DRUMS
Steam and water drums can be provided for any OEM’s natural circulation boiler design, or capacity. Drums up to 84” diameter are available, including those requiring single thickness tube and wrapper sheets, or different thickness tube and wrapper sheets. In-house stress relieving capability is available, as is all required NDE to ASME and ASNT requirements.


   HEADERS
Replacement headers are available for any application, including superheaters, reheaters, economizers, and waterwalls. We have extensive experience with the latest materials currently required for all operating units, including natural circulation and supercritical designs. During fabrication, the headers are produced under the strictest surveillance of our Quality Control Department to insure complete compliance with all necessary codes.

GENERATING TUBES
Generating tubes for all OEM boiler designs are available and are typically tubes extending between the mud/water and steam drums that convert a large volume of water into steam. Generating tubes are normally manufactured from various grades of carbon steel, including SA-178 Gr. A, SA-178 Gr. C, SA-192, and SA-210 A1. Where designs require that the generating tubes be swaged to a smaller diameter at each end, our shops can comply and will insure that acceptable levels of hardness are maintained through specific annealing processes so that the tubes can be rolled properly into the drums. Each tube row configuration is matched to insure that the new tubes will be properly aligned with the existing tubes in each row. This is particularly important if your existing arrangement has baffles, vibration restraints, or other attachments.

WATERWALLS
Waterwall configurations, materials, and designs vary greatly for each boiler design. Most waterwalls today are of the membrane type construction, although we can also offer waterwalls utilizing tangent tube construction. We have numerous panel welding machines at our manufacturing facilities capable of producing membrane-type waterwalls from a variety of tube sizes, materials, and fin widths. Where bent panels are required to insure correct alignment of all tubes, a panel gang bender is utilized. Weld overlay can be applied where operating conditions justify it.

   SUPERHEATERS
Replacement superheaters for in-kind replacement, as well as improved performance and/or extended life, can be furnished for any OEM’s unit. Procedures necessary to insure acceptable bend geometry and material mechanical characteristics, as well as those required to manufacture any design with any of the materials needed to meet today’s performance and code requirements, are available. When appropriate, weld overlay can also be provided.

   REHEATERS
Reheaters are often exposed to very high temperatures during start-up. Premature failure in reheaters can often be attributed to poorly designed support and alignment systems, as well as inadequate tube material selection for the high temperatures to which they are exposed. Replacement reheaters can be designed to meet your operating requirements utilizing the centuries of experience available within the Babcock Power Services Group. Revised designs, utilizing the correct materials and the latest manufacturing techniques, can be offered to help insure that your unit will operate reliably and efficiently. Where appropriate, weld overlay can also be applied.

ECONOMIZERS
Complete design capabilities are available within the Babcock Power Services Group to produce any type of economizer for any type of boiler, including bare tube, bar-fin tube, spiral wound and H-fin. After consulting with our client about the operating conditions of a specific unit, and the desired performance and operating enhancements, a complete evaluation is conducted, and a final solution proposed. Consideration is given to the type of fuel being fired, flue gas characteristics, potential for plugging, gas velocity and temperature, sootblower requirements, operating hours, load variation, and unit history. After complete evaluation, a solution is offered, selecting the appropriate tube size and material, as well as the correct finning surface, if appropriate, including BTA’s “H”-fin surface for dirty flue gas applications.