Maintenance | Pulp & Paper Surface Condenser Replacement

Fabricated a condenser casing around the Lamella plate assembly so that the old unit could be removed and replaced during the Nov 2019 shut.

Key Elements:

  • Stainless Steel 304 plate Fabrication of casing and Inlet water box.
  • Surface Condenser Casing around 1.5m deep x3m wide and 5m high.
  • Water box fitted to condenser shell, domed end, 1.75m radius, 2.5m wide 3m high.
  • 1m Inlet Header plus vessel 500mm diam by 2m long.
  • Pipe outlet nozzles and pipe nozzles.

Challenges:

  • OJI Discovered late that replacement was required for Nov shut. Fabrication accelerated after October award to meet installation during shut.
  • Fabricated blow heat evaporator casing around Lamella Condensation assembly.
  • Old unit ‘rotten’ and difficult to remove and lift out safely.
  • Surface Condenser located in the hazardous gas area of the P&P plant.
  • All nozzles, inlets and outlets had to match up with existing site pipes and ducts.
  • Walkways removed and replaced.

Andritz Oy | Pulp Mill Services

"PFS have recently undertaken the fabrication and installation of a Recovery Boiler air system upgrade at Carter Holt Harvey's Kinleith Pulp and Paper Mill in New Zealand for Andritz Oy of Finland. This work included the installation of new boiler waterwall panels, ducting and piping.

There were nine new waterwall panels installed, each consisting of six tubes 63.5 mm 00, and so in total there were 108 site welds required. Recovery boiler tube welds are 100% radio graphed and inspected to a very exacting specification. PFS achieved the unusually high standard of zero failures, which is a result they can be proud of. This is equal to world best practice. PFS manufactured and installed the ductwork including the three sets of aerofoil flow meters. This was a challenging job with tight tolerances and was well done.

We found PFS reliable, well organised, honest and easy to do business with. Their safety systems were very good. They achieved the critical time schedule required and with consistently good quality. We would be pleased to work with PFS again."

 Timo La berg, Project manager

RX Plastics Ltd, Hamilton

"I like to take this opportunity to say well done to all your engineering staff that has worked on any of the rotational moulding tooling that we have sent in for modifications or repairs, the general consensus from staff members here is that they are very impressed with the finish and workmen ship that has been done. I have found the finish to be of a high standard that is comparable to an expert mould making company and we will continue to send tooling in to be repaired / modified knowing it will be good hands.

Also I would like to say well done to all the on-site service staff that have worked on tooling at our factory; this has also been complete in a very tidy manner and to a high standard. I have always found them very professional to work with."

 Jamie Robertson, Maintenance Manager

CHH

"109 welds completed 100% pass rate - outstanding!

Congratulations to the PFS team for achieving their goal of 100% butt weld pass rate. This was a tough goal given our high acceptance standards and was not achieved by accident - but was a result of good planning, training, weld preparation and a team of skilled welders."

 Warren Blakemore

Manager | Canpac | Fonterra

"A short email to say thanks to you and the team for the support and repair work on the incinerator last week, line has been started and heat applied. I really appreciated the professionalism of your team and their attitude to safety and engineering, please pass on my thanks"

 Paul Hogben, Maintenance Services

Canpac

"I would like to write to you both to thank you for the prompt response and good capable work that was carried out at Fonterra - Canpac by your tradesmen in the repair of our Oven Incinerator. We were particularly impressed by the quiet and efficient manner that the tradesmen just got down to work and the professional manner in which the work site was organised. It was quite clear that ‘safety’ was paramount and that the men were well equipped with the resources to isolate the work space from the adjacent Production environment."

 Paul Clark, Project Engineer

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