AUMA actuators will support an asset management system at the Rhine port steam power plant (RDK) in Karlsruhe, Germany.

The modular actuation technology will be installed in RDK 8, a new block currently under construction at the 912 MW plant. Features of the AUMA product supplied include integral controls and Profibus DP-V2 interfaces.

Addressing a requirement for non intrusive functionality, the actuators will enable the plant to set all operation parameters via local controls without using tools or opening the housing. The RDK 8 scheme also confirms AUMA’s capability supporting difficult access locations – local operation centres are assisted by an actuation solution with integral controls mounted in easy access locations.

Central time-stamped reports provided by AUMA actuators will capture events including switching/setting procedures or failures. When alerted, the DCS will store locally time stamped events to provide detailed analysis of any failures. Device parameter settings will, therefore, be optimised during both the commissioning phase and during operation.

AUMA has a forty year track record supplying the power industry and the Rhine port application is the latest in a serious of prestigious power plant applications. AUMA recently supplied over 2000 actuators to a National Thermal Power Corporation plant in Sipat, India: supporting the major scale scheme, products supplied include AUMA’s substantial SA 48.1 actuator with 32 000 Nm output torque. 

••• 

Technology breakthrough for coal power plants: No NOx, SOx, Furans, Dioxins and collects 99.9 per cent clean carbon dioxide 

On the heels of the Interagency Task Force on Carbon Capture and Storage meeting on May in Washington, D.C, USA Green Energy Group has announced a “Patent Pending Coal Combustion to Steam Process System”.

USA Green’s process system uses 50 per cent less coal without reducing the production of steam. USA Green’s process system removes NOx, SOx and other emission impurities down to EPA standards while capturing 99.9 per cent commercial grade CO2 which meets the EPA’s requirements for sequestration.

USA Green’s process system has been verified by fully licensed and registered United States based third party science and technology researchers and analysts. USA Green’s process system breakthrough can retrofit and nearly eliminate all emissions and pollutants from coal power plants, steel mills, refineries and other similarly situated fossil fuels.

USA Green Energy Group, LLC’s CEO says “the company has satisfied our strict benchmarks for performance at each phase of development. The company is positioned to dive in the clean energy technology sector and our timing could not be better.

Environmental, national security, and the reliance of imports are all concerns at our national and global door steps, and I am pleased to bring our company to the next phase of operations as a solution to each of these concerns.”

USA Green’s units do not require a traditional boiler system and can be installed utilizing existing steam turbine generators and power transmission without regular boiler room maintenance.

USA Green Energy, LLC owns this “Patent Pending Coal Combustion to Steam Process System” and the production and installation of their units does not require the installation of gas emission scrubbers presently required on coal combustion plants. Our system removes 99 per cent of SOx and NOx in the exhaust stream.

With the installation of this “Patent Pending Coal Combustion to Steam Process System,” fuel costs are reduced by as much as 50 per cent and SOx and NOx are eliminated. Installing USA Green Energy Group, LLC’s process system is relatively easy and replaces existing coal fired boilers which keeps existing steam generators and removes the traditional boiler rooms.

“USA Green will make coal the economic and environmental energy source of choice and the availability of technology licensing agreements furnishes us with a worldwide market”, says Hirson. 

••• 

Transmission and Distribution: Areva signs agreement with National Grid UK

Areva’s transmission and distribution (T&D) division has signed a strategic partnership with the UK division of National Grid, one of the world’s largest investor-owned energy companies, to develop 3D training modules to familiarize employees with products.

In May 2008, National Grid ordered a high voltage Gas-insulated Substation from Areva T&D and subsequently required an efficient method of providing new employees with essential product knowledge, as well as maintaining the level of current employees.

The Areva T&D Technical Institute demonstrated the innovative training benefits that 3D development can provide, owing to techniques used in the manufacture of certain Areva T&D product lines.

Signed on December 10, 2009, this partnership marks what will be the first 3D training module in the transmission and distribution industry. The module will be developed and implemented at the National Grid training center in Eakring, United Kingdom.

“This collaboration between National Grid & Areva T&D demonstrates the ambition of both companies to providing cutting-edge learning solutions for our employees,” said John Tyler, training delivery manager at Eakring. “3D modeling of Areva T&D equipment will help our employees better understand the new equipment currently being installed on our site.”

“Through this new agreement, we provide National Grid with our most advanced technology and thus further reinforce the long-standing cooperation between our two companies,” said Gerhard Seyrling Vice President Innovation & Performance Improvement at Areva T&D. 

••• 

Bearings enable precise adjustment of wind turbine blades

In order to optimize operating efficiency, wind turbines need to be aligned to wind conditions. In order to achieve this, the tower and rotor blades must be adjusted so that they make optimal use of the wind, whilst also ensuring that the blades are not subjected to excessive loads that could cause damage.

Developed specifically for wind tracking of the nacelle and adjustment of rotor blades on wind turbines, Schaeffler’s slewing rings are available with outside diameters up to 4000mm, for use on wind turbines with outputs up to 5 MW.

Due to their design, these slewing rings can transmit radial and axial forces, as well as tilting moments. The slewing rings are available as single or double row, four-point contact bearings, without gear teeth or with internal and/or external gear teeth, enabling precise angular adjustment at varying loads.

In order to control the output of the wind turbine, the angle of the blade must be continuously adjusted to the wind speed via the rotary movement of the blade adjustment bearing. Adjusting the blades therefore controls the speed of the rotor, which ensures relatively uniform electricity generation.

In some cases, very high forces are generated from the dynamic load of the rotor blades, which must be transferred securely via the bearing raceways and screw connections of the blade bearings into the rotor hub. For this, double row, four point contact bearings with or without gear teeth on the inner or outer rings are used.

Slewing rings are also required to adjust and optimize the position of the nacelle to the direction of the wind. The wind loads and the dynamic inertia forces are transferred via the bearing raceways and screw connections into the head of the tower. Here, single row, four point contact bearings with or without gear teeth on the inner or outer rings are primarily used.

Due to the company’s unique expertise in supplying bearing solutions for wind turbines – including zinc thermal sprayed surfaces, multi-layer painting, finished seal running surfaces and high-strength tempered steel (e.g. 42CrMo4V) – Schaeffler is able to provide slewing rings that offer the highest levels of reliability, rating life and protection against premature damage such as fatigue in the raceway and surface corrosion. Due to the bearing material with its protective surface coating, the slewing rings are suitable for temperatures down to -30 ºC.

By using state-of-the-art production facilities and the highest level of manufacturing expertise, Schaeffler is able to produce superior quality slewing rings, which are used in multi-megawatt class wind turbines across the world. By using state-of-the-art bearing design and calculation software, Schaeffler is also able to ensure that the highest levels of quality and reliability for bearings and slewing rings are met.

Schaeffler uses its own in-house software, BEARINX, to model and calculate slewing rings. The external forces acting on the rolling bearings, internal loads in the rolling bearings, comparative stresses of the shafts and other critical parameters, can be presented in diagrams and tabular form. The internal load distribution of the bearing can be calculated precisely – including contact pressures taking account of the raceway osculation.

Based on individual rolling contact loads, BEARINX can also be used to determine the calculated bearing life more accurately than ever before. For more detailed analyses, FEA calculations can be used to determine how adjacent constructions affect the rolling bearings, and vice versa.

 ••• 

MHI receives first pump order from BHEL 

Mitsubishi Heavy Industries, Ltd. (MHI) and Bharat Heavy Electricals Ltd. (BHEL), a government-owned company in India to which MHI has licensed technologies for thermal power plant-use pumps, jointly received an order for 18 pumps as part of a steam turbine generator package to be installed at a new thermal power generation plant.

The pumps are for Units 1 and 2 of a 1320 MW supercritical-pressure coal fired plant to be built by NTPC Ltd. at Barh in Bihar, in eastern India – NTPC’s Barh II Project. This event marks the first order BHEL and MHI have received jointly. The delivery is scheduled in 2011.

The 18 pumps to be delivered are boiler feedwater pumps, boiler feedwater booster pumps and condensate pumps, six each. Three of each type will be installed respectively at the plant’s Units 1 and 2.

MHI expects demand in India for supercritical-pressure coal-fired power plants with generation capacities in excess of 500 MW to increase significantly to accommodate the country’s enormous electricity needs. 

••• 

NV Energy installs GE Energy’s Bently Nevada wireless solution to increase power plant reliability 

No matter where an asset sits in the plant, the need to understand its health has become increasingly vital.

While most facilities continuously monitor critical machinery, less-critical assets – often called
‘essential assets’ – cannot typically justify the expense of a continuous monitoring system.

As such, these assets tend to be addressed with portable data collection programs where operators make rounds at monthly or quarterly intervals, manually collecting data. However, these data collection intervals are rarely satisfactory for essential assets and problems can progress from ‘OK’ to ‘Serious’ from one data collection interval to the next. Or, in some cases, manual data collection is simply not practical or possible due to the nature of the asset – jeopardizing the safety
of the employee tasked with collecting data.

To address such challenges and elevate plant reliability, industrial facilities are increasingly turning to wireless. NV Energy highlights this trend with their recent installation of GE Energy’s Bently Nevada Essential Insight.mesh wireless condition monitoring system. The system was installed at the company’s Ft. Churchill Operating Station in Yerington, Nevada with the goal of reducing operating expenses and increasing reliability.

Before the installation of Essential Insight.mesh, these assets were infrequently monitored. The wireless condition monitoring systems helps to improve plant reliability and efficiency by extending condition monitoring to a broader array of essential assets that were previously underserved and classified as mid- to low-criticality.

“We were excited to be the first plant in NV Energy to utilize this new technology,” says Greg Bushman, Plant Manager at Ft. Churchill. “We have always used Bently Nevada condition monitoring for our critical assets, so it seemed like a natural fit to extend this to our essential assets, as well.”

Over the course of two days, the entire wireless system was deployed and configured on a wide range of rotating machines including boiler feed pumps, condensate pumps, AC lube oil pumps, service water pumps, circulation water pumps, and an FD fan. The system consisted of 21 vibration sensors, seven wSIM nodes, three Repeaters, and System 1 software.

The system began returning useful information almost immediately as anomalies were detected on cooling water pumps, and confirmed the need to plan and schedule repairs.

Because the data from these assets is transmitted wirelessly to the plant’s Electronics Room where a System 1 display computer is located, it is now within easy reach of plant operators and is integrated with
all of the data from other
monitored assets.

This provides operators with plant-wide analysis and insight capabilities on the mechanical condition of their assets, allowing data-driven decisions and thus reducing costs of plant operations and maintenance. Armed with these benefits, and the considerably lower costs of installation and deployment, customers can more confidently and easily justify expansion of online condition monitoring to a broader spectrum of assets in their plants such as remote deep-well pumps, cooling towers, and more.

By helping plants extend affordable, online monitoring to more asset types, they can operate smarter – increasing efficiency, reliability, and uptime, which can translate to a reduction in operating expenses. 

••• 

New High-Temperature Accelerometer for Automotive Exhaust System Testing

Model 357B65 high-temperature, piezoelectric charge output accelerometer from the Vibration Division of PCB Piezotronics, Inc. operates in temperatures ranges of -65 to +900 º F (-54 to +482 ºC), and is designed for vibration studies in the high-temperature, ambient environments found in power generation turbines and equipment, aircraft engines, and automotive vehicle engine test and exhaust systems.

The Model 357B65 accelerometer connects to laboratory-style charge amplifiers or in-line charge converters, which condition the output signal for recording or analysis. The robust sensor is structured with a piezoceramic sensing element and an all-welded, hermetically-sealed Inconel housing. It features a sensitivity of 4 pC/g, measurement range of ±500 g, a 3000 g shock limit and 10-32 coaxial electrical connector.

PCB Piezotronics, Inc. is a manufacturer of force, torque, load, strain, pressure, acoustic and vibration sensors, as well as the pioneer of ICP technology. This instrumentation is used for test, measurement, monitoring, and feedback control requirements in automotive, aerospace, industrial, R&D, military, educational, commercial, and OEM applications.

From ready-to-ship stock products, to custom-made specials, PCB includes 24-hour customer support, a strategic global distribution network, and a Lifetime Warranty. 

••• 

Metso’s Intelligent Control Valves help process plants to meet environmental regulations 

Metso’s automation business has announced the launch of a comprehensive range of control valves, now known as Metso’s iCV (Intelligent Control Valves).

The new iCVs are fully suited to both general and demanding applications, especially in hydrocarbon processing plants. They help process plants to meet environmental regulations by using control valve constructions that provide superior performance, reliability and control accuracy.

The company’s latest control valve offering consists of eccentric rotary plug valves, V-port segment valves, Neles RotaryGlobe valves, high-performance eccentric disc valves and top-entry rotary control valves.

Metso claims the range provides the key to reducing fugitive emissions by eliminating the gland-packing leakages often associated with rising stem globe valves.

Emissions and unwanted leakage, whether of hydrocarbons, water or steam, always constitute a loss of both valuable end product and energy. Metso’s non-leakage, live-loaded valve packing is designed to prevent the loss of raw material and to also effectively eliminate the need for gland-packing maintenance and the maintenance costs associated with this.

The superior control performance of Metso’s iCV results from the frictionless, backlash-free valve and actuator construction and valve-position control built into the Neles ND9000 intelligent valve controller. The ND9000 valve controller provides ‘best in class’ performance that minimizes process variability and enables true predictive-maintenance capabilities thanks to its unique embedded online diagnostics. 

••• 

Gas Turbine Efficiency’s innovative technology reduces emissions for energy industry 

Orlando, Florida, USA based Gas Turbine Efficiency plc (GTE), a leader in energy and aviation products and services, is using its extensive experience in water injection and power augmentation to assist energy industry clients with tighter regulatory requirements in NOx emission limits.

A recent case study from GTE shows how one of the company’s power generation customers successfully installed a single skid that incorporated both the water injection and power augmentation systems on their two GE MS50001Ps and three P&W FT4A engines.

GTE Engineers performed site audits to identify logistical, size, and design constraints for the system. They defined the design specific parameters for a single skid that could incorporate a Water Injection system with a Power Augmentation system.

The combined system is capable of interfacing with virtually any control system and gas turbine fuel system. The GTE Water Injection system would provide cleaner and lower level emissions while the Power Augmentation system would provide increased output and optimized performance. GTE also employed a high-speed electronic valve to control NOx water flow rates and a water actuated stop valve to provide positive, failsafe shutoff to meet the additional specification requirement.

“This product is a great example of GTE’s growing portfolio of high value, practical and contemporary solutions for power generation,” says Steven Zwolinski, Chief Executive Officer at GTE. “At GTE we continually assess the rapidly evolving landscape of factors that drive customer needs – economic, environmental, dispatch and efficiency.”

The attached published data has quantified the benefits of installing the universal system and reports a reduction in NOx emissions that not only met the regulatory requirements, but was lower than the emission limit set forth. In addition, there was a five to eight percent adjustable increase in power output.

From an environmental standpoint, by installing the universal system, a power plant has the potential to reduce NOx emissions to meet or exceed regulatory changes in emission limits with the added benefit of increasing their power output and optimizing their engine’s performance. 

••• 

Megger adapts relay test sets for the future 

With the new and patented GOOSE Message Interface from Megger, it is now possible to use existing conventional test sets for testing protective relays and other items of substation equipment that communicate via the IEC 61850 networking protocol.

The new interface makes possible big savings, as there is no longer a need to purchase costly new test equipment for networked substations. Additional key benefits of the GOOSE Message Interface are that it allows engineers and technicians to continue using equipment with which they are familiar, and also that it avoids the early obsolescence of test sets that are not IEC 61850 compatible, many thousands of which are currently in use.

In substations where IEC 61850 is used, relays, circuit breakers and other devices communicate with each other by means of GOOSE (Generic Object Oriented Substation Event) messages transmitted over the network. Megger’s innovative GOOSE Message Interface intercepts these messages and translates them into binary (on/off) signals that are compatible with conventional test sets. Likewise, the unit translates binary signals from the test set into GOOSE messages.

All messages are processed by the interface in less than 0.5 mS, which means that no noticeable time delays are introduced into test sequences.

The GOOSE Message Interface has ten binary inputs and ten binary outputs, and a port for connecting it to the IEC 61850 substation network. The relationship between the inputs, outputs and the GOOSE messages is freely programmable by the user.

The GOOSE Message Interface therefore acts as a universal adaptor that can be used with any type of relay test set – it is not limited to test sets from a specific manufacturer.

As the binary outputs of the GOOSE Message Interface provide sufficient power to drive external electromechanical relays directly, the unit is also an invaluable aid in the testing of substation control and interlocking systems and, in this application, it can be used as a standalone device, without the need for a relay test set.

A further advantage of the new unit from Megger is that it provides a complete solution to network security problems related to the testing of substations, as it does not require a PC to be connected to the substation network, and also features physically isolated Ethernet ports.

It can even be used as a GOOSE firewall, allowing standard network analysis software running on a PC to be used to analyze traffic on the substation network. 

••• 

Flip-up welding helmet from esab 

ESAB, the world-leading manufacturer of welding and cutting equipment, has introduced a newly designed flip-up welding helmet, the Globe-Arc.

Following the ESAB family design, the new hybrid shell is made from strong Zytel material, offering full head a face protection and is very lightweight. The compact design allows for welding in very tight places, whilst reducing the visible light entering the back of the helmet caused by other welding light.

The new flip visor has an upper retention stop, which eliminates visor drop-down when welding or grinding together with shake proof quarter turn retainers to allow for quick removal and replacement.

The Globe-Arc is suitable for all welding applications as the visor provides effective protection from UV and IR radiation when the visor is open and closed, and is available in different shade levels. The helmet has a wide field of vision through both the large main and flip-up visors which provides increased work safety. The visor has a flat top brow for easy put downs and to prevent scratching.

ESAB’s new comfort headgear, which is constructed from quality nylon with a large adjustment ratchet and comfort sweat band, is fitted to the helmet. 

••• 

Hallam Energy helps Sizer Ltd fulfill its burning ambitions 

Hallam Energy, which works with businesses and organisations to transfer energy engineering expertise, has worked with Rotherham-based Sizer Ltd to diversify its current pelletizing technology and equipment into the new biomass and wood pelleting sectors.

Sizer Ltd is best known for making pellets for animal feed but is now diversifying into the new biomass and wood pelleting sectors. The company will now develop products and technology which can help meet recycling targets and reduce power consumption.

Wood pellets are a recently-introduced biomass fuel that offer combustion efficiencies of more than 90 per cent and produce emissions that are very low in comparison to other forms of combustion heating, making this one of the less-polluting heating options available.

Hallam Energy, part of Sheffield Hallam’s Materials and Engineering Research Institute (MERI), conducted a study of raw material pre-conditioning for reducing the production cost and improving the quality of wood pellets for use in combustion.

It means the company, formerly Newburgh Pelleting, in Bessemer Way, Rotherham, can enter the expanding biomass and recycling industries and help reduce power consumption.

The company used an Innovation Voucher and support from Sheffield Hallam’s Innovation Futures team to develop a new Sizer S compact pellet press to help diversify the business.

Dr Abhishek Asthana from Hallam Energy, said: “Hallam Energy is focused on applying the skills and expertise developed through our research to real world problems, which is why we were able to help Sizer.” “Through this work, Hallam Energy has been able to increase energy efficiency and to adopt a sustainable approach to its future business development.”

Roger Pearson, from Sizer, said: “Hallam Energy’s engineering and biomass expertise helped us greatly in understanding the mechanics behind biomass pelleting as we expand our business into both domestic and key international markets.” Students from Sheffield Hallam University have also been helping Sizer to build international links in the Far East.

Students from Sheffield Hallam University have also been helping Sizer to build international links in the Far East. The firm has set the students the task of sourcing information on agents within Thailand, Vietnam and Cambodia, as part of its ambitious global. 

••• 

RuggedCom and Itron partnership for smart grid solutions 

RuggedCom Incorporated, a leading provider of rugged communications networking solutions designed for mission-critical applications in harsh environments, and Itron Incorporated, a major technology provider to the global energyindustry, have announced a partnership that will expand the scope of both companies’ smart grid offerings.

RuggedMAX, an IEEE 802.16-2005 (WiMAX 802.16e) certified solution, will be integrated into Itron’s OpenWay smart metering solution as an additional WiMAX backhaul communications option for utilities. RuggedMAX recently passed interoperability and communications testing with OpenWay.

RuggedCom’s utility-grade, flexible RuggedMAX solution provides high-speed, secure, prioritized, and long-range broadband wireless connectivity.

It offers fixed and mobile connectivity — where permitted by FCC and Industry Canada rules — by supplying a comprehensive solution of base stations and subscriber units for fixed and vehicular deployments. The RuggedMAX solution provides advanced metering backhaul as well as distribution automation and field force communications using a single infrastructure — ensuring dedicated bandwidth for mission-critical applications with full quality of service (QoS) implementation.

Itron smart grid technologies are demonstrating how built-in, high-speed two-way communications give consumers more information about their energy usage, allow utilities to offer customers greater choice in rate plans, and provide higher reliability at lower cost.

The product family includes a variety of base stations and subscriber stations with differing output powers, form factors and frequency options.

“The collaboration with Itron is part of our commitment to work with leading providers of Smart Grid solutions in the areas of AMI and DA,” explains Elik Jaeger, vice president RuggedWIRELESS for RuggedCom. “RuggedMAX is a, utility grade, standards-based solution that has been designed to meet the unique needs of utility customers. Solutions implemented today using RuggedMAX will allow utilities to add additional features and functionality in the future.”

The product family has gone through extensive end to end network interoperability testing to support multiple different ASN gateway platforms in order to give customers flexibility by leveraging the full WiMAX ecosystem. 

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