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Babcock & Wilcox
ALFA provided Babcock & Wilcox with both an in-depth furnace analysis using embedded contact thermocouples throughout the charged product; and finite element multi-dimensional mathematical modeling services to determine resultant and optimized temperature gradients for both stainless steel and high nickel alloy boiler tube weldment assembly bundles. This project involved both cladding and chromizing tube life enhancing practices. The heat treat furnaces were top and bottom hot air fired 75 ton (75 long x 15 wide x 20 high) large car bottoms charged with tube weldment assembly bundles that varied from 54 to 16 long composed of 2.5 to 1.75 OD tubes x 0.165 to 0.295 wall; up to 8-high stacked loads using 8 high C-Steel I-Beam separators all loaded on a base car constructed of multiple piers. The charged tube bundle assemblies had individual weights approaching 15,000 pounds each. ALFA partnered with B&W R&D to optimize existing practices, apply new sophisticated control technologies, use new tube bundle stacking arrangement, use new separator design structure, and improve their combustion system and firing practices.


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