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Mega Steel
Completed & delivered to site

Q2 2023 Power station – Assiut

Energy & Power Generation

Pipelines and heat-exchanger equipment for power stations

Supply of pipelines and heat-exchanger equipment for power generation plants.

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Technical Documentation & Operations Gallery

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Pipelines and heat-exchanger equipment for power stations
Pipelines and heat-exchanger equipment for power stations Pipelines and heat-exchanger equipment for power stations Pipelines and heat-exchanger equipment for power stations

Client Requirement & Operating Constraints

A power station expansion needed steam and cooling-water pipelines and shell-and-tube heat exchangers for a new generating unit.

Strict defined criteria:

  • Heat exchangers built to TEMA class R.
  • Rated for steam temperatures up to 400°C.
  • Post-weld heat treatment of thick-wall lines.

Mega Steel Scope of Work (Execution Phases)

  1. Phase 01

    Thermal & Mechanical Design

    Heat-transfer area and shell and tube-sheet thicknesses calculated.

  2. Phase 02

    Tube-Sheet Machining

    Tube sheets drilled on CNC machines to tight tolerances.

  3. Phase 03

    Tube-Bundle Assembly

    Tubes inserted and hydraulically expanded into the tube sheets.

  4. Phase 04

    Heat Treatment & Testing

    Weld heat treatment and pressure tests on shell and tube sides.

Engineering Materials & Alloys Used

Certified, documented engineering

  • ASTM A335 P11 alloy pipes
  • Copper-nickel exchanger tubes
  • SA-516 Gr.70 steel plates
  • Rock-wool thermal insulation

ENGINEERING BOTTLENECKS

The Project’s Complex Engineering Challenges

  • Thermal Expansion of the Lines

    Long steam lines expand a lot and can load the connected equipment.

  • Tight Tube Expansion

    Any leak between tube and sheet mixes steam with cooling water.

ENGINEERED RESOLUTION

Innovative Engineering Solutions Applied

  • Stress Analysis & Expansion Loops

    Full pipe stress analysis with added expansion loops and sliding supports.

  • Controlled Hydraulic Expansion

    Hydraulic expansion at a calculated pressure with helium leak testing.

Custom Engineering Fabrication Solutions

Do you have a project that needs pressure vessels or specialised mechanical fabrication?

Send your materials list, engineering drawings or samples for immediate review by our engineers, who will define the best technical path and schedule.

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