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1
Power Day - Colombia 2006
Boiler & Environmental Plant Services Division
2
Our Roots
3
Brands Supported byALSTOM Power Service
Boilers Air Pollution Control
Coal and Ash Handling
Technical Services
JuJulyly 20020066
5
Technical Service Capabilities
Operation & Maintenance TrainingCustom Onsite TrainingO&M Training and OperationsSeminars
Operation & Maintenance TrainingCustom Onsite TrainingO&M Training and OperationsSeminars
Engineering ServicesTechnical Field ServicesDedicated EngineersDesign and Performance StudiesOutage & Maintenance PlanningRemote MonitoringCondition AssessmentHeat Rate Improvement AssessmentEnvironmental Equipment Services
Engineering ServicesTechnical Field ServicesDedicated EngineersDesign and Performance StudiesOutage & Maintenance PlanningRemote MonitoringCondition AssessmentHeat Rate Improvement AssessmentEnvironmental Equipment Services
Performance Services Boiler & PP Performance EvaluationWater Chemistry ConsultationRemote Monitoring SystemsInstrumentation Supply and RentalSpecialized Testing of Thermal, Fluid and Chemical ProcessesBoiler Water Flow Measurement
Performance Services Boiler & PP Performance EvaluationWater Chemistry ConsultationRemote Monitoring SystemsInstrumentation Supply and RentalSpecialized Testing of Thermal, Fluid and Chemical ProcessesBoiler Water Flow Measurement
6
Technical Field Services
Field Services EngineersOver (100) Field Service Engineers Average 15 years experience
275 Customers at over 475 plants sites serviced yearlyServes Utilities & Industrial Customers
Range of Expertise• Boiler Operation • Boiler Inspections • Pulverizers • Burners • Pressure Parts • Stokers • Ash Handling • Precipitators Fabric Filters Scrubbers Wet
Dry FGD ESP Controls SCR HRSG
Field Services EngineersOver (100) Field Service Engineers Average 15 years experience
275 Customers at over 475 plants sites serviced yearlyServes Utilities & Industrial Customers
Range of Expertise• Boiler Operation • Boiler Inspections • Pulverizers • Burners • Pressure Parts • Stokers • Ash Handling • Precipitators Fabric Filters Scrubbers Wet
Dry FGD ESP Controls SCR HRSG
7
Non-Fleet Capability
Non-Fleet Parts and Service CapabilityRiley EngineersB&W Knowledge baseUCC Engineers A.S.H. Knowledge baseCross TrainingTraining materials developed
Non-Fleet Parts and Service CapabilityRiley EngineersB&W Knowledge baseUCC Engineers A.S.H. Knowledge baseCross TrainingTraining materials developed
8
Inspection Services
• Pre-outage logistics and work scope definition
• Pre-outage unit walk-downs
• Detailed inspections during the outage
• Daily punch lists and items requiring immediate attention
• Coordination with repair labor personnel
• Initial report with critical findings and recommendations
• Final detailed reports with photos, findings & recommendations
• On-line retrieval (via our website) of final reports
• Pre-outage logistics and work scope definition
• Pre-outage unit walk-downs
• Detailed inspections during the outage
• Daily punch lists and items requiring immediate attention
• Coordination with repair labor personnel
• Initial report with critical findings and recommendations
• Final detailed reports with photos, findings & recommendations
• On-line retrieval (via our website) of final reports
Benefits: OEM Recommendations
Features:
9
Dedicated Engineer Program
• Dedicated Resource with continuity for interface
• History with Plants (OEM)
• Linked with Plant Inventory & Parts Support
⎯Interface with inventory program
⎯Upgrades, outage planning, work scope development
• Single Point Contact Person
• Access to Alstom Resources & Knowledge
• Augments Plant Staffing
• Multiple Pricing Packages
• Dedicated Resource with continuity for interface
• History with Plants (OEM)
• Linked with Plant Inventory & Parts Support
⎯Interface with inventory program
⎯Upgrades, outage planning, work scope development
• Single Point Contact Person
• Access to Alstom Resources & Knowledge
• Augments Plant Staffing
• Multiple Pricing Packages
Benefits: Improved EFOR, Reliability, Availability, Heat Rate
Features:
MAINTENANCE SPEND ($)
AVA
ILA
BIL
ITY
(%)
TYPICAL MAINTENANCE STRATEGY
EVALUATION
1
2
10
OEM Experience
Conducted pioneering research on:material properties, heat transfer, chemical processes
Over 50 Technical Papers since 1960’s (tubing only):Availability Analysis and Reliability Improvement ProgramsWater Chemistry Corrosion and Erosion Tubing
Other
0
50
100
150
200
250
WaterwallsSH / RHEconomizers
0
20
40
60
80
Erosion Tube AttachmentsInternal Corrosion WeldingOverheating Maintenance Procedures
Tube failures are major cause of Forced Outage.
Hundreds of Studies and Consultations yearly
11
• Investigate and support unit operational issues
⎯ Unit performance, efficiency, optimization
⎯Operational flexibility
⎯Emission reduction
Nox, Opacity,etc
⎯Coal Fineness, coal flow, airflow
⎯Mill Capacity and operations
⎯Operator training
• Investigate and support unit operational issues
⎯ Unit performance, efficiency, optimization
⎯Operational flexibility
⎯Emission reduction
Nox, Opacity,etc
⎯Coal Fineness, coal flow, airflow
⎯Mill Capacity and operations
⎯Operator training
• Investigate and support unit maintenance and availability issues
⎯ Assist with outage scopes, cost estimates, and budget planning
⎯Pulverizer overhauls and cost/time reductions
⎯Pulverizer upgrades and justifications
⎯Pulverizer troubleshooting (maintenance and operational)
⎯ Boiler tube leak root cause analysis
⎯Structural issues
• Investigate and support unit maintenance and availability issues
⎯ Assist with outage scopes, cost estimates, and budget planning
⎯Pulverizer overhauls and cost/time reductions
⎯Pulverizer upgrades and justifications
⎯Pulverizer troubleshooting (maintenance and operational)
⎯ Boiler tube leak root cause analysis
⎯Structural issues
Performance Evaluations
12
Outage Planning
• Outage inspection planning
⎯ ALSTOM inspection check list
⎯ Historical review of problem areas
• Outage inspection planning
⎯ ALSTOM inspection check list
⎯ Historical review of problem areas
• Long Range Maintenance Planning
⎯ Use inspection history and finding to create work list
⎯ Use justifications to prioritize work list
• Long Range Maintenance Planning
⎯ Use inspection history and finding to create work list
⎯ Use justifications to prioritize work list
• Team to develop schedule
⎯ Staffing requirements
• Team to develop schedule
⎯ Staffing requirements
13
Condition Assessment
Condition Assessment is the implementation of specific activities focused on determining the present state of a component.
– Engineering calculations– Nondestructive testing– Metallurgical evaluations– Engineering experience
ALSTOM's approach to Plant Condition Assessment involves the application of three steps to achieve the desired goals.
– Pre-outage reviews– Outage activities– Post-outage evaluation
Long Term Overheating
Sootblower Erosion
Sootblower Erosion
Sootblower Erosion
Dissimilar Metal Weld Failures
Dissimilar Metal Weld Failures
Damage Mechanisms
14
Condition Assessment Process
Goal Setting &Pre-Outage Review
Post-OutageEvaluation
OutagePhase
Steps include:Historical review
Operating models
Engineering analyses
Risk assessment
Steps include:Review outage
inspection findings
Analyze material samples
Perform supplemental engineering analyses
Steps include:Visual examinations
Nondestructive testing
Selection of material samples
15
Steam and high energy piping seam weld inspectionsMT,UT,VT,PT, RTNear Drum Inspection ServiceGirth Weld InspectionReplicationHardness TestingRemote Field Eddy CurrentMetallurgical AnalysisStress AnalysisFull Length Imaging ScannerLaser Profilometry
Condition Assessment Offerings
Multidisciplinary
16
Steam and high energy piping seam weld inspectionsMT,UT,VT,PT, RTNear Drum Inspection ServiceGirth Weld InspectionReplicationHardness TestingRemote Field Eddy CurrentMetallurgical AnalysisStress AnalysisFull Length Imaging ScannerLaser ProfilometryScale Thickness Analytical Testing Service (STATS)Phased Array
2.1 Condition Assessment Offerings
17
Multidisciplinary
Nondestructive inspection– Visual, UT, MT, PT, Radiography, Eddy-
current,Dimensional Measurements
Metallurgical Evaluation– Metallographic replicas, hardness testing,
destructive examination of samples (microstructural analysis, creep testing, etc.)
Engineering Analysis– Simple Code calculations to finite element
analysis (thermal, structural, vibration, fluid dynamics, etc.)
Boiler Know-how– Experience, tools and solutions.
OD
ID
Weld
Parent
Type IV
CG HAZ
18
Assessment of Headers
Tube Nipple Cracks– Tube side or header side– Tube flexibility– Thermal fatigue
Tee Cracks– Crotch or external– Piping flexibility– Thermal fatigue
and creep
Ligament Cracks– At and between bore holes– Axial or circumferential– Thermal fatigue and creep
19
Assessment of Piping
MSH-1
MSH-4
MSH-2
MSH-5
MSH-6
MSH-3
MSH-7
MSH-8
MSH-9
MSH-10
MSH-11
MSH-12
MSH-13
MSH-14L
MSH-14R
MSH-15L
MSH-15R
SHO1 2
3 4 56 7
Long seamweld
scanningand analysis
Wye blockanalysis
Movement at Hangers
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
MS
H-1
MS
H-2
MS
H-3
MS
H-4
MS
H-5
MS
H-6
MS
H-7
MS
H-8
MS
H-9
MS
H-1
0
MS
H-1
1
MS
H-1
2
MS
H-1
3
Mov
emen
t (in
)Design
Measured
Elastic
Creep
Creep analysis for accurate assessment
Girth weld analysis
20
Research and Development
Over $1M in R&D invested over the last 3 years for boiler CA tools improvements
– Automation– Technology– New Testing Methods– Software– Training Tools
Used for long seam and girth weld inspections
21
Performance Testing & ServicesSpecialized 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– Most Commonly Used Boiler and Emissions Test
Equipment– Will Train Customers To Use Rental Equipment
Such As Emissions Analyzers– Will Beat Any Competitor’s Published Rental Rates
For Available Equipment
22
Operation & Maintenance Training
Custom Onsite Training / Hot Topics– Customized for specific plant equipment– Customized for new units and/or modifications
Quickstudy Interactive Training (CD-ROM)– Customized computer based training for specific
plant equipment operation training
Web-based Training -Boiler Basics Courses– Topics
• Boiler Types, Water & Steam Circuits, Air & Gas Circuits, Fossil Fuel Basics
23
COAL PULVERIZERMAINTENANCE SEMINAR
• RB, RS, RPS, RP type mills supplied by ALSTOMPower Inc., ABB, and Combustion Engineering, Inc.• Babcock & Wilcox MPS and EL type Pulverizers
• Riley Power Inc. ATRITA® Pulverizers
Trained Over 150 Customers in our Group Pulverizerseminars during last 2 years
Group training offered on various topics– Boiler Inspections– Pressure Part Availability– Pulverizer O&M (Fleet and Non-Fleet)
Operation & Maintenance Training (Cont.)
24
Gas/Steam Turbine
Repairs & Retrofits
(Richmond, VA)
Gas/Steam Turbine
Repairs & Retrofits
(Richmond, VA)
Air Pollution Control SystemService on all major OEM Brands- Precipitators - Fabric Filter- Venturies- Wet & Dry Scrubbers
Boiler Island
PulverizersAll Major OEM Brands- Combustion Engineering / Raymond- B & W MPS 89- B & W E & EL- Riley Atrita 550 series
Feeders (Stock)- Bunker Outlet Valves- Bunker Bottoms- Knifegate Valves- Yard & Fuel Feeders
ESP / FF
Economizer
Fly Ash
Bottom Ash
APH
Ash Handling SystemAll Major OEM Brands (ASH & UCC)- Clinker Ginders including rebuilds- Line Isolation Valves- Type E Values- Pipes/ fittings / wearbacks
Firing System Products- Burners- High Energy Ignitor- Diagnostic Flame Indicator- Ignitor Control Cabinet- Ignitor Valve Train Assembly
WFGD
Gearboxes(Rebuild Services)- Pulverizer- Conveyor Drive- Cooling tower- APH
Pressure Parts- Stock all OEM sizes- Local Fabrication- Outage Kits
Summary: Full Service Company
25
Boiler & Environmental Plant ServicesRegional Customer Services Resources
Service Centers (6)Technology Centers (5)Area Service Managers (9)Field Service Engineers (76)Cust Service Managers (21)Cust Service Reps (19)Sales Managers (25)Sales Reps (10)
26
27
C u s t o m e r S e r v i c e
INDUSTRIAL BOILER MARKET PRODUCTS/SERVICES
Superheater AssembliesAttachments/DMW’s
Drum Internals
Economizers-U Bends
Generating BankTube Shields
Drum Enclosures& Gaskets
Sootblower Openings& Sootblowers
Casing & Insulation
Floor Tubes/Panels& Refractory
BURNER COMPONENTS-Burner Components-Registers-Tips-Burner Barrels-Diffusers-Valves-Scanners-Ignitors
Burner Tubes/Panels
Safety Valves
Water WallPanels
Access Doors
TECHNICAL SERVICES-Boiler Inspection-Condition Assessment-Engineering Reports-All forms of NDE including NDIS
Roof Tubes
ALL TYPES OF BOILER MFR’S SERVICED 24/7
VU BOILER
28
C u s t o m e r S e r v i c e
INDUSTRIAL BOILER MARKET PRODUCTS/SERVICESBURNER COMPONENTS-Registers-Tips-Burner Barrels-Diffusers-Valves-Scanners-Ignitors
TECHNICAL SERVICES-Boiler Inspection-Condition Assessment-Engineering Reports-All forms of NDE including NDIS
RefractoryCasing/Insulation
Safety Valves
Economizers-U Bends
Access Doors
Drum Enclosures& Gaskets
Sootblower Openings& Sootblowers
Generating BankTube Shields
Side WallTubes
Drum Internals
Superheater AssembliesAttachments/DMW’s
Rear WallTubes
ALL TYPES OF BOILER MFR’S SERVICED 24/7VP BOILER
29
INDUSTRIAL BOILER MARKET PRODUCTS/SERVICESDrum Internals
-Smelt Spouts(Dry - Wet)-Enclosures-Openings
Port RodderDamper Systems
Draft TapRodder Systems
Generating Banks
EconomizersU-Bends
RefractoryCasing/Insulation
SuperheaterTubes
Liquor Nozzles/Goosenecks
-Floor Tubes(Chromized/Composite)
-Floor Tiles
TECHNICAL SERVICES-Boiler Inspection-Condition Assessment-Engineering Reports-All forms of NDE including NDIS
Wall Panels
C u s t o m e r S e r v i c e
ALL TYPES OF BOILER MFR’S SERVICED 24/7CHEMICAL RECOVERY BOILER
30
INDUSTRIAL BOILER MARKET PRODUCTS/SERVICESTECHNICAL SERVICES-Boiler Inspection-Condition Assessment-Engineering Reports-All forms of NDE including NDIS
Burner Components-Doors-Ignitors
AIR FLOW
LP Drum
HP DrumIP Drum
RHTR 1
DrumInternals
HPSH 1
Casing/Insulation
RHTR 2HPSH3
SCR/CO CATALYST
HPSH 2
DUCT BURNER (IF APPLICABLE)
LP EVAPORATOR
HP ECONIP EVAPORATOR 1
HP ECON
IP EVAPORATOR
IPSH - LPSH
HPECON 1
KEY:HP - High PressureIP - Intermediate PressureLP - Low PressureRHTR - ReheaterSH - Superheater
Flame Scanners
Control Equipment
C u s t o m e r S e r v i c e
HRSG
31
Where’s your wear ?Pressure Parts
32
PRESSURE PARTS - ALSTOM
33
Total Plant Capabilitiesand Solutions
Why is your WEAR ?
Results of the WEAR
Where is your WEAR ?
What is the cost of your WEAR ?
Response to the Wear
Solutions to WEAR .
34
Total Plant Capabilitiesand Solutions
WHY the WEAR ?
35Under Pressure
Installed Base
World Installed Capacity by Age
1997 1987 1977 1967 1957
0
20
40
60
80
100
120
2 7 12 17 22 27 32 37 42 47
Source: UDI
Age of Power Plant
Year of Commission
Hydro
Nuclear
ConventionalSteam
Gas Turbine
GW
Customers « Under Pressure »
Large number of conventionalboilers near nominal 30 year life
36
RESULTS OF THE WEAR
Total Plant Capabilitiesand Solutions
37
50
55
60
65
70
75
80
85
90
95
January February March April May June July August September October November December
2005 KWb 2004 KWb 2003 KWb 2002 KWb
2001 KWb 2000 KWb 1999 KWb
ALSTOM Power Inc.
“Spring” Outages
“Fall” Outages
Under Pressure
Electric Power Production U.S.by Kilowatts
Market DriversPressure Parts
Planned vs Un-planned Boiler Outages
38
Pressure Part Outage Days by Type
Under Pressure
39
Total Plant Capabilities and Solutions
Where is the WEAR ?
40
NERC/EFOR DATA
Forced Outage MWHrs per Unit Year (1993-2002)
05000
10000150002000025000
30000350004000045000
50000
Boiler
Tubes
Boiler
OtherSteam
Turbine
Balanc
e of P
lantGen
erator
Boiler
Piping
Externa
lPers
onnel
Errors
Polluti
on C
ontrol
ES&HSource: NERC 1993-2002
Boiler Tube Forced Outage MWHrs per Unit Year (1993-2002)
0
5000
10000
15000
20000
25000
Other Reheater Superheater Waterwall EconomizerSource: NERC 1993-2002
41
Total Plant Capabilities and Solutions
Cost of the WEAR
42
NERC/EFOR Global DataAverage Replacement Power Cost of One Forced Outage
$0
$500,000
$1,000,000
$1,500,000
$2,000,000
$2,500,000
$3,000,000
0 100 200 300 400 500 600 700 800 900 1000 1100
Megawatts
Cost
of O
ne F
orce
d O
utag
e
Under Pressure
43
Total Plant Capabilities and Solutions
Response to the WEAR
44
Boiler Tube StockALSTOM designs 85% coverageNon-Fleet at 40/50% coverageIndustrial at 60% coverage
Regional ManufacturingOptimized facilities Low cost optionsTubing implanted in shop for quick
turnaround Responsiveness
Drawing retrievalShop cost standardsShop capacity reporting
Engineering SupportShop level – CAD DrawingsReverse engineeringDesign Standards
EmergenciesDesigned for immediate response
ALSTOM Local SC Presents
Better Inventory Coverage3 to 1 overall differential2 to 1 on Non FleetLower costs, increase avail/response
Local Fabrication CoverageLow Cost Niche ProductsLead Time ReductionBetter service levels
Quote Response24 hoursLead Time Reduction
Key ElementSmall shop service with OEM
engineering support
Cost AvoidancesSignificant Cost SavingsReduction of MTTR
Customer Competitive Edge
Reduction of MTTR
45
ALSTOM Regional Service Centers Saves Timeand Money by Strategically Located Tubing andFabrication Capabilities
Pressure Part Tubing & Manufacturing:– 2.5M feet & 2500 different Spec.– Straight Tubing– Fabricated tubing– Assemblies– Panels– Serving all OEM Equipment– Emergency straight or Fabricated
Tube shipments in 4 hours or less– 24/7 Service
46
The Foundation of Future OpportunitiesOur speed satisfies customers’ immediate needs providing opportunities for larger projects at fleet and non-fleet installations
50 in 4 / 80 in 8 The % of U.S. utility plants reached in driving hours from our network of pressure part facilities
2.5 Million Foot, 2.5 Thousand Spec InventoryThe largest in the industry providing :
85% coverage for ALSTOM units50% coverage for Non-Fleet units60% for Industrial units
Seek
Build
Secure
47
Plant Description Em
erge
ncy
Date Job Rec.
Ship Due Date
Hours Saved MW
Savings at
$5/MW Generation
Savings
48 5
Plant A 1 Emergency Tube X 03/22/05 03/22/05 48 70 5 16,800.00$
Plant A Loose Tube "WW" Panels X 08/12/05 08/12/05 48 70 5 16,800.00$
Plant A Bent Tube X 10/11/05 10/12/05 48 100 5 24,000.00$
Plant A 4 Bent Tubes X 02/16/05 02/18/05 48 350 5 84,000.00$
Plant A 12 Emergency Tube Bends X 02/24/05 02/26/05 48 350 5 84,000.00$
Plant A 2 Bent tubes X 03/13/05 03/13/05 48 350 5 84,000.00$
Plant A 90 Degree Bend X 07/14/05 07/14/05 48 350 5 84,000.00$
Plant A Double Offsets Mark #1 & #2 X 09/09/05 09/09/05 48 350 5 84,000.00$
Plant A 90 Degree Bend X 09/12/05 09/12/05 48 350 5 84,000.00$
Plant B 1 Bent tube X 10/11/01 10/14/05 48 350 5 84,000.00$
Plant B 1 Bent tube X 04/07/05 04/07/05 48 350 5 84,000.00$
Plant B Loose Tube Bends 09/28/05 10/05/05 0 350 5 -$
Plant B DMW 09/28/05 10/05/05 0 350 5 -$
Plant B DMW's 10/05/05 10/11/05 0 350 5 -$
Plant B Stock Bend X 10/26/05 10/26/05 48 350 5 84,000.00$
Plant B Stock Bend X 10/27/05 10/27/05 48 350 5 84,000.00$
Plant B Bent Tube X 10/28/05 10/29/05 48 350 5 84,000.00$
Plant CFinishing RH Outside Loop w/48" Leg 06/10/05 08/26/05 0 0 5 -$
Plant C SH Scissor X 10/08/05 10/09/05 48 500 5 120,000.00$
Plant D Coutant Nose Bend 06/13/05 06/17/05 48 500 5 120,000.00$
Plant D 6 Emergency Tube Bends X 09/25/05 09/25/05 48 500 5 120,000.00$ 1,341,600.00$ Total Generation Saving Year to Date
Cost Savings Model
48
Fast Tubing Service
Stock Bend ProgramFabricated Loose Tubes
Straight TubingPanels
Fast Tubing Service
Stock Bend ProgramFabricated Loose Tubes
Straight TubingPanels
Additional ALSTOM Service
49
E-mail / Fax Form
Easy Ordering• Straight tubing• “U” Bends• Dissimilar metal weld inserts• Single bend tubes• Offset tubes• Double bend tubes• Waterwall panels• Bifurcates• Sketch-a-tube
Benefits• Efficient• Ensures accurate communication• Serves as a check list for required
information
Easy Ordering• Straight tubing• “U” Bends• Dissimilar metal weld inserts• Single bend tubes• Offset tubes• Double bend tubes• Waterwall panels• Bifurcates• Sketch-a-tube
Benefits• Efficient• Ensures accurate communication• Serves as a check list for required
information
50
• Identification System• Unique part number• Arrangement drawings • Fabrication details • Applicable quantities• Eliminates errors• Facilitates planning process
• Benefits• Accurate and quick
identification• Interchangeability determined• No redundant inventory• Low cost• Helps minimize downtime
• Identification System• Unique part number• Arrangement drawings • Fabrication details • Applicable quantities• Eliminates errors• Facilitates planning process
• Benefits• Accurate and quick
identification• Interchangeability determined• No redundant inventory• Low cost• Helps minimize downtime
Stock Bend Program
51
Total Plant Capabilitiesand Solutions
WEAR Solutions
52
Tube Shields
53
Tube Upgrades
With operational issues identified – material upgradescan be a cost effective solution.
• Current stock , 2.5 K Specifications / 2.5 m Feet
• Material Upgrades • Waterwall/Economizers - SA210a1 for Sa192.• SH/RH
T22 for T11TP347H for TP304T22 for T2
• All above have minimal costs to to stock procurement leverage
54
Debris Free Strainer
Simple and effective new product to eliminate Debris from Drum Drains
Sized to fit drain on your Drum
Complete installation package.
All necessary hardware
Low cost product with spectacular results
55
Parametric ModelingAccess Door
Automated Modeling/Engineering• Bent Tube Configurations• Access Doors & Seal plates• Design Details• Stock Material availability• Cost estimates
Structured Response• “see” the design • Manipulate structure• Three Dimensional – live• Significant Engineering Reduction
56
Parametric Modeling – Seal Box Configuration Sheet
57
AutoCAD Inventor Version No. 8 Parametric Model Output -
58
Fabricated Tubing
From Straight
To Fabricated
Our tubing stock allows us to bring you fabricatedtubes quickly to meet your delivery requirements
for emergencies and outages in progress.
Our tubing stock allows us to bring you fabricatedtubes quickly to meet your delivery requirements
for emergencies and outages in progress.
59
Our Tubing Stock
• 2.5 million feet • 2,500 specifications• Hard to find sizes,
specs• Indoor storage
ChattanoogaRMSC - Aurora, CONESC - Harrisburg, PASelected supply partners
• 2.5 million feet • 2,500 specifications• Hard to find sizes,
specs• Indoor storage
ChattanoogaRMSC - Aurora, CONESC - Harrisburg, PASelected supply partners
60
• The largest U.S. purchaser of boiler tubing
• Mill run purchases
• General inventory stock
• Specific contract fabrication requirements
• Domestic and off-shore tube mills
• Combine requirements across multiple contracts
• Increase order quantities
• Purchase overruns
• Inventory surplus tubing from completed contracts
• The largest U.S. purchaser of boiler tubing
• Mill run purchases
• General inventory stock
• Specific contract fabrication requirements
• Domestic and off-shore tube mills
• Combine requirements across multiple contracts
• Increase order quantities
• Purchase overruns
• Inventory surplus tubing from completed contracts
Our Purchasing Advantage
61
Burner Ignition&
Flame Monitoring
Don’t Let Poor Reliability Wear You Down
62
Burner Ignition andFlame Monitoring
Focus is on improving total plant reliability
Product designs incorporate latest technology
Modern communication and diagnostic capability
Experience leads to positive results
63
LIMELIGHT TM Ignitors and Flame Monitors
Ignitor SystemsNatural Gas to 18 MMBTu/hrNo. 2 Oil to 12 MMBTU/hr
High Energy IgnitionDirect ignition of #2 or #6 Oil
Flame MonitoringMulti frequency SpectrometerUV or IR Flame ScannerIonic Flame Detector
64
Side Horn Type Ignitor
Faster start ups through increased reliability.
Improvements in spark power, spark fouling and flame proving
65
High Performance, High Capacity Bluff Body Gas Pipe Ignitor
Details of Bluff Body
Higher capacity and improved ignitor reliability Bluff body design promotes better fuel/air mixing
Bluff Body withSpark and Flame rods
IgnitorInternals
66
Oil Pipe Ignitor Flame
No Carbon DepositsLow Opacity Flames during Cold Unit Start-up
67
LIMELIGHT™ Oil Atomizer
Lower opacity and improved reliability of ignitor operationOil droplet size reduced to increase flammability
68
NEWHigh Capacity Oil Pipe Ignitor
5” Oil Pipe Ignitor rated for 5-15 MMBtu
Based on proven designs for 3” oil pipe ignitor and high capacity oil side ignitor
Two (2) oil atomizers for pilot flame and boost
Quick, easy initial lightoff with staged ignition of the boost atomizer for full capacity
69
Solid Flame Rod and Spark Rod
Eliminates overheating wire and electrical failureSolid Rods for DFI and Spark - Replaces electrical wire 100% ceramic jacket improves insulationElectrical Connections - Improved grounding prevents arcing
70
LIMELIGHT™ DFI Upgrade
Latest design ignitor flame proving device allows for optimum reliability of your ignitors
LIMELIGHT™ DFI Upgrade
Latest design ignitor flame proving device allows for optimum reliability of your ignitors
Diagnostic Flame Indicator (DFI)
71
Provides flame monitoring and operating indicators
Based on detection of ionic flame monitoring principleImproved flame detection reliability
– 40 volts DC excitation to the flame rod increases the signal to noise ratio
– Improved grounding loop, decreased noise from transformer
– Stronger signals and improved signal processing power
Flame proven indicator and flame signal strength bar chart indicator
“First-out” Trip indication for trouble shooting
Reliability history for ignitor performance metrics
Communication capability - Digital/Analog I/O, RS 232 and CANBUS
technology for PC networking capability
Capable of remote monitoring and diagnostic
Diagnostic Flame Indicator (DFI)
72
PC Network andRemote Monitoring
Network ignitor modules allows remote monitoring and tuning from a central location
73
High Energy Ignitor (HEI)
HEI 12 Joule Exciter with Shunted Spark Tip
Increased lightoff reliabilityReduced maintenance of ignitor tipMore power released per unit of timeSelf cleaning pulsed energy release
74
LIMELIGHT™ High Energy Ignition
• Energy output 12 joules• Eliminates need for expensive auxiliary fuels• Spark rate - light oil - 4 sparks/sec• Spark rate - heavy oil - 20 sparks/sec• More power per unit of time
75
LIMELIGHT™ Ignitor Cabinet
Houses ignitor electronics local to the ignitorIncorporates electric spark device for fuel ignitionIncorporates ALSTOM’s diagnostic flame indicator for flame monitoring and safetyEnables self diagnostic of ignitorreliability and first out trip indicationsAvailable as simple interface for BMS or as self contained ignitor controller without BMS
76
LIMELIGHT™ Ignitor Pipe Trains
Oil Pipe Train– Oil and Atomizing Air Automatic Shut-off Valve– Oil Flow Controller– Air Pressure Regulator
Gas Pipe Train– Double Block and Vent Automatic Shut-off Valve– Gas Flow Regulating Valve
77
LIMELIGHTTM Ignitor Experience
Rapid success of new product upgrades introduced in 2002Approximately 1,000 upgrades sold on 100 boilers worldwideMultiple repeat orders from satisfied customersDesign input from dedicated engineers brought customer voice into design points
78
Reliability Results18 mo Operation, 48 Ignitors
0
100
200
300
400
500
600
700
800
900
A1 A3 A5 A7 B1 B3 B5 B7 C1 C3 C5 C7 D1 D3 D5 D7 E1 E3 E5 E7 F1 F3 F5 F7
Ignitor Location
Num
ber o
f Sta
rts
or F
ails
Starts Fails
79
LIMELIGHT™ HEIR Electric Ignitor
High Energy Ignitor with RetractEnergy output 12 joulesDirect lightoff of #2 or #6 fuel oilEliminates the need for higher cost gas or #2 oil ignitors for #6 oil burnersSpark rate - light oil - 4 sparks/sec Spark rate - heavy oil - 20 sparks/sec
Shown with EVERKOOLTM Oil Gun
80
Electric Ignitor for Main Burner
Easier access, less congestionFewer moving parts and controls
81
BenefitsImproves Reliability– Increase spark intensity and frequency– 12 joule energy pulse is more intense than previous models– Released at rate of 4 sparks per second or 20 sparks per second – More power per unit of time improves reliability of ignition– Power in the right place at the right time (fuel, air, heat)
Reduced Maintenance– Self-cleaning tip resists fouling from unburned fuel and
combustion products - eliminating the need to frequently take the ignitor apart for cleaning
– Solid semi-conductor spark generator improves life vs. older style semi-conductor coating
High Energy Ignitor (HEI)
82
EVER-KOOLTM Oil Guns
Features and Benefits• Incorporates our standard and proven parallel-pipe oil gun design• Oil guns remain in their firing position at all times - ready for
immediate service• Retract mechanism not required• Control systems simplified by reduced number of interlocks• Reduces coking of any oil that may remain after purging• Provides increased accessibility to the windbox front area
Features and Benefits• Incorporates our standard and proven parallel-pipe oil gun design• Oil guns remain in their firing position at all times - ready for
immediate service• Retract mechanism not required• Control systems simplified by reduced number of interlocks• Reduces coking of any oil that may remain after purging• Provides increased accessibility to the windbox front area
83
Flame Monitoring
Tangential Fireball Individual Flame Discrimination
84
Full feature Flame Monitor
Reliability in operation– No nuisance trips– High Reliability equipment with safe failure modes– Minimal maintenance requirements
Simple to set-up and maintain– Easy adjustment– Easy interface to BMS / DCS
Allows maximum boiler operational flexibilityGives additional information useful for troubleshooting problems
85
What makes a great scanner ?
Two (2) scanners in one - multiple setpoints and contacts for different fuelsEnhanced flame signal collection capability– Don’t lose any valuable information
Advanced frequency analysis– see all aspects of the flame– process multiple frequencies simultaneously
Superior reporting of all flame events– identify a good flame– identify flame changes as indication of burner or milling
performance Modern communication capability– Plant network– Remote diagnostics through internet
86
LIMELIGHTTM Flame Spectrometer
Newest Design Third Generation Scanner. Reliably detects flames in both Tangential and Wall Fired BoilersCompact packaging resulting from modern electronicsUses 7 discrete sensors for optimum ability to Analyze flameImproved ability to discriminate between support fuel flame, other burner flames and the flame to be monitoredStraight-forward connection to Burner Management System with minimum wiringImprovements based on previous experience with older generation flame scannersAvailable as an upgrade kit for older flame scanner models
87
Infrared Visible Ultraviolet
1400 700 600 500 400 200
| | | | | |
The latest generation LIMELIGHT, uses seven sensors spread from Infrared to Ultraviolet to improve flame detection, improve the ability to distinguish one burner from another and improve the ability to discriminate the type of fuel being burned.
Flame Spectrometer Fundamentals
88
What an Older FlameScanner Sees
Coal Spectra
89
What the LIMELIGHTTM
Spectrometer Sees
90
LIMELIGHTTM Spectrometer Successful Experience
•TXU Martin Lake 3 x 850 MW Coal and Oil• Dedicated engineer program identifies oil operation as EFOR
issue• EVERKOOLTM Oil Guns and HEIR ignitors improve reliability and
boiler warm up time• Superior flame discrimination from Spectrometer allows oil
flame discrimination across the load range
•Midwest Utility 2 X 100 MW• Dedicated engineer program identifies flame scanner issue
based on current operation• Fuel switch to PRB affected ignition points and impacted coial
flame scanning capability of existing scanner• Original ignitors were replaced with low capacity oil guns with
NFPA Class 3 electric ignitor requiring flame discrimination• Coal flame scanning improved, oil flame scanning achieved
91
NEWLIMELIGHTTM Exacta Scanner
Single photodiode flame scanner for basic flame scanning requirementsHigh performance at reduced cost Typically, single fuel flame scanning but can be used for multiple fuels under certain circumstancesDesigned for ignitor flame monitoring as well as tangential and wall fired main fuel firing
92
Infrared Visible Ultraviolet
1400 700 600 500 400 200
| | | | | |
IR/Visible light frequency for oil/coal flame monitoring
Flame Scanner Fundamentals
93
Infrared Visible Ultraviolet
1400 700 600 500 400 200
| | | | | |
UV sensor for gas flame monitoring
Flame Scanner Fundamentals
94
LIMELIGHTTM Exacta Flame Scanner
Ignitor Flame Monitoring
Upgrade or replacement for differential pressure switches or ionic flame rodsOptical flame scanner with UV or IR detectors for gas or oil ignitorsEasy to use Kamlock fitting to mount to ignitorFlexible electronics mounting
95
115 VAC24 VDC
To BMS
To BMS
To BMS
To BMS
To BMS
To BMS
Secure Network
DigitalNetworkTo DCS
Located near BMS
Network InterfaceModule
LIMELIGHT™ Flame Monitor Network Installation
96
Flame Monitor Summary
Flame Spectrometer for all fuels, full spectrum flame analysisExacta Flame Scanner for more specific flame monitoringNetwork capable – allows tuning of all scanners from single locationNetwork configuration can reduce wiring approximately 75%Flexible mounting configurations for all burnersAll flame monitors are adaptable for direct mount or fiber opticconfigurations
97
Where’s Your WearPulverizer
Wear in the fuel preparation system
98
DEFINITION OF WEAR
Change in dimensions due to the gradual removal of discrete particles from contacting surfaces in motion
99
COAL CHARACTERISTICS
& WEAR
HHV - boiler feed requirementReactivity - finenessHGI – mill capacityAsh – wear particles
100
COAL PROPERTIES
HHV
Mill load at MCRWear is a function of thru-put
101
COAL PROPERTIES
REACTIVITYDetermines required finenessFineness impacts recirculationFineness impacts ash particle residence time Wear increases w/ ash res. Time
FINENESS CAPACITY FACTOR
FINENESS (% THRU 200 MESH)C
APA
CIT
Y FA
CTO
R
HIGHLOW
HIGH
102
COAL PROPERTIES
OVER/UNDER BURDENHigh Silica = Alpha Quartz = High WearSand can build up hurting performanceRock can cause mechanical damage
103
TYPES OF WEAR
Abrasion – Gouging, cutting & plowing by
material entrapped between mating surfaces
– Rolls and bullringErosion– Scratching, cutting by material
flowing over stationary surface– Pulverizer classifier, coal piping and
nozzle tip
104
ABRASION
Wear particles harder than surface being abradedUnder pressure particles become
cutting toolsWear rates vary with pressure & relative hardness
105
EROSION
Wear particles harder than surface being abradedHighly velocity dependent v3+
Increases with size & quantity of wear particlesFunction of the angle of impact
106
ADDRESSING WEAR IN THE
FUEL PREPARATION SYSTEM
Basic Methods To Increase Part LifeIncrease part thicknessImprove materialsLine itChange flow patterns
107
ADDRESSING WEAR IN THE
FUEL PREPARATION SYSTEM
Simple Part life extenders to meet outage requirements
Can the part be made thicker?Can we coat it with a sacrificial coating?– Hard face weld– Thermal spray (Tungsten Carbide, Ceramic, Chrome Carbide)
Low cost Minimum performance impact
108
ADDRESSING WEAR IN THE
FUEL PREPARATION SYSTEM
MATERIAL UPGRADES
White iron castingsCeramicsWear resistant plateWeld overlays
109
MATERIAL UPGRADES
WHITE IRON CASTINGS
Cast to optimized shapeCost effective for multiple copiesHigher upfront costs due to first time pattern charges
110
TYPES OF WHITE IRON CASTINGS
NI-HARD MATERIALS– INDUSTRY STANDARD IS NOMINAL 500 BHN – ALSTOM’S CROWN 700™ IS MINIMUM 700 BHN
HIGH CHROME– ALSTOM’S COMBALLOY-HC™ HEAT TREATED 700 BHN– MAXIMIZES CARBIDES FOR MAX WEAR LIFE– GENERALLY OUT LASTS CROWN 700™ BY 50% TO 100%
111
CERAMICS
DYNAWEAR™ Alumina TileDYNAWEAR II ™ Vacuum Bonded Alumina TileDYNAWEAR III ™ Tungsten Carbide Brazed Bonded ProductsExotics – CERMASilicon Carbide
112
ALUMINA TILE
Very good in low angle impingementSupplied attached to fabricationsVacuum bonded for thin tiles & smooth surfacesWeldable (attached w/ weld plugs )Short lead times
113
CERMA™EXOTIC CERAMICS
Reaction bonded silicon carbideMetal toughened silicon carbideMaximum erosion protectionUsed for exhauster periphery & throat linersCast to shapePatterns and tooling required
114
SILICON CARBIDE
Exhauster and Mill Outlet LinersGood for direct impingement flows Cast to shapePatterns required
115
WEAR RESISTANT PLATE
AR Plate in 400 & 500 BrinnellChrome Carbide weld overlay plateShort lead timesStandard fabrication methods Minimum to no additional Engineering
116
WELD OVERLAY MATERIALS
COMBUSTALLOY ™ Very high carbide loaded weld material for rolls92 W ™ High Chrome carbide weld material for Journal RollsMisc. Hard facing wire to protect local areas of fabrications
117
ADDRESSING WEAR BY TYPE - ABRASION
Harder component material w/o becoming brittle– White irons for impact resistance– High carbide weld overlays– Very well supported ceramics
Reduce grinding pressure Improve pyrite rejection
118
ADDRESSING WEAR BY TYPE – EROSION
Harder component material Increased material thicknessAdjust flow patterns – Reduce velocity– Minimize quantity of wear particles
119
ADDRESSING EROSION THRU FLOW MANAGEMENT
Lowering velocity reduces wear– Deprives wear particles of energy– 10% lower vel. = 33+ % wear reduction
Redirecting flow – Flow breakers– System design changes
120
ADDRESSING EROSION THRU FLOW MANAGEMENT
CFD COMPUTER MODELING1ST Collect actual field wear patterns
121
CFD COMPUTER MODELING
2nd Develop model to match wear patterns
122
WEAR MODELING FLOW BREAKERS
Smooth Body Liner Body Liners w/ flow breakers
High Separator Body Wear Reduced Separator Body Wear
123
CLASSIFIER FLOW PATTERN MODELS
Three different design vane wheel assemblies
Vane wheels w/o deflectorsClassic deflector vane wheelFLOW-PRO ™
124
VANE WHEELW/0 DEFLECTORS
Vel
ocity
(ft/s
)
High velocityHigh sep body wearPoor distributionLow vane wear
125
CLASSIC VANE WHEELV
eloc
ity (f
t/s)
Excellent distributionLow sep.Body wearVanes wear
126
FLOW-PRO VANE WHEEL™V
eloc
ity (f
t/s) Low velocity
Low wearCoal kept out of vane area
127
INTERESTING WEAR IMPROVEMENT GADGETS
– Crown 700™ Deflector Liner Stud
128
Burner System
Distributor
Orifice
Coal exitspulverizer
Piping
NozzleTip
Discharge Valve
129
DYNAWEAR IITM Riffle Distributor Housing
Features• Vacuum bonded 1/8” thick tile
lines high wear area• Vacuum bonding ensures tiles
will not separate from the base metal due to impact or bending stresses
• Minimal effect on pressure drop and component weight
Features• Vacuum bonded 1/8” thick tile
lines high wear area• Vacuum bonding ensures tiles
will not separate from the base metal due to impact or bending stresses
• Minimal effect on pressure drop and component weight
Benefits• No modifications to the housing
required• Double the life of your housing
at 1.5 times the cost• Saves on maintenance time
Benefits• No modifications to the housing
required• Double the life of your housing
at 1.5 times the cost• Saves on maintenance time
130
Coarse-Cut Riffle Elements
Features• Interchangeable with existing
standard elements• Aerodynamically designed directional
vanes ensure proper flow• Elements can be stacked to provide
greater coal distribution flexibility
Features• Interchangeable with existing
standard elements• Aerodynamically designed directional
vanes ensure proper flow• Elements can be stacked to provide
greater coal distribution flexibility
Benefits• Wider openings help reduce pressure
loss. In a 4-way exhauster: 2-4” pressure gain may be experienced
• Available with DYNAWEAR II™ vacuum bonded ceramics, doubling the life at 1.5 times the cost
• Reduced maintenance cost• Potential distribution improvement
Benefits• Wider openings help reduce pressure
loss. In a 4-way exhauster: 2-4” pressure gain may be experienced
• Available with DYNAWEAR II™ vacuum bonded ceramics, doubling the life at 1.5 times the cost
• Reduced maintenance cost• Potential distribution improvement
131
Fuel Pipe Orifice
Key Function:Coal pipe orifices are selectively installed in coal pipes to
balance out pressure drops and equalize the split of total coal and air leaving a given pulverizer.
Key Function:Coal pipe orifices are selectively installed in coal pipes to
balance out pressure drops and equalize the split of total coal and air leaving a given pulverizer.
132
QUICKCHANGETM
Removable Orifice
Benefits • Pull-out design cuts orifice
replacement time to a fraction of previous designs
• Easy to inspect visually
• Can accommodate orifices made of various wear-resistant materials (CROWN 700TM or ceramics)
• Fast, easy replacement with boiler on-line (after pulverizer is taken out of service)
Benefits • Pull-out design cuts orifice
replacement time to a fraction of previous designs
• Easy to inspect visually
• Can accommodate orifices made of various wear-resistant materials (CROWN 700TM or ceramics)
• Fast, easy replacement with boiler on-line (after pulverizer is taken out of service)
133
DYNAWEARTM Fuel Pipe Orifice
Benefits
• Double the wear over cast iron or Ni-Hard, reducing cost of ownership
• Individual tiles or complete set of tiles can be replaced without replacement of the outer steel ring, reducing replacement cost
Benefits
• Double the wear over cast iron or Ni-Hard, reducing cost of ownership
• Individual tiles or complete set of tiles can be replaced without replacement of the outer steel ring, reducing replacement cost
Features
• Wear surface protected with interlocking high-density aluminaceramic tiles
• Outside steel ring provides proper diameter geometry
• Direct replacement to previous design
Features
• Wear surface protected with interlocking high-density aluminaceramic tiles
• Outside steel ring provides proper diameter geometry
• Direct replacement to previous design
134
Fuel Piping
Even Distribution:• Coal particles tend to
concentrate in narrow streams or ropes during transport
• Deflector blocks • Break up and diffuse the coal
rope prior to its entering the coal nozzle.
• Fuel Inlet Elbow - one block
• Last elbow in horizontal run -two blocks
Even Distribution:• Coal particles tend to
concentrate in narrow streams or ropes during transport
• Deflector blocks • Break up and diffuse the coal
rope prior to its entering the coal nozzle.
• Fuel Inlet Elbow - one block
• Last elbow in horizontal run -two blocks
Erosion:• Wear in coal pipe elbows is
due to the acute change in coal air stream direction.
• Highest wear elbows• The first elbow downstream of
the pulverizer • The first elbow after a riffle
distributor. • Fuel Inlet elbow
• For wear protection at these locations one or more kicker blocks may be installed with the blunt side facing downstream .
Erosion:• Wear in coal pipe elbows is
due to the acute change in coal air stream direction.
• Highest wear elbows• The first elbow downstream of
the pulverizer • The first elbow after a riffle
distributor. • Fuel Inlet elbow
• For wear protection at these locations one or more kicker blocks may be installed with the blunt side facing downstream .
135
Fuel Piping
Types of fuel piping:– Original installation
• Cast ductile iron• Ni-Hard (no longer supplied)• Carbon steel
– Replacement types• Cast ductile iron• Carbon steel• Ceramic lined
Mechanically interlockedVacuum bonded
136
Fuel Piping
137
DYNAWEARTM Fuel Piping
Features and Benefits• Ceramic-lined for increased wear
protection• Lined with 1” thick pressed, high
density alumina wear tiles• Mechanically-interlocked and
adhesively bonded • Direct replacement to existing cast
and steel piping and elbows• Inside diameter maintained to
ensure proper fuel flow• Pre-engineered tiles tapered to
ensure proper fit• Deflector blocks of solid ceramic
alumina tiles are available
Features and Benefits• Ceramic-lined for increased wear
protection• Lined with 1” thick pressed, high
density alumina wear tiles• Mechanically-interlocked and
adhesively bonded • Direct replacement to existing cast
and steel piping and elbows• Inside diameter maintained to
ensure proper fuel flow• Pre-engineered tiles tapered to
ensure proper fit• Deflector blocks of solid ceramic
alumina tiles are available
138
DYNAWEAR IITM Fuel Piping
Features• Smooth radius steel bends• Vacuum bonded 1/8” thick tile
lines high wear area• Excellent application for other
OEM fuel piping
Features• Smooth radius steel bends• Vacuum bonded 1/8” thick tile
lines high wear area• Excellent application for other
OEM fuel piping
Benefits• Vacuum bonding ensures tiles
will not separate from the base metal due to impact or bending stresses
• Can be installed without modifying support system
Benefits• Vacuum bonding ensures tiles
will not separate from the base metal due to impact or bending stresses
• Can be installed without modifying support system
139
Fuel Nozzle
Key Function:
• Directs (by tilting tip) the coal and air mixture to raise or lower flame in order to control furnace heat absorption and thus heat absorption in the superheater and reheater sections.
• Compensates for the effects of ash deposits on furnace-wall heat absorption
• Allows partial control over NOx emission
Key Function:
• Directs (by tilting tip) the coal and air mixture to raise or lower flame in order to control furnace heat absorption and thus heat absorption in the superheater and reheater sections.
• Compensates for the effects of ash deposits on furnace-wall heat absorption
• Allows partial control over NOx emission
140
Quick-PointTM Coal Nozzle Positioning Device
Features• Easy positioning of coal nozzle• Adjustment of nozzle from rear of
compartment• Rollers allow easy movement
Benefits• Time savings for installation,
positioning and removal of coal nozzle
•A typical installation experience is half of jacking bolt design
• Easier access to positioning mechanism, more precise adjustment
• Allows conventional tools to be used for adjustment
Features• Easy positioning of coal nozzle• Adjustment of nozzle from rear of
compartment• Rollers allow easy movement
Benefits• Time savings for installation,
positioning and removal of coal nozzle
•A typical installation experience is half of jacking bolt design
• Easier access to positioning mechanism, more precise adjustment
• Allows conventional tools to be used for adjustment
141
Fuel Piping
142
DYNAWEARTM Coal Nozzle
Features and Benefits• Approximately 3 times the
wear life at only twice the cost • Pre-engineered tapered tiles
ensure proper tile attachment• Minimal gapping between
tiles (1/16” allowable)• 2000º F degree cement • Fabricated shell can be
relined• Offset seams between rows
to eliminate channel erosion• Scalloped flange design front
section for proper air cooling to tip
Features and Benefits• Approximately 3 times the
wear life at only twice the cost • Pre-engineered tapered tiles
ensure proper tile attachment• Minimal gapping between
tiles (1/16” allowable)• 2000º F degree cement • Fabricated shell can be
relined• Offset seams between rows
to eliminate channel erosion• Scalloped flange design front
section for proper air cooling to tip
143
Nozzle Tip
Key Function:• Tilted by nozzle, directs
mixture of coal and air• Even distribution of coal
in the air
Key Function:• Tilted by nozzle, directs
mixture of coal and air• Even distribution of coal
in the air
Key Features:• Resistance to high
temperature of furnace flames
• Resistance to coal erosion• Prevent air/coal leakage
inside the nozzle
Key Features:• Resistance to high
temperature of furnace flames
• Resistance to coal erosion• Prevent air/coal leakage
inside the nozzle
144
AEROTIPTM Coal Nozzle Tips
Features and Benefits• Rounded corner - inner & outer
shroud to prevent coal deposits• Recessed inner shroud &
splitter plates to protect from furnace heat
• Tapered trailing edges to promote aerodynamic fuel flow
• Hardfaced leading edges to protect against erosion
• Bulbous outer shroud to eliminate secondary air bypass during tilt
Features and Benefits• Rounded corner - inner & outer
shroud to prevent coal deposits• Recessed inner shroud &
splitter plates to protect from furnace heat
• Tapered trailing edges to promote aerodynamic fuel flow
• Hardfaced leading edges to protect against erosion
• Bulbous outer shroud to eliminate secondary air bypass during tilt
145
FASTip™ Two-Piece Format
Features:• Two piece design• Entire inner shroud and forward
section or outer make up front section
• Replaceable from furnace side• Pivot pins, reach rod and link pin
accessible from furnace sideBenefits:• Nozzle tip replacement from
within the furnace• Replacement time significantly
reduced, savings of up to 50%• Component cost reduced by
replacing only front section
Features:• Two piece design• Entire inner shroud and forward
section or outer make up front section
• Replaceable from furnace side• Pivot pins, reach rod and link pin
accessible from furnace sideBenefits:• Nozzle tip replacement from
within the furnace• Replacement time significantly
reduced, savings of up to 50%• Component cost reduced by
replacing only front section
146
FASTip™ Feature can be applied to most nozzle tip types
FASTip™ Feature can be applied to most nozzle tip types
FASTip™ One-Piece Format
Features• One piece design• Replaceable from furnace side• Patented pivot pin and locking
rod
Benefits• Nozzle tip replacement from
within the furnace• Replacement time significantly
reduced, savings up to 50%• Entire tip replaced reduces fit
up problems
Features• One piece design• Replaceable from furnace side• Patented pivot pin and locking
rod
Benefits• Nozzle tip replacement from
within the furnace• Replacement time significantly
reduced, savings up to 50%• Entire tip replaced reduces fit
up problems
147
Hardfacing Options for Coal Nozzle Tips
Features Hardfacing of splitter plate leading
edges standard. Sample of other options:
• Splitter plates• Top & bottom inner coal shroud
plates• Inner coal shroud side plates
with corners• Hardfacing thickness available in
single (~1/8”) and double pass (~1/4”)
• Available for all coal nozzle tips
Features Hardfacing of splitter plate leading
edges standard. Sample of other options:
• Splitter plates• Top & bottom inner coal shroud
plates• Inner coal shroud side plates
with corners• Hardfacing thickness available in
single (~1/8”) and double pass (~1/4”)
• Available for all coal nozzle tips
Benefits• Improved erosion resistance• May double service life
Benefits• Improved erosion resistance• May double service life
148
The correct coveragefor the
wear protection you need
The correct coveragefor the
wear protection you need
Ninedifferent options
available
Ninedifferent options
available
Hardfacing Options for Coal Nozzle Tips
149
Second pass hardfacing completed
Second pass hardfacing completed
Splitter plate with double pass hardfacing
Splitter plate with double pass hardfacing
Hardfacing for Coal Nozzle Tips
150
Where’s your wear?EL Type Pulverizers
151
EL Mill Wear Areas
High Velocity Erosion, ImpactsAnd High Temperature
Low Velocity Erosion
High Stress Abrasion and Impacts
Low Stress Abrasion
152
EL Mill Wear Areas
Bearing Plate
Housing and Liners
Rings and Balls
Yokes
Louver, Cone and Discharge Section
Turret Section
Swing Valves
Turret Plate
Spring Bolts
153
Swing Valve Seats
154
Turret Liners
155
Ceramic Lined Turret
• Advanced wear resistant materials• Factory assembled for installation cost reduction
156
EL Mill Wear Areas
Louver, Cone and Discharge Section• Low Stress Abrasion• Low Velocity Erosion
157
Louver and Vanes
Available in Abrasion Resistance Plate or Vacuum Bonded Ceramics
158
Ceramic LinedCenter and Tailing Sections
159
Center Section Exterior Liners
Patches in many shapes and sizes
Easy to repair or protect against local wear
160
EL Mill Wear Areas
Spring Bolts• Low Velocity Erosion
• Bearing Wear
161
EL Mill Housing
162
EL Mill Housing
Vacuum Bonded Liners Field Welded to Housing
• Faster than field Weld Overlay Repairs• Longer lasting than Weld Overlay Repair
163
EL Mill Housing Liners
Smooth Style
Bolt Thru Style
• Eliminates wear around vanes
• Eliminates jams between ring and vane
• Reliable attachment
164
EL Mill Housing Liners
150 micron, 100 mesh particles
Improved Flow Original Design Flow
165
Grinding Rings and Balls
Problem Areas• Top Ring Centering• Grinding Ball Grading• Bottom Ring Centering• Bottom Ring Cracking
• Quality parts• Experienced Field Engineers• Training programs
166
Thermal Barrier Coated Bottom Ring
EL Grinding Parts
Better reliability with PRB Coal
167
EL Mill Wear Areas
Bearing Plate• Low Stress Abrasion• Impacts • Temperature
168
Optimized Wear Solutions
High Velocity Erosion, ImpactsAnd High Temperature
Low Velocity Erosion
Low Stress Abrasion
High Stress Abrasion and Impacts
• Wide selection of wear materials• Application Options• Alternate designs to minimize wear
Lower Maintenance Cost
169
EL Mill Wear Summary
Alstom utilizes a Continuous Improvement Program to migrate the performance of the EL Mill– Ever improving design– Flexible with changing market demands
Alstom offers advanced wear resistant components for all key locations in the mill– Extended time between outages– Short installation times
Alstom provided rebuild and rotation options– Cost reduction
• Component• Installation labor
170
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© COPYRIGHT 2006 ALSTOM Power Inc. All rights reserved.
This presentation, or any part thereof, may not be reproduced in any form without the written permission of the publisher.
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