Welders NV

Custom Process Equipment for

Aggressive Environments

Design and Construction of High Integrity Equipment

in Heat- and Corrosion-Resistant Alloys
www.welders.be
Introduction
Welders, a Belgian Independent
Company, has been committed
for 60 years to serving Process
Industries worldwide, particularly
Hydrocarbon and Chemical Pro-
cessing Industries.
Specialised in the Design, Engi-
neering and Fabrication of high-
integrity Custom Process Equip-
ment destined to aggressive
environments, Welders manufac-
tures pressure vessels, reactors,
columns, heat exchangers, piping
systems and specialised compo-
nents, in heat and corrosion-re-
sistant alloys. Heavy Ends Column in Alloy G30

Drawing upon its unique diverse

technical expertise and wealth
of experience, it handles a wide
spectrum of high-performance
materials.
Welders has spearheaded the
use of Duplex and Super Duplex
stainless steels and built-up an
unequalled know-how in the fa-
brication of equipment in Nickel,
Nickel- base alloys, Titanium and
Zirconium, designed for the most
demanding applications.
Dryer Heat Exchanger in Duplex Stainless Steel

Recognised throughout the indus-

try, Welders’ products are used by
90% of the world’s largest chemi-
cal groups, Top 5 oil majors and
many leading regional power
houses.
A global player, Welders has over
the last decade shipped some
3000 major items to some 180
blue-chip customers in 80 coun-
tries on the 5 continents.
The outstanding loyalty rate is a
vibrant testimonial of customers’
satisfaction in Welders’ services
and of its equipment high qua-
lity and dependability. These are
further guaranteed by compliance
with ISO 9001 Standards and the
ASME U-Stamp requirements. Brine Cooler in Titanium Gr.2
 Manufacturing Facilities
Welders 15000m² spacious mo-
dern production facilities, inclu-
ding 6000m² covered area, feature
a range of varied and flexible cut-
ting, forming and fabrication ma-
chines and generous lifting capa-
city.

Latest state-of-the-art welding

equipment comprises computer-
controlled stations, automatic wel-
ding beams and orbital welding
machines for tube-to-tubesheet
and tube-to-tube joints. The most
appropriate welding processes
are selected for each application
in function of the specific require-
ments: SMAW, SAW, PAW, GTAW,
GMAW.P or FCAW.

Facilities include one dust-free

room and glove boxes, mainly
used for the welding of exotic ma-
terials.

Engineering Capabilities

Welders’ fully fledged Design and

Engineering Department operates
a comprehensive system, using
both purpose developed in-house
programmes and software of inter-
national repute for thermal rating,
stress analysis, wind load and
seismic resistance calculations,
as applicable. Combined with the
expertise gained in 6 decades, it
enables Welders’ engineers to op-
timise the equipment sizing and
configuration and to maximize its
cost-effectiveness.

Welders is familiar with most international codes and standards, including :

• ASME • API • DIN
• TEMA • AD Merkblätter • EN
• ANSI • CODAP • WRC
• BS 5500 • NACE • Stoomwezen
Quality First

Welders’ Quality Assurance Sys-

tem has been certified to ISO
9001, since 1994. Welders N.V.
is also allowed to use the ASME
U-Stamp and has been awarded
the Manufacturer License of Spe-
cial Equipment (Pressure Vessels
Category A2), for the People's Re-
public of China.

Visual Control of Limpet Coils

A comprehensive range of N.D.E.

is available in-house, including
hydrostatic testing, Radiographic
Examination, Helium Testing, Ul-
tra Sonic Testing, Magnetic Par-
ticle Examination, Positive Ma-
terial Identification and Acoustic
Emission. Destructive testing is
carried-out by specialised labora-
tories, ensuring independent as-
sessment.
Welders equipment is routinely
certified by internationally repu-
ted Inspection Agencies, such as :
Lloyds Register of Shipping, T.U.V.,
Germanischer Lloyd, Apave, Bu-
reau Veritas, Stoomwezen, D.N.V.,
AIB Vinçotte, Apragaz, ABS..
Hydrostatic Testing of Stacked Heat Exchangers in Titanium Gr.2
 Expertise in Heat Transfer Equipment
Welders has established a uni-
que specialisation in heat transfer
equipment thanks to the constructi-
on of over 1000 large-capacity heat
exchangers, coolers, condensers,
evaporators, etc. featuring an ex-
change surface exceeding 3,500m²
and up to 4m diameter.

A large chunk of Welders’ shell

and tube heat exchangers and tube
bundles goes for the replacement
of equipment for rehabilitation, ca-
pacity expansion or energy saving
purpose.

This provides Welders’ engineers

Crude Oil Heater with Titanium Finned Tubes
Gas Cooler Tube Bundle in Alloy C276
with a unique hands-on exposure to
the multi-faceted factors affecting
heat exchangers performance. Of-
ten combined with material upgra-
ding, this calls for the comprehen-
sive review and adaptation of design
and the switch to new fabrication
techniques. This represents a chal-
lenging task in view of generally res-
tricted space availability. Drawing
upon this unique experience, Wel-
ders’ engineers are ideally geared
to optimise your heat exchangers
rating, maximise cost-effectiveness
and select the most appropriate
procedures, thus contributing to
trouble-free operation, easier main-
tenance and greater efficiency of
your heat transfer equipment.
Welders has gained a wealth of ex-
perience in the supply of heat ex-
changers using sea or brackish
water, for both new projects and
retrofitting. This particularly applies
to the Middle East and Asia Pacific
regions where treated water is fre-
quently unavailable for many appli-
cations: Off Shore Platforms, Heavy
Oil Treatment, Gas processing, Re-
fineries and downstream industries.

Besides Titanium and Duplex Stain-

less Steel currently preferred mate-
rials for these environments, Wel-
ders well-proven expertise extends
to Super Austenitic Stainless Steels,
U-Tube Bundle in
Duplex S.S. under Nickel-base alloys and Copper Nic-
construction kel, allowing Welders to meet virtu-
ally any sea water challenge.
Thermoplates in 316L S.S. electro-
polished

Heat Exchanger in Titanium Gr.2

Heat Exchangers in Zirconium 702

High Pressure Reboiler in SS 316L / 321

Gas Cooler in Titanium Gr.2 / Gr.3

Cooling Coil in Super Duplex

Air Preheater in Alloy 800HT Reheaters in Alloy 31

PRODUCT RANGE
Welders manufacturing activities focus on Heat Transfer Equipment, Pressure Vessels, Columns, Reactors,
Tanks, Internals, Rotating parts, Burners, Pipings and Fittings.

Pressure Vessels, Reactors, Tanks

Materials of contruction:
Stainless steels :

• Austenitic:
300 & 400 series,
Urea and Nitric Acid Grades

• Super Austenitic:
Uranus B6 ®, Sanicro 28 ®, 254 SMO
and 654 SMO ®, 1925 & 3127 hMo®

• Ferritic-Austenitic:
UNS S31803, S32205, S32550,
S32750, S32760.

Nickel and Nickel-Base Alloys: Flashdrum in 1925 hMo

• Nickel: 200 – 201
• Nickel-base alloys: Monel ®,
Inconel ®, Incoloy ®, Hastelloy ®

Copper Nickel Alloys

Reactive Metals:
Titanium, Tantalum, Zirconium

Clad and Lined Materials:

• Carbon steel clad with high alloys

or exotics
• FRP, Epoxy, Glass Flake Lining

Autoclaves in Alloy 31 with Limpet Coils

Reactor in Alloy B2

310S Reactor under heat treatment Reactor in Inconel clad Carbon Steel
Columns and Towers

Reboiler Column in Stainless Steel 904L Waste Acid Stripper in Alloy G3

Chlorine Absorption Tower in Titanium Gr.2 Hydroliser Column in Duplex S.S.

Internals

Sieve Tray in 2RE69 ® for Urea Reactor

Ferrules in 2RE69 ® Tray in Alloy B3

for Urea Stripper

Sparger in Tantalum
 Rotating components

Agitator in 904L Pump Casing in UNS S32760

Combustion Equipment

Air nozzle Assembly in Alloy 800H Air Burner in Alloy 825 with Zirconium
Sprayed Nozzles

Burner Assembly in Alloy 625

Piping

Pipework in Titanium Gr.2 / Gr.7

High Pressure Manifolds in

Alloy 800H
High Pressure Catalyst Tubes
in Alloy 625
Leadership in Zirconium

Thanks to a close collaboration

with world’s leading chemical pro-
ducers, Welders has, since 1981,
built-up a unique expertise in the
handling and fabrication of Zir-
conium materials for demanding
applications in the most corrosive
chemical processes
Heat Exchanger in Zr 702

Significantly, Welders has con-

structed a wide range of equip-
ment destined to the production of
Formic and Acetic Acids, amongst
the most aggressive media.

Formic Acid Column in Zr 702

Welders recent track record inclu-
des some 40 heat exchangers in
various configurations and designs
(condensers, reboilers, coolers,...)
in both solid and clad forms, 4 co-
lumns and reactors, spools and
fabricated pipework as well as
internals and fittings and compo-
nents for rotating equipment.

Acid Column Condenser with Zr 702 tubes

Many repeat orders testify to the

end-users’ total satisfaction in
Welders services and capabilities.
A prominent item among these re-
ferences is one 38m long column
in Solid Zirconium 702.

Acid Removal Column in Zr 702

 Titanium: A well established tradition
Over 30 years experience in the
construction of equipment in Ti-
tanium for critical applications in
highly corrosive atmospheres un-
derpins Welders know-how and
demonstrates its capacity to meet
the most demanding challenges in
oil and gas, chemical, petroche-
mical, fertilisers, pulp and paper
and metallurgical industries – or
wherever brackish or seawater is
used as cooling medium.
Reactor in Titanium Gr.2

Floating Heads in Titanium Gr.2

Anolyte Tank in Titanium Gr.2

Partial view of Heat Exchanger in Titanium Gr.2 Titanium Tube Bundles for Refinery Shutdown
Spearheading the use of Ferritic Austenitic Stainless Steels
In close association with reputed
Welding Research Institutes, Wel-
ders has for the past 20 years pio-
neered the design and fabrication
of equipment in Duplex and Super
Duplex Stainless Steels catego-
ries.
Thanks to the experience gained
with different codes (ASME,
Stoomwezen, AD Merkblätter and
CODAP), coupled with varied end-
user exacting specifications, our Reboiler Column in Duplex S.S.
engineers have built-up a unique
know-how in the forming, machi-
ning, welding, assembly, testing
and treatment of this very distinct
stainless steel category.
Welders N.V. has gained internati-
onal recognition by demonstrating
time and again that it could meet
critical requirements such as limi-
ted ferrite range, controlled grain
size, restricted Nickel contents,
etc.

Stripping Column and Internals in Super Duplex S.S.

Critically, welding processes are

selected in function of the alloy
characteristics and properties to
suit each specific application, not
only to impart mechanical integrity
but also and more importantly to
enhance corrosion resistance to
the process media.

Reactor in Duplex S.S.

Welders has passed with flying
colours the most exacting corrosi-
on tests designed and performed
by the most uncompromising end-
users and validated by our impec-
cable track record in service.
Very valuable experience has been
gained in processes such as VCM
/ PVC, Urea / Ammonia, Fertilizers,
Resins, Amines, Glycol, Pharma-
ceuticals, Refineries, Sea Water
Cooling
Gas Cooler in Duplex S.S.
 Familiarity with Industry Needs
Thanks to its continuous dedication to serving process industries, Welders is familiar with the specific
requirements of and challenges stemming from exacting applications in the production or treatment of
numerous corrosive media, particularly in: Off-shore - Gas Processing - Refineries - Chemicals and
Petrochemicals : (Chlor Alkali, Fertilizers, Inorganic Acids, Salt and Inorganic Compounds, Nitrogen Industries, Organic
Acids, Plastics, Synthetic Fibers, Petroleum Derivates, Exhaust Gas, etc.) - Pharmaceuticals - Metallurgy - Mining
- Pulp and Paper - Sea water-based cooling systems - Power generation - Environment protection.
Fertilizer Industries

Reboiler in Duplex S.S. Pigtails in Alloy 800H

Calciner Drum in Alloy 600

Organic Acids

Flash Tank in Alloy B2 Heater fitted with Zirconium 702 tubes

Chlor Alkali

Brine Receiver in Titanium Gr.2 HCL Condenser in Alloy 400

Finishing Evaporator in Carbon Steel Clad with Nickel 200 Caustic Evaporator

PVC / VCM Industries

Condenser in UNS S32760 Slurry Stripper Cyclone in 904L

 ADDITIONAL SERVICES
Welders is in a position to offer the following services to its valued
customers.

• Equipment rehabilitation and upgrading

• Column dressing and Heat Exchanger insulation
• Fast-track status, including emergency logistics and crash de-
liveries
• Special finish : fine mechanical or electrolytic polishing
• Trouble shooting
• Supervision of erection and commissioning
• Advice on material selection

Air lifting of a Heavy Duty Heat Exchanger

References
Welders is proud to count amongst its customers the following prestigious end-users:

ADGAS EGYPTIAN PETROCHEMICALS MAERSK OIL SAMSUNG

ADNOC EMISAL MONSANTO SAUDI ARAMCO
AIR LIQUIDE EXXON CHEMICAL NESTE SHELL
AIR PRODUCTS EXXON MOBIL NIOC SOLVAY
AKZO FPC NORSK HYDRO SONATRACH
ARCELOR GASCO NPC SRC
BASF G.E. PLASTICS OCP TAMINCO
BAYER HERCULES OMNICHEM TESSENDERLO CHEMIE
BEKAERT HYUNDAI PETROCHEMICALS ORC TEXACO
BOREALIS ICI PETROBRAS 3M
BP CHEMICALS INEOS PHENOLCHEMIE TOTAL
CELANESE JANSSEN PHARMACEUTICA PRAYON UCB
CHEVRON JPMC PROCTER & GAMBLE UMICORE
DEGUSSA KEMIRA OY QAFCO UNION CARBIDE
DISTRIGAS KNPC RCF YARA
DOW CHEMICAL KOC RELIANCE ZENECA
DSM KUMHO RHODIA
DU PONT LINDE RHONE POULENC
EASTMAN LYONDELL SABIC

Selected by International Engineering Companies and Contractors

Welders has supplied equipment in accordance with the specifications and requirements of top International Engineering Companies
and Contractors from all over the world, including:
ABB Global, Badger, Bechtel, Chiyoda, Comprimo, CTIP, Daelim, Davy, Edeleanu, E.I.L., Fluor Daniel, Foster Wheeler, Haldor Topsoe,
Hyundai, Jacobs, JGC, John Brown, Kellogg, Kemira, Krebs, KTI, Kvaerner, Kumho, LG Engineering, Linde, Lurgi, Lummus, M.E.S.,
Parsons, Raytheon, SKEC, Snamprogetti, SNC Lavalin, Stone & Webster, Technip, Texaco, Toyo Engineering, Tractebel, TPL, Uhde,
etc.
 What our customers say about us
An outstanding loyalty rate shows customers complete satisfaction,
as expressed in the following testimonials
'We wish to inform you that another heat exchanger is required. Because of our previous experience toge-
ther and in order to save time and avoid bureaucratic delays, we decided to assign this job to your company,
if you are interested.'

Chairman, Chemical Producer, The Middle East

'The equipment in Super Duplex was supplied on schedule in 1999 and has been operating very success-
fully since then. We are very pleased with Welders N.V. performance and services and several orders have
been placed with them for similar items, with the same level of satisfaction.'

General Manager, VCM Manufacturer, Egypt

'In May 1996, the Manager of our office and workshop was invited to inspect the Zirconium heat exchan-
gers. The result of the inspection was that the Zirconium equipment used over 7 years in extremely corrosive
conditions was faultless and will serve without problems for many years to come.'

Engineering Company, Finland

'We wish to express our utmost satisfaction for your performance in the overall handling of this strategic
project for us.'

Engineering Manager, Chemical Producer, France

'We are very happy to inform you that the equipment has reached our site and is under installation during our
shutdown. This could be possible thanks to wholehearted efforts made by you and in spite of many hurdles.
We thank you for the cooperation extended to us.'

Chief Manager, Purchase, Urea Plant, India

We would like to express our satisfaction over the way this job was carried out. In particular, the welding of
B3 was of perfect quality, the equipment supplied on schedule and within the budget.
Our heartfelt thanks for the excellent collaboration.'

Project Buyer, Fertilizer Plant, Belgium

Contact details:

WELDERS N.V.
IZ NOORD V – WIJNGAARDVELD 5
B-9300 AALST – BELGIUM

Phone: +32(0)53 77 76 77
Fax: +32(0)53 77 37 97
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Email: welders@welders.be
www.welders.be