longevity solutions

LONGEVITY SOLUTIONS
FEEDWATER HEATERS · CONDENSERS · HEAT EXCHANGERS ·
PRESSURE VESSELS · AIR PREHEATERS · ISOLATION DAMPERS
AFTE R M A R K ET S E RVI C E S A N D PA R TS
EXPERIENCE. KNOW-HOW.
C O M M I T M E N T.
S P X H E AT T R A N S F E R
AFTERMARKET
More Than Service - Longevity Solutions
SPX Heat Transfer stands for over 80 years of
experience in the design, manufacture, evaluation,
repair, reconstruction and replacement of Yuba
Feedwater Heaters, Ecolaire Steam Condensers and
other condensers, feedwater heaters, boilers, heat
exchangers, pressure vessels and related equipment.
This broad range of experience provides the
foundation for our extensive aftermarket products
and services offering. Our dedicated field service
organization plans, manages and executes each
project, from coordinating on-site safety requirements
to overseeing third-party contractor services, when
required.
Years of hands-on experience and expertise serving
the power, utility and petrochemical industries make
SPX Heat Transfer the logical single source for
managing thermal equipment performance throughout
its life cycles.
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SERVICES OVERVIEW
Value-Dr i ve n A f t erm a rk e t O f f e r in g s
To Maxim i z e Perf o rm a n c e a n d I n v e s t m e n t
Regardless of the age, condition, needs or original equipment manufacturer (OEM) of your thermal equipment
and components, the SPX Heat Transfer field service team is committed to provide one value-driven source
for the wide scope of aftermarket services, from routine inspections and preventive maintenance to complete
reconstruction and replacement projects.
GENUINE OEM PARTS
SPX Heat Transfer provides replacement OEM parts for a broad range of thermal equipment including
steam surface condensers, shell and tube heat exchangers, feedwater heaters, air and gas preheaters and
related components.
Including these legacy brands:
• ABB Alstom Power Inc.
• Alstom Power Inc.
•Balcke-Dürr®
•Rothemühle®
• Ecolaire Heat Transfer Co.
• GEC Alsthom
• Joy Power Products
• Alstom Energy Systems
• Ecolaire Condenser
• Ecolaire Process Management Co.
• Ingersoll Rand
• Yuba Heat Transfer LLC
TECHNICAL SERVICES
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Internal and external visual and non-destructive evaluation (NDE) inspection services
• Dye penetrant • Magnetic particle • Ultrasonic • Borescope • Thermal imaging
Condition and life span evaluations
• Thermal/mechanical evaluations
• National Board Inspection Code (NBIC) Vessel re-rate assistance
• Megawatt (MW) output upgrade evaluation
• Inspection and remediation services
• Borescope inspections
• Feedwater heater, steam condenser, air preheater and heat exchanger internal inspections
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SERVICES OVERVIEW
RECONSTRUCTION
AND REPLACEMENT
On Site:
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Condenser and feedwater heater tube bundle, tube sheet,
baffles/supports and tube replacement
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Channel, shell and nozzle section replacement
Re-tubing of heaters, condensers and heat exchangers
Condenser tube bundle replacement
Condenser assembly and installation
Water box repairs, rebuild or replacement
Water box internal lining and coatings repair or
replacement
Balcke-Dürr/Rothemühle air and gas preheater repair
and parts replacement, refurbishment and modernization
Feedwater heater and heat exchanger rebuilds
Turn-key removal and replacement
Safety planning and field execution
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Field testing
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In Factory:
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Engineering services
Rebuilds – feedwater heaters and heat exchangers
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Re-tubing
Value-Dr i ve n S o l ut i o n s
To Maxim i z e Perf o rm a n c e a n d I n v e s tm e n t
EXTEND™ SERVICE
SOLUTIONS
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Scheduled inspection services
Baseline ID eddy current, remote field testing and UT
tubing inspection
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Comprehensive inspection reports
Preventive maintenance scheduling
EXTEND service contracts
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Asset management programs
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TECHNICAL SERVICES
SPX Heat Transfer provides a full
TECHNICAL SERVICES CHECKLIST
complement of consultative technical
services to evaluate, diagnose and upgrade
condensers, boilers and other thermal
equipment to ensure your operation is
compliant and efficient. Our plant and field
Internal and external visual and NDE
inspection services
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service operations adhere to strict industry
codes and standards, including:
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Certification by the American Society of
Mechanical Engineers (ASME) and the
National Board of Boiler and Pressure
Vessels Inspectors (NBIC)
• ASME “U” stamp – pressure vessels
• ASME “S” stamp – power boilers
• National Board “R” stamp – metallic repairs
ASME Section IX Welder Performance
Qualification (WPQ)
ASME Section V Nondestructive examination
ASME B31.1 power piping standards
NBIC vessel repair, alteration and re-rate
standards
Tubular Exchanger Manufacturers
Association Inc. (TEMA) standards
Heat Exchanger Institute (HEI) standards
Heat Transfer Research, Inc. (HTRI)
ISO 9001:2008 quality management system
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omplex channel and pass partition plate manway
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closures
Tube cleaning:
• Felt plug
• Sponge
• Flexible scraper
ID eddy current tube inspection
Dye penetrant inspection:
• Internal welds
• Channel
• Tube sheet interface
• Pass plate
• Tube-to-tube sheet welds
Weld repairs:
• Cracks and defects identification and repairs
• Post-weld heat treatment stress relief
Corrosion and stress damage assessment:
• Root cause evaluation
• Remediation planning
• Operating parameters assessment
and recommendations
Know-Ho w P u t In t o P ra c tic e
Condition and lifespan evaluation
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ife extension remediation planning
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Equipment replacement justification
Thermal/mechanical evaluation:
• In-house engineering design review
• System tolerance for MW output upgrade
• Computational fluid dynamics and finite
element analyses
• A
SME VIII design impact vs. original
Certificate of Compliance (COC)
Inspection and remediation services
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ube sheet, tubes and welded end joint inspection
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• Leak detection – air soap bubble test
• ID eddy current test
Individual tube testing:
• Hydrostatic burst pressure
• Vacuum leak detection
Large volume tube and tube sheet vacuum
leak testing
Re-expansion of leaking tubes and/or tube
end welding
NBIC Vessel re-rate assistance
Borescope inspections
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traight beam UT inspection
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ASME code impact vs. original
Allowable stress table change impact
Megawatt output upgrade evaluation
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ube vibration damage
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Remediation by tube staking
Tube side erosion remediation
Shell side flow accelerated corrosion
prevention
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robe - 5/16" OD x 50'-0" long:
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• Articulating probe tip
• Sized for most heater or condenser tubes
• Still image and video capabilities with text notation
• Less impact on outage schedule than shell removal
Feedwater heater and heat exchanger internal
inspections
• Corrosion/steam impingement damage detection:
• Condensing zone tubes and support plates
• DSH shroud and baffles
• DC shroud and baffles
• DC end plate
• Impingement plates
• Shell wall erosion
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M O D E R N I Z AT I O N O F
A I R P R E H E AT E R S
SPX Heat Transfer provides engineering,
Evaluation services include:
manufacturing and field services to evaluate
and modernize air and gas preheaters, including
Component Inspection — recommended interval is
Rothemühle regenerative heat exchangers and other
8-12 months prior to next planned outage
rotor and stator type air preheaters.
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New, improved components, including customdesigned sealing systems and heating elements, are
incorporated into the preheater upgrades, offering
lower leakage and less wear, better heat efficiency
and less pressure drop and providing excellent
resistance to corrosion, erosion, plugging and
temperature shock.
Modernization services include:
Advantages of upgrades and modernization to
• Design calculations
• Layout design
• Design engineering
• Project management
• Manufacturing supervision
• Quality management
• Manufacturing of key components
• Shipment logistics
• Site supervision
•Commissioning
• Performance testing
• After-sale scheduled inspections and maintenance
minimize leakage and air-to-flue gas flow include
plant megawatt savings and significant fan amperage
reduction. The resulting ability to recover previously
lost energy output and provide additional power to
the grid allows payback of the capital investment in a
matter of months.
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Sealing system collar seals
Levelness of stators/rotors
Position of shaft
Condition of sealing system, sector plates, sleeves
Condition of heating surface
• Cold, intermediate, hot layer
Adjustment of sealing system
Efficiency of cleaning system
Collection of operating values
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RECONSTRUCTION
AND REPLACEMENT
RENEWING THERMAL EQUIPMENT
TO MAXIMIZE SERVICE LIFE
Whether your heat transfer equipment has
experienced a structural failure or is not
performing to specification, SPX Heat Transfer
can provide a range of solutions to maximize
performance, from restoration services to
turn-key removal and replacement.
ON SITE RECONSTRUCTION CHECKLIST
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afety planning and field execution:
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• Comprehensive Job Safety Analysis (JSA)
process
• OSHA 30-Hour Construction Industry
certified field service supervisors
• OSHA 10-Hour Construction Industry certified
labor force
• Exemplary safety record – 5 years with no
recordable injuries
Tube bundle, tube sheet, baffles and
supports replacement
Channel, shell and nozzle section replacement
Re-tubing
Condenser bundle replacement
Condenser assembly
ater box repairs or replacement
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Feedwater heater and heat exchanger rebuilds
TURN-KEY VESSEL REMOVAL and
REPLACEMENT
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esign, engineering, demolition and construction
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Crane services and rigging
Pipe preparation and welding
FIELD TESTING
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eak detection
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Eddy current testing
Individual and large tube vacuum testing
in-factory services checklist
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ebuilding feedwater heaters and heat exchangers
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Re-tubing
Engineering studies
EXTEND SERVICE
PROGRAMMED INSPECTION
AND MAINTENANCE
Let SPX Heat Transfer design an EXTEND
service contract to meet your specific
requirements. Reliable, consistent performance
PREVENTIVE MAINTENANCE
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results in reduced downtime, fewer emergencies and
from thermal equipment is best achieved
through careful monitoring and routine
inspection and maintenance of thermal
unplanned outages and extended component life
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performed by SPX Heat Transfer service specialists
reduce life cycle costs, SPX Heat Transfer
provide the services necessary to maintain
your pressure vessels, steam condensers,
air preheaters and other thermal equipment
Refer to pages 6 and 7 for a discussion of some of the
component inspections, maintenance and repairs routinely
components. To increase vessel longevity and
offers the EXTEND Service Program. We can
Regularly scheduled proactive care of thermal equipment
Extend premium service –
asset management program
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regardless of age, model or OEM.
By creating a custom database, SPX Heat Transfer can
track all maintenance and repair work performed on
your condensers, feedwater heaters, heat exchangers,
INSPECTIONS
EXTEND Service starts with a thorough
preheaters and other thermal equipment
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Data collected and housed on our secure site include
inspection and detailed inspection report,
equipment identification, age, condition of specific
completed by members of the SPX Heat Transfer
components, inspection records, repair history and
field service organization. The initial inspection
performance tests
includes:
• Structural integrity
• Mechanical components
• Water distribution
• Thermal performance
•Safety
• Findings summary
• Immediate recommendations
• Long-term maintenance plan
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Asset management services include budgetary needs for
maintenance to extend service life as well as projections
for reconstruction and replacement
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S PX H E AT T R A N S F E R L LC
TULSA, OK 74116 USA
P: 918 234 6000
F: 918 234 3345
Bethlehem, PA 18017
P: 610 250 1000
F: 610 250 1010
[email protected]
spxheattransfer.com
In the interest of technological progress, all products are
subject to design and/or material change without notice.
Rothemühle products are offered with consent of Licensor,
Balcke Dürr GmbH.
ISSUED 09/2014 HT AFT-14
COPYRIGHT © 2014 SPX HEAT TRANSFER LLC