Alstom Products and Services

for Foster Wheeler Plants

With Alstom
You're in control!
POWER
Alstom, a leader
2
At Alstom, we combine our capabilities and experience
to enhance the productivity and performance of your
boilers, pulverizers, feeders, air pollution control
systems, ash handling systems and auxiliary equipment.
Our focus is customer service and we understand the
challenges faced by plant owners, operators, maintenance
personnel and management. Whether it is a replacement
or upgraded part, a rebuilt assembly, a custom fabrication
or inventory management program, Alstom provides
exceptional value and service to our customers.
Alstom is a leader in the design, manufacturing and servicing of utility and industrial power generation
systems. While our heritage dates to the late 1800s, our capabilities continue to expand and point
us to the future. Alstom is ISO 9001:2008 registered.
SAFETY | We believe that safety is a key indicator of operational excellence for both
Alstom and its customers. Our commitment to safety hinges on strong leadership,
timely communication and the involvement of all employees. Our target is zero
safety incidents.
EXPERIENCE | With an installed base of over 400 GW of power generation capacity spanning over 100 years,
we believe you cannot fnd a partner whose experience in the power industry matches ours. We are dedicated to
meeting your needs and exceeding your expectations. Our track record proves it.
INNOVATION | Each and every day, Alstom applies leading edge technology to develop new products and
services to meet your maintenance and operational challenges regardless of your boiler type or fuel.
Your performance is our measure of success.
LOGISTICS | The right products and services when and where you need them. That is our commitment. With
a wide range of capabilities and options for replacement parts supply, technical services, and construction services,
Alstom is your complete boiler services solution. We offer the industrys most comprehensive and innovative
replacement parts and service programs.
CUSTOMER SERVICE | Alstoms feld service engineers, customer service representatives and construction
managers have one goal exceeding your service expectations. Our strategically located service and distribution
centers enable us to provide fast response and reliable solutions to meet your needs.
SAFETY AND EXPERIENCE
3
CONTENTS
Alstom Solutions for Foster Wheeler Plants .................................................................................5
MBF-type Pulverizers..........................................................................................................................7
Coal Feeders .....................................................................................................................................21
Boiler Electronics...............................................................................................................................29
Burner Fabrications ...........................................................................................................................37
Pressure Parts ..................................................................................................................................43
Ash Systems .....................................................................................................................................47
The Alstom Advantage ......................................................................................................................49
Contact Information ..........................................................................................................................55
WORKING WITH ALSTOM IS NOT LEAVING THE OEM, IT'S COMING TO ONE
4
Introduction to...
TODAY'S POWER INDUSTRY IS NOT THE SAME AS IT WAS TEN YEARS AGO; WE HAD MORE TIME. | We had more time to
plan, to schedule, to inventory parts, to train new resources, to investigate best practices for maintenance and operations.
MORE TIME TO BREATHE!
The daily demands on power producers in America today are unprecedented and constantly changing. In order to meet these
challenges, you need a solid partner. You need a resource you can count on, one that knows power generation equipment.
Ten years ago this partner would have been your Original Equipment Manufacturer (OEM). Today, those credentials alone are not
good enough. For you to be successful, your partner needs to be more than "the guy that has been around forever". In order to
meet the demands on your plant, you need the people and resources of the world's largest power plant OEM. You need a partner
that measures success by the speed and quality of parts and services provided to you. You need a partner that measures their
success by yours.
YOU NEED ALSTOM!
As one of the world's largest Engineering and Manufacturing OEM for the power generation industry, Alstom understands your
needs and your equipment.
We have been providing our customers with Alstom parts and services for Foster Wheeler plants for many years.
The following information offers the potential to unleash this resource as a tool for your success.
LET US SHOW YOU HOW!
Alstom Solutions for Foster Wheeler Plants
Boilers | 3-27
Figure 3-19 | A Combined Circulation

tangentially ring, coal-red reheat steam generator

THE ALSTOM ADVANTAGE
5
ALSTOM HAS THE PEOPLE AND THE PRODUCTS FOR YOUR POWER PLANT
SOLUTIONS. | We know your power plant maintenance and operational needs.
Pressure Parts
Superheater Panels
Superheater or
Reheater Panels
Furnace Side Wall
Furnace Front Wall
Boiler Electronics
Coal Feeders
Pulverized-Coal
Piping to Burners
Pulverizers
Bottom Ash System
Each section that follows provides an overview of some of the products and services available for your Foster Wheeler plant.
In other words, if you generate steam to produce power or to support your manufacturing processes, Alstom is ready to
provide the products and services you need.
For more information contact your local Alstom representative.
This catalog
provides a glimpse
into what we can do
to help you operate
with improved:

Safety

Environmental compliance

Equvalent Forced Outage

Rate (EFOR)

Effciency
WORKING WITH ALSTOM IS NOT LEAVING
THE OEM, IT'S COMING TO ONE
6
Notes
MBF-type Pulverizer
15 MBF MILL PULVERIZERS
Introduction
THE MBF-TYPE PULVERIZER IS FOSTER WHEELER'S LATEST DESIGN. | This
roll and race style is the replacement for the previous MB-style design.
While the MBF was frst released in the 1970s there are a number of
sites that have converted the MB to the MBF style for the capacity and
maintenance improvements that come with the MBF. There are also a number
of locations that have hybrid MBF/MPS and MB/HP designs.
The MBF-type pulverizer grinds the coal by crushing it between the rolls and
the race as well as through attrition. The race is the segmented grinding ring,
and the rolls are the three wheel-like assemblies that pivot from spring-loaded
roller assemblies that provide the grinding force available to pulverize the coal.
The selection of the coal milling process type is based primarily on the size of the
incoming coal and the desired size, quantity and distribution of the fnal product.
The MBF-type pulverizer primarily utilizes a combination of the crushing and
attrition processes where much of the grinding action is coal-on-coal.
Size Capacity lbs/hr
MBF 18 32,300
MBF 18.5 37,500
MBF 19 43,500
MBF 19.5 50,500
MBF 20 58,600
MBF 20.5 67,900
MBF 21 78,700
MBF 21.5 91,300
MBF 22 106,000
MBF 22.5 122,000
MBF 23 142,000
MBF 23.5 165,000
MBF 24 191,000
MBF 24.5 222,000
MBF 25 258,000
OFFERINGS:
Repairs and Rebuilds
MBF Replacement Parts Inventory
Complete Roller Assemblies
Advanced Static Classifiers
Inventory Management Program
Technical Services
Installation
7
MBF-type Pulverizer-Replacement Parts
Pivot Bracket Assembly
16
MBF-TYPE PULVERIZERS
8
17
MBF-TYPE PULVERIZERS
MBF-type Pulverizer-Replacement Parts
Pivot Bracket Assembly
Item Item Description Alstom Part No.
PIVOT BRACKET W/TAB
PIVOT SHAFT
TAPER PIN
TAPERED SLEEVE
ECCENTRIC ASSEMBLY FREE END
ECCENTRIC ASSEMBLY
THRUST RING
SEAL
THRUST RING - RETAINING
COAL SHIELD BRACKET
COAL SHIELD
ROLL AIR SEAL CHAMBER
SPRING PAD ASSEMBLY
SPRING PAD - SHIM SET
WASHER - PLAIN
NUT- HEX
SCR - CAP HEX SOC HD
CAP HEX SOC HD
LH SCR - CAP HEX HD
WASHER - HARD PLAIN
BOLT HEAD PROTECTOR
WASHER - LOCK REG SPG
NUT - HEX
SCR - CAP HEX SOC HD
SCR - CAP HEX HD
WASHER - PLAIN
SCR - CAP HEX HD
NUT - HEX
SCR - CAP HEX HD
LOCTITE MOLY PASTE
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
GP-17265-A
GP-17414
GP-17268
GP-17269
GP-17424
GP-17425
GP-17468
V00-7272
GP-17469
GP-17467
GP-16566
GP-17292
GP-17293
GP-17294
MD8-0021-AC
11-2001
13-4274
V00-7278
MD8-00053-LH
MD8-00058-BU
GP-12170
15-2007
11-2000
13-4174
MD8-00053-NK
MD8-00218-BW
MD8-00053-VK
11-2002
MD8-00094-KH
V00-7280

9
Roller Assembly
MBF-type Pulverizer-Replacement Parts MBF-type Pulverizer-Replacement Parts
Roller Assembly
18
MBF-TYPE PULVERIZERS
18
35
40
50
60
45
55
110
105
15
70
75
30
25
20
10
85
100/
95
115/
120
130/
125
115/
120
80
5
65
10
19
MBF-TYPE PULVERIZERS
Roller Assembly
MBF-type Pulverizer-Replacement Parts
Item Item Description Alstom Part No. Comments
Roller Assembly Shaft
Hub for Tire Roller
Roller Tire
Seal Assembly
Oil Seal
O-Ring
Roll Seal Sleeve
O-Ring 14"OD x .25" Cross Viton
Cylindrical Bearing
Roll Bearing Spacer - INNER
Roll Bearing Spacer - OUTER
Spherical Bearing
Roll Bearing Retainer
O-Ring 21.5"OD X .25" Cross Viton
Bearing Cover
Roller Clamp Ring
Plug-Sq. HD Solid 1.25
Vent Valve
SCR-SET HEX KHL CUP .312" X 1.50"L
SCR-CAP HEX SOC HD 1.5-6 X 23"
SCR-CAP HEX HD 1.5" X 5"L
Lock Washer Hi-Collar 1.5"
Plug-Sq. HD Solid 1.5
SCR-SET HEX SOC FLT PT 1.13 X 1.25
SCR-CAP HEX HD 1.5" X 4"L
Washer Plain Type B 1.5"
7/8" HEX HD CAP SCR - Magnetic Plug
Crush Washer
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
MBF-23-1514
MBF-23-1512 / GP-17297
GP-9471-B
MBF-23-1540
V00-6217
V00-5577
MBF-23-1546
V00-6219
MP-10658 / V00-7154
MBF-23-1515
MBF-23-1516
GP-10738 / V00-7029
MBF-23-1521
V00-6220
MBF-23-1513
MBF-23-1525
12-6006
0352315
MD8-00082-HK
V00-5821
MD8-00092-YP
MD8-00017-AC
12-6007
V00-5822
MD8-00053-4871
MD8-00218-DA
MBF-8004099
MBF-8000181
2 Req. per assembly
2 Req. per assembly
6 Req. per assembly
3 Req. per assembly
3 Req. per assembly
3 Req. per assembly
3 Req. per assembly
14 Req. per assembly
14 Req. per assembly
3 Req. per assembly
3 Req. per assembly
MBF-type Pulverizer-Replacement Parts
Roller Assembly
11
Asset Planning
MBF-type Pulverizer MBF-type Pulverizer
Asset Planning
20
MBF-TYPE PULVERIZERS
Asset Planner
Intent:
To assist clients with identifying areas for improving operation and reducing mill maintenance and mobilization costs.
Purpose:
Provides the client with a method of identifying specifc maintenance or wear areas within the mill. Once identifed, Alstom can offer
assistance in providing upgraded materials or products to extend wear life in those areas.
How Used:
Use this worksheet as an outage planning tool and to document wear and areas for improvement. The worksheet can be used by the
client during mill outage inspections to document specifc problems or wear areas.
With the assistance of an Alstom Technical Services Engineer, adverse conditions in operation or adjustments in the mill can be
addressed. If the results require an upgrade, products can be offered to improve those areas.
10. Pivot bracket
2. Center feed pipe
11. Plunger shims
3. Classifer drum
12. Coal shield
4. Classifer blade and
linkage
13. Grinding table
segments
5. Classifer cone
14. Air ports
6. Classifer reject housing
15. Scrapers
7. Grinding section
housing liners
16. Air Seal
8. Spring
mechanism
17. Coal reject chute
doors
9. Roller
18. Speed reducer
1. Burner shut-off damper
18
12
21
MBF-TYPE PULVERIZERS
Asset Planning
MBF-type Pulverizer MBF-type Pulverizer
Asset Planning
21
MBF-TYPE PULVERIZERS
Asset Planning
MBF-type Pulverizer
18. Speed reducer
21
MBF-TYPE PULVERIZERS
Asset Planning
MBF-type Pulverizer
18. Speed reducer
R081507
Parts Description As Found Life Cycle Years Suggested Upgrade
ASSET PLANNING AND LIFE CYCLE WORKSHEET
MPS89 Pulverizer
Burner Shut-off Damper
Center Feed Pipe
Classifier Drum
Classifier Blade and Linkage
Classifier Cone
Classifier Reject Housing
Griding Section Housing Liners
Spring Mechanism
Rollers
Pivot Bracket
Plunger Shims
Coal Shield
Grinding Table Segments
Airports
Scrapers
Air Seal
Coal Reject Chute Doors
Speed Reducer
Pressure Spring
Spring Frame
Flexible Seal Air Supply Pipe
Top Housing
Swing Valve
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Fuel Delivery System Asset Planning and Life Cycle Worksheet
Pulverizer Overhaul Frequency
MAINTENANCE
PERFORMANCE
Type (Wear Parts,
major, gearbox,....) Current Goal
Pulverizer Fineness
% Retained on 50 Mesh
% Through 200 Mesh
Current Design Goal
< 1%
Current Design Goal
70%
Pulverizer Coal Flow
Tonnage or lbs/hr
Current Design Size
118
89
75
210,000 LB/HR
124,000 LB/HR
80,000 LB/HR
Goal
Current Design Analysis
% VM
% FC
% Ash
% Sulfur
% Moist
% Carbon
% H
2
% O
2
HHV
Grindability
Goal
Fuel Specifications
1 2 3 4 5
1 2
4
5
3
9
10
11
17
15
6
8
12
13
14
22
21
19
20
23
18
16
7
21
MBF-TYPE PULVERIZERS
Asset Planning
MBF-type Pulverizer
18. Speed reducer
R081507
Parts Description As Found Life Cycle Years Suggested Upgrade
ASSET PLANNING AND LIFE CYCLE WORKSHEET
MPS89 Pulverizer
Burner Shut-off Damper
Center Feed Pipe
Classifier Drum
Classifier Blade and Linkage
Classifier Cone
Classifier Reject Housing
Griding Section Housing Liners
Spring Mechanism
Rollers
Pivot Bracket
Plunger Shims
Coal Shield
Grinding Table Segments
Airports
Scrapers
Air Seal
Coal Reject Chute Doors
Speed Reducer
Pressure Spring
Spring Frame
Flexible Seal Air Supply Pipe
Top Housing
Swing Valve
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Fuel Delivery System Asset Planning and Life Cycle Worksheet
Pulverizer Overhaul Frequency
MAINTENANCE
PERFORMANCE
Type (Wear Parts,
major, gearbox,....) Current Goal
Pulverizer Fineness
% Retained on 50 Mesh
% Through 200 Mesh
Current Design Goal
< 1%
Current Design Goal
70%
Pulverizer Coal Flow
Tonnage or lbs/hr
Current Design Size
118
89
75
210,000 LB/HR
124,000 LB/HR
80,000 LB/HR
Goal
Current Design Analysis
% VM
% FC
% Ash
% Sulfur
% Moist
% Carbon
% H
2
% O
2
HHV
Grindability
Goal
Fuel Specifications
1 2 3 4 5
1 2
4
5
3
9
10
11
17
15
6
8
12
13
14
22
21
19
20
23
18
16
7
Asset Planner Asset Planner
13
CROWN Plus Wear Resistant Material
MBF-type Pulverizer Upgrades MBF-type Pulverizer Materials
22
MBF-TYPE PULVERIZERS
CAST STEEL
Cast steel components can be repaired much more reliably than cast iron.
Alstom offers many of the key MBF components as a Cast Steel part.

Roller Hub

Pivot Bracket
CERAMIC
Ceramic Lining and Vacuum Bonded Liners
The use of ceramic lining is best for high erosion, low impact locations. Alstom offers the most comprehensive wear solutions for all
wear issues.

Vacuum Bonded Tiles
Thin Dynawear II ceramic tiles are bonded directly to
the component. This is especially useful where space or
component size doesnt allow thick tile. This arrangement is
impact resistant, but limited to moderate temperatures.
1/4 Vacuum bonded tiles
Simple or complex geometry
Many standard offerings available

Brazed Tungsten Carbide
Very high wear resistance and excellent impact resistance.
More expensive than the ceramic options and used in
specialized locations.

Plug Welded Tile
This is most common ceramic application. Used in cones,
wall liners and turrets.
ROLLER HUB
PIVOT BRACKET
14 14
23
MBF-TYPE PULVERIZERS
CROWN Plus Wear Resistant Material
MBF-type Pulverizer Upgrades MBF-type Pulverizer Materials
LABORATORY TEST RESULTS
FIELD TEST RESULTS
CROWN PLUS IS AN ALSTOM-PROPRIETARY MATERIAL THAT HAS DEMONSTRATED
EXTENDED WEAR LIFE WHEN COMPARED TO CURRENT WHITE IRON PRODUCTS. |
CROWN Plus wear resistant material for upper millside liners has been proved to offer the best
performance-to-cost ratio and the best value.
Although Alstom has solutions that extend roller life, extending time between overhauls is
limited by abrasion in the upper millside area. Ductility is also an issue because these liners
are near the grinding zone. During development, Alstom tested its new CROWN Plus upper
millside liners against CROWN 700 liners at three host sites that were burning high silica
or PRB coals, both of which display signifcant wear rates. The host sites using CROWN
700 liners had a service life of less than 12 months with the high silica coal, and less than 14
months with PRB coal. The abrasiveness of the coal wore completely through the 3/4 thick CROWN 700 liner, while the CROWN
Plus material exhibited only 1/8 to 1/4 wear at approximately the same run time.
The charts below demonstrate that, in both laboratory and host test sites, CROWN Plus upper millside liners have a longer wear life
than other castings.
BENEFITS:

Longer wear life

Extended time between
overhauls

Best wear available for a
casting
GOOD CROWN 700
BETTER High Chrome
BEST CROWN Plus
Host
Fuel
Traditional Traditional Crown Plus CROWN Plus
Site Alloy Component Life Predicted Life Performance Factor
A PRB CROWN 700 18 months 51 months 2.8 x
B PRB CROWN 700 18 months 33 months 1.8 x

C High Silica
CROWN 700
12 months 84 months 7.0 x
& High Chrome

Alloy Abrasion Wt. Loss Cavitation Wt. Loss
Expected Life Compared
to CROWN 700
CROWN 700 36.6 10.3 1.0 x
High Chrome 25.7 2.4 1.4 x
CROWN Plus 6.4 2.4 5.7 x
Weight loss in milligrams
15 15
24
MBF-TYPE PULVERIZERS
MBF-type Pulverizer Upgrades
Advanced Static Classifer (ASC)
ALSTOM HAS APPLIED OUR SUCCESSFUL CE/ALSTOM DESIGNS TO IMPROVE THE
PERFORMANCE OF THE MBF MILL. | The inverted cone in the classifer eliminates the
discharge doors, which can become stuck open. This results in an increase of coal passing
thru the 50 mesh screen.
Curved blades reduce turbulence and aid coal distribution in the classifer drum.
Improvements can be maximized if the ASC is paired with Alstom's rotating air ports.
Eliminates Design Issues with OEM Internal Linkage

No more binding

Reduced blade misalignment

No interruption of coal/air entering classifer

No more classifer linkage wear
Externally Adjustable

Accurate adjustments can be made during operation
Standard FW Blades (Optional)

High Chrome blades also offered
16
MBF-type Pulverizer Upgrades
25
MBF-TYPE PULVERIZERS
Air Seal Upgrade

Reduces dust leakage around mill bottom
8 segments instead of 2
Upper air seal has new dust guard
Increased seal count

Easy maintenance
Drill template included
Designed to clamp onto table
Holes are slotted to aid adjustment
Advanced Static Classifer (ASC)
Triple Lip Seal
BEARINGS OFTEN FAIL DUE TO OIL CONTAMINATION. |
The Triple Lip Seal upgrade reduces contamination. Two seals
keep the dirt out, while one seal keeps oil in.

Reduces downtime due to roller assembly failures

No permanent modifcation to roller assembly necessary
Triple Lip Seal
Air Seal Upgrade
Weld Overlay on High Chrome Rollers
ALSTOM APPLIES A WELD OVERLAY ON HIGH CHROME ROLLERS FOR
INSTALLATIONS SUBJECT TO EXTREMELY SEVERE WEAR. | The overlay,
which contains a high proportion of chromium carbides, is applied using an
automated open arc welding process. The result is an overlay formed with a
tough erosion-resistant matrix.
17
MBF-type Pulverizer
26
MBF-TYPE PULVERIZERS
COAL SHIELD

Long wear
Bolt head protectors
Multiple wear material options
PLUNGER SHIM

Easier maintenance
Replaceable & adjustable
BRONZE ECCENTRIC BEARING

Easier maintenance and adjustment
Does not freeze in place
Self-lubricated with graphite
Upgrades
Plunger Shims
Coal Shield
Eccentric Bearing
18
27
MBF-TYPE PULVERIZERS
MBF-type Pulverizer Rebuilds
Roller Assembly Rebuilds Upgrades
Alstom offers high quality MBF-type roller rebuilds and new roller assemblies.
Based on inspection, additional services can include:

Replace all worn out parts

Repair components as needed

Rebuild to strict procedures and tolerances

Include upgrades upon customer request

Pressure test
Gearbox Rebuilds
THE MBF-TYPE GEARBOX IS A WELL-DESIGNED AND BUILT MACHINE. IT CAN PROVIDE LONG, RELIABLE SERVICE
WHEN PROPERLY ASSEMBLED AND MAINTAINED. | After 20 years or more of service, a rebuild or replacement may be
needed to maintain reliability. Alstom can rebuild a gearbox and return it in as-new condition.
Based on inspection, additional services can include:

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

Rebuild to as-new conditions

Rental agreements

Purchase options
19
28
MBF-TYPE PULVERIZERS
Notes
Weld overlay process.
20
Coal Feeders
7 STOCK COAL FEEDERS
AS THE ALTERNATIVE OEM FOR STOCK

FEEDER PARTS | the Alstom/Merrick team is well positioned to

support your need to improve performance, availability and reliability.
Any of the parts described in the following pages can be supplied individually, as part of a kit, or included in an
Inventory Management Program (IMP).
Replacement Parts and Upgrades
IMPROVING PERFORMANCE, AVAILABILITY
AND RELIABILITY OF COAL FEEDERS
21
8 COAL FEEDERS
Coal Feeders Replacement Parts
Alstom Products for STOCK Coal Feeders
Replacement parts
for most model
STOCK feeders:

Fast delivery

Competitive pricing

Outage kits/Inventory
programs
22
9 STOCK COAL FEEDERS
Coal Feeders Upgrades
Main Drive Upgrade
THE MAIN DRIVE UPGRADE | is an economical replacement for the outdated eddy
current clutch/torque limiter clutch and motor system and the leaky gearbox. It
improves the reliability and performance of the feeder, as well as corrects an inherent
designed-in oil leak problem that can pose a safety risk. This system was designed to
be integrated, allowing you to keep the majority of your existing spare parts inventory.
The Variable Frequency Drive (VFD) allows for increases in capacity at no additional
cost by a simple programming change.
The Main Drive
Upgrade
Components:

Direct drive Sumitomo
reducer with adapter

A/C inverter duty motor

Variable Frequency Drive
(VFD) for control of
motor speed

Speed encoder
ADVANTAGES:

Eliminates inherent oil
leaks

More accurate control with
easy adjustment

Minimizes changes

Maximizes use of
existing parts
The main drive upgrade eliminates oil leaks while providing
an accurate linear signal which can be easily reprogrammed to
accommodate changes in capacity.
Photo showing signs of chronic oil leak
problems with the main drive system.
BENEFITS:

Reduces maintenance costs

Lowers cost of operation

Improves safety (no oil
leaks)

Improves parts availability

Facilitates wider fuel use

Improves reliability

Reprogrammable at no cost

Low conversion cost
23
10 COAL FEEDERS
Coal Feeders Upgrades
Cleanout Drive Upgrade
THE CLEANOUT DRIVE UPGRADE INCLUDES AN ELECTRONIC SHEAR PIN RELAY WITH
OUTPUT CONTACT. | The electronic shear pin is easily calibrated for the motor current
overload. The instant that a current overload condition occurs the shear pin will trip, which
will stop the drag chain drive motor. It will also close the auxiliary contact, which can be
connected to the boiler control system to let the
operator know that the drag chain has stopped
due to an overload. The shear pin can be easily
reset by pushing the reset button, once the
condition has been cleared. The existing system
typically does not provide this type of electronic
failure indication.
New Alstom upgrade. Electronic shear pin or shock relay offers excellent protection against
feeder overload.
Cleanout Drive
Upgrade
Components

Direct drive Sumitomo
reducer with adapter

A/C constant speed motor

Electronic shear pin relay
Dirty Installation: Shows signs of leaking
which is not only a maintenance problem,
but a safety hazard.
Cleanout Drive
Feature / Function
Advantages Benefits to User
Constant speed motor
replaces cleanout drive
either LH or RH
Eliminates inherent oil leak Reduces maintenance costs
Lowers cost of operation
Improves safety
Improves parts availability
Interfaces with all
existing internal
components
Minimizes changes Keeps maintenance costs low
Low conversion cost
Adaptable to existing equipment
Includes electronic shear
pin relay
Better protection from overload
than torque-limiting clutch
Lower maintenance costs
Improves availability
24
11 STOCK COAL FEEDERS
Coal Feeders Upgrades
GENETIX

Touch Screen Controller

THE GENETIX TOUCH SCREEN CONTROLLER IS THE WORLDS FIRST TOUCH SCREEN PROCESS CONTROLLER
SPECIFICALLY DESIGNED FOR WEIGHING APPLICATIONS. | It replaces most conventional gravimetric relay control
systems and will ensure that the coal feeding process is consistently accurate, reliable and repeatable.
The GENETIX Process Controller can be confgured for virtually all feeding requirements including:

Gravimetric control for feeder systems

Static weighing and belt scale integrators

Continuous or batching belt feeders

Feature / Function Advantages Benefits to User
User friendly interface
On screen help
Built in simulator
Function key
validation
Easy to learn
Easy to use
Lower cost for training
Reduction in programming errors
Lower cost of operation
Improves reliability
Easy to use
Integrated electronics
package
Reduction of failure-
prone components
Elimination of relays
Reduces maintenance
Improves reliability
Improves accuracy
Sensor monitor and
graphic trending
Well organized
More detailed
information available
Improves availability
Reduces maintenance costs
Data highway
capable
Simpler interface
to plant control
system with
standard protocols
Lower cost installation
Low cost integration in any boiler control
system or DCS
Critical component
redundancy
Better fault
tolerance
Less down time
25
12 COAL FEEDERS
Coal Feeders Upgrades
Weigh Suspension System Upgrade for Belt Feeders
OUR WEIGH SUSPENSION SYSTEM UPGRADE WITH LOAD CELL AND
ADJUSTABLE IDLER BRACKET, | which is used in conjunction with a Merrick or
STOCK microprocessor, provides an accurate, calibrated fuel delivery measurement
to the boiler. The adjustable idler bracket uses the existing weigh roller that can be
removed easily without the use of tools.
ADVANTAGES:

Electronic load cell replaces
mechanical system

Improves accuracy for a
more repeatable signal

Simple design

Microprocessor adjusts the
speed of the belt based on
load of material
BENEFITS:

Reduces maintenance costs

Improves effciency with
tighter control

Improves reliability
SIMPLE WAY TO
IMPROVE RELIABILITY
Weigh Suspension System
26
13 STOCK COAL FEEDERS
Coal Feeders Upgrades
Roller Belt Support Assembly
THE ROLLER BELT SUPPORT ASSEMBLY IS AN ALSTOM UPGRADE TO THE SLIDER-
BED BELT SUPPORT ON SELECTED STOCK COAL FEEDERS. | The roller system is
designed for less friction and resulting wear of the feeder belt.
No physical or hardware changes are required to install the roller belt support assembly.
ADVANTAGES:

Eliminates wear to the coal
feeder belt

Less horsepower required
to move the feeder belt

Enables faster calibration of
coal feeder

Rollers can be replaced
without disassembly of
the tail end of the coal
feeder and removal of
the belt
BENEFITS:

Improves reliability

Reduces operational cost

Improves availability
YEARS OF TROUBLE FREE SERVICE
Roller Belt Support Assembly
27
14 STOCK COAL FEEDERS
Notes
COAL FEEDERS
28
Notes
Boiler Electronics
29
BOILER ELECTRONICS
Pipe Igniters
THE EVER-KOOL OIL PIPE IGNITER IS AN ALTERNATIVE TO RETRACTABLE OIL GUN
DESIGNS. | A constant supply of strategically located cooling air allows the oil fring equipment
to stay in fring position even when not in use. Only the spark tip inserts during operation and
subsequently retracts from the fame to keep it cool. The igniter has a smaller footprint and is
always in fring position.
BENEFITS:

Consistently demonstrates
over 95% reliability

Improved combustion
airfow

Lower pressure drop

Easy installation and
maintenance

Offers clean and reliable
operation with minimal
opacity during start ups

Easy retroft with existing
igniter system hardware

New bluff body design
provides improved fame
stability

High Energy Igniter (HEI)
THE LIMELIGHT GAS BLUFF BODY PIPE IGNITER IS AN UPGRADE | to conventional 3 eddy
plate gas pipe igniters and provides increased availability. This high heat output igniter is useful
in a wide range of applications. It offers a clean and effcient method for boiler warm-up and
fame stabilization periods.
STABLE FLAME/WIDE RANGE
Capacity from 0.5 18.0 MMBtu/hr
LIMELIGHT Gas Bluff Body Pipe Igniters
Control Cabinets
30
BOILER ELECTRONICS
LIMELIGHT Igniter Valve Train Assemblies
Boiler Electronics
Gas Valve Train
Oil Valve Train
FEATURES:

Oil train includes air pressure
regulator, oil fow controller
and single actuator
automatic trip valve for both
oil and atomizing air

Valve, actuator, and limit
switch enclosure designed
as a unit

Gas train includes double
block and vent valve
arrangement and globe
valve for gas fow regulation

Designed for a wide range of
heat input capacities

Compatible with our
LIMELIGHT igniter control
cabinet

Fuel/air strainer and flter
option available
SAFETY SHUTOFF VALVES ARE PROVIDED IN CONVENIENT PRE-ASSEMBLED
PACKAGES AND ARE IDEAL FOR HANDLING OIL AND GAS FIRING EQUIPMENT. |
Alstom provides fail-safe valves as they close with loss of electrical power (deenergize-
to-trip) or instrument air. Energize-to-trip valves can be provided if preferred.

BENEFITS:

In-kind replacement for
old or obsolete equipment

Easy maintenance

Easy installation

Code compliance
31
BOILER ELECTRONICS
Control Cabinets
Boiler Electronics
THE LIMELIGHT IGNITER CONTROL CABINET IS AN IGNITION SUPERVISION AND
SAFETY SYSTEM DESIGNED FOR CONSISTENT OPERATION. | It can be used for oil, gas
and dual fuel igniters in Utility, Pulp and Paper and Industrial environments.
Flexible by design, the LIMELIGHT Igniter Control Cabinet can be custom built or supplied in
a standard confguration.
Alstom offers its control cabinet as a stand-alone product or packaged with an upgraded
Alstom valve train. A control cabinet is available for virtually all valve trains, including:

Tandem oil/air valve isolation for oil igniters

Double block and vent isolation for gas igniters
The LIMELIGHT Igniter Control Cabinet is designed to provide self-diagnostics and
troubleshooting capabilities.
A window kit allows the displays of the LIMELIGHT fame monitor to be visible at a glance.
BENEFITS:

Safely and reliably controls
igniter operation

Meets NFPA and CGA
codes

Self diagnostics and
troubleshooting

Suitable for interface
with existing burner
management systems

Consistent operation

Reduces start-up period
FEATURES:

Standard NEMA 4 or 4X in
a 16W x 20H x 6D sized
enclosure

Simple connection to
new or existing burner
management system

Functionality can be
hardwired relays or PLC
based

First-out igniter trip
alarms available

Incorporates latest design
LIMELIGHT Diagnostic
Flame Indicator (DFI)
LIMELIGHT Igniter Valve Train Assemblies
LIMELIGHT

Coal Flow Monitor

32
BOILER ELECTRONICS
LIMELIGHT Flame Scanners
Boiler Electronics
FLAME SCANNERS CONFIRM THAT FUEL ENTERING THE FURNACE IS IGNITING. | Unignited fuel entering the furnace could
cause an explosion. An essential element of a boilers safety system, fame scanners must be both rugged and reliable while
providing consistent and accurate fame safety information.

The LIMELIGHT Flame Spectrometer is an advanced fame detector
with enhanced diagnostic capability.
Our new LIMELIGHT Flame Spectrometer
incorporates the speed and precision of digital
signal processing as well as full detection of
infrared, visible and UV light in seven bands,
making it the most fexible fame scanner available
and most suitable for burner optimization.
INCREASED SAFETY
BENEFITS:

Superior fame detection,
reduced nuisance trips and
increased sensitivity for
low load operation

Reduced cost of
installation - compatible
with previously installed
fame scanners, cable and
guidepipes

Reduces CapEx

Reduces maintenance
costs
The LIMELIGHT Exacta Flame Scanner is a simple replacement for
several generations of older scanners.
The LIMELIGHT Exacta Flame Scanner continues that legacy while incorporating the
latest in digital signal processing and communication capability. Depending on the fuel
being fred, it can be provided with fame detection technology that employs any one of
the following:

UV Ultraviolet

VL Visible Light

BR Broad Range, Infra Red and Visible Light
.
FEATURES:

Temperature rating is
165 F (75 C)

Can discriminate between
different fuels

Provides fame quality
analysis
FEATURES:

Temperature rating is
185 F (85 C)

Can discriminate between
different fuels

4 contact and 2 analog
outputs per channel
33
BOILER ELECTRONICS
LIMELIGHT

Coal Flow Monitor

Boiler Electronics
LIMELIGHT Coal Flow Monitor Sensor Head and electronics enclosure
Application: Used to monitor fow exiting the feeder
THE LIMELIGHT COAL FLOW MONITOR IS A HIGH QUALITY, INDUSTRIAL GRADE
INSTRUMENT | capable of providing a signal indicating fow of coal in gravity chutes
and feeders.
The Alstom instrument is a non-contact detector. It has no moving parts or probes
that can degrade or break off in the coal fow.
The LIMELIGHT Coal Flow Monitor utilizes a low power microwave beam to sense
motion within the chute or channel. The microwave technology is unaffected by heat,
humidity, ambient noise or light, pressure, vacuum, high or low temperatures, or dust;
thus providing maximum reliability.
ADVANTAGES:
Improves sensitivity
and more reliable coal
detection
Senses small and large
particles of varying
densities
Eliminates the sound rod
Self-calibrating
BENEFITS:

Improves reliability

Reduces maintenance
costs

Quicker start-ups

Reduces installation
time by 50%
RELIABLE SOLUTION TO COAL FLOW
MONITORING FOR FEEDER OUTLET
LIMELIGHT Flame Scanners
34
BOILER ELECTRONICS
Boiler Electronics
EVER-KOOL Oil Gun and Spray Tips
ALSTOMS NON-RETRACTING EVER-KOOL OIL GUN ELIMINATES RETRACT
MECHANISMS AND THEIR ASSOCIATED HARDWARE AND MAINTENANCE. |
The EVER-KOOL air-cooled design allows the oil gun to remain inserted in the fring
position when not in use without damage. This high performance oil gun meets all
current safety and code requirements and is an excellent alternative to traditional
retractable systems.
Internal Mix Tips
For parallel pipe or concentric style oil guns
Improves atomization for problem fuels
Accommodates a wide range of steam quality
External Mix Tips
For parallel pipe or concentric style oil guns
Reduces steam/air consumption
No pressure differential regulator required
No tip resizing required when changing atomization
medium or fuel
FEATURES:

Ready for immediate service

No moving parts retract
mechanism not required
BENEFITS:

Reduced coking of any
remaining oil after purging

Reduced maintenance

Improved light-off reliability

Safer than retractable
oil guns

Reduced opacity
APPLICATIONS:

Utility, industrial, pulp and
paper boilers
EVER-KOOL Oil Gun Flame
30 MMBtu/hr and up
NO MOVING PARTS
REDUCED MAINTENANCE
35
BOILER ELECTRONICS
Boiler Electronics
THE BOILER DATA ADVISOR CAN PREDICT | equipment failures and detect excursions from
normal plant operating conditions hours or even days before a conventional Distributed
Control System (DCS) can trigger alerts. The Boiler Data Advisor provides the deepest
insight into plant performance, quickly and accurately locating the source of impending
failures.
The BDA provides engineers, plant operators and maintenance personnel the time to take
preventive action, avoiding costly downtime, equipment damage, or reduced effciency.
BENEFITS:

Increased proftability
early fault detection leads
to increased availability,
reduction of forced outages,
and mitigation of collateral
damage

Higher performance
patented methods provide
the earliest warning about
operational abnormalities

Fewer unplanned outages
facilitates better preventive
maintenance decisions
The Boiler Data Advisor is a condition monitor that helps power plants
reach higher levels of availability and predictive maintenance as well
as better performance.
Boiler Data Advisor (BDA) EVER-KOOL Oil Gun and Spray Tips
36
BOILER ELECTRONICS
Notes
Boiler Fabrications
37
BURNER FABRICATIONS
Boiler Access and Observation Doors
Oval Hinged Access Door Specialty Access Doors:
CUSTOMIZED WITH
OBSERVATION
& LANCING PORTS
FEATURES:

Door liner refractory
suitable for high
temperature applications

Built-in grab bar for
entering and exiting

Standard sizes and shapes
that ft most applications

Custom designs for
specialized applications

1 x 1 gasket

Tube opening confgured
to provide additional
cooling

Can include Pressure
Parts for turnkey
solutions
BENEFITS:

Improved reliability
and combustion cycle
effciency with less air
leakage

Corrosion resistant

Improved safety
SAFE AND SECURE. | All Alstom boiler access doors are designed and fabricated to prevent accidental
latching and unlatching. The positive seal and gas-tight design eliminates leakage and ensures optimal
thermal performance as well as personnel safety. Prior to shipping, all Alstom boiler access doors
are fully assembled and tested in the shop in the vertical upright position to ensure the door opens
smoothly and freely.
Discharge Valves
QUICKCHANGE Orifce Assembly
38
BURNER FABRICATIONS
Boiler Fabrications Replacement Parts
Fuel Delivery System
Coal Piping
THE FUEL DELIVERY SYSTEM BETWEEN THE PULVERIZER AND THE BURNERS IS AN AREA SUBJECT TO EXTREME WEAR. |
This is particularly true of elbows and orifce assemblies. The fuel delivery system includes:

Coal pipe

Discharge Valve

Orifce
Alstom offers coal pipe, hangers and orifce assemblies designed for long life in this diffcult environment. Alstoms design takes
into account the newest NFPA code requirements with components designed to protect your equipment and, more importantly,
your people. NFPA code says, in part, Brittle materials having a plastic elongation of less than eight percent (8%) prior to tensile
rupture shall not be used for piping except as abrasion-resistant lining.
Types of Fuel Piping
Original Installation
Cast ductile iron
Ni-Hard (reference Alstom SIL 2004-01)
Carbon steel, induction bent
Replacement types
Cast ductile iron
Carbon steel, induction bent
Ceramic lined
Mechanically interlocked (DYNAWEAR)
Vacuum bonded (DYNAWEAR II)
Excessive wear problems in coal piping can be mitigated through the use of
high-wear liner materials such as DYNAWEAR or DYNAWEAR II Wear
Resistant Products .
This Ni-Hard elbow was doused with cold water while on
fre. Dangerous pipe blow-outs, like this one, can be avoided
by using proper pipe and liner materials, and by following
approved safety protocols.
DYNAWEAR II Vacuum-Bonded Ceramic Tiles installed
in the outer radius of the elbow provides protection to the
highest wear area of the pipe. Note that the non high-
wear areas inside the pipe do not need to be lined.
DYNAWEAR Ceramic-lined Elbow showing angled
defector block installed at highest wear point in
outer radius.
Defector
Block
39
BURNER FABRICATIONS
Boiler Fabrications Replacement Parts
Discharge Valves
QUICKCHANGE Orifce Assembly
DISCHARGE VALVES ARE USED TO ISOLATE
THE PULVERIZER FROM THE FURNACE. | Older
power plant fuel delivery systems may not have
discharge valves in place. However, due to safety
concerns, they are now a required part of the
design per NFPA Code.
Discharge valves, when properly installed, provide
a level of safety and allow mill maintenance to be
performed without major disruptions to furnace
operations.
THE UNIQUE DESIGN OF THE QUICKCHANGE ORIFICE ASSEMBLY SAVES TIME
ASSOCIATED WITH REPLACING COAL PIPE ORIFICES WHILE ALLOWING THE USE
OF ORIFICES MADE OF WEAR-RESISTANT MATERIALS. | The QUICKCHANGE Orifce
simplifes the replacement by accommodating orifces of varying inside diameters and
materials. It consists of a drawer-style housing which, when unbolted, can be pulled out
with the boiler on-line (but with the pulverizer out of service and the associated barrier
valves closed at the windbox) for fast, easy access and replacement.
* The NFPA Code requires the use of two valves per burner line a barrier or dust tight
valve at the pulverizer end, and a dust tight valve at the furnace end. Discharge valves must
be ftted as close to the pulverizer and furnace portals as possible.
BENEFITS:

Pull-out design reduces
orifce replacement time

Visual inspection made
easier

Can accommodate orifces
made of various wear-
resistant materials

Fast, easy orifce
replacement with boiler
on-line and pulverizer out
of service
Fuel Delivery System
Coal Piping
Burners New and Rebuilt
40
BURNER FABRICATIONS
Coal Delivery System Rebuilds
Boiler Fabrications Rebuilds
BURNER SLIDE GATE REBUILDS. | Alstom offers the parts and services to rebuild existing
Burner Slide Gate Assemblies.
A great candidate for Rebuild Rotation Programs, Alstom can rebuild a set of Burner Slide
Gates and store them at one of our regional service centers to support planned outages or
emergency requirements. Alstom offers this service in an effort to provide a cost savings
to the customer versus the purchase of a new component.
Rebuild Scope
Basic Services

Receive

Disassemble

Evaluate condition

Replace worn components as necessary

Add or replace wear materials

Reassemble

Paint & ship
Before After
BENEFITS:

Approximately 50% cost of
new assembly

Short lead times

Upgraded materials
available

New equipment warranty
41
BURNER FABRICATIONS
Burners New and Rebuilt
Boiler Fabrications New and Rebuilt
Coal Delivery System Rebuilds
NEW AND REBUILD SERVICES ARE AVAILABLE FOR FOSTER WHEELER BURNERS
AND ALSTOM'S RSFC BURNERS AS A COST EFFECTIVE ALTERNATIVE TO
PURCHASING A NEW COMPONENT. | Simply crate and ship the worn burner to one
of Alstom's rebuild facilities and we will inspect and replace all worn and damaged
components and restore all welds to strict specifcations. In addition, Alstom provides
rebuild services for all OEMs' burners.
When complete, Alstom will return the rebuilt burner to you in the same shipping crate
to minimize the possibility of damage during shipment.
Rebuild Scope
Basic Services

Ship in an enclosed container to minimize
further damage

Replace missing tiles

Replace stainless shroud

Replace distorted pipes

Replace adjusting bars

Replace worn blades

Repair all welds

Paint

Ship back to customer in original shipping container
Good repair and overlay only the worn areas that were designated as being
"minimal" based on UT results
Better build up and overlay the typical high-wear areas
Best build up and overlay the entire internal surface
BENEFITS:

Burners are rebuilt to strict
specifcations

Up to a 60% savings vs. the
cost of a new burner

Fast turn around

Extensive inventory support
RSFC = Radially Stratifed Flame Core
Best Repair Option
Better Repair Option
Good Repair Option
Alstom Repair Options
42
BURNER FABRICATIONS
Notes
Pressure Parts
43
PRESSURE PARTS
Capabilities
BENEFITS:

Reduced mean time to
repair

Increased unit availability

Increased unit reliability

Improved profitability
ALSTOM HAS OVER 100 YEARS OF BOILER PRESSURE PARTS EXPERIENCE. |
We offer the products, logistics, quality and technological expertise to help keep your boiler
up and running. As a leader in coal-fired utility, marine and industrial power plants, we are
dedicated to helping our customers keep the down-time costs to a minimum while maximizing
their profits. We have the capacity and capability to back up our commitment, and we have a
proud history of achievement and innovation.
Boilers | 3-27
Figure 3-19 | A Combined Circulation

tangentially ring, coal-red reheat steam generator

Boiler Electronics
Coal Feeders
Pulverized-Coal
Piping to Burners
Pulverizers
Bottom Ash System
PRESSURE PARTS
Superheater Panels
Superheater or
Reheater Panels
Furnace Side Wall
Furnace Front Wall
44
PRESSURE PARTS
AmStar 888 Thermal Spray Cladding
Pressure PartsCoatings
AMSTAR 888 THERMAL SPRAY CLADDING PROVIDES DEPENDABLE AND
PREDICTABLE WATERWALL PROTECTION IN BOILERS WHERE HIGH
TEMPERATURE GASEOUS CORROSION AND/OR EROSION MAY OCCUR. | AmStar
888 cladding is applied using a patented alloy exclusive to Alstom. AmStar 888 has been
engineered by Alstoms Thermal Spray Division to produce mechanical and metallurgical
properties that result in lower residual stress incurred during the application process,
allowing thickness levels from 5 mils to >100 mills, where appropriate. It also eliminates
cracking and spalling.
In addition, AmStar 888 will not fail at the substrate level, allowing Alstom to refurbish
the cladding with virtually 100% success where mechanical damage has occurred. Its
erosion and corrosion properties protect against multiple metal loss mechanisms.
AmStar 888 Thermal Spray
Cladding can be applied at your
site or in one of Alstoms Regional
Service Centers. See your Alstom
representative for application
details.
FEATURES:

Will not delaminate, crack
or spall

Thicknesses from 5 mills to
> 100 mills

Defect-free substrate
coverage

Designed for maintainability
BENEFITS:

Signifcantly reduces
Equivalent Forced Outage
Rate (EFOR)

Dependable and predictable
tube protection

Quality applications
regardless of scope

Engineered solution -
recommendations are made
based on specifc problem
APPLICATIONS:

Pulverized coal boilers

Circulating fuidized bed
boilers (CFBs)

Waste to energy boilers

Black liquor recovery boilers
45
PRESSURE PARTS
Pressure Parts Locations
2 Mega Centers
ROCKY MOUNTAIN SERVICE CENTER
(RMSC) DENVER, COLORADO

Modern 100,000 square foot facility designed for efficiency

and material handling ease

Fully operational and staffed 7 days a week

On-site engineering and design graphics personnel

Emergency service on such pressure parts:

Panels Loose bent tubes
DMWs Steam/fluid-cooled spacers
Industrial superheaters Finned tubes

Quality employees = Quality products

Qualified welders
Benders with exceptional fabrication experience
Extensive layout knowledge

State-of-the-art pressure parts facility

Hot and cold bending Rotoblaster
Finning Annealing furnace
Paneling On-hand inventory
Assembly
TO IMPROVE OUR SERVICE TO OUR CUSTOMERS | and to build capacity for the future, we have invested in infrastructure
improvements at two key locations.
TUBING DISTRIBUTION CENTER
(TDC) CHATTANOOGA, TENNESSEE

100,000 square foot indoor tubing facility

24/7 emergency availability

Beveling and cut-to-length

Rotoblasting, stenciling, printing and rust inhibitors

Electronic MTRs
Chattanooga, TN (TDC)
Rocky Mountain, CO (RMSC)
AmStar 888 Thermal Spray Cladding
46
PRESSURE PARTS
Pressure Parts
Full Service Provider
ALSTOM IS A LEADING TECHNICAL SERVICES SUPPLIER. | Our industry leading
technical service teams offer a wide range of services to our pressure parts customers.
From assisting customer maintenance and operations personnel to detailed condition
assessments, our technical service teams provide the widest range of services in the
industry.
CONDITION ASSESSMENTS. | The full capabilities of Alstoms Technical Services,
Materials Technology Center and Power Plant Laboratories are brought to bear to
determine root causes of tube failures. But we go further than simple metallurgical
reports; Alstom develops detailed solutions and recommendations to prevent future
emergencies, and to improve future plant availability.
ALSTOM OUTAGE PLANNING. | A well-planned outage is critical to optimizing your
maintenance time and budget. An experienced Alstom representative, supported by
our extensive technical resources, will work with you to review your outage needs and
schedule. After this review, we can fabricate the components, stock them and then
deliver them on time.
BOILER IN A BOX. | The Alstom Outage Kit is a prepackaged collection of tubing,
parts and components that have been identified as being potentially necessary during
an outage. Each kit has a map detailing the location of each part; everything is
centralized and easy to find, including essential paperwork like mill certifications.
Parts are pulled from the box as needed, saving time and money. You pay only for
what you use.
NON-ALSTOM BRANDS | WE SERVICE THEM ALL
OTHER OEM CAPABILITIES
Alstom has the tubing and expertise to address boiler issues for Foster Wheeler boiler
designs.
Alstom maintains an ever expanding inventory of tubing sizes and specifications and
wants to work with you to evaluate your tube list and determine what is critical to your
operating needs.
OFFERINGS:

Fabrication of key pressure
parts components

Loose tubes straight or
fabricated

Waterwall and burner
panels

Assemblies and circuitry for
superheaters,
reheaters and economizers

Tube shields, attachments
and hardware

Weld and laser overlay
and thermal/abrasion
coatings for increased wear
protection

Complete boiler tubing
replacements

Convenient, one-vendor,
complete service
Ash Systems
47
ASH SYSTEMS
Integrated Bottom Ash Solutions
Plant Integration
ALSTOMS SUBMERGED SCRAPER CONVEYOR (SSC) BOTTOM ASH SOLUTION GREATLY
REDUCES MAINTENANCE COSTS | common to conventional ash handling systems. A well-engineered
SSC replaces existing systems with a cost effective and less risky bottom ash solution.
An SSC reduces environmental risks of ash ponds and the costs of permitting, maintaining and dredging
those ponds. An SSC integrated into other bottom ash systems reduces water usage by reusing most of
the bottom ash supply water. Power consumption is reduced by minimizing the number of motors
needed to power multiple high, medium and low pressure pumps used in traditional sluicing and
dewatering systems. In addition, taking pyrites and economizer ash directly into the SSC reduces the
maintenance costs associated with hoppers, piping, dewatering, and storing ash.
ADVANTAGES:

No high maintenance
boiler sluice jet systems

No dewatering tanks

No boiler to pond
piping systems

Reduced environmental
risk by eliminating the
need for ash ponds

Reduced parasitic
power consumption

Reduced water use

THE PYRITES SYSTEM | can be sluiced directly into the SSC while
at the same time using the SSCs water bath as a source for the
sluicing water. This eliminates once-through water use and the
pyrites dewatering tanks.
ECONOMIZER ASH | can be transported to the SSC on dry drag con-
veyors for removal along with the boiler bottom ash and pyrites.
A CLOSED LOOP WATER COOLING AND RECIRCULATING
SYSTEM | is an option where water consumption must be
minimized. With minimum makeup water required, the SSC
water can be cooled and recirculated requiring a minimum
amount of water across the entire ash removal process.
Full Service Provider
48
ASH SYSTEMS
Ash Systems
Wet Bottom Ash Solutions
WET BOTTOM ASH SYSTEMS, ESPECIALLY THEIR MAINTENANCE, ARE AN O&M HEADACHE. | Alstom has a suite of solutions to
improve the reliability and safety of your Wet Bottom Ash Removal system.
Gate Frames,
Renewable Seats,
Gate Liners
10" and 12" Cylinders and
Cylinder Extensions
Gate Enclosures
4" Lancing Door
Clinker Grinders Jet Pumps
Bottom Ash Gates
24" X 24" and 30" X 30"
Wet Bottom Ash Solutions
The Alstom Advantage
49
THE ALSTOM ADVANTAGE
Service Capabilities
EQUIPMENT SUPPORTED
In addition to servicing Alstom equipment, we also provide aftermarket service for the following brands:
COAL FEEDERS | ABB, Combustion
Engineering, Stock Equipment,
Merrick Industries
COAL PULVERIZERS | ABB,
Combustion Engineering,
Babcock & Wilcox, Riley,
Foster Wheeler
STEAM GENERATORS | ABB,
Combustion Engineering, Babcock &
Wilcox, Riley, and Foster Wheeler
STOKERS | ABB, Combustion
Engineering, Detroit Stoker, Riley,
Westinghouse, Hoffman, Taylor
FIRING SYSTEMS | ABB, ICL, NEI, Clark
Chapman, CSL, RV Industries, Foster
Wheeler, B&W, Combustion Engineering
ASH HANDLING SYSTEMS | ABB,
Combustion Engineering, Allen-
Sherman-Hoff, United Conveyor, Flkt
AIR POLLUTION CONTROL | ABB,
Combustion Engineering, Flkt,
Walther, Carborundum, Hamon-
Research Cottrell, Wheelabrator,
Peabody, Rockwell
OVER 100 YEARS OF EXPERIENCE + SOLUTION BASED PRODUCTS & SERVICES
+ COMMITMENT TO CUSTOMER SERVICE = THE ALSTOM ADVANTAGE. | Alstom
provides reliable delivery of products and services to meet the demands of the
power industry. We are a dedicated customer service organization that delivers the
responsiveness our customers require.
Alstom provides the quality and resources of an OEM while backing our products
with comprehensive support. Our products are designed to help our customers
meet the performance, availability and reliability requirements for their power
plant equipment.
MARKETS SERVED
Our experience and customer base include:

Utility companies

Regional electric cooperatives

Federal, municipal power producers

Independent power producers

Pulp and paper companies

Industrials such as chemical plants, steel mills and refneries

In other words, if you generate steam to produce power or to support your
manufacturing processes, Alstom is ready to provide the products and services you need.
The Alstom Advantage
50
THE ALSTOM ADVANTAGE
Service Capabilities
WE ARE A GLOBAL PROVIDER OF PRODUCTS AND SERVICES TO THE POWER
INDUSTRY. | We maintain a local presence to help ensure that our customers equipment
and systems run reliably and effciently with the availability they demand.
FIELD TECHNICAL SERVICE ENGINEERS | Alstom has extensive capabilities in the form
of Field Technical Service Engineers to assist with your outage inspection and operation and
maintenance needs.
Our feld service engineers are located near our customers to provide the response they need.
This full-time force of professionally trained engineers and technicians receive constant
training to help ensure they are knowledgeable in the latest trends and available technology.
OUTAGE PLANNING | Effective outages require effective planning, a continuous process
that begins well in advance of the scheduled event. Alstom stands ready to participate in
this process to help ensure timely decisions, problem avoidance and achieved goals.
The services Alstom provides include:

Setting overall outage objectives

Work scope determination

Prioritization of outage tasks

Identifcation of material and parts needs

Expediting delivery of required material and parts
INSPECTION SERVICE | To help ensure an effective outage, we offer our inspection service
that includes:

Pre-outage logistics and work scope defnition

Pre-outage unit walk-downs

Detailed inspections during the outage

Daily punch lists and defnition of items requiring immediate attention

Coordination with repair labor personnel

Initial report with critical fndings and recommendations

Final detailed inspection report complete with photos,
recommendations and fndings

On-line retrieval of our fnal report for convenient viewing
and downloading
Alstoms Technical
Services capabilities
cover major plant
equipment and
systems and include:

Outage planning

Inspection services

Condition assessments

Maintenance support

Performance testing

Training programs

Dedicated engineers
Alstoms Technical
Services include:

A team of over 100

feld-based service
engineers, NDE specialists,
performance test engineers
and technicians

Problem solvers

Equipment inspectors,
testers, and evaluators

Performance specialists
The Alstom Advantage
51
THE ALSTOM ADVANTAGE
The Alstom Advantage
Technical Services
CONDITION ASSESSMENT | Alstom delivers the
technology to manage risks through the integration of
Advanced NDE and inspection technology, including:

Ultrasonic examination

Linear phased array

Dye penetrant testing

Remote feld eddy current

Wet fuorescent magnetic particle testing

Boroscope with internal video

Visual examinations as well as service
capabilities through:

Power Plant Laboratory facilities

Material Technology Center

Field service engineers
MAINTENANCE SUPPORT SERVICE | To help ensure your equipment
performs to your expectations, we offer our Maintenance Support Service
whereby we:

Determine equipment condition and need for repairs

Compare components to
original specifcations and
help make adjustments

Participate in developing
work scope and associated
tasks

Direct maintenance
personnel in proper
disassembly and
assembly procedures

Coordinate execution of the
work scope

Develop a daily punch list
prioritizing work tasks

Provide a fnal report documenting work performed and
recommendations
DEDICATED ENGINEER PROGRAM | We provide an experienced Alstom Technical Services Engineer for exclusive use for a
specifc time period.
The Dedicated Engineer becomes an on-site member of the plant team, spearheading the Alstom support. The result is responsive
service in determining root causes of problems and timely development and implementation of solutions to help reach and exceed
station goals.
TRAINING PROGRAMS | Alstom's training programs provide power
plant professionals with the knowledge and skills they need to operate
and maintain the equipment and systems. Alstom's portfolio includes:

Standard and customized training

HOT TOPIC training programs

Computer-based QUICKSTUDY Learning System

Regional training seminars
PERFORMANCE TESTING AND EVALUATIONS |
The performance evaluation and testing team
supports data gathering and analysis to help optimize
plant performance. Offerings include:

Specialized testing of thermal, fuid and chemical
processes (emissions and circulation)

Boiler and power plant performance evaluation

Water chemistry consultation for boilers

Instrumentation supply and rentals of most
commonly used boiler and emissions test equipment
TECHNICAL SERVICES TAILORED FOR YOU
AND YOUR BUDGET
The Alstom Advantage
52
THE ALSTOM ADVANTAGE
Inventory Management Programs
STRATEGICALLY LOCATED
TO SERVE OUR CUSTOMERS
Denver, CO
*
Tyler, TX
*
Chattanooga, TN
*
Erlanger, KY
*
Harrisburg, PA
*
Suwanee, GA
*
ALSTOMS SERVICE CENTER
NETWORK, STRATEGICALLY LOCATED
ACROSS THE COUNTRY, | provides
emergency component repairs, parts,
complete component overhauls, custom
fabrications and cost-saving inventory
management programs to meet our
customers needs.
ROCKY MOUNTAIN SERVICE CENTER
DENVER, COLORADO
MIDWEST SERVICE CENTER
ERLANGER, KENTUCKY
ADVANTAGES:

After-hours response team

Guaranteed parts availability

Eliminates exposure to
obsolete inventory

Applicable to most plant
equipment

Programs can be expanded
to include other plants with-
in the customers system

One week standard shipment
after receipt of order

Minimizes exposure to raw
materials price fuctuations
BENEFITS:

Reduces carrying costs

Defers cash outlay

Increases cash fow by
delivering products when
needed

Simplifes purchasing
WITH OUR PROVEN INVENTORY MANAGEMENT EXPERTISE | purchasing strength
and strategically located regional service centers, participation in an Alstom Inventory
Management Program can offer customers signifcant benefts from guaranteed
shipments to improved cash fow.
IMPROVES CASH FLOW AND GUARANTEES
PARTS AVAILABILITY
The Alstom Advantage
53
THE ALSTOM ADVANTAGE
The Alstom Advantage
Outage Kits
A COST-EFFECTIVE WAY TO MANAGE PLANNED
AND UNPLANNED UNIT OUTAGE REPAIRS
OUTAGE KITS | are pre-packaged supplies of equipment-specifc replacement
parts that support planned or unexpected unit outages and rebuilds.
Emergencies cost money! Outage Kits can help minimize costly delays in
making repairs.
Outage Kits are the perfect solution when emergencies strike, or to have
available as part of a planned preventative maintenance cycle or Inventory
Management Program.
ADVANTAGES:

Custom or standard
kits

Reduces maintenance
costs

Convenient and
organized

Simplifes purchasing
BENEFITS:

Right parts available
when you need them

Only pay for the parts
that are used

Instant part availability

Save time and money
The customer and
Alstom develop a
list of parts to be
included in each kit.
Each kit includes a
detailed chart of the
location of each part.
Alstom then ships
these parts to the
customer in a
pre-packaged kit
form two weeks prior
to the planned outage
or rebuild.
Customer
withdraws parts
from the kit,
as needed.
Unused items
are shipped back
to Alstom for
re-stocking.
The customer then
issues a purchase
order to Alstom
for any parts
consumed.
HOW ALSTOMS OUTAGE KIT PROGRAM WORKS:
The Alstom Advantage
54
THE ALSTOM ADVANTAGE
APComPower
A World of Experience Right Next Door
PLANT UPGRADES/MAJOR MODIFICATIONS

Fuel conversions

Combined cycle operations

Balanced draft conversions

Emission control systems

COMPONENT INSTALLATION, REPAIR AND REPLACEMENT, BALANCE OF PLANT

Fuel fring systems

Pressure vessels

Pulverizers

HRSGs

Air heaters

Fans

Ash handling systems

Steam and gas turbines

Condensers

Fabricated steel, ducts, silos and hoppers

Burners

Insulation and lagging

Stokers

Refractory

Wet/Dry precipitators

Instrumentation and controls

Wet/Dry scrubbers

Stacks

Fabric flters

Foundations

SCRs

Pressure Parts

Piping
Proven Expertise
in the Latest
Technologies:
As a wholly-owned subsidiary
of a global leader in power
generation equipment,
APComPower has in-depth
experience in:

Coal, gas and oil-fred utility

plants

Industrial plants (including

pulp and paper mills,
petrochemical systems
and municipal power
operations)

Steam and gas turbines

HRSGs

Fluidized bed boilers

Emission control systems

(all types including wet and
dry FGD and SCR systems)
Most recently, APComPower
has led the way in successfully
constructing the latest CO2
capture technologies.
APCOMPOWER IS THE UNION CONSTRUCTION ARM OF ALSTOM SERVING THE U.S.
AND PUERTO RICO. | APComPower and Alstom together form an integrated design and
erection frm. For more than 70 years, APComPower has been providing a seamless range of
services to the utility and industrial power industry. These services include core maintenance
during routine outages, retroft upgrades to the boiler island, and environmental equipment
upgrades and retrofts. To date, we have installed 20% of the U.S. base. Now, APComPower
also offers maintenance services for gas and steam turbines.
In todays highly competitive markets, economies of scale can make all the difference in
whether a project is successful or not. As part of Alstom, APComPower has access to the
worldwide resources of one of the worlds largest and most innovative manufacturers of
power generation equipment from standard and custom-designed products and systems,
to centralized support groups based in Windsor, CT, covering:

Environment, Health and Safety

Quality

Material technology

Construction and welding engineering

Your 1-Stop Choice for Boiler Services and Parts
Call us Toll free: 1.866.257.8664
or
Direct: 1.860.285.2100
E-mail: windsorparts@power.alstom.com
Fax: 1.860.285.3101
If you know your partys extension
To use our Names Directory
To speak with a Customer Service Representative
To reach the Company Operator
If you would like this menu repeated
All other calls stay on the line
We provide 24 hour, 7 days a week
emergency service.
Press:
WITH ALSTOM...
YOURE IN CONTROL
Alstom
200 Great Pond Drive
Windsor, CT 06095-0500
Tel: 860.285.2100
Toll Free: 866.257.8664
Fax: 860.285.3101
www.alstom.com/power
Alstom Canada
1430 Blair Place, Suite 600
Ottawa, ON K1J 9N2
Tel: 613.747.5222
Fax: 613.747.5828
www.alstom.com/power
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