The Welder 01/2013 - ESAB

01 / 2013
THE WELDER
ESAB YardFeeders
bring cored wire
welding to every
corner of Gudrun.
PAGE // 3

CompetenCe is key
to success.
“Competence” is a combination of knowledge, skills, and behavior used to improve performance.
With tough economic climates for the majority of enterprises, welding in recent years has not been easy.
With higher demands on productivity than ever before, there are greater demands on welding skills at
the supplier. It is therefore necessary to use robust and quality-assured welding products and processes.
ESAB has always focused on creating products and solutions that serve our customers because we
have the experience, knowledge, and a heritage we are proud of. Our passion is committed to pioneering
innovation that customers can translate directly into enhanced quality and improved profit margins.
ESAB also works closely to help you, as our customers, take away the bottlenecks you have in your
welding production. This is achieved through a well-proven method that is called Value Engineering.
Do not hesitate to contact us if you want to know more about this.
In this issue of our magazine, you can read how ESAB has applied their welding competence and
technology to assist Norwegian Offshore Fabricator Aibel AS and Belleli Energy CPE who design and
manufacture large pressure vessels for petrochemical and energy.
In addition, you can read about ESAB’s new welding power sources, AristoMig ®
4004i Pulse, excellent for
advanced welding in aluminium and stainless steel, as well as two brand new plasma cutting machines,
PowerCut 400 and PowerCut 700, and the new ESAB Warrior Tech welding helmet.
We trust you will enjoy keeping up-to-date with
developments and products by ESAB. In addition,
why not subscribe to our local e-newsletter
which you can do by visiting our website,
www.esab.co.uk/newsletter.
Enjoy the magazine and the spring.
Gary Kisby
Sales & Marketing Director, UK & Ireland
ESAB
CONTENTS
3 // FEATURE
ESAB YardFeeders bring cored wire
welding to every corner of Gudrun
7
Belleli Energy CPE uses Aristo ®
1000, the
only AC/DC “on the fly” power source for
submerged arc welding
ESAB NEWS
18th International SCHWEISSEN &
SCHNEIDEN, Essen, Germany
Successful start of ESAB’s
Pipeweld Roadshow
10 //
11 //
12 //
13 //
13 //
14 //
New ESAB Origo spectacles for
welder protection
Lightweight inverter-based
welding equipment delivers high
quality and high productivity
Portable plasma cutters combine
performance with ease of use
New ESAB TIG torches put the
welder’s needs first
ESAB sets new standards with
Aristo Fluid pre-weld anti-spatter
New Warrior Tech reactive
welding helmet
CONTEST
What have you welded lately?
For regular updates from ESAB,
sign up for our e-newsletter at
www.esab.co.uk/newsletter or
scan the QR code.
1 2
9
10
PRODUCT NEWS
14 //

ESAB YARDFEEDERS BRING
CORED WIRE WELDING TO
EVERY CORNER
OF GUDRUN.
Norwegian offshore fabricator Aibel AS relies on ESAB’s process solutions to assemble
an immense platform topside from globally built components.
The construction of Gudrun’s topside provided Aibel with a jigsaw puzzle of globally
built components to be assembled in their home base of Haugesund, Norway. For this
immense welding job, the company applied newly purchased ESAB Origo TM
Mig 4001i
inverters with Origo TM
YardFeed 2000 wire feeders and FILARC PZ6138 all-positional
cored wire.
Gudrun – one of Norway’s major reserves
The Gudrun oil and gas field, discovered in 1974 in North
Sea production licence 025, is one of Norway’s major
reserves with an estimated 70 million barrels of oil and
48 million cubic meters of gas. The plan for development
and operation was sanctioned in June 2010 and first
production is planned in the first quarter of 2014.
Norwegian state oil company Statoil will use a fixed
platform with a 10,000 ton topside and a 7,400 ton steel
jacket for extraction and partial stabilising of oil and gas.
The platform will be connected to existing installations
of the adjacent Statoil operated Sleipner field for further
processing. From there, oil is transported to the onshore
Kårstø processing plant for removal of water and sand
while gas, after taking out carbon dioxide, will be
exported to Europe through the Gassled system
(www.offshore-technology.com/projects/gudrunfield/).
Øyvind Sætre Aibel
Figure 1 // ESAB Origo Mig 4001i inverter with Origo
YardFeed 2000 used on one of the Gudrun platform decks.
The partly assembled topside is visible in the background.
Aibel AS to engineer and construct
Gudrun topside
The realisation of the Gudrun platform by Statoil is a real
global enterprise. The jacket (installed in August 2011) and
accommodation units are manufactured in, respectively,
Verdal and Stord in Norway, platform modules in Thailand,
and a helicopter deck in China.
The topside, except living quarters, is fully realised by Aibel
AS, to be completed by July 2013. The engineering was
done by Aibel’s design office in Oslo, whereas individual
deck modules were built at Aibel yards in Thailand, Poland,
and Haugesund, Norway. Modules were shipped to
Haugesund where the deck is now assembled indoor in
Aibel’s immense construction hall, before transportation
to the Gudrun field for installation in July 2013.
Aibel, as a corporation, is a relatively new name in
the business, but the company has a long track record
in engineering, procurement, construction, and
commissioning. Roots date back more than a century
with forerunners such as Haugesund Mekanisk Verksted
(HMV), Umoe, and ABB. It employs around 5,500 persons
in Norway and abroad and generates an annual turnover
of approximately 8.6 billion NOK. The fabrication of the
Gudrun deck demonstrates its ability to handle complex
international projects in the oil and gas industry.
Relations between Aibel and ESAB date back to the
HMV era in the seventies and eighties when North Sea
oil and gas exploration was coming on steam. In these
days, several advanced welding consumables for thick
construction sections in offshore fabrication were
developed in close cooperation with Norwegian yards.
The rutile all-positional cored wire FILARC PZ6138,
still in use at Aibel, is a good example. Today, ESAB
supplies the majority of welding consumables used by
the company.
New power sources for
welding Gudrun
With the challenging Gudrun project coming, Aibel
decided to make a substantial investment in new power
sources for the Haugesund yard. Welding management
and welders jointly defined a wish list with key features
derived from day to day practice in offshore fabrication.
Subsequently, it invited four suppliers to provide their
power source that best matched the requirements of the
welding department.
Following requirements were formulated for the new
power sources, with lighter weight being the number
one feature:
n Separate wire feeder; as light as possible to be hand
carried to the work site. Use of 5 kg welding wire spools
to reduce weight. Welding cables of 10-25 m length to
ensure a sufficiently wide reach from the power source.
Euro connector for universal torch connection.
Lightweight remote control, flowmeter, and spare gas
supply valve are preferred.
n The weight of the power source itself must allow it to
be hand pushed on a two-wheel trolley. Lifting hooks for
transport by crane onto scaffolding.
n Power sources to enable at least the MMA and FCAW
processes. Capacity of 300-350 A at 40% duty cycle
and 230 V primary power with the possibility to change
to 380-460 V, 50/60 Hz (multi voltage).
n Panel on feeder with Volt and Amperage setting.
Memory positions to store parameter settings.
Availability of synergic lines is an advantage, but not
a necessity. Choice of 2- and 4-stroke. Release of
excess gas when the gun button is pressed.
n Light and convenient air-cooled 350 A torch with 3 m
hose package and Euro connector.
n Two-wheel trolley with hooks for coiled cable packages.
n Supplier must have service centre in Norway to quickly
carry out warranty repairs.
UNITED
KINGDOM
GUDRUN
NORWAY
DENMARK
GERMANY
Figure 2 // Top: Graphic impression of the platform.
Bottom: Location of the Gudrun oil & gas field.
3 // FEATURE FEATURE // 4

Figure 3 // Modules from Thailand arriving at the Aibel
yard in Haugesund.
Origo Mig 4001i inverter with
Origo YardFeed 2000 winner at Aibel
Aibel put four machines from four different suppliers to
the test in a two-month investigation involving 13 of their
best welders. To get a good view on their performance,
the power sources were used in actual production along
with existing welding equipment and with the same
welding consumables.
One of the machines from another supplier was soon
taken out of the test, because of its unstable wire burn-off
in FCAW which was regarded to be a potential cause
of welding defects. This required very precise parameter
settings and could, nevertheless, not be solved
satisfactorily. An aspect of this machine which the
welders really disliked was the switch on the door of the
wire feeder that needed to be activated to allow welding.
A second machine did not have the required voltage
display on the wire feeder needed by the welder to set
the welding parameters. The supplier was asked to
change this, but they failed to come up with a solution.
The machine had otherwise good welding characteristics.
Real competition took place between ESAB and the
supplier of many of the MMA/FCAW power sources
used by the yard at that moment. The latter has a solid
reputation among welders at Aibel, while ESAB is
respected for its automated TIG, plasma, and subarc
solutions and for its excellent welding consumables.
Odds were even in this respect, so the decision had to
come from a comparison on design and performance
of the machines.
ESAB’s Origo Mig 4001i with Origo YardFeed 2000 and
power source number three are comparable equipment
and both suited for heavy duty offshore fabrication.
Both feature primary switching inverter technology,
separate wire feeders, and good welding characteristics.
Differences are minor, but yet big enough to make Aibel
decide in favour of ESAB.
Most important was the minor amount of error codes
generated by Origo Mig 4001i with Origo YardFeed 2000
and reported by the welders. Error codes result in a
lower duty cycle and loss of productivity. This, in
combination with a display panel of power source number
three that had to be changed and repaired two times, was
one of the main reasons to finally opt for the ESAB
solution which performed without any problems. Another
decisive factor was the lower weight of the Origo
YardFeed 2000 of 11.3 kg versus 13.6 kg for the feeder of
supplier number three. Also there was more space around
the 5 kg wire spool, making it easier to replace. The ability
to activate three different parameter settings from the
welding gun was another well appreciated feature that
helped ESAB win the contest.
A real workhorse for heavy duty
fabrication
At 40 kg for the Origo Mig 4001i power source and
11 kg for Origo YardFeed 2000, the equipment can be
categorised as low weight. Weight increases by 14 kg
with the water-cooled version (Origo Mig 4001iw) and
another 19 kg for the cooling agent. Yet the equipment
is robust and built for heavy industries such as
shipbuilding and offshore fabrication – durable and
dependable. In total, Aibel ordered 10 air-cooled and 20
water-cooled versions with MA23 panels mounted on
the wire feeder.
Figure 4 // MA23 – ESAB’s basic panel for MMA, FCAW
and MIG/MAG.
MA23 is the most basic panel, giving MMA, FCAW, and
MIG/MAG short and spray arc are generally applied in
welding main offshore structures with stick electrodes and
cored wires respectively. The panel enables CC/CV power
source characteristics, has a digital V/A meter, 2- and
4-stroke, step-less inductance setting, gas purge and wire
inching, remote control, and three memory positions for
parameter settings. It meets most of Aibel’s requirements
in terms of welding processes and functionality. More
advanced features like pulsing, QSet, and synergic lines
are not available with the MA23 panel and are not
necessary in this type of heavy wall thickness welding.
There is always the possibility to later upgrade the
machines with the more advanced MA24 panel, for
instance to enable the welding of stainless and nickelbase
materials.
The panel is mounted on the Origo YardFeed 2000 wire
feeder, so that the welder can do all necessary settings
at the welding site. A remote control for regulation at the
arc is optional, but Aibel decided it was not necessary to
purchase any. ESAB offers connection cables from 10 m
to 50 m in length enabling a corresponding working
radius (plus gun hose assembly) of the power source.
Longer cables, however, mean more weight for the welder
to carry. With low weight being the major requirement,
Aibel opted for the shortest length of 10 m, accepting the
limited working radius.
FILARC PZ6138 cored wire still
going strong
Introduced in the mid-eighties, the FILARC PZ6138 all
positional rutile cored wire is still the benchmark product
in offshore fabrication combining a number of unique
properties. Amongst others, the Norwegian offshore
industry called for the development of a low-hydrogen
cored wire with excellent weldability for the productive
joining of low-temperature steel. The outcome, at the time,
was sensational.
Used in Ar/CO 2 shielding gas, the rutile based slag
formulation provides welding properties that were not
seen before with cored wires. PZ6138 has a soft spatterfree
arc that always operates in the spray arc mode with a
good penetration and good wetting onto the plate edges.
It is extremely “welder-friendly” which makes it easier for
the welder to produce sound welds. The availability of all
positional rutile cored wires, such as PZ6138, helped the
offshore industry in combating typical positional welding
defects such as lack of fusion and slag inclusions.
Another aspect much needed by the offshore
industry was the very high productivity of PZ6138 in
manual positional welding – up to three times as fast as
commonly used stick electrodes. This, in combination
with excellent low-temperature CVN (-60°C) and CTOD
(-15°C) mechanical properties and low-hydrogen weld
metal over the full parameter envelope, soon made this
cored wire the most popular welding consumable in
North Sea offshore fabrication. Nowadays, the wire is also
widely applied in new offshore fabrication areas in the
Middle East and Far East and in Brazil. Later introduced
and based on PZ6138 are PZ6138 SR (stress relieving)
and PZ6138S SR (CO 2 shielding gas + stress relieving).
The fabrication of the Gudrun platform is proof that
FILARC PZ6138 is still going strong in offshore
fabrication. It is widely applied in primary construction,
among others, for welding the super critical box nodes
connecting the several stories of the deck.
Figure 5 // FILARC PZ6138SR all positional rutile
cored wire.
Figure 6 // Spectacular view on the welding of one of the
box nodes of the Gudrun platform. The lightweight Origo
YardFeed 2000 wire feeder with 5 kg cored wire spool is
easily hand carried to the welding site.
Figure 6 shows the actual welding of one of the box
nodes with PZ6138 all positional rutile cored wire.
The lightweight Origo YardFeed 2000 wire feeder is
carried to the welding site and positioned within reach of
the welder. Welding parameters are set and fine-tuned
with the MA23 panel on the feeder.
FEATURED PRODUCTS
n Origo Mig 4001i multi-process inverter-
powered welding equipment, designed for
welding construction and stainless steel
with Origo YardFeed 2000, digital wire feeder
with working radius up to 50 m.
n FILARC PZ6138 all positional cored wire.
Well established in the offshore sector and
other demanding constructions like pressure
vessels, etc. An impact property down to
-60°C and it is CTOD-tested at -10°C.
5 // FEATURE FEATURE // 6

BELLELI ENERGY CPE USES
ARISTO 1000, THE ONLY AC/DC
“ON THE FLY” POWER SOURCE
FOR SUBMERGED ARC WELDING.
The ESAB Aristo 1000 AC/DC power source, combined with an ESAB A2-Multitrac
tractor, is being used for filling runs inside circumferential joints and for plating restoration
in the area of the joint.
Founded in 1997 in Mantova, Italy, Belleli has become
the market leader in the industries of power generation,
chemistry and petrochemical plants, in desalination,
and in the construction of storage tanks in Europe and
Middle East.
Belleli Energy is divided in two separated entities,
Belleli Energy Critical Process Equipment (CPE), based
in Mantova, and Belleli Energy (EPC), based in Dubai.
The two Belleli Energy companies in Italy employ
450 people. These are specialized in large plants
manufacturing (Belleli Energy EPC) and in the
manufacturing of high technology components for
energy, chemistry, and petrochemical industries
(Belleli Energy CPE). As well as the Mantova plant
(conferred to Belleli Energy CPE), the production
structure includes the plants of Jebel Ali and
Hamriyah, in Arab Emirates and several fabrication
plants in different Middle East countries
(Arab Emirates, Qatar, Saudi Arabia, and others).
Belleli Energy EPC is specialized in the design,
manufacturing, assembly, and maintenance of plants
and systems for desalination, petrochemical, energy,
storage, and fuel processing.
Belleli Energy CPE designs and manufactures large
pressure vessels for petrochemical and energy
(reactors, columns, exchangers, separators, etc.). Today,
Belleli Energy CPE is a world leader in the manufacturing
of special and advanced components for refineries,
petrochemical plants, and plants for urea and ammonia
synthesis, among the others.
Ninety percent of the production is targeted to oversea
markets, for the most important engineering companies
and main contractors in the world in the petrochemical,
desalination, and energy plant sectors. “Our main markets
are actually extra-European countries like Russia, Turkey,
Korea, and Brazil,” says Michele Musti, European Welding
Engineer, Belleli Energy CPE. “In the urea plants sector
we have also recently received orders from emerging
countries like Bangladesh.”
The internal design, engineering, and manufacturing
capabilities allow Belleli Energy CPE to ensure the
integrity of materials, processes, and products, from
raw materials to finished products. The company
manufactures some of the largest process equipment
existing in the world and transports it by ships from
its own dockyard. The Mantova plant is the largest
European plant for the manufacturing of large thickness
reactors and heat exchangers. The latest example of this
capability has been the delivery of two reactors, each
weighing 1656 tons for a length of 56 meters, addressed
to Lukoil Neftochim refinery in Bulgaria.
AC and DC welding
“We mainly produce high thickness steel vessels (up to
325 mm), like hydro-cracking and hydro-treating reactors
for refineries,” says Musti. “Furthermore, we produce
high pressure exchangers and urea plants. We are also
certified for the nuclear power sector, though in this
case the applications are less frequent due to the market
shrinking.”
While low thickness tubular bodies (to 150 mm) are
calendared and longitudinally welded, high thickness
bodies are generally manufactured using forged steel
ferrules, that are jointed through circumferential welding.
“Forged steel is more expensive, but requires less
working, because it is not necessary to execute
longitudinal welding,” Musti explains. “In recent years,
the thicknesses have been significantly increased,
therefore the only solution that is technologically possible
is forged steel. To resist corrosive environments, the
cylindrical bodies are internally covered by a plating
deposition performed with ESW process, while the
plating restoration is performed with SAW process.”
This kind of production requires several operations: after
the circumferential welding of the external side of large
thickness forged ferrules, with “narrow-gap,” multiple runs
submerged arc welding process, for the joints to be
completed it is necessary to perform the welding recovery
by a grinder on the internal side of the cylindrical body
and then to restore the plating in the joint area. These
operations are performed with different technologies,
Musti explains: “The welding recovery of base material
joint in 2,25Cr 1Mo 0,25V must be performed with
square-wave AC current, while the plating restoring of
the internal side requires the use of DC current.”
Previously, for these operations to be performed with the
tractor, two separate power supplies were required
that had to be exchanged during the process, therefore
significantly increasing the time. To solve the problem
in the best way, it is therefore preferable to use a single
power supply that is able to automatically exchange by
a simple switch from AC current to DC current (possibly
without interruptions) like the new Aristo 1000 AC/DC
by ESAB.
In fact, by pressing a simple pushbutton on the PEK
panel, the Aristo 1000 AC/DC power supply allows
the operator to switch from DC current to AC current
without extinguishing the welding arc. For instance, when
circumferential welding is being performed, the first run
is normally executed in DC for the best penetration to
be obtained. With the “on the fly” function it is not
necessary to turn off the welding at the end of the first
run; on the contrary, it is possible to continue the welding
by converting the process to AC, with a resulting
significant increase of productivity for each welding.
Moreover, the risk of welding defects is drastically
reduced, thanks to the full elimination of the stop/start
sequence. By using a PLC control it is possible to
program the full cycle, from the first to the last run,
and to perform the welding without interruptions.
Quality of the welding run and
flexibility
“We chose the new ESAB power supply because it can
perform both DC and AC current weldings,” Musti says.
“This allows us to execute both the base material joining
welds, in AC current, and the plating restoration of the
internal part, in DC current, when previously two
different products were required. Now, when it is
necessary to weld reactors that show access difficulties
we use an internal tractor, the same single equipment
offers us the flexibility required to execute both the joining
welds in AC current and the plating restore operations in
DC current. In addition the welding quality and accuracy
are excellent.”
Belleli Energy CPE appreciated other features of the
new ESAB power supply: “As well as being flexible, the
machine is also very modern and well trimmed,” Musti
says. “In addition, we were already using other welding
equipment and consumables by ESAB and it was
therefore natural to use the Aristo 1000 AC/DC power
supply.”
In the future it could be interesting to use this system also
on manipulators, in applications where now two separate
power supplies are being used. Also the possibility of
cable extension offered by Aristo 1000 AC/DC, thanks to
ESAB patented Cable Boost technology, will be useful in
the manufacturing of rather long reactors and, in general,
in the situations where it is not possible to take the power
supply close to the welding zone. In automatic plants, for
example, you often require the use of very long welding
cables. Specifically in AC current, the inductance value
resulting from cable length gives rise to serious voltage
drop and square-wave deformation problems that can
compromise the stability of the set welding parameters.
The Cable Boost technology solves the problem,
by storing energy and releasing the energy to recover the
set levels.
Figure 1 // Top: Macrograph of a welding on SA 182 F22
V base material, thickness 325 mm, performed with SAW
tandem AC/AC process. Bottom: ESAB Aristo 1000 AC/DC
power source, combined with an ESAB A2-Multitrac
tractor, being used for filling runs inside circumferential
joints.
7 // BELLELI BELLELI // 8

Promises have been fulfilled
“In our production, quality is an issue, because a finished
reactor can’t show any defect: it would be unthinkable
to correct a mistake on an internal run in a thickness of
325 mm,” Musti concludes. “ESAB equipment, and the
new Aristo 1000 AC/DC power supply in particular, have
always perfectly fulfilled this quality requirement and
are mainly used to weld carbon steel with submerged
arc. The new Aristo 1000 AC/DC power supply and the
relevant control system have perfectly fulfilled their
promises.”
The equipment has been commissioned approximately six
months ago and is now being used on large size reactors.
In Belleli Energy CPE dockyard, equipped with cranes of
900 tons each, the ship is waiting for the next load.
ESAB spotlight on Welding
and Cutting
ESAB will be participating at the 18th international
SCHWEISSEN & SCHNEIDEN trade fair which will take
place at Messe Essen between 16 and 21 September,
2013.
During the weeklong event the exhibition will show an
overview of the latest developments and trends from the
world of joining technology.
The 2009 exhibition impressively demonstrated the
unique position of the SCHWEISSEN & SCHNEIDEN as
the world’s No. 1 trade fair of this industry. No other event
in the industry can be compared to the show in terms of
quality or size. In 2009, the show attracted over 52,000
visitors from various industries. Over 41% were overseas
visitors from outside Germany. It is only at Essen where
customers can see, touch, and experience products in a
competitive setting.
ESAB is a complete supplier that produces consumables
and equipment for virtually every welding and cutting
process and application. Powered by innovation and
uncompromising standards, ESAB continuously seeks
new and improved ways of serving customers.
FEATURED PRODUCTS
n Aristo 1000 AC/DC; AC/DC inverter power
source for efficient submerged arc welding.
n
OK Autrod 12.32: is a manganese-alloyed
wire and OK Flux 10.62: high basic flux.
A combination has excellent impact toughness
down to -60°C and it is CTOD-tested at -15°C.
It is used for multi-run welding of thick sections
of high strength steels at low temperatures and
can be used also for narrow gap welding.
18th InternatIonal
SChWeISSen & SChneIDen,
EssEn, GErmany.
At the Essen Fair, ESAB will show and demonstrate leading
technological advances in the industry – something not to
be missed!
For further information on ESAB’s participation at the fair
visit www.esab.com.
SucceSSful Start of eSaB’S
PiPeweld Roadshow.
ESAB’s one-day event, Pipeweld Roadshow, focuses
on demonstrating the key benefits of various processes
and applications for pipeline industry. The roadshow and
ESAB specialists recently visited the U.K., Belgium, and
Poland as part of the global tour.
ESAB offers a complete solution for pipeline welding with
knowledge about the processes, applications, welding
equipment, and consumables. ESAB’s welding specialists
demonstrate pipe welding and equipment in action.
ESAB’s Pipeweld product range supports and inspires
our partners to think about alternative ways to gain the
most productivity. Participants demonstrated how the
ESAB portfolio offers excellent operability and mechanical
performance. The event combines both theoretical
presentations and demonstration focusing on:
ESAB’s welding safety eyewear is renowned for combining the highest standards of eye protection with the ultimate in
wearer comfort. All ESAB spectacles use a polycarbonate to provide protection against impact as well as UV, IR rays, and
visible glare. This combination is again featured in the new Origo Spec range.
A replacement for ESAB’s successful Pro range, the highly durable Origo Specs conform to EN 166 and have an
optical rating of 1, meaning no distortions and perfect clarity. There is a variety of lens configurations from clear,
amber, smoked, and Shade 5 UV/IR with the highest optical class and featuring a special hard coating on the
lens to prevent scratching. The hard-coated lens also promotes longer service life and unimpaired vision.
At only 24 grams, the lightweight, wrap-around style offers
both comfort and good protection from all angles. Other
features include an integral neck cord and non-slip nose pads.
Visit us online at www.esab.co.uk for more information.
n Root welding with cellulosic electrodes
n Hot pass techniques
n Filling techniques, self-shielding, solid wires & FCW
n Demonstrations, automatic welding
During the recent events each region held 2 one-day shows
and in total the road show was visited by more than 140
guests in Scotland, Belgium, and Poland where one show
was conducted for Czech and Slovakian participants.
The next stop will be Dubai.
During the demonstration ESAB explains that modern
solutions for automatic pipeline welding can use:
n Cellulosic electrodes for the two first layers (speed
and quality)
n Basic electrode for the third layer (base for the next layers)
n Filling and cap layer with flux cored wire
ESAB offers a complete solution for pipe welding and
has developed unique products in recent years to meet
the challenges in the pipe welding industry.
Full details about our Pipeweld product range
and future events can be found on our website at
www.esab.com/global/en/news/events.cfm.
New eSAB OrigO
SPECTACLES
for welder protectioN.
9 // BELLELI ESAB NEWS // 10

Lightweight inverter-based
weLding equipment delivers
high quality and high
productivity.
Designed for high productivity and quality welding
applications, the new Aristo Mig 4004i Pulse power source
belongs to ESAB’s top-of-the-range Aristo family of
welding equipment. The pulse function makes it
suitable for advanced welding in aluminium and
stainless steel. Aristo Mig 4004i Pulse power source
connected to the wire feeders Aristo Feed 3004 or
Aristo YardFeed 2000 forms a complete MIG/MAG
package. The Aristo Feed 3004 is offered with a choice
of the advanced U6 or more sophisticated U8 2 control
panels and the Aristo YardFeed 2000 is available with
the U6 control panel. Together, these products can boost
productivity, enhance weld quality, and save money
through reduced energy consumption.
The Aristo Mig 4004i Pulse is designed for a modern
welding, lightweight, multi-process welding power source
that can be used for MIG, pulsed MIG, MAG, MMA, or
TIG. Compared with conventional welding equipment, the
electronically-controlled Aristo Mig 4004i Pulse weighs
70% less and has a footprint that is 70% smaller. This
new equipment is therefore easy to transport and much
easier to use in confined spaces. Typical applications
include the manufacture of trucks, busses, trailers,
off-highway equipment, trains, and railway rolling stock,
as well as wind turbine towers, structural steelwork,
shipbuilding/offshore, and general industrial fabrication.
To help in achieving high deposition rates, the Aristo Mig
4004i Pulse delivers a welding current of 300 A and
voltage of 32 V at a 100% duty
cycle. At a 60% duty cycle these
figures rise to 400 A and 36 V.
Pre-programmed synergic
lines set the optimum
welding parameters when
welding with different
combinations of material,
wire, and shielding gas.
While the U6 control panel
has a memory to store up
to ten welding schedules,
the U8 2 can store 255,
plus this panel caters
for customised
synergic lines.
Another feature that contributes to high-quality welds,
even in the hands of less experienced operatives, is the
QSet intelligent welding system that automatically
fine-tunes the welding parameters “on the fly” so the
operative only has to adjust the wire feed speed. In
addition, the LiveTIG start function electronically limits
the start current, and SuperPulse (available with the U8 2
control panel) controls the heat input for bridging variable
gaps with a spatter-free arc. Creep start, gas pre-flow,
and hot start functions all help to provide a soft and more
direct start with less spatter. TrueArcVoltage (applicable
when using a torch from the PSF range) measures the
actual arc voltage at the contact tip to ensure the welding
performance is not adversely influenced by the length of
the interconnection cable, return cable, or the welding
torch assembly.
As well as boosting productivity and enabling lesserskilled
operatives to produce high-quality welds,
the Aristo Mig 4004i Pulse and associated equipment
also reduces operating costs through lower energy
consumption. The COOL 1 cooling unit, used in
conjunction with water-cooled torches, switches off
automatically after 6.5 minutes of inactivity to reduce
energy consumption while the equipment is at idle,
as do the cooling fans in the power source. Furthermore,
the fourth-generation inverter technology achieves a
power factor of 0.94, resulting in further energy savings.
Visit your closest ESAB distributor shop to test weld
our new pulse power source or visit us online at
www.esab.co.uk.
Portable Plasma cutters
combine performance with
ease of use.
Meet our new PowerCut 400 and PowerCut 700 portable
plasma cutting packages suitable for use on all
electrically conductive materials in production, assembly,
repair, and maintenance applications. Well balanced and
with a convenient, comfortable carrying handle, the
PowerCut 400 and 700 can be carried easily from one
work site to the next, or to exactly where it is needed in
the workshop. However, the PowerCut 700 machine can
also be fitted with a CNC interface so that it can be
connected directly to a cutting table.
Despite its compact dimensions (466 mm x 160 mm x
340 mm) and low weight (14.5 kg including the torch), the
PowerCut 400 is a powerful machine with a number of
features that enhance the quality of cut and ease of use.
The maximum material thickness that can be cut when
operating from 230 V is 10 mm for a high-quality cut or
13 mm when the finish is less important. When operating
from 110 V the maximum thicknesses are 7 mm and 10
mm, respectively.
PowerCut 700 has a compact (559 mm x 211 mm x
381 mm), lightweight (21.3 kg including the torch) design
and could easily be taken to the job site. The maximum
material thickness that can be cut is 15 mm for a
high-quality cut or 20 mm when the finish and speed is
less important. Both PowerCut 400 and 700 can also
be powered from engine-driven welders when working
remotely without access to a main power supply.
The Dynamic Arc Control controls the pilot arc when
cutting grate or mesh for continuous operation
without any arc outages. To enhancing the cut quality
and improving the ease of use, particularly when
operatives are inexperienced, the PowerCut 400 and
700 have been designed for drag cutting along straight
edges or around templates. Another user-friendly feature
is the Voltage Booster that helps to achieve drop cuts
on thicker plates.
Each PowerCut 400 and 700 is supplied complete with
a PT-39 plasma torch and a kit of wear parts. The
PT-39 torch has been specially designed to be compact,
lightweight, and ergonomic, with a comfortable grip
and compact head that provides better arc visibility.
For connecting the PowerCut 700 to a table for CNC
cutting applications, ESAB offers an interface kit that
includes a PCB, cable harness, and connector.
The plasma cutters arrive fully assembled – ready to go
out of the box.
Visit your closest ESAB distributor shop to view
our new PowerCut 400/700 or visit us online at
www.esab.co.uk for more information.
11 // PRODUCT NEWS PRODUCT NEWS // 12

New eSAB TIG Torches put
the welder’S NeedS firSt.
ESAB’s versatile new range of TXH TIG welding torches have been designed with the
needs of the welder in mind. They have a highly ergonomic design, are convenient to
operate, and produce high quality results in all common TIG welding applications.
The torches are designed for use with all TIG welding machines that have an OKC
connection. Remote versions will operate with CAN-bus controlled machines.
There is a range of air-cooled and water-cooled TXH torch packages available
including the remote versions. Flexible head versions ensure welding tasks can
be carried out in difficult access areas, while the 401w HD torch is designed for
heavy duty applications up to 400 A.
Welding diameters range from 1.0 mm – 3.2 mm for the TXH 121 torch to 1.0 mm –
4.8 mm for the TXH 401w model. All torches comply with EN60974-7 GOST-R and
CCC standards.
TXH torches can be specified with or without a gas valve and with or without
a flexible neck, according to individual preference and intended usage. The
welding torch heads are lightweight and durable. They have a highly effective
cooling system and are manufactured with high temperature resistant silicone
rubber. Copper components ensure cooler running temperatures, while also
maximising the torch’s current capacity and therefore welding performance.
Visit us online at www.esab.co.uk for more information.
ESAB SEtS nEw StAndArdS
with Aristo Fluid pre-weld
Anti-spAtter.
ESAB’s new Aristo Fluid pre-weld anti-spatter is based on an advanced formula that will help
to prevent spatter and molten metal from sticking to a work piece during welding. This will in
turn reduce the need for subsequent chipping, sanding, and grinding of the work piece thereby
reducing cost and increasing efficiency and productivity.
Aristo Fluid has a high strength formula that is up to three times stronger than alternative
products currently available. The combination of high concentration and high heat resistance,
together with the efficiency of the BOV system, means that Aristo Fluid can offer tangible cost
savings. Add these benefits to a competitive price and Aristo Fluid is set to appeal to many
different markets including plant fabrication and maintenance work, the automotive industry,
civil construction, agriculture, and general fabrication.
Visit us online at www.esab.co.uk for more information.
New WARRIOR
Tech reactive
weldiNg helmet.
Designed for use in all welding applications, ESAB’s
new Warrior Tech welding helmet meet the needs of
welding professionals requiring a high specification,
ergonomically designed lightweight helmet that provides
protection from dangerous UV/IR radiation, heat,
and spatter.
Critical for any welder is the performance of the lens
and with the Warrior Tech, four welding arc sensors
provide high response levels and a wider sensory
coverage than many alternative helmets of this type.
It has a large viewing area of 98 mm x 48 mm and this
wider than normal field of vision increases spatial
awareness. It features shade adjustment between DIN9
and DIN13 with its automatic shade darkening filter (ADF)
lens. This lens also gives the welder optimal viewing
clarity and excellent optical quality.
What have you welded lately?
Submit your welding story and
become a part of our Fabrication
Hall of Fame
We know you’re proud of your work, and we want to see
it! Send us info on the metal masterpieces you’ve created
with ESAB products, and see how they stack up against
your fellow welders across Europe. We may even feature
your story in our next e-newsletter.
Send your story and details together with a picture to
info@esab.co.uk.
All stories published in the e-newsletter qualify the
submitter for ESAB prizes, including the new Warrior
Tech welding helmet.
The helmet offers optimal performance for most
fabrication and out-of-position welding. Its sensitivity
control is a useful adaptable feature when welding
with low amperages, such as when TIG welding, and
ensures a better reaction to darker arc light.
The delay control allows the welder to set how long the
lens stays dark after the welding arc stops. A short delay
will help to get the job done faster during tack welding,
while a longer delay is useful for high amperage welding.
The delay and sensitivity can be adjusted from the inside.
Ergonomically designed for high operator comfort, the
helmet’s headband is fully adjustable over the head and
there are three longitudinal adjustments to increase field
of vision. For enhanced comfort, the angled front pad
sits flat on the forehead to reduce frontal lobe pressure.
The shell has “B” grade impact safety rating.
Visit us online at
www.esab.co.uk
for more information.
13 // PRODUCT NEWS PRODUCT NEWS // 14

Designed for
high productivity
welding.
Designed for high productivity and quality welding applications, the new Aristo ® Mig 4004i Pulse power
source belongs to ESAB’s top-of-the-range Aristo ® family of welding equipment. The pulse function makes
it suitable for advanced welding in aluminium and stainless steel.
New technology gives a footprint that is 70% smaller than conventional power sources. The wire feeder
is offered with a choice of the advanced U6 or more sophisticated U8 2 control panels to suit your needs.
For more information, contact your ESAB representative or your nearest distributor.
ESAB, Hanover House, Queensgate, Britannia Road, Waltham Cross, Herts. EN8 7TF. UK.
Tel +44 (0) 1992 760698 Fax +44 (0)1992 717191 Email: info@esab.co.uk www.esab.co.uk