Economisers Coils

Economiser Coils are designed as efficiency improving boiler feedwater heaters, recovering waste heat from flue gases to significantly enhance fuel economy, increase steaming capacity, extend boiler life, and reduce pollution. We expertly fabricate various types of Economizers , including plain tubular, finned ( H-Type or Spiral welded) , and cast iron gilled economizers, along with other feedwater heater evaporator coils. Recognizing the common challenge of tube erosion, especially at bends, we offer innovative solutions like cassette baffles, half / full stainless steel (SS) tube sleeves, Erosion Protection Plates and also Chromium Carbide/Tungsten carbide Coatings to proactively extend the operational life of these critical components.

Superheater Coils

Superheater coils are the most critical component in modern thermal power plants, as their ability to withstand extremely high metal temperatures directly dictates a boiler's capacity and enhances fuel economy by reducing steam consumption in turbines. We have fabricated thousands of these complex coils, including Radiant, Pendant, Final along with Reheaters, for boilers ranging from 10 to 800 MW. Our expertise covers intricate, compact shapes using boiler-quality steel grades from carbon to stainless steel, with tube sizes from 32mm to 76.2mm OD and thicknesses from 3mm to 12mm, designed for metal temperatures up to 670°C.

Studded Bed Coils & Tubes

Studded Tubes are engineered to significantly increase surface area reduce erosion , thereby achieving higher heat transfer rates in applications like Fluidized Bed Coils, Fluidized Bed Superheaters, and refinery Reheaters. We utilize automatic stud welding machines with the drawn arc method, capable of welding studs up to 13mm in diameter at a dense pitch of 63 stud planes per meter. Our process accommodates similar or dissimilar material grades, from Carbon Steel to Alloy Steel (up to 9 Cr) and Stainless Steels. For surfaces exposed to high erosion velocity from flue gases, we offer specialized Chromium / Tungsten Carbide coating to prevent frequent replacements some of which extend Life of Bed Coils to 20 years .

Boiler Bank Tubes

Boiler Bank Tubes, also known as Steam Generating Tubes, are precisely bent tubes that convert water into steam while carrying a mixture of both phases. Fabricated in various sizes and shapes, their larger bending radii demand specialized tube bending expertise to prevent wrinkles, surface cracking, or irregularities, thereby ensuring smooth, efficient, and long-lasting boiler operation. We supply these replacement shaped tubes—typically made from seamless or ERW tubes ranging from 50.8 mm OD x 3.25 mm Thk to 82.55mm OD x 7.60 mm Thk, often with swaged ends, welded fins to diverse industries including Sugar, Refineries, Steel Plants, and Utility/Captive Power Plants.

Pipes & Tubes

We supply steel pipes, tubes, and fittings across a comprehensive size range (8mm to 1016mm OD, 1mm to 76.2mm Thk.), all accompanied by MTC and IBR Certificates. These components are critical for diverse applications, including steam/line piping, boilers, superheaters, economizers, water walls, headers, air pre-heaters, heat exchangers, and rifle bore tubes.

Our offerings are classified by manufacturing method (Seamless - Hot Finished & Cold Drawn; Welded - ERW, SAW, CDW, SW, MMAW) and steel chemistry (Carbon Steel - low, medium, high carbon, manganese; Alloy Steel - based on chrome & moly; Stainless Steel - based on nickel, chrome, moly). It's crucial to note the distinction in end use: tubes transfer heat through their walls, while pipes transfer heat through their bore.

We adhere to numerous international specifications, including: ASME/ASTM: A178, A179, A192, A210 Gr. A1/C, SA 209 - T1a, b A213-T2, T11, T12, T22, T23, T5, T9, T91, T92, TP 304H, TP 321H, TP 347H, TP347 HFG, TP310 CbN, Super 304 H, SA 214/A53/A106 Gr. A, B, C, A335-P1, P11, P12, P5, P9, P91 A312-TP304L, TP 316L, A333 Gr. 1/6. A 423, A333 Gr. 1/6, SA 556, SA 234 WPB, WP5, WP11 etc.

DIN: 17175/EN10216-2/ St. 35.8/45.8/16M03/13CrMo4-5/10CrMo9-10/X20Cr MoV11-1 etc. BS 3059: Part I/II - Gr. 320, 360, 440, 243, 620, 622, BS 6323. ΕΝ: 10216-2- GB 5310: 20G, 15CrMoG, 12Cr1MoVG. GOST: 20, 12XIMF, 15XM, 15X1MIF.

Finned Tubes

Our finned tubes represent the pinnacle of engineering excellence, backed by our unwavering commitment to quality. Essential for gas-liquid heat exchange where film coefficient ratios exceed two, our offerings include: Longitudinally Finned Tubes produced by our proprietary low-distortion automatic welding machines for low-capacity boilers; H-Fins or Spiral welded fins, boasting superior anti-wear and anti-fouling properties with high-fusion flash resistance welding for compact, stable designs, including dual-tube "double H" types; L-Fins, where an L-shaped helical strip is mechanically secured to fully enclose and protect the tube for moderate service up to 177°C; and G-Fins, with helical strips wound into pre-cut grooves and mechanically closed for extreme working conditions up to 371°C.

Headers

Headers are vital components in all boiler types, designed to collect steam from generating tubes and constantly operate under high pressure, typically ranging from 300 psi to 4000 psi. Given this critical function, we meticulously fabricate headers, with sizes varying from 100mm to 600mm NB depending on boiler capacity. We ensure precise welding of various-sized stubs or alternatively, sockolets and weldolets to the main header body to provide the necessary openings. Our rigorous quality process includes obtaining Chief Inspector of Boilers' approval for stub bevelling and weld preparation, both before tack-welding and again after full welding, during hydraulic pressure testing Each header is stamped by the ASME Inspector before leaving our facility, guaranteeing adherence to stringent standards.