We produce world class boiler components of prime quality which meet the requirements of relevant codes & standards and customer specified requirements. We benchmark our products to the best quality standards and constantly upgrade our system for superior performance.
Water wall panel
Water wall panels are normally being over the furnace bed of a Boiler assembly and forms a wall. It is made of tubes and fins in which the water is evaporated to steam with the use of flue gases. We manufacture the gas tight & leak proof water wall panels with the use of fully automated “Panel processing welding machine” which can have swaged ends or plain ends.
We produce panels having tube OD from 38.1mm to 88.9mm and thickness from 3.6mm upto 9.0mm with maximum length of 24Mtrs and maximum width of 2.7Mtrs. We achieve straightness within a tolerance of ±3mm using welding processes SAW, GMAW & FCAW.
Headers
Headers are the important parts of all types of boilers. Steam from the tubes is collected into headers with high pressure which may vary from 300psi to 2000psi. Since headers are always under pressure, we take utmost care while fabricating them.
Depending on the boiler capacity, headers fabricated by us vary from 100mm to 600mm NB. The stubs, branches, fittings like end caps, equal / unequal tees, weldolet, sockolet of various sizes are very carefully welded to the main body of the header to provide the desired openings from the headers.
Coils >> Economiser coils
These are boiler feed-water heaters in which the heat from waste flue gas is recovered to raise the temperature of feed water supplied to the boiler, thereby increasing the fuel economy, steaming capacity, life of the boiler with reduced atmospheric pollution.
We fabricate various types Economizers Coils, (Plain tubular Economizers, Finned Economizers, Feed water heaters Evaporator Coils, Screen coils etc.)
We manufacture Coils in Carbon steel or alloy steel up to 114mm Dia with CNC cold bending machine with a minimum radius 38.1mm and tube butt welding by GTAW process. We offer innovative solutions to extend the life of the coils by providing half tubes sleeves for upper tubes, SS full Sleeved tubes etc., to prevent erosion.
Coils >> Superheater coils
Superheater coils are the most critical Boiler components of the modern day Thermal Power Plants and are subject to very high metal temperatures and are being used to generate super heated steam.
We have fabricated thousands of Superheater coils such as radiant, primary, final, reheaters etc., which are complicated very close and compact shapes with tube sizes ranging from 38.1mm OD to 114.3mm OD and thickness from 3mm of 12mm in all types of Boiler quality Steel Grades ranging from Carbon to Alloys and Stainless steels.
Coils >> Studded tubes & Bed coil tubes
Studded tubes are used to increase the surface areas to achieve higher heat transfer rates. They are used in fluidized bed coils and fluidized bed superheaters. They are also used in refineries as reheaters.
We engage automatic stud welding machines using arc drawn method capable of welding studs up to maximum of 25mm dia even at very close pitch.
The material grade of studs and tubes can be similar or dissimilar grades ranging from carbon steel to alloy steel (up to 9 Cr) to stainless steels. We can also give special HVOF Chromium Carbide coating on surfaces subjects to High Erosion Velocity of Flue gases to avoid frequent replacements.
Evaporator modules
Evaporator assembly is being used in the modern thermal plants to increase the Boiler efficiency. The hot water from the drum is collected through downcomers and saturated steam is produced in the evaporators with the help of flue gases. The saturated steam is forwarded to the superheaters.
Since, the evaporators are one of the most critical parts in the boilers, we produce the evaporator assemblies, evaporator modules, and evaporator coils etc., with undue care. Being under very high pressure and temperature, we produce the evaporator bends strictly to meet the standard requirements ensuring the flow area, maximum ovality and minimum thickness in the extrados of tube bends.
Panel with header assembly
Water wall panels are used in boilers in place of steam generating tubes to reduce heat loss due to their gas tight nature and to reduce insulation costs.
We fabricate water wall panels using automated panel processing welding machine and then weld it to the headers. We integrate the openings with the use of jumper tubes along with seal box in the panels.
Bed coil assembly
Bed coil assemblies are used to elevate the steam temperature received from the super heater coils. Normally bed coil tubes are stud welded to enhance the uniform heat distribution. We fabricate the studded bed coils, bed coil assemblies along with steam inlet and outlet headers.
Screen coils
We manufacture the studded screen coils to preheat the water with the use of flue gases and effectively improve the fuel efficiency.
We form the screen coils with the CNC, NCX tube bending machines and perform the screen panel welding with our own specialized semi-automated welding arrangement which qualified to meet the pressure vessel code.
To improve the flue gas efficiency and for uniform heat distribution, studs are fusion welded to the screen coils and to prevent erosion of tubes we provide stainless steel studs and stainless steel attachments to withstand elevated temperature.
Piping
The piping in the boiler plants includes feed piping, steam piping, connection piping, drain / blow down piping, attemperators etc.
We produce the entire piping system required for the boiler assembly with the ranging base materials in carbon steel, Low (0.5Mo), Medium (1.25-2.25Cr, 1Mo) and High (9Cr 1Mo) alloy steel materials including stainless steel materials of any thickness.
Welding processes GTAW, SMAW & SAW are used for fabrication and the welding processes are qualified & validated as per the pressure vessel code ASME Sec-IX Latest amendment.
Along with our core competency of Project Management and Manufacturing, we also provide additional services like Detailed Engineering, Field Engineering, Raw Material Procurement, Erection Supervision / Assistance and Logistics Assistance. While we extend all our expertise, our clients could engage more of their time with the end customer.
Detailed engineering
We offer state of the art Detailed Engineering Services for Boiler components through highly skilled employees, software tools and developed applications to ensure optimum quantities, work-volumes, constructability, operability, maintainability and safety of Process and Power plants.
We can execute complete Detail Engineering of high pressure Boiler components based on the design inputs provided. We integrate the system requirements (IMS) during the detail engineering process itself.
Field engineering
We do the art of field engineering services for existing boilers and its components to maximize the operating efficiency. We collaborate and work with some of the best field experts in the industry to asses, analyze, and provide solutions to complex problems.
Raw material procurement
We execute the raw material procurement service from reputed suppliers and accept the material after comprehensive inspection as per the applicable code of construction. We involve the customer or third party inspection agencies along with our own inspection engineers as per the terms of contract.
Erection supervision / assistance
We extend our service in the field of erection to supervise the erection sequence as per the established standard. We assist to gear up the sequences in erection with our experts.
Logistics assistance
Logistics is the management of flow of things between the point of origin and the point of consumption in order to meet the customer requirements.
We assist for the inbound as well outbound logistics in which the inbound is the primary process of logistics that includes purchasing, movement of part processed or partially finished products from suppliers. The outbound logistics is the process of movement of finished products and related information.
We undertake the scope of stuffing the goods into the containers, loading the finished products on trucks & trailers along with the legal clearance. We let flow the related information, legal clearances, special instructions etc., to the point of customer.