Cleanroom Revenues to Exceed $14 Billion Next Year
Sales of cleanroom hardware and consumables are projected to be $14.39 billion
in 2015 according to the adjusted forecasts in McIlvaine World Cleanroom
Markets. (www.mcilvainecompany.com)
Asia will dominate the market with hardware expenditures of $4.3 billion and
consumables expenditures of $4.5 billion. The Asian market has grown rapidly due
to the following factors:
• Construction of international generic drug manufacturing plants
• New semiconductor manufacturing facilities
• Dominance of the region in the production of flat panel displays
• Photovoltaic manufacturing expansion
• General industry growth in the region
Over the last several decades the suppliers of computers and the components have
increasingly outsourced the manufacturing of their proprietary chips. Taiwan has
become the leading supplier of chips to the component suppliers. China is
rapidly building semiconductor manufacturing plants to try to keep up with the
huge demand for chips in mobile devices.
The international drug companies have been losing market share to generics
manufacturers. The strategy to compete with them is to build generic
manufacturing facilities in China and India. So a number of the world’s largest
pharmaceutical companies have invested heavily in the region.
Hardware includes the complete cleanrooms including the HVAC systems, walls and
floors. All of these products are uniquely designed to minimize particle release
to the air. Consumables include garments, wipes, furniture and chemicals.
For more information on World Cleanroom Markets, click on:
http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/474-n6f-world-cleanroom-markets
Revenue Potential for Outsourcing of Fossil-Fired Power Plant Processes Is More
than $20 Billion/yr
Fossil-fired power plants around the world expend more than $400 billion to
operate their facilities. More extensive outsourcing could improve operation of
these facilities with at least a 10 percent savings. This is a multibillion
dollar opportunity concludes the McIlvaine company in the latest additions to
Fossil and Nuclear Power Generation: World Analysis and Forecast.
(www.mcilvainecompany.com)
There are many ways to reduce costs. They include:
• Reduce fuel costs and increase efficiency
• Reduce other consumables expenditures
• Decrease labor
• Decrease other maintenance and operating costs
• Improve fleet operations
• Generate additional revenue streams
The operation of power plants is becoming increasingly complex. Fortunately,
there are new tools to deal with the complexity. These tools can be most
efficiently employed by specialists. Remotely located optimization systems can
operate plants more efficiently than onsite personnel. Maintenance tasks can be
scheduled based on need rather than routine. This is in part due to smart valves
and pumps which communicate their health automatically.
Fleets which include renewable generation (wind and solar) increase the
complexity of management due to energy source fluctuations. The complexity in
environmental laws which require a fine balance between opposing needs make
outside expertise particularly important. SO2 can be decreased, but CO2 is
increased. NOx can be decreased, but CO is increased. The operator must
continually strike the optimum balance. Day-to-day changes in the prices of
pollution allowances, fuel and other factors make it desirable to outsource
decisions to a supplier who can invest in the software and infrastructure to
deal with these challenges.
There is a big potential to reduce the expenditure for consumables. For example,
all the filter purchases can be outsourced. Continuous monitoring tools such as
broken bag detectors and continuous emissions monitors capable of measuring
individual metals, acid gases and other pollutants allow a third party to
remotely make filter inspection and replacement decisions. A medium size power
plant can have more than 15,000 filters in operation. Savings in purchasing and
inventory can be significant with the large volumes involved.
The ownership and operation of pollution control systems can be outsourced.
NIPSCO has outsourced the ownership and operation of a flue gas desulfurization
system at the Bailly station since the 1990s. Air Products and Mitsubishi formed
a partnership to provide the operation and maintenance. The program was quite
successful in meeting emissions goals and minimizing consumption of limestone
and energy.
Another big potential is for outsourcing of a “continuing education” program for
plant personnel. There are both general as well as specific needs. Many general
training options are available, but outsourcing provides a unique option for
supplying the specific day-to-day needs to make the important decisions.
For more information on Fossil and Nuclear Power Generation: World Analysis and
Forecast, click on:
http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/113-n043
Headlines for Utility E-Alert – August 29, 2014
UTILITY E-ALERT
#1189 – August 29, 2014
Table of Contents
COAL – US
• Minnesota Power to Operate Baghouse at Boswell 4 by 2016
• EPA wants comments on Four Corners proposed Permit for upgrade on Two
Coal-fired Units
• Mississippi Supreme Court sides with Mississippi Power on Emissions Control
Regulations
• Consumers Energy nearing completion of $250 Million Upgrade Project at Karn/Weadock
• Duke Energy retiring Coal Operations at W.C. Beckjord Station in Ohio
GAS/OIL - US
• Lackawanna Energy to build 1,300 MW Power Plant in Pennsylvania
• Calpine to acquire Fore River 809 MW Gas-fired Power Plant in Massachusetts
from Exelon
• Duke Energy will buy existing Natural Gas-fired Power Plant in Polk County, FL
GAS/OIL - WORLD
• Reliance Power opts out of Gas-fired Power Plant in Dadri Uttar Pradesh, India
• Group Five wins R4 Billion Ghana deal to build a 350 MW Combined Cycle Power
Plant
• APR Energy signs Contract for Peaking Power Plant in Australia
• L&T to construct 225 MW Sikalbaha Gas-fired Power Plant in Bangladesh
• Santerre Limited to develop a 200 MW Combined Cycle power plant in Ghana
• Foster Wheeler HRSG for Kimberly Clark Facility in Mexico
CO2
• Petra Nova Groundbreaking at the NRG W.A. Paris Plant - September 5, 2014
BUSINESS
• Dynegy cuts exposure to Wholesale Power with Deals worth US$6.25 Billion
• Scrubber Market veering from Hardware to Consumables
HOT TOPIC HOUR
• Lots of choices for Demineralization and Degasification of HRSG Water - Hot
Topic Thursday, August 28
• Is Hot Gas Filtration the New Path for Coal Plants? – “Hot Topic” September 4,
2014
• Upcoming Hot Topic Hours
For more information on the Utility Tracking System, click on:
http://home.mcilvainecompany.com/index.php/databases/2-uncategorised/89-42ei
“Power Plant Pumps” is the “Hot Topic” on September 11, 2014
This webinar on September 11 will be both organizational and informative. It is
all part of a whole knowledge system for gas turbine combined cycle plant
operators -- Gas Turbine and Combined Cycle Decisions . The free website and
periodic webinars empower the operators to buy the best products rather than the
most familiar or least expensive.
The webinar on the 11th will try to answer the question: What are the most
important and difficult decisions you will have to make regarding pumps?
Here are some of the questions which will be addressed:
Where do you use variable speed drives? (William Livoti of WEG will lead this
segment of the discussion.)
What type of boiler feedwater pump is best?
With fast start HRSGS and constant cycling, what pump innovations will counter
some of the negative consequences of this operating mode?
What pump issues facing GTCC operators which are unique to this type of power
generation?
What are the pump needs if zero liquid discharge technology is mandated?
What other questions are GTCC operators asking?
Here is a list of pumps used in gas turbine combined cycle plants:
Primary Pump Systems include:
o Boiler Feed Pumps (primary and startup)
o Condensate Pump
o Cooling Water Circulation Pump
o Cooling Water Make-up Pump
o Heater Drain Pumps
Boiler Feed Pumps
o High pressure, high flow barrel type multi-stage centrifugal pumps rated ~5000
gpm and 2400 psi for major utility power plant systems (pressures will vary for
subcritical vs. supercritical).
Condensate Pumps
o High flow centrifugal pumps rated ~5000 gpm to move condensate from the
condenser hot well to a deaerator and back to the feed water stream ahead of the
boiler.
Once-through Systems
o Pump surface water through cooling unit and directly back to source (lake,
river or ocean).
Loop Systems
o Circulating Pumps
• Large centrifugals rated 100,000 gpm or more. Total coolant flow more than
200,000 gpm for a 400 MW plant.
o Makeup Water Pumps
• Large centrifugals rated 5,000 gpm. Makeup is typically two percent to three
percent of total flow and is required to replace water lost to windage,
evaporation, and blowdown.
Secondary Pumps include:
o Chemical Feed Pumps
o Chemical Transfer Pumps
o Fuel Transfer Pumps
o Fuel Injection Pumps
o Slurry Pumps and De-watering Pumps (used in zero liquid discharge systems)
o Lubrication Pumps
o Service Water Pumps, Fire Service Pumps, others.
o Fogging nozzles
o Ammonia injection for NOx control
The power plants participating in the webinar will have free access to Gas
Turbine and Combined Cycle Decisions . In order to make the webinar most
valuable to these operators, it is recommended that they review the following
information on the site.
VFDs can make a big difference in optimizing pump energy consumption in cooling
tower makeup
William Livoti writing in “Empowering Pumps“discusses some of the potential
regulations which will force recycling of cooling water. He says that power
plants need to assess their pump requirements and consider variable speed drives
to reduce energy consumption. He cites the advantages when handling off peak
loads. A specific example is given for the VFD saving with cooling water makeup
pumps.
HERE ARE SOME OF THE ARTICLES REPORTED IN CCJ
Hydro, Inc. is largest independent pump rebuilder
As the largest independent pump rebuilder, Hydro works hand-in-hand with pump
users to optimize the performance and reliability of their pumping systems.
Hydro’s mission was developed in 1969 when Hydro realized that as an independent
pump rebuilding company, Hydro had a unique capability of analyzing and
understanding various designs as well as their successes or failures in specific
applications and operating environments.
3 suppliers of pumps for City of Tallahassee combined cycle addition City of
Tallahassee, FL Unit 2A, A B Hopkins Generating Station
City of Tallahassee, FL Unit 2A, A B Hopkins Generating Station Size 300 MW
Commercial operating date: June 2008 EPC contractor: BE&K, Inc. Owner’s
engineer: Sargent & Lundy Type of plant: Combined Cycle Gas Turbine
Manufacturer: GE Energy Wet Cooling Tower: Hamon-Custodis (existing) Boiler-feed
pumps: Flowserve Corp Boiler-feed-pump drives: Voith Turbo, Inc. Condensate
pumps: Existing Condensate booster pumps: ITT Goulds Pumps Booster-pump drives:
Voith Turbo, Inc. Circulating-water pumps: Johnson Pump, an SPX brand
(Existing).
Pump relocation is one best practices at the CTOTF® spring meeting
Circulating pumps for the evap cooling systems serving 7EAs located in the
western desert were installed on the second level inside the inlet air house.
Failure of a pump required its replacement under demanding conditions, high off
the ground, and likely when the GT was in operation. Certainly not ideal. Plant
personnel relocated the two pumps (one redundant) for each unit at ground level.
There have been no pump failures or system degradation issues since the
modification was made.
Tenaska Lindsay Hill Generating Station ammonia pump problem
The facility’s anhydrous-ammonia forwarding pumps did not allow for double-valve
isolation during maintenance. These pumps are only required for use on very cold
days. This requires additional maintenance and laying them up for periods of
non-use. The system had single-valve isolation from the ammonia storage tank to
the suction of the pumps, a potential safety risk for the O&M team.Solution.
Plant management decided to install double-block-and-bleed capabilities to the
liquid suction line from the storage tank and liquid return line to the storage
tank.
OTHER ARTICLES APPEARING IN THE MCILVAINE GAS TURBINE AND COMBINED CYCLE
DECISIONS UNDER THE KEYWORD “PUMPS”
Bottom of Form
MHI and Sheyang Pump have had joint agreement since 2006 for the Chinese boiler
feedwater pump market
MHI and Shenyang Pump Co., Ltd. (SPC) have agreed to establish a joint venture
company (JV) in Shenyang, Liaoning Province, China to conduct sales and
engineering relating to pumps. The agreement was signed on March 23 in Shenyang.
With establishment of the JV, MHI aims to make a full-scale entrance into the
Chinese pump market, where demand for pumps of all kinds is expected to increase
vigorously. The focus is on pumps for thermal power plants. Creation of the new
JV will enable MHI and SPC to build further experience in collaborative
activities, as a prelude to possible establishment in the future of a
manufacturing JV to serve as a local production base for a variety of pump
products.
Sulzer high pressure barrel casing pump designed for boiler feedwater
The HPT is a pump specifically designed for boiler feed applications in thermal
power stations. The pumps are optimized to provide high-efficiency operation
over an extended period of time, thus reducing operating and maintenance costs.
MHI supplies ring section boiler feedwater pumps for combined cycle operation
MHI supplies a variety of pumps for combined cycle and coal-fired power plants.
Several boiler feedwater designs are available depending on pressures and other
parameters. The ring section type is used in combined cycle.
Flowserve Boiler Feedwater pumps have beneficial features
The boiler feedwater pumps must handle high pressures and fairly high flow rates
and for these services between bearing multistage pumps are commonly used. For
very high pressure, double case pumps are sometimes required; Flowserve models
DMX and WXH are commonly used. These between bearings, multistage pumps offer
the following features and benefits: Choice of axially or radically split case
-- Ease of maintenance. Choice of volute or diffuser case construction --Fluid
dynamics best suited for application. Double-suction first-stage impeller
(option) ------------Minimizes NPSHR Flanged balance drum or hydraulically
balanced rotating unit--------Balances hydraulic thrust and reduces vibration
Finned bearing housing--- Maximizes heat dissipation.
The standardized Sulzer Pumps MD raqnge meets GTCC boiler feed requirements
Although most once-through HRSGS are subcritical, their BFPs have to provide
very high pressure. In order to increase pressure, BFPs have more stages and
shafts with higher torque capacity than conventional pumps. The Sulzer MD range
meets these requirements.
Mitsubhishi and BHEL team up to provide power plant pumps in India
Bharat Heavy Electricals Ltd, the country’s biggest power equipment supplier,
signed an agreement with Mitsubishi Heavy Industries Ltd in 2007 under which the
Japanese firm will license technologies relating to pumps used in thermal power
plants.
SPX's Diffuser Type Pump
The SPX's diffuser type pump CUP-FT/FK (2 Pole), ClydeUnion Pumps, offer flows
up to 4,840 m3/h, delivering up to 8,200 m, on maximum temperatures of 350°C,
with operating speed up to 3,600 rpm.
GE - DHM Series Pumps
High-pressure diffuser barrel multistage DDHM pumps (API610 / ISO13709 type BB5)
are designed for ultra-reliability and efficiency in the most demanding onshore
and offshore water-injection applications. They are also well suited for boiler
feedwater, pipeline, amine, energy recovery and CO2 injection. During the
selection process, we can tailor the complete system to specific customer
objectives in terms of CAPEX, OPEX and operability. This service includes
matching of the main and booster pumps as a crucial step in optimizing
performance.
Boiler feedwater pump for Dubai Fertilizer from SPX Clyde Union
This quote for a $300K BFP is not for GTCC but does provide very useful and
detailed information of what is included and terms and conditions. The unique
appearance of a document such as this on the internet adds to its value.
SPX offers pumps and many other components for GTCC plants
This brochure covers the complete range of SPX products for the power industry.
Good diagrams on GTCC show the boiler feed pumps and other offerings. Since SPX
also offers complete cooling tower systems they can offer pumps as part of
packages or separately.
Grundfos has pumps for steam boilers and district heating
Grundfos supplies the high pressure multi stage pumps for steam boilers. It is a
leader in pumps for district heating. Gas turbine combined cycle plants are
often replacing coal plants in district heating systems. At the same time, the
distribution systems are being upgraded with new pumps.
The webinar is free to power plants. Click here to view schedule and register
For more information on the Utility Tracking System, click on:
http://home.mcilvainecompany.com/index.php/databases/2-uncategorised/89-42ei
McIlvaine Hot Topic Hour Registration
On Thursday at 10:00 a.m. Central time, McIlvaine hosts a 90 minute web meeting
on important energy and pollution control subjects. Power webinars are free for
subscribers to either Power Plant Air Quality Decisions or Utility Tracking
System. The cost is $300.00 for non-subscribers.
See below for information on upcoming Hot Topic Hours. We welcome your input
relative to suggested additions.
SUBJECT
September
4 Hot Gas Filtration
11 Power Plant Pumps
18 Power Water Monitoring
25 Power Plant Water Treatment Chemicals
October
2 Precipitator Improvements
16 Power Plant CEMS
23 Sediment Removal and Remediation
30 Coal-fired Power Plant NOx Reduction Innovations
November
6 Power Plant Cooling
13 Boiler Feedwater Treatment
December
18 Power Plant Pump Innovations
Click here for the Subscriber and Power Plant Owner/Operator Registration Form
Click here for the Non-Subscribers Registration Form
Click here for the Free Hot Topic Hour Registration Form
----------
You can register for our free McIlvaine Newsletters at:
http://home.mcilvainecompany.com/index.php?option=com_rsform&formId=5
Bob McIlvaine
President
847-784-0012 ext 112
rmcilvaine@mcilvainecompany.com
www.mcilvainecompany.com