CCJ ONscreen Webinar Recordings

Achieving Efficiency and Reliability in Air-Cooled Condensers with Effective Cleaning, Testing and Inspection

Presented by Gary Fischer, BS, MBA of Conco Services Corporation

Achieving the perfect balance of efficiency and reliability in your Air-Cooled Condenser (ACC) is attainable through effective cleaning, testing and inspection.

Presentation Takeaways

Because of the large surface area of ACC units and the absence of cooling water, operating costs can be much higher than water-cooled equivalents, especially in hot summer months. Conco’s automated ACC cleaning uses a computer driven carriage and precision water jets that match fin geometry to safely and quickly remove fouling and debris.

Conco engineer Gary Fischer will discuss fouling tendencies in ACC units, the real-time impacts of fouling, the importance of keeping fin tubes free of debris, offline and online ACC cleaning options, as well as a case study of choked finned tubing in a Montana, USA plant.


Optimizing Generator Testing and Inspection During Your Turbine Outage

Developing and Implementing an Effective Generator Assessment Program
Presented by Phil Karwowski, EthosEnergy Group

The generator is routinely overlooked when developing an operation and maintenance program. As fleets mature, the potential for availability-limiting events caused by the generator continues to increase. However, if an operation and maintenance program is developed early to coincide with the outage windows of the turbine, forced outages can be minimized and availability requirements managed. EthosEnergy offers such a plan with its Generator Assessment Program (GAP).

Presentation Highlights

  • Discussion of different levels of testing and recommended inspections
  • Review of key potential failure mechanisms identified and corrected during outages.
  • Successful risk management and life cycle optimization by implementing a proactive GAP.


E12 HEPA Filter Technology pays biggest dividends on must-run engines

Technological advancements in HEPA filters
Presented by Tom Kelmartin, W. L. Gore & Associates, Inc.

  • How to Keep 360 Billion Cubic Feet of Air Clean
  • Efficiency vs. Life Span – How to have both
  • E10- vs E12 – A 135X Difference
  • Using Membrane Technology to Eliminate Corrosion
  • Economic Analysis – Saving $$$

Case studies: Would switching to HEPA benefit your plant?
Presented by Ryder Pingry, W. L. Gore & Associates, Inc.

Proven applications include:

  • Refinery – Heavy Industry, Urban, Costal Conditions – Over 2 yrs+
  • Power – Coastal Florida – 2 years – Almost Zero Dp Change
  • Chemical/Refinery – Industrial – Fouling and Power Loss Eliminated


501F Compressor Solutions

Rotor Unstacking and Compressor Rotor Repair
Presented by Fernando Romero, Sulzer Rotating Equipment Services

The case studies in this presentation showcase two separate instances where cracks were detected on the W501 compressor low pressure stubs. The presentation includes a basic overview of the rotor design and construction as well as a step by step explanation of the unstacking process. A repair solution is presented as it was applied on the first rotor where such failure was detected. The solution was implemented successfully and the rotor has been in operation for more 36,000 hours.

501F Compressor Diaphragm Repair
Presented by Fernando Romero & Matt Walton, Sulzer Rotating Equipment Services

501F compressor diaphragm wear and tear is a natural occurrence for any operator. In this presentation Sulzer reviews 501F diaphragm construction and the primary damage and failure modes typically seen in these machines. Typical and advanced inspection and repair processes will be reviewed to guide users’ understanding of disassembly and repair methodology and what to observe during shop/major repairs. After viewing, users will have gained insight to generally diagnose compressor diaphragms that need to be repaired versus rows that can be left in the machine.


Full Course: Generator Monitoring, Inspection, Maintenance

Clyde Maughan, President, Maughan Generator Consultants LLC

Topics covered:

Session 1: Impact of design on reliability

Session 2: Problems relating to operation

Session 3: Failure modes and root causes

Session 4: Monitoring capability & limitations

Session 5: Inspection basic principles

Session 6: Test options and risks

Session 7: Maintenance basic approaches


The Role of a Plant Chemist in a CCGT Plant    

David Addison, Principal, Thermal Chemistry Ltd

Topics covered: CCGT/HRSG chemistry (routine, strategic, troubleshooting), key chemist activities, communications paths, using chemical service providers, plant staffing considerations. 



GT Exhaust System Inspection, Maintenance 

David Clarida, President, Integrity Power Solutions LLC  

Topics covered: Pre-outage and outage checklists for exhaust plenum ductwork and exhaust frames and diffusers, repairs vs. replacements, new technology, case studies for 7EA and 7FA turbines.



Improving Cooling Tower Performance

David Brumbaugh, President, DRB Industries LLC

Topics covered: Overview and maintenance checklists for heat transfer (fill, drift eliminators, louvers), water distribution (basins, nozzles, flow control valves), structural (casing, fan deck), and mechanical (blades, fans, gear boxes, motors) components.