The assembly consisted of 4 units with several machined items to close tolerance. A trial assembly was carried out to ensure shaft housings line up. The item was then disassembled and transported to site for reassembly. The project was a novel method of recovery low grade energy from water flowing in canals.
Quenos at Altona, Victoria runs a polymerisation plant. The main process is a high severity ethylene pyrolysis furnace. Material used in the furnace is Incoloy alloy 803 (UNS S 350045). This alloy provides an exceptional level of high temperature corrosion resistance in oxidation, sulfidation and carburisation environments along with excellent stress - rupture strengths at elevated temperatures. The tubing internally finned to increase turbulence inside the tube and enhance heat transfer in the furnace tubes (dia 51 x 7mm). U-Neek manufactured all 8 banks of the furnace, complete with tube bending, critical welding of tubes to heaters, header flange welding, hydrotesting of equipment, complete NDT and MDR provided.
This project involved adding an extra 5% surface area to the economiser to allow the 500MW boiler to run at 525MW capacity. Notable was the manufacture of 1D bends (dia 50.8 on 50.8 radius). U-Neek organised all material including directly importing seamless steel tube from overseas mills. Tube size was dia 50.8 x 4.2mmthk. Welding comprised of several hundred butt weld joints.
This project involved the manufacture of high temperature reheater elements for a power boiler. The project involved exacting requirements on bending boiler tube, fit up and assembly, welding processes requiring weld procedures to be qualified. Completed elements underwent a stress relief heat treatment and full QA/QC documentation was provided in an MDR. Notable mention was welding of high nickel alloys (50%Ni,50%Cr) to 2.25% Chromium steels.