Boiler Projects & Services

Balcke-Dürr´s exprience in boilers goes back to 1883 when the „Dürr Kesselwerke“ was founded. Nowadays Balcke-Dürr is a service provider for OEM and non-OEM boiler.

Engineering and Capabilities

Inspection, root cause analysis and consultation
Boiler process optimization studies in regards to performance, life time extension and fuel replacement
Design and optimization of new heating surface and bundles
Boiler overhaul including firing technology
Site works including disassembly and installation

Pressure Parts – Bundles

Contact heat exchanger bundles for evaporation, super heating and re-heating of boiler steam. No matter if header-type design or single harp design, we are able to exchange and improve any bundle type. 1:1 replacement or with addtional protective equipment such as coating (Cladding), shells or baffle walls.

OEM and non-OEM applications
Usage in various boiler areas (Evaporator / Superheater / Reheater / Economizer etc.)
Single or divided bundles, header-tube or single harp design
Exchange via roof, from the ground, via boiler house side walls or through the ash hopper from the ground up
Max. bundle specification: -100 t and 3.500 x 4.500 x 8.000 mm (W x H x L)

Heat Exchanger bundles

Pressure parts

Pressure Parts – Membrane Walls

Membrane wall panels (tube-fin-tube design) for evaporator heating surfaces with product specification and granted conformity according to original design or harmonized standard. Adjustment of existing design by applying protective coating (Cladding). A variety of specifications for material, layer, technique etc. can be considered.

Tube-Fin-Tube design
Horizontal, vertical & diagonal alignment
Tube pitch up to 120 mm
Installation of single segments / panels
- Max. dimension of 1.000 mm x 6.500 mm per panel
Quality documentation
- NDT during installation process by UT (Phased Array Method)
- MT & VT experience allowing reduction of X-ray windows and minimization boiler downtimes

Cladding

Protective Coating of membrane walls (single or double sided possible), sole heat exchanger tubes and headers by weld overlay. Special Ni- based alloys will be welded manually or automatically on to the base material. Ensurance a maximum of Fe-content in the overlap area of base material and coating. Thickness can be chosen individually from 1 to 2 mm.

Thermanit 625, 686
Workshop cladding with ≤ 3% Fe-content and 1-2 mm thickness
On Site repair cladding manually with ≤ 8% Fe-content and 2 mm thickness
On site connection of cladded parts by InCla-Welding method (non-alloyed root layer– austenitic filler and cover layer)
Applicable for various parts (tubes, headers, membrane walls, fins)

Cladding

Boiler Service and Auxiliaries

From single inspection up to preventive maintenance of boiler pressure parts we offer a broad range of services.
Complementary solutions in regards to maintenance of high pressure systems and auxiliaries are standard practices to us.

Extract from our service competences

Pressure parts as tailor-made or specific replacements
Inspection and exchange of safety valves & silencers
Maintanence of secondary & tertiaire air circulation as well as NH3 injection system
Replacement or overhaul of headers, steam drums or injection coolers

Installation & Disassembly / Site Works

Based on our tailor-made installation concepts we will exchange any boiler part to ensure and increase availability. Starting from on site inspection, developing individual solutions as well as risk assesments we will constantly find a suitable way for realization of our client`s desired project scope.

Installation studies
Installation concepts and execution (e.g. access & transport routes, lifting plan, welding technology)
Project Management, Site Supervision, Quality Control, HSE Management
Establishing single point of contact to the customer
Quality documentation
Highest requirements towards Safety