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Alstom Pulverizer Catalog.pdf - APComPower, Inc.

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POWER SERVICE


1<br />

<strong>Alstom</strong> Power <strong>Inc</strong>. (<strong>Alstom</strong>) is recognized<br />

around the world as a leader in the design,<br />

manufacturing and servicing of power<br />

generation equipment. While our heritage<br />

dates to the late 1800’s, our capabilities<br />

continue to expand and point us to the future.<br />

At <strong>Alstom</strong>, we combine our<br />

capabilities and experience to<br />

enhance the productivity and<br />

performance of your boilers,<br />

pulverizers, air pollution control<br />

systems, ash handling systems<br />

and auxiliary equipment.<br />

We are an organization<br />

that focuses on customer<br />

service and understands<br />

the challenges faced by<br />

plant owners, operators,<br />

maintenance personnel<br />

and management.<br />

Whether it is a simple<br />

replacement part, a<br />

rebuilt assembly, a<br />

custom fabrication or<br />

inventory management<br />

program, <strong>Alstom</strong><br />

provides value and<br />

service to our customer.


Table of Contents<br />

Introduction to the <strong>Alstom</strong> <strong>Pulverizer</strong> ......................................................................................................3<br />

Achieving <strong>Pulverizer</strong> PAR (Performance – Availability - Reliability) ..........................................................5<br />

Grinding Rolls and Grinding Segments ......................................................................................................6<br />

FLOW-PRO Vane Wheel Technology ......................................................................................................9<br />

Advanced Static Classifier ........................................................................................................................11<br />

Exhauster Products ..................................................................................................................................12<br />

<strong>Pulverizer</strong> Gearbox Services ....................................................................................................................16<br />

Pre-Assembled Components ....................................................................................................................17<br />

Other <strong>Pulverizer</strong> Upgrades ......................................................................................................................19<br />

<strong>Pulverizer</strong> Journal Rebuild Services and Products ....................................................................................21<br />

R 3 Component Rotation Programs ..........................................................................................................23<br />

The <strong>Alstom</strong> Advantage ............................................................................................................................24<br />

Regional Service Centers..........................................................................................................................25<br />

2


3<br />

Introduction to the <strong>Alstom</strong> <strong>Pulverizer</strong><br />

In 1923 Combustion Engineering (CE)<br />

acquired the Raymond Brothers Impact<br />

<strong>Pulverizer</strong> Company considered one of the<br />

nation’s leading manufacturers of pulverizing<br />

and grinding equipment.<br />

In 1933 CE introduced the CE bowl-type<br />

pulverizer based on original Raymond<br />

Brothers technology. Today this design<br />

is owned by <strong>Alstom</strong> and with over<br />

70 years of continuous development<br />

and improvement <strong>Alstom</strong><br />

pulverizers are highly respected<br />

within the power industry.<br />

<strong>Alstom</strong> pulverizers span the<br />

globe and have been built in<br />

a variety of sizes and<br />

capacities. We offer a full<br />

line of parts, service and<br />

solutions to help ensure<br />

that your pulverizers<br />

provide optimum<br />

operation.<br />

<strong>Alstom</strong> Family<br />

of <strong>Pulverizer</strong>s<br />

The designation of the<br />

pulverizer provides<br />

information pertaining to<br />

the pulverizer<br />

configuration, physical size<br />

of the bowl and the type of<br />

operating system.<br />

The “RB” indicates a steep-sided<br />

bowl type of pulverizer that<br />

operates under a negative pressure<br />

and uses an exhauster fan.<br />

<strong>Pulverizer</strong> Size Base Capacity lbs/hr<br />

312 3,550<br />

352 4,450<br />

412 8,000<br />

473 13,300<br />

533 20,300<br />

593 28,200<br />

633 36,500<br />

673 41,500<br />

713 50,100<br />

753 59,100<br />

Note: Not all pulverizer sizes and capacities are listed.<br />

RB <strong>Pulverizer</strong>


The “RS” indicates a shallow-bowl pulverizer<br />

that operates under a negative pressure on a<br />

balanced draft furnace. An “RPS” indicates a<br />

shallow-bowl pulverizer that operates under<br />

a slightly positive pressure and was originally<br />

associated with pressurized furnaces. Both<br />

these pulverizer types are used with an<br />

exhauster fan.<br />

<strong>Pulverizer</strong> Size Base Capacity lbs/hr<br />

403 10,200<br />

503 21,200<br />

603 36,800<br />

663 48,500<br />

703 58,000<br />

743 68,500<br />

783 80,500<br />

803 87,500<br />

843 100,000<br />

863 106,000<br />

Note: Not all pulverizer sizes and capacities are listed.<br />

RS/RPS <strong>Pulverizer</strong><br />

The “RP” indicates a shallow-bowl type<br />

pulverizer that operates under a positive<br />

pressure. Early systems were associated with<br />

either a pressurized or balanced draft furnace.<br />

Today few, if any, pressurized coal-fired<br />

furnaces are produced. These pulverizers<br />

utilize a primary air fan.<br />

<strong>Pulverizer</strong> Size Base Capacity lbs/hr<br />

603 36,800<br />

663 48,500<br />

743 68,500<br />

763 74,500<br />

803 87,500<br />

863 106,000<br />

943 132,000<br />

1003 150,000<br />

1043 170,000<br />

1103 200,000<br />

Note: Not all pulverizer sizes and capacities are listed.<br />

RP <strong>Pulverizer</strong><br />

4


5<br />

The HP pulverizer was developed in the<br />

mid-1980s. This pulverizer incorporates<br />

design changes to extend grinding element<br />

life and reduce replacement part costs,<br />

maintenance costs and down time.<br />

The HP pulverizer design incorporates a<br />

vane wheel, an improved horizontal<br />

scraper assembly, a tall top classifier for<br />

improved classification and a planetary gear<br />

drive assembly.<br />

<strong>Pulverizer</strong> Size Base Capacity lbs/hr<br />

603 36,800<br />

663 48,500<br />

743 68,500<br />

803 87,500<br />

863 106,000<br />

943 132,000<br />

1003 150,000<br />

1103 200,000<br />

1203 250,000<br />

1303 300,000<br />

Note: Not all pulverizer sizes and capacities are listed.<br />

HP <strong>Pulverizer</strong><br />

Achieving <strong>Pulverizer</strong> Par<br />

Performance • Availability • Reliability<br />

The power industry demands that plant<br />

equipment perform up to expectations.<br />

With over 70 years of pulverizer experience,<br />

offering of the latest technology and our<br />

commitment to service, <strong>Alstom</strong> provides<br />

unequaled support to our customers.<br />

Proper fuel preparation is key to boiler<br />

operation. <strong>Pulverizer</strong>s must perform well<br />

under all conditions, be available whenever a<br />

change in load dictates and remain reliable<br />

whenever in service. Only with this<br />

combination will your game be up to PAR.<br />

Through continuous research <strong>Alstom</strong> offers<br />

state-of-the-art components incorporating the<br />

latest wear-resistant materials designed to<br />

increase product life and reduce maintenance<br />

costs. Mechanical upgrades supplied by<br />

<strong>Alstom</strong> improve pulverizer operation and help<br />

reduce maintenance costs while our<br />

performance improvements help maximize<br />

pulverizer capacity and performance.<br />

Strategically located <strong>Alstom</strong> Service Centers<br />

maintain a vast stock of replacement parts<br />

and also serve as the focus for <strong>Alstom</strong>’s<br />

Inventory Management Programs.<br />

Additionally these <strong>Alstom</strong> facilities provide<br />

timely and comprehensive rebuild services of<br />

pulverizer and boiler components.<br />

Wear-resistant components, mechanical<br />

upgrades and performance improvements<br />

help <strong>Alstom</strong>’s customers achieve <strong>Pulverizer</strong><br />

PAR and stay at the top of their game.


Wear Resistance<br />

<strong>Inc</strong>rease product life and<br />

reduce maintenance<br />

Mechanical Upgrades<br />

Improve operation and<br />

reduce maintenance<br />

Performance<br />

Improvement<br />

Regain lost capacity and<br />

increase performance<br />

Grinding Rolls and Grinding Segments<br />

Raw coal enters the pulverizer that<br />

is combined with classifier<br />

tailings and then fed into the<br />

grinding zone. The<br />

grinding zone consists<br />

of the driven bowl<br />

and three roll<br />

assemblies. The roll<br />

assemblies are<br />

free to rotate on<br />

the coal bed. A<br />

spring imparts<br />

thousands of<br />

pounds of force to<br />

the rotating<br />

grinding roll.<br />

This force causes the grinding roll to grind<br />

the coal and reduce it in size. Both the<br />

grinding roll and the bowl segments will<br />

wear over time causing the pulverizer to<br />

lose grinding efficiency.<br />

Replacement grinding rolls and segments are<br />

available in a variety of materials that will<br />

maximize life and reduce downtime for<br />

change out. Choosing the right grinding<br />

surface material for your pulverizer will be<br />

dependent on your coal properties. <strong>Alstom</strong>’s<br />

experts can help you make the right choice.<br />

4<br />

2<br />

3<br />

1<br />

Logistics and Distribution<br />

Service Centers<br />

Inventory Management<br />

Following the Coal Path<br />

First and second areas of coal<br />

contact are the bowl grinding<br />

segments (1) and the grinding<br />

rolls (2) followed by the vane<br />

wheel (3) and the pulverizer<br />

outlet classifier section (4).<br />

6


7<br />

XWIN® Grinding Roll and Grinding<br />

Segment Technology<br />

Maintenance on any piece of equipment<br />

around your plant is a fact of life, but it<br />

doesn’t have to be a continuous way of life.<br />

<strong>Pulverizer</strong> grinding rolls and grinding<br />

segments wear over time. Downtime for<br />

replacement of bowl grinding segments and<br />

grinding rolls means that your equipment is<br />

not available for operation.<br />

<strong>Alstom</strong> offers bowl grinding segments<br />

and grinding rolls that exhibit a<br />

wear life much greater than<br />

chrome carbide overlaid grinding<br />

rolls. This significantly extends<br />

the pulverizer roll and<br />

grinding segment life and<br />

substantially lowers the<br />

maintenance cost for<br />

replacing these<br />

components.<br />

Xwin® grinding roll showing “honeycomb” design<br />

<strong>Alstom</strong>’s pulverizer technology<br />

is now combined with Xwin®<br />

cast product technology for bowl<br />

segments and grinding rolls. This<br />

technology developed by<br />

Magotteaux, <strong>Inc</strong>. has shown dramatic<br />

results on <strong>Alstom</strong> RB pulverizers and has<br />

also been applied to <strong>Alstom</strong>’s RS, RP, and<br />

RPS shallow bowl pulverizers.<br />

Xwin is a registered trademark of Magotteaux, <strong>Inc</strong>.<br />

Magotteaux utilizes a metal matrix composite<br />

(MMC) to produce the Xwin® grinding<br />

segments and grinding rolls that are designed<br />

to be superior to any other grinding roll or<br />

grinding segment currently offered.<br />

Xwin® grinding segments<br />

This composite combines the extreme wear<br />

resistance of ceramic with the mechanical<br />

properties of cast alloys. MMC is composed of<br />

ceramic particles imbedded and reinforced<br />

with a high chrome alloy evenly distributed in<br />

a honeycomb design.<br />

Use of the new MMC results in reduced wear<br />

and a higher resistance to breakage over<br />

traditional monometallic grinding rolls.<br />

The Xwin® grinding roll demonstrates a<br />

considerable improvement in wear life,<br />

better fineness, decreased spillage, lower<br />

pulverizer amps and reduced wear on the<br />

classifier components. The overall benefits<br />

are improved performance, improved<br />

efficiency and reduced operating and<br />

maintenance costs.


Grinding Roll Hard<br />

Surfacing Technology<br />

As an alternative, grinding rolls can be<br />

resurfaced using COMBUSTALLOY Chrome<br />

Carbide Weld Wire (CE52 & CE92) or hybrid<br />

heavy tread, a tungsten carbide weld.<br />

Applying the best wear material in the<br />

highest wear areas helps assure the longest<br />

life from the roll while keeping costs down.<br />

Summary<br />

<strong>Alstom</strong> offers a variety of options for<br />

replacement grinding rolls and grinding roll<br />

surfaces. Whether you choose a complete<br />

grinding roll replacement or elect resurfacing<br />

there are several wear-resistant options that<br />

are designed to extend the wear life of the<br />

grinding roll. The results include better<br />

fineness, decreased spillage, lowering<br />

pulverizer amps and wear on the<br />

classifier components. Your benefits are<br />

improved performance, improved efficiency<br />

and reduced costs.<br />

8


9<br />

FLOW-PRO Vane Wheel<br />

Vane wheel technology was originally<br />

pioneered by <strong>Alstom</strong> and has been in use<br />

for over 25 years.<br />

Prior to the use of a vane wheel <strong>Alstom</strong><br />

pulverizers utilized three fixed openings to<br />

admit primary air to the area above the bowl.<br />

Coal settling out, high wear areas and poor<br />

distribution to the classifier were all factors<br />

that led to the advent of the vane wheel.<br />

Through careful computational flow<br />

modeling (CFM) <strong>Alstom</strong> has been<br />

able to continuously improve the<br />

vane wheel assembly.<br />

As illustrated in the CFM for<br />

the original vane wheel<br />

design, there are low<br />

velocities in the upper<br />

body with good mixing in<br />

the mid and upper body<br />

area, good classification<br />

in the lower body area<br />

and even distribution to<br />

the classifier area.<br />

The model also<br />

illustrates that there are<br />

high velocities above<br />

the vane wheel vanes<br />

that can lead to localized<br />

wear and recirculation of<br />

coal/air in the vane area.<br />

Flow Modeling for Original Vane Wheel Design<br />

<strong>Alstom</strong> has developed a new primary<br />

classifier, the low profile FLOW-PRO<br />

Vane Wheel, to manage the critical air and<br />

coal mixing occurring around the outer<br />

diameter of the bowl. The FLOW-PRO<br />

Vane Wheel retains the time proven flow<br />

patterns through the pulverizer with reduced<br />

wear and greater simplicity.<br />

This is achieved by lowering the deflector<br />

liners of the classic vane wheel from the zone<br />

where the coal has been entrained by the<br />

airflow down to the elevation where the air<br />

meets the coal. The lowered deflector liners<br />

catch the primary air (PA) flow while it’s still<br />

clean and redirects it inward over the bowl<br />

rim where it entrains the coal. The coal is<br />

rolled immediately back over the bowl and<br />

decelerated to allow the large particles to<br />

drop back to the table for further<br />

pulverization. The remaining smaller coal<br />

particles are directed up through the separator<br />

body at relatively low velocity for reduced<br />

wear, enhanced drying and improved<br />

classifier efficiency.<br />

Flow Modeling for FLOW-PRO Vane Wheel Design


Features<br />

• Deflector liners are located down in the<br />

clean air region for reduced wear<br />

• 360 degree flow path for even flow<br />

distribution to the classifier<br />

• Promotes reduced velocities for reduced<br />

down stream wear<br />

• Coal flow patterns are kept off the mill body<br />

virtually eliminating body wear<br />

• The flow control gap between the rotation<br />

and stationary components is out of the<br />

erosion zone<br />

• Wingtips retained for efficient air velocity<br />

and spillage control<br />

• The small size and steep angle of<br />

the deflector liners do not<br />

provide any coal hide out<br />

areas<br />

• A selection of wear<br />

materials and vane<br />

wheel attachment<br />

methods are<br />

available<br />

Benefits<br />

• <strong>Inc</strong>reased<br />

pulverizer<br />

availability<br />

• Reduced<br />

maintenance<br />

costs<br />

As illustrated here,<br />

the new FLOW-PRO<br />

Vane Wheel incorporates<br />

a resized deflector along with<br />

high-grade liner materials for the<br />

deflector, vane and wing tips. The<br />

CFM and the force and velocity analysis<br />

illustrate more uniform flow velocities that<br />

substantially reduces localized wear.<br />

Original Liner Design FLOW-PRO Liner Design<br />

Wear Outfitted Vane Segments<br />

<strong>Alstom</strong> can customize vane segments to<br />

suit our customer’s needs for both complete<br />

FLOW-PRO Vane Wheels or replacement<br />

parts for an existing vane wheel assembly.<br />

Since <strong>Alstom</strong> designed and built your<br />

pulverizers there is no second-guessing as to<br />

what parts will fit and work.<br />

AR plate inner shroud<br />

Theory Behind FLOW-PRO<br />

Force and Velocity Analysis<br />

Replaceable vane liners<br />

mad from Triten plate<br />

Stoody overlay<br />

<strong>Alstom</strong> Customizes Vane Wheel Segments<br />

10


11<br />

Advanced Static Classifier<br />

The final path the coal takes before leaving<br />

the pulverizer is through the classifier<br />

section. While using well-maintained grinding<br />

rolls and grinding ring segments<br />

and ensuring the correct velocities through<br />

the vane wheel are critical to pulverizer<br />

performance, the classifier is equally<br />

important to pulverizer performance.<br />

<strong>Alstom</strong>’s advanced static classifier (ASC)<br />

has been developed through computer<br />

flow modeling at its Power Plant<br />

Laboratory. The ASC has been<br />

modeled to improve classifier<br />

efficiency. Better fineness<br />

control has been achieved<br />

while maintaining the<br />

same pressure drop.<br />

Fineness testing has<br />

proven that the amount<br />

of 50 mesh particles<br />

has been reduced.<br />

For high wear areas<br />

on the ASC, <strong>Alstom</strong><br />

offers such options as<br />

DYNAWEAR II<br />

Vacuum Bonded<br />

Ceramics, AR Plate<br />

and CROWN 700<br />

Castings. The ASC is<br />

currently available for all<br />

<strong>Alstom</strong> pulverizer types<br />

and sizes.<br />

The ASC is designed to provide better fineness<br />

classification and improved efficiency through<br />

calculated window height and length<br />

dimensions, an extra deflector ring and new<br />

profile classifier blades. The improved fineness<br />

occurs at the same classifier settings with<br />

lower pressure drops. The ASC’s components<br />

are supplied in wear-resistant materials<br />

resulting in increased service life.<br />

Computer Flow Modeling<br />

Extra deflector ring (1)<br />

Calculated window height<br />

and length (2)<br />

New profile classifier blades (3)


Exhauster Products<br />

RB, RS and RPS pulverizers use exhausters<br />

to transport the coal from the pulverizer to<br />

the boiler. Following the coal path in the<br />

pulverizer the next area of coal contact is<br />

the exhauster section.<br />

<strong>Alstom</strong> can supply<br />

fully assembled,<br />

dynamicallybalanced<br />

exhauster wheel<br />

assemblies ready<br />

for immediate<br />

installation.<br />

<strong>Alstom</strong> also<br />

rebuilds<br />

exhauster wheel<br />

assemblies to<br />

strict procedures at<br />

its Regional Service<br />

Centers. DYNAWEAR<br />

II Vacuum Bonded and<br />

DYNAWEAR III Tungsten<br />

Carbide Brazed Bonded<br />

Products can be selected to achieve<br />

extended wear life and maximize run time<br />

and outage cycle time.<br />

Series 843 Whizzer Wheel Assembly<br />

Series 633 Exhauster<br />

12


13<br />

Whizzer Wheel Fan Blade Options<br />

A variety of options are available for the<br />

exhauster’s fan blades based on particular<br />

wear profiles experienced. DYNAWEAR II<br />

Vacuum Bonded Ceramic is used for standard<br />

wear, DYNAWEAR III Tungsten Carbide is<br />

used for extreme wear and impact and<br />

DYNAWEAR II Vacuum Bonded CERMA<br />

Material is used where extreme wear without<br />

impact is observed.<br />

• OPTION 1<br />

DYNAWEAR II<br />

Wear Protection<br />

– Basic<br />

• OPTION 2<br />

DYNAWEAR II<br />

Wear Protection<br />

– Standard<br />

• OPTION 3<br />

DYNAWEAR II<br />

Wear Protection<br />

– Heavy<br />

• OPTION 4<br />

DYNAWEAR II<br />

Wear Protection<br />

– Extreme<br />

Color Material<br />

Yellow Vacuum Bonded<br />

Blue Vacuum Bonded<br />

Red Brazed Tungsten Tile<br />

DYNAWEAR II Vacuum<br />

Bonded Ceramics can be<br />

installed on your fan blades<br />

at your site or at an <strong>Alstom</strong><br />

shop. When ceramics are<br />

installed at your site, caps are<br />

used for attachment. When<br />

ceramics are installed in our shop<br />

caps are not required which means<br />

longer life during continuous<br />

operation. Shop pre-assembled fans<br />

are pre-balanced before delivery<br />

reducing manhours at installation.<br />

Shop pre-assembly also reduces errors<br />

during ceramic installation.<br />

No ceramic caps means longer wear life


Exhauster Liner Wear Components<br />

<strong>Alstom</strong> offers throat liners, periphery liners,<br />

bolt-on casing side liners and bearing side<br />

liners in DYNAWEAR II Vacuum Bonded<br />

Ceramics and CERMA Wear-Resistant<br />

Material. Additionally exhauster throat and<br />

periphery liners are designed to match the<br />

<strong>Alstom</strong>’s original internal clearances and<br />

liner profiles.<br />

Ceramic Throat and Periphery Liners<br />

CERMA Throat Liners for Extreme Wear Protection<br />

Ceramic Bearing Side Cover Liners<br />

Ceramic Intake Side Cover Liners<br />

HEF Exhauster Wheels<br />

The HEF Exhauster Wheel is an upgrade for<br />

“spider-design” exhauster wheel assemblies<br />

and has proven to be a more efficient design.<br />

Predictable and significant pulverizer<br />

capacity improvements can be achieved<br />

on all RB, RS and RPS mills. Each situation<br />

must be reviewed individually to determine<br />

the potential for capacity increases.<br />

Benefits<br />

• Predictable pulverizer capacity<br />

improvements of up to 10-12%<br />

• Spare pulverizer capacity may be achieved<br />

• Lost capacity due to fuel switching may<br />

be reclaimed<br />

• For similar coal flows, power consumption<br />

can be decreased<br />

HEF Exhauster Wheel with Wear-Resistant<br />

DYNAWEAR II Vacuum Bonded Ceramics<br />

14


15<br />

Exhauster Fan Bearing Housing Cooling System<br />

Exhauster fan bearings typically operate in an<br />

oil bath condition without the aid of oil<br />

filtration or cooling. These bearings are<br />

exposed to extreme duty conditions especially<br />

as the exhauster fan components begin to<br />

wear. The life of the bearings is highly<br />

dependent on the temperature at which they<br />

are operated and the condition of the<br />

lubricating oil in the bearing housing.<br />

<strong>Alstom</strong> offers a bearing housing<br />

cooling system retrofit for your<br />

exhauster to help increase the life<br />

of exhauster fan bearings.<br />

Features<br />

• 110 VAC motor<br />

• Circulating pump<br />

• Heat exchanger<br />

• Connection tubing<br />

• Lockable ball valves<br />

• Mounting base plate<br />

Benefits<br />

• Bearings operate at<br />

lower temperatures<br />

• Bearing lubrication<br />

remains cleaner<br />

between outages<br />

• Down time due to<br />

bearing failures is<br />

reduced


<strong>Pulverizer</strong> Gearbox Services<br />

<strong>Alstom</strong> offers:<br />

• Off-site gearbox rebuilds<br />

• Pre-assembled gearbox shafts<br />

• Upgraded bearing seal arrangements<br />

<strong>Alstom</strong> can also supply all the necessary<br />

components such as bearings, gears and<br />

shafts required for you to rebuild your<br />

own gearboxes.<br />

Whatever your gearbox requirements are,<br />

whether it is a full gearbox rebuild offsite or<br />

supplying components for your gearbox<br />

rebuild on-site, <strong>Alstom</strong> can fulfill your needs.<br />

Triple Reduction Gearboxes in Shop<br />

RB Bushing Type Gearbox<br />

RB Roller Bearing Gearbox<br />

HP <strong>Pulverizer</strong> Planetary Gearbox<br />

16


17<br />

Worm Shaft / Worm Gear Assembly Rebuilds and Upgrades<br />

Your pulverizer worm gear can be sent to an<br />

<strong>Alstom</strong> Regional Service Center for rebuilding<br />

under controlled conditions using proven<br />

processes and procedures.<br />

Features<br />

• OEM inspection and assembly procedures<br />

are used<br />

• All work is performed to the latest <strong>Alstom</strong><br />

engineering specifications, including the<br />

latest parts design improvements, inspection<br />

and quality procedures<br />

• Quality <strong>Alstom</strong> parts in stock for timely<br />

rebuilds<br />

• One year new equipment warranty<br />

• Optional wear material, sealing system<br />

upgrades are available<br />

R 3 Component Rotation Programs to fit your<br />

outage schedule are available.<br />

<strong>Pulverizer</strong> Worm Shaft Split Mechanical Oil Seal Upgrade


Pre-Assembled Components<br />

<strong>Alstom</strong> can deliver complete subassemblies<br />

ready for immediate installation. This will<br />

reduce your down time and help to ensure<br />

accurate fit up of components.<br />

Examples include:<br />

• Main shaft assemblies<br />

• Worm shaft assemblies<br />

• Bowl and bowl hub assemblies with<br />

grinding segments and vane wheel<br />

segments installed<br />

• Journal assemblies with grinding rolls and<br />

wear liners installed<br />

• Separator tops with classifiers and<br />

cone assemblies<br />

Preassembled from <strong>Alstom</strong>’s Shop to Your Site<br />

Benefits of Pre-Assembled<br />

Gearbox Shafts<br />

A pre-assembled shaft reduces gearbox<br />

overhaul time by as much as 50%. When<br />

you order fully assembled shafts they are<br />

built specifically for your pulverizer size<br />

and eliminate component-by-component<br />

assembly at your site. Special jigs and<br />

fixtures are no longer required to<br />

assemble components nor is an oil bath<br />

for bearing assembly.<br />

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19<br />

Other <strong>Pulverizer</strong> Upgrades<br />

EZ ACCESS <strong>Pulverizer</strong> Access Doors<br />

<strong>Alstom</strong> can supply additional access doors for<br />

RP, RPS, RS and HP pulverizers.<br />

Features / Benefits<br />

• Provides easy entry and exit for<br />

pulverizer maintenance<br />

• When combined with the<br />

FLOW–PRO Vane Wheel<br />

Assembly, this door provides<br />

effortless access to the above<br />

bowl area<br />

• Easy to install<br />

• Hinged for safe and<br />

quick entry<br />

• Meets NFPA code<br />

requirements<br />

• Available for all<br />

<strong>Alstom</strong> pulverizer<br />

sizes<br />

EZ Access <strong>Pulverizer</strong><br />

Access Doors can be<br />

supplied for the<br />

following locations on<br />

your pulverizer:<br />

• Millsides<br />

• Converter heads<br />

• Separator bodies<br />

• Exhausters<br />

Horizontal Pivot Scraper Upgrade<br />

<strong>Alstom</strong>’s horizontal pivot scraper assembly<br />

is an improvement over other pyrite scraper<br />

designs because of enhanced operation and<br />

service life. It is easier and safer to install<br />

and maintain, and can be installed as a<br />

replacement with little or no rework of<br />

existing parts.<br />

Traditional scraper assemblies use vertical<br />

mounted bushings that tend to wear and<br />

allow the scraper to droop and wear directly<br />

on floor liner. <strong>Alstom</strong>’s design moves the pivot<br />

from the floor area to a horizontal position<br />

above the mill bottom.


The improved assembly support allows the<br />

scraper to do a better job clearing debris from<br />

the mill bottom. The torsion spring provides<br />

enough resistance to move debris from the<br />

mill bottom, but also allows the arm to fold<br />

back over larger immovable objects such that<br />

neither the assembly nor the rest of the mill<br />

are damaged. The new horizontal scraper<br />

design eliminates the task of removing the<br />

entire assembly as a unit from the mill to<br />

replace wear parts.<br />

The original scraper design had an assembly<br />

weight of about 150 pounds, the new<br />

design allows individual components<br />

weighing about 30 pounds to be replaced.<br />

This means quicker, safer servicing of<br />

the scraper assembly.<br />

Split Bearing Race Retainer<br />

<strong>Alstom</strong>’s split bearing race retainer can be<br />

installed without costly bowl hub removal. It<br />

is supplied in two halves that are clamped<br />

around the main vertical shaft. Two trim drive<br />

brackets are supplied with the split bearing<br />

retainer and are located below the bowl hub<br />

to prevent the split bearing retainer from<br />

moving upward.<br />

The inner race retainer prevents the inner<br />

race from creeping up the main shaft. The<br />

split bearing retainer also functions as a wear<br />

sleeve for the oil seal. The oil seal no longer<br />

runs against the main vertical shaft<br />

eliminating any wear on the main vertical<br />

shaft that could lead to costly down time for<br />

shaft replacement or repair.<br />

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21<br />

<strong>Pulverizer</strong> Journal Rebuild Services and Products<br />

As a leading supplier of quality pulverizer<br />

equipment and replacement parts, <strong>Alstom</strong><br />

offers one of the industry’s most complete<br />

and cost-effective journal rebuilding services.<br />

<strong>Alstom</strong>’s services include journal inspections<br />

and maintenance, grinding roll resurfacing or<br />

replacement and design upgrades. These<br />

offerings, which include extended<br />

warrantees, can reduce inventory costs<br />

by 25-35 percent and result in longer<br />

lasting products that save power<br />

producers money.<br />

Features<br />

• All work is performed to the<br />

latest <strong>Alstom</strong> engineering<br />

specifications, including<br />

the latest parts design<br />

improvements,<br />

inspection and<br />

quality procedures.<br />

• R 3 Component<br />

Rotation Programs to<br />

fit your outage<br />

schedule are available.<br />

• Quality <strong>Alstom</strong> parts<br />

in stock<br />

• One year new<br />

equipment warrantee<br />

• Optional wear material,<br />

sealing system and<br />

ribbed roll upgrades<br />

are available<br />

• OEM inspection and<br />

assembly procedures<br />

are used<br />

Benefits<br />

• <strong>Alstom</strong> quality and reliability<br />

• All work backed by <strong>Alstom</strong>’s<br />

engineering experience<br />

• Our shop rebuilds can be more cost effective<br />

than on-site rebuilding<br />

• Allows a reduction in your parts inventory<br />

and carrying costs<br />

HP <strong>Pulverizer</strong> Journal with<br />

Double Upper Bearings and Spring<br />

RB <strong>Pulverizer</strong> Journal and Spring<br />

RP <strong>Pulverizer</strong> Journal and Spring


Double Upper Bearing Journal Assemblies and Upgrades<br />

The double upper bearing assembly replaces<br />

the single upper journal bearing with two<br />

tapered roller bearings. This improved design<br />

increases the radial capacity design of the<br />

upper bearing and reduces thrust loads on the<br />

lower bearing resulting in an increased life for<br />

both bearings.<br />

The double upper bearing assembly was<br />

designed through an intensive engineering<br />

analysis of pulverizer journals under actual<br />

operating conditions. Utilizing field data<br />

collected from several pulverizers, journal<br />

loadings were accurately determined by<br />

computer analysis. This allowed the final<br />

bearing selection and location to be<br />

optimized. As a result the<br />

loadings for both the upper<br />

and lower bearings<br />

were decreased.<br />

The double upper<br />

bearing journal<br />

design also<br />

includes improved<br />

oil and air seals<br />

for protection<br />

against<br />

contamination<br />

of the journal<br />

bearing lubricant.<br />

The double upper<br />

bearing journal is<br />

available as an upgrade<br />

to an existing journal<br />

assembly. It can also be<br />

supplied as part of a new journal<br />

shaft assembly or the entire journal can<br />

be replaced as an assembly.<br />

Original Design<br />

Current Standard<br />

22


23<br />

Journal Spring Rebuilds and Upgrades<br />

<strong>Alstom</strong> Service Centers can rebuild journal<br />

springs and incorporate upgrades designed to<br />

suit your operating requirements.<br />

<strong>Alstom</strong> offers an upgraded journal pressure<br />

spring for 963 – 1003 RP pulverizers<br />

equipped with the small separator top. They<br />

have been designed to prevent failure of this<br />

component from stress fatigue.<br />

A pressure spring failure leads to uneven<br />

loading on the bowl assembly, and if<br />

uncorrected, will lead to the failure of the<br />

main vertical shaft.<br />

The spring itself has been redesigned to lower<br />

stress on each coil at the same compression.<br />

A new bellows protects against coal leaks and<br />

allows greater visibility of spring oscillation.<br />

R 3 Component Rotation Programs<br />

<strong>Alstom</strong> offers customers<br />

a systematic method for<br />

rebuilding boiler related<br />

equipment and<br />

returning this<br />

equipment to service.<br />

<strong>Alstom</strong>’s Regional<br />

Service Centers are the<br />

focus of this program<br />

combining their extensive<br />

inventory, rebuild portfolio<br />

and proven processes to<br />

provide a unique service.<br />

The R 3 program is based on<br />

Rebuilding, Restocking and<br />

Replacing components.<br />

Rebuilding<br />

Complete disassembly and inspection of a<br />

component takes place. Worn out parts are<br />

replaced and components repaired. The<br />

components are rebuilt to strict procedures<br />

and tolerances. Upgrades to components<br />

can be included.<br />

Restock<br />

Once a rebuild is completed the component is<br />

placed in the customer’s exclusive stock<br />

inventory at a Regional Service Center nearest<br />

the plant.<br />

Replace<br />

Rebuilt components are returned to a<br />

customer when needed to replace a similar<br />

component requiring service. The replaced<br />

component is then sent back to the<br />

Service Center for rebuilding and to<br />

continue the process.<br />

Rebuilding is an economical alternative to<br />

buying new equipment. Rebuilt equipment is<br />

kept at an <strong>Alstom</strong> location until needed freeing<br />

up plant storage space. The process eliminates<br />

down time waiting for a component to be<br />

rebuilt and placed back in service. <strong>Pulverizer</strong><br />

components that are available in this program<br />

include journal assemblies, grinding rolls,<br />

gearboxes and worm shaft assemblies.


The <strong>Alstom</strong> Advantage<br />

<strong>Alstom</strong> combines its<br />

more than 100<br />

years experience in<br />

designing and<br />

building the coal<br />

pulverization<br />

equipment, its<br />

solution-based<br />

products and<br />

commitment to<br />

customer service<br />

into the <strong>Alstom</strong><br />

advantage.<br />

<strong>Alstom</strong> provides timely<br />

delivery of its pulverizer<br />

products to meet the demands<br />

of the power industry. We have<br />

been a dedicated customer service<br />

organization for nearly 50 years ensuring the<br />

responsiveness that our customers require.<br />

<strong>Alstom</strong> provides OEM quality while backing<br />

our products with comprehensive support.<br />

Our products are engineered by the OEM and<br />

are designed to help our customers meet the<br />

performance, availability and reliability<br />

requirements for their pulverizer equipment.<br />

<strong>Alstom</strong> Inventory Management Programs<br />

provide customers with the security of<br />

knowing replacement parts will be available<br />

when needed. And our rebuild programs will<br />

provide added service life to pulverizer<br />

components at a fraction of the cost of<br />

new equipment.<br />

This brochure is intended to provide only<br />

an overview of <strong>Alstom</strong>’s products and<br />

capabilities in servicing your pulverizer<br />

equipment. For more detailed information<br />

please contact your <strong>Alstom</strong> Power<br />

Service office.<br />

<strong>Alstom</strong> looks forward to the opportunity to<br />

provide you the highest quality products<br />

when you need them at value-driven prices<br />

to help you achieve pulverizer PAR.<br />

24


25<br />

<strong>Alstom</strong> Power <strong>Inc</strong>. Regional Service Centers<br />

7253 Grayson Road<br />

Harrisburg, PA 17111<br />

717.564.7210<br />

Fax No: 717.564.7297<br />

1500 Jamike Avenue<br />

Erlanger, KY 41018<br />

859.488.0920<br />

Fax No: 859.488.0970<br />

19672 E. 34 th Drive<br />

Aurora, CO 80011<br />

303.375.8261<br />

Fax No: 303.373.4600<br />

355 Satellite Boulevard NE, Suite 600<br />

Suwanee, GA 30024<br />

678.714.8299<br />

Fax No: 678.714.7177<br />

10293 County Road 2213<br />

Tyler, TX 75707<br />

903.534.5661<br />

Fax No: 903.534.5647


<strong>Alstom</strong> Power <strong>Inc</strong>.<br />

2000 Day Hill Road<br />

Windsor, CT 06095-0500<br />

Tel: 860.282.5400<br />

Fax: 860.285.9611<br />

www.service.power.alstom.com<br />

PSE/BPROB/PVPGSV07/eng/PSER1/06.07/US/6260<br />

© 2007 <strong>Alstom</strong> Power <strong>Inc</strong>. 06095. <strong>Alstom</strong>, the <strong>Alstom</strong> logo and any alternative version thereof are trademarks and service marks of <strong>Alstom</strong>. The other names mentioned, registered or not, are the property of their respective companies. This document<br />

is submitted in confidence and is to be used solely for the purpose for which it is furnished. Any technical and other data contained in this document is provided for information only. Neither <strong>Alstom</strong> nor its officers or employees accept responsibility for<br />

or should be taken as making any representation, warranty or guarantee (whether expressed or implied) as to the accuracy or completeness of such data or the achievement of any projected performance criteria where these are indicated. <strong>Alstom</strong><br />

reserves the right to revise or change this data at any time without further notice.

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