Strategic Investment Engineering : A Comprehensive Analysis by 3S Engineering Extends the Operational Life of a 37-Year-Old Boiler

Project Background
Collaborating with Balai Besar Bahan dan Barang Teknik (B4T) Bandung, 3S Engineering embarked on a project addressing the challenge of assessing the feasibility and remaining lifespan of a 37-year-old Waste Heat Boiler (WHB).

Methodology and Approach
Our multidisciplinary approach encompassed material science, measurement, vibration analysis, fracture mechanics, and numerical methods. Leveraging various technologies, including in-situ metallography, hardness testing, visual inspection, Non-Destructive Testing (NDT), computational fluid dynamics (CFD) via ANSYS, and finite element analysis (ABAQUS), ensured a comprehensive analysis.

Challenges
The project faced challenges in synchronizing activities across diverse fields. The need for a cohesive team with uniform expertise and speed was crucial. Overcoming this required meticulous planning, intensive communication, and strong leadership under tight deadlines.

Outcome
The project achieved significant outcomes:

1. Operational Viability of WHB:
   
   • Assurance of the WHB’s operational viability.
   • Extension of its lifespan by 10 years beyond design limits.
2. Recommendation for Periodic Inspections:
   
   • Proposal for periodic inspections every 1.5 years.
   • Ensured ongoing operational stability for the client.
3. Strategic Planning and Resource Utilization:
   
   • Allowing the client to defer new boiler investments.
   • Strategic planning for future replacements.

This collaboration underscored our ability to harmonize diverse expertise effectively, offering solutions that reinforce industrial equipment longevity and optimize resource utilization.