Boiler Superheat Upgrade Project at Virginia Tech
PROJECT STATS
- Add superheat surface within a boiler to increase power production
- Remove a portion of generating tubes and replace them with superheat tubes
- Approximately 1,100 tubes replaced
- Complete tear-down of the boiler side walls and roof
- Project completion accomplished within the required deadline
- Project successfully completed under budget by approximately half of the original estimate
About this PROJECT.
This project was comprised of adding a superheat surface within one of the boilers in order to increase power production from the turbine generator that produces electricity for the campus. Prior to completing this upgrade, two boilers were required to produce the needed energy for the turbine generator; and this project resulted in only one boiler operating to produce the same energy.
A superheat surface within the boiler was added by removing a portion of generating tubes and replacing them with superheat tubes. In total, approximately 1,100 tubes were replaced. The greater heating surface increased the operating temperature of the boiler by 200 degrees, thereby increasing power production from the turbine generator.
The project required a complete tear-down of the boiler side walls and roof, which included the replacement of the boiler skin and casing as well as new insulation and refractory. The major challenge of this project was the limited physical access to the equipment requiring significant labor combined with a very tight deadline for project completion.
What IT TOOK TO ACHIEVE THIS PROJECT.
Why WACO was chosen
Waco has completed many successful projects at Virginia Tech, and has a very solid reputation with the University. Waco also has a mechanical maintenance contract there. Additionally, Waco maintains an R-Stamp with the National Board of Boiler and Pressure Vessel Inspectors. This enables Waco to perform repairs and upgrades on boilers and other pressure vessels, and was a contributing factor toward the award of the contract.
Summary of Results
Walter Mandzak, an experienced boilermaker and Sean Davies, an experienced project manager, led the Waco team to complete this project. The superheat upgrade project was fully tested and succeeded at increasing power production from the boiler. The overall cost of the project to Virginia Tech was about half what was originally estimated. This project represents a great example of Waco’s technical expertise and ability to complete projects efficiently as a means to reduce expenses to the university.
Contact Waco at 888-822-7285 for more information.