion in
Boilers |
Power |
June 20, 2013 |
$125.00 |
Dry Sorbent Injection and
Material Handling for APC
|
Power |
June 27, 2013 |
$400.00 |
Power Generation Forecast for
Nuclear, Fossil and Renewables |
Market
Intelligence |
July 11, 2013 |
$125.00 |
New Developments in Power Plant
Air Pollution Control |
Power |
July 18, 2013 |
$125.00 |
Measurement and Control of HCl |
Power |
July 25, 2013 |
$125.00 |
GHG Compliance Strategies,
Reduction Technologies and
Measurement |
Power |
August 1,
2013 |
$125.00 |
Update on Coal Ash and CCP
Issues and Standards |
Power |
August 8, 2013 |
$125.00 |
Improving Power Plant Efficiency
and Power Generation |
Power |
August 15, 2013 |
$125.00 |
Control and Treatment Technology
for FGD Wastewater |
Power |
August 22, 2013 |
$125.00 |
Status of Carbon Capture and
Storage Programs and Technology |
Power |
August 29, 2013 |
$125.00 |
Pumps for Power Plant Cooling
Water and Water Treatment
Applications |
Power |
To register for the Hot Topic Hour, click on:
http://www.mcilvainecompany.com/brochures/hot_topic_hour_registration.htm.
Headlines for the February 22, 2013 – Utility E-Alert
UTILITY E-ALERT
#1113– February 22, 2013
Table of Contents
COAL – US
COAL – WORLD
GAS/OIL - US
GASIFICATION
NUCLEAR
BUSINESS
HOT TOPIC HOUR
For more information on the Utility Environmental Upgrade Tracking System,
click on:
http://home.mcilvainecompany.com/index.php?option=com_content&view=article&id=72
China is the Leading Purchaser of Air Pollution Control Equipment
China will lead the world in air pollution control (APC) investments. In
the next five years, China will spend $76 billion for APC equipment. On a
purchasing parity basis (the cost in Europe or the U.S.), the value is $143
billion. This is the conclusion of the McIlvaine Company by aggregating the data
in the six world market reports which McIlvaine publishes relative to air
pollution control.
When you think of Beijing ambient air quality also think of Los Angeles.
Both areas are subject to unfavorable climatic conditions. Pollution tends to
stagnate rather than be blown somewhere else. Los Angeles has spent more than
any other city to obtain clean air, but its ambient air quality is not nearly as
good as that of most U.S. cities.
The combination of poor climatic conditions and rapid industrialization have
created a health threat which the Chinese have recognized and are highly focused
on reducing the potential harm.
Labor rates in China are increasing. Certain components such as selective
catalytic reduction (SCR) catalyst are selling at close to world prices.
However, in general, the Chinese are able to build and install air pollution
systems at half the cost of the Europeans or the Americans. Over the next
five years, they will install APC systems with an equivalent value of $143
billion (purchasing parity basis).
APC Investment 2013-2018
($ Billions) |
||
Category |
Actual |
PP |
Scrubbers |
30 |
60 |
SCR and other NOx
Control |
18 |
28 |
Precipitators and Fabric
Filters, all Industries |
20 |
40 |
Thermal Treatment |
5 |
9 |
Monitoring (ambient and stack) |
3 |
6 |
Total |
76 |
143 |
The biggest category will be scrubbers. Most of the scrubber investment
will be in the power industry. However, the chemical, steel, mining, refining
and other industries will also be purchasers. China will spend more on NOx
control with SCR than the rest of the world combined. China will also spend more
for electrostatic precipitators than the rest of the world.
For more information on:
Air & Water Pollution Monitoring World Markets,
click on:
http://home.mcilvainecompany.com/index.php?option=com_content&view=article&id=106extsup1.asp
Electrostatic Precipitators: World Market,
click on:
http://home.mcilvainecompany.com/index.php/component/content/article?id=48#no18
World Fabric Filter and Element Market,
click on:
http://home.mcilvainecompany.com/index.php/component/content/article?id=48#n021
FGD World Markets,
click on:
http://home.mcilvainecompany.com/index.php?option=com_content&view=article&id=48#n027
Scrubber/Adsorber/Biofilter World Markets,
click on:
http://home.mcilvainecompany.com/index.php/component/content/article?id=48#n008
Thermal/Catalytic World Air Pollution Markets,
click on:
http://home.mcilvainecompany.com/index.php/component/content/article?id=48#n007
Scrubber Revenues to Approach $6.9 Billion in 2014
Expenditures for industrial (not power) scrubbers will be just under $6.9
billion in 2014. This is the latest forecast in the McIlvaine
Scrubber/Adsorber/Biofilter World Markets. (www.mcilvainecompany.com)
Scrubber Revenues ($ Millions)
Subject |
2014 |
Absorber |
3,148 |
Adsorber |
1,319 |
Biofilter |
544 |
Dry Scrubber |
539 |
Other |
262 |
Particulate |
1,084 |
Total |
6,896 |
This forecast does not include the flue gas desulfurization scrubbers used in
power plants. These are included in a separate report because this application
is large enough to equal all the other applications combined. The forecast does
include scrubbers used in the iron and steel, pulp and paper, chemical,
refining, mining and even those used for odor control at municipal wastewater
plants.
The forecast includes absorbers used for acid gases, adsorbers with carbon or
other media to adsorb gases or liquids, biofilters which utilize microorganisms
to convert volatile organic compounds, dry scrubbers which use spray driers or
fluid beds to absorb noxious gases, particulate scrubbers which take out
particles from the air and a group of miscellaneous scrubbing types including
condensation.
Asia is outspending the other regions. This is due to the substantial
industrial expansion taking place. Steel and mining have been the most
active applications. More recently, the construction of waste-to-energy plants
and the expanded use of scrubbers in the chemical industry have changed the mix.
International suppliers account for only 40 percent of the market. Most of the
market is served by in-country firms or those whose range is only a few
countries. Most scrubbers are fabricated from steel plate. Therefore, scrubber
manufacturers are more likely to be designers who subcontract the actual
scrubber construction. Many contracts include the scrubber wash water
recycle and wastewater treatment processes along with the scrubber, fan,
ductwork and stack. Recovery and reuse of the scrubber wash water is
generally an economic and environmental necessity.
For more information on Scrubber/Adsorber/Biofilter World Markets
http://home.mcilvainecompany.com/index.php/component/content/article?id=48#n008
Offshore Wind Makes Steady Progress
While offshore wind farms are very popular in Europe they are just beginning to
make headway in the United States. McIlvaine tracks these developments in
Renewable Energy Projects and Update.
Massachusetts Approves Cape Wind/NSTAR Power Purchase Agreement
Cape Wind secured another major milestone with the approval by the Massachusetts
Department of Public Utilities (DPU) of the 15-year Power Purchase Agreement
(PPA) with NSTAR to buy Cape Wind’s energy, capacity and renewable energy
credits.
The NSTAR /Cape Wind PPA is for 27.5 percent of Cape Wind’s power. In December,
2011, the Massachusetts Supreme Judicial Court unanimously upheld the DPU’s
approval of Cape Wind’s PPA with National Grid for 50 percent of Cape Wind’s
power.
Theodore Roosevelt IV, Managing Director of Barclays and Cape Wind’s Financial
Advisor said, “Taken together, these two PPAs provide Cape Wind with the
critical mass to continue securing project financing.”
Successful
Bidders in Northern Ireland Offshore Energy Leasing Rounds Announced
The Crown Estate announced the award of development rights for three offshore
renewable energy sites in Northern Ireland's coastal waters.
This follows competitive tender processes over the last ten months that
attracted significant interest from national and international renewable energy
development companies.
The projects, which together could deliver 800 MW of electricity, comprise an
area located off the south east coast of County Down for development of a 600 MW
offshore wind farm and areas off the north east coast of County Antrim for two
tidal stream projects each of up to 100 MW near to Torr Head and Fair Head.
All parties have now signed legal agreements with The Crown Estate, as they have
responsibility for leasing the seabed for renewable energy in all UK waters.
This will enable the companies to take their proposals forward and carry out
detailed surveys and planning work before their proposals are submitted to the
relevant Northern Ireland bodies for consent.
The companies who have been awarded rights to develop the offshore renewable
energy opportunities in Northern Ireland are:
· First
Flight Wind Limited for the 600 MW offshore wind area: a joint venture between
Dong Energy of Denmark and RES-B9 (NI) Offshore Wind Limited, which combines the
local wind development experience of Northern Ireland company B9 Energy with
Renewable Energy Systems, part of the RES Group, an international renewable
energy project developer.
· Tidal
Ventures Limited for the 100 MW tidal opportunity at Torr Head:a joint venture
between OpenHydro Group, a designer and manufacturer of tidal turbines, and Bord
Gáis Energy one of Ireland's leading energy providers.
· DP
Marine Energy Limited with DEME Blue Energy for their 100 MW tidal stream energy
project off Fair Head: this project is a consortium comprising Cork based DP
Marine Energy Limited and the Belgian marine engineering company DEME Blue
Energy.
E.ON Names Newhaven Port as Operations and Maintenance Base for Proposed Rampion
Offshore Wind Farm
E.ON has announced that Newhaven port would be the operations and maintenance
base for its proposed Rampion Offshore Wind Farm if the development is granted
approval. The decision has been made following a rigorous technical
assessment of both Newhaven and Shoreham Ports.
The move could create up to 85 full time permanent jobs with the majority being
recruited locally. It would also see part of Newhaven Port being
modernized and redeveloped through E.ON's investment in the new facility, which
would support the operation and maintenance of the proposed offshore wind farm.
The operations and maintenance base would contain office space, equipment
storage and vessel mooring which would be used by a team dedicated to operating
and maintaining the wind farm for the lifetime of the project1. A separate
planning application would need to be made to the local planning authority for
the O&M site before the development could take place.
The proposed offshore wind farm, which would be located 13 km off the Sussex
coast at its nearest point, could feature between 100 and 195 turbines depending
on the model used. The site could accommodate an installed electrical
capacity of up to 700 MW, which E.ON estimates could generate enough electricity
to supply the equivalent of around 450,000 homes.
Wood Group Awarded Multi-Million Pound Contract for Major UK Offshore Wind Farm
Wood Group has been awarded a £17 million management contract to fabricate,
install, commission, operate and maintain two weather monitoring stations in one
of the UK’s largest offshore wind farm developments off the Norfolk and Suffolk
coast. The project will be delivered by the Wood Group Kenny business unit,
including leading renewable energy consultancy SgurrEnergy. The masts will
collect vital wind data that will be used to design the wind farm and estimate
the long term energy production of the site.
SgurrEnergy will manage the supply, installation and commissioning of the full
instrumentation, power and ancillary top side monitoring equipment using Carl C
lattice tower met masts. Fabrication and offshore installation management of the
monopile structure to support the equipment platform and tower met mast will be
undertaken by Wood Group Kenny, applying its extensive offshore industry
experience.
Fabrication of the meteorological (met) masts will start in November 2012 and
installation in the East Anglia Offshore Wind Zone is planned for summer 2013.
As part of the operation and maintenance contract Wood Group Kenny has already
recruited four employees to fill key positions within the project.
Vattenfall and SWM Have Commissioned the Accommodation Platform for DanTysk
Offshore Wind Farm
From 2014 onwards, quiet rooms with a shower, internet access and a TV will make
everyday life more comfortable for the members of the DanTysk Wind Farm
maintenance team — right in the middle of the harsh North Sea. Vattenfall and
the Stadtwerke Munich have now commissioned the Schleswig-Holstein based company
Nobiskrug, whose headquarters is in Rendsburg, to build the offshore
accommodation platform. The platform will be built in the Abu Dhabi MAR dockyard
Kiel. The beginning of construction work is scheduled for spring 2013; the
platform should then be erected on the DanTysk wind farm 70 km from Sylt in
autumn 2014. The platform will be able to cater for up to 50 people and will be
in use 365 days a year.
The idea of housing service teams in living quarters directly on offshore wind
farms has not been seen in Germany before. The idea originates from the oil and
gas industries. As well as providing accommodation for the crew, the living
quarters will include a catering complex, washing facilities, workshops, storage
areas, offices and room for leisure activities. "Anyone who's experienced the
harsh climate of the North Sea, with its strong winds and waves, will understand
the importance of good working and living conditions for the maintenance teams
on site. In Germany we're facing particular challenges because offshore wind
farms are located up to 100 kilometers from the coast," explains Holger Grubel,
head of the DanTysk project. "At these distances it simply isn't possible for
crews to commute by ship every day. It would take too long to transfer crew
members and the risk of some of them getting sea sick and being unable to work
would be too high. The accommodation platform will be anchored on solid ground
which means a safer and more comfortable environment for our teams," says
Grubel.
In total there will be 80 wind turbines at the DanTysk wind farm, generating 288
MW of climate neutral electricity for around 400,000 households. Installation of
the wind turbines at DanTysk is due to start in December 2012. The entire wind
farm is planned to be up and running in 2014.
For more information on Renewable Energy Projects and Update
please visit
http://www.mcilvainecompany.com/brochures/Renewable_Energy_Projects_Brochure/renewable_energy_projects_brochure.htm
----------
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Bob McIlvaine
President
847-784-0012 ext 112
rmcilvaine@mcilvainecompany.com
www.mcilvainecompany.com
191 Waukegan Road Suite 208 | Northfield | IL 60093
Ph: 847-784-0012 | Fax: 847-784-0061
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