Day & Zimmermann, through our DZ Atlantic unit, is the largest condenser retubing contractor in the United States, providing a comprehensive portfolio of services and related support services. We bring innovative, cost-effective and responsive services to all of our condenser projects, utilizing the most advanced methods, tooling, and equipment in the business.
Condenser Retubing
Hundreds of millions of linear feet of retubing experience translates into a deep working knowledge of the characteristics, idiosyncrasies, and inherent challenges of every type of tube material, tubesheet material, and the many combinations of the two. It also provides us with unique insight into the innovative solutions that help our customers tackle these challenges within their individual plant designs.
Day & Zimmermann employs one of the most experienced and knowledgeable teams of project managers, engineers, condenser mechanics and tool technicians in the industry, ensuring all projects are completed on-time and on-budget. Our $3 million inventory of specialized condenser retubing equipment, much of which has been built or modified to our exacting specifications, consists of the full complement of both primary and back-up equipment required to meet the heavy-duty demands of retubing projects.
Our innovative designs have resulted in the award of nine U.S. Patents and numerous foreign patents for condenser-related products, processes and equipment, including:
-
Cradle-Lock® Anti-Vibration Tube Stakes
The industry standard for tube vibration resolution, Cradle-Lock’s patented design cradles tubes midway between support plates, locking them into a vibration-free unit and eliminating the need to rebundle as a possible solution to vibration problems.
-
S-Flex® and S-Flex II® Rubber Dog Bone Expansion Joints
The patented S-Flex® Dog Bone Expansion Joint and S-Flex II® Expansion Joint System (which includes hardware) are unique designs for rubber turbine-to-condenser expansion joint replacements. The S-Flex® features a unique, flexible “S” shape and improvements to the fabric core configuration. The S-Flex II® is utilized in new construction or to replace troublesome stainless steel bellows or rubber “U” expansion joints. We currently have more than 250 belts and systems in operation.
-
The Eliminator
Aptly named by our condenser crews, the Eliminator is an all-in-one machine that pulls old tubes from condensers at the tubesheet, flattens them, and chops them into 4” to 6” pieces in a single operation, eliminating significant labor hours. The Eliminator, originally developed to address tube inside-diameter (ID) contamination, also slits tubes into two pieces, thereby exposing the ID for decontamination.
Leak Detection
Our leak detection teams use the precision technology of mass spectrometry and helium to locate condenser air and water inleakage as small as 4x10-4 CFM. Any system under vacuum or that can be pressurized can be tested, including turbines, condensers, condenser tubes, generators, air-cooled condensers and Cardox fire protection systems.
Acc-U-Clean® Adjustable Tube Cleaner
Effective on virtually all forms of scaling, biofouling, and corrosion, the Acc-U-Clean® Adjustable Tube Cleaner maintains its integrity (constant pressure), pass after pass and is proven to last twice as long as other cleaners. The unique Acc-U-Clean® design features twelve independent blades positioned around a neoprene core and held in place by a flexible spring steel sleeve.
In addition to the above services, Day & Zimmermann can support general condenser consulting services, tube pullout testing, and vibration analysis. We also provide a wide array of related products including brass and fiber jacketed tube plugs, basket tip connections, and tube inserts.