185MW Steam Turbine Condenser for APP Indonesia OK18 Successfully Completed

1. Project Background

Asia Pulp & Paper (APP), one of the world’s largest pulp and paper groups, launched the OK18 production line as part of its major expansion plan in the Asia-Pacific region. The project' s captive power plant is equipped with a 185MW steam turbine, which requires a high-efficiency condenser with exceptional heat-transfer performance, long-term reliability, and strong corrosion resistance.

As a leading heat exchanger and power plant equipment manufacturer, Boyu Industry (Shandong Boyu Heavy Industry) was awarded the contract to design, fabricate, and test the complete 185MW surface condenser for the OK18 project. The project further demonstrates the company's deep capabilities across the power, energy, and industrial sectors.

2. Project Challenges

APP set several stringent technical requirements for this critical condenser:

High heat-transfer efficiency & low back pressure performance
The condenser must maintain stable low back pressure under fluctuating load conditions to ensure optimal turbine efficiency.

Large-scale tube bundle manufacturing complexity
The 185MW unit requires a massive heat-transfer area, with extremely tight tolerances for tube-to-tubesheet alignment and assembly accuracy.

Long-term corrosion resistance
Pulp and paper industry cooling water contains impurities, making material selection, welding quality, and anti-corrosion strategies critical.

Tight project schedule
The project timeline required fast-track engineering, manufacturing, and final testing, leaving no room for delay.

3. Boyu Industry's Engineering & Manufacturing Solutions

Boyu Industry integrated its engineering, production, and quality assurance teams to deliver a complete technical solution.

Optimized Heat-Transfer Design

• High-efficiency tube bundle layout to reduce steam-side pressure drop

• Enhanced heat-transfer configuration, improving overall condenser performance by more than 5%

• CFD-supported flow optimization to secure stable turbine back pressure

Rigorous Material Selection & Supply Chain Coordination

• Core components manufactured from SA-516, SA-179, and SA-210, widely recognized for strength and corrosion resistance

• Long-term partnerships with premium steel mills ensure reliable material traceability and rapid delivery

Precision Manufacturing Process

• One-piece machining of tube sheets to guarantee drilling accuracy

• Combination of automated tube expansion and GTAW/TIG welding to ensure long-term sealing reliability

• All welds inspected per ASME standards, including RT, UT, and PT examinations

Strict Quality Control & Testing

• Full ITP-based quality assurance system with multi-stage inspections

• Complete hydrostatic and pneumatic testing—no leakage, no deformation

• Performance verification aligned with APP's actual operating conditions

4. Manufacturing Success: The Condenser Is Now Complete

After several months of coordinated engineering and high-precision manufacturing, Boyu Industry successfully completed and released the 185MW condenser for shipment.

Key equipment highlights include:

• Large heat-exchange area with stable structural design

• Highly uniform tube bundle layout and excellent assembly precision

• Smooth weld profiles with dense internal structure

• Test results significantly exceeding design requirements

APP' s on-site inspectors praised the overall quality, workmanship, and manufacturing standards, confirming the equipment meets top global expectations.

5. Customer Value Delivered

The successful completion of this condenser provides APP Indonesia with clear operational and economic benefits:

• Higher steam turbine efficiency and reduced power generation costs

• Extended condenser service life with lower maintenance and lifecycle costs

• Improved reliability across the entire cold-end system

• Shortened construction schedule, helping OK18 achieve on-time commissioning

6. Conclusion

The successful delivery of the 185MW steam turbine condenser marks a significant milestone for Boyu Industry in serving the international power and pulp sectors. It further strengthens the company’s presence in Indonesia and the broader Southeast Asian market.

Moving forward, Boyu Industry will continue to provide high-performance condensers, heat exchangers, and engineered thermal equipment that meet ASME, GB, and global power industry standards, delivering reliable, efficient, and long-lasting solutions to customers worldwide.