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Upgrading & Retrofit
Industries need upgrading and retrofit of existing boiler plants for various reasons, e.g.:
- New technology, which will improve the performance
- Environmental requirements
- Change of operating mode
- Change of fuel
- Automation
- Lifetime extension
- Low availability
- Restrictions to build a new plant
Retrofit
Retrofit is defined as bringing a boiler plant up to the initial performance level.
The advantages of retrofit over replacement by a new plant are short downtime periods combined with much lower costs. The lifetime of the plant is often prolonged as many of the replaced components have a limited lifetime. Due to the relatively low investment, the payback time is shorter for a retrofit than for a new plant. Problems associated with building a new plant, like site location, permits, procurements etc. are avoided.
Upgrading
Upgrading is defined as bringing a boiler plant beyond initial performance level.
Both retrofit and upgrading can minimize the risk of unplanned stops of the plant due to the need for repair.
Aalborg Industries is a leader in upgrading and retrofit jobs and has achieved higher performance and extended lifetime for plants world-wide.
Upgrading of boiler plants is done to improve energy utilization and meet environmental requirements resulting in added value for the customer.
Automation means cost saving in operating manpower.
Fulfilling environmental requirements means approval by authorities to operate the plant.
Scope of supply for upgrading
Plant survey: Examination of the present condition of boiler plant and evaluation of possibilities for upgrading.
- Necessary redesign and engineering to ensure the required performance.
- Feasibility study: Calculation of financial consequences such as investment, earning, savings in operating cost (cost benefit analysis), and pay-back time
- Assistance to apply for funds from energy saving authorities
- Actual construction, supply of auxiliary equipment, dismantling, reinstallation, and commissioning of the upgraded plant
Typical areas for upgrading
- Burner system
- Replacement or upgrading of old burners
- New burners in connection with conversion of fuel
- Dual fuel systems
- Handling of residual fuel
- BMS package ( Burner Management System )
- Control Systems
- DCS ( Distributed Control System )
- BCP ( Boiler Control System )
- RSS ( Remote Surveillance System )
- ROS ( Remote Operating System )
- Redesign of combustion chamber in connection with fuel conversion
- Noise and vibration problems
- Steam quality
- Feed water chemical dosing
- Improvement of flue gas emission impact on external environment
- Improvement of boiler economy by addition of economizer etc.
- Better utilization of exhaust gas energy by addition of heat exchangers producing hot water for heating purposes or in cooling processes
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