Conforma Clad expands power gen applications

Conforma Clad Inc., a provider of severe wear solutions for metal components, has introduced infiltration brazed tungsten carbide protection for shaft seal sleeves, burner components, and boiler tubes used in coal fired power plants. Infiltration brazing is used to bond tungsten carbide to the base material forming a hard, uniform protective cladding that provides wear resistance against abrasion, erosion, corrosion, and thermal shock.


Conforma Clad protected boiler tubes provide greater erosion resistance than stainless steel and nickel alloy castings alone
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Conforma Clad’s shaft seal sleeves are effective in both mechanical seals and standard packing seals, where pump failures caused by severe wear are persistent problems. Tungsten carbide cladding is metallurgically bonded to outside diameter (OD) and inside diameter (ID) sleeve surfaces. Surfaces are diamond ground to accommodate fine finishes and tight tolerances. Diameter ranges from 19.05 mm to 304.8 mm, and length ranges from 12.7 mm to 762 mm are available.

The direct cladding of burner tips, nozzles, and barrels, and custom shields for barrel and burner inlet pant legs are also available with Conforma Clad tungsten carbide. These applications are used to protect burner components from severe erosion, even in the presence of thermal shock. Conforma Clad offers protection for burner components produced by Riley Power Inc., The Babcock & Wilcox Company, Foster Wheeler Corporation, Alstom, Advanced Boiler Technology Group (ABT), and other manufacturers.

Conforma Clad protected boiler tubes installed in erosive areas, including gas paths and soot blower lanes, provide greater erosion resistance than stainless steel and nickel alloy castings alone. The tube cladding also has a high coefficient of heat transfer and is able to withstand severe thermal shock.

A slimline, compact solution

Swagelok Company has introduced the Kenmac series slimline process monoflange assemblies to replace multi-valve assemblies with a single manifold. This compact design minimizes potential leak points, reduces stress from loading and vibration and can reduce installation and maintenance time.


Swagelok slimline process monoflange assemblies minimize potential leak points, reduce stress from loading and vibration, and can reduce maintenance time
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Swagelok’s new monoflange assemblies offer an efficient instrumentation feed from process systems for light process fluids. The monoflange assemblies are primarily used in the power, petrochemical, chemical, and oil & gas industries.

Onsite detection of debris in oil

Condition monitoring of machinery lubricants is an established method of predicting and avoiding impending machinery breakdown. Now, with Kittiwakes’ ferrous debris monitoring technology, worn machinery parts can be identified early and replaced before any serious damage occurs.


With the addition of the pqF to the Analex range of ferrous wear debris monitors, used oil sample analysis can now be undertaken quickly and easily in any environment to suit the user’s needs
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The ANALEXpq range of ferrous debris monitors from Kittiwake Developments Limited provide the most accurate means of detecting and measuring ferrous wear debris in lubricating oils, hydraulic oils and greases. These rugged, compact and stable monitors deliver retrievable data quickly and simply, ensuring fast, accurate and consistent management of lube condition samples. Ideal for all industrial sectors from power plants, to mines and quarries, transport and heavy construction, the latest addition to Kittiwake’s range, the ANALEXpqF ferrous debris monitor, improves production efficiency, reduces equipment downtime and increases operational profitability.

The ANALEXpqF is a rugged, portable unit designed for use on-site or in remote field locations where laboratory analysis is often impractical or impossible. The pqF provides engineers with a means of ‘on-the-spot’ measurement of ferrous wear debris in the lubricant samples. Such information assists the engineer in planning preventative maintenance programmes and helps ensure informed decision-making when assessing plant and equipment condition.

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The ANALEXpqF is designed to detect uncombined ferrous debris in the oil or grease samples. Samples may be presented for analysis in a variety of media. Automatic recalibration is performed between each sample measurement and data from each test is stored in the internal memory, which may then be transferred to a database on a host PC via an RS232 interface.

Oxygen monitoring technology helps ScottishPower boilers

ScottishPower Generation Limited (Generation UK) has placed an order for several new Rosemount Analytical Oxymitter 4000 oxygen analysers from Emerson Process Management to measure flue gas oxygen levels at one of the UK’s main coal-fired power plants. The move follows an earlier order for 16 of the Rosemount oxygen analysers placed by Generation UK in a previous refurbishment of the 2400 MW power station at Longannet.

The Longannet power station on the Firth of Forth in Scotland is the second largest coal fired power station in the UK, having four 600 MW units. Generation UK relies on continuous oxygen monitoring using the oxymitter transmitters to maintain the optimal efficiency and good operation of its steam boilers. It is also important for the operation of its continuous emission monitoring system.

The original 16 transmitters were installed to measure the flue gas oxygen levels in two of the four coal fired boilers. The Rosemount Analytical Oxymitter 4000 was chosen because of the fast response of the zirconia sensor, together with excellent accuracy and repeatability. The ease of installation of the Oxymitter 4000 transmitter design and minimum maintenance requirement provide additional benefits.


ScottishPower Generation Limited has ordered further Rosemount Analytical Oxymitter 4000 oxygen analysers from Emerson Process Management
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Two lengths of probe – 1.83 m and 2.74 m – were used to position the sensors across the large ducts, allowing any stratification of the flue gas composition to be detected.

Experience over the year since these 16 units were installed has shown the reliability of these Oxymitter units. Being Smart transmitters using Hart communications, routine checks and calibrations could be carried out from ground level using the Emerson 275 Hart communicator, a significant advantage.

Bently Nevada enhances condition monitoring capabilities

GE Energy has announced an important enhancement to its Bently Nevada condition monitoring product offerings with a new digital interface for direct communication between its Trendmaster Pro hardware and plant control and automation systems.

The Trendmaster Pro system provides online machinery health monitoring for general-purpose equipment assets. It employs an innovative, distributed monitoring architecture designed to cost-effectively collect mechanical condition information from thousands of sensors and measurement points, connected via a special industrial ‘sensor bus’ network. The collected data is concentrated in field-mounted devices called Dynamic Scanning Modules (DSMs). With the introduction of a ModbusSM digital interface, it is now possible for DSMs to communicate directly with process control and automation systems, without the need for additional intervening hardware or software.

The Trendmaster system’s hardware has previously been compatible only with special-purpose software – GE’s System 1 platform – where detailed waveform analysis, trending and alarming is performed. While this solution is appropriate for the majority of applications and offers the highest level of diagnostic sophistication and capabilities, selected customers have indicated the desire for an entry-level solution that could instead use the basic trending/alarming functionality integral to their existing process control system, rather than the advanced capabilities of System 1. The new interface was developed specifically to meet this customer need, providing user-defined data sets to their existing process control system via Modbus, resulting in a very cost-effective solution.

Other users may still require the diagnostic sophistication of System 1 software while integrating selected Trendmaster data into their process control system. The new Modbus interface has also been designed to address this need. While customers have always been able to export this data from System 1 software, there are instances where exporting this data directly from DSM hardware can be more cost-effective. The ability to now interface with process control systems via hardware or software allows customers more flexibility in their integration strategies.

Says Ricardo Artigas, president of energy services for GE Energy, “We’re confident that this enhancement will make the benefits of online condition monitoring more easily accessible. These systems generally pay for themselves in well under a year by reducing asset failures, process interruptions and unnecessary maintenance. This digital interface makes it even easier and more affordable for customers to take that ‘first step’ towards managing their assets more effectively.”

New switch

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The Model 685A01 is ideally suited for predictive maintenance on pumps, fans, blowers, compressors, gearboxes, as well as any other rotating equipment

The IMI Sensors Division of PCB Piezotronics, Inc. has introduced its Model 685A01, an electronic vibration switch with explosion-proof housing. The vibration switch provides early warning of machine deterioration and will shut the machine down when the trip level is exceeded, preventing catastrophic damage and expensive repairs.

Schade stockyard technology chosen for Chinese power plant

China’s Zhejiang Guohua Zheneng Electric Power has chosen Schade stockyard technology for its new thermal power plant to be built in Qiangjiao Port in Ninghai, China, by Guohua Electric Power and Zhejiang Energy Sources Group.

With its proven track record in building semi-portal, portal or bridge-type reclaimers for longitudinal or circular stockyards and blending beds, Schade was chosen to engineer and build two circular coal strockyards with a semi-portal reclaimer.

The plant will feature two identical stockyards storing 260 000 m3 of coal each. The coal to be stored in the building will be retained by a concrete wall supporting the outer rail of the semi-portal reclaimer as well as the roofing structure. With a 120 m rail diameter, the stockyards will range among the largest circular stockyards with semi-portal scraper reclaimers worldwide.


Sketch of the semi-portal scraper reclaimer for coal
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Feeding of the stockyards is performed with a slewing stacker with a capacity of 3000 t/h. The semi-portal scraper reclaimer is designed to reclaim in a variable range up to 1500 t/h. Both the stacker and reclaimer turn continuously through 360°. Shipment of the equipment is scheduled for early 2005. The contract also includes domestic manufacture of selected components and structural steel based on Schade design and engineering.

The Ninghai coal fired power plant, designed in cooperation with the Chengdu Southwest Electric Power Design Institute and the State Power Corporation of China, is located in the province of Zhejiang, 80 km south of Ningbo.

SCHADE, a pioneer in the design and construction of stackers and reclaimers have demonstrated their high standard in engineering and construction of stockyards and blending beds with more than 600 references worldwide in all major industry sectors.

Extended eyes

New to the Orbimatic product range is an inspection mirror set which make the inspection of weld coupons easy.

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The kit consists of a light source with a 110 mm shaft. An angled inspection mirror is mounted at the end of the shaft to allow the operator to inspect weld root penetration. Two mirrors are supplied in the kit, one 16 mm diameter and the other 20 mm diameter. This inspection mirror kit offers a cost effective means of weld inspection and is an essential item for any QA/QC inspectors.

EU expansion produces major order for Loos International

Loos International recently booked the largest single order in the company’s 140-year history. The major project covers a total of ten large boilers and is worth over g4.3 million.

The order came from Polish systems engineering company Elektrim-Megadex (now SNC-Lavalin Megadex), which ordered the ten boilers via the Loos sales and service subsidiary Loos Centrum in Warsaw.


The finished LOOS hot water boilers shortly before delivery
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The planners, Energoprojekt in Poland, implemented the concept in collaboration with the Lithuanian planning offices Energetikos Linjos, Energija and ETC right down to the last detail.

Seven type UT-HZ hot water boilers with a total thermal capacity of 185 MW and three type UL-S steam boilers with a total steam capacity of 54 t were completed in two stages ready for delivery. The steam boilers were destined for the State Enterprise Ignalina Nuclear Power Plant in Visaginas, Lithuania. The hot water boilers will be used in a combined heat and power station on the outskirts of the city of Visaginas.

The Ignalina nuclear power plant is to be withdrawn from the network step by step in a multi-stage safety plan and is therefore being financed via the European Bank for Reconstruction and Development (EBRD), based in London. The steam boilers are intended for cooling the reactors and are fitted with an integrated flue gas heat exchanger to ensure maximum energy savings.

The professional project management and international focus of Loos sales are what made the success of this order possible in the first place. Confidence in Loos quality and positive experiences with Loos boiler systems, based on earlier very successful projects, were the deciding factors for placing the orders.

Peter Brotherhood secures steam turbine contract in Belgium

Peter Brotherhood Ltd., which specialises in the design and manufacture of steam turbines, has built a 4.9 MW multi-stage steam turbine as part of a contract to supply a municipal waste incineration plant in Pont de Loup, near Charleroi in Belgium.

The Peterborough, UK, based company manufactured the steam turbine as part of a project to refurbish the municipal waste incineration plant that is owned by ICDI. Peter Brotherhood will also be responsible for supervising the installation and commissioning the equipment.

Cegelec SA, the main contractor on the project, placed the order in June 2003. The whole project will incorporate the civil engineering works, an incinerator/boiler package, an air-cooled condenser and a stream turbine plus the electrical equipment for the connection to the local grid. Flue gas cleaning equipment, pipework systems and a DeNOX system will also be provided.


The waste-to-energy system will not only eliminate domestic waste collected from the surrounding area but will also supply electrical power to the grid
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This is a significant order for Peter Brotherhood and is the first time that it has installed a steam turbine in a land-based power plant in Belgium. Engineers at the company have designed the steam turbine to fit into the space available within the existing building. The waste-to-energy system will not only eliminate domestic waste collected from the surrounding area but will also supply electrical power to the grid and therefore generate income for the plant.

Colin Lake of Peter Brotherhood said: “We were awarded the contract because we were able to offer the customer the best combination of efficiency, price, delivery and commercial conditions. We have completed the manufacturing part of the contract within the specified time scale using our project management expertise and look forward to bringing the project to a satisfactory conclusion in the next few months.”

Peter Brotherhood designs and manufactures steam turbines and turbo-alternator sets in the range 1 to 40 MW. It specialises in supplying machines for renewable and sustainable applications. Last year Peter Brotherhood supplied a 3.45 MW condensing steam turbine for a municipal waste incineration plant at Stallingborough, near Grimbsy, UK and has supplied similar machines for waste-to-energy plants throughout Europe.

Plug Power expands

Plug Power has announced the availability of GenCore 5T24, a 24 V, 5 kW backup fuel cell system that will be marketed to wireless service providers. The GenCore 5T24 complements the Company’s other available products within the GenCore platform; the 5B 48 V for industrial applications and the 5T 48 V for wireline/wireless applications, which began shipping late last year.

“Expanding our portfolio to include the 24 V product enables us to address the critical backup power needs in a wider range of power requirements for a variety of wireless communication platforms,” said Mark Sperry, Chief Marketing Officer.

To date, Plug Power has delivered more than 75 GenCore systems to customers requiring a backup power alternative. The GenCore 5T24 is Network Equipment Building Systems (NEBS) Level 3 compliant, meets the GR-487-CORE Generic Requirements for Electronic Equipment Cabinets, has Underwriters Laboratory (UL) listing and has been certified as FCC Class B compliant. The 5T24 is available for immediate customer shipment.

All GenCore products are based on Plug Power’s proprietary, modular and scalable 5 kW power platform, which allows a high degree of flexibility to meet diverse customer needs.