Condenser Services

Condenser & Heat Exchanger Retubing

Day & Zimmermann is the largest retubing contractor in the U.S. Our experience with all types of tube and tubesheet materials, including titanium, translates into a working knowledge of the characteristics, idiosyncrasies, and inherent challenges that accompany every retubing project. It also provides us with a unique perspective in developing technical approaches tailored to fit each plant’s design.

Our team of Condenser Experts specializes in a wide-range of retubing services and capabilities. Retubing projects comprise many layers of work tasks and activities, sequenced in accordance with our proven approaches that will deliver an optimized outage schedule.

Rubber Dog Bone Expansion Joint Replacement

In addition to providing its patented S-Flex® and S-Flex II® rubber expansion joints and system, Day & Zimmermann offers a full complement of installation services to meet your maintenance needs, whether it’s simply vulcanizing or a complete turnkey expansion joint replacement using our experienced personnel and specialized tooling and equipment to complete the project.

Condenser & Heat Exchanger Tube Cleaning

Day & Zimmermann has a long history of successfully cleaning steam surface condenser and other heat exchanger tubes using a variety of tube cleaners and methods, including low and high pressure water systems, air and water systems, and rotary type systems. We own all the necessary tube cleaning tooling and equipment, including pumps and guns, which allows us to support multiple projects at one time or clean two or more units simultaneously.
By removing most types of deposits, from bio-fouling to calcite-type scaling, our tube cleaning equipment and services help restore condensers and heat exchangers to their designed cleanliness factor and efficiency.

Uplift, Vibration, & Bean Strip Analysis

D&Z performs Uplift Analyses when changing existing tube material to a lighter-weight material or thinner wall thickness to determine whether additional weight or anchors must be added to hold the condenser down as it tries to “lift” from the foundation. We use current Heat Exchanger Institute (HEI) Standards for Steam Surface Condenser to compare the (designed for) existing tube material and the new tube material.
D&Z performs Vibration Analyses to determine whether the existing support plate spacing exceeds the maximum allowable spacing in accordance with HEI standards. The analysis considers steam flow, tube size, pitch, tube material, circulating water flow, neck area, and existing support plate spacing. The analysis specifies the maximum allowable unsupported tube spacing for the design operating conditions and identifies the condenser pressure at which the maximum allowance unsupported spacing occurs.

Tube Pullout Testing

During the pre-outage planning phase of a retubing project, pullout testing may be recommended to develop the required tube expansion criteria and parameters. This test is critical to obtain optimum tube-to-tubesheet joint strength during the project execution phase. Testing is designed specifically for each application to replicate expected field conditions. These test results will be compared against others in our database to establish the initial parameters and basis for the technical procedures developed that will be used during the execution of the project. 

D&Z maintains an extensive database of pullout testing results on a variety of material combinations and types, including tube and tubesheet material, tubesheet thickness, serrated and non-serrated tubes, and flared and non-flared. We analyze this data to determine:

  • Tube pullout strength under a range of loads  
  • Average wall reduction  
  • Which torque value will provide optimal tube-to-tubesheet seal during tube expansion 
  • How serrations affect tube pullout strength

Leak Detection

The Day & Zimmermann team has thousands of hours of experience in leak location and complete testing services. Our leak detection teams use mass spectrometry and helium to precisely locate condenser air and water in-leakage as small as 3x10-4 CFM. Any system under vacuum or able to be pressurized can be tested, including turbines, condensers, condenser tubes, generators (off and on-line), air-cooled condensers, and Cardox® fire protection systems.

How Can We Help You?

Please contact us for additional information or any questions you may have.   We will follow up with you as requested.

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