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AFTE R MAR KET S E RVICE S AN D PARTS
LONGEVITY SOLUTIONS
FEEDWATER HEATERS · CONDENSERS · HEAT EXCHANGERS ·
PRESSURE VESSELS · AIR PREHEATERS · ISOLATION DAMPERS
S P X H E AT T R A N S F E R A F T E R M A R K E TMore 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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E X P E R I E N C E . K N O W - H O W .C O M M I T M E N T .
S P X H E AT T R A N S F E R A F T E R M A R K E TMore Than Service - Longevity Solutions
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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.
G E N U I N E O E M P A R T S
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
T E C H N I C A L S E R V I C E S• 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
S E R V I C E S O V E R V I E WValue-Dr iven Aftermarket Offer ings To Maximize Performance and Investment
R E C O N S T R U C T I O N A N D R E P L A C E M E N T
On Site:
• Condenser and feedwater heater tube bundle, tube sheet,
baffles/supports and tube replacement
• 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
• Field testing
In Factory:
• Engineering services
• Rebuilds – feedwater heaters and heat exchangers
• Re-tubing
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S E R V I C E S O V E R V I E W
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E X T E N D ™ S E R V I C E S O L U T I O N S
• Scheduled inspection services
• Baseline ID eddy current, remote field testing and UT
tubing inspection
• Comprehensive inspection reports
• Preventive maintenance scheduling
• EXTEND service contracts
• Asset management programs
Value-Dr iven Solut ions To Maximize Performance and Investment
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SPX Heat Transfer provides a full
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
service operations adhere to strict industry
codes and standards, including:
• 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
TECHNICAL SERVICES CHECKLIST
Internal and external visual and NDE
inspection services
❏ Complex channel and pass partition plate manway
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
T E C H N I C A L S E R V I C E S
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Inspection and remediation services
❏ Tube sheet, tubes and welded end joint inspection
• 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
Borescope inspections
❏ Probe - 5/16" OD x 50'-0" long:
• 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
Condition and lifespan evaluation
❏ Life extension remediation planning
❏ Equipment replacement justification
❏ Thermal/mechanical evaluation:
• In-house engineering design review
• System tolerance for MW output upgrade
• Computational fluid dynamics and finite
element analyses
• ASME VIII design impact vs. original
Certificate of Compliance (COC)
NBIC Vessel re-rate assistance
❏ Straight beam UT inspection
❏ ASME code impact vs. original
❏ Allowable stress table change impact
Megawatt output upgrade evaluation
❏ Tube vibration damage
❏ Remediation by tube staking
❏ Tube side erosion remediation
❏ Shell side flow accelerated corrosion
prevention
Know-How Put Into Pract ice
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M O D E R N I Z A T I O N O F A I R P R E H E A T E R S
SPX Heat Transfer provides engineering,
manufacturing and field services to evaluate
and modernize air and gas preheaters, including
Rothemühle regenerative heat exchangers and other
rotor and stator type air preheaters.
New, improved components, including custom-
designed 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.
Advantages of upgrades and modernization to
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.
Evaluation services include:
Component Inspection — recommended interval is
8-12 months prior to next planned outage• 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
Modernization services include:
• 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
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M O D E R N I Z A T I O N O F A I R P R E H E A T E R S
1 0
R E N E W I N G T H E R M A L E Q U I P M E N T T O M A X I M I Z E S E R V I C E L I F E
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.
TURN-KEY VESSEL REMOVAL AND REPLACEMENT
❏ Design, engineering, demolition and construction
❏ Crane services and rigging
❏ Pipe preparation and welding
FIELD TESTING
❏ Leak detection
❏ Eddy current testing
❏ Individual and large tube vacuum testing
IN-FACTORY SERVICES CHECKLIST
❏ Rebuilding feedwater heaters and heat exchangers
❏ Re-tubing
❏ Engineering studies
ON SITE RECONSTRUCTION CHECKLIST
❏ Safety planning and field execution:
• 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
❏ Water box repairs or replacement
❏ Feedwater heater and heat exchanger rebuilds
R E C O N S T R U C T I O N A N D R E P L A C E M E N T
P R O G R A M M E D I N S P E C T I O N A N D M A I N T E N A N C E
Let SPX Heat Transfer design an EXTEND
service contract to meet your specific
requirements. Reliable, consistent performance
from thermal equipment is best achieved
through careful monitoring and routine
inspection and maintenance of thermal
components. To increase vessel longevity and
reduce life cycle costs, SPX Heat Transfer
offers the EXTEND Service Program. We can
provide the services necessary to maintain
your pressure vessels, steam condensers,
air preheaters and other thermal equipment
regardless of age, model or OEM.
PREVENTIVE MAINTENANCE
• Regularly scheduled proactive care of thermal equipment
results in reduced downtime, fewer emergencies and
unplanned outages and extended component life
• Refer to pages 6 and 7 for a discussion of some of the
component inspections, maintenance and repairs routinely
performed by SPX Heat Transfer service specialists
EXTEND PREMIUM SERVICE – ASSET MANAGEMENT PROGRAM
• By creating a custom database, SPX Heat Transfer can
track all maintenance and repair work performed on
your condensers, feedwater heaters, heat exchangers,
preheaters and other thermal equipment
• Data collected and housed on our secure site include
equipment identification, age, condition of specific
components, inspection records, repair history and
performance tests
• Asset management services include budgetary needs for
maintenance to extend service life as well as projections
for reconstruction and replacement
INSPECTIONS
EXTEND Service starts with a thorough
inspection and detailed inspection report,
completed by members of the SPX Heat Transfer
field service organization. The initial inspection
includes:• Structural integrity
• Mechanical components
• Water distribution
• Thermal performance
• Safety
• Findings summary
• Immediate recommendations
• Long-term maintenance plan
E X T E N D S E R V I C E
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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 12/2015 HT AFT-14
COPYRIGHT © 2015 SPX HEAT TRANSFER LLC
S PX H EAT TRAN S FE R LLCTULSA, OK 74116 USAP: 918 234 6000F: 918 234 3345BETHLEHEM, PA 18017P: 610 250 1000F: 610 250 [email protected]