NZ Steel traditionally procured this sort of work from Europe. By getting us to do the work, the lead time was significantly reduced.
Key Features:
- ‘Hockey stick’ Boiler Tubing Sch80 Pipe connected to 2# header pipes to form skirt.
- Boiler tubing with 180 deg bends to return flow back to header.
- Specialized jig designed for the fabrication of the skirt.
- Hydro was planned by Project Engineers to get it properly vented and drained.
- 3rd Party NDT of all boiler tube welding to ASME code.
- Fabrication to zero tolerance to fit Skirt to existing process plant.
Challenges:
- Rolling headers to the exact circumference to fit perfectly on jig design.
- Fitting the two headers together with very limited clearance.
- Template, ex 3D design, to fix all refractory 1200 off twigs in perfect position.
- Welding each end of 140 off 180-degree bends to boiler tubing to comply with code and specifications.
- A special frame was designed and used to vent all air as the assembly was filled for Hydro.
- After hydro high pressure, heated air was used to remove water and dry tubes.
- Successful Installation during a short shut due to preplanning and high-quality fabrication.
