alstom parts for foster wheeler plants
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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
3
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
6
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
MbF-type Pulverizer-replacement Parts
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
19MBF-TYPE PulvErIzErS
roller Assembly
MbF-type Pulverizer-replacement Parts
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
MbF-type Pulverizer-replacement Parts
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
21MBF-TYPE PulvErIzErS
Asset Planning
MbF-type PulverizerMbF-type Pulverizer
Asset Planning
21MBF-TYPE PulvErIzErS
Asset Planning
MbF-type Pulverizer
18. speed reducer
21MBF-TYPE PulvErIzErS
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
21MBF-TYPE PulvErIzErS
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
22 MBF-TYPE PulvErIzErS
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
23MBF-TYPE PulvErIzErS
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
24 MBF-TYPE PulvErIzErS
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
25MBF-TYPE PulvErIzErS
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
26 MBF-TYPE PulvErIzErS
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
27MBF-TYPE PulvErIzErS
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
28 MBF-TYPE PulvErIzErS
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
Coal Feeders — upgrades
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
Coal Feeders — upgrades
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
Coal Feeders — upgrades
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
Coal Feeders — upgrades
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
31BOIlEr ElEcTrOnIcS
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
32 BOIlEr ElEcTrOnIcS
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
• Reduces maintenance costs
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
33BOIlEr ElEcTrOnIcS
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
• Reduces maintenance costs
• Quicker start-ups
• Reduces installation time by 50%
reliable solution to Coal FlowMonitoring For Feeder outlet
lIMElIGhT™ Flame Scanners
34 BOIlEr ElEcTrOnIcS
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
35BOIlEr ElEcTrOnIcS
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
36 BOIlEr ElEcTrOnIcS
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
39BurnEr FABrIcATIOnS
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
40 BurnEr FABrIcATIOnS
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
41BurnEr FABrIcATIOnS
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
42 BurnEr FABrIcATIOnS
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
the alstom advantage
51ThE AlSTOM AdvAnTAGE
the alstom advantage
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
the alstom advantage
52 ThE AlSTOM AdvAnTAGE
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 with- in 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
the alstom advantage
53ThE AlSTOM AdvAnTAGE
the alstom advantage
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:
the alstom advantage
54 ThE AlSTOM AdvAnTAGE
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: windsorparts@power.alstom.comFax: 1.860.285.3101
If you know your party’s extension
To use our names directory
To speak with a customer Service representative
To reach the company Operator
If you would like this menu repeated
All other calls stay on the line
We provide 24 hour, 7 days a week emergency service.
Press:
WITH ALSToM...YoU’re IN CoNTroL
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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