Rebuild and Repair Services For Power Plant Equipment
Rebuild and Repair Services For Power Plant Equipment
Rebuild and Repair Services For Power Plant Equipment
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<strong>Rebuild</strong> <strong>and</strong> <strong>Repair</strong> <strong>Services</strong><br />
<strong>For</strong> <strong>Power</strong> <strong>Plant</strong> <strong>Equipment</strong><br />
Stretch Your Maintenance Budget<br />
<strong>Power</strong><br />
with Alstom behind me…<br />
I’m in control!
ebuild <strong>and</strong> repair <strong>Services</strong><br />
At Alstom, we combine our capabilities <strong>and</strong> experience<br />
to enhance the productivity <strong>and</strong> performance of boilers,<br />
pulverizers, feeders, air pollution control systems, ash<br />
h<strong>and</strong>ling systems <strong>and</strong> auxiliary equipment. Our focus<br />
is customer service <strong>and</strong> we underst<strong>and</strong> the challenges<br />
WITH ALSTOM…I’M IN CONTROL<br />
Alstom is a leader in the design, manufacturing <strong>and</strong> servicing of utility <strong>and</strong> industrial power generation<br />
systems. While our heritage dates to the late 1800s, our capabilities continue to exp<strong>and</strong> <strong>and</strong> point us<br />
to the future.<br />
Saf e t y | We believe that safety is a key indicator of operational excellence for both Alstom <strong>and</strong> its customers.<br />
Our commitment to safety hinges on strong leadership, timely communication<br />
<strong>and</strong> the involvement of all employees. Our target is zero safety incidents.<br />
ex p e r i e n c e | With an installed base of over 400 GW of power generation capacity <strong>and</strong> a track record<br />
spanning over 100 years, we believe you cannot find a partner whose experience in the power industry matches<br />
ours. We are dedicated to meeting your needs <strong>and</strong> exceeding your expectations. Our track record proves it.<br />
in n o v a t i o n | Each <strong>and</strong> every day, Alstom applies leading edge technology to develop new products <strong>and</strong><br />
services to meet your maintenance <strong>and</strong> operational challenges regardless of your boiler type or fuel.<br />
Your performance is our measure of our success.<br />
LogiSticS | The right products <strong>and</strong> services when <strong>and</strong> where you need them. That is our commitment. With<br />
a wide range of capabilities <strong>and</strong> options for replacement parts supply, technical services, <strong>and</strong> construction services,<br />
Alstom is your complete boiler services solution. We offer the industry’s most comprehensive <strong>and</strong> innovative<br />
replacement parts <strong>and</strong> service programs.<br />
cuS t o m e r Se r v i c e | Alstom’s field service engineers, customer service representatives <strong>and</strong> construction<br />
managers have one goal – exceeding your service expectations. Our strategically located service <strong>and</strong> distribution<br />
centers enable us to provide fast response <strong>and</strong> reliable solutions to meet your needs.<br />
faced by plant owners, operators, maintenance personnel<br />
<strong>and</strong> management. Whether it is a replacement or<br />
upgraded part, a rebuilt assembly, a custom fabrication<br />
or inventory management program, Alstom provides<br />
exceptional value <strong>and</strong> service to our customers.
co n t e n t S<br />
ALSTOM PULVERIZER REBUILD SERVICES<br />
Introduction to the Alstom Pulverizer ..........................................................................................4<br />
Journal Assembly <strong>Rebuild</strong>s ...........................................................................................................7<br />
Grinder Roll Resurfacing ..............................................................................................................8<br />
Journal Spring <strong>and</strong> Door <strong>Rebuild</strong>s ................................................................................................9<br />
Fan Bearing Housing Assemblies ..............................................................................................10<br />
Separator Bodies <strong>and</strong> Tops ........................................................................................................11<br />
Exhauster Products ...................................................................................................................12<br />
Pulverizer Gearbox <strong>Rebuild</strong>s .......................................................................................................16<br />
Worm Shaft/Worm Gear Assembly <strong>Rebuild</strong>s ......................................................................17<br />
Pre-Assembled Components .....................................................................................................18<br />
Product Upgrades ......................................................................................................................19<br />
Double Upper Bearing Journal Assemblies ...........................................................................19<br />
Magnum Journal Upgrade ....................................................................................................20<br />
Proseal 350 Upgrade ............................................................................................................21<br />
LM-45 Journal Seal Upgrade ................................................................................................22<br />
Journal Pressure Spring Upgrade ..........................................................................................23<br />
EL-type PULVERIZER REBUILD SERVICES<br />
Introduction to the EL-type Mill .................................................................................................24<br />
Rotating Assemblies ..................................................................................................................25<br />
Yoke <strong>Repair</strong>s ...............................................................................................................................26<br />
Air Seal <strong>Repair</strong>s ..........................................................................................................................27<br />
Bearing Plate <strong>Repair</strong>s .................................................................................................................28<br />
Spring Bolt <strong>Rebuild</strong>s ...................................................................................................................29<br />
Gearbox Overhauls .....................................................................................................................30<br />
Gear Casing <strong>Rebuild</strong>s .................................................................................................................31<br />
Pinion <strong>Rebuild</strong>s ...........................................................................................................................32<br />
Product Upgrades ......................................................................................................................33<br />
Ceramic Lined <strong>and</strong> Vacuum Bonded Liners..........................................................................33<br />
Keyless Shaft Upgrade .........................................................................................................34<br />
SuperNut® Upgrade .............................................................................................................35<br />
MPS-type PULVERIZERS<br />
Introduction to the MPS-type Mill ............................................................................................36<br />
Roll Wheel <strong>Rebuild</strong>s ...................................................................................................................37<br />
Bracket <strong>and</strong> Hub <strong>Repair</strong>s ......................................................................................................38<br />
Yoke <strong>and</strong> Air Seal <strong>Repair</strong>s ..........................................................................................................39<br />
Ring Seat <strong>Repair</strong>s .......................................................................................................................40<br />
Gearbox Overhauls .....................................................................................................................41<br />
Product Upgrades ......................................................................................................................42<br />
Ceramic Lined <strong>and</strong> Vacuum Bonded Liners..........................................................................42<br />
Triple Lip Seal Upgrade .........................................................................................................43<br />
2
3<br />
BOP GEARBOX REBUILD SERVICES<br />
BOP (Balance of <strong>Plant</strong>) Service Capabilities .............................................................................44<br />
BURNER & FABRICATED COMPONENTS REBUILD SERVICES<br />
Burner Slide Gate <strong>Rebuild</strong>s ........................................................................................................46<br />
Fuel Elbow <strong>and</strong> Orifice <strong>Repair</strong>s ..................................................................................................47<br />
Coal Compartment <strong>Rebuild</strong>s ......................................................................................................48<br />
RSFC Burner <strong>Rebuild</strong>s ............................................................................................................49<br />
Oil Gun <strong>and</strong> Retract Mechanism <strong>Rebuild</strong>s .................................................................................50<br />
VOLUMETRIC FEEDER REBUILDS, REPAIRS, PRODUCTS AND SERVICES<br />
Volumetric Feeder <strong>Rebuild</strong> <strong>Services</strong> ..........................................................................................52<br />
Product Upgrades ......................................................................................................................53<br />
Feeder Drive Conversion ......................................................................................................53<br />
Feed Roll Shaft Needle Bearing-to-Bushing Conversion .....................................................54<br />
Endplug Upgrade ..................................................................................................................55<br />
Stainless Steel Body Liners ...................................................................................................56<br />
Stainless Steel Feed Roll Spider <strong>and</strong> Blade Assembly ..........................................................57<br />
Hinged Gate Mechanism Assembly Upgrade .......................................................................58<br />
Side Opening Inspection Door Upgrade ...............................................................................59<br />
QUICKLATCH – Inspection Door Upgrade .......................................................................59<br />
CLINKER GRINDER REBUILDS, REPAIRS, PRODUCTS AND SERVICES<br />
Clinker Grinder <strong>Rebuild</strong>s .............................................................................................................60<br />
Product Upgrades ......................................................................................................................61<br />
Ashbrade Grinder Packing .................................................................................................61<br />
Segmented Rolls for Double Roll Grinders............................................................................62<br />
THE ALSTOM ADVANTAGE<br />
Service Capabilities ....................................................................................................................64<br />
Technical <strong>Services</strong> ......................................................................................................................65<br />
Alstom Service <strong>and</strong> Distribution Centers ...................................................................................67<br />
<strong>Rebuild</strong> <strong>and</strong> <strong>Repair</strong> <strong>Services</strong> .......................................................................................................68<br />
R3 Component Rotation Programs ...........................................................................................68<br />
Outage Kit <strong>Services</strong> ...................................................................................................................69
Alstom Pulverizer <strong>Rebuild</strong><br />
<strong>Services</strong><br />
IntRoductIon to the Alstom PulveRIzeR<br />
IN 1923 COMBuSTION ENGINEERING (CE) ACquIREd THE RAYMONd BROTHERS IMPACT PuLvERIzER COMPANY, |<br />
considered one of the nation’s leading manufacturers of pulverizing <strong>and</strong> grinding equipment.<br />
In 1933 CE introduced the CE Bowl type pulverizer based on original Raymond Brothers technology. Today, this design is owned<br />
by Alstom. With over 70 years of continuous development <strong>and</strong> improvement Alstom pulverizers are highly respected within the<br />
power industry.<br />
Alstom pulverizers span the globe <strong>and</strong> have been built in a variety of sizes <strong>and</strong><br />
capacities. We offer a full line of parts, services <strong>and</strong> solutions to help ensure that your<br />
pulverizers provide optimum operation.<br />
Alstom fAmIly of PulveRIzeRs<br />
THE dESIGNATION OF THE PuLvERIzER PROvIdES INFORMATION |<br />
pertaining to the pulverizer configuration, physical size of the bowl, <strong>and</strong> the<br />
type of operating system.<br />
The “RB” indicates a steep sided bowl type of pulverizer that operates under<br />
a negative pressure <strong>and</strong> uses an exhauster fan.<br />
Pulverizer 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 <strong>and</strong> capacities are listed.<br />
RB Pulverizer<br />
ALSTOM PuLvERIzER REBuILdS<br />
4
5 ALSTOM PuLvERIzER REBuILdS<br />
Alstom Pulverizer <strong>Rebuild</strong> services<br />
The “Rs” indicates a shallow-bowl pulverizer that operates<br />
under a negative pressure on a balanced draft furnace. An<br />
“RPs” indicates a shallow-bowl pulverizer that operates under<br />
a slightly positive pressure <strong>and</strong> was originally associated with<br />
pressurized furnaces. Both these pulverizer types are used with<br />
an exhauster fan.<br />
RS/RPS Pulverizer<br />
Pulverizer 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 <strong>and</strong> capacities are listed.<br />
The “RP” indicates a shallow-bowl type pulverizer that operates<br />
under a positive pressure. Early systems were associated with<br />
either a pressurized or balanced draft furnace. Today few, if any,<br />
pressurized coal fired furnaces are produced. These pulverizers<br />
utilize a primary air fan.<br />
RP Pulverizer<br />
Pulverizer 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 <strong>and</strong> capacities are listed.
Alstom Pulverizer <strong>Rebuild</strong> services<br />
The “hP” pulverizer was developed in the mid-1980s. This<br />
pulverizer incorporates design changes to extend grinding<br />
element life <strong>and</strong> reduce replacement part costs, maintenance<br />
costs <strong>and</strong> down time.<br />
The HP pulverizer design incorporates a vane wheel, an<br />
improved horizontal scraper assembly, a tall top classifier for<br />
improved classification <strong>and</strong> a planetary gear drive assembly.<br />
Pulverizer 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 <strong>and</strong> capacities are listed.<br />
HP Pulverizer<br />
ALSTOM PuLvERIzER REBuILdS<br />
6
BenefIts:<br />
• Excellent quality <strong>and</strong><br />
reliability<br />
• More cost effective <strong>and</strong><br />
efficient than on-site<br />
rebuilding<br />
• Reduces inventory <strong>and</strong><br />
carrying costs<br />
• Extends operation time<br />
between outages<br />
7 ALSTOM PuLvERIzER REBuILdS<br />
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Journal Assembly <strong>Rebuild</strong>s<br />
ALSTOM OFFERS ONE OF THE INduSTRY’S MOST COMPLETE ANd COST-EFFECTIvE<br />
JOuRNAL REBuILdING SERvICES. | All work is performed to the latest Alstom engineering<br />
specifications, including the latest parts, design improvements, inspection <strong>and</strong> quality<br />
procedures. These offerings, which include extended warranties, can reduce inventory costs by<br />
70 percent or more <strong>and</strong> result in longer lasting products that save power producers money.<br />
RP Pulverizer Journal <strong>and</strong> Spring<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Inspection<br />
• Maintenance<br />
• Grinding roll resurfacing or replacement<br />
• Blue fitting of lower journal housing to<br />
grinding roll<br />
Options<br />
• Wear material upgrades<br />
• Ribbed roll upgrade<br />
• Sealing system upgrades<br />
RB Pulverizer Journal <strong>and</strong> Spring HP Pulverizer Journal with Double Upper Bearings<br />
<strong>and</strong> Spring
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Grinder Roll Resurfacing<br />
ALSTOM’S COMPETITIvELY-PRICEd RESuRFACEd ROLLS ARE FIELd-PROvEN TO<br />
LAST LONGER THAN SIMILAR CAST ROLLS. | In addition, Alstom offers a number of<br />
materials that can reduce roll replacement costs by more than 50 percent (depending on<br />
operating conditions) <strong>and</strong> boost a pulverizer’s fineness capability without increasing its<br />
parasitic power requirements.<br />
All resurfacing work is performed at Alstom’s<br />
Regional Service Centers, which offer:<br />
• Quick turnaround<br />
• A variety of competitively priced welding<br />
materials<br />
• A high-quality, state-of-the-art open-arc<br />
welding process<br />
• Customized inventory management/ rotation<br />
programs<br />
• Vast OEM knowledge of pulverizers<br />
Applying the best wear material in the highest<br />
wear areas helps assure the longest life from the<br />
roll while keeping costs down.<br />
<strong>Rebuild</strong> scope<br />
BenefIts:<br />
• Increases pulverizer<br />
availability<br />
• Improves pulverizer<br />
performance<br />
• Improves pulverizer<br />
efficiency<br />
• Reduces replacement<br />
costs by more than<br />
50%<br />
Basic <strong>Services</strong><br />
• Inspection to check roll integrity<br />
• Restoration to OEM dimensions<br />
• Notification if severely worn rolls are not suitable for rebuilding<br />
• Notification if rebuilding costs will be excessive<br />
Wear material options<br />
• COMBUSTALLOY Hardsurfacing Material – This internationally-patented<br />
material offers wear resistance up to four times greater than Ni-Hard.<br />
• 100CE92 – Alstom’s private label wire<br />
• Integra 750, a tungsten carbide weld material<br />
ALSTOM PuLvERIzER REBuILdS<br />
8
the tWenty-tWo<br />
PoInt InsPectIon<br />
PRocess Includes<br />
InsPectIon of the<br />
folloWIng AReAs:<br />
• Bearing guard nut<br />
• Thrust bearing<br />
• Spring adjusting bolt <strong>and</strong><br />
bushing<br />
• Ball bushing<br />
• Spring clamp thrust bearing<br />
<strong>and</strong> piston rings<br />
• Inner <strong>and</strong> outer spring coils<br />
• Spring adjusting stud<br />
• Spring clamp cylinder<br />
• Spring Cup<br />
• Spring seat<br />
• door mounting holes<br />
• Trunnion seats<br />
• Journal stop bolt, lock nut,<br />
<strong>and</strong> bushing<br />
9 ALSTOM PuLvERIzER REBuILdS<br />
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Journal Spring <strong>and</strong> door <strong>Rebuild</strong>s<br />
ALSTOM POWER PROvIdES REBuILd SERvICES FOR RS/RPS JOuRNAL<br />
PRESSuRE SPRING ANd dOORS. | This rebuild includes disassembly, inspection, parts<br />
replacement, <strong>and</strong> reassembly of the pressure spring assembly to the journal opening<br />
cover door. This rebuild requires special tools, as well as special fixtures to assemble<br />
<strong>and</strong> set the correct spring pressure. This rebuild can be performed on journal pressure<br />
springs with or without the journal opening cover door.<br />
The rebuilds are performed in Alstom Service Centers utilizing original manufacturing<br />
drawings <strong>and</strong> approved Mechanical Procedures. In addition, there is a complete<br />
inspection form. The form includes order information, such as dates, order numbers, etc,<br />
but it also includes locations for technicians to include condition assessments as well as<br />
areas to fill in measurements.<br />
Each rebuild order has a list of “normally replaced parts” that are on-h<strong>and</strong> before the<br />
rebuild begins. Once the inspection process is completed, the shops work with Alstom<br />
Engineering to determine approved repairs <strong>and</strong> additional replacement parts. This<br />
ensures a quality rebuild that is complete without excessive lead times.<br />
Process:<br />
After receipt of the assembly, a visual inspection is performed. Any issues or concerns<br />
are recorded on the inspection sheet. The next step is removal of the spring assembly<br />
from the door, <strong>and</strong> the disassembly <strong>and</strong> inspection of the spring components <strong>and</strong> the<br />
door itself. Once inspection has been completed, <strong>and</strong> replacement parts acquired, the<br />
components are reassembled onto the door. The final step is the adjustment of the<br />
spring compression using the special hydraulic fixture. The assembly is then ready for<br />
final inspection, paint, <strong>and</strong> preparation for shipping.
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Fan Bearing Housing Assemblies<br />
ALSTOM PROvIdES quALITY FAN BEARING ASSEMBLY REBuILdS. | All work<br />
is performed at efficient, cost-effective <strong>and</strong> properly equipped service centers that<br />
provide OEM quality parts <strong>and</strong> services with the reliability you need. Alstom’s Pulverizer<br />
Engineering department is consulted on all parts that are in questionable condition to<br />
determine if a repair is feasible.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Components are inspected <strong>and</strong> checked to OEM tolerances<br />
• Critical areas such as the bearing bores <strong>and</strong> shaft diameters are measured<br />
<strong>and</strong> recorded<br />
• Parts that are not within design tolerances are replaced or rebuilt to print<br />
specifications<br />
fan shaft<br />
• Cleaned<br />
• Inspected for scoring, grooving or other irregularities<br />
fan Bearing housing<br />
• Cleaned<br />
• Inspected for burrs, scoring, grooving, or other irregularities<br />
BenefIts:<br />
• Twelve (12) month<br />
warranty on all new parts<br />
<strong>and</strong> workmanship<br />
• Reduces inventory<br />
requirements <strong>and</strong> the<br />
associated carrying costs<br />
• Work is performed at<br />
efficient, cost-effective <strong>and</strong><br />
properly equipped service<br />
centers<br />
• OEM quality <strong>and</strong> service<br />
reliability<br />
ALSTOM PuLvERIzER REBuILdS<br />
10
BenefIts:<br />
• Save up to 50% vs. cost of<br />
new component<br />
• Faster turn around vs.<br />
new purchase<br />
Figure 1 – Separator Body before repair<br />
Figure 2 – Completed Separator Body<br />
Figure 3 – Completed Separator Top<br />
11 ALSTOM PuLvERIzER REBuILdS<br />
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Separator Bodies <strong>and</strong> Tops<br />
ALSTOM OFFERS REBuILdS ANd REPAIRS | for both shallow bowl mill <strong>and</strong> deep bowl<br />
mill separator bodies <strong>and</strong> tops.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• All liners (bolt-on or ceramic) are removed<br />
• Any wear compounds from the body / top surface are removed<br />
• Surface areas are cleaned<br />
• The following areas are inspected:<br />
separator Body<br />
- Flatness of the upper <strong>and</strong> lower mounting flange surfaces <strong>and</strong> the three<br />
journal mounting surfaces<br />
- Parallelism of upper <strong>and</strong> lower mounting flanges<br />
- Bolt holes of upper <strong>and</strong> lower mounting flanges<br />
separator top<br />
- Flatness of the mounting surface to the body<br />
- Multiport outlet / converter head mounting surface<br />
- Deflector regulator assemblies removed <strong>and</strong> checked for proper operation<br />
- Radius bends in separator top<br />
• Each component is mapped (reference Figure 1) <strong>and</strong> “As Received” measurements<br />
are recorded<br />
• Areas for repair are marked on the component surface<br />
• “After <strong>Repair</strong>” measurements are recorded once repairs are complete<br />
• Alstom’s engineering department is consulted when any measurement exceeds<br />
design tolerance<br />
• Bolt holes of the upper <strong>and</strong> lower mounting flanges for each component are checked<br />
against an appropriate template<br />
• Each hole is cleaned with an appropriate tap <strong>and</strong> the thread gauge is checked<br />
• The rebuilt separator body /top is painted <strong>and</strong> liners are installed
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Whizzer Wheel fan Blade options<br />
Exhauster Products<br />
A variety of options are available for the exhauster’s fan blades based on<br />
particular wear profiles experienced:<br />
• DYNAWEAR II Vacuum Bonded Ceramic is used for st<strong>and</strong>ard wear<br />
• DYNAWEAR III Tungsten Carbide is used for extreme wear <strong>and</strong><br />
impact<br />
• DYNAWEAR II Vacuum Bonded CERMA Material is used where<br />
extreme wear without impact is observed.<br />
DYNAWEAR II Vacuum Bonded <strong>and</strong> DYNAWEAR III Tungsten Carbide<br />
Brazed Bonded Products can be selected to achieve extended wear life <strong>and</strong><br />
maximize run time <strong>and</strong> outage cycle time.<br />
RB, RS, ANd RPS PuLvERIzERS uSE ExHAuSTERS TO TRANSPORT THE<br />
COAL FROM THE PuLvERIzER TO THE BOILER. | Alstom rebuilds exhauster<br />
wheel assemblies to strict procedures at its Regional Service Centers.<br />
ALSTOM PuLvERIzER REBuILdS<br />
12
13 ALSTOM PuLvERIzER REBuILdS<br />
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Exhauster Products<br />
Pre-Assembled Advantages<br />
dYNAWEAR II vACuuM BONdEd CERAMICS CAN BE INSTALLEd<br />
ON YOuR FAN BLAdES AT YOuR SITE OR AT AN ALSTOM SERvICE<br />
CENTER. | When ceramics are installed at your site, caps are used for<br />
attachment. When ceramics are installed at our shop, caps are not<br />
required. This means longer life during continuous operation. Shop preassembled<br />
fans are pre-balanced before delivery reducing man-hours<br />
at installation. Shop pre-assembly also reduces errors during ceramic<br />
installation.<br />
Alstom’s pre-assembled fan eliminates the weakest<br />
wear link on fan blades, the fan blade fastener ceramic<br />
caps.<br />
no ceRAmIc cAP meAns<br />
longeR WeAR lIfe
Alstom Pulverizer <strong>Rebuild</strong> services<br />
exhauster liner Wear components<br />
Alstom offers:<br />
• Throat liners<br />
• Periphery liners<br />
• Bolt-on casing side liners<br />
• Bearing side liners<br />
Material Options:<br />
• DYNAWEAR II Vacuum Bonded Ceramics<br />
• CERMA Wear-Resistant Material.<br />
Additionally, exhauster throat <strong>and</strong> periphery liners are<br />
designed to match Alstom’s original internal clearances<br />
<strong>and</strong> liner profiles.<br />
CERMA throat liners for extreme wear protection<br />
Exhauster Products<br />
Ceramic throat <strong>and</strong> periphery liners<br />
ALSTOM PuLvERIzER REBuILdS 14
BenefIts:<br />
• Enhances pulverizer<br />
capacity up to 12%<br />
• May result in spare<br />
pulverizer capacity<br />
• May reclaim lost capacity<br />
due to fuel switching<br />
• decreases power<br />
consumption for similar<br />
coal flows<br />
15 ALSTOM PuLvERIzER REBuILdS<br />
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Exhauster Products<br />
exhauster liner Wear components<br />
Ceramic bearing side cover liners<br />
Ceramic intake side cover liners
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Pulverizer Gearbox <strong>Rebuild</strong>s<br />
WHATEvER YOuR GEARBOx REquIREMENTS ARE, ALSTOM CAN<br />
FuLFILL YOuR NEEdS. | We can completely rebuild your gearbox at<br />
one of our off-site facilities or supply all the components necessary such<br />
as bearings, gears <strong>and</strong> shafts to rebuild your gearbox on-site. Alstom<br />
additionally offers pre-assembled gearbox shafts <strong>and</strong> upgraded bearing seal<br />
arrangements for your convenience.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Clean<br />
• Dimensionally inspect<br />
• Provide evaluation report to customer<br />
Based on inspection, additional services for Triple reduction Gearbox<br />
can include:<br />
• Replacement of all components deemed unacceptable<br />
• Rebuilt to as-new condition<br />
• Clean <strong>and</strong> inspect lubrication system<br />
• Perform “No-Load” spin test<br />
• Submit final report to customer<br />
Based on inspection, additional services for Pancake Gearbox can include:<br />
• Machine gear housing halves <strong>and</strong> bores back to OEM tolerances<br />
• Reassemble, set up bearing endplay <strong>and</strong> gear patterns<br />
Triple reduction gearbox in shop HP Pulverizer planetary gearbox<br />
RB roller bearing gearbox<br />
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Faster turn around vs. new<br />
purchase<br />
• Rotation program available<br />
ALSTOM PuLvERIzER REBuILdS<br />
16
17 ALSTOM PuLvERIzER REBuILdS<br />
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Worm Shaft / Worm Gear Assembly <strong>Rebuild</strong>s<br />
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Faster turn around vs. new<br />
purchase<br />
• Rotation program available<br />
sAves 50% vs. neW<br />
IN AddITION TO COMPLETE GEARBOx REBuILdS ALSTOM CAN ALSO REBuILd<br />
JuST THE PuLvERIzER WORM GEAR. | The worm gear can be sent to an Alstom<br />
Regional Service Center where the rebuild is completed under controlled conditions using<br />
proven processes <strong>and</strong> procedures.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Inspect<br />
Pulverizer worm shaft split mechanical oil seal upgrade
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Pre-Assembled Components<br />
ALSTOM CAN dELIvER COMPLETE SuBASSEMBLIES REAdY FOR IMMEdIATE<br />
INSTALLATION. | This will reduce your down time <strong>and</strong> help to ensure accurate fit up of<br />
components.<br />
type of assemblies provided include:<br />
• Main shaft assemblies<br />
• Worm shaft assemblies<br />
• Bowl <strong>and</strong> bowl hub assemblies with grinding segments <strong>and</strong> vane wheel segments<br />
installed<br />
• Journal assemblies with grinding rolls <strong>and</strong> wear liners installed<br />
• Separator tops with classifiers <strong>and</strong> cone assemblies<br />
Pre-assembled from Alstom’s<br />
shop to your site<br />
BenefIts of<br />
PRe-AssemBled<br />
geARBox shAfts:<br />
A pre-assembled shaft<br />
reduces gearbox overhaul<br />
time by as much as 50%.<br />
When you order fully<br />
assembled shafts they are<br />
built specifically for your<br />
pulverizer size <strong>and</strong> eliminate<br />
component-by-component<br />
assembly at your site. Special<br />
jigs <strong>and</strong> fixtures are no<br />
longer required to assemble<br />
components nor is an oil bath<br />
for bearing assembly.<br />
ALSTOM PuLvERIzER REBuILdS<br />
18
feAtuRes:<br />
• Two tapered roller bearings<br />
vs. single bearing<br />
• Improved oil <strong>and</strong> air seal<br />
design<br />
AdvAntAges:<br />
• Reduced thrust loads for<br />
upper <strong>and</strong> lower bearings<br />
• Increased radial capacity<br />
• Better protection against<br />
lubricant contamination<br />
• Longer time between<br />
outages<br />
BenefIts:<br />
• Longer wear life<br />
• Improved reliability<br />
19 ALSTOM PuLvERIzER REBuILdS<br />
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Product upgrades<br />
ALSTOM CONTINuES TO dESIGN ANd dEvELOP OEM PuLvERIzER PROduCTS THAT<br />
WILL MEET THE CHANGING NEEdS OF OuR CuSTOMERS. | These upgrades provide<br />
longer wear life, reduce maintenance costs, eliminate a number of mechanical problems <strong>and</strong><br />
improve the overall reliability of your mill.<br />
double upper Bearing Journal Assemblies<br />
The double upper bearing assembly replaces the single upper journal bearing with two<br />
tapered roller bearings. This improved design increases the radial capacity design of the<br />
upper bearing <strong>and</strong> reduces thrust loads on the lower bearing resulting in an increased<br />
life for both bearings.<br />
The double upper bearing assembly was designed through an intensive engineering<br />
analysis of pulverizer journals under actual operating conditions. Utilizing field data<br />
collected from several pulverizers, journal loadings were accurately determined<br />
by computer analysis. This allowed the final bearing selection <strong>and</strong> location to be<br />
optimized. As a result the loadings for both the upper <strong>and</strong> lower bearings were<br />
decreased. The new design also includes improved oil <strong>and</strong> air seals for protection<br />
against contamination of the journal bearing lubricant.<br />
This component is available as an upgrade to an existing journal assembly. It can<br />
also be supplied as part of a new journal shaft assembly or the entire journal can be<br />
replaced as an assembly.<br />
IncReAsed tIme<br />
BetWeen outAges
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Magnum Journal upgrade<br />
THIS uPGRAdE CAN ExTENd JOuRNAL LIFE | while maintaining the existing journal<br />
assembly envelope.<br />
IncReAsed JouRnAl lIfe<br />
feAtuRes:<br />
• Larger capacity upper <strong>and</strong><br />
lower journal bearings<br />
• New or modified journal<br />
assembly components<br />
within original envelope:<br />
- upper journal<br />
housing<br />
- Lower journal<br />
housing<br />
- Bearing seats<br />
- Journal shaft<br />
AdvAntAges:<br />
• Choice of newly<br />
manufactured shaft <strong>and</strong><br />
housing components<br />
or remanufactured<br />
components<br />
• Can use grease lubricant<br />
instead of oil eliminating<br />
oil changes<br />
• Proven seal technology<br />
prevents the ingress of<br />
coal contamination into<br />
the grease lubricant <strong>and</strong><br />
journal assembly tapered<br />
roller bearings<br />
• Lower bearing loads <strong>and</strong><br />
contact stresses resulting<br />
in longer bearing life<br />
• Greatly reduces the<br />
possibility of premature<br />
bearing failure due to<br />
bearing contamination<br />
BenefIts:<br />
• Extends operating<br />
window between outages<br />
• Improves reliability<br />
ALSTOM PuLvERIzER REBuILdS<br />
20
feAtuRes:<br />
• Replaceable wear sleeve<br />
that protects journal shaft<br />
from further wear<br />
• Three oil seals increase<br />
the resistance to oil<br />
contamination<br />
• Greater chemical resistance<br />
<strong>and</strong> higher operating<br />
temperatures while<br />
maintaining excellent<br />
resiliency<br />
AdvAntAges:<br />
• Oil seal effectiveness is<br />
maximized by the hard,<br />
ultra-smooth finish of wear<br />
sleeve<br />
• A grooved journal shaft<br />
can be salvaged without<br />
creating an additional<br />
stress riser<br />
• Three oil seals increase<br />
the resistance to oil<br />
contamination<br />
BenefIts:<br />
• Increases mill availability<br />
• Reduces maintenance costs<br />
• Longer journal life<br />
21 ALSTOM PuLvERIzER REBuILdS<br />
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Proseal 350 upgrade<br />
ALSTOM OFFERS AN uPGRAdE TO SEALING YOuR ExISTING JOuRNAL<br />
ASSEMBLY IN THE PROSEAL 350 SEAL. | This triple lip sealing system with<br />
wear sleeve offers the protection of three lip seals. Two of the lip seals act to keep<br />
contaminates out of the journal oil reservoir while the third seal keeps the oil from<br />
leaking out of the journal. The wear sleeve protects the journal shaft from any gouging<br />
or scoring that may occur during normal operation.<br />
PRotects JouRnAl<br />
fRom contAmInAtIon
Alstom Pulverizer <strong>Rebuild</strong> services<br />
LM-45 Journal Seal upgrade<br />
THE LM-45 SEAL SYSTEM IMPROvES PuLvERIzER AvAILABILITY ANd JOuRNAL<br />
LIFE | by protecting the bearing from contamination. The design uses upgraded<br />
materials <strong>and</strong> a new lip seal arrangement, along with foam particle barriers to prevent<br />
contaminants from entering the journal cavity. The new seal also has less rotating parts<br />
which decreases wear <strong>and</strong> improves reliability.<br />
feAtuRes:<br />
• Non-contact design<br />
minimizes heat buildup<br />
• O-rings on shaft drive<br />
seal rotor<br />
• Ribbed, heavy-duty onepiece<br />
construction<br />
AdvAntAges:<br />
• Less contamination<br />
• Maintenance free self<br />
cleaning <strong>and</strong> lubricating<br />
• Longer service life<br />
• Easy to install<br />
BenefIts:<br />
• Improves pulverizer<br />
availability<br />
• Improves pulverizer<br />
reliability<br />
• Reduces maintenance<br />
ImPRoved AvAIlABIlIty<br />
And RelIABIlIty<br />
ALSTOM PuLvERIzER REBuILdS<br />
22
feAtuRes:<br />
• Increased spring length<br />
• Increased diameter of the<br />
bars used in making the<br />
coils<br />
• Reduced the K factor of the<br />
spring by 20%<br />
• Spring cover replaced by<br />
bellows<br />
AdvAntAges:<br />
• Reduced journal spring<br />
failures due to stress<br />
• Reduced chance of main<br />
vertical shaft failure due<br />
to uneven loading of bowl<br />
assembly<br />
BenefIts:<br />
• Improves pulverizer<br />
availability<br />
• Improves pulverizer<br />
reliability<br />
23 ALSTOM PuLvERIzER REBuILdS<br />
Alstom Pulverizer <strong>Rebuild</strong> services<br />
Journal Pressure Spring upgrade<br />
ONE CAuSE OF A PuLvERIzER SHuTdOWN IS THE FAILuRE OF THE JOuRNAL<br />
PRESSuRE SPRING. | A pressure spring failure can lead to uneven loading of the bowl<br />
assembly <strong>and</strong>, if uncorrected, failure of the main vertical shaft.<br />
Alstom has redesigned the journal pressure spring assemblies utilized on the 963 –<br />
1003 RP Pulverizers equipped with the original small separator top.<br />
The increased number of coils <strong>and</strong> increased diameter results in lower stress on each coil<br />
at the same compression.<br />
The replacement of the spring cover with bellows protects against coal leaks <strong>and</strong> allows<br />
greater visibility of spring oscillation to verify the three springs are operating in unison.<br />
A spool piece is provided to accommodate the increased length of the spring that is<br />
external to the journal.<br />
ImPRoves PulveRIzeR<br />
AvAIlABIlIty And RelIABIlIty
EL-type Pulverizer <strong>Rebuild</strong><br />
<strong>Services</strong><br />
Introduction to EL-type Mill<br />
THE EL-TYPE MILL EMPLOYS THE BALL/RACE CONCEPT FOR GRINdING COAL. | A rotating race drives the balls <strong>and</strong> a<br />
stationary race applies grinding force. The Fuller Company created some of the early ball-race mill concepts in the early 1900’s.<br />
The mill series really started with the A-type mill <strong>and</strong> then progressed to the E-type mill. The A-type mill was designed <strong>and</strong> built by<br />
Fuller-Lehigh around 1917. Fuller-Lehigh continued with the ball race concept through the B, C, D <strong>and</strong> E type mills. Many were sold to<br />
Babcock <strong>and</strong> Wilcox (B&W) for pulverized coal fired boilers. In the 1950’s, B&W bought the E-type mill design <strong>and</strong> started their own<br />
production.<br />
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<br />
the throat geometry <strong>and</strong> classifier were improved. The improvement increased the performance of the E-type mill by 25%. Many<br />
operating E-type mills were converted to the EL-type.<br />
The EL-type mill declined in popularity as boiler size rapidly increased in the 1960’s. The ball race concept has vibration <strong>and</strong><br />
mechanical limitations in very large sizes. The Cyclone firing scheme that did not require pulverizers also became popular for B&W<br />
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<br />
designed. It did not work well <strong>and</strong> the entire concept was dropped in favor of the roll/ring MPS-type mill.<br />
There are many E <strong>and</strong> EL-type mills still acceptably operating in the USA. The mill has particular advantages <strong>and</strong> disadvantages over<br />
competing mill types. In its day, the low height gave an advantage of lower boiler setting heights. The mill is compact <strong>and</strong> serviced<br />
from just one side, an advantage in plant layout. The grinding zone is<br />
the main advantage <strong>and</strong> disadvantage. It has no rollers, bearings or<br />
machinery to service, which avoids the inherent possibility of failures.<br />
However, it does not effectively use the wear materials. The grinding<br />
components of a large EL-type mill weigh 15,000 lb when new <strong>and</strong><br />
perhaps 10,000 lb when worn. Almost two thirds of the wear material<br />
is scrapped. Still, the EL-type mill remains a workhorse in power plants<br />
across the USA.<br />
EL-TYPE PuLvERIzERS<br />
24
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Saves 20–30 man-hours<br />
vs. on-site repairs<br />
• 90% contact pattern on blue<br />
fit of yoke to main shaft<br />
Building rotating assembly<br />
Rotating assembly ready for shipment<br />
25 EL-TYPE PuLvERIzERS<br />
el-type Pulverizer <strong>Rebuild</strong> services<br />
Rotating Assemblies<br />
THE MILL REBuILd SCHEduLE IS TIGHT ANd YOu ARE WORRIEd ABOuT BLuE<br />
FITTING THE YOKE ANd GEAR CENTER IN AN uNCONTROLLEd ENvIRONMENT. |<br />
It has to be done correctly for long shaft life <strong>and</strong> reliability, but the schedule must be met.<br />
A ready to run rotating assembly is the answer. Alstom will inspect, repair <strong>and</strong> rebuild<br />
your spare yoke, gear center <strong>and</strong> other parts or supply new ones. A new high quality shaft<br />
will be made <strong>and</strong> blue fit to the yoke <strong>and</strong> gear center. Run outs of the mounting faces are<br />
checked <strong>and</strong> cut if needed.<br />
Available for EL 64, 70 <strong>and</strong> EL 76 Rotor Assemblies<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Clean<br />
• Dimensionally inspect<br />
Based on inspection, additional services can include:<br />
• NDT yoke <strong>and</strong> gear center for cracks<br />
• Weld repair/machine yoke, <strong>and</strong> install new yoke bushing <strong>and</strong> drive pin<br />
• New main shaft – See ‘Alstom upgraded keyless main shaft option’<br />
• New SuperNut upgrade – See ‘Alstom upgraded keyless main shaft option’<br />
• Blue fit gear center to main shaft<br />
• Blue fit yoke to main shaft<br />
• Machine yoke seating surface <strong>and</strong> gear center as required<br />
• Document blue fit with photos <strong>and</strong> inspection documents<br />
• Paint<br />
Gear center contact to shaft Yoke contact to shaft
el-type Pulverizer <strong>Rebuild</strong> services<br />
THE YOKES IN AN EL-TYPE MILL ExPERIENCE AGGRESSIvE WEAR CONdITIONS,<br />
HOWEvER, THEY ARE REPAIRABLE ANd RARELY NEEd REPLACEMENT. | Alstom<br />
reconditions all yoke sizes <strong>and</strong> styles. Alstom weld repairs, hard surfaces, machines <strong>and</strong><br />
re-bushes the yoke back to as-new condition.<br />
The fit between the main shaft <strong>and</strong> the yoke is critical to long <strong>and</strong> reliable shaft life. A<br />
rebuilt yoke has a st<strong>and</strong>ard machined bushing taper. The yoke must be h<strong>and</strong> fit to the<br />
main shaft during assembly. As an alternative, Alstom offers fitting <strong>and</strong> bluing to mate<br />
the yoke to the main shaft. See the Rotating Assemblies section for this service.<br />
<strong>Repair</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Blast to clean<br />
• Dimensionally <strong>and</strong> NDT inspect<br />
Based on inspection, additional services can include:<br />
• Weld up worn areas as required<br />
• Weld up bushing bores<br />
• Wear protect (hardface) high wear areas<br />
• Tap wedge ring holes<br />
• Machine wedge ring area<br />
• Machine grinding ring seating surface<br />
• Install new yoke bushing <strong>and</strong> drive pin<br />
• Paint<br />
Yoke <strong>Repair</strong>s<br />
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Saves 20–30 man-hours<br />
vs. on-site repairs<br />
EL-TYPE PuLvERIzERS<br />
26
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Faster turn around vs. new<br />
purchase<br />
27 EL-TYPE PuLvERIzERS<br />
el-type Pulverizer <strong>Rebuild</strong> services<br />
Air Seal <strong>Repair</strong>s<br />
AIR SEALS ARE CRITICAL TO CONTAIN THE HOT PRIMARY AIR WITHIN THE<br />
MILL ANd PREvENT duST-LAdEN HOT AIR FROM CONTAMINATING THE MILL<br />
GEARBOx. | They also reduce heat transfer into the gearbox. If your gearbox oil is running<br />
hot or contaminated, the air seal may need replacement or repair.<br />
Alstom can repair the air seal for the EL 64, 70 <strong>and</strong> 76 mills with new bronze inserts<br />
saving substantial cost over replacement. If the top of the air seal is worn or damaged,<br />
Alstom can cut off the damage <strong>and</strong> weld in a new seal carrier <strong>and</strong> save the housing.<br />
<strong>Repair</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Blast to clean<br />
• Dimensionally inspect<br />
Based on inspection, additional services can include:<br />
• Remove old seals<br />
• Weld up air seal area as required<br />
• Replace seal carrier if necessary<br />
• Machine to accept new bronze labyrinth seals<br />
• Install new seals<br />
• Install new air pipe(s)<br />
• Paint
el-type Pulverizer <strong>Rebuild</strong> services<br />
BEARING PLATES WEAR FROM REJECTS RuBBING ON THE TOP<br />
SuRFACE. | Bearing plates are repaired using inserts to replace the worn<br />
material. In rare cases, a bearing plate is damaged beyond repair <strong>and</strong> a new<br />
one is required. Alstom offers the original cast iron material <strong>and</strong> an improved<br />
steel bearing plate for popular mill <strong>and</strong> shaft sizes.<br />
<strong>Repair</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Blast to clean<br />
• Dimensionally <strong>and</strong> NDT inspect<br />
Based on inspection, additional services can include:<br />
• Clean tapped holes<br />
• Prime, paint/cosmoline protect<br />
• Sleeve bore<br />
• Machine flat top <strong>and</strong> bottom mounting surfaces<br />
• Replace seal <strong>and</strong> cover rim area<br />
• Replace seal <strong>and</strong> cover floor area<br />
• Replace seal, cover, floor <strong>and</strong> air seal mounting surface<br />
Bearing Plate <strong>Repair</strong>s<br />
<strong>Repair</strong>ed top bearing plate<br />
Worn top bearing plate Bearing plate repairs <strong>and</strong> rebuilds<br />
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Rotation programs<br />
available<br />
EL-TYPE PuLvERIzERS<br />
28
BenefIts:<br />
• Save up to 50% vs.<br />
purchasing new<br />
• Rotation program<br />
available<br />
Spring bolt – BEFORE<br />
29 EL-TYPE PuLvERIzERS<br />
el-type Pulverizer <strong>Rebuild</strong> services<br />
Spring Bolt <strong>Rebuild</strong>s<br />
Alstom can rebuild your EL 64, 70, <strong>and</strong> 76 Mill size spring bolt assemblies.<br />
<strong>Repair</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Clean<br />
• Dimensionally inspect<br />
Based on inspection, additional services can include:<br />
• <strong>Repair</strong> housing<br />
• Replace key<br />
• Recondition retaining ring<br />
• Replace nut <strong>and</strong> adjusting bolt <strong>and</strong> hardware<br />
• Paint<br />
• Fill with grease<br />
Spring bolt – AFTER
el-type Pulverizer <strong>Rebuild</strong> services<br />
FOR THE EL-TYPE GEARBOx, THE TIME BETWEEN REPAIRS OR<br />
REPLACEMENT dEPENdS MOSTLY ON OPERATION. | A properly loaded<br />
mill will run much longer than low or dry operation. <strong>For</strong>eign material causes<br />
high shock loads that can damage the gearbox <strong>and</strong> shorten its life.<br />
Alstom has all the parts <strong>and</strong> services required to return the gearbox back to<br />
original condition or improve the equipment for today’s dem<strong>and</strong>s. We also offer<br />
rental agreements <strong>and</strong> purchase options.<br />
Alstom has the capability of rebuilding the full lower half of the EL-type mill<br />
as a single unit or the individual sub-components depending on the customer<br />
preference.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Clean<br />
• Inspect<br />
Based on inspection, additional services can include:<br />
• Replacement parts such as gears, bearings, shafts, seals<br />
• <strong>Rebuild</strong> to as-new conditions<br />
ReAssemBle the<br />
loWeR hAlf of youR<br />
el-tyPe mIll In A<br />
shoP envIRonment<br />
Gearbox Overhauls<br />
Line boring rebuilt gearbox in Alstom shop<br />
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Rotation programs<br />
available<br />
• <strong>Rebuild</strong> individual subcomponents<br />
or entire lower<br />
mill<br />
• delivered before you take<br />
your operating mill off-line<br />
EL-TYPE PuLvERIzERS<br />
30
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Rotation programs<br />
available<br />
Rebuilt gear cases available<br />
31 EL-TYPE PuLvERIzERS<br />
el-type Pulverizer <strong>Rebuild</strong> services<br />
Gear Casing <strong>Rebuild</strong>s<br />
REPLACEMENT OF THE EL GEAR CASE WITH A NEW COMPONENT CAN BE vERY<br />
ExPENSIvE ANd HAS A LONG LEAd TIME. | While Alstom can supply new gear<br />
casings, we have developed a rebuild process for restoring EL gear cases to original<br />
specifications without compromising the quality or structural integrity of the component.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Blast clean<br />
• Dimensionally inspect<br />
Based on inspection, additional services can include:<br />
• Sleeve bearing bore<br />
• Re-machine bearing <strong>and</strong> oil pump pedestal<br />
• Re-machine upper flange area <strong>and</strong> pedestal, parallel <strong>and</strong> to original dimension<br />
• Paint inside cast surfaces with gearbox sealer<br />
• Paint outside, non-machined surfaces, of gear case with high temperature paint<br />
• Final inspect gear case<br />
• Cosmoline protect machined surfaces to prevent rust
el-type Pulverizer <strong>Rebuild</strong> services<br />
ALSTOM CAN REBuILd YOuR EL 64, 70 ANd EL 76 PINION ASSEMBLIES. | The<br />
pinion assemblies can be rebuilt individually or as a sub-component of the lower half<br />
of the mill.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
Pinion Housing & Assembly<br />
• Disassemble<br />
• Clean<br />
• Inspect<br />
Based on inspection, additional services can include:<br />
Pinion Housing<br />
• Re-machine housing ends<br />
• Cosmoline protect<br />
Pinion Assembly<br />
• Dimensionally record bores <strong>and</strong> shaft diameters<br />
• NDT shaft <strong>and</strong> pinion gear<br />
• Replace bearings <strong>and</strong> packing<br />
• Reassemble/Cosmoline protect<br />
EL pinion assembly – AFTER<br />
Pinion <strong>Rebuild</strong>s<br />
EL pinion assembly – BEFORE<br />
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Faster turn around vs. new<br />
purchase<br />
EL-TYPE PuLvERIzERS<br />
32
dynAWeAR<br />
description:<br />
Adhesive bonded alumina<br />
ceramic tiles<br />
Applications:<br />
• Static applications only<br />
• Typically in:<br />
- upCones<br />
- Wall liners<br />
- Turrets<br />
features:<br />
• Pre-engineered,<br />
mechanically interlocked<br />
system<br />
• Blome grout<br />
Advantages:<br />
• Simplified installation<br />
• Blome grout aids<br />
installation <strong>and</strong> helps fill<br />
voids between tiles<br />
Benefits:<br />
• Extends time between<br />
overhauls<br />
• Easy to fabricate<br />
• Reduces costs<br />
33 EL-TYPE PuLvERIzERS<br />
el-type Pulverizer <strong>Rebuild</strong> services<br />
uPgRAdes ImPRove<br />
RelIABIlIty And AvAIlABIlIty<br />
Product upgrades<br />
THE FOLLOWING uPGRAdES ARE AvAILABLE FOR THE EL 64, 70 ANd 76 MILLS.|<br />
These products directly replace the OEM product in fit <strong>and</strong> form but will last longer, <strong>and</strong><br />
are more reliable.<br />
ceramic lined <strong>and</strong> vacuum Bonded liners<br />
Ceramic lining is the best wear solution for high erosion, low impact locations.<br />
Alstom offers the most comprehensive wear solutions available.<br />
dynAWeAR II<br />
description:<br />
vacuum bonded product<br />
available in alumina ceramic<br />
tiles, silicone carbide tiles or<br />
tungsten carbide tiles<br />
Applications:<br />
• Static <strong>and</strong> dynamic<br />
applications<br />
features:<br />
• Customized application<br />
to fit your specific wear<br />
pattern<br />
• Tensile strength: 6000+ psi<br />
• Shear bond strength:<br />
4000+ psi<br />
Advantages:<br />
• Impact resistant<br />
• Can be used with complex<br />
shapes<br />
Benefits:<br />
• Reduces costs<br />
• Easy to fabricate<br />
• Extends time between<br />
outages<br />
dynAWeAR III<br />
description:<br />
Brazed tungsten carbide tiles.<br />
Applications:<br />
• Static <strong>and</strong> dynamic<br />
applications<br />
Note: The brazing method<br />
restricts use with certain<br />
types of materials.<br />
features:<br />
• High wear resistance<br />
• Excellent impact resistance<br />
Advantages:<br />
• Longer run time before<br />
replacement is required<br />
Benefits:<br />
• Reduces total cost of<br />
ownership<br />
• Extends time between<br />
overhauls
el-type Pulverizer <strong>Rebuild</strong> services<br />
ALSTOM HAS dEvELOPEd A MAIN SHAFT dESIGN THAT ELIMINATES THE<br />
KEYWAY, MAKING THE SHAFT TWICE AS STRONG. | By precisely mating the<br />
shaft to the hub or yoke <strong>and</strong> seating it firmly with the SuperNut (see following page),<br />
the drive torque is transferred without a keyway.<br />
Major modifications are not required for this conversion. The original bearings, gear<br />
centers, hubs <strong>and</strong> yokes are used, although the yoke bushings must be replaced.<br />
Reduces shAft BReAkAge,<br />
ImPRovIng PulveRIzeR<br />
AvAIlABIlIty<br />
Keyless Shaft upgrade<br />
feAtuRes:<br />
• vacuum arc re-melted<br />
forging<br />
• Certified chemical <strong>and</strong><br />
mechanical properties<br />
• ultrasonically inspected<br />
• Precision CNC machined<br />
• Polished keyways<br />
• Shot-peened high stress<br />
areas<br />
• Final magnetic particle<br />
inspection<br />
AdvAntAges:<br />
• Twice as strong as the<br />
st<strong>and</strong>ard design<br />
• No major modifications<br />
required<br />
• SuperNut technology<br />
• Available for all EL-type<br />
pulverizer sizes<br />
BenefIts:<br />
• Improves reliability<br />
• Reduces maintenance costs<br />
• Reduces shaft breakage<br />
EL-TYPE PuLvERIzERS<br />
34
feAtuRes:<br />
• Increased number of<br />
smaller bolts<br />
AdvAntAges:<br />
• Easily tightened with<br />
torque wrench<br />
• No yoke heating required<br />
• Produces 500,000+ lbs of<br />
seating force (st<strong>and</strong>ard nut<br />
produces 5,500 lbs)<br />
• Yoke can still be removed<br />
with a st<strong>and</strong>ard puller<br />
• Better shaft taper sealing<br />
• Easy installation<br />
• Efficient disassembly<br />
BenefIts:<br />
• Improves reliability<br />
• Reduces maintenance costs<br />
• Improves safety<br />
• Reduces shaft breakage<br />
when used in conjunction<br />
with keyless shaft upgrade<br />
35 EL-TYPE PuLvERIzERS<br />
el-type Pulverizer <strong>Rebuild</strong> services<br />
SuperNut upgrade<br />
THE ALSTOM SuPERNuT uPGRAdE WAS dESIGNEd TO ALLOW THE REMOvAL<br />
OF THE KEYWAY IN THE SHAFT TAPER AREA, | the weakest part of the shaft, where<br />
most shaft failures occur.<br />
Other benefits of the SuperNut include repeatable installation force, <strong>and</strong> a much safer<br />
installation, since you will not need to “slug” on a hex nut, which can be dangerous, <strong>and</strong><br />
of unknown force.<br />
The SuperNut uses many smaller bolts to produce the seating force. The yoke is not<br />
heated <strong>and</strong> the nut is not hammered. <strong>For</strong>ce is accurately applied by torquing the smaller<br />
bolts – a simple one-man job.<br />
The shaft seating force of the SuperNut is greater than the heating method resulting in<br />
a better assembly.<br />
Additionally, with the SuperNut upgrade the yoke can still be pulled from the shaft after<br />
years of service. Alstom has removed yokes for repair <strong>and</strong> has reused the SuperNut<br />
without difficultly.
mPs-type Pulverizer <strong>Rebuild</strong><br />
services<br />
Introduction to the MPS-type Mill<br />
THE MPS-TYPE MILL WAS ORIGINALLY dESIGNEd BY PFEIFFER AG OF<br />
GERMANY. BABCOCK & WILCOx (B&W) BOuGHT A LICENSE TO BuILd<br />
THE MPS-TYPE MILL IN 1971. | The first commercial operation in the USA<br />
was in 1973. B&W needed a fast replacement to resolve problems with the<br />
CR 77 mill. That license has since expired.<br />
There are several sizes of MPS-type mills. The most common is the MPS 89.<br />
This mill was supplied in a number of versions, K, N, NR <strong>and</strong> G.<br />
Alstom supplies all the replacement parts, wear parts <strong>and</strong> major casting for<br />
all the MPS 89 models. Alstom also supplies major components for the MPS<br />
75 <strong>and</strong> MPS 118 mills.<br />
MPS-TYPE PuLvERIzERS<br />
36
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Rotation programs<br />
available<br />
37 MPS-TYPE PuLvERIzERS<br />
mPs-type Pulverizer <strong>Rebuild</strong> services<br />
Roll Wheel <strong>Rebuild</strong>s<br />
Alstom offers high quality MPS-type roll wheel rebuilds <strong>and</strong> new roll wheel assemblies.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Clean<br />
• Dimensionally inspect<br />
Based on inspection, additional services can include:<br />
• Replace all worn out parts<br />
• <strong>Repair</strong> components as needed<br />
• <strong>Rebuild</strong> to strict procedures <strong>and</strong> tolerances<br />
• Include upgrades upon customer request<br />
• Pressure test
mPs-type Pulverizer <strong>Rebuild</strong> services<br />
In an effort to save money <strong>and</strong> significantly reduce lead-time, Alstom offers the service to<br />
repair MPS-type roll wheel brackets <strong>and</strong> hubs.<br />
Bracket <strong>Repair</strong> scope<br />
• Clean <strong>and</strong> inspect bracket<br />
• Document received condition of bracket<br />
• Dye penetrant check bore <strong>and</strong> key area for cracks<br />
• Dimensionally check bore<br />
• Metal spray bore <strong>and</strong> machine to original specification<br />
• Weld repair excessive wear areas on lifting lug <strong>and</strong> pivot block sections of bracket<br />
Bracket – BEFORE<br />
BenefIts:<br />
• 60% savings vs. cost of a<br />
new casting<br />
• Reduces lead-time<br />
Bracket <strong>and</strong> Hub <strong>Repair</strong>s<br />
Bracket – AFTER<br />
hub <strong>Repair</strong> scope<br />
• Document received condition of hub<br />
• Weld build up <strong>and</strong> machine OD to original specification<br />
• Weld build up <strong>and</strong> machine ID to original specification<br />
• Weld bottom hub <strong>and</strong> machine to original specifications<br />
• Machine fit hub to roll <strong>and</strong> seal retainer<br />
Hub – AFTER<br />
BenefIts:<br />
• 50% savings vs. cost of a<br />
new casting<br />
• Reduces lead-time<br />
Hub – BEFORE<br />
MPS-TYPE PuLvERIzERS<br />
38
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Faster turn around vs. new<br />
purchase<br />
39 MPS-TYPE PuLvERIzERS<br />
mPs-type Pulverizer <strong>Rebuild</strong> services<br />
Yoke <strong>and</strong> Air Seal <strong>Repair</strong>s<br />
AIR SEALS ARE CRITICAL TO CONTAIN THE HOT PRIMARY AIR WITHIN THE MILL<br />
ANd PREvENT duSTY HOT AIR FROM CONTAMINATING THE MILL GEARBOx. |<br />
They also reduce heat transfer into the gearbox. If the gearbox oil is running hot or is<br />
contaminated, the air seal may need replacement or repair.<br />
Alstom reconditions all MPS-type yoke <strong>and</strong> air seal sizes <strong>and</strong> styles. Reconditioning<br />
includes weld repairs (yoke), hard surfacing (yoke), any required machining <strong>and</strong><br />
re-bushing. When complete, the yoke / air seal is returned in as-new condition.<br />
<strong>Repair</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Blast clean<br />
• Magnetic particle inspect for cracks (yoke only)<br />
Based on inspection, additional services can include:<br />
• Provide evaluation report to customer<br />
• Sleeve yoke seal area<br />
• Sleeve ring seat locating shoulder<br />
• Re-machine yoke to OEM specs, including upper ring seat surface<br />
• Clean all tapped holes<br />
• Prime paint/Cosmoline protect
mPs-type Pulverizer <strong>Rebuild</strong> services<br />
NORMAL OPERATION CAN CAuSE A RING SEAT TO CRACK OvER TIME. | Type of coal<br />
<strong>and</strong> operating conditions can affect how long a ring seat will operate before cracks occur.<br />
These cracks can affect overall pulverizer performance. Alstom can repair your ring seat to<br />
as new condition <strong>and</strong> save you time <strong>and</strong> money.<br />
Ring seat <strong>Repair</strong> scope<br />
Basic Service<br />
• Blast clean<br />
• Magnetic particle inspection for cracks<br />
• Submit crack repair proposal<br />
• Submit machinery rebuild proposal<br />
Weld <strong>Repair</strong><br />
• Arc out <strong>and</strong> rebuild cracks<br />
• Gr in d<br />
• Stress relieve<br />
Machinery <strong>Repair</strong><br />
• Clean <strong>and</strong> tap holes<br />
• Re-machine to OEM specs<br />
Ring seat – after repair<br />
Ring Seat <strong>Repair</strong>s<br />
BenefIts:<br />
• Reduces lead times vs. new<br />
purchase<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
MPS-TYPE PuLvERIzERS<br />
40
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Rotation programs<br />
available<br />
• <strong>Rebuild</strong> the individual subcomponents<br />
of the mill<br />
41 MPS-TYPE PuLvERIzERS<br />
mPs-type Pulverizer <strong>Rebuild</strong> services<br />
Gearbox Overhauls<br />
THE MPS-TYPE GEARBOx IS A WELL-dESIGNEd ANd BuILT MACHINE. IT<br />
CAN PROvIdE LONG, RELIABLE SERvICE WHEN PROPERLY ASSEMBLEd ANd<br />
MAINTAINEd. | After 20 years or more of service, a rebuild or replacement may be<br />
needed to maintain reliability. Alstom can rebuild a gearbox <strong>and</strong> return it in as-new<br />
condition.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Clean<br />
• Inspect<br />
Based on inspection, additional services can include:<br />
• Replacement of parts such as gears, bearings, shafts, seals<br />
• <strong>Rebuild</strong> to as-new conditions<br />
• Rental agreements<br />
• Purchase options
dynAWeAR<br />
description:<br />
Adhesive bonded alumina<br />
ceramic tiles<br />
Applications:<br />
• Static applications only<br />
• Typically in:<br />
- upCones<br />
- Wall liners<br />
- Turrets<br />
features:<br />
• Pre-engineered,<br />
mechanically interlocked<br />
system<br />
• Blome grout<br />
Advantages:<br />
• Simplified installation<br />
• Blome grout aids<br />
installation <strong>and</strong> helps fill<br />
voids between tiles<br />
Benefits:<br />
• Extends time between<br />
overhauls<br />
• Easy to fabricate<br />
• Reduces costs<br />
uPgRAdes ImPRove<br />
RelIABIlIty<br />
And AvAIlABIlIty<br />
mPs-type Pulverizer <strong>Rebuild</strong> services<br />
Product upgrades<br />
THE FOLLOWING uPGRAdES ARE AvAILABLE FOR ALL MPS-TYPE MILLS. | These<br />
products directly replace the OEM production fit <strong>and</strong> form but will last longer <strong>and</strong> are<br />
more reliable.<br />
ceramic lined <strong>and</strong> vacuum Bonded liners<br />
Ceramic lining is the best wear solution for high erosion, low impact locations. Alstom<br />
offers the most comprehensive wear solutions available.<br />
dynAWeAR II<br />
description:<br />
vacuum bonded product<br />
available in alumina ceramic<br />
tiles, silicone carbide tiles or<br />
tungsten carbide tiles<br />
Applications:<br />
• Static <strong>and</strong> dynamic<br />
applications<br />
features:<br />
• Customized application<br />
to fit your specific wear<br />
pattern<br />
• Tensile strength: 6000+ psi<br />
• Shear bond strength:<br />
4000+ psi<br />
Advantages:<br />
• Impact resistant<br />
• Can be used with complex<br />
shapes<br />
Benefits:<br />
• Reduces costs<br />
• Easy to fabricate<br />
• Extends time between<br />
outages<br />
dynAWeAR III<br />
description:<br />
Brazed tungsten carbide tiles.<br />
Applications:<br />
• Static <strong>and</strong> dynamic<br />
applications<br />
Note: The brazing method<br />
restricts use with certain<br />
types of materials.<br />
features:<br />
• High wear resistance<br />
• Excellent impact resistance<br />
Advantages:<br />
• Longer run time before<br />
replacement is required<br />
Benefits:<br />
• Reduces total cost of<br />
ownership<br />
• Extends time between<br />
overhauls<br />
MPS-TYPE PuLvERIzERS<br />
42
feAtuRes:<br />
• Three seal arrangement<br />
AdvAntAges:<br />
• Reduces risk of oil<br />
contamination<br />
BenefIts:<br />
• Increases mill availability<br />
• Increases bearing life<br />
PRevents oIl contAmInAtIon, PRomotIng<br />
longeR comPonent WeAR lIfe<br />
43 MPS-TYPE PuLvERIzERS<br />
mPs-type Pulverizer <strong>Rebuild</strong> services<br />
Triple Lip Seal upgrade<br />
ALSTOM’S TRIPLE LIP SEAL dESIGN HELPS ENSuRE OIL CAvITY INTEGRITY<br />
WHICH IS NECESSARY FOR LONG PuLvERIzER OPERATION PERIOdS. | This<br />
arrangement adds an additional layer of security. There are two seals to keep the<br />
contaminants out <strong>and</strong> one seal to keep the oil in. Better lubrication will allow bearings to<br />
run longer <strong>and</strong> increase pulverizer availability.
AS INduSTRY LEAdING SuPPLIERS FOR PROduCTS ANd SERvICES TO THE<br />
POWER INduSTRY, | Alstom <strong>and</strong> Horsburgh & Scott have decided to blend their<br />
individual expertise by entering into an alliance to rebuild / repair power plant<br />
gearboxes. We can rebuild / repair any gearbox anywhere in the power plant.<br />
The Alstom – Horsburgh & Scott team has the following capabilities:<br />
Balance of <strong>Plant</strong> Gearbox<br />
<strong>Rebuild</strong>s<br />
Service Capabilities<br />
<strong>Rebuild</strong> enclosed drives (from any manufacturer)<br />
• Concentric<br />
• Parallel shaft<br />
• Right angle bevel<br />
• Differential<br />
• Planetary<br />
• Wor m<br />
engineering Analysis<br />
• Upgrades<br />
• Modernization<br />
• Re-ratio<br />
• Problem solving<br />
field services<br />
• Installation supervision<br />
• Disassembly / reassembly<br />
• Enclosed drive evaluation <strong>and</strong> recommendation<br />
• Housing machining / re-boring<br />
• Predictive <strong>and</strong> preventive maintenance<br />
• Annual / periodic inspections<br />
• Re-engineering<br />
• Worldwide service<br />
A PARtneRshIP thAt WIll<br />
seRve All youR PlAnt<br />
geARIng needs<br />
we SuPPorT THe<br />
followInG BrAndS:<br />
• Amarillo<br />
• Adamson United<br />
• Atlas Car<br />
• Babcock & Wilcox<br />
• Beardslee & Piper<br />
• Blaw Knox<br />
• Brad-Foote<br />
• Clevel<strong>and</strong><br />
• David Brown<br />
• D. O. James<br />
• Dodge<br />
• Dominion<br />
• Dorstener<br />
• Ecodyne<br />
• Elliot<br />
• Falk<br />
• Farrel<br />
• Fessler<br />
• Flender<br />
• Foote/Jones<br />
• <strong>For</strong>dees<br />
• General Electric<br />
• Hansen<br />
• Hayward Gordon<br />
• Hitachi<br />
• Kawasaki<br />
• Krupp<br />
• Link-Belt<br />
• Lohmann &<br />
Stolterfoht<br />
• Lufkin<br />
• Marley<br />
• Mesta<br />
• M or gan<br />
Construction<br />
• Morgardshammer<br />
• Noma<br />
• NRM<br />
• Nuttall<br />
• P&H<br />
• Patterson Gear<br />
• Philadelphia Gear<br />
• Production<br />
Machinery<br />
• Renk/Tache<br />
• Sumitomo<br />
• Western<br />
• Westech<br />
• Westinghouse<br />
• Whiting<br />
• Wilson<br />
BALANCE OF PLANT<br />
44
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Faster turn-around vs. new<br />
purchase<br />
• Rotation program available<br />
Original AGMA 8 gear upgraded to AGMA 10<br />
Housing refurbished Coal conveyor drives<br />
Rail car positioner<br />
45 BALANCE OF PLANT<br />
Balance of <strong>Plant</strong> gearbox <strong>Rebuild</strong>s<br />
The Alstom – Horsburgh & Scott team can also provide gearing upgrades as<br />
part of the rebuild / repair service.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Clean<br />
• Dimensionally inspect<br />
• Provide evaluation report to customer<br />
Based on inspection, additional services for Triple reduction Gearbox<br />
can include:<br />
• Replacement of all components deemed unacceptable<br />
• <strong>Rebuild</strong> to as-new condition<br />
• Clean <strong>and</strong> inspect lubrication system<br />
• Perform “No-Load” spin test<br />
• Submit final report to customer<br />
Based on inspection, additional services for Pancake Gearbox can include:<br />
• Perform repair machining to gear housing halves <strong>and</strong> bores back to OEM<br />
tolerances<br />
• Reassemble, set up bearing endplay <strong>and</strong> gear patterns
ALSTOM OFFERS THE PARTS ANd SERvICES TO REBuILd ExISTING BuRNER<br />
SLIdE GATE ASSEMBLIES AT OuR REGIONAL SERvICE CENTERS. | A great<br />
c<strong>and</strong>idate for R3 Rotation Programs, Alstom can rebuild a set of burner slide gates<br />
<strong>and</strong> store them at one of our Regional Service Centers to support planned outages<br />
or emergency requirements. Alstom offers this service in an effort to provide a cost<br />
savings to the customer versus the purchase of a new component.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Evaluate condition<br />
• Replace worn components as necessary<br />
• Add or replace wear materials<br />
• Reassemble<br />
• Paint <strong>and</strong> ship<br />
Burner slide gate – BEFORE<br />
Burner <strong>and</strong> Fabricated<br />
Component <strong>Rebuild</strong> <strong>Services</strong><br />
Burner Slide Gate <strong>Rebuild</strong>s<br />
Burner slide gate – AFTER<br />
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Shorter lead time vs.<br />
purchasing new<br />
• upgraded materials<br />
available<br />
• New equipment warranty<br />
BuRNER/FABRICATEd COMPONENT REBuILdS<br />
46
Burner <strong>and</strong> fabricated component <strong>Rebuild</strong> services<br />
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Shorter lead time vs.<br />
purchasing new<br />
47 BuRNER/FABRICATEd COMPONENT REBuILdS<br />
Fuel Elbow <strong>and</strong> Orifice <strong>Repair</strong>s<br />
FuEL ELBOWS ANd ORIFICES RESIdE IN THE COAL PIPING SYSTEM. | These<br />
components typically experience localized wear due to coal roping. In most cases the<br />
entire component does not need to be replaced; only areas that have experienced<br />
erosion. Alstom repairs ceramic fuel elbows <strong>and</strong> orifices.<br />
These components are great c<strong>and</strong>idates for R3 Rotation Programs. Alstom can repair<br />
<strong>and</strong> store them at one of our Regional Service Centers to support planned outages<br />
or emergency requirements. Alstom offers this service in an effort to provide a cost<br />
savings to the customer versus the purchase of new components.<br />
<strong>Repair</strong> scope<br />
Basic <strong>Services</strong><br />
• Evaluate condition<br />
• Issue a comprehensive inspection report<br />
• <strong>Repair</strong> as necessary<br />
• Add or replace wear materials<br />
• Paint <strong>and</strong> ship
Burner <strong>and</strong> fabricated component <strong>Rebuild</strong> services<br />
THE COAL COMPARTMENT ASSEMBLY CONSISTS OF THE STATIONARY COAL<br />
NOzzLE, NOzzLE TIP, LINKAGES ANd SuPPORTS. | Alstom rebuilds / repairs all<br />
components within this assembly regardless of the material or design.<br />
A great c<strong>and</strong>idate for R3 Rotation Programs, Alstom can rebuild / repair compartment<br />
assemblies <strong>and</strong> store them at one of our Regional Service Centers to support planned<br />
outages or emergency requirements. Alstom offers this service in an effort to provide a<br />
cost savings to the customer versus the purchase of new components.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Evaluate condition<br />
• Issue a comprehensive inspection report<br />
• <strong>Repair</strong> or replace components<br />
• Add or replace wear materials<br />
• Paint <strong>and</strong> ship<br />
Coal compartment assembly – AFTER<br />
Coal Compartment <strong>Rebuild</strong>s<br />
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Shorter lead time vs.<br />
purchasing new<br />
• upgraded materials<br />
available<br />
• New equipment warranty<br />
Coal compartment assembly – BEFORE<br />
BuRNER/FABRICATEd COMPONENT REBuILdS<br />
48
Burner <strong>and</strong> fabricated component <strong>Rebuild</strong> services<br />
BenefIts:<br />
• Burners are rebuilt to OEM<br />
Specification<br />
• up to a 60% savings<br />
vs. the cost of a new<br />
burner<br />
• Fast turn around<br />
• Extensive inventory<br />
support<br />
RSFC Burner – BEFORE<br />
RSFC Burner – AFTER<br />
49 BuRNER/FABRICATEd COMPONENT REBuILdS<br />
RSFC Burner <strong>Rebuild</strong>s<br />
ALSTOM OFFERS REBuILd SERvICES FOR RSFC (RAdIALLY STRATIFIEd FLAME<br />
CORE) BuRNERS AS A COST EFFECTIvE ALTERNATIvE TO PuRCHASING A NEW<br />
COMPONENT. | Simply crate <strong>and</strong> ship the worn burner to Alstom’s rebuild facility <strong>and</strong><br />
we will inspect <strong>and</strong> replace all worn <strong>and</strong> damaged components <strong>and</strong> restore all welds<br />
to original specification.<br />
When complete, Alstom will return the rebuilt burner to you in the same shipping<br />
crate to minimize the possibility of damage during shipment.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Replace missing tiles<br />
• Replace stainless shroud<br />
• Replace distorted pipes<br />
• Replace adjusting bars<br />
• Replace worn blades<br />
• Replace all welds<br />
• Check to original specifications<br />
• Paint<br />
• Ship back to customer in original shipping container
Burner <strong>and</strong> fabricated component <strong>Rebuild</strong> services<br />
OIL GuNS ARE uSEd IN COAL-FIREd FuRNACES duRING START-uP TOO BRING<br />
THE FuRNACE FROM A “COLd” ENvIRONMENT TO AN ENvIRONMENT HOT<br />
ENOuGH TO CONTINuOuSLY BuRN COAL. | Once the coal fireball has been introduced<br />
<strong>and</strong> is stable within the furnace, the oil guns can be taken out of service. Retract<br />
mechanisms are one method of removing the oil gun from the heat of the furnace after<br />
boiler startup has been completed.<br />
Alstom provides quality rebuilds <strong>and</strong> new assemblies for oil guns <strong>and</strong> retract mechanisms<br />
at our local services centers.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Clean<br />
• Dimensionally inspect<br />
Oil Gun <strong>and</strong> Retract Mechanism <strong>Rebuild</strong>s<br />
Based on inspection, additional services can include:<br />
• Replacement or refurbishment of all components that do not meet original specification<br />
• <strong>Rebuild</strong> to as-new condition<br />
• Submit final report to customer<br />
BenefIts:<br />
• Saves approximately 50%<br />
vs. purchasing new<br />
• Reduced lead time vs. new<br />
purchase<br />
• Rotation programs<br />
available<br />
BuRNER/FABRICATEd COMPONENT REBuILdS<br />
50
51 BuRNER/FABRICATEd COMPONENT REBuILdS<br />
notes
ALSTOM HAS BEEN SuPPLYING NEW ANd REBuILT PuLvERIzER<br />
vOLuMETRIC FEEdERS FOR OvER 60 YEARS. | A Volumetric Feeder rebuild by<br />
Alstom results in a like-new feeder at a cost <strong>and</strong> lead time much less than those<br />
for new equipment. St<strong>and</strong>ard as well as customized upgrades are offered as part of<br />
the rebuild to meet operational <strong>and</strong> maintenance needs. Customers are contacted<br />
before the rebuild begins <strong>and</strong> provided with additional scope <strong>and</strong> upgrade options.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Clean<br />
• Dimensionally inspect<br />
Based on inspection, additional services include:<br />
• Replace all worn out parts<br />
• <strong>Repair</strong> components as needed<br />
• <strong>Rebuild</strong> to strict procedures <strong>and</strong> tolerances<br />
• Include upgrades upon customer request<br />
Volumetric Feeder<br />
<strong>Rebuild</strong> <strong>Services</strong><br />
volumetric Feeder <strong>Rebuild</strong> <strong>Services</strong><br />
BenefIts:<br />
• Reduces maintenance costs<br />
• Reduces inventory costs by<br />
25-35 percent<br />
• Saves up to 50% of<br />
replacement cost<br />
• Extends product life<br />
• Rotation programs<br />
available<br />
vOLuMETRIC FEEdER REBuILdS<br />
52
AdvAntAges:<br />
• Class 3 gearbox<br />
• New design protects the<br />
drive <strong>and</strong> feeder from<br />
damage due to jams<br />
• Solid state speed control<br />
• More efficient motor<br />
operation at all feeder<br />
speeds<br />
• Feeder motor speed<br />
indicator<br />
BenefIts:<br />
• Fewer parts to maintain<br />
• Reduces maintenance costs<br />
• Fewer breakdowns<br />
• Parts inventory reduction<br />
• Increases feeder reliability<br />
Reduce mAIntenAnce<br />
costs WhIle<br />
ImPRovIng RelIABIlIty<br />
53 vOLuMETRIC FEEdER REBuILdS<br />
volumetric feeder <strong>Rebuild</strong> services<br />
Product upgrades<br />
ALSTOM CONTINuES TO dESIGN ANd dEvELOP vOLuMETRIC COAL FEEdER<br />
PROduCTS | that will meet the changing needs of our customers. These upgrades:<br />
• provide longer wear life<br />
• reduce maintenance costs<br />
• eliminate a number of mechanical problems<br />
• improve overall reliability <strong>and</strong> availability<br />
Feeder drive Conversion<br />
ALSTOM HAS dEvELOPEd A FEEdER dRIvE CONvERSION FOR OuR<br />
vOLuMETRIC COAL FEEdERS TO REduCE MAINTENANCE COSTS ANd<br />
dOWNTIME ANd IMPROvE FEEdER RELIABILITY. | This conversion kit is<br />
available for most Alstom pulverizer installations with 16 lb. through 125 lb. feeders<br />
using Vari-Stroke drives <strong>and</strong> Hilliard clutches or Adjusto-Speed drives in the<br />
following size designations:<br />
• 312 to 753 RB mill<br />
• 463 to 863 RS mill<br />
• 463 to 863 RPS mill<br />
• 463 to 863 RP mill<br />
The kit includes a new<br />
in-line variable speed<br />
motor coupled to the<br />
feed roll shaft through a<br />
chain drive. It replaces<br />
the current Vari-Stroke<br />
or Adjusto-Speed drive.<br />
Additional components can<br />
be customized to suit your<br />
special requirements.<br />
The materials along with<br />
an assembly drawing with<br />
installation instructions <strong>and</strong> wiring diagrams for the speed control <strong>and</strong> remote operator<br />
station are supplied as part of this kit. All field wiring <strong>and</strong> installation is supplied by the<br />
customer.
volumetric feeder <strong>Rebuild</strong> services<br />
Feed Roll Shaft Needle Bearing-to-Bushing Conversion<br />
THE FEEd ROLL SHAFT NEEdLE BEARING-TO-BuSHING CONvERSION KIT<br />
WAS dEvELOPEd TO ALLOW COAL TO FEEd TO YOuR PuLvERIzER AT A MORE<br />
uNIFORM RATE. | This is accomplished by varying the rotational speed of a spider <strong>and</strong><br />
blade assembly, which form fixed volume rotating pockets. With the current design,<br />
the shaft of the feed roll spider rotates in a pair of needle bearings located in the feed<br />
roll endplugs. These needle bearings are subjected to high temperatures <strong>and</strong> substantial<br />
contamination which dem<strong>and</strong>s frequent manual lubrication. To eliminate this labor<br />
intensive need, the new design incorporates high strength bronze bushings with graphite<br />
endplugs.<br />
The bronze bushings are manufactured from a high strength alloy. The graphite endplug<br />
provides a dry lubrication which does not attract <strong>and</strong> hold contamination or break down<br />
with heat. A shrink fit is utilized to retain the bushings in the feed roll endplugs. The<br />
bushings are designed to run against the same bearing inner races used for the needle<br />
bearings. These inner races, with a 16 micron finish hardened to 58 Rockwell C, provide<br />
an inexpensive replaceable surface <strong>and</strong> fit directly on the existing feed roll shaft. This<br />
bushing arrangement is designed to operate at temperatures up to 550°F.<br />
The bronze bushings with graphite are a direct replacement of the originally supplied<br />
needle bearings. No modifications are required.<br />
shaft needle Bearing-to-Bushing conversion<br />
AdvAntAges:<br />
• Insensitive to temperature<br />
• Eliminates manual<br />
lubrication<br />
• direct replacement of<br />
existing needle bearings<br />
BenefIts:<br />
• Increases wear life<br />
• Increases feeder/mill<br />
availability<br />
• Reduces maintenance costs<br />
unIfoRm coAl feed<br />
RAte to the PulveRIzeR<br />
vOLuMETRIC FEEdER REBuILdS<br />
54
AdvAntAges:<br />
• Cylinder can be replaced<br />
without having to replace<br />
the cast endplug<br />
• Simple upgrade with direct<br />
parts replacement<br />
• design can be used on<br />
right-h<strong>and</strong> <strong>and</strong> left-h<strong>and</strong><br />
feeders<br />
BenefIts:<br />
• Reduces maintenance costs<br />
• Reduces total cost of<br />
ownership<br />
sImPle And loW cost<br />
endPlug uPgRAde<br />
55 vOLuMETRIC FEEdER REBuILdS<br />
volumetric feeder <strong>Rebuild</strong> services<br />
Endplug upgrade<br />
THE vOLuMETRIC FEEdER ENdPLuG uPGRAdE ALLOWS REPLACEMENT OF A<br />
WORN CYLINdER WITHOuT HAvING TO REPLACE THE WHOLE CASTING. | This<br />
three-piece design replaces the original one-piece cast feed body endplug – cylinder. The<br />
new endplug assembly consists of a cast feed roll plug which is the major part of the<br />
original casting, a spacer, <strong>and</strong> the feed roll sleeve. Only the sleeve is exposed to wear.<br />
<strong>For</strong> contracts after 1955, these three-piece feeder body endplugs are a direct<br />
replacement part. No field modification is required. Contracts dating before 1955 may<br />
require additional parts to use the multi-piece endplug <strong>and</strong> will need to be researched<br />
on an individual contract basis.
volumetric feeder <strong>Rebuild</strong> services<br />
Stainless Steel Body Liners<br />
ALSTOM’S vOLuMETRIC FEEdER STAINLESS STEEL BOdY LINERS WERE<br />
dEvELOPEd TO PROTECT THE FEEdER BOdY FROM WEAR AS THE COAL FLOWS<br />
THROuGH THE FEEdER. | The stainless steel liners provide a replaceable wear-resistant<br />
surface. Coal flow to the pulverizer will improve over time as the liner surfaces become<br />
polished <strong>and</strong> friction is reduced. The feeder body liners are designed to fit into existing<br />
feeders.<br />
The stainless steel body liners have been incorporated as st<strong>and</strong>ard supply since the early<br />
1960’s. These liners have proved to be very successful, <strong>and</strong> some earlier feeders have<br />
since been retrofitted. This liner upgrade is appropriate for all pre-1960 contracts <strong>and</strong><br />
should be reviewed for post-1960 contracts.<br />
AdvAntAges:<br />
• Protect feeder bodies from<br />
wear<br />
• Provides improved coal<br />
flow<br />
• Reduces feeder pluggage<br />
• Easily installed or replaced<br />
BenefIts:<br />
• Reduces maintenance costs<br />
• Improves availability<br />
unIfoRm coAl feed<br />
RAte to the PulveRIzeR<br />
vOLuMETRIC FEEdER REBuILdS<br />
56
sImPlest WAy to<br />
Reduce coAl dePosIts<br />
57 vOLuMETRIC FEEdER REBuILdS<br />
volumetric feeder <strong>Rebuild</strong> services<br />
Stainless Steel Feed Roll Spider <strong>and</strong> Blade Assembly<br />
AdvAntAges:<br />
• Simple direct replacement<br />
• Reduces coal hide-out areas<br />
• Stainless steel material<br />
to provide a smoother,<br />
friction-free surface<br />
BenefIts:<br />
• Improves boiler control<br />
• Improves availability<br />
• Reduces load restrictions<br />
caused by coal feed<br />
problems<br />
ALSTOM HAS dEvELOPEd A STAINLESS STEEL FABRICATEd FEEd ROLL SPIdER<br />
ANd BLAdE ASSEMBLY TO REduCE THE LIKELIHOOd OF COAL dEPOSITING<br />
IN THE FEEd ROLL POCKET. | The material is stainless to provide a smoother, more<br />
friction-free pocket. To reduce wear to the spider, the order of rotation has been<br />
reversed from the original design with cast iron spiders. The new assembly has the<br />
sacrificial spider blade rotating into the coal, followed by the spider. When the coal is<br />
dumped, it slides off the smooth backside of the spider.<br />
The new stainless steel feed roll spider <strong>and</strong> blade assembly is a direct replacement of the<br />
originally supplied spider assembly. No modifications are required.
volumetric feeder <strong>Rebuild</strong> services<br />
Hinged Gate Mechanism Assembly upgrade<br />
THE HINGEd GATE MECHANISM ASSEMBLY uPGRAdE WAS dEvELOPEd TO<br />
AddRESS FEEdER FAILuRES THAT LEAd TO INTERRuPTEd PLANT OPERATION. |<br />
The hinge gate mechanism levels the coal in each section of the feed roll assembly as it<br />
rotates. This maintains a constant volume of coal in each section <strong>and</strong> helps to provide the<br />
proper coal feed rate to the pulverizer. If the hinge gate mechanism fails, the hinge gate can<br />
rotate away from the feed roll. This allows too much coal to enter the pulverizer, resulting<br />
in spillage <strong>and</strong> other operational problems. <strong>Repair</strong>ing the hinge gate mechanism typically<br />
requires taking the feeder off-line, which can impact the ability to maintain unit load.<br />
Alstom’s new design eliminates the spring rod h<strong>and</strong>le, includes a more durable lever<br />
attachment <strong>and</strong> a redesigned cam follower to substantially reduce failures associated with<br />
the current design. This reduces maintenance <strong>and</strong> repair costs <strong>and</strong> improves feeder reliability<br />
<strong>and</strong> availability.<br />
feeder hinged gate mechanism Assembly<br />
AdvAntAges:<br />
• New robust design reduces<br />
failures<br />
• Allows for easy adjusting<br />
during installation<br />
• Enables easy adjustment<br />
BenefIts:<br />
• Easy installation<br />
• Reduces maintenance<br />
• Improves feeder reliability<br />
<strong>and</strong> availability<br />
sImPlest WAy to ImPRove<br />
feedeR RelIABIlIty And<br />
AvAIlABIlIty<br />
vOLuMETRIC FEEdER REBuILdS<br />
58
AdvAntAges:<br />
• Simple conversion utilizing<br />
existing feeder body studs<br />
• Can be oriented to open to<br />
either side<br />
BenefIts:<br />
• Increases safety<br />
• Increases convenience<br />
59 vOLuMETRIC FEEdER REBuILdS<br />
volumetric feeder <strong>Rebuild</strong> services<br />
Side Opening Inspection door upgrade<br />
quICKLATCH –<br />
Inspection door upgrade<br />
ALSTOM’S SIdE OPENING INSPECTION dOOR FOR THE INdEPENdENT<br />
vOLuMETRIC FEEdER IS AN uPGRAdE TO THE ORIGINAL dESIGN. | The new<br />
assembly mounts on the existing dog studs on one side of the feeder door opening <strong>and</strong><br />
the two remaining dogs on the other side are used to keep it closed. This allows the full<br />
weight of the door assembly to ride on the new hinges as it pivots open. The door is<br />
symmetrical so it can be mounted to open to either side. This modification can be used<br />
as is or in conjunction with Alstom’s QUICKLATCH design which replaces the access<br />
dogs with a lift <strong>and</strong> swing latch assembly<br />
THE quICKLATCH FEEdER INSPECTION dOOR uPGRAdE PROvIdES RAPId<br />
INTERNAL ACCESS TO ALSTOM’S NEGATIvE PRESSuRE vOLuMETRIC FEEdERS<br />
WHILE MAINTAINING NFPA COdE REquIREMENTS IN THE CLOSEd POSITION. | The<br />
QUICKLATCH upgrade must be used in conjunction with the Side Opening Inspection Door<br />
Upgrade which relocates the hinges from below the door to the side. In this orientation the<br />
weight of the inspection door is carried on the hinges.<br />
At this time the QUICKLATCH feeder inspection door conversion is applicable only to<br />
Volumetric Feeders on suction mills (RB <strong>and</strong> RS mills).<br />
AdvAntAges:<br />
• Provides quick access to<br />
feeder internals<br />
• Latch assembly meets<br />
NFPA requirements<br />
• use with feeders normally<br />
operated under negative<br />
pressure<br />
• quick release safety pin to<br />
prevent accidental openings<br />
BenefIts:<br />
• Improves feeder access<br />
• Increases convenience<br />
• Improves safety
ALSTOM OFFERS AN ARRAY OF NEW ANd REBuILT SINGLE ROLL ANd<br />
dOuBLE ROLL CLINKER GRINdERS. BRANdS THAT ALSTOM SuPPORTS<br />
INCLudE: | Allen-Sherman-Hoff, United Conveyer Corp.*, AR Industries,<br />
Combustion Engineering, ABB <strong>and</strong> Alstom.<br />
<strong>Rebuild</strong> scope<br />
Basic <strong>Services</strong><br />
• Disassemble<br />
• Clean<br />
• Dimensionally inspect<br />
• Replace the following parts:<br />
– Packing<br />
– Shaft sleeves<br />
– Wear rings<br />
– O-Rings<br />
– Bearings<br />
– All high chrome wetted parts (single rolls only)<br />
– Connecting hardware<br />
Based on inspection, additional services include:<br />
• Replacement of the following parts:<br />
– Bearing supports<br />
– Housings<br />
– Covers<br />
– Metal seals<br />
– Shaft <strong>and</strong> roll assemblies (double roll only)<br />
• Housing (repair more likely than replacement)<br />
* (type of service available depends on size <strong>and</strong> model number)<br />
Clinker Grinder <strong>Rebuild</strong><br />
<strong>Services</strong><br />
Clinker Grinder <strong>Rebuild</strong>s<br />
BenefIts:<br />
• Saves approximately 40%<br />
vs. purchasing new<br />
• Extends product life<br />
• Rotation programs<br />
available<br />
CLINKER GRINdER REBuILdS<br />
60
single Roll models<br />
uP to 2 tImes the seRvIce<br />
• 27” x 20”<br />
lIfe of tRAdItIonAl PAckIng<br />
• 33” x 30”<br />
ASHBRADE Grinder Packing – lantern ring,<br />
packing rings <strong>and</strong> gl<strong>and</strong> follower<br />
61 CLINKER GRINdER REBuILdS<br />
clinker grinder <strong>Rebuild</strong> services<br />
ALSTOM CONTINuES TO dESIGN ANd dEvELOP CLINKER GRINdER PROduCTS | that will meet the challenging needs of our<br />
customers. These upgrades provide:<br />
• Longer wear life<br />
• Reduced maintenance costs<br />
• Improve overall reliability <strong>and</strong> availability<br />
BenefIts:<br />
• Significantly reduces water<br />
leakage from grinder<br />
stuffing boxes<br />
• Service life of ASHBRAdE<br />
Packing has been found to<br />
be up to two times longer<br />
than traditional packing<br />
• Life span better matches<br />
grinder rebuild cycles<br />
• Available for most grinder<br />
models<br />
Product upgrades<br />
ASHBRAdE Grinder Packing<br />
ASHBRAdE GRINdER PACKING IS dESIGNEd FOR SINGLE ROLL ANd dOuBLE ROLL<br />
CLINKER GRINdERS ANd IS AN uPGRAdE TO MOST COMMON TYPES OF PACKING<br />
uSEd TO SEAL THE STuFFING BOx AREAS TO MINIMIzE WATER LEAKAGE. |<br />
ASHBRADE Packing can be installed in most existing grinder models replacing the<br />
traditional lantern ring <strong>and</strong> packing ring assemblies. It is not necessary to purchase a new<br />
grinder or modify the castings of an existing grinder to take full advantage of this upgrade.<br />
Key features of the ASHBrAde Grinder Packing lantern ring include:<br />
• Three piece metal design to h<strong>and</strong>le the compression force when installing the four packing<br />
rings<br />
• Sufficient width along the grinder sleeve to stay positioned under the sealing port yet<br />
allow proper water or grease sealing<br />
• Properly shaped forward faces that conform to existing stuffing box profiles<br />
• An offset design with tighter shaft sleeve clearances in the direction of the packing rings<br />
<strong>and</strong> an improved water flow path towards the grinding area<br />
• When used with the recommended higher pressure seal water, the lantern ring provides<br />
better flushing of grit that historically gets under packing rings <strong>and</strong> scores shaft sleeves<br />
ASHBRADE Grinder Packing can be installed into an existing clinker grinder in the field. It<br />
is also a major feature of an Alstom Grinder <strong>Rebuild</strong> Program performed at our Regional<br />
Service Centers. Here grinder rebuild specialists have the experience, tools <strong>and</strong> formal rebuild<br />
procedures necessary to provide proper installation of all grinder parts <strong>and</strong> packing.<br />
The grinder models for which ASHBRADE Grinder Packing is applicable include<br />
the following:<br />
double Roll models<br />
• 2’ - 0”<br />
• 2’ - 10”<br />
• 3’ - 0”
clinker grinder <strong>Rebuild</strong> services<br />
Segmented Rolls for double Roll Grinders<br />
ALSTOM OFFERS REPLACEABLE SEGMENTEd ROLLS FOR uSE ON ITS FAMILY OF<br />
dOuBLE ROLL GRINdERS | Alstom has now applied the technology used in its Single Roll<br />
grinder design to its 2’-0”, 2’-10” <strong>and</strong> 3’-0” Double Roll Grinders.<br />
Instead of using a hollow Ni-Hard roll, Alstom employs multiple Ni-Hard cam segments<br />
bolted to a cam support box, which, in turn, is supported by three internal bosses welded to<br />
a steel shaft. The cam segments can be individually replaced as teeth break off, even while<br />
the grinder is still installed under the gate housing.<br />
During a rebuild, which can be performed at one of Alstom’s regionally located service<br />
centers; each cam is removed <strong>and</strong> inspected for reuse or replacement. The main shaft is<br />
also inspected. In most cases the shaft can be reused if proper sleeves <strong>and</strong> packing were<br />
used during operation.<br />
feAtuRes:<br />
• Individual, bolt-on Ni-Hard<br />
cam segments<br />
• Cam support box with<br />
internal bosses<br />
AdvAntAges:<br />
• Replace only those cam<br />
segments that are worn or<br />
broken<br />
• Reusable shaft*<br />
BenefIts:<br />
• Reduces total cost of<br />
ownership<br />
• Improves availability<br />
• Extends run time between<br />
outages<br />
* Providing proper sleeves <strong>and</strong> packing<br />
were used during operation.<br />
CLINKER GRINdER REBuILdS<br />
62
63 CLINKER GRINdER REBuILdS<br />
notes
The Alstom Advantage<br />
100 YEARS OF ExPERIENCE + SOLuTION-BASEd PROduCTS & SERvICES +<br />
COMMITMENT TO CuSTOMER SERvICE = THE ALSTOM AdvANTAGE | Alstom<br />
provides reliable delivery of products <strong>and</strong> services to meet the dem<strong>and</strong>s of the<br />
power industry. We are a dedicated customer service organization that delivers the<br />
responsiveness our customers require.<br />
Alstom provides the quality <strong>and</strong> resources of an OEM while backing our products with<br />
comprehensive support. Our products are designed to help our customers meet the<br />
performance, availability <strong>and</strong> reliability requirements for their power plant equipment.<br />
mARkets seRved<br />
equIPment suPPoRted<br />
In addition to servicing Alstom equipment, we also provide after market service for the following br<strong>and</strong>s:<br />
COAL FEEdERS | ABB, Combustion<br />
Engineering, Stock <strong>Equipment</strong>,<br />
Merrick Industries<br />
COAL PuLvERIzERS | ABB,<br />
Combustion Engineering, Babcock<br />
& Wilcox, Riley Atrita®, Foster<br />
Wheeler<br />
Service Capabilities<br />
Our experience <strong>and</strong> customer base include:<br />
• Utility companies<br />
• Regional electric cooperatives<br />
• Federal, municipal power producers<br />
• Independent power producers<br />
• Pulp <strong>and</strong> paper companies<br />
• Industrials such as chemical plants, steel mills <strong>and</strong> refineries<br />
In other words, if you generate steam to produce power or to support your manufacturing<br />
processes, Alstom is ready to provide the products <strong>and</strong> services you need.<br />
STEAM GENERATORS | ABB,<br />
Combustion Engineering, Babcock &<br />
Wilcox, Riley, <strong>and</strong> Foster Wheeler<br />
STOKERS | ABB, Combustion<br />
Engineering, detroit Stoker, Riley,<br />
Westinghouse, Hoffman, Taylor<br />
FIRING SYSTEMS | ABB, ICL, NEI,<br />
Clark Chapman, CSL, Rv Industries,<br />
Foster Wheeler<br />
ASH HANdLING SYSTEMS | ABB,<br />
Combustion Engineering, Allen-<br />
Sherman-Hoff, united Conveyor, Fläkt<br />
AIR POLLuTION CONTROL | ABB,<br />
Combustion Engineering, Fläkt,<br />
Walther, Carborundum, Hamon-<br />
Research Cottrell, Wheelabrator,<br />
Peabody, Rockwell<br />
THE ALSTOM AdvANTAGE<br />
64
Alstom’s technical<br />
services capabilities<br />
cover major plant<br />
equipment <strong>and</strong><br />
systems <strong>and</strong> include:<br />
• Outage planning<br />
• Inspection services<br />
• Condition assessments<br />
• Maintenance support<br />
• Performance testing<br />
• Training programs<br />
• dedicated engineers<br />
Alstom technical<br />
service includes:<br />
• A team of over 100<br />
field-based service<br />
engineers, NdE specialists,<br />
performance test engineers<br />
<strong>and</strong> technicians<br />
• Problem solvers<br />
• <strong>Equipment</strong> inspectors,<br />
testers, <strong>and</strong> evaluators<br />
• Performance specialists<br />
65 THE ALSTOM AdvANTAGE<br />
technical services<br />
WE ARE A GLOBAL PROvIdER OF PROduCTS ANd SERvICES TO THE POWER<br />
INduSTRY. | We maintain a local presence to help ensure that our customers’ equipment<br />
<strong>and</strong> systems run reliably <strong>and</strong> efficiently with the availability they dem<strong>and</strong>.<br />
FIELd TECHNICAL SERvICE ENGINEERS | Alstom has extensive capabilities in the form<br />
of Field Technical Service Engineers to assist with your outage inspection <strong>and</strong> operation <strong>and</strong><br />
maintenance needs.<br />
Our field service engineers are located near our customers to provide the response they need.<br />
This full time force of professionally trained engineers <strong>and</strong> technicians receive constant<br />
training to help ensure they are knowledgeable in the latest trends <strong>and</strong> available technology.<br />
OuTAGE PLANNING | Effective outages require effective planning, a continuous process<br />
that begins well in advance of the scheduled event. Alstom st<strong>and</strong>s ready to participate in<br />
this process to help ensure timely decisions, problem avoidance, <strong>and</strong> achieved goals.<br />
the services Alstom provides include:<br />
• Setting overall outage objectives<br />
• Work scope determination<br />
• Prioritization of outage tasks<br />
• Identification of material <strong>and</strong> parts needs<br />
• Expediting delivery of required material <strong>and</strong> parts<br />
INSPECTION SERvICE | To help ensure an effective outage, we offer our<br />
inspection service that includes:<br />
• Pre-outage logistics <strong>and</strong> work scope definition<br />
• Pre-outage unit walk-downs<br />
• Detailed inspections during the outage<br />
• Daily punch lists <strong>and</strong> definition of items requiring immediate attention<br />
• Coordination with repair labor personnel<br />
• Initial report with critical findings <strong>and</strong> recommendations<br />
• Final detailed inspection report complete with photos, recommendations<br />
<strong>and</strong> findings<br />
• On-line retrieval (via our website) of our final report for convenient viewing<br />
<strong>and</strong> downloading
CONdITION ASSESSMENT | Alstom delivers the<br />
technology to manage risks through the integration of<br />
Advanced NDE <strong>and</strong> inspection technology, including:<br />
• Ultrasonic examination<br />
• Linear phased array<br />
• Dye penetrant testing<br />
• Magnetic particle testing<br />
• Remote field Eddy current<br />
• Wet fluorescent particle testing<br />
• Boroscope with internal video<br />
• Remote field eddy current<br />
• Visual examinations<br />
as well as service capabilities through:<br />
• <strong>Power</strong> <strong>Plant</strong> Laboratory facilities,<br />
• Material Technology Center,<br />
• Field service engineers<br />
PERFORMANCE TESTING ANd EvALuATIONS |<br />
The performance evaluation <strong>and</strong> testing team<br />
supports data gathering <strong>and</strong> analysis to help optimize<br />
plant performance. Offerings include:<br />
• Specialized testing of thermal, fluid, <strong>and</strong> chemical<br />
processes (emissions <strong>and</strong> circulation)<br />
• Boiler <strong>and</strong> power plant performance evaluation<br />
• Water chemistry consultation for boilers<br />
• Instrumentation supply <strong>and</strong> rentals of most<br />
commonly used boiler <strong>and</strong> emissions test equipment<br />
technical services<br />
dEdICATEd ENGINEER PROGRAM | We provide an experienced Alstom Technical <strong>Services</strong><br />
Engineer for exclusive use for a specific time period.<br />
The Dedicated Engineer becomes an on-site member of the plant team spearheading the<br />
Alstom support. The result is responsive service in determining root causes to problems <strong>and</strong><br />
timely development <strong>and</strong> implementation of solutions to help reach <strong>and</strong> exceed station goals.<br />
technIcAl seRvIces<br />
tAIloRed foR you And<br />
youR Budget<br />
MAINTENANCE SuPPORT SERvICE | To help ensure your equipment<br />
performs to your expectations, we offer our Maintenance Support Service<br />
whereby we:<br />
• Determine equipment condition <strong>and</strong> need for repairs<br />
• Compare components to<br />
original specifications <strong>and</strong><br />
help make adjustments<br />
• Participate in developing<br />
work scope <strong>and</strong> associated<br />
tasks<br />
• Direct maintenance<br />
personnel in proper<br />
disassembly <strong>and</strong><br />
assembly procedures<br />
• Coordinate execution of the<br />
work scope<br />
• Develop a daily punch list<br />
prioritizing work tasks<br />
• Provide a final report documenting work performed <strong>and</strong><br />
recommendations<br />
TRAINING PROGRAMS | Alstom's training programs provide power plant<br />
professionals with the knowledge <strong>and</strong> skills they need to operate <strong>and</strong><br />
maintain the equipment <strong>and</strong> systems. Alstom's portfolio includes:<br />
• St<strong>and</strong>ard <strong>and</strong> customized training<br />
• HOT TOPIC training programs<br />
• Computer-based QUICKSTUDY Learning System<br />
• Regional training seminars<br />
wITH AlSTom...<br />
You’re In conTrol<br />
THE ALSTOM AdvANTAGE<br />
66
67 THE ALSTOM AdvANTAGE<br />
Alstom service <strong>and</strong> distribution centers<br />
AdvAntAges:<br />
• After hours response team<br />
• Guaranteed parts availability<br />
• Eliminates exposure to<br />
obsolete inventory<br />
• Applicable to most plant<br />
equipment<br />
• Programs can be exp<strong>and</strong>ed<br />
to include other plants with-<br />
in the customer’s system<br />
• One week st<strong>and</strong>ard shipment<br />
after receipt of order<br />
• Minimizes exposure to raw<br />
materials price fluctuations<br />
BenefIts:<br />
• Reduces carrying costs<br />
• defers cash outlay<br />
• Increases cash flow by<br />
delivering products when<br />
needed<br />
• Simplifies purchasing<br />
stRAtegIcAlly locAted<br />
to seRve ouR customeRs<br />
InventoRy mAnAgement PRogRAms<br />
With our proven inventory management expertise, purchasing strength <strong>and</strong> strategically<br />
located regional service centers, participation in an Alstom Inventory Management Program<br />
can offer customers significant benefits – from guaranteed shipments to improved cash flow.<br />
ImPRoves cAsh floW And guARAntees<br />
PARts AvAIlABIlIty<br />
ALSTOM’S SERvICE CENTER NETWORK, STRATEGICALLY<br />
LOCATEd ACROSS THE COuNTRY, | provides emergency<br />
component repairs, parts, complete component overhauls,<br />
custom fabrications, <strong>and</strong> cost saving inventory management<br />
programs to meet our customers’ needs.<br />
denver, CO<br />
*<br />
Tyler, Tx<br />
*<br />
Erlanger, KY<br />
*<br />
Chattanooga, TN<br />
*<br />
Suwanee, GA<br />
*<br />
Ro c k y Mo u n t a i n Se R v i c e cen t e R –<br />
Den v e R, co l o R a D o<br />
MiD w e S t Se R v i c e cen t e R –<br />
eR l a n g e R, ke n t u c k y<br />
Harrisburg, PA<br />
*
Alstom service <strong>and</strong> distribution centers<br />
REBuILd/REPAIR SERvICES | As a leading supplier of quality power<br />
plant equipment <strong>and</strong> replacement parts, Alstom offers one of the industry’s most<br />
complete <strong>and</strong> cost-effective rebuild <strong>and</strong> repair services.<br />
Alstom’s rebuild/repair services include component inspections <strong>and</strong> maintenance,<br />
replacement of worn parts <strong>and</strong> design upgrades. These offerings, which include<br />
extended warrantees, can reduce inventory costs by 25-35% <strong>and</strong> result in longer lasting<br />
products that save power producers money.<br />
R3 comPonent RotAtIon PRogRAms<br />
Alstom offers customers a systematic method for rebuilding boiler related equipment<br />
<strong>and</strong> returning this equipment to service. Alstom’s Regional Service Centers are the focus<br />
of this program combining our extensive experience, inventory, rebuild portfolio <strong>and</strong><br />
proven processes to provide a unique service.<br />
The R3 program is based on <strong>Rebuild</strong>ing, Restocking <strong>and</strong> Replacing components.<br />
<strong>Rebuild</strong><br />
Complete disassembly <strong>and</strong> inspection of a component. Worn out parts are replaced <strong>and</strong><br />
components repaired. The components are rebuilt to strict procedures <strong>and</strong> tolerances.<br />
Upgrades to components can be included.<br />
Restock<br />
Once a rebuild is completed, the component is placed in the customer’s exclusive stock<br />
inventory at the Regional Service Center nearest the plant.<br />
Replace<br />
Rebuilt components are returned to a customer when needed to replace a similar<br />
component requiring service. The replaced component is sent back to the Service Center<br />
R3 = ReBuIld + Restock + RePlAce<br />
ImPRovIng AvAIlABIlIty WhIle ReducIng cost<br />
AdvAntAges:<br />
• All work is done in a<br />
controlled environment<br />
using the latest<br />
technology<br />
• All work is done to<br />
engineering specifications<br />
• R3 Component Rotation<br />
Programs are available to<br />
fit your outage schedule<br />
• Extensive parts inventory<br />
to support rebuilds/<br />
repairs<br />
• OEM inspection <strong>and</strong><br />
assembly procedures are<br />
used<br />
• Component upgrades<br />
available<br />
BenefIts:<br />
• Reduce Inventory costs<br />
25-30%<br />
• Shorter lead times<br />
• All work backed by<br />
Alstom’s engineering<br />
experience, quality <strong>and</strong><br />
reliability<br />
THE ALSTOM AdvANTAGE<br />
68
AdvAntAges:<br />
• Custom or st<strong>and</strong>ard<br />
kits<br />
• Reduces maintenance<br />
costs<br />
• Convenient <strong>and</strong><br />
organized<br />
• Simplifies purchasing<br />
BenefIts:<br />
• Right parts available<br />
when you need them<br />
• Only pay for the parts<br />
that are used<br />
• Instant part availability<br />
• Save time <strong>and</strong> money<br />
The customer <strong>and</strong><br />
Alstom develop a<br />
list of parts to be<br />
included in each kit.<br />
Each kit includes a<br />
detailed chart of the<br />
location of each part.<br />
69 THE ALSTOM AdvANTAGE<br />
outage kit services<br />
OuTAGE KITS | are pre-packaged supplies of equipment-specific replacement<br />
parts that support planned or unexpected unit outages <strong>and</strong> rebuilds.<br />
Emergencies cost money! Outage Kits can help minimize costly delays in<br />
making repairs.<br />
Outage Kits are the perfect solution when emergencies strike, or to have<br />
available as part of a planned preventative maintenance cycle or Inventory<br />
Management Program.<br />
Alstom then ships<br />
these parts in<br />
pre-packaged kit<br />
form to the customer<br />
two weeks prior to the<br />
planned outage<br />
or rebuild.<br />
A cost-effectIve WAy to mAnAge PlAnned<br />
And unPlAnned unIt outAge RePAIRs<br />
hoW Alstom’s outAge kIt PRogRAm WoRks:<br />
Customer<br />
withdraws parts<br />
from the kit,<br />
as needed.<br />
Items not needed<br />
from any given kit<br />
are shipped back<br />
to Alstom for<br />
re-stocking.<br />
The customer then<br />
issues a purchase<br />
order to Alstom<br />
for any parts<br />
consumed.
your 1-stop choice for Boiler services <strong>and</strong> Parts<br />
call us toll free: 1.866.257.8664<br />
or<br />
direct: 1.860.285.2100<br />
Press:<br />
If you know your party’s 4 digit extension<br />
<strong>For</strong> Shipping <strong>and</strong> delivery information<br />
To speak with a Customer Service Representative<br />
If you would like the company directory<br />
If you would like this menu repeated<br />
All other calls stay on the line<br />
e-mail: windsorparts@power.alstom.com<br />
fax: 1.860.285.3101<br />
We provide 24 hour, 7 days a week emergency service.<br />
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 <strong>and</strong> any alternative version thereof are trademarks <strong>and</strong> service marks of Alstom. The other names mentioned, registered or not, are<br />
the property of their respective companies. The technical <strong>and</strong> other data contained in this document is provided for information only. Neither Alstom, its officers <strong>and</strong> employees accept responsibility for or should be taken as making any<br />
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<br />
the right to revise or change this data at any time without further notice.<br />
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<br />
registered trademark of Riley <strong>Power</strong>, Inc. LIMELIGHT is a trademark of Alstom <strong>Power</strong> Inc. GENETIx is a registered trademark of Merrick Industries, Inc.<br />
Alstom <strong>Power</strong> Inc.<br />
200 Great Pond drive<br />
Windsor, CT 06095-0500<br />
Tel: 860.285.2100<br />
Toll Free: 866.257.8664<br />
Fax: 860.285.3101<br />
www.power.alstom.com