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Petrochemical
> REFORMING furnaces
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AUTOMATIC
TIG WELDING
Many of Duraloy's petrochemical weld joints are produced
using our state-of-the-art automatic TIG welding equipment.
Duraloy uses the Dimetrics "Gold Trac®" Dual-Sync
Pulse Automatic TIG Welding System. This welding system
employs a computer-controlled dual wire feed that increases
weld deposition by about 30% per pass, thus reducing
welding times and reducing heat input into the weld
joint. This process has also reduced the weld repair
rate to almost zero. Duraloy has recently purchased
matching orbital equipment to make the tube-to-fitting "closure" welds.
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HANGER CLEVIS
These statically cast clevis' are used to support or hang other structural components while in a furnace. The large holes cast in the sides have parts aligned between the "forks" of the casting then a large pin is inserted through the holes to hold the component in place.
These parts can be cast in any alloy, but are typically done in Duraloy's proprietary alloy Super 22H®, or HK-40 alloy as required.
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HYDROGEN REForMER OUTLET HEADER TEE
This outlet tee is used in the accumulation header for a hydrogen reformer. The fabrication is made from statically cast MO-RE-21®, wrought IN800HT, a carbon steel "skirt". The inside of the skirt is insulated with castable ceramic prior to shipment.
The entire fabrication is subjected to both Liquid Penetrant Inspection (LPI) and radiographic examination, after all fabrication is completed.
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HYDROGEN TUBES
These fabricated reformer tube assemblies have been produced in Duraloy Technologies' proprietary alloy grade TMA6311® and are scheduled to be installed in a hydrogen reformer furnace.
These assemblies are made up of three centrifugally cast tubes, and when fabricated into full assemblies including flanges and "pigtails", measure over 48 feet (14.6 meters) in total length.
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CATALYST CONE ASSEMBLY
These fabricated components are used in the lower
section of a catalyst tube assembly.
The cone and tube are made of cast, heat resistant
material, like MO-RE 10, while the base flange is
normally a forged Cr-Ni alloy material. The entire
assembly is fabricated at Duraloy and installed in the
tube before shipment.
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LARGE DIAMETER HEMISPHERIC PIPE CAPS
These hemispherical pipe caps are cast in Duraloy's proprietary alloy MO-RE-21® and are welded to the ends of pipes that are transferring fluids at high temperature and pressure.
They will have a weld-prep bevel placed on the open end prior to fabrication.
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REFORMER
ACCUMULATION HEADER ASSEMBLY
Duraloy offers complete fabrication and testing of reformer accumulation headers.
Typically these headers are made from a centrifugally cast tube made from Duraloy's
proprietary alloy MO-RE-21®. The tube is machined inside and out, then 800H
weld-o-lets are welded in to form the header assembly. After welding in the weld-o-lets,
end caps are welded to close the end of the headers and then each weld-o-let
joint is drilled through to insure proper dimensional alignment.
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REFORMER
TUBES
These tubes have been cast and blasted and are
now ready to go to the machining area. Prior to
going to the machining area, all petrochemical
tubes are zyglo inspected (a form of liquid penetrant
inspection) to detect surface cracks or tears that
are too small for the naked eye to detect. In our
tube machining area, they will be pull-bar bored
and beveled prior to fabrication.
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Duraloy
produces reformer tubes for the hydrogen, ammonia,
and CO2 markets. Our customers include both new equipment
designers, like engineering firms, and end users, who
are purchasing replacements, spares, or upgraded alloy
tubes.
Duraloy produces reformer tubes in a variety of alloys, including our proprietary
alloys MO-RE-10®, MO-RE-10MA®, MO-RE-40MA® and TMA6300® alloys.
We perform all of the fabrication operations, including
welding, radiography, and hydro-testing in our Scottdale,
PA facility.
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These reformer
tube assemblies are in our fabrication bay ready
to have flanges, reducers and pigtails welded on.
You can see the white LPI developer, used on the
tube-to-tube weld seams to check for cracks in the
cover weld pass. After the addition of the pigtails
and top-flanges, the assemblies will be radiographed,
hydro-tested then final inspected, prior to shipment.
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| duraloy®,
THE DURALOY LOGO, MO-RE®, SUPERTHERM®, TMA®, 22H®,
and
Super 22H® are
registered trademarks of Duraloy Technologies, Inc.,
in the United States, Canada and the European Community.
All Rights Reserved.
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| 120 Bridge Street • Scottdale,
PA 15683 • TEL:
724-887-5100 • FAX: 724-887-5224 Copyright © 2008
Duraloy Technologies, Inc. All rights reserved. |
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