Svetsaren 1/2008 - Esab

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26 - Svetsaren no. 1 - 2008
A complete and reliable partner for pipe mills. The latest ESAB equipment and consumables for longitudinal welding. EGBERT SCHOFER, ESAB AB, LAXÅ, SWEDEN AND MARTIN GEHRING, ESAB AB, GOTHENBURG SWEDEN. The demand for SAW-welded pipes has grown steadily over many years, with a significant increase in both 2006 and 2007. Worldwide, more than 150 pipe mills produce an estimated 30,000,000 tonnes of SAW welded pipes. When this production is split between longitudinal and spiral welded pipes, we see a ratio of around 57/43%. ESAB is an established, reliable partner in the pipe mill segment, offering flux and wire as well as equipment components and controls. When it comes to welding equipment for the pipe mill industry, ESAB is known to have delivered hundreds of highly efficient power sources, very strong wire feeders, special internal and external welding heads and customised process controllers. ESAB is particularly strong in the retrofit business, boosting the productivity of existing lines by increasing the amount of wires, both internally and externally, and also by exchanging old controls for new process controllers, including data logging and interface to local network systems. Nevertheless, ESAB has never attempted to offer complete production lines. The company’s aim is clearly to stay in welding – ESAB’s core business. However, the drastically increased demand in SAW pipe welding, and our customers’ desire to reduce the number of suppliers, has made ESAB strengthen its focus on the segment and extend its range of products with, for example, specialised internal booms and advanced return current systems. Here, a number of new products are highlighted. They have been supplied exclusively to key customers for longitudinal pipe welding applications - although their benefits are equally valid for spiral welding. Continuous tack welding equipment Once rough formed, pipe coming out of the forming machine, can be tack welded by ESAB’s continuous tack welding equipment. The tack welding process itself is GMAW with solid wire of 3 or 4mm diameter under CO 2 or a mixture of CO 2 with some 5-10% argon. To enable speeds up to 6m/min, it uses a powerful ESAB type LAF 1600 rectifier. This highly efficient power source has a secondary output of 1600A with 44V at 100% duty cycle and can be used for high efficiency GMAW and SAW- welding processes. The welding head is the well proven A6 S Arc Master, mounted on a heavy duty cross slide, enabling adaptation to different pipe diameters as well as the positioning of the welding head in the middle of the weld preparation (Figure 1). The SAW wire contact equipment has durable, spring loaded contact jaws and an extra gas nozzle in front of the contact equipment. Together with a wire straightness device at the in feeding side of the motor, this set-up has the great advantage of the most reliable wire contact combined with a spatter protected gas nozzle. The front mounted laser sensor guides the welding head via the cross slide and is also protected with a spatter shield. ESAB`s PEH digital process controller steers and controls the welding process under given welding parameters. Up to 10 different welding process parameters can be stored for different pipe dimensions, if needed. Internal boom The internal boom has to fulfil many requirements. It needs to carry the welding head, including laser, video system, all current cables, flux support and suction hose, control cables and other parts. It requires the boom to be stable but, at the same time, as small as possible to also fit smaller pipes in 20” dimension. In the past, the maximum length was seldom more than 12m, plus run on and run off plates. Today, we sometimes need up to 18 or even 24m booms (spiral welding), Photo courtesy NOKSEL company Svetsaren no. 1 - 2008 - 27
Page 1 and 2: THE ESAB WELDING AND CUTTING JOURNA
Page 3 and 4: Svetsaren ENERGY Articles in Svetsa
Page 5 and 6: Contents 07 15 18 23 26 32 34 37 Te
Page 7 and 8: Template for monster platform chall
Page 9 and 10: Table 2. Preheat and interpass proc
Page 11 and 12: Figure 4. FCAW of the sleeves - the
Page 13 and 14: Figure 11. Vertically-up welding wi
Page 15 and 16: Port of Marseille sees LNG storage
Page 17 and 18: of the roof, involving an overall c
Page 19 and 20: Figure 1. One of the monopiles bein
Page 21 and 22: equipment and the welding heads get
Page 23 and 24: Zorya-Mashproekt relies on ESAB for
Page 25: 25 ±2° 25 ±2° 4 +1 ring copper
Page 29 and 30: the power source via the welding he
Page 31 and 32: the coating thickness can be reduce
Page 33 and 34: Deformation control was a major obs
Page 35 and 36: ESW Inconel strip cladding - soluti
Page 37 and 38: Mechanised pipeline welding in the
Page 39 and 40: motion, while changing from standin
Page 41 and 42: Cladding of valves for petrochemica
Page 43 and 44: Techint and ESAB Brazil - partners
Page 45 and 46: Table 2. OK 48.08 technical feature
Page 47 and 48: Manufacture of mobile gasoline tank
Page 49 and 50: Table 2. Mechanical properties: but
Page 51 and 52: Belleli Energy SpA reactors at the
Page 53 and 54: Figure 2. Cross section of an SAW w
Page 55 and 56: The Shell Gas-to-Liquids (GTL) Proc
Page 57 and 58: Quality and productivity. Weld qual
Page 59 and 60: FLEXIBLE HEAVY-DUTY SOLUTIONS FOR M
Page 61 and 62: spatter, smaller droplets and pause
Page 63 and 64: ESAB LAUNCHES NEW ORIGO WELDING MAC
Page 65 and 66: TRAMTRAC TM II - A COST-EFFICIENT A
Page 67 and 68: OK FLUX 10.77 - SPIRAL PIPEMILL FLU
Page 69 and 70: OK FLUX 10.18 + OK BAND NICU7 NEW A
Page 71 and 72: Gas Consumable Current Arc voltage

Svetsaren 1/2008 - Esab

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