2008 WRBA Conference 

Redding, California March 11-13

 

WRBA  Conference notes and Steering Committee Minutes

 

            The 2008 conference was called to order by Chairman Ray Karcher at 12:00 PM Tuesday March 11th by Chairman Ray Karcher. Ray offered a welcome to attendees and started the introduction of attendees and the companies they represented. Companies represented included Plum Creek, Biomass One, Seattle Steam, Avista Washington, Sierra Pacific, Roseburg Forest Products, Collins Pine, Douglas County Lumber, Ferris Lumber and Nippon Paper. Ray then introduced the Steering Committee Members, this included Paul Prescott, Ray Karcher, John Boyd, Ross Stevenson, Jack Hinnman, Darby Randklev, Shawn Gleason and Robin Styers. Ray then gave a reminder to the vendors regarding their presentations and the format the WRBA uses. He then indicated that all cell phones must be turned off or set to vibrate as a courtesy to the presenters, cell calls to be taken outside the meeting presentation area. Ray then briefly discussed the finances of the organization, the tour that would be held on Wednesday of the Shasta Dam Power Plant and the fact that this year represented the 40th year of the WRBA. Ray also described the anniversary prize for all registered members, a WRBA logo Carhart Jacket . Ray then opened up the meeting for the presentations.

 

Presentation #1 Click the link to view the presentation

Jon Robson

Wellons Water Technologies

 

Dry Kiln Corrosion:  It is important to monitor the kiln for corrosion. It is important to monitor the kiln for corrosion with the most common type being Carbon Dioxide Corrosion. The intermittent operation and variations in pressures and flows can allow for air or oxygen in-leakage.  Build up in steam traps can restrict flows through kilns.  One method of preventing corrosion is by using pre-weighted metal strips which are commonly called corrosion coupons viewing and reading these coupons can save thousands of dollars in repairs and repair parts.  Proper insertion of the corrosion coupons is important as they must be inserted into the flow of steam in order to give you a more accurate analysis of any corrosion that may be going on.  On a short term basis filming amines can be used to protect the kiln but if you expect the kiln to be down for an extended period of time it is best to drain the kiln while it is still warm in an attempt to get all the moisture out.  It is best to treat corrosion before it starts and one way of doing that is to pre-treat, & use a de-alkalizer.  A more complex way to treat corrosion is using an RO skid with a cleaner in place.  RO’s take out 95-98% of all minerals, they can however create issues with plugging and must be monitored vigilantly. The use of a de-alkalizer and pre-treatment are also methods used to combat Dry Kiln Corrosion. A properly treated and monitored kiln means less down time for your company which equals greater productivity.

 

Ø      Ray took the opportunity to have a raffle presentation of a gift certificate to a lucky attendee.

 

 

Presentation #2 Click the link to view the presentation

Michael Gamburg

CTI Control Technologies

 

Ultra Low NOx Burner Retrofit:   The allowable NOx emission’s is a value that is constantly changing and becoming tighter and tighter as more and more cities are limiting the amount that is generated from many industries due to the increasing environmental concerns.  There are two types of NOx, Thermal NOx and Prompt NOx. 80% of NOx created when firing on gas is Thermal NOX. Prompt NOx is formed in sub-stoichiometric regions in the furnace. If Prompt NOx is reduced or eliminated the potential for Thermal NOx can be reduced or eliminated. There are many ways in which a company can reduce thermal NOx and have a positive impact on the environment.  An example is adding a VFD to your Forced Draft Fan, upgrading combustion controls, & upgrading your burner management system are just some of the many changes that can be made.  Another positive step is to monitor your air distribution in your burners.  Poor airflow balance can lead to flame imbalance which can lead to increased emissions, stability, & vibration problems.  The use of Ammonia or UREA Injection is another method of controlling NOx that is very effective. By making these changes to your boiler system before new industrial requirements are put into place you may be able reduce NOx emissions and decrease the potential for Title 5 modifications or restrictions.

 

 

Ø      Ray took the opportunity to raffle a gift certificate to Home Depot; it was won by Bob Fredricks of Plum Creek.

 

Presentation #3

Bob Morrow

Detroit Stoker Company

 

Cast Material for Stokers:   There are many types and qualities of iron for boiler replacement parts and they will need to be selected based on the particular performance you are seeking.  The cost of cast products is dependent on type of alloys, qualities desired and the prices paid for recovered cast metals on the world market. Flake Graphite has good heat dissipation characteristics large graphite is a softer material.  Cast Steel is known for its superior strength, elongation and increased hardiness for wear resistance.  Stainless Steel Casting can be resistant to high temperature and corrosion. Until recently there were no specifications for heat resistance that has changes and is a critical component to evaluate when selecting replacement cast parts.  Silicon affords the highest protection against high temperatures.  The downside to silicon is that it also promotes carbides.  Efficient operations should look not only at the process and its performance but the materials in replacement components, they should be equally important in contributing to overall performance and uptime.

 

Ø      Ray raffled of a Best Buy Gift Certificate that was won by Tom Kronberger of Douglas County lumber.

Presentation #4 Click the link to view the presentation

Steve Lawn and Jeremy Totman

T-2 Corporation

 

 Biomass Recovery & Transportation:  Biomass fuels are becoming more difficult                                                                                                                           to purchase from industry, as a result of the economic slowdown; forest & range lands are filling in the gaps.  Using Woody Biomass has it challenges as well.  Access to biomass may not be as easy as getting your fuel from a mill process. Components that can play a factor in the cost of woodlands fuels are distance from the end user processing costs, trucking costs, weather can also be a factor as well as competing uses.  Biomass fuel can be processed in two (2) different types of grinders.   The type of Biomass fuel you will use with will determine which grinder will most efficiently do the job.  Long material is best ground up in a horizontal grinder as it is fed from a track while a tub grinder feeds material from the top.  Biomass harvesting days can be long but also productive with 10 to 20 loads per day per equipment side.  The recovery of Biomass fuel can help reduce fire hazards in our forest lands as well as the environment reducing our dependency on other environmentally polluting fuel sources and the ability to burn these fuels under controlled conditions.

 

 

Ø      Ray closed the conference presentations for the day and adjourned the group to a Steering Committee Meeting.

 

 

Members present included Paul Prescott, Bob Benguard, Dave Swenson, Robin Styers, Tom Kronberer, Bob Fredricks, Lee Starkell, Ray Karcher, John Boyd, Dave Lopstead, Patrick Rogers and Bob Clark.

 

Items discussed:

 

·        Conference locations for 2009

·        What do our mailings look like, should we have a quarterly mailing, create a brochure to encourage new membership?

·        Set agenda early

·        Encourage younger member participation on Steering Committee

·        What does maintenance of Web Site cost the WRBA?

·        Update of Vendor Form include a listing of all vendors, Vendor display type either low table top middle or tall wall unit, this would help with staging in the Vendor Display area.

·        Most Vendors did not like downtown Portland due to cost and difficulty of transportation

·        How many Vendors

·        List all vendors on web site until following year to thank them for participation and support

·        Review bylaws do they need to be updated

·        Allowing Vendors on the Steering Committee

·        What are the responsibilities of a Committee Member?

·        Patrick Rogers Volunteered to be the first Vendor member of the Steering Commit

 

Ø      Ray adjourned Group for Dinner at the hotel and Nalco sponsored Texas Hold-em Tournament

 

Ø      The second day of the conference was opened by Ray Karcher at 8:00 AM

 

Presentation #5 Click the link to view the presentation

Tim Schonischon – Biomass Combustion Part Four

Schonischon Engineering

 

Biomass Combustion:  Overfire Air Systems for Wood Fired Boilers can be very beneficial in achieving complete combustion and control of emissions.  Some countries are  developing “Corn Stover” which consists of chopped up corn stalks as a biomass fuel, overfire air is important in this combustion process. An important key in making Overfire Air Systems work is to have as much overall coverage as possible.  One method used to achieve this is by offsetting the jets in an “Interlaced Arrangement”.  This will help in achieving as much overall coverage possible instead of having coverage in one area which can be the result when the “Stacking” method is used.  Jet characteristics, penetration, & deflection are as equally important as overall coverage.  In an overall combustion process you are trying to create a higher temperature.  By doing this you will generally have lower NOx.  Uniform coverage with fuel on the grates is very important in controlling Nox and CO emissions. If you have a bright spot in a fire you will typically find a higher temperature in that concentrated area. Lowering the air flow, temperature and achieving uniform fuel coverage can result in lower NOx output and a decreased amount of sticky ash which adheres to the heat transfer surfaces.  Firing with an oxygen rich mix can result in increasing CO and increasing difficulties achieving emission control levels and requirements. Having an efficient Overfire Air System in place will help achieve lower CO and NOx emissions.

 

 

Ø      Adjourned for a break and Vendor time while next presentation set up

 

 

Presentation #6 Click the link to view the presentation

Rich Abrams

Babcock Power

 

Advanced Emissions Control System for Biomass Boilers:   New England is the leader in the country for establishing new Bio Mass Boiler Emission Standards; they are utilizing a relatively new technology, Regenerative Selective Catalytic Oxidization.  Many States are moving to follow New England’s regulation standards for allowable NOx Emissions from new boilers. These emission level requirements are getting lower and lower every day.  Implementing a Regenerative Selective Catalytic Reduction system has many benefits.  Construction costs are minimal compared to the benefits received when comparing to other technologies when you look at cost per ton of reduction.  They are very reliable, potentially reduce energy consumption for operation, are accessible, and have bypass and online cleaning capabilities, as well as a high NOx removal efficiency. For best performance the unit is installed at the end of the exhaust stream to prevent contamination from other constituents is the exhaust stream. A 15 Mw power Plant would be looking at a 3-4 million dollar investment to install this technology. From time of order to installation along with a two day down time for tie in takes about six months. 

 

Ø      Break and Raffle, Gift Certificates won by Andy Anderson and Dean Hall

 

Presentation #7 Click the link to view the presentation

Nick Westerburg

Westerburg and Associates

 

Energy Conservation in the Boiler Room:  A new technology used to achieve energy efficiency in the boiler room is an energy audit. This tool will evaluate and assess areas of that have possibilities for changes or improvements to improve performance. Areas of your system that do not have insulation or wet insulation due to missing lagging are areas where corrections can be made to increase your efficiency.  Periodically inspecting your steam traps and maintaining a log for performance is another area where an audit could point out and provide improved performance.  Steam traps typically have a failure rate of 15-30 % in the first five years and an audit and record keeping will help you identify these areas of performance recovery. Monitoring these periodically and making repairs will help to maintain and may even increase your energy efficiency. Using vent condensers to recover energy in your boiler system can also aid in your energy conservation efforts.  With energy costs on the rise implementation of periodic inspections, completion of repairs and seeking areas that are in need of improvement can improve the overall efficiency of your plant.

 

Ø      Raffle: Home Depot Gift Certificate won by Lewis Eck

 

Presentation #8 click link to view the presentation

Patrick Rogers

NALCO

Condenser Waterside Efficiency & Water Treatment Best Practices:  Patrick gave a brief explanation of what a Condenser is and its importance in a properly operating system. Condenser tube walls are relatively thin in order to achieve highest performance and can develop leaks or lost performance after a short period of operation without an effective water treatment program.  This can lead to a 1% loss in back pressure or leaks.  A 1% loss in back pressure does not sound like much but that loss in terms of daily, monthly, and yearly loss can be significant.  The information you receive by using dip slides to measure for bacteria in your towers is usually available after only two (2) days.  While this is a relatively quick this should not be your only way of monitoring bacteria in your condenser tubes and towers.  You could have a biofilm in your condenser tubes not indicated by the dip slide test results.  The best representation to determine long term corrosion rates are usually found by testing for bacteria using corrosion coupons.  By maintaining your efficiency you can reduce scale, biological formations, and corrosion. Proper corrosion protection can extend equipment lifetime. When working with Condensers and Cooling Tower Systems being pro-active is the best operating scenario. Continuous monitoring is the best weapon to use in achieving maximum performance from you Condenser.

 

v     Patrick also announced the winners of the Nalco sponsored Texas Hold ‘Em Tournament

v     Winners were:

v     1st place: Rob Gorman $100.00 Sears Gift Certificate

v     2nd Place: Ryan Kershaw $50.00 Sears Gift Certificate

v     3rd place:                             Texas Hold-em Set

 

 

Ø      Adjourn for lunch and tour of Shasta Dam Power Plant

 

Ø      Return from tour and board busses for dinner and visit at Turtle Bay exploration Park

 

Ø      Breakfast 7:00 AM – 8:00 AM

 

Ø      Ray opens the Conference at 8:00 AM

 

Presentation #9 Click the link to view the presentation

Alan Werner

Werner and Associates

 

Boiler Room Virtual Energy Audit:  By investing the time to completely input the realities of your plant operation many benefits can be obtained. Areas that have been overlooked can be addressed and theoretical Data and Information can be projected to “see” areas of potential improvement before engaging in actual modifications of your plant. Implementing a computer “Energy Monitor” can be a good way to find areas that need improvement in running your plant more efficiently. An “Energy Monitor” computer program can track your information whether your plant uses steam or electricity.  Prior to making any actual changes you can make modifications to your plant via the computer to see if the modifications will help in your energy efficiency goal.  Maintaining an “Operator’s Log” is another positive step in an energy audit.  By taking steps to determine and improve your plants energy efficiency you will be able to determine your plant’s overall efficiency.  In order to achieve the best operating scenario energy in should equal energy out or conditions that closely approach that ideal condition. This tool is useful in optimizing operating efficiency, as a training tool, for documentation and record keeping, to provide ROI’s for planned modifications and as a method of further automating systems in your plant.


Presentation #10

Michael Brenner

Siemens Water Technologies

 

Detection, Trouble Shooting, & Removal of Common Boiler Water Impurities:  The ASME and the AMBA have strict guidelines on boiler water specifications and water steam purity.  Contaminants in your boiler feed water can lead to foaming in the boiler & caustic corrosion.  Technologies that remove impurities include, softening agents, split stream dealkalizers, demineralization, and reverse osmosis systems these represent only a few of the processes the desired end result.  Another highly effective method at removing ions and colloidal particles subject to fouling is by utilizing Membrane Systems.  Membrane Systems though require pretreatments. Resin based pre-treatments are highly effective in removing dissolved ions; they however, are not good filters for removing fine particulates.  Using a resin based system before using a membrane can prevent scaling build-up thus preserving quality, quantity, and efficiency.  By maintaining the membrane system it may last you three (3) years. You should start with the desired end results in mind, proceed with detection of impurities by water analysis and finish with the proper removal technology for your requirements.

 

Ø      Break and Raffle

Ø      Proctor Dixon Raffle – I-Pod won by Dean Hull

Ø      WRBA Raffle $25.00 Home Depot Gift Certificate won by Dale Scheirbeck

 

Presentation #11 Click the link to view the presentation

Barbara Hins Turner Centrallia Community Community College

Bob Clark Pan Global Training

 

Technology Training Update:  Every Plant Manager must ask him or herself Do I need training in my plant, what type of training is required and what method of delivery will best suit the needs of our facility. The correct and proper training program of your operators is critical in the safety, operation and performance of your plant. Inefficient operations of steam generation equipment can be attributed to increased downtime, increased plant operating costs, and corrosion, and repair costs as well as with increases in accidents and injuries to plant personnel.  There are three components to consider when selecting a training package. The first is the component required component development, and component delivery method.  With all the technological advances today training is the solution to improving the bottom line. There are opportunities in the classroom, via the internet and tremendous educational journals, books and technical papers.

 

 

Presentation #12

Bob Kappa

S.P.M. and Applied Industries

 

Predicting Electric Motor Bearing Failures:  Shock Pulse Monitoring. There are several types of maintenance programs used in our plants they include, Reactive repair after it breaks, Scheduled maintain on a schedule, Predictive calculate when will it fail and Pro-active why did it fail and what can we do to eliminate that failure. Preventing collateral damage caused by bearing failure is true cost avoidance.  Two (2) factors determine the life of a bearing, speed and load.  Increasing speed on the bearing will reduce the life of that bearing by ½.  Increasing the load on the bearing will reduce the life of the bearing 8-10 times.  There are generally two (2) options for maintenance of motor bearings, lube or change it.  Preventative or predictive maintenance is best done by monitoring the health of your equipment and make changes accordingly changing out a worn bearing if it appears worn can prolong the life of your equipment and insure a reduction in operating cost. Costs associated with the different types of maintenance are, run to failure ~ $31.00 per horsepower, Preventative ~ $20.00 per horsepower and the least expensive Predictive ~ $12.00 per horsepower. The Shock Pulse Monitoring Technology is a proven technology that can be used to reduce both operating costs due to unexpected breakdowns and schedule critical components for repair or replacement during scheduled maintenance downtimes. This technology can create a data file that can be used to make decisions as to equipment replacements or upgrades as well as supplement a CCMs maintenance protocol.

 

 

v  RAFFLES

·        SPM and Applied:  4” Grinder won by Randy Shaffer

·        Siemens: Siemens Shirt won Jerry Gregorsen

·        Industra: Fishing Pole won by Marshall Anderson

·        Avogadro: Two tickets to Pro Ball game of your Choice won by Jim Turner

 

v  WRBA Grand Prize Raffle  RFP Steam Team Hat and $500.00 Gift Certificate to Sports Authority won by Ron Vandenburg

 

·        Completion of General WRBA Business and Close of Conference

 

Ø      Adjourn for Lunch

 

 

Steering Committee Meeting

Discussions included

 

          Ray opened this meeting with the announcement of the suggested date and location of next year’s conference as well as the Chairman and Co-chair for next year. Spokane, Washington and Dave Swenson as Chair and Paul Prescott as Co-chair.

 

 

Summary of Steering Committee Meeting Discussions:

 

 

We are recruiting as always for new members willing to participate on the Steering Committee. As a member of the Steering committee you will have duties and tasks that will need to be completed in support of the association. The conference is dependent upon the completion of these tasks and support of the Chairman and Co-chairman is critical to ensure the life of this valuable organization.

 

·        Wellons comments on conference Vendor set up could be better managed, have extended breaks to afford more time with members, have a no host hourdeoveres and bar before dinner,

·        Add ability to pay for conference membership with credit card or pay pal or…..

·        Create a forum for active members to hold discussions on our web site

·        Officers for next year will be:

·        Chairman Dave Swenson

·        Co-Chairman Paul Prescott

·        Location will be Spokane with Eugene the second choice if there are problems with Spokane

·        The Vendor Form should have location for the abstracts of the Vendors who will be making presentations

·        Items to add to vendor form include a check box for vendors who are interested in setting up a hospitality suite with the hotel

·        Add to Vendor Form Events Manager at hotel if Vendors have specific requirements and wish to arrange with the hotel prior to the conference

·        The available facilities for Vendors such as projectors, Electrical Connections etc

·        Create a Steering Committee Member guidelines and responsibilities section in the bylaws

·        Creation of a WRBA business card and brochure

·        Further discussion of a vendor member of the steering committee

·        Need to revise the bylaws

·        After brochure is created ask supporting vendors to display at other shows

·        Mass email to vendors for participation on steering committee if so approved by Steering Committee

·        Need for a more accurate accounting and reporting of finances and WRBA monies

·        Ray to get Dave on the bank account and signatures set up for next year

·        Ray to have all bills paid by the Friday after the conference with all bills paid by end of business on 03-14-2008

·        John Boyd requested the expenditure of monies for supplies to support the conference such as our logo folders and other necessary office supplies. Approved by Steering committee.

·        Lisa Harvey-Boyd to continue as the Web Master for the organization.

·        2008 expenses include:

            Jackets $5,700.00

            Rooms $15,000.00

            Raffles $750-800.00

            Scholarship to Centralia Community College $2,000

·        Hire an accountant to provide a third party accounting of finances and accounts to give us an internal report

·        Bill Schatz of ESCO Corporation may be able to provide printing of business cards and tri-fold forms

 

 

All attendees and vendors agreed that this year’s conference was well organized and received by all. The direction we have taken for continued improvement and development of the conference should ensure that this organization continues to grow and prosper. We will continue to look for vendor input, new membership and active participants willing to take on the responsibilities of steering this organization to continued success in the future. The overall benefit of this organization to its members and the companies they are employed by is the reason for our ongoing improvement process.