Feedwater Heater Remove and Replace


A project in Kansas required precise engineering to remove and replace two feedwater heaters during a planned outage at a power plant. The two heaters were stacked on two floors surrounded by a structure that could not be moved and was not within reach of the overhead cranes.

Barnhart used a light slide system to slide the lower heater forward, jack it up with Pull-up Jacks, lay heavy slide track underneath and roll it out with powered saddle rollers to the awaiting overhead crane. Limited capacity on the turbine deck floor required cribbing under the heavy slide system to be located directly over support beams in the floor.


Barnhart's engineers determined that the upper heater would have to be slid out with light slide gantries, suspended and lowered through a hole in the floor.


The upper heater was lowered with air hoists to powered saddle rollers, turned and maneuvered on a prepared surface of fabricated steel plates, and rolled the remainder of the way on heavy slide track to the awaiting overhead crane. The process was executed in reverse for replacing the upper and lower feedwater heaters. Precise engineering resulted in minimal downtime for the customer. Barnhart had planned to complete the job in 16 shifts, but was able to complete it in only 12.