Business Partners

Prevent the damaging effects of stray voltages on rotating shafts

Some rotating machines, because of their electrical or mechanical characteristics, induce an electrical potential (voltage) on their shafts during operation. Experts at Bently Nevada, Minden, Nev, warn that if this voltage is not managed, or if the grounding system fails, the voltage seeks an alternative path to ground. That path is the metal component closest to the shaft—typically a bearing or seal.

   The electric arcing that occurs, called electrostatic discharge, erodes metal surfaces and opens the tight clearances that these components depend on for proper operation (Fig 1). If undetected, electrostatic discharge will gradually destroy the bearing or seal, change the rotor dynamics of the machine, and may even damage the shaft.

   Carbon brushes are most commonly used for shaft grounding, say engineers at Magnetic Products & Services Inc, Holmdel, NJ, even though they consider them unsuitable for such duty. Reasons may include one or more of the following:

  • They do not operate satisfactorily in the presence of oil and dirt.
  • Satisfactory performance is possible only when cooling air contains at least 3 gr/ft3 of water vapor.
  • A carbon-brush current density of 40-60 amp/in.2 must be maintained at the brush contact surface. This goal is virtually impossible to achieve at normal, very low grounding currents.

   Failure to satisfy any of these conditions can initiate the build-up of a highly resistive glaze at the carbon-brush contact surface, and this is conducive to arcing and over-heating. Note, too, that if copper straps are used for grounding, the need for frequent maintenance can be expected. They can become fouled with dirt in just a few days of operation.

  Cutsforth Inc, Bloomington, Minn, introduced in mid-December a grounding system featuring dual copper grounding ropes that is said to maintain shaft voltages at lower levels than traditional solutions—even in dirty environments and where ventilation and cooling air are not filtered. The system’s universal mounting feature permits its installation on all OEM models and frames (access details at www.cutsforth.com/shaftgrounding.php).

   To maintain shaft voltage at a very low level, Cutsforth uses a redundant collection system that includes both grounding ropes and carbon brushes, both of which can be removed and replaced with the machine in service (Fig 2). It’s as simple as flipping a switch, according to CEO Rob Cutsforth. The design also allows for quick measurement of shaft voltage with a standard voltmeter.

   Cutsforth is a product design, manufacturing, and services company specializing in removable generator brush holders and online collector-ring truing services. 

Pratt & Whitney forms strategic alliance with Wood Group GTS

Pratt & Whitney Power Systems (PWPS) announced at Power-Gen International in Las Vegas in mid-December that it has formed a strategic alliance with Wood Group GTS to jointly service the industrial gas turbine aftermarket. Specifically, GTS has been granted an exclusive 10-yr license for the sale and distribution of PWPS-manufactured combustion hardware, hot-gas-path (HGP) components, and  high-technology repair services.

   The guarantee on parts availability helps GTS compete against the OEMs and other third-party providers of long-term service agreements. PWPS benefits by having a proactive partner with world-class maintenance capabilities to help keep its shops humming, while retaining the right to directly sell parts and repair services on a transactional basis.

   Recall that PWPS and GTS have worked together successfully for years in the aero market. Their joint-venture company, Wood Group Pratt & Whitney, has service shops dedicated to the inspection, overhaul, and repair of FT4 and LM2500 engines. For the “F” technology market, PWPS President Peter Christman remarked, “The combination of PWPS’ engineering, new-part manufacturing and repair technology, and GTS’ service experience and risk-management strategies is a compelling proposition.”

   FT4000 Swiftpac®. Also announced at the conference was the development of the FT4000 Swiftpac®, which is based on one of the aviation industry’s most widely used aircraft engines—the PW4000 turbofan. It has more than 26-million hours of operating experience on the Airbus A330 and Boeing 777 airframes. The FT4000 Swiftpac will be offered in 60- and 120-MW compact power blocks designed for simple-cycle, combined-cycle, or cogeneration service.

   The new land-based package promises 41% efficiency without the complexities of intercooling. It features relies a modified core compressor and turbine from its aero parent—maintaining more than 90% parts commonality with the PW4170 and PW 4090 engines. Plus, it has a new LP compressor and power turbine, both designed for durability and enhanced onsite maintainability. An advanced airfoil design and variable geometry contribute to optimized performance. Wet compression is provided boost power output at ambient temperatures above ISO conditions.

   An FT4000 prototype will be available in 2013, production units the following year.

   APR Energy. Finally, PWPS presented the details of a strategic partnership with UK-based APR Energy plc to jointly address global temporary power needs and to increase the availability of mobile turbines.

   Executives noted that the partnership already has facilitated APR orders totaling 100 MW on a flexible delivery schedule. Under the terms of the global agreement, APR is the [IT] exclusive [RM] provider of PWPS’ FT8® Mobilepac® rental power solutions. The company also benefits from a 12-month warranty, five-year service agreement, and access to dedicated global support from the engine maker—including project management, engineering, and aftermarket resources.

   The FT8 Mobilepac can be installed at a prepared site in eight hours and be producing 25 MW of emergency power within a day. The generating unit comes in two trailers, has dual-fuel capability, and can be connected to 50- or 60-Hz grids. The first trailer contains the gas turbine, electric generator, exhaust collector, diffuser, and engine lube-oil system; the second carries 15-kV switchgear, control system, operator panel, protective relays, batteries and charger, motor control center, and hydraulic start package.

Wood Group helps powerplant owner/operators reduce life-cycle costs

Wood Group GTS was built through the acquisition of many companies offering specialized services for industrial gas turbines. Integration of such diverse resources is challenging and takes time. GTS’ goal of providing the industry a comprehensive O&M solution focused on equipment life-cycle cost reduction is now a reality, the editors were told at Power-Gen International in mid-December.

   The final pieces of the “puzzle” fell into place with the acquisition of Dublin-based Shanahan Engineering at the end of 2009, the acquisition of Gas Turbine Efficiency Ltd (GTE) in November 2011, and the signing of the license agreement with PWPS described in the previous article.

   The Shanahan purchase provided GTS a geographic footprint in the Eastern Hemisphere and a closer working relationship with equipment OEMs, which is important for projects where new equipment is required. The EPC contractor also brought to Wood Group its plant commissioning and maintenance-service expertise.

   That acquisition already has borne fruit. Wood Group expects to complete the conversion of two 7EA simple-cycle peakers in California to a 335-MW combined-cycle plant in the mid-2012 timeframe and it is under contract to build an 800-MW combined cycle in Israel powered by a dozen LM6000s.

   The GTE acquisition expanded Wood Group’s capabilities in several areas and made a meaningful contribution to the company’s ability to provide gas-turbine performance-based solutions. To illustrate:

  • The compressor cleaning system developed by GTE is installed on more than 800 stationary gas turbines and has over 20-million hours of run-time.
  • ECOMAX™ automated engine tuning technology continues to generate positive feedback for its ability to protect GTs against emissions excursions, lean blowouts, and excessive parts wear caused by high combustor dynamics.
  • Skid-based fuel systems from GTE, installed in many plants, are equipped  to condition gas for optimal combustion as well as to measure its flow and determine its composition.
  • Fogging systems boost power output on hot days.

   The PWPS agreement enabled GTS to enter the “F” technology market with comprehensive maintenance solutions complete with a long-term service contracts. Wood Group CEO Mark Papworth said the company’s “package provides a truly ‘independent’ and high-quality solution for F-technology units to mitigate the technical and commercial risks of turbine operation.” He added that “We have a track record of service innovation and of lowering the cost of ownership for industrial gas turbines.”

   Wood Group’s Frank Avery, who manages the company’s Power Plant Services business unit, and PWPS VP Chuck Levey explained during a press conference why the two companies formed this alliance and how 7FA owner/operators benefit (Fig 3).  Opportunity was a major factor in the “why.” Many existing service agreements will expire over the next several years, the business leaders said, opening the door for third-party providers. Focus of the alliance is to grow the companies’ share of this emerging market.

   “How” 7FA operators will benefit from the alliance include the following, Avery and Levey told the group:

  • Doing business with a leading independent services provider which puts customer interests first.
  • Providing customer assurance with proven solutions for new-parts supply and high-technology repair services.
  • Achieving lower equipment life-cycle cost by working with a team having a solid track record of service innovation.
  • Optimizing turbine performance through a basket of services that include dynamics monitoring and tuning, power augmentation, etc.

   Commercial success was only a heartbeat from the signing of the agreement with PWPS. On the last day of Power-Gen, Wood Group announced that it had inked a multi-million-dollar deal with Associated Electric Cooperative Inc, Springfield, Mo, to manage the utility’s Dell Power Plant (Fig 4)—a 2 x 1 7FA-equipped combined cycle (access “Completing a half-built mothballed plant presents special challenges” in the 4Q/2007 archives at www.ccj-online.com).  A long-term gas-turbine maintenance contract is part of the arrangement.

   GTS is responsible for care and custody of the plant, taking full responsibility for daily operations and routine maintenance, as well as performing all major maintenance services on the gas turbines and balance of plant—including supply of engine HGP parts, repairs, and field service. Wood Group also will install its ECOMAX automated tuning system to optimize GT performance.

Wood Group a world leader in gas-turbine MRO services

Wood Group GTS consists of five business units with Mark Papworth as CEO. The firm has been in business for more than 25 years, has annual revenues of over $1 billion, a global customer base, and more than 4000 employees in 15 countries. Wood Group’s primary objective: Apply its expertise to increase the performance and reliability of critical rotating equipment so customers can maximize the return on their power-generating and mechanical-drive assets. The five business units are:

  • Power Plant Services, headed by industry veteran Frank Avery, provides O&M, repair, and overhaul services for simple-cycle, cogeneration, and combined-cycle facilities. This group is responsible for the operational performance and system reliability for its customers’ power generation assets. More than 20,000 MW of installed capacity worldwide currently is under contract. Service agreements are offered in a full range of flexible contractual models to meet all scales of operation, including the following: full care and custody, integrated services, individual services.
  • Oil, Gas & Industrial Services, directed by Iain Murray, primarily serves oil companies—national, international, and independents—much the same way Avery’s organization serves electric power producers.  
  • Power Solutions, under the direction of Mark Dobler, operates like an EPC contractor to provide new, serviceable, and refurbished power generation packages and ancillary equipment.
  • A fourth business unit manages the company’s business relationships with its joint-venture partners. Recall that GTS provides OEM-approved maintenance, repair, and overhaul services for aero engines manufactured by Rolls-Royce, Pratt & Whitney, and GE Energy.
  • ASU, the fifth unit, encompasses all businesses that do not fit in the first four—including aero, steam, and union field services. It is headed by Nick Blaskoski.

   The GTS management team considers the company the world’s leading independent provider of maintenance, repair, and overhaul services for industrial gas turbines made by all OEMs.

Turner relocates to Bangkok

Marcus Turner, a familiar face at user-group conferences both as the chief marketing officer of Gas Turbine Efficiency and as CEO of Control Center LLC (one of the companies acquired by GTE), is the new VP sales for Asia/Pacific at Wood Group GTS. He relocated to Bangkok at the end of 2011. Catch up with Turner at this new email address: marcus.turner@woodgroup.com.

Luzzatto hired to ‘take Chromalloy to the next level’

Chromalloy is a global technology leader in advanced repairs, coatings, and replacement parts for critical components required in commercial-airline, military, and industrial gas turbine applications. The company has a history of developing innovative and proprietary coatings and processes that allow engines to achieve higher efficiencies by operating at higher temperatures. 

   Before the acquisition of Sequa Corp, Chromalloy’s parent, by The Carlyle Group in July 2007, the company focused on aircraft engines (on-wing and stationary) and had a relatively low profile on the frame side of the electric power industry. Chromalloy was characterized by many geographically dispersed manufacturing, coating, and repair facilities, several of which might be involved in a particular scope of work. At times, communication with at least some shops was challenging.

   Armand F Lauzon Jr, who was appointed president of Chromalloy in 2008, overhauled business units and reorganized facilities to prepare the company for growth. Among his most visible and recent accomplishments, Lauzon dedicated a $30-million investment casting facility in Tampa in late 2010 and an adjacent $5-million ceramic core facility in 2011. Both plants are equipped to support F-class gas-turbine fleets. A new Engineering Center of Excellence recently opened in Palm Beach Gardens, Fla; it will do double duty as corporate headquarters.

   Lauzon also established joint ventures and strategic partnerships in the aircraft engine and industrial turbine markets—primarily with OEMs and their customers. Last October, with Chromalloy positioned for success in the energy sector, Sequa announced  that Lauzon had been promoted to CEO (he retains his position as CEO of Sequa Corp) and Carlo Luzzatto, a seasoned energy-industry executive, had been hired to “take Chromalloy to the next level.”

   Luzzatto, an electrical engineer by education  (Univ of Genoa, Italy), came to Chromalloy with experience in both the electric-power and oil and gas industries. He had business-unit leadership responsibilities at both Ansaldo Energia and GE. Straight-talking, relaxed, and confident, Luzzatto left no doubt during his presentation at Power Gen that he knows well Chromalloy’s businesses, customers, and prospects, and the challenges of the energy markets.

   A primary goal is to grow Chromalloy’s business in the energy sector, which today is less than 20% of revenues. Objective is to increase that amount by 20% in 2012. Luzzatto stressed that Chromalloy was now a “total cycle” company, equipped to take new parts from the foundry to the engine. Perhaps his most interesting slide was one that estimated the global annual worth of service, repairs, and parts (but not upgrades) for all gas turbines in electric-power production at about $16 to $17 billion. A pie chart on that slide showed a typical breakdown in expenditures for an F-class gas turbine at 68% spare parts, 18% repairs, and 14% field service. Adding the first two percentages is indicative of Chromalloy’s potential.

Camfil Farr pursues business from the GT inlet to the top of the stack

Camfil Farr had a big-booth presence at Power-Gen—a stand to both showcase new products for gas-turbine owner/operators and to introduce new salespeople. There are perhaps a dozen companies competing for your gas-turbine and generator air filter business. Difficult to differentiate a product and make a buck in that environment, as Camfil Farr knows well. If you thought of this company as a filter supplier, it’s time to rethink your impression.

   The Camfil Farr representatives left no doubt they were solutions providers from the air inlet to the top of the stack and had the products and engineering capabilities to prove it. A lot of the company’s experience is European-based but a gas turbine is a gas turbine no matter where it is, the editors were told. Competitors for inlet and exhaust systems and enclosures are the OEMs and Braden Manufacturing LLC, the leading third-party supplier for this equipment.

Alstom launches Next Generation GT24

Alstom rolled out the details on the Next Generation GT24 and companion KA24 combined cycle at a mid-September customer meeting in its new Chattanooga manufacturing facilities. At that time, the first engine in this new F-class series was being fabricated in the Tennessee plant for a customer in Mexico.

   Some industry observers say Alstom may find it challenging to sell a new F-class machine against the G, H, and J gas turbines offered by Siemens Energy Inc, GE Energy, and Mitsubishi Power Systems Americas Inc. But the company doesn’t think so. Alstom believes it has a competitive advantage because the GT24 is designed to provide the operational flexibility generating companies need to be successful in the profitable ancillary services market—including spinning reserve, back-up of intermittent renewables, etc.

   The defining characteristic of the GT24 is its two-stage combustion system known industry-wide as “sequential combustion.” The first stage consists of the company’s EV annular combustor and a single-stage HP turbine; the second, SEV (Sequential EnVironmental) burners in an annular combustor and a four-stage LP turbine. Sequential combustion combined with four rows of variable compressor guide vanes enable extended turndown capability and high part-load efficiency. Regarding the latter, heat rate is virtually flat from 100% to 80% of rated capability.

   At present, the GT24 is available only in a 660-MW (net), 2 x 1 combined-cycle configuration—known as KA24-2. The 1 x 1 single-shaft version offered when the product line was introduced 15 years ago is no longer available. The GT24 is not designed for simple-cycle service. Gross heat rate (LHV) of the 2 x 1 is 8531 Btu/kWh. Compressor pressure ratio is 35.4:1 and exhaust-gas flow and temperature are 1113 lb/sec and 1107F, respectively. Alstom engineers claim that when fully optimized, the KA24-2 is capable of producing more than 700 MW and operating at over 60% efficiency (both gross numbers).

   Part-load performance. At 50% of combined-cycle rated output, relative efficiency is 95% of that at full load—or five percentage points higher than typically possible with a conventional single combustor. Low-load pollutant emissions are enviable as well. At 40% of rated output, NOx emissions typically are between 2 and 3 ppm. Interestingly, at full load, NOx is just below 15 ppm. Sequential combustion offers no advantage over a single combustor regarding CO emissions.

   While it typically makes little, if any, sense to operate a multi-shaft combined cycle at less than about 40% of rated capacity (because you can shut down one gas turbine and run 1 x 1 with better performance results), the KA24-2 can benefit owner/operators chasing wind by “parking” at 20%—or less, depending on ambient conditions.

   Here’s how that works: Let’s assume must-take wind picks up. The operator backs off on combined-cycle output to maximize renewables generation, down to a nominal 20% of rated load. At that point, NOx emissions are very close to those at full load because the SEV combustor is shut down and the EV combustor is operating at maximum capability. Several hours later, wind dies down—suddenly perhaps. The operator can ramp up by 450 MW within 10 minutes to meet grid requirements.

   Maintenance cycles are of interest to all owner/operators. Alstom expects a 36,000-hr interval to the first hot-gas-path (HGP) overhaul when the unit runs in the maintenance-optimized mode; 28,000 hours for the performance-optimized mode. Three borescope inspections are required during the operating run. There are no combustion and major inspections for the GT24.

Siemens elbows its way into the crowded mid-range GT market

Siemens Energy promoted many products and services from its two-story Power-Gen booth, possibly the largest in the exhibition in terms of square feet. But not much appeared to be new—at least in the editors’ minds.

   Perhaps of greatest interest to gas-turbine owners and operators in the electric-power and oil-and-gas sectors was the company’s aggressive promotion of its almost-new 37-MW SGT-750 engine. It was introduced in November 2010. The Siemens Oil & Gas Div, Houston, is responsible for this machine in addition to all other engines rated from 5 to 47 MW which were purchased from Alstom in spring 2003.

   The SGT-750 is designed for both power generation (50 or 60 Hz) and gas compression (and other mechanical-drive applications). It will compete primarily against the well-known LM6000, Frame 6B, and RB211 machines offered by GE Energy and Rolls-Royce. Distinguishing features of the SGT-750 include the following:

  • A 13-stage horizontally split compressor with a 24:1 compression ratio and two rows of variable guide vanes for performance optimization.
  • Two-stage turbine driver for the compressor.
  • Mineral-oil-lubricated tilting-pad bearings.
  • Can-annular combustion system with dry low-emissions burners (15 ppm NOx corrected to 15% O2). There are eight cans.
  • Two-stage free turbine with a nominal speed of 6100 rpm.
  • Core engine can be swapped-out for maintenance within 24 hours.
  • Efficiency: 40% on natural gas.
  • Exhaust flow: 250 lb/sec at 864F.
  • Online performance monitoring and data analysis.

   Siemens announced its first order for the SGT-750 at Power Gen. Purchaser is Wingas GmbH, a joint venture between BASF subsidiary Wintershall and Russia’s Gazprom. It will be installed in the landfall cogeneration station for the Nord Stream pipeline in Lubmin, Germany. The pipeline will link Europe with gas reserves in Siberia. Electric power will be fed to the grid, exhaust heat will be used to reheat the pipeline gas to the temperature required for its distribution.

Monitor the control room on your iPhone, iPad

Emerson Process Management Power & Water Solutions introduced at its busy Power-Gen booth EDS Mobile, one of the electric-power industry’s first native applications for users of Apple’s iPhone and iPad devices. It uses standard Apple input gestures such as swipe, tap, drag, zoom, and automatic screen orientation.

   The motivation for EDS Mobile, said EPM President Bob Yeager, was “the opportunity to give our customers more flexibility in how they manage operations by offering our EDS technology on a mobile platform.”

   EDS Mobile provides remote users a high-fidelity representation of what the operator sees in the control room. More specifically, EDS gathers information from control systems at a single unit or fleet of units, as well as from other enterprise systems, into one place, presenting near-real-time data such as read-only process diagrams, alarm lists, and trends. Historical data can be accessed as well.

Using a widget menu, EDS Mobile also delivers key performance indicators (KPI), which can be customized to match customer metrics in the a

reas of fuel usage, plant availability, emissions, generation revenue, efficiency, and power factor. Each KPI icon contains multiple data points, enabling users to drill down to view detailed information and trends in near real time. To illustrate: CO2, CO, SO2, NOx, and opacity data can be viewed through the emissions widget.

   The app was demonstrated on an iPad by an Emerson engineer who stressed that there were multiple firewalls between the source of the data and the viewer. Also, that by being read-only, it does not violate any security rules promulgated to date by the North American Electric Reliability Corp.

Thor Precision opens rotor hardware shop

Thor Precision Inc, Greenville, SC, guided by founding partner and industry veteran Paul Pelinsky (ppelinsky@thorprecision.com) opens a value-added service center for aftermarket rotor hardware. Focus is on bolting for GE frame gas turbines—3, 5 (single shaft and two-shaft), 6B, 7E, and 9E—including compressor, turbine, unit, and load-coupling sets.

   The firm’s leadership team has more than 80 years of experience in the manufacturing of rotor hardware. Consulting staff includes a hardware engineer/metallurgist. All parts are reverse-engineered from OEM originals to guarantee fit, form, and function. Specifications exceed OEM standards and components come with complete raw material and manufacturing lot traceability. 

 

Products/services

Cutsforth Inc’s (Cohasset, Minn) height setter allows the end user to adjust the critical brush-mount height from the surface of the collector ring

  Brush key is a new portable brush and spring changing tool that can be used for Cutsforth’s brush holders and shaft grounding products (Fig 6).  (Fig 5). It also assures that the position of the brush holder is perpendicular to the center of the shaft. Easy and accurate refitting of the brush rigging is accomplished every time.

Ludeca Inc, Doral, Fla, offers Levalign® Expert as an accurate and easy method for measuring flatness and straightness of machine bases and foundations, split machine casings, as well as flatness and parallelism of circular, rectangular, and odd-shaped flanges. System consists of a self-leveling rotating laser and a sensor which interface wirelessly with a dedicated geometric measurement computer (Fig 7).

Membrana, Charlotte, NC, introduced a 14 x 40 Liqui-Cel® Membrane Contractor that extends the product line’s capacity from 400 to 550 gpm in a single device, making the it the largest membrane contractor degassing device on the market. The additional capacity requires the use of fewer contractors and connections resulting in a smaller footprint and lower capital expense. The new design’s increased area also reduces radial flow velocity which results in a low pressure drop (Fig 8).

Olympus NDT’s, (Waltham, Mass) instrument rental program offers the latest videoscopes, video cameras, ultrasonic thickness gages, ultrasonic flaw detectors, phased- array instruments, and XRF alloy and environmental analyzers as a cost-effective, short-term solution. The program enables rental of the latest technology loaded with the most up-to-date software, as well as the option to rent an instrument that you’ve used before. Rentals can be arranged for a single day or for several months and can earn credit toward purchase of the instrument.

   The new IPLEX UltraLite videoscope from Olympus offers an easy-to-hold lightweight ergonomic design along with a rugged IP55 compliant casing that stands up to rain, sand, and dust. The device is also available with a wide range of interchangeable optical tip adapters fitted with a bright LED that provides illumination for the viewing field.

BASF Catalysts Div, Florham Park, NJ, reported that its NOxCAT™ AD series of ammonia destruction catalysts have successfully controlled ammonia emissions to less than 10 mg/Nm3 with no net impact on NOx.

Parker Hannifin Corp’s  Instrumentation Products Div unveiled a new line of quality-assured Type 316/316L domestic and non-domestic seamless stainless steel tubing to complete its tubing, fittings, tubing tools, and training offerings. The line was designed for hydraulic and instrumentation applications in harsh media or corrosive environments where safety, integrity, reliability, and leak prevention are essential (Fig 9).

Mistras Group Inc’s Acoustic Combustion Turbine Monitoring System (ACTMS™) was successful in detecting and locating an S1 vane crack in an F-class combustion turbine at a NextEra Energy Resources combined-cycle generation facility. Jim Keener, VP of Power Generation Technical Services for NextEra Energy said the system was “effective in detecting stationary airfoil cracking on running combustion turbine compressors.”

First Independent Rotor Services, Houston, Tex, has designed a unique F/7F rotor transportation skid that provides better support over long distances. The new design, which is made with 100% domestic steel, has machined diameters on the support end in which the journals or shaft areas can rest, and which allows for a 0.625 in. stabilizing layer of rubber or other padding to wrap around the journals (Fig 10). The design also includes supports bolted on top that secure the rotor axially during transport. Because there are so few rotor transport skids available—and none to rent—FIRST will manufacture new skids as needed.

ESCO Tool, Holliston, Mass, introduced the MILLHOG® APS-438 air- powered saw and EscoTrack™ system which allows operators to cut sections of waterwall boiler tubes with increased efficiency. The leading edge of the blade cuts each pipe with +/-0.125 in. accuracy and is easy to attach and align. The track fully supports the saw, provides a smooth cutting action, and can produce a straight 4.375-in. deep cut while at the same time reducing operator fatigue. Saw requires 80 cfm of 90-psig air. It features a 3-hp pneumatic motor and uses 12-in. abrasive FRP blades that can cut stainless steel, Inconel®, ash pipe, and lined pipe. The steel track comes in 5-ftft. sections and attaches using weld tabs.

Indeck Power Equipment Co’s (Wheeling, Ill) new line of trailer-mounted O-Type rental boilers feature higher efficiency and greater reliability to meet institutional, utility, and industrial steam applications during planned outages or unexpected emergencies. The fleet includes units rated 40, 60, and 75 klb/hr at 395 psig. Boilers are designed for ease of delivery, install, and set-up. Piping is easily accessible and installation requires only a single electrical connection (Fig 11).

Mettler-Toledo Thornton, Bedford, Mass, announced a new water calculator application for smart phones and mobile devices. The free application enables specialists to easily calculate conductivity, resistivity, and total dissolved solids conversions, flow and flow velocities, temperature versus resistivity and conductivity of ultrapure water, sample and process flow rate unit conversions, and temperature conversions between Centigrade and Fahrenheit.

Swan Analytical USA’s (Wheeling, Ill) AMI Analyzer Sodium P features a measurement range of 0.1–10,000 ppb for analyzing dissolved sodium in feedwater, steam, and condensate. It allows for continuous monitoring of sample flow and reagent addition and creates a reliable reagent delivery system with easy grab sample capability. With the elimination of unnecessary moving parts, the instrument is a complete, ready-to-use system that arrives factory-tested, calibrated, and mounted on a stainless steel panel. The programmable instrument is also available as a dual sample stream option.        

E H Wachs, Lincolnshire, Ill, announces a new remote control for pneumatic machine tools. The Air Control Module (ACM), which needs no additional power sources, provides remote control operation of split frames or other pneumatic tools. Additionally, it allows operation from up to 26 ft away for enhanced comfort and safety (Fig 12).

ESCO Tool, Holliston, Mass, announces the portable Wart MILLHOG® right- angle, ID-clamping end-prep tool for preparing pipe for orbital welding in pipe fabrication and boiler maintenance applications. The tool can bevel, face, and bore simultaneously— including compound bevels and “J” preps—and provides consistent, contaminant-free end preps with torque-free performance (Fig 13). It operates over a 1.25 ID to 4.5 in. OD range with only six clamps and includes a robust gear drive supported by dual-opposed tapered roller bearings, a blade lock system, and TiN coated blades.

 

   Commander MILLHOG® pipe milling and prep tool performs any angle of weld prep, including compound and multi-angle, on high-temperature/

high-pressure heavy wall stainless steel, Super Duplex, P-91, and other hard alloy pipes. The tool features one mandrel and only seven sets of clamps for a full 3.75 in. ID to 14 in. OD range and pulls a thick chip without cutting oils. It is available with either pneumatic or hydraulic motors and includes dual-opposed tapered roller bearings and oversized clamps that spread the radial load for smoother welding end preps (Fig 14).

Multifab Inc, Sharon Hill, Pa, has introduced the DNT Series M-Flex 600 pipe and duct connection material which uses a new style of PTFE capable of maintaining strength during continuous operation to 600F. The material can be used in wet or dry situations while maintaining zero porosity. It also offers extreme flexibility, a 6:1 compression ratio, and demonstrates excellent non-flammability properties.

Turbine Technology Services Corp’s (Orlando, Fla) CMS-1000 monitors combustor dynamics in advanced-class gas turbines. The system, which can be portable or permanently installed, facilitates the optimization of a plant’s combustion system while taking control of emissions.

Swift Filters Inc, Oakwood Village, Ohio, added to its website an interactive industrial filter element cross reference tool with 200 manufacturers and filter brands comprising over 59,000 entries. The tool allows users the ability to quickly find the filter replacement which is functionally and dimensionally interchangeable with any specific OEM filter.

GE Power & Water, Atlanta, has introduced a flexible fuel-blending technology for 7FAs that allows operators to use process gas to displace some natural gas. The new solution allows for the blending of up to 5% hydrogen in a DLN2.6 combustion system and enables operators to use hydrogen as part of the fuel mix.

 

People

Joe Lesch, long a contributor to the CCJ, who retired as a VP of Chromalloy in January 2011 after 27 years of service, has opened his own shop, Lesch Consulting LLC. He is well known in the aero community for his knowledge of airfoil design, coatings, metallurgy, and engine overhaul. Less well known is that Lesch managed the O&M of Frame 7 assets for the first decade of his professional career. Contact him at josephalesch@att.net.

Gary D Keefe was appointed Johnson Matthey’s regional sales manager for the Southeast, based in Atlanta; Charles F Salotti, regional sales manager for the Southwest, based in Houston.

William (Will) Day was appointed VP/GM of the NAES Power Contractors office in Hillsboro, Ore. Day has over 30 years of regional sales manager for the Southwest, based in Houston.experience in power generation, including leadership roles at NRG Energy and Cajun Electric Power Cooperative.

Will Zmyndak is the new director of operations at Chromalloy’s Orangeburg (NY) advanced coatings and repair facility. He is a veteran of the aviation industry and has extensive experience with turbine-airfoil coating and casting. Zmyndak will lead manufacturing activities at the plant, which will continue to focus on new protective barrier coatings for gas turbines.

Jesse Murray was appointed manager of plant engineering and technical services for NV Energy’s Frank A Tracy Generating Station, located a few miles east of Reno, Nev.

Ron Shaver was recently appointed VP Operations at the Allied Power Group’s Houston protective coatings, heat treatment, and compressor repair facility. Shaver will oversee day-to-day operations at the facility.

Alan Martin and Dan Baldwin, both boiler engineering and service experts, were hired to bolster HRST Inc’s presence in the Gulf Coast area. Martin will be working out the Buna (Tex) office, Baldwin out of the Monroe (La) office.

Kurt Peninger joined Stellar Energy Systems as a division VP. He has 25 years of experience in the power industry, half of that at GE

Mike Cook recently joined HIP LLC’s Mechanical Field Services Group as technical services director. Most recently he was technical director at Wood Group’s HIT Field Services. 

Keith Brady, managing director of Rolls Wood Group, a 50-50 joint venture between Rolls-Royce plc and Wood Group, presented Modern Apprentice certificates to the first seven engineering apprentices to complete their four-year programs at the JV’s new training center. The program combines classroom experience with on-the-job training, mentoring, and college-day release.

 

Company news

Siemens Energy plans to build a new combustion test center for gas turbines in Ludwigsfelde, about 10 miles south of Berlin. The investment of 66-million euros will allow the OEM to study and validate the combustion processes in gas turbines at its own test center. The goal is higher engine efficiency.

   The company continues to expand its worldwide network of GT manufacturing facilities by investing more than $350 million in a new plant in Charlotte, creating 700 new jobs. The facility will supply countries with 60-Hz grids with gas and steam turbine/generators.

Allied Power Group, Houston, received certification from the International Standards Organization (ISO) for its quality system, which was established for repair of IGT components. The company’s 85,000-ft2 shop/office facility specializes in the repair of gas and steam turbine parts. It will be expanded by 32,000 ft2 to accommodate compressor repairs, thermal spray coating, heat treatment, heavy mechanical department, and in-house metallurgical lab for coating qualification.

Structural Integrity Associates Inc,  San Jose, Calif, acquired the Inspection Services Group of FBS Inc, State College, Pa, and entered into a strategic alliance with FBS to add new guided-wave technologies for nondestructive evaluation and/or structural health monitoring of piping systems and other critical components. A new Guided Wave Technology Center will be opened in State College to focus on the advancement and delivery of guided wave services for the energy industry.

NAES Corp and Fluitec International sign a preferred vendor agreement that will give NAES-operated plants the preferential services, scheduling priority, and cost concessions commensurate with the volume of business represented by the NAES-operated fleet. The solutions, products, and knowledge provided by Fluitec will allow NAES to optimize the performance of its lubricated assets across the fleet.

   NAES announced a new project services team to the Turbine Services Div. The team, which includes industry veterans Russell James, Rob Broglio, Rick Stanford, and Debi Patrick, will provide new management, sales, proposal, and support expertise to the division.

Siemens AG acquired Dutch sister companies NEM BV and NEM Energy Services (NES), both specialists in HRSGs for combined-cycle powerplants. The acquisition enhances Siemen’s position in the HRSG business and enables the company to expand capacities and bolster expertise for the future.

BASF announced that the Research and Development Council of New Jersey awarded a team of the company’s catalyst inventors the 2011 Thomas Alva Edison Patent Award for outstanding environmental contributions. The patent covers an emissions treatment system that removes NOx and particulate matter from diesel engine exhaust using a single component. The invention is an improvement over current technologies using two separate components because it saves space while also reducing weight and backpressure.

Air New Zealand Gas Turbines partnered with Consolidated Asset Management Services and Redwood II Operating Co LLC to form ANZGT Field Services, a new company that will offer improved services for customers in North America. Led by General Manager Frank Oldread, the company is operating out of a 20,000-ft2 state-of-the-art facility in Bakersfield, Calif.                               

Southern Research Institute plans a new SCR test facility that will allow utilities and others to independently test and evaluate catalyst performance.

NORD-LOCK, Elk Grove Village, Ill, acquires Superbolt Inc (US) and P&S Vorspannssysteme AG (Switzerland). The acquisition groups together products designed for critical bolting applications used in heavy industry and moves NORD-LOCK toward its goal of being the undisputed global leader in secure bolting.

 

Contracts

Rolls-Royce was awarded a contract to supply Petrobras with 32 RB211 power generation packages for eight floating production, storage, and offloading vessels used for processing hydrocarbons and storing oil (Fig 15).The equipment is for deployment in the Lula oilfields in the Santos Basin off the coast of Brazil.

Wood Group GTS won a long-term mobilization support and O&M contract from the new Bayonne Energy Center LLC. Wood Group is working closely with the owner’s EPC contractor and will assume full responsibility for the 512-MW plant once it is commissioned in spring 2012. The facility will have eight dual-fuel, rapid-start Rolls-Royce Trent 60 gas turbines.

   Wood Group GTS was also awarded an $11 million, multi-year contract by Empresa de Generacion Electrica de Arequipa SA to supply combustion and hot-gas-path capital parts for two GE Frame 6B gas turbines at the 71-MW Central Termica Pisco powerplant. Included in the contract is a provision for operational and critical spares along with repair of capital parts.

   A 12-yr contract to supply parts for 14 6Bs located at various sites in Oman has also been awarded to Wood Group GTS. Under the terms of the contract, Wood Group, will assist in modeling new parts demand fleet-wide thereby optimizing parts usage. The turbines are used in natural-gas extraction from established fields.

   A contract to overhaul a Solar Taurus™ 60 gas turbine installed along the Shaanxi-Beijing pipeline has been awarded to Wood Group GTS by a major Chinese oil and gas producer.

    A new parts order for GE 7EAs marks the first purchase by global gas and energy solutions provider Air Liquide from Wood Group GTS. The parts will be installed in Air Liquide’s Baoyou Cogen facility in Texas and at a plant in Louisiana.

   Dow Chemical Co USA has awarded a contract to Wood Group GTS for hot-gas-path components for an ABB 11D5 gas turbine located at the Plaquemine Chemical Plant in Southern Louisiana.

   A contract valued at over $2.7 million was successfully completed with the fitting of Wood Group GTS hot-gas-path capital parts in a Formosa Plastics Corp 7EA gas turbine at Point Comfort, Tex, one of the largest petrochemical facilities in the nation.

Rolls Wood Group’s gas turbine maintenance contract with the Shell UK Ltd was extended to 2015. The contract includes maintenance, repair, and overhaul services for 27 gas turbines operating on seven offshore platforms in the North Sea. The engines are in electric generation and gas compression service.

Innovative Steam Technologies (IST) was awarded three new power generation contracts including the design and supply of two OTSG units for the Lansing (Mich) Board of Water & Light. The second contract is for the design and supply of an OTSG unit for Windsor Locks, Conn, to be installed at the Algonquin Cogeneration Power Plant. The third contract, for the design and supply of an OTSG for Acarsoy Enerji in Denizli, Turkey, will be installed at the Arcasoy Enerji combined-cycle plant and will recover exhaust heat from an LM6000.

Everest Sciences Corp was awarded a contract for an ECOCool™ turbine inlet cooling system for a Solar Taurus 60 turbine located at a pipeline compression facility in Wyoming. The client, a large, integrated natural gas company, will rely on the ECOCool unit to enable the gas turbine to produce more power at greater efficiency while reducing operating costs and increasing revenue.

Vogt Power International Inc, Louisville, has been tapped by Siemens AG to supply HRSGs and associated equipment for the Lakeside 2 generating facility located in Vineyard, Utah. Vogt Power will design and deliver two supplementary-fired triple-pressure reheat HRSGs for use behind Siemens SGT6-5000F gas turbines.

   Vogt Power also announced it will supply HRSGs to the Siemens Energy’s Termozulia III project in La Canada de Urdaneta, Venezuela. Vogt Power will deliver two unfired triple-pressure HRSGs for use behind Siemens SGT6-5000F turbines. It will incorporate Vogt’s SMART design which features a high level of pre-assembly—modules, casing, interconnecting piping, and some structural steel all in one box—thereby streamlining onsite construction.

   The Electric Generating Authority of Thailand selected Vogt Power to supply HRSGs and associated equipment for two combined-cycle plants—one located in Ayutthaya and the other in Songhkla. The company will deliver two unfired triple-pressure level HRSGs with reheat for operation behind Siemens SGT6-5000F turbines.

 

Plant news

The Guadalupe Power Project, Marion, Tex, owned by MinnTex Power Holdings LLC, has contracted NAES Corp for O&M services. The plant has two 2 x 1 combined-cycle power blocks powered by F-class gas turbines and an extensive zero liquid discharge water/waste treatment facility.

West Deptford Energy, owned by LS Power Group, completed financing for the construction of a 738-MW natural-gas-fired combined-cycle plant in West Deptford Township, NJ. The project will utilize state-of-the-art turbine technology with advanced emission controls. Construction is to begin early in 2012.

Wolf Hollow, a 720-MW Texas combined-cycle, has been purchased by Exelon Corp. The plant will benefit from Exelon’s plans to invest nearly $5 billion in cost-effective, clean energy projects as part of the company’s Exelon 2020 strategy. 

Sentinel Energy Center, is now under construction in California. Co-owned by Competitive Power Ventures Inc, GE Energy Financial Services, and Diamond Generating Corp, the $900 million gas-fired 800-MW plant is located near Desert Hot Springs.