MECHANISATION AUTOMATION - Esab

More documents

Recommendations

Info

Industrial applicationsThe figures 4 to 9 show projects in which light mechanisationwas used. They are all based on the use of coredwire. Also refer to page 21, reviewing a recent pipelineproject in the Netherlands using Railtrac equipment andcored wire.Figure 8. Welding ofsteel fender piles for asuspension bridge inArgentina. Railtrac andbasic flux-cored wireOK Tubrod 15.27. SeeSvetsaren 2/2003 forthe full story.About the authorFigure 7. Welding of the suspended roof structure of theBenfica stadium in Lisbon. Railtrac and structural all-positionflux-cored wire PZ6113. See Svetsaren 2/2003 for the full story.Juha Lukkari joined ESAB OY in Finland, in 1974, aftergraduating from the Helsinki University of Technology. Hehas held several positions in the company and is currentlyhead of Technical Customer Service.For more information contact: juha.lukkari@esab.fiDoor opening contract in ChinaIn November 2004, ESAB in Laxå, Sweden, sold its firstflash butt chain welding machine to Zhang Jia Kou CoalMining Machinery Ltd Co - China’s largest and mostmodern coal mining chain and equipment producer. Thecompany is a part of China Coal Mining EngineeringEquipment Import & Export Co.The machine is designed for different kinds of chains;from 30 mm to 60 mm bar diameter. The basic chainsare collector links for lifting chains and large coal miningchains, some with one forged and one welded link insuccession.The machine is based on the SVU - series of flash butt weldingmachines, upgraded with a higher clamping force andsome additional useful functions. The machine featuresan automatic setting to obtain a constant secondary voltagewith mains fluctuating +/-15%. Also, the machine adapts tothe temperature of the link (from T room up to 800° C).PRODUCT DATA:Upset force:Clamping force:Transformers (AC):Weight:350 kN480 kN2x 250 kVA12,800 kg.For more information contact:sylve.antonsson@esab.seESAB supplies rail welding equipment to India and CroatiaESAB in Laxå, Sweden has recentlydelivered two automatic flash buttwelding machines for rails; designedto produce long, high quality rails ofall types.The deliveries - through Geismar,France - were to the Bhilai SteelTECHNICAL DATA:Clamping force:Upset force:Max current for standard rail (UIC 60):Weight:Plant in India and HZ- Infrastrukturain Croatia. The Bhilai machine is partof a complete rail welding factorysupplied by Geismar; the Croatiancontract is a single machine order.The ZFR 11 GC 6T machines havebuilt-in trimming units, and include196 Metric tons96 Metric tons70.000 Amps38.000 kgscompressor-type cooling units andexhaust systems. Other featuresinclude PC control with forces andspeeds controlled in closed loopsvia sensors and a high responseproportional valve, and full loggingof all welding parameters andthe most recent 1000 alarms. Thewelding process uses DC- currentwhich gives equal load on the threephases.For more information contact:sylve.antonsson@esab.se10 • Svetsaren no. 1 • 2005
Railtrac flexible tool for Dutchpipeline constructor NACAPBy: Frits Woldinga, NACAP B.V. , The Netherlands and Sjabbe Datema, ESAB Nederland B.V.International pipeline contractor NACAP B.V, with its head office in Eelde, The Netherlands,developed a flexible method for the welding of pipelines on land, utilising two ESABRailtrac FW 1000 welding tractors and OK Tubrod 15.09 flux-cored wire. The advantagescompared with commonly used mechanised pipeline welding systems are found in a lowerinvestment and shorter set-up times before welding. The new method was successfullyapplied on a 17 km pipeline crossing the northern part of the Netherlands.The pipeline, for which the equipment was developed,is in X70 grade steel with a diameter of 42 inch and anominal wall thickness of 14.0 mm. Sections to passunder canals are 16.4 or 19.9 mm in thickness. Weldmetal toughness requirements are min. 40J at -40°C.NACAP developed the system in-house and afterextensive testing official welding procedure qualificationswere made. The equipment comprises some features thatare non-standard to the ESAB equipment and the designincludes an extremely light welding tent.The method uses two Railtrac FW 1000 tractorssimultaneously walking the pipe circumference from 6‘o clock to 12 ‘o clock; clockwise and counter clockwise.The diameter of pipelines in general are smaller thanthe type of applications for which Railtrac has beendeveloped, having originated from shipbuilding practice.The aluminium rail coming with the equipment wouldrequire more fixtures around the pipe circumferenceto avoid buckling when tension is applied. Even theslightest unroundness in the orbit of the tractor wouldhave a negative effect on the weld quality. Instead ofadapting the standard ESAB rail, NACAP decided todevelop its own, more rigid rail equipped with fastcoupling gear.The 2nd adaptation to the equipment, done by ESABat the request of NACAP, involved a change from onedrive wheel to two drive wheels, one on either side of thetractor. This increased the stability of the tractor whiletravelling the pipe circumference at a high speed.The system uses two ESAB AristoMig 400winverter controlled power sources with Aristofeedwire feed units.Figure 1: Railtrac at work.First the root pass, hot pass and two filler layers aredeposited vertically down with MMA with cellulosicelectrodes. The subsequent filling is done with Railtracusing OK Tubrod 15.09 all-position rutile cored-wirewelded under Ar/CO 2mixed gas.OK Tubrod 15.09 has a fast freezing slag that supportsthe weld pool well in positional welding at very highdeposition rates. The slag easily releases leaving behind aclean weld for subsequent passes. One parameter settingcould be applied for all beads in this kind of application.NACAP preferred to use three optimised parametersettings while travelling from 6 to 12 ‘o clock.Svetsaren no. 1 • 2005 • 11
Page 1 and 2: THE ESAB WELDING AND CUTTING JOURNA
Page 3 and 4: Orbital-TIG - a great wayto join pi
Page 5 and 6: joint volume is reduced by a factor
Page 7 and 8: Light mechanisation.Easy and cost-e
Page 9: Figure 4. Manufacturing of stainles
Page 13 and 14: Submerged arc welding of steelsfor
Page 15 and 16: onshore wind towers, whereas the to
Page 17 and 18: Results of mechanical testingThe we
Page 19 and 20: Figure 1. Welding tool with seam tr
Page 21 and 22: Retrofitting of automaticwelding Sy
Page 23 and 24: Mechanised welding of pipelinesBy:
Page 25 and 26: such as that from a rutile flux-cor
Page 27 and 28: Cutting technology in shipbuildingB
Page 29 and 30: Status of plasma cutting.In the que
Page 31 and 32: Improved productivityin automated a
Page 33 and 34: A CENTURY OF INNOVATION16-pound (7
Page 35 and 36: NOMAD finalisedFigure 1. The bridge
Page 37 and 38: OrigoMag C150/C170/C200/C250A recen
Page 40: ESAB ABBox 8004 S-402 77 Gothenburg

MECHANISATION AUTOMATION - Esab

Create successful ePaper yourself

Delete template?

Save as template?