alstom parts for foster wheeler plants

Alstom Products and Services for Foster Wheeler Plants

With Alstom… You're in control!

PoWer

Alstom, a leader

2

At Alstom, we combine our capabilities and experience

to enhance the productivity and performance of your

boilers, pulverizers, feeders, air pollution control

systems, ash handling systems and auxiliary equipment.

Our focus is customer service and we understand the

challenges faced by plant owners, operators, maintenance

personnel and management. Whether it is a replacement

or upgraded part, a rebuilt assembly, a custom fabrication

or inventory management program, Alstom provides

exceptional value and service to our customers.

Alstom is a leader in the design, manufacturing and servicing of utility and industrial power generation systems. While our heritage dates to the late 1800s, our capabilities continue to expand and point us to the future. Alstom is ISO 9001:2008 registered.

Safety | We believe that safety is a key indicator of operational excellence for both Alstom and its customers. Our commitment to safety hinges on strong leadership, timely communication and the involvement of all employees. Our target is zero safety incidents.

experience | With an installed base of over 400 GW of power generation capacity spanning over 100 years, we believe you cannot find a partner whose experience in the power industry matches ours. We are dedicated to meeting your needs and exceeding your expectations. Our track record proves it.

innovation | Each and every day, Alstom applies leading edge technology to develop new products and services to meet your maintenance and operational challenges regardless of your boiler type or fuel. Your performance is our measure of success.

LogiSticS | The right products and services when and where you need them. That is our commitment. With a wide range of capabilities and options for replacement parts supply, technical services, and construction services, Alstom is your complete boiler services solution. We offer the industry’s most comprehensive and innovative replacement parts and service programs.

cuStomer Service | Alstom’s field service engineers, customer service representatives and construction managers have one goal – exceeding your service expectations. Our strategically located service and distribution centers enable us to provide fast response and reliable solutions to meet your needs.

SAFETY And ExPErIEncE

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contentS

Alstom Solutions for Foster Wheeler Plants .................................................................................5

MBF-type Pulverizers..........................................................................................................................7

coal Feeders .....................................................................................................................................21

Boiler Electronics...............................................................................................................................29

Burner Fabrications ...........................................................................................................................37

Pressure Parts ..................................................................................................................................43

Ash Systems .....................................................................................................................................47

The Alstom Advantage ......................................................................................................................49

contact Information ..........................................................................................................................55

WOrkInG WITh AlSTOM IS nOT lEAvInG ThE OEM, IT'S cOMInG TO OnE

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Introduction to...

TOdAY'S POWEr InduSTrY IS nOT ThE SAME AS IT WAS TEn YEArS AGO; WE hAd MOrE TIME. | We had more time to plan, to schedule, to inventory parts, to train new resources, to investigate best practices for maintenance and operations.

More tiMe to breathe!The daily demands on power producers in America today are unprecedented and constantly changing. In order to meet these challenges, you need a solid partner. You need a resource you can count on, one that knows power generation equipment.

Ten years ago this partner would have been your Original Equipment Manufacturer (OEM). Today, those credentials alone are not good enough. For you to be successful, your partner needs to be more than "the guy that has been around forever". In order to meet the demands on your plant, you need the people and resources of the world's largest power plant OEM. You need a partner that measures success by the speed and quality of parts and services provided to you. You need a partner that measures their success by yours.

you need alstoM!As one of the world's largest Engineering and Manufacturing OEM for the power generation industry, Alstom understands your needs and your equipment.

We have been providing our customers with Alstom parts and services for Foster Wheeler plants for many years.

The following information offers the potential to unleash this resource as a tool for your success.

let us show you how!

Alstom Solutions for Foster Wheeler Plants

Boilers | 3-27

Figure 3-19 | A Combined Circulation® tangentially firing, coal-fired reheat steam generator

ThE AlSTOM AdvAnTAGE

5

AlSTOM hAS ThE PEOPlE And ThE PrOducTS FOr YOur POWEr PlAnT SOluTIOnS. | We know your power plant maintenance and operational needs.

Pressure Parts

Superheater Panels

Superheater or reheater Panels

Furnace Side Wall

Furnace Front Wall

boiler electronics

Coal Feeders

Pulverized-Coal Piping to burners

Pulverizers

bottom ash system

Each section that follows provides an overview of some of the products and services available for your Foster Wheeler plant. In other words, if you generate steam to produce power or to support your manufacturing processes, Alstom is ready to provide the products and services you need.

For more information contact your local Alstom representative.

this catalog provides a glimpse into what we can do to help you operate with improved:• Safety

• Environmental compliance

• Equvalent Forced Outage rate (EFOr)

• Efficiency

working with alstoM is not leaving the oeM, it's CoMing to one

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notes

MbF-type Pulverizer

15MBF MIll PulvErIzErS

IntroductionThE MBF-TYPE PulvErIzEr IS FOSTEr WhEElEr'S lATEST dESIGn. | This roll and race style is the replacement for the previous MB-style design.

While the MBF was first released in the 1970’s there are a number of sites that have converted the MB to the MBF style for the capacity and maintenance improvements that come with the MBF. There are also a number of locations that have hybrid MBF/MPS and MB/hP designs.

The MBF-type pulverizer grinds the coal by crushing it between the rolls and the race as well as through attrition. The race is the segmented grinding ring, and the rolls are the three wheel-like assemblies that pivot from spring-loaded roller assemblies that provide the grinding force available to pulverize the coal.

The selection of the coal milling process type is based primarily on the size of the incoming coal and the desired size, quantity and distribution of the final product. The MBF-type pulverizer primarily utilizes a combination of the crushing and attrition processes where much of the grinding action is coal-on-coal.

size Capacity lbs/hr

MBF – 18 32,300MBF – 18.5 37,500MBF – 19 43,500MBF – 19.5 50,500MBF – 20 58,600MBF – 20.5 67,900MBF – 21 78,700MBF – 21.5 91,300MBF – 22 106,000MBF – 22.5 122,000MBF – 23 142,000MBF – 23.5 165,000MBF – 24 191,000MBF – 24.5 222,000MBF – 25 258,000

oFFerings:

repairs and rebuilds

MBF replacement Parts Inventory

Complete roller Assemblies

Advanced Static Classifiers

Inventory Management Program

Technical Services

Installation

7

MbF-type Pulverizer-replacement Parts

Pivot Bracket Assembly

16 MBF-TYPE PulvErIzErS8

17MBF-TYPE PulvErIzErS


Pivot Bracket Assembly

item item description alstom Part no. PIvOT BrAckET W/TAB PIvOT ShAFT TAPEr PIn TAPErEd SlEEvE EccEnTrIc ASSEMBlY FrEE End EccEnTrIc ASSEMBlY ThruST rInG SEAl ThruST rInG - rETAInInG cOAl ShIEld BrAckET cOAl ShIEld rOll AIr SEAl chAMBEr SPrInG PAd ASSEMBlY SPrInG PAd - ShIM SET WAShEr - PlAIn nuT- hEx Scr - cAP hEx SOc hd cAP hEx SOc hd lh Scr - cAP hEx hd WAShEr - hArd PlAIn BOlT hEAd PrOTEcTOr WAShEr - lOck rEG SPG nuT - hEx Scr - cAP hEx SOc hd Scr - cAP hEx hd WAShEr - PlAIn Scr - cAP hEx hd nuT - hEx Scr - cAP hEx hd lOcTITE MOlY PASTE

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150

GP-17265-A GP-17414 GP-17268 GP-17269 GP-17424 GP-17425 GP-17468 v00-7272 GP-17469 GP-17467 GP-16566 GP-17292 GP-17293 GP-17294 Md8-0021-Ac 11-2001 13-4274 v00-7278 Md8-00053-lh Md8-00058-Bu GP-12170 15-2007 11-2000 13-4174 Md8-00053-nk Md8-00218-BW Md8-00053-vk 11-2002 Md8-00094-kh v00-7280

9

roller Assembly

MbF-type Pulverizer-replacement PartsMbF-type Pulverizer-replacement Parts

roller Assembly

18 MBF-TYPE PulvErIzErS18

35

40

50

60

45

55

110

105

15

70

75

30

25

20

10

85

100/ 95

115/ 120

130/ 125

115/ 120

80 5

65

10


roller Assembly


item item description alstom Part no. Comments roller Assembly Shafthub for Tire rollerroller TireSeal Assembly Oil Seal O-ringroll Seal SleeveO-ring 14"Od x .25" cross vitoncylindrical Bearingroll Bearing Spacer - InnErroll Bearing Spacer - OuTErSpherical Bearingroll Bearing retainerO-ring 21.5"Od x .25" cross vitonBearing coverroller clamp ringPlug-Sq. hd Solid 1.25vent valveScr-SET hEx khl cuP .312" x 1.50"lScr-cAP hEx SOc hd 1.5-6 x 23"Scr-cAP hEx hd 1.5" x 5"llock Washer hi-collar 1.5"Plug-Sq. hd Solid 1.5Scr-SET hEx SOc FlT PT 1.13 x 1.25Scr-cAP hEx hd 1.5" x 4"lWasher Plain Type B 1.5"7/8" hEx hd cAP Scr - Magnetic Plug crush Washer

5101520

253035404550556065707580859095100105110115120125130

MBF-23-1514MBF-23-1512 / GP-17297GP-9471-BMBF-23-1540v00-6217v00-5577MBF-23-1546v00-6219MP-10658 / v00-7154MBF-23-1515MBF-23-1516GP-10738 / v00-7029MBF-23-1521v00-6220MBF-23-1513MBF-23-152512-60060352315Md8-00082-hkv00-5821Md8-00092-YPMd8-00017-Ac12-6007v00-5822Md8-00053-4871Md8-00218-dAMBF-8004099MBF-8000181

2 req. per assembly

2 req. per assembly

6 req. per assembly3 req. per assembly3 req. per assembly3 req. per assembly3 req. per assembly14 req. per assembly14 req. per assembly3 req. per assembly3 req. per assembly


roller Assembly

11

Asset Planning

MbF-type PulverizerMbF-type Pulverizer

Asset Planning

20 MBF-TYPE PulvErIzErS

Asset Planner

intent: To assist clients with identifying areas for improving operation and reducing mill maintenance and mobilization costs.

Purpose: Provides the client with a method of identifying specific maintenance or wear areas within the mill. Once identified, Alstom can offer assistance in providing upgraded materials or products to extend wear life in those areas.

how used: Use this worksheet as an outage planning tool and to document wear and areas for improvement. The worksheet can be used by the client during mill outage inspections to document specific problems or wear areas.

With the assistance of an Alstom Technical Services Engineer, adverse conditions in operation or adjustments in the mill can be addressed. If the results require an upgrade, products can be offered to improve those areas.

10. Pivot bracket

2. Center feed pipe

11. Plunger shims

3. Classifier drum

12. Coal shield

4. Classifier blade and linkage

13. grinding table segments

5. Classifier cone

14. air ports

6. Classifier reject housing

15. scrapers

7. grinding section housing liners

16. air seal

8. spring mechanism

17. Coal reject chute doors

9. roller

18. speed reducer

1. burner shut-off damper

1812


Asset Planning

MbF-type PulverizerMbF-type Pulverizer

Asset Planning


Asset Planning

MbF-type Pulverizer

18. speed reducer


Asset Planning

MbF-type Pulverizer

18. speed reducer

R081507

Parts Description As Found Life Cycle Years Suggested Upgrade

ASSET PLANNING AND LIFE CYCLE WORKSHEETMPS89 Pulverizer

Burner Shut-off DamperCenter Feed PipeClassifier DrumClassifier Blade and LinkageClassifier ConeClassifier Reject HousingGriding Section Housing LinersSpring MechanismRollersPivot BracketPlunger ShimsCoal ShieldGrinding Table SegmentsAirportsScrapersAir SealCoal Reject Chute DoorsSpeed ReducerPressure SpringSpring FrameFlexible Seal Air Supply PipeTop HousingSwing Valve

123456789

10111213141516 17181920212223

Fuel Delivery System Asset Planning and Life Cycle Worksheet

Pulverizer Overhaul Frequency

MAINTENANCE

PERFORMANCE

Type (Wear Parts,major, gearbox,....) Current Goal

Pulverizer Fineness% Retained on 50 Mesh

% Through 200 Mesh

CurrentDesign Goal< 1%

CurrentDesign Goal70%

Pulverizer Coal FlowTonnage or lbs/hr

CurrentDesignSize1188975

210,000 LB/HR 124,000 LB/HR80,000 LB/HR

Goal

CurrentDesignAnalysis% VM% FC% Ash

% Sulfur% Moist

% Carbon% H2% O2HHV

Grindability

GoalFuel Specifications

1 2 3 4 51 2

4

5

3

9

1011

17

15

6

8

12

13

14

22

21

19

20

23

18

16

7


Asset Planning

MbF-type Pulverizer

18. speed reducer

R081507

Parts Description As Found Life Cycle Years Suggested Upgrade

ASSET PLANNING AND LIFE CYCLE WORKSHEETMPS89 Pulverizer

Burner Shut-off DamperCenter Feed PipeClassifier DrumClassifier Blade and LinkageClassifier ConeClassifier Reject HousingGriding Section Housing LinersSpring MechanismRollersPivot BracketPlunger ShimsCoal ShieldGrinding Table SegmentsAirportsScrapersAir SealCoal Reject Chute DoorsSpeed ReducerPressure SpringSpring FrameFlexible Seal Air Supply PipeTop HousingSwing Valve

123456789

10111213141516 17181920212223

Fuel Delivery System Asset Planning and Life Cycle Worksheet

Pulverizer Overhaul Frequency

MAINTENANCE

PERFORMANCE

Type (Wear Parts,major, gearbox,....) Current Goal

Pulverizer Fineness% Retained on 50 Mesh

% Through 200 Mesh

CurrentDesign Goal< 1%

CurrentDesign Goal70%

Pulverizer Coal FlowTonnage or lbs/hr

CurrentDesignSize1188975

210,000 LB/HR 124,000 LB/HR80,000 LB/HR

Goal

CurrentDesignAnalysis% VM% FC% Ash

% Sulfur% Moist

% Carbon% H2% O2HHV

Grindability

GoalFuel Specifications

1 2 3 4 51 2

4

5

3

9

1011

17

15

6

8

12

13

14

22

21

19

20

23

18

16

7

22.5 122,000 lb/hr142,000 lb/hr

165,000 lb/hr

23

23.5

Asset Planner Asset Planner

13

crOWn Plus™ Wear resistant Material

MbF-type Pulverizer — upgradesMbF-type Pulverizer — Materials


Cast steelcast steel components can be repaired much more reliably than cast iron. Alstom offers many of the key MBF components as a cast Steel part.• roller hub• Pivot Bracket

CeraMiCCeramic lining and vacuum bonded linersThe use of ceramic lining is best for high erosion, low impact locations. Alstom offers the most comprehensive wear solutions for all wear issues.

• Vacuum Bonded TilesThin dynawear II™ ceramic tiles are bonded directly to the component. This is especially useful where space or component size doesn’t allow thick tile. This arrangement is impact resistant, but limited to moderate temperatures.

— 1/4” vacuum bonded tiles— Simple or complex geometry— Many standard offerings available

• Brazed Tungsten Carbidevery high wear resistance and excellent impact resistance. More expensive than the ceramic options and used in specialized locations.

• Plug Welded Tile This is most common ceramic application. used in cones, wall liners and turrets.

roLLer HUB PIVoT BrACKeT

1414


crOWn Plus™ Wear resistant Material

MbF-type Pulverizer — upgradesMbF-type Pulverizer — Materials

laboratory test results

Field test results

crOWn PluS IS An AlSTOM-PrOPrIETArY MATErIAl ThAT hAS dEMOnSTrATEd ExTEndEd WEAr lIFE WhEn cOMPArEd TO currEnT WhITE IrOn PrOducTS. | crOWn Plus wear resistant material for upper millside liners has been proved to offer the best performance-to-cost ratio and the best value.

Although Alstom has solutions that extend roller life, extending time between overhauls is limited by abrasion in the upper millside area. ductility is also an issue because these liners are near the grinding zone. during development, Alstom tested its new crOWn Plus upper millside liners against crOWn 700™ liners at three host sites that were burning high silica or PRB coals, both of which display significant wear rates. The host sites using CROWN 700 liners had a service life of less than 12 months with the high silica coal, and less than 14 months with PrB coal. The abrasiveness of the coal wore completely through the 3/4” thick crOWn 700 liner, while the crOWn Plus material exhibited only 1/8” to 1/4” wear at approximately the same run time.

The charts below demonstrate that, in both laboratory and host test sites, crOWn Plus upper millside liners have a longer wear life than other castings.

beneFits:• Longer wear life

• Extended time between overhauls

• Best wear available for a casting

good –––Crown 700better –high Chromebest ––––Crown Plus

host Fuel traditional traditional Crown Plus Crown Plus site alloy Component life Predicted life Performance Factor

A PrB crOWn 700 18 months 51 months 2.8 x B PrB crOWn 700 18 months 33 months 1.8 x c high Silica crOWn 700 12 months 84 months 7.0 x & high chrome

alloy abrasion wt. loss Cavitation wt. loss expected life Compared to Crown 700crOWn 700 36.6 10.3 1.0 xhigh chrome 25.7 2.4 1.4 xcrOWn Plus 6.4 2.4 5.7 x

Weight loss in milligrams

1515


MbF-type Pulverizer — upgrades

Advanced Static Classifier (ASC)

AlSTOM hAS APPlIEd Our SuccESSFul cE/AlSTOM dESIGnS TO IMPrOvE ThE PErFOrMAncE OF ThE MBF MIll. | The inverted cone in the classifier eliminates the discharge doors, which can become stuck open. This results in an increase of coal passing thru the 50 mesh screen.

Curved blades reduce turbulence and aid coal distribution in the classifier drum.

Improvements can be maximized if the ASc is paired with Alstom's rotating air ports.

eliminates design issues with oeM internal linkage • no more binding

• reduced blade misalignment

• No interruption of coal/air entering classifier

• No more classifier linkage wear

Externally Adjustable • Accurate adjustments can be made during operation

standard Fw blades (optional) • high chrome blades also offered

16

MbF-type Pulverizer — upgrades


air seal upgrade• reduces dust leakage around mill bottom — 8 segments instead of 2 — upper air seal has new dust guard — Increased seal count• Easy maintenance — drill template included — designed to clamp onto table — holes are slotted to aid adjustment

Advanced Static Classifier (ASC)

triple lip seal BEArInGS OFTEn FAIl duE TO OIl cOnTAMInATIOn. | The Triple lip Seal upgrade reduces contamination. Two seals keep the dirt out, while one seal keeps oil in. • reduces downtime due to roller assembly failures• No permanent modification to roller assembly necessaryTriple Lip Seal

Air Seal Upgrade

weld overlay on high Chrome rollers AlSTOM APPlIES A WEld OvErlAY On hIGh chrOME rOllErS FOr InSTAllATIOnS SuBjEcT TO ExTrEMElY SEvErE WEAr. | The overlay, which contains a high proportion of chromium carbides, is applied using an automated open arc welding process. The result is an overlay formed with a tough erosion-resistant matrix.

17

MbF-type Pulverizer


Coal shield • long wear — Bolt head protectors — Multiple wear material options

Plunger shiM• Easier maintenance — replaceable & adjustable

bronze eCCentriC bearing• Easier maintenance and adjustment — does not freeze in place — Self-lubricated with graphite

upgrades

Plunger Shims

coal Shield

Eccentric Bearing

18


MbF-type Pulverizer — rebuilds

roller Assembly rebuildsupgrades

Alstom offers high quality MBF-type roller rebuilds and new roller assemblies.

based on inspection, additional services can include:

• replace all worn out parts

• repair components as needed

• rebuild to strict procedures and tolerances

• Include upgrades upon customer request

• Pressure test

Gearbox rebuildsThE MBF-TYPE GEArBOx IS A WEll-dESIGnEd And BuIlT MAchInE. IT cAn PrOvIdE lOnG, rElIABlE SErvIcE WhEn PrOPErlY ASSEMBlEd And MAInTAInEd. | After 20 years or more of service, a rebuild or replacement may be needed to maintain reliability. Alstom can rebuild a gearbox and return it in as-new condition.

based on inspection, additional services can include:

• replacement of parts such as gears, bearings, shafts, seals

• rebuild to as-new conditions

• rental agreements

• Purchase options

19


notes

Weld overlay process.

20

Coal Feeders

7STOck cOAl FEEdErS

AS ThE AlTErnATIvE OEM FOr STOck® FEEdEr PArTS | the Alstom/Merrick team is well positioned to support your need to improve performance, availability and reliability.

Any of the parts described in the following pages can be supplied individually, as part of a kit, or included in an Inventory Management Program (IMP).

replacement Parts and upgrades

iMProving PerForManCe, availability and reliability oF Coal Feeders

21

8 cOAl FEEdErS

Coal Feeders — replacement Parts

Alstom Products for STOck coal Feeders

replacement parts for most model stoCk feeders:• Fast delivery

• Competitive pricing

• Outage kits/Inventory programs

22

9STOck cOAl FEEdErS

Coal Feeders — upgrades

Main drive upgrade

ThE MAIn drIvE uPGrAdE | is an economical replacement for the outdated eddy current clutch/torque limiter clutch and motor system and the leaky gearbox. It improves the reliability and performance of the feeder, as well as corrects an inherent “designed-in” oil leak problem that can pose a safety risk. This system was designed to be integrated, allowing you to keep the majority of your existing spare parts inventory. The variable Frequency drive (vFd) allows for increases in capacity at no additional cost by a simple programming change.

the Main driveupgrade Components:• Direct drive Sumitomo

reducer with adapter

• A/C inverter duty motor

• Variable Frequency Drive (VFD) for control of motor speed

• Speed encoder advantages:• Eliminates inherent oil

leaks

• More accurate control with easy adjustment

• Minimizes changes

• Maximizes use of existing parts

The main drive upgrade eliminates oil leaks while providing an accurate linear signal which can be easily reprogrammed to

accommodate changes in capacity.

Photo showing signs of chronic oil leak problems with the main drive system. beneFits:

• Reduces maintenance costs

• Lowers cost of operation

• Improves safety (no oil leaks)

• Improves parts availability

• Facilitates wider fuel use

• Improves reliability

• Reprogrammable at no cost

• Low conversion cost

23

10 cOAl FEEdErS


cleanout drive upgrade

ThE clEAnOuT drIvE uPGrAdE IncludES An ElEcTrOnIc ShEAr PIn rElAY WITh OuTPuT cOnTAcT. | The electronic shear pin is easily calibrated for the motor current overload. The instant that a current overload condition occurs the shear pin will trip, which will stop the drag chain drive motor. It will also close the auxiliary contact, which can be connected to the boiler control system to let the operator know that the drag chain has stopped due to an overload. The shear pin can be easily reset by pushing the reset button, once the condition has been cleared. The existing system typically does not provide this type of electronic failure indication.

new Alstom upgrade.Electronic shear pin or shock relay offers excellent protection against feeder overload.

Cleanout drive upgrade Components• Direct drive Sumitomo

reducer with adapter

• A/C constant speed motor

• Electronic shear pin relay

dirty Installation: Shows signs of leaking which is not only a maintenance problem, but a safety hazard.

Cleanout drive Feature / Function advantages benefits to user

constant speed motor replaces cleanout drive – either lh or rh

Eliminates inherent oil leak • Reduces maintenance costs• Lowers cost of operation• Improves safety• Improves parts availability

Interfaces with all existing internal components

Minimizes changes • Keeps maintenance costs low• Low conversion cost• Adaptable to existing equipment

Includes electronic shear pin relay

Better protection from overload than torque-limiting clutch

• Lower maintenance costs• Improves availability

24

11STOck cOAl FEEdErS


GEnETIx® Touch Screen controller

ThE GEnETIx TOuch ScrEEn cOnTrOllEr IS ThE WOrld’S FIrST TOuch ScrEEn PrOcESS cOnTrOllEr SPEcIFIcAllY dESIGnEd FOr WEIGhInG APPlIcATIOnS. | It replaces most conventional gravimetric relay control systems and will ensure that the coal feeding process is consistently accurate, reliable and repeatable.

The GENETIX Process Controller can be configured for virtually all feeding requirements including:

• Gravimetric control for feeder systems

• Static weighing and belt scale integrators

• continuous or batching belt feeders

Feature / Function advantages benefits to user

user friendly interface – On screen help – Built in simulator – Function key

validation

• Easy to learn • Easy to use

• Lower cost for training• Reduction in programming errors• Lower cost of operation• Improves reliability• Easy to use

Integrated electronics package

• Reduction of failure- prone components

• Elimination of relays

• Reduces maintenance• Improves reliability• Improves accuracy

Sensor monitor and graphic trending

• Well organized

• More detailed information available

• Improves availability• Reduces maintenance costs

data highway capable

• Simpler interface to plant control system with standard protocols

• Lower cost installation• Low cost integration in any boiler control

system or dcS

critical component redundancy

• Better fault tolerance

• Less down time

25

12 cOAl FEEdErS


Weigh Suspension System upgrade for Belt Feeders

Our WEIGh SuSPEnSIOn SYSTEM uPGrAdE WITh lOAd cEll And AdjuSTABlE IdlEr BrAckET, | which is used in conjunction with a Merrick or STOck microprocessor, provides an accurate, calibrated fuel delivery measurement to the boiler. The adjustable idler bracket uses the existing weigh roller that can be removed easily without the use of tools.

advantages:• Electronic load cell replaces

mechanical system

• Improves accuracy for a more repeatable signal

• Simple design

• Microprocessor adjusts the speed of the belt based on load of material

beneFits:• Reduces maintenance costs

• Improves efficiency with tighter control

• Improves reliability

siMPle way toiMProve reliability

Weigh Suspension System

26

13STOck cOAl FEEdErS


roller Belt Support Assembly

ThE rOllEr BElT SuPPOrT ASSEMBlY IS An AlSTOM uPGrAdE TO ThE SlIdEr-BEd BElT SuPPOrT On SElEcTEd STOck cOAl FEEdErS. | The roller system is designed for less friction and resulting wear of the feeder belt.

no physical or hardware changes are required to install the roller belt support assembly.

advantages:• Eliminates wear to the coal

feeder belt

• Less horsepower required to move the feeder belt

• Enables faster calibration of coal feeder

• Rollers can be replaced without disassembly of the tail end of the coal feeder and removal of the belt

beneFits:• Improves reliability

• Reduces operational cost

• Improves availability

years oF trouble Free serviCe

roller Belt Support Assembly

27

14 STOck cOAl FEEdErS

notes

cOAl FEEdErS28

notes

boiler electronics

29BOIlEr ElEcTrOnIcS

Pipe IgnitersThE EvEr-kOOl™ OIl PIPE IGnITEr IS An AlTErnATIvE TO rETrAcTABlE OIl Gun dESIGnS. | A constant supply of strategically located cooling air allows the oil firing equipment to stay in firing position even when not in use. Only the spark tip inserts during operation and subsequently retracts from the flame to keep it cool. The igniter has a smaller footprint and is always in firing position.

beneFits:• Consistently demonstrates

over 95% reliability

• Improved combustion airflow

• Lower pressure drop

• Easy installation and maintenance

• Offers clean and reliable operation with minimal opacity during start ups

• Easy retrofit with existing igniter system hardware

• New bluff body design provides improved flame stability

• High Energy Igniter (HEI)

ThE lIMElIGhT GAS BluFF BOdY PIPE IGnITEr IS An uPGrAdE | to conventional 3” eddy plate gas pipe igniters and provides increased availability. This high heat output igniter is useful in a wide range of applications. It offers a clean and efficient method for boiler warm-up and flame stabilization periods.

stable FlaMe/wide range

Capacity from 0.5 – 18.0 MMbtu/hr

lIMElIGhT™ Gas Bluff Body Pipe Igniters

control cabinets

30 BOIlEr ElEcTrOnIcS

lIMElIGhT™ Igniter valve Train Assemblies

boiler electronics

Gas valve Train

Oil valve Train

Features:• Oil train includes air pressure

regulator, oil flow controller and single actuator automatic trip valve for both oil and atomizing air

• Valve, actuator, and limit switch enclosure designed as a unit

• Gas train includes double block and vent valve arrangement and globe valve for gas flow regulation

• Designed for a wide range of heat input capacities

• Compatible with our LIMELIGHT igniter control cabinet

• Fuel/air strainer and filter option available

SAFETY ShuTOFF vAlvES ArE PrOvIdEd In cOnvEnIEnT PrE-ASSEMBlEd PAckAGES And ArE IdEAl FOr hAndlInG OIl And GAS FIrInG EquIPMEnT. | Alstom provides fail-safe valves as they close with loss of electrical power (deenergize- to-trip) or instrument air. Energize-to-trip valves can be provided if preferred.

beneFits:• In-kind replacement for

old or obsolete equipment

• Easy maintenance

• Easy installation

• Code compliance


control cabinets

boiler electronics

ThE lIMElIGhT IGnITEr cOnTrOl cABInET IS An IGnITIOn SuPErvISIOn And SAFETY SYSTEM dESIGnEd FOr cOnSISTEnT OPErATIOn. | It can be used for oil, gas and dual fuel igniters in utility, Pulp and Paper and Industrial environments.

Flexible by design, the lIMElIGhT Igniter control cabinet can be custom built or supplied in a standard configuration.

Alstom offers its control cabinet as a stand-alone product or packaged with an upgraded Alstom valve train. A control cabinet is available for virtually all valve trains, including:

• Tandem oil/air valve isolation for oil igniters

• double block and vent isolation for gas igniters

The lIMElIGhT Igniter control cabinet is designed to provide self-diagnostics and troubleshooting capabilities.

A window kit allows the displays of the LIMELIGHT flame monitor to be visible at a glance.

beneFits:• Safely and reliably controls

igniter operation

• Meets NFPA and CGA codes

• Self diagnostics and troubleshooting

• Suitable for interface with existing burner management systems

• Consistent operation

• Reduces start-up period

Features:• Standard NEMA 4 or 4X in

a 16”W x 20”H x 6”D sized enclosure

• Simple connection to new or existing burner management system

• Functionality can be hardwired relays or PLC based

• “First-out” igniter trip alarms available

• Incorporates latest design LIMELIGHT Diagnostic Flame Indicator (DFI)

lIMElIGhT™ Igniter valve Train Assemblies

lIMElIGhT™ coal Flow Monitor


lIMElIGhT™ Flame Scanners

boiler electronics

FlAME ScAnnErS cOnFIrM ThAT FuEl EnTErInG ThE FurnAcE IS IGnITInG. | unignited fuel entering the furnace could cause an explosion. An essential element of a boiler’s safety system, flame scanners must be both rugged and reliable while providing consistent and accurate flame safety information.

The LIMELIGHT Flame Spectrometer is an advanced flame detector with enhanced diagnostic capability.

Our new lIMElIGhT Flame Spectrometer incorporates the speed and precision of digital signal processing as well as full detection of infrared, visible and uv light in seven bands, making it the most flexible flame scanner available and most suitable for burner optimization.

inCreased saFety

beneFits:• Superior flame detection,

reduced nuisance trips and increased sensitivity for low load operation

• Reduced cost of installation - compatible with previously installed flame scanners, cable and guidepipes

• Reduces CapEx


the liMelight exacta Flame scanner is a simple replacement for several generations of older scanners.

The lIMElIGhT Exacta Flame Scanner continues that legacy while incorporating the latest in digital signal processing and communication capability. depending on the fuel being fired, it can be provided with flame detection technology that employs any one of the following:

• uv – ultraviolet

• vl – visible light

• Br – Broad range, Infra red and visible light

.

Features:• Temperature rating is

165º F (75º C)

• Can discriminate between different fuels

• Provides flame quality analysis

Features:• Temperature rating is

185º F (85º C)

• Can discriminate between different fuels

• 4 contact and 2 analog outputs per channel


lIMElIGhT™ coal Flow Monitor

boiler electronics

lIMElIGhT coal Flow Monitor Sensor head and electronics enclosure

Application: Used to monitor flow exiting the feeder ThE lIMElIGhT cOAl FlOW MOnITOr IS A hIGh quAlITY, InduSTrIAl GrAdE InSTruMEnT | capable of providing a signal indicating flow of coal in gravity chutes and feeders.

The Alstom instrument is a non-contact detector. It has no moving parts or probes that can degrade or break off in the coal flow.

The lIMElIGhT coal Flow Monitor utilizes a low power microwave beam to sense motion within the chute or channel. The microwave technology is unaffected by heat, humidity, ambient noise or light, pressure, vacuum, high or low temperatures, or dust; thus providing maximum reliability.

advantages:• Improves sensitivity

and more reliable coal detection

• Senses small and large particles of varying densities

• Eliminates the sound rod

• Self-calibrating

beneFits:• Improves reliability


• Quicker start-ups

• Reduces installation time by 50%

reliable solution to Coal FlowMonitoring For Feeder outlet

lIMElIGhT™ Flame Scanners


boiler electronics

EvEr-kOOl™ Oil Gun and Spray Tips

AlSTOM’S nOn-rETrAcTInG EvEr-kOOl OIl Gun ElIMInATES rETrAcT MEchAnISMS And ThEIr ASSOcIATEd hArdWArE And MAInTEnAncE. | The EVER-KOOL air-cooled design allows the oil gun to remain inserted in the firing position when not in use without damage. This high performance oil gun meets all current safety and code requirements and is an excellent alternative to traditional retractable systems.

internal Mix tips• For parallel pipe or concentric style oil guns• Improves atomization for problem fuels• Accommodates a wide range of steam quality

external Mix tips• For parallel pipe or concentric style oil guns• Reduces steam/air consumption• No pressure differential regulator required• No tip resizing required when changing atomization

medium or fuel

Features:• Ready for immediate service

• No moving parts – retract mechanism not required

beneFits:• Reduced coking of any

remaining oil after purging

• Reduced maintenance

• Improved light-off reliability

• Safer than retractable oil guns

• Reduced opacity

aPPliCations:• Utility, industrial, pulp and

paper boilers

EvEr-kOOl Oil Gun Flame – 30 MMBtu/hr and up

no Moving Parts reduCed MaintenanCe


boiler electronics

ThE BOIlEr dATA AdvISOr cAn PrEdIcT | equipment failures and detect excursions from normal plant operating conditions hours or even days before a conventional distributed control System (dcS) can trigger alerts. The Boiler data Advisor provides the deepest insight into plant performance, quickly and accurately locating the source of impending failures.

The BdA provides engineers, plant operators and maintenance personnel the time to take preventive action, avoiding costly downtime, equipment damage, or reduced efficiency.

beneFits:• Increased profitability–

early fault detection leads to increased availability, reduction of forced outages, and mitigation of collateral damage

• Higher performance–patented methods provide the earliest warning about operational abnormalities

• Fewer unplanned outages–facilitates better preventive maintenance decisions

the boiler data advisor is a condition monitor that helps power plants reach higher levels of availability and predictive maintenance as well as better performance.

Boiler data Advisor (BdA)EvEr-kOOl™ Oil Gun and Spray Tips


notes

boiler Fabrications

37BurnEr FABrIcATIOnS

Boiler Access and Observation doors

oval Hinged Access Door Specialty Access Doors: cuSTOMIzEd WITh OBSErvATIOn & lAncInG POrTS

Features:• Door liner refractory

suitable for high temperature applications

• Built-in grab bar for entering and exiting

• Standard sizes and shapes that fit most applications

• Custom designs for specialized applications

• 1” x 1” gasket

• Tube opening configured to provide additional cooling

• Can include Pressure Parts for turnkey solutions

beneFits:• Improved reliability

and combustion cycle efficiency with less air leakage

• Corrosion resistant

• Improved safety

SAFE And SEcurE. | All Alstom boiler access doors are designed and fabricated to prevent accidental latching and unlatching. The positive seal and gas-tight design eliminates leakage and ensures optimal thermal performance as well as personnel safety. Prior to shipping, all Alstom boiler access doors are fully assembled and tested in the shop in the vertical upright position to ensure the door opens smoothly and freely.

discharge valves

QUICKCHANGE™ Orifice Assembly

38 BurnEr FABrIcATIOnS

boiler Fabrications — replacement Parts

Fuel delivery System

coal Piping

ThE FuEl dElIvErY SYSTEM BETWEEn ThE PulvErIzEr And ThE BurnErS IS An ArEA SuBjEcT TO ExTrEME WEAr. | This is particularly true of elbows and orifice assemblies. The fuel delivery system includes:

• coal pipe

• discharge valve

• Orifice

Alstom offers coal pipe, hangers and orifice assemblies designed for long life in this difficult environment. Alstom’s design takes into account the newest nFPA code requirements with components designed to protect your equipment and, more importantly, your people. nFPA code says, in part, “Brittle materials having a plastic elongation of less than eight percent (8%) prior to tensile rupture shall not be used for piping except as abrasion-resistant lining.”

types of Fuel Piping• Original Installation — cast ductile iron — ni-hard (reference Alstom SIl 2004-01) — carbon steel, induction bent

• replacement types — cast ductile iron — carbon steel, induction bent — ceramic lined • Mechanically interlocked (DYNAWEAR™) • Vacuum bonded (DYNAWEAR II™)

Excessive wear problems in coal piping can be mitigated through the use of high-wear liner materials such as dYnAWEAr or dYnAWEAr II Wear resistant Products .

This ni-hard elbow was doused with cold water while on fire. Dangerous pipe blow-outs, like this one, can be avoided by using proper pipe and liner materials, and by following approved safety protocols.

dYnAWEAr II vacuum-Bonded ceramic Tiles installed in the outer radius of the elbow provides protection to the highest wear area of the pipe. note that the non high-wear areas inside the pipe do not need to be lined.

dYnAWEAr ceramic-lined Elbow showing angled deflector block installed at highest wear point in outer radius.

Deflector block


boiler Fabrications — replacement Parts

discharge valves

QUICKCHANGE™ Orifice Assembly

dISchArGE vAlvES ArE uSEd TO ISOlATE ThE PulvErIzEr FrOM ThE FurnAcE. | Older power plant fuel delivery systems may not have discharge valves in place. however, due to safety concerns, they are now a required part of the design per nFPA code.

discharge valves, when properly installed, provide a level of safety and allow mill maintenance to be performed without major disruptions to furnace operations.

ThE unIquE dESIGn OF ThE quIckchAnGE™ OrIFIcE ASSEMBlY SAvES TIME ASSOcIATEd WITh rEPlAcInG cOAl PIPE OrIFIcES WhIlE AllOWInG ThE uSE OF OrIFIcES MAdE OF WEAr-rESISTAnT MATErIAlS. | The QUICKCHANGE Orifice simplifies the replacement by accommodating orifices of varying inside diameters and materials. It consists of a drawer-style housing which, when unbolted, can be pulled out with the boiler on-line (but with the pulverizer out of service and the associated barrier valves closed at the windbox) for fast, easy access and replacement.

* The nFPA code requires the use of two valves per burner line — a barrier or dust tight valve at the pulverizer end, and a dust tight valve at the furnace end. discharge valves must be fitted as close to the pulverizer and furnace portals as possible.

beneFits:• Pull-out design reduces

orifice replacement time

• Visual inspection made easier

• Can accommodate orifices made of various wear-resistant materials

• Fast, easy orifice replacement with boiler on-line and pulverizer out of service

Fuel delivery System

coal Piping

Burners — new and rebuilt


coal delivery System rebuilds

boiler Fabrications — rebuilds

BurnEr SlIdE GATE rEBuIldS. | Alstom offers the parts and services to rebuild existing Burner Slide Gate Assemblies.

A great candidate for rebuild rotation Programs, Alstom can rebuild a set of Burner Slide Gates and store them at one of our regional service centers to support planned outages or emergency requirements. Alstom offers this service in an effort to provide a cost savings to the customer versus the purchase of a new component.

rebuild scope Basic Services

• receive

• disassemble

• Evaluate condition

• replace worn components as necessary

• Add or replace wear materials

• reassemble

• Paint & ship

Before After

beneFits:• Approximately 50% cost of

new assembly

• Short lead times

• Upgraded materials available

• New equipment warranty


Burners — new and rebuilt

boiler Fabrications — new and rebuilt

coal delivery System rebuilds

nEW And rEBuIld SErvIcES ArE AvAIlABlE FOr FOSTEr WhEElEr BurnErS And AlSTOM'S rSFc™ BurnErS AS A cOST EFFEcTIvE AlTErnATIvE TO PurchASInG A nEW cOMPOnEnT. | Simply crate and ship the worn burner to one of Alstom's rebuild facilities and we will inspect and replace all worn and damaged components and restore all welds to strict specifications. In addition, Alstom provides rebuild services for all OEMs' burners.

When complete, Alstom will return the rebuilt burner to you in the same shipping crate to minimize the possibility of damage during shipment.

rebuild scope Basic Services

• Ship in an enclosed container to minimize further damage

• replace missing tiles

• replace stainless shroud

• replace distorted pipes

• replace adjusting bars

• replace worn blades

• repair all welds

• Paint

• Ship back to customer in original shipping container

good — repair and overlay only the worn areas that were designated as being "minimal" based on uT results

better — build up and overlay the typical high-wear areas

best — build up and overlay the entire internal surface

beneFits:• Burners are rebuilt to strict

specifications

• Up to a 60% savings vs. the cost of a new burner

• Fast turn around

• Extensive inventory support

RSFC = Radially Stratified Flame Core

best repair option

better repair option

good repair option

alstom repair options


notes

Pressure Parts

43PrESSurE PArTS

capabilitiesbeneFits:• reduced mean time to

repair

• Increased unit availability

• Increased unit reliability

• Improved profitability

AlSTOM hAS OvEr 100 YEArS OF BOIlEr PrESSurE PArTS ExPErIEncE. | We offer the products, logistics, quality and technological expertise to help keep your boiler up and running. As a leader in coal-fired utility, marine and industrial power plants, we are dedicated to helping our customers keep the down-time costs to a minimum while maximizing their profits. We have the capacity and capability to back up our commitment, and we have a proud history of achievement and innovation.

Boilers | 3-27

Figure 3-19 | A Combined Circulation® tangentially firing, coal-fired reheat steam generator

Boiler Electronics

coal Feeders

Pulverized-coal Piping to Burners

Pulverizers

Bottom Ash System

Pressure Parts

superheater Panels

superheater or reheater Panels

Furnace side wall

Furnace Front wall

44 PrESSurE PArTS

AmStar 888® Thermal Spray cladding

Pressure Parts—Coatings

AMSTAr 888 ThErMAl SPrAY clAddInG PrOvIdES dEPEndABlE And PrEdIcTABlE WATErWAll PrOTEcTIOn In BOIlErS WhErE hIGh TEMPErATurE GASEOuS cOrrOSIOn And/Or ErOSIOn MAY Occur. | AmStar 888 cladding is applied using a patented alloy exclusive to Alstom. AmStar 888 has been engineered by Alstom’s Thermal Spray division to produce mechanical and metallurgical properties that result in lower residual stress incurred during the application process, allowing thickness levels from 5 mils to >100 mills, where appropriate. It also eliminates cracking and spalling.

In addition, AmStar 888 will not fail at the substrate level, allowing Alstom to refurbish the cladding with virtually 100% success where mechanical damage has occurred. Its erosion and corrosion properties protect against multiple metal loss mechanisms.

AmStar 888 Thermal Spray cladding can be applied at your site or in one of Alstom’s regional Service centers. See your Alstom representative for application details.

Features:• Will not delaminate, crack

or spall

• Thicknesses from 5 mills to > 100 mills

• Defect-free substrate coverage

• Designed for maintainability

beneFits:• Significantly reduces

Equivalent Forced Outage Rate (EFOR)

• Dependable and predictable tube protection

• Quality applications regardless of scope

• Engineered solution - recommendations are made based on specific problem

aPPliCations:• Pulverized coal boilers

• Circulating fluidized bed boilers (CFBs)

• Waste to energy boilers

• Black liquor recovery boilers

45PrESSurE PArTS

Pressure Parts — locations

2 Mega centers

roCky Mountain serviCe Center (rMsC) – denver, Colorado• Modern 100,000 square foot facility designed for efficiency

and material handling ease

• Fully operational and staffed 7 days a week

• on-site engineering and design graphics personnel

• emergency service on such pressure parts: — Panels — loose bent tubes — dMWs — Steam/fluid-cooled spacers — Industrial superheaters — Finned tubes

• Quality employees = Quality products — qualified welders — Benders with exceptional fabrication experience — Extensive layout knowledge

• state-of-the-art pressure parts facility — hot and cold bending — rotoblaster — Finning — Annealing furnace — Paneling — On-hand inventory — Assembly

TO IMPrOvE Our SErvIcE TO Our cuSTOMErS | and to build capacity for the future, we have invested in infrastructure improvements at two key locations.

tubing distribution Center (tdC) – Chattanooga, tennessee• 100,000 square foot indoor tubing facility

• 24/7 emergency availability

• Beveling and cut-to-length

• rotoblasting, stenciling, printing and rust inhibitors

• Electronic MTrs

chattanooga, Tn (Tdc)

rocky Mountain, cO (rMSc)

AmStar 888® Thermal Spray cladding

46 PrESSurE PArTS

Pressure Parts

Full Service Provider

AlSTOM IS A lEAdInG TEchnIcAl SErvIcES SuPPlIEr. | Our industry leading technical service teams offer a wide range of services to our pressure parts customers. From assisting customer maintenance and operations personnel to detailed condition assessments, our technical service teams provide the widest range of services in the industry.

cOndITIOn ASSESSMEnTS. | The full capabilities of Alstom’s Technical Services, Materials Technology center and Power Plant laboratories are brought to bear to determine root causes of tube failures. But we go further than simple metallurgical reports; Alstom develops detailed solutions and recommendations to prevent future emergencies, and to improve future plant availability.

AlSTOM OuTAGE PlAnnInG. | A well-planned outage is critical to optimizing your maintenance time and budget. An experienced Alstom representative, supported by our extensive technical resources, will work with you to review your outage needs and schedule. After this review, we can fabricate the components, stock them and then deliver them on time.

BOIlEr In A BOx. | The Alstom Outage kit is a prepackaged collection of tubing, parts and components that have been identified as being potentially necessary during an outage. Each kit has a “map” detailing the location of each part; everything is centralized and easy to find, including essential paperwork like mill certifications. Parts are pulled from the box as needed, saving time and money. You pay only for what you use.

NoN-ALSToM BrANDS | WE SErvIcE ThEM Allother oem capabiLitieSAlstom has the tubing and expertise to address boiler issues for Foster Wheeler boiler designs.

Alstom maintains an ever expanding inventory of tubing sizes and specifications and wants to work with you to evaluate your tube list and determine what is critical to your operating needs.

oFFerings:• Fabrication of key pressure

parts components

• Loose tubes – straight or fabricated

• Waterwall and burner panels

• Assemblies and circuitry for superheaters, reheaters and economizers

• Tube shields, attachments and hardware

• Weld and laser overlay and thermal/abrasion coatings for increased wear protection

• Complete boiler tubing replacements

• Convenient, one-vendor, complete service

ash systems

47ASh SYSTEMS

Integrated Bottom Ash SolutionsPlant integration

AlSTOM’S SuBMErGEd ScrAPEr cOnvEYOr (SSc) BOTTOM ASh SOluTIOn GrEATlY rEducES MAInTEnAncE cOSTS | common to conventional ash handling systems. A well-engineered SSc replaces existing systems with a cost effective and less risky bottom ash solution.

An SSc reduces environmental risks of ash ponds and the costs of permitting, maintaining and dredging those ponds. An SSc integrated into other bottom ash systems reduces water usage by reusing most of the bottom ash supply water. Power consumption is reduced by minimizing the number of motors needed to power multiple high, medium and low pressure pumps used in traditional sluicing and dewatering systems. In addition, taking pyrites and economizer ash directly into the SSc reduces the maintenance costs associated with hoppers, piping, dewatering, and storing ash.

advantages:• No high maintenance

boiler sluice jet systems

• No dewatering tanks

• No boiler to pond piping systems

• Reduced environmental risk by eliminating the need for ash ponds

• Reduced parasitic power consumption

• Reduced water use

ThE PYrITES SYSTEM | can be sluiced directly into the SSc while at the same time using the SSc’s water bath as a source for the sluicing water. This eliminates once-through water use and the pyrites dewatering tanks.

EcOnOMIzEr ASh | can be transported to the SSc on dry drag con-veyors for removal along with the boiler bottom ash and pyrites.

A clOSEd lOOP WATEr cOOlInG And rEcIrculATInG SYSTEM | is an option where water consumption must be minimized. With minimum makeup water required, the SSc water can be cooled and recirculated requiring a minimum amount of water across the entire ash removal process.

Full Service Provider

48 ASh SYSTEMS

ash systems

Wet Bottom Ash Solutions

WET BOTTOM ASh SYSTEMS, ESPEcIAllY ThEIr MAInTEnAncE, ArE An O&M hEAdAchE. | Alstom has a suite of solutions to improve the reliability and safety of your Wet Bottom Ash removal system.

gate Frames,renewable seats,gate liners

10" and 12" Cylinders andCylinder extensions

gate enclosures

4" lancing door

Clinker grinders Jet Pumps

bottom ash gates24" X 24" and 30" X 30"

Wet Bottom Ash Solutions the alstom advantage

49ThE AlSTOM AdvAnTAGE

Service capabilities

EquIPMEnT SuPPOrTEdIn addition to servicing Alstom equipment, we also provide aftermarket service for the following brands:

cOAl FEEdErS | ABB, combustion Engineering, Stock Equipment, Merrick Industries

cOAl PulvErIzErS | ABB, combustion Engineering, Babcock & Wilcox, riley, Foster Wheeler

STEAM GEnErATOrS | ABB, combustion Engineering, Babcock & Wilcox, riley, and Foster Wheeler

STOkErS | ABB, combustion Engineering, detroit Stoker, riley, Westinghouse, hoffman, Taylor

FIrInG SYSTEMS | ABB, Icl, nEI, clark chapman, cSl, rv Industries, Foster Wheeler, B&W, combustion Engineering

ASh hAndlInG SYSTEMS | ABB, combustion Engineering, Allen-Sherman-hoff, united conveyor, Fläkt

AIr POlluTIOn cOnTrOl | ABB, combustion Engineering, Fläkt, Walther, carborundum, hamon-research cottrell, Wheelabrator, Peabody, rockwell

OvEr 100 YEArS OF ExPErIEncE + SOluTIOn BASEd PrOducTS & SErvIcES + cOMMITMEnT TO cuSTOMEr SErvIcE = ThE AlSTOM AdvAnTAGE. | Alstom provides reliable delivery of products and services to meet the demands of the power industry. We are a dedicated customer service organization that delivers the responsiveness our customers require.

Alstom provides the quality and resources of an OEM while backing our products with comprehensive support. Our products are designed to help our customers meet the performance, availability and reliability requirements for their power plant equipment.

Markets served Our experience and customer base include:

• utility companies

• regional electric cooperatives

• Federal, municipal power producers

• Independent power producers

• Pulp and paper companies

• Industrials such as chemical plants, steel mills and refineries

In other words, if you generate steam to produce power or to support your manufacturing processes, Alstom is ready to provide the products and services you need.

the alstom advantage

50 ThE AlSTOM AdvAnTAGE

Service capabilities

WE ArE A GlOBAl PrOvIdEr OF PrOducTS And SErvIcES TO ThE POWEr InduSTrY. | We maintain a local presence to help ensure that our customers’ equipment and systems run reliably and efficiently with the availability they demand.

FIEld TEchnIcAl SErvIcE EnGInEErS | Alstom has extensive capabilities in the form of Field Technical Service Engineers to assist with your outage inspection and operation and maintenance needs.

Our field service engineers are located near our customers to provide the response they need. This full-time force of professionally trained engineers and technicians receive constant training to help ensure they are knowledgeable in the latest trends and available technology.

OuTAGE PlAnnInG | Effective outages require effective planning, a continuous process that begins well in advance of the scheduled event. Alstom stands ready to participate in this process to help ensure timely decisions, problem avoidance and achieved goals.

the services alstom provides include:

• Setting overall outage objectives

• Work scope determination

• Prioritization of outage tasks

• Identification of material and parts needs

• Expediting delivery of required material and parts

InSPEcTIOn SErvIcE | To help ensure an effective outage, we offer our inspection service that includes:

• Pre-outage logistics and work scope definition

• Pre-outage unit walk-downs

• Detailed inspections during the outage

• Daily punch lists and definition of items requiring immediate attention

• Coordination with repair labor personnel

• Initial report with critical findings and recommendations

• Final detailed inspection report complete with photos, recommendations and findings

• On-line retrieval of our final report for convenient viewing and downloading

alstom’s technical services capabilities cover major plant equipment and systems and include:• Outage planning

• Inspection services

• condition assessments

• Maintenance support

• Performance testing

• Training programs

• dedicated engineers

alstom’s technical services include:• A team of over 100

field-based service engineers, ndE specialists, performance test engineers and technicians

• Problem solvers

• Equipment inspectors, testers, and evaluators

• Performance specialists




Technical Services

cOndITIOn ASSESSMEnT | Alstom delivers the technology to manage risks through the integration of Advanced NDE and inspection technology, including:

• Ultrasonic examination

• Linear phased array

• Dye penetrant testing

• Remote field eddy current

• Wet fluorescent magnetic particle testing

• Boroscope with internal video

• Visual examinations as well as service capabilities through:

– Power Plant Laboratory facilities

– Material Technology Center

– Field service engineers

MAInTEnAncE SuPPOrT SErvIcE | To help ensure your equipment performs to your expectations, we offer our Maintenance Support Service whereby we:

• Determine equipment condition and need for repairs

• Compare components to original specifications and help make adjustments

• Participate in developing work scope and associated tasks

• Direct maintenance personnel in proper disassembly and assembly procedures

• Coordinate execution of the work scope

• Develop a daily punch list prioritizing work tasks

• Provide a final report documenting work performed and recommendations

dEdIcATEd EnGInEEr PrOGrAM | We provide an experienced Alstom Technical Services Engineer for exclusive use for a specific time period.

The Dedicated Engineer becomes an on-site member of the plant team, spearheading the Alstom support. The result is responsive service in determining root causes of problems and timely development and implementation of solutions to help reach and exceed station goals.

TrAInInG PrOGrAMS | Alstom's training programs provide power plant professionals with the knowledge and skills they need to operate and maintain the equipment and systems. Alstom's portfolio includes:

• Standard and customized training

• HOT TOPIC training programs

• Computer-based QUICKSTUDY™ Learning System

• Regional training seminars

PErFOrMAncE TESTInG And EvAluATIOnS | The performance evaluation and testing team supports data gathering and analysis to help optimize plant performance. Offerings include:

• Specialized testing of thermal, fluid and chemical processes (emissions and circulation)

• Boiler and power plant performance evaluation

• Water chemistry consultation for boilers

• Instrumentation supply and rentals of most commonly used boiler and emissions test equipment

teChniCal serviCes tailored For you and your budget



Inventory Management Programs

strategiCally loCatedto serve our CustoMers

denver, cO*

Tyler, Tx*

chattanooga, Tn*

Erlanger, kY*

harrisburg, PA

*

Suwanee, GA*

AlSTOM’S SErvIcE cEnTEr nETWOrk, STrATEGIcAllY lOcATEd AcrOSS ThE cOunTrY, | provides emergency component repairs, parts, complete component overhauls, custom fabrications and cost-saving inventory management programs to meet our customers’ needs.

Rocky Mountain SeRvice centeR – DenveR, coloRaDo

MiDweSt SeRvice centeR – eRlangeR, kentucky

advantages:• After-hours response team

• Guaranteed parts availability

• Eliminates exposure to obsolete inventory

• Applicable to most plant equipment

• Programs can be expanded to include other plants within the customer’s system

• One week standard shipment after receipt of order

• Minimizes exposure to raw materials price fluctuations

beneFits:• reduces carrying costs

• defers cash outlay

• Increases cash flow by delivering products when needed

• Simplifies purchasing

WITh Our PrOvEn InvEnTOrY MAnAGEMEnT ExPErTISE | purchasing strength and strategically located regional service centers, participation in an Alstom Inventory Management Program can offer customers significant benefits – from guaranteed shipments to improved cash flow.

iMProves Cash Flow and guaranteesParts availability




Outage kits

a Cost-eFFeCtive way to Manage Planned and unPlanned unit outage rePairs

OuTAGE kITS | are pre-packaged supplies of equipment-specific replacement parts that support planned or unexpected unit outages and rebuilds. Emergencies cost money! Outage Kits can help minimize costly delays in making repairs.

Outage Kits are the perfect solution when emergencies strike, or to have available as part of a planned preventative maintenance cycle or Inventory Management Program.

advantages:• custom or standard

kits

• reduces maintenance costs

• convenient and organized

• Simplifies purchasing

beneFits:• right parts available

when you need them

• Only pay for the parts that are used

• Instant part availability

• Save time and money

The customer and Alstom develop a list of parts to be included in each kit. Each kit includes a detailed chart of the location of each part.

Alstom then ships these parts to the customer in a pre-packaged kit form two weeks prior to the planned outage or rebuild.

customer withdraws parts from the kit, as needed.

unused items are shipped back to Alstom for re-stocking.

The customer then issues a purchase order to Alstom for any parts consumed.

how alstoM’s outage kit PrograM works:



APcomPowerA World of Experience – right next door

PlAnT uPGrAdES/MAjOr MOdIFIcATIOnS• Fuel conversions • Combined cycle operations• Balanced draft conversions • Emission control systems

cOMPOnEnT InSTAllATIOn, rEPAIr And rEPlAcEMEnT, BAlAncE OF PlAnT• Fuel firing systems • Pressure vessels• Pulverizers • HRSGs• Air heaters • Fans• Ash handling systems • Steam and gas turbines• Condensers • Fabricated steel, ducts, silos and hoppers• Burners • Insulation and lagging• Stokers • Refractory• Wet/Dry precipitators • Instrumentation and controls• Wet/Dry scrubbers • Stacks• Fabric filters • Foundations• SCRs • Pressure Parts• Piping

Proven expertise in the latest technologies:As a wholly-owned subsidiary of a global leader in power generation equipment, APcomPower has in-depth experience in:

• Coal, gas and oil-fired utility plants

• Industrial plants (including pulp and paper mills, petrochemical systems and municipal power operations)

• Steam and gas turbines

• hrSGs

• Fluidized bed boilers

• Emission control systems (all types including wet and dry FGd and Scr systems)

Most recently, APcomPower has led the way in successfully constructing the latest cO2 capture technologies.

APcOMPOWEr IS ThE unIOn cOnSTrucTIOn ArM OF AlSTOM SErvInG ThE u.S. And PuErTO rIcO. | APComPower and Alstom together form an integrated design and erection firm. For more than 70 years, APComPower has been providing a seamless range of services to the utility and industrial power industry. These services include core maintenance during routine outages, retrofit upgrades to the boiler island, and environmental equipment upgrades and retrofits. To date, we have installed 20% of the U.S. base. Now, APComPower also offers maintenance services for gas and steam turbines.

In today’s highly competitive markets, economies of scale can make all the difference in whether a project is successful or not. As part of Alstom, APComPower has access to the worldwide resources of one of the world’s largest and most innovative manufacturers of power generation equipment – from standard and custom-designed products and systems, to centralized support groups based in Windsor, CT, covering:

• Environment, Health and Safety• Quality• Material technology• Construction and welding engineering

your 1-stop Choice for boiler services and PartsCall us toll free: 1.866.257.8664

ordirect: 1.860.285.2100

e-mail: [email protected]: 1.860.285.3101

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alstom200 Great Pond driveWindsor, cT 06095-0500 Tel: 860.285.2100Toll Free: 866.257.8664Fax: 860.285.3101www.alstom.com/power

alstom Canada1430 Blair Place, Suite 600Ottawa, On k1j 9n2 Tel: 613.747.5222Fax: 613.747.5828www.alstom.com/power

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