November 2014 by Energy-Tech Magazine

NOVEMBER 2014

ENERGY-TECH A WoodwardBizMedia Publication

www.energy-tech.com

Dedicated to the Engineering, Operations & Maintenance of Electric Power Plants In Association with the ASME Power Division

2014/2015 Innovation Guide

We didn’t build the first Boiler. But in all your born days, you won’t find a manufacturer today that makes a boiler that performs better than a RENTECH boiler. It’s no yarn. Each of our boilers is custom-designed by RENTECH engineers and built in state-of-the-art facilities to operate efficiently in its unique application in a variety of industries. Our innovative, cost-effective technology will add value to your day-to-day operations with lasting benefits for the competitiveness of your business. Don’t wait another day, call us about your next boiler project.

WWW.RENTECHBOILERS.COM

325.672.3400

ENERGYT ECH P.O. Box 388 • Dubuque, IA 52004-0388 800.977.0474 • Fax: 563.588.3848 Email: sales@WoodwardBizMedia.com www.energy-tech.com Energy-Tech (ISSN# 2330-0191) is published monthly in print and digital format except in January and July, when it is published in digital format only by WoodwardBizMedia, a division of Woodward Communications, Inc. WoodwardBizMedia assumes no responsibility for inaccuracies, errors or advertising content. Entire contents © 2014 WoodwardBizMedia. All rights reserved; reproduction in whole or in part without permission is prohibited. Printed in the U.S.A. Group Publisher Karen Ruden – kruden@WoodwardBizMedia.com General Manager Randy Rodgers – randy.rodgers@WoodwardBizMedia.com Managing Editor Andrea Hauser – ahauser@WoodwardBizMedia.com Editorial Board (editorial@WoodwardBizMedia.com) Kris Brandt – Rockwell Automation Bill Moore – Director, Technical Service, National Electric Coil Ram Madugula – Executive Vice President, Power Engineers Collaborative, LLC Kuda Mutama – Engineering Manager, TS Power Plant Editorial views expressed within do not necessarily reflect those of Energy-Tech magazine or WoodwardBizMedia. Advertising Sales Executives Tim Koehler – tkoehler@WoodwardBizMedia.com Joan Gross – jgross@WoodwardBizMedia.com Thea Somers – thea.somers@WoodwardBizMedia.com Creative/Production Manager Hobie Wood – hwood@WoodwardBizMedia.com Graphic Artist Valerie Vorwald – vvorwald@WoodwardBizMedia.com Address Correction Postmaster: Send address correction to: Energy-Tech, P.O. Box 388, Dubuque, IA 52004-0388 Subscription Information Energy-Tech is mailed free to all qualified requesters. To subscribe, go to www.energy-tech.com or contact Linda Flannery at circulation@WoodwardBizMedia.com Media Information For media kits, contact Energy-Tech at 800.977.0474, www.energy-tech.com or sales@WoodwardBizMedia.com. Editorial Submission Send press releases to: Editorial Dept., Energy-Tech, P.O. Box 388, Dubuque, IA 52004-0388 Ph 563.588.3857 • Fax 563.588.3848 email: editorial@WoodwardBizMedia.com. Advertising Submission Send advertising submissions to: Energy-Tech, 801 Bluff Street, Dubuque, Iowa 52001 E-mail: ETart@WoodwardBizMedia.com.

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Business Spotlight Directory

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Editor’s Note and Calendar Advertisers’ Index Energy Showcase

oN tHE WEB Learn more about Energy-Tech University’s upcoming training session, Gas and Steam Turbine Reliability: Failure Prevention and Life Extension, Dec. 3-5 in Chicago, Ill. Visit www.energy-tech.com/etu for more information and to sign up. Cover photo: Copyright © 2014 Ingram Image Ltd. All rights reserved.

A division of Woodward Communications, Inc.

2014/2015 Innovation Guide

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Editor’s Note

Your 2015 bucket list Put Energy-Tech events on your list With two months to go – how close are you to meeting all of your goals for 2014? Are there still a few outliers, some details to take care of? Did you forget about your goals altogether after you stuffed that list in the drawer last February? Don’t worry, it’s OK.You’re not alone. A new year means a new start, so write down your list for 2015 – and while you’re at it, include one or two of the following ideas from Energy-Tech: 1. If you haven’t yet, sign up for an Energy-Tech webinar or training course.We have free one-hour options and longer course seminars for a reasonable fee. All of it is professional training, from the comfort of your desk. Give it a try and let us know what you think. And if you have a travel budget to use, join us in Chicago, Ill., Dec. 3-5, for our next Energy-Tech University course, Gas and Steam Turbine Reliability: Failure Prevention and Life Extension, with Steve Reid from TG Advisers Inc.Visit www.energy-tech.com/etu for more information. 2. Stop at the Energy-Tech booth during one of the upcoming power conferences.We’ll be at Electric Power in Rosemont, Ill., April 21-23, and the ASME Power & Energy Conversion conference in San Diego, June 28-July 2.We love to meet our readers, so stop by and say hello. 3. If you’re on social media, come be social with us! Like us on Facebook or join our group on LinkedIn – all it takes is a quick search for Energy-Tech magazine.We won’t overwhelm your feed, but we will let you know about upcoming events and interesting articles or conversations we’re reading around the web. Join the conversation with us. 4. Encourage a colleague to sign up for the magazine.With so many new engineers entering the workforce, the expertise shared in Energy-Tech can help your new staff come up to speed. Signing up is free and takes a few minutes – just visit www.energy-tech.com to get started. 5. Email me an article idea or topic.We’re here to help you – so if there’s a topic you want to know more about, tell us. If there’s a project you want to share, let me know who I should contact about it. Many of our most popular articles have been reader ideas or suggestions that were turned into a piece in the magazine. My email is ahauser@woodwardbizmedia.com, I look forward to hearing from you. I hope this year’s Innovation Guide helps you prepare for 2015, and I hope we see you as you work toward your goals in the coming year. Until then, thanks for reading.

CALENDAR Nov. 3-4, 2014 CCGT 2014: O&M and Lifecycle Management for CCGT Power Plants Houston, Texas www.tacook.com/ccgt-usa Nov. 11-14, 2014 Advanced Vibration Control Syria, Va. www.vi-institute.org Dec. 3-5, 2014 Turbine-Generator Troubleshooting and Failure Prevention, with Energy-Tech University Chicago, Ill. www.energy-tech.com/ETU Dec. 9-11, 2014 Power-Gen International Orlando, Fla. www.power-gen.com Feb. 16-20, 2015 Introduction to Machinery Vibrations (IMV) Tempe, Ariz. www.vi-institute.org March 23-27, 2015 Basic Machinery Vibrations (BMV) Knoxville, Tenn. www.vi-institute.org April 21-23, 2015 Electric Power Conference & Exhibition Rosemont, IL www.electricpowerexpo.com May 11-15, 2015 Advanced Vibration Analysis (AVA) Houston, Texas www.vi-institute.org June 15-19, 2015 Rotor Dynamics and Modeling (RDM) Syria, Va. www.vi-institute.org See full calendar on page 31.

Submit your events by e-mailing editorial@woodwardbizmedia.com.

Andrea Hauser 4

ENERGY-TECH.com

2014/2015 Innovation Guide

Mark your calendar now for the BEST technical conference in power generation

June 28-July 2, 2015 San Diego, California

The 2015 ASME Power Conference will be held in San Diego, California.

If you want to engage in operating, maintenance, and equipment issues with the experts inside the power plant, as well as find out the latest methods and cutting-edge technology that can improve how power plants operate in the future, then you are invited to participate.

ASME 2015 Technical Tracks: Track 1

Fuels & Combustion, Material Handling, Emissions

Track 2

Steam Generators

Track 3

Heat Exchangers & Cooling Systems

Track 4

Turbines, Generators & Auxiliaries

Track 5

Plant Operations & Maintenance

Track 6

Reliability, Availability & Maintainability (RAM)

Track 7

Plant Systems, Structures, Components & Materials Issues

Track 8

Simple & Combined Cycles

Track 9

Advanced Energy Systems Renewables (Wind, Solar & Geothermal)

Media Sponsor

Track 10

Energy-Water Nexus

Track 11

Thermal Hydraulics & CFD

Track 12

Nuclear Plant Design, Licensing & Construction

Track 13

Performance Testing & Performance Test Codes

Track 14

Student Paper Competition Track Image Courtesy Joanne DiBona, ÂŠ SanDiego.org

Alignment/Balancing/Vibration New RS5 sensor from Ludeca • The RS5 sensor is a smarter, faster and highly accurate sensor for the mid-range shaft alignment market segment. Its XL HD detector, combined with the powerful InfiniRange functionality makes its measurement range virtually unlimited, even over long spans of 10m (33´). Its 5-axis technology makes it the only sensor in this segment to offer simultaneous Live Move tracking in both planes for machine corrections.This allows live monitoring of horizontal and vertical machine corrections at the same time, with the sensor at any rotational shaft position. The powerful synergy between the new, faster CPU and the MEMS inclinometer ensures a finer and faster acquisition of misalignment data during a continuous sweep. Hundreds of measurement readings are automatically taken during shaft rotation, ensuring highly repeatable results even in harsh conditions with vibration and under unfavorable mechanical constraints such as coupling backlash. The RS5 sensor permits highly accurate results to be obtained with as little as 60 degrees of shaft rotation, starting and ending anywhere. Users can easily view and compare results in the results table, which stores readings before starting with alignment corrections. • www.ludeca.com Two firsts for new SKF shaft alignment tool • SKF launched the first of a new generation of shaft alignment tools.The new TKSA 11 is the only instrument of its type to feature inductive proximity sensors, and an app for smartphones or tablets.This makes the TKSA 11 an ideal entry-level tool for maintenance or production engineers to carry out shaft alignment quickly, simply and accurately for motor, fan, pump and compressor applications, among many others. The TKSA 11 incorporates two inductive proximity sensors within a compact and robust electronic measuring unit, which is attached to the moveable machine side, on shafts or coupling sleeves, with a reference

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bar being attached to the fixed machine side. With an easy to use app, the user is guided through the measurement and correction of shaft misalignment, while a live view of the measuring unit and horizontal machine position facilitates accurate alignment. The new measurement technology allows the TKSA 11 to be used in bright sunlight and enables constantly high measurement accuracy, regardless of the distances between the mounting brackets; this makes it able to align narrow couplings or be used in confined spaces. Optional extension rods and extension chains are also available to use with large couplings and shafts, further extending the application range of the TKSA 11. • www.skf.com

Ash/Coal Handling Equipment Dust suppression units UL & CSA certified • Three direct-drive designs from Dust Control Technology (DCT) were certified for the U.S. and Canada: the DustBoss DB-30, DB-45 and DB-60.They are believed to be the first atomized misting units for dust control to earn the coveted recognition, reinforcing the manufacturer’s position as a leader in safety for dust control equipment. Using standards developed by UL and CSA, the evaluation and certification process was conducted by SGS, a globally respected Nationally Recognized Testing Laboratory (NRTL) accredited by OSHA.The organization is an ISO Guide 65 Certification Body accredited by International Accounting Standards (IAS) to list products in the U.S.The NRTL program was created by OSHA in 1995 to standardize

testing across multiple providers and has become the measure of safety testing for equipment manufactured around the world. The DustBoss series of oscillating atomizing sprayers is designed for safe and effective open area dust and odor suppression, with a variety of safety features, such as fans with heavy-duty guarding, atomizer rings with pressure output that’s safe enough for bare fingers and industrial strength, steelframed wheeled carriages or skid mounts. The high-powered fans distribute the atomized mist at noise levels below OSHA approved decibel thresholds and low water usage allows safer control of runoff. • www.dustboss.com

2014/2015 Innovation Guide

Bearings/Seals Long-lasting desiccant breather from Des-Case • Des-Case Corp. launched a new line of desiccant breathers called Extended Series, which will help companies extend the life of their lubricants and equipment, as well as the amount of time between maintenance intervals and, most importantly, maintenance budgets.

The series of four variously-sized breathers addresses a number of industrial needs, bringing greater protection and productivity to tank farms, wind turbines, large gearboxes and applications in both high humidity environments and remote locations. The line features higher airflow, more moisture adsorbing desiccant, check-valve technology and longer life. Though simplistic in appearance, Des-Case desiccant breathers are highly sophisticated filters for industrial lubricants, removing dirt and water from the headspace of equipment. Contaminants such as dirt and water in industrial lubricants can lead to equipment breakdown if not filtered out. As the original inventor in 1983 of the desiccant breather, Des-Case has a history of keeping lubricants clean and dry with breathers and fluid handling products, helping equipment run at the highest optimum level, maximizing uptime, reducing costs and achieving greater production output. • www.descase.com Increased energy output, efficient fan operation • Replacing bearing shaft seals every eight to 10 months requires significant maintenance time and money, and causes plant downtime. Non-contact, centrifugal pressure design Centritec Seals on combustion fans enable longer seal life. After one year of continuous and monitored operation, the bearings and the seal arrangement within the pillow block bearing (which were enclosed by Centritec Seals) show no signs of failure or impending failure, proving that the Centritec Seals’

performance surpasses that of other seal designs. While providing longer lifespan, Centritec Seals also provide better operational efficiency compared to other seal options, such as contact lip seals or hybrid seals. By significantly reducing parasitic drag, Centritec Seals utilize up to 30 watts less power in their operation per seal, resulting in additional energy savings. • www.centritecseals.com Metallized Carbon Corp. bearings for dry running at high temperature • Metcar bearings are ideal for use in continuous dryers, high temperature conveyors, kiln cars and high temperature ventilation dampers. Because Metcar carbongraphite bearings rely on graphite for their self-lubricating properties, they are not subject to the shortcomings associated with petroleum-based lubricants at elevated temperatures. They are dimensionally stable, and are not subject to melting, softening or deformation. The Metcar high temperature bearings are designed for use at temperatures ranging from 350°F-1,000°F in oxidizing atmospheres, and from 350°F-6,000°F in non-oxidizing atmospheres. Plastic and composite bearing materials can soften, deform or melt at such high temperatures. Metcar bearings for dry running can be provided to customer prints or customdesigned for specific application dimensions and tolerances. Standard pillow blocks and flange blocks with Metcar bearing inserts are available with cast iron, stamped steel or stamped stainless steel housings. Metcar high temperature bearings are also available shrink-fitted into metal housings or metal retaining rings. • www.metcar.com

Non-Intrusive Flow Measurements in the HRSG Industry t Highly accurate and reliable flow measurement up to 750 °F t No process stops for installation t Virtually maintenance free t Decreased downtimes and forced outages

The Ideal Solution for: t Phase detection – steam or water in the HRSG during startup t Controlling drain valves during heavy cycling t Measurement of auxiliary liquidsystems – water treatment, cooling tower flows, natural gas www.flexim.com · salesus@flexim.com

FLEXIM AMERICAS Corporation · Toll free: 1 888 852 74 73 2014/2015 Innovation Guide ENERGY-TECH.com

Boilers/Boiler Tubing Rentech Boilers Systems continues to lead the industry – producing new, innovative boiler designs • Our boiler manufacturing experience and passion for customer service has made a significant difference to our customers, who include the largest independent power producers, refining, petrochemical and industrial companies in North America. At RENTECH, we aren’t resting on our reputation – we are continually building one! Market leader in large-fired packaged boilers During the past 4 years, we have supplied more largefired packaged boilers than any other manufacturer in the North American market for units > 100,000 lb/hr in size. Our packaged boiler design has been specified time and again for critical industrial processes, turbine warm-up and auxiliary boiler applications because of its rugged design and proven reliability. A 100 percent membrane wall construction eliminates the need for refractory and enables quick startup to achieve full steam capacity of the boiler in a fraction of the time that it takes with older designs. In addition to significantly reducing maintenance and operating costs, a water-cooled membrane wall furnace offers additional benefits in reducing emissions. Integrated solutions for achieving lower emissions Our approach to achieving lower emissions starts with optimization of the boiler design. Coupled with RENTECH’s knowledge of low emissions burner and catalytic reduction technologies, we are capable of supplying a system that fully complies with all performance criteria and is backed by a single-source guarantee.

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HRSGs for small- and medium-sized gas turbines We specialize in, and are the largest supplier of, HRSGs for today’s high-efficiency gas turbines that operate in the 3-40 MW size range. Our expertise in high-fired applications incorporates full optimization of the ductburner performance while utilizing Catalytic Oxidation and SCR for control of emissions from the entire system. • www.rentechboilers.com Industrial Watertube Boilers/Waste Heat Boilers/ SCR Systems Design Features: • 100 percent headered membrane water wall construction • No refractory walls or seals • Fully drainable convective super-heater that eliminates the problems associated with radiant designs • Customized designs for applications requiring lowest emissions • Standard 5-year warranty on front and rear furnace walls • Turnkey Capabilities: • Integrated Low NOX Burner and SCR/CO catalyst systems guaranteed to achieve less than 5 ppmvd • Installation and start-up services • Comprehensive engineering and design evaluation of other boiler systems rebuilds, upgrades and major modifications of existing boilers

2014/2015 Innovation Guide

Boilers/Boiler Tubing New 75,000 pph Superheat Trailer-Mounted Boilers 750°F/750psig • Many heavy processing industries like petroleum, chemical and pulp/paper rely on superheated steam to accomplish production. Indeck carries a complete line of superheat boilers which incorporate the latest safety features for industrial applications. Indeck’s 75,000 pph superheat boilers were designed to be the most energy efficient boilers in its class in the industry. Each boiler is constructed in accordance with ASME code at 750 psig and 750°F design with low NOX burner and combustion controls. They also meet FM/IRI insurance standards and NFPA 85, are set to fire either natural gas or #2 fuel oil, come complete with the manufacturer’s standard boiler trim, and are capable of parallel positioning or 3-element feedwater/ fully metered. For ultra-low NOX (9PPM) applications, Indeck’s optional Indeck Selective Catalytic Reduction

System I-SCR is paired with each boiler to meet stringent emission requirements as mandated by EPA and Boiler MACT compliance. Visit www.indeck.com/rental_boilers.htm for the complete rental product offering. • www.indeck.com

2014/2015 Innovation Guide ENERGY-TECH.com

Boilers/Boiler Tubing Watlow flange heaters meet BPVC • Watlow recently received a Certificate of Conformance from the American Society of Mechanical Engineers (ASME) designating that its flange heaters meet the Boiler and Pressure Vessel Code (BPVC), Section IV revised requirements, and can apply the ‘H’ stamp to its flange heater assemblies. Watlow’s ASME certified flange heaters have long immersed length capability to reduce costs by keeping the pipe and flange sizes to the smallest possible design size. This product is available with a variety of heating elements and flange materials (including square flanges) to meet specific requirements, and eyebolt holes or lift lugs are drilled and tapped to facilitate lifting for large units into the vessel. Typical applications include boilers, high temperature water boilers and steam generators. • www.watlow.com

Compressors IntraFlow technology improves efficiency, extends operating range • Danfoss Turbocor Compressors Inc. (DTC) released its new line of VTT compressors. The VTT series of compressors will be available with nominal capacity ranges from 200-350 tons for voltage applications between 380-460 volts, as well as 575 volts. These models are intended for water-cooled or evaporative cooled chiller applications and will carry the ETL and CE PED mark. Based on proven TT series compressor technology, the VTT models are oil-free, variable-speed, magnetic bearing centrifugal compressors. The VTT series of compressors is the first to introduce IntraFlow technology, an innovative and patent pending technology for improving compressor efficiency and providing an extended stable operating range while simplifying capacity control. The VTT compressors also will include newly developed control electronics capable of communicating via USB, Ethernet, and wireless. Other new features include USB drive data recording, shaft speed detection, motor and drive cooling and condensation protection. These compressors also will have the capability to download firmware and configuration updates remotely without requiring any hardware exchanges.

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The 350-ton compressor will be the first from the VTT series to be available and deliveries will start in the third quarter of 2014. • www.turbocor.com FS-Elliott focuses on energy efficiency with the launch of R1000 Control System • FS-Elliott Co., LLC released the R1000, the newest addition to the Regulus control system line. Building on FS-Elliott’s long-standing expertise in centrifugal compressor control, the R1000 introduces powerful new features that enable plant operators to master one of a facility’s highest operating expenses — energy costs. The R1000 features Ambient Compensation Control, a local control mode designed to automatically adjust the compressor set point based on changes in ambient conditions. As a result, the traditionally static surge control line becomes a dynamic entity, allowing the compressor to be safely controlled closer to the true surge line. This innovative control feature reduces waste by maximizing turn-down and minimizing bypass air, ensuring energy savings at off-peak operation. The R1000 takes compressor control one-step further by employing Pressure Band Optimization to avoid unnecessary discharge by optimizing the amount of air produced based on the minimum pressure required to meet system demand. The R1000 will come standard on FS-Elliott’s Polaris+ line of centrifugal compressors and is the first and only control system in the industry to feature a 9˝, full touchscreen display as standard. • www.fs-elliott.com

Condition Monitoring/ Remote Monitoring/ Predictive Maintenance SKF adds machinery protection function • An upgrade of the SKF @ptitude Analyst surveillance condition monitoring software and the SKF Multilog IMx-M 19˝ rack based machinery monitoring system gives operators of critical rotating machinery an integrated solution that monitors asset condition and protects against catastrophic failure. SKF launched the SKF @ptitude Analyst 2013 version 8.1 software upgrade, which enhances the capability of this analysis and reporting software, as well as an upgrade to the on-line protection system, Multilog IMx-M. When used in combination to monitor plant semi critical and critical rotating assets, these two products offer both machinery protection and improved maintenance efficiency. SKF @ptitude Analyst is a surveillance condition monitoring application under SKF @ptitude Suite; SKF’s software suite for plant-wide Condition Based Maintenance. It offers a comprehensive solution with powerful diagnostic and analytical capabilities that enables users to manage asset condition data from offline portable and on-line permanently installed devices with a single software program. The software is easy to use and offers interconnectivity with multiple enterprise-wide software programs and systems, enabling the information gathered to be accessed throughout the organization. • www.skf.com

2014/2015 Innovation Guide

Gassonic Observer-i Ultrasonic Gas Leak Detector • Designed with Artificial Neural Network (ANN) intelligence and real-time broadband acoustic sound processing technology, the Gassonic Observer-i Ultrasonic Gas Leak Detector sets a new global industry standard in highly reliable ultrasonic gas leak detection with unprecedented suppression of false alarms. With the incorporation of ANN technology, the breakthrough Gassonic Observer-i Detector makes it possible to fully analyze the sound spectrum down to 12 kHz. The ANN algorithm has been “trained” to automatically distinguish between unwanted acoustic background noise and dangerous gas leaks. This advanced design provides a broader leak detection range, which also increases sensitivity to smaller gas leaks without interference from unwanted background noise. ANN technology also enables the leadingedge Gassonic Observer-i Detector to be installed without time consuming “training” sequences, and provides industry-leading detection distance (up to 28m). In addition, ANN technology ensures that the Gassonic Observer-i Detector has the same gas leak detection coverage in high and low noise areas. Furthermore, because it is selfadaptive, the detector requires no alarm set points to be configured, nor do alarm set points need to be adjusted if background ultrasound changes with time. The Gassonic Observer-i Detector features the patented Senssonic self-test function. This well-proven self-test checks the device’s electrical integrity and microphone every 15 minutes and ensures the Gassonic Observer-i Detector is operational at all times. Both the microphone and the microphone windscreen are constantly monitored to ensure that the detector always has optimal sensitivity and detection coverage. • www.gassonic.com

Designed to simultaneously remove solid and gaseous particulates from dryers and other processing operations, the Series 9000 features a specially designed fine droplet scrubbing liquid spray zone within a confined involute section that eliminates any bypass of untreated gas. A fully open, cyclonic entrainment removal section without internal dropContinued on page 14

Steam Turbine High Pressure

Valve Actuator Refurbishment

Emissions Testing/ Controls Series 9000 preformed spray scrubbers remove solid/gas particulates • Bionomic Industries Inc., an industry-leading manufacturer of proven air pollution abatement, product and heat recovery technologies, released its new high performance Series 9000 Preformed Spray Scrubber.

A Division of MD&A

Renewal Parts Maintenance 4485 Glenbrook Rd. | Willoughby, OH 44094 ph. 440-946-0082 | www.RenewalParts.com

PARTS | SERVICES | REPAIRS

2014/2015 Innovation Guide ENERGY-TECH.com

Condition Monitoring/Remote Monitoring/Predictive Maintenance

Precision Signal Simulator from MTI Instruments â&#x20AC;˘ The 1510A Precision Signal Simulator/Function Generator from MTI Instruments combines high precision voltage and charge mode signal generation in a single handheld device packed with features. Designed for machinery and gas turbine maintenance, the 1510A produces accurate and precise voltage, charge and speed signals necessary for system troubleshooting, testing and calibration. This handheld 1510A can be programmed to generate two independent signals of different wave forms (SINE, SQUARE, TRIANGLE and PULSE) and different frequencies up to 100 kHz. Each output channel can be independent or synchronized with each other. A USB port allows remote control and programming of the unit. 12

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2014/2015 Innovation Guide

This one of a kind function generator also includes the ability to generate keyphasor speed signals and has a variable phase control to simulate machinery imbalance conditions for testing and calibration of data acquisition systems. A unique low voltage bridge mode allows simulation of strain gauge signals. The 1510A’s charge output simulates signals from piezoelectric accelerometers. A jog function for the amplitude and voltage controls allows users to slowly vary the signal when evaluating the performance of data acquisition systems. MTI also offers several accessories, including software that allows setup and remote operation from a PC, and an assortment of cables such as BNC to BNC signal cables, single-ended and differential charge cables, to facilitate connections to your equipment. The 1510A is a tool that improves productivity and machinery availability, as well as ensuring equipment and system accuracy. From the high visibility protective boot and built in rechargeable battery to its spill-proof keypad, the 1510A is guaranteed to make signal simulation easier and more accurate than ever. • www.mtiinstruments.com

üSimulate Speed and Sensor Signals üSweep Function üDual Channels w/ Synchronization üRechargeable Battery (up to 6 hrs. of continuous use per charge)

TEL: (518) 218-2550 URL: www.MTIinstruments.com EMAIL: sales@mtiinstruments.com

scan code for complete specifications

2014/2015 Innovation Guide ENERGY-TECH.com

let removal components makes the scrubber highly reliable with extremely low maintenance. The scrubber consumes less energy than a venturi scrubber, is designed to meet PM 2.5 and PM 10 regulations for particulate in the 1 to more than 5 micron range, and is available in sizes to handle gas volumes from 1,000 through 75,000 cfm. • www.bionomicind.com TRIBO.dsp U3400H receives CSA certification • Auburn’s TRIBO.dsp U3400H is the industry’s first twowire, loop powered, wide dynamic range particulate monitor for both high and low temperature applications utilizing HART protocol. Auburn’s TRIBO. dsp U3400H was awarded Hazardous Location Certification by CSA International, a leading provider of product testing and certification services. CSA tests products for national and international standards. Simple to install and requiring no operator sensitivity adjustment, it is ideal for all emission monitoring and process flow applications where a continuous 4-20 mA signal is needed. The HART protocol adds even more functionality for the operator, allowing bi-directional communication with the unit for remote access and control. The U3400H is designed to be wired directly to a PLC, DCS, data loggers or any control device capable of providing the 24V loop power, while simultaneously receiving the continuous 4-20 mA signal. The 3400H is a perfect choice for multiple point applications needing a comprehensive Bag Leak Detection System. • www.auburnsys.com Scrubpac VentClean Systems for emissions control • Bionomic Industries Inc. expanded its line of ScrubPac VentClean Systems. Specifically designed to scrub storage tank and railcar vent emissions caused by breathing and filling operations, the VentClean Scrubber is the latest addition to Bionomics’ highly successful ScrubPac family of “packaged” scrubber systems. Due to its unique design, the versatile scrubber can handle single as well as multiple emission sources, with large variations in venting rates while providing equally high removal efficiency. VentClean is available in four model sizes L, M, H & the new larger capacity EH, to handle gas capacities up through 1,500 acfm. It also is available in two unique operating configurations that easily adapt to a variety of scrubbing liquid preferences. Type 1 is economically priced and configured to use water on a once-through basis. Type 2 incorporates a special circulation pump and uses water at a reduced consumption rate, or a chemical reagent such as sodium hydroxide on a recirculated batch basis. Typical applications include removal of acids, ammonia, alcohols, formaldehyde, amines, sodium bisulfite, hydrogen sulfide and many other water-soluble contaminants. • www.bionomicind.com 14

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Generators/Engine Generators Emergency power-gen equipment from HiPower Systems • HiPower Systems released its new generator connection cabinets. The generator connection cabinets connect permanently to an automatic transfer switch, or ATS, an electrical device that switches a load between two sources (this may also need to be installed). With these cabinets in place, a company can connect a temporary or towable, commercial-grade generator to the building’s power supply without the need for an electrician. Once the generator is delivered, a company can have power up and running within minutes. In addition to its industrial diesel and natural gas generators, HiPower Systems manufactures a wide array of portable generators in a broad range of prime power ratings from 25 KVA (The HRMW 25 T6) to 1150 KVA (The HRMW 1150 T6). Available for rent at equipment companies across the U.S. and Canada, all of these generators are surrounded by high-grade, sound-attenuated and spill-proof enclosures. • www.hipowersystems.com Atlas Copco launches Tier 4 Final QAS 25 generator • Atlas Copco Portable Energy released its new QAS 25 generator, equipped with an Isuzu 4LE engine and a Diesel Oxidation Catalyst (DOC) to achieve Tier 4 Final emission levels. The QAS 25 generator is ideal for heavy-duty use in several industries, including rental, oil and gas and construction. It is also an exceptional option for powering events. It can be used for prime or standby power and is designed to withstand the rigor of demanding use in the field. The QAS 25’s overall durability, as well as the quality and dependability of its interior components, give it one of the highest resale values in the industry. For example, the QAS 25 is mounted on a durable frame and surrounded by a robust enclosure formed from galvanneal steel and powder coated for a long-lasting, scratch- and corrosion-resistant surface. The unit’s versatility can be seen but not heard. The QAS 25 enclosure is sound attenuated and has a vertical radiator and exhaust discharge to ensure low dBA levels for use on noisesensitive jobsites, residential areas or at events. Its voltage selector switch allows operators to adjust the machine’s output to 480 and 208/240 volt 3-phase settings, as well as 120/240 volt single phase for varying applications and equipment. For additional safety, the locking front panel voltage adjust potentiometer prevents unintentional adjustments to the voltage, which can cause overheating or equipment damage. This versatility gives users greater flexibility on the jobsite and can increase utilization at rental centers. The 120vac GFCI duplex receptacles are always powered, giving users the ability to operate small hand 2014/2015 Innovation Guide

tools while running larger loads, such as vendor stands or jobsite trailers. • www.atlascopco.com

Instrumentation & Controls Calibrator with swipe screen technology • GE Measurement & Control announced the new DPI 611 hand-held pressure calibrator from the GE Druck family of products.The DPI 611 business builds on the legacy of the DPI 610, which is an industrial workhorse of pressure test and calibration. A robust and easy-to-use device, it is twice as efficient at generating pressure, half the size of its predecessor, and has twice the pressure accuracy and three times better electrical accuracy.The DPI 611 is the latest addition to GE’s integrated calibration and communication solutions platform and is designed for use throughout the process, oil and gas, power generation and general engineering sectors. The new instrument is the first dedicated pressure calibrator to feature swipe screen touch technology. Its intuitive screen interface displays a comprehensive application dashboard, and a task menu allows simple, three-touch set-up for any pressure test or calibration. A “Favorites” facility also enables quick access to frequently used tasks and custom configurations, which are easily stored. Results are displayed on the large screen and can be documented in 8GB of user memory. The instrument can automate processes to significantly reduce calibration times by running pre-defined procedures, calculating errors and reporting PASS/FAIL errors. The DPI 611 integrates seamlessly with leading calibration and maintenance software, including 4Sight from GE, to help maintain compliance with industry standards and regulations and improve process and operational efficiency. • www.ge-mcs.com New EPC-250 engine performance controller replaces pneumatic controls • The Altronic Controls EPC-250 Engine Performance Controller is designed to provide continually optimized control of air/fuel ratio and ignition timing on large, fuel-admitted integral and separable compressor packages. Incorporating an 8.4˝ Midas HMI and a purpose-built Altronic control module, the EPC-250 is a drop-in replacement for the Altronic EPC-200. It is ideal for retrofit

of existing electronic or pneumatic controls on large, integral compressor engines. A user-defined RPM map is used as the primary control for the 4-20mA ignition timing output. Engine air/fuel ratio is most often controlled by exhaust by-pass vs. an on-board 4-20mA output mapped to engine fuel pressure. Other controller inputs, including air manifold temperature, air manifold pressure and fuel BTU quality can be used as biasing factors for either/both control maps to provide an enhanced level of control and optimization across a wide range of engine makes, models and application requirements. Two digital offsets are also available to account for load and detonation-related events. The EPC-250 incorporates trending, data logging and remote operation. In addition to air/fuel ratio and timing functions, it also provides six user-programmable, solid-state relay outputs to support common start/stop requirements, including purge, crank, crankdisconnect, etc. • www.altronic-llc.com QuadraTherm® 640i/780i Air Flow Meters receive global agency approvals • Sierra Instruments announced its QuadraTherm® 640i/780i air flowmeters received global approvals for the following standards of safe operation in potentially hazardous environments: cFMus (U.S. and Canada), ATEX (E.U.) and IECEx (International).These signify that QuadraTherm is certified as flame-proof, protected from dust ignition sources and meets all design criteria for electricallypowered flowmeters used in areas where combustible gases might be present. The IECEx and ATEX certification • • programs ensure • • • • SELL • RENT• LEASE explosion-proof • • and hazardous area - 24 / 7 • • EMERGENCY SERVICE compliance in the • • European Union and • • • international destina- • • • tions. The cFMus • • certification program • • IMMEDIATE DELIVERY ensures explosion • • • • proof and hazard• • ous area compli10HP TO 250,000#/hr 250,000#/hr Nebraska 750 psig 750 TTF • • ance in the United Nebraska 1025 psig 900 TTF • 150,000#/hr 150,000#/hr Nebraska 750 psig 750 TTF • 150,000#/hr Nebraska 350 psig States and Canada. • • 115,000#/hr Nebraska 350 psig Nebraska 750 psig With approvals, • • 80,000#/hr 75,000#/hr Nebraska 350 psig Nebraska 350 psig • • 60,000#/hr QuadraTherm is 40,000#/hr Nebraska 350 psig • 20,000#/hr Erie City 200 psig approved for applica- • 10-1000HP Firetube 15-600 psig • • ALL PRESSURE AND TEMPERATURE COMBINATIONS tions in hazardous SUPERHEATED AND SATURATED • • RENTAL FLEET OF MOBILE plant areas like facili- • • TRAILER-MOUNTED BOILERS • 75,000#/hr 75,000#/hr Optimus 750 psig 750 TTF • ties management, Nebraska 350 psig • Nebraska 350 psig chemical processing, • 60,000#/hr 50,000#/hr Nebraska 500 psig • • 40,000#/hr Nebraska 350 psig wastewater and natu- • 30,000#/hr Nebraska 350 psig • 75-300HP Firetube 15-600 psig ral gas throughout • • ALL BOILERS ARE COMBINATION GAS/OIL the E.U. and interna- • ENGINEERING • START-UP • FULL LINE OF BOILER • AUXILIARY SUPPORT EQUIPMENT. • • tional communities. Electric Generators: 50KW-30,000KW • • WEB SITE: www.wabashpower.com The • • 847-541-5600 • FAX: 847-541-1279 QuadraTherm • • E-mail: info@wabashpower.com • • provides the best POWER EQUIPMENT CO. • • accuracy +/- 0.5

BOILERS

CALL: 800-704-2002 O O O

•

wabash

444 Carpenter Avenue, Wheeling, IL 60090

2014/2015 Innovation Guide ENERGY-TECH.com

•

percent of reading above 50 percent of full scale for flow meter air measurement and other gases; built-in flow conditioning (inline version); multivariable outputs; flow ranges up to 60,000 sfpm (305 smps); qTherm®, Dial-A-Gas®, Dial-A-Pipe; and Hazardous Area approvals. The QuadraTherm is available in two models: the 640i insertion and 780i inline. The QuadraTherm family has a no-drift sensor with lifetime warranty; multivariable output: mass flow, temperature, pressure (optional); measures all inert and all non-condensing clean gases; flammable gases (methane, propane, hydrogen and digester gas); repeatability for mass flow rate is +/- 0.15 percent ;ValidCal Diagnostics to validate calibration in the field; and gas accuracy is +/- 1°C (1.8°F). • www.sierrainstruments.com Emerson replaces vintage gas turbine controls with Ovation tech • Emerson Process Management replaced the OEM turbine controls at the municipally owned City of Piqua Power System with its Ovation turbine control technology. The control replacements were part of a larger project to improve the operation and reliability of the two 40-year-old peaking units. The original controls installed on the unit 8 and 9 turbines – a GE Frame 5 and Westinghouse W191 – were extremely unreliable, often resulting in unplanned downtime, according to Piqua Power System. Emerson completed each controls replacement project in just five months, compared with the eight to nine months typical for such projects. The accelerated timetable made it possible for the City of Piqua to return the units to service in time for the upcoming peak winter and summer months. As part of the turbine controls replacement project at Unit 8, Emerson also performed fuel valve and extended exhaust thermocouple replacements. During the Unit 9 controls retrofit, Emerson also replaced the pressure switch and gauge cabinet, starting diesel engine controls, ignition system, liquid fuel flow divider and vibration system. • www.emersonprocess.com Transmitter measures pressure without impulse lines, capillary tubes • Endress+Hauser introduced the Deltabar FMD71 level transmitter, which uses two pressure sensor modules, each connected electronically to a single transmitter. Using a Ceraphire ceramic sensor in the pressure sensor modules, the transmitter calculates the differential pressure from both sensors and transmits the level, volume or mass via 4-20 mA with HART as a standard two-wire loop-powered device. One sensor module measures the hydrostatic pressure (HP) and the other one the head pressure (LP). Each sensor sends a digital signal corresponding to temperature compensated measured pressure to the transmitter. This electronic system elimi16

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nates issues of traditional differential pressure measurements by doing away with impulse lines or capillaries and their related issues of icing, clogging, leaks, condensation and changing ambient temperatures. For applications where heavy environmental washdown is a concern, the FMD71 automatically incorporates Endress+Hauser’s dehydration module when a hygienic process connection is utilized. The dehydration module draws moisture from the ambient air inside the cell before it affects the sensor. The FMD71 offers a standard 4-20mA HART capable output. The dP level measurement is the default 4-20mA signal while dP level, head pressure and sensor temperature can all be assigned as HART variables. Each sensor in the FMD71 system has 0.075% reference accuracy, maximum nominal pressure measurement of -15 to 600 psig, and a -40°F to 302°F process temperature capability. • www.us.endress.com New option on All-Star Bimetal thermometers • Palmer Wahl Instrumentation Group made additions to the 316 stainless steel case, fitting and stem options on its popular line of All-Star Bimetal thermometers. Now available on Palmer All-Star Series Bimetal thermometers, 316 hermetically sealed stainless steel case, fitting and stem options are designed with deepwater drilling and off-shore oil rigs in mind. Models that include the 316SS case, fitting and stem option are IP67 rated – dust tight and water tight up to 1m. Fahrenheit ranges from -100°F up to 1,000°F and Celsius ranges from -50°C up to 500°C are available, with over-range protection of up to 50 percent of range and accuracy within 1 percent of full scale. A quick lock cam-action bezel ring with heavy duty, heat resistant hermetically sealed gasket seals out moisture to prevent lens icing or fogging. Pointer is adjustable for recalibration using an external reset nut and is standard with all models. Choose from easy reading 5˝ (127 mm) or space-saving 3˝ (76 mm) dials with anti-parallax dial design and linear scale with black graduations and numerals on a low-glare white background, featuring a high visibility tapered-tip black pointer for ease of reading. Available in stem lengths up to 60˝ (152 cm), the single helix bimetallic coil sensing element is located in the bottom 2.5˝ of the thermometer stem and is a high-torque, low mass design with silicon on coil for superior heat transfer characteristics, fast response and consistent repeatability. Design meets the American Society of Mechanical Engineers B-40.3 standard. • www.palmerwahl.com New FPI-X Mag Flow Meter measures accurately in swirl • Process and plant engineers contending with swirl and other flow disturbances in the line will find the new FPI-X Dual Sensor Electromagnetic Flow Meter from McCrometer delivers accurate and repeatable measurement under extreme flow conditions unachievable with other technologies. The McCrometer FPI-X flow meter reliably achieves ±0.5 percent accuracy under the most severe swirling flows. Designed for use in close proximity to cascading or multiple pump arrays, this meter delivers the advantage of accurate measurement where no flow meter previously could serve. Whether installed near pumps, valves, elbows, headers or any 2014/2015 Innovation Guide

other equipment that makes it impossible to create a symmetrical velocity flow profile in the pipe, the FPI-X will outperform traditional mag meters. The FPI-X mag meter provides measurement in difficult sites that otherwise require multiple meters in various locations, saving customers both money and installation time. The FPI-X also eliminates the expensive flow conditioners and piping modifications necessary with other meters. The FPI-X flow meter features a field-proven dual sensor configuration designed with multiple electromagnetic coils installed throughout both sensors to produce a magnetic field across the complete cross sectional area of the pipe. Placing voltage sensors in two planes across the pipe compensates for differences in velocity caused by severe flow disturbances. More velocity sensors results in a more accurate measurement. • www.mccrometer.com

Maintenance Services/Repair/ Safety/Software O&M New handheld IR temperature meters from Meggitt • New handheld thermometers from Meggitt Sensing Systems read temperatures of hard to reach or moving machinery for a variety of industrial applications. The MAC050 and MAC100 add to the MachineryMate® line of tools used to assist in machinery health. Using laser sighting for accurate detection, the rugged thermometers can measure up to 1,832°F (1,000°C). Also capable of contact readings, the meters are supplied with K-type thermocouples for applications where emissivity is unknown. The high performance MAC100 is capable of Bluetooth connectivity for data streaming, analysis and trending, and has user selectable emissivity. MAC meters are an affordable and safe solution for obtaining temperature data. Machine equipment conditions can be quickly gauged, reducing unplanned downtime and increasing efficiency. • www.meggittsensingsystems.com Jofra ASC-400 Advanced Signal Calibrator • The newly introduced Jofra ASC-400 portable multi-signal calibrator from Ametek Test & Calibration Instruments is a highly functional calibrator that provides laboratory accuracy in a device that is compact enough to fit into a tool box or operate with one hand for easy field calibration, process monitoring or maintenance functions. When paired with new and improved advanced pressure modules, the ASC-400 becomes a true pressure calibrator, with features such as leak test, switch test, scaling and online percent error calculations. Co-developed by Ametek’s Crystal Engineering, the new modules feature fast, safe and easy-to-use Crystal Pressure fittings (CPF) for quick connect/disconnect. The modules are engineered for in-plant, field or laboratory use and are ready to use once they are plugged into ASC-400.

The ASC-400 features a high-contrast color display and an extremely user-friendly interface. The instrument’s accuracy is designed to meet the demands of modern pressure sensors and transmitters. The ASC-400 is capable of simultaneous readback from device-under-test of mA,V and pressure. When used with JofraCal calibration software, it can document as well. The device is able to perform fast RTD simulation and works with pulsed transmitters and PLCs. It also can be used as a highaccuracy thermometer through the use of RTDs and CvD equations. The compact calibrator features a full numerical keypad with cursor and function keys. In addition, fuseless protection protects the instrument from voltage overloads up to 250 VAC, preventing the need for expensive repairs and recalibration. It can be carried in a handy soft case with a pocket for test leads and an opening in the top that provides easy access to the test terminals. • www.jofra.com Tube, pipe beveling tools in battery, electric models • A line of welding end prep tools were introduced by Esco Tool in battery and electric powered models for machining tube and pipe where air is not available. The Esco Mongoose Millhog is a self-centering, right-angle drive I.D. clamping tool that now comes in a rechargeable 18 V battery powered model for true portability and a 950 W electric motor for use where air is not available. Only requiring 2.25˝ minimum clearance for beveling tube and pipe from 5/8˝ I.D. to 3˝ O.D., these tools are ideal for getting into tight spaces and provide chatter-free operation without cutting oils. Featuring TiN coated cutter blades that mount securely in a wedge-style blade locking system and have a radical chip breaker that directs the chip away from the surface to minimize heat generation, Esco Mongoose Millhog tools only require nine sets of clamps for their entire range. Either power option can be field-retrofit to the pneumatic tool by changing four bolts. The Esco Mongoose Millhog is priced from $4,195 complete. Battery and electric motors can be purchased separately to retrofit pneumatic models. • www.escotool.com Minimize wildlife-related power outages with new guard • Eaton recently introduced its new ground terminal wildlife guard, an expanded product offering of the Wildlife Protection System from its Cooper Power Systems business. In addition to the existing terminal wildlife guards, the latest offering reduces service interruption from animal interference while maintaining the reliability and performance of distribution arresters. Designed for traditional heavy-duty and riser pole applications, the ground terminal protector has a universal fit that can be quickly added to any standard distribution arrester. It has the Continued on page 22

2014/2015 Innovation Guide ENERGY-TECH.com

Maintenance Services/Repair/Safety/Software O&M Cutsforth Brush Holder services and products • EasyXchange® Brush Holder Maintenance Service: Let Cutsforth keep your brush holders functioning like new The Cutsforth EasyXchange® Brush Maintenance service provides a unique, long-term approach to system maintenance that will aid in the maximization of asset availability, elevate quality through standardization of work processes and increase workplace safety. No extended service contract is required, but Cutsforth recommends that brush holder maintenance be performed annually for optimal performance. Cutsforth will extend a warranty to brush holder assembly for each customer brush holder involved in the EasyXchange program, no matter the date of original installation. All inspections and maintenance work will be completed by certified Cutsforth technicians. Cutsforth also will provide data reports, highlighting signs of selective action, overheating or other risk factors associated with exciter or commutation cycles connected to the brush or the brush holder. The Cutsforth EasyXchange Service includes: • Restoration of brush holder fit finish and function to likenew condition • Inspect brush box for evidence of accidental damage and repair as needed • Extended one-year warranty regardless of original inservice date • Thermal and ultrasonic cleaning of all components • Maintain quality inspection records for each service Cutsforth EASYChange Removable Carbon Brush Holders Cutsforth’s EASYChange® Removable Carbon Brush Holders bring a safer, more reliable solution to the challenges of carbon brush maintenance on generators under load. This unique brush holder reduces the chance of forced outages, improves personnel safety, increases reliability, extends collector ring length of service and reduces routine collector ring maintenance costs. The quality, craftsmanship and innovative design are readily apparent when comparing Cutsforth’s brush holder with OEM and other aftermarket solutions. The EASYchange brush holder replaces cartridge, plug-in and magazine style holders without rigging modifications in most cases. In addition to making online brush changes safer and easier, the “pistol grip” holders prevent common brush holder and collector ring problems present with most OEM style carbon brush holders. The successful design is attributed to a collaborative effort combining Dave Cutsforth’s 40+ years in the industry and the design skills of Dave’s son and Cutsforth’s CEO, Rob Cutsforth. Cutsforth currently has over 20,000 of its patented brush holders in power plants across the U.S. Notably, none of the power plants that have installed EASYchange have had a brush holder related failure or removed them to change to an OEM or other aftermarket brush holder. Ongoing design improvements exemplify this company’s continuous commitment to innovation and customer satisfaction. Emergency field services also are available for collector ring and brush holder failures that have caused a forced outage. Cutsforth can get you back online faster than

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Before application of Cutsforth’s EASYChange® Removable Carbon Brush Holders

After application of Cutsforth’s EASYChange® Removable Carbon Brush Holders

OEM and motor repair shops with its turnkey products and services. In addition to EASYchange brush holders, Cutsforth also is an industry expert in Online Truing of collector rings and commutator exciters online and under load. Online Truing brings rings and commutators back into operational round without the expense of a forced outage. • www.cutsforth.com

2014/2015 Innovation Guide

Maintenance Services/Repair/Safety/Software O&M Re-lighting For Our Future … Damn the Accountants! • We have all heard about LED lighting and its potential benefits, including energy savings, a better option for the environment, lower maintenance cost, available utility subsidies, makes great PR … the list goes on. So why isn’t this industry the first to make the change in all of our facilities? Many are advocates of making the switch to LED, but face challenges simply due to the structure of budgeting and accounting. As a supplier of rugged industrial and explosion proof lighting, we see this accounting and budget battle constantly – between the capital acquisition budget and the maintenance budget. When our facilities were built, the capital cost of the lighting was built into the facility budget. It was a small piece of the overall capital pie. Maintenance budgets were crafted to allow for maintenance of this legacy lighting – mainly changing light bulbs and ballasts as they blew. LED lighting has arrived, and in many cases, such as the office, it is as simple as changing the old style incandescent or fluorescent bulb to an LED replacement. These simple bulb replacements still fall under the ‘maintenance budget’ standard, so no issue there. However replacing legacy lighting with LED technology for other applications, such as roadway, high bay, parking lot, fuel storage handling and processing, is not always as simple as changing the bulb … it requires changing the fixture. The standard accounting dogma is that changing all of the fixtures in a parking lot or building requires the fixtures to be classified as fixed assets to be capitalized and depreciated. Despite the cost savings and environmental impact, the reality is that capital budgets are always skewed to purchase production equipment and facilities or to meet the latest regulatory challenges. As capital budgets are trimmed, new lighting is cut - after all the upkeep of that lighting comes out of the maintenance budget. LED replacement lighting

gets caught in the middle of this budget battle, and is often left to ‘next year’s budget.’ Only management can overcome this gridlock and mandate to keep these projects funded. Many companies have done so and now continue to reap the rewards. If you are ready to commit, seek a supplier that is committed to providing you a total solution incorporating the best in class LED fixtures and controls, along with the ability to demonstrate a true cost of ownership and return on investment – just swapping fixtures is not always the most effective solution. Plan to visit us at Power-Gen in Orlando in Booth# 626 where we can show you the most innovative lighting for your facility. We also invite you to contact us at 800-739-9169 or www.unimar.com/contact/ Making the switch now to advanced lighting technology just makes sense … it’s good for the company and it’s good for our future. The accountants will get over it. For more information, contact Unimar at 1-800-739-9169 or www.unimar.com/contact/.

Visit us at our upcoming show! Power-Gen | December 9-11 | Booth #626

Orange County Convention Center | Orlando, FL

LED FAA Obstruction Lighting; Industrial White Lighting Reduced Maintenance Cost Highly reliable Class 1 Division 2 products for hazardous locations

315-699-4400 www.unimar.com

2014/2015 Innovation Guide ENERGY-TECH.com

Maintenance Services/Repair/Safety/Software O&M

Glance™ Real Time Mobile Process Data Glance™ is a HTML5 web-based client that runs on all modern devices and desktop browsers without requiring add-ons. Users have the ability to connect directly to OPC and OSIsoft PI systems and build real-time displays in a lightweight integrated graphical builder. Users can upload an existing fleet-wide library of PI ProcessBook® displays with just a few clicks. For PI System Users the ability to login and upload existing OSIsoft™ PI ProcessBook® files is made possible in just a few clicks. It performs a onetime conversion of PI Processbook files into a web-friendly format while maintaining performance and the user’s experience. Uploading, organizing, and searching thousands of existing displays is now easier. For OPC users the ability to build anywhere is now possible. Users can utilize the Glance™ Display Builder on any web-enabled device to create and modify real-time displays that include OPC data. Visualize industrial control systems in a responsive, thin client environment that performs like a native application. Create displays in just minutes with the Builder’s simple and intuitive ribbon toolbar. The drawing tools (values, trends, gauges, etc.) are user-friendly and require minimal training. Glance™ employs standard OPC Data Access (DA) and OPC Historical Data Access (HDA) specifications to retrieve and visualize real-time and historical data from any compliant OPC Server.

Glance™ Features Overview • Intuitive Navigation Tree view allows users to find displays within their corporate or asset hierarchy quickly. • Purely Web Lightweight web-based client runs on all modern mobile devices and desktop browsers with no add-ons required. Graphical process screens update dynamically in real-time utilizing HTML5! • Interactive Trends The ability to zoom, expand, and pan with simple gestures.

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Integrated Web-Based Display Builder

• Single Point of Use A single website interface does it all: stores, organizes, searches, views real-time information, mines data, builds dynamic process displays, etc. • HTML5 Display Builder Web-based screen builder that looks and feels like a desktop application. • Affordable Licensing Models Typically Glance™ is licensed on a per named-site basis with unlimited tags and end-users, giving all who are connected the ability to view and build displays. • Built on Industry Standards Supports streaming real-time and archived process information from both OPC servers and OSIsoft PI Systems. • Lightning Fast Searchable Metadata Allows users to find the desired information within a fleet-wide library of displays. Try the live demo at http://glance.ecg-inc.com Special View-Only demo username: mag1 password: alarm Engineering Consultants Group is a consulting company out of Akron, Ohio that specializes in offering innovative software products for over 15 years. Please visit our website for more information about our products and services: www.ecg-inc.com or contact us at 3394 West Market Street Akron, OH 44333-3306. Phone: 330-869-9949 © 2014 Engineering Consultants Group, Inc. All Rights Reserved. PI ProcessBook and the PI System are trademarks of OSIsoft, LLC. The Matrikon logo is a trademark of Matrikon Inc.The Kepware logo and KEPServerEX are trademarks of Kepware Technologies, Inc. All other trademarks or trade names used herein are the property of their respective owners. 091714

2014/2015 Innovation Guide

Predict-It Predictive Modeling for Process Data • Predict significant and critical process events • Monitor critical equipment in real-time process environment • Problem alerts conform to your operational criteria

Web-Based Management Console

• Ease of model creation and management • Software “expands” to efficiently execute large number of models

Correlation Tool Within The Model Builder

Engineering Consultants Group 3394 West Market Street • Akron, OH 44333-3306 www.ecg-inc.com Phone: 330-869-9949 • Sales@ECG-Inc.com

ability to protect against flashovers between live and ground terminals and provides electrical insulation through a compact, inexpensive and effective system. Exceeding the 1656™- 2010 standard from the Institute of Electrical and Electronics Engineers (IEEE®), both the line terminal and ground terminal wildlife guards have the ability to withstand wet power frequency flashovers, cold temperatures and ultraviolet and salt fog aging. Guard ratings are available up to 22 kilovolts (kV) compared to the 5 kV industry standards. • www.cooperpower.com Combustible gas leak detector for industrial systems • Maintenance technicians have a safe, effective way to detect gas leaks in industrial systems – the Spectroline Pro-Chek CG Combustible Gas Leak Detector (P/N CG-1000), designed for finding leaks in natural gas systems, propane tanks, pipelines, regulators and valves, heat exchangers and much more.The unit detects natural gas, propane, ammonia, methanol, ethanol, ethane, butane and other gases. The PRO-Chek CG is certified intrinsically safe for use in combustive/explosive environments. It’s twice as sensitive as competitive units, and features an adjustable sensitivity control that helps pinpoint the exact location of every leak. Additional features include a variable-intensity audible alarm and flashing LEDs to quickly determine the size and strength of the leak. An auto-zeroing function blocks out background gas levels in the test area. • www.spectroline.com Trap Pac Pro spill containment • The Trap Pac Pro is the newest innovation in spill containment.This Pac holds two complete spill systems in one color-coded, heavyduty case. One side contains an Oil-Based Spill Pac with enough sorbents for a 10-gallon spill.The other side holds a reusable, 100-gallon Tank Trap containment pool for containing oil, diesel fuel, hydraulic fluid and more.These two systems together take the guesswork out of spill response. Matching color-coded equipment labels can be used to identify possible leak sources before they happen, so employees know exactly what spill response product to use.The Trap Pac Pro also comes in a Chemical/Hazmat version for aggressive chemicals, acids and solvents. • www.andax.com

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Prolong EP-2 Multi-Purpose Grease for industrial equipment • To protect industrial equipment from wear and corrosion, Prolong Super Lubricants offers EP-2 Multi-Purpose Grease formulated with the company’s exclusive AFMT (AntiFriction Metal Treatment) technology. which reduces heat and friction in harsh, demanding environments. Prolong EP-2 Multi-Purpose Grease with AFMT is a calcium sulfonate grease that delivers exceptional corrosion protection, high dropping point and mechanical stability, providing excellent resistance to water and oxidation, high load carrying ability and superior performance in a wide temperature range. For industrial applications, EP-2 increases the longevity of bearings in bulldozers, conveyor lines and cables for reduced downtime and maximum productivity. Prolong EP-2 Grease with AFMT is available in 35lb pails and 120 and 400lb drums. • www.prolong.com Thermoflow releases new web-based plant design expert • Thermoflow launched its new web-based Plant Design Expert (webPDE), providing combined-cycle and gas turbine cogeneration plant developers with highly automated preliminary design capabilities.The new webPDE equips designers with a streamlined executive-level version of Thermoflow’s industrystandard GT PRO software, allowing users to generate a plant conceptual design, heat rate and economics estimate on the fly from their mobile device. The new webPDE allows plant developers to run multiple design cases in a batch and display their results in side-by-side columns. Its user interface was rewritten in a browser-friendly language and was made as “thin” as possible to minimize data transfer between the user’s mobile device and Thermoflow’s server. The actual “heavy” calculation engine resides on Thermoflow’s server, enhancing security and minimizing clutter and potential overload to the user’s mobile device. Thermoflow’s webPDE now is available on a subscription basis. Prior to launching the solution, the company beta-tested the software with a select group of customers to ensure proper functionality on a wide range of devices — this included Apple iPads and iPhones, Android phones and tablets, Windows tablets and conventional Windows-based PCs. • www.thermoflow.com

2014/2015 Innovation Guide

Nozzles/Spray/Pumps/ Valves/Actuators

™

BUTTERFLY VALVES

“The Leader in Automated Valves” • 2”-24” Wafer and Lug Design • Numerous Seat Options including TFE Encapsulated, Viton, Buna, EPDM, Neoprene • Multiple Disc Options including Bronze, 316SS, Nickel Plated Ductile Iron, TFE Coated Complete Automation capabilities from our large inventory: • Direct Actuator Mount • TRIAC Rack and Pinion Pneumatic • TRIAC Electric on-off and modulating

A-T Controls introduces complete line of manual and automated industrial butterfly valves • Now A-T Controls, the leader in automated ball valves, adds its expertise and capacity to a complete line of manual and automated butterfly valves. Standard ductile iron, and stainless steel bodies are complemented with multiple seat and disc combinations, including TFE coated discs and TFE encapsulated EPDM seats for excellent corrosion resistance. EPDM, buna,Viton and neoprene seats are complemented with nickel plated ductile iron, aluminum bronze, nylon coated and 316SS discs. A broad range of 2˝-24˝ butterfly valves are automated with the TRIAC pneumatic and electric actuators and accessories from our extensive inventories in Houston, Texas and Cincinnati, Ohio. • www.a-tcontrols.com.

Triac Division 9955 International Boulevard Cincinnati, Ohio 45246 (513) 247-5465 FAX (513) 247-5462 e-mail: sales@a-tcontrols.com www.a-tcontrols.com

A-T Controls Canada 28 Don St. Penetanquishene, Ontario Canada L9M 1E5 705-549-0896 e-mail: damos@sympatico.ca

2014/2015 Innovation Guide ENERGY-TECH.com

Nozzles/Spray/Pumps/Valves/Actuators Rotork Type K Damper Drives offer power plants convenient access to the world’s most complete selection of pneumatic, electric, electrohydraulic, rotary and linear damper drives for their facilities. • Damper drives can significantly improve the efficiency and reliability of large and small boilers, furnaces, process heaters and other demanding power plant processes. Rotork has tens of thousands of damper drives in service throughout the U.S. and rest of the world. Furthermore, Type K damper drives are supported by Rotork Site Services’ extensive network of factory-trained technicians. How important are damper drives to your power plant facility, and what does the user gain with accurate combustion air and flue gas control? The precise control and fast operation of important dampers will increase the BTU/fuel ratio, as well as the MW/fuel ratio. Added benefits are reduced emissions, improved boiler draft control and lower fuel consumption, which can result in dramatic cost savings. Another important benefit is that Type K damper drives provide very fast operation and can be set to fail CW, CCW or last position. Type K assists industrial boiler owners who are required to comply with the EPA’s new boiler MACT rules. In 2012, the U.S Environmental Protection Agency published the Type K DM series on windbox applicaNational Emission Standards tion, replacing 2.5˝ x 5.0˝ cylinders. for Hazardous Air Pollutants for Major Sources: Industrial, Commercial and Institutional Boilers and Process Heaters; Final Rule Jan. 31, 2012, in the Federal Register. That ruling affected approximately 1,700 existing major source facilities with an estimated 14,316 boilers and process heaters. The Boiler Maximum Achievable Control Technology (Boiler MACT) Rule requires boiler owners to carry-out tune-up procedures either annually or bi-annually. Two major components of the tune-up procedure where Type K damper drives directly influence boiler performance are the accurate control of the air-to-fuel ratio and in optimizing CO emissions. Many boilers employ old-style technology that is neither accurate enough nor powerful enough to position the dampers quickly and precisely to mitigate emissions. Type K damper drive retrofits provide a better, cleaner burn. Retrofitting existing dampers with Type K drives is usually quick and easy and provides many important benefits, such as: • High speed continuous modulation of ID/FD fan and inlet guide vanes • Improved modulation and control of secondary air dampers • Improved automation and burner management 24

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• Quick response to plant demand • Improved reliability in high temperature environments, up to +300°F (+149°C) • Precise damper and burner positioning • Simple commissioning and diagnostics • Low running costs, Type K Drop-In-Place retrofit matches virtually maintenance- any damper drive replacement. free • Wide range of controls system interfaces, including pneumatic, analog and bus network communication. Type K offers a Drop-In-Place retrofit solution that precisely fits the new damper drive into the application with no field modifications. The Rotork Type K Drop-In-Place retrofit program provides end-users with a high-performance drive that can be installed without any field engineering or fabrication using basic hand tools in a short time. Existing connecting rods and linkages are reused without modification. With a Type K direct-mount or pedestal-mount retrofit drive: • The new drive will match the legacy drive footprint or mounting surface • The drive shaft and drive lever are in the exact same place relative to the floor mount or direct mount bolt holes • The drive lever will be dimensionally identical to the existing lever and will rotate through the same arc • No costly field design and fabrication. Key features of a Type K damper drive include: • 100% duty cycle, with a continuous modulating service rating of 3,600 starts per hour without overheating • High speed/high-torque, up to 20,800 lbf. ft. with stroke speed as low as 3 seconds full scale • Easily serviced with open-frame design • Excellent in harsh, high-temperature environments • Virtually zero air bleed in resting state – reduces air consumption. Network Connectivity: Type K offers digital communications fully compatible with major open fieldbus protocols, including Profibus, Foundation Fieldbus, HART and Modbus. For more information, send e-mail to typek@rotork.com, visit www.rotork.com or contact us at Rotork Controls, Inc., 10410 Vista Park Rd., Dallas, TX 75238. Phone: 214-343-9980

2014/2015 Innovation Guide

Enhance plant-wide performance with Rotork actuator and damper-drive solutions Rotork provides high-performance, cost-effective valve actuator and damper drive solutions throughout your entire power plant. Solutions that can help you maximize plant performance, minimize maintenance problems, and help you meet stringent safety and environmental regulations. Hundreds of different valve actuators and damper drives are required throughout a typical power plant facility. Rotork can meet all of your needs by offering motor-operated, fluid power, electro-hydraulic, and manual gear operators. Actuators and drives suited for harsh, rugged operating conditions, inside and out, servicing every size and style of valve from small process control valves to superlarge isolation valves as well as rotary, linear, or quarter-turn combustion-air and flue-gas dampers. Furthermore, the advanced technological capabilities of Rotork smart actuators can help you easily upgrade connectivity and provide a smart window to your process that includes important predictive maintenance data to help you improve productivity and efficiency as well as cut maintenance costs. Whether you are building a new plant or are currently operating a fossil-fuel, nuclear, or green-energy facility, we can help. Rotork actuators and drives are currently servicing hundreds of power plants around the world. Our more-than 50-years experience and proven expertise can help you, too. Contact us today.

IQ3 electric actuator with smart window technology

SM6000 S2 heavy-duty electric damper drive

Rotork Controls, Inc. 675 Mile Crossing Blvd. Rochester, NY 14624 phone: 585 247 2304 email: info@rotork.com

www.rotork.com

Redefining Flow Control

Type K pneumatic rotary damper drive

Nozzles/Spray/Pumps/ Valves/Actuators Vertical centrifugal pumps for use in the smallest locations • SPX offers a range of centrifugal pumps from its Johnson Pump brand designed for high reliability in numerous offshore utility applications.This includes the innovative, spacesaving CombiFlex series of vertical centrifugal pumps.The vertical build of these pumps, combined with several suction and pressure flange positions, enable them to fit into small locations, making them ideal where space is a premium on offshore platforms and ships. A choice of materials and shaft sealing options enables these pumps to meet a wide range of applications, including fresh and seawater pumping, bilge and ballast pumping, effluent and other general service pumping requirements. They provide high pump efficiency in a heavy duty design that uses a very rigid shaft to ensure reliability. The pumps have mechanical sealing to EN 12756, are available with the benefit of a top pull out principle using spacer coupling and are designed for easy maintenance. The CombiFlexBloc model has the impeller mounted directly on an extended motor or stub shaft to provide an even more compact unit with a standard coupling. The CombiFlex pumps use a motor mounting flange which enables exact positioning and alignment of the electric motor. A coupling guard and protective elements between the lantern elements protect all the pump’s rotating and internal parts. They provide a compact, economic, space-saving solution for the transfer of thin, clean or slightly contaminated liquids and are available for capacities up to 1,500 m3/h, heads up to 100 m and working pressures of up to 10 bar. • www.spx.com

Dresser-Rand introduces new Magnum HammerHead™ Valve • Dresser-Rand launched its new Magnum HammerHead valve, designed for high molecular weight applications at both low and high compressor speeds. The new valve can be applied to all brands of reciprocating compressors. Computational fluid dynamics (CFD) and finite element analysis (FEA) were used to develop the HammerHead valve’s geometry, improving the valve flow area by as much as 60 percent compared to standard Magnum valves. Minimal valve losses translate into improved compressor efficiency. While undergoing development, flow testing revealed that the HammerHead valve surpassed all other valve types tested, including poppet, plate and ring-type valves. Setting the HammerHead valve apart from other poppet valves is its ability to be applied at high compressor speeds. Its unique element design minimizes tensile stresses, and the streamlined flow path with optimized seat, guard and lift areas, ®

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maximizes valve flow area and is more tolerant of particles and liquids in the gas. Only one element is used for all valve sizes, which simplifies inventory management, minimizes replacement costs and increases interchangeability. The results delivered by the new valves, so far, include lower power consumption and a corresponding increase in compressor flow. • www.dresser-rand.com New butterfly valve design from Hayward • Hayward Flow Control introduced its patent pending BYV Series Butterfly Valve. The BYV Series incorporates the most advanced thermoplastic design and construction for butterfly valves in the industry. Available in multiple thermoplastic materials from sizes 2˝12˝/DN50-300, the BYV Series has an extremely robust one-piece body construction and is lighter weight than metal valves of equal size. The revolutionary hand lever features a 72 spline interlock mechanism allowing for 19 stopping positions at every 5 degrees. The engineered hand lever material incorporates a UV inhibitor for enhanced performance in outdoor applications. The BYV also features reinforced lug holes and can be ordered with overmolded 316 stainless steel lugs for dead end service or isolation needs. The BYV Series is available in ANSI150 and DIN/EN PN10 flange patterns, with a pressure rating of 150 PSI/10 Bar at 70°F non-shock across all sizes and materials. Additional options include field installable 316 stainless steel lugs, gear operators, pneumatic or electric actuators, manual limit switches, stem extensions, 2˝ square operating nut and chain operator for gear boxes. • www.haywardflowcontrol.com New advanced FIT AODD Pumps from Wilden • Wilden introduced the Advanced FIT line of Air-Operated Double-Diaphragm (AODD), which precisely “FIT” bolt-tobolt and pipe-to-pipe in existing fluid-handling piping systems to provide increased performance with no re-piping necessary. They have been engineered to be an easy, cost-effective way to enhance and upgrade existing pump performance with superior bolted product containment. Additional features and benefits of Wilden Advanced FIT AODD include: re-engineered fluid path increases flow rates up to 54 percent vs. current Wilden models, exact FIT from bolt-down footprint to inlet and discharge connection heights, fewer fasteners and easy accessibility with power tools for faster assembly/disassembly and shorter downtime, labor-saving manifold flexibility to assist in tight-fitting installations and bolted configuration for superior product containment with NPT or BSPT threads or ANSI or DIN flanges, among other features. • www.psgdover.com

2014/2015 Innovation Guide

Piping/Tubing/Joints Pipe, fittings and flanges from Rolled Alloys â&#x20AC;˘ Rolled Alloys is an innovator in the metals industry with extensive processing capabilities, website and e-business platforms, alloy development and a highly trained sales and metallurgical staff ready to aid customers with their alloy requirements. Rolled Alloysâ&#x20AC;&#x2122; clients are increasingly looking to them as a supplier of value, not just metal. One of the largest suppliers of stainless steels, nickel, cobalt and titanium alloys, Rolled Alloys maintains 13 locations across North America and Asia, with additional representatives in Europe. For additional information about Rolled Alloys, its materials selection and additional processing services, please contact Brian Sabbadini at 734-847-9470, or visit www.rolledalloys.com.

2014/2015 Innovation Guide ENERGY-TECH.com

Nozzles/Spray/Pumps/ Valves/Actuators Custom vanes, rotors, end plates for rotary pumps • Metallized Carbon Corp. released custom vanes, rotors, and end plates for use in rotary vane pumps pumping both liquids and gases. The carbon-graphite components provide superior lubrication in most environments, and are ideal for pumping liquids with poor lubricating qualities, strong chemicals that attack metals, and to pump air, vacuum, combustion products and gasoline vapors. Metallized Carbon’s carbon-graphite vanes, rotors and end plates are used in such dry running applications as automotive anti-smog pumps and gasoline vapor pick up pumps, breathable air pumps and vacuum pumps. Carbon graphite vanes can withstand the rubbing of the vane tip against the housing bore and the rubbing of the side of the vane against the slots in the rotor. Lightweight carbon graphite rotors save energy and withstand the rubbing against the vane and the end plates. Carbon graphite end plates are pressure tight and dimensionally stable so that they can make a close clearance seal with the rotor and vanes. They also withstand the rubbing of both the vanes and rotor. • www.metcar.com

and J-preps. It sells for $6,595.00 and is available for rent. • www.escotool.com All electric pipe bending machine boosts manufacturing throughput • Unison all-electric pipe bending machine can help improve production accuracy and throughput of complex large-bore hydraulic piping systems. The machine also is designed to help improve manufacturing efficiency by reducing the number of steps required to fabricate piping parts. Based on Unison’s Breeze platform, it can accommodate tubes and pipes up to 180 mm (7˝) in diameter. The machine’s exceptionally high torque capability, combined with precision CNC control and force sensing clamp and pressure dies, means that thick-walled pipes made from hard materials can be bent easily, and very accurately without deformation. Parts manufactured from duplex stainless steel are a typical example – the machine is capable of bending 130 mm diameter pipes that have a wall thickness of up to 11 mm. • www.unisonltd.com

Testing & Inspection

Piping/Tubing/Joints Electric pipe beveling tool works without compressed air • A new portable end prep tool that is ideal for metal fabricating shops and other applications where compressed air isn’t available was introduced by Esco Tool. The Esco Millhog Mini Electric Pipe Beveling Tool features an 1,800 watt 110/230 VAC, 40-60 Hz motor and a self-centering draw rod mechanism that rigidly mounts into a tube or pipe I.D. Developed for end prep applications where compressed air is not available, it utilizes the same wedge-lock blade locking system as the air-powered model and pulls a thick chip without oils. Suitable for boiler tubes and pipes from 1-1/4˝ I.D. to 6-5/8˝ O.D., the Esco Millhog Mini Electric Pipe Beveling Tool has 2-speed operation: Low speed of 18 RPM for stainless steel, P-91, and exotic alloys and High speed 60 RPM for mild and carbon steels. Ideal for repetitive end preps, it can perform any angle of prep, including compound bevels

Starter leak detection kit for oil-based fluid systems • Spectronics Corp. introduced the OPK-441 Industrial Leak Detection Kit, a new starter kit designed to effectively pinpoint the exact source of all leaks in hydraulic equipment, compressors, engines, gearboxes and fuel systems. The kit features the Optimax 400 violet light LED flashlight, a compact, high-intensity unit that quickly reveals all leaks in small- to medium-sized industrial systems — even in cramped areas that are inaccessible to larger lamps. It also includes an 8 oz (237 ml) twin-neck bottle of patented Oil-Glo 44 concentrated fluorescent oil dye, which is compatible with all synthetic and petroleum-based fluids. When a leaking system is scanned with the Optimax 400 flashlight, Continued on page 32

ENERGY-TECH.com

2014/2015 Innovation Guide

Testing & Inspection endoGRINS® gradient-index lenses are built into Borescopic visual inspection • World-class image quality, overnight delivery and prices one-half our exclusive line of Hawkeye Precision Borescopes. Gradient Lens Corporation carries more than to one-third that of comparable borescopes – that’s ® 80 models of rigid, flexible and video borethe innovative Hawkeye Precision Borescopes! scopes, as well as video microscopes. All are Its newest rigid and flexible video borescopes in stock and ready for overnight delivery. • display high-quality inspection images on a video www.gradientlens.com or 800-536-0790 monitor, laptop or desktop computer. The images can be saved, documented and e-mailed. The newest addition to the Hawkeye line is a prime example, the new ® Hawkeye V2 Video Borescope. The new Hawkeye V2 represent the next generation of fully portable, articulating video borescopes manufactured by Gradient Lens Corporation. (www.gradientlens.com/V2) These new scopes deliver 5x higher image quality than fiber optic borescopes and are made in Bright, B right, High-Res the U.S. Operators can quickly Video & Photos and easily inspect turbine blades, Large Range-of-Focus combustion chambers, cooling 90° Prism & Quality Construction Close-Focus tubes in heat exchanges, gear 4-Way Articulation tips available! boxes and more, all without the 4 & 6 mm Diameters need for costly and time consumStarting at only $8,995 ing engine and system teardown. Fully portable, Hawkeye V2 Video Borescopes are 4-way articulating and come complete with video monitor and light source, VIDEO BORESCOPES all in one easy-to-use device. Ideal for cooling tube inspection! Hawkeye V2 Videoscopes are We’ve improved the image quality in the new Hawkeye® either 4 mm or 6 mm in diameter, V2 with a higher resolution, more light sensitive camera, and have flexible, rugged, 4-layer delivering bright, crisp, clear images! The new 5” LCD tungsten sheathing. They are Monitor provides comfortable viewing, and intuitive, available in lengths up to 6.0 m. easy-to-use controls, allow photo and video capture Quickly inspect cooling tubes at the touch of a button! We’ve increased the 4-way Custom lengths are available upon inside heat exchangers, turbine articulation range, and improved the feel. It’s still small, blades, and much more! request. lightweight, portable, delivers great image quality, and For more than 20 years, is priced starting at only $8995. Available in 4 and Gradient Lens Corporation has 6 mm diameters. Optional 90° Prism and Close-Focus designed, engineered and manuadapter tips available. factured precision optical instruMade in USA ments. The company sells more gradientlens.com/V2 800.536.0790 industrial borescopes than any other manufacturer. Its patented

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2014/2015 Innovation Guide ENERGY-TECH.com

testing & inspection

YOU GENERATE THE POWER WE’LL GENERATE THE SOLUTIONS

We Connect the Dots Over the past 30 years, Structural Integrity has built a team of over 200 industry experts providing comprehensive solutions to the energy industry. We connect the dots from problem to resolution, from regulations to compliance, from nondestructive examination, to engineered solutions, even custom equipment. You can look to us for our: • Knowledge of power plants, codes, and how things work. • Extensive experience and leadership. • High quality, hard work, and responsiveness.

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The Structural Integrity Advantage • Powered by talent and technology, Structural Integrity Associates (SI) offers a one-stop-shop for innovative solutions. And we never shy away from a challenge. With 30 years of success in failure prevention, SI offers a diverse menu of turnkey engineering services to every sector of the energy industry. Our signature services offer a unique blend of state-of-theart science and old-fashioned customer service. One Call Does it All Structural Integrity does it all – from straightforward inspections to managing complex undertakings, like license renewal. Whatever the size of your project, you can expect excellence from SI. We serve a diverse client base as well, including nuclear and fossil plant owners; oil and gas transmission pipeline companies, civil infrastructure and renewable energy sources, such as hydro, geothermal and wind generation. State-of-the-Art Services: • Advanced Nondestructive Examination • Materials Evaluations • Remaining Life Assessments • Stress & Failure Analysis • Remediation and Repair • Data Management • Forensic Engineering • Expert Witness Support • Training To serve our global client base, SI has over a dozen branch offices throughout the U.S. and Canada, as well as affiliates in China, Taiwan, Korea and Spain. Our Team The SI team includes more than 250 of the industry’s best and brightest. As leaders in their respective fields, the professionals at SI are sought after to provide a fresh perspective on engineering issues and expert opinions to utility, industrial, legal and insurance firms. We also partner with other leading firms with unique specialties that complement our own. With access to experts in every field of engineering, Structural Integrity takes a multidisciplinary approach that gives clients the facts they need to make informed decisions. You Generate the Power. We’ll Generate the Solutions. Call 1-877-4SI-POWER (1-877-474-7693) or email info@structint.com to put the power of Structural Integrity to work for you.

2014/2015 Innovation Guide

training & Education 2014-2015 Training Seminars, Conferences & Trade Shows Nov. 3-4, 2014 CCGT 2014: O&M and Lifecycle Management for CCGT Power Plants Houston, Texas www.tacook.com/ccgt-usa Nov. 11-14, 2014 Advanced Vibration Control Syria, Va. www.vi-institute.org dec. 3-5, 2014 Turbine-Generator Troubleshooting and Failure Prevention, with Energy-Tech University Chicago, Ill. www.energy-tech.com/ETU dec. 9-11, 2014 Power-Gen International Orlando, Fla. www.power-gen.com

Feb. 16-20, 2015 Introduction to Machinery Vibrations (IMV) Tempe, Ariz. www.vi-institute.org

June 15-19, 2015 Rotor Dynamics and Modeling (RDM) Syria, Va. www.vi-institute.org

March 23-27, 2015 June 28-July 2, 2015 Basic Machinery Vibrations (BMV) ASME Power & Energy 2015 Knoxville, Tenn. San Diego, Calif. www.vi-institute.org www.asmeconferences.org/powerenergy2015 April 21-23, 2015 Electric Power Conference & Exhibition Rosemont, IL www.electricpowerexpo.com

sept. 21-25, 2015 Machinery Vibration Analysis (MVA) Salem, Mass. www.vi-institute.org

May 11-15, 2015 Advanced Vibration Analysis (AVA) Houston, Texas www.vi-institute.org

oct. 12-16, 2015 Balancing of Rotating Machinery (BRM) Knoxville, Tenn. www.vi-institute.org

Gas and Steam Turbine Reliability â&#x20AC;&#x201C; Failure Prevention and Life Extension Instructed by

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2014/2015 Innovation Guide

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the dye glows a bright yellow/green at all leak sources to reveal the precise location of every leak. Rounding out the kit is an 8 oz (237 ml) spray bottle of Glo-Away dye cleaner, dye treatment tags and fluorescenceenhancing glasses. All components are packed in a rugged carrying case. • www.spectroline.com Broad-Beam UV Lamp for industrial leak detection • Spectronics Corp. introduced the powerful Spectroline Tritan 365 (Part No. TRI-365HA), a multi-LED, broad-beam UV leak detection lamp. When used with Spectroline fluorescent dyes, it pinpoints fluid leaks in a wide range of industrial systems, such as hydraulic equipment, compressors, engines, gearboxes, fuel systems and much more. The Tritan 365 features three ultra-hi-flux UV LEDs for fluorescent leak detection, plus a white light LED for general component inspection in dimly lit areas. The lamp’s broad-beam profile provides extrawide area coverage – 45˝ (114 cm) diameter at a 20’ (6.1 m) distance – making it ideal for quick leak checking of large surface areas. Extremely compact and lightweight, the Tritan 365 weighs just 16 oz (454 g). The lamp’s compact head gets into cramped areas larger lamps can’t reach. A three-way rocker switch allows easy control of the light sources and a lightweight, angled lamp body ensures fatigue-free inspections. Instant-on operation allows the lamp to reach full intensity immediately. Also available is the Tritan 365M (Part No. TRI-365MHA) portable, battery-operated AC/ DC lamp kit. Along with the Tritan 365 UV lamp, the kit includes a rechargeable NiMH battery pack, AC and DC cord sets, a smart AC charger and UV-absorbing glasses. All components are packed in a convenient carrying case. • www.spectroline.com

Are Shaft Currents Destroying Your Machinery? Failure to properly ground rotating equipment can result in expensive bearing, seal, & gear damage.

Turbines: Parts, Components, Accessories FT4000™ aero-derivative gas turbine • PW Power Systems Inc. completed the initial verification tests for its latest aero-derivative power solution, the FT4000 gas turbine. Test results compiled during the past two months demonstrate performance, emissions and structural design integrity consistent with pretest predictions and customer requirements. Successful testing validates both operational and performance characteristics of the FT4000 gas turbine, paving the way for commercial introduction scheduled for December 2015. With a modular design that includes proven features of the successful FT8 SwiftPac power plant, the FT4000 engine, which is powered by a Pratt & Whitney PW4000 derivative gas generator, offers a nominal 60-120 MW package of reliable peaking and base-load power in a compact footprint. The FT4000 engine is designed for simplecycle, combined-cycle or cogeneration applications. The FT4000 SwiftPac unit provides the highest power output of any aero-derivative gas turbine generator package available in the market. • www.pwps.com High-speed shear spacer protects turbomachinery drives • The Kop-Flex high-speed shear spacer coupling uses a patented double-tube design, precision machining and bearings, and special metal treatments to provide predictable shear during torque overloads on turbo drivetrains, allowing safe coast down of systems turning at up to 20,000 rpm. Developed to protect gas-turbine-powered generator drives during electrical faults, the shear spacer also is ideal for drives on compressors, pumps, fans and trains subject to shock torques. The patented shear cartridge uses special bearings between two tubes to maintain concentricity and overall centering after high-speed separation. The double-bearing design, precision grooving, shot peening and a corrosion resistant coating combine to increase fatigue resistance and promote reliable operation through the life of the coupling. The high-speed shear spacers are available in all catalog coupling sizes capable of handling speeds up to 20,000 rpm and millions of inch-pounds (or Newton-meters) of torque. The high-speed shear spacer is an improvement compared to standard shear spacers and shear pins, which can create issues when used above 3,600 rpm due to balancing issues and fretting potential when using pins. • www.PowerTransmissionSolutions.com

SOHRE TURBOMACHINERY® INC. 128 Main Street, P.O. Box 1099 Monson Massachusetts, USA 01057-1099 32 ENERGY-TECH.com PH: 413.267.0590 • 800.207.2195 • FX: 413.267.0592 tsohre@sohreturbo.com • www.sohreturbo.com

2014/2015 Innovation Guide

Turbines: Parts, Components, Accessories Fulmer improves its plug-in brush holder • Fulmer Company of Export, Pa., improved the design of its single pocket, cartridge style, plug-in holder, a product that offers a revolution in brush changing for turbine-generator reliability. OEM approved, Fulmer’s product is a direct replacement for the original brush holders used on GE,Westinghouse and other manufacturers’ generators. And no expensive, timeconsuming rigging modification is required to install the holder, just remove the old holder, clean the rigging and install the Fulmer FC101 style holder. In fact, brushes can be removed on-line, without any service interruption.

The longer brush box creates better brush support and can accommodate a 4˝ brush, greatly lengthening brush life and reducing the frequency of brush changes. Lightweight and ergonomically built, the holder also offers two styles of removable insulated handles. The “shorter” handle with flash guard protects fingers from brush shunts, while the optional, extended handle can be used for holders that are difficult to access. And a portable Brush Load Fixture enables operators to quickly and easily change brushes. Economically priced, the holder utilizes standard brushes and terminals and improves machine performance by reducing brush selectivity and improving air flow and cooling. Fulmer Company is the largest North American manufacturer of brush holders for DC machines, and a supplier to major global OEMs and aftermarket customers. OEMs include GE, Siemens, Toshiba and others. Major aftermarkets include power generation, railroad, transit, mining, steel and motor repair shops. Fulmer Company is certified to the ISO 9001:2008 standard by Det Norske Veritas. • www.fulmercompany.com

A REVOLUTION IN BRUSH CHANGING FOR TURBINE-GENERATOR RELIABILITY The NEW Cartridge-Style Plug-In Brush Holder It is now possible to easily and safely change brushes on live equipment! The solution the industry has long awaited is now available from the leader in brush holder technology, Fulmer Company. ■ Brushes changed on-line, without service interruption, using a simple changing fixture ■ Direct replacement for many OEM styles with no rigging modification required ■ Longer brush box to provide better brush support and allow the use of a 4” brush, increasing brush life and reducing the frequency of changes ■ Rugged, lightweight and ergonomically built ■ Removable insulated handle with flash guard

BRUSH CHANGING MADE EASY

THE FULMER WAY.

Fulmer Company A Wabtec Company 3004 Venture Court Westmoreland Industrial Park III Export, Pennsylvania 15632 Phone 724-325-7140 www.fulmercompany.com 2014/2015 Innovation Guide ENERGY-TECH.com

AGMA, OSHA, ANSI, IEC, DIN, EU and ATEX standards and requirements. • www.chemineer.com

Water Intake Systems/ Filtration Equipment/ Water Treatment/Monitoring Chemineer Model 20 HT/GT with the RL-3 Ragless Impeller • Combining the Chemineer Model 20 HT/GT mixer with the Chemineer RL-3 impeller creates the ideal mixer for wastewater treatment plant applications since the high-efficiency gearbox of the Model 20 and the unique characteristics of the RL-3 impeller work together to eliminate downtime and maintenance costs, increase performance and extend the service life of the agitator. The Chemineer Model 20 HT/GT mixers incorporate a modular design package that reduces the number of replacement parts that need to be carried in inventory by the customer. The wide range of speeds available provides improved process control and greater application versatility. The Model 20 HT/GT agitators are designed to meet

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Neptune Clear Bromine Feeders for chemical feed applications • Neptune Chemical Pump Co. launched its Model CLR-25 and CLR-50 Clear Bromine Feeders. They have been designed to be a convenient and efficient way to properly feed solid biocide or other corrosive water-treatment chemicals into closed-loop systems in cooling towers. The design and operation of the CLR-25 and CLR-50 models mean that they have the versatility to handle ball, stick, tablet and other forms of bromine. Regarding delivery rates, the CLR-25 unit has a total capacity of 11.3 kg (25 lbs), with an outlet feed rate of 2.5-4.8 kg (5.5-10.6 lbs) and a flow range from 3.8-37.8 L/min (1-10 gpm). The CLR-50 model has a total capacity of 22.7 kg (50 lbs) with an outlet feed rate of 3.6-7.3 kg (8-16 lbs) and a flow range of 3.8-3.78 kg (1-10 lbs). Other design features and benefits of both the CLR-25 and CLR-50 models include a clear PVC body that allows the bromine to be viewed without opening the cap, two threaded bottom inlets and drain connections, a 15.2 cm (6˝) top opening with threaded, O-ring enclosure, maximum pressure to 8.6 bar (125 psi) and maximum temperature to 38°C (100°F). • www.neptune1.com

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Swan offers on-site services • Swan Analytical USA Inc. developed a new services program aimed at serving power generation steamwater cycle sampling, raw water, boiler feed water and other clean water applications. The program provides start-up, training, ongoing maintenance and retrofit services for on-line analytical water quality monitors and controllers from a variety of manufacturers. One unique element of this program is detailed service call reporting with a forward looking plan for the clients’ service needs. • www.swan-analytical-usa.com

2014/2015 Innovation Guide

Moyno system targets dewatered sludge cake • The Moyno 2000 HS system is a significant technology advancement for the wastewater treatment industry. It can pump filter cake farther distances with higher volumetric efficiencies than any other progressing cavity pump. Its twin-screw feeder supplies a constant, pressurized feed rate to the pump, resulting in a 100 percent pump cavity fill rate. The Moyno2000 HS System features an integral hopper with a twin-screw auger feeder and specially designed progressing cavity pump that efficiently handles dewatered municipal sludge to over 50 percent solids. The enhanced design of the Ultra-Feed pump rotor provides superior volumetric efficiency. The Moyno 2000 HS System combines high pump efficiency with low discharge pressure to provide unmatched performance in high solids sludge cake transfer. Compared to hydraulically driven, piston ram type pumps and open conveyors, the Moyno 2000 HS System requires lower capital investment, lower operating costs and less maintenance. For application versatility, the Moyno 2000 HS System offers varying twin screw feeder and hopper lengths to match wide feed areas from centrifuges and 1m through 3m length belt filter presses. The twin screw feeder and the hopper length can be readily modified without changing the pump arrangement. Additional features of the Moyno 2000 HS System include a concentric rotation of the augers in a close

tolerance pressure tube, which allows the twin screw feeder to generate positive stuffing pressure to the pump inlet; intermeshing augers provide self-cleaning action so filter cake will not stick to the augers and fill in the flights; hopper sidewalls are completely vertical leading into the augers, which does not allow filter cake to bridge; and the twin screw feeder can be run at a separate speed from the pump rotation, allowing control over the amount of stuffing pressure, among many other features. • www.moyno.com Submit your product and service news to editorial@ woodwardbizmedia.com.

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2014/2015 Innovation Guide ENERGY-TECH.com

Business Spotlight Directory A-T Controls

Cutsforth Inc.

11363 Deerfield Road Cincinnati, OH 45242 P: 513-247-5465 www.a-tcontrols.com A-T Controls designs, develops and manufactures valves, actuators and valve control products, including manual ball valves and automated ball valve packages; actuators for the automation of industrial valves; positioners for precise modulating control; electrical solenoid valves for on/off control; limit switches for end of travel position indication; and valve control accessories, including gearboxes and overrides, block and bleed valves, dribble control systems, lock-up valves, flow and speed control, dome indicators, filter/ regulators and more.

87837 Rock Haven Road Coasset, MN 55721 P: 800-290-6458 www.cutsforth.com Cutsforth focuses on products and services for brush rigging, commutators and collector rings. Products include Cutsforthâ&#x20AC;&#x2122;s removable brush holders, shaft grounding and collector ring manufacturing. Services include online collector ring and commutator truing, collector ring removal and installation, helical groove restoration, vibration analysis and onsite consulting. Cutsforth products increase safety and reliability while reducing maintenance costs and forced outages.

Engineering Consultants Group Inc. 3394 West Market Street Akron, OH 44333 P: 330-869-9949 www.ecg-inc.com

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ECG, Inc. offers the power industry innovative products and services. Examples of our unique solutions include: fuel tracking software, a fleet-wide constraint management and availability monitoring solution, pulverized diagnostic equipment, and a bolton notification software application for PI System users. As an OSISoft Partner and Microsoft Certified Partner, ECG develops customized software solutions that enhance the monitoring, reporting, and forward communication of process information data.

Fulmer Company 3004 Venture Court Export, PA 15632 P: 724-325-7140 www.fulmercompany.com Fulmer Company is an ISO 9001:2008 compliant manufacturer of brush holders, castings, springs and machined parts for power generation, supplying major OEMs globally with engineered designs for new and direct retrofit applications. Our improved FC-101 cartridge-style plug-in brush holder enables brush changes on-line, without service interruption, offering a revolution in turbine-generator reliability.

Dedicated to the Engineering, Operations & Maintenance of Electric Power Plants

2014/2015 Innovation Guide

Business spotlight directory Gradient Lens Corporation 207 Tremont Street Rochester, NY 14608 P: 800-536-0790 www.gradientlens.com Gradient Lens Corporation manufacturers more than 80 models of patented Hawkeye® Rigid, Flexible and Video Borescopes. World-class image quality, overnight delivery, and prices one-half to one-third that of comparable borescopes – that’s the innovative Hawkeye Precision Borescopes! Our newest rigid and flexible video borescopes display high-quality inspection images on portable video monitors, and laptop or desktop computers.

Indeck Power Equipment Co. 1111 Willis Avenue Wheeling, IL 60090 P: 800-446-3325 www.indeck.com The Indeck Group of Companies is involved in the design and manufacturing of steam and hot water systems. These include water-tube packaged boilers, high temperature hot water generators, rental boilers, heat recovery steam generators and solid fuel boilers, utilizing stoker and bubbling bed technologies. In addition, Indeck also owns the largest inventory of stock boilers available for rent or purchase.

MTI Instruments Inc. 325 Washington Ave. Extension Albany, NY 12205 P: 800-342-2203 www.mtiinstruments.com MTI Instruments Inc. (MTII) has been supplying precision measurement solutions for more than 50 years to industries worldwide. MTII’s products use a comprehensive array of technologies to solve real world applications, including manufacturing, automotive, commercial/military aviation and electronics. Some of the technologies we use to solve measurement applications include capacitance, fiber-optic and 1D and 2D laser sensors.

2014/2015 Innovation Guide

Rentech Boiler Systems Inc. 5025 East Business 20 Abilene, TX 79601 P: 325-672-3400 www.rentechboilers.com Rentech designs and manufactures high quality custom boilers in a variety of categories, including: fired packaged boilers, waste heat boilers, heat recovery steam generators, specialty boilers and emissions control systems.

Rolled Alloys P.O. Box 310 Temperance, MI 48182 P: 734-847-9470 www.rolledalloys.com One of the largest suppliers of stainless steels, nickel, cobalt and titanium alloys, Rolled Alloys maintains 13 locations across North America and Asia, with additional representatives in Europe. For more information about the company, please visit www.rolledalloys.com.

Coming in December 2014 Look for the next issue of Energy-Tech magazine and read about: • Gas Turbines • Predictive Maintenance • Balancing/Vibration/ Alignment • Maintenance Matters: Scrubbers • ASME: Turbines, Generators & Auxiliaries

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Business Spotlight Directory Rotork Controls Inc.

November 2014 Advertisers’ Index A-T Controls Inc.

www.a-tcontrols.com

CU Services

www.cuservices.net

Cutsforth, Inc.

www.cutsforth.com

www.eagleburgmann-ej.com

EagleBurgmann

ECG Engineering Consultants Group

www.ecg-inc.com

www.flexim.com/us

www.floscan.com

www.fulmercompany.com

www.gradientlens.com

Hexeco

www.hexeco.com

Indeck Power Equipment Co.

www.indeck.com 9,39

Flexim FloScan Instrument Co. Inc. Fulmer Co. Gradient Lens Corp.

Miller-Stephenson Chemical

www.miller-stephenson.com

www.mtiinstruments.com

Renewal Parts Maintenance

www.renewalparts.com

Rentech Boiler Systems, Inc.

www.rentechboilers.com

www.rolledalloys.com

www.rotork.com

www.sohreturbo.com

Structural Integrity Associates Inc. www.structint.com/energy-tech

Unimar - Light & Control Solutions

www.unimar.com

www.wabashpower.com

MTI Instruments

Rolled Alloys Rotork Controls Inc. Sohre Turbomachinery Inc.

Wabash Power Equipment

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675 Mile Crossing Blvd. Rochester, NY 14624 P: 585-247-2304 www.rotork.com Rotork’s electric valve actuator division offers an electrical solution to industrial valve control and actuation applications of virtually any size, description and complexity. Rotork’s unrivalled range of marketleading products offers a robust and economic solution for every valve duty and operating environment.

Structural Integrity Associates Inc. 47 Water St. Suite 200 Mystic, CT 06355 P: 877-474-7693 www.structint.com/energy-tech Structural Integrity is a trusted partner in the energy industry. We do it all: inspection and monitoring, materials evaluations and remaining life assessments, stress and failure analyses, remediation and repair. We manage aging plant assets, oversee fabrication, help with seismic and structural analysis, customize inspection systems, offer ASME Code support, and provide expert opinions.

Unimar 3195 Vickery Rd. N. Syracuse, NY 13212 P: 315-699-4400 www.unimar.com As the leader in smarter obstruction lighting solutions designed specifically to meet your needs, Unimar learns every aspect of your regulatory needs and provides unmatched expertise in designing and building your lighting system. Then we follow up with knowledgeable customer support. The result is greater reliability, economy and performance.

2014/2015 Innovation Guide

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