|Project: GM Wentzville, MS - Coal to Natural Gas Conversion|
Client: General Motors
Scope: Lipten is converting two coal-fired boilers to fire natural gas at the GM Wentzville assembly facility in Missouri. Lipten has converted many boilers from coal to natural gas firing; several of them at GM facilities.
The project includes installation of new vertical-firing natural gas burners. Vertical burners were chosen instead of horizontal burners for this application to provide: optimum flame geometry for the specific furnace configuration, improved water circulation patterns, improved thermal efficiency, better overall boiler performance, avoidance of flame impingement and simplified operation. The project also includes new forced draft fans, natural gas supply systems, electrical modifications, custom Programmable Logic Controller (PLC) control systems from Lipten’s Controls Division and additional system modifications required to convert coal boilers to fire natural gas. This project will be completed by the end of 2013.
|Project: 63MW CHP - Indiana|
Client: Primary Energy
Scope: Lipten provided engineering, procurement and construction services for a 63MW cogeneration facility. At this facility, flue gas from a 38 MW Gas turbine is utilized in a Once Through Steam Generator (OTSG). The flue gas then goes thru a condensing economizer which recovers additional heat. The condensing economizer transfers heat from over 1 Million lbs/hr of flue gas to cold water.
This may be the first application in the world to utilize both a steam generator and condensing economizer on 38 MW GE Frame 6B Gas Turbine. The heat recovery from the OTSG and condensing economizer can offset more than 200,000 lbs/hr of steam generation from the traditional steam boilers. This means less fuel is used for steam generation, equating to significantly reduced operating costs and lower emissions. This project represents an excellent example of Lipten’s core focus of creating value for our customers and helping them deliver on their commitments to shareholders.
|Project: Natural Gas Pipeline Compression Facility – Oklahoma|
Client: Natural Gas Pipline Company
Scope: Lipten provided engineering, procurement and construction services for a project that involved the replacement of two Heat Recovery Steam Generators (HRSG) and two steam turbines. Other new equipment included: Two deaerators with feedwater systems, turbine gland steam condenser, turbine related control valves, turbine bypass desuperheater station, turbine seal steam desuperheater station, and HRSG blowdown systems. Building modifications were also included where required to remove the existing equipment and install the new equipment. The project included the furnishing and installing of structural steel, piping, piping systems and insulation.
This combined cycle facility consists of two units, each with a gas turbine, HRSG and a steam turbine to drive tandem natural gas compressors. Waste heat from the gas turbine is directed into the Heat Recovery Steam Generator (HRSG) where steam is produced to drive the steam turbine. The older existing HRSG’s are vertical flow forced circulation type steam generators. The older HRSG’s are currently producing approximately 22,500 lb/hr steam at 840 °F and 320 psig. The new system produces up to 30,200 lb/hr of high pressure steam from the same amount of waste gas. This will significantly increase the overall efficiency of the facility.
|Project: 70,000 lb/hr Steam Boiler and Condensing Heat Exchanger|
Client: Food Manufacturing Company – Nebraska
Scope: This project involves engineering and installation of a 70,000 lb/hr steam boiler and condensing heat exchanger. Lipten designed the custom controls associated with the boiler and heat recovery system.
The condensing heat exchanger utilizes the exhaust gas from the boiler to heat makeup water for delivery to the Deaerator, thus reducing the fuel (steam) requirements of the Deaerator (boiler) to bring the water up to saturation temperature.
A typical boiler flue gas heat exchanger (known as an economizer) would be designed such that heat transfer would maintain the flue gas temperature above ~300°F so that the water vapor in the flue gas does not condense and ruin the stack, heat exchanger and boiler. Since this system is specially designed with stainless steel components it can transfer more heat to the make up water from the flue gas, thus increasing overall central utility plant efficiency.
|Project: New Central Energy Plant, Chicago, IL|
Client: Food Manufacturing Company
Scope: This project involves a turn-key steam and chilled water Central Energy Plant (CEP) for a food manufacturing company in Chicago, Illinois. The project also involves the demolition of an abandoned five-story refinery building, tank farms and warehouse. The new facility’s premium control systems provides a high degree of monitoring capabilities and controllability. Safety, reliability and efficiency are important aspects of all Lipten central energy plant projects.
Lipten’s 3-D model of the Energy Center includes the building, support steel, equipment, piping and instruments. The 3-D model creates a virtual energy center that enables Lipten Engineers and the client to “step-inside” and view the Energy Center prior to construction. This allows design modifications to be made at the engineering phase rather than after construction resulting in a much more desirable outcome at less expense to the client.
|Project: Custom Central Energy Plant Controls – Madison WI|
Client: Food Manufacturing Company
Scope: Lipten provided three (3)COMBUSTIONPAC™ boiler control systems and a balance of plant MASTERPAC™ control system. At this location two boilers can meet full steam demand and the third boiler is ready for stand-by. The boilers can be remotely sequenced such that equal operating hours of all three boilers can be achieved throughout the year. Lipten's custom controls allow the three boilers to share two heat exchangers. Flue gas and process water is directed such that optimal heat transfer is achieved regardless of boiler sequencing.
Lipten’s scope included new control systems as well as startup and training of the plant operators on the Lipten control systems. A comprehensive plant Standard Operating Procedure (SOP) with photos, equipment tags and step-by-step instructions was also developed by Lipten.
|Project: Galena Park Mill|
Client: U.S. Gypsum - Galena Park, TX
Scope: Ultra low NOx steam generation system with ultra low NOx burner, forced draft combustion air fan, main and pilot gas valve train, PLC-based combustion control, burner management systems, all required field instrumentation, economizer, boiler stack and surrounding building.
|Project: Follansbee Coke Plant Powerhouse|
Client: Wheeling Pittsburgh Steel Corp. - Steubenville, OH
Scope: Two 73,000-pph superheated package boilers with dual fuel burners (coke oven gas and natural gas), 320,000-pph deaerator, two combustion air fans (one with electric/steam dual drives), two dual fuel valve trains and two Combustion Pac burner management systems.
|Project: Vacuum Arc Degasser Boiler Controls Upgrade|
Client: MacSteel - Jackson, MI
Scope: One new CombustionPac™ Full Metered-Cross Limited Boiler Control Package, new natural gas control valve, three element feedwater controls, combustion air fan, integrated oxygen trim system. Project included closely staged demolition, installation, startup and load testing; all within a seven (7) day shutdown period.
|Project: East Fishkill|
Client: International Business Machines - East Fishkill, NY
Scope: All demolition. New equipment for each boiler: low NOx dual fuel burner, forced draft combustion air fan, flue gas recirculation system, main and pilot gas valve train, PLC-based Combustion Control and Burner Management Systems, all required field instrumentation, stack gas oxygen analyzer and opacity monitoring equipment.
|Project: Edward H. McNamara Terminal|
Client: Metro Energy, LLC - Detroit, MI
Scope: Furnish new generators with low NOx dual fuel burner, forced draft combustion air fan, provisions for flue gas recirculation system, main and pilot gas valve train, fuel oil and atomizing air valve train, PLC-based Combustion Control and Burner Management Systems, field instrumentation and stack gas oxygen analyzer.