Bronswerk Heat Transfer has developed the Solid Block Header Air-Cooled Cooler, a design that eliminates up to 90% of all header welds. For the operator this brings huge benefits, both during project execution as well as during its operating lifetime.
As we like to say: the best weld is not a weld, a fact that most of our customers and welding engineers agree on. Due to heat input, the quality of the base metal degrades, which is particularly an issue with dual phase materials such as Duplex or when a high alloy is selected for corrosion protection. Non-Destructive Examination needs to be applied on header welds with a risk of finding non-conformities and unexpected delays. Finally, the end product is a compromise as the weld and HAZ quality is lower than that of the base material. That is why Bronswerk Heat Transfer applies a header with virtually no welds, which is a much better controlled manufacturing process and delivers a higher quality end product.
During its lifetime, Air-Cooled Coolers are subject to regular inspections. Depending on the service, these could include NDE on the various welds and checks for delamination, in particular for Hydrogen Service. For the Solid Block Header, the base material is often a forging providing much better material quality and no risk for delamination or HIC (Hydrogen Induced Cracking). The significantly reduced number of welds will ease the workload during Turn-Around and in particular eliminates the risk for repair work.
From a Health and Safety Perspective, the pressurized fluid in our High Pressure Air-Cooled Cooler is contained in a much smaller diameter and volume than in conventional designs. This ensures less potential energy in case something goes wrong.
Bronswerk Heat Transfer has been working on innovative, custom-made new products since 1940 and assists in improving the efficiency of existing plants.
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