Equipment Roundup

Improved 11 mm Proximity Transducer System

Bently Nevada has improved their 11 mm eddy current proximity transducer system. The new 3300 XL consolidates the standard 11 mm and 14 mm probe sizes of the 7200 Series into a single 11 mm package as well as incorporating all of Bently Nevada’s latest technology.

The 3300 XL 11 mm System consists of a 3300 XL 11 mm Proximitor Sensor, a 3300 XL 11 mm probe, and a 3300 XL 11 mm extension cable. It boasts a 3.94 V/mm output that gives the system a standard linear range of 4 mm. The system also has an extended range of 4.6 mm for longer axle position or rod position/rod drop measurements.

The probe is available in various configurations including reverse-mount applications, and comes with a ground-loop resistant triaxial cable.

The Proximitor Sensor is available in either high-density DIN-rail mount or traditional panel mount configurations. It has the same level of RFI immunity achieved by the 3300 XL 8 mm System to reduce installation costs and lower emission levels to meet European standards.

The PowerCache PC2500-farad ultracapacitor

The PC2500-farad ultracapacitor from PowerCache, part of Maxwell Technologies, supplies power to systems during peak loads and outages.

The PC2500 caches 7800 Joules of energy at a nominal 2.5 V for high powered discharges ranging from fractions of a second to one minute. It provide approximately ten times the power density of ordinary batteries. It can also provide short-term ride-through power for critical applications. It reduces significant costs and safety risks that can result from power interruptions in an industrial plant, hospital, factory, or other industrial areas.

The PC2500 is charged from and used in conjunction with a primary power supply. It is small in size and has the ability to relieve power intensive systems of peak power functions, and can extend a system’s life while reducing its overall cost.

The PC2500 is capable of accepting charges at the identical rate of discharges for systems that can benefit from regenerative energy.

The TDGS gas-lubricated seal from Burgmann

TDGS – the metal bellows-type seal for single-stage steam turbines from Burgmann
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Burgmann Dichtungswerke GmbH of Germany has produced a high efficiency gas-lubricated seal for single-stage steam turbines.

The TDGS boasts wear-free operation, and extremely low leakage rates. Interruption-free operation is achieved as the TDGS uses metal bellows as a secondary seal for the stationary seal face which guarantees a high level of reliability.

The bearings can withstand temperatures up to 450deg;C because of this second seal. It can withstand an operating pressure limit of 25 bar, obtain a sliding velocity of 120 m/s and can be used in steam turbines with a shaft diameter of up to 180 mm.

The TDGS uses self-clean technology to further ensure interruption-free operation.

The sealing face of the rotating seat is machined with three-dimensional V-grooves. These grooves have inclined groove bottoms with no sharp edges at the groove exit where dirt particles can accumulate. All of the particles are drawn through the sealing gap so dirt deposits are prevented.

New isolation valves launched

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Anderson Greenwood Instrumentation Products, part of the Tyco Engineering Products Group, has launched a new range of large bore isolation valves. These valves are designed for use in severe temperatures of up to 649à‚°C and pressures as high as 10 000 psi.

These valves are ideal for isolation of pressure measurement instrumentation in power, petroleum, petrochemical and process plants, especially where valve plugging is a concern.

The range includes a metal seated, straight-through hand valve which has the same high flow capacity as gate valves, but with the high performance, bubble-tight shut-off characteristics as globe valves. The range also includes a globe patterned valve with needle or ball stem ends.

The isolation valves are available with a soft or metal seats which are easily removed and can be replaced in-situ. This eliminates the need for valve removal if the seat becomes damaged.

Low life-time cost with TrafoStar

ABB’s TrafoStar transformer is built of standardized, service-proven components and modules, ensuring flexible, dependable and tailor made transformer designs. The designs have come from the consortium of several different companies that make ABB, putting all of their best idea practices and joint know-how into this one transformer. The TrafoStar offers high reliability and low maintenance that equates to low life-cycle costs for the customer.

All designs of the TrafoStar utilize mitred 450 conventional or step-lap joints. Rigid clamping using Ascecond, a semi-conducting tape, keeps the core sheets of the large units together and gives the core a smoother, more efficient electrode shape.

TrafoStar utilizes Nitril rubber gaskets in grooves for superior tightness over many years. Particular attention is paid to the drying and filling process to ensure that all voids are filled and that solid insulation material is thoroughly impregnated with oil. The superior design skills and attention to detail using 6-Sigma measurements of each production step ensure that every customer receives the highest standard of transformer.

New fuel management system for reciprocating gas engines

Dresser-Rand has designed a new advanced management system for reciprocating gas engines. The OptiJect Fuel Management System can accommodate injection pressures of up to 500 psi. The system manages the fuel delivery and power cylinder balancing of large bore engines by using a new electric controller, a hydraulic pressure system, and new electro-hydraulic injector valve.

Because the system allows for adjustment of injection timing, fuel distribution and mixing within the cylinder can be optimized over an engine’s entire operating range. This reduces exhaust emissions, improves fuel consumption, and decreases operating and maintenance costs by providing an enhanced fuel-air mix. The system can be fitted into most two or four cycle directed-injected reciprocating gas engines.

Overspeed correction system from Compressor Controls Corporation

The Guardian Overspeed Prevention (OSP) system, from the Compressor Controls Corporation, monitors the speed of a turbine and will initiate a trip command if an overspeed condition appears. The OPS system consists of three identical speed modules, which individually measure a frequency input signal from a passive or active magnetic pick-up sensor. A trip condition exists when two out of three speed modules detect that the speed has increased above the preconfigured overspeed values.

The Overspeed Prevention system provides a reliable, economical solution for proper operation. Single failures of the supervisor module continually monitors the three speed modules for proper operation. The OSP system is in a do-it-yourself instillation configuration.

Big end bearings temperature monitor

Amot Controls has introduced a Bearing Temperature Monitoring System which is specifically designed to minimize failure of big end bearings in large diesel or gas engine turbines.

The monitoring system measures the temperature of the individual bearings, and gives an early warning of any impending failure. These failures can destroy other expensive engine components such as connecting rods and crankshaft journals, and endanger personnel if a crankcase explosion occurs.

The Bearing Temperature Monitoring System can be placed directly behind the shell bearing, and it monitors temperatures across the entire width of the bearing to give a quick and precise signal of potential danger. The temperature changes are transferred to the control system by being converted into a 4-20 mA or 0-5 V signal.

Scottish investment produces 12 000 volt Multiform switchgear

The new Multiform electrical switchgear from Lounsdale Electric offers maintenance free operation and reduced ownership costs to its customers. The 12 000 V switchgear was developed with cooperation from Scottish Enterprise Renfrewshire who aimed to strengthen Lounsdale’s market position and secure future jobs at the plant.

As part of the design, the Multiform underwent an internal arc proof test in which a fault is created within the system, and monitors detect how the switchgear will contain and direct the electrical faults explosive energy. The switchgear surpass the industry set safety standards.

The 12 000 V electrical switchgear has vastly reduced the number of parts in the circuit breaker from several hundred to only seven, which provides the end users with three times the life expectancy from their equipment – with 100 000 operations.

Alan Foster, operations manager, Lounsdale Electric, said, “The advantages of this new system to our customers are the enhanced operator safety and reduced whole life cost thanks to the internal arc proof design and a maintenance free revolutionary operating mechanism for the circuit breaker.”

The Multiform range is aimed primarily at industrial users, building services installations and regional electricity companies.

Huge cost savings and reduced down time for Europe’s largest pumped storage station

Furmanite has recently undertaken a massive maintenance project for one of Europe’s largest pumped storage power stations, saving several weeks of shutdown time.

The Dinorwig station in North Wales, UK, can produce up to 1200 MW of power to meet sudden demand. When the plant’s pump-turbine regulating ring bearing and top cover journal face was damaged it looked like the station would have to be shut down for several weeks resulting in massive costs and lost generating time. So First Hydro – which operates the station and is owned by Edison Mission Energy – asked Furmanite for advice.

The damaged was caused to the top cover and horizontal journal faces by the bearings retainer screws working loose. The damage had to be repaired before replacing the bearing, but stripping the turbine and removing the top cover would have entailed several weeks’ shutdown and transportation of the cover which is 5.5 m in diameter, and weights 100 t.

Furmanite developed its circular self levelling milling technology to re-machine the top cover journal face in-situ, and fit stainless steel liners as a counterface for the self lubricating bearing. Incorporated in to the design was the ability for the machine to be assembled around the main drive shaft.

To guide the machine, which rotates around the main drive shaft, a special split bearing sleeve was designed. This was set concentric to the top cover outside the diameter using a clocking arm. The flatness of the top cover horizontal bearing was maintained by the machine’s self levelling technology, which controls the milling cutter height via an electro-hydraulic interface from the pre-set, special split, purpose built datum ring. This ring was manufactured to go around the drive shaft and mount the top cover. The flatness of the ring was essential, so it was measured using Furmanite’s precision scanning laser system.

The operation removed 3 mm of material from the journal faces which allowed the stainless steel wear plate sections to be fitted. The vertical bearing face diameter was measured during the machining using a precision circumference tape, and the flatness of the horizontal bearing face was within 0.15 mm.

This procedure also allowed the Dinorwig power plant to move away from grease lubricated bronze as the new bearing was self lubricating. First Hydro was keen to move away from grease for environmental reasons and to improve working conditions.

The set-up, machining, and fitting of the stainless steel liners and the replacement of the bearings took just nine days working in 24 hour shifts. The work has now been carried out on three of the power station’s six turbine units.

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