At a U.S. Power Plant, a customer was experiencing frequent bearing deterioration in their non-Bachmann louver dampers. The bearings required replacement twice in only a few years. The frustrated customer invited Bachmann to investigate and recommend a long term solution. Taking the customer’s unique application into consideration, it was determined the original OEM design was not especially suited for the intended usage causing the need for frequent repair and replacement of the supplied bearings. While heat was one of the suspected causes of premature failure, the Bachmann field service and support team, after extensive research, discovered that the repeated failures were most likely due to the inability of their graphite composition to hold up to the constant vibration and oscillation of the dampers. The conclusion was a custom designed ceramic coated bearing upgrade with split style for easy field installation. The retrofit upgrade was completed with much success at the end of 2017 and has proven to resolve the problems and frustrations for the customer. Bachmann’s customized approach wins again.
Bachmann Industries, Inc. was recently awarded two contracts from its South Korean customer for the Track 4A and Melaka projects located in Malaysia. The order is for the design and supply of five (5) HRSG Stack Dampers. This is a significant order for Bachmann Industries. With all five units requiring a gas path diameter of Ø9 meters, these will be the largest HRSG Stack Dampers Bachmann has supplied in its history.
Bachmann’s parts and service team is focused on extending operational life of GT Exhaust systems worldwide. The Bachmann aftermarket team recently completed supply and supervision of full drive system overhauls and replacement expansion joints on bypass systems behind GE 7FA turbines at two different North American sites.
A “penny wise, pound foolish” approach is costly in the long run
Coal-fired power plant duct systems are designed so that emissions control systems, such as precipitators, desulphurization systems, fans, and selective catalytic reduction systems can be inspected and maintained while the main process remains online. Essential to achieving this is the installation of effective, safe, reliable and easy-to-operate isolation equipment at the auxiliaries’ inlets and outlets.
The long-term effectiveness of isolation equipment – dampers — is a prime consideration for the end-user. The damper leakage rate is a critical focal point, both in terms of operating efficiency and personnel safety.
The degree of isolation required depends upon the damper’s primary function in a system. If the function does not require 100% isolation, then various types of dampers could be used to provide sealing efficiencies ranging from 99.00% to 99.99%.
Isolation of flue gas can be accomplished utilizing a guillotine, louver, or diverter/flap damper, and the different damper types provide different leak-proof capabilities.
Choosing the wrong type of damper for isolation can be problematic or even catastrophic. Even a small amount of leakage can have serious implications.
If the damper must isolate a portion of the system for occasional maintenance, the damper must provide 100% isolation in order to be considered “man-safe.”
Consider this: Although 99% sealing efficiency may seem like a very high value, a 1% leakage area in a typical duct could represent a hole large enough to get a person’s head and shoulders through. Just a 1% leakage area would actually allow leakage of 3-10% of the full load flow — the flow through the full-open damper at the Full Load rating of the device being isolated or controlled. (Under typical plant conditions, a damper is considered to have “low” leakage if leakage is less than 2% of its wide-open flow.)
Sealing performance is the key criterion in a specification for isolating equipment. A critical side effect of the concept of sealing efficiency is the assessment of the method by which a vendor achieves, and guarantees, 100% isolation. All dampers leak to some extent, and anyone who states otherwise is not being truthful.
For a damper to be considered a “zero-leak” device it requires an air-purge system. A clean air barrier is introduced between the tandem sealing elements at a pressure greater than the greatest differential on either side of the blade, preventing cross-blade leakage of untreated gas and simultaneously ventilating the isolated area.
All too often, a vendor will use a large volume of seal air to hide the shortcomings of the basic sealing system. Large seal air fans are sometimes fitted in duplicate. This, however, does not factor that the most probable reason for fan failure is a loss of power, whereupon, neither fan will run. Thus, the seals must be capable of providing, over an extended period, a high sealing efficiency without external assistance so that maintenance personnel can be sure of leaving an isolated section safely in the event of an emergency.
A heinous error when purchasing isolation equipment is to set aside the superior design of an experienced supplier on the grounds of capital cost alone.
Decades worth of evidence make it abundantly clear that well-functioning isolation equipment cannot be bought for “bargain basement” prices, and the long-term implications of buying inferior equipment is always far more expensive and riskier than buying the right equipment from the start.
Before any price comparisons are made, the evaluating engineer must be satisfied that the equipment meets the end user’s needs and can actually achieve the guarantees claimed. He should assess the claims made on the basis of the information provided and his, and other users’, experience.
To determine true operational value and safety, equipment evaluation must be on the basis of sound engineering principles, not just on initial cost.
New Ownership Paves Way for Growth
Returning to its roots as a value-oriented supplier of custom-engineered industrial process equipment, Clyde Bergemann Bachmann, Inc. has been acquired by private investors and will once again be known as Bachmann Industries, Inc.
Prior to the acquisition, the company comprised the air-gas handling division of the multinational Clyde Bergemann Power Group (CBPG). CBPG acquired Bachmann Industries, Inc. in 2009 and renamed it Clyde Bergemann Bachmann. The group recently decided to sell the non-core asset as part of a restructuring.
“The transition to new ownership will be seamless,” said Mike Sellinger, who has been with the company for over 20 years and will continue as its president. “Aside from a switch back to the Bachmann Industries name, customers won’t notice a change. We are principally an engineering firm and will continue to provide our quality solutions that define the well-known Bachmann legacy,” he said.
Bachmann’s history dates back to the 1970s when the original Bachmann company was founded by industrial pioneer Lothar Bachmann. Bachmann Industries evolved into a leading worldwide supplier of gas flow control equipment and services. “Our innovative designs for dampers; combustion exhaust and bypass systems; and large expansion joints really changed the way plants looked at processes,” said Sellinger. “Quality makes a big difference in the cost-effectiveness of operations.”
Sellinger said Bachmann’s new ownership will allow the company to be more agile and responsive in providing solutions that are tailored to customer requirements and specifications. This, he said, will be a springboard to help the business grow in key markets. As it has for decades, Bachmann will serve customers in the power and industrial sectors around the globe. The company’s equipment can be found in power, petrochemical, pulp and paper, and thermal process facilities on six continents. Bachmann offers both new and aftermarket products and services.
About Bachmann Industries, Inc.
Headquartered in Auburn, Maine, Bachmann Industries is a global supplier of dampers, expansion joints and exhaust systems for:
- Gas Turbine Exhaust Systems
- Air Pollution Control Systems
- Petrochemical and Industrial Process Systems
The company serves a wide range of industries, including:
- Power Utility
- Industrial Power
- Pulp & Paper
- Thermal Processing
Specializing in customized solutions, Bachmann Industries designs and engineers work in-house and outsources manufacturing through a strategic global network of qualified fabrication partners.