Category Archives: News & Updates



Washington, PA – Greenbank Energy Solutions and Constellation Clearsight are excited to announce the latest break-through in inspection robotics – drone deployable non-destructive examination inspection services. Clearsight’s new drone performs thickness measurment using Ultrasonic Testing (UT), Electro Magnetic Acoustic Transducer (EMAT) and Dry-Film Thickness (DFT).

The industry-leading Clearsight drone reaches new heights with its effortless 360-degree flying abiility while maintaining any angle and inspecting components in any direction.

Please view this exciting video and witness this amazing offering for yourself.


Download our brochure:  Clearsight_Drone-Deployable-NDE-1.pdf

Download our technical data:  Clearsight_NDE-Technical-Sheet-2-1.pdf

Call today for more details and an appointment to speak to our inspection team.

Announcing a New Business Collaboration

A Joint Business Collaboration Between Exelon Clearsight LLC. and The Greenbank Group, Inc.

Far more than just drone services.

(Washington PA) October 1, 2021

The Greenbank Group through its operating companies (CBP Engineering Corp. and Greenbank Energy Solutions Inc.) will provide Sales assistance/advice/support and consulting to Clearsight LLC. for strategic planning, product/services development. The Greenbank Group will actively support Clearsight LLC. sales efforts in the Power Generation, Power Transmission and Distribution, Oil & Gas, Mining, Paper Mills, and Cement/Concrete markets by providing introductions and sales opportunities to key potential customers throughout the Americas.

The Clearsight LLC services that will be supported by the Greenbank Group. Inc. include unmanned aerial systems and robotics (drone) inspection services, and related technical services including concrete inspections, condenser inspections, submersible inspections, on-line/planning inspections, emergent system response investigation, transmission inspections, distribution inspections, storm restoration response, asset assessments, vegetation assessments and modeling, data analysis, 2D and 3D photogrammetry, LiDAR processing, 3D point cloud models, unmanned systems consulting and training, ingestion analysis and data storage.

“The Clearsight products and services offer safe and efficient inspection for an endless number of inspection applications and is a perfect fit for the Greenbank Group companies (CBP Engineering and Greenbank Energy Solutions) sales efforts. Our vast network of seasoned professionals are excited to and capable of bringing the Clearsight inspection technology to all markets. The need for this ROV inspection technology is obvious in this time for businesses that are focused on safety and improving cost efficiencies.” Said Sales Director of The Greenbank Group Inc. Mr. Donald Halulko.

Combustion Optimization – Achieving Operational Flexibility & Improving Load Turndown

Combustion Optimization – Achieving Operational Flexibility and Improving Load Turndown

by Steven McCaffrey, President

Greenbank Energy Solutions Inc.
Part of The Greenbank Group, Inc.
185 Plumpton Avenue
Washington, PA 15301-1948
Click this link to view and download the paper:

Presented at the Electric Power Research Institute “Flexible Operations Conference: Conventional and Combined Cycling Damage and Management”
Tulsa, OK
June 6-8, 2018


Acoustic steam leak detection for your Heat Recovery Steam Generator (HRSG)

The Greenbank LA 202 Acoustic Leak Detection System is the longest standing system of its type available. Since 1974 there have been over three-hundred systems installed worldwide.  The modular, expandable system has been designed to meet virtually every application requirement for performance and economy.

Research has proven that true acoustic measurement of sound level in a confined space is more accurate through a wider band width than indirect piezo measurement. However, to provide the ultimate system flexibility, Greenbank can provide either airborne or structure borne sensors as the application requires.

Damage to steam and water piping systems by corrosion, thermal-mechanical fatigue, or slagging have long affected conventional coal-fired boilers. HRSG designs can be affected by some of these issues as well, causing unscheduled outages and lost revenue.

A well-designed acoustic leak detection system enables operators to continually monitor and trend real-time performance of various systems in the unit and provide early detection of a potential problem. Strategically placed sensors enable operators to safely determine the location of a leak or malfunction and schedule required maintenance based on severity. The modularity of the LA202 system allows for additional points to be added at any time with minimal cost and effort.

Typical Applications:

  • Boiler Tubes
  • Superheater / Reheater
  • Main Headers
  • Waterwalls
  • Attemperators
  • Isolation Valves / Relief Valves
  • Pipeline Flow / No Flow

Download our brochure here.



Greenbank Energy Solutions Inc would like to introduce our new product line: HEP Dynamic Classifiers


Improved Fuel and Air Distribution

Today’s stringent environmental regulations, low NOx combustion systems and burners, as well as efficient operation of boilers, demand rigorous control pf the air/coal ratio to each burner from the classifier. The HEP Classifier has the ability to balance the air/coal ratio in each coal pipe served by a classifier, with externally adjustable guide vanes at the outlet to each coal pipe. These guide vanes are designed and positioned to either capture or divert the pulverized coal from entering the outlet. Field experience has demonstrated that individual coal pipes can be balanced with +-2-5% variation.

Improved Particle Size Distribution

The HEP Classifier provides burners with a finer, more evenly ground coal. More precise distribution of the coal particles avoids oversized particles that would otherwise pass, unburned, through the boiler furnace. Better particle distribution also allows the unit to operate at lower excess air levels and allows greater turndown without auxiliary fuel for stabilization. For proper NOx and combustion control, even distribution of the primary air and coal is essential and it is necessary to control the air/coal ratio to each burner.

Increased Boiler Turndown and Fuel Flexibility

Improved particle size distribution, together with more even coal distribution to the burners, produces a more stable flame, reducing the boiler load level where the support fuel must be started. Actual operating experience has shown this to be 10% or more below previous minimum operating levels.

Increased Mill Efficiency

Whether you need additional pulverizer capacity as the result of fuel switching or for a low NOx burner installation, the HEP Classifier can deliver.

Increased Combustion Efficiency

The HEP Classifiers ability to create a finer, more evenly ground coal for the burners, allows optimum combustion efficiency – that means better performance and less unburned carbon in the bottom and fly ash.

Faster Response to Boiler Load Demand

Rotor speed control is provided with a ramp time function that adjusts both the acceleration and de-acceleration of the rotor. This feature creates a temporary difference between the actual rotor speed and the speed demanded by the control system, allowing fast response to boiler load demands.

Installation of the HEP Dynamic Classifier

Custom designed for the specific coal pulverization and burner configurations, HEP Classifiers make retrofit installations easy and economical:

  • Low overall height makes conversion of existing mill easy.
  • HEP Classifiers come “pre-packaged” for quick flange connection to your existing coal pulverizers and coal burner distribution system.
  • Minimal time is required to “re-tune” the boiler and firing system.
  • Standard HEP Classifier configurations are available for all manufactures and types of coal pulverizers.

Download our brochure here.


GESI releases a new product…. On-Line solids MassFlo metering

The mass flow rate of PF in each feed pipe is known to be crucial parameters influencing the operation of pneumatic conveyors, combustion efficiency and atmospheric emissions of the plant. These parameters should ideally be measured and subsequently controlled to achieve fully balanced and optimal PF.

GESI’s new MassFlo – Online Flow Measurement System

GESI's new MassFlo - Online Flow Measurement System

Optimizing Fuel Flow in Pulverized Coal and Biomass-Fired Boilers

3-5 February 2016, San Diego, California

        Greenbank Energy Solutions, Inc in conjunction with IEA Clean Coal Centre presented the following program at this year's EUEC 2016 show in San Diego. Optimizing Fuel Flow in Pulverized Coal and Biomass Fired Boilers


Greenbank Energy's Steve McCaffrey, and IEA Clean Coal Centre's Malgorzata (Maggie) Wiatros-Motyka presented at this year’s Energy, Utility & Environment Conference (EUEC) conference at the San Diego Convention Center. Speaking on Optimizing Fuel Flow in Pulverized Coal and Biomass Fired Boilers.

EUEC is USA’s largest professional networking & educational event of its kind with 2,000 delegates, 400 speakers and 200 exhibits. EUEC facilitates information exchange and fosters cooperation between industry, government, and regulatory stake-holders for the protection of our environment and energy security.

LA 202 Acoustic Leak Detection System Turns 40 Years Old

LA 202 Acoustic Leak Detection Systems – Marks 40 years of success.images

Air Bourne Sensor

Air Borne Sensor

The Greenbank Energy Solutions LA 202 Acoustic Leak Detection System is the longest standing monitoring system of its type available in the world.

Since 1974, there have been over three-hundred systems installed worldwide. The modular, expandable system has been designed to meet virtually every application requirement for performance and economy.

Structure Borne Sensor

Structure Borne Sensor

This time tested and proven Greenbank Energy Solutions product provides detection of boiler tube leaks when they are not detectable by traditional methods. This allows management time to plan a repair strategy and schedule a controlled outage, for tube repairs at a time which is less expensive to the plant.

Operators will benefit from reduced downtime as a direct result of minimizing the degree of damage requiring repair. All of which contribute to greater plant availability, efficiency and reductions in operational costs.

LA 202 Product Features

LA 202 Product Details

LA 202 Leak Detection


The Case for Fuel Delivery System Upgrades on Utility Boilers

                            The Case for Fuel Delivery System Upgrades on Utility Boilers


ASME Research Committee on Energy, Environment and Waste
The Fuel Delivery System Upgrades for Utility Boilers Subcommittee

Subcommittee Authors:
Robert E. Sommerlad1, Donald B. Pearson2, Grant E. Grothen3, and Steven McCaffrey4

1 Consultant
2 The Babcock & Wilcox Company (Retired); Secretary, PRB Coal Users Group
3 Burns & McDonnell
4 Greenbank Energy Solutions, Inc.

Presented at:
Fuel Combustion Strategies 15th Annual
ROSEMONT, IL               MAY 14-16, 2013

Fuel Delivery Systems TRACK Plant Management & OperationCoalGen13
Coal-Gen 2013
CHARLOTTE, NC          AUGUST 14-16, 2013


The Case for Fuel Delivery System Upgrades on Utility Boilers – Presentation

The Case for Fuel Delivery System Upgrades on Utility Boilers – White Paper

Greenbank Energy Solutions Releases New Product Modification

Limestone VARB

Limestone VARBGreenbank Energy Solutions Inc, in partnership with the University of Nottingham and Greenbank Advanced Instrumentation & Measurement (GAIM) in the UK, have developed a suite of technologies for optimizing the distribution of coal and limestone to the burners at coal fired power stations, and limestone feed to the bed of CFB’s (Circulating Fluidized Bed).

The VARB is a non-intrusive passive device designed to break the material rope, equalize the split of the material at pipe junctions and homogenize material distribution across the pipe, with minimal pressure drop in the pipeline. It is used for a variety of material where metered distribution is required.

Click here to learn more – Greenbank Limestone Control System

The Greenbank Group, Inc. adds Technical Sales Coverage

The Greenbank Group, Inc. is pleased to announce the addition of Paul M. Lovich as Technical Salesman for their Boiler Optimization and Abrasion Resistant Products.

Paul has been selling  Boiler Control Upgrades, Flow Control, Steam Conditioning and Distribution, Boiler Chemistry and Boiler Damper Controls products since 1980.

He has an extensive background in valves and field instrumentation for industrial and utility applications

Over the past 30 years, Paul has represented companies such as Honeywell IAC, ABB Field Instruments, Metso Automation, Forney, Fireye, Tyco, Robinson Industries and ITT Engineered Valves.

Paul has generated sales of products and services to a wide range of markets and companies including Dominion Resources, Virginia Power, Reliant Energy, AEP, Allegheny Power, E.I. DuPont, Westvaco, Appleton Paper, Consol Energy, Siemens Air Pollution Control, Dan River Textiles, and Philip Morris.

Please contact Paul at

Latin American Sales Coverage

Pablo Espinoza is a Chilean National and Mechanical Engineer who joined The Greenbank Group recently.

Twenty years experience working with private mining, energy generators, manufacturing company’s and governmental institutions in Latin America, his career has been focused on implementing technically and economically feasible solutions to improve the efficiency of the processes though the application of better practices and technology innovation.

He has been a University lecturer of Mechanical Engineering and has been in charge of the National Cleaner Productions Center in Chile.

He is in charge of the Latin American market for the Greenbank Group in Washington, PA. He is fluent in English and Portuguese. Spanish is his mother tongue, He has a Master´s degree from the University of Delaware, USA and a Master’s from the Technical University Federico Santa Maria, Chile.

Please contact Pablo at