riley power presentation

ONE SOURCE ONE PURPOSE MANY SOLUTIONS

© 2013 Information contained herein is proprietary and confidential to Babcock Power Inc.

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Riley Power Inc.

BPI Corporate Presentation

Republic of Korea

January 14-18, 2013


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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


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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


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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


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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


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Experience the Full Spectrum

Nuclear Power

Renewable Energy

Combined Cycle

Traditional Utilities


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Babcock Power Products


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Located Throughout the U.S.

TEi - Los Angeles

JoplinSapulpa Lyman

• Feedwater heaters

• Condensers

• HRSGs

• Pressure parts

• Weld Overlay

• Tube stock


• Machining center

• MSRs

BPS / BPE WorcesterVPI - Louisville

ONE SOURCE ONE PURPOSE MANY SOLUTIONS


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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


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• 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


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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


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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


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Fuel Equipment Design

• Combustion System Design

• Pulverizer System Design

• CFD Modeling

• Field Testing / Emissions Control

• Fuels Technology

Burner CFD

VS III™ Burner


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Pulverizer Engineering

• Pulverizer Process / System & Equipment Design

• Drying / size reduction / pulverization

• Pneumatic transport / two component flow

• Classification

• Mechanical design

• Materials for Erosion / Wear


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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


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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


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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


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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


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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


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650-1600 psi

650-955°F100,000 -500,000 Lbs/hr

Stoker Combustion

Biomass Boiler Industrial(wood, wood waste, bagasse, coffee grounds, etc.)

Experience


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650-750 psi

650-825 °F100-1000 Tons/day

• Stoker Combustion

Municipal Solid Waste (MSW) and

Refuse Derived Fuel (RDF)

Experience


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Temp

750-900°F

PressureSteam Flow

700-1500 psi100,000-500,000 Lbs/hr

Refinery

Gases,

CO Gas

Waste Gases (Industrial)

Experience


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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


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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


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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


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Plan View


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Front View

Rear View


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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


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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


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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


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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


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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


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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.


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• 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


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• 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


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• 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


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• 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


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• 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


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– 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


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• Boilers

• HRSGs

• Pollution control equipment

• Piping

• Condensers


• 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


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• 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


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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

riley power presentation

Documents

babcock power today

deutsche babcock

assets of babcock borsig

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babcock borsig files

power market market

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