Alstom Products and Services for Foster Wheeler Plants
With Alstom… You're in control!
Power
Alstom, a leader safety and Experience
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.
S afety | 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.
E xperience | 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.
L ogistics | 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.
C ustomer 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.
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At Alstom, we combine our capabilities and experience
challenges faced by plant owners, operators, maintenance
to enhance the productivity and performance of your
personnel and management. Whether it is a replacement
boilers, pulverizers, feeders, air pollution control
or upgraded part, a rebuilt assembly, a custom fabrication
systems, ash handling systems and auxiliary equipment.
or inventory management program, Alstom provides
Our focus is customer service and we understand the
exceptional value and service to our customers.
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
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Introduction to... Working with Alstom is not leaving the OEM, it's coming to one 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!
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Alstom Solutions for Foster Wheeler Plants The Alstom advantage Alstom has the people and the products for your Power plantBoilers | 3-27 solutions. | We know your power plant maintenance and operational needs.
Pressure Parts
This catalog provides a glimpse into what we can do to help you operate with improved:
• Safety • Environmental compliance • Equvalent Forced Outage
Superheater Panels Superheater or Reheater Panels
Rate (EFOR)
• Efficiency Boiler Electronics Furnace Side Wall Coal Feeders
Furnace Front Wall
Pulverized-Coal Piping to Burners
Pulverizers
Bottom Ash System
Figure 3-19 | A Combined Circulation® tangentially firing, coal-fired reheat steam generator
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.
working with alstom is not leaving the oem, It's coming to one
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Notes
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MBF-type Pulverizer Introduction The 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 MBF – 18.5 MBF – 19 MBF – 19.5 MBF – 20 MBF – 20.5 MBF – 21 MBF – 21.5 MBF – 22 MBF – 22.5 MBF – 23 MBF – 23.5 MBF – 24 MBF – 24.5 MBF – 25
32,300 37,500 43,500 50,500 58,600 67,900 78,700 91,300 106,000 122,000 142,000 165,000 191,000 222,000 258,000
OFFERINGS: Repairs and Rebuilds MBF Replacement Parts Inventory Complete Roller Assemblies Advanced Static Classifiers Inventory Management Program Technical Services Installation
MBF Mill Pulverizers
715
MBF-type Pulverizer-Replacement Parts Pivot Bracket Assembly
16 8
MBF-Type Pulverizers
MBF-type Pulverizer-Replacement Parts Pivot Bracket Assembly Item 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
Item Description
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
Alstom Part No. 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
MBF-type PULVERIZERS
917
MBF-type Pulverizer-Replacement Parts Roller Assembly
75
80
5
85 10
30 25 20 35
45
40 55
50
65
105
100/ 95
130/ 125
60 115/ 120 110 115/ 120
15 70
10 18
MBF-Type Pulverizers
MBF-type Pulverizer-Replacement Parts Roller Assembly Item Item Description 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
Roller Assembly Shaft Hub for Tire Roller Roller Tire Seal Assembly Oil Seal O-Ring Roll Seal Sleeve O-Ring 14"OD x .25" Cross Viton Cylindrical Bearing Roll Bearing Spacer - INNER Roll Bearing Spacer - OUTER Spherical Bearing Roll Bearing Retainer O-Ring 21.5"OD X .25" Cross Viton Bearing Cover Roller Clamp Ring Plug-Sq. HD Solid 1.25 Vent Valve SCR-SET HEX KHL CUP .312" X 1.50"L SCR-CAP HEX SOC HD 1.5-6 X 23" SCR-CAP HEX HD 1.5" X 5"L Lock Washer Hi-Collar 1.5" Plug-Sq. HD Solid 1.5 SCR-SET HEX SOC FLT PT 1.13 X 1.25 SCR-CAP HEX HD 1.5" X 4"L Washer Plain Type B 1.5" 7/8" HEX HD CAP SCR - Magnetic Plug Crush Washer
Alstom Part No. MBF-23-1514 MBF-23-1512 / GP-17297 GP-9471-B MBF-23-1540 V00-6217 V00-5577 MBF-23-1546 V00-6219 MP-10658 / V00-7154 MBF-23-1515 MBF-23-1516 GP-10738 / V00-7029 MBF-23-1521 V00-6220 MBF-23-1513 MBF-23-1525 12-6006 0352315 MD8-00082-HK V00-5821 MD8-00092-YP MD8-00017-AC 12-6007 V00-5822 MD8-00053-4871 MD8-00218-DA MBF-8004099 MBF-8000181
Comments
2 Req. per assembly
2 Req. per assembly
6 Req. per assembly 3 Req. per assembly 3 Req. per assembly 3 Req. per assembly 3 Req. per assembly 14 Req. per assembly 14 Req. per assembly 3 Req. per assembly 3 Req. per assembly
MBF-Type Pulverizers
11 19
MBF-type Pulverizer Asset AssetPlanning Planner 1. Burner shut-off damper 4. C lassifier blade and linkage
2. Center feed pipe
3. Classifier drum 5. Classifier cone
6. C lassifier reject housing
7. Grinding section housing liners
11. Plunger shims 8. Spring mechanism
13. Grinding table segments
10. Pivot bracket 12. Coal shield 9. Roller 15. Scrapers 16. Air Seal
14. Air ports 17. Coal reject chute doors 18. Speed reducer
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.
12 20 18
MBF-Type Pulverizers
AND LIFE CYCLE WORKSHEET S89 Pulverizer Asset Planning
MbF-type MbF-type MBF-typePulverizer Pulverizer
AND LIFE CYCLE WORKSHEET Fuel Delivery System Asset Planning and Life Cycle Worksheet S89 PulverizerParts Description As FoundPlanning Life Cycle Years Suggested Upgrade Asset Asset Planning
Asset Planner
1 2 3 4 5 1 6 2 7 3 8 4 9 5 10 6 11 7 12 8 13 9 14 10 15 11 16 12 17 13 18 14 19 15 20 16 21 17 22 18 23 19 20 21 22 23
1 2 3 4 5 Burner Shut-off Damper Center Feed Pipe Fuel Delivery System Asset Planning and Life Cycle Worksheet Classifier Drum Parts Description As Found Life Cycle Years Suggested Upgrade Classifier Blade and Linkage 1 2 3 4 5 Classifier Cone Burner Shut-off Damper Classifier Reject Housing Center Feed Pipe Griding Section Housing Liners Classifier Drum Spring Mechanism Classifier Blade and Linkage Rollers Classifier Cone Pivot Bracket Classifier Reject Housing Plunger Shims Griding Section Housing Liners Coal Shield Spring Mechanism Grinding Table Segments Rollers Airports Pivot Bracket Scrapers Plunger Shims Air Seal Coal Shield Coal Reject Chute Doors Grinding Table Segments Speed Reducer Airports Pressure Spring Scrapers Spring Frame Air Seal Flexible Seal Air Supply Pipe Coal Reject Chute Doors Top Housing Speed Reducer Swing Valve Pressure Spring Spring Frame Flexible PERFORMANCE Seal Air Supply Pipe Top Housing Fuel Specifications Pulverizer Fineness Swing Valve Goal Analysis Design Current % Retained on 50 Mesh
Design < 1%
Current
PERFORMANCE
Goal
% FC % Ash
% Through Fineness 200 Mesh Pulverizer Design % Retained Current on 50 Mesh
Goal
70% Design
Goal
Current
% VM
% Sulfur Analysis %%Moist VM
Fuel Specifications Design
Current
Goal
%% Carbon FC
< 1% % Through 200 Mesh Design
Current
70%
MAINTENANCE
Goal
Pulverizer Overhaul Frequency Type (Wear Parts, major, gearbox,....)
Current
MAINTENANCE
Goal
Pulverizer Overhaul Frequency Type (Wear Parts, major, gearbox,....)
%Ash H2 % O2 %%Sulfur %HHV Moist Grindability % Carbon % H2 % O2 HHV Grindability Size
Current
Goal
Pulverizer Coal Flow Tonnage or lbs/hr Design
Current
118 22.5
210,000 122,000LB/HR lb/hr
23 89
142,000 lb/hr Coal Flow 124,000 LB/HR Pulverizer 165,000 lb/hr or lbs/hr 80,000 LB/HR Tonnage
75 23.5 Size
Design
118
210,000 LB/HR
89
124,000 LB/HR
75
80,000 LB/HR
Current
Goal
Goal
R081507
MBF-Type Pulverizers MBF-TYPE PulvErIzErS
13 21
21
MBF-TYPE PulvErIzErS R081507
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MBF-type Pulverizer — Materials CAST STEEL
Cast 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
• •
ROLLER HUB
PIVOT BRACKET
CERAMIC
Ceramic Lining and Vacuum Bonded Liners The 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 Tiles
Thin 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
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MBF-Type Pulverizers
•
Brazed Tungsten Carbide Very 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.
MBF-type Pulverizer — Upgrades CROWN Plus™ Wear Resistant Material 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.
Benefits:
• Longer wear life • E xtended time between
overhauls Although Alstom has solutions that extend roller life, extending time between overhauls is Best wear available for a limited by abrasion in the upper millside area. Ductility is also an issue because these liners casting 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.
Laboratory Test Results Life Compared Alloy Abrasion Wt. Loss Cavitation Wt. Loss Expected to CROWN 700 Crown 700 36.6 10.3 1.0 x High Chrome 25.7 2.4 1.4 x Crown Plus 6.4 2.4 5.7 x Weight loss in milligrams
Field Test Results Host Crown Plus CROWN Plus Fuel Traditional Traditional Site Alloy Component Life Predicted Life Performance Factor
A PRB CROWN 700 B PRB CROWN 700 C High Silica CROWN 700 & High Chrome
18 months 18 months
51 months 33 months
2.8 x 1.8 x
12 months
84 months
7.0 x
GOOD–––– CROWN 700 BETTER–– High Chrome BEST––––– CROWN Plus
MBF-Type Pulverizers
15 23
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
24 16
MBF-Type Pulverizers
MBF-type Pulverizer — Upgrades
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.
Triple Lip Seal
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 necessary
• •
Air Seal Upgrade
• R educes 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
•
Air Seal Upgrade
MBF-type Pulverizers
25 17
MBF-type Pulverizer Upgrades COAL SHIELD
Coal Shield
• Long wear
— Bolt head protectors — Multiple wear material options
Plunger Shims
Plunger shim
• Easier maintenance
Bronze eccentric bearing
•
Easier maintenance and adjustment — Does not freeze in place — Self-lubricated with graphite
26 18
MBF-Type Pulverizers
— Replaceable & adjustable
Eccentric Bearing
MBF-type Pulverizer — Rebuilds Roller Assembly Rebuilds 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 Rebuilds The 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
MBF-Type Pulverizers
27 19
Notes
Weld overlay process.
28 20
MBF-Type Pulverizers
Coal Feeders Replacement Parts and Upgrades 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).
Improving performance, availability and reliability of coal feeders
stock coal feeders
7 21
Coal Feeders — Replacement Parts Alstom Products for STOCK Coal Feeders Replacement parts for most model STOCK feeders:
• Fast delivery • C ompetitive pricing • O utage kits/Inventory programs
228
coal feeders
Coal Feeders — Upgrades Main Drive Upgrade The Main Drive Upgrade Components:
• D irect drive Sumitomo reducer with adapter
• A /C inverter duty motor • V ariable Frequency Drive
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.
(VFD) for control of motor speed
• Speed encoder
ADVANTAGES:
• Eliminates inherent oil leaks
• M ore accurate control with easy adjustment
• Minimizes changes • Maximizes use of existing parts
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 The main drive upgrade eliminates oil leaks while providing an accurate linear signal which can be easily reprogrammed to accommodate changes in capacity.
stock coal feeders
9 23
Coal Feeders — Upgrades Cleanout Drive Upgrade Cleanout Drive Upgrade Components
• D irect drive Sumitomo reducer with adapter
• A /C constant speed motor • Electronic shear pin relay
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. Dirty Installation: Shows signs of leaking which is not only a maintenance problem, but a safety hazard.
Electronic shear pin or shock relay offers excellent protection against feeder overload.
Cleanout Drive Feature / Function
10 24
Advantages
New Alstom upgrade.
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
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 failureprone components • Elimination of relays
• Reduces maintenance • Improves reliability • Improves accuracy
Sensor monitor and graphic trending
• Well organized
• Improves availability • Reduces maintenance costs
• More detailed information available
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
stock coal feeders
11 25
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 way to Improve reliability
• Simple design • M icroprocessor adjusts the speed of the belt based on load of material
Benefits:
• Reduces maintenance costs • Improves efficiency with tighter control
• Improves reliability Weigh Suspension System
26 12
coal feeders
Coal Feeders — Upgrades Roller Belt Support Assembly Advantages:
• Eliminates wear to the coal feeder belt
• Less horsepower required
The Roller Belt Support Assembly is an Alstom upgrade to the sliderbed 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.
to move the feeder belt
• Enables faster calibration of coal feeder
• R ollers can be replaced
without disassembly of the tail end of the coal feeder and removal of the belt
Benefits:
• Improves reliability • R educes operational cost • Improves availability
Roller Belt Support Assembly
Years of trouble free service
stock coal feeders
27 13
Notes
14 28
stockfeeders coal feeders coal
Boiler Electronics Pipe Igniters THE 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:
• C onsistently demonstrates over 95% reliability
• Improved combustion airflow
• Lower pressure drop • Easy installation and maintenance
• O ffers clean and reliable operation with minimal opacity during start ups
• Easy retrofit with existing igniter system hardware
• N ew bluff body design
provides improved flame stability
LIMELIGHT™ Gas Bluff Body Pipe Igniters
• H igh 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.
Capacity from 0.5 – 18.0 MMBtu/hr
Stable flame/wide range
Boiler Electronics
29
Boiler Electronics LIMELIGHT™ Igniter Valve Train Assemblies Features:
• O il train includes air pressure regulator, oil flow controller and single actuator automatic trip valve for both oil and atomizing air
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 (deenergizeto-trip) or instrument air. Energize-to-trip valves can be provided if preferred.
• Valve, actuator, and limit
switch enclosure designed as a unit
• G as train includes double
block and vent valve arrangement and globe valve for gas flow regulation
• D esigned for a wide range of heat input capacities
• C ompatible with our
LIMELIGHT igniter control cabinet
• Fuel/air strainer and filter
Gas Valve Train
option available
Oil Valve Train
Benefits:
• In-kind replacement for
old or obsolete equipment
• Easy maintenance • Easy installation • C ode compliance 30
Boiler Electronics
Boiler Electronics Control Cabinets 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)
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 • D ouble 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
• M eets NFPA and CGA codes
• Self diagnostics and troubleshooting
• Suitable for interface
with existing burner management systems
• C onsistent operation • R educes start-up period
Boiler Electronics
31
Boiler Electronics LIMELIGHT™ Flame Scanners 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.
features:
• Temperature rating is 165º F (75º C)
• C an discriminate between different fuels
• P rovides flame quality analysis
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.
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:
• • VL – Visible Light • B R – Broad Range, Infra Red and Visible Light UV – Ultraviolet
.
features:
• Temperature rating is 185º F (85º C)
• C an discriminate between different fuels
• 4 contact and 2 analog outputs per channel
increased safety
32
Boiler Electronics
benefits:
• Superior flame detection,
reduced nuisance trips and increased sensitivity for low load operation
• R educed cost of
installation - compatible with previously installed flame scanners, cable and guidepipes
• R educes CapEx • R educes maintenance costs
Boiler Electronics LIMELIGHT™ Coal Flow Monitor 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 • R educes maintenance costs
• Q uicker start-ups • R educes installation time by 50%
LIMELIGHT Coal Flow Monitor Sensor Head and electronics enclosure
Reliable solution to coal flow monitoring for feeder outlet
Boiler Electronics
33
Boiler Electronics EVER-KOOL™ Oil Gun and Spray Tips Features:
• R eady for immediate service • N o moving parts – retract mechanism not required
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.
Benefits:
• R educed coking of any
remaining oil after purging
• R educed maintenance • Improved light-off reliability • Safer than retractable oil guns
• R educed opacity APPLICATIONS:
• U tility, industrial, pulp and paper boilers
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
EVER-KOOL Oil Gun Flame – 30 MMBtu/hr and up
34
Boiler Electronics
No moving parts reduced maintenance
Boiler Electronics Boiler Data Advisor (BDA) 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. 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
• H igher performance–
patented methods provide the earliest warning about operational abnormalities
• Fewer unplanned outages– facilitates better preventive maintenance decisions
Boiler Electronics
35
Notes
36
Boiler Electronics
Boiler Fabrications Boiler Access and Observation Doors 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.
Oval Hinged Access Door
Specialty Access Doors:
CUstomized with observation & lancing ports
FEATURES:
• D oor liner refractory
suitable for high temperature applications
• B uilt-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
Burner Fabrications
37
Boiler Fabrications — Replacement Parts Fuel Delivery System 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 • D ischarge Valve • O rifice
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.”
Coal Piping
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 •M echanically 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.
Deflector Block
DYNAWEAR Ceramic-lined Elbow showing angled deflector block installed at highest wear point in outer radius.
38
Burner Fabrications
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 highwear areas inside the pipe do not need to be lined.
Boiler Fabrications — Replacement Parts Discharge Valves 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 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.
QUICKCHANGE™ Orifice Assembly 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.
Benefits:
• Pull-out design reduces
orifice replacement time
• V isual inspection made easier
• C an accommodate orifices made of various wearresistant materials
• Fast, easy orifice
replacement with boiler on-line and pulverizer out of service
Burner Fabrications
39
Boiler Fabrications — Rebuilds Coal Delivery System Rebuilds Benefits:
• A pproximately 50% cost of
Burner Slide Gate Rebuilds. | Alstom offers the parts and services to rebuild existing Burner Slide Gate Assemblies.
• Short lead times • U pgraded materials
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.
• N ew equipment warranty
Rebuild Scope
new assembly
available
Basic Services
• R eceive • D isassemble • Evaluate condition • R eplace worn components as necessary • Add or replace wear materials • R eassemble • P aint & ship
Before
40
Burner Fabrications
After
Boiler Fabrications — New and Rebuilt Burners — New and Rebuilt 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.
Benefits:
• B urners are rebuilt to strict specifications
• U p to a 60% savings vs. the cost of a new burner
When complete, Alstom will return the rebuilt burner to you in the same shipping crate to minimize the possibility of damage during shipment.
• Fast turn around • E xtensive inventory support
RSFC = Radially Stratified Flame Core
Rebuild Scope
Good Repair Option
Basic Services
• Ship in an enclosed container to minimize further damage
• R eplace missing tiles • R eplace stainless shroud • R eplace distorted pipes • R eplace adjusting bars • R eplace worn blades • R epair all welds • P aint • Ship back to customer in original shipping container
Better Repair Option
Alstom Repair Options Good — repair and overlay only the worn areas that were designated as being "minimal" based on UT results
Best Repair Option
Better — build up and overlay the typical high-wear areas Best — build up and overlay the entire internal surface
Burner Fabrications
41
Notes
42
Burner Fabrications
Pressure Parts Capabilities 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
Benefits:
• R educed mean time to repair
• Increased unit availability • Increased unit reliability • Improved profitability
Pressure Parts Superheater Panels Superheater or Reheater Panels
Boiler Electronics Furnace Side Wall Coal Feeders
Furnace Front Wall
Pulverized-Coal Piping to Burners
Pulverizers
Bottom Ash System
Figure 3-19 | A Combined Circulation® tangentially firing, coal-fired reheat steam generator
Pressure Parts
43
Pressure Parts—Coatings AmStar 888® Thermal Spray Cladding FEATURES:
• W ill not delaminate, crack or spall
• Thicknesses from 5 mills to > 100 mills
• D efect-free substrate coverage
• D esigned for maintainability BENEFITS:
• Significantly reduces
Equivalent Forced Outage Rate (EFOR)
• D ependable and predictable tube protection
• Q uality applications regardless of scope
• Engineered solution -
recommendations are made based on specific problem
APPLICATIONS:
• P ulverized coal boilers • C irculating fluidized bed boilers (CFBs)
• W aste to energy boilers • B lack liquor recovery boilers
44
Pressure Parts
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.
Pressure Parts — Locations 2 Mega Centers To improve our service to our customers | and to build capacity for the future, we have invested in infrastructure improvements at two key locations.
Rocky Mountain Service Center (RMSC) – Denver, Colorado
• M odern 100,000 square foot facility designed for efficiency and material handling ease
• F ully operational and staffed 7 days a week • O n-site engineering and design graphics personnel • E mergency service on such pressure parts:
— Panels — Loose bent tubes — DMWs — Steam/fluid-cooled spacers — Industrial superheaters — Finned tubes
— Qualified welders — Benders with exceptional fabrication experience — E xtensive layout knowledge
— Hot and cold bending — Finning — Paneling — Assembly
• Q uality employees = Quality products
• S tate-of-the-art pressure parts facility
— Rotoblaster — Annealing furnace — On-hand inventory
Chattanooga, TN (TDC)
Tubing Distribution Center (TDC) – Chattanooga, Tennessee
• 100,000 square foot indoor tubing facility • 2 4/7 emergency availability • B eveling and cut-to-length • R otoblasting, stenciling, printing and rust inhibitors • E lectronic MTRs
Rocky Mountain, CO (RMSC)
Pressure Parts
45
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.
Offerings:
• Fabrication of key pressure parts components
• Loose tubes – straight or fabricated
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.
• W aterwall and burner
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.
• Tube shields, attachments
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.
panels
• A ssemblies and circuitry for superheaters, reheaters and economizers and hardware
• W eld and laser overlay
and thermal/abrasion coatings for increased wear protection
• C omplete boiler tubing replacements
• C onvenient, one-vendor, complete service
Non-Alstom Brands | WE Service them all Other OEM C apabilities Alstom 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.
46
Pressure Parts
Ash Systems Integrated Bottom Ash Solutions Plant Integration
Advantages:
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.
• 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.
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.
ECONOMIZER ASH | can be transported to the SSC on dry drag conveyors for removal along with the boiler bottom ash and pyrites.
Ash Systems
47
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 and Cylinder Extensions
Gate Enclosures
Bottom Ash Gates 24" X 24" and 30" X 30" 4" Lancing Door
Clinker Grinders
48
ASH SYSTEMS
Jet Pumps
The Alstom Advantage Service Capabilities 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:
• U tility 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.
Equipment Supported In 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, AllenSherman-Hoff, United Conveyor, Fläkt Air Pollution Control | ABB, Combustion Engineering, Fläkt, Walther, Carborundum, HamonResearch Cottrell, Wheelabrator, Peabody, Rockwell
The Alstom Advantage
49
The Alstom Advantage Service Capabilities 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
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 • E xpediting delivery of required material and parts
Inspection Service | To help ensure an effective outage, we offer our inspection service that includes:
logistics and work scope definition • Pre-outage • P re-outage unit walk-downs • D etailed inspections during the outage • D aily punch lists and definition of items requiring immediate attention • C oordination 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
50
The 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 • V isual 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:
• D etermine equipment condition and need for repairs • C ompare components to original specifications and help make adjustments
• P articipate in developing
work scope and associated tasks
• D irect maintenance
personnel in proper disassembly and assembly procedures
• C oordinate execution of the work scope
• D evelop a daily punch list prioritizing work tasks
• P rovide a final report documenting work performed and recommendations
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
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 • H OT TOPIC training programs • C omputer-based QUICKSTUDY™ Learning System • R egional training seminars
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.
technical services tailored for you and your budget
The Alstom Advantage
51
The Alstom Advantage Inventory Management Programs Advantages:
• After-hours response team • Guaranteed parts availability • Eliminates exposure to obsolete inventory
• A pplicable to most plant equipment
• P rograms can be expanded
to include other plants within the customer’s system
• O ne week standard shipment after receipt of order
• M inimizes exposure to raw
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 guarantees parts availability 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.
materials price fluctuations
Benefits:
• Reduces carrying costs • Defers cash outlay • Increases cash flow by
Midwest Service C enter – Erlanger, K entucky
delivering products when needed
• Simplifies purchasing
Rocky Mountain Service C enter – Denver, C olorado
Harrisburg, PA
*
Denver, CO
*
Erlanger, KY
*
Chattanooga, TN
*
Suwanee, GA
Tyler, TX
*
Strategically located to serve our customers 52
The Alstom Advantage
*
The Alstom Advantage Outage Kits 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
• R educes maintenance costs
• Convenient and organized
• Simplifies purchasing Benefits:
• R ight parts available
when you need them
• O nly pay for the parts that are used
• Instant part availability • Save time and money
A cost-effective way to manage planned and unplanned unit outage repairs
How Alstom’s Outage Kit Program works: 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.
The Alstom Advantage
53
The Alstom Advantage APComPower A World of Experience – Right Next Door 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:
• C oal, 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.
54
The Alstom Advantage
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 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
• • • • • • • • • • • •
• • • • • • • • • • •
Your 1-Stop Choice for Boiler Services and Parts Call us Toll free: 1.866.257.8664 or Direct: 1.860.285.2100
Press: 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
E-mail:
[email protected] Fax: 1.860.285.3101 We provide 24 hour, 7 days a week emergency service.
With Alstom... You’re in control
AMSTAR 888®, CERTIFIED REBUILD™, e-tool™, EVER-KOOL™, LIMELIGHT™, PV-PRO™, QUICKCHANGE™, Dynawear™ and RSFC™ are trademarks of ALSTOM Technology Ltd.
GENETIX is a registered trademark of Merrick Industries, Inc., INVALCO is a registered trademark of FMC Technologies, Inc., Xwin is a registered trademark of Magotteaux, STOCK® is a trademark of Commerzbank AktienGeselschaft.
TPW/BPROB/FSTWHL12/eng/PSER1/06.12/US/7616 © Alstom 2011. Alstom, the Alstom logo and any alternative version there of are trademarks and service marks of Alstom. The other names mentioned, registered or not, are the property of their respective companies. The technical and other data contained in this document is provided for information only. Alstom reserves the right to revise or change this data at any time without further notice.
Alstom 200 Great Pond Drive Windsor, CT 06095-0500 Tel: 860.285.2100 Toll Free: 866.257.8664 Fax: 860.285.3101 www.alstom.com/power
Alstom Canada 1430 Blair Place, Suite 600 Ottawa, ON K1J 9N2 Tel: 613.747.5222 Fax: 613.747.5828 www.alstom.com/power
