Rebuild and Repair Services For Power Plant Equipment

Rebuild and Repair Services 

For Power Plant Equipment 

Stretch Your Maintenance Budget 

Power 

with Alstom behind me… 

I’m in control!

ebuild and repair Services 

At Alstom, we combine our capabilities and experience 

to enhance the productivity and performance of boilers, 

pulverizers, feeders, air pollution control systems, ash 

handling systems and auxiliary equipment. Our focus 

is customer service and we understand the challenges 

WITH ALSTOM…I’M IN CONTROL 

Alstom is a leader in the design, manufacturing and servicing of utility and industrial power generation 

systems. While our heritage dates to the late 1800s, our capabilities continue to expand and point us 

to the future. 

Saf e t y | We believe that safety is a key indicator of operational excellence for both Alstom and its customers. 

Our commitment to safety hinges on strong leadership, timely communication 

and the involvement of all employees. Our target is zero safety incidents. 

ex p e r i e n c e | With an installed base of over 400 GW of power generation capacity and a track record 

spanning over 100 years, we believe you cannot find a partner whose experience in the power industry matches 

ours. We are dedicated to meeting your needs and exceeding your expectations. Our track record proves it. 

in n o v a t i o n | Each and every day, Alstom applies leading edge technology to develop new products and 

services to meet your maintenance and operational challenges regardless of your boiler type or fuel. 

Your performance is our measure of our success. 

LogiSticS | The right products and services when and where you need them. That is our commitment. With 

a wide range of capabilities and options for replacement parts supply, technical services, and construction services, 

Alstom is your complete boiler services solution. We offer the industry’s most comprehensive and innovative 

replacement parts and service programs. 

cuS t o m e r Se r v i c e | Alstom’s field service engineers, customer service representatives and construction 

managers have one goal – exceeding your service expectations. Our strategically located service and distribution 

centers enable us to provide fast response and reliable solutions to meet your needs. 

faced by plant owners, operators, maintenance personnel 

and management. Whether it is a replacement or 

upgraded part, a rebuilt assembly, a custom fabrication 

or inventory management program, Alstom provides 

exceptional value and service to our customers.

co n t e n t S 

ALSTOM PULVERIZER REBUILD SERVICES 

Introduction to the Alstom Pulverizer ..........................................................................................4 

Journal Assembly Rebuilds ...........................................................................................................7 

Grinder Roll Resurfacing ..............................................................................................................8 

Journal Spring and Door Rebuilds ................................................................................................9 

Fan Bearing Housing Assemblies ..............................................................................................10 

Separator Bodies and Tops ........................................................................................................11 

Exhauster Products ...................................................................................................................12 

Pulverizer Gearbox Rebuilds .......................................................................................................16 

Worm Shaft/Worm Gear Assembly Rebuilds ......................................................................17 

Pre-Assembled Components .....................................................................................................18 

Product Upgrades ......................................................................................................................19 

Double Upper Bearing Journal Assemblies ...........................................................................19 

Magnum Journal Upgrade ....................................................................................................20 

Proseal 350 Upgrade ............................................................................................................21 

LM-45 Journal Seal Upgrade ................................................................................................22 

Journal Pressure Spring Upgrade ..........................................................................................23 

EL-type PULVERIZER REBUILD SERVICES 

Introduction to the EL-type Mill .................................................................................................24 

Rotating Assemblies ..................................................................................................................25 

Yoke Repairs ...............................................................................................................................26 

Air Seal Repairs ..........................................................................................................................27 

Bearing Plate Repairs .................................................................................................................28 

Spring Bolt Rebuilds ...................................................................................................................29 

Gearbox Overhauls .....................................................................................................................30 

Gear Casing Rebuilds .................................................................................................................31 

Pinion Rebuilds ...........................................................................................................................32 


Ceramic Lined and Vacuum Bonded Liners..........................................................................33 

Keyless Shaft Upgrade .........................................................................................................34 

SuperNut® Upgrade .............................................................................................................35 

MPS-type PULVERIZERS 

Introduction to the MPS-type Mill ............................................................................................36 

Roll Wheel Rebuilds ...................................................................................................................37 

Bracket and Hub Repairs ......................................................................................................38 

Yoke and Air Seal Repairs ..........................................................................................................39 

Ring Seat Repairs .......................................................................................................................40 

Gearbox Overhauls .....................................................................................................................41 


Ceramic Lined and Vacuum Bonded Liners..........................................................................42 

Triple Lip Seal Upgrade .........................................................................................................43 

2

3 

BOP GEARBOX REBUILD SERVICES 

BOP (Balance of Plant) Service Capabilities .............................................................................44 

BURNER & FABRICATED COMPONENTS REBUILD SERVICES 

Burner Slide Gate Rebuilds ........................................................................................................46 

Fuel Elbow and Orifice Repairs ..................................................................................................47 

Coal Compartment Rebuilds ......................................................................................................48 

RSFC Burner Rebuilds ............................................................................................................49 

Oil Gun and Retract Mechanism Rebuilds .................................................................................50 

VOLUMETRIC FEEDER REBUILDS, REPAIRS, PRODUCTS AND SERVICES 

Volumetric Feeder Rebuild Services ..........................................................................................52 


Feeder Drive Conversion ......................................................................................................53 

Feed Roll Shaft Needle Bearing-to-Bushing Conversion .....................................................54 

Endplug Upgrade ..................................................................................................................55 

Stainless Steel Body Liners ...................................................................................................56 

Stainless Steel Feed Roll Spider and Blade Assembly ..........................................................57 

Hinged Gate Mechanism Assembly Upgrade .......................................................................58 

Side Opening Inspection Door Upgrade ...............................................................................59 

QUICKLATCH – Inspection Door Upgrade .......................................................................59 

CLINKER GRINDER REBUILDS, REPAIRS, PRODUCTS AND SERVICES 

Clinker Grinder Rebuilds .............................................................................................................60 


Ashbrade Grinder Packing .................................................................................................61 

Segmented Rolls for Double Roll Grinders............................................................................62 

THE ALSTOM ADVANTAGE 

Service Capabilities ....................................................................................................................64 

Technical Services ......................................................................................................................65 

Alstom Service and Distribution Centers ...................................................................................67 

Rebuild and Repair Services .......................................................................................................68 

R3 Component Rotation Programs ...........................................................................................68 

Outage Kit Services ...................................................................................................................69

Alstom Pulverizer Rebuild 

Services 

IntRoductIon to the Alstom PulveRIzeR 

IN 1923 COMBuSTION ENGINEERING (CE) ACquIREd THE RAYMONd BROTHERS IMPACT PuLvERIzER COMPANY, | 

considered one of the nation’s leading manufacturers of pulverizing and grinding equipment. 

In 1933 CE introduced the CE Bowl type pulverizer based on original Raymond Brothers technology. Today, this design is owned 

by Alstom. With over 70 years of continuous development and improvement Alstom pulverizers are highly respected within the 

power industry. 

Alstom pulverizers span the globe and have been built in a variety of sizes and 

capacities. We offer a full line of parts, services and solutions to help ensure that your 

pulverizers provide optimum operation. 

Alstom fAmIly of PulveRIzeRs 

THE dESIGNATION OF THE PuLvERIzER PROvIdES INFORMATION | 

pertaining to the pulverizer configuration, physical size of the bowl, and the 

type of operating system. 

The “RB” indicates a steep sided bowl type of pulverizer that operates under 

a negative pressure and uses an exhauster fan. 

Pulverizer size Base capacity lbs/hr 

312 3,550 

352 4,450 

412 8,000 

473 13,300 

533 20,300 

593 28,200 

633 36,500 

673 41,500 

713 50,100 

753 59,100 

Note: Not all pulverizer sizes and capacities are listed. 

RB Pulverizer 

ALSTOM PuLvERIzER REBuILdS 

4

5 ALSTOM PuLvERIzER REBuILdS 

Alstom Pulverizer Rebuild services 

The “Rs” indicates a shallow-bowl pulverizer that operates 

under a negative pressure on a balanced draft furnace. An 

“RPs” indicates a shallow-bowl pulverizer that operates under 

a slightly positive pressure and was originally associated with 

pressurized furnaces. Both these pulverizer types are used with 

an exhauster fan. 

RS/RPS Pulverizer 


403 10,200 

503 21,200 

603 36,800 

663 48,500 

703 58,000 

743 68,500 

783 80,500 

803 87,500 

843 100,000 

863 106,000 


The “RP” indicates a shallow-bowl type pulverizer that operates 

under a positive pressure. Early systems were associated with 

either a pressurized or balanced draft furnace. Today few, if any, 

pressurized coal fired furnaces are produced. These pulverizers 

utilize a primary air fan. 

RP Pulverizer 


603 36,800 

663 48,500 

743 68,500 

763 74,500 

803 87,500 

863 106,000 

943 132,000 

1003 150,000 

1043 170,000 

1103 200,000 

Note: Not all pulverizer sizes and capacities are listed.


The “hP” pulverizer was developed in the mid-1980s. This 

pulverizer incorporates design changes to extend grinding 

element life and reduce replacement part costs, maintenance 

costs and down time. 

The HP pulverizer design incorporates a vane wheel, an 

improved horizontal scraper assembly, a tall top classifier for 

improved classification and a planetary gear drive assembly. 


603 36,800 

663 48,500 

743 68,500 

803 87,500 

863 106,000 

943 132,000 

1003 150,000 

1103 200,000 

1203 250,000 

1303 300,000 


HP Pulverizer 


6

BenefIts: 

• Excellent quality and 

reliability 

• More cost effective and 

efficient than on-site 

rebuilding 

• Reduces inventory and 

carrying costs 

• Extends operation time 

between outages 



Journal Assembly Rebuilds 

ALSTOM OFFERS ONE OF THE INduSTRY’S MOST COMPLETE ANd COST-EFFECTIvE 

JOuRNAL REBuILdING SERvICES. | All work is performed to the latest Alstom engineering 

specifications, including the latest parts, design improvements, inspection and quality 

procedures. These offerings, which include extended warranties, can reduce inventory costs by 

70 percent or more and result in longer lasting products that save power producers money. 

RP Pulverizer Journal and Spring 

Rebuild scope 

Basic Services 

• Inspection 

• Maintenance 

• Grinding roll resurfacing or replacement 

• Blue fitting of lower journal housing to 

grinding roll 

Options 

• Wear material upgrades 

• Ribbed roll upgrade 

• Sealing system upgrades 

RB Pulverizer Journal and Spring HP Pulverizer Journal with Double Upper Bearings 

and Spring


Grinder Roll Resurfacing 

ALSTOM’S COMPETITIvELY-PRICEd RESuRFACEd ROLLS ARE FIELd-PROvEN TO 

LAST LONGER THAN SIMILAR CAST ROLLS. | In addition, Alstom offers a number of 

materials that can reduce roll replacement costs by more than 50 percent (depending on 

operating conditions) and boost a pulverizer’s fineness capability without increasing its 

parasitic power requirements. 

All resurfacing work is performed at Alstom’s 

Regional Service Centers, which offer: 

• Quick turnaround 

• A variety of competitively priced welding 

materials 

• A high-quality, state-of-the-art open-arc 

welding process 

• Customized inventory management/ rotation 

programs 

• Vast OEM knowledge of pulverizers 

Applying the best wear material in the highest 

wear areas helps assure the longest life from the 

roll while keeping costs down. 


BenefIts: 

• Increases pulverizer 

availability 

• Improves pulverizer 

performance 


efficiency 

• Reduces replacement 

costs by more than 

50% 


• Inspection to check roll integrity 

• Restoration to OEM dimensions 

• Notification if severely worn rolls are not suitable for rebuilding 

• Notification if rebuilding costs will be excessive 

Wear material options 

• COMBUSTALLOY Hardsurfacing Material – This internationally-patented 

material offers wear resistance up to four times greater than Ni-Hard. 

• 100CE92 – Alstom’s private label wire 

• Integra 750, a tungsten carbide weld material 


8

the tWenty-tWo 

PoInt InsPectIon 

PRocess Includes 

InsPectIon of the 

folloWIng AReAs: 

• Bearing guard nut 

• Thrust bearing 

• Spring adjusting bolt and 

bushing 

• Ball bushing 

• Spring clamp thrust bearing 

and piston rings 

• Inner and outer spring coils 

• Spring adjusting stud 

• Spring clamp cylinder 

• Spring Cup 

• Spring seat 

• door mounting holes 

• Trunnion seats 

• Journal stop bolt, lock nut, 

and bushing 



Journal Spring and door Rebuilds 

ALSTOM POWER PROvIdES REBuILd SERvICES FOR RS/RPS JOuRNAL 

PRESSuRE SPRING ANd dOORS. | This rebuild includes disassembly, inspection, parts 

replacement, and reassembly of the pressure spring assembly to the journal opening 

cover door. This rebuild requires special tools, as well as special fixtures to assemble 

and set the correct spring pressure. This rebuild can be performed on journal pressure 

springs with or without the journal opening cover door. 

The rebuilds are performed in Alstom Service Centers utilizing original manufacturing 

drawings and approved Mechanical Procedures. In addition, there is a complete 

inspection form. The form includes order information, such as dates, order numbers, etc, 

but it also includes locations for technicians to include condition assessments as well as 

areas to fill in measurements. 

Each rebuild order has a list of “normally replaced parts” that are on-hand before the 

rebuild begins. Once the inspection process is completed, the shops work with Alstom 

Engineering to determine approved repairs and additional replacement parts. This 

ensures a quality rebuild that is complete without excessive lead times. 

Process: 

After receipt of the assembly, a visual inspection is performed. Any issues or concerns 

are recorded on the inspection sheet. The next step is removal of the spring assembly 

from the door, and the disassembly and inspection of the spring components and the 

door itself. Once inspection has been completed, and replacement parts acquired, the 

components are reassembled onto the door. The final step is the adjustment of the 

spring compression using the special hydraulic fixture. The assembly is then ready for 

final inspection, paint, and preparation for shipping.


Fan Bearing Housing Assemblies 

ALSTOM PROvIdES quALITY FAN BEARING ASSEMBLY REBuILdS. | All work 

is performed at efficient, cost-effective and properly equipped service centers that 

provide OEM quality parts and services with the reliability you need. Alstom’s Pulverizer 

Engineering department is consulted on all parts that are in questionable condition to 

determine if a repair is feasible. 



• Components are inspected and checked to OEM tolerances 

• Critical areas such as the bearing bores and shaft diameters are measured 

and recorded 

• Parts that are not within design tolerances are replaced or rebuilt to print 

specifications 

fan shaft 

• Cleaned 

• Inspected for scoring, grooving or other irregularities 

fan Bearing housing 

• Cleaned 

• Inspected for burrs, scoring, grooving, or other irregularities 

BenefIts: 

• Twelve (12) month 

warranty on all new parts 

and workmanship 

• Reduces inventory 

requirements and the 

associated carrying costs 

• Work is performed at 

efficient, cost-effective and 

properly equipped service 

centers 

• OEM quality and service 

reliability 


10

BenefIts: 

• Save up to 50% vs. cost of 

new component 

• Faster turn around vs. 

new purchase 

Figure 1 – Separator Body before repair 

Figure 2 – Completed Separator Body 

Figure 3 – Completed Separator Top 



Separator Bodies and Tops 

ALSTOM OFFERS REBuILdS ANd REPAIRS | for both shallow bowl mill and deep bowl 

mill separator bodies and tops. 



• All liners (bolt-on or ceramic) are removed 

• Any wear compounds from the body / top surface are removed 

• Surface areas are cleaned 

• The following areas are inspected: 

separator Body 

- Flatness of the upper and lower mounting flange surfaces and the three 

journal mounting surfaces 

- Parallelism of upper and lower mounting flanges 

- Bolt holes of upper and lower mounting flanges 

separator top 

- Flatness of the mounting surface to the body 

- Multiport outlet / converter head mounting surface 

- Deflector regulator assemblies removed and checked for proper operation 

- Radius bends in separator top 

• Each component is mapped (reference Figure 1) and “As Received” measurements 

are recorded 

• Areas for repair are marked on the component surface 

• “After Repair” measurements are recorded once repairs are complete 

• Alstom’s engineering department is consulted when any measurement exceeds 

design tolerance 

• Bolt holes of the upper and lower mounting flanges for each component are checked 

against an appropriate template 

• Each hole is cleaned with an appropriate tap and the thread gauge is checked 

• The rebuilt separator body /top is painted and liners are installed


Whizzer Wheel fan Blade options 

Exhauster Products 

A variety of options are available for the exhauster’s fan blades based on 

particular wear profiles experienced: 

• DYNAWEAR II Vacuum Bonded Ceramic is used for standard wear 

• DYNAWEAR III Tungsten Carbide is used for extreme wear and 

impact 

• DYNAWEAR II Vacuum Bonded CERMA Material is used where 

extreme wear without impact is observed. 

DYNAWEAR II Vacuum Bonded and DYNAWEAR III Tungsten Carbide 

Brazed Bonded Products can be selected to achieve extended wear life and 

maximize run time and outage cycle time. 

RB, RS, ANd RPS PuLvERIzERS uSE ExHAuSTERS TO TRANSPORT THE 

COAL FROM THE PuLvERIzER TO THE BOILER. | Alstom rebuilds exhauster 

wheel assemblies to strict procedures at its Regional Service Centers. 


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Pre-Assembled Advantages 

dYNAWEAR II vACuuM BONdEd CERAMICS CAN BE INSTALLEd 

ON YOuR FAN BLAdES AT YOuR SITE OR AT AN ALSTOM SERvICE 

CENTER. | When ceramics are installed at your site, caps are used for 

attachment. When ceramics are installed at our shop, caps are not 

required. This means longer life during continuous operation. Shop preassembled 

fans are pre-balanced before delivery reducing man-hours 

at installation. Shop pre-assembly also reduces errors during ceramic 

installation. 

Alstom’s pre-assembled fan eliminates the weakest 

wear link on fan blades, the fan blade fastener ceramic 

caps. 

no ceRAmIc cAP meAns 

longeR WeAR lIfe


exhauster liner Wear components 

Alstom offers: 

• Throat liners 

• Periphery liners 

• Bolt-on casing side liners 

• Bearing side liners 

Material Options: 

• DYNAWEAR II Vacuum Bonded Ceramics 

• CERMA Wear-Resistant Material. 

Additionally, exhauster throat and periphery liners are 

designed to match Alstom’s original internal clearances 

and liner profiles. 

CERMA throat liners for extreme wear protection 


Ceramic throat and periphery liners 

ALSTOM PuLvERIzER REBuILdS 14

BenefIts: 

• Enhances pulverizer 

capacity up to 12% 

• May result in spare 

pulverizer capacity 

• May reclaim lost capacity 

due to fuel switching 

• decreases power 

consumption for similar 

coal flows 




exhauster liner Wear components 

Ceramic bearing side cover liners 

Ceramic intake side cover liners


Pulverizer Gearbox Rebuilds 

WHATEvER YOuR GEARBOx REquIREMENTS ARE, ALSTOM CAN 

FuLFILL YOuR NEEdS. | We can completely rebuild your gearbox at 

one of our off-site facilities or supply all the components necessary such 

as bearings, gears and shafts to rebuild your gearbox on-site. Alstom 

additionally offers pre-assembled gearbox shafts and upgraded bearing seal 

arrangements for your convenience. 



• Disassemble 

• Clean 

• Dimensionally inspect 

• Provide evaluation report to customer 

Based on inspection, additional services for Triple reduction Gearbox 

can include: 

• Replacement of all components deemed unacceptable 

• Rebuilt to as-new condition 

• Clean and inspect lubrication system 

• Perform “No-Load” spin test 

• Submit final report to customer 

Based on inspection, additional services for Pancake Gearbox can include: 

• Machine gear housing halves and bores back to OEM tolerances 

• Reassemble, set up bearing endplay and gear patterns 

Triple reduction gearbox in shop HP Pulverizer planetary gearbox 

RB roller bearing gearbox 

BenefIts: 

• Saves approximately 50% 

vs. purchasing new 

• Faster turn around vs. new 

purchase 

• Rotation program available 


16



Worm Shaft / Worm Gear Assembly Rebuilds 

BenefIts: 




purchase 


sAves 50% vs. neW 

IN AddITION TO COMPLETE GEARBOx REBuILdS ALSTOM CAN ALSO REBuILd 

JuST THE PuLvERIzER WORM GEAR. | The worm gear can be sent to an Alstom 

Regional Service Center where the rebuild is completed under controlled conditions using 

proven processes and procedures. 




• Inspect 

Pulverizer worm shaft split mechanical oil seal upgrade


Pre-Assembled Components 

ALSTOM CAN dELIvER COMPLETE SuBASSEMBLIES REAdY FOR IMMEdIATE 

INSTALLATION. | This will reduce your down time and help to ensure accurate fit up of 

components. 

type of assemblies provided include: 

• Main shaft assemblies 

• Worm shaft assemblies 

• Bowl and bowl hub assemblies with grinding segments and vane wheel segments 

installed 

• Journal assemblies with grinding rolls and wear liners installed 

• Separator tops with classifiers and cone assemblies 

Pre-assembled from Alstom’s 

shop to your site 

BenefIts of 

PRe-AssemBled 

geARBox shAfts: 

A pre-assembled shaft 

reduces gearbox overhaul 

time by as much as 50%. 

When you order fully 

assembled shafts they are 

built specifically for your 

pulverizer size and eliminate 

component-by-component 

assembly at your site. Special 

jigs and fixtures are no 

longer required to assemble 

components nor is an oil bath 

for bearing assembly. 


18

feAtuRes: 

• Two tapered roller bearings 

vs. single bearing 

• Improved oil and air seal 

design 

AdvAntAges: 

• Reduced thrust loads for 

upper and lower bearings 

• Increased radial capacity 

• Better protection against 

lubricant contamination 

• Longer time between 

outages 

BenefIts: 

• Longer wear life 

• Improved reliability 



Product upgrades 

ALSTOM CONTINuES TO dESIGN ANd dEvELOP OEM PuLvERIzER PROduCTS THAT 

WILL MEET THE CHANGING NEEdS OF OuR CuSTOMERS. | These upgrades provide 

longer wear life, reduce maintenance costs, eliminate a number of mechanical problems and 

improve the overall reliability of your mill. 

double upper Bearing Journal Assemblies 

The double upper bearing assembly replaces the single upper journal bearing with two 

tapered roller bearings. This improved design increases the radial capacity design of the 

upper bearing and reduces thrust loads on the lower bearing resulting in an increased 

life for both bearings. 

The double upper bearing assembly was designed through an intensive engineering 

analysis of pulverizer journals under actual operating conditions. Utilizing field data 

collected from several pulverizers, journal loadings were accurately determined 

by computer analysis. This allowed the final bearing selection and location to be 

optimized. As a result the loadings for both the upper and lower bearings were 

decreased. The new design also includes improved oil and air seals for protection 

against contamination of the journal bearing lubricant. 

This component is available as an upgrade to an existing journal assembly. It can 

also be supplied as part of a new journal shaft assembly or the entire journal can be 

replaced as an assembly. 

IncReAsed tIme 

BetWeen outAges


Magnum Journal upgrade 

THIS uPGRAdE CAN ExTENd JOuRNAL LIFE | while maintaining the existing journal 

assembly envelope. 

IncReAsed JouRnAl lIfe 

feAtuRes: 

• Larger capacity upper and 

lower journal bearings 

• New or modified journal 

assembly components 

within original envelope: 

- upper journal 

housing 

- Lower journal 

housing 

- Bearing seats 

- Journal shaft 

AdvAntAges: 

• Choice of newly 

manufactured shaft and 

housing components 

or remanufactured 

components 

• Can use grease lubricant 

instead of oil eliminating 

oil changes 

• Proven seal technology 

prevents the ingress of 

coal contamination into 

the grease lubricant and 

journal assembly tapered 

roller bearings 

• Lower bearing loads and 

contact stresses resulting 

in longer bearing life 

• Greatly reduces the 

possibility of premature 

bearing failure due to 

bearing contamination 

BenefIts: 

• Extends operating 

window between outages 

• Improves reliability 


20

feAtuRes: 

• Replaceable wear sleeve 

that protects journal shaft 

from further wear 

• Three oil seals increase 

the resistance to oil 

contamination 

• Greater chemical resistance 

and higher operating 

temperatures while 

maintaining excellent 

resiliency 

AdvAntAges: 

• Oil seal effectiveness is 

maximized by the hard, 

ultra-smooth finish of wear 

sleeve 

• A grooved journal shaft 

can be salvaged without 

creating an additional 

stress riser 

• Three oil seals increase 

the resistance to oil 

contamination 

BenefIts: 

• Increases mill availability 

• Reduces maintenance costs 

• Longer journal life 



Proseal 350 upgrade 

ALSTOM OFFERS AN uPGRAdE TO SEALING YOuR ExISTING JOuRNAL 

ASSEMBLY IN THE PROSEAL 350 SEAL. | This triple lip sealing system with 

wear sleeve offers the protection of three lip seals. Two of the lip seals act to keep 

contaminates out of the journal oil reservoir while the third seal keeps the oil from 

leaking out of the journal. The wear sleeve protects the journal shaft from any gouging 

or scoring that may occur during normal operation. 

PRotects JouRnAl 

fRom contAmInAtIon


LM-45 Journal Seal upgrade 

THE LM-45 SEAL SYSTEM IMPROvES PuLvERIzER AvAILABILITY ANd JOuRNAL 

LIFE | by protecting the bearing from contamination. The design uses upgraded 

materials and a new lip seal arrangement, along with foam particle barriers to prevent 

contaminants from entering the journal cavity. The new seal also has less rotating parts 

which decreases wear and improves reliability. 

feAtuRes: 

• Non-contact design 

minimizes heat buildup 

• O-rings on shaft drive 

seal rotor 

• Ribbed, heavy-duty onepiece 

construction 

AdvAntAges: 

• Less contamination 

• Maintenance free self 

cleaning and lubricating 

• Longer service life 

• Easy to install 

BenefIts: 


availability 


reliability 

• Reduces maintenance 

ImPRoved AvAIlABIlIty 

And RelIABIlIty 


22

feAtuRes: 

• Increased spring length 

• Increased diameter of the 

bars used in making the 

coils 

• Reduced the K factor of the 

spring by 20% 

• Spring cover replaced by 

bellows 

AdvAntAges: 

• Reduced journal spring 

failures due to stress 

• Reduced chance of main 

vertical shaft failure due 

to uneven loading of bowl 

assembly 

BenefIts: 


availability 


reliability 



Journal Pressure Spring upgrade 

ONE CAuSE OF A PuLvERIzER SHuTdOWN IS THE FAILuRE OF THE JOuRNAL 

PRESSuRE SPRING. | A pressure spring failure can lead to uneven loading of the bowl 

assembly and, if uncorrected, failure of the main vertical shaft. 

Alstom has redesigned the journal pressure spring assemblies utilized on the 963 – 

1003 RP Pulverizers equipped with the original small separator top. 

The increased number of coils and increased diameter results in lower stress on each coil 

at the same compression. 

The replacement of the spring cover with bellows protects against coal leaks and allows 

greater visibility of spring oscillation to verify the three springs are operating in unison. 

A spool piece is provided to accommodate the increased length of the spring that is 

external to the journal. 

ImPRoves PulveRIzeR 

AvAIlABIlIty And RelIABIlIty

EL-type Pulverizer Rebuild 


Introduction to EL-type Mill 

THE EL-TYPE MILL EMPLOYS THE BALL/RACE CONCEPT FOR GRINdING COAL. | A rotating race drives the balls and a 

stationary race applies grinding force. The Fuller Company created some of the early ball-race mill concepts in the early 1900’s. 

The mill series really started with the A-type mill and then progressed to the E-type mill. The A-type mill was designed and built by 

Fuller-Lehigh around 1917. Fuller-Lehigh continued with the ball race concept through the B, C, D and E type mills. Many were sold to 

Babcock and Wilcox (B&W) for pulverized coal fired boilers. In the 1950’s, B&W bought the E-type mill design and started their own 

production. 

B&W made an improvement to the E-type mill to create the EL-type mill in the late 1950’s. The ball race concept was retained, but 

the throat geometry and classifier were improved. The improvement increased the performance of the E-type mill by 25%. Many 

operating E-type mills were converted to the EL-type. 

The EL-type mill declined in popularity as boiler size rapidly increased in the 1960’s. The ball race concept has vibration and 

mechanical limitations in very large sizes. The Cyclone firing scheme that did not require pulverizers also became popular for B&W 

boilers. B&W made one last effort in the ball race concept in the late 1960’s. The Counter Rotating (CR) Type ball race mill was 

designed. It did not work well and the entire concept was dropped in favor of the roll/ring MPS-type mill. 

There are many E and EL-type mills still acceptably operating in the USA. The mill has particular advantages and disadvantages over 

competing mill types. In its day, the low height gave an advantage of lower boiler setting heights. The mill is compact and serviced 

from just one side, an advantage in plant layout. The grinding zone is 

the main advantage and disadvantage. It has no rollers, bearings or 

machinery to service, which avoids the inherent possibility of failures. 

However, it does not effectively use the wear materials. The grinding 

components of a large EL-type mill weigh 15,000 lb when new and 

perhaps 10,000 lb when worn. Almost two thirds of the wear material 

is scrapped. Still, the EL-type mill remains a workhorse in power plants 

across the USA. 

EL-TYPE PuLvERIzERS 

24

BenefIts: 



• Saves 20–30 man-hours 

vs. on-site repairs 

• 90% contact pattern on blue 

fit of yoke to main shaft 

Building rotating assembly 

Rotating assembly ready for shipment 

25 EL-TYPE PuLvERIzERS 

el-type Pulverizer Rebuild services 

Rotating Assemblies 

THE MILL REBuILd SCHEduLE IS TIGHT ANd YOu ARE WORRIEd ABOuT BLuE 

FITTING THE YOKE ANd GEAR CENTER IN AN uNCONTROLLEd ENvIRONMENT. | 

It has to be done correctly for long shaft life and reliability, but the schedule must be met. 

A ready to run rotating assembly is the answer. Alstom will inspect, repair and rebuild 

your spare yoke, gear center and other parts or supply new ones. A new high quality shaft 

will be made and blue fit to the yoke and gear center. Run outs of the mounting faces are 

checked and cut if needed. 

Available for EL 64, 70 and EL 76 Rotor Assemblies 




• Clean 


Based on inspection, additional services can include: 

• NDT yoke and gear center for cracks 

• Weld repair/machine yoke, and install new yoke bushing and drive pin 

• New main shaft – See ‘Alstom upgraded keyless main shaft option’ 

• New SuperNut upgrade – See ‘Alstom upgraded keyless main shaft option’ 

• Blue fit gear center to main shaft 

• Blue fit yoke to main shaft 

• Machine yoke seating surface and gear center as required 

• Document blue fit with photos and inspection documents 

• Paint 

Gear center contact to shaft Yoke contact to shaft


THE YOKES IN AN EL-TYPE MILL ExPERIENCE AGGRESSIvE WEAR CONdITIONS, 

HOWEvER, THEY ARE REPAIRABLE ANd RARELY NEEd REPLACEMENT. | Alstom 

reconditions all yoke sizes and styles. Alstom weld repairs, hard surfaces, machines and 

re-bushes the yoke back to as-new condition. 

The fit between the main shaft and the yoke is critical to long and reliable shaft life. A 

rebuilt yoke has a standard machined bushing taper. The yoke must be hand fit to the 

main shaft during assembly. As an alternative, Alstom offers fitting and bluing to mate 

the yoke to the main shaft. See the Rotating Assemblies section for this service. 

Repair scope 



• Blast to clean 

• Dimensionally and NDT inspect 


• Weld up worn areas as required 

• Weld up bushing bores 

• Wear protect (hardface) high wear areas 

• Tap wedge ring holes 

• Machine wedge ring area 

• Machine grinding ring seating surface 

• Install new yoke bushing and drive pin 

• Paint 

Yoke Repairs 

BenefIts: 



• Saves 20–30 man-hours 

vs. on-site repairs 


26

BenefIts: 




purchase 



Air Seal Repairs 

AIR SEALS ARE CRITICAL TO CONTAIN THE HOT PRIMARY AIR WITHIN THE 

MILL ANd PREvENT duST-LAdEN HOT AIR FROM CONTAMINATING THE MILL 

GEARBOx. | They also reduce heat transfer into the gearbox. If your gearbox oil is running 

hot or contaminated, the air seal may need replacement or repair. 

Alstom can repair the air seal for the EL 64, 70 and 76 mills with new bronze inserts 

saving substantial cost over replacement. If the top of the air seal is worn or damaged, 

Alstom can cut off the damage and weld in a new seal carrier and save the housing. 







• Remove old seals 

• Weld up air seal area as required 

• Replace seal carrier if necessary 

• Machine to accept new bronze labyrinth seals 

• Install new seals 

• Install new air pipe(s) 

• Paint


BEARING PLATES WEAR FROM REJECTS RuBBING ON THE TOP 

SuRFACE. | Bearing plates are repaired using inserts to replace the worn 

material. In rare cases, a bearing plate is damaged beyond repair and a new 

one is required. Alstom offers the original cast iron material and an improved 

steel bearing plate for popular mill and shaft sizes. 





• Dimensionally and NDT inspect 


• Clean tapped holes 

• Prime, paint/cosmoline protect 

• Sleeve bore 

• Machine flat top and bottom mounting surfaces 

• Replace seal and cover rim area 

• Replace seal and cover floor area 

• Replace seal, cover, floor and air seal mounting surface 

Bearing Plate Repairs 

Repaired top bearing plate 

Worn top bearing plate Bearing plate repairs and rebuilds 

BenefIts: 



• Rotation programs 

available 


28

BenefIts: 

• Save up to 50% vs. 

purchasing new 

• Rotation program 

available 

Spring bolt – BEFORE 



Spring Bolt Rebuilds 

Alstom can rebuild your EL 64, 70, and 76 Mill size spring bolt assemblies. 




• Clean 



• Repair housing 

• Replace key 

• Recondition retaining ring 

• Replace nut and adjusting bolt and hardware 

• Paint 

• Fill with grease 

Spring bolt – AFTER


FOR THE EL-TYPE GEARBOx, THE TIME BETWEEN REPAIRS OR 

REPLACEMENT dEPENdS MOSTLY ON OPERATION. | A properly loaded 

mill will run much longer than low or dry operation. Foreign material causes 

high shock loads that can damage the gearbox and shorten its life. 

Alstom has all the parts and services required to return the gearbox back to 

original condition or improve the equipment for today’s demands. We also offer 

rental agreements and purchase options. 

Alstom has the capability of rebuilding the full lower half of the EL-type mill 

as a single unit or the individual sub-components depending on the customer 

preference. 




• Clean 

• Inspect 


• Replacement parts such as gears, bearings, shafts, seals 

• Rebuild to as-new conditions 

ReAssemBle the 

loWeR hAlf of youR 

el-tyPe mIll In A 

shoP envIRonment 

Gearbox Overhauls 

Line boring rebuilt gearbox in Alstom shop 

BenefIts: 




available 

• Rebuild individual subcomponents 

or entire lower 

mill 

• delivered before you take 

your operating mill off-line 


30

BenefIts: 




available 

Rebuilt gear cases available 



Gear Casing Rebuilds 

REPLACEMENT OF THE EL GEAR CASE WITH A NEW COMPONENT CAN BE vERY 

ExPENSIvE ANd HAS A LONG LEAd TIME. | While Alstom can supply new gear 

casings, we have developed a rebuild process for restoring EL gear cases to original 

specifications without compromising the quality or structural integrity of the component. 



• Blast clean 



• Sleeve bearing bore 

• Re-machine bearing and oil pump pedestal 

• Re-machine upper flange area and pedestal, parallel and to original dimension 

• Paint inside cast surfaces with gearbox sealer 

• Paint outside, non-machined surfaces, of gear case with high temperature paint 

• Final inspect gear case 

• Cosmoline protect machined surfaces to prevent rust


ALSTOM CAN REBuILd YOuR EL 64, 70 ANd EL 76 PINION ASSEMBLIES. | The 

pinion assemblies can be rebuilt individually or as a sub-component of the lower half 

of the mill. 



Pinion Housing & Assembly 


• Clean 

• Inspect 


Pinion Housing 

• Re-machine housing ends 

• Cosmoline protect 

Pinion Assembly 

• Dimensionally record bores and shaft diameters 

• NDT shaft and pinion gear 

• Replace bearings and packing 

• Reassemble/Cosmoline protect 

EL pinion assembly – AFTER 

Pinion Rebuilds 

EL pinion assembly – BEFORE 

BenefIts: 




purchase 


32

dynAWeAR 

description: 

Adhesive bonded alumina 

ceramic tiles 

Applications: 

• Static applications only 

• Typically in: 

- upCones 

- Wall liners 

- Turrets 

features: 

• Pre-engineered, 

mechanically interlocked 

system 

• Blome grout 

Advantages: 

• Simplified installation 

• Blome grout aids 

installation and helps fill 

voids between tiles 

Benefits: 

• Extends time between 

overhauls 

• Easy to fabricate 

• Reduces costs 



uPgRAdes ImPRove 

RelIABIlIty And AvAIlABIlIty 


THE FOLLOWING uPGRAdES ARE AvAILABLE FOR THE EL 64, 70 ANd 76 MILLS.| 

These products directly replace the OEM product in fit and form but will last longer, and 

are more reliable. 

ceramic lined and vacuum Bonded liners 

Ceramic lining is the best wear solution for high erosion, low impact locations. 

Alstom offers the most comprehensive wear solutions available. 

dynAWeAR II 

description: 

vacuum bonded product 

available in alumina ceramic 

tiles, silicone carbide tiles or 

tungsten carbide tiles 

Applications: 

• Static and dynamic 

applications 

features: 

• Customized application 

to fit your specific wear 

pattern 

• Tensile strength: 6000+ psi 

• Shear bond strength: 

4000+ psi 

Advantages: 

• Impact resistant 

• Can be used with complex 

shapes 

Benefits: 




outages 

dynAWeAR III 

description: 

Brazed tungsten carbide tiles. 

Applications: 


applications 

Note: The brazing method 

restricts use with certain 

types of materials. 

features: 

• High wear resistance 

• Excellent impact resistance 

Advantages: 

• Longer run time before 

replacement is required 

Benefits: 

• Reduces total cost of 

ownership 


overhauls


ALSTOM HAS dEvELOPEd A MAIN SHAFT dESIGN THAT ELIMINATES THE 

KEYWAY, MAKING THE SHAFT TWICE AS STRONG. | By precisely mating the 

shaft to the hub or yoke and seating it firmly with the SuperNut (see following page), 

the drive torque is transferred without a keyway. 

Major modifications are not required for this conversion. The original bearings, gear 

centers, hubs and yokes are used, although the yoke bushings must be replaced. 

Reduces shAft BReAkAge, 

ImPRovIng PulveRIzeR 

AvAIlABIlIty 

Keyless Shaft upgrade 

feAtuRes: 

• vacuum arc re-melted 

forging 

• Certified chemical and 

mechanical properties 

• ultrasonically inspected 

• Precision CNC machined 

• Polished keyways 

• Shot-peened high stress 

areas 

• Final magnetic particle 

inspection 

AdvAntAges: 

• Twice as strong as the 

standard design 

• No major modifications 

required 

• SuperNut technology 

• Available for all EL-type 

pulverizer sizes 

BenefIts: 



• Reduces shaft breakage 


34

feAtuRes: 

• Increased number of 

smaller bolts 

AdvAntAges: 

• Easily tightened with 

torque wrench 

• No yoke heating required 

• Produces 500,000+ lbs of 

seating force (standard nut 

produces 5,500 lbs) 

• Yoke can still be removed 

with a standard puller 

• Better shaft taper sealing 

• Easy installation 

• Efficient disassembly 

BenefIts: 



• Improves safety 

• Reduces shaft breakage 

when used in conjunction 

with keyless shaft upgrade 



SuperNut upgrade 

THE ALSTOM SuPERNuT uPGRAdE WAS dESIGNEd TO ALLOW THE REMOvAL 

OF THE KEYWAY IN THE SHAFT TAPER AREA, | the weakest part of the shaft, where 

most shaft failures occur. 

Other benefits of the SuperNut include repeatable installation force, and a much safer 

installation, since you will not need to “slug” on a hex nut, which can be dangerous, and 

of unknown force. 

The SuperNut uses many smaller bolts to produce the seating force. The yoke is not 

heated and the nut is not hammered. Force is accurately applied by torquing the smaller 

bolts – a simple one-man job. 

The shaft seating force of the SuperNut is greater than the heating method resulting in 

a better assembly. 

Additionally, with the SuperNut upgrade the yoke can still be pulled from the shaft after 

years of service. Alstom has removed yokes for repair and has reused the SuperNut 

without difficultly.

mPs-type Pulverizer Rebuild 

services 

Introduction to the MPS-type Mill 

THE MPS-TYPE MILL WAS ORIGINALLY dESIGNEd BY PFEIFFER AG OF 

GERMANY. BABCOCK & WILCOx (B&W) BOuGHT A LICENSE TO BuILd 

THE MPS-TYPE MILL IN 1971. | The first commercial operation in the USA 

was in 1973. B&W needed a fast replacement to resolve problems with the 

CR 77 mill. That license has since expired. 

There are several sizes of MPS-type mills. The most common is the MPS 89. 

This mill was supplied in a number of versions, K, N, NR and G. 

Alstom supplies all the replacement parts, wear parts and major casting for 

all the MPS 89 models. Alstom also supplies major components for the MPS 

75 and MPS 118 mills. 

MPS-TYPE PuLvERIzERS 

36

BenefIts: 




available 

37 MPS-TYPE PuLvERIzERS 

mPs-type Pulverizer Rebuild services 

Roll Wheel Rebuilds 

Alstom offers high quality MPS-type roll wheel rebuilds and new roll wheel assemblies. 




• Clean 



• Replace all worn out parts 

• Repair components as needed 

• Rebuild to strict procedures and tolerances 

• Include upgrades upon customer request 

• Pressure test


In an effort to save money and significantly reduce lead-time, Alstom offers the service to 

repair MPS-type roll wheel brackets and hubs. 

Bracket Repair scope 

• Clean and inspect bracket 

• Document received condition of bracket 

• Dye penetrant check bore and key area for cracks 

• Dimensionally check bore 

• Metal spray bore and machine to original specification 

• Weld repair excessive wear areas on lifting lug and pivot block sections of bracket 

Bracket – BEFORE 

BenefIts: 

• 60% savings vs. cost of a 

new casting 

• Reduces lead-time 

Bracket and Hub Repairs 

Bracket – AFTER 

hub Repair scope 

• Document received condition of hub 

• Weld build up and machine OD to original specification 

• Weld build up and machine ID to original specification 

• Weld bottom hub and machine to original specifications 

• Machine fit hub to roll and seal retainer 

Hub – AFTER 

BenefIts: 

• 50% savings vs. cost of a 

new casting 

• Reduces lead-time 

Hub – BEFORE 


38

BenefIts: 




purchase 



Yoke and Air Seal Repairs 

AIR SEALS ARE CRITICAL TO CONTAIN THE HOT PRIMARY AIR WITHIN THE MILL 

ANd PREvENT duSTY HOT AIR FROM CONTAMINATING THE MILL GEARBOx. | 

They also reduce heat transfer into the gearbox. If the gearbox oil is running hot or is 

contaminated, the air seal may need replacement or repair. 

Alstom reconditions all MPS-type yoke and air seal sizes and styles. Reconditioning 

includes weld repairs (yoke), hard surfacing (yoke), any required machining and 

re-bushing. When complete, the yoke / air seal is returned in as-new condition. 





• Magnetic particle inspect for cracks (yoke only) 



• Sleeve yoke seal area 

• Sleeve ring seat locating shoulder 

• Re-machine yoke to OEM specs, including upper ring seat surface 

• Clean all tapped holes 

• Prime paint/Cosmoline protect


NORMAL OPERATION CAN CAuSE A RING SEAT TO CRACK OvER TIME. | Type of coal 

and operating conditions can affect how long a ring seat will operate before cracks occur. 

These cracks can affect overall pulverizer performance. Alstom can repair your ring seat to 

as new condition and save you time and money. 

Ring seat Repair scope 

Basic Service 


• Magnetic particle inspection for cracks 

• Submit crack repair proposal 

• Submit machinery rebuild proposal 

Weld Repair 

• Arc out and rebuild cracks 

• Gr in d 

• Stress relieve 

Machinery Repair 

• Clean and tap holes 

• Re-machine to OEM specs 

Ring seat – after repair 

Ring Seat Repairs 

BenefIts: 

• Reduces lead times vs. new 

purchase 




40

BenefIts: 




available 

• Rebuild the individual subcomponents 

of the mill 



Gearbox Overhauls 

THE MPS-TYPE GEARBOx IS A WELL-dESIGNEd ANd BuILT MACHINE. IT 

CAN PROvIdE LONG, RELIABLE SERvICE WHEN PROPERLY ASSEMBLEd ANd 

MAINTAINEd. | After 20 years or more of service, a rebuild or replacement may be 

needed to maintain reliability. Alstom can rebuild a gearbox and return it in as-new 

condition. 




• Clean 

• Inspect 


• Replacement of parts such as gears, bearings, shafts, seals 

• Rebuild to as-new conditions 

• Rental agreements 

• Purchase options

dynAWeAR 

description: 

Adhesive bonded alumina 

ceramic tiles 

Applications: 

• Static applications only 

• Typically in: 

- upCones 

- Wall liners 

- Turrets 

features: 

• Pre-engineered, 

mechanically interlocked 

system 

• Blome grout 

Advantages: 

• Simplified installation 

• Blome grout aids 

installation and helps fill 

voids between tiles 

Benefits: 


overhauls 



uPgRAdes ImPRove 

RelIABIlIty 

And AvAIlABIlIty 



THE FOLLOWING uPGRAdES ARE AvAILABLE FOR ALL MPS-TYPE MILLS. | These 

products directly replace the OEM production fit and form but will last longer and are 

more reliable. 

ceramic lined and vacuum Bonded liners 

Ceramic lining is the best wear solution for high erosion, low impact locations. Alstom 

offers the most comprehensive wear solutions available. 

dynAWeAR II 

description: 

vacuum bonded product 

available in alumina ceramic 

tiles, silicone carbide tiles or 

tungsten carbide tiles 

Applications: 


applications 

features: 

• Customized application 

to fit your specific wear 

pattern 

• Tensile strength: 6000+ psi 

• Shear bond strength: 

4000+ psi 

Advantages: 

• Impact resistant 

• Can be used with complex 

shapes 

Benefits: 




outages 

dynAWeAR III 

description: 

Brazed tungsten carbide tiles. 

Applications: 


applications 

Note: The brazing method 

restricts use with certain 

types of materials. 

features: 

• High wear resistance 

• Excellent impact resistance 

Advantages: 

• Longer run time before 

replacement is required 

Benefits: 


ownership 


overhauls 


42

feAtuRes: 

• Three seal arrangement 

AdvAntAges: 

• Reduces risk of oil 

contamination 

BenefIts: 

• Increases mill availability 

• Increases bearing life 

PRevents oIl contAmInAtIon, PRomotIng 

longeR comPonent WeAR lIfe 



Triple Lip Seal upgrade 

ALSTOM’S TRIPLE LIP SEAL dESIGN HELPS ENSuRE OIL CAvITY INTEGRITY 

WHICH IS NECESSARY FOR LONG PuLvERIzER OPERATION PERIOdS. | This 

arrangement adds an additional layer of security. There are two seals to keep the 

contaminants out and one seal to keep the oil in. Better lubrication will allow bearings to 

run longer and increase pulverizer availability.

AS INduSTRY LEAdING SuPPLIERS FOR PROduCTS ANd SERvICES TO THE 

POWER INduSTRY, | Alstom and Horsburgh & Scott have decided to blend their 

individual expertise by entering into an alliance to rebuild / repair power plant 

gearboxes. We can rebuild / repair any gearbox anywhere in the power plant. 

The Alstom – Horsburgh & Scott team has the following capabilities: 

Balance of Plant Gearbox 

Rebuilds 

Service Capabilities 

Rebuild enclosed drives (from any manufacturer) 

• Concentric 

• Parallel shaft 

• Right angle bevel 

• Differential 

• Planetary 

• Wor m 

engineering Analysis 

• Upgrades 

• Modernization 

• Re-ratio 

• Problem solving 

field services 

• Installation supervision 

• Disassembly / reassembly 

• Enclosed drive evaluation and recommendation 

• Housing machining / re-boring 

• Predictive and preventive maintenance 

• Annual / periodic inspections 

• Re-engineering 

• Worldwide service 

A PARtneRshIP thAt WIll 

seRve All youR PlAnt 

geARIng needs 

we SuPPorT THe 

followInG BrAndS: 

• Amarillo 

• Adamson United 

• Atlas Car 

• Babcock & Wilcox 

• Beardslee & Piper 

• Blaw Knox 

• Brad-Foote 

• Cleveland 

• David Brown 

• D. O. James 

• Dodge 

• Dominion 

• Dorstener 

• Ecodyne 

• Elliot 

• Falk 

• Farrel 

• Fessler 

• Flender 

• Foote/Jones 

• Fordees 

• General Electric 

• Hansen 

• Hayward Gordon 

• Hitachi 

• Kawasaki 

• Krupp 

• Link-Belt 

• Lohmann & 

Stolterfoht 

• Lufkin 

• Marley 

• Mesta 

• M or gan 

Construction 

• Morgardshammer 

• Noma 

• NRM 

• Nuttall 

• P&H 

• Patterson Gear 

• Philadelphia Gear 

• Production 

Machinery 

• Renk/Tache 

• Sumitomo 

• Western 

• Westech 

• Westinghouse 

• Whiting 

• Wilson 

BALANCE OF PLANT 

44

BenefIts: 



• Faster turn-around vs. new 

purchase 


Original AGMA 8 gear upgraded to AGMA 10 

Housing refurbished Coal conveyor drives 

Rail car positioner 

45 BALANCE OF PLANT 

Balance of Plant gearbox Rebuilds 

The Alstom – Horsburgh & Scott team can also provide gearing upgrades as 

part of the rebuild / repair service. 




• Clean 



Based on inspection, additional services for Triple reduction Gearbox 

can include: 

• Replacement of all components deemed unacceptable 

• Rebuild to as-new condition 

• Clean and inspect lubrication system 

• Perform “No-Load” spin test 


Based on inspection, additional services for Pancake Gearbox can include: 

• Perform repair machining to gear housing halves and bores back to OEM 

tolerances 

• Reassemble, set up bearing endplay and gear patterns

ALSTOM OFFERS THE PARTS ANd SERvICES TO REBuILd ExISTING BuRNER 

SLIdE GATE ASSEMBLIES AT OuR REGIONAL SERvICE CENTERS. | A great 

candidate for R3 Rotation Programs, Alstom can rebuild a set of burner slide gates 

and store them at one of our Regional Service Centers to support planned outages 

or emergency requirements. Alstom offers this service in an effort to provide a cost 

savings to the customer versus the purchase of a new component. 




• Evaluate condition 

• Replace worn components as necessary 

• Add or replace wear materials 

• Reassemble 

• Paint and ship 

Burner slide gate – BEFORE 

Burner and Fabricated 

Component Rebuild Services 

Burner Slide Gate Rebuilds 

Burner slide gate – AFTER 

BenefIts: 



• Shorter lead time vs. 


• upgraded materials 

available 

• New equipment warranty 

BuRNER/FABRICATEd COMPONENT REBuILdS 

46

Burner and fabricated component Rebuild services 

BenefIts: 





47 BuRNER/FABRICATEd COMPONENT REBuILdS 

Fuel Elbow and Orifice Repairs 

FuEL ELBOWS ANd ORIFICES RESIdE IN THE COAL PIPING SYSTEM. | These 

components typically experience localized wear due to coal roping. In most cases the 

entire component does not need to be replaced; only areas that have experienced 

erosion. Alstom repairs ceramic fuel elbows and orifices. 

These components are great candidates for R3 Rotation Programs. Alstom can repair 

and store them at one of our Regional Service Centers to support planned outages 

or emergency requirements. Alstom offers this service in an effort to provide a cost 

savings to the customer versus the purchase of new components. 




• Issue a comprehensive inspection report 

• Repair as necessary 


• Paint and ship


THE COAL COMPARTMENT ASSEMBLY CONSISTS OF THE STATIONARY COAL 

NOzzLE, NOzzLE TIP, LINKAGES ANd SuPPORTS. | Alstom rebuilds / repairs all 

components within this assembly regardless of the material or design. 

A great candidate for R3 Rotation Programs, Alstom can rebuild / repair compartment 

assemblies and store them at one of our Regional Service Centers to support planned 

outages or emergency requirements. Alstom offers this service in an effort to provide a 

cost savings to the customer versus the purchase of new components. 




• Issue a comprehensive inspection report 

• Repair or replace components 


• Paint and ship 

Coal compartment assembly – AFTER 

Coal Compartment Rebuilds 

BenefIts: 





• upgraded materials 

available 

• New equipment warranty 

Coal compartment assembly – BEFORE 


48


BenefIts: 

• Burners are rebuilt to OEM 

Specification 

• up to a 60% savings 

vs. the cost of a new 

burner 

• Fast turn around 

• Extensive inventory 

support 

RSFC Burner – BEFORE 

RSFC Burner – AFTER 


RSFC Burner Rebuilds 

ALSTOM OFFERS REBuILd SERvICES FOR RSFC (RAdIALLY STRATIFIEd FLAME 

CORE) BuRNERS AS A COST EFFECTIvE ALTERNATIvE TO PuRCHASING A NEW 

COMPONENT. | Simply crate and ship the worn burner to Alstom’s rebuild facility and 

we will inspect and replace all worn and damaged components and restore all welds 

to original specification. 

When complete, Alstom will return the rebuilt burner to you in the same shipping 

crate to minimize the possibility of damage during shipment. 



• Replace missing tiles 

• Replace stainless shroud 

• Replace distorted pipes 

• Replace adjusting bars 

• Replace worn blades 

• Replace all welds 

• Check to original specifications 

• Paint 

• Ship back to customer in original shipping container


OIL GuNS ARE uSEd IN COAL-FIREd FuRNACES duRING START-uP TOO BRING 

THE FuRNACE FROM A “COLd” ENvIRONMENT TO AN ENvIRONMENT HOT 

ENOuGH TO CONTINuOuSLY BuRN COAL. | Once the coal fireball has been introduced 

and is stable within the furnace, the oil guns can be taken out of service. Retract 

mechanisms are one method of removing the oil gun from the heat of the furnace after 

boiler startup has been completed. 

Alstom provides quality rebuilds and new assemblies for oil guns and retract mechanisms 

at our local services centers. 




• Clean 


Oil Gun and Retract Mechanism Rebuilds 


• Replacement or refurbishment of all components that do not meet original specification 

• Rebuild to as-new condition 


BenefIts: 



• Reduced lead time vs. new 

purchase 


available 


50


notes

ALSTOM HAS BEEN SuPPLYING NEW ANd REBuILT PuLvERIzER 

vOLuMETRIC FEEdERS FOR OvER 60 YEARS. | A Volumetric Feeder rebuild by 

Alstom results in a like-new feeder at a cost and lead time much less than those 

for new equipment. Standard as well as customized upgrades are offered as part of 

the rebuild to meet operational and maintenance needs. Customers are contacted 

before the rebuild begins and provided with additional scope and upgrade options. 




• Clean 


Based on inspection, additional services include: 

• Replace all worn out parts 

• Repair components as needed 

• Rebuild to strict procedures and tolerances 

• Include upgrades upon customer request 

Volumetric Feeder 

Rebuild Services 

volumetric Feeder Rebuild Services 

BenefIts: 


• Reduces inventory costs by 

25-35 percent 

• Saves up to 50% of 

replacement cost 

• Extends product life 


available 

vOLuMETRIC FEEdER REBuILdS 

52

AdvAntAges: 

• Class 3 gearbox 

• New design protects the 

drive and feeder from 

damage due to jams 

• Solid state speed control 

• More efficient motor 

operation at all feeder 

speeds 

• Feeder motor speed 

indicator 

BenefIts: 

• Fewer parts to maintain 


• Fewer breakdowns 

• Parts inventory reduction 

• Increases feeder reliability 

Reduce mAIntenAnce 

costs WhIle 

ImPRovIng RelIABIlIty 

53 vOLuMETRIC FEEdER REBuILdS 

volumetric feeder Rebuild services 


ALSTOM CONTINuES TO dESIGN ANd dEvELOP vOLuMETRIC COAL FEEdER 

PROduCTS | that will meet the changing needs of our customers. These upgrades: 

• provide longer wear life 

• reduce maintenance costs 

• eliminate a number of mechanical problems 

• improve overall reliability and availability 

Feeder drive Conversion 

ALSTOM HAS dEvELOPEd A FEEdER dRIvE CONvERSION FOR OuR 

vOLuMETRIC COAL FEEdERS TO REduCE MAINTENANCE COSTS ANd 

dOWNTIME ANd IMPROvE FEEdER RELIABILITY. | This conversion kit is 

available for most Alstom pulverizer installations with 16 lb. through 125 lb. feeders 

using Vari-Stroke drives and Hilliard clutches or Adjusto-Speed drives in the 

following size designations: 

• 312 to 753 RB mill 

• 463 to 863 RS mill 

• 463 to 863 RPS mill 

• 463 to 863 RP mill 

The kit includes a new 

in-line variable speed 

motor coupled to the 

feed roll shaft through a 

chain drive. It replaces 

the current Vari-Stroke 

or Adjusto-Speed drive. 

Additional components can 

be customized to suit your 

special requirements. 

The materials along with 

an assembly drawing with 

installation instructions and wiring diagrams for the speed control and remote operator 

station are supplied as part of this kit. All field wiring and installation is supplied by the 

customer.


Feed Roll Shaft Needle Bearing-to-Bushing Conversion 

THE FEEd ROLL SHAFT NEEdLE BEARING-TO-BuSHING CONvERSION KIT 

WAS dEvELOPEd TO ALLOW COAL TO FEEd TO YOuR PuLvERIzER AT A MORE 

uNIFORM RATE. | This is accomplished by varying the rotational speed of a spider and 

blade assembly, which form fixed volume rotating pockets. With the current design, 

the shaft of the feed roll spider rotates in a pair of needle bearings located in the feed 

roll endplugs. These needle bearings are subjected to high temperatures and substantial 

contamination which demands frequent manual lubrication. To eliminate this labor 

intensive need, the new design incorporates high strength bronze bushings with graphite 

endplugs. 

The bronze bushings are manufactured from a high strength alloy. The graphite endplug 

provides a dry lubrication which does not attract and hold contamination or break down 

with heat. A shrink fit is utilized to retain the bushings in the feed roll endplugs. The 

bushings are designed to run against the same bearing inner races used for the needle 

bearings. These inner races, with a 16 micron finish hardened to 58 Rockwell C, provide 

an inexpensive replaceable surface and fit directly on the existing feed roll shaft. This 

bushing arrangement is designed to operate at temperatures up to 550°F. 

The bronze bushings with graphite are a direct replacement of the originally supplied 

needle bearings. No modifications are required. 

shaft needle Bearing-to-Bushing conversion 

AdvAntAges: 

• Insensitive to temperature 

• Eliminates manual 

lubrication 

• direct replacement of 

existing needle bearings 

BenefIts: 

• Increases wear life 

• Increases feeder/mill 

availability 


unIfoRm coAl feed 

RAte to the PulveRIzeR 


54

AdvAntAges: 

• Cylinder can be replaced 

without having to replace 

the cast endplug 

• Simple upgrade with direct 

parts replacement 

• design can be used on 

right-hand and left-hand 

feeders 

BenefIts: 



ownership 

sImPle And loW cost 

endPlug uPgRAde 



Endplug upgrade 

THE vOLuMETRIC FEEdER ENdPLuG uPGRAdE ALLOWS REPLACEMENT OF A 

WORN CYLINdER WITHOuT HAvING TO REPLACE THE WHOLE CASTING. | This 

three-piece design replaces the original one-piece cast feed body endplug – cylinder. The 

new endplug assembly consists of a cast feed roll plug which is the major part of the 

original casting, a spacer, and the feed roll sleeve. Only the sleeve is exposed to wear. 

For contracts after 1955, these three-piece feeder body endplugs are a direct 

replacement part. No field modification is required. Contracts dating before 1955 may 

require additional parts to use the multi-piece endplug and will need to be researched 

on an individual contract basis.


Stainless Steel Body Liners 

ALSTOM’S vOLuMETRIC FEEdER STAINLESS STEEL BOdY LINERS WERE 

dEvELOPEd TO PROTECT THE FEEdER BOdY FROM WEAR AS THE COAL FLOWS 

THROuGH THE FEEdER. | The stainless steel liners provide a replaceable wear-resistant 

surface. Coal flow to the pulverizer will improve over time as the liner surfaces become 

polished and friction is reduced. The feeder body liners are designed to fit into existing 

feeders. 

The stainless steel body liners have been incorporated as standard supply since the early 

1960’s. These liners have proved to be very successful, and some earlier feeders have 

since been retrofitted. This liner upgrade is appropriate for all pre-1960 contracts and 

should be reviewed for post-1960 contracts. 

AdvAntAges: 

• Protect feeder bodies from 

wear 

• Provides improved coal 

flow 

• Reduces feeder pluggage 

• Easily installed or replaced 

BenefIts: 


• Improves availability 

unIfoRm coAl feed 

RAte to the PulveRIzeR 


56

sImPlest WAy to 

Reduce coAl dePosIts 



Stainless Steel Feed Roll Spider and Blade Assembly 

AdvAntAges: 

• Simple direct replacement 

• Reduces coal hide-out areas 

• Stainless steel material 

to provide a smoother, 

friction-free surface 

BenefIts: 

• Improves boiler control 


• Reduces load restrictions 

caused by coal feed 

problems 

ALSTOM HAS dEvELOPEd A STAINLESS STEEL FABRICATEd FEEd ROLL SPIdER 

ANd BLAdE ASSEMBLY TO REduCE THE LIKELIHOOd OF COAL dEPOSITING 

IN THE FEEd ROLL POCKET. | The material is stainless to provide a smoother, more 

friction-free pocket. To reduce wear to the spider, the order of rotation has been 

reversed from the original design with cast iron spiders. The new assembly has the 

sacrificial spider blade rotating into the coal, followed by the spider. When the coal is 

dumped, it slides off the smooth backside of the spider. 

The new stainless steel feed roll spider and blade assembly is a direct replacement of the 

originally supplied spider assembly. No modifications are required.


Hinged Gate Mechanism Assembly upgrade 

THE HINGEd GATE MECHANISM ASSEMBLY uPGRAdE WAS dEvELOPEd TO 

AddRESS FEEdER FAILuRES THAT LEAd TO INTERRuPTEd PLANT OPERATION. | 

The hinge gate mechanism levels the coal in each section of the feed roll assembly as it 

rotates. This maintains a constant volume of coal in each section and helps to provide the 

proper coal feed rate to the pulverizer. If the hinge gate mechanism fails, the hinge gate can 

rotate away from the feed roll. This allows too much coal to enter the pulverizer, resulting 

in spillage and other operational problems. Repairing the hinge gate mechanism typically 

requires taking the feeder off-line, which can impact the ability to maintain unit load. 

Alstom’s new design eliminates the spring rod handle, includes a more durable lever 

attachment and a redesigned cam follower to substantially reduce failures associated with 

the current design. This reduces maintenance and repair costs and improves feeder reliability 

and availability. 

feeder hinged gate mechanism Assembly 

AdvAntAges: 

• New robust design reduces 

failures 

• Allows for easy adjusting 

during installation 

• Enables easy adjustment 

BenefIts: 

• Easy installation 


• Improves feeder reliability 

and availability 

sImPlest WAy to ImPRove 

feedeR RelIABIlIty And 

AvAIlABIlIty 


58

AdvAntAges: 

• Simple conversion utilizing 

existing feeder body studs 

• Can be oriented to open to 

either side 

BenefIts: 

• Increases safety 

• Increases convenience 



Side Opening Inspection door upgrade 

quICKLATCH – 

Inspection door upgrade 

ALSTOM’S SIdE OPENING INSPECTION dOOR FOR THE INdEPENdENT 

vOLuMETRIC FEEdER IS AN uPGRAdE TO THE ORIGINAL dESIGN. | The new 

assembly mounts on the existing dog studs on one side of the feeder door opening and 

the two remaining dogs on the other side are used to keep it closed. This allows the full 

weight of the door assembly to ride on the new hinges as it pivots open. The door is 

symmetrical so it can be mounted to open to either side. This modification can be used 

as is or in conjunction with Alstom’s QUICKLATCH design which replaces the access 

dogs with a lift and swing latch assembly 

THE quICKLATCH FEEdER INSPECTION dOOR uPGRAdE PROvIdES RAPId 

INTERNAL ACCESS TO ALSTOM’S NEGATIvE PRESSuRE vOLuMETRIC FEEdERS 

WHILE MAINTAINING NFPA COdE REquIREMENTS IN THE CLOSEd POSITION. | The 

QUICKLATCH upgrade must be used in conjunction with the Side Opening Inspection Door 

Upgrade which relocates the hinges from below the door to the side. In this orientation the 

weight of the inspection door is carried on the hinges. 

At this time the QUICKLATCH feeder inspection door conversion is applicable only to 

Volumetric Feeders on suction mills (RB and RS mills). 

AdvAntAges: 

• Provides quick access to 

feeder internals 

• Latch assembly meets 

NFPA requirements 

• use with feeders normally 

operated under negative 

pressure 

• quick release safety pin to 

prevent accidental openings 

BenefIts: 

• Improves feeder access 

• Increases convenience 

• Improves safety

ALSTOM OFFERS AN ARRAY OF NEW ANd REBuILT SINGLE ROLL ANd 

dOuBLE ROLL CLINKER GRINdERS. BRANdS THAT ALSTOM SuPPORTS 

INCLudE: | Allen-Sherman-Hoff, United Conveyer Corp.*, AR Industries, 

Combustion Engineering, ABB and Alstom. 




• Clean 


• Replace the following parts: 

– Packing 

– Shaft sleeves 

– Wear rings 

– O-Rings 

– Bearings 

– All high chrome wetted parts (single rolls only) 

– Connecting hardware 

Based on inspection, additional services include: 

• Replacement of the following parts: 

– Bearing supports 

– Housings 

– Covers 

– Metal seals 

– Shaft and roll assemblies (double roll only) 

• Housing (repair more likely than replacement) 

* (type of service available depends on size and model number) 

Clinker Grinder Rebuild 


Clinker Grinder Rebuilds 

BenefIts: 



• Extends product life 


available 

CLINKER GRINdER REBuILdS 

60

single Roll models 

uP to 2 tImes the seRvIce 

• 27” x 20” 

lIfe of tRAdItIonAl PAckIng 

• 33” x 30” 

ASHBRADE Grinder Packing – lantern ring, 

packing rings and gland follower 

61 CLINKER GRINdER REBuILdS 

clinker grinder Rebuild services 

ALSTOM CONTINuES TO dESIGN ANd dEvELOP CLINKER GRINdER PROduCTS | that will meet the challenging needs of our 

customers. These upgrades provide: 

• Longer wear life 

• Reduced maintenance costs 

• Improve overall reliability and availability 

BenefIts: 

• Significantly reduces water 

leakage from grinder 

stuffing boxes 

• Service life of ASHBRAdE 

Packing has been found to 

be up to two times longer 

than traditional packing 

• Life span better matches 

grinder rebuild cycles 

• Available for most grinder 

models 


ASHBRAdE Grinder Packing 

ASHBRAdE GRINdER PACKING IS dESIGNEd FOR SINGLE ROLL ANd dOuBLE ROLL 

CLINKER GRINdERS ANd IS AN uPGRAdE TO MOST COMMON TYPES OF PACKING 

uSEd TO SEAL THE STuFFING BOx AREAS TO MINIMIzE WATER LEAKAGE. | 

ASHBRADE Packing can be installed in most existing grinder models replacing the 

traditional lantern ring and packing ring assemblies. It is not necessary to purchase a new 

grinder or modify the castings of an existing grinder to take full advantage of this upgrade. 

Key features of the ASHBrAde Grinder Packing lantern ring include: 

• Three piece metal design to handle the compression force when installing the four packing 

rings 

• Sufficient width along the grinder sleeve to stay positioned under the sealing port yet 

allow proper water or grease sealing 

• Properly shaped forward faces that conform to existing stuffing box profiles 

• An offset design with tighter shaft sleeve clearances in the direction of the packing rings 

and an improved water flow path towards the grinding area 

• When used with the recommended higher pressure seal water, the lantern ring provides 

better flushing of grit that historically gets under packing rings and scores shaft sleeves 

ASHBRADE Grinder Packing can be installed into an existing clinker grinder in the field. It 

is also a major feature of an Alstom Grinder Rebuild Program performed at our Regional 

Service Centers. Here grinder rebuild specialists have the experience, tools and formal rebuild 

procedures necessary to provide proper installation of all grinder parts and packing. 

The grinder models for which ASHBRADE Grinder Packing is applicable include 

the following: 

double Roll models 

• 2’ - 0” 

• 2’ - 10” 

• 3’ - 0”

clinker grinder Rebuild services 

Segmented Rolls for double Roll Grinders 

ALSTOM OFFERS REPLACEABLE SEGMENTEd ROLLS FOR uSE ON ITS FAMILY OF 

dOuBLE ROLL GRINdERS | Alstom has now applied the technology used in its Single Roll 

grinder design to its 2’-0”, 2’-10” and 3’-0” Double Roll Grinders. 

Instead of using a hollow Ni-Hard roll, Alstom employs multiple Ni-Hard cam segments 

bolted to a cam support box, which, in turn, is supported by three internal bosses welded to 

a steel shaft. The cam segments can be individually replaced as teeth break off, even while 

the grinder is still installed under the gate housing. 

During a rebuild, which can be performed at one of Alstom’s regionally located service 

centers; each cam is removed and inspected for reuse or replacement. The main shaft is 

also inspected. In most cases the shaft can be reused if proper sleeves and packing were 

used during operation. 

feAtuRes: 

• Individual, bolt-on Ni-Hard 

cam segments 

• Cam support box with 

internal bosses 

AdvAntAges: 

• Replace only those cam 

segments that are worn or 

broken 

• Reusable shaft* 

BenefIts: 


ownership 


• Extends run time between 

outages 

* Providing proper sleeves and packing 

were used during operation. 

CLINKER GRINdER REBuILdS 

62

63 CLINKER GRINdER REBuILdS 

notes

The Alstom Advantage 

100 YEARS OF ExPERIENCE + SOLuTION-BASEd PROduCTS & SERvICES + 

COMMITMENT TO CuSTOMER SERvICE = THE ALSTOM AdvANTAGE | Alstom 

provides reliable delivery of products and services to meet the demands of the 

power industry. We are a dedicated customer service organization that delivers the 

responsiveness our customers require. 

Alstom provides the quality and resources of an OEM while backing our products with 

comprehensive support. Our products are designed to help our customers meet the 

performance, availability and reliability requirements for their power plant equipment. 

mARkets seRved 

equIPment suPPoRted 

In addition to servicing Alstom equipment, we also provide after market service for the following brands: 

COAL FEEdERS | ABB, Combustion 

Engineering, Stock Equipment, 

Merrick Industries 

COAL PuLvERIzERS | ABB, 

Combustion Engineering, Babcock 

& Wilcox, Riley Atrita®, Foster 

Wheeler 

Service Capabilities 

Our experience and customer base include: 

• Utility companies 

• Regional electric cooperatives 

• Federal, municipal power producers 

• Independent power producers 

• Pulp and paper companies 

• Industrials such as chemical plants, steel mills and refineries 

In other words, if you generate steam to produce power or to support your manufacturing 

processes, Alstom is ready to provide the products and services you need. 

STEAM GENERATORS | ABB, 

Combustion Engineering, Babcock & 

Wilcox, Riley, and Foster Wheeler 

STOKERS | ABB, Combustion 

Engineering, detroit Stoker, Riley, 

Westinghouse, Hoffman, Taylor 

FIRING SYSTEMS | ABB, ICL, NEI, 

Clark Chapman, CSL, Rv Industries, 

Foster Wheeler 

ASH HANdLING SYSTEMS | ABB, 

Combustion Engineering, Allen- 

Sherman-Hoff, united Conveyor, Fläkt 

AIR POLLuTION CONTROL | ABB, 

Combustion Engineering, Fläkt, 

Walther, Carborundum, Hamon- 

Research Cottrell, Wheelabrator, 

Peabody, Rockwell 

THE ALSTOM AdvANTAGE 

64

Alstom’s technical 

services capabilities 

cover major plant 

equipment and 

systems and include: 

• Outage planning 

• Inspection services 

• Condition assessments 

• Maintenance support 

• Performance testing 

• Training programs 

• dedicated engineers 

Alstom technical 

service includes: 

• A team of over 100 

field-based service 

engineers, NdE specialists, 

performance test engineers 

and technicians 

• Problem solvers 

• Equipment inspectors, 

testers, and evaluators 

• Performance specialists 

65 THE ALSTOM AdvANTAGE 

technical services 

WE ARE A GLOBAL PROvIdER OF PROduCTS ANd SERvICES TO THE POWER 

INduSTRY. | We maintain a local presence to help ensure that our customers’ equipment 

and systems run reliably and efficiently with the availability they demand. 

FIELd TECHNICAL SERvICE ENGINEERS | Alstom has extensive capabilities in the form 

of Field Technical Service Engineers to assist with your outage inspection and operation and 

maintenance needs. 

Our field service engineers are located near our customers to provide the response they need. 

This full time force of professionally trained engineers and technicians receive constant 

training to help ensure they are knowledgeable in the latest trends and available technology. 

OuTAGE PLANNING | Effective outages require effective planning, a continuous process 

that begins well in advance of the scheduled event. Alstom stands ready to participate in 

this process to help ensure timely decisions, problem avoidance, and achieved goals. 

the services Alstom provides include: 

• Setting overall outage objectives 

• Work scope determination 

• Prioritization of outage tasks 

• Identification of material and parts needs 

• Expediting delivery of required material and parts 

INSPECTION SERvICE | To help ensure an effective outage, we offer our 

inspection service that includes: 

• Pre-outage logistics and work scope definition 

• Pre-outage unit walk-downs 

• Detailed inspections during the outage 

• Daily punch lists and definition of items requiring immediate attention 

• Coordination with repair labor personnel 

• Initial report with critical findings and recommendations 

• Final detailed inspection report complete with photos, recommendations 

and findings 

• On-line retrieval (via our website) of our final report for convenient viewing 

and downloading

CONdITION ASSESSMENT | Alstom delivers the 

technology to manage risks through the integration of 

Advanced NDE and inspection technology, including: 

• Ultrasonic examination 

• Linear phased array 

• Dye penetrant testing 

• Magnetic particle testing 

• Remote field Eddy current 

• Wet fluorescent particle testing 

• Boroscope with internal video 

• Remote field eddy current 

• Visual examinations 

as well as service capabilities through: 

• Power Plant Laboratory facilities, 

• Material Technology Center, 

• Field service engineers 

PERFORMANCE TESTING ANd EvALuATIONS | 

The performance evaluation and testing team 

supports data gathering and analysis to help optimize 

plant performance. Offerings include: 

• Specialized testing of thermal, fluid, and chemical 

processes (emissions and circulation) 

• Boiler and power plant performance evaluation 

• Water chemistry consultation for boilers 

• Instrumentation supply and rentals of most 

commonly used boiler and emissions test equipment 

technical services 

dEdICATEd ENGINEER PROGRAM | We provide an experienced Alstom Technical Services 

Engineer for exclusive use for a specific time period. 

The Dedicated Engineer becomes an on-site member of the plant team spearheading the 

Alstom support. The result is responsive service in determining root causes to problems and 

timely development and implementation of solutions to help reach and exceed station goals. 

technIcAl seRvIces 

tAIloRed foR you And 

youR Budget 

MAINTENANCE SuPPORT SERvICE | To help ensure your equipment 

performs to your expectations, we offer our Maintenance Support Service 

whereby we: 

• Determine equipment condition and need for repairs 

• Compare components to 

original specifications and 

help make adjustments 

• Participate in developing 

work scope and associated 

tasks 

• Direct maintenance 

personnel in proper 

disassembly and 

assembly procedures 

• Coordinate execution of the 

work scope 

• Develop a daily punch list 

prioritizing work tasks 

• Provide a final report documenting work performed and 

recommendations 

TRAINING PROGRAMS | Alstom's training programs provide power plant 

professionals with the knowledge and skills they need to operate and 

maintain the equipment and systems. Alstom's portfolio includes: 

• Standard and customized training 

• HOT TOPIC training programs 

• Computer-based QUICKSTUDY Learning System 

• Regional training seminars 

wITH AlSTom... 

You’re In conTrol 


66


Alstom service and distribution centers 

AdvAntAges: 

• After hours response team 

• Guaranteed parts availability 

• Eliminates exposure to 

obsolete inventory 

• Applicable to most plant 

equipment 

• Programs can be expanded 

to include other plants with- 

in the customer’s system 

• One week standard shipment 

after receipt of order 

• Minimizes exposure to raw 

materials price fluctuations 

BenefIts: 

• Reduces carrying costs 

• defers cash outlay 

• Increases cash flow by 

delivering products when 

needed 

• Simplifies purchasing 

stRAtegIcAlly locAted 

to seRve ouR customeRs 

InventoRy mAnAgement PRogRAms 

With our proven inventory management expertise, purchasing strength and strategically 

located regional service centers, participation in an Alstom Inventory Management Program 

can offer customers significant benefits – from guaranteed shipments to improved cash flow. 

ImPRoves cAsh floW And guARAntees 

PARts AvAIlABIlIty 

ALSTOM’S SERvICE CENTER NETWORK, STRATEGICALLY 

LOCATEd ACROSS THE COuNTRY, | provides emergency 

component repairs, parts, complete component overhauls, 

custom fabrications, and cost saving inventory management 

programs to meet our customers’ needs. 

denver, CO 

* 

Tyler, Tx 

* 

Erlanger, KY 

* 

Chattanooga, TN 

* 

Suwanee, GA 

* 

Ro c k y Mo u n t a i n Se R v i c e cen t e R – 

Den v e R, co l o R a D o 

MiD w e S t Se R v i c e cen t e R – 

eR l a n g e R, ke n t u c k y 

Harrisburg, PA 

*

Alstom service and distribution centers 

REBuILd/REPAIR SERvICES | As a leading supplier of quality power 

plant equipment and replacement parts, Alstom offers one of the industry’s most 

complete and cost-effective rebuild and repair services. 

Alstom’s rebuild/repair services include component inspections and maintenance, 

replacement of worn parts and design upgrades. These offerings, which include 

extended warrantees, can reduce inventory costs by 25-35% and result in longer lasting 

products that save power producers money. 

R3 comPonent RotAtIon PRogRAms 

Alstom offers customers a systematic method for rebuilding boiler related equipment 

and returning this equipment to service. Alstom’s Regional Service Centers are the focus 

of this program combining our extensive experience, inventory, rebuild portfolio and 

proven processes to provide a unique service. 

The R3 program is based on Rebuilding, Restocking and Replacing components. 

Rebuild 

Complete disassembly and inspection of a component. Worn out parts are replaced and 

components repaired. The components are rebuilt to strict procedures and tolerances. 

Upgrades to components can be included. 

Restock 

Once a rebuild is completed, the component is placed in the customer’s exclusive stock 

inventory at the Regional Service Center nearest the plant. 

Replace 

Rebuilt components are returned to a customer when needed to replace a similar 

component requiring service. The replaced component is sent back to the Service Center 

R3 = ReBuIld + Restock + RePlAce 

ImPRovIng AvAIlABIlIty WhIle ReducIng cost 

AdvAntAges: 

• All work is done in a 

controlled environment 

using the latest 

technology 

• All work is done to 

engineering specifications 

• R3 Component Rotation 

Programs are available to 

fit your outage schedule 

• Extensive parts inventory 

to support rebuilds/ 

repairs 

• OEM inspection and 

assembly procedures are 

used 

• Component upgrades 

available 

BenefIts: 

• Reduce Inventory costs 

25-30% 

• Shorter lead times 

• All work backed by 

Alstom’s engineering 

experience, quality and 

reliability 


68

AdvAntAges: 

• Custom or standard 

kits 


costs 

• Convenient and 

organized 

• Simplifies purchasing 

BenefIts: 

• Right parts available 

when you need them 

• Only pay for the parts 

that are used 

• Instant part availability 

• Save time and money 

The customer and 

Alstom develop a 

list of parts to be 

included in each kit. 

Each kit includes a 

detailed chart of the 

location of each part. 


outage kit services 

OuTAGE KITS | are pre-packaged supplies of equipment-specific replacement 

parts that support planned or unexpected unit outages and rebuilds. 

Emergencies cost money! Outage Kits can help minimize costly delays in 

making repairs. 

Outage Kits are the perfect solution when emergencies strike, or to have 

available as part of a planned preventative maintenance cycle or Inventory 

Management Program. 

Alstom then ships 

these parts in 

pre-packaged kit 

form to the customer 

two weeks prior to the 

planned outage 

or rebuild. 

A cost-effectIve WAy to mAnAge PlAnned 

And unPlAnned unIt outAge RePAIRs 

hoW Alstom’s outAge kIt PRogRAm WoRks: 

Customer 

withdraws parts 

from the kit, 

as needed. 

Items not needed 

from any given kit 

are shipped back 

to Alstom for 

re-stocking. 

The customer then 

issues a purchase 

order to Alstom 

for any parts 

consumed.

your 1-stop choice for Boiler services and Parts 

call us toll free: 1.866.257.8664 

or 

direct: 1.860.285.2100 

Press: 

If you know your party’s 4 digit extension 

For Shipping and delivery information 

To speak with a Customer Service Representative 

If you would like the company directory 

If you would like this menu repeated 

All other calls stay on the line 

e-mail: windsorparts@power.alstom.com 

fax: 1.860.285.3101 

We provide 24 hour, 7 days a week emergency service. 

Our normal office hours are 8:00 am to 4:30 pm EST/EDT.

PSE/BPROS/RRvWLM10/eng/PSER1/04.10/uS/7137 © ALSTOM 2010. Alstom, the Alstom logo and any alternative version thereof are trademarks and service marks of Alstom. The other names mentioned, registered or not, are 

the property of their respective companies. The technical and other data contained in this document is provided for information only. Neither Alstom, its officers and employees accept responsibility for or should be taken as making any 

representation or warranty (whether express or implied) as to the accuracy or completeness of such data or the achievement of any projected performance criteria where these are indicated. Alstom reserves 

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

STOCK is a registered trademark of the Stock-Schenck Process Group. diamondback is a registered trademark of J.R. Johanson, Inc. Merrick Industries, Inc. is a licensed manufacturer of the diamondback Hopper System. Atrita is a 

registered trademark of Riley Power, Inc. LIMELIGHT is a trademark of Alstom Power Inc. GENETIx is a registered trademark of Merrick Industries, Inc. 

Alstom Power Inc. 

200 Great Pond drive 

Windsor, CT 06095-0500 

Tel: 860.285.2100 

Toll Free: 866.257.8664 

Fax: 860.285.3101 

www.power.alstom.com

Rebuild and Repair Services For Power Plant Equipment

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