
Retubing Condensers
Retubing condensers
The turnkey approach for retubing condensers is a key competence within the Boiler Services Department. Specialized engineers in processing and mechanical construction work closely together with our service specialists. The Stork Thermeq Project Manager coordinates each project which – in general – consists of five different activities:
Condenser inspections
- Visual inspection
- Eddy Current tests
- UT testing
- Water quality determination
Engineering
- Process calculations
- Analyzing the capacity and performance of the condenser according to the HEI-standard (= Heat Exchange Institute).
- Alternatives for tube materials (e.g. titanium, stainless steel, copper alloys or other material) and dimensions
- Calculating tube vibrations and tube supports
- Optional calculations:
- cooling water system
- vacuum system
- condensate system
- dumptubes
- Mechanical Engineering
- CFD-simulations for analyzing mechanical conditions
- Recalculating the spring supports
- Detail drawings of condensers, tubesheets, inner steel and other mechanical parts
Tube expansion test
Before starting the retubing of the condenser, Stork Thermeq can perform a tube expansion test. During this test the rolled joints will be analyzed:
- for strength of the rolled joints
- for leakages: a leak test by PTT (Penetrant Test).
- Condition of the expanded tube materials
Retubing condenser
- Site preparation
- Dismantling waterboxes
- Calibration tests of instruments
- Plan internal logistics
- Removing existing tubes
- Cut tubes inside condenser
- Pull tubes from tubesheet
- Disposal of tube material
- Cleaning
- Tubesheet preparation for expansion
- Preparation of internal tube supports
- Inside cleaning of the condenser
- Assembly
- Supply new tube materials
- Install possible vibration correction solution
- Place new tubes
- Expand tubes in the tubesheet
- Finishing tube ends
- Clean the tubesheets and tubes
- Leaktest
- Testing the expanded tubes
Tube sheet protection by applying coating
- Many condensor tubesheets are protected with a coating, such as Plastocor or similar. This coating material is applied in general overhauls and retubing projects.
Your benefits
- Single point of contact: General project management as main contractor for engineering and service activities
- Experienced in condensor retubing projects and applying alternative tube materials (e.g. titanium, stainless steel and copper alloys)
- Turnkey approach: from inspections, engineering up to final tube leak tests