Svetsaren_nr2 definitief (Page 1) - Esab

are being secured from Western Europe, the Far East
and the USA, as a result of growing international
recognition. CIMTAS now constructs regularly for
clients such as Bechtel, Framatome-Proser, MHI, GE,
Cargill, NEM, CMI, UOP (Europe), GE Hydro, FWI,
KTI, Technip, KBR, BP, BASF, UOP(USA), Nuovo
Pignone. Quality, in-time delivery and customer
satisfaction are central elements in the company
philosophy, whereas internally a zero accident target
and an environmental protection plan are given high
priority using a consistent awareness campaign.
ESAB and CIMTAS
Serving a dynamic fabricator such as CIMTAS calls for
the availability of a contact person and nearby stock. The
day-to-day business with CIMTAS is handled by ESAB’s
local dealer Özmetal, which is located in Istanbul and
houses a substantial stock of consumables, equipment
and spare parts. However, when new solutions are
needed, ESAB’s representative office acts as an
intermediary between CIMTAS and the many resources
of ESAB worldwide, based on an understanding of the
client’s business and needs. In recent years, this has
resulted in a mutually satisfactory partnership with
knowledge sharing, many improvements and steadily
increasing welding and cutting productivity.
The organisation of welding
The Gemlik works employs around 240 welders and
three EWEs. Welder education, certification and
project training are done internally at the CIMTAS
Training Centre, which is well equipped with a
representation of the 110 MIG/MAG power sources, 26
single-wire and tandem SAW installations, 70 SMAW
units and 150 TIG machines which are used in the
workshops. The company has access to its own
metallographic and mechanical laboratory.
Apart from windmill towers, the mainstream of projects
at the Gemlik works comprises heat recovery steam
generator modules and power piping spools, involving a
great deal of pipe welding in CMn steel, various creep
resistant grades and stainless steel, including advanced
grades like P91, as well as nickel alloys.
Base materials are cut and bevelled in the semifinishing
hall and are taken to the various manufacturing
halls by separate routes for each project. CNC
plasma equipment is used to cut stainless and high-alloy
pipe and plate and to cut the branch openings in carbon
steel pipes. Various types of oxyfuel cutting equipment,
including CNC, are available for products of all kinds.
Power piping spools and manifolds are produced in
both low-alloyed and stainless steel. In this case, SAW
is used for the circumferential welds and the
attachment of flanges using ESAB columns & booms,
rollers and turntable installations and LAE 800 power
sources (Figure 1). Manual TIG (using turntables) and
SMAW is used for the numerous branch connections,
fittings and flanges with ESAB consumables corresponding
to the base materials.
Figure 1. Circumferential welding of a manifold.
Figure 2. A complete ESAB solution for the
mechanised TIG welding of stainless pipes.
Mechanised TIG (Figure 2) is used in the stainless
piping shop, producing increased TIG productivity at
the required weld quality on larger pipe-pipe and pipeflange
connections. The TIG hot-wire process, with a
self-developed fixturing and purging device, is used to
weld alloyed steel casing panels.
ESAB orbital TIG welding units are used in tubeto-sheet,
pipe-to-pipe and header-to-stub welding in
the production of heat exchangers, boilers and pipe
46 • Svetsaren no. 2 • 2002