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.

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.

• Burner Openings
• Finned Economizer
• Generating Tubes
• Screen Tubes

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.

• Performance analysis
• Model testing
• FEA analysis
• Heater train studies
• Vibration analysis
• Repair vs. replace planning
• Equipment modifications
• Training seminars

• 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