Power plant service

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With service and manufacturing centers around the world, ANDRITZ is well-positioned to offer the full support you need. We are your dependable partner – helping you achieve the highest availability and optimum performance over the entire life-cycle of your system.

Your dependable partner

ANDRITZ power plant service specialists

know their way around power plant opera-

tions and flue gas treatment systems. They

can be by your side in an instant (either

physically or through remote diagnostics)

with analytical tools and expert assistance

to help you decide the most cost-effective

course of action. From routine and pre-

ventative maintenance to performance

enhancements and modernizations, you

can depend on ANDRITZ power plant ser-

vice to analyze your operations, assess

the condition of the equipment, and advise

how to improve the efficiency and per-

formance of your plant, including the flue

gas treatment system. To complement our

services, we manufacture and stock a full

range of replacement parts. Specialists can

assist in shutdown planning, on-site coor-

dination, supervision, and the actual shut-

down work. Regardless of which services

are needed, plant operators can depend

upon ANDRITZ in-depth knowledge, years

of experience, and competitive pricing to

deliver results.

At your side. Talk to us about your goals

for streamlined operations and higher

performance.

CONTENTS

Your dependable partner 02

Full support for the life of 03 your plant

Services for a wide range 04 of applications

At your side 06

All-in-one solutions 09

Maintenance and upkeep 10 guarantees

Made-to-measure 13

The extra mile 14

Examining the chemistry 16

Automation and diagnostic tools 17

Recent references 18

03

Full support for the life of your plant A range of comprehensive servicesField service and consultation

Inspection

Maintenance

Annual outage and scheduled

maintenance

Long-term service agreement (LTSA)

Plant operation

Measurement and analysis

Plant condition assessment

Online monitoring

Training

Service product development

Life cycle calculation

Process studies

Process tuning

Circulation studies

OPE agreements

Rebuilds and modernizations

Performance improvement

Retrofit

Plant upgrades

Firing system upgrades

Pressure part refurbishment/

replacement

Plant behavior

Emission reduction

Co-firing of biomass

Oxy firing CFB

Grate-fired over fire air systems

Replacement and wear parts

Replacement 1:1

Spare parts inventories

Wear components

OPE agreements

OPE process agreements

OPE maintenance agreements

04

Industrial applications

BFB/EcoFluid

Biomass / multi-fuel

5-250 t/h

CFB/PowerFluid

Biomass / multifuel

RDF, coal

50-500 t/h

< 180 MWel

< 640,000 Nm³/h

Burners: Upgrades for different fuels

Fuel oil

Natural gas

Bio gas

Bio oils (pitch oil, tall oil)

Burners: Upgrades of

auxiliary equipment

Pumping units

Control units

Valve units

Safety related control systems for burners

SulfitePower and SodEx

Sulphite liquor

Sodium liquor

Chemical recovery

Grate-fired

Coal

Bark

Multi-fuel

Services for a wide range of applicationsYour partner for a comprehensive spectrum

PowerBlast

Blast furnace, coke oven, converter gas

100-600 t/h

Utility boilers

Oil/gas boilers

Utility and industrial applications

Bottom-supported: up to 200 t/h

Minimum refractory installation

Tailor-made designs

Capacities up to 600 t/h

HRSG

Vertical or horizontal

Up to triple-pressure reheat

Highest efficiency

Kraft recovery

Air pollution control

Power stations

Industry

Energy from waste and biomass

Wet limestone FGD / FGC

Multi-stage systems

CO2 absorption

Turbo-CDS / TurboSorp

Dry sorption

SCR technology

ANDRITZ offers power plant service for a wide range of technologies and applications.

Modernization of one drum boiler in Zweckel, Germany

05

06

Expert reports on damage and

condition assessments

On thermally stressed components in pow-

er plants the determination of the residu-

al service life and condition assessments

comprising:

Inspection and walkdown of the com-

plete boiler plant installation

Elaboration of examination programs

Field service and consultation

Pre-annual outage inspection

services

Inspection of boilers and related compo-

nents during a pre annual outage inspec-

tion with detailed metallurgical analysis of

associated components, developing annu-

al outage S.O.W.

Annual outage and planned

maintenance services

Pre-outage maintenance strategy devel-

oped in combination with pre-inspection

report and our maintenance methodology

provides customers with optimized mainte-

nance scenario solutions.

Long-term service agreements (LTSA)

Permanent on site full service provision of

all skill sets and equipment required for to-

tal maintenance support.

Case studies

Service provides individual analytical ex-

pertise for all engineering and operational

disciplines of power plants, including wet

flue gas desulphurization plants. Subse-

quent test runs in conjunction with the cli-

ent display the performance to the plant

and render the provision of a sustainable

solution.

CFD – Computational fluid dynamics

A CFD simulation provides a localized and

time resolved representation of the flow or

combustion in single and multiple-phase

flow processes.

At your sideExpert assistance when and where you need itClean air is the basis of a healthy life on earth. Air pollution causes harm or discom-fort to people and other living organisms all over the world. The damage of the natural environment in our atmosphere is a threat to human health. Therefore it is our obligation to minimize the impact of air emissions from power generation processes.

CFD analyses

Flow optimization of all types of ducts

Wet flue gas desulphurization

optimization

Flow optimization of burners

Combustion analyses of solid, liquid and

gaseous fuels

NOx reduction types of boilers

07

Destructive and non-destructive exami-

nation of materials in all processes

On site replica technology on the site

and subsequent metallographic

evaluation

Fatigue calculation

Assessment of the residual service life

Reporting and elaboration of expert

reports

These are performed by ANDRITZ power

plant service in close cooperation with the

plant operator leading to the development

of individual proposals aimed at increasing

the service life and measures needed to im-

prove the overall plant situation.

Rebuilds and modernizations

Fuel conversions fossil-biomass

Co-firing or conversion of conventional fos-

sil fuels to alternative fuels, biomass and

novel fuels etc.

Firing system upgrades

Upgrade/conversion of vintage firing tech-

nology with technology consistent with cur-

rent efficiency, stability and reliability de-

mands.

Emission reduction/compliance

studies

Plant environmental review, emission con-

trol analysis and expert council on compli-

ance requirements to the current and future

environmental legislation.

Boiler CFD modelling

Full suite of CFD technologies to assist and

support process deliverables needed for

the above modernization services.

Spare and wear parts

Supply and warranty for the complete ex-

change of replacement parts and logistical

support to develop minimum strategic in-

ventory levels.

OPE agreements

ANDRITZ services will help you raise the

Overall production efficiency (OPE) of your

plant.

Plant upgrade in Ataka, Egypt

Measurement and analyses

Inspection of heat recovery steam generator in Csepel, Hungary

08

09

Count on us for maintenance, modernization, or fabrication.

All-in-one solutions

The foundation for all of our services is a spirit of partnership, clear and open communications, and professional competence – on time and within budget.

Listening, analyzing, organizing

Even though we operate in different indus-

tries and segments (power stations, indus-

trial boilers, renewables, or Energy-from-

waste) the foundation for our work is quite

similar. At times, the most important service

we provide is to listen well, analyze the cur-

rent situation, and provide recommenda-

tions to help you improve your operations.

For repairs and urgent situations, this can

sometimes be accomplished with a tele-

phone call. For optimization and modern-

ization opportunities, the work is much

more involved. But, every time our service

starts with a personal discussion.

We listen to you and ask questions to un-

derstand your requirements and priorities.

For the unanswered questions, we analyze

the current condition of your plant, pore

over the available data, and determine the

site-specific prerequisites. Based on this

information, we develop solutions and ad-

vise you of the possible alternatives.

Our proposals and recommendations help

you to make informed decisions and serve

as the foundation for the work to be done.

The following pages describe our service

deliverables:

Plant maintenance and operation

Modernization and performance

enhancements

Technical support

Manufacturing

Meeting expectations All-in-one service solutions from your technology partner

10

Maintenance and upkeep guarantees for reliable and streamlined operationRegular maintenance, good housekeeping, periodic inspections, and the access to the correct replacement parts are all essential for smooth operation of your plant. By establishing a disciplined approach to these activities, plant availability will remain high throughout its entire life-cycle. Taking a long-term perspective in planning for these factors and relying on a dependable partner to help execute them will reduce your overall operating costs and maintain your efficiencies.

Our commitment

The main objective of predictive and

planned maintenance is to keep equipment

availability high at the lowest overall cost.

You can call on us whenever you need us,

and we will be on site promptly with the

skilled specialists, the proper tools, and the

needed parts to assist you. Our support

is founded on an all-encompassing service

provision.

Plant maintenance

Regular and professional plant mainte-

nance is not only the key prerequisite for

efficient operations, it is a decisive factor

in extending the life of your equipment. We

are eager to offer you the support you re-

quire to keep your plant maintained. We of-

fer maintenance services on a one-off ba-

sis or through long-term contracts and ser-

vice-level agreements. These agreements

can include regular inspections, overhauls,

replacement parts, and 24/7 technical and

process assistance within a clearly defined

framework. For you, this means high reli-

ability and maximum availability, combined

with cutting edge technology.

Inspections eliminate surprises

Even with regular maintenance, plants that

operate around the clock are well-served

to conduct an annual inspection. For many

applications, this is also a regulatory re-

quirement. We can help with this important

work. Our specialists can inspect all major

equipment from fuel delivery to the stack.

They will analyze operating data and the op-

erating performance during prior periods.

They check components for signs of wear

and, if necessary, take samples (fuel, ash,

flue gas treatment residues, etc.). Based

on these results, they will recommend the

actions to be taken during an annual over-

haul to maximize your plant’s service life in

a written quotation. This provides you with

solid decision-making criteria and protects

you against unwelcome surprises.

Annual outages: you call the shots

You determine the timing and scope of the

annual overhaul and we provide swift and

professional implementation. We outline

the procedures, organize the workforce, ar-

range for the correct tools, and ensure that

the needed wear and replacement compo-

nents arrive on-site when needed. Depend-

ing on your preference, the overhaul work

can be handled completely by our people,

with the assistance of your staff, or exclu-

sively by your team under the supervision of

one of our overhaul experts. When the job

is complete, you will receive a final report

detailing the work performed and the parts

replaced, along with recommendations for

optimizing the future operation and main-

tenance of your plant.

11

Experienced personnelmake sure projects are handled

reliably and on schedule.

Entrust operations to us and we

will take care of maintenance

For companies where power generation is

not their core competence, one solution

we offer is to outsource the operation and

maintenance of their plant to ANDRITZ. In

many cases, this is a more cost-effective

solution as it ensures professional opera-

tion and environmental compliance. Con-

tract operations and maintenance is not a

problem for us. We have decades of ex-

perience in plant engineering and opera-

tions, backed by a global support network.

Customers benefit from our global expe-

rience and are ensured that their plant is

being operated and maintained on the ba-

sis of the latest technical findings and in

compliance with all aspects of safety. They

can depend on us to ensure high availabil-

ity and safeguard the plant’s rated capac-

ity and output.

Operation and maintenance

Inspections

Annual overhauls

Long-term service agreements

Replacement parts

Performance improvement

12

13

Our experience in planning, construction and assembly emphasises our competence in plant operation.

Made-to-measureSupportOur service specialists are focused on the needs of each customer. Our commitment goes far beyond maintenance, operation, and modernization. You can depend on us to go the extra mile.

Parts management:

from planning to delivery

Spare parts management can be com-

plex and cost-intensive. Inventorying the

parts requires adequate space on-site.

ANDRITZ power plant service specialists

can handle the parts management activi-

ties for your plant – ensuring fast, compe-

tent, and reliable procurement and delive-

ry of wear components and replacement

parts. We will take care of sourcing and fa-

bricate custom components when needed

at our at our manufacturing facilities. For

you, this translates into cost savings, time

savings, aand not having to worry about

maintaining precious storage space.

We put your plant through its paces

In addition to standard inspections and

analyses, we also can offer you assess-

ments to determine the residual life of spe-

cific components. We check wall thicknes-

ses, examine structures, calculate stress

conditions, and provide our best projec-

tions. On the basis of this, you can decide

whether to initiate life-prolonging measures

or to opt for the replacement of operation-

critical components.

Broader fuel flexibility and

biomass instead of fossil fuels

We have the experience base and theore-

tical knowledge to help your team plan for

the conversion of your plant to new fuel ty-

pes. Our capabilities range from the reca-

libration of your plant for new fuel charac-

teristics within the same fuel category to

supporting you in the switch to new fuels –

such as co-combustion of biomass or the

substitution of fossil fuels.

Computer simulation:

virtual optimization

Our specialists can create computer-based

simulations of your plant to identify opti-

mization opportunities. Based on real-time

measurements, our proprietary software

will calculate energy and substance flows,

allowing us to analyze your specific oper-

ations. With computational fluid dynamics

(CFD) simulations, we emulate combustion

processes, answer flow-related questions,

and provide recommendations to optimize

your facility.

Long-term service agreement

14

The extra milefor application and burnersA suite of different technologies to assist and support you.

Online monitoring for the opti-

mization of operating parameters

Online monitoring, based on a direct con-

nection between your automation system

and our service center, supports your staff

in operating and optimizing the operation of

your facility. This remote monitoring and as-

sistance is particularly valuable during the

commissioning phase, for the analysis of

substance flows, or for obtaining data to

identify improvement potential.

In-house laboratory

Our laboratories are equipped with modern

fixed and mobile instrumentation and, more

importantly, are staffed with professionals

who are intimately familiar with all facets

of plant operation. This special knowledge

distinguishes ANDRITZ from its counter-

parts.

As much as humanly possible, our recom-

mendations are based on facts, physical

measurements, and chemical analyses.

Thanks to their extensive experience, our

specialists are able to draw the right con-

clusions and make significant contributions

to solving plant problems and optimizing

operations.

Taking it a step further

Our mix of deliverables goes beyond these

specialities. Talk to us about the services

listed in the adjacent table. And if there is

anything you need that is not listed, please

contact us. We are at your side.

Technical support

Feasibility and cost-effectiveness

studies

Construction supervision

Commissioning

Condition surveys

Instrumentation and analyses

Monitoring

Service product development

Training programs

15

Velocity vectors

16

Analytical chemistry

Fuel analysis

Rheological examinations of oils and

byproducts of pulping technology

Analysis of specimens taken from the

water and steam cycles of boilers

Analysis of deposits and corrosion prod-

ucts on the flue gas and the water side

Combustion tests with special fuels and

biomass

Examing the chemistryAnalysis begins with a detailed investigationANDRITZ provides analytical services for all engineering and operationaldisciplines in power plants.

Environmental analysis

Process and waste waters

Waste and landfill sampling

Sewage sludge and compost

Solid, liquid, and gaseous combustion

products

Reactivity tests of materials used in flue

gas cleaning plants

Residues

Analysis of flue gas cleaning products

Determination of the concentrations of

elements in dust, ash, slag, sediment,

and residue

17

OPE Process tools

Advanced condition diagnostics

ACDOptimization of process performance

OPP

Acoustic emission measurements

AE

Upper level controls

ACE

Portable IR camera

IRC

Safety related systems

SRS

Control loop tuning

Tuning

OPE process agreements

OPE agreements

OPE maintenance agreements

Portable measurements

ANDRITZ OPE agreements Raising the overall production efficiencyWith ANDRITZ OPE, you have access to our professionals who know how to extract the maximum performance over the lifetime of your equipment. We work closely with your operations and maintenance experts, and local partners, to apply the most modern maintenance technologies and tools for achieving the best results.

Benefits

Production

Maximum production

Millwide knowledge and experience

Reliability and cost efficiency

Upgrades and optimization

Savings and time

Reduced life-cycle costs

Short and effective shutdowns

Longer intervals between shutdowns

Successful start-ups

Environment and energy

Improved energy efficiency

Reduced consumption of chemicals,

water and raw materials

Minimal environmental impact

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OMVCustomer: J.Christof GmbH / OMV Schwechat, AustriaCapacity: 250 t/h steam output, one El Paso boiler Scope: RehabilitationFuel: Fuel oil, natural gas, Start-up: 2009

ZweckelCustomer: E.ON Kraftwerke GmbH, GermanyCapacity: 65 t/h steam output, one drum boilerScope: Burner upgrade, ESP upgradeFuel: Fuel oilStart-up: 2008

DonawitzCustomer: Voest Alpine Stahl Donawitz, AustriaCapacity: 230 t/h steam output, one drum boilerScope: ModernizationFuel: Natural gas, blast furnace gas, converter gasStart-up: 2006

Golbey Norske SkogCustomer: Norske Skog Golbey, FranceCapacity: 140 t/h steam outputScope: Modification of BFB boilerFuel: Wood, sludgeStart-up: 2005

LinzCustomer: voestalpine Stahl GmbH, AustriaCapacity: 460 t/h steam outputScope: ModernizationFuel: Blast furnace gas, natural gasStart-up: 2007

Klabin S.ACustomer: Klabin S.A, BrazilCapacity: 250t/h, CFB boilerScope: Annual shut down advisory and spare partsFuel: Wood, fuel oilStart-up: 2008

Ataka Power StationCustomer: East Delta Electricity Production Company, EgyptCapacity: 485 t/h steam outputScope: Pressure parts, air-heater, burnersFuel: Fuel oil, natural gasStart-up: 2011

BergkamenCustomer: RWE Power AG, GermanyCapacity: 2.249.000 Nm3/h flue gas streamScope: Modernization of FGDFuel: Bituminous coalStart-up: 2007

VasilikosCustomer: Electricity Authority of Cyprus, CyprusCapacity: 390 t/h steam output, one drum boilerScope: Consultancy for burner modificationFuel: Fuel oilStart-up: 2007

Recent references

19

Evergreen Community PowerCustomer: ECP, USACapacity: 150t/h steam output, CFB boiler Scope: Operation monitoring and consultancy, spare partsFuel: Biomass, incinerationStart-up: 2009

Portucel SetubalCustomer: Portucel Setubal, PortugalCapacity: 110 t/hScope: Economizer modification of BFB retrofitFuel: Bark, wood biomass Start-up: 2008

IKPP Perawang Customer: PT Indah Kiat, IndonesiaCapacity: 400 t/hScope: Furnace walls rebuild for CFB boilerFuel: Coal, BarkStart-up: 2002

SCA ÖstrandCustomer: SCA, SwedenCapacity: 200 t/hScope: Wood dust burner for BFB boilerFuel: Bark, wood dust, oil Start-up: 2010

Dalkia PoznanCustomer: Dalkia Poznan, PolandCapacity: 110 t/hScope: Conversion coal fired boiler to BFBFuel: Wood and agro biomassStart-up: 2011

UPM TervasaariCustomer: UPM, FinlandCapacity: 162 t/hScope: Recovery boiler conversion to gas firedFuel: GasStart-up: 2010

Portucel SetubalCustomer: Portucel Setubal, PortugalCapacity: 110 t/hScope: Rebuild of power boiler, BFB retrofit Fuel: Bark, wood biomassStart-up: 2012

UPM TervasaariCustomer: UPM, FinlandCapacity: 101 t/hScope: Air preheater and eco modification for BFBFuel: Bark, peat, biomassStart-up: 2010

Eisenhüttenstadt IKWCustomer: Energiewirtschaft Oderbrücke, GermanyCapacity: 142 t/h steam output, special heat recovery steam generator Scope: Planning, supervisory and execution of annual shutdownFuel: Natural gas, blast furnace gas; Start-up: 1997

All data, information, statements, photographs and graphic illustrations made in this leaflet are without any obligation and raise no liabilities to or form part of any sales contracts of ANDRITZ AG or any affiliates for equipment and/or systems referred to herein. © ANDRITZ AG 2015. All rights reserved. No part of this copyrighted work may be reproduced, modified or distrib-uted in any form or by any means, or stored in any database or retrieval system, without the prior written permission of ANDRITZ AG or its affiliates. Any such unauthorized use for any purpose is a violation of the relevant copyright laws. ANDRITZ AG, Stattegger Strasse 18, 8045 Graz, Austria.

www.andritz.com

CONTACT

AUSTRIAANDRITZ AGWaagner-Biro-Platz 18074 Raaba-Grambach, AustriaPhone: +43 (316) 501-0Fax: +43 (316) 501-482info-aee@andritz.com

ANDRITZ AGEibesbrunnergasse 201120 Vienna, AustriaPhone: +43 50805-0Fax: +43 50805-51021info-aee@andritz.com

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CHINAAE&E Environmental Engineering (Shanghai) Co., Ltd.Room 706, East Block, China Merchants Plaza, No. 333 Chengdu Road (N.),Shanghai, 200041, P.R. ChinaPhone: +86 (21) 52981616

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PP.SER.01.eng.06.15