Supply of a Grade A980 Vertical Interstage Condenser
In October 2017 Atlas Copco awarded us a contract to supply a Grade A980 Vertical Interstage Condenser, for use within the food industry. Having previously manufactured horizontal condensers, this was the first time we manufactured a vertical condenser inclusive of expansion bellows. This was an interesting fabrication, which provided many challenges including changing customer requirements and design changes during production. Initially, material restrictions in terms of grades of material to be used and country of origin were constraining but as this item was intended for use within the food industry, absolute quality and fitness for purpose was of paramount importance.
“Following the success of today’s testing/final inspections of the Stainless Steel Vertical Condenser, I just wanted to quickly extend my sincerest gratitude to everyone who has contributed in any shape or form in ensuring the unit was completed on time and to a very high standard/quality.
I have observed some great work throughout the lifecycle of this order, for example… Materials procured in an efficient manner and delivered in line with the agreed manufacture schedule, inward goods robustly controlled, material certificates and associated documentation correctly archive/filed away, progress clearly and regularly communicated and fabrication work activities continuously managed/organised.”
Design Engineer Atlas Copco
The shell was made from rolled plate fabricated into a tube. The tube sheets, covers and flanges were manufactured from plasma cut discs before machining using conventional vertical boring and CNC machining. Bosses, flanges, condenser tubes and pipes were procured before being cut to length and prepared by our fabrication section, prior to welding and assembly. All weld procedures had to be approved and our customer stipulated that the fabrication shop must be kept spotlessly clean throughout the entire manufacturing process to prevent any weld contamination, for which Velden received a special commendation on completion of the project. The next critical step was the expansion of all the condenser tubes within the fabrication. Two hydro tests plus a shell test followed to ensure the vessel was watertight and fit for purpose before the outer cover, viewing window with wiper were fitted and the entire structure was pickled and passivated to enhance the cosmetic appearance before the item was shipped ahead of schedule in January and on budget. Full data books including material certification were also supplied. This order exemplifies the commitment Velden have to supplying complete engineered solutions by managing the entire project procurement process including machining, approvals, fabrication, welding, testing, finishing, certification and bespoke shipment.