www.clydebergemannpowergroup.com

Major Refinery

Contract with OMV

The Best of Boiler

Efficiency

Clyde Bergemann’s

High-Performance

Expansion Joints Can

Take the Pressure

Page 5 Page 6 Page 9

Turkey – Economic Boom at the Bosphorus Read More on Page 2

Edition 2 | 2013

Concurrently with this trend, the country‘s energy market is expanding as well. De-mand for electricity grew by an average of 6.7% p.a. between 1990 and 2010, reach-ing 245,000 GWh in 2012. By 2020, con-sumption is forecast to increase to 433,900 GWh. Production is based essentially on three energy sources, i.e., natural gas, coal and hydropower. At present, Turkey is still dependent on large imports, mainly of oil and gas from Russia and Iran. In the years to come, it will be a main objective to re-duce this dependence on foreign countries and to invest massively in domestic energy sources and grid expansion. For the period up to 2013, around EUR 100 billion have been earmarked for these purposes.

A major part in this scenario will be played by domestic coal – according to Mr. Taner Yildiz, the Minister of Energy. Its share is to go up to 30% (from 18% today) of the overall electricity output. Used in modern lignite-fired power plants, this fuel is ex-pected to cut back the production of energy based on imported natural gas. By 2023, the government aims to provide close to EUR 20 billion for power plant projects with an ag-gregate capacity of 17,000 MW. Today, the installed capacity of the country‘s coal and lignite fired power plants amounts to nearly 12,500 MW.

In addition, a nuclear power plant is under construction on the southern coast. A con-tract for another one was awarded to an MHI/Areva consortium last April.

A major growth potential also lies in the petrochemical sector. As demand for pet-rochemical and processed petroleum prod-ucts increases and today‘s import rates are high, vigorous efforts are being undertaken to expand local capacities. Analysts put the petrochemical products market at around $ 8.5 billion in 2012. By 2023, this figure is expected to rise to at least $ 20 billion. By far the largest and most crucial high-volume project at present is the planned erection of a chemical industry park on the Aliaga pen-

Cover Story: Turkey ................................................................... 2

www.cbpg.com – The New Global Webpage ............................ 4

Clyde Bergemann Wins Major Contract with OMV .................... 5

High-Performance Expansion Joints Can Take the Pressure ........ 6

New Innovative Batch Mixing System for One of the World‘s Largest Cement Producers .................... 7

DRYCONTM System Trial at Clyde Bergemann Beekay India ........ 8

Clyde Bergemann Australia Secures its Largest FPSO Waste Heat Recovery Order ...................................................... 8

The Best of Boiler Efficiency ...................................................... 9

SMART Explosion on Course for Success ..................................10

Clyde Bergemann Wesel Provides Boiler Cleaning Equipment for Power Plant in Bukpyung, Korea .........11

Large Saudi Arabian Contract for First Oil-Fired Boiler Using SMART CleanTM Technology ......................................................12

Mexico’s CFE Carbon II Power Plant Fully Implements SMART Clean ........................................................13

“Schwarze Pumpe” Switches to SMART Clean System..............14

Russian Energy Innovations Conference Features Clyde Bergemann Experts ...........................................15

28 “Young Talents” Meet in Shanghai ......................................16

Clyde Bergemann Africa Celebrates Three Years without Lost Time Injury at Medupi ................................17

25th Anniversary and History of Clyde Bergemann Power Group Americas Inc. .........................18

Events Diary & Personnel ..........................................................20

CONTENT

Publisher: Clyde Bergemann Power Group Inc., Schillwiese 20, D-46485 Wesel (Germany)

Responsible for content: Franz Bartels | Editorial: Claudia Denniger, Clyde Bergemann Power Group, eMail: claudia.denniger@cbpg.com |

Stacy Gentry, Clyde Bergemann Power Group Americas (USA), eMail: stacy.gentry@us.cbpg.com | Graphic design: TEMA Technologie Marketing AG |

Reprints are permissible only after consultation with the editorial offices.

insula by the Aegean coast. Here, a range of activities spanning refinery, petrochemi-cal processes, power and logistics are to be combined into one integral complex. The overall investment involved will amount to $ 7 – 8 billion by today‘s estimates.

Another previously neglected segment is likewise moving increasingly into the focus of investors‘ attention – the mining sector. Turkey holds 2.5 % of the world‘s mineral resources, ranking 10th on the global scale for product diversity. Most of this potential has remained untapped until today; the sec-tor accounts for a mere 1.5 – 2.0 % of GDP.

Since mining received so little attention in recent years, local companies are experi-encing a huge demand backlog. The Istan-bul Mineral Exports‘ Association expects a real production growth of 4 % in 2013 compared to the previous year. Exports are expected to increase by close to 8 % to US$ 4.5 billion, eventually swelling to over $ 15 billion by 2023. The forecast long-term uptrend in raw material prices across global

markets makes investment in this industry even more attractive.

Growth at a high level, on the other hand, is characterizing the situation in the cement industry. Cement making has seen a steady expansion in recent years due to the favor-able overall economic trend and large-scale con struction projects. According to data pu blished by the Turkish Cement Manufac-turers‘ Association, overall output in 2012 attained 63.9 million metric tons of cement and 54.8 million metric tons of clinker. The association forecasts a rise in cement out-put to 99.8 million metric tons by 2023, given the large number of planned building projects. In terms of production quantities, Turkey in 2011 ranked sixth on the world leader board after China, India, Iran, the U.S.A. and Brazil. In Europe, the country is the largest cement manufacturer accord-ing to information released by the Turkish Ministry of Economics. In iron and steel making, too, all signs are pointing to growth although this output rise is driven not so much by the domestic market than

The Bosphorus Bridge in Istanbul, Turkey connects Asia to Europe

Franz Bartels | President & CEO

Our Cover Story:

Turkey – Its Huge Infrastructure Projects Place It High Up Among Industrial Nations

Turkey is among the countries exhibiting the fastest economic growth worldwide. In 2010 and 2011, it attained growth rates of around 9%, on a par with China. For the current year a rate of 5% is expected.

Much of what is currently planned in Turkey is of a once-in-a-lifetime order of magnitude, even by the standards of large industrial groups. Infrastructure projects worth around EUR 200 billion are in the planning stage. These include a rail link between the country‘s European and Asian parts, to be achieved via an undersea tunnel under the Bosphorus strait, the planned Northern Marmara Highway (E80) intended to run from Portugal to the Iranian border via Istanbul, and – first and foremost – the large Istanbul new airport. This project, rated for an annual traffic of 70 million passengers in its first 2017 realization stage, was awarded to a consortium of several Turkish contractors for EUR 22.15 billion last May. A sub-sequent expansion to as much as 150 million passengers is planned and would make this the world‘s largest air-port in today‘s terms.

2 NEWS 2 | 2013 NEWS 2 | 2013www.cbpg.com 3

UK-based Clyde Bergemann Doncaster (CBD) has won a turnkey project for the Petrobrazi oil refinery in Romania with OMV Petrom S.A. The plant is being retrofitted and CBD will provide new Air Pollution Control technologies to the existing refinery.

OMV Petrom S.A.’s parent company is in-dustrial giant OMV, Austria’s largest indus-trial company listed on the Vienna Stock Ex-change. The capacity of the refinery, situated in Ploiesti, Prahova County will be increasing as part of a modernisation program. The overall program aims to contribute to a cleaner environment and provide a positive impact on the energy efficiency of the refin-ery. The modernisation will be completed by 2014. The refinery produces gasoline, diesel, aviation fuel Jet A-1, automotive liquefied petroleum gas (LPG), heavy fuel oil, LPG-aragaz and light fuel oil. It also generates benzene, toluene, propylene and special products including sulphur and petroleum coke.

As part of the modernization upgrade and expansion program Clyde Bergemann is to supply and install a new Electrostatic Pre-cipitator (ESP) and a Dust Removal System

(DRS) including stack to meet the emissions regulations in Romania. The ESP, DRS and stack will be located on a Fluid Catalytic Cracking (FCC) unit process on the outlet of the existing Waste Heat Recovery Boiler.

The ESP will utilize Clyde Bergemann’s ESI (Electric Single Impulse) rapping system lo-cated on the casing roof. Maintenance can be carried out during operation.

To collect particulate matter the filter is equipped with factory built MODULOK™ modular collector plates. The MODULOKTM collecting electrode is specifically designed to achieve exact plate alignment and struc-tural integrity. It is characterized by an excel-lent rapping response for dislodging the col-lected particulate. Its modular design allows a significant reduction of on site construc-tion time.

The client was keen to work with Clyde Bergemann due to the proven track record in delivering complex turnkey projects. Last year Clyde Bergemann was awarded a simi-lar project for a new ESP and DRS System for the Petromidia Refinery’s FCC Unit with Rompetrol Group. Clyde Bergemann’s ability to execute a complex program which tied in with the crucial on-site outage was a key driver in their success for this project.

OMV Petrom’s planned 2010 – 2015 mod-ernization program is at a cost of more than € 750 M. Site work on Clyde Bergemann’s contract, valued at € 4.3 M, will start in De-cember 2013 and the construction phase of work is due to be completed in July 2014.

“Winning this contract with OMV Petrom is excellent news; we are looking forward to building on a long standing relationship with OMV,” said Franz Bartels, President & CEO of the Clyde Bergemann Power Group. And he summarizes: “When it comes to Air Pollu-tion Control, our technologies make an im-portant contribution for an optimized, more efficient and low-emission operation.”

Clyde Bergemann Wins Major Refinery Contract with OMV

Stuart Westley, CBDSWestley@cbmh.co.uk

by the export business. In 2012, Turkey was Europe‘s second largest steelmaking nation with a total production of around 36 million metric tons, ranking 8th on a global scale. For 2013, a further rise in crude steel output to around 38 million metric tons is being forecast. This uptrend is attrib-utable mainly to domestic demand, which is already picking up once more due to fur-ther stimulus from the construction sector in addition to the government‘s generally growth-oriented policies.

With a view to providing superior on-site support to these numerous local projects, Clyde Bergmann will be represented by its own Izmir-based subsidiary company, Clyde Bergmann Turkey, in this market as of Sep-tember 2013. Franz Bartels, the group‘s President & CEO, commented: “With a lo-cal presence, our comprehensive product portfolio and innovative solutions, we are prepared perfectly well to meet the needs of the Turkish market. Whether it´s power, petrochemicals, raw materials or it´s related

www.cbpg.com – The New Global Webpage of the Clyde Bergemann Power Group – is Online

Since Sept. 1, 2013 the new global website of the Clyde Bergemann Power Group is online.

Based on the information of different coun-tries and business fields, the “Team Web-page“, consisting of our marketing experts from the U.S., England and Germany, devel-oped the common platform. The site offers

sector projects – we will be able to bring to bear our experience and expertise, as docu-mented by many reference installations all over the world.“

The ESP process

Franz Bartels, CBPGfranz.bartels@cbpg.com

Claudia Denniger, CBPGclaudia.denniger@cbpg.com

e. g. information on products and services, on the group companies, a reference data-base and worldwide job offers. It is currently available in English and German, other lan-guages will be implemented in a next step.

Franz Bartels | President & CEO

Dirty Air Clean Air

MODULOKTM

Uncharged particles

Negative discharge electrodes

Negative charged particles

4 NEWS 2 | 2013 NEWS 2 | 2013www.cbpg.com 5

Working with a worldwide cement pro-ducer, Clyde Bergemann implemented a SMARTBlend system as an alternative to the traditional Batch Mixer technology deployed at the customers’ existing depots.

SMARTBlend is a new innovative alternative system used for the production of blended cements (such as CEM 2/3/4), where con-veying of the final blended product to a destination is a key requirement after effi-cient dosing and mixing. The SMARTBlend system is designed to produce a maximum rate of 120 TPH of finished CEM III blended cement with an approximate 55% / 45% ra-tio of Ground Granulated Blastfurnace Slag (GGBS) and cement. Through the use of in-vertor driven drive unit rates of each SMART-Feed can operate at between 30 – 75 TPH, allowing different rates of CEM II between 60 – 120 TPH, or to completely alter the ma-terials and ratio’s options to switch to CEM II production using 70% / 30% blends of ce-ment/fly-ash. Each SMARTFeed is fed with material from the flat store via a fluidized floor air slide system and an inclined screw to a buffer hopper above the SMARTFeed. It can, however, be considered for any in-dustrial application where conveying of an accurate and homogeneous final blend of material or fuel is critical to an intensive pro-duction process.

Following detailed internal reviews, com-parisons and approval processes with the cement producer, it was determined that the new SMARTBlend process was indeed a simpler yet more elegant solution, while at the same time having lower overall costs and energy needs compared to alternative traditional batch mixer methods. Clyde Bergemann was awarded the order for the supply of a SMARTBlend system comprising of 2 SMARTFeed units with con-trols to be incorporated into the overall new project – making this project a “world first”.The overall project involved conversion of an existing coal bunker to a flat bulk storage facility with individual compartments for the raw materials, cement and GGBS and fin-ished product, along with tanker unloading and loading facilities for raw and finished materials. Clyde Bergemann have been de-

signing Continuous Injection Systems for process use since the early 1980’s and have a well-earned world-wide reputation for this sophisticated side of the pneumatic convey-ing business.

SMARTBlend typically replaces more com-plex multi-process Batch Mixing plants, or other semi-integrated storage, weigh/dos-ing, conveying systems. Connected to a suit-able raw material supply, the SMARTBlend system will dose, blend and convey to des-tination in one continuous fully integrated on-line process.

SMARTBlend Benefits:

• Blended cements can be made anywhere raw materials are available, at variable rates and production run options – small runs direct to truck, long runs for bulk silo storage. No requirement to be located at the cement plant and modular systems available.

• Elegant and efficient, a simple system replaces complex multi-production pro-cesses, far simpler to install, operate and maintain, total flexibility.

• Precise dosing of raw materials gives guaranteed quality assurance on ratio’s. NO separate mixing process required; a fully homogeneous mix of final blended product is achieved, equal if not better than industry CV standards and batch type mixing.

• Smaller building, less maintenance, lower running costs, and lower overall cost when considering total package against conventional processes.

As the gas and oil industry becomes revital-ized, particularly in North America, a grow-ing need is emerging for highly engineered expansion joints suitable to match the criti-cal service requirements of refining and gas processing applications.

Many processes, such as fluid catalytic cracking (FCC) and advanced gas processing technologies, present tough challenges that necessitate highly engineered components built to provide safe, reliable long-life service under demanding operating conditions.

Clyde Bergemann’s High-Performance Expansion Joints Can Take the Pressure

New Innovative Batch Mixing System Created for One of the World’s Largest Cement Producers

Steve Bowmar, CBDsbowmar@cbmh.co.uk

Mike Sellinger, CBAUmike.sellinger@us.cbpg.com

Designed and manufactured in strict ac-cordance with industry benchmark stan-dards established by ASME B31.3 and the Expansion Joint Manufacturers Association (EJMA), Clyde Bergemann expansion joints, which incorporate Bachmann® technology, contribute to system integrity at petrochem plants around the world.

Soon, Clyde Bergemann will begin fabricat-ing high-end metal expansion joints at its new state-of-the-art manufacturing facility in Jesup, Georgia, in Southeastern U.S. (see related article on page 18).

Expansion joints play a key role in the tran-sitioning of piping or ducting from one area of a plant’s process to another. The purpose of an expansion joint is to accommodate dy-namic differentials such as temperature or pressure between connected parts and to absorb movement that may occur between system components. These highly engi-neered metal expansion joints are designed to meet demanding specifications to with-stand extreme conditions and/or the corro-sive media traveling within a system.

Clyde Bergemann’s Air-Gas Handling Di-vision is among only a small number of suppliers worldwide who are capable of producing large, high-performance metal expansion joints for critical service. Experi-enced in meeting even the most demanding of specifications, Clyde Bergemann has sup-plied custom-engineered expansion joints for over 30 years.

“We provide equipment that’s put to the test day-in, day-out and performs extremely well,” said division President Mike Sellinger. “We have industry-leading technology and expertise in making world-class expansion joints that stand up to unique challenges.”

Bachmann™ High-Performance Metal Expansion Joints

Specification Round Rectangular

Size 16" (406 mm) to 240” (6100 mm)

Unlimited; field-spliced for shipping

Pressure Full vacuum to 500 psig (35 bar)

Full vacuum to 25 psig (1.7 bar)

Temperature Cryogenic to 2000 °F (1093 °C)

Ambient to 2000 °F (1093 °C)

Materials Stainless steel to high nickel alloy

Stainless steel tohigh nickel alloy

Compliant with EJMAand ASME B31.3, B31.1

Yes Yes

CustomizationA full range of specialized custom designs and accessories are available

3050 mm (120") Diameter x 9754 mm (384") long tied universal metal expansion joint with tee, (5) piece miter elbow, floating turning vane, and refractory lining for refinery CO boiler application.

6 NEWS 2 | 2013 NEWS 2 | 2013www.cbpg.com 7

The Best of Boiler Efficiency

Clyde Bergemann has played a key role in driving technological developments in intelli-gent boiler cleaning technology and process optimization for more than 100 years. The original companies have grown into a multi-national group with subsidiaries and partner companies in more than 40 countries.

To ensure the diverse portfolio remains focused on current market needs, Clyde Bergemann‘s global development team of experienced engineers and sales specialists participate in an ongoing knowledge shar-ing process.

Just recently, the entire product range was reviewed from the perspectives of:

• Efficiency (Ensuring high boiler efficiency and availability rates),

• Flexibility (Even in flexible boiler operating regimes and changing fuel mix or varying fuel quality) and

• Cost effectiveness (Documentation of cost effectiveness in procurement and operation).

In this context, numerous products were subjected to a design review, with techni-cal innovations and improvements applied across the product range.

The result is reflected in an extensive range of state-of-the-art products and solutions for a vast variety of applications in boiler cleaning and efficiency enhancement.

Detailled information can be found on our new webpage: www.cbpg.com

Clyde Bergemann Beekay India (CBBK), a joint venture between CBI and BSBK Engi-neers, India, has successfully manufactured and assembled the first DRYCON bottom ash handling system in India for Maruti Clean Coal Pvt. Ltd.

All key components including pans and newly designed jaw crushers have been fa-bricated at the new manufacturing facility of BSBK Engineers. Additional components, such as chain, sprocket and flight attach-ments, have been provided by Clyde Berge-mann GmbH in Germany.

The unit, to operate under a 300 MW boiler, has been designed for a standard ash con-veying capacity of 26 t/h and a design capa-city of 35 t/h. Total length of the conveyor

Customers Witness DRYCON Bottom Ash Handling System Trial at Clyde Bergemann Beekay India

is 45 metres. The basic design of the DRY-CON™ was provided by Clyde Bergemann DRYCON GmbH in Germany, detailed engi-neering and manufacturing drawings were prepared by the CBBK team in India.

After the final assembly, CBBK invited pro-spective customers to witness the dry run of DRYCON™ in August. Approximately 50 representatives comprising Boiler OEMs, Consultants, EPC contractors and end users from various companies including NTPC, BHEL, L&T, Alstom, TATA Power, TATA Pro-jects, and S&L, travelled from various cities to witness the operation. The feedback was extremely positive and encouraging.

The unit was shipped to site and is scheduled to become operational by the end of 2013.

Rudra P. Ganguly, CB Beekay Indiarudra.ganguly@in.cbpg.com

This will be the second operating DRYCON unit in India after world’s largest capacity dry bottom ash handling system at Mettur Thermal Power Station, with a standard conveying capacity of 45 t/h and design capacity of 90 t/h. The system was commis-sioned in 2012 and is performing according to customer expectation.

Additionally, CBBK started manufacturing activities for 2 x 150 MW units for Nagai Power at BSBK which are scheduled to be commissioned during mid 2014.

CBA Secures its Largest FPSO Waste Heat Recovery Order

Clyde Bergemann Australia (CBA) secured its largest ever order for Waste Heat Re-covery Units (WHRU) for Floating Produc-tion Storage and Offloading (FPSO) vessels in May 2013 from SBM Offshore of The Netherlands.

Six WHRUs and two exhaust stack/silencers for two floating FPSO vessels to be located in Brazilian waters will be delivered in early January 2014.

CBA was selected as a repeat supplier on the basis of the successful Cidade de Ihabela project previously delivered to SBM Offshore. The project, located in Brazil’s Tupi field, consists of eight FPSOs totalling 26 WHRUs, all of which have been supplied by CBA. This order brings CBA’s total num-ber of WHRUs supplied to the FPSO market to 37 in only five years.

Gerard Grant, CBA gerard.grant@au.cbpg.com

Bhaumik Patel, CBGbhaumik.patel@de.cbpg.com

CBA continues to build upon its global com-petitive advantage by developing in-house engineering and project management ca-pabilities along with expanding supply chain expertise in collaboration with other CBPG companies around the world.

“It was CBA’s demonstration over a number of years as a quality WHRU supplier that de-livers on time with consistently high quality and an emphasis on health, safety and the en vironment that secured this order,” observed CBA General Manager Sales & Marketing, Gerard Grant. “CBA continues to develop a highly successful participation with CBPG companies to support growth in Energy Recovery business around the world. From Brazil to China to Europe, CBA has received fantastic support from CBPG stake-holders. This success also lays a foundation to pursue new product development.

Currently the CBA team is developing a new product for the emerging float-ing LNG market (FLNG). As FLNG facilities typically require a large amount of steam, CBA can perfectly combine its Energy Recovery expertise and floating produc-tion know ledge.

Retractable Sootblower Part Retractable

SootblowerOscillating Sootblower Axial Sootblower Rake Sootblower

Water Lance Blower (1)

Wallblower (2)

Rotating Element

SootblowerShower-Clean System Explosion System Rapping System

Application• for use in superheater

and reheater

• with heavy fouling

• flue gas temperatures

up to 1,500 °C

• for use in superheater

and reheater

• with light to medium

fouling

• flue gas temperatures

up to 800 °C

• for use in heat exchangers,

focused on specific

cleaning areas in

super heater and reheater

• with light to medium

fouling

• flue gas temperatures

up to 1,100 °C

• for cleaning of heat exchanger

surfaces in the air preheater

• with light to medium fouling

• flue gas temperatures up to

1,100 °C

• for use in cleaning

SCR catalysts

• with light to medium

fouling

• flue gas temperatures

up to 650 °C

• for the cleaning of

furnace walls(1)

• for furnace walls of

power plant boilers (2)

• with heavy slagging

• flue gas temperatures

up to 1,600 °C

• for cleaning of heat

exchanger surfaces

in the economiser

• with light fouling

• flue gas temperatures

< 500 °C

• for cleaning of furnace

and empty passes

• in waste and biomass

boiler

• flue gas temperature

up to 1,000 °C

• cleaning medium: water

• targeted cleaning

of heating surfaces

• especially suitable in

incineration plants

• for inaccessible areas

with compact size

and footprint

• for cleaning of super -

heater in lateral gas paths,

reheater and economiser

• remove deposits from

the heating and reaction

surfaces without any

additional cleaning

medium

Principle of Function

Product-

name

Travel Range

0.3 – 20 m

Product-

name

Travel Range

0.3 – 8 m

Product-

name

Travel Range

0.3 – 6 m

Product-

name

Travel Range

0.3 – 10 m

Product-

name

Travel Range

0.3 – 8 m

Product-

name

Travel Range

0.255 – 2.55 m

P-Se

ries Compact and robust design for

application in fossil-fired power

plants and industrial boiler

PS-H0.3 – 10 m

PS-HBup to 6 m

PS-P0.3 – 6 m

PS-Aup to 10 m

PS-ARup to 5.5 m

PX-H 10 – 12 m(9 – 10 m possible)

PS-PBup to 6 m

PS-AMulti-Media up to 6 m

R-S

erie

s

Reinforced dual rack design

for long travel ranges

RS-H10 – 16 m (0.5 – 10 m possible)

RS-HBup to 8 m

RS-P0.5 – 6 m

RS-Aup to 14 m

RS-ARup to 8 m

RX-H14 – 20 m

RS-PB0.5 – 6 m

SMA

RT S

erie

s

An advanced, flexible,

versatile design for targeted

heat exchanger cleaning

SMART RS4 – 12 m(2 – 4, 12 – 14 m possible)

SMART

Jetblower up to 8.25 m

SMART

Cannon(1)

SMART Shower-Clean System SMART ExplosionSMART Rapping System

SMART Helix Water

0.5 – 8 m

V-S

erie

s

Spindle design – compact

and economical

VX-H 0.5 – 2.4 m

VX-HBup to 1.4 m

VX-Aup to 1.2 m

VS-H (2)

up to 0.255 m

F-Se

ries

Chain drive design – compact

and economical for fired heaters

FS-H0.5 – 5.5 m

FS-A Multi-Media up to 1.2 m

D-S

erie

s

Compact, economical alternative

for use in economisers

DB

www.cbpg.com

Clyde Bergemann Products for on-load boiler cleaning

V-Series

D-Series

F-Series

R-Series

SMART-Series

P-Series

(1)(2)

8 NEWS 2 | 2013 NEWS 2 | 2013www.cbpg.com 9

SMART Explosion on Course for Success

As of March 1, 2013, the Clyde Bergemann Power Group (CBPG) gained the license to sell, install and service explosion generators for on-load boiler cleaning developed and fabricated by the Swiss company Explosion Power.

Under the name “SMART Explosion“ the product – mainly used in waste incineration and biomass plants as well as industrial boil-ers – was introduced to the CBPG product portfolio. Its use is particularly advantageous where no steam for cleaning is to be used or space requirements are low.

SMART Explosion induces vibrations into the heating surfaces, thereby removing fouling. By carrying out this operation within suit-ably short time intervals (e.g. once per hour), the build-up of ash deposits is avoided alto-gether.

System’s Operating Principle

Upon enabling the signal by a Programma-ble Logic Controller (PLC), dosing tanks are filled with the necessary small amounts of natural gas and oxygen to the preset pres-sure level. At this point the two gases are still fully separated from each other, i.e., they are not explosive. A free-moving piston shuts off the discharge opening, creating a gas-tight seal. Next, the solenoid transfer valves for natural gas and oxygen are opened and allow both gases to flow into the explo-sion tank where they now form an explo-sive mixture. The glow plug is activated and generates the explosion. Under the sudden pressure rise to approximately 350 bar in the explosion chamber, the piston shoots back and clears the discharge opening.

The pressure wave is directed through the discharge pipe into the boiler where it spreads in a linear and then spherical pat-tern. Once the pressure wave has left the explosion generator the piston is pressed against the discharge opening by nitrogen pressure to close it again. The generator is now ready for the next run.

The explosion pressure wave induces short vibrations similar to those produced by a rapping system in the walls and tube bun-

dles. Dust and accretions of foreign matter are thus removed. The penetration depth and cleaning effect can be expected to ex-tend to 10 meters. Optimum cleaning action is achieved with boiler tubes which are free to vibrate.

In Use in Smallest Spaces

One of the first jobs that Clyde Bergemann has completed, particularly highlights the advantages of the system. The customer, an operator of a biomass boiler with a steam production of 40 t/h, had to improve the overall efficiency and the availability of his system and counteract the increasing foul-ing on the bundle heat exchanger in the sec-ond and third path. To install the cleaning devices an installation space of just under two meters of depth was available. Soot-blowers could have been accordingly used only after extensive construction work in-cluding the rebuild of a part of the boiler and installation of additional stages and a stairway for the reception and inspection of the components. Using SMART Explosion, these measures could be completely omit-ted. The explosion generators were installed using existing platforms and staircase.

The system is already in operation and works to the full satisfaction of the operator.

Other projects – also in waste incinerators and industrial boilers – are currently being planned and/or implemented. SMART Ex-plosion has already established itself in the short term as the ideal complement of the Clyde Bergemann product portfolio in the area of on-load boiler cleaning equipment.

Clyde Bergemann Wesel Provides Boiler Cleaning Equipment for 2 x 595 MW Power Plant in Bukpyung, Korea

In March 2013, Clyde Bergemann GmbH secured the contract for boiler cleaning sys-tems for Korea’s first privately funded coal-fired power plant in Bukpyung.

The operator, STX Electric Power, started in December 2012 with the construction of two 595 MW units at the “Bukpyung Na-tional Industrial Complex.” Unit 1 is to be completed in February 2016, followed by Unit 2 in June of that year.

The contract for the construction of the boiler was awarded to BHI Co. Ltd., a new, ambitious supplier from Korea. BHI has re-cently been added to the list of suppliers for the construction of large power plants (exceeding 500 MW) by the Korean govern-ment. Since 2005, BHI operates under Foster Wheeler license, initially for the construction of heat recovery steam generators (HRSG), and beginning 2008 also for pulverized coal-fired boiler (PC boiler).

After intensive preparation and support of the BHI design team in the planning phase, the company opted for on-load boiler clean-ing systems from Clyde Bergemann. One de-ciding factor was that BHI wanted to work with a trustworthy supplier that has already

proven its capabilities in Korea. An extensive reference list and the good reputation of the Clyde Bergemann products in the Korean market opened the door.

The Clyde Bergemann scope of supply includes:

• 160 wall blowers for cleaning the combustion chamber walls. The VS-H type sootblowers are ideal for areas with high slagging and can be used at temperatures up to 1,600 °C,

• 120 sootblowers type PX-H with a travel range of 11.3 meters – suitable for flue gas temperatures up to 1,500 °C to be used in the convective area, and

• decentralized controls technology.

P-Series

Arndt Benninghoff, CBG arndt.benninghoff@de.cbpg.com

Manfred Frach, CBG manfred.frach@de.cbpg.com

10 NEWS 2 | 2013 NEWS 2 | 2013www.cbpg.com 11

Large Saudi Arbainan Contract for First Oil-Fired Boiler Using SMART CleanTM Technology

Alstom, a global supplier of power plant equipment and services, won the contract to supply five new oil fired power boilers at the Yanbu Plant in Saudi Arabia. The Yanbu plant will produce 3100 MW power to meet the increasing electricity demands in the re-gion. Clyde Bergemann was selected as the boiler cleaning supplier for this large project, receiving the purchase order in August with a value of over $ 4 million USD.

Mexico’s CFE Carbon II Power Plant Fully Implements SMART Clean™

Clyde Bergemann Power Group Americas Inc. was recently awarded two orders for SMART Clean™ Intelligent Sootblowing Systems that will be installed in Units 1 & 2 at CFE Carbon II Power Plant in Northern Mexico.

Carbon II is one of the three coal fired plants existing in Mexico and belonging to the State run Comisión Federal de Electric-idad (CFE). These two units are Mitsubishi Heavy Industries, Ltd (MHI) boilers generat-ing 350 MW each, and currently have Dia-mond Power sootblowers installed. This plant also has two more Units (3 & 4), which are Foster Wheeler boilers, also generating 350 MW. Unit 4 has already installed the SMART Clean™ Intelligent Sootblowing System (ISB) which was supplied two years ago and Unit 3 is currently in the commis-sioning stage for the same system.SMART Clean™ is a boiler cleaning optimi-zation system that is designed to realize plant’s performance and operational objec-tives regardless of the changes in factors

Hector Inigo hector.inigo@us.cbpg.com

influencing the slagging and fouling condi-tions in the boiler. The system accomplishes the plant targets by using real time intelli-gent feedback.

While traditional sootblower control sys-tems are designed to merely operate clean-ing devices on a fixed cycle time basis, a SMART Clean™ system is designed to intel-ligently respond to the real-time heat trans-fer in the boiler. This eliminates initiating cleaning events in areas that are already clean, that can result in tube erosion. Con-versely, the system targets areas that are fouled by managing when to clean, where to clean and how intensely to clean. Using this system can provide cost savings to the plant by allowing the plant to burn lower cost coals, improve boiler efficiency, reduce steam consumption, and eliminate outages due to clinker falls and tube leaks. With these two orders, Carbon II Power Plant will be fully implemented with our SMART Clean™ Intelligent Sootblowing System.

The system for Unit 2 was delivered in September 2013 and the system for Unit 1 end of November 2013. Commissioning and startup will be subject to CFE’s avail-ability for the units shut down.

The scope of delivery includes

• 130 Modular, 39‘ travel full retractable sootblowers

• 40 Modular 18‘ travel half retractable sootblowers

• 5 Pressure regulating valve stations• 5 SMART Clean™ systems• The shipment starts July 2014 and

continues through March 2015.

This marks the first oil fired utility boiler to use SMART Clean™ technology. SMART Clean™ is designed to intelligently respond to the real-time heat transfer in the boiler and target areas that are fouling. This elimi-nates initiating cleaning events in areas that are already clean, that can result in tube ero-sion. Conversely, the system targets areas that are fouled by managing when to clean, where to clean and how intensely to clean. Using this system provides costs savings and improved reliability to plants by allowing plants to burn a variety of fuels, improve boi-ler efficiency, reduce steam consumption, and eliminate outages due to fouling issues.

Tim Martin, CBAT tim.martin@us.cbpg.com

SMART Clean™

Clea

ning Devices

Sensors

Controls

Analysis

12 NEWS 2 | 2013 NEWS 2 | 2013www.cbpg.com 13

After Vattenfall Europe AG replaced its existing boiler diagnostic system in its plant in Lippendorf with Clyde Bergemann’s SMART Clean system in the years 2011 – 2013, they now continue with the conversion of the power plant “Schwarze Pumpe“ in Branden-burg, Germany.

In the past, deposit build up in the furnace was removed based on preset cycle times and with fixed blowing patterns. Varying fuel qualities and the impact of co-combustion of auxiliary fuels increasingly caused slagging, along with increased cleaning efforts and ef-ficiency losses, leading to boiler shutdowns.

In preparation for demand-driven, targeted cleaning, Clyde Bergemann assessed the condition of the evaporator walls using an infrared camera and the main areas of

slagging were detected. As a result of the findings and the local conditions different variants for an optimal system configuration were proposed.

For monitoring of the lower furnace area Clyde Bergemann is providing six “SMART InfraScan” cameras. Using infrared sensors, the system constantly measures the surface temperature of the boiler walls and calcu-lates the temperature distribution. The data obtained are transferred to the diagnostic system “SMART Furnace“, which sets the optimal cleaning strategy based on the on-line analysis and operating data from the main control system and starts the cleaning procedures.

For further optimization, four additional wa-ter cannons were implemented in the main

800 MW Lignite – Fired Power Station “Schwarze Pumpe” Utilizes Clyde Bergemann’s Boiler Diagnosis System SMART CleanTM

burner area of the steam generators and the blowing figures of the existing cleaning equipment were reconfigured and matched.Clyde Bergemann’s scope of supply included planning, engineering and manufacturing as well as commissioning and training of oper-ating and service personnel.

Evgeny Kruglov, CBG evgeny.kruglov@de.cbpg.com

units. The delivered equipment and system helps the power plant to eliminate water us-age and will provide the power plants own-ers with a saleable by-product in the rapidly developing commercial market for fly ash in Russia.

Bottom ash handling design capabilities were also presented for a new unit at Abankan-saya power plant in Russia. To conclude the presentation the benefits of lowering emis-sion levels with the use of air pollution con-trol technologies were discussed. CBD offers large-scale, custom-engineered air pollution

Russian Energy Innovations Conference Features Clyde Bergemann Experts

Bernd Köster, CBG bernd.köster@de.cbpg.com

In April 2013 Russian energy equipment supplier SibEnergo Group hosted an inter-national conference themed “Innovations in power generation industry for enhancement of efficiency and ecological friendliness of power generating facilities in the Siberian Federal District: Global experience.”

The two-day conference in Novosibirsk, central Russia, was performed under the auspices of official representatives of the Russian authorities, the German Ministry of Economics and the SibEnergoGroup. 250 experts and guest speakers from Germany, the United Kingdom, the Czech Republic, Slovakia, Mongolia, Kazakhstan, and Russia participated in the event alongside with a number of power generation industry pro-fessionals, the global producers of power generating equipment and machinery and representatives of executive authorities.

Clyde Bergemann Power Group pre-sented two case studies that high-lighted successes in the boiler ef-ficiency and materials handling business fields.

Evgeny Kruglov, Sales Director Russia & CIS at Clyde Berge-mann Germany, presented a project for the targeted use of diagnostic and analytic software for intelligent on-load boiler cleaning, “SMART Clean”. Situation, solution steps and implementation were documented impressively by the example of a 920 MW lignite-fired power plant. And so were the results: reduction of superheater spray rates by 7.8 kg/s, of cleaning steam in the convec-tive area by 1.2 kg/s, as well as flue gas temperature after the economizer by 3.1 °C. Increased efficiency and cost effectiveness!

Yurii Kolomiets, Project Manager at UK-based Clyde Bergemann Doncaster (CBD), presented a case study on a pneumatic conveying project based on Russia’s larg-est coal-fired power plant, Reftinskaya. CBD delivered fly ash handling equipment on all ten of the plant’s bituminous coal-fired

control systems enabling customers to oper-ate their facilities in compliance with regula-tory standards on emission levels. Currently CBD is designing and supplying a fabric filter for Reftinskaya Power Plant.

Evgeny Kruglov, CBG

Yurii Kolomiets, CBD

14 NEWS 2 | 2013 NEWS 2 | 2013www.cbpg.com 15

As of July 2013, the CBZ safety team based at Medupi Power Station in South Africa celebrated three consecutive years with-out a Lost Time Injury (LTI). CBZ is respon-sible for the dust handling and conditioning systems for all six of the project’s 800 MW units.

Thanks to steadfast attention to safety by the CBZ team, the significant safety mile-stone was successfully achieved even in the midst of a challenging environment. Terry Bosch, Site Manager at Medupi and his team, in particular the Safety Officer Gerar-dine Henning and Junior Safety Officer Ly-nette Hughes and their coworkers, worked intently to keep the team focused and safe.

“The achievement is far greater than a piece of paper,” said CBZ Projects Manager Peter Brown. “For three years, every one of the workers with CBZ on Medupi – including employees as well as subcontractors – have gone home safely to his or her family after work every day.”

Congratulating the Medupi team on their impressive safety record, CBZ Managing Di-rector Ralf Belka said, “We take the safety of our people and our customers very seri-ously and make a diligent effort to ensure that we all work safely at all times.”

Well on their way: Kriel and Matla Power Station

Not to be left behind, the CBZ maintenance teams at South Africa’s Kriel Power Station and Matla Power Station achieved two years

“An incredible experience“, “a once in a lifetime chance”, “it was a great pleasure and an honour to be part of the Young Talents Team“. These are just some of the thoughts expressed recently by participants in Clyde Bergemann’s young professionals development initiative, the Young Talents Program.

without an LTI and the crew at Mondi Rich-ards Bay achieved one year LTI free.

CBZ has maintenance contracts at Kriel Pow-er Station for three years to look after the maintenance of the Water Cannons and at Matla Power Station for five years for main-tenance services on the sootblowers and boiler auxiliaries. Recently, the Mondi Soot-blower Maintenance contract was extended for another year as of July 2013.

“One of CBZs core values is: Safety is a non-negotiable shared responsibility and we are proud that our people take it seriously”, Ralf concluded.

At a four-day conference held in Shanghai, China, in April, 28 Young Talents from CBPG companies based all over the world had the opportunity to interact with their colleagues and senior management and also to get to know President & CEO Franz Bartels in a more informal atmosphere. The Young Tal-ents Conference provided the perfect plat-form for promising individuals from the global Clyde Bergemann Power Group to collaborate and expand their views and un-derstanding.

This year’s program “Young Talents – Going for Excellence” offered a diverse experience with many presentations, including those

Clyde Bergemann Africa (CBZ) Celebrates Three Years Without a Lost Time Injury (LTI) at Medupi

28 “Young Talents” Meet in Shanghai – “Going for Excellence”

given by Qiang Xu, COO and Vice President of CB SE-Asia, about CBPG’s engagement in Asia and by Hans Schwade about the 25-year success story of Clyde Bergemann Americas.

The Young Talents also had the chance to actively develop their skills and capabilities through presentations to the management team and involvement in a number of inter-active workshops. In addition, the Young Talents had the opportunity to learn from leadership sessions with Clyde Bergemann Power Group executives topped by a discus-sion round with the CEO Franz Bartels on the CBPG strategy.

Marietjie Coetzee, CBZ marietjiec@cbz.co.za

Caren Borges, CBPG caren.borges@cbpg.com

28 Young Talents

But it was not just work for the Young Talents as they were given the chance to explore the amazing city of Shang-hai and the Chinese culture in a team-building exercise and enjoyed a day-time factory visit to Shanghai Electric Lingang Heavy Machinery Base – one of the largest diversified equipment manufacturing groups in China.

16 NEWS 2 | 2013 NEWS 2 | 2013www.cbpg.com 17

This year Clyde Bergemann Power Group Americas Inc. (CBAM) reached an important milestone, its silver 25th Anniversary. It has also been an important year for CBAM with the establishment of Clyde Bergemann Jesup, a CBAM fabrication shop that helps to satisfy the growing demand for Air Pollution Control and Materials Handling solutions.

Clyde Bergemann Power Group Americas Inc. 25th Anniversary and History

Stacy Gentry stacy.gentry@us.cbpg.com

History of CBAM

In the 1980s all of Bergemann’s sales, pro-duction, and service was done in Wesel, Germany. Bergemann did business then with mostly the parent company, Deutsche Babcock, and other European boiler OEMs. A proposal to enter the US market was developed, and an acquisition candidate, Blalock Power Products, was identified. In 1988 Bergemann USA (BUSA) was estab-lished in Atlanta, Georgia.

BUSA, while continuing the strong focus on aftermarket, then introduced the Berge-mann line of boiler cleaning equipment tar-geting the pulp and paper market.

In 1989 the Anthony Ross company in Beaverton, Oregon, the market leader for automatic port cleaners for recovery boilers, was acquired to help strengthen BUSA’s position in the pulp and paper market. BUSA gradually took the market share away from competition and by the early 2000s gained boiler efficiency market leadership for pulp and paper.

In 1996 Bergemann USA and Bergemann in Germany were acquired by Clyde Blowers becoming Clyde Bergemann. A huge mile-stone for BUSA was the following purchase of Copes Vulcan in 1997 which was the ba-sis for the Clyde Bergemann spares and ser-vice entry into the US power market. From there Clyde Bergemann began to extend the product range into power boiler appli-cations.

From 2000–2007 Clyde Bergemann ex-panded its market coverage by establishing regional sales offices throughout the United States: Erie, Fort Collins, Atlanta, Chicago, Plano and Malvern. In 2003, Clyde Berge-mann do Brasil was founded focusing main-ly on pulp and paper.

From the mid 2000’s Clyde Bergemann be-gan to expand its business activities in the US beyond Boiler Efficiency. With the acqui-sition of Environmental Elements Corp in 2005, Clyde Bergemann entered the Air Pollution Control market designing and supplying proprietary, large-scale, custom-engineered air pollution control systems en-abling customers to operate their facilities in compliance with regulatory standards. The systems include particulate control, acid gas removal, and mercury and trace metal removal.

In 2006 Clyde Bergemann Canada became a legalized sales office. 2006 also saw the formation of Clyde Bergemann Power Group Americas (CBAM) introducing a new regionalized organizational structure within the Clyde Bergemann Power Group (CBPG).

In 2007, Clyde Bergemann established a base for Materials Handling in the US with the acquisition of Delta Ducon, Inc., provid-ing high performance ash and bulk material conveying. With the acquisition of Bach-mann Industries, Inc. 2009 the company entered the Air Gas Handling business pro-viding Bachmann brand air-gas handling equipment comprising of damper systems, expansion joints, and gas turbine exhaust systems.

In 2010, Clyde Bergemann was established in Colombia with the founding of the sales office Clyde Bergemann Colombia. In 2011 a common aftermarket organization for CBAM was established and as previously mentioned 2013 saw the opening of the CBJES fabrication facility.

The past 25 years have seen a successful growth of the Boiler Efficiency business for Clyde Bergemann Power Group Ameri-cas Inc. and the extension into Air Pollu-tion Control, Materials Handling, and Air

Gas Handling. These new business fields will continue to provide further significant growth opportunities in the future with the new environmental regulations being the driving main force.

Clyde Bergemann Power Group Americas Inc. celebrated their 25th Anniversary in the Atlanta office on Friday, May 31st, 2013. The day consisted of shop tours for outside guests, luncheon, and special recognition and awards to those who have helped build Clyde Bergemann Power Group Americas Inc. into what it is today.

Hans Schwade, former President & CEO of Clyde Bergemann Power Group Americas Inc. (left) receives the 25th anniversary certificate from Dominick Garton, President & CEO of the Clyde Bergemann Power Group Americas Inc. – Boiler Efficiency Division (right)

HISTORY OF CLYDE BERGEMANN POWER GROUP AMERICAS

25

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18 NEWS 2 | 2013 NEWS 2 | 2013www.cbpg.com 19

20 NEWS 1 | 2013

Mark van der MoolenHe joined the Clyde Bergemann Power Group as Group Legal Director.

Hans Schwade After more than 25 years responsibility for the Group’s operations in the Americas, Hans Schwade has retired from his position as VP and COO of the Clyde Bergemann Power Group Americas division to take over the position as CBPG Chief Technology Officer.

Greg GolubHe has been appointed as VP and Group COO of the Clyde Bergemann Power Group Americas division.

Sonny HaqHe took over the position as Managing Director of the Clyde Bergemann Power Group Americas Inc. – Air Pollution Control Division, Hanover.

Huiying ZhuangHe took over the position as new VP for Technology & Sales Support of Clyde Bergemann Power Group Americas Inc. – Air Pollution Control Division, Hanover.

Steve CraggHe took over the position as Managing Director of Clyde Bergemann Doncaster, UK with effect from November 1st, 2013.

Events Diary Personnel

DATE NAME OF EVENT COUNTRY, LOCATION

January 2014

Jan. 28. – 30. Energy Generation Conference

USA, Bismarck, ND

February 2014

Feb. 3. – 5. World Biomass Power Markets

The Netherlands, Amsterdam

March 2014

Mar. 11. – 13. Western Regional Boiler Conference

USA, Port Angeles, WA

April 2014

Apr. 7. – 9. BLRBAC USA, Atlanta, GA

May 2014

May 7. – 9. NAWTEC USA, Washington, DC

May 19. – 20. CIBO Fluidized Bed Combustion Conference

USA, Hershey, PA

June 2014

June 3. – 5. POWER-GEN Europe Germany, Cologne