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Fabrication and Welding

Fabrication and welding form the core of Simgetek’s business.

Pressure vessels, heat exchangers, storage tanks, special process equipment and heavy welded structures are produced with qualified welding procedures, by certified welders, in facilities certified to the major international fabrication codes.

Products We Fabricate

  • Pressure vessels, columns and towers
  • Heat exchangers, including large-diameter shell-and-tube units
  • Special process equipment such as converters, reactors, separators, demisters and scrubbers
  • Hydromechanical equipment
  • Fixed-roof and floating-roof storage tanks and spherical storage tanks
  • Heavy welded machine parts and steel structures
  • Pipe spools and pipeline equipment such as pig launchers and receivers
  • Industrial steam boilers
  • Gas ducts, chutes, hoppers and cyclones

Welding Processes

Processes applied:

FCAW, SAW (including tandem welding solutions), ESW, SMAW, GMAW, GMAW (RMD), PAW and GTAW

 

Having several processes available allows the welding method to be chosen according to the material, thickness, position and the quality requirements of the applicable code, rather than equipment limitations.

Mechanised and Automated Welding

  • Column-and-boom submerged arc welding systems
  • Tractor-type submerged arc welding
  • Plasma arc welding with column, boom and turning rolls
  • Dedicated plasma arc welding station for pipe applications
  • Tube-to-tubesheet orbital welding for heat exchangers
  • Automatic pipe-to-pipe welding systems
  • Powered and idler turning rolls for the controlled rotation of heavy cylindrical equipment
  • Electroslag (ESW) welding machine
  • Magnetic-track FCAW welding machine

 

Mechanised welding is preferred wherever the geometry allows; it provides consistent heat input and repeatable weld quality on long seams and on parts that must be rotated during welding.

Materials

Fabrication is carried out in carbon steel, stainless steel and high-alloy materials. Among others, our project experience covers:

 

  • Carbon and low-alloy steels such as SA-516 Gr.70, S235JR, S275JR, S355J2, P265GH, P355GH, 16Mo3 and P460NL1
  • Austenitic stainless steels such as SS304L, SS316L, SS321 and SS321H
  • High-alloy and duplex grades such as SS904L, Duplex 2205 and Super Duplex 2507
  • Nickel alloys such as Hastelloy C276
  • Creep-resistant alloy steels such as P11, P22 and P91

Welding Procedures and Certification

  • Welding Pro-Write — ASME and AWS compliant welding procedure management
  • Fabrication certification: ASME U, U2 and S stamps, National Board NB and R, AD 2000-HP0, EN ISO 3834-2 and EN 1090 EXC-4

 

Welding procedures and welder qualifications are kept up to date and reviewed for every project. Welding activities are documented so that every seam can be traced back to its procedure, its welder and its inspection record.

Inspection and Testing

  • Visual inspection and dimensional control
  • Non-destructive testing, including radiographic, ultrasonic, magnetic particle and penetrant methods
  • Positive material identification (PMI)
  • Hardness testing
  • Ferrite content measurement
  • Hydrostatic and pneumatic tests with pressure and temperature recording
  • Leak tests, including helium leak testing where specified