South Korea - Clyde Bergemann Power Group

Edition 1 | 2015
South Korea – A Sustainable Economic
Growth with a Developing Energy Policy
Read More on Page 2
Clean Energy Solutions
Two Contracts for
Clyde Bergemann
on the Way to the
the Extension of the
Stack Dampers
Pagbilao Power Plant
Deliver Cost Savings
in the Philippines
Through Efficiency
Customer: the Clyde
Bergemann Road Show
Europe 2015
Page 8
www.clydebergemannpowergroup.com
Page 11
Page 12
CONTENT
28 % (24.5 GW), coal-fired power plants
take the largest share of capacity, followed
by natural gas-fired plants (23.4 GW) and
nuclear power plants (20.7 GW).
South Korea – A Sustainable Economic Growth with a
Developing Energy Policy............................................................ 2
Clyde Bergemann Europe Receives US$10 Million Order for
Dust and SO2 Reduction Systems for Polish Power Plant.............. 4
Clyde Bergemann Delivers Cleaning Technology for
2 x 900 MW Power Plant “Opole” in Poland.............................. 5
Franz Bartels | President & CEO
Steel ‘H’ Optimized Design Proves a Key Selling Point
for Muja Power Station in Western Australia.............................. 6
®
Globally Successful: Clyde Bergemann Supplies Cleaning
Equipment for Ultra-Supercritical Power Plant in Morocco.......... 7
Clean Energy Solutions on the Way to the Customer:
the Clyde Bergemann Road Show Europe 2015.......................... 8
Clyde Bergemann Wins Contract for Electrostatic Precipitator
(ESP) Rebuild in Michigan, USA.................................................. 9
Drax Bestows Silver Safety Award to Clyde Bergemann.............10
Clyde Bergemann Europe Secures two Contracts for the
Extension of the Pagbilao Power Plant in the Philippines............11
Clyde Bergemann Stack Dampers Deliver
Cost Savings Through Efficiency................................................12
First New SMART Clean™ Technology for
Utility in North America.............................................................13
Successful Implementation of Hg Removal at
Western US Utility Plants...........................................................14
Clyde Bergemann Colombia Provides Fly Ash Solutions
for Gecelca Termoguajira Power Plant.......................................15
Events Diary..............................................................................16
Personnel..................................................................................16
Our Cover Story:
South Korea –
A Sustainable Economic
Growth with a Developing
Energy Policy
Over the past four decades, South Korea has
demonstrated tremendous growth and sustained efforts to become a high-tech industrialized economy. In 2014, it was the world’s 13th
largest economy in terms of GDP and seventh
largest, in terms of energy consumption with
280 million toe (tonnes of oil equivalent) of
primary energy. With limited natural resources
(no oil and only small reserves of natural gas
and anthracite coal) the country is highly dependent on external energy sources: 96 % of
primary energy is imported. The Korean government is therefore permanently challenged
to offer ecologically and economically sound
solutions for its energy supply.
According to the energy statistics published by the Korea Energy Economics Institute (KEEI), the total electricity generating capacity in the country more than doubled
between 1995 and 2013 when it reached 87 GW. With
The majority of electricity was generated in
coal-fired (39 %) and nuclear (27 %) power
plants. Most of the remainder came from
natural gas (24 %), complemented with
smaller shares from hydro (1.7 %) and other
renewable energy sources (1.9 %)*.
In the past, the Korean government directed
its energy policy foremost on securing a reliable supply in order to support economic
growth. With energy-intensive industries
like steel and petrochemicals, electricity
consumption increased five times faster than
the OECD average over the past decade.
Regardless of how: supply was expanded
whenever consumption increased.
Around 2000, the focus changed slightly
when discussions about renewable forms of
energy came up as an option to respond to
climate change. Since fossil fuel fired plants
were being questioned, nuclear energy
seemed to be a promising option. Based on
those conditions and ideas, South Korea’s
Cabinet published the First National Basic
Energy Plan in 2008, highlighting “Low Carbon, Green Growth” as the core of the Republic’s new vision. The plan supported the
decrease of fossil fuels as a primary energy
source (including oil) from 83 % to 61 % by
2030, while increasing the ratio of new &
renewable energies to 11 % from 2 %. The
nuclear power ratio among total generating
facilities should be increased up to 41 %.
Then, in 2011, the catastrophe at Fukushima
happened. The calls for an expansion of nuclear power fell silent. Still, with 24 reactors,
the country has the largest density of nuclear power plants in the world. Four more are
under construction.
While developing the second plan, the government originated a civilian-government
working group, including participants from
industry, civic groups, and universities. The
new energy policy framework for the period
2014 – 2035 was released in January 2014.
The document outlines a reduction of nuclear power to 29 % in favor of renewable energies and natural gas. Remaining shortages
in generating units shall be provided by coaland gas-powered plants. An additional new
Electricity Plan (6th Basic Plan for Long-Term
Electricity Supply and Demand) released in
January 2014, documents plans to raise coal
plant capacities to 44.9 GW by 2027, and
to install 15 more coal-fired facilities with a
capacity of 12.5 GW by the end of 2017.
South Korea is on its way to …”shift its
attention from the supply side to the consumption side”, as Seung Il Cheong, South
Korea’s Director for Energy Industry Policy,
wrote in an article for Siemens**. Next to increasing capacity in the proposed mix, there
is a necessity to improve energy efficiency.
Smart grids are seen as “…highly promising
technology”** to enable a more efficient
use of energy on the one hand, supported
by initiatives to significantly reduce energy
consumption on the other hand.
The Clyde Bergemann Power Group has
been a reliable partner of the South Korean
power industry for more than 30 years. Our
equipment can be found in 70 % of the installed utility power plants in the country.
Last year, newly built plants “Bukpeyong”,
“Shin Boryeong” and “Yeosu” were all provided with high-tech cleaning systems from
Clyde Bergemann. Further deliveries are on
their way.
Franz Bartels | President & CEO
Franz Bartels,
Clyde Bergemann Power Group
franz.bartels@cbpg.com
Publisher: Clyde Bergemann Power Group Inc., Schillwiese 20, D-46485 Wesel (Germany)
Responsible for content: Franz Bartels | Editorial: Claudia Denniger, Clyde Bergemann Power Group, e-mail: claudia.denniger@cbpg.com
Graphic design: TEMA Technologie Marketing AG
Reprints are permissible only after consultation with the editorial offices.
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NEWS 1 | 2015
* Korea Energy Economics Institue, “Energy Statistics 2014”
**Seung Il Cheong, “South Korea: a Paradigm Shift in Energy Policy”, Living Energy No. 8, July 2013
www.cbpg.com
NEWS 1 | 2015
3
Clyde Bergemann Europe Receives US$10 Million Order for
Dust and SO2 Reduction Systems for Polish Power Plant
Clyde Bergemann Delivers Cleaning Technology
for 2 x 900 MW Power Plant “Opole” in Poland
The Clyde Bergemann Power Group Europe
(CBEU) has been awarded a contract to design, supply and commission SO2 and dust
reduction systems for the cogeneration
plant in Będzin, Poland. CBEU’s scope for the
project includes a Circulating Dry Scrubber
(CDS), a Pulse Jet Fabric Filter (PJFF) system
and associated material handling systems
to reduce SO2 to 130 mg/m3 and dust to
15 mg/m3.
The operator, Elektrociepłownia Będzin
S.A., saw the need to adopt the plant to
meet the newly defined Emission Limit Values (ELV) that are a part of the European
Industrial Emissions Directive (IED). The
IED entered into force in January 2011 and
requires existing large combustion plants to
meet minimum standards for the emissions
of toxic air pollutants such as acid gases and
particulate matters in a short term time.
CBEU’s customer is SBB Energy, a Polish
engineering company and the engineering, procurement and construction (EPC)
contractor, providing the full package of
DeNOx and DeSOx control for the Będzin
cogeneration plant.
The Będzin project ties together the global
expertize of the Clyde Bergemann Power
Group to offer an optimal solution: Clyde
Bergemann Polska coordinates the pro­
ject close to the customer and is responsible for the local fabrication and services.
They are supported by Clyde Bergemann
Doncaster (UK) who supply all associated
material handling systems. The CDS and PJFF
technology is provided by Clyde Bergemann
CBPG’s package was chosen due to its solut-ion, compared to other offerings viewed
by SBB.
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NEWS 1 | 2015
Hanover, the Group´s core competence
center for air pollution control solutions.
“This order clearly shows the benefits we
can offer our customers through our global
capabilities”, says Franz Bartels, President &
CEO of the Clyde Bergemann Power Group.
“Our broad product range and expertize
coupled with a global presence enable us to
offer tailor made solutions eye to eye with
our customers.”
The European Sales Team of the Clyde Bergemann Power Group proudly announced that
it gained the contract to supply the cleaning
technology for the new build units 5 and 6
of the Opole power plant in Poland.
the sides and opposite wall from a distance
of up to 25 metres. The SMART Cannon’s
cleaning radius and flexibility lend it unbeatable efficiency in areas like these, where water is the preferred medium for cleaning.
Clyde Bergemann´s customer Alstom is in
charge of building the two 900 MW units
5 and 6 for the new ultra-supercritical (USC)
coal-fired plant, operated by the stateowned Polska Grupa Energetyczna (PGE).
Alstom’s scope of supply includes the overall
project management, erection and general
design of the entire plant as well as its commissioning and the support of the consortium members.
For cleaning the convective part of each
boiler, use is made of 60 retractable “PS-H”
sootblowers and 10 part retractable “PSHB” sootblowers. Additionally, 36 “RSGAR” rake sootblowers are envisaged for the
Selective Catalytic Reduction (SCR) plant.
Clyde Bergemann Germany was assigned
with the design, manufacturing and delivery of the boiler cleaning solutions as well as
associated optimization and controls technology.
A total of 12 SMART Cannons will be installed in the furnace area of each unit. The
patented SMART Cannon technology ensures an extremely effective cleaning system
for this part of the boiler. Its construction
with two linear drives and a spherical cannon guide provides a horizontal and vertical blowing arc of 90°. Based on in-house
developed control technology, the water jet
creates a meander-shaped pattern cleaning
PS-H sootblowers are deployed to clean the
superheater surfaces. Cleaning is undertaken by having the lance tube moved helically
into the boiler with two opposite high-performance nozzles over a 10 metre travel.
The PS-HB part retractable sootblowers are
used in areas with lower flue gas temperatures. The blowing tube is fitted with highperformance nozzles along its entire length,
and remains partially in the flue gas path
where it is held on bearings permitting it
to move to realize complete coverage. During the cleaning process the blowing tube is
moved helically over its travel of 3.2 metres
in the flue gas path.
for Opole 5 and 6 feature a blowing rake
equipped with cross-arms having nozzles.
For cleaning, these are aimed optimally at
the reactor heating surface. The blowing
rake continues to move axially in the flue gas
path during its cleaning cycle.
Overall, Clyde Bergemann’s scope of
supplies and services includes
• the cleaning devices along with a control
system individually adapted to the boiler;
• SMART Furnace, a platform for intelligent
boiler cleaning, comprising of a software
for continuous monitoring and evaluation
of slagging in the furnace with the help
of 40 heat flux sensors;
• erection control, cold and hot
commissioning
• spare parts for commissioning and
• two years operation.
Once operational, the plant will be Poland’s
largest hard coal-fuelled facility, and will
supply electricity to the equivalent of two
million homes.
Arnd Benninghoff, CBEU
arnd.benninghoff@de.cbpg.com
The most optimum solution for cleaning
the SCR is provided with the RSG-AR rake
sootblowers. The 2 x 36 blowers envisaged
Design work for the project has already
begun with implementation scheduled to
start in the first half of 2016.
Piotr Zarmutek, CBP
piotr.zarmutek@pl.cbpg.com
www.cbpg.com
NEWS 1 | 2015
5
Steel ‘H’® Optimized Design Proves a Key Selling Point
for Muja Power Station in Western Australia
Globally Successful: Clyde Bergemann Supplies Cleaning
Equipment for Ultra-Supercritical Power Plant in Morocco
Pictures showing key points CBA considered such as maintaining the existing header connections (Left) and using space available (Right)
Synergy Corporation, a Western Australian Power company, approached Clyde
Bergemann Australia (CBA) in early
2014 looking for a long term solution
for erosion reduction in their finned
Economizers at Muja Power Station
Stage “C” boilers 5 & 6. Each boiler has a
maximum continuous rating of 215 MW
and approximately 85 % of the 51,000
tonnes of ash passes over the economizer each year. The customer was
looking for an economizer to reduce
the frequency of tube failures due to
erosion and reduce ash build up within
the Economizer causing flow distortion
accelerating potential failure points.
(53 years) in delivering successful energy
recovery solutions for coal fired power plants
around the world.
CBA undertook a review of technical factors
to consider when offering a revised design
for Synergy Corporation. Key technical issues such as reduced fouling by widening
the fin gap to assist in reducing gas velo­city
over the economizer while reviewing the
trade off in reduced heat transfer performance were considered. CBA explored the
possibility of utilizing some additional space
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NEWS 1 | 2015
By maintaining the existing header connection points and using additional space (see
pictures) CBA managed to optimize the steel
‘H’® solution to achieve the same thermal
performance as the existing Economizer.
CBA widened the fin gap to reduce erosion
potential by up to 60 % and by opening
the gaps this allows for increased area for
ash flow to occur reducing potential future
block- ages.
The graph below highlights the effects of
flue gas velocity on erosion potential. This
was a key area of differential that CBA demonstrated to secure an order.
Synergy is Western Australia’s largest power
producer and retailer with in excess of one
million customers (52 % market share) located along the south western side of the
Australian continent. Their generation assets
are wide and varied including coal fired boilers, gas fired power plants, gas turbines and
wind farms delivering in excess of 10,000
Gigawatts of electricity annually.
CBA specializes in the design and manufacture of steel ‘H’® Economizers for a variety of applications. CBA has a long history
above the existing Economizer and found
the customer accepted this solution.
In November 2014, Synergy placed the order
with CBA for the newly designed steel ‘H’®
Economizer that will be designed and manufactured in Sydney and road freighted 4,000
km to site, Muja Power Station on the other
side of the country. The Economizer will be
delivered in mid 2015.
Effects of Flue Gas Velocity on Erosion Potential
The first coal-fired project in Morocco using state-of-the-art ultra-supercritical
technology will be equipped with cleaning technology from the Clyde Bergemann
Power Group. The 2 x 693 MW plant located near the coastal city of Safi in the
southwest will be the second-largest coal-fired power station in Morocco and is
supposed to cover around 25 percent of the country’s power demand.
Since the 1990s, the government of Morocco has emphasized energy as a central role
for its economic and social development. In
1995, an ambitious program was set in place
with the aim of extending access to electri­
city to the general rural population. The
network now embraces 98 % of the population, compared with 18 % two decades ago.
In 2009, the government developed a National Energy Strategy focusing on five main
areas: to optimize the fuel mix in the electricity sector; accelerate the development of
energy from renewable sources (esp. wind,
solar and hydropower); make energy efficiency a national priority; encourage more
foreign investment in the energy sector
and promote greater regional integration.
Signifi­
cant progress has been made since
then in the power sector. An additional
2 Gigawatts of coal-fired power capacity
was assigned to significantly reduce the average cost of base load power, one of them
being the Safi power plant.
The plant will be the first coal-fired project
in Morocco to use ultra-supercritical technology, which is characterized by a 10 %
higher efficiency compared to conventional
plants, significant CO2 reductions and lower
fuel costs.
The Safi Energy Company – a joint venture
between Morocco’s Nareva, France’s GDF
Suez and Japan’s Mitsui – secured a $2.6 billion in financing in September 2014 to take
over the project. Safi awarded the construction contract worth $1.77 billion to South
Korea’s Daewoo Engineering.
Clyde Bergemann’s scope of supplies includes for each unit 32 VS-H wallblowers
and 38 PX-H retractable sootblower for the
cleaning of the furnace and the convective
areas respectively.
posite backward inclined high-performance
nozzles is axially moved into the boiler. As
soon as the nozzle head has reached the
blowing position, the blowing process
begins. During this process, the tube wall
is cleaned in circular form. After performing the necessary number of rotations the
nozzle head returns to its rest position.
PX-H retractable sootblowers are deployed
for cleaning heat exchangers in areas with
flue gas temperatures up to 1,500 °C.
Cleaning is achieved by having the lance
tube moved helically into the boiler with two
opposite high-performance nozzles blowing
steam over an 11 meter travel.
Design work has already started with deliveries being scheduled for January and May
2016.
Bernd Mussmann, CBEU - Sales
bernd.mussmann@de.cbpg.com
The VS-H uses steam as cleaning medium
and can be applied at flue gas temperatures
< 1,600 °C. The nozzle head with two op-
Gerard Grant, CBA
gerard.grant@au.cbpg.com
www.cbpg.com
NEWS 1 | 2015
7
Clyde Bergemann Wins
Contract for Electrostatic
Precipitator (ESP) Rebuild
in Michigan, USA
Clean Energy Solutions on the Way
to the Customer: the Clyde Bergemann
Road Show Europe 2015
“We invite you to invite us”: The sales team of the Clyde Bergemann Power
Group Europe (CBEU) launches its first roadshow through 14 European countries
and we invite you to share this exciting experience.
Over a period of six months, the truck is going to visit customers and inform them about
the group’s powerful portfolio of products
and systems for effective on-load boiler
cleaning and ash handling as well as reliable
combustion gas control and cleaning.
In addition to information about new products and systems, the team has examples of
the successful implementation of optimization and modernization on board: valuable
expertize that can save cost and offer a competitive edge for the operators.
The truck may be accompanied – including
its detailed route and the latest experience
reports – from early May through the Linked­
In page of the Clyde Bergemann Power
Group (https://www.linkedin.com/company/
clyde-bergemann)
Claudia Denniger, CBPG
claudia.denniger@cbpg.com
The Genesee Power Station in Flint, MI
is a biomass-fired steam boiler which
burns wood waste, plus about 2% tirederived fuel. The turbine/generator
output is approximately 35 MW. Genesee contracted the Clyde Bergemann
Power Group Americas (CBAM) for an
Electrostatic Precipitator (ESP) rebuild.
The scope includes design, supply and
installation of new internals comprised
of new collecting plates and RigitrodeTM
electrodes for the first and third fields
of the existing ESP.
The Genesee ESP is a single chamber Joy
Western rigid frame unit (circa 1995) collecting fly ash from a biomass-fired boiler. It is
equipped with three mechanical fields, each
with approximately 12 feet of treatment
length and one electrical section per field.
Collecting plate panels are segmented (18”)
g-section with one Rigid Discharge Electrode (RDE) opposite each segment, 29 rows
per field and lane spacing is 12”. In the inlet
field the emitter tabs are flared or “spread”.
This Joy design uses vertical trusses (four per
electrical field) to minimize sway. Cleaning
on both frames is by pneumatic rapping system. Fly ash is collected in a trough hopper
with continuous evacuation via a drag conveyor. The ESP is downstream of the ID fan.
Annual inspection information compiled
over the years on the ESP determined it had
reached its life cycle on some critical internal
components. Issues included missing Discharge Electrodes and Collecting Electrodes
in the first and third fields, material thinning
outlet ducting of the ESP, air in leaking causing ash accumulation and eroding the ducting resulting in poor ESP performance.
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NEWS 1 | 2015
www.cbpg.com
While the RFQ indicated the desire to replace all supports and framing for both the
collecting and discharge electrodes, CBAM
assessed that such supports and framing
could be reused and proposed a more cost
effective approach for upgrading the ESP.
Recent inspections indicated the high voltage framing to be in satisfactory condition
and the field arrangement revealed a reduction in collecting area would be required to
accommodate different collecting system
supports.
CBAM proposed a retrofit that utilized a
shop assembled collecting plate design with
the same hanger mechanism currently in
use in the ESP design. For the high voltage
discharge electrodes, CBAM Rigitrodes were
used, however, the pins were turned 90 degrees from their normal orientation to allow
attachment to the high voltage framing in a
method similar to that currently in use in the
Joy ESP. This retrofit includes reusing all rapper hardware, also the existing rapper anvil
beams and rapper trains.
After inspection and working with the customer, CBAM secured the order for rebuilding the ESP. The customer was confident
with CBAM after cooperating over two plus
years providing annual inspections and a
cost effective solution.
John Malone
john.malone@us.cbpg.com
NEWS 1 | 2015
9
Clyde Bergemann Europe Secures two
Contracts for the Extension of the
Pagbilao Power Plant in the Philippines
Drax Bestows Silver Safety Award
to Clyde Bergemann
Drax Power has officially awarded Clyde Bergemann with the Contractor Safety
Excellence Silver Award for 2014 at the Leeds Royal Armouries venue in the UK.
Clyde Bergemann Doncaster has worked at
Drax Power Station for over a year on the
Biomass Ash Segregation system and Ash
Handling on unit 3. The team members
comprises of Colin Gebbie, Mark Barnes,
Martin Beecham, Grayham Wilson, Rizwan
Chaudhry & Carl Reading have completed
more than 15,000 man hours without a
lost-time incident.
Steve Cragg, Clyde Bergemann Doncaster’s
Managing Director said: “This is a great
achievement. As a company, safety is always at the forefront of everything we do
and part of our core values. I know the
team at Drax work hard every day to maintain the safest working environment for
their colleagues and others who come onto
and work on the site.”
Photograph depicts:
The Biomass Ash Segregation system (silo)
at Drax Power Station on phase following
the completion of the project with Colin
Gebbie, Senior Contract Manager, Clyde
Bergemann Doncaster & David McLachlan,
Lead Engineer Materials Handling, Drax,
presenting the Contractor Safety Excellence
Silver Award.
Steve Cragg
steve.cragg@uk.cbpg.com
When unit 3 of the lignite-fired power
plant Pagbilao is going live in the second half of the year, two Business
Units of the Clyde Bergemann Power
Group Europe (CBEU) will have participated. In October 2014, the European
team secured the contract for cleaning
technology for the 420 MW boiler. A
short time later, the fly and bottom ash
handling systems could also be booked.
With an installed capacity of 735 MW, Pagbilao today is the Philippines second largest
coal-fired power plant. In order to meet the
growing energy demand, Japanese
TeamEnergy Corp. and Aboitiz Power initiated the extension of the site in September
2014, planning to add another 420 MW.
The 976 million USD project is carried out
by the Pagbilao Energy Corp. (PEC), a joint
venture between TPEC Holdings Corp. and
Therma Power Inc., both wholly owned
subsidiaries of Team Energy and Aboitiz.
Mitsubishi Hitachi Power Systems, Ltd.
(MHPS), working jointly with Daelim Industrial Co., Ltd. of Korea, has received the full
turnkey contract.
On-load Cleaning Equipment
Guaranteeing High Boiler Efficiency
Being responsible for the boiler construction, MHPS Nagasaki mandated that Clyde
Bergemann be responsible for the layout
and implementation of the boiler cleaning
equipment. The order was preceded by an
intensive planning phase, in which the
CBEU sales team was able to score with
deep technical expertize and close project
monitoring.
The scope of supply includes 50 VS-H wall
blower for the cleaning of the furnace heating surfaces, 36 PS-H retractable sootblower with a travel range of 7.8 m to clean the
superheater and reheater (up to 1,500 °C)
and 8 PS-HB part retractable sootblower
with a travel range of 3.9 m for the economizer. The hardware for the electrical control of the cleaning equipment is also included.
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NEWS 1 | 2015
www.cbpg.com
Separately, the concept for fly and bottom
ash handling systems
was presented by the Clyde
Bergemann specialists of the
“Materials Handling” unit. Their
scope of supply includes combustion
chamber hoppers, jaw crushers, a bottom
ash conveying system and an associated
silo with redundant truck loading facility.
Comprehensive System for Bottom
and Fly Ash Handling
The delivered hoppers pass the hot slag in
six parallel outlets. Each leg of the hopper
is equipped with a grating and a hydraulic
driven crusher combination at the outlet.
Oversized particles lying on the grating automatically activate the hydraulic jaw
crusher elements so that all the bottom ash
falls through the grating.
For further transportation and cooling of
the bottom ash, the patented DRYCON
steel plate conveyor is used. Transport
chains are connected to the plate conveyor
elements via connecting pins which are
driven by an electric drive motor. The DRYCON technology makes it possible to easily
transport the bottom ash to the silo with
just one conveyor belt, over a distance of
64.5 m at an incline of 40°. Other commercially available systems have to resort to a
second conveyor for significantly shallower
angles. Not only does this increase the
costs of purchase but also has a negative
effect on follow-on costs, for example for
commissioning and spare part provision.
Clyde Bergemann’s scope of supply also includes a pneumatic conveying system, forwarding fly ash from the air preheater and
economizer directly to the 310 m3 silo. It
involves a vacuum system with a total of
two ash separators on the silo roof.
A redundantly designed truck loading facility is located below the silo. It consists of a
rotary valve, weighing equipment, an ashmoistening paddle mixer and truck loading
equipment. The ash is moistened under
controlled conditions and loaded into open
trucks at a loading rate of approximately
40 t/h without producing dust.
Bernd Mussmann, CBEU
bernd.mussmann@de.cbpg.com
NEWS 1 | 2015
11
First New SMART Clean™ Technology
for Utility in North America
Clyde Bergemann Stack Dampers Deliver
Cost Savings Through Efficiency
Customer-Engineered,
Cost-Effective Solutions
Boiler stack dampers, also known as
weather dampers, are used to prevent
system heat loss and to keep moisture
out of a boiler when the unit is offline.
Good heat retention allows for a faster
startup when the system is ready to
come back online, which in turn provides increased plant efficiency.
Stack dampers are composed of two or more
tightly-closing louver blades and a drive system arranged in a housing mounted across
an exhaust stack. The damper shuts to block
heat egress from the stack when the boiler
is not in operation, and then opens as the
system comes back up. When the damper is
closed, a channel at the top of the damper
diverts rain or other moisture away from the
stack, thereby keeping dampness out of the
system. Typically, a stack damper is found
within the body of the stack or may be located at the top of the stack, depending on
the customer’s requirements or preference.
Quality Design for Long-Term,
Trouble-Free Operation
Clyde Bergemann has become the global
stack damper supplier of choice, with tightsealing stack dampers that guarantee 99.5%
sealing efficiency, a high effectiveness level
that delivers important cost savings to the
end user. Using proven Bachmann™ technologies, Clyde Bergemann engineers each
stack damper for a 30-year design life, the
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NEWS 1 | 2015
industry standard. A key difference from
competitors’ products is that Clyde Bergemann’s quality design provides long-term,
trouble-free operation. The construction
materials used are carbon steel for housings and blades, with ASTM 17-4PH stainless steel for the shafting. Most competitors
skimp by using carbon steel for the shafting,
which over time can result in a seized shaft
and frozen blades – a disruptive, expensive
failure. Clyde Bergemann’s robust design
eliminates this worry.
Clyde Bergemann’s design also incorporates
a proven castle bushing counterweight relief system. This system ensures that, upon
a specified pressure, the damper blades will
automatically open in the event the system
is accidentally brought online without the
damper first being opened. Thus, the design
safeguards against damaging “dead-heading” of the system.
Each stack damper supplied by Clyde Bergemann
is custom-engineered to
meet the specific customer requirements as
well as the ever-changing
performance of today’s combustion
turbines. Modern turbines are much larger
than their predecessors of only a few years
ago, and Clyde Bergemann has kept pace
with the evolving technology, supplying
dampers ranging from small diameter to
those measuring up to 24 feet (7.3 meters)
or more.
Clyde Bergemann has developed cost-effective solutions for both, new and existing damper applications, offers standard
stack damper systems as well as custom
solutions. For example, if an existing stack
does not already have a damper, a system
kit which allows for modification of the
stack to incorporate damper blades and a
drive system can be supplied. This means
the new damper can be built directly inside
the stack. Furthermore, damper rebuild kits
are available to repair existing stack dampers that are not functioning properly. This
involves replacing the existing blades with
a complete Clyde Bergemann blade system
for long-term, reliable performance.
Global Network, Global Successes
Clyde Bergemann’s high-quality stack
dampers are built in house, at their own fabrication facility in Jesup, GA, USA, as well
as throughout a global network of qualified
suppliers. This ensures an economical solution for the customer, no matter where in
the world the project site is located. Furthermore, Clyde Bergemann can supply stack
damper units either in segments or fully assembled, providing an option for additional
savings in site erection costs.
With over 15 years of experience, Clyde
Bergemann is recognized globally as the
stack damper supplier who offers the most
technical and cost-effective damper products with the best deliveries in the market
today. Just recently, Clyde Bergemann received an order for 12 stack dampers that
will be installed at heat recovery steam
generators (HRSGs) at a power generation
facility in Saudi Arabia, and multiple orders
to supply a total of 14 dampers for several
power plants across the U.S. and Algeria.
Scott Owing, CBAU
scott.owings@us.cbpg.com
www.cbpg.com
The Clyde Bergemann Power Group
Americas (CBAM) sold the first new
version of SMART Clean in the Utility
market to a power plant in the southwest United States.
The Utility, which has 3 super critical combustion engineering boilers with 800 MW
gross power generation, first purchased
SMART Clean in 2009 as a solution to their
2 – 3 forced outages per year due to sootblower tube erosion.
SMART Clean is a boiler cleaning optimization system, designed to intelligently respond to real-time heat transfer in the boiler and target areas that are fouling while
simultaneously adjusting the sootblower
cleaning flow based on how tenacious the
deposit is. Since the system was first installed, SMART Clean has eliminated all
tube erosion outages, as well as improving
economizer exit gas temperature by 20F
providing a 0.6% plant heat rate improvement.
analyzes what effect sootblowing in a particular area will have on boiler efficiency
before the sootblowing actually takes
place. This allows the system to operate the
sootblowers that will have the greatest impact on improving boiler efficiency. In addition to the new SMART Clean platform, the
Utility purchased four SMART Retractable
Sootblowers to install in their superheater
tube bank, where conventional sootblowers are unable to keep clean.
Installation and commissioning of the
SMART Clean upgrade will take place late
March 2015, with results expected to begin
in summer.
Tim Martin
tim.martin@us.cbpg.com
In November 2014, the CBAM sales team
presented the additional capabilities of the
new the SMART Clean platform to operations management. The new platform will
further improve plant heat rate an additional 0.4 % by using a “what if” analysis that
NEWS 1 | 2015
13
Successful Implementation of Hg Removal
at Western US Utility Plants
A large Utility located in the western
United States, contracted Clyde Bergemann Power Group Americas (CBAM)
for the supply and installation of Calcium Halide Injection (CHI) systems
and Wet Flue Gas Desulfurization
scrubber (WFGD) re-emission Control
Additive (RC) systems to assist with
compliance of the EPA Mercury and Air
Toxic Standards (MATS). CBAM assembled a competitive and valuable solution for the customer for both the supply and installation of equipment at
four different sites in the state of Wyoming, all fired with Powder River Basin
sub-bituminous coal.
On units using electrostatic precipitators
(ESP) to control particulate emissions and
WFGD to control sulfur-dioxide emissions,
CBAM is providing CHI systems to increase
the levels of mercury oxidation and RC systems to maintain acceptable levels mercury
capture in the WFGD to assist these units
with MATS compliance.
On units with Pulse Jet Fabric Filters (PJFF) to
control particulate, CBAM is providing CHI
systems to increase the levels of mercury
oxidation, with final capture with Activated
Carbon Injection (ACI) systems.
To date, CBAM delivered a successful project
to the customer with recent commissioning
and start-up of the equipment and systems
necessary to dose the units with Calcium
Halide and re-emission control additives.
The project management and installation of
equipment was directed by the CBAM office
in Malvern, PA and required close contact,
project management and direction to work
through existing site plan limitations to develop and refine final design, layout, electrical, and other site interface details.
The CBAM team worked closely with the
Utility site staff as each site required adjustments to the equipment locations from
those initially proposed locations. With the
equipment design and interface confirmed,
CBAM used both in-house construction resources and outside contractors, where
needed, to deliver the installation and commissioning of the equipment; met budget
and schedule requirements, and provided
the Utility with a successful project updating
the Wyoming fleet with MATS compliance
solutions.
Clyde Bergemann Colombia Provides Fly Ash Solutions
for Gecelca Termoguajira Power Plant
The Termoguajira power station in
Dibulla, Guajira, Colombia is a coal fired
plant with two units equaling 320 MW.
While being entrusted with sootblower
maintenance and repair works, Clyde
Bergemann Colombia (CBCOL) detected
problems the operator was having with
the current fly ash system. The existing
pneumatic vacuum system was continuously getting plugged and had many
leaks, leaving the plant covered with
ash. The problem arose and deteriorated when the plant – due to an increase
of electricity demand – had to run all
units at full load for which it was obviously not constructed.
are used to meter ash into a vacuum
conveying system. Also the CBPG team
is going to apply PERMA/lok 5 valves, to
upgrade their currently installed valves
that are used for on/off control. The
PERMA/lok 5 valves are designed especially for heavy duty material handling
applications. Ash piping and Connectors are included as well. Implementation will start in June 2015.
CBCOL used the opportunity and presented itself as a supplier of Material
Handling solutions, discussed the problem with the customer, offered a detailed analysis and a firm proposal.
By walking the system and doing additional calculations, the Clyde Bergemann specialists were able to propose
replacement equipment that provided
solutions to their ash handling needs.
The scope included upgraded Ash Intake Valves that will be mounted directly below the hopper outlets which
James Fisher
james.fisher@us.cbpg.com
Hector Inigo
hector.inigo@us.cbpg.com
14
NEWS 1 | 2015
www.cbpg.com
NEWS 1 | 2015
15
Events Diary
Date 2015
Name of Event
Country
Date 2015
Name of Event
Country
Reinhold APC
Atlanta, GA, USA
Power Gen International
Las Vegas, USA
July
May
04. – 07.05.2015
World of Coal Ash
Nashville, TN, USA
13. – 14.07.2015
06. – 07.05.2015
VDI Conference – Corrosion
in Waste to Energy Plants
Düsseldorf,
Germany
December
06. – 08.05.2015
ICCI – International Energy
and Environment Fair
Istanbul, Turkey
08. – 10.12.2015
POWER-GEN Europe
Amsterdam,
The Netherlands
June
09. – 11.06.2015
Personnel
Mr. Michael (Mike) Sedler
Stephan Bovet
... joined CBAM as President of the new
business unit, the Air Pollution Control
Aftermarket Division (CBKC). Mike will establish an office in the Kansas City area and
build a team to support our aftermarket
growth targets. CBKC is responsible for all
APC Spare Parts, Service and APC Equipment Rebuilds.
... became Group IT Coordination Manager
with effect from 1st March 2015. In his new
function he will further develop our CBPG IT
strategy. Among other things he will focus
on Group wide IT standards, joint IT platforms and Group IT clusters.
Robert (Bob) Wagner
Dr. Danny Tandra
... is appointed as Director Controlling for
the CBAM Division. In this new position Bob
is responsible to provide proper reporting
and analyses for CBAM, accurate forecasting including cash forecasts at the
CBAM level and oversight of large CBAM
projects.
... is appointed Director of Technology and
Business Development for Clyde Bergemann
Atlanta. To his previous responsibilities in the
Technology and Product Development areas
of CBAT he is now also responsible for the
Product Management and Sales Support.
Vanita Parmar
Joseph Ontko
... took over the position of Corporate
Global Marketing Manager. She will lead
our Group marketing team with effect from
1st March 2015.
... took over the position as CBAT Controller
with effect from February 16, 2015.
Peipei Zhang
Tim Martin
... is appointed as Compliance Delegate for
Clyde Bergemann Power Group SE-Asia.
She will support the local organisation in
this area and improve the communication
with our Group Compliance Director.
... took over the position as Director of
Operations for Clyde Bergemann Atlanta.
He is responsible for the overall operational
excellence of the Atlanta facility.
16 NEWS 1 | 2015