Germany — Heat Exchanger Repair & Semi-Automated Welding
Client: Emsstahl GmbH (main contractor) Site: German workshop Industry: Heat exchanger services Period: Workshop campaign Services: Heat Exchanger Services · Industrial Welding
Context
Emsstahl GmbH is a German industrial contractor in the heat exchanger repair and workshop fabrication space. MIDAS was engaged through Emsstahl for a workshop-mode heat exchanger repair scope involving semi-automated welding on tube-side and shell-side work.
Heat exchanger overhauls in a workshop setting require tight tolerances, controlled heat input, and welders qualified specifically on tube-to-tubesheet and shell-weld procedures. The semi-automated aspect — orbital or carriage-driven — adds a machine-qualification dimension on top of the welder qualification.
Scope
Workshop campaign — heat exchanger repair with semi-automated welding:
- Tube-bundle inspection and repair
- Shell-side welding restoration
- Semi-automated welding (orbital or carriage-driven) on matched procedures
- Welder qualification verification against the shop’s WPS stack
- Documentation pack aligned to the client’s QC regime
Approach
Material and procedure matching. Stainless and carbon steel materials handled per the client’s WPS library. MIDAS welders qualified on the relevant procedures under EN ISO 9606-1, with procedure qualification records (PQR) and welding procedure specifications (WPS) matched before production welding commenced.
Semi-automated welding. The scope included semi-automated welding — requiring machine-procedure qualification alongside welder qualification. MIDAS welders had the relevant 141 (TIG) and machine-process endorsements.
Documentation discipline. Test packs produced per unit, with weld maps, heat-number traceability, and NDT coordination handled against the client’s acceptance criteria.
Outcome
The German workshop campaign is the proof point behind our heat exchanger workshop capability — we deploy qualified crews into German workshop environments under Emsstahl’s supervision with our own welding coordination stack (EN ISO 14731).
Technical summary
| Scope | Heat exchanger repair with semi-automated welding |
| Standards | ISO 3834-2, EN 13480-4, EN ISO 9606-1, EN ISO 15614-1 (WPS qualification) |
| Welding processes | 141 TIG (manual and orbital), semi-automated carriage welding |
| Material | Carbon and stainless steel, per client WPS library |
| Output | Repaired heat exchanger units with full test pack |
| Duration | Workshop campaign |
| Delivered via | Emsstahl GmbH |
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