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About Mitsubishi Hitachi Power Systems, Ltd.
Mitsubishi Hitachi Power Systems, Ltd. (MHPS) based in Yokokama /Japan, is a global energy
plant constructor player and has a total of 58 subsidiaries (9 in Japan, 49 in other countries).
The company was established as a joint venture in February 2014. It unites the thermal power
plant divisions of Mitsubishi Heavy Industries, Ltd. and Hitachi, Ltd. MHPS employs some
23,000 staff (consolidated) and its aim is to be No. 1 in thermal power plant construction.
Content Internationally on the Go 2
Service as a Key Business 4
Maintaining Performance 6
Trendsetting Technologies 8
Fitting Solutions for Any Application 9
Lignite Coal Dust Burner 10
Firing Systems 11
Grate Firing – Roller Grate 12
Stoker Firing – Moving Grate 14
Pulverizers 16
Assembly Planning 20
Conversion – Modernisation – Maintenance 21
Commissioning 22
Shield for Accelerated Boiler Service (SABS®) 24
Boiler Service 28
Quality Management & QC Monitoring 30
References 32
BUSINESS ACTIVITIES / PRODUCTS OF MITSUBISHI HITACHI POWER SYSTEMS, LTD.
Power Generating Plant Peripheral Equipment
Steam Turbines
Environmental Plants SCR (DeNOX) Systems / Flue Gas desulfurization
Gas TurbinesGas Turbine Combined Cycle (GTCC) Power Plants
Integrated Coal Gasifi-cation Combined Cycle (IGCC) Power Plants
Boiler & Turbine Generation Plants
Geothermal Power Plants
Boilers
Generators
2
Internationally on the Go
About Mitsubishi Hitachi Power Systems Europe GmbH
Mitsubishi Hitachi Power Systems Europe GmbH (MHPSE) is a 100 % subsidiary of Mitsubishi
Hitachi Power Systems, Ltd. (MHPS). The energy plant constructor headquartered in Duisburg
both designs and builds thermal power plants (coal, gas). With its references MHPSE ranks
amongst the market and technology leaders. The company also supplies key components
such as utility steam generators, environmental engineering equipment, turbines and coal
grinding systems.
Along with supplying key components, MHPSE also concerns itself with pro-active service.
Green technologies – in energy storage and biomass, for instance – are further examples of
the energy plant constructor’s innovation and reliability.
MEERANER DAMPF KESSELBAU GMBH
Manufacturing of premium components for utility steam generators
(e. g. pressure parts) for power plants
DONGES STEEL TEC GMBH
One of Germany’s leading steel and bridge constructors;
manufacturing of steel structures for power plants
BABCOCK FERTIGUNGSZENTRUM GMBH
Production of first-class components for power plants
(e. g. coal mill), mainly for MHPSE
MITSUBISHI HITACHI POWER SYSTEMS EUROPE GMBH
Subsidiaries and Related Companies
Powerful Services 3
Everything from a single source
In supplying spare parts, revamping components, raising efficiency and extending the plant
life cycle, Mitsubishi Hitachi Power Systems Europe provides extensive service solutions for
power plants and components. The company has obtained comprehensive references
thanks to a 100 year+ track record in designing, constructing and commissioning energy
plants. This applies both to the new construction business and also to repairing external
and in-house facilities as well as servicing/optimizing components (e.g. grinding systems,
turbines, grates).
The expertise gained covers all types and sizes of power plants and firing systems
for all conventional fuels:
■■ Water tube boilers (natural circulation)
■■ Heat recovery boilers (process)
■■ Heat recovery boilers
(downstream of gas turbine)
■■ Waste-to-energy systems
■■ Fluidized bed systems
■■ Special boilers (chemical industry)
■■ Benson® steam generators
The Service business includes construction, commissioning, quality management, documen-
tation and a 24-hour emergency service. MHPSE specialists provide solutions from a single
source and thus ensure that orders are handled reliably and efficiently.
4
Service as a Key Business
Beater wheel of an NV mill
Service for mills
Whether it is lignite or hard coal, whether they are our own products or from other
manu facturers: Mitsubishi Hitachi Power Systems Europe has comprehensive expertise in
the optimisation of crushing and grinding plants. Our experienced service specialists
determine reliable and operationally safe solutions to significantly improve the performance of
coal mills. Spare parts, repairs and a comprehensive on-site service complete the portfolio.
Our services at a glance:
Optimisation
■■ Adaptation to changed
coal properties
■■ Increase of throughput and
grinding fineness
■■ Milling of non-standard fuels
■■ Classifier / fuel laden vapour
separator optimisation
■■ Process engineering consulting
■■ Mill instrumentation and control
systems
Upon request, our specialists will perform comprehensive mill measurements and will
utilise specifically developed, highly precise CFD calculations (Computational Fluid Dynamics).
Spare parts / repairs
■■ Installation of complex components
■■ Overhauling of components, repair
■■ Complete solutions / overall packages
(from removal to commissioning)
On-site service
■■ Providing staff for performing
conversions
■■ Long Term Service Agreements,
LTSA
Powerful Services 5
Service for turbines
Maintaining performance and availability: That is the premise for the service for turbines.
Due to many decades of experience in the construction and commissioning of steam /gas
turbines within the Group, our experts can perform a comprehensive fault analysis in case
of mechanical, electric and instrumentation and control system problems. A 24 / 7 hotline
and instant service for gas turbines are a matter of course. Our services in the area of
turbine service also include:
On-site service
■■ Combustion chamber inspection
(gas turbines)
■■ Hot gas routes inspection
(gas turbines)
■■ Main inspection (gas turbines)
■■ Training of the customers’ staff
■■ Service for generators
■■ Elimination of mechanical, electrical
and instrumentation and control
system problems
Engineering
■■ Support for modification, modernisation
and conversion
■■ Planned / unplanned maintenance
■■ Long Term Service Agreements, LTSA
1 Removal of the second generator stage
2 + 3 Removal and cleaning of the turbine housing during
inspection of the hot gas routes
1 2
3
6
Maintaining Performance
Construction / Commissioning
Whether new plant construction, revamping or servicing individual components is involved,
the Service division of Mitsubishi Hitachi Power Systems Europe provides both technical staff
and equipment for construction and commissioning of power plant installations and their
components.
This is undertaken whatever the location and country with regard to:
■■ New steam generator construction
■■ Inspection, repairs and
maintenance work
■■ Boiler implementation
■■ Field site inspection
■■ Plant optimization
■■ Measuring technology
■■ Power plant chemistry
■■ Personnel instructional training
■■ 24hr hotline service
Spare parts
Mitsubishi Hitachi Power Systems Europe can resort to both manufacturing facilities
within the Group and from associated companies. That makes MHPSE an ideal partner for
optimising work and obtaining spare parts.
Our spare parts service includes the following components:
■■ Feeders
■■ Grinding systems
■■ Firing systems
■■ Ash extractors
■■ Gas and steam turbines
■■ Boiler pressure parts
■■ Stoker firing
Whether it is new plant construction, modernisation or maintenance of individual components – we provide the specialist staff and equipment
Powerful Services 7
Optimal furnaces for every kind of fuel
For over 50 years Mitsubishi Hitachi Power Systems Europe GmbH has been successful in
constructing and manufacturing burners, as well as developing combustion concepts for
wordwide plant engineering.
Whether in power plants strictly for power generation or in industrial power plants for steam
and power generation, the furnace systems of Mitsubishi Hitachi Power Systems Europe
are applied in almost all areas of energy conversion and are always optimally adapted to the
prevailing requirements.
Fuels have different chemical components, combustion properties, calorific values and
flame velocities. This demands a careful selection of the type of combustion, the burner
arrangement in the furnace, as well as the burner construction.
To not only achieve the legislative limits for air pollutants imposed for the protection of the
environment but rather stay below them, we are constantly further developing our furnace
systems in cooperation with the UMSICHT Fraunhofer Institute and the Chair of Environ mental
Process Engineering and Plant Design at the Duisburg-Essen University (LUAT – Lehrstuhl
für Umweltverfahrens- und An lagentechnik). As a result, our plants have already been trend-
setting for many years in the field of primary corrective measures for pollutant reduction.
According to customers requirements, we carry out thermodynamic calculations, create
concepts based on these models for the modernisation, rehabilitation, repair, conversion,
as well as fuel adaptation, including all the related E-C&I components.
From planning, basic and detailed engineering to the delivery and construction as well as
commissioning and acceptance, we implement the concepts up to final hand-over of the
plant, and guarantee an interface-free optimal integration into the energy production system.
Firing systems
■■ Burner and firing systems for fossil fuels
■■ Burner and firing systems for process gases
■■ Thermal disposal of residues
■■ Claus Plants for sulphur recovery
■■ Firing systems for GT exhaust gases
Steam atomisation for liquid fuels
8
Trendsetting Technologies
Our types of burners and their different applications
Independent of the different combustion characteristics of the fuels being used, we have the
suitable burner types and combustion systems. This diversity of combination options ensures
the optimal solution for any field of application.
Fuels Type of furnace Burner design
■■ Natural gas■■ Light fuel oil (LFO)■■ Heavy fuel oil (HFO)■■ Hard coal■■ Lignite■■ Coke-oven gas
■■ Front firing■■ Boxer firing■■ Tangential firing■■ Bottom firing■■ Top firing
■■ Swirl burner■■ Stage burner■■ Jet burner
■■ CO exhaust gas■■ Blast furnace gas■■ Sour natural gas■■ Tail gas■■ Contaminated air ■■ Contaminated steam
■■ Combustion chamber■■ Front firing■■ Tangential firing■■ Bottom firing
■■ Swirl burner■■ Multi-nozzle burner■■ Claus burner
■■ Waste water■■ Salt residues■■ Residual coke / petroleum coke■■ Slugdes
■■ Preceding combustion chamber■■ Front firing■■ Top firing
■■ Special burner■■ Cyclone
■■ Residual gases NOX , HCN, NH3 burdend
■■ Reactors with 2 or 3 air stages / fuel staging
■■ Central burner■■ Stage burner■■ Multi-nozzle burner
Low NOX pulverised coal burner
Powerful Services 9
Fitting Solutions for Any Application
Harmonised range of products
In medium-sized power plants, pre-fabricated pulverised lignite dust is increasingly used as
fuel to avoid costly milling machinery.
Our round swirl burners with their primary NOX -reducing measures have also been success-
fully in use for this fuel for years. Likewise, the formation of nitrogen oxides (NOX ) is reduced
by the staged air supply, and low emission values are achieved with the combustion of
pre-fabricated pulverised lignite dust.
Pulverised coal furnace for hard coal and lignite
The round swirl burners, used and proven in power plants for years, have been further
developed and improved by staged air in the burner, resulting in Low-NOX furnaces,
and are therefore also known as “Low NOX” pulverised coal burners.
The possibility to adjust the various airflows, permits an adaptation to a broad range of fuels.
Here, too, similar to gas-oil combustion, the generation of nitrogen oxides (NOX) is reduced
by the sub-stoichiometric combustion in the core of the flame. The simultaneous avoidance
of temperature peaks during combustion decreases the rate of formation of thermal
nitrogen oxides.
Another NOX-reducing measure is the staged combustion over the entire combustion cham-
ber. The combustion air is hereby provided in stages both to every burner level as well as
across the whole combustion chamber. Downstream of the overfire air injection, the sub-
sequent residing time of the solid fuel particles in the respective combustion areas determines
the burnout and the degree of NOX reduction.
Another possibility of NOX reduction is the injection of a reduction fuel between the last
highest burner level and the upper air. One such typical reduction fuel consists of a mixture
of recirculated flue gas and natural gas.
For hard coal and lignite furnaces, our scope of delivery comprises of all components of the
combustion system including all necessary auxiliary equipment, such as:
■■ Pre-fabricated dust silo
■■ Inertisation plants
■■ Weighing equipment
■■ Pneumatic conveying equipment
■■ Burners
■■ Burner control units
■■ Measurement and control components
■■ Coal mills
■■ Pulverized fuel lines
■■ External flue gas recirculation
■■ Coal feeders
■■ Ash removal plants
10
Lignite Coal Dust Burner
OIL / GAS FURNACES
MHPSE uses special burner systems for low NOX combus-
tion of fuels with a high calorific value, such as oil and gas.
OUR COMBUSTION FOR BLAST FURNACE GAS AND COKING GAS
Blast furnace gas comes from the blast furnace process
and is characterized by low calorific values. An additional
difficulty is the usually very low pressure of the gases,
requiring the lowest possible pressure drop across the
burner. Particular attention must therefore be paid to the
burner design for achieving a proper fuel / air mixture.
LOW BTU GAS FURNACES
Gases with low heating values, such as low-calorific
gases from process technologies, require special gas
burner designs.
FURNACE SYSTEMS FOR GT EXHAUST GASES
In combination power plants whose steam generator
plants are equipped with gas and steam turbines, the
energy conversion processes permit an increase of net
efficiencies of more than 50 %.
PLANTS FOR NOX REDUCTION
In our plants the already existing NOX is reduced again
and reduction rates of up to 95 % can be attained.
Powerful Services 11
Firing Systems
Roller grates – the robust, low maintenance grate concept
Whether in power plants purely for power generation, or in industrial power plants for steam
or power generation: The firing systems of Mitsubishi Hitachi Power Systems Europe GmbH
are applied in almost all fields of energy conversion and are always optimally adapted to the
specified requirements.
Environmentally-friendly combustion requires special concepts and measures for household
and municipal waste, RDF, treatment of residues as well as biomas. The use of the thermal
energy generated from grate firing offers an appropriate and economic alternative to landfilling.
Different grate systems are selected depending on the calorific values. Medium and high
calorific waste requires grate systems with grate bar cooling systems to limit the grate bar
temperature, such as our patented air- and /or water-cooled moving grates.
For low or medium calorific residues, however, quite often the robust roller grate systems with
the more economical cast iron surfacing are frequently used.
Whatever the composition or calorific value of your waste may be, with our numerous grate
system currently in use that have proven themselves for many year, we definitely have a
suitable combustion grate for your case.
Our service portfolio:
■■ Air- and water-cooled combustion grates
■■ Feeding devices & ash extraction systems
■■ Systems for primary / secondary air and recirculation flue gas
■■ Ignition and auxiliary firing system
■■ Firing optimisation
■■ Fluid dynamics simulations (CFD studies)
■■ Combustion control systems
12
Grate Firing – Roller Grate
Technical parameters of the roller grate
Fields of application
■■ LCV from 5,000 to 14,000 kJ / kg
■■ Max. throughput up to 40,000 kg / h
Advantages
■■ Robust and low-maintenance grate system
■■ Intensive turning and mixing of the waste
■■ Fast drying and ignition of the fuel
■■ Use of low-alloyed grate bars (cast iron)
■■ Long service time of the grate bars
(thermal load only on the upper side of the roller grate,
the lower part is cooled by the air flow)
Structural data
Roller diameter 1,500 mm
Grate widths 2,000 – 8,000 mm
Number of air zones / grate sifting hoppers up to 4,250 mm of width = 6 up to 4,500 mm of width = 12
Grate inclinations 20°, 25° or 30°
Grate length (based on roller size) 6 rollers = 14,810 mm 7 rollers = 17,390 mm
Design data
Rotation speed of a roller 0.6 rph to 12 rph (rounds per hour)
Range of LCV 5,000 kJ / kg – 14,000 kJ / kg
Thermal grate load 0.5 MW / m² – 0.75 MW / m²
Mechanical grate load 200 – 280 kg / m²
Waste throughput 8 t / h – 37.5 t / h at reference calorific value of 9,300 kJ / kg
Firing rate 21 MW – 100 MW at reference calorific value of 9,300 kJ / kg
Primary air pre-heating up to 200 °C possible
Powerful Services 13
Your fuel – our know-how
Our grate technologies, which have proven successful in operation for many years,
deliver the solution for thermal disposal even at the highest calorific values.
The mechanical and thermal grate surface load, as well as the layout data of the respective
firing diagram are the decisive variables for the layout of the grate bar. Furthermore, the
ignition and burn-out behaviour of the fuel, as well as the waste size and burn-out quality
determine the grate lengths and fuel layer height.
Fuel Method
Household waste, municipal waste, industrial waste, biomass
Air-cooled moving grate
Household waste, municipal waste, bio refuse, RDF, industrial waste
Air / water-cooled moving grate
Household waste, municipal waste, RDF, industrial waste
Water-cooled moving grate
Projects / Products of Mitsubishi Hitachi Power Systems Europe (selection)
Project Technology Total capacity
EVI-Europark Emlichheim Germany 2 Lines 365,000 t / a
Spreerecycling Spremberg Germany 1 Lines 240,000 t / a
Moscow MSZ 3 Russia 2 Lines 360,000 t / a
MVA Spittelau Vienna Austria 2 Lines 250,000 t / a
swb Bremen Medium calorific power plant (MKK) Germany
1 Line 230,000 t / a
swb Bremen Germany 4 Lines 500,000 t / a
Our know-how is protected by various German and international
patents and registered designs.
14
Stoker Firing – Moving Grate
Our own grate technology makes the difference
Built as a module, each grate carriage has two primary combustion air zones. A grate track
with a length of 9,200 – 10,800 mm, used for example for thermal disposal of domestic waste,
consists of three grate carriages, whereby the number of grate tracks will be determined by
the waste throughput.
The grate carriages of the moving grate supported on ball bearings are activated by push
rods connected to a hydraulically operated shaft. Since the ball bearings of the grate carriage
do not require any lubrication, the operation at higher combustion air temperatures is possible
without any problem.
Air-cooled
The patented air cooled grate bars are dimensioned for a longer lifetime. This is possible by
using a second wear front plate, located behind the frontside. The outer frontside guarantees
the function of the grate bar and therefore also the extension of the lifetime, even at higher
thermal wear. The grate bar can be constructed so that it is possible to use it for “one side”
or “two side-reverse” bar.
Area of application:
■■ Unrestricted use for mid and low LCV
LCV = < 12,000 kJ / kg
Economic and operational benefits:
■■ Long lifetime resulting from the use of our grate technology with wear front wall
Water-cooled
Manufactured from cast iron with a width of 240 mm, the grate bars are cooled with casted
in water tubes. Their seal effectiveness is also guaranteed at higher temperatures.
Area of application:
■■ Unrestricted use for the LCV range from 6,000 to 20,000 kJ / kg
and with restrictions even to 30,000 kJ / kg
Economical aspects:
■■ 32,000 h operation guarantee
■■ 8,000 h (operation) dry running operation
with service life extension
■■ Availability > 8,000 h per year
■■ Increased operational safety
■■ Reduction of maintanance costs
■■ Extension of the inspection intervals
■■ Reduced number of spare parts to keep in stock Water-cooled grate bar
Feed principle
Air-cooled grate bar
Powerful Services 15
High grade and reliable
Mitsubishi Hitachi Power Systems Europe plans and designs high-grade grinding systems for
thermal power plants. The plant constructor has extensive know-how and detailed references
in coal mills and related components.
The in-house manufacturing facility at subsidiary Babcock Fertigungszentrum GmbH, Ober-
hausen ensures that MHPSE supplied components are high grade in quality and dependable
in their functioning.
The company supplies the following components for the construction of new power plants
fired either with bituminous coal or lignite:
■■ Raw coal bunker design
■■ Internal coal feeding equipment
■■ Grinding systems for lignite
■■ Grinding systems for bituminous coal
■■ Grinding systems for biomass
■■ Hopper ash extraction systems
■■ Ash dewatering and recooling systems
■■ ESP and / or fly ash disposal systems
■■ Ash transport and loading equipment for
loading on ships, trucks and rail wagons
In addition our experienced technicians and engineers determine customized solutions for
performance increases, load change speeds and grinding fineness.
MPS® Mill
16
Pulverizers
Grinding systems for bituminous coal
In the mills, the raw coal is simultaneously pulverized, dried and evenly distributed to the coal
burners. Hot air or flue gases transfer the pulverized fuel to the burner and reduce the
moisture in the coal.
MPS® Bowl & Roller Mill
The MPS® bowl & roller mill from Mitsubishi Hitachi Power Systems Europe grinds and dries
hard coals and difficult-to-grind lignite with a low moisture content to pulverized fuel and
distributes them evenly directly to the burners.
Various-sized mills for throughputs ranging from 10 t/h to 200 t/h can be supplied. Constant
refinements and impro vements have led to excellent crushing results with high fineness
grades from raw coal found throughout the world. The positive operating properties and low
energy requirements have contribu ted in no small measure to the success of these mills.
RKD Tube Ball Mill
The Mitsubishi Hitachi Power Systems Europe RKD tube ball mill grinds and dries difficult-
to-pulverize hard coals (particularly low-volatile coals such as lean coal and anthracite).
This mill type can deal with approx. 150 t /h of coal. Depending on size and space, the
tube ball mill can be designed with drum or neck bearing and be of the single or double
pass type.
b
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A Rotary classifier
B Oversize return
C Neck bearing
D Drive gear rim
E Grinding ball filling
F Feed spiral conveyor
G Classifier riser
RKD Mill MPS® MillA Rotary classifier
B Classifier drive
C Grinding rollers
D Hydro-pneumatic system
E Grinding table
F Gear
G Motor
Powerful Services 17
Grinding systems for lignite
Pulverizing lignite is particularly challenging in view of its high moisture content and the
considerable throughputs involved. Here again Mitsubishi Hitachi Power Systems Europe
has the right products in this segment.
DGS® Integral Fan Distributor and Beater Mill
MHPSE supplies DGS® mills of various sizes up to a 180 t/h throughput for drying and
pulverizing raw lignite and brown coals with a high moisture content.
DGS® technology involves the raw coal and flue gases being initially put through the
pre-crushing beater section of the beater wheel. This ensures excellent air and coal dust
distribution into the beater wheel. Crushing in the DGS® mill is usually so intensive that
adequate grinding fineness can be obtained in one working operation – without the need
of an additional classifier. This both raises the pressure balance and cuts back on energy
requirements.
NV Wet Coal Fan Mill
The NV mills ranging from 10 t/h to 140 t/h throu ghputs are for crushing high moisture
content lignites for direct injection into the furnace. Together with the flue gases, the raw lignite
is brought for crushing purposes into the beater wheel. It acts as a fan impeller fitted
with beater plates. Baffle-type classifiers ensure that the required fuel fineness for combustion
is fulfilled.
The high-tech NV mill more than meets the ongoing demands worldwide of operational
availability and low costs.
The DGS® mill has stood the test of time particularly with difficult-to-work lignites –
something that explains its considerable lifetime and unrivalled properties.
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A Gate valve housing
B Grinding chamber door
C Grinding chamber
D Beater wheel
E Baffle-type classifier
F Double bearing
G Motor
NV Mill
A Flue gas gate valve
B Inlet housing
C Beater shaft
D Beater wheel
E Coupling
F Motor
G Bearing
DGS® Mill
18
Pulverizers
Mill Feeders
Designed as coal bunker dischargers, the mill feeders supply the pulverizers with raw coal –
evenly dosed and in keeping with boiler load requirements. Even under very demanding
requirements, the Mitsubishi Hitachi Power Systems Europe designed mill feeders operate
both reliably and safely.
Experienced MHPSE staff establish the optimum feeder in keeping with the requested fuel
quantity, design directives (including DIN EN 12952-9, NFPA 85 F) and customer require-
ments (for instance, volumetric and gravimetric metering). Other selection factors are the
various bulk material properties, such as coal flow and erosion behavior. The belt speed is
determined by the quantity conveyed. Purge air is supplied to the housing to stop condensate
forming and, in turn, to stop corrosion.
Belt conveyor
The corrugated edge belt conveyor ensures high outputs, uniform bunker discharge and
continuous mill charging – even under low conveying rates. This design permits volumetric /
gravimetric metering and quantities conveyed of up to 120 t/h. Conveyed material falling to
the bottom of the feeder is transferred to the coal downcomer by the simultaneously
running scraper chain.
Drag-chain conveyor
Drag-chain conveyors are meant for limited conveyed quantities of up to approx. 40 t/h –
this can, in special cases, be raised to 70 t/h. The fuel is discharged opposite to the direction
of conveying. The drag-chain conveyor principle allows both a compact design with minimum
spacing between bunker discharge and conveyor dumping as well as a possible large
spacing between material charging and dumping.
In hard coal boiler units, belt conveyors are used to discharge the raw coal from the bunker. In lignite plants, drag-chain conveyors together with belt conveyors are used to discharge the raw coal from the bunker.
Raw coal
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Raw coal
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A Bed depth limiter
B Belt drive station
C Belt tensioning station
D Corrugated edge belt
E Scraper chain
F Lower belt supporting roller
G Bunker shut off gate
H Conveyor-type weigher (optional)
Belt conveyor
A Bed depth limiter
B Belt drive station
C Tensioning station
D Forged fork link chain
E Bunker shut off gate
Drag-chain conveyor
Powerful Services 19
Decades of Experience
As an internationally leading company in the field of industrial and power plant service,
Mitsubishi Hitachi Power Systems Europe GmbH also offers extensive service apart from
comprehensive engineering. This service covers the areas of assembly, commissioning
and quality management.
The basis for this service is our decades-long experience in large power plant, boiler and
furnace construction, starting with the disassembly and reassembly concepts all the way to
the contractually compliant hand-over to the customer. Already in the planning stage we put
special value on predictive and detailed processing. We can execute extensive and
challenging projects on schedule and goal-directed. Potential problems are thus recognised
early on and taken into consideration. Our experienced commissioning team accompanies
the completion of the work to the end of assembly and at an early stage makes itself
acquainted with the local conditions of the overall plant. After having finished the erection
works, commissioning begins incl. functional checks, boiler cleaning, load tests and test run,
training of the operating staff and transfer to the customer. In parallel, a quality management
that accompanies both the project and the order ensures an implementation in compliance
with the applicable regulations.
Our installation team – your partner
Installation planning focuses on all areas of industrial and power plants including their ancillary
equipment, regardless of where the plant is located. The relevant specialised departments of
our parent company support every construction site for the entire duration of construction.
This direct involvement ensures maximum flexibility at all times and in every situation, allowing
for joint handling and implementation of solutions even for unusual or unexpected situations.
Assembly planning
■■ Conversion – modernisation – new construction
■■ Maintenance & inspections
■■ Boiler relocation
■■ Site supervision
■■ 24-hour service
NEW PLANT CONSTRUCTION
And when constructing new plants, we also supply experienced construction super-
visors through to site management in addition to our specialists. The specialised
knowledge and leadership skills of our experts guarantee quality and success! That is
why we attach great importance to the qualifications and continuous education of our
employees.
Construction is carried out on the basis of detailed engineering documents, which are
prepared by our experienced staff and then undergo continuous internal and external
quality assurance and checking for compliance with project scheduling. Moreover,
our 24-hour on-call service takes care of short-term deployment of personnel even
outside regular working hours in order to respond to damage events, assess and repair
damages through to restoring plant availability.
20
Assembly Planning
We bring your plant up to date!
Revamping and modernisation
New environmental regulations, changed operating parameters or constant demand to
increase efficiency have, amongst other reasons, made it necessary to modernise or even
replace existing plants.
Mitsubishi Hitachi Power Systems Europe GmbH sees itself as a partner that is committed to
finding the optimal and most efficient solution for our customers. In this regard, we place
particular emphasis on ensuring a smooth continued operation of the remaining plant sections
during the revamping works. To be able to assure this, we conduct thorough plant walk-
through inspections and determine together with the customer the respective interfaces.
Planning is based on the information gathered and our findings and focuses on optimum work
processes and co-ordinated deployment of personnel and equipment with the ultimate goal
of keeping any possible downtimes to the minimum. After all, time is money!
With our experienced installation team, we revamp and modernise both plants built by us and
by third parties in Germany as well as in other countries. And the size or type of boiler does not
even matter to us thanks to our decades of experience in plant construction and engineering.
Maintenance / reconditioning
A boiler unit is only efficient, if it operates smoothly without any disturbances. And that does
not happen automatically! Problems arise without regular and proper maintenance and
upkeep. Failure to ensure the aforementioned requirements might result in long-term
problems and damages that could necessitate a complete replacement instead of repairs.
That also applies to individual components and sections through to the whole plant. Usually,
however, the most cost-effective solution is to recondition. This alternative is also based on
an in-depth overhaul of the current situation. In this case, we try to assess the condition of
individual components and the entire plant and then determine the scope of work required.
Lists of spare parts that are in stock are prepared, and missing parts are ordered. To ensure
a smooth overhaul, we provide highly qualified personnel who have many years of experience
and corresponding equipment.
For our customers we also carry out the realization of existing plants and their ancillary installations at new sites:
■■ Project planning
■■ Dismantling and re-assembly
■■ Quality control
■■ Restarts
Powerful Services 21
Conversion – Modernisation – Maintenance
PLANT OPTIMISATION – TAPPING POTENTIALS
Customer requirements regarding the performance of their plants change continuously.
It does not matter if operating necessities, official regulations or changed service
conditions make a plant optimisation necessary, we develop specific tailored solutions
for you and optimise your plant to suit your needs.
Process-related analysis of current situation and weaknesses
That includes measures for boosting operating efficiency and for improving incineration
as well as for decreasing emissions. We carry out a targeted analysis of the current
situation and weak points in order to identify the potential that is still available in the plant.
Preparation of inspections performed by the authorities and authorised inspectors
An integral part of the tasks we perform for our customers includes implementing
optimisation potential and targeted preparation of plants for inspections by the authorities
or authorised inspectors.
Preparation of operating instructions
It goes without saying this that entails comprehensive documentation of our work and
preparation of operating instructions.
POWER PLANT CHEMISTRY – THE RIGHT CONDITIONING
We will gladly answer your questions about power plant chemistry and make plant-specific
suggestions for a wide array of aspects like water-chemical method of operation and
chemical conditioning.
We have experience in preventing boiler units from entering shutdown, will prepare the
optimum concept and implement it for you. After extended standstills, revamping
activities or construction of new facilities, we also take care of the requisite cleaning
tasks for water and steam piping systems and the boiler’s pressure parts by means of
boiling out, blowing out or acid cleaning.
We offer complete test management for fuels like biomass. From systematic sampling,
storage, reserve samples and analysis through to interpretation of analytical results by
way of comparison.
Commissioning and start-up
Our commissioning and start-up service unit is your competent partner for performing
all processes with regard to the commissioning of power plant systems and their components.
Our service unit is also at your disposal during operation, after revamping, shutdowns or
inspections with the following services:
Power plant chemistry
■■ Water treatment
■■ Standstill conservation of plants
■■ Boiler cleaning both water / steam-side and flue-gas-side
■■ Fuel analytics
22
Commissioning
CLIENT SUPPORT – INSPECTION, REPAIR & MAINTENANCE
Industrial and power plants and especially waste-to-energy plants with stokers and
air pollution control systems, e.g. electric filters, are subjected to thermal, chemical
and mechanical stresses in a wide variety of forms during operation. The results include
material deterioration, corrosion and erosion in the area of boiler walls, heating surfaces
and the associated components and units.
Inspections
As part of regular inspections, boiler units are taken off-line and assessed after specified
runtimes are reached. The scope of the inspection is established in close consultation
with the customer. We support our customers both in the assessment of the boiler
units and in the performance of inspections and utilise our specialists to minimise plant
downtime, even in multiple shifts, if necessary.
Repairs and maintenance
And when it comes to repairs – be it during planned or unplanned shutdowns – we offer
fast assistance without any bureaucracy by providing both our specialists and the
requisite equipment.
Regular maintenance is crucial for preventing any damage-related, unplanned shut-
downs and to ensure the operability, safety and availability of a plant. By supplementing
your plant personnel with our maintenance specialists, you ensure a high level of
modernisation and availability, maximum effectiveness and thus long-term good operating
efficiency of your plant.
Powerful Services 23
More quickly back on the grid
The Shield for Accelerated Boiler Service (SABS®) is a newly developed protection system
which enables a protected workspace to be formed in the most diverse of areas inside a
power plant.
The SABS® consists of a flexible, stretchable special canvas. It covers the entire cross-section
of a selected area and protects the workspace underneath from any falling objects. The
SABS® also includes all components needed for transport, installation and operation.
The components of SABS® are patented.
Especially in the operation of fossil-fired steam generators, deposits develop at the bank
tubes and steam generator walls. They are made up of precipitating slag and ash particulates
and accumulate over time, coating the steam generator tubes. This has a detrimental effect
on the heat transfer, leading to a considerable reduction in boiler efficiency. That is why steam
generators need to be regularly cleaned, inspected for wear and possibly repaired. This
involves shutting down the steam generator to allow the required repairs to be carried out
in the furnace and in the convective area. The risk with this work is that those working in the
furnace could be hit and injured by falling lumps of slag and ash. Thus, workspace is not safe
and needs to be protected by means of special safety installations.
The protective devices used to date, such as safety nets and scaffolds, only afford limited
protection and, in the case of scaffolding, need a considerable time to install. The SABS® has
clear-cut benefits in comparison with conventional forms of safety equipment. In contrast to
conventional safety nets, SABS® tightly seals off the edges and offers reliable protection from
falling objects. The workspace underneath it is secure - and in comparison to safety scaffolds,
installing SABS® yields considerably less time and work force investments, which reduces
outage periods as well as inspection costs.
By using the Shield for Accelerated Boiler Service (SABS®) devised by Mitsubishi Hitachi
Power Systems Europe GmbH, a completely protected workspace can be formed within
a very short time. This both significantly cuts the outage periods and costs of a steam
generator and, at the same time, markedly raises personnel safety.
Thanks to its high degree of flexibility and its modular setup, the application of the
SABS® system is not limited to the furnace of fossil-fired coal power stations. It can also be
deployed wherever working spaces surrounded by perimeter walls are to be protected from
falling objects.
SABS® is a registered Trademark of Mitsubishi Hitachi Power Systems
Europe GmbH
24
Shield for Accelerated Boiler Service (SABS®)
The components of the SABS® system
The SABS® consists of the following modular functional units: SABS® canvas, supporting
structure, lifting and traversing equipment. These functional units are described in more
detail in the following sections.
SABS® canvas
The SABS® canvas is lifted into the steam generator as possible just underneath the super-
heater screen (figure bottom).
Together with the canvas compensator 1.2 , the canvas 1.1 ends flush with the walls of the
area to be protected. By means of guy wires and edge ropes guided through the net openings
of the boiler, the canvas is connected to the supporting structure and interlocked with it.
1.21.1
SABS® canvas in the utility steam generator
Positioning and tightening of the SABS® canvas at the Boxberg power plant, unit Q
Powerful Services 25
Performance characteristics of SABS®
The SABS® was developed in collaboration with Vattenfall Europe Generation (VEG) and
the original specifications – in terms of drop energy, solidity, load bearing capacity and heat
resistance – have been matched with the experiences of VEG. In the course of developing
the SABS®, these specifications have been met – and eventually surpassed as well –
in all instances.
Flexible area of application
The SABS® system is a new, flexible safety concept for carrying out installation and inspection
work on steam generators.
By using the Shield for Accelerated Boiler Service (SABS®) developed by Mitsubishi Hitachi
Power Systems Europe, a completely protected workspace can be formed within a very short
time. This allows for a considerable reduction of outage periods and costs as well as a
significant increase in personnel safety.
The system’s modular setup is the basis for flexible and efficient use of the SABS®. Thanks
to its high degree of flexibility and its modular setup, the application of the SABS® system is
not limited to the furnace of fossil-fired coal power stations. It can also be deployed wherever
working spaces surrounded by perimeter walls are to be protected from falling objects.
Achieved SABS® performance characteristics Requirements
Drop energy 2,500 J
Resistance to piercing and abrasion
750 kg load bearing capacity
Heat resistance
Drop energy of over 5,000 J obtained (340% increase of seam resistance)
Canvas coating for achieving piercing and abrasion resistance
Load bearing capacity in excess of 3,000 kg
Heat resistance up to ~ 400 °C
Results
26
Shield for Accelerated Boiler Service (SABS®)
The service concept
The average reaction span before the arrival of the service crew on-site is 12 hours.
The deployment phase refers to the time during which the customer carries out inspection
work on the steam generator. During this time, inspection rounds are regularly carried out
on the canvas. If necessary, it is cleared of any excess weight from material that has
dropped down.
It takes approximately 6 hours to disassemble the SABS® once the inspection work is
over. Time is saved not only by shorter periods for assembly and disassembly, but also by
inspection work being carried out at the same time both above and below the SABS®.
To ensure the safety of the canvas for deployments that follow, the SABS® canvas is tested
and repaired after each and every use referring to: cleaning and inspection. This process is
fully documented and hence provides complete transparency for all those involved.
The SABS® system is ready for the next deployment provision) following repair and storage
of the canvas and equipment.
With the SABS® service, Mitsubishi Hitachi Power Systems Europe provides customers with
a solution matching their wishes and optimally suited to individual requirements. Matters such
as area coverage and service availability – even with multiple, non-scheduled outages –
are included in the portfolio.
The latest state of technology
The soiling of the bank heat recovery sections or incrustations on the membrane walls seem
to play a dominant role in the generation of risk from potentially falling masses, which to date
is relevant, in particular, at lignite-fired power plants. But this current trend to increasingly use
imported coal, the quality of which is increasingly getting worse, is leading in part also in hard
coal power plants to these incrustations typical of lignite and to a situation of changing
fundamental prerequisites for safety. Therefore, the use of safety equipment in the combus-
tion chamber of hard coal fired power plants is gaining in importance.
The further development of SABS® focuses primarily on the energy sector, such as the use
within the flue gas recirculation pit, the empty pass and the absorber of the power plant
systems. Another area of application are waste-to-energy plants which also display a high
degree of soiling.
The added value generated by the use of SABS® is multi-layered and can therefore not be
clearly assessed monetarily. The increased safety, in particular, due to the use of SABS®
represents a new state of technology which has to be valued considerably higher in com-
parison to the time and cost savings.
✓ Dependable safety
✓Short assembly- and disassembly spans
✓Reduction of scaffolding costs
✓Parallel operation possible both above and below the shield
✓Tried-and-tested traversing concept can be retained
✓Complete shielding service from one single source
Summary of the added value of SABS®
Powerful Services 27
Boiler service & rehabilitation
Mitsubishi Hitachi Power Systems Europe GmbH (MHPSE) is a leading global provider of
services for energy and power generation plants.
We provide a complete array of services for modernization of power plants and combustion
plants, which differ in design and size for all conventional fuels. These include:
■■ Boiler technology
■■ Combustion technology
■■ Flue gas cleaning
■■ Coal grinding systems service
■■ Assembly and construction
■■ Commissioning
■■ Spare parts
Our extensive expertise in boiler technology has enabled us to provide customer-oriented
service and rehabilitation for steam generators and its components, e. g. mill, burner and firing
systems, coal feeders, conveyors etc. We have an experienced team offering comprehensive
solutions for fossil-fired power plants including its parts as well as steam generators.
Our Competence
■■ Technical consulting and studies
■■ Concept, basic and detail engineering
■■ Design revision, e. g. thermal /
process calculation
■■ Failure diagnosis / Troubleshooting
■■ Increase in power, efficiency and
availability
■■ Life time extending measures
■■ Optimisation and replacement of parts
■■ Conversion i. e. fuels, components
■■ Rehabilitation and modernization
■■ Retrofit, modification and upgrading
■■ Overhaul
■■ Shut down planning
■■ Inspection, revision, repair
■■ Maintenance
(scheduled and unscheduled)
■■ Supervision
■■ Procurement, manufacturing,
construction and commissioning
■■ Spare and wear parts
(OEM and non-OEM)
28
Boiler Service
Industrial boiler & stoker firing systems
Mitsubishi Hitachi Power Systems Europe GmbH (MHPSE) is not only a leading provider of
service for the core of every power plant – the steam generator, but also supplies key
components for industrial power plants:
■■ Natural circulation boilers
■■ Firing systems
■■ Burners
■■ Stoker firing systems
■■ Components for firing systems
■■ Spare parts
Our customer-orented solutions are based on MHPSE’s comprehensive engineering
know-how. In addition to our engineering, we are able to supply and deliver systems, perform
assembly and commissioning worldwide.
Natural Circulation Boilers:
■■ Direct fired boilers / Superheaters
■■ Heat recovery boiler downstream gas turbine
■■ Boilers for chemical processes, e. g. steel industry
■■ Boilers for waste disposal plants
■■ Boiler downstream fluidized bed firing systems
■■ Special boilers, converter boilers
Firing Systems / Burners for:
■■ Natural gas / Light and heavy fuel oil
■■ Blast furnace gas / Lean gas / CO gas
■■ Waste water and waste gas
■■ Thermal residue disposal
■■ GT gas in combination with natural gas (CCPP process)
■■ Sulphur extraction (Claus Plants)
Stoker Firing Systems:
■■ Boiler for waste-to-energy plant
■■ After burning grate
■■ Roller grate
■■ Moving grate
■■ Grate bars
■■ Ash / Slag extractor
■■ Ignition / Support firing
Powerful Services 29
Support of performance processes by our QC
An essential component of our company’s philosphy is to ensure our products’ adherence to
national and international quality criteria and compliance with the required standards and
regulations.
To this end, our energy system service is subject to a demanding and systematic quality
management according to DIN EN ISO 9001:2008 and SCC:2011.
We possess highly modern testing and measurement equipment and are thus always able to
carry out precise material testing during the manufacture, assembly and commissioning of
steam generator plants, on schedule at all times.
Furthermore, we perform
■■ Video endoscopic pipe interior inspections for all usual diameter ranges
■■ Welding seam inspections by means of ultrasound, radiographic imaging,
dye penetration and magnetic particle testing procedure
■■ Service life as well as load testing
■■ Steam generator plant inspections
At regular intervalls we demonstrate the successful operation of our quality management as well as our
approvals and expert knowledge by audits.
■■ DIN EN ISO 9001:2008
■■ Safety Certificate for Contractors
(SCC**): 2011
■■ DGRL 97 / 23 EG-Modul H1
■■ DIN EN 1090-1, EXC 3
■■ AD-HP 0, TRD 201
■■ AD-2000 / HP-0
■■ WHG § 19 L
■■ DIN EN ISO 15614-1
■■ DIN EN 287-1
■■ DIN EN ISO 3834-2
■■ DIN EN ISO 14731
■■ DIN EN 473 (VT, PT, MT, UT, RT)
■■ ASME Stamp “S”
■■ National Board Stamp “NB” / “R”
Our range of services:
■■ Quality management & QC monitoring
■■ Manufacturing, assembly, site inspections
■■ Welding and inspection planning
■■ Damage analyses
■■ Mechanical-technological and non-destructive testing examinations
■■ Inspection documentations
30
Quality Management & QC Monitoring
Quality – our most important product
With the Integrated Management System (IMS) we have implemented for years, we ensure that all
products designed, manufactured, delivered, assembled and commissioned at Mitsubishi Hitachi
Power Systems Europe GmbH satisfy the prescribed requirements of our customers and the
supervisory authorities to their complete satisfaction.
Therefore, our valid process tests, for instance, with all the usual materials and material
combinations employed in plant engineering, are the basis of our welding technology.
Our qualified personnel examines throughout the compliance with the quality requirements
according to DIN EN ISO 3834-2. Apart from the quality quality monitoring, we also carry out
special service life and breaking load tests, total boiler examinations and damage analyses.
Testing procedures
Here, we employ mechanical-technological as well as non-destructive testing procedures
such as:
Crack detection
■■ Magnetic powder testing
■■ Dye penetration test
Microstructural examination
■■ Metallographics
■■ Replica
■■ Incident-light microscopy
(macro-microscopy)
Wall-thickness measurement
■■ Radiographic imaging and
ultrasound testing
Welding seam testing
■■ Examination by means of x-ray
and ultrasound
Mix-up testing
■■ Spectral analysis
Visual composition investigation
■■ Endoscopy
We accompany the execution of the work from the beginning of production through
the construction monitoring and the creation of the QC documentation all the way up to the
hand-over to the customer and guarantee thereby a high quality throughout.
Crack detection Microstructural examination Wall-thickness measurement
Powerful Services 31
Projects / products of Mitsubishi Hitachi Power Systems Europe (selection)
Project Technology Capacity Work carried outDrax Power Ltd. Drax Power Station Selby, UK
Electrical power genera-tion plant, Unit 4, 5, 6
660 MWel, 2,400 MWth, 165 bar, 570 °C
Engineering, manufacturing, delivery, construction and commissioning of 60 low NOX coal burners each unit including plant optimisation
Drax Power Ltd. Drax Power Station Selby, UK
Electrical power genera-tion plant, Unit 1, 2, 3
660 MWel, 2,400 MWth, 165 bar, 570 °C
Engineering, manufacturing, delivery and commissioning of 48 low NOX Biomass burners each unit
Wien Energie, MVA Spittelau, Vienna, Austria
Waste-to- energy plant Line 1, 2
14 MWel, 45 MWth, 55 t/h, 40 bar, 400 °C
Engineering, manufacturing, delivery, construction and commissioning of 2 complete boilers for a waste-to-energy plant including stoker grate firing, flue gas cleaning, steel structure and auxiliaries
Co-generation plant Würzburg Germany
Combined- cycle power plant
45 MWel, 115 MWth, 72 bar, 515 °C
Dismantling the existing coal boiler and installing a new combined-cycle power plant incl. heat recovery boiler, ducts, steelwork, pipework, chimneys, fittings, gas turbine, integration of the existing steam turbine, C&I technology, civil works including foundations and pile driving.
MSZ 3 Moscow Russia
Waste-to- energy plant
10 MWel, 46 MWth, 115 t / h, 37 bar, 360 °C
Engineering, design, supply, construction and commis-sioning of the air-cooled moving grate firings in accordance with 17. BImSchV, including ignition and auxiliary firing system, ash removal, slag removal, combustion air systems and E-C&I technology and detailed engineering for the combustion control system.
Medium calorific power plant, MKK-Bremen Germany
Refuse derived fuel power plant
27.5 MWel, 100 MWth, 127 t / h, 39 bar, 400 °C
Engineering, design and supply of: combustion grate, ash removal, slag removal; construction and commissioning of: boiler pressure parts, combustion grate, air and flue gas ducts, steelwork, feed water tank, pumps, valves, pipe-work, live steam piping, refractory, insulation and E-C&I technology and the detailed engineering for the combus-tion control system.
Engineering, design and production of about 1,000 m² cladded vaporiser walls for the 1st pass with Alloy 625 and a minimum layer thickness of >2 mm. In addition, the required cladding work with an area of about 80 m² was carried out on site.
Nikola Tesla, Obrenovac Serbia
Electrical power generation plant
305 MWel, 900 MWth, 920 t / h, 183 bar, 543 °C
Improving the efficiency of and generally overhauling the lignite-fired power station unit including pressure parts, oil and coal firing system, E-C&I technology, turbine, generator, air and flue gas ducts, feed water treatment, forced draught fans, induced draught fans, soot blower, rotary air pre-heater, ash removal, electrical precipitator, pumps, valves, live steam piping, refractory, insulation and auxiliary equipment.
Energy power plant Bernburg Germany
Refuse derived fuel power plant, Lines 1– 3
each 26 MWel, 67 MWth, 80 t / h, 41 bar, 410 °C
Engineering, supply, construction and commissioning of 3 combustion grates for lines 1– 3, including slat conveyor ash removal, combustion air systems including E-C&I technology and detailed engineering for the combustion control system.
32
References
Projects / products of Mitsubishi Hitachi Power Systems Europe (selection)
Project Technology Capacity Work carried outN. V. Elektriciteits-Produktiemaat-schappij Zuid- Nederland (EPZ) Maasbracht Netherlands
Electrical power generation plant
646 MWel, 1,694 MWth, 1,960 t / h, 196 bar, 540 °C
Conversion of unit A & B to low NOx firing and eliminating boiler vibrations. Apart from supplying pressure part components, low NOx gas burners, natural gas valve stations, fresh air and flue gas ducts, pipework, valves and resonators, construction and commissioning were also carried out.
Agroenergética de Algodonales, El Tejar Spain
Biomass power plant
5 MWel, 25 t / h, 72 bar, 450 °C
Based on a detailed inspection of the existing flue gas cleaning system, the necessary modernisation and repair work was planned and carried out including supervision of the construction and the obtaining of all spare parts.
Versorgungs- und Verkehrsgesellschaft Saarbrücken GmbH Germany
Combined cycle power plant
33 MWel 44 t / h 55 bar 450 °C
Design, delivery, installation, commissioning and trial run of a heat recovery boiler with auxiliaries
VW Kraftwerk GmbH Kassel, Germany
Combined cycle power plant
45 MWel 110 MWth 126 t / h 96 bar 515 °C
Engineering, fabrication, delivery, installation and commis-sioning of a heat recovery boiler including steel structure, feed water system, air and exhaust gas ducts, chimney, FD fan and forced-draught ducts, pumps, valves, dampers, piping, E-C&I, refractory, insulation
SWB Energie und Wasserversorgung Bonn / Rhein-Sieg GmbH Germany
Combined cycle power plant
25 MWel 113 MWth 100 t / h 145 bar 540 °C
Engineering, fabrication, delivery, installation and commis-sioning of a heat recovery boiler including steel structure, feed water system, air and exhaust gas ducts, chimney, FD fan and forced-draught ducts, pumps, valves, dampers, piping, E-C&I, refractory, insulation
voestalpine Stahl GmbH Linz, Austria
Steam generator with blast furnace gas firing
120 MWth 135 t / h 70 bar 525 °C
Engineering, delivery, dismantling, installation and commissioning of a steam generator with blast furnace gas and natural gas firing, combustion air and GT ducts, flue gas and recirculation ducts, E-C&I, piping and valves, insulating
Sabiya Power Plant Kuwait
Electrical power generation plant
300 MWel 975 t / h 146 bar 540 °C
Dismantling of damaged pressure parts, installation of boiler pressure parts, superheater, membrane walls, steam-water pipes and header, burner system, steel structure and platforms, insulation and brick linings, expansion joints, hangers, auxiliaries
Kostolac B2 Serbia
Lignite coal fired boiler
330 MW 8 N270.45 Retrofit / replacement of classifier, coal change, capacity increase, improved classifier outlet fineness
Mega IV Greece
Lignite coal fired boiler
650 MW 8 DGS® 180 Retrofit / replacement of classifier, coal change, capacity increase, improved classifier outlet fineness
Nicola Tesla A5 Serbia
Lignite coal fired boiler
330 MW 6 DGS® 100 Retrofit / replacement of burners and mills, revolution grinding desk / beater wheel, coal change, capacity in-crease, improved classifier outlet fineness, low NOX firing
Mehrum Germany
Bituminous coal fired boiler
650 MW 3 MPS® 190 Retrofit / replacement of classifier, coal change, capacity increase, improved classifier outlet fineness
Amer Netherlands
Biomass fired boiler
600 MW 6 MPS® 235 Retrofit / replacement of mill, biomass grinding
Powerful Services 33
Mills and components activities of MHPSE (selection)
Project Technology Capacity Design
Kusile Unit 1 – 6 South Africa
Bituminous coal fired boiler
6 x 800 MW 117 t/h
Belt conveyor, according to NFPA 3.5 bar 6 x 5 MPS® mill, size 265 incl. gear box Submerged scraper conveyor
Medupi Unit 6 – 1 South Afric a
Bituminous coal fired boiler
6 x 794 MW 114 t/h
Belt conveyor, according to NFPA 3.5 bar 6 x 5 MPS® mill, size 265 incl. gear box Submerged scraper conveyor
Maasvlakte Netherlands
Bituminous coal fired boiler
1,100 MW 84 t/h
Belt conveyor, according to TRD 1.0 bar 5 MPS® mill, size 255 incl. gear box Submerged scraper conveyor
Duke Cliffside USA
Bituminous coal fired boiler
900 MW 72 t/h
6 MPS® mill, size 235 incl. gear box
Datteln 4 Germany
Bituminous coal fired boiler
1,100 MW 84 t/h
Belt conveyor, according to TRD 1.0 bar 5 MPS® mill, size 255 incl. gear box Submerged scraper conveyor
Moorburg Unit A + B Germany
Bituminous coal fired boiler
2 x 820 MW 76 t/h
Belt conveyor, according to TRD 1.0 bar 2 x 4 MPS® mill, size 245 incl. gear box Submerged scraper conveyor
Rotterdam Netherlands
Bituminous coal fired boiler
800 MW 65 t/h
Belt conveyor, according to TRD 1.0 bar 4 MPS® mill, size 225 incl. gear box
Wilhelmshaven Germany
Bituminous coal fired boiler
800 MW 65 t/h
Belt conveyor, according to TRD 1.0 bar 4 MPS® mill, size 225 incl. gear box
Walsum 10 Germany
Bituminous coal fired boiler
750 MW 68 t/h
Belt conveyor, according to TRD 1.0 bar 4 MPS® mill, size 225 incl. gear box
Genesee Power Generation Station Phase 3 Canada
Bituminous coal fired boiler
495 MW 58.9 t/h
6 MPS® mill, size 225 incl. gear box
Shentou II Power Plant Phase 2 China
Bituminous coal fired boiler
2 x 500 MW 60.5 t/h
2 x 6 MPS® mill, size 225 incl. gear box
Kogan Creek Australia
Bituminous coal fired boiler
750 MW 80 t/h
Belt conveyor, according to NFPA 3.5 bar 6 MPS® mill, size 255 incl. gear box
Mid American Energy Company USA
Bituminous coal fired boiler
830 MW 80 t/h
6 MPS® mill, size 255 incl. gear box
Shanxi Wangqu Thermal Power Plant China
Bituminous coal fired boiler
2 x 600 MW 51.6 t/h
2 x 6 MPS® mill, size 200 incl. gear box
Paroseni Co-Generation Power Plant Romania
Bituminous coal fired boiler
180 MW 39.5 t/h
Belt conveyor, according to NFPA 3.5 bar 4 MPS® mill, size 212 incl. gear box
Iskenderun Sugözü Power Plant Turkey
Bituminous coal fired boiler
2 x 605 MW 77.8 t/h
Belt conveyor, according to TRD 1.0 bar 2 x 4 MPS® mill, size 255 incl. gear box
Boxberg R Germany
Lignite coal fired boiler
660 MW 113 t/h
8 NV mill, size 110 Submerged scraper conveyor
Boxberg Q Germany
Lignite coal fired boiler
900 MW 140 t/h
8 NV mill, size 130 Submerged scraper conveyor
Lippendorf III Germany
Lignite coal fired boiler
933 MW 116 t/h
8 NV mill, size 110
Megalopolis IV Greece
Lignite coal fired boiler
850 MW 956.4 t/h (steam)
6 DGS® mill, size 180 Submerged scraper conveyor
Elbistan B Turkey
Lignite coal fired boiler
4 x 360 MW 4 x 1,037 t/h (steam)
4 x 6 DGS® mill, size 180
Schkopau Germany
Lignite coal fired boiler
2 x 450 MW 2 x 1,365 t/h (steam)
2 x 8 DGS® mill, size 65
Dezhou Unit 2 + 1 China
Special fuels fired boiler
70 t/h 2 x 6 RKD mill, size 420 x 650 Submerged scraper conveyor
Lausward Unit D + B Germany
Bituminous coal fired boiler
46 t/h 2 RKD mill, size 340 x 500
Lausward Unit A1 Germany
Bituminous coal fired boiler
28 t/h 1 RKD mill, size 340 x 500
Herne 4 Germany
Bituminous coal fired boiler
500 MW 85 t/h
3 RKD mill, size 500 x 700
Herne 3 Germany
Bituminous coal fired boiler
300 MW 55 t/h
2 RKD mill, size 440 x 650
34
References
Service / retrofit activities for grinding and firing systems (selection)
Project Technology Capacity Work carried out
Kostolac B2 Serbia
Lignite coal fired boiler
330 MW 8 N270.45 Retrofit / replace of classifier, coal change, capacity increase, improved classifier outlet fineness
Mega IV Greece
Lignite coal fired boiler
650 MW 8 DGS® 180 Retrofit / replace of classifier, coal change, capacity increase, improved classifier outlet fineness
Nicola Tesla A5 Serbia
Lignite coal fired boiler
330 MW 6 DGS® 100 Retrofit / replace of burners and mills, revolution grinding desk / beater wheel, coal change, capacity increase, improved classifier outlet fineness, low NOX firing
Weisweiler F / E Germany
Lignite coal fired boiler
2 x 300 MW / 2 x 300 MW
2 x 6 DGS® 60 / 2 x 6 DGS® 60 Retrofit / replace of mills, coal change, capacity increase
Mehrum Germany
Bituminous coal fired boiler
650 MW 3 MPS® 190 Retrofit / replace of classifier, coal change, capacity increase, improved classifier outlet fineness
Nicola Tesla A4 /A3 Serbia
Lignite coal fired boiler
330 MW / 330 MW
6 DGS® 100 / 4 DGS® 100 Retrofit / replace of mills, revolution grinding desk / beater wheel, coal change, capacity increase, improved classifier outlet fineness
Weisweiler D / G + H Germany
Lignite coal fired boiler
300 MW / 600 MW
8 N80.75 / 8 DGS® 130 Retrofit / replace of mills, coal change, capacity increase
Mega IV Greece
Lignite coal fired boiler
650 MW Bottom ash Retrofit / replace of bottom ash handling, higher unit availability
Buschhaus Germany
Lignite coal fired boiler
650 MW 6 DGS® 90 Retrofit / replace of classifier, coal change, capacity increase
Wilhelmshaven Germany
Bituminous coal fired boiler
720 MW 4 MPS® 225 Nozzle ring, higher unit availability
Kiel Germany
Bituminous coal fired boiler
320 MW 4 MPS® 180 Retrofit / replace of classifier, coal change, capacity increase
Heyden Germany
Bituminous coal fired boiler
900 MW 4 MPS® 255 adjustable grinding force, revolution grinding desk / beater wheel, retrofit / replace of P.F. pipes, coal change, capacity increase
Amer Netherlands
Biomass fired boiler
600 MW 6 MPS® 235 Retrofit / replace of mill, biomass grinding
Veltheim Germany
Bituminous coal fired boiler
330 MW MPS® 150 Retrofit / replace of classifier and mill, coal change, capacity increase, reducing of unburnt carbon, improved classifier outlet fineness
Reuter Germany
Bituminous coal fired boiler
320 MW MPS® 170 Retrofit / replace of burners, classifier, p.f. pipes and sealing air system, low NOX firing, reducing of unburnt carbon, improved classifier outlet fineness
Milliken USA
Bituminous coal fired boiler
150 MW MPS® 150 Retrofit / replace of mill air fans, classifier, mill, P.F. pipes and sealing air system, coal change, capacity increase, low NOX firing, improved classifier outlet fineness
Powerful Services 35
MITSUBISHI HITACHI POWER SYSTEMS
EUROPE GMBH
Schifferstraße 80, 47059 Duisburg, Germany
Phone +49 203 8038-0, Fax +49 203 8038-1809
[email protected], www.eu.mhps.com
Service Emergency Number +49 172 2608481
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