Gillian Chew

Reheat Attemperator

Reheat Attemperator Background Reheat Attemperators are used as a final control element of steam temperature into the IP section (sometimes LP section depending on plant design) of the Steam Turbine. The steam extracted from the HP section of the turbine is passed back through the boiler and reheater prior to entering the next stage of the turbine.  These attemperators spray water into the reheat line to control the steam temperature. Like superheat attemperators, reheat attemperators are subject to the changes made in controlling flue gas temperature in combustion. However, the reheat steam pressures exiting the HP are much less than superheat steam pressures entering them – meaning the pressure drop across reheat temperature control valves is much greater. This dynamic can create cavitating process conditions creating rapid and excessive trim wear in these valves.  Using REXA Linear and Rotary actuators in reheat temperature control applications increases cycling power plants’ efficiency allowing for minimal valve throttling capabilities, tight shutoff and maximum trim life. Learn more in the full Application Spotlight below!  Literature Download the Attemperator Spray Control Application Spotlight! Download

Reheat Attemperator Read More »

Inlet Guide Vanes

Background on Inlet Guide Vanes Inlet Guide Vanes (IGVs) deliver air to the inlet of a gas turbine’s axial compressor. While maintaining proper fuel-to-air ratio through various load ranges, they minimize the potential for unwanted emissions. In present-day Combined Cycle power plants, IGVs ultimately control the exhaust gas temperature – a critical input to the Heat Recovery Steam Generator (HRSG). Stable control of the exhaust gas temperature enhances the combined unit’s level of efficiency.  Many current day turbines use low NOx combustors that require a lean air-fuel mixture. As hot gas temperatures decrease, the formation of NOx also decreases. With a higher air mix, it’s critical to control the exact amount of air in the combustors – especially during low loads.  The REXA Solution REXA’s Electraulic™ Actuators provide responsive, repeatable control for IGV applications on all major manufacturers’ combustion turbines. Designed for continuous modulating service, the patented self-contained and closed-loop hydraulic circuit within our actuators provides stiff and stable control in the harshest environments. This system does not need any filters or oil-based maintenance.  A membrane keypad on the enclosure cover ensures simple set-up and calibration. Actuator performance is unmatched within the industry with adjustable dead-band to 0.05% of stroke, resolution of <0.1% and frequency response of 1.5 to 5.0 Hz. Literature Download our full Application Spotlight on Inlet Guide Vanes to learn more! Download

Inlet Guide Vanes Read More »

Superheat Attemperator

Superheat Attemperator Background Attemperators have been a key component of Combined Cycle Power Plants for many years. Back when these units were base-loaded, spray water control wasn’t an issue. In today’s world, however, plants are ramping up and down daily – consequently putting a strain on steam temperature control regulation. Controlling superheat temperature enables plants to maximize efficiency and improve heat rate.  Depending on their type and design, each plant uses multiple strategies across various systems to accurately control temperature. Almost all use superheat spray valves as the “final” control of steam temperature entering the turbine. Since plants need to cycle to lower loads more frequently, many now use feed-forward, cascade and adaptive-predictive control strategies which result in tighter control of superheat steam temperatures. With the wrong actuator operating the superheat spray valves, numerous issues can arise.  REXA Linear and Rotary actuators are key components in helping plants achieve their efficiency goals by maximizing performance through tighter resolution, stiff repeatable positioning and high duty cycle operation. Learn more in the full Application Spotlight below!  Literature Check out the full Application Spotlight to learn more!  Download

Superheat Attemperator Read More »

Turbine Bypass System Control

Turbine Bypass System Control What are Turbine Bypass Systems? Turbine bypass systems in Combined Cycle Power Plants (CCPPs) are utilized to ramp units online and offline, stably controlling Main Steam Pressure and Reheat Pressure in the Heat Recovery Steam Generator. In addition, these systems safely maintain vacuum at the condenser. CCPPs are cycled more frequently, therefore making turbine bypass systems utilized more often – further proving how critical they are to plant operations.  Potential Problems Improperly functioning turbine bypass system valves represent more than just an inconvenience to effective operation of CCPPs. They routinely contribute to unscheduled downtime and trip events. Every unscheduled trip event adds to equivalent plant starts, and greatly reduces the planned maintenance intervals as part of Long-Term Service Agreements (LTSAs), causing plants to spend millions of dollars before they should be required to do so.  Our Solution Through responsive and repeatable performance, our Electraulic™ Actuation enables CCPPs to optimize transitions and eliminate nuisance trips during ramp-up, ramp down and emergency response scenarios. Our actuators provide hydraulic control capable of steps to .05% resolution – completely eliminating the effects of stick-slip inherent of pneumatic actuators. We design our actuators for continuous modulating service and provide stiff, stable control even in the harshest environmental conditions (-40°F to +250°F).  Customer Testimonial “Performance issues with our pneumatically-operated turbine bypass valves were an ongoing problem at our plant for years. The previous actuators were not stiff enough in ramping/de-ramping and blending scenarios. The resulting valve hysteresis caused unstable operation, degradation to the valve trim and long transitioning periods. Upgrades to REXA actuation have reduced ramp times by as much as 20 minutes, leading to increased generation revenue, and has completely eliminated unwanted trip events. This was the best investment we have made at my plant in my tenure…”  Literature Download our Turbine Bypass System Optimization Application Spotlight! Download

Turbine Bypass System Control Read More »

Feedwater Regulator for Drum Boilers

Feedwater Regulator for Drum Boilers Keeping accurate and stable drum level control is vital to optimal plant operation, but there are many challenges that are inherent with this process. Innate to level control on a drum style boiler is a dynamic called “shrink and swell”, which is caused by the formation of vapor bubbles in the boiler evaporation tubes as steam demand changes. On increase of steam demand, the drum pressure decreases which, in turn, causes additional steam to be created through water evaporation, and causes expansion of the vapor bubbles below the surface of the water. This phenomenon causes the drum level to rise initially, instead of the drop that would be expected upon more steam leaving the drum (swell). Likewise, on a decrease of steam demand, the pressure in the drum increases and the drum level initially drops (shrink). In order to control drum level accurately, the effects of “shrink and swell” are typically compensated for in the control system with a cascade/feed-forward control strategy that utilizes steam flow and feedwater flow transmitters in conjunction with the drum level and drum pressure transmitter measurements.  Literature Download the Feedwater Regulators Application Spotlight! Download

Feedwater Regulator for Drum Boilers Read More »

Filter Flow Control

Filter Flow Control The filtration process removes suspended particles from water by passing the water through a medium. After a period of run-time, a filter needs to be “backwashed” to remove the captured particles from that run-period. Particle capture rate is important in ensuring filtered water contains no micro-organisms that could be harmful to people. Micro-organisms can be difficult to disinfect/remove from water, so operators measure the turbidity of water to gauge the capture rate of a filter. Ideally, an efficient filter runs the longest and captures the most particles (has the lowest turbidity).  In a traditional gravity fed filtration system, the most critical valve application is the effluent control valve (commonly a butterfly valve). This valve typically sits at the bottom of the filter where it controls the rate of water flow moving through the filter. Commonly, accurate modulating control of filter flows with this valve is imperative to maintaining a constant, stable flow in a filter. The more stable the flow, the greater the capture rate. Surges in flow can occur when flow rates are not stable, which can allow suspended matter to pass through the filter – effectively increasing the turbidity of the filter effluent.  REXA  Linear  and  Rotary  Actuators have a history of success in the water treatment industry with controlling filter effluent valves. Maintenance-free operation of these modulating valves over decade-long periods is common. More importantly, the position accuracy of REXA  Linear  and  Rotary  Actuators (dead-band as tight as 0.05) can modulate a filter effluent butterfly valve disc in very finite increments that eliminate hunting. Precise position accuracy will stable flows through a filter, allowing for more efficient particle capture and lower turbidity.  Literature Download the Filtration Filter Effluent Control Application Spotlight! Webinar Download

Filter Flow Control Read More »

Water Storage

Water Storage REXA has a history of providing solutions for water storage applications. Some of our customers have sought the modulating capabilities of REXA to accurately meter flows into and out of their water storage infrastructure. Others have required the reliability and fail-safe capabilities of REXA for applications used to protect the stored water during emergency conditions. In either case, REXA has the product and experience to help you

Water Storage Read More »

Ozone Control

Ozone Control Controlling a gaseous service via a butterfly valve with any degree of accuracy is 100% dependent on the positioning of that butterfly disc. On small valves sizes common in the ozone treatment process, the position accuracy is even further emphasized, and the slightest movement of a butterfly disc can result in significant flow changes. The positioning accuracy of REXA Linear and Rotary Actuators truly shines on this service, as the dead-band accuracy (as tight as 0.05%) can position butterfly valve discs in small enough increments to promote accurate flow control, improving the ozone treatment process efficiency.

Ozone Control Read More »

Raw Water Influent Flow Control

Raw Water Influent Flow Control Reliable control of  incoming flows is very important to starting the wastewater treatment process off on the right foot. Incoming flows are being modulated, any flow swings due to actuator hunting can cause upsets further along in the treatment processes. For this service, it is more important that the actuators are reliable, in order to avoid any possible disruption to the desired incoming flow rates. REXA has a history of offering both reliable and accurate flow control for this important service

Raw Water Influent Flow Control Read More »