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Weekly selected highlights in flow control, treatment and combustion from the many McIlvaine publications.

• Hot Gas APC Markets, Decision Groups and SMUEs
• Surry Valves can be one of many valve decision guides
• High Performance Valves Role in IIoT and Remote Monitoring

 Hot Gas APC Markets, Decision Groups and SMUEs

The Hot Gas webinar on November 8 provided a good forum to discuss the impact of IIoT on the hot gas air pollution control market. This included the role of subject matter experts and groups to provide the needed Industrial Internet of Wisdom (IIoW) to empower IIoT. The subject matter expert interacts with a focused group to then become a subject matter ultra-expert (SMUE). The specific example was the dry scrubbing systems as two NAES plants.

Bob McIlvaine provided a market forecast for hot gas air pollution control the second speaker was Peter Spinney who made some important points relative to combustion optimization software based on decades of experience and as a founder of NEUCO which is now part of GE.  These systems can achieve:

.        Boiler efficiency increase of 0.5-0.75%

.        CO controlled to desired limit

.        Better ramping and load-following performance

.        Reduced opacity excursions

.        Avoided tail-chasing behavior

.        Better adherence to fan and mill amp limits

.        Improved situational awareness and process insight

NO_x control optimization software can

.        Reduce Reagent Usage

.        Lengthen Maintenance Intervals

.        Avoid Ammonia Slip

.        Reduce risk of Ammonium Bisulfate & Sulfur Trioxide deposits

.        Control "Blue-Plume" Opacity Excursions

.        Tighter, condition-based gas temperature control

.        Better Manage System Interactions

Peter is by all criteria a subject matter expert on solid fuel combustion optimization. If an international decisions group on this subject is formed and Peter is an active participant, he will become a subject matter ultra-expert.

Another individual of equal stature in the webinar Wednesday was Richard Thompson of FERCo. In McIlvaine Coal-fired Decisions, there are 28 articles covering FERCo presentations including several on In Situ Determination of Catalyst Activity, which will be an important tool in remote monitoring and participation by the catalyst suppliers.

Relative to combustion optimization FERCo

• Has demonstrated the MIC One, a microwave system that obtains on-line assessment and balancing of the coal flow distribution between burner lines of a pulverizer.
• Fabricated a multipoint NO, O₂, and CO instrument with continuously updated contour plots.
• Developed a new analyzer for rapid determination of coal ash LOI.

So if both Peter and Richard participate in the group designated CD 15 below, they would both contribute and receive insights.

Jeff DeNigris of Malvern discussed the use of their Insitec particle analyzer system to determine the sorbent size after grinding. It is economical to buy granular trona and then to mill it on site.  The particle size is critical to SO₂ capture. The online analyzer provides key information to the remote O&M operator. Other uses include activated carbon for mercury capture.

He also briefly discussed automated measurement of charge neutralization potential for flocculation in scrubber wastewater treatment. So Malvern is involved in both the slurry measurement (M2) and free flowing solids measurement (M3).

Crane Fluid Handling was also a participant. Two webinar blogs were excerpted to show insights on slurry valves and pumps. Jake Spence of Crane analyzed designs.

"Another important part of a slurry pump is its casing, which handles all of the pressure. Slurry pump casings should have larger gaps between the impeller and the cutwater tongue to reduce wear and to prevent large solid particles from getting stuck. Because of the additional space, there is more recirculation inside a slurry pump casing under various operating conditions. Again, this accelerates wear compared to a typical water pump."

Blogs should be interconnected to groups. In this case it would be a slurry pump group CD 17.  This would also include input from the mining and dredging industries. McIlvaine has recent TCO comparisons of slurry pumps used in dredging and mining because larger slower impellers are more expensive but have less abrasion.  Alternatively thicker casings mean longer life.

The final speaker was Stewart Nicholson of Primex. He discussed the need to separate process decisions from operation and maintenance. In an organization operating a number of dry scrubbers such as NAES, the decoupling of process decisions and the utilization of Primex experts to coordinate them allows NAES to move its operation and maintenance personnel from plant to plant depending on demand and the price of fuels. One of two coal-fired power plants may be down but the gas turbine plant operating 24/7 if the gas price is low. Primex is working toward becoming the process management supplier for the range of processes within both solid fuel and gas-fired power plants.

Relative to dry scrubbers, Primex has become an SMUE by founding a group of dry scrubber users (DSUA) and then continuing to participate in this group. NAES has achieved large reductions in operating costs with the following activities from Primex and the remote monitoring system based on OSIsoft software. The big feature of the process management is facilitating action and achieving results.

Primex provides weekly, monthly, and quarterly interactions with the plants.

Weekly

.        Interprets Data to assess Critical System Parameters

.        Provide "First Layer" Diagnosis & Troubleshooting

Monthly

.        Report & Interpret Key Performance Indicators

.        Identify Safety/Reliability/Efficiency Opportunities

.        Recommend & Facilitate Actions

Quarterly

.        Facilitate Onsite Team Meeting

.        Brainstorm & Discuss New Opportunities

.        Update Strategy & Action Plan

The achievement by Primex is noteworthy. Two days of presentations by end users at the DSUA conference provided convincing testimony to the program value. The question is now to duplicate this on a large scale.

A decisions group on dry scrubbing can work with DSUA and provide an international presence. If the group also creates a decision system and conducts regular webinars, it will be valuable to dry scrubber user 10,000 miles away as well as to one within easy travel distance.

IIoW is going to require significant expenditure and innovative thinking to be fully successful. IIoW also will require investment and innovation. It is unclear who should fund the groups and how the groups should be organized.

There will be a large number of groups needed to create IIoW. Here are just some of the ones relevant to dry scrubbing. The names in red represent speakers or contributors to the discussion.  The numbers in green represent subject areas where decision groups and subject matter ultra- experts are needed.

Subject matter experts become subject matter ultra-experts (SMUEs) based on maximum utilization of the decision insights created by the group. There are 100s of subject areas which warrant decision groups and SMUES. They all should interconnect with each other.

The process SMUEs (ID 1-4) will need to extract the wisdom from all the decision groups. So the solution to the valve sticking problems in dry scrubber systems in coke manufacturing plants created by groups M1 and CD18 needs to be communicated to the process SMUE in group ID4.

We look forward to your comments and suggestions in this unique effort.

You can view the webinar at:  https://youtu.be/qMPMyXWgO98

The full set of power points will be included in  

44I Coal Fired Power Plant Decisions

N031 Industrial IOT and Remote O&M

42EI Utility Tracking System

Surry Valves can be one of many valve decision guides

One of the decision groups is for slurry valves.  Fujikin lime slurry valves have been a concern and focus for improved maintenance. The SMUE is working with the component suppliers for better valve and bag designs.  Primex has redesigned bags due to unique process problems and then licensed the design to FLS, a major bag supplier.

Mcilvaine contends that the system is flawed when the SMUE has to redesign a component. (We have an interview with Shell on this subject in our Valve Insights) The better answer is a decision group on bags and one on slurry valves.  Valve suppliers  already have experience with lime and limestone slurries in other industries besides power.  Here is a Crane flow sheet on limestone slurries in a nickel plant.

A decision group benefiting from the range of slurry experience would be the best approach to the spray drier lime slurry valve problem.

High Performance Valves Role in IIoT and Remote Monitoring

If general purpose valves are the foot soldiers of IIoT then high performance valves belong in the armoured division.  Their performance is much more critical to the outcome of the battle to improve plant performance. IIoT promises to revolutionize industry but only if it is accompanied by IIoW (Industrial Internet of Wisdom). Decisive classification of high performance valve applications, valve designs, and materials is critical to IIoT success. High performance valves are defined and the program is explained at High Performance Valve Classification Program

Background articles and presentations are found in the Mcilvaine Global Decision Orchard under High Performance Valve.  If you prefer to view by company, application or process click on Full Display

Specific Initiatives

Four Severe Service Valve Decisive Classification Analyses are presently being assembled.  We invite contributions for any of them.  Please send your comments to Bob Mcilvaine at rmcilvaine@mcilvainecompany.com

Choke Valves in Oil and Gas

The choke valve market ranges between $250 million and $400 million per year depending on the definition and where we are in the oil and gas cycle. A significant portion of choke valve sales are to oil and gas companies. The definition also has a major effect on the revenue determination. The terms choke, control and axial are used in different ways.  With some definitions, the market is much larger than with others.  Here are some ways the term is defined:

·        Flow path: Angle most important - if it is axial it is control, if it is angle it is choke.

·        Trim:  If one type of trim is used it is most suitable for choke, if another it is for control.

·        Location:  If it is extraction it is choke, if it is other applications it is control.

·        Valve type:  For some valve suppliers "choke" is just one of a number of applications and not a type of valve.

With remote monitoring and IIoT evaluation of choke valve performance it is important that the relevant decisive classification of applications, valve types, and materials be clarified.  This is an ongoing project.  To view the questions and present status click on: Choke Valve Decision Guide

Power Industry Steam Valves

There are similarities and differences in the steam cycle valve requirements for nuclear, ultra-supercritical coal, supercritical coal, and gas turbine combined cycle plants.  What sizes are required?  What valve types are recommended for each application What is the appropriate support (trunnion, floating or a unique design)?  What materials are best for base load and rapid cycling applications? Power Industry Steam Valves 

Oil and Gas Gate Valves for greater than 5000 psi service

Subsea and shale applications are where one finds most of the gate valves with requirements for greater than 5000 psi service.  What are the specific applications, gate valve designs, and materials which are best for each specific application? This analysis is in the early stages.  We have identified some suppliers and their products and are asking them for comments.  We welcome input from all sources. Oil and Gas Gate Valves Greater than 5000 psi Decision Guide

Rising Stem Ball Valves

Rising stem ball valves are used in the oil and gas industry as well as in petrochemical plants. This analysis initially only has details on valves used more switching molecular sievers.  At this time there is only a partial analysis suppliers.  We need your input relative to additional applications, additional suppliers, and input on valve sizes and cost.  Rising Stem Ball Valves

Molecular Sieve Switching Valves

Many valves have been used on this service but few are performing as might be wished. Three valve designs are usually found in molecular sieve unit switching valve service: (1) metal-seated ball valves; (2) metal-seated, triple off-set butterfly valves; and (3) metal-seated, non-contacting, rising stem ball valves. Some rotary valve options such as the triple offset butterfly valves are relatively inexpensive to purchase and may perform adequately in the near term. Operators, however, have generally found them to be deficient in sealing capability, expected service life and total cost of ownership. Process disruption, high MRO expense and the inability to deliver a minimum of five years of continuous service between planned shutdowns have all been persistent negatives.

Historicallythe rising stem ball valve (RSBV) has been used in this application. But the selection is complicated and depends to some extent on the severe conditions existing. Zero-leakage carbide coated metal seated ball valves can be a preferred option in particularly severe service.

With remote monitoring and IIOT evaluation of valve performance it is important that the relevant decisive classification of applications, valve types, and materials be clarified.  This is an ongoing project.  To view the questions and present status click on: http://www.mcilvainecompany.com/Decision_Tree/subscriber/Severe_Service_Valve_04_14_16.pdf