ONE SOURCE ONE PURPOSE MANY SOLUTIONS
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Riley Power Inc.
BPI Corporate Presentation
Republic of Korea
January 14-18, 2013
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Origins of Babcock Power Inc.
1891-1898 Deutsche Babcock formed by B&W
1913 Riley was founded
1990-1995 Deutsche Babcock acquires Riley and consolidates Borsig, Balke-Duerr, Steinmuller, Noell, and Vogt-NEM
1996-2000 Deutsche Babcock renamed Babcock Borsig
1997 Thermal Engineering International formed to buy Senior Engineering - includes SWECO, BTA, Senior Australia and Greens Economizers
1999 TEi merges with Balcke-Duerr to form BDT Engineering Heat Exchanger - group retains TEi name.
2001 BDT is absorbed into Babcock Borsig
2002 Babcock Borsig files for insolvency
2002 The management of Babcock Borsig’s USA based assets and a passive investor group (Hudson Investors) acquires Riley, TEi and Vogt-NEM
2002 November 29, 2002 Babcock Power Inc. is established
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
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Our History of Strength
• A long history of providing superior technology
– Struthers Wells founded in 1851
– Henry Vogt Machine Co. founded in 1880
– Riley founded in 1913
– Thermal Engineering founded in 1916
– Boiler Tube Company of America founded in 1918
• Babcock Power Today
– Acquired substantially all U.S. assets of Babcock Borsig
– Privately held
– Diverse products and services for power market
– Market leader in environmental solutions
– Experience with large capital projects
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Acquisitions and Partnerships
• Nov. 2003
– TEi acquired the assets of Engineers and Fabricators Co. (EFCO)
• May 2005
– TEi acquired the intellectual property assets of Struthers Industries
• Oct. 2005
– BPS acquired the intellectual property and assets of Cladding Technology
• Aug. 2007
– Exclusive License Agreement for Riley Power’s Subcritical Coal-fired Technology with Cethar Limited in India
• April 2008
– Agreement with ThermoEnergy to develop Advanced Carbon Capture
• Sep. 2009
– BPS acquired assets of Welding Technologies Inc.
• Jan. 2010
– License Agreement with Siemens for Benson Supercritical technology
– Riley Power in turn sub-licensed Cethar
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Extensive In-House Technology and Expertise
• Products and services built
on hundreds of years of
engineering experience for:
– Coal fired power plants
– Nuclear power plants
– Gas and Oil fired plants
– CSP Plants
– Environmental systems
– Waste-to-Energy systems
– Biomass
– Solar
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Experience the Full Spectrum
Nuclear Power
Renewable Energy
Combined Cycle
Traditional Utilities
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
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Babcock Power Products
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
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Located Throughout the U.S.
TEi - Los Angeles
JoplinSapulpa Lyman
• Feedwater heaters
• Condensers
• HRSGs
• Pressure parts
• Weld Overlay
• Tube stock
• Feedwater heaters
• Machining center
• MSRs
BPS / BPE WorcesterVPI - Louisville
ONE SOURCE ONE PURPOSE MANY SOLUTIONS
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Babcock Power Services
Pressure Part Manufacturing
• Replacement in-kind
• Weld overlay services
• Accessories
Tube Inventory
New Units
Repair / Rehab
Outage Services
Maintenance Agreements
Weld Overlay
Orbital Welding & Machining
New Units
• Utility boilers
• WTE Systems
• Industrial Boilers
• Solar Steam
Generators
Manufacturing
Engineering
Replacement Parts
Projects
Field Services
Engineering Services
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Babcock Power Services
• Steam Generation Systems
– Utility boilers
– WTE Systems
– Industrial boilers
– Solar steam generators
• Replacement Components
– Low NOx burners
– Pulverizers, mills
– Pressure parts
• Aftermarket Services
Full Service Provider
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Boiler Performance
• Boiler Design Systems
Boiler Design Features for specific fuels fired
Heat Transfer Modeling (new and After-market)
Boiler Circulation
Fluid Flow / Steam and Water (pressure loss, distribution)
Boiler Tube Metals Design (ASME)
Steam Temperature Control Methods
Boiler Efficiency Calculations (ASME)
• Combustion Calculations
Air and Gas Flows
Fouling and Slagging Analysis
• Boiler Performance Testing
ASME PTC 4 or 4.1
Data Evaluation
Testing Procedures
• Boiler Auxiliary Equipment specifications
Fans
Sootblowers
Dampers
• Performance Modifications
Upgrades
Fuel Changes
Efficiency Improvements
Emissions Studies
• Tube Failure Problem Analysis
• Presentations and Report Writing
Superheater
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Graphics Software
• Design and Detailing
Pro/Engineer Wildfire 4, 3D AutoCAD 2010, 2D AutoCAD 2010
• Engineer To Order (Design Automation and programmed tasks)
Pro/TOOLKIT, Smart Assembly, AutoLISP, JAVA, Visual Basic, MS Excel
• 3D Review
Navisworks
• Dynamic Graphics and Animations
Dassault 3DVIA, Pro/Photorender
• Data Storage
Windchill, DCAP
Mechanical Design Graphics
3D CAD Assembly
Driven by the Layout Values
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Fuel Equipment Design
• Combustion System Design
• Pulverizer System Design
• CFD Modeling
• Field Testing / Emissions Control
• Fuels Technology
Burner CFD
VS III™ Burner
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Pulverizer Engineering
• Pulverizer Process / System & Equipment Design
• Drying / size reduction / pulverization
• Pneumatic transport / two component flow
• Classification
• Mechanical design
• Materials for Erosion / Wear
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Stress/Structural Steel
• Thermo-Mechanical Finite Element
Analyses (FEA)
• Natural Frequency and Vibration
FEA
• Duct, SCR, DFGD engineering
• ASME Section I BPVC Code
engineering
• ASME Piping analyses (B31.1)
• ASME Fitness for Service
engineering
• AISC Structural steel engineering
and graphics
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Code Committee Affiliations
Importance of Code Committee Affiliations• Direct access to Code committee members
• Quick code interpretations and questions
• Quickly aware of all code updates and changes
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Code Committee Representation
ASME, Boiler and Pressure Vessel Code
� Section I, Power Boilers J. Hunter / M. Lewis
� Section I, Solar Boilers J. Hunter, Chairman
� Section I, Materials J. Hunter, Secretary / S. Knowles
� Section I, Design M. Lewis
� Section IX, Welding G. Chandler
� B31.1 Power Piping B. Holbrook / M. Barcelona
ASME, Board on Performance Test Codes
� PTC 4, Fired Steam Generators B. Vitalis
� PTC 4.2, Coal Pulverizers J. Bianca
� PTC 48, Overall Plant Performance B. Vitals
� PTC 52, Concentrating Solar Power Plants C. Gillum
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Fuels Experience
• CoalLignite, Subbituminous, Bituminous, Anthracite
• Oil#2 - #6 Crude
• GasNatural Gas, Process Gases, Waste Gases
• RefuseMunicipal Solid Waste, Refuse Derived Fuel
• Petroleum CokeFluid, Delayed
• BiomassWood waste, Wood Chips, Wood Sawdust, Wood Bark, Bagasse,
Sunflower Seed Hulls, Coffee Grounds, Furfural, Paper Waste
• Solar
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Experience
650-1650 psi
400-1200 psi
PressureTempSteam Flow
650-1005°F100,000-750,000 Lbs/hr
Pulverized Coal
650-950 °F75,000-500,000 Lbs/hr
Stoker Coal
Stoker and Pulverized Coal Industrial Boilers
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
PressureTempSteam Flow
650-1600 psi
650-955°F100,000 -500,000 Lbs/hr
Stoker Combustion
Biomass Boiler Industrial(wood, wood waste, bagasse, coffee grounds, etc.)
Experience
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
PressureTempSteam Flow
650-750 psi
650-825 °F100-1000 Tons/day
• Stoker Combustion
Municipal Solid Waste (MSW) and
Refuse Derived Fuel (RDF)
Experience
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Temp
750-900°F
PressureSteam Flow
700-1500 psi100,000-500,000 Lbs/hr
Refinery
Gases,
CO Gas
Waste Gases (Industrial)
Experience
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
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PressureTempSteam Flow
2000-2800 psi
1005/1005°F
750,000-4,500,000 Lbs/hr
Pulverized Coal, Oil, Natural Gas
Utility Boilers
(subcritical, natural circulation)
Also:
After market design upgrade on sub-critical utility boilers
up to 6,000,000 lbs/hr (900MW)
Experience
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
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PressureTemp
3800-4500 psi
1050/1050°F
400-1300 MW
•After market pressure parts supply(Furnace Walls, SH, RH and Economizer)
After Market In-kind and Upgraded Pressure Part Replacement (B&W, CE, FW, Riley)
Utility Boiler Supercritical Boiler Technology
Experience
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Typical
200 – 300 MW
Boiler Design
SH Flow 2,500,000 Lb/hr
SH Pressure 2,604 psig
SH Temp 1055°F
RH Flow 1,313,000 Lb/hr
RH Pressure 535 psig
RH Temp 1055°F
Excess Air 20%
Coal Firing
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Plan View
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
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Front View
Rear View
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
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Furnace Design
• Furnace exit gas temperature 2400°F
• Furnace Dimensions
Depth 42’-3”
Width 40’-3”
Height 158’-3”
• Retention Times
– Top Burners to SH tip 1.6 Sec.
– OFA to SH tip 1.2 Sec.
• Furnace Depth Vs. Flame Length
– Flame Length (Maximum) 26 ft (4 Mills in Service) 32 ft (3 Mills in Service)
• Furnace Area Heat Release 58,850 Btu/hr/sq. ft
• Furnace Volume Heat Release 10,265 Btu/hr/cu. Ft
• Plan Area Heat Release 1.27 x 106 Btu/hr/sq ft
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Boiler Design Features for Slagging Coal
• Increased spacing in the convection section
• The use of the Radiant Superheater “church window”design
• SH panel “overlap” the furnace exit arch to reduce “hot spots”and flue gas stratification
• In-line bare tube economizer
• Large furnace for increased absorption and lower furnace exit gas temperature (FEGT)
• Increased sootblower coverage
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Boiler Design Features
• Ribbed tubing in the furnace
• Large steam drum during swelling conditions
• Multiple superheater spray locations
• Additional steam mixing headers and crossover pipes
• Split superheater/reheater convective pass
• Upgraded tube, header and piping material
• Increased SH/RH spray flow capacity
Sliding Pressure Operation
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
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Mechanical Design Features for Sliding Pressure
• Upgraded boiler metallurgy (tube, header and piping) for higher oxidation limits and thinner wall
• The furnace SH pendants use less welded tube attachments and use steam cooled alignment systems and church key designs
• High temperature seal box design with thermal sleeves for improved flexibility
• Economizer inlet header designed per EPRI recommendations
• HTSH & HTRH header tube connector welds ground smooth
• Use of block forgings for tee, wye and lateral connections rather than fabricated nozzle connections
• Manufacturing QC programs exceed typical ASME NDE requirements
• Shop provided safe-end all dissimilar welds
• Improved flexibility
– Linked buckstay design
– Roof and wall connection to headers
– Downcomer and piping
– Windbox connections
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
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Solar Boiler
Ivanpah Steam Generator
37
• Three steam generators
• 845,000 lbs/hr steam
• 2,480 psig steam pressure
• 1013 F superheat temperature
• 905 F reheat temperature
• Forced circulation
• Solar field contains approximately
56,000 heliostats
• Heliostat field approximately 1.2 x
1.2 miles
• Air cooled condenser
Steam Generator
Support Structure
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Solar Boiler
38
Steam drum and
internal piping
Steam Generator
Evaporator
Superheater
Reheater
Forced recirculation pumps
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
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Solar Boiler
Ivanpah, September 2012
39
Solar mirror fields
Steam generator and structure
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
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Constructability
Constructability has a direct input into the final
mechanical design.• Component size for access
• Location of field welds
• Type of field welds (safe-end requirements)
• Modulization
• Design Flexibility
• Component weight for lifting
• Construction sequence
Construction plan mutually developed by the Plant,
constructor and pressure part manufacturer.
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Courtesy AEP Cardinal
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Courtesy AEP Cardinal
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Babcock Power Services
• Solutions for ALL boilers
– Majority of pressure parts
can be replaced “in-kind” or
“as built”
– Option to upgrade existing
components with Riley
designs
– Our engineering, design and
sales teams bring decades if
experience with multiple
OEM’s
– Extensive inventory of parts
in multiple locations
BPI Pressure Parts
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Babcock Power Services
Ball Tube Mills
MPS Pulverizers
ATRITA® Pulverizers
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Babcock Power Services
• Riley Power OEM Parts
• Tangentially Fired Burner
Parts
• MPS Pulverizer Parts
• EL Mill Pulverizer Parts
• CE/Alstom Pulverizer Parts
• Gearbox Rebuilds/Gearing
Riley Power Parts
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Babcock Power Services
• Cladding Technology
– Patented process apply
tungsten carbide to pulverizer
wear parts
• RB/RP/RPS/HP Mills
– Compared to OEM rolls and
other overlay processes, more
than doubles wear life
• Roll Wheel assembly re-builds
• Journal assembly re-builds
• Replacement worm gears
– RS/RP/RPS
CE/Alstom Rebuild Program
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Babcock Power Services
• Burners for Any OEM’s
Installation
• Riley’s CCV® (Controlled
Combustion Venturi)
– Coal types — lignite, sub bit.,
PRB, bituminous, pet. coke
blends
– Wall, corner and TURBO®
Furnace
– Unit capacities up to 1,300
MWs
• Oil & Gas - wall fired
Low NOx Burner Technology
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Babcock Power Services
• Riley’s VSIII™
– Lowest level of NOx control
– Mitigates waterwall flame
impingement
– On-line flame length
adjustment
– Scanner/igniter compatibility
– Tertiary Air vane control
Low NOx Burner Technology – The Next Generation
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
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Babcock Power Services
• Located in South Carolina, USA
• 20 Acre Site
• 150, 000 sq ft under roof
• Three Bays
• Five Tube Benders
• 50,000 sq ft Tube Warehouse
BTA Lyman Operations
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
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Babcock Power Services
– Superheaters
– Reheaters
– Wall panels
– Economizers
– Headers
– Loose tubes
– Imtec doors
– Tubular products
– Port Punchers
– Laminar Flow Dampers
– Weld Overlay
– Re-design service
– Erosion/Corrosion protection
BTA Products
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Babcock Power Services
• Boilers
• HRSGs
• Pollution control equipment
• Piping
• Condensers
• Feedwater heaters
• Provides open-shop direct hire
construction services to the
utility and industrial market for
the new installation, repair, and
maintenance of boilers and
related equipment
Plant Installation, Repair and Maintenance
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Babcock Power Services
• Power Generation
– Boiler Overlay/Buildup
– Boiler Tube Butt Welding Waterwall
– Auto/Manual GTAW CrMo and P-91
– High Energy Pipe Welding
Specialty Welding
• Pulp & Paper– Batch Digester
Overlay/Buildup
– Continuous Digester
Overlay/Buildup
– Digester Scaffold
– Power & Recovery
Boiler Repair
• Petrochemical – Cokers, Towers and
Reactors
– Weld Overlay/Buildup of Vessels
– Auto GTAW Pipe Welding
– ID Nozzle Overlay
– Piping and Vessel Overlay
– Turnkey Services
– Clad Plate for Fabrication
Comprised of Two Specialty Welding Departments:
Automated Mig Overlay & Orbital Machine Welding
© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.
All Rights Reserved
Babcock Power Inc.
• One Source, Multiple Fuels and Products– Coal, biomass, solar and WTE – boilers, steam generators, fuel
handling and firing systems, repair, replace and construct
• OEM Testament– Percentage of Babcock Power equipment and services installed
and executed on other OEM’s equipment grows year after year
• Innovation
– Continually striving to improve and create products to meet our
customers requirements on time and within budget
Like Nowhere Else