Boiler ServicesA Full Range of Capability

shi-fw.comThe power of sustainable energy solutions

2 Boiler Services

With more than a century of designing, fabricating, erecting and starting our own equipment, we have the experience and capability to assess your boiler, recommend improvements, and predict the impact on performance, reliability and operation before any fieldwork is started.

Service is an integral part of our business. Preventive condition monitoring, expert maintenance, rapid response repair work, and replacement part deliveries are key factors in achieving maximum plant reliability and cost effective performance year after year.

Through our long-term service agreements, we provide comprehensive and cost effective maintenance programs, ranging from boiler inspections to outage equipment supply and construction services, resulting in minimum unplanned repair work.

Full Service Provider

Global Service Centers

Hampton

VarkausNorrköping

Sosnowiec

Seoul

Hanoi

Bangkok Chonburi

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Global Service Shop NetworkWe have been fabricating steam generation equipment for over 100 years. Our manufacturing facilities in Poland, Thailand, Finland and Sweden, along with our partner shops, form our global manufacturing supply network. This arrangement ensures the best combination of cost and schedule regardless of your location, or the complexity of your project.

FAKOP Sp. z o.oEstablished: 1880Location: Sosnowiec, PolandProduction Area: Several bays covering 11,000 sq. metersCapacity: 400,000 man hours per yearCertifications: ISO 9001, ISO 14001, OHSAS 18001, PED, ASME S & U

stamp, Germany and Poland service certifications (HPO and UDT), EN 1090, laboratory certified EN ISO/IEC 17025

Service (Thailand) Ltd. Established: 2000Location: Chonburi, ThailandProduction Area: 4,000 sq. metersCapacity: 160,000 man hours per yearCertifications: ASME S & R stamp, NB certificate

Service Center (Finland)Established: 2000Location: Varkaus, Finland (eastern province)Production Area: 4,000 sq. meters of floor space Capacity: 100,000 man hours per yearCertifications: ISO 9001, ISO 3834-2, OHSAS 18001, ISO 14001

Service Center (Sweden)Established: 1995Location: Norrköping, SwedenProduction Area: 3,000 sq. metersCapacity: 75,000 man hours per yearCertifications: ISO 9001, ISO 3834-2, OHSAS 18001

We are committed to being the most economical manufacturer of high-quality steam generation components.

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Replacement PartsEngineered pressure partsWe have been fabricating steam generation equipment for over 100 years. We can fabricate virtually any steam generator pressure part from highly complex redesigned coils and panels to simple in-kind replacement parts.

Our best-in-class-quality manufacturing capability and worldwide sourcing of tubing, piping and attachments enables us to meet your needs at very competitive pricing. We have a proven track record of significant cost reduction.

u Superheater, reheater and economizer coilsu Horizontal and verticalu 360° spiral weld overlay available

u Furnace and heat recovery area membrane panelsu SLR and MCR tubing availableu 180° fireside weld overlay available

u Roof tubesu Dissimilar metal weld spool piecesu Headers—all circuitsu Jumper bends, loose tubes, straight tubing

Non-pressure partsWe have satisfied many customers with a full line of high quality replacement boiler and air pollution control equipment parts for our own units as well as for units manufactured by others. Our replacement parts are known for their world class quality, competitive pricing and short delivery schedules.

We continually improve the design and materials of our replacement parts to consistently outperform original OEM parts. All of our parts are backed by a comprehensive warranty and customer service second to none

Bottom Ash Coolers CFB Grid Floors

Loop Seal Expansion Joints

Vortex Finders

Arrowhead Nozzles Stripper Cooler Transfer Chutes

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Basic MaintenanceBasic plant maintenance is a core component of our service offering. We tailor our basic maintenance services to best suit the individual needs of our customers and deliver these services through our local service centers. Our basic maintenance service spans a broad range of service scopes and capabilities covering all types of boilers and air pollution control equipment.

u Outage and emergency servicesu Inspection & specialist servicesu Spare part servicesu Equipment tuning and optimizationu Material failure analysis and solutionsu Refractory maintenance and upgradesu Maintenance planning and staffingu Boiler operation and maintenance

trainingu Construction services and supervision

Tuning for plant optimizationu Comply with new regulations

u Reduce maintenance

u Improve plant heat rate and capacity

u Improve stack emissions

u Reduce limestone and ammonia use

Refractory upgradesu Inspection and evaluation

of refractory failures

u Upgrading refractory formulations and installation methods

u Customized solutions for refractory applications

Improving your ash systems u Ash cooler operation improvements

u Retrofit drum and screw cooler solutions for expanding fuel range

Upgraded CFB loop seal expansion jointsu Ash packing resistant designs

u Customized for ease of retrofit

u Upgraded materials to tolerate both severe temperature and expansion

Improving CFB vortex finder reliability, life and maintenanceu Flexible cast segmented vortex

finder retrofits

u Upgraded plate vortex finder designs

Quick-change durable fluid bed grid nozzlesu Solves erosion and corrosion

problems

u Flexible twist-lock or seal weld drop-in style for ease of replacement

u Cost effective retrofit solution

FEATURED PROJECTS

INEOS refineryLocation: Grangemouth, UKCustomer: INEOS Olefins & Polymers EuropeStart-Up Year: 2000Steam Flow: 64 kg/sService Provided: HRSG boiler, superheater

replacementService Year: 2016

Helen Salmisaari Location: Helsinki, FinlandCustomer: Helen OYStart-Up Year: 1984Capacity: 170 MWeService Provided: PC boiler, superheaters 1&3

replacement Service Year: 2018

LaanilaLocation: Oulu, FinlandCustomer: Laanilan Voima OyStart-Up Year: 2015Capacity: 40 MWthService Provided: Transfering and rebuilding auxiliary

boiler to new plantService Year: 2015

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FEATURED PROJECTS

Enefit Retort Gas ProjectLocation: Narva, EstoniaCustomer: EnefitStart-Up Year: 2017Capacity: 100 MWeFuel: Oil shale, retort gas

TSE Naantali SCR retrofitLocation: Naantali, FinlandCustomer: TSE OyStart-Up Year: 2015Capacity: 110 MWeFuel: Coal

ESE Mikkeli Step Grid RetrofitLocation: Mikkeli, FinlandCustomer: ESEStart-Up Year: 2013Capacity: 25 MWeFuel: Forest residues, bark, peat

Technology Modifications and UpgradesOur experienced service team provides a full range of Technology, Modernization and Upgrade (TMU) services globally:u Fuel range expansions and

conversionsu Capacity upgrades and process

improvementsu BFB & CFB retrofitsu CFB scrubber, DSI and fabric filter retrofitsu Biomass gasifiers retrofitsu Plant optimization studies,

CFD, 3D modelling

TMU projects are always tailored to the clients’ needs to achieve optimized cost effective solutions for power, steam & heat production. We provide the latest technology to clients so they can achieve the highest value from their existing boilers in a changing environment of fuels, emission limits and capacity needs.

Pressure part re-design starts with detailed CFD modeling and engineering: u Fuel combustion and heat

absorption modelingu Heating surfaces fouling analysisu Metal temperature analysisu CFB 3D furnace modelling

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CFB Scrubber Retrofits

WaterHydrated Lime

Flue Gas and Fly Ash

Air

Solid By-product

Air

AbsorberuSelf-cleaning

CFB process minimizes maintenance

uCarbon steel design avoids expensive liners and alloys

uMultiple venturi design allows wide range of capacities

uLong gas and solid mixing time for high pollutant capture and maximum lime utilization

Solid Recirculationu Reliable non-mechanical air slide proven

by years of use in the power industry

Fabric FilteruOptimized pulse

frequency across filter sectors allows efficient solid recirculation, dust capture and long bag life

Absorber BottomuFlue gas inlet chamber drops out large particles

Rotary Valve

Shut Down Valveu Fast acting shut down valve to allow purge

of absorber solids during a boiler trip

Basin Electric Dry Fork StationLocation: Gillette, WY, USACustomer: Nooter EriksonPlant Capacity: 420 MWeStart-Up Year: 2011Fuel: PRB CoalGas Flow: 3,060,000 m3/hrSO2 Removal: Up to 96%SO3 Removal: Up to 99%

Harbin Electric Soma KolinLocation: Soma, TurkeyCustomer: Harbin Electric InternationalPlant Capacity: 2 x 225 MWeStart-Up year: 2016Fuel: Turkish LigniteGas Flow: 2 x 1,217,200 m3/hrSO2 Removal: 79%SO3 Removal: 95%

ZabrzeLocation: Zabrze, PolandCustomer: Fortum Heat PolskaPlant Capacity: 75 MWeStart-Up year: 2018Fuel: Waste RDF, biomass

and bituminous coalGas Flow: 457,920 m3/hrHCl Removal: 98.6%HF Removal: 96.4%

FEATURED PROJECTS

A flexible multi-pollutant technologyOur Circulating Fluid Bed (CFB) Scrubber efficiently captures all acid gases, metals and particulate matter down to the lowest levels. It is a versatile and flexible technology that can clean up flue gases from boilers and industrial processes using the least amount of water and project capital.

Our multi-pollutant CFB scrubbers reliably and economically capture:u Oxides of sulfuru HCI, HF, Hgu PM10 and PM2.5

While providing many benefits over conventional technology:u Uses 30-40% less water

than wet FGDsu 50% lower capital cost

than wet FGDsu Best capture of acid gases

and metalsu Excellent capture of oxides

of sulfuru Very low operating cost and need

for lime reagent with calcium rich boiler ash (ideal for CFB boilers)

u Low maintenance since it doesn’t utilize lime slurry and rotary atomizers

If you do not need a full scrubber, we also offer advanced baghouse and DSI technology to reduce your plant’s dust, metals and acid gas emissions.

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Bubbling Fluidized Bed Conversions

IgelstaverketLocation: Södertalje, SwedenCustomer: Söderenergi AbStart-Up Year: 1995Capacity: 120 MWthFuel: Waste wood, oil, coal, peatOriginal Boiler Type: PC

Stora EnsoLocation: Hyltebruk, SwedenCustomer: Stora Enso Hylte ABStart-Up Year: 2006Capacity: 66 MWthFuel: De-Inking/bio sludge, demo woodOriginal Boiler Type: Grate/axon

FEATURED PROJECTS

We have converted over 30 pulverized coal, stoker-fired and gas/oil-fired boilers to bubbling fluidized bed units, greatly expanding the fuel flexibility and economic life of these boilers.

Our Bubbling Fluid Bed steam generators have a history of reliable operation and have brought value to many clients due to their ability to burn high moisture and high ash fuels. We have progressively advanced the state of BFB technology by incorporating design improvements like our rugged step grid, staged air mixing and gas recirculation systems.

u Stepped grid for most difficult fuelsu Conventional grid for cleaner fuelsu Fuel gas recirculation for bed temperature

control avoids in-bed tubesu High gas residence time to ensure lowest

dioxin, CO, and fly ash carbonu Multiple levels of secondary air

to minimize NOx formationu Retractable soot blowing to maintain

high boiler efficiency and long tube life

Original unit fuelsGrate FiredChemical RecoveryPulverized CoalPulverized PeatOilMgOLa MontPyrite Roasting

Converted unit fuelsAnthraciteCoalPeatGraphiteBarkWood Residue

Wood ChipsWaste FiberPrimary SludgeBio SludgeDe-inking Sludge

Metsä Board SimpeleLocation: Simpele, FinlandCustomer: Metsä BoardStart-Up Year: 1997Capacity: 27 MWeFuel: Bark, forest residues, peat, mill sludgesOriginal Boiler Type: Pulverized peat

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Metallurgical Waste Heat Boiler Service

General design features:u Tough small-diameter

standard tube membrane wallsu Omega-tubes for robust heat

transfer surfaceu Smooth surface composite-

tube to prevent corrosionu Weld overlays applied

to extend wall lifeu Robust but flexible

rapped tube surfacesu Efficient dust removal

arrangementu Gas flow profile optimized

by CFDu Unique patented spring

hammer rapping system

FEATURED PROJECTS

We provide a full range of services for our own metallurgical waste heat boilers as well as units from all other suppliers. These services include:u Capacity upgradesu Modernizationsu Replacement tube walls, pendant screens and tube bundlesu Spare partsu Repair servicesu Condition assessment services

Boliden HarjavaltaLocation: Harjavalta, FinlandCustomer: BolidenStart-Up Year: 1972WHB gas volume: 50,000 Nm3/hService Provided: Modification of radiation partsService Year: Lifetime support since 1972

Garfield SmelterLocation: Magna, Utah, USACustomer: Kennecott Utah CopperStart-Up Year: 1994 WHB gas volume: 60,000 Nm3/hService Provided: Replacement of front of radiation

section with omega tube wallService Year: 2014

Chagres Smelter Location: Chagres, ChileCustomer: Anglo American Start-Up Year: 1992 WHB gas volume: 22,000 Nm3/hService Provided: Capacity upgrade, new baffle wall,

full replacement of radiation screens and convection tube banks, spring hammer cleaning

Service Year: 2005

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FEATURED PROJECTS

SmartBoilerTM

SmartBoilerTM is an advanced tool which enables plant operators and/or managers to monitor their boiler’s operation. SmartBoilerTM is cost efficient, providing operational support and troubleshooting services by our experienced performance engineers, remotely from our home office.

Value added by SmartBoilerTM:u Optimizes boiler operation for lower

plant operating cost, plant downtime and extended boiler life

u Reduces limestone, ammonia, additives, soot blowing and ash generation

u Less fuel feed, ash removal, erosion, corrosion and agglomeration problems

u Fast fix reduces plant downtime

u Live remote diagnosis and corrective action advice from our boiler experts

u Precise rapid dispatch of material and staff

u Boiler experts will have data history for improved diagnosis

u Predictive maintenance lessens outage cost and schedule

u Early detection of problems before they lead to forced outages

u Optimized component replacement schedules

u Improved planning of outage activities and schedule for pre-ordering of materials and labor

Metsä Board Simpele Smart BoilerLocation: Simpele, FinlandCustomer: Metsä BoardStart-Up Year: 1997Capacity: 27 MWeFuel: Bark, forest residues, peat, mill sludges

MGT Teesside LimitedLocation: MGT Teesside LimitedCustomer: MGT Teesside LimitedStart-Up Year: 2020Capacity: 299 MWeFuel: Wood pellets, wood chips

Customer plant

Control room

SmartBoilerTM server and diagnostics

How it works

Remote connection

SFW process specialistsuEfficiency analysesuDeviation managementuDisturbance managementuOperator support servicesuTroubleshooting servicesuRegular process reporting

IT specialistsuDaily system administrationuSoftware updatesuVirus and data protection

Optimized boiler process: better availability and better economics

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Long Term Service Agreements

FEATURED PROJECTS

Through our long term service agreements (LTSAs), we provide comprehensive and cost effective maintenance programs, ranging from boiler inspections to outage equipment supply and construction services, resulting in minimum unplanned repair work.

LTSAs are an ideal and care free solution especially for customers with lean plant organizations. They area tailor made solution containing all needed services to match the customer’s specific requirements and needs.

u Ensure resources are always available for each task needed in boiler maintenance ranging from experienced pressure vessel welders up to world class technical experts.

u Ensure that the plant operators are well aware of our latest product improvements and accumulated know-how from new boiler projects.

u Allows the full potential from your new boiler investment

u Ensure high plant availability.

On-site LTSA services can include:u On-site support teamu Technical advisors deployed to site as needed u Process tuning u Material, refractory, process, I&C and operation specialists u Condition monitoring of boiler parts and equipmentu Outage supervisingu Outage maintenance and/or repairsu Spare part stocking and deliveryu Emergency support

Off-site LTSA services can include:u Operation support and remote diagnostics via SmartBoilerTM

u Engineering and specialist supportu Condition monitoring of boiler and air pollution control equipmentu Maintenance scheduling and outage planningu Execution of outages

INEOS refineryLocation: Grangemouth, UKCustomer: INEOS Olefins & Polymers EuropeBoiler type: HRSGStart-Up Year: 2000Steam Flow: 64 kg/sScope: Plan and execute annual outages

works for pressure partsLTSA Service Period: 2013-present

Tammervoima WTELocation: Tampere, FinlandCustomer: Tammervoima OyBoiler type: WTE grate boilerStart-Up Year: 2016Capacity: 58 MWthScope: Both mechanical and EIC: Daily

maintenance, plan and execute annual outages, emergency services.

LTSA Service Period: 2016-present

NeVe, SuosiolaLocation: Rovaniemi, FinlandCustomer: Napapiirin Vesi ja Energia OyBoiler type: CFB and BFBStart-Up Year: 1995Capacity: 96 MWthScope: Plan and execute annual outages,

emergency services. Operation support and process tuning.

LTSA Service Period: 2015-present

Metsänneidonkuja 8Fl-02130 Espoo, FinlandT +358 (0) 10 393 11

Relanderinkatu 2Fl-78201 Varkaus, FinlandT +358 (0) 10 393 11

ul. Staszica 3141-200 Sosnowiec, PolandT +48 (0) 32 368 1300

ul. Chmielna 85/87 00-805 Warsaw, PolandT +48 (0) 22 581 00 36

Lindövägen 75602 28 Norrköping, SwedenT +46 (0) 11 285 330

Petersstrasse 12047798 Krefeld, GermanyT +49 151 108 51366

53 Frontage Rd, PO Box 9000Hampton, NJ 08827 USAT +1 908 713 2700

8th Floor, UC Tower 500 Fushan RdPudong New AreaShanghai 200122 ChinaT +86 (0) 21 5058 2266

20th Floor Bhiraj Tower at EmQuartier, 689 Sukhumvit Rd Klongton Nuea, WattanaBangkok 10110 ThailandT +66 (0) 2 0417140 3

Suite 706-708, 7th Floor, Central Bldg31 Hai Ba Trung St Hanoi, VietnamT +84 (0) 4 39393809

7th floor, 621, Yeong-dong-daero, Gangnam-gu, Seoul, Korea 06087 T +82 2 3446 8325

Room 901A, 9th Floor Vicente Madrigal Bldg, Ayala AveMakati City 6793, Philippines

WISMA GKBI #1606, Jl. Jend. Sudirman No.28, Jakarta 10210 IndonesiaT +62 (21) 5795 1095

ThinkPark Tower, 1-1 Osaki 2-chome Shinagawa-ku, Tokyo 141-6025, JapanT +81 (0) 3 6737 2000

We are the premier global supplier of innovative circulating fluidized bed (CFB) technologies, providing sustainable value to our customers through our relentless drive for environmentally sound and reliable power solutions while we grow.