About us
ENERGOREMONT Sp.
z o.o. is an engineering company with many years of experience specialising in manufacturing, retrofit and overhaul of shell and tube heat exchangers commonly used in large-scale energy generation, as well as in the paper, chemical and sugar industries.
All types of coolers, turbine condensers, heaters, evaporators, chemical equipment, disposal equipment and other heat exchanger systems can be fault-free if they are properly designed and assembled – and this is precisely what ENERGOREMONT Sp.
z o.o. does.
The most important part of any exchanger is the tube-to-tubesheet joint.
Thanks to ENERGOREMONT Sp.
z o.o.’s approach and technology, tubes can be easily replaced and are practically a consumable item.
All tube replacement activities are performed efficiently and without the risk of damaging the tubesheet or other structural elements.
Another distinctive feature of our technology is its high work pace (high mechanisation and automation), which means that even a short standstill is enough to restore original equipment properties.
Technical challenges associated with the installation of tubes in exchangers with the highest operating parameters, where the tubesheet thickness reaches 500 mm, are a separate issue.
ENERGOREMONT Sp. z o.o.’s patented technology and equipment for
hydraulic tube expansion across the entire tubesheet thickness can be used to achieve an absolutely tight tube-to-tubesheet joint.
This results in the tube being clamped in the hole with only minimal (about 3–5%) crushing of the tube’s inner surface.
Another challenge is the assembly of new turbine condensers, where thin-walled stainless steel tubing (wall thickness of 0.3–0.5 mm) must be precisely clamped into a relatively flaccid stainless steel tubesheet.
The design of such highly efficient condensers is a compromise between efficiency, capital cost and technology.
In this instance, traditional joining methods that have been used for nearly 200 years are unworkable. Only
straight flaring tools with an integral feed unit used by ENERGOREMONT Sp. z o.o. produce high precision flared joints with a repetitive flaring rate of ± 1%.
The company has been addressing technical issues since its inception, making profit by providing overhaul services based on its innovative solutions.
The engineering employees, who determine the direction of further development of the company, have a significant share in the company’s employment structure.
Thanks to the cooperation between our employees, technical universities and renowned design studios, we successfully manufacture new and efficient shell and tube heat exchangers that meet the highest quality standards while focusing on the environment and human safety. We continuously invest in state-of-the-art machines and equipment for manufacturing heat exchanger components.
Kazimierz Ruszniak
President of the Management Board in ENERGOREMONT Sp.
z o.o.
Company history
We set up the company in Lublin and were looking forward to new opportunities offered by our own business.
Our driving force were the tools and methods we had developed for the hydraulic removal of tubes from turbine condensers.
We had already been working on this project as amateurs for at least three years, at that time as employees of Zakłady Remontowe Energetyki Lublin S.A.
We obtained the first authorisation to manufacture pressure equipment components from the Office of Technical Inspection.
We built a manufacturing facility in Suchodoły.
All outbuildings were adapted to the needs of the company.
The office still operates in Lublin in leased premises.
- With good financial opportunities, after signing significant contracts with Kozienice Power Plant, we bought a plant in Krasnystaw and concentrated all our activities in one place.
- We expanded our product and service portfolio and obtained further authorisations from the Office of Technical Inspection to repair steam boilers, water boilers, and fixed pressure tanks.
- We joined the Polish Chamber of Power Industry and Environmental Protection.
- We presented our technology outside Poland for the first time – during an overhaul of a turbine condenser in Tatabanyi, Hungary.
- We started cooperation with Centralne Biuro Konstrukcji Kotłów S.A. in Tarnowskie Góry, which resulted in many projects,
such as
joint retrofit of U-tube high-pressure exchangers.
To this day, cooperation with CBKK provides a significant part of the company’s turnover.
- We started cooperation with the Institute of Heat Engineering, Warsaw University of Technology (ITC PW).
The new profiles of condenser bunches developed at ITC PW and applied in the retrofit of the turbine condenser of the 110MW unit in the Skawina Power Plant enabled us to achieve better results than those guaranteed in the contract.
- We completed the implementation of the Quality Management System compliant with the requirements of ISO 9001, as confirmed by certificates from UDT-CERT and TÜV NORD.
- We obtained certification from UDT-CERT confirming the ability of the company to meet the requirements of Modules H, H1 and G under Directive 97/23/EC.
- We completed the implementation of the Environmental Management System compliant with the requirements of ISO 14001:2004 and the Occupational Health and Safety Management System compliant with the requirements of PN-N 18001:2005, as confirmed by certificates from TÜV NORD.
- Manufacturing of spiral oil coolers was added to our portfolio.
- We commissioned the first section of the assembly plant together with the adjacent infrastructure (blasting chamber, coating booth, water jet cutting machine).
- After many years of testing, we introduced the technology of hydraulic tube expansion in tubesheets of exchangers for the highest operating parameters.
- Finally, we demolished the low-rise buildings for the second section of the assembly plant, thus extending the first section, completed a year earlier, to a total length of 95 m.
- We equipped the plant with further technologically advanced machines, such as
a CNC machining centre and automatic submerged arc welding (SAW) machine. - We expanded the area of the plant by purchasing the land adjacent to the company together with the existing buildings and adapting it to the needs of warehouse management and installed a gantry crane.
- We celebrated the 20th anniversary of ENERGOREMONT Sp.
z o.o.
- Purchase and set-up of the WRD 130 Machining Centre (a turning, milling, and boring machine), specifically designed for handling the most demanding tube sheets (with a drilling depth of up to 700 mm). The maximum machining area is 2500 x 7000 mm.
- Purchase and set-up of the WRD 130 Machining Centre (a turning, milling, and boring machine), specifically designed for handling the most demanding tube sheets (with a drilling depth of up to 700 mm). The maximum machining area is 2500 x 7000 mm.
- The implementation, after several years of trials, of CobraTM technology for the rapid tube removal from heat exchangers. During tube extraction, the head immediately compresses the tube into briquettes that can be used as a furnace charge.
- Celebrating the 30th anniversary of ENERGOREMONT Sp. z o.o.
- The third phase of the assembly unit expansion is now underway. This 1600 m² unit is now fully operational, and includes the installation of additional cranes, increasing the total lifting capacity to 60 tonnes.
- Implementation of briquetting heads in an installation version.
- Development work has begun on multifunctional heads operated by robots.
- After several years of trials, industrial-scale tube dismantling using magnetic induction technology has been successfully applied.
- The installation of photovoltaic panels (50 kW) and heat pumps is in progress, which will fully cover the heating and hot water supply needs for the workshop and the office building.
- Work is also underway to implement robots for the installation of new heat exchanger tubes.