pressure vessels manufacturer since 1968 - duro felguera · manufacturing of large complex pressure...

Pressure vessels manufacturer since 1968

MA

YO

de

20

14 /

Dep

ósi

to L

egal

: AS

-019

61-

2014

dfdurofelguera.com

ISO 9001

ISO 14001

OHSAS 18001

DF Calderería PesadaTravesía del Mar, s/n33212 Gijón - Asturias - Spain

N 43º 32’ 34’’W 5º 40’ 58’’

T. +34 985 32 26 00F. +34 985 30 00 [email protected]

COMPANY OVERVIEWDF. A Global Company

DF Calderería Pesada

CAPABILITIESFacilities

Human ResourcesQuality

BUSINESS LINESLarge Equipment

Storage Mounded BulletsHeavy Wall & Special Reactors

Coke DrumsFluid Catalytic Cracking Units (FCCs)

Unit PackagesModular ConstructionNuclear Components

Health, Safety and EnvironmentGeographical References

DF Permanent Offices Worldwide

Contents040406

08081011

121416182022242628

303132


An international company with over 150 yearsexperience, specialized in turnkey projects for sectorsundergoing major growth.

A Global Company

DF. A Global Company 04 / 05

1858 1900 1905 1966-1967 1970 2009

The company Duro y Cía. isset up to go into the businessof manufacturing ironproducts in Asturias.

Transformation into SociedadMetalúrgica Duro Felguera(SMDF).

The company starts tradingon the Madrid stockexchange.

The company converts intoan industrial equipmentmanufacturer.

Start of international businessand development towardsindustrial construction andassembly.

Opening of the newheadquarters in Gijón wherethe company’s registeredaddress is transferred.

DF Headquarters.Gijón, Spain.

DF is a multinational companyspecializing in the executionof turnkey projects for theEnergy, Mining & Handlingand Oil & Gas sectors. Thecompany also providesspecialized services such aserection, commissioning,operation and maintenancefor electrical and industrialfacilities and has its owncapital goods manufacturingworkshops.

DF was set up in 1858 and hasbeen quoted on the MadridStock Market since 1905. Theheadquarters are located inGijón in the north of Spainand the company employsover 2,000 professionals.

It operates worldwide and ispresent in numerous countriesin Europe, America, Oceania,Asia and Africa. It haspermanent offices in Mexico,Brazil, Colombia, Venezuela,Argentina, Chile, Peru, India,China, Indonesia, SaudiArabia, Dubai and Abu Dhabi.


Founded in 1968, DFCP has become oneof the most reliable pressure vesselsmanufacturing companies in the world

DF CaldereríaPesada

DF Calderería Pesada 06 / 07

DF Calderería Pesada (DFCP) is located in Gijón(Asturias), by the northern coast of Spain.

Backed up by its wide experience in themanufacturing of large complex pressurevessels, DFCP is capable of effectively meetingCustomer’s needs, putting at their disposal itsstrong expertise.

Furthermore, DFCP is certified according tothe main international Codes and standardsand by mayor technologists, for bothpetrochemical and nuclear projects.

DFCP’s business activities includethe following areas:

• Refining• Oil&Gas• Petrochemical• Chemical• Nuclear• Energy• Liquid gas storage (LPG, LNG)• Iron and steel works• Off-shore / On-shore

DFCP’s facilities inGijón, Spain.

DF Calderería Pesada Facilities 08 / 09

Equipped with state-of-the-artmanufacturing technology, DFCP is ableto cope with the most demanding marketrequirements

Facilities

Our facilities over 76,000m2 and only 1.5kmfrom the Port of Gijón are equipped with state-of-the-art manufacturing technologies andprovide direct access to the sea through theirown dock.

Our main manufacturing capabilities can besummarized as follows:

• Plate bending machines up to 330mm thick• Hydraulic presses up to 4,000 tons• Narrow gap welding up to 350mm thick• Roller beds supporting up to 1,200 tons• Automatic flush grinding, edge preparation

and back gouging• Rotating tables supporting up to 120 tons• High efficiency overlay welding processes

(SAW/ESW)• Vertical lathe up to 10m diameter• Heat treatment facility and modular furnace

(adaptable to any size) for PWHT, ISR, DHT• Painting facility• Self-Propelled Modular Transporters (SPMTs)• Own dock and barge

DF Calderería Pesada Human Resources / Quality 10 / 11

Highly skilled staff in every specialty field

HumanResources

Our in-house engineering capabilities includemechanical design and finite element analysisaccording to international Codes and standards(ASME Code Section VIII, Divisions 1 & 2; ASMECode Section III, Division 1; PD5500; CODAP,AD-Merkblätter, Stoomwezen, TEMA, GOST,EEMUA,...).

DFCP is strongly commited to investing inResearch & Development. The aim of our R&Dactivities is to continuously strengthen DFCP'stechnological capabilities, and to anticipatemarket needs.

With more than 45 years developing projectsworldwide, DFCP has gained a large experiencein forming, welding and heat treating bothconventional and alloyed steels, providing ourCustomers with the knowledge of our weldingengineers, as well as the skills of our qualifiedwelders and welding operators.

QualityDFCP’s Quality and Environmental ManagementSystem ensures product quality from receipt ofraw materials to the shipment of the finishedproduct, while linking environmentalmanagement with day-to-day planning andoperation.

Thus, DFCP’s management systems meet thehighest quality standards specified by the moststringent international codes.

• ISO 9001:2008• ISO 14001:2004• OHSAS 18001:2007• N Certificate (N-3646) ASME III (Nuclear)• NPT Certificate (N-3758) ASME III (Nuclear)• NS Certificate (N-3881) ASME III (Nuclear)• U Certificate (U-20976) ASME VIII Div.1• U2 Certificate (U2-25364) ASME VIII Div.2• S Certificate (S-25363) ASME I• NB (ID 5125) National Board• R Certificate (R-2325) National Board• PED 97/23/CE Mod H1

The use of off-line photogrammetric techniquesspecifically developed by DFCP for thedimensional control along the production processprovides us with a complete record of theequipment dimensions in several manufacturingstages in a non-contact, flexible, and accurateway. This technique may also be used at site todetermine equipment deformations during in-service life by comparison with records takenduring shop manufacturing.

The extensive use by DFCP of the most up-to-date NDE methods, like TOFD and Phased Arrayultrasonic inspection, allows us to provide ourCustomers with the highest quality and reliabilitydelivered on time.

Business Lines 12 / 13

Assuming the highest market requirements

Business Lines

• LARGE EQUIPMENT• STORAGE MOUNDED BULLETS• HEAVY WALL & SPECIAL REACTORS• COKE DRUMS• FLUID CATALYTIC CRACKING UNITS (FCCs)• UNIT PACKAGES• MODULAR CONSTRUCTION• NUCLEAR COMPONENTS


DF Calderería Pesada Large Equipment 14 / 15

No size limitation

Large Equipment

DFCP’s workshop capacities make possible thefabrication of large equipment in one piecewithout size limitations. In addition, the use ofSPMTs eliminates height and load capacityrestrictions, providing a safe and reliablealternative to the use of large cranes andenabling smooth deliveries through our dockand barge.

Thus, DFCP specializes in the manufacturingof fully dressed columns, including assemblyof internals, external insulation, ladders andplatforms, electric connections, instrumentation,etc., which substantially reduces field work.

For those projects where size limits are imposedby conditions such as road transport limitationsto access inland locations, DFCP develops thenecessary engineering and procedures to enablemodularization and final completion at site.

DF Calderería Pesada Storage Mounded Bullets 16 / 17

Proven experience in design, shopfabrication and site installation of StorageMounded Bullets

Storage Mounded Bullets Horizontal mounded bullets for storage ofliquefied gases or combustible liquids providean intrinsically passive and safe environment,eliminating risks such as high temperature incase of fire or dynamic pressure from nearbyexplosion.

DFCP has proven experience in carrying outmechanical design and shop fabrication of thistype of equipment according to internationallyrecognised Codes and guides (PD 5500, ASMESection VIII, EEMUA, F. Mang,...), and deliveringLPG mounded bullets ranging up to 8,500m3

as per Customers' requirement, with more than100m length and 10m diameter.

The scope of these projects usually includesmechanical design, engineering, supply,fabrication, testing, transportation, field erectionand installation.

DF Calderería Pesada Heavy Wall & Special Reactors 18 / 19

Long experience in Chrome-molybdenumVanadium-enhanced heavy wall Reactors

Heavy Wall& Special Reactors

This business line comprises reactors forrefineries, chemical, petrochemical and fertilizersindustry, such as HDT, HDC, Platforming, Aromaxor Powerformer Reactors, Ammonia Converters,Urea Reactors, etc.

DFCP is able to provide the world-leadingtechnologists and main Customers with thenecessary capabilities for the successful designand completion of this kind of complexfabrications.

The use of innovative welding technologies andmanufacturing processes developed by ourengineers has enabled us to achieve excellencein the manufacturing of equipment in a widevariety of materials and thicknesses.

DFCP is one of the few companies in the worldcapable to successfully fabricate and deliverChrome-molybdenum Vanadium-enhancedheavy wall Reactors. DFCP also holds referenceson the manufacturing of vessels over 180mm,with explosion bonded or roll bonded plate,and overlay welded with stainless steel or nickel-base alloys,...

DF Calderería Pesada Coke Drums 20 / 21

More than 40 references in Coke Drumsmanufacturing with all different licensors

Coke Drums

Coke Drums are critical components inrefineries. Their severe operation conditionsinvolve cyclic heating and cooling that causethermal stresses to the drum walls and can leadto through-wall cracking.

DFCP is qualified by all different licensors forthe design and manufacture of Coke Drumsand has supplied more than 40 Coke Drums sofar, which demonstrate the feasibility of DFCP’sin-house developed procedures and thereliability as manufacturer of this criticalequipment.

DFCP provides wide experience in the fatigueanalysis of Coke Drums under the severe thermalcycles to ascertain and optimize their life span,as well as in the development of reliablemanufacturing processes to ensure shapecontrol and the required quality of the weld.

DF Calderería Pesada Fluid Catalytic Cracking Units (FCCs) 22 / 23

More than 100 references in FCC reactorsand regenerators, including revampsand site works

Fluid CatalyticCracking Units (FCCs)

DFCP is one of the most experienced manufacturersof FCC units in the world. Over the years DFCP hasgathered expertise not only in manufacturing reactorsand regenerators in our facilities, including cyclonesand refractory installation, but also in field erection,extensive revampings and specialized repair worksduring scheduled plant shutdowns.

DFCP is also wide experienced in stress analysis ofthese units under mechanical and thermal loadsunder design conditions, and also duringtransportation, handling and lifting operations, inorder to evaluate eventual risks.

DF Calderería Pesada Unit Packages 24 / 25

Process design, installation of internalsand instrumentation

Unit Packages

DFCP can provide process design, equipmentfabrication as well as installation of internalsand instrumentation. Holding the responsibilityfor the full scope of supply (design process,procurement of materials, manufacturingprocess and final inspection activities) providesconsiderable advantages to the project. Finalsite assembly of the Unit Package does notrequire additional trial fit up or provision oftemplates. The Unit Packages are ready for finalconnection at site.

This concept drastically reduces the necessarymeans and resources at site (manpower,ancillary equipment, etc.) and avoids interfaceproblems, minimizing the project overallexecution time.

DFCP has supplied more than 100 differentunits under this concept: Test, LP/HP or FWKO(Free Water Knock-Out) Separators,Electrostatic Coalescers, LP Expander OutletDrums, Desalters, Degassers, Dehydrators,...


Design, fabrication and delivery of large-scalemodules

Modular Construction

Modular Construction 26 / 27

The modularization approach is most indicated in orderto gain cost and schedule advantages, and at the sametime to reduce risks associated to site assembly andinstallation.

DFCP's facilities with direct access to the sea, combinedwith the additional working areas available at the nearbyPort of Gijón, provide our Customers with the necessarymeans to fabricate and deliver large-scale modules inOil&Gas and other industrial segments.

Completed skids and modules are shipped to site fullyinstalled, including insulation, cable trays, instruments,cabinets, junction boxes, heat tracing,...


N-type Certificate Holder according toASME Code Section III, Division 1

Nuclear Components

Nuclear Components 28 / 29

DFCP currently holds N, NPT and NS Certificatesof Authorization of the American Society ofMechanical Engineers (ASME). This certificationsignifies DFCP capability to meet the highestquality requirements of the nuclear market.

Taking advantage of its extensive experiencein the manufacturing of large and complexvessels, DFCP can provide its Customers withthe skills and competences in both design andmanufacturing required for the production ofnuclear facility components, such as:

• Class 1, 2, 3 & MC Vessels• Class 1, 2 & 3 Piping Systems• Class 2 & 3 Storage Tanks• Class CS Core Support structures• Class 1, 2 & 3 Shop Assembly

Since the 1990s, DFCP hasdeveloped projects forseveral InternationalScientific Large Facilitiesinvolving the fabrication oflarge complex equipment.DFCP has available strongand diverse experience inthe most advancedmanufacturing andinspection techniques,applied to components inexotic materials and largesizes, allowing us to meetthe requirements of suchprojects.


Health, Safety and EnvironmentHealth and safety issues are fully integrated into DFCP’sday-to-day operations and management in order todevelop and maintain a healthy and safe environment.

DFCP strives to eliminate any foreseeable hazards toprevent incidents. In order to achieve this goal, weconduct periodic reviews of the potential impact ofour activities on the environment, as well as on thehealth and safety of our employees and visitors.

We are committed to the environmental sustainabilityof our manufacturing processes and actively pursueenergy efficiency measures in production andconsumption of energy as part of our overall strategy.

DFCP is focused on the development and integrationin its production processes of high qualitymanufacturing technologies and advanced materials.The implementation of sustainable manufacturing toolsand methodologies provides the capability of efficientlyproducing and delivering high quality products.Furthermore, the development of innovativemanufacturing processes enables the use of newmaterials with enhanced mechanical properties,optimizing sizes and weights, and generatingremarkable advantages in production, handling andinstallation of heavy equipment.

Energy audits are carried out to assess appropriateenergy-saving measures and to develop our energyefficiency strategy. Special care is taken in conductingour business with respect for people and theenvironment, complying with all applicable regulatoryrequirements and industry best practices.

GeographicalReferences

EUROPE• Austria• Belarus• Belgium• Bulgaria• Croatia• Czech Republic• France• Germany• Ireland• Lithuania• Netherlands• Norway• Portugal• Russia• Serbia• Spain• Sweden• Switzerland• Turkey• UK

NORTH AMERICA• Canada• Costa Rica• Cuba• Mexico• Trinidad & Tobago• USA• Virgin Islands

SOUTH AMERICA• Argentina• Bolivia• Brazil• Chile• Peru• Venezuela

AFRICA• Algeria• Egypt• Libya• Nigeria• South Africa

MIDDLE EAST• Iran• Israel• Jordan• Kuwait• Oman• Qatar• Saudi Arabia• UAE

ASIA & OCEANIA• Australia• Azerbaijan• Bangladesh• China• India• Indonesia• Kazakhstan• South Korea• Thailand

GijónSPAIN

Health, Safety and Environment / Geographical References 30 / 31

Equipment manufactured and shipped toworldwide destinations


SPAINHeadquarters

Parque Científico TecnológicoC/ Ada Byron, 9033203 Gijón. AsturiasTel.: +34 985 199 000

MEXICODURO FELGUERA, S.A.

Moliere 13, piso 8ºColonia Chapultepec PolancoDelegación Miguel HidalgoMéxico DF, CP 11560Tel.: +52 55 [email protected]

VENEZUELADURO FELGUERA, S.A.

Av. Francisco de MirandaEdif. Banco del Orinoco, piso 2Oficina 2-DUrb. La Floresta, Municipio ChacaoCaracas 1060Tel.: +58 (0212) 285 [email protected]

Calle Gurí, Edificio Torre CEM, Piso 7Oficinas P7-01 y P7-02Sector Alta VistaPuerto Ordaz - Estado BolívarTel.: +58 286 7180123 / 9719773/ 9719120

BRAZILDURO FELGUERA, S.A.

Rua da Quitanda nº 52, 11ª andarRio de Janeiro, CEP: 20.011-030Tel.: +55 21 2505 [email protected]

ARGENTINADURO FELGUERA, S.A.

Lola Mora 421, Torre I, Piso 7,Oficina 701Madero Harbour - Puerto MaderoC.A.B.A. C1107DDABuenos AiresTel.: +54 11 [email protected]

COLOMBIADURO FELGUERA, S.A.

Edificio Teleport Business CenterCalle 113 Nº7-45 Torre B Ofic. 506BogotáTel.: [email protected]

INDIADURO FELGUERA, S.A.

3rd Floor, 10-50-24/A, Sravya ManorSiripuram, Visakhapatnam - 530 003Andhra PradeshTel.: +91 89 1255 8343/[email protected]

CHINADURO FELGUERA, S.A.

Suite 2001, Westgate Mall1038 Nanjing Xi Lu200041, Shanghai, P.R.Tel.: +86 21 621 [email protected]

INDONESIADURO FELGUERA, S.A.Ariobimo Sentral Building 3rd fl.Jl. HR Rasuna Said Kav.X-2/5Jakarta - 12950,Tel.: [email protected]

MIDDLE EASTSAUDI ARABIADURO FELGUERASAUDI ARABIA LLC.

GCH Business Centre at Fifth Floor,AlFalak Building,King Abdul Aziz StreetAl [email protected]

UAEDUBAIDURO FELGUERA GULFGENERAL CONTRACTING, LLC.(ENERGY)

Aspin Tower. Office 3504Sheikh Zayed [email protected]

ABU DHABIDURO FELGUERA MIDDLE EASTGENERAL CONTRACTING LLC.(OIL & GAS)

Gulf Business CenterAl Dharwish [email protected]

DF Permanent Offices Worldwide

PERUDURO FELGUERA, S.A.

Avenida Jorge Basadre 145 Edificio Basadre, Oficina 202Distrito de San IsidroCP: Lima 27Tel.: +51 1242 [email protected]

pressure vessels manufacturer since 1968 - duro felguera · manufacturing of large complex pressure...

Documents