Electricity and Control February 2022

PLANT MAINTENANCE, TEST + MEASUREMENT : PRODUCTS + SERVICES

New high-pressure heaters for Eskom power stations

fit. Furthermore, the tube bending process required spe- cific heat treatment, which is currently being tested and proven in its efficiency. Warwick Ham, Boiler Process Engineering Group Leader at Steinmüller Africa said, “All our pre-fabrication preparation and testing methods are critically impor- tant to meet our clients’ specific requirements. Through mock-up testing for the header to the nipple welding and heat treatment for tube bending, we are confident we can deliver top-quality final products.” The HP heaters are supplied with engineering and manufacturing guarantees, which are confirmed by an external reviewer on completion of the design and fab- rication, respectively. Steinmüller Africa’s HP heaters are expected to perform for over 30 years, which can be ex- tended with repairs and maintenance services. Serving the petrochemical, power generation, sugar and steel industries, Steinmüller Africa offers end-to-end solutions for utility-scale companies using turbines, boil- ers and HP heaters. It can meet specified design codes, including ASME, EN, British standards, API, HEI, TRD and TEMA. Senior Process Engineer Keyur Kumar Patel says, “We engineer, design, test, fabricate and install all necessary boiler and HP heater equipment using our in-house ex- perts and leading services.” With the help of Oerlikon Automatic Welding and Cojafex Induction Bending machines, unique to the African continent, as well as other world-class machinery, Steinmüller Africa offers a set of customised products and services. Additionally, with an internal logistics team and crane division, which offers load capacities of over 100 tonnes, materials delivery and on-site installation can be achieved across Africa.

Steinmüller Africa, turnkey solution provider for high- temperature and -pressure static equipment, is working on two orders to supply a total of 14 new high-pressure (HP) heaters which will form part of the upgrades at Eskom’s Mpumalanga-based sister plants, Tutuka and Duhva power stations. As specified in Eskom’s requirements, the header-type HP heaters will range from 12 to 14 m long, with 2 m di- ameters. Using Steinmüller Africa’s customised designs, the heaters will achieve various pressures, ranging from 1.5 to 30 MPa, and handle very high temperatures, be- tween 230 and 300°C. The project required six new designs, three process and three mechanical, which were developed swiftly, despite the challenges posed by Covid-19. Having received the orders in August 2020 and February 2021 and to meet the tight design and planning deadlines while also adhering to Covid-19 protocols, the Steinmüller Africa team worked 12-hour shifts around the clock, some remotely and others in the office. This was achieved using 3D modelling software, Inventor. Now well into material procurement phase, the com- pany has begun initial fabrication on Tutuka’s HP heaters and those for Duhva are due to follow in the next few months. Steinmüller Africa expects to complete all HP heaters by 2024, as both power stations’ equipment is reaching mid-life status and requires replacement. The company undertook extensive preparation and testing procedures to ensure Eskom’s exact specifica- tions are met. The engineering team completed various iterations, modifying procedures and production of the header to nipple welding. By re-developing the process- es of drilling, re-aligning, fit-up, welding, non-destructive testing (NDT) and ultrasonic testing (UT), the company created a new process and set of protocols based on existing European methodologies. Steinmüller Africa also extensively tested the ma- chinery best suited to meet requirements when bending snake or serpentine tubes. Automated, semi-automated and manual machines were all tried and tested for best

For more information contact Steinmüller Africa. Tel: +27 (0)11 806 3209

Email: Keyur.patel@bilfinger.com Visit: www.steinmuller.bilfinger.com

Final fitments on a high-pressure heater tube bundle before the shell is placed over it.

U-Bends of a tube bundle on a HP heater.

24 Electricity + Control FEBRUARY 2022