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Alstom Pulverizer Catalog
Alstom Pulverizer Catalog
Alstom Power Inc. (Alstom) is recognized around the world as a leader in the design, manufacturing and servicing of power generation equipment. While our heritage dates to the late 1800s, our capabilities continue to expand and point us to the future. At Alstom, we combine our capabilities and experience to enhance the productivity and performance of your boilers, pulverizers, air pollution control systems, ash handling systems and auxiliary equipment. We are an organization that focuses on customer service and understands the challenges faced by plant owners, operators, maintenance personnel and management. Whether it is a simple replacement part, a rebuilt assembly, a custom fabrication or inventory management program, Alstom provides value and service to our customer.
Table of Contents
Introduction to the Alstom Pulverizer ......................................................................................................3 Achieving Pulverizer PAR (Performance Availability - Reliability) ..........................................................5 Grinding Rolls and Grinding Segments ......................................................................................................6 FLOW-PRO Vane Wheel Technology ......................................................................................................9 Advanced Static Classifier ........................................................................................................................11 Exhauster Products ..................................................................................................................................12 Pulverizer Gearbox Services ....................................................................................................................16 Pre-Assembled Components ....................................................................................................................17 Other Pulverizer Upgrades ......................................................................................................................19 Pulverizer Journal Rebuild Services and Products ....................................................................................21 R3 Component Rotation Programs ..........................................................................................................23 The Alstom Advantage ............................................................................................................................24 Regional Service Centers ..........................................................................................................................25
RB Pulverizer
The RS indicates a shallow-bowl pulverizer that operates under a negative pressure on a balanced draft furnace. An RPS indicates a shallow-bowl pulverizer that operates under a slightly positive pressure and was originally associated with pressurized furnaces. Both these pulverizer types are used with an exhauster fan. Pulverizer Size 403 503 603 663 703 743 783 803 843 863 Base Capacity lbs/hr 10,200 21,200 36,800 48,500 58,000 68,500 80,500 87,500 100,000 106,000
The RP indicates a shallow-bowl type pulverizer that operates under a positive pressure. Early systems were associated with either a pressurized or balanced draft furnace. Today few, if any, pressurized coal-fired furnaces are produced. These pulverizers utilize a primary air fan. Pulverizer Size 603 663 743 763 803 863 943 1003 1043 1103 Base Capacity lbs/hr 36,800 48,500 68,500 74,500 87,500 106,000 132,000 150,000 170,000 200,000
RS/RPS Pulverizer
RP Pulverizer 4
The HP pulverizer was developed in the mid-1980s. This pulverizer incorporates design changes to extend grinding element life and reduce replacement part costs, maintenance costs and down time. The HP pulverizer design incorporates a vane wheel, an improved horizontal scraper assembly, a tall top classifier for improved classification and a planetary gear drive assembly. Pulverizer Size 603 663 743 803 863 943 1003 1103 1203 1303 Base Capacity lbs/hr 36,800 48,500 68,500 87,500 106,000 132,000 150,000 200,000 250,000 300,000
HP Pulverizer
Wear Resistance Increase product life and reduce maintenance Mechanical Upgrades Improve operation and reduce maintenance Performance Improvement Regain lost capacity and increase performance
2 Following the Coal Path First and second areas of coal contact are the bowl grinding segments (1) and the grinding rolls (2) followed by the vane wheel (3) and the pulverizer outlet classifier section (4).
Magotteaux utilizes a metal matrix composite (MMC) to produce the Xwin grinding segments and grinding rolls that are designed to be superior to any other grinding roll or grinding segment currently offered.
This composite combines the extreme wear resistance of ceramic with the mechanical properties of cast alloys. MMC is composed of ceramic particles imbedded and reinforced with a high chrome alloy evenly distributed in a honeycomb design. Use of the new MMC results in reduced wear and a higher resistance to breakage over traditional monometallic grinding rolls.
Alstoms pulverizer technology is now combined with Xwin cast product technology for bowl segments and grinding rolls. This technology developed by Magotteaux, Inc. has shown dramatic results on Alstom RB pulverizers and has also been applied to Alstoms RS, RP, and RPS shallow bowl pulverizers.
Xwin is a registered trademark of Magotteaux, Inc.
The Xwin grinding roll demonstrates a considerable improvement in wear life, better fineness, decreased spillage, lower pulverizer amps and reduced wear on the classifier components. The overall benefits are improved performance, improved efficiency and reduced operating and maintenance costs.
Summary
Alstom offers a variety of options for replacement grinding rolls and grinding roll surfaces. Whether you choose a complete grinding roll replacement or elect resurfacing there are several wear-resistant options that are designed to extend the wear life of the grinding roll. The results include better fineness, decreased spillage, lowering pulverizer amps and wear on the classifier components. Your benefits are improved performance, improved efficiency and reduced costs.
Features
Deflector liners are located down in the clean air region for reduced wear 360 degree flow path for even flow distribution to the classifier Promotes reduced velocities for reduced down stream wear Coal flow patterns are kept off the mill body virtually eliminating body wear The flow control gap between the rotation and stationary components is out of the erosion zone Wingtips retained for efficient air velocity and spillage control The small size and steep angle of the deflector liners do not provide any coal hide out areas A selection of wear materials and vane wheel attachment methods are available
Benefits
Increased pulverizer availability Reduced maintenance costs As illustrated here, the new FLOW-PRO Vane Wheel incorporates a resized deflector along with high-grade liner materials for the deflector, vane and wing tips. The CFM and the force and velocity analysis illustrate more uniform flow velocities that substantially reduces localized wear.
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Extra deflector ring (1) Calculated window height and length (2) New profile classifier blades (3)
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Exhauster Products
RB, RS and RPS pulverizers use exhausters to transport the coal from the pulverizer to the boiler. Following the coal path in the pulverizer the next area of coal contact is the exhauster section.
Alstom can supply fully assembled, dynamicallybalanced exhauster wheel assemblies ready for immediate installation. Alstom also rebuilds exhauster wheel assemblies to strict procedures at its Regional Service Centers. DYNAWEAR II Vacuum Bonded and DYNAWEAR III Tungsten Carbide Brazed Bonded Products can be selected to achieve extended wear life and maximize run time and outage cycle time.
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DYNAWEAR II Vacuum Bonded Ceramics can be installed on your fan blades at your site or at an Alstom shop. When ceramics are installed at your site, caps are used for attachment. When ceramics are installed in our shop caps are not required which means longer life during continuous operation. Shop pre-assembled fans are pre-balanced before delivery reducing manhours at installation. Shop pre-assembly also reduces errors during ceramic installation.
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HEF Exhauster Wheel with Wear-Resistant DYNAWEAR II Vacuum Bonded Ceramics Ceramic Bearing Side Cover Liners
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Pre-Assembled Components
Alstom can deliver complete subassemblies ready for immediate installation. This will reduce your down time and help to ensure accurate fit up of components. Examples include: Main shaft assemblies Worm shaft assemblies Bowl and bowl hub assemblies with grinding segments and vane wheel segments installed Journal assemblies with grinding rolls and wear liners installed Separator tops with classifiers and cone assemblies
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Traditional scraper assemblies use vertical mounted bushings that tend to wear and allow the scraper to droop and wear directly on floor liner. Alstoms design moves the pivot from the floor area to a horizontal position above the mill bottom.
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The improved assembly support allows the scraper to do a better job clearing debris from the mill bottom. The torsion spring provides enough resistance to move debris from the mill bottom, but also allows the arm to fold back over larger immovable objects such that neither the assembly nor the rest of the mill are damaged. The new horizontal scraper design eliminates the task of removing the entire assembly as a unit from the mill to replace wear parts. The original scraper design had an assembly weight of about 150 pounds, the new design allows individual components weighing about 30 pounds to be replaced. This means quicker, safer servicing of the scraper assembly.
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Original Design
Current Standard
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Alstom combines its more than 100 years experience in designing and building the coal pulverization equipment, its solution-based products and commitment to customer service into the Alstom advantage. Alstom provides timely delivery of its pulverizer products to meet the demands of the power industry. We have been a dedicated customer service organization for nearly 50 years ensuring the responsiveness that our customers require. Alstom provides OEM quality while backing our products with comprehensive support. Our products are engineered by the OEM and are designed to help our customers meet the performance, availability and reliability requirements for their pulverizer equipment.
Alstom Inventory Management Programs provide customers with the security of knowing replacement parts will be available when needed. And our rebuild programs will provide added service life to pulverizer components at a fraction of the cost of new equipment. This brochure is intended to provide only an overview of Alstoms products and capabilities in servicing your pulverizer equipment. For more detailed information please contact your Alstom Power Service office. Alstom looks forward to the opportunity to provide you the highest quality products when you need them at value-driven prices to help you achieve pulverizer PAR.
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355 Satellite Boulevard NE, Suite 600 Suwanee, GA 30024 678.714.8299 Fax No: 678.714.7177
10293 County Road 2213 Tyler, TX 75707 903.534.5661 Fax No: 903.534.5647
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Alstom Power Inc. 2000 Day Hill Road Windsor, CT 06095-0500 Tel: 860.282.5400 Fax: 860.285.9611
PSE/BPROB/PVPGSV07/eng/PSER1/06.07/US/6260 2007 Alstom Power Inc. 06095. 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. This document is submitted in confidence and is to be used solely for the purpose for which it is furnished. Any technical and other data contained in this document is provided for information only. Neither Alstom nor its officers or employees accept responsibility for or should be taken as making any representation, warranty or guarantee (whether expressed or implied) as to the accuracy or completeness of such data or the achievement of any projected performance criteria where these are indicated. Alstom reserves the right to revise or change this data at any time without further notice.
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