Industrial Equipment Built to LastTubular Air Pre-heater Inspection, Repair, and Rebuilds

Corrosion Monitoring Services, Inc. (CMS) has been helping customers assess, monitor, and repair air heaters

since 1982. In fact, CMS has repaired or rebuilt thousands of tubular air pre-heaters (APH) in North America

and overseas. In the process, the company has established a reputation for delivering quality products and

services on-time and on-budget.

CMS has significantly advanced APH technology by developing patented and proprietary solutions that

significantly improve equipment performance and service life. Analysis data proves that under-performing

air heaters can negatively affect other important parts of your operation. This equipment includes gas and

air fans, bag houses, precipitators and scrubbers that depend on the APH units to deliver preheated air

within a specific pressure, volume and temperature range.

Today, CMS is the only company in the world that offers complete, performance assessment, integrated

corrosion assessment and repair services for tubular air pre-heaters. Our inspection and assessment programs

provide an accurate and comprehensive picture of the entire air heater system, pinpointing all areas of tube

damage and potential financial impacts.

Our experienced inspection specialists start the process

using custom-designed tools to inspect your equipment

and look for damage that affects your daily performance

and sometimes leads to unscheduled downtime. In addition,

we have developed a proprietary Air Leakage Calculator

(a unique software tool) that uses your own operating data

to determine precisely where your system performance is

impacted and what you are losing in the process. This

approach has saved our customers millions of dollars

and helped them realize payback in as little as a few months.

CMS stocks over a million linear feet of steel at

our climate controlled warehouse and ready to

respond to your needs at a moments notice.

2

CMS offers cutting-edge solutions installed

with proprietary tools and patented systems

operated by the industries’ most experienced

team of professionals.

“�All�work�went�very�smoothly�from�the�pre-planned�set-up�to�execution�and�demobilization�and�final�walk�through�with�owner�representatives.�The�CMS�work�flow�was�like�a�well-oiled�machine.�It�is�apparent�that�CMS has a commitment from top-down leadership to emphasize safety, specialized work force, and great project execution. CMS delivered all they committed to deliver and within the time frame agreed to.” — Jack I. Williams, Project Engineer, WestRock

3

CMS Services a Broad Spectrum of Industries

Customers in a wide variety of industries call on CMS, whether they need emergency service or have long-range

plans to improve operations. Working with different companies in difficult and unique operating environments

has exposed our teams to the wide variety of challenges faced by different configurations in all types of thermal

plants. Some of the solutions to those often difficult problems are applicable across industry sectors. We take

pride in using our experience to your advantage.

BIO PROCESSING (1)

CEMENT (2)

CHEMICAL PROCESSING (3)

COAL POWER (4)

FOOD PROCESSING (5)

PULP & PAPER (6)

WATER ENERGY (7)

1

3

2

4

765

4

Cascading Problems Corrode Your Operating EfficiencyInstalling mechanical plugs to isolate damaged air heater tubes is one short-term strategy for regaining

at least some of your fan and boiler capacity and slowing down and the development of new tube failures.

However, it’s important to realize that something is causing tubes to fail and that the damage mechanisms

will still be at work even after the plugs are installed. Those problems are often cascading in nature, causing

hidden inefficiencies and other issues not just in your APH, but throughout the process.

Here are just a few facts about damaged air heaters and how they might be costing you efficiency and

corroding your profits:

External Corrosion, Air Side Dew Point CorrosionABS Corrosion

• A 2009 EPA study reported that just a 40˚F

increase in outlet APH temperature results

in a 1% reduction in net boiler efficiency.

• A 1% boiler efficiency penalty is commonly

observed where just 12% air leakage has

developed. Fly-ash based fouling or

mechanically plugged tubes can result

in similar performance impacts.

• Tubular air heater leakage can account for as

much as 25% of total fan horsepower, not only

using more energy, but decreasing the life

expectancy of the fan and motor.

• Leaking air heaters increase emissions and

reduce the effectiveness of downstream

pollution control equipment because of

increased fuel and gas flow.

• One problem leads to another, as temporarily

repaired APH units actually decrease the surface

area for heat transfer and thus the temperature

of combustion air, while increasing gas outlet

temperature, pressure drop and net fuel

consumption.

• In many cases, boiler operators are forced to

de-rate their plants due precisely to air heater

leakage and fouling. Statistics from the NERC

GADS database demonstrate that between

2007 and 2011 a total of 3,233,636 MWH of

forced de-rates were due to “Combustion

Air & Gas Causes”.

5

CMS Delivers Solutions You Can Depend OnCMS has spent decades focusing on customer needs and working with them to develop solutions that get them

back up and running quickly. From preliminary inspection to on-time delivery, we have developed competitive

advantages that we apply to the benefit of our customers. Here are just a few of the advantages CMS offers:

Planning Fabrication

• Air Pre-Heater Calculator (applied to

“as found” and “follow-up” monitoring

performance) to assist in quantifying the

real value of performance

• Root-cause analysis capabilities to select

the best option for repairs

• Financial impact reporting for repair option

determination and budgeting decisions

• Financial impact reporting detailing energy

savings and emission reduction estimates (e.g.:

mercury, ash, CO, CO2, SO2, SO3 emissions)

• Corrosion/erosion resistant tubular

air-pre Heater components

• One-stop shop fabrication facilities, eliminating

third party supplier risks and costs

• Exclusive distributor of CR50TM tubing,

stocked and available for quick-shipping

and emergency repairs

• Exclusive distributor of corrosion resistant

internally rifled tubing that can provide

significant heat rate improvements in

horizontal tubular air heaters.

• Pre-assembled tubing options for in-situ repairs

enable rebuilding of critical equipment without

costly displacement of surrounding structures.

Safe, On-time Installation Guaranteed Performance

• Rapid Repair™ Conveyer System

• Mobilization ready repair response systems

that can be on the way to our customers

quickly in emergency situations

• OSHA Sharp perfect score

• Rescue-training confined

space attendants (NFPA

1007 & 1670 certified)

• Extended service life of tubular air pre-heaters

• Air-Tight™ Quality Assurance

• Five-year Convective Tube Solution™ warranty

(our bottom line for reliability, backed by CMS)

• Five-year EROS warranty covering fly ash

erosion failures

6

Built to Last

CMS replaced all tubing in the CSWS RRF facility’s Unit 11 and 13 air

heaters with corrosion resistant CR50 alloy and Convective Tube Solution.

Performance of the boilers improved immediately. The custom repair

resulted in several other notable gains, including fans, pollutions control

and bag house performance. The overhaul resolved the chronic and rapid

failures that damaged each of the units over many years.

“ When CMS comes to the site, they have a crew that’s very professional. Their foremen have been top notch compared to other�contractors�that�are�out�there.�I’ve�been�around�a�long�time,�and they have an excellent workforce.” — John O’Rourke, Plant Manager, CSWS RRF, Hartford, CT

7

The CMS team has hundreds of years combined on-site experience

solving customer problems with custom solutions that enhance

operating efficiency. President Alex Turner (center, row two) stands

behind the company with the top safety record in the business!

Air Heater Repair Services to Fit Your NeedsCMS offers the industry’s widest variety of solutions for APH repair and replacement. We develop a solution that

fits your own unique requirements. On request, our experienced team can quickly help you evaluate your needs

based on site inspection and data analysis, using our proprietary Air Leakage Calculator. We can then tailor a

solution to improve your operation, including partial tube repair, in-situ repair, Convective Tube Solution™, CMS

Eros™ as well as other options.

Our goal is to get you back up and running to maximum efficiency as quickly as possible, so that you are able

to realize measurable improvements immediately. We also work hand-in-glove with your management team to

develop strategies that reduce associated costs required to complete necessary repairs.

“ You get technology that is going to give you performance and service life that doesn’t exist otherwise. We can often tailor our repairs to the exact damage mechanisms that are occurring.” — Alex Turner,

President, CMS

8

CMS in action on the job site. Our team of professionals have repaired and/or

rebuilt hundreds of air heaters in the field, often in tight turnaround timeframes.

9

PARTIAL TUBE REPAIRIn many cases, damage to air heater tubes is localized and limited to one section of the tube. This is especially

true when erosion is the primary damage mechanism and failures are located close to the tubesheet plate.

When local damage is identified, CMS frequently recommends partial tube repairs of the air heater.

In a partial tube repair, CMS removes only the damaged section of the tube and installs structurally secure,

air-tight replacement tubes, using its specialty tooling and custom pre-fabricated couplers. This method

preserves the undamaged section of the tube and is often as effective as a full-length re-tube, but a fraction

of the cost. Since 1985, CMS has performed thousands of partial tube repairs and is the industry’s leading

provider of this solution.

Benefits of partial tube repair include:

• Addresses root cause of damage

• Scope can be performed in short outages

• Enables air heater repair without removing surrounding structures

• Minimal scaffolding

• Crane rental not required

• Warrantied seal between parent and replacement tubing

• Material or design upgrades available

Since 1985, we have performed more partial air heater repairs than anyone in North America.

Air Heater Repair Services to Fit Your Needs

10

IN-SITU REPAIR Access to an air heater is frequently limited by overhead obstructions or

the location of adjacent equipment, such as economizers or dust collectors.

In many cases, these obstructions make it difficult, if not impossible, to install

full length replacement materials, without taking an extended outage.

CMS developed the in situ method of repair, allowing tubular air heaters to be

rebuilt from the inside out, without removing any of the surrounding structure.

Throughout its projects, CMS uses Rapid Repair™ Conveyer Systems that have

been custom designed for the sole purpose of rebuilding tubular air heaters. These proprietary tools allow for

major repair projects to be performed in a faction of the time that would otherwise be required.

The goal is minimal disruption of your ongoing operations, enabling a rapid return to full capacity, but with much

improved efficiency. In addition to saving you time, the in-situ process significantly reduces associated costs and

schedule for the repair by minimizing the need for scaffolding and crane procurement. We plan and execute our

work within your footprint!

CMS’s turnkey repair process begins months in advance, when we fabricate materials in our own shop. We don’t

rely on third-party sources, which maximizes our quality control, minimizes costs, and reduces lead times, all are

time-proven benefits that we pass on to our customers.

Our experienced project managers and engineers work with you to determine the best possible solution that

allows for seamless installation during an outage. We stand by our products and services, backing them with

expert service, and in some cases, a five-year warranty.

Benefits of in-situ repair include:

“�We�have�a�CFB�boiler�with�a�tubular�air�pre�heater.�CMS�replaced�the�first�pass�of�each�the�SA�and�PA� air heaters in our plant in 2009. They replaced the air heater sections in a timely manner without any safety incidents.

“ We now have a tight air heater that performs great and the Corten® material proved to hold up to the�cold�end�corrosion�we�were�experiencing�prior�to�2009.�I�would�recommend�them�to�anyone� desiring to have this type of work performed. They have successfully enhanced their QC program and their safety standards are world class.” — Dan Twigg, Boiler Team Leader here at AES Warrior Run Power Plant in Cumberland, MD

Air Heater Repair Services to Fit Your Needs

• Rapid repair scheduling and mobilization

• Performed safely and efficiently within

you footprint

• Custom solution, rather than a

“one-size-fits-all” approach

• Warrantied repairs (in some cases)

11

CONVECTIVE TUBE SOLUTION™The CMS Convective Tube Solution™ is the tubular air heater industry’s first and only long term solution

to aggressive dew point corrosion damage. Cold-end corrosion, localized cold spots, and heat sinks in an

air heater can have devastating effects on operating and, ultimately, your financial performance. Damage

develops when the surface temperature of tubing drops below the acid dew point. Acid condensation often

leads to losses in wall thickness. Failure rates vary, depending on the fuel source and boiler configuration,

but ongoing corrosion, plugging, and other issues that affect APH performance can have the following

damaging impacts on an operation.

The patent pending Convective Tube Solution™ is a product of precision engineering and more than 30

years of experience inspecting and repairing tubular air heaters. During the repair, CMS upgrades the metallurgy

of the tubing. Modifications to the design of the tube and tubesheet plate are performed during field installation.

Repairs result in the effective elimination of dew point corrosion failures and fly ash plugging. A few of the many

benefits that come with CMS’s Convective Tube Solution™ include:

A rapid return on investment: By eliminating cold-end corrosion,

the CMS Convective Tube Solution™ significantly reduces net fuel

consumption and parasitic losses. At no cost to customers, CMS

can use its proprietary Air Leakage Calculator to provide a thorough

analysis showing the financial impact of an APH’s current condition

and an estimated return on investment timeline for repairs.

Customers have achieved payback in as little six months and are

realizing significant ongoing savings. Examples of the calculator

and analysis can be provided on request.

Air Heater Repair Services to Fit Your Needs

• Reduces surface area available for heat transfer

• Lowers boiler efficiency

• Increases pressure drop

• Increases fan and emissions equipment

energy requirements

• Damages/wears ancillary equipment

and infrastructure

• Reduces downstream pollution control

performance

• Unit steam capacity and generation restrictions

• Reduces dew point corrosion and increases

life expectancy 3X minimum average

• Significantly diminishes cold-end ash fouling

and reduces or eliminates washing

• Improves air heater and system performance

• Helps reduce wear on ancillary equipment

• Reduce excess energy consumed plant-wide

• Includes a 5-year warranty against dew point

corrosion and fly ash fouling. This added

benefit includes annual inspections and

condition assessments performed at no charge.

CMS Convective Tube eliminates cold-end corrosion.

12

CMS EROS™ The EROS™ is a CMS Inc. patent-pending design that provides long term relief from problems associated with

fly ash erosion. Fly ash erosion often occurs within the first 3-5 inches at the gas inlet of the tube up to the top

tubesheet plate. In an EROS™ repair, CMS removes only the damaged area of the equipment and upgrades the

design and metallurgy of the replacement material to prevent reoccurrence of damage. The EROS™ design also

ensures that wear damage occurs to the sacrificial areas only (overlay plate and sleeves).

An EROS® repair project provides you with the following benefits:

• Upgraded metallurgy at the area most vulnerable to erosion damage

• No increase in air heater pressure drop

• EROS® specially hardened inserts can be joined to undamaged sections of tubing

• Significantly reduces long-term maintenance costs

• Includes an air heater preventive maintenance program

• Includes an optional 5-year warranty against erosion failures

HERO™ APH EXTERNAL CORROSION GUARDSPart of our ongoing development of the Hero™ APH,

our CMS patent-pending

external corrosion guards provide an extra measure of protection

against water damage to your air heater. Our external corrosion

guards can be installed above the bottom of tubesheet plate or

above the baffle level, depending on customer requirements. This

small but important feature, delivers big benefits, including:

• Pre-fabricated in advance of repair, leading to ease of installation

• Provides sacrificial steel to protect tube outer diameter at

BTS and anti-vibration baffles

• Significantly extends service life of replacement tubing

Air Heater Repair Services to Fit Your Needs

CMS’s patent-pending corrosion guards provide

some insurance against potential water damage.

13

AIR LEAKAGE CALCULATORIs your Air Pre-heater corroding your profit margins? More importantly, when the air heater degradation

begins, failure is not a linear process. A failed leaking tube may bring a zone near the tube below the acid

dew point creating failures all around. The CMS proprietary Air Leakage Calculator enables you to pinpoint

problems in your system that are costing you money. Our unique software, which took years to develop, will

pass performance related audits utilizing ASME type boiler and air heater calculations. The calculator analyzes

boiler efficiency, air heater leakage, impacts to auxiliary power. The evaluation assesses impacts to emissions

and associated equipment operating cost and cost of materials purchases and disposal. In addition, our energy

calculator can even be used to estimate energy savings and reduction in emissions.

Once a unit model is created, a follow-up analysis can be performed at any time with little effort. You can track the

unit and air heater performance over time with little effort. All it takes is a phone call and a download file of the

previously selected process data.

Some APHs begin leaking the moment they go online. Using our calculator, we have measured leakage

>50% in some units. Our unique monitoring is able to factor out the impacts on performance due to cooling

water variations and weather changes which impact both turbine and fan performance.

After the initial analysis, we are able to continue monitoring your system and can provide periodic reports

on request. A follow-up analysis requires little effort from site and CMS because the model has already been

established and tested. And our analysis comes complete with a nondisclosure agreement to protect your

proprietary in-house data.

Air Heater Repair Services to Fit Your Needs

CMS’s air heater calculator can pinpoint problems in your APH and other parts of your operation.

Corrosion and plugging (as shown here) often leads to cascading problems up- and down-stream

that impact your company’s bottom line. CMS uses the industry’s most analytical tools to help you

select the right repair or replacement option that meets your budget and operating requirements.

14

130

135

140

145

150

155

160

165

170

Net

Po

wer

Pro

du

ced

FD

Fan

Air

Flo

w

Blue = Airflow

Red = Net Power MW

1200

1250

1300

1350

1400

1450

1500

1550

Performance analysis may include review of historical data as shown above. In this case, the increase in leakage

is seen in the flow from the forced draft fan. As the leakage increases, the net generation decreases. This is one

example of hidden inefficiencies in your operating system, providing you with knowledge that puts you back in

control, so that you can quickly assess and repair damaged equipment.

Air Heater Repair Services to Fit Your Needs

Example Case 1 Example Case 2 VALUES USED IN DISCOUNTED CASH FLOW ANALYSIS

-37,777 -67,723 (67,723)

-108,574 -109,571 (109,571)

-20,979 -20,979 (20,979)

-342,144 -342,144 (342,144)

-263,247 -263,247 (263,247)

-772,720 -803,664 (803,664)TOTAL CASH FLOW IMPACT Based on current condition

Based on current conditionGross margin loss due to increase in station service

Based on current conditionGross margin loss due to reduction in plant output

Due to increase in emission control consumables: Based on current condition

Fuel Cost due to increase in station service: Based on current condition

ITEMIZED LIST OF FINANCIAL IMPACTS

CASH FLOW IMPACT BASIS

Fuel Cost due to loss of boiler efficiency: Based on current condition

15

Air Heater Repair Benefits

A repaired or rebuilt air heater, using CMS

patent-pending designs and corrosion resistant

tubing, can extend the life of your APH and other

critical equipment.

Environmental

A damaged air pre-heater is a liability that can cost you more than system efficiency and bottom-line profits.

By eliminating air leakage and returning the air pre-heater to ‘as built’ condition with improved materials for

erosion and corrosion protection, Corrosion Monitoring Services has helped boiler operators across the United

States achieve and exceed their environmental objectives and operate at MAXIMUM operational efficiency.

CMS works to ensure that your APH performs as designed and helps keep you operating safely within

applicable regulatory requirements.

The detrimental effects of a corroded air pre-heater can lead to environmental issues. Don’t let these

potential problems compromise your operation:

• Increased waste water

• Disposal of excess fly ash due to increased fuel demands

• Emissions of mercury, CO, CO2 , SO2 , and SO3

• Excess auxiliary power to operate fans required to move the air leakage and provide sufficient

flow through plugged tubes

• Increased use of additives needed to keep a treat the additional fuel for system operational

• Potential for forced outages and catastrophic failure of the unit or equipment

An often neglected system, the air pre-heater serves

an essential role in the efficiency of the boiler system

and in the pollution control process. At CMS, we

have significantly advanced the technology, under-

standing, and approach for the inspection and repair

of these systems.

Regardless of the industry, CMS provides

long term operational solutions that protect

air pre-heaters from erosion, corrosion, and fly

ash fouling. Our inspection and repair solutions

have helped hundreds of utilities, pulp and paper

mills and other processing plants optimize their

operational efficiency, regain capacity, and improve

the performance of their pollution control systems.

16

In many cases, our customers have delayed repairs until operational impacts are already a significant problem.

Usually at that time the rate of deterioration is advanced and cannot be ignored. Our calculator can determine

this in advance before leakage becomes a derating of operating requirements.

Since the fan curve is shifted due to molecular weight of diluted gas and ambient conditions, this unit is derated

at times during summer months. The cost easily justifies repairs.

Financial

The cumulative financial impact of air heater efficiency is rarely adequately measured or observed,

but the results speak for themselves. By eliminating leakage in the system, plants can realize up to

a 4% reduction in net fuel consumption.

Not only do improvements to your APH units cut overall energy consumption, but they should help reduce

your maintenance and waste disposal costs. If the boiler is the heart of your operation, then the air pre-heaters

are its lungs. Ultimately, repair should extend the APH units’ life and everything that they touches in your system,

from fans to boilers to pollution control equipment. 902 Equity Drive · St. Charles, IL 60174

T 800 637 6592 · F 630 762 9301 WWW.CMSINC.US

Plant Type Boiler Type Capacity Air Heater Configuration Estimated Change in Leakage (%)

Annual Cost Savings

Bio Mass Sub Traveling Grate 50 MW Two AH Two Air Streams 7.3% $1,290,000Bio Mass Sub Vibrating Grate Stoker 20 MW One AH 24.7% $4,940,000Bio Mass Sub Zurn Drum CFB 42 MW Two AH in Series 11.0% $790,000

Coal Super Wall Fired 960 MW One AH 6.7% $9,480,000Coal Sub PC B&W Wall Fired 180 MW One AH 27.0% $6,070,000Coal Sub B&W Wall Fired 655 MW 2 RAH & 1 TAH in Parallel 13.6% $1,860,000Coal Sub PC RS Wall Fired 180 MW One AH 23.2% $800,000Coal Sub FW CFB 47 MW One AH Two Air Streams 24.4% $720,000

Paper Mill Sub Traveling Grate 35 MW One AH 20.2% $820,000Paper Mill Sub FW CFB 17 MW One AH Two Air Streams 16.0% $1,260,000Paper Mill Sub B&W Stirling 52 MW One AH 27.6% $970,000Paper Mill Sub Traveling Grate Multiple One AH 21.0% $470,000Paper Mill Sub Stoker Boiler 5 MW One AH 25.0% $180,000

Refuse Sub Spreader Stoker 23 MW One AH 31.8% $1,187,218Refuse Sub Traveling Grate Stoker 34 MW One AH 38.0% $482,417

Note: Annual Cost Savings does not reflect cost of repair.Cost Factors: Contacts:

1) Loss of Boiler and Air Heater Efficency Lonnie A. Coffey (Thermal Analysis)2) Fuel for Auxiliary Power 865-806-1791 - Lcoffey@C4combustion.com3) Emission Control Consumables4) Revenue loss for increased Auxiliary Power Jack McKeegan (Financial Analysis)5) Revenue loss for reduced Generating Capacity 630-762-9300 - JMCKeegan@cmsinc.us

CMS AIR HEATER CALCULATOR RESULTS -- RECENT EXAMPLES

A proud member of the OSHASAFETY HEALTH ACHIEVEMENT

RECOGNITION PROGRAM

17

Inspection Services Corrosion Monitoring Services, Inc. (CMS) has been helping customers identify, assess, repair and monitor air

heaters and other equipment since 1982. CMS offers a complete range of inspection services that not only

determine the exact extent of existing damage, but can also identify the root cause and its probable failure

rate so that you can proactively plan your next steps for a longer term solution.

Our inspectors use acoustic eye, pressure testing and other inspection equipment and techniques to isolate

corrosion and erosion damage in electric utility, refinery, chemical processing, pulp & paper, biomass and

waste-to-energy operations throughout North America.

Comprehensive assessment programs conducted by the industry’s most experienced APH inspectors provide

an accurate picture of air heaters and other critical equipment, pinpointing corrosion, fouling, and other damage

that hampers operations, drains energy, and dilutes profits.

After we complete any inspection, all of our findings and recommendations are detailed in an Executive Summary

Report. Depending on the type of inspection performed, the Executive Summary might include corrosion rate

charts, ultra-sonic readings, failure rate metrics, detailed tubesheet maps, and maintenance recommendations.

The thoroughness of a CMS inspection helps identify where your equipment is damaged and is the first

step toward ensuring that the condition of the air heater never compromises operational or pollution control

objectives. Meeting those important objectives starts and by hiring a contractor that has deciphered and

solved nearly every air heater problem you can imagine – an experienced team member you can depend on.

We offer a variety of inspection services to analyze the condition of your equipment and work with you to

determine the best course of action. Reliable diagnosis of the problem is the first step in the right direction.

18

Agile Services to Meet Immediate NeedsCMS also offers its customers general mechanical maintenance services performed by our highly skilled

and trained staff. (See our list of common repair and inspection services below.) Because we are committed

to your bottom line, CMS blends mobilization charges, benefiting you by putting our onsite crews to work

on your equipment issues, without incurring additional mobilization charges.

INDUSTRIAL REPAIR & INSPECTION SERVICESInspect Repair

Air Heaters 3 3

Expansion Joints 3 3

Ash Hopper 3 3

Dust Collectors 3 3

Bag House 3 3

Condenser 3 3

Evaporator 3 3

Air and Gas Ducts 3 3

Stacks 3 3

Turning Vanes 3 3

High Angle Inspection 3 3

Augers 3 3

19

CMS’s custom inspection trailers provide resources on-site, and facilitates on-time delivery of our products and services as well as troubleshooting to address unforeseen challenges. CMS maintains a fleet of fully equipped trailers to mobilize for in-situ repair and unit replacement projects.

ACOUSTIC EYE INSPECTIONCMS innovative acoustic eye inspection solution is

designed specifically for detecting faults commonly

found in industrial tube systems. These could include

leaks, increases in internal diameter caused by wall

loss, full or partial blockages, as well as other issues

that negatively impact your operations.

Using portable acoustic pulse reflectometry (APR)

equipment, CMS inspectors direct one-dimensional

acoustic waves at tubular systems to detect defects

in cross sectional areas of the tubing. If the pulse

encounters a discontinuity in cross section, a

reflection is created, and we are able to quickly

isolate problem areas. Once we’ve identified any

holes, blockages, or other issues in your air heater

or other equipment, we are able to repair those

systems and improve your operating efficiency.

HIGH ANGLE ROPE INSPECTIONCMS offers high angle rope access inspections

to assess difficult-to-reach or inaccessible areas.

During a high angle inspection, CMS provides

a highly trained inspector, who has also received

>80 hours of NFPA rope access training. In

addition to your air heater, our professionals

can inspect the condition of your ductwork,

casings, expansion joints, hoppers and chimneys.

Additional advantages of high angle rope access

inspections include:

• Many times more cost efficient than erecting

scaffolding to access hard-to-reach locations

• Identification of localized damage, which helps

customers avoid unexpected budget busters

caused by emergency repairs

• Detailed maps and reports to assist in planning

for future outages

20

PRESSURE TESTING Pressure testing is an effective tool that can

be used to identify tube failures and determine

the overall health of an air heater. During this

procedure, a CMS inspector pressurizes each

tube and records air leakage rates as they occur

in damaged equipment.

When our inspectors identify failed tubes,

they remove them from service by installing

a mechanical plug at each end of the tube.

Removing a failed tube from service is a quick

way to improve boiler efficiency and reduce fan

energy. CMS recommends this option as a

temporary-only solution to get you back up

and running more efficiently.

INSPECTOR QUALIFICATIONS Our highly trained and skilled inspectors significantly

enhance quality control and help prevent costly

outages on equipment by evaluating wear and

internal degradation.

CMS inspectors are hand-picked and spend years in

training before leading any inspection. We provide

in-house seminars and training to ensure that our

inspectors recognize, understand, and respond to

each damage mechanism. Our staff communicates

with your team on a regular basis to help keep you

apprised of any significant findings that require im-

mediate attention.

After your inspection is complete, you will receive a

comprehensive executive summary that focuses on

the current condition of your air heater and the root

cause for its deterioration. You can rely on our many

years of experience to help ensure that you spend

capital wisely during future maintenance and select

a solution that is built to last.

21

Safety FirstLike the customers in the industries CMS serves, we take safety seriously. CMS Safety Services are unique within

the industry. Most of our safety officers and confined space attendants are current or former firefighters with

decades of experience responding to confined space emergencies. We pride ourself in both the rigorous and

extensive training that our employees receive and the cutting edge equipment that we supply during outages.

On a daily basis, our Rescue Services Crews help our customers in a variety of capacities, providing standby

rescue services, high angle training, and confined space inventories. In fact, we provide complete outsourcing of

outage safety needs, including suppling all confined space attendants and safety officers to direct the outage.

Our safety record speaks for itself. In fact, CMS earned an OSHA SHARP perfect score. Although we work hard to

minimize risks, we are still able to meet your demanding inspection, repair, and replacement schedules in a timely

fashion. We just do it safely!

Confined Space Safety Services

CMS repair crews participate in comprehensive and specialized confined space safety training before they ever

work on a job site. In fact, we are the only tubular air heater inspection and repair contractor in the U.S. that offers

NFPA 1007 and 1670 worker-to-rescue training certification. All of our employees are Confined Space Rescue

Trained (NFPA 1670 and 1006, OSHA 29 CFR 1910.134, ANSI Z 117.1) and have received a minimum of 86 hours

of hands-on confined space rescue training using a full-scale permit-required confined space simulator.

CMS has taken an industry-leading approach to training and qualifying confined space attendants (CSAs).

After receiving a minimum of 86 hours training, each CSA is certified as an Emergency Rescue Technician (ERT).

The ERT training includes advanced confined space rescue techniques/operations, Incident Command System

(ICS), supplied air respirators (SAR), self-contained breathing apparatus (SCBA), rapid intervention team (RIT)

operations, complex patient packaging techniques, first-aid, CPR, and AED. Rescue training even includes

advanced high angle rope rescue techniques for complex operations. Many of our confined space attendants

are former or current firefighters, who have extensive rescue training and real-world experience.

Standby Rescue

Due to the level of training and rescue equipment brought to each job site by CMS, our working crew can double

as a standby rescue team. We can also augment plant or contractor safety needs that may arise during an outage.

Worker to Rescuer Training

CMS has developed a customized training program known as “worker-to-rescuer”. Completing the worker

to rescuer training program enables our employees to transition from their traditional roles as workers into

a fully qualified and competent team capable of responding to any confined space emergency.

22

CMS employees receive extensive training in safety and rescue in our model air heater that simulates actual conditions.

Some employees are former or current firefighters, with extensive experience in handling emergencies.

“�CMS’s�safety�program�is�world�class�compared�to�others�that�I�see�in�the�industry.�They’ve�got�an�excel-lent�program,�and�they’re�a�contractor�that�I�wouldn’t�hesitate�to�do�business�with�again.�You�can�have�all�of the best equipment, but if you don’t have the best people to operate it, you’re not running optimally.” — John O’Rourke, Plant Manager, CSWS RRF, Hartford, CT

23

SAFETY SERVICESStandby Rescue 3

Rescue Trained Confined Space Attendants 3

Consulting 3

Onsite Training 3

Confined Space Inventory 3

Equipment Rental 3

Safety Services 3

High Angle Inspection 3

Corrosion Monitoring Services, Inc.

902 Equity DriveSt. Charles, IL 60174

Phone : (630) 762-9300Fax : (630) 762-9301

www.cmsinc.us