Materials and welding expertise for production plant operators

– to keep your production running

For plant and maintenance managers with their own production: welding consulting for repairs and maintenance, welding qualification for in-house work and process optimization – with the goal of maximum plant availability.

Plant availability Repair welding Maintenance Welding qualification Peer review Process optimization TÜV interface

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CHALLENGE

Production plant operators fight daily against unplanned downtime – and for every hour their plants keep running.

A repair weld on a plant component is due – the material and procedure must be chosen quickly and correctly.

Your own workshop is to carry out repairs in line with standards – welding qualification and process stability are missing or outdated.

Recurring damage on the same plant components – the cause is unclear and the economic loss is rising.

The TÜV or another notified body sets requirements for in-house manufacturing – the interface must be managed professionally.

24h

Availability during acute downtime

100%

Independent of plant manufacturers

worldwide

On-site assignments at your plant

TÜV +

Interface to all notified bodies

Plant shutdown, repair weld or planned maintenance?

We come to your plant – nationwide, even at short notice. Plant availability is our benchmark.

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SERVICES

Three core services for plant and maintenance managers

Welding consulting for maintenance & repair

Consulting on the right material, procedure and filler selection for repair and maintenance welding on existing plants – including heat management concepts for critical material combinations.

Repair welding concepts for existing components
Material identification on old components
Heat management and preheating concepts on site
Consulting for unknown or critical materials
Failure analysis as a preliminary stage to repair

Repair welding PMI / PMI analysis

Welding qualification for in-house work

Support for welding procedure qualifications and welder qualifications for your in-house manufacturing and maintenance – so that in-house work meets standards and is suitable for authorities.

WPS / WPQR according to DIN EN ISO 15614
Welder qualification tests according to DIN EN ISO 9606
Interface to TÜV, DEKRA, Lloyd’s and SLV
Peer review of in-house welding plans
Setting up and maintaining your qualification documentation

ISO 15614 ISO 9606 ISO 3834

Process analysis & improvement

Systematic analysis of your in-house welding, brazing-soldering and manufacturing processes – to identify the causes of recurring damage, downtime and scrap. Development of concrete procedure concepts with measurable results.

Process analysis by experts on site
Development of procedure and work-sample concepts
Root cause analysis for recurring damage
Optimization of repair processes
Building independent QA structures

Availability Process optimization In-house QA

PLANT AVAILABILITY – OUR EVALUATION BENCHMARK

Our benchmark: how much more does your plant deliver? The goal: maximum running time for your plant.

Reduction of unplanned downtime

Recurring damage has causes – usually in the material, the welding procedure or the heat treatment. We identify the root and deliver a solution that eliminates the problem for good.

Faster recommissioning

When the plant is down, every hour counts. We come on site at short notice, advise on the repair strategy and ensure that the repair is carried out in line with standards and quickly at the same time.

Acute, planned or strategic – we provide support in every phase

ACUTE

Plant shutdown & emergency repair

A critical component fails, the plant is down. We come on site at short notice, advise on a safe repair strategy and support quick recommissioning – even with unknown materials and critical heat treatments.

PLANNED

Maintenance windows & inspections

For planned shutdowns, we develop repair concepts, welding instructions and inspection plans in advance. This way you make optimal use of the maintenance window and avoid costly delays during the inspection.

STRATEGIC

Building your own workshop capability

When in-house maintenance is to deliver more permanently: building welding qualification, standard-compliant documentation and process stability – so that you become more strategically independent of external services.

PROJECT REFERENCES (ANONYMIZED)

From practice – what we have achieved for production plant operators

CHEMICAL PLANT

Repair welding of heat exchanger with material identification

Emergency repair on a heat exchanger of unknown material history. PMI analysis on site, identification of the base material and development of a repair WPS within 12 hours.

→ Plant back in operation after 36 hours instead of the planned 5 days

FOOD PRODUCTION

Stainless steel welding qualification for in-house workshop

Setting up a complete welding qualification for stainless steel 1.4301/1.4571 in the in-house maintenance workshop. WPS, welder qualification tests and ISO 3834-compliant documentation.

→ 80% of repairs have since been handled in-house, response time halved

PAPER MILL

Root cause analysis of recurring shaft cracks

Systematic root cause analysis after three shaft fractures within 18 months. Identification of a combination of material weakness and heat treatment error.

→ Switch to higher material grade, no further fracture in 3 years of operation

COLLABORATION

How a collaboration works

Request

Acute, planned or strategic – a short description of your situation. In case of downtime, direct contact by phone.

Initial consultation

Within 24 hours: assessment of the effort, clarification of the need for an on-site visit and scheduling.

On-site appointment

Consulting at the plant, material analysis, repair concept or qualification support – directly in your workshop.

Report & implementation

Clear documentation, standard-compliant WPS and recommended actions – usable for in-house work or official acceptance.

WHY TECHNICAL CENTER

What sets us apart from general testing laboratories

On site instead of from the office

We come to your plant, see the installation and know the situation from our own observation. Pure desk-based consulting is no real help in everyday maintenance.

Repair experience instead of new-build theory

Welding on existing plants is different from welding on new construction – unknown materials, existing residual stresses, confined spaces. We know the particularities.

Plant availability as the benchmark

Every one of our recommendations is measured by how much it increases your plant availability. Theoretically elegant solutions are not automatically practical.

Fast availability

In case of downtime, we are reachable within 24 hours and usually on site within 24-48 hours.

TYPICAL OCCASIONS

When plant and maintenance managers contact us

A plant component fails during operation – quick repair consulting with material identification needed
Recurring damage on the same plant parts – the cause has not yet been permanently resolved
The in-house workshop is to be qualified for a new material or procedure range
Before a planned plant inspection: prepare repair concepts and WPS for the planned interventions
The TÜV or another notified body sets requirements for in-house manufacturing – interface and support needed
Strategic positioning of in-house maintenance – deliver more in-house, less outsourcing

No acute downtime, but a need for strategic consulting for your maintenance?

A non-binding initial consultation is possible at any time.

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FREQUENTLY ASKED QUESTIONS

What plant and maintenance managers want to know before their first request

How quickly can you be on site in case of an acute plant shutdown?

In case of acute downtime, we are available by phone within 24 hours and usually on site within 24-48 hours. With direct contact by phone, we can often discuss first steps toward material identification and a repair strategy in the very first conversation, so that you can act immediately.

Can you identify materials on existing plants when documentation is missing?

Yes. We carry out PMI analyses (Positive Material Identification) on site at the plant – using mobile spectrometers. This lets us determine the base material of a component in a few minutes and immediately propose a suitable repair strategy. For particularly critical materials or disputed findings, we supplement this with laboratory analyses.

Can you qualify our in-house workshop for standard-compliant welding manufacturing?

Yes. We support the complete setup of standard-compliant in-house manufacturing: welding procedure qualification (WPS / WPQR), welder qualification, building qualification documentation according to ISO 3834 and, where applicable, the interface to the notified body for pressure equipment applications. You reduce outsourcing and response times – and become more strategically independent.

What to do about recurring damage on the same component?

Recurring damage almost always has a systematic cause – in the material, the welding procedure, the heat treatment or the operating conditions. We carry out a systematic root cause analysis (failure analysis, materials testing, operating data evaluation) and develop a permanent solution. The result is usually: no more damage, instead of monthly recurring repairs.

Can you also take over the interface to the TÜV or other authorities?

Yes. We speak the language of the notified bodies (TÜV, DEKRA, Lloyd’s, SLV) and take over the technical preparation and support of audits and acceptances for your in-house activities. You concentrate on operations – we make sure the official documentation is right.