H₂O Condenser

Project Overview

Bundaberg Walkers undertook a critical project commissioned by a refinery community which involved the fabrication of three 254 SMO sea water condensers. The project’s significance lay in addressing the issue of odorous emissions from the plant, which had been affecting the nearby community. 254 SMO, a high-end alloyed super austenitic stainless steel, was chosen for its exceptional resistance to chloride stress corrosion cracking (SCC).

The welding of this material posed a unique set of challenges, primarily related to the precise control of welding parameters. To ensure the highest quality, we conducted a thorough inspection, including 100% visual examination and 10% radiographic examination. Our accreditation from the National Association of Testing Authorities (NATA) underscores our commitment to delivering excellence in this critical endeavour.

Project Detail

Alumina Refinery: Vapour Condenser

Client:

Jord International Pty Ltd

Challenge

The decision to switch to 254 SMO was driven by the imperative to combat stress corrosion cracking in an environment with elevated chlorides. While this material offers superior corrosion resistance, its characteristics, including low thermal conductivity and high thermal expansion, posed unique challenges. To address them, we conducted exhaustive trials with a range of welding machines, feeders and consumables. It’s important to note that many of these specialised consumables and materials had to be sourced internationally, as they were not readily obtainable within Australia. This meticulous approach was essential to ensure the material’s suitability and reliability in the demanding conditions it would face.

Solution

Welding the vessel required close collaboration with welding consumables and equipment suppliers to fine-tune the welding processes. This involved extensive trials with various welding machines, feeders and consumables. Additionally, meticulous welding sequences and execution plans were developed to align the boilermakers’ experience and procedures with the required quality standards. Due to the urgency of execution and the need to minimise production delays, numerous materials had to be air-freighted to the site, ensuring that timelines were met and project disruptions were kept to a minimum.

54%

Reduction in community odour

+$1.9M

In material costs

8640 Hours

Of work

79km

Of welding wire

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Decades of diverse project excellence define Bundaberg Walkers Engineering. Explore our impressive portfolio, showcasing unwavering innovation and commitment to excellence across various sectors.

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