Weekly IIoT Webinars cover the Range of Markets from Power to Cleanrooms and from Centrifuges to Turbines
McIlvaine services cover flow control and treatment for many different industries. The new effort relative to IIoT N031 Industrial IOT and Remote O&M touches on all the industries and all the products which McIlvaine analyzes. Each week there will be an IIoT webinar focused on an industry or subject. A supplier of stainless steel or filter media may not immediately see the relevance of IIoT to his research and marketing efforts. However, IIoT will continuously deliver a myriad of white papers relative to specific fibers, filter media, and stainless vessels and piping. It will provide the materials supplier with knowledge which will help him develop products best suited to each process. IIoT will have major impacts throughout the supply chain. The webinar on Thursday, March 2 will cover IIoT and Remote O&M for coal-fired power plants. You can register for this event plus see scheduled IIoT webinars through August at Weekly IIoT Webinars
Coal-fired Boiler IIoT needs to draw on Accumulated Materials Wisdom
IIoT promises to deliver higher efficiencies and lower operating costs to coal-fired boiler operators around the world. Much of the progress will be dependent on better choices of existing materials and development of new ones.
When linked to remote O&M centers coal-fired boilers in developing countries can perform to the same high levels as units in countries with the greatest reservoir of materials knowledge.
Low cost sensors and wireless transmission will instantly generate huge amounts of data which is analyzed and acted upon by digital process management programs. All the programs need to incorporate a succession of data to information, to knowledge, to wisdom. The digital management from data to knowledge is well advanced, but the digital management to move from knowledge to wisdom is in its infancy. There needs to be a major effort to develop the Industrial Internet of Wisdom (IIoW) to interconnect the expertise of suppliers of materials, products, processes and plants. There needs to be interconnection between plants within a utility as well as with associations, research institutions, and the media. Materials suppliers do not generally deal directly with the end users, so interconnection of this group will be the most challenging.
With IIoT the corrosion rates of materials in the high temperature and pressure regimes created by ultra-supercritical operation will be comprehensively and continuously analyzed. There have been new alloys and new coatings created to deal with temperatures above 1000°F in the steam cycle. There are multiple coating materials and multiple means of application to a range of products from piping to valves.
In the McIlvaine service 44I Coal-fired Power Plant Decisions (formerly PPAQD), there is an ongoing evaluation of high performance valves for temperatures in excess of 750°F. This includes the coatings and other materials but also the valve design (ball, valve, gate) and the seal and component design (trunnion vs. ball etc.). This is just one of the many in depth studies related to coal-fired boilers that the McIlvaine Company has conducted over the years.
McIlvaine has taken the further step of compiling information on all plants within a utility organization. In 4S01 Berkshire Hathaway Energy Supplier and Utility Connect, McIlvaine is gathering information on the high efficiency condensate filter media at one plant vs. the lower efficiency media at another. For each of the boiler baghouses McIlvaine has surveyed the media material (fiberglass vs. PPS vs, P84) media construction (membrane laminate vs. multi nonwoven vs. woven) weight of material, and bag life.
All of these details become important in optimizing plant performance. McIlvaine conducted nine hours of webinars for BHE on reducing NOx at three units. Combustion optimization strategies offered by GE, Siemens, and Emerson had to be tailored to the temperature limitations of the filter media. A new catalytic high temperature filter media offered great promise but was eventually determined to be too costly a process modification.
In IIoT the first principle is to provide structure. This is equally true for IIoW. Among the initiatives already undertaken by McIlvaine to provide part of the structural foundation are the Decision Guides.
• 1ABC Fabric Filter
• 3ABC FGD and DeNOx Knowledge Systems
• 4ABC Electrostatic Precipitator Knowledge Systems
• N031 Industrial OIT and Remote O&M
IIoW is in its infancy and needs to keep pace with the IIoT progress. McIlvaine will be reaching out to all interested parties. On Thursday, March 2, there will be a webinar on IIoT and Remote O&M for coal-fired boilers. Weekly webinars on products, processes and industries will identify opportunities.
For more information on the weekly webinars click on Weekly IIoT Webinars
IIoT & Remote O&M for Coal-fired Power Plants
The following Table of Contents shows the subjects which are already or will be covered in the Coal-fired Power section in the IIoT and Remote O&M service. Material will be continuously added to the website. Contributions including InterwebviewsT are welcomed. There will be a webinar devoted to this subject on March 2 and then periodically in the future.
Table of Contents (Present and Future)
MARKETS

• Power Plant IIoT and Remote O&M Market by Regions and Year through 2030
• Coal-fired Boiler Forecast
• Potential for Third Party O&M
• $125 Billion/yr Power Plant IoT Instrumentation, Software, and Service Opportunity
• Market Segmentation by Major Component
• Drivers Impacting Product Markets
• Regulatory Drivers
o National and Local Regulations impacting Air and Water (The newsletter archives have monthly reporting of regulations in various countries from 1999 forward).
o Move Towards Electronic Reporting for All New Regulations (Not Simply Emailing Documents)
• Smart Instrumentation Opportunity
• Component Monitoring in Power Plants
• Remote O&M, Data Analytics and Subject Matter Experts
• Venture Capital backed new Entries in IIoT
OVERVIEW

• Changing routes to Market due to Remote O&M
• Changing Pace of Innovation due to IIoT
• Potential for International Suppliers to reach the Booming Asian Coal-fired Market
• How McIlvaine can help coordinate IIoT and IIoW
COMPONENT MONITORING

• Valves - webinars and data in the system on valves for FGD, ultrapure water, boiler feedwater, steam
• Pumps - analysis of energy saving with VFD in boiler feedwater, special designs to improve pumps for FGD recycle slurries
• Compressors - webinar on compressor choice for FGD
• Fans - coverage of axial and radial fans for air preheating, flue gas, FGD
• Filters - use in wastewater, ultrapure water, condensate, lubrication
Air Pollution - thousands of pages and many hours of webinars already in 44I Coal-fired Power Plant Decisions (formerly PPAQD) with analysis of mercury, NOx, SO2, CO, CO2, NO2, HCl mass particulate and opacity CEMS. In addition there are complete services on the technologies for Electrostatic Precipitation, FGD, NOx, and Fabric Filtration
• NOx Control Inventory Management and Telemetry Services from Yara
DATA ANALYTICS

• XMPLR
PROCESSORS

• Schneider ePAC Controller managed from Open Ethernet Backbone
• Rockwell Mobility Collaboration
• Yokogawa focus on process automation controlling gases and liquids
• SCADA Systems (SCADA is the glue for IIoT)
• SCADA Digitalization through Data Management, Information Management, Energy Management, Diagnostics Management and Open Communications - Siemens
• PLC Logging-Data Archiving - Siemens
• Process Historian - Comprehensive Archiving - Siemens
• SCADA Digitalization through Information Management - Siemens
• Data Management Logging - Siemens
• Web-based Operator Control and Monitoring
• Open Communication - Siemens
• ExxonMobil's Plan for the Future of Process Automation
• Eaton DR Evolution - Products & Solutions
• Kontron Second Largest ECT Provider
SOFTWARE

• Schneider Electric Wonderware System Platform Industrial Automation Solution
• Schneider Electric Enterprise Control System
• GE Digital
• Wind River (Intel)
• Huawei ICT
• Bosch Software Innovations
• SoftDEL
• OSISoft
• Seeq Interactive, Visual Tools to Analyze Industrial Process Data
• ValvKeep and OSHA Process Safety Management
• ValvKeep Lays the Foundation for Remote O&M
• Donaldson Remote Monitoring of Bulk Filtration Systems
• Analysis of IoT Pump Opportunities by John Hilberg of Accudyne
• AMI
• Meshify IoT Solutions for Pumps and Other Flow Control and Treatment Processes
• Decisive Classification is the Key to Integration with Software
• Platform Levels and why Level 3 is the Future
• GE Power and Tepco will jointly Develop Solutions for Japanese Fleet Using Predix
DISTRIBUTED CONTROL SYSTEMS

• ABB - Symphony
• Alstom (GE?) - Alspa
• Emerson - Ovation
• GE - Mark VI
• Hitachi (now MHPS) - HIAC and DIAYSYS
• Honeywell - Experion
• Metso - DNA
• Rockwell - Plantpax
• Schneider Electric (Invensys) - Foxboro
• Siemens - SPPA-P3000
• Yokogawa - Centum
ADVANCED PROCESS CONTROL

• Artificial Intelligence
o Fuzzy Logic
o Expert Systems
• Model Based Optimization
o Neural Networks
o Model Predictive Control
o Model Free Adaptive Control
SENSORS
Sensors used in combustion optimization

• Oxygen
o Tunable diode laser spectroscopy - presentations by Yokogawa, Siemens, and Zolo in McIlvaine webinars
o CO
o NOx
o Temperature
o Carbon-in-ash
o Coal Flow
o Air Flow
o Flame Detectors
COMBUSTION OPTIMIZATION
• GE NeuCo CombustionOpt - 2 presentations in McIlvaine PacifiCorp webinars
• ABB Predict & Control
• Emerson SmartProcess - presentation in McIlvaine PacifiCorp webinar
• Schneider Electric Invensys Connoisseur
• Siemens SPPA-P3000 - presentation in McIlvaine PacifiCorp webinar with inclusion of Zolo TDL
• EUtech EUcontrol
• STEAG Powitec PiT Navigator
SMART SOOTBLOWING

• GE NeuCo SootOpt - presentation in McIlvaine webinar
• Taber Knowledge-based Sootblowing
• Siemens SPPA-P3000
• Online monitoring of corrosive species
• Metso Corrored
• Zolo SALT
• Advanced optical sensors and imaging
• Optical fibre sensors, Fabry-Perot interferometer, Fibre Bragg grating
• Gas sensors using microstructured fibres
• Distributed optical fibre sensing
• Embedded optical fibre sensors
• Advanced spectroscopic techniques
• Raman spectroscopy
• Flame imaging
HIGH TEMPERATURE MICROSENSORS

• High temperature gas sensors (solid electrolyte, conductometric, microresonant)
• High temperature silicon-based sensors (temperature pressure)
• Metallic thin film sensors
WIRELESS SENSOR NETWORKS
REMOTE MONITORING

• Remote Monitoring Service Architecture - Emerson
• Remote Monitoring with Service in the Cloud - Emerson
• Bringing in the Suppliers for Maintenance Expertise - Emerson
• MHPS is Remotely Monitoring Coal-fired Plants from the Philippines
• MHPS Combining OSIsoft Monitoring Software with Cloud Based Analytics in Strategic Alliance
• Remote Water Chemistry Control - Nalco
• Nalco Data Management for Cooling Towers
• Sensor Improvement Enhances Remote Monitoring - Mettler Toledo
• Thermo Remote Monitoring and Diagnostic Service includes Proactive Support for Laboratories
THIRD PARTY O&M

• Uniper and India Power Joint Venture for Power Plant Services
• Luminant
• Duke
• Potential for BHE facilitated by McIlvaine Program
Gas Turbines and Reciprocating Engines coverage was enhanced by 50 Minute Webinar Last Week
On February 23 McIlvaine conducted a 50 minute webinar in which major subjects were briefly addressed and more detailed information was briefly displayed for subsequent review. The titles of individual sections are shown below:
Conclusions from the session:

• Gas turbine rotating parts are already being remotely monitored.
• The IIoT systems can be extended to include all GTCC components.
• A number of third parties are already providing remote O&M.
• Utility systems such as owned by Luminant, Southern and Duke are providing their own fleet wide IIoT and remote monitoring systems.
• The biggest IIoT revenue potential is for large scale power generation.
• The IIoT and remote monitoring percentage of OPEX will be higher for small gas turbines and I.C. engines.
• ROI is highest for remote compressor stations and offshore platforms.
• Distributed generation with CHP is a very big potential.
• Remote monitoring services such as offered by Luminant can be expanded to provide IIoT for the complete CHP system.
• Gas engines delivering heat, power and CO2 for indoor agriculture offer a small but very rapidly growing opportunity.
IIoT is Creating New Market Paths to the $100 Billion Gas Turbine Repair, Replace and Service Market
The Industrial Internet of Things (IIoT) is a powerful new force shaping the way gas turbine products are purchased. The impact of IIoT is being continually assessed in 59EI Gas Turbine and Reciprocating Engine Supplier Program.

• The inventory of existing gas turbine plants is growing at six percent per year and in the next few years the base will grow to two million MW. There are 30,000 individual units which routinely require service, replacement or repair of instrumentation, valves, pumps, filters, nozzles, and other components. There is a continual need for filter elements, treatment chemicals, lubricants, catalysts, reagents and other consumables. The market for replacement products, repair and services is $100 billion per year and will grow by more than six percent per year.

• IIoT provides remote delivery of comprehensive information about the operation and health of individual components. This data can be analyzed to identify problems and will create opportunities for the sale of better products to replace the existing ones. IIoT is creating new channels to market in contrast to the sale of products directly to a single end user.
Gas Turbine, Reciprocating Engine IIoT & Remote O&M Table of Contents
(Present and Future)
MARKETS

• Gas Turbine and Reciprocating Engine IIoT and Remote Markets for Components
• IIoT is Creating New Market Paths to the $100 Billion Gas Turbine Repair, Replace and Service Market
• Market Segmentation by Major Component
• Valves and Pumps Lead Component Purchases
• Drivers Impacting Product Markets
• Regulatory Drivers
• Gas Turbine Opportunities for Valve Companies Shaped by IIoT
• Multiple Gas Turbine Valve Purchasers with IIoT
• Inlet Air Filter Monitoring can be combined with Digitized Sourcing Programs

SUPPORT PROGRAM

• Gas Turbine Product and Services Enhanced by IIoT
• This program will help you make the Paradigm shift caused by IIoT and Remote Monitoring
• Example of Bi Weekly GT Supplier Alert
• Monthly GTRE Update
• Projects Updated Every Few Weeks. Here is the Update for November 26, 2016
• Details on GTCC in Each Country
• IIoT and Remote O&M Programs allow the Large Owners to Coordinate Operations Across the Fleet
• Lots of data relative to each component has to be gathered in a digital process management program. If the owner already has that information, the cost of program implementation with be far less.
• Operating ZLD Systems from McIlvaine GTCC Supplier Program
• New ZLD projects from McIlvaine GTCC Supplier Program

SOFTWARE

• AEP Monitoring with IBM Maximo and Siemens PrismMoni
• ABB Symphony Plus DCS for Collection and Analysis of Plant Data
• Schneider Electric is providing Comprehensive Services for Power Plants
• C3IoT Platforms used at all 24 ENGIE Business Units
• AECC replaces CEMS with Predictive System for Seven Gas Turbines

THIRD PARTY O & M

• Turbine Services Supports Sites with Different Make Turbines
• ProEnergy is One of Many Third-Party O&M Firms and the Trend is Accelerating
• IHI has Flexible Suite of O&M Services
• NRG Energy Services can provide Digital Process Management and Remote Monitoring of its Own and Client Facilities
• NRG Energy Services providing O&M to Golden Spread for Two Large Gas Turbine Plants
• Wood

REMOTE MONITORING

• Remote O&M, Data Analytics and Subject Matter Experts
• Laborelec (ENGIE) has Remote Monitoring and Niche Expertise Capability
• Ethos Energy operates Monitoring and Diagnostic Center
• Siemens Monitors More Than 9,000 Turbines at its European Data Center
• GE Gas Turbine Remote Monitoring Center
• Ansaldo Remote Monitoring and Diagnostic Center
• IHI Remote Monitoring Center for Gas Turbines
• MHPS Supplies Records of Daily Activity and Insights on Performance and Availability
• Parker has Condition Monitoring for Gas Turbines
• Parker Condition Monitoring for Gas Turbines

INDIVIDUAL COMPANY OPPORTUNITIES

• Braden
• Berkshire Hathaway

ENGINE APPLICATIONS

• Diesel and Natural Gas Internal Combustion Generators by State
• Drivers for the Growth in Use of Gas for Power Generation
• Factors Favoring Growth in the use of Stationary Engines for Power Generation
• Age of Gas
• Natural Gas Production by Type
• Developing Countries will have Greatest Growth in Consumption
• Projected Number of New Stationary CI (Diesel) Engines per Year from 2011 through 2017
• Distributed Power
• Existing CHP Compared to On-Site Technical Potential by Sector
• Total U.S. CHP Technical Potential Across All Facility Types
• Existing Commercial CHP Capacity by Prime Mover
• Remote Monitoring of Compressor Station Engines with Rockwell PlantPAx
• Wärtsilä Condition Monitoring
• Wärtsilä DMP Concept
• CBM Way of Working
• How Engine Health is Determined
• Cummins CHP Systems provide up to 90% Energy Efficiency
• CO2 Cleaned and Returned to Greenhouse to Gain 30% Plant Growth (600 ppm)
• H&H SCR System Reduces NOx and delivers CO2 to the Greenhouse. System could be Remotely Monitored
• Clarke Energy Greenhouse System
• Biogas Engines
• Power by Biogas ICEs vs. Central Power Plants
For more information click on N031 Industrial IOT and Remote O&M

Bob McIlvaine
President
847 784 0012 ext. 112
rmcilvaine@mcilvainecompany.com
www.mcilvainecompany.com
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