Aftermarket Products & Services for Coal Plants
PEOPLE, AVAILABILITY, AND QUALITY OF DELIVERABLES
New pulverizers, pulverizer system upgrades (requiring guarantees), addition of classifiers, hydraulic systems, etc.
Riley Power’s extensive offering of low NOx burners are designed to work with any OEM’s wall-fired or corner-fired steam generator, for both new construction, as well as for existing units. All burners can be designed to operate with or without overfire air, as well as other low NOx technologies, such as SCR and SNCR.
Replacement of wall or corner-fired burners possibly accompanied by new emission guarantees and/or boiler performance guarantees. Partial replacements with incremental emissions reductions.
Redesign of boiler for performance improvements including guarantees. Replacements “in-kind” utilizing off-shore fabrication with or without guarantees.
Burners and/or pressure parts, quoted with TEiC (open shop) or with union labor (subcontract with preferred installation contractors).
Provide design and supply or full EPC fuel conversion including coal to gas and coal to oil.
Riley Power’s in-house engineering capabilities allow for fast-drawing creation on components requiring repair or replacement. Once completed these components are typically fabricated or repaired in-house while the burners are in process of being rebuilt. OEM burners that we service:
- GE / ALSTOM Corner T-fired Burner – Coal Nozzle Assemblies
- Foster Wheeler Coal Burners
- B&W XCL Burner Nozzles
Components Riley Power rebuilds at our Duncan, South Carolina & Tyler, Texas locations:
- Ball Tube Mill Gearbox
- ALSTOM / GE Gearboxes, Journal Assemblies
- Raymond (Arvos) Roller & Gearbox Assemblies
- Hitachi VS Type Roll Wheel Assemblies
- B & W MPS Series Roller & Gearbox Assemblies
- Foster Wheeler MBF Roller Assemblies
Process:
- Prior to applying weld, visual & dye penetrant inspections are done to ensure any existing cracks or flaws have been identified.
- Riley power will then restore to OEM diameter or specification.
- No filler material is used in any part of the process.
- Riley Power has a variety of competitively priced weld wires available, should our premium wire not be required depending on application.
We provide parts for the following OEMs:
- ALSTOM / GE
- Foster Wheeler
- IHI
- Hitachi
Inspections
Riley Power provides inspections of boiler design, auxillaries, instrumention and controls, fuel firing systems and stress analysis complemented with qualified field service personnel. We provide detailed inspection reports in a meeting held with your plant personnel to review the findings. A copy of the team’s field notes is left to assist plant to implement immediate or short-term repairs as required. A formal final report is issued containing finding, conclusions and recommendations.
Drone Inspections
Condition Assessments
Riley Power provides customized condition assessments of boiler components. We determine the current condition of your boiler, pressure part components and/or associated auxiliaries and provide results that can be used for planning scheduled outages and to help avoid forced outages. Our assessments are reliable and accurate and provide better control over operating and maintenance budgets.
Performance & Emission Testing
Riley Power provides a variety of testing services and engineering studies to assess your unit’s performance. Our testing services include: baseline performance assessment, efficiency and heat rate improvement, fuel system balancing and combustion optimization and cycling operation and equipment turndown capability studies.
- Structural Steel Design
- Balance Draft Conversions
- Emissions Reductions
- Boiler Capacity Upgrades
- Performance Optimization
- Life Assessment
- Computational Fluid Dynamics
- Boiler Technology
- Combustion Technology
- Mechanical Design
- Fuel Conversion
Training opportunities include:
- New Systems Training
- System Operation Training
- Maintenance Training
For more than six decades, Riley Power Inc. (RPI) has provided expert boiler metallurgical analyses. Our metallurgical laboratory is capable of conducting extensive analyses services, including destructive and nondestructive condition assessments, failure analysis, finite element analysis, quality control and any other materials related concerns.
Original Equipment Manufacturer Serving Pressure Parts Needs for Over One Century
Superheaters
Superheater materials, configuration, and design vary significantly. Some of these materials may require heat treatment to ensure prolonged life. BTA can assist with up-grading your superheater components. Superheaters often have tight radius bends. BTA has specific hot-forming procedures to assure acceptable bend geometry and material mechanical characteristics.
Headers
BTA can supply you with all your replacement header needs: machined, welded, tested, and stress relieved, if required. During the fabrication process, the pressure parts produced are under the strictest surveillance of BTA’s Quality Control Department to ensure compliance with the ASME codes.
Reheaters
Reheaters are exposed to very high temperatures during startup. Premature failure in reheaters is often related to poorly designed support and alignment systems, as well as inadequate tube material selection for the high temperatures to which they are exposed.
BTA can assist you when contemplating the redesign of your reheater.
Waterwalls
Waterwall materials, configuration, and design vary greatly depending on the style of boiler. Most waterwalls utilize a membrane panel construction. BTA uses a fully automatic, submerged arc process to weld both sides of the panel.Bent panels are typically fabricated on a panel bender to assure correct alignment of tubes.
Economizers
With extensive experience, the latest technology, surface materials and configurations, BTA has complete economizer design capabilities. We begin with the optimum surface for the application. We consult with you on your type of fuel, heat source, flue gas characteristics, operating hours, load variation, available draft, fouling, pluggage, sootblower requirements, gas velocity, and temperatures to provide you with the optimum solution.
Boiler Tube Company of America is a leader in providing boiler replacement pressure part components that improve unit performance by extending component life. Primary to achieving extended life is the use of Boiler Tube Company of America’s spiral clad tubing that utilizes state-of-the-art welding technology. Boiler Tube Company of America has developed a Hot Wire Gas Tungsten Arc welding process using Wave Pulse Technology (patented). Use of the Wave Pulse Technology with automatic hot wire TIG utilizing a fully integrated robotic microprocessor controlled system results in reduced weld metal dilution chemistry throughout the thickness of the overlay and favorable fusion properties.
Check our current inventory here.
BTA maintains one of the largest and most extensive tube inventories in the USA. Included are a wide array of sizes and wall thicknesses, in both seamless and welded tubes, commonly used in steam generators. We also have vast experience solving a variety of problems on all types of steam generators in many different industries. Often times we can recommend alternate materials or a redesigned configuration to resolve the existing problem more effectively.
- Burner Openings
- Finned Economizer
- Generating Tubes
- Screen Tubes
IMPROVE EFFICIENCY, OPERATION AND CONSUMPTION WITH THE GOAL OF REDUCING OPERATION & MAINTENANCE SPENDING
SCR Upgrades
It is as important to establish good distribution of flue gas flow, temperature, particulate, and NOx upstream of the ammonia injection system as it is to maintain ammonia distribution to the SCR. Optimizing distribution:
- Reduces effects of unit firing & flow configurations
- Provides homogenous flue gas and particulate mixing at the catalyst face
- Maintains mixing at low load operation
- Reduces the catalyst minimum operating temperature
- Reduces number of NOx monitors
- Reduces ABS formation
- Improves air heater efficiency
DSI Upgrades
Coupling sorbent injection with Babcock Power mixing technology ensures full mixing in short section of ductwork across the operating load range improving removal and reducing sorbent consumption. BPE Delta DSI systems reduce the number of lances required by more than 50% compared to a traditional DSI system. Locating the DSI system upstream of the SCR provides additional benefits including:
- Reducing catalyst minimum operating temperature
- Increasing sorbent residence time and therefore reducing lime consumption
- Reducing ABS scaling
- Improving air heater efficiency
- Reducing ammonia slip
- Increasing catalyst life
- Removing a fraction of HCl upstream of the WFGD system
Wet Scrubber Upgrades
WFGD scrubber upgrades normally involve applying new technology to existing systems to achieve optimal efficiency. Initially, an understanding of current problems is essential. Older models often have poor gas distribution and fail to remove significant amounts of SO2. They also present inefficient spray patterns over the cross section of the absorber. Babcock Power Environmental can successfully overcome these problems by utilizing its world-leading technology and experience. BPE will also optimize the system water balance to reduce effluent discharge and address water balance issues at reduced load operation. BPE is partnering up with a number of sub-suppliers to provide a lowest cost ZLD approach tailored to individual utility requirements.
Dry Scrubber Upgrades
Optimized operation of Circulating Dry Scrubbers include dewpoint monitoring control to increase SO2 removal and/or reduce lime consumption. Optimizing CDS bed pressure drop with flue gas flow reduces flue gas recirculation requirements at reduced loads and optimize system operation. Modeling is used to improve flue gas flow and temperature distribution to Spray Dry Absorbers at reduced loads to eliminate the requirement to place absorbers in and out of service on a system that is cycling on load. There are also options to replace high maintenance rotary atomizers.
EXPERTLY ENGINEERED DOOR SOLUTIONS FOR MAXIMUM SAFETY AND COST SAVINGS.
Boiler Tube Company of America/Imtec has been manufacturing Access Doors for the power industry since 1984. We have over 20,000 units installed and have experience in all areas of the power plant from the boiler to the stack.
The FLEXISEAL doors have one or more yokes with closing screws that act on center point(s) of the door. This flexes the door plate toward the interior and assures a tight seal with the gasket. When opening the door, special safety features in the latch and screw mechanism(s) will assure that the latch pin cannot be removed easily until the door plate with its gasket is safely retracted from the sealing surface on the frame plate, thereby revealing any dangerous internal pressure and also preventing damage to the gasket.
Imtec’s boiler doors with matching tube panels are available with a max operating temperature of 2800 degrees. The boiler door must withstand high operating and excursion gas temperatures. Therefore, on boiler doors type BC the inner side of the door plate is equipped with high efficiency insulation supported by interior shelves and all contained in a protective Insulation pan which is protected by a 2” layer of castable refractory. For flexibility and heat expandability the pan is made with slots and in movable sections from heat resistant steel. When installed, this insulation pan must be closely surrounded by water wall tubes shaped in a fashion to match the conical shape of the insulation pan.
Imtec Catalyst doors are designed to minimize the time required to remove and reinstall your Catalyst Modules. In most cases we can reduce the time needed to remove and reinstall casing/doors by 75% thus resulting in a very short payback period.
We have over 500 numerous installations of our doors in various plants throughout the U.S. A reference list is available upon request.
Imtec Catalyst doors are designed to minimize the time required to remove and reinstall your Catalyst Modules. In most cases we can reduce the time needed to remove and reinstall casing/doors by 75% thus resulting in a very short payback period. We offer doors that will work regardless of the type of removal you are performing (tracks, monorail or carts). Our patented door also allows for it to be raised above the floor level to swing out of the way.
We have over 500 installations of our doors in various plants throughout the U.S. A reference list is available upon request.
Imtec’s duct doors are available in three different styles: uninsulated, insulated and double doors with various operating temperatures from 400 degrees to 1000 degrees.
Imtec’s boiler doors without tube panels are available with a max operating temperature of 1800 degrees. The boiler door must withstand high operating and excursion gas temperatures. Therefore, on boiler doors type BM the inner side of the door plate is equipped with high efficiency insulation supported by interior shelves and all contained in a protective insulation pan which, for flexibility and heat expandability, is made with slots and in movable sections from heat resistant steel. When installed, this insulation pan must be closely surrounded by either refractory, a steel casing or water wall tubes shaped in a fashion to match the conical shape of the insulation pan.
Imtec’s penthouse doors are available in three standard sizes. With operating temperatures of 1000 degrees, these large penthouse doors permit quick access and rapid cooling of the boiler penthouse at forced outages.
Imtec’s roof doors are available in two different styles, with operating temperatures from 400 degrees to 1000 degrees.
DESIGN SOLUTIONS FOR ALL YOUR HEAT TRANSFER EQUIPMENT
- Anode
- Basket Tips
- Baffle Plates
- Channel Assemblies/Covers
- Connectors
- Demister
- Diaphragm Plates
- Expansion Joints
- Extrusion Seals / Sealant
- Gaskets
- Kits – Vaccum System
- Lantern Ring
- Manway Assemblies/Covers
- Manway Handling Device
- Orifices
- O-Rings
- Packing
- Partition Covers/Bolting Ring
- Pressure Gauges
- Rapture Discs
- Relief Valves
- Small Heat Exchanger
- Spray Nozzles
- Studs, Nuts, Bolts, Washers
- Temperature Gauges
- Thermocouples
- Thermowells
- Tube Bundle Replacement
- Tube Expander Tool Set
- Tube Plugs
- Tubesheet (Stationary/Floating)
- Tube Stakes
- Torus Ring
- U-Tubes
- Performance analysis
- Model testing
- FEA analysis
- Heater train studies
- Vibration analysis
- Repair vs. replace planning
- Equipment modifications
- Training seminars
Extend the Life of Your Asset
- Projectile
- Rotary
- Eddycurrent
- Pneumatic Vacuum
- Hydro & Air
- Shell
- Cable design
- Solid rod design
- Mechanical
- Explosive
Troubleshooting and repair of Condensers, Feedwater heaters or any type of Shell and Tube Heat Exchanger issues by trained and qualified personnel.
- Condenser
- U-Tube
- Feedwater Heaters
- Lube Oil Coolers
- Condenser
- U-Tube Feedwater Heater
- Lube Oil Cooler
- Condenser
- U-Tube Feedwater Heater
- Lube Oil Cooler
- Condenser
- U-Tube Feedwater Heater
- Lube Oil Cooler
TOP PEOPLE, REGIONAL LOCATIONS, WE DELIVER
TEIC Construction Services leads the industry with more than 20 years experience in providing direct-hire, on-site construction services for the installation, repair, alteration and maintenance of boilers and boiler-related equipment nationally. Our services include:
• Gas Conversions
• Ash Dewatering Systems
• Auxiliary Boiler Installation
• Environmental Control Systems
Focused on doing outage work the right way, TEiC provides open shop direct-hire construction services for new and existing plants. TEiC provides on-site construction services for the installation, alteration, repair, or maintenance of any OEM’s boiler and boiler related equipment, including but not limited to pressure parts, firing systems, air heaters, fans, feedwater heaters, condensers, piping, and ductwork.
With a proven track record of safety, on-time completion, and customer satisfaction, you can count on TEiC to meet all your requirements of new or existing installations.
Balance of Plant Services (BOP)
- Structural Steel
- Piping & Valves
- Duct Work
- Conveyors
