Focus Japan: New Projects forBoiler Cleaning Equipment,DRYCON and Steel ‘H’Economizers

04

SMART Clean Compact in a Spanish Biomass Plant

12

Joining Forces – Combined Young Talent Event for Classes 3 and 4

16

EDITION 2 | 2018

The new Clyde Bergemann logo in use all over the world.

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The following interview focuses on two main initiatives: the optimization of the production processes in Europe and the first “tangible” digitization project.

Dr. Mueller, during the last interview you mentioned that the optimization of pro-cesses would be a main initiative for Clyde Bergemann moving forward. We are now hearing of specific optimization efforts for our production sites in Emmelsum and Tal-linn – could you tell us more about this?DR. CHRISTIAN MUELLER: We have, in addition to other internal processes, analyzed the current situation of those two important production sites concerning capacities, costs and responsi-bilities. Unlike all other plants, Germany (CBW) and Estonia (CBE) need to work hand in hand when producing sootblowers: the colleagues in Wesel are responsible for the production of the feed and lance tubes, the central warehouse and the procurement. Tallin provides the steelwork, painting and final assembly.

This sounds like a logistical challenge …DR. CHRISTIAN MUELLER: The physical distance between the two sites definitely presents a lo-gistical challenge and demands flexibility and a high degree of responsiveness – because we want to make sure to deliver on time. We have deliberately not further pursued any logistical improvements, but chosen a different approach. We found it particularly important to focus on the strengths of the different sites and thereby identify potential for optimization. It soon be-came clear that CBE‘s areas of expertise includes steelworks and the painting of large volume components. CBW has extensive experience when it comes to an efficient and accurate as-sembly and painting of lance and feed tubes. This, combined with the existing central ware-house and the procurement, shows that every-thing is at the right place for the final assembly already. Accordingly, we are going to relocate the final assembly to Germany and focus on the production of the sootblower beams and – of course – DRYCON in Estonia.

NEWS FROM THE EXCO

NEWS FROM THE EXCO

02 _ Interview with Dr. Christian Mueller

PROJECTS

04 _ Clyde Bergemann Equipment Supports New Power Plant Projects in Japan

05 _ Another Order for DRYCON™ in Japan

06 _ Clyde Bergemann Continuing Success of Steel ‘H’ Economizers in Japan

07_ Brazilian Steel Mill Coke Plant to Restore 30 GW by Replacing Existing Fin Tubes with Clyde Bergemann’s Patented Steel ‘H’ Tubes

08 _ Conversion of Taichung Power Plant from Wet to Dry Ash Handling with DRYCON™

09 _ Orders for Boiler Efficiency and Materials Handling Equipment for Avonmouth Energy Recovery Facility, UK

10 _ Clyde Bergemann Wesel Delivers Boiler Cleaning Equipment for Boiler Overhauls of Turkish Power Plants

11 _ Clyde Bergemann Supports Korean Dust Emission Reduction Program with Cleaning Equipment for Gas-Gas Heaters at Boryeong Power Plant #3

12 _ Increased Process Efficiency and Savings in Lucena Biomass Plant Through the Use of SMART Clean Compact

13 _ Shanghai Clyde Bergemann Supplies Low Temperature Economizer Systems for New Power Plant Hunutlu in Turkey

14 _ Clyde Bergemann Americas Introduces Fitness-to-Operate Sootblower Maintenance Program

EVENTS & PERSONNEL

16 _ Young Talent Meeting in Scotland

18 _ Alex Ramsay Celebrates 50 Years of Service at Clyde Bergemann

19 _ People in the Company

20 _ Personnel

Publisher: Clyde Bergemann GmbH, Schillwiese 20, D-46485 Wesel (Germany)Responsible for content: Dr. Christian MuellerEditorial: Claudia Denniger, email: claudia.denniger@cbpg.com, Charlene Alcantar, email: charlene.alcantar@uk.cbpg.com, Georgia Roy, email: georgia.roy@us.cbpg.com Graphic design: Lisa SchamschulaReprints are permissible only after consultation with the editorial office.

CONTENT

Creating a win-win situation for both par-ties?DR. CHRISTIAN MUELLER: I think we can even call it a win-win-win situation. We will be able to eliminate past bottlenecks and weaknesses by allocating the new responsibilities, thus not only achieve relief and simultaneously improve effi-ciency in the two sites but in the whole Euro-pean organization.

We are also making visible progress in digi-tization. Between November 2018 and Jan-uary 2019 our Service people are carrying out a test run with „SMART Glasses“. Can you tell us more?DR. CHRISTIAN MUELLER: SMART Glasses are wear-able computer glasses that transmit the reality, alongside visual content such as images, texts or drawings. If a customer faces an acute problem, our on-site service technicians can access our experts around the globe. They can use video conferencing and share the same field of view through the glasses. That’s the basis to come to a joint solution.

But it needs more than clever glasses? DANIEL BARTELS (Senior Manager Digitization): True! The most important part is the underlying ser-vice platform that we obtain from a renowned supplier. This platform not only enables us to connect our people globally using data glass-es, smartphones or tablets. It also allows us to share and manage knowledge across our loca-tions, e. g. operating instructions, documents or drawings. By using so called „Augmented Reality“ functionalities – overlaying of informa-

News from the ExCotion in real time next to the visible area – we are able to train or support our people on-site without the need to send a specialist.

We will for sure become more efficient and our customers will benefit as well!DR. CHRISTIAN MUELLER: We will be able to act and solve problems faster and trans-fer knowledge more widely, thus increasing the qualification of our service team even further. Additionally, it is truly interesting to test such a new kind of technology in an early stage, there-by taking a leading role adding value-added ser-vices for the customer.

How are the platform and the SMART Glasses supposed to be used?DANIEL BARTELS: For testing the system we have bought 10 licenses and three SMART Glasses. We may use the platform – in addition to the data glasses – also with our smartphones. The test includes Clyde Bergemann Wesel, Scan-dinavia, Poland, Scotland and Atlanta. Many participants from the European subsidiaries have already been trained. In November we will continue with Atlanta via online seminars. The colleagues in Shanghai started a comparable initiative. They use an alternative software plat-form and a different type of glasses that does not display the captured images on an integrat-ed screen but projects it directly in the field of vision of the user.

We are looking forward to getting more information about first experiences in the next edition of CB News!

SMART Glasses in use: the Service Technicians learn about and test the data glasses during the training

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PROJECTS PROJECTS

Clyde Bergemann GmbH in Wesel, Ger-many (CBW) was able to secure orders for cleaning equipment for two new projects, a 645 MW power plant for an Iron Works Company and 2 x 650 MW for a Steel Pro-ducing Company. For both projects, CBW will supply sootblowers and relating equip-ment for the boiler as well as for the gas-gas-heater area.

IRON WORKS POWER PLANTFor the expansion of an Iron Works Power Plant north-east of Tokyo, Clyde Bergemann was en-gaged to deliver on-load cleaning technology for the boiler, namely wall deslaggers and long retractable sootblowers. Wall deslaggers are particularly used for the cleaning of the furnace walls, areas with heavy slagging and flue gas temperatures reaching up to 1,600 °C. Long retractable sootblowers with a travel length of up to 11.2 meters will additionally be deployed in the superheater/reheater area of the boiler. Furthermore, CB received the order to supply the cleaning equipment for the gas-gas heater. From CB’s comprehensive portfolio, the boiler cleaning specialists chose reinforced sootblow-ers with a dual rack design for long travel rang-es (> up to 12.8 meters) to guarantee a safe and thorough cleaning and systems operation.

After important order intakes for DRYCON™ systems in Japan, Clyde Berge-mann achieved further success by winning the order for the supply of their propri-etary system for the new-build power plant Misumi.

The ultra-supercritical 1,000 MW plant in Hamada, Shimane prefecture, Japan, is an addition to the existing 1,000 MW plant that went into operation in 1998. The Chugoku Electric Power Co., Inc. awarded domestic Su-mitomo Heavy Industries, Ltd. (SHI), with the construction of the complete ash handling system. SHI opted once more for Clyde Berge-mann’s DRYCON™ system to cool and convey the bottom ash. Clyde Bergemann’s scope of supply includes isolating gates with jaw crusher function as well as the DRYCON™ steel plate conveyor. The collection hoppers below the boiler catch the hot bottom ash. Each hopper leg is

Clyde Bergemann Equipment Supports New Power Plant Projects in Japan

Clyde Bergemann Strengthens its Market Position in Japan by Gaining Another Order for its Dry Bottom Ash Handling Solution DRYCON™

equipped with a grating and a hydraulic driven crusher combination at the outlet, shredding over-sized particles to an acceptable size.

The subsequent DRYCON™ automatically transports and cools the bottom ash with tem-peratures of up to 1000 °C by utilizing air. In counter flow to the hot ash it draws ambient air along the conveyor and effectively transfers heat back into the boiler. The fully enclosed system with a conveying capacity of about 20 t/h and a total conveying length of approx. 50 meters completely eliminates the use and treat-ment of water. Thus, it is not only an econom-ically, but also environmentally sound solution when it comes to bottom ash handling.

Deliveries are scheduled for June 2021.

CONTACTAndre Engelmann

Clyde Bergemann GmbH, Weselandre.engelmann@de.cbpg.com

POWER PLANT FOR A STEEL PRODUCING COMPANYIn addition to an existing 1,400 MW power station, two more 650 MW units are proposed on the site of the works' blast furnace. The new power station is supposed to serve its home-town as well as the surrounding area and will not only feature cutting-edge, ultra-supercriti-cal generating but also advanced environmen-tal equipment of the highest standards. Clyde Bergemann was once more entrusted with the supply of the cleaning equipment both for the boiler and the gas-gas heater area of unit 1 and 2. The Iron Works Plant project is already under execution, the cleaning equipment for Unit 1 and 2 of the power plant for the Steel Pro-ducing Company are due for delivery in May 2020 and 2021. Three comparable projects, Safi, Nakayama and Suzukawa, have already been completed. Those repeat orders demonstrate Clyde Berge-mann’s ability to serve their customers globally with the right products, knowledge and com-mitment.

CONTACTUtsav Dutta, Clyde Bergemann GmbH,

Germanyutsav.dutta@de.cbpg.com

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A Japanese boiler company in collaboration with their Australian entity, have placed two large con-tracts for the supply of Economizer elements with Clyde Bergemann Australia (CBA). The contracts are for the design and supply of Steel ‘H’® finned tube Economizers and erosion protection.

Clyde Bergemann Continuing Success of Steel ‘H’ Economizers in Japan

Both Economizers will be manufactured in Australia and delivered to Japan where they are installed in a Utility Power Generation Plant and a Pulp & Paper Mill. Due to CBA’s extensive experience in designing and supplying Economizers in many applications made for a compel-ling reason to select this technical solution over other alternatives.

The Steel ‘H’® and Double ‘H’® fins are resistance welded with precise indexing over the entire length of the tube surface to ensure reliable heat transfer. The advantage of Steel ‘H’® is that the fins and tubes are in-line and as such will provide direct passage of gas through the bundles and by shielding the tubes in specific areas ex-tend the life of the Economizer. Steel ‘H’® Economizers comprise one steel fin welded to a single tube. A Double ‘H’® Economizer comprises one steel fin welded to two tubes. The final solution involving combinations of Steel ‘H’®and Double ‘H’® Economizer has a unique combi-nation of features providing a compact, low cost design with erosion protection capable of being fitted in the shop, which additionally proved a more cost effective alternative than installing in the field.By installing Erosion shields in both upper and lower sections of the Economizer in the workshop will benefit the operators when protecting the economizers from not only flue gas erosion but sootblower erosion also. This has the effect of increasing the lifespan of the new Economizers providing long term maintenance savings

to the plant while providing the same thermal per-formance as the existing Economizer.

Erosion protection in the new Economizers along with maintaining the Thermal Duty have proven key factors in being selected as the supplier. CBA will take full responsibility including de-sign and manufacture of the Economizers. The manufacturing is due to commence in October 2018 and will be completed in April 2019.

CONTACTGerard Grant

Clyde Bergemann Australiagerard.grant@au.cbpg.com

Clyde Bergemann do Brazil (CBdB) was recently awarded the order to replace the existing spi-ral fin tubes of four Waste Heat Boilers at a Steel Mill Coke Plant in Rio de Janeiro, Brazil. By imple-menting the Double ‘H’® tubes in the Evaporator and Economizer of the Boilers, not only plugging in the spiral fin elements will be eliminated, additionally 2.7 ton/h of steam production per boiler will be regained, representing approximately 30 Gigawatt in one year. Significant savings will also be realized due to reduced outages for offline cleaning.

As a result of persistent plugging problems in the existing spiral fin elements, the Steel Mill contacted CBdB, a long-term partner for boiler cleaning and efficiency systems. To-gether with their sister company, Clyde Bergemann Australia (CBA),

Brazilian Steel Mill Coke Plant to Restore 30 Gigawatt by Replacing Existing Fin Tubes with Clyde Bergemann’s Steel ‘H’ Tubes

a specialist in Waste Heat Recovery solutions for more than 50 years, they executed an engineering study proposing the deployment of their proprietary technology, Double ‘H’® Economizers. The Double ‘H’® Economizer has a unique combination of features pro-viding a compact, low cost design. Double ‘H’® fins are resistance welded with precise indexing over the entire length of the tube surface to ensure reliable heat transfer. The advantage of replacing with Double ‘H’® is that the fins and tubes are in-line and as such will provide direct passage of gas through the bundles, reducing pressure drop and minimizing dust clogging.The Steel Mill has 12 Waste Heat Recovery (WHR) Boilers in total and CBdB recently provided a sootblowing system for two of them with great success. 13 new steam sootblowers were installed to replace four low

pressure air blowers. The combina-tion of the sootblowing system with the new Double ‘H’® tubes replacing the existing spiral finned tubes will provide a massive runtime extension from currently three months to great-er than one year once installed. By implementing this change and subsequent reduction of ash clogging issues will bring back steam gener-ation from approximately 60 % to nominal capacity.CBA will undertake the design work, CBdB the project management and the fabrication of the elements. The order will be executed in collaboration with Imetame, a local EPC contractor. Deliveries are planned progressively from December 2012 through to the end of February 2019.

CONTACTAlexandre Baiero

Clyde Bergemann do Brasilalexandre.baiero@br.cbpg.com

PROJECTS

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PROJECTS

Collaboration the Key as Clyde Bergemann Awarded with Orders for Boiler Efficiency and Materials Handling Equipment for Avonmouth Energy Recovery Facility, UK

Clyde Bergemann Supports Conversion of Taichung Power Plant from Wet Bottom Ash Handling to an Eco-Friendly Dry Ash System Using their DRYCON™ Technology

Clyde Bergemann Power Group have been entrusted by CNIM, EPC of the new-build 36 MW Energy Recovery Facility in Avonmouth, UK, with the delivery of boiler cleaning and materials handling equipment. Once opera-tional the facility will use safe, environmen-tally sustainable and reliable technology to divert 320,000 tons of non-recyclable waste away from landfill, providing enough ener-gy to power 44,000 homes.

Clyde Bergemann secured the orders for a range of boiler efficiency equipment due to competitive pricing and flexible delivery capa-bility. Strong collaboration between CB col-leagues in Belgium, Germany and Scotland resulted in a package offer which fully met the customer’s requirements. Additionally, Clyde Bergemann EP Tech (Italy) was entrusted with the delivery of the mechanical ash removal system from the bag filters.

CNIM, an international specialist in waste treatment and waste-to- energy solutions, once again se-lected Clyde Bergemann bespoke cleaning and materials handling solutions for two lines each with waste incineration capaci-ty of 20 tonnes per hour. To re-move residues of the fuels safely and effectively while the plants are operating and ensure boiler availability and efficiency, a soot-

With an installed coal-fired generation capacity of 10 x 550 MW, Taichung Power Plant is amongst the five largest coal-fired power stations in the world. Six of the older units so far reclaim their ash by-products by mixing the ash with water to form slurry which is then further conveyed to ash retention ponds. The ever growing need to conserve water due to stricter land usage regulations made Taiwan Power Compa-ny, the owner of the plant, consider a conversion to dry ash handling. In May 2018, Clyde Bergemann GmbH in Wesel, Germany (CB) received the order to supply their patented, environmental friendly dry ash conveying solution “DRYCON“ for lower costs and emissions and increased efficiency to convert the first of six units.

The turnkey contractor for the removal of the old Sub-merged Scraper Conveyor and the installation of the new dry system, ATE Energy International Co., entrusted Clyde Bergemann as its exclusive partner with the overall system design, the delivery of the DRYCON™ and peripheral de-vices as well as installation and commissioning supervision. Clyde Bergemann’s solution consists of a fabric compen-

sator, a transition hopper with isolating gates and the DRYCON™ steel plate conveyor. DRYCON™ automatically transports and cools the bottom ash by drawing ambient air along the conveyor and effectively transferring heat back into the boiler. The fully enclosed system with a width of 1.8 meters and a total conveying length of 42 meters completely eliminates the use and treatment of water. Therefore the system is a significant upgrade dramatically improving the local environment. The DRYCON™ also in-creases combustion efficiency by reducing thermal energy losses, re-entering unburnt carbon and therefore reducing CO2 emissions and subsequently operating costs.

Deliveries are already scheduled for January 2019, with let-ters of intent received for the conversion of five more units.

CONTACTAndre Engelmann

Clyde Bergemann GmbH, Germanyandre.engelmann@de.cbpg.com

PROJECTS

blowing system, rapping system and shower cleaning system was required for each line.To process and remove the fly ash from the bag filters, customized lump breakers, screw and drag chain conveyors completed the scope of supplies.

Equipment commissioning and site operations are progressing well to plan.

CONTACTFilippo Nizzi

Clyde Bergemann Forest, Belgiumfilippo.nizzi@be.cbpg.com

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PROJECTS PROJECTS

With a growing electricity consumption and demand on the one hand and domes-tic coal sources on the other, Turkey not only plans on expanding its fleet of coal-fired power plants but also invests in effi-ciency enhancements and modernizations of the existing installed base. As a partner for both new-builds and upgrades, Clyde Bergemann recently received new orders for boiler cleaning equipment for the modernization of two lignite fired power plants.

As part of the boiler overhauls of the two power plants, located closely together in the South of Turkey, Clyde Bergemann was entrust-ed with the exchange and modernization of the boiler cleaning equipment in all five units. The two lignite fired units with a capacity of 210 MW each became operational in the late 1980s. At that time, the sootblower systems for cleaning the boiler were delivered by Diamond Power, a competitor in the field of sootblowers.

In 2014, an Emission Reduction Pro-gram was submitted by the Korean state requesting the retrofit of Flue Gas Desul- furization (FGD) plants for a number of coal- fired power plants in the country. The main retrofit being the replacement of the rotating gas-gas heaters (GGH) with sealed ‘dust-free‘ static units. In total, 23 units will be upgraded over the next three to four years, each of which requires around 50-90 sootblowers.

The FGD process necessitates the installation of a flue gas cooler upstream and flue gas re-heat-er downstream the FGD (see graphic below). The latter serves the function of re-heating the flue gas temperature high enough to ensure the needed buoyancy for the cleaned gases to elevate and flow out through the stack.One of the coal-fired power stations that re-quires upgrading is a 4,000 MW (8 x 500 MW) plant on South Korea's west coast. Clyde Berge-mann’s agent Kwangwon won the order to sup-ply the sootblowers via Clyde Bergemann with the controls and local steelwork delivered by themselves.

Clyde Bergemann Supports Korean Dust Emission Reduction Program with Cleaning Equipment for Gas-Gas Heaters at Boryeong Power Plant #3

Both heat exchangers will be equipped with sootblowers to remove the deposits caused by ash and sulfur. Especially at the re-heater, the corrosive atmosphere due to low flue gas temperature (below the dew point) necessitates sootblowers with special lance tube materials.Clyde Bergemann will therefore supply 36 PS-H retractable sootblowers for the cooler with 316 stainless steel lances for corrosion protection each 6.8 m long, and 20 PX-H for the re-heater with Cr-Mo alloy steel lances each 10.3 m long. Both sootblowers types are especially suitable for the fouling expected in such plants and are designed to meet the functional requirements typically expected for GGH cleaning applica-tions. The sootblowers are equipped with special gear motors meeting the stringent requirements of the rather long retractable sootblowers as well as conforming to the premium efficiency class IE3 (IEC 60034-1). Further to that, stainless steel terminal boxes are envisaged to meet the ambient corrosive environment.

CONTACTMichael Goble

Clyde Bergemann Doncaster (UK)michael.goble@uk.cbpg.com

Now, approximately 30 years later, the exist-ing devices are replaced by Clyde Bergemann’s part retractable sootblowers, which are espe-cially suitable for cleaning of the superheater/reheater area of the boiler. Based on the ex-perience during operation, some remained in their old position, some were relocated to guarantee a comprehensive cleaning efficiency.

The other 3 x 210 MW power plant went on-line between 1993 and 1995. Here again, a replacement and update of the old equipment was necessary and Clyde Bergemann was cho-sen once more for the supply of the new boiler cleaning equipment. With a subsidiary in Istanbul, Clyde Bergemann Turkey, customers benefit from experienced de-sign, project management and aftermarket sup-port – whether it’s new-build, upgrade or rebuild!

CONTACTMetin Öztropak

Clyde Bergemann Turkeymetin.oeztropak@tr.cbpg.com

Clyde Bergemann Wesel (CBW) Delivers Boiler Cleaning Equipment for the Boiler Overhauls of Turkish Power Plants

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PROJECTS PROJECTS

Bioenergetica Santamaria, S. A. operates a biomass/gas cogeneration plant of app. 14 MW located in Lucena, Cordoba (Spain). Due to the type and composition of the biomass (olive husk), the operator expe-rienced heavy fouling and deposits in the boiler, forcing costly shutdown each 3-4 months to clean the boiler. To rectify this problem, Clyde Bergemann's applications specialists proposed to implement SMART Clean Compact - a boiler cleaning optimiza-tion system, particularly designed for small industrial boilers, waste incinerators and biomass plants.

The Lucena plant went into operation in 2006. As the originally installed cleaning devices from a competitor did not lead to satisfying results,

Increased Process Efficiency and Savings in Lucena Biomass Plant Through the Use of SMART Clean Compact

Shanghai Clyde Bergemann Supplies Low Temperature Economizer Systems for New Power Plant Hunutlu in Turkey

benefits achieved by the energy recovery. Picking corrosion-resistant alloy steels is not a favorable solution, both with regard to material weight, as well as cost. A traditional low-temperature economizer system is connected to the steam- water system of the unit, using relatively low-priced ND (09CrCuSb) steel material, an anti- acid corrosion material which contains copper elements. After operation for a period of time, there will be copper elements in the steam-water system, tending to form copper precipitate inside the steam turbine and affect the turbine efficien-cy. In the bidding process, Shanghai Clyde Berge-mann analyzed the advantages and disadvantag-es of the various systems and provided detailed economic comparisons. The proposal provided by SCB, consisting of a combined carbon/austenitic steel approach, has been highly appreciated by the owner and SCB succeeded in winning the bid.

Since 2014, more than 25 units of low tempera-ture heat transfer systems have already been equipped and are operating successfully. The whole project will be designed and manufactured according to ASME-codes and CE Directives. Delivery time will be between November 2019 and April 2020.

CONTACTWu Mei

Shanghai Clyde Bergemannmei.wu@cn.cbpg.com

In July 2015 a joint venture with China's Shanghai Electric Power as the main share-holder, gained the construction and genera-tion license for a new ultra-supercritical 2 x 660 MW thermal power plant in the South of Turkey. Based on its design expertise and references, Shanghai Clyde Bergemann (SCB) was awarded the order to supply a set of low temperature economizer systems for each unit.

To ensure the secure supply of energy in a market with increasing demand, the Turkish government approved the new construction of a highly effi-cient, ultra-super critical coal-fired power plant in the Adana province. AVIC-INTL Project Engi-neering Company and CLP Power Engineering, responsible for the construction of the plant, entrusted Shanghai Clyde Bergemann with the delivery of low-temperature economizer systems for each unit, which are located upstream of the Electrostatic Precipitators (ESPs).

Generally, those kind of heat exchangers operate mostly below acid dew point, thus resulting in the necessity to use corrosion-resistant material. The biggest challenge is to get the best balance between investment costs and the economic

Bioenergetica Santamaria got in contact with Clyde Bergemann’s application specialists al-ready in 2008. In a first step in 2009, six retractable and part re-tractable sootblowers were additionally installed in the boiler, which were already able to increase the performance. The next bigger step was taken in 2010: To reli-ably clean the open passes, Clyde Bergemann’s Shower-Clean System (SCS) was implemented on the boiler roof. The SCS is suitable to clean the lower side of the boiler roof, the membrane walls and the plate heating surfaces of the fur-nace and open radiation passes at high flue gas temperatures up to 1.000 °C using water as cleaning medium. This led to constant low flue gas temperature and an increased heat transfer in the open passes.In 2017, 10 additional part retractable soot-blowers were installed in the Economizer.

Although the cleaning equipment was now sufficiently suitable to clean the boiler, the operators learned in the course of time, that the manually triggered cleaning systems could not reliably guarantee a trouble-free plant operation. Based on long-lasting experience and developments, Clyde Bergemann proposed the deployment of the online optimisation system SMART Clean Compact. SMART Clean Compact uses thermodynamic, model-based algorithms to analyze and interpret the plant process. The performance of all described cleaning devices is controlled and triggered on the basis of the submitted data. The result obtained is an opti-mum boiler output and stable operating para- meters. The operator will not only benefit from a smooth and consistent boiler operation, but also save costs associated with off-line cleaning valuable steam needed for sootblowing.

CONTACTPedro Fernandez

Clyde Bergemann Ibéricapedro.fernandez@es.cbpg.com

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AFTERMARKETAFTERMARKET

As the average age of North America’s recovery boilers approaches 40 years – well in excess of their typical design life – the FTO program is designed to offer customers a more maintenance focused approach to operating safe, stable, and cost efficient boilers.

Sootblowers can pose a significant threat of injury and costly damage to surrounding equipment if they are not adequately maintained or if critical issues are not being addressed early. All accidents are preventable but the chal-lenge is to do it in a systematic and cost effective way. This challenge is real, especially when the sootblowers are aging and there are several different types of sootblowers to maintain.Aging equipment, which requires more attention, when coupled with lack of capacity of trained maintenance per-sonnel, can often force us to run the sootblower to failure. This maintenance practice is generally unsafe and counters the recommended operating procedure but unfortunately is not uncommon.

Clyde Bergemann’s FTO program offers three levels of maintenance focus. Level 1: Basic Maintenance & Emergency HandlingIn this first level, the program offers:• Training: Hands on basic maintenance & emergency

handling training for the maintenance team.• Sensor Technology: Utilize Clyde Bergemann’s pro-

prietary sensor technology to monitor the health of the sootblowers and send alerts to assist the mainte-

Clyde Bergemann Americas Introduces Fitness-to-Operate (FTO) Sootblower Maintenance Program

nance team to detect and resolve problems early and avoid costly repairs.

• Remote Support: The maintenance team has access to Clyde Bergemann engineering resources via phone or online support to help them troubleshoot difficult problems or simply just for asking any technical ques-tions.

• Critical Spare Parts: Guaranteed expedited order-to-delivery time for critical parts.

Level 2: Safety & Reliability – The Clyde Bergemann FTO team will schedule sootblower safety and reliability inspections. Frequency of the walkdown depends on the severity of the sootblower health condition. The inspection includes:• Non-Destructive-Test (NDT): Perform NDT in the

field on lance/feed tubes using state of the art NDT equipment such as a Phased Array Ultrasonic Testing (PAUT) to examine the weld integrity and Ultrasonic Thickness Measurement to detect potential corrosion/thinning in the tube.

• Alignment Inspection: Sootblower misalignment stress occurs when the lance tube is not fully aligned with the sootblower travel path, causing the lance and feed tubes to experience abnormal loading. This abnormal loading can result in premature lance and feed tube fatigue failure. If not identified and fixed, the fatigue failure can cause the tube to break off completely and exposes those in the area to heavy steam flow. The lance tube may also launch inside the boiler like a projectile and damage the boiler tubes.

• Presence of Corrosive Boiler Flue Gas in the Lance & Feed tubes: The lance tube may also be suscepti-ble to corrosion (especially in the weld joint between the stainless steel and high strength alloy steel) if the scavenging air system is not in good operating con-dition. It will allow hostile boiler flue gas to enter the lance tube, causing tube corrosion.

The customer will receive a detail report about the safety & reliability of their sootblowers, along with the recom-mended corrective & preventive actions. Once approved by the customer, Clyde Bergemann FTO team will perform the corrective and preventive actions.

Level 3: Complexity & Maintenance Cost Reduction – Semiannually, the Clyde Bergemann FTO team will provide a sootblower audit with a goal to identify cost saving and complexity reduction opportunities. Part standardization is one of the key elements to reduce the complexity of the sootblower maintenance program. The customer will re-ceive semiannual complexity & maintenance cost reduc-tion opportunity reports and cost & benefits analysis.

“In listening to our customer’s daily challenges with their aging equipment and limited resources, we have been working hard to come up with solutions that help them find a way through this difficult situation. We want to find the right solution for every mill that faces the challenges of reducing their costs while keeping control of safety and getting the equipment’s reliability and perfor- mance

Level 3Complexity & Maintenance Cost

Reductions

Level 1Basic Maintenance &Emergency Handling

Clyde Bergemann's FTO Programm

Level 2Safety & Reliability

where it needs to be,” said Dominick Garton, President of Clyde Bergemann Power Group Americas (CBAM). “Our group of trained experts is committed to deliver a high quality Fitness-to-Operate (FTO) program that will help our customers properly maintain their equipment in the most cost effective safe way.”

CONTACTDanny Tandra

Clyde Bergemann Inc., Atlanta , USAdanny.tandra@us.cbpg.com

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FAIRS, CONFERENCES & EVENTS

Two days, 21 participants, three training sessions and six targeted presentations – In late Septem-ber participants from seven countries attended a combined Young Talents Closing Event in Glasgow, Scotland. Young Talents classes 3 and 4 shared their ideas and experiences in an event full of collabora-tion, cooperation and development.

The idea to bring classes 3 and 4 together was born during the Young Talents Meeting in Munich in May of this year. At this meeting, the class 4 participants presented in six teams on three topics. These topics included:1. New communication channels and effective use for

Clyde Bergemann 2. Digital transformation of business processes, products

& services at Clyde Bergemann 3. New product ideas for Clyde Bergemann

Having seen those presentations, the Management Team decided to build on this by adding more knowledge and

Joining Forces – Combined Young Talent Closing Event for Class 3 and 4

experience to each team in the form of the previous Young Talent class. The Management Team then challenged the newly formed teams to create a proposal for an element of a Clyde Bergemann Mobile Application focusing on different functional areas of the organization. The groups covered a sub-topic of either “service & parts”, “data man-agement” or “communications”. One team would further develop a potential new market idea for metals recovery in bottom ash, addressing the “new product” brief.

LEARNING ...The schedule included two training and development sessions, facilitated by APEX coaches, prior to the team presentations. These diverse and engaging sessions in-cluded 360-degree participant feedback, workshops on presentation skills and open discussions on the role of personal styles in business. These workshops provided a perfect forum for participants to enhance and develop their presentation skills, building new competences prior to the key presentations to the Management Team. These

focused and engaging training sessions were well received by all participants.

... AND PRESENTING!Following on from the previous sessions, Dr. Mueller (Pres-ident & CEO), Daniel Bartels (Senior Manager Digitization) and Claudia Denniger (Director of Marketing & PR and Head of the Young Talent Initiative) watched the presenta-tions as well as the team performance with keen interest. Each presentation was followed by a question and answer session and detailed individual feedback from both the Management Team and APEX specialist coaches.

INCREASING INFLUENCEThe final day included a third workshop focusing on how the Young Talents can increase their influence within our organization and progress their careers. These closing sessions offered an opportunity to exchange experiences with others and give feedback. The APEX coaches utilized a breakout session to encourage peer-review, something

the Young Talents group really engaged with, this ended the formal training element of the program. MORE THAN WORKTypically, Young Talents events are not all about presenta-tions and training exercises - this event was no different. The team also enjoyed a bagpipe experience at the Na-tional Piping Center, an evening event where the Young Talents got the opportunity to learn about (and try to play!) Scotland’s national instrument. The meal that followed included traditional Scottish favorites such as Haggis and Cranachan, for those brave enough to try them. The eve-ning culminated in the Sky Bar with views across Glasgow. Overall, the combined Young Talent closing event was a great opportunity for everyone to come together with colleagues from around the world and to strengthen long and useful inter group relations. All attendees thoroughly enjoyed the event and the opportunity to collaborate with both new and existing Young Talent colleagues. The imple-mentation of one of the ideas presented is now underway. This brings to a close the Young Talents program for these groups who now graduate with the skills required to en-hance their careers within Clyde Bergemann Power Group.

Details regarding Young Talents Class 5 will be shared in due course as they are finalized.

By Colin Millar (Clyde Bergemann Scotland) and Vinod Menon (Clyde Bergemann Indonesia)

www.cbpg.com NEWS 2 | 2018 1918 NEWS 2 | 2018 www.cbpg.com

PERSONNELPERSONNEL

PEOPLE IN THE COMPANY: BHAUMIK PATEL

What are the basic stations of your career at Clyde Bergemann? I started as a design engineer in June 2005 at Clyde Bergemann Wesel (CBW) being tasked to lead the pro-gramming of the new product con-figurator and thereby got an insight in the complete product portfolio at CBW. In 2010, I was entrusted by Dr. Mueller, Director of R & D and Tech-nology of Clyde Bergemann then, to take the responsibility as a Product Manager – Sootblowers & Equipment. Three years later, I was asked to lead the Product Management team, fol-lowed by heading the Technology & Sales Support team in October 2014. Since May 2018, I have taken up responsibilities of additionally heading the newly formed “Projects Center” at CBW.

This is a steady success story! Why did you originally pick Clyde Bergemann as your employer?Being a mechanical engineer, it was always a dream to at least spend a few years working in Germany, the Mecca of the engineering world. After my Masters Degree from Wayne State University in Detroit, a cold ap-plication through the Clyde Berge-mann website then saw my resume landing in Wesel, Germany. A few calls later with the Head of HR, fol-lowed by a 3-day visit to Wesel, I somehow landed from down-town Detroit to down-town Wesel. It’s been a while at CBW ever since.

What are your core activities today? We had been looking into bring-ing in all technical & technology related teams into the realms of one core team. This saw us forming the “Projects Center” at CBW where the design, technical proposals & pro-

best of their abilities. There are rough patches every now and then, but I am glad to inherit a rather well-motivated team.

What was the most memorable situation during your time with Clyde Bergemann? I have a multitude of good memories during the past decade and more at CB. Fighting hands-in-hands with our sales colleagues to win major projects brought immense joy, still does. Working out technical issues with the colleagues at the Projects Center and the manufacturing team, drives me. I could name each outing where we have gone out with the team in the past to vent the heat out, and have thoroughly enjoyed each of these. Singling one out would be dif-ficult, but will never forget the day when I went home and announced my appointment as a Product Manag-er Sootblowers & Equipment at CBW.

What is your favorite thing to do when you are not working?Hit the dumb-bells, do some weight lifting – just kidding! I like listening to music over a glass of beer and singing loudly along, watching my daughters shake their heads out of hopelessness!

Cooking lessons

with his team

and “associates”

curement, projects and complaints management teams form one unit to serve the contracts side of our busi-ness more efficiently. My core activi-ties as the head is to ensure efficient management of contracts and other related projects for higher profitability.

What is "leadership" for you? I have a rather simple approach, the execution of which, may change from time to time. Leadership for me is to be there for my team whenever they need me and guide them through their activities to ensure the goals and objectives of the company are met. I am learning each day how best I can do that.

How do you motivate yourself and your team? The best way to motivate oneself or others around you is to look into the eye of the storm, just to put it poetically! We have lately been in-volved in a few situations where one would think that it would be difficult to come out from. However, address-ing the problem internally and find-ing ways to solve it, just like a puzzle, motivates me. Having a good team around helps the cause many folds. The team on the other hand, needs trust and belief from my side, to be motivated. I have a strong belief in my team-mates, knowing that each is capable of doing his or her part to the

Technology center in Sidcup, Kent), and the business System 25 being implemented within the company around the early nineties, which also coincided with new ownership for the com-pany (Jim McColl).As the company developed and expanded, the title of Draughtsman had become obsolete, and other duties out with drawing creation were added to Alex’s skill set (e.g. detail sheets, in-struction manuals and dealing with customers). The title of Project Engineer was born – a title he holds proudly to this day.After the company’s relocation to Bridgeton, the subsequent fire and then the brand new offices, Clyde Blowers expanded and bought Forest Engineering from Belgium (1993) and Bergemann of Wesel (1996), hence the renam-ing Clyde Bergemann.With the takeover of Bergemann, also came the introduction of a new product line, as had happened with Forest. This led to an entourage from Wesel arriving in Glasgow, including Mi-chael Balkenborg and Ute Augustine who spent a week in the Glasgow office. With them came masses of information on their sootblower de-signs, and Alex was the lucky recipient selected to digest all this exciting knowledge. Alex played a key role in this visit and the companies inte-grating their knowledge and experiences.As it turned out Alex became good friends with Michael, and continued to be in contact on a social level, one of the many friends Alex has made in his 50 years with the company. Fast forward to 2019, and Alex is celebrating 50 years’ service, a great achievement; he is still an invaluable member of the Clyde Bergemann Scotland team today; a fountain of knowledge and a great colleague and friend to many.

Well done and thank you!

Alex Ramsay left Edinbarnet Junior Sec-ondary School at the end of 1968 and his father, who was Chief Draughtsman with Clyde Blowers at the time, arranged an interview for him with Mr. Harold Macin-tosh, their Head of Engineering. After his successful interview, he started as a “Print Boy” in the drawing office on Monday Jan-uary 6th, 1969.

Alex decided to make the most of his new job and took on an apprenticeship, beginning Oc-tober 1969, as he turned 16. This consisted of six months in the inspection department, one year in the fitting shop, one year working on the milling machines, one year working on the heavy lathe and six months training in various

other roles – broach, drilling, turning ma-chines and stores.

Subsequently, Alex spent a further six months in the drawing office, which was normal practice for apprentices at the time. At the end of which, after a written exam, Alex was given the op-tion of staying in the drawing office, or taking a position on the

shop floor. He opted to take the position of Junior Draughtsman for

four and a half years, and on reach-ing twenty-five became a fully-fledged

Draughtsman.Alex remained in this role until the introduc-tion of the ‘Computer Age’, with AutoCAD (at the time training was a three day course at a

“My Time with the Blowers”Alex Ramsay Celebrates 50 Years of Service at Clyde Bergemann Scotland

Clyde Blowers Limited

Office Building in the

mid to late 60sClyde sootblower production in the early 1960s

PERSONNEL

Clyde Bergemann Estonia (CBE) Celebrates its 25th Anniversary!

27 years ago Bergemann and RAS Ilmarine, a state owned Estonian company specializing in the produc-tion of cleaning equipment for heating surfaces, began doing business with each other. In July 1993 Berge-mann and Ilmarine entered into a joint venture and this year CBE proudly celebrates its 25th anniversary!

The joint venture Bergemann Ilmarine started with 60 work-ers. Today seven of the original staff continue to work for CBE. The loyalty of the workers is also demonstrated by the fact that 45 current workers have worked in CBE for more than 10 years. Through the years the total number of workers has steadily grown and have now reached ap-proximately 100!

2018 is a special year for Estonia as a country as well as it celebrates its 100th anniversary. To thank our workers for their efforts throughout the years we organized a party dedicated to Estonia 100 at the Hotel Viru that took place October 5, 2018. Hotel Viru is one of the first hotels in Tallinn and is also the preferred hotel for all CBE visitors. The party was well attended and a huge success. We look forward to continuing our growth and success for many more years to come.

“We. Together. Committed to Process Efficiency.”

Clyde Bergemann Estonia:

growing together over the last 25 years

Ralph Ludwig (Vice President & COO Clyde Bergemann

Europe), Kaarel Pääsuke (Managing Director Clyde Bergemann

Eesti AS) and Maido Tiimus (Quality Engineer who helped to

translate to Russian) during the 25-year-celebration

As per August 2018, Ms Mei Wu was appointed Chief Engineer of Shanghai in addition to her current responsibility as R & D Manager for Shanghai Clyde Bergemann (SCB).Ms. Mei Wu graduated from Xi’an Jiaotong University (major: thermal energy and power engineering, master of engineering) and National University of Singapore

(major: electrical engineering, master of engineering). In her first job, she worked in the R & D department of Dongfang Boiler Co., Ltd., before she joined SCB in

February 2012 as Deputy Chief Engineer and R & D Manager. Her main task was the development and design of new products. In her new role as Chief Engineer

she is additionally responsible for the overall technical works.

Wu Mei replaces Mr. Xinmin Gao who will support the team as the Technical Consultant of SCB in the future. Mr. Gao joined SCB as Chief Engineer in January 1997 and is able to look back on more than 20 years of dedicated work! We would like to thank Mr. Xinmin Gao for his great contribution to the company's technology development during his tenure as Chief Engineer and look forward to our cooperation in the coming years.