6- Colombia Presentation Revised k

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)

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


INDUSTRIAL BOILER MARKET PRODUCTS/SERVICESBURNER COMPONENTS-Registers-Tips-Burner Barrels-Diffusers-Valves-Scanners-Ignitors


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


Wall Panels


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


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


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


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


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


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


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


1400 700 600 500 400 200

| | | | | |

IR/Visible light frequency for oil/coal flame monitoring

Flame Scanner Fundamentals

93


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



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



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


• 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


• Can be installed without modifying support system

Benefits• Vacuum bonding ensures tiles


• 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


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


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


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

www.service.power.alstom.com

© 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.

6- Colombia Presentation Revised k

Documents

Transcript of 6- Colombia Presentation Revised k