Alstom Products and Services

for STOCK Feeders and

Related Equipment
Improving Performance, Availability
and Reliability

With Alstom
Youre in control!

Alstom Coal Feeder Solutions

SAFETY AND EXPERIENCE

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.

S AFETY | 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.

E XPERIENCE | With an installed base of over 400 GW of power generation capacity spanning over 100 years,
we believe you cannot find a partner whose experience in the power industry matches ours. We are dedicated to
meeting your needs and exceeding your expectations. Our track record proves it.

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.

L OGISTICS | 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.

C USTOMER SERVICE | Alstoms field service engineers, customer service representatives and construction
managers have one goal exceeding your service expectations. Our strategically located service and distribution
centers enable us to provide fast response and reliable solutions to meet your needs.

At Alstom, we combine our capabilities and experience

challenges faced by plant owners, operators, maintenance

to enhance the productivity and performance of your

personnel and management. Whether it is a replacement

boilers, pulverizers, feeders, air pollution control

or upgraded part, a rebuilt assembly, a custom fabrication

systems, ash handling systems and auxiliary equipment.

or inventory management program, Alstom provides

Our focus is customer service and we understand the

exceptional value and service to our customers.

Contents
Introduction to Coal Feeders
A New Generation of Feeders.......................................................................................................4

Alstom Replacement Parts and Services for STOCK Coal Feeders

Upgrades and Replacement Parts................................................................................................5
Main Drive Upgrade...............................................................................................................6
Cleanout Drive Upgrade.........................................................................................................7
GENETIX Touch Screen Controller.....................................................................................8
Weigh Suspension System Upgrade for Belt Feeders...........................................................9
Roller Belt Support Assembly .............................................................................................10
Adjustable Leveling Bar.......................................................................................................10
Replacement Parts for STOCK Coal Feeders...........................................................................11
Starting the Quote Process.........................................................................................................16

Coal Delivery Products

Bunker Outlet Valves..................................................................................................................17
Knife Gate Valves........................................................................................................................17
Acoustic Flow Monitor Upgrade.................................................................................................18
LIMELIGHT Coal Flow Monitor..............................................................................................19
Diamondback Hopper..............................................................................................................20

Merrick Coal Feeder Products

Model 496 Feeder.......................................................................................................................21
Belt Conveyor Scale....................................................................................................................23

The Alstom Advantage

Service Capabilities.....................................................................................................................25
Technical Services.......................................................................................................................26
Alstom Service and Distribution Centers....................................................................................28
Outage Kits.................................................................................................................................29
APCom Power............................................................................................................................30

Contact Information

31

Introduction to Coal Feeders

AUTOMATED ACCURACY
A NEW
GENERATION
OF FEEDERS
TODAYS STATE OF THE
ART COAL FEEDERS |
deliver coal to the pulverizer
via variable speed motors.
The rate
of delivery is
automatically
adjusted by the weight of
the coal measured at the
feeder. Mechanical linkages
and levers have been all
but eliminated. Based on
the demand for fuel from
the plant control system,
the speed is automatically
adjusted so an accurate
flow of coal is supplied.
Accurate coal flow results in
accurate fuel to air ratios in
the furnace, and ultimately
tighter control of the
combustion process.
Benefits of accurate coal
flow include:

Reduced NOx emissions

Reduced CO and opacity
excursions
Reduced furnace slagging
configurations
Reduction in loss of
ignition (LOI)

COAL FEEDERS ARE AN INTEGRAL PART OF TODAYS PULVERIZED COAL STEAM

GENERATION UNITS. | Overall plant availability and environmental compliance are
dependent on the accurate and reliable metering of coal to the pulverizer, and ultimately
into the furnace.

Feeder technology has evolved as the demands for accuracy and reliability have
changed. The earliest feeders were designed to provide a continuous volume of coal.
This was typically accomplished by varying the rotational speed of a star shaped
spool piece with a fixed volume. In theory, the faster the star rotated, the more coal
would be metered to the pulverizer. In reality, this design resulted in inconsistent coal
delivery due to variation in coal size (air spaces) and bridging that comes
with high moisture materials. The result was an inconsistent supply of
coal to the pulverizer.
In addition to accuracy problems, reliability of this feeder type was also
a constant concern. Constant speed motors with a complex mix of
clutches and spring-held linkage were sure to keep plant maintenance
staff busy.

Coal Feeders
Upgrades and Replacement Parts
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 as well as safety.
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).

IMPROVING PERFORMANCE, AVAILABILITY

AND RELIABILITY OF STOCK FEEDERS

COAL FEEDERS

Coal Feeders
Main Drive Upgrade
The Main Drive
Upgrade components:

Direct drive Sumitomo

reducer with adapter

A/C inverter duty motor

Variable Frequency Drive

THE MAIN DRIVE DRIVE UPGRADE | replaces the outdated eddy current clutch and
motor system. It improves the reliability of the feeder and optimizes performance, as well
as correcting an inherent designed-in oil leak problem that can pose a safety risk. The
Main Drive and Cleanout Drive (next page) systems were designed to be integrated, thus
allowing you to keep the majority of your existing inventory of spare parts. The variable
frequency drive (VFD) allows for increases in capacity at no additional cost by a simple
programming change.

(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
Reprogrammable to

accomodate capacity changes

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

Supports fuel use variation
Improves reliability
Low conversion cost
The main drive system upgrade eliminates oil leaks while providing
an accurate linear signal which can be easily reprogrammed to
accommodate changes in capacity

COAL FEEDERS

Coal Feeders
Cleanout Drive Upgrade
THE CLEANOUT DRIVE UPGRADE INCLUDES AN ELECTRONIC SHOCK RELAY WITH A
NO/NC OUTPUT. | The electronic shock relay is DIN Rail mounted and easily calibrated. The
instant that a current overload condition occurs, the shock relay trips and stops the drag chain
drive motor. It also closes the auxiliary contact and can be connected to the boiler control
system to let the operators know that the drag chain is not operating. The existing system
typically does not provide this type of electronic failure indication.
The electronic shock relay will mount into an existing cabinet next to the drag chain
motor starter and the cleanout drive upgrade. The shock relay is easily reset by pushing
the reset button once the overload condition is cleared.

Cleanout Drive Upgrade components:

Direct drive Sumitomo reducer with adapter
A/C constant speed motor
Electronic shock relay

ADVANTAGES:

Eliminates inherent oil

leaks

Better protection from

overload

BENEFITS:

Reduces maintenance costs

Lowers cost of operation
Improves safety
(no oil leaks)

Low conversion cost

Adaptable to existing
equipment
Improves parts availability

Dirty Installation: Conventional clean out

unit shows signs of leaking which is not
only a maintenance problem, but a safety
hazard
Electronic shock relay offers excellent protection against feeder overload

New Unit: New Alstom cleanout drive

upgrade

COAL FEEDERS

Coal Feeders
GENETIX Touch Screen Controller
ADVANTAGES:

User-friendly interface
Reduction of failure prone
components
Elimination of relays
More detailed information
Simpler interface to plant

control system with

standard protocols
Better fault tolerance

BENEFITS:

Reduces programming
errors
Lower cost of operation
Improves reliability
Easy to use
Reduces maintenance
Improves accuracy
Improves availability
asily integrated in any
Easily

THE GENETIX CONTROLLER WITH COLOR TOUCH-SCREEN INTERFACE IS THE WORLDS

FIRST TOUCH SCREEN PROCESS CONTROLLER SPECIFICALLY DESIGNED FOR WEIGHING
APPLICATIONS . | The GENETIX Controller ensures the coal feeding process is consistently
accurate, reliable and repeatable.
The design utilizes the most advanced technology available in the industry. It provides for easy
integration into many classic boiler control systems or the more advanced DCS. The graphic
LCD touch-screen display enables user-friendly operation, presents and communicates data
in an organized and efficient manner.
The GENETIX Process Controller can be configured for virtually all feeding
requirements including:
Gravimetric control for feeder systems
Static weighing and belt scale integrators
Continuous or batching loss-in-weight feeders
Continuous or batching belt feeders

boiler control system

or DCS
Lower installation cost

DNA key allows for instantaneous

storage and backup of all
programming and calibration
parameters.

COAL FEEDERS

Coal Feeders

Weigh Suspension System Upgrade for Belt Feeders

MERRICKS 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

EASY WAY TO
IMPROVE RELIABILITY

Simple design
Microprocessor adjusts the
speed of the belt based on
load of material

BENEFITS:

Reduces maintenance costs

Improves efficiency with
tighter control

Improves reliability
Weigh Suspension System

COAL FEEDERS

Coal Feeders
Roller Belt Support Assembly
ADVANTAGE:

Minimizes wear to coal

feeder belt

Less horsepower required

to move 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:

Reduces maintenance costs

Reduces operational costs
Improves accuracy and
repeatability

THE ROLLER BELT SUPPORT ASSEMBLY IS DESIGNED TO PROVIDE YEARS OF TROUBLEFREE SERVICE. | In most cases the original slider-bed belt support pan requires regular
replacement. This pan is known to develop wear holes that have the potential to damage the
feeder belt itself.
The roller system is designed for less friction and, thus, less wear against the feeder belt. Not
only is damage to the feeder belt minimized, less horsepower is required to move the feeder belt.
Additionally, the roller belt support assembly allows the coal feeder to calibrate more quickly.
No physical or hardware changes are required to install the roller belt support assembly. The
drop-in idler unit uses five (5) special rollers with bearings located within the assemblys
support frame. These bearings are permanently sealed. The rollers can be replaced without
disassembling the tail end of the coal feeder and removal of the entire belt. Once the support
frame is installed, it should
never need replacement.
This design has been in use in
industry for more than 50 years
on similar belt feeders.

MINIMIZES FEEDER
BELT WEAR

Adjustable Leveling Bar

THIS EASY-TO-INSTALL ADJUSTABLE LEVELING BAR UPGRADE REPLACES OLD
MECHANICAL LEVELING BAR SYSTEMS WITH A TURNBUCKLE ASSEMBLY. | All internal
leveling components are retained as well as the original level indicator. The simple design
requires no field welding and installs in less than one hour as compared to the OEM design
which requires welding and takes eight to ten hours to install.

ADVANTAGES:

Uses existing internal

leveling bar components

Fast installation
No field welding
BENEFITS:

INSTALLS IN LESS THAN

1 HOUR
WITH NO WELDING

10

COAL FEEDERS

Low cost of installation

Easy to install
Simple and reliable

Coal Feeders
Replacement Parts for STOCK Coal Feeders
THE ALSTOM/MERRICK TEAM SUPPORTS CUSTOMERS NEEDS FOR REPLACEMENT
STOCK COAL FEEDER EQUIPMENT | with a portfolio of products and capabilities to
ensure reliable and efficient system operation. We offer over 2000 replacement parts for
STOCK coal feeders, providing you with an excellent alternative supplier to the OEM. All
parts are factory new and warrantied.

ADVANTAGES:

High quality
OEM warranty
Custom outage kits
available

OVER 2000 REPLACEMENT PARTS

FOR STOCK COAL FEEDERS

Incorporate into Inventory

Management Programs

BENEFITS:

A low risk, high value

supplier of replacement
parts for STOCK feeder
equipment

COAL FEEDERS

11

Coal Feeders
Replacement Parts for STOCK-type Coal Feeders: Groups 1-10

POPULAR FEEDER REPLACEMENT PARTS

Part Master Description

PLATE BELT
SUPPORT WELDMENT
INLET SKIRT - LH
INLET SKIRT - RH
INLET SKIRT END
INLET SKIRT END
BEARING HOUSING
FOR INLET ROLLER
Note: Used on 36 Feeder Only
MAIN DRIVE MOTOR
VERTICAL MOUNT
CAPACITOR
SWITCH, DISCHARGE,
PLUG-MONITOR
BLADE
BRG COVER
LOAD CELL ASSEMBLY
WEIGHING MODULE ASSY.
KIT TAPE
Note: Calibration Kit
PIN DRAG LINK ASY GRAVIMETRIC
ASSY WEIGHING MODULE WEIGH

12

COAL FEEDERS

Part Group
1
1
1
1
1
1

2
2
2
2
2
2
2
2
3
3

Part Master Description

ASSY WEIGHING MODULE WEIGH

ASSY WEIGHING MODULE WEIGH
ASSY WEIGHING MODULE WEIGH
TUBE BLEED DRAG
LINK GRAVIMETRIC
JAM NUT
GASKET
BEARING COVER GASKET
BEARING CAP - FEEDER ASSY.
BUSHING
STUD-COUPLING DRIVE
COUPLING ASY HEAD PULLEY
BEARING HOUSING COVER
HEAD PULLEY
FINAL ASSY COUPLING
FOR MAIN DRIVE
HALF COUPLING
HEX HEAD STRIPPER BOLT
ELEVATOR BOLT
BLADE, SCRAPER
BELT SCRAPER ASSY
BLADE RUBBER BELT SCRAPER

Part Group
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
4
4
4

10

Coal Feeders
Replacement Parts for STOCK-type Coal Feeders: Groups 1-10
POPULAR FEEDER REPLACEMENT PARTS
Part Master Description

BEARING
BELT 16-7 LONG X 33
WIDE WIDTH
Note: Belt for 24 Feeder
BELT 198.4 LONG X 33
WIDE WIDTH
Note: Belt for 24 Feeder
BELT - STYLE RC
RECESSED/FLEXCO
Note: Belt for 24 Feeder
BELT - HOT VULCANIZED SPLICE
Note: Belt for 36 Feeder
PIN BELT SPLICE HINGE
FOR A 46
Note: Part of Belt
COVER LIGHT FEEDER ASY
BALL
GLASS BULLSEYE
SPRAY NOZZLE
GASKET - END DOOR
FEEDER END DOOR GASKET
GASKET BULLSEYE
WASHER
BOLT .75 - 10 4.75L
WEAR SLEEVE
COUPLING - 7/8 BORE
SIGHT GAUGE, HELICAL GEAR BOX
SHAFT ASSY CLEANOUT CONVEYOR
SHAFT & SPROCKET ASY
FEEDER COUPLING
FEEDER COUPLING
GASKET-WEIGHT LEVER COMPARTMENT
SPREADER TENSION FRAME
TAKE-UP PULLEY
GASKET - TENSION ROLL DOOR
HEIGHT INDICATOR TENSION ROLLER
SHAFT PIVOT TENSION ROLLER
ARM TENSION ROLLER ASY
GASKET
STOP NUT
BEARING
WEIGH ROLL
KIT WEIGHSPAN REBUILD
SEAL
CAP PLUG 2X
BEARING HOUSING
BRG BALL 2 SEAL MM020ID
FITTING, GREASE FOR COAL FEEDERS
BLOCK SUPPORT DRAG LINK ASY
LINK FOR CLEANOUT CONVEYOR CHAIN
DRAG CHAIN WING ATTACHMENT 12
CHAIN PIN INCLUDED
IN X892-RO

Part Group
4
4

4
4

4
4A
5
5
5
5
5
5
5
5
6
6
6
6
6
6
6
7
7
7
7
7
7
7
8
8
8
8
8
8
8
8
8
8
8
9
9
9

Part Master Description

SHAFT AND SPROCKET WELDMENT

HOSE END
BELT TAKE-UP SCREW
WASHER
RETAINER RING INTERNAL
BULKHEAD FITTING
MACHINE TUBE WITH SINGLE
FITTING GREASE ELBOW BODY
CLEANOUT CONVEYOR CHAIN ASSY
BELLOWS (BELT & CHAIN)
Note: Used on 61
Model Feeder Only
BEARING
Note: Used on 61
Model Feeder Only
SEAL
Note: Used on 61
Model Feeder Only
SEAL
DRIVE ASY TAKE-UP VOLUMETRIC
Note: Used on 61
Model Feeder Only
TAKE-UP ASSEMBLY
Note: Used on 61
Model Feeder Only
DRIVE ASY TAKE-UP
Note: Used on 61
Model Feeder Only
DRIVE ASY TAKE UP GRAVIMETRIC
Note: Used on 61
Model Feeder Only
RUBBER RING GASKET FOR TAKE-UP
TAKE-UP DRIVE BLOCK
CHAIN TAKE-UP BOLT
GEAR ASSY
TAKE UP SCREW
TAKE-UP DRIVE HOUSING
DOWEL PIN 1/4 - 7/8 LONG
HOLDER LAMP 660W 600V
PIN
SHAFT TAKE UP PULLEY
PULLEY WELDMENT TAKE-UP
BEARING BALL
TAKE-UP DRIVE HOUSING
COLLAR CDS - 1.50 X .75
CLUTCH GEAR FEEDER TAKE UP
Note: Used on 61
Model Feeder Only
SPRING HELICAL COMPRESSION
Note: Used on 61
Model Feeder Only
SHIM KIT
Note: Used on 61
Model Feeder Only

Part Group
9
9
9
9
9
9
9
9
9
9

9 and 10
9 and 10

9 and 10

9 and 10

9 and 10

10
10
10
10
10
10
10
10
10
10
10
10
10
10
10

10

10

COAL FEEDERS

13

Coal Feeders
Replacement Parts for STOCK-type Coal Feeders: Groups 11-17

14

COAL FEEDERS

Re

17

Coal Feeders
Replacement Parts for STOCK-type Coal Feeders: Groups 11-17
POPULAR FEEDER REPLACEMENT PARTS
Part Master Description

PADDLE CONTROL SWITCH

GASKET PAPER TREATED SPIRAL
LIMIT SWITCH
BALL BEARING - RADIAL 1.68 ID
SHIM - UPPER HOUSING COVER
BEARING TAPER ROLLER
SHIM - UPPER HOUSING COVER
BEARING
SEAL (HELICAL INPUT SHAFT)
SHIM - BEARING CAP
SIGHT GAUGE - .75 PTM
DRAIN PLUG
GASKET PLASTIC 3.87 X 2.62 KIT
SEAL
SHIM KIT - REDUCER HOUSING
SHIM (BEARING CAP)
COUPLING ASY TORQUE LIMITER
COUPLING
SEAL
SEAL
(WORM GEAR SHAFT-STEEPLE)
SHIM KIT GASKET BRG COVER 3.5
WORM GEAR SHAFT STEEPLE
SHIM - REDUCER HOUSING
SHIM - REDUCER HOUSING
SHIM (REDUCER HOUSING)
SHIM (REDUCER HOUSING)
SHIM - UPPER HOUSING COVER
SHIM (BEARING CAP)
BUSHING TORQUE ARM
3.5 REDUCER
Note: Used on Model 82 Feeder Only
PIN - SHEAR
Note: Used on Model 82 Feeder Only
SHEAR PIN
Note: Used on Model 82 Feeder Only
MOTOR ADAPTING KIT
Note: Used on Clean Out
Upgrade Only
ARM TORQUE DRIVEN 3.50 CD
Note: Used on Model 82 Feeder Only
SHAFT EXTENSION FOR PULSER
COUPLING FOR COAL FEEDERS
SEAL - UPPER SPUR GEAR
GASKET PLASTIC (SHIM)
GASKET PLASTIC (SHIM)
SHIM
SIGHT GAUGE, WORM GEAR BOX
SEAL (HELICAL INPUT SHAFT)
GASKET PLASTIC (SHIM)
BRG BALL RDL 2.36ID MRC 212SZ
Note: Used on 36 Model Feeder Only
BALL BEARING 2.559 ID X
Note: Used on MOSES Upgrade Only
SHIM
WEAR SLEEVE SEAL - UPPER SPUR
BEARING (HELICAL INPUT SHAFT)
GASKET PLASTIC (SHIM)

Part Group
14
14
14 and 15
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16

Part No.

Part Master Description

ROLLER BEARING
(WORM GEAR SHAFT)
SLEEVE WEAR
2.389-2.815, .688 W
SEAL - WORM GEAR SHAFT
SHIM
(BRG COVER - WORM SHAFT)
GASKET PLASTIC (SHIM)
GASKET PLASTIC (SHIM)
SHIM
SHIM
SHIM
WORM GEAR SHAFT
SPUR GEAR UPPER
HOUSING PULSER
AND BEARING COVER
BEARING - HELICAL INPUT SHAFT
PLUG
WORM GEAR SHAFT 5 REDUCER
MAGNETIC HUB ASSY
1/2 14 PIPE PLUG NPSTRAIGHT
WEAR SLEEVE SEAL
SHIMS CAP ADAPTOR HELICAL
SHIM
SHIM
SHIM
STEEPLER REDUCER
OUTPUT SHAFT
WORM SHAFT
GEAR WORM - 36:1
36T RH 7.00 PD
WORM GEAR
MAGNETIC HUB ASSY

Part Group
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17

16
16

16
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17

COAL FEEDERS

15

Coal Feeders
HERE IS WHAT WE NEED TO START THE QUOTE PROCESS:

Feeder Questionnaire
Specification sheet or feeder

see below

design sheet

(from feeder instruction manual)

Valve Index Sheet and drawing

(from feeder instruction manual)

Stackup drawing

(from feeder instruction manual)

Variable parts list

(from feeder instruction manual)

Spare parts list

(from feeder instruction manual)

Return to: Customer Service

Phone: 866-257-8664 Fax: 866-285-3101
Email: windsorparts@power.alstom.com

16

COAL FEEDERS

Coal Delivery Products

ADVANTAGES:

Self cleaning design

prevents material
accumulation

Jam proof operation

Gate removes easily

without removing valve

Stainless steel contact

surfaces for corrosion
resistance

Pressurized construction
integrity with interior
access

IN ADDITION TO REPLACEMENT PARTS FOR STOCK AND ALSTOM EQUIPMENT

FEEDERS AND UPGRADES, | the Alstom/Merrick team can supply a wide range of feederrelated components and equipment to keep your coal delivery system operating reliably and
at peak performance.

Bunker Outlet Valves

BUNKER OUTLET VALVES PROVIDE
RELIABLE ON/OFF MATERIAL
CONTROL | and are available in a variety
of sizes and models. Fast-acting gates
are designed for dependable penetration
of a standing column of coal. Rugged,
stainless steel construction makes these
valves suitable for harsh environments.

BENEFITS:

Lower maintenance costs

Safer to operate
Self cleaning
Jam proof

KNIFE GATE AND BUNKER

OUTLET VALVES PROVIDE
A RELIABLE SEAL FOR
MATERIAL FLOW LINES

Knife Gate Valves

KNIFE GATE VALVES ARE USED FOR BURNER LINE OR FEEDER ISOLATION APPLICATIONS.
| Among the most durable types of shut-off valves available, they provide positive closure of
pressurized material flow lines. A 3-point blade support system provides a wiping action to seat the
gate. The gate blade fully retracts out of the material flow stream to prevent flow restriction and to
minimize blade wear.
Knife Gate Valves are offered with manual, pneumatic,
hydraulic, or electric actuators. Standard or custom
designs provide positive shut-off and protection from
coal dust and fly ash contamination.

ADVANTAGES:

Design optimizes wear life

Retractable blade to
reduce wear

Positive pressure seal and

operation up to 500F

NFPA 85 rated

(explosion proof)

BENEFITS:

Reduces maintenance
Increases wear life
Increases reliability

COAL DELIVERY

17

Coal Delivery Products

Acoustic Flow Monitor Upgrade
ADVANTAGES:

Easy to install
No nuclear licensing or
administrative issues

Easy to calibrate and

make adjustments

Reliable, updated
technology

BENEFITS:

Application: Used to monitor coal entering the feeder

THE ACOUSTIC FLOW MONITOR UPGRADE IS A KEY COMPONENT THAT DETECTS
MATERIAL FLOW AND FLOW INTERRUPTIONS | in pipes and downspouts in coal
feed systems before the feeder. It provides an alarm signal when stoppage occurs.
The robust stainless steel design provides better reliability than its nuclear predecessor.
There are no nuclear licensing or administrative issues. This upgrade mounts directly at
the feeder inlet and is a direct replacement for earlier generations. It is easy to install and
the detector probe is easily replaced, reducing maintenance time and costs. Upgraded
electronics allow for unit adjustments and calibration at the control unit.

Low cost of installation

Lower maintenance
costs

Easy to operate

New Acoustic Flow Monitor ready for installation

New Acoustic Flow Monitor installed at valve inlet

NON-NUCLEAR SOLUTION TO COAL FLOW

MONITORING FOR FEEDER INLETS

18

COAL DELIVERY

Coal Delivery Products

LIMELIGHT Coal Flow Monitor
Application: Used to monitor flow exiting the feeder
THE LIMELIGHT COAL FLOW MONITOR IS A HIGH QUALITY, INDUSTRIAL
GRADE INSTRUMENT | capable of providing a signal indicating flow/no-flow conditions
of coal in gravity chutes and feeders downstream of the feeder. It is a direct replacement
for Combustion Engineering and ABB coal flow detection devices found on Combustion
Engineering and STOCK coal 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 flow.
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.

RELIABLE SOLUTION TO COAL FLOW

MONITORING FOR FEEDER OUTLET

ADVANTAGES:

Improves sensitivity

and more reliable coal

detection

Senses small and large

particles of varying
densities

Eliminates the sound rod

Self-calibration eliminates
tuning

Mounting arrangement

is identical to original
Combustion Engineering
and ABB coal flow
monitor

BENEFITS:

Improves reliability
Reduces maintenance
costs

Quicker start-ups
Reduces
installation time
by 50%

LIMELIGHT Coal Flow Monitor Sensor Head and electronics enclosure

COAL DELIVERY

19

Coal Delivery Products

Diamondback Hopper System
MERRICK/ALSTOM HAS ENHANCED ITS LINE OF SERVICES FOR THE POWER
GENERATION INDUSTRY | by developing an alliance with Diamondback Technology (DBT).
DBT combines over 40 years of research with hands-on experience to solve solids handling
problems. Together, Merrick and DBT can provide engineered solutions to flow problems from
the bunker to mill.
This is an ideal package for retrofit of volumetric feeders or batch scales that are experiencing
pluggage problems. The Diamondback Hopper System is suitable for many different
applications within the plant including:

Single and multiple outlet bunkers

Bottom tunnel coal reclaim hoppers
Truck dump hoppers
Dozer-loaded reclaim points
In many cases, the Diamondback Hopper System eliminates the need for noisy vibrators, air
cannons, or rotary valves. In addition, the Diamondback Hopper System eliminates costly
maintenance and downtime because it provides uniform flow with no moving parts.

UNIFORM FLOW WITH

NO MOVING PARTS

20

COAL DELIVERY

ADVANTAGES:

Use in a variety of
applications

Provides uniform flow

with no moving parts

Stainless steel

construction increases
service life

BENEFITS:

Improves reliability
Reduces maintenance
costs

Better performance

Merrick Coal Feeder Products

Model 496 Feeder
High Accuracy
THE MODEL 496 FEEDER UTILIZES MERRICKS SIGNATURE LOW TENSION BELT
WEIGHING TECHNOLOGY THAT REDUCES THE HARMFUL EFFECTS OF BELT
REACTION ERROR. | As a result, this feeder offers the most cost-effective way to
provide the highest accuracy possible.
Other belt feeders feature a high tension belt system, which can only deliver acceptable
accuracy by adding expensive, precision-tolerance components and costly custommachining to tune each individual weigh system. Such tight tolerances cannot be
maintained outside of the factory due to the excessive wear associated with the harsh
coal-feeding environment.

MERRICKS MODEL 496

COAL FEEDER IS THE
IDEAL CHOICE IF YOUR
EXISTING FEEDER NEEDS
REPLACEMENT. | Merrick
feeders are designed and
manufactured under the
strictest guidelines using
only the highest quality

The Model 496 Feeder is engineered to provide cost effective operation at unparalleled
accuracy of up to +/-0.25%.

materials and components

All-Electronic Controls

uptime.

MERRICK PIONEERED ELECTRONIC CONTROL SYSTEMS FOR BELT FEEDERS

AND CONTINUES TO BE THE WORLD LEADER IN THIS TECHNOLOGY. | The Model
496 Coal Feeder comes equipped with Merricks revolutionary microprocessor controller
the Genetix Touch Screen Controller which features the versatility and ruggedness
of an industry-standard PLC (Programmable Logic Controller) to provide the safest,
most versatile and connectable Gravimetric Coal Feeder Control System available.

UNPARALLELED
ACCURACY

to maximize efficiency and

Unique In-feed Design

OUR UNIQUE IN-FEED DESIGN ALSO BOOSTS ACCURACY AND DURABILITY. |
The in-feed of the Model 496 Feeder is contoured to allow coal to follow its natural
angle of repose as it is deposited onto the belt. This natural transition from vertical flow
to horizontal flow minimizes belt tension variations and provides a uniform load profile,
allowing lower belt tension and increased weigh accuracy. A slotted in-feed design is
also available for feeding difficult to handle coals.

MERRICK COAL FEEDER PRODUCTS

21

Merrick CoalNOTES
Feeder Products
Model 496 Feeder (contd.)
THE RIGHT CHOICE
The Model 496 Feeder
when combined with the
Merrick Control System
provides the following
features:

Advanced all-electronic
microprocessor control
technology

Open systems connectivity

Critical component
redundancy

Continuous process
monitoring

BENEFITS:

Provides the highest

accuracy available

Prolongs belt life

Provides safe and reliable
operation

22

MERRICK COAL FEEDER PRODUCTS

Long Belt Life

A HIGH-TENSION BELT INSTALLATION MAGNIFIES MISALIGNMENTS | due to slight offset
tolerances or increased wear. A high-tension approach also requires more operating horsepower
while significantly increasing wear on all rotating parts.
Merricks slack belt design promotes longer belt life and eliminates the need for a V-guide belt and a
troublesome, counterweighted tensioning pulley. Simple, easy-to adjust screw take-ups are used to
track and tension the belt.

Safety
SAFETY IS A TOP PRIORITY AT MERRICK INDUSTRIES. | The Model 496 feeder is tested to
conform with NFPA criteria. Additionally, all internal electronics are either explosion-proof or
intrinsically safe.

Merrick CoalNOTES
Feeder Products
Belt Conveyor Scale
ADVANTAGES:

Maintenance free design

Easy to install
BENEFITS:

Reliable, repeatable
weighing stability

Reduces maintenance

THE MODEL 475 BELT SCALE IS DESIGNED TO MEET OR EXCEED THE ACCURACY
REQUIREMENTS | of the National Institute of Standards and Technology (NIST)
Handbook 44. The loading frame offers better reliability by eliminating the need for
bearings, pivots and friction points. The suspension is not influenced by off-center belt
loading. This results in unsurpassed weighing stability and accuracy.
A certificate of conformance, Number 92-196, was issued under the National Type
Evaluation Program (NTEP) of the National Conference of Weights and Measures
for this product. The certificate is for capacities of 14.5-145 lb/ft. at belt speeds of
100-800 ft/min. with weighbridge lengths of 9-20 feet.

costs

Improves accuracy

SUPERIOR ACCURACY AND RELIABILITY

MERRICK COAL FEEDER PRODUCTS

23

24

The Alstom Advantage

Service Capabilities
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 refineries
In other words, if you generate steam to produce power or to support your
manufacturing processes, Alstom is ready to provide the products and services you need.

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, AllenSherman-Hoff, United Conveyor, Flkt
AIR POLLUTION CONTROL | ABB,
Combustion Engineering, Flkt,
Walther, Carborundum, Hamon
Research-Cottrell, Wheelabrator,
Peabody, Rockwell

THE ALSTOM ADVANTAGE

25

The Alstom Advantage

Technical Services
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 field-

based service engineers, NDE

specialists, performance test
engineers and technicians

Problem solvers
Equipment inspectors,

testers, and evaluators

Performance specialists

ALSTOM IS A GLOBAL PROVIDER OF PRODUCTS AND SERVICES TO THE UTILITY AND

INDUSTRIAL POWER INDUSTRY. | We maintain a local presence to help ensure that our
customers equipment and systems run reliably and efficiently with the availability they
demand.
FIELD TECHNICAL SERVICE ENGINEERS | Alstom has extensive capabilities in the form
of Field Technical Service Engineers to assist with your outage inspection and operation and
maintenance needs.
Our field service engineers are located near our customers to provide the response they need.
This full-time force of professionally trained engineers and technicians receives constant
training to help ensure they are knowledgeable in the latest trends and available technology.
OUTAGE PLANNING | Effective outages require effective planning, a continuous process
that begins well in advance of the scheduled event. Alstom stands ready to participate in
this process to help ensure timely decisions, problem avoidance and achieved goals.
The services Alstom provides include:

Setting overall outage objectives

Work scope determination
Prioritization of outage tasks
Identification of material and parts needs
Expediting delivery of required material and parts
INSPECTION SERVICE | To help ensure an effective outage, we offer our inspection service
that includes:

Pre-outage logistics and work scope definition

Pre-outage unit walk-downs
Detailed inspections during the outage
Daily punch lists and definition of items requiring immediate
attention

Coordination with repair labor personnel

Initial report with critical findings and recommendations
Final detailed inspection report complete with photos,
recommendations and findings

On-line retrieval of our final report for convenient viewing

and downloading

26

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 field eddy current
Wet fluorescent 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 specifications and
help make adjustments

Participate in developing

work scope and associated

tasks

Direct maintenance

personnel in proper
disassembly and
assembly procedures

Coordinate execution of the

work scope

Develop a daily punch list

prioritizing work tasks

PERFORMANCE TESTING AND EVALUATIONS |

The performance evaluation and testing team
supports data gathering and analysis to help optimize
plant performance. Offerings include:

Specialized testing of thermal, fluid and chemical

processes (emissions and circulation)

Boiler and power plant performance evaluation

Water chemistry consultation for boilers
Instrumentation supply and rentals of most

commonly used boiler and emissions test equipment

Provide a final report documenting work performed and

recommendations

TRAINING PROGRAMS | Alstom's training programs provide power

plant professionals with the knowledge and skills they need to operate
and maintain the equipment and systems. Alstom's portfolio includes:

Standard and customized training

Computer-based QUICKSTUDY Learning System
Regional training seminars

DEDICATED ENGINEER PROGRAM | We provide an experienced Alstom Technical Services Engineer for exclusive use for a
specific time period.
The Dedicated Engineer becomes an on-site member of the plant team, spearheading the Alstom support. The result is responsive
service in determining root causes of problems and timely development and implementation of solutions to help reach and exceed
station goals.

TECHNICAL SERVICES TAILORED FOR YOU

AND YOUR BUDGET

THE ALSTOM ADVANTAGE

27

The Alstom Advantage

Alstom Service and Distribution Centers
BENEFITS:

No need to purchase 100% of

committed parts

Reduces carrying costs

Defers cash outlay
Increases cash flow by

delivering products when

needed

INVENTORY MANAGEMENT PROGRAMS

With our proven inventory management expertise, purchasing strength and strategically
located regional service centers, participation in an Alstom Inventory Management Program
can offer customers significant benefits from guaranteed shipments to improved cash flow.
ALSTOMS SERVICE CENTER NETWORK IS STRATEGICALLY LOCATED ACROSS
THE COUNTRY, | providing emergency component repairs, parts, complete component
overhauls, custom fabrications, and cost saving inventory management programs to meet
our customers needs.

Guarantees parts
availability

Simplifies purchasing

BENEFITS:

Reduce Inventory costs

R3 COMPONENT ROTATION PROGRAMS

Alstom offers customers a systematic method for rebuilding boiler related equipment and
returning this equipment to service. Alstoms Regional Service Centers are the focus of this
program combining our extensive experience, inventory, rebuild portfolio and proven processes
to provide a unique service.
The R3 program is based on Rebuilding, Restocking and Replacing components.

25-30%

Shorter lead times

All work backed by

Alstoms engineering
experience, quality and
reliability

Rebuild
Complete disassembly and inspection of a component. Worn out parts are replaced and
components repaired. The components are rebuilt to strict procedures and tolerances.
Upgrades to components can be included.

Restock
Once a rebuild is completed, the component is placed in the customers exclusive stock
inventory at the Regional Service Center nearest the plant.

Replace
Rebuilt components are returned to a customer when needed to replace a similar component
requiring service. The replaced component is sent back to the Service Center.

STRATEGICALLY LOCATED
TO SERVE OUR CUSTOMERS
Harrisburg, PA

Denver, CO

Erlanger, KY

Chattanooga, TN

R3 = REBUILD + RESTOCK + REPLACE

IMPROVING AVAILABILITY WHILE REDUCING COST

28

THE ALSTOM ADVANTAGE

Suwanee, GA

Tyler, TX

The Alstom Advantage

Outage Kits
OUTAGE KITS | are pre-packaged supplies of equipment-specific replacement
parts that support planned or unexpected unit outages and rebuilds.
Emergencies cost money! Outage Kits can help minimize costly delays in
making repairs.
Outage Kits are the perfect solution when emergencies strike, or to have
available as part of a planned preventative maintenance cycle or Inventory
Management Program.

ADVANTAGES:

Custom or standard
kits

Reduces maintenance
costs

Convenient and
organized

Simplifies purchasing
BENEFITS:

Right parts available

when you need them

Only pay for the parts

that are used

Instant part availability

Save time and money

A COST-EFFECTIVE WAY TO MANAGE PLANNED

AND UNPLANNED UNIT OUTAGE REPAIRS

HOW ALSTOMS OUTAGE KIT PROGRAM WORKS:

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.

THE ALSTOM ADVANTAGE

29

The Alstom Advantage

APComPower
A World of Experience Right Next Door
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-fired 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.

30

THE ALSTOM ADVANTAGE

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 firm. 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, retrofit upgrades to the boiler island, and environmental equipment
upgrades and retrofits. 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
PLANT UPGRADES/MAJOR MODIFICATIONS
Fuel conversions
Combined cycle operations
Balanced draft conversions
Emission control systems

COMPONENT INSTALLATION, REPAIR AND REPLACEMENT, BALANCE OF PLANT

Fuel firing 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 filters
Foundations
SCRs
Pressure Parts
Piping

Your 1-Stop Choice for Boiler Services and Parts

Call us Toll free: 1.866.257.8664

or
Direct: 1.860.285.2100
Press:
If you know your 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

E-mail: windsorparts@power.alstom.com
Fax: 1.860.285.3101
We provide 24 hour, 7 days a week
emergency service.

WITH ALSTOM...
YOURE IN CONTROL

QUICKSTUDY and LIMELIGHT are trademarks of Alstom Power Inc.

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. GENETIX is a
registered trademark of Merrick Industries, Inc.

PSE/BPROB/STCKFQ10/eng/PSER1/02.10/US/7090 ALSTOM 2013. Alstom, the Alstom logo and any alternative version thereof are trademarks and service marks of Alstom. The other names mentioned, registered or not, are the
property of their respective companies. The technical and other data contained in this document is provided for information only. Neither Alstom, its officers and employees accept responsibility for or should be taken as making any
representation or warranty (whether express or implied) as to the accuracy or completeness of such data or the achievement of any projected performance criteria where these are indicated. Alstom reserves
the right to revise or change this data at any time without further notice.

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