Boiler Construction pbf

STEEL YARD

•All Material is received, verified and checked by QC inspectors for A.S.M.E. code compliance, before being staged and allocated for a specific Sales Order.

CNC Plasma Cutting System

• All Carbon and Stainless steel plate material is cut on our CNC Plasma System. • The plasma system is linked to our Engineering Department where drawings can be ed directly to the shop floor for cutting. • The plasma cutting system cuts material at an 80-90 IPM pace.

ROLL OPERATION

•All Pressure Vessel shells, furnaces and turnaround shells are rolled on a 3 point Webb roll.

Weld Tack-Up •The rolled material is fit up and tack welded together. The weld seam is prepared for the Submerged Arc welding process.

Automatic Weld Process •All pressure vessels longitudin al and circumfere ntial welds are double butt welded, using the Submerge d Arc welding process.

Submerged Arc Code Welds

•The Final Submerged Arc welds on Longitudinal and Circumferent ial seams are inspected inside and out for any type of discontinuity.

Material Testing •All longitudinal and circumferential welds are then X-Rayed inhouse. • Furnaces and Wetback boiler turn-around shell longitudinal welds are bend tested to requirements.

•The tube holes are drilled with exact tolerances and precise finishes by utilizing a CNC drilling machine.

Tubesheet Drilling

•The tube holes are drilled with exact tolerances and precise finishes by utilizing a CNC drilling machine.

Pressure Vessel Assembly

• The Tube sheets are installed by type of boiler. Dry back boilers receive the rear Tube sheet first. Wetback boilers install the front Tube sheet first.

Pressure Vessel Assembly Area

•All nozzles, couplings, Man hole ways and loading eyes are installed and welded to engineering specifications.

Corrugator

•Corrugated furnaces allow furnaces to be built with less material thickness and provide more means of expansion.

•All corrugated furnaces are specified through Superior’s engineering department,

Furnace

•Furnaces are inspected to insure all dimensions meet the requirements of the A.S.M.E. type of furnace.

Pressure Vessel Assembly Area

•All welders used to assemble A.S.M.E. code boilers and vessels, have taken and ed certification tests prior to welding in this area. In the pit area,A.S.M.E. code certified welders put the boiler in a flat position to complete the Full Penetration Groove Weld on the Tube sheet and furnace.

Pit Area •In the pit area,our A.S.M.E. code certified welders put the boiler in a flat position to complete the Full Penetration Groove Weld on the Tube sheet and furnace.

Heat Treatment Oven •The heat treat oven is used to perform post weld heat treatment of welds, required by the A.S.M.E. code and Superior’s engineering department

TUBE YARD •The diameter of tube depends on the boiler design.

Tubes

•Tubes that are staged and ready for insertion into the tubesheets.

Tubing

•The tubes are set into the tube sheet at lengths specified by the A.S.M.E. code. This is showing our tube technician cutting the tubes to the precise length of 3/16”. The proper tolerance for flaring and rollerbeading of the tubes.

Tubing

•The tubes are then rolled to provide a precise thermodynamic bond between tube sheet and tube. Tube ends are rollerbeaded to provide a smooth surface for hot gases to flow.

Tubing

•When boiler is completed in tubing the vessel will be placed on its base or skid. The first of two required A.S.M.E. code required hydrostatic tests are performed at this point.

Skid Production

•The skid area is where we produce the base for the boilers. The skids are designed to properly the boiler and provide easy access for maintenance and inspection.

Refractory

Poured and vibrated refractory is used for all doors, blocks, bridges and burner mounts. The type of refractory used depends on the temperature of service it is specified to.

Small Parts Area •This station is where front smoke boxes, rear doors, stacks, burner rings and davits are manufactured.

•Completed front and rear smoke boxes are completed and ready for installation on a Wet back boiler.

Assmbling Area

•This station is responsible for installing front smoke boxes, rear doors, The placement of the stack, refractory blocks, bridges, turbulators and the burner mount.

Insulation Area

•2” thick mineral wool insulation used, to prevent heat loss. The insulation is covered with 22 gauge sheet metal.

Final Assembly Area Boilers are lined up in the 3 station Fire test area to perform the Electrical, Low Fire test, Full Fire test, and Final piping Hydro-test of the boiler.

Paint Prep

After all the boiler components have been properly masked, the boiler will be wiped down with a solvent to remove all oils and dirt, to give the best possible paint adhesion

Ready for Shipment The boiler’s openings and electrical boxes are wrapped and made ready to be loaded on a truck for delivery.

Shipping Area

Boiler being prepared for shipment

APACHE

•Dryback boiler with turbulators. •30 HP – 2200 HP. •Steam & Hot Water. •XI-D Tubes can be supplied after SBW Engineering Review

Mohawk •

• 3- DrybackB oiler. • 30 HP – 1000 HP. • Steam & Hot Water

• 3- Wetback. • 70 HP – 1800 HP. • Steam & Hot Water. • Will be used for Heavy oil application s only.

“Super” Seminole • 3- Wetback Boiler with XI-D tubes. (1st of tubes only.) Will replace Seminole Gas & Oil #2 applications. • 70 HP – 1800 HP. • Steam & Hot Water. • Guarantee Efficiencies. •