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