When it comes to the maintenance and upkeep of a manufacturing plant, welding is a crucial factor in most cases. Staying focused on the health and safety aspect of the welding trade will help you to make sure that both your employees and your equipment are kept safe. When welding-related maintenance projects arise, it’s important to follow the correct safety procedures to minimize the risk of any accidents occurring. We’ve put together a list of tips for you to keep in mind when you need to use welding in the maintenance of your plant.
In order to ensure that all safety procedures are complied with, it’s important that employees read all safety manuals for any welding equipment to be used. Unless a piece of equipment is used on a regular basis meaning that employees are practiced in how to use it safely, employees should always take the time to go over the safety instructions for any welding equipment that they have been assigned to use, even if they have used it before in the past. This is especially important if an employee has been given a new piece of equipment to use for a welding project.
Practice Makes Perfect
As with every skill, welding takes practice in order to make sure that the right techniques are used and in a safe manner. Because of this, it’s important that any employees who will be using welding material when needed are given ample opportunity to practice and fine-tune their welding skills. Employees who have not done any welding work for a while will be more at risk than those who have regular practice and are comfortable using the machinery.
It is of vital importance that any employee who will be doing welding work is provided with the essential protective gear, such as goggles, a welding helmet, gloves, and specially designed clothing that will protect welders from the extreme heat and sparks caused by using welding equipment. For great welding protective gear, check out Lincoln Electric's welding store.
When it comes to safe welding, preparation is key. It’s important that all the equipment and materials are properly prepared before beginning a job, and it’s also vital that any tools are checked for any faults which may have arisen that could cause risk or damage. The surfaces to be joined should also be prepared by removing as much dirt, debris and rust as possible, and if a solvent is needed in order to do this, it’s crucial that the area is solvent-free before welding begins. It’s also essential that you clear the space before beginning a job and remove any items that could be a trip hazard. Removing any flammable materials from the area is a crucial step that should not be ignored.
Do you have any further information that you’d like to pass on regarding welding safety when it comes to the maintenance and upkeep of a power or manufacturing plant? Whether you work at a plant or are an experienced welder, we’d love to hear from you in the comments.
Weld Purge Monitors® are an essential tool for the Process Industries with various models serving different levels of weld purge requirement.
There are applications that can be satisfied with Monitors measuring down to 100 ppm and..... for the higher specification industries such as Aerospace, Food and Drinks, Semi-conductor, Biofuels etc that need to achieve oxgyen levels down to 10 ppm there are other models.
One such model has just been developed for the Process Industries and that is the PurgEye® 200 which is now rolling off the production lines partially to meet an order for 30 units from the Far East.
This is a hand held, battery driven monitor that will read very accurately down to 10 ppm.
It is probably the lowest cost Weld Purge Monitor® of its kind even though it contains an internal electro-mechanical pump for drawing samples of gas automatically over the sensor before discharging it to atmosphere.
The lifetime sensor eliminates the need for changing cells once every year or so, subject to the type
of usage the “wet” cells receive.
Alarm signals can be given by the PurgEye® 200 to show when the purge gas level is within or outside the preset range.
The PurgEye® ‘Family Range’ of Weld Purge Monitors® comprises:
- Low cost PurgEye® 100 hand held unit for measuring down to 100 parts per million
- PurgEye® 300 that accurately measures free flowing gas down to 10 ppm and less,
- PurgEye® 500 that uses an internal electro-mechanical pump to draw the gas across the sensor
- PurgEye® 600 which is a computer controlled model measuring from atmospheric oxygen levels down to 10 ppm accurately and...
- PurgEye® 1000 which has a remote sensor for accurately measuring oxygen level down to 10 ppm
- as well as the PurgEye® 200 that is described above
The VIKING™-2 Helmets offer the best optical clarity in the welding industry today
Lincoln Electric has developed a new generation of VIKING™ auto-darkening welding helmets designed to deliver improved optics and superior comfort. Backed by a three-year warranty, these helmets offer better optical quality as well as durability in tough welding environments.
The auto-darkening cartridges in the VIKING™-2 series offer a top EN 379-1/1/1/1 optical clarity rating. The ratings correspond to four important categories. Each category is graded on a scale of 1-3, with a score of 1 representing the highest optical quality rating and 3 representing the lowest. The new VIKING-2 Helmets score a perfect 1/1/1/1 clarity rating.
- Improved optical clarity with a perfect 1/1/1/1 rating
- Pivot-style headgear for greater comfort
- Three-year warranty
The best-in-class optics, improved headgear and three-year warranty are standard on the company’s VIKING 3350, 2450, 2450D and 1840 -2 Series helmets.
Thermatool has recently completed supply and installation of a CFI Solid State High Frequency Welder at Marcegaglia UK’s manufacturing facility in Dudley, West Midlands UK.
The 200KW Solid State HF Welder was selected by Marcegaglia UK as a result of an upgrade project to its electro-welded tube sections. Mark Thomas, Production Manager at Marcegaglia UK comments; “The decision to upgrade was not taken lighlty and involved a lengthy discussion, evaluation and decision process. We were all given opportunities to evaluate the welder and Thermatool were happy to undertake and provide energy consumption comparisons. Following an initial production assessment we have seen that the right decision was made.”
Thermatool engineers were at hand to provide on-site support, service and operator training throughout the installation and commissioning process. Wayne Hine, Thermatool Director of Sales adds; “ Following acceptance of the CFI welder now in production at Marcegaglia UK’s facility, we will now continue to work with the production staff providing further equipment training packages at Thermatool’s European headquarters in Basingtoke. The addition of a Thermatool CFI Solid State HF Welder to Marcegaglia UK’s electro welded tube sections ultimately allows for a greater throughput of tube being produced per shift, controlling repeatability and efficiently delivering an improved, value added end product.”
Marcegaglia UK, part of the worldwide Marcegaglia Group, is devoted to the manufacturing of high quality electro-welded carbon steel tubes for a wide range of applications. The production lines at Marcegaglia Uk are equipped to offer a wide range of specific tube finishes. Tubes are non-destructive eddy-current tested inline to prevent weld seam defects - Additionally, destructive testing includes tensile, flare and flattening. The 28,000m2 plant has a yearly output capacity of over ninety thousand tonnes of finished products, making the UK’s largest precision tubes manufacturer.
British company PWM (Pressure Welding Machines) Ltd celebrated 30th years of service to the wire and cable industry on stand 9B41 at wire 2014 on the 8th April 2014
PWM, based in Kent, England, designs, manufactures and supplies high-performance cold welding machines and dies to wire and cable manufacturers worldwide.
PWM’s first machines were small, manually operated cold welders for joining fine wire and strip. The M10, M25, and M30 models for wire sizes 0.10mm to 1.80mm, are all still produced today.
Over the years, PWM gradually expanded its range and introduced larger, powered cold welders, including the P1500 rod welder for joining large rod sections up to 30mm diameter. Recent innovations include the portable air/hydraulic powered HP100 and HP200 machines, which provide effortless welds on wire and strip 1mm to 5mm and 2mm to 6.50mm. All PWM machines and dies are precision engineered in-house to stringent quality standards by PWM’s own team of skilled engineers and technicians.
PWM now employs 19 people in the UK and has a worldwide network of experienced agents who, together with the UK team, provide fast and effcient on-site support with full back-up and after-sales service.
PWM’s on-going research and development programme ensures that it continues to offer wire and cable manufacturers the most advanced and comprehensive range of cold welders in the world. To explain the cold weld process, the company recently developed a series of videos demonstrating the technique, which can be viewed at www.pwmltd.co.uk .
Two-year extended warranty offer provides quick repairs and peace of mind to welders
As the only extended warranty program in the welding industry, Lincoln Electric’s welding equipment warranty extension program offers repair for an additional two years, building on the standard three-year warranty included with the purchase of the company’s welders and wire feeders. For just a small percentage of the machine purchase price, the extended warranty cost includes the price of parts, labor and any required shipping. When a customer elects to purchase the two-year warranty extension, they are protected by the most comprehensive warranty in the welding industry – the only equipment warranty program to cover parts and labor through five years of ownership.
Making use of the two-year extended warranty is simple. Visit www.lincolnelectric.com to locate one of more than 500 certified Lincoln Electric field service shops nearby and arrange for shipment or delivery. Provide a receipt showing date of purchase, or allow the shop to check the serial number date code to confirm the machine is still under warranty. Then, the shop will file a claim and repair the machine – with no additional cost to the consumer. If parts need to be shipped to the field service shop from Lincoln Electric, more than 95 percent of made to stock parts are shipped next day.
“In the rare case that your machine develops a service issue, you want to know you’ll receive a quick repair – and that getting the machine fixed will be an easy process,” says John Weigman, service manager at Lincoln Electric.
“We’ve put the full effort of our company behind this program, training our certified repair shops to recognize problems quickly and provide fast service to our customers,” Weigman adds. “Taking advantage of the extended warranty provides an effective, inexpensive way for welders to have peace of mind for an additional two years, with minimal added expense.”
To purchase an extended warranty, consumers can talk with their distributor, or visit the Lincoln Electric website. The two-year extended warranty can be purchased up to two years after initial machine purchase with no increase in price. The total warranty period begins on the purchase date – consumers are encouraged to keep the extended warranty certificate and their purchase invoice as evidence of the warranty. The extended warranty program is available in the United States and Canada.
In the field of welding, every application has different technical requirements. Each welding torch manufacturer has to find the best solution to meet customer's requirements according to the alloy to be welded, the bevel and the type of the root, and the working conditions: the perfect weld without any porosity, without traces of discoloration or residues, thus avoiding further expensive interventions or even the scrapping of the work piece.
Part of the welding and cladding lance ranges
Polysoude has taken this problem into account: a problem which costs a large amount of time in terms of research and development. One would have thought that an additional amount of shielding gas could guarantee an excellent result, but the result would only be a modification of the behavior of the gas streams. Due to the empirical experience, this company is nowadays recognized as a specialist in this field for many industrial applications. Over the time a great variety of specific torches have been developed, for automated or mechanized TIG welding and for cladding solutions.
Different ranges of torches have been designed & manufactured for both of these technologies, and validated every time in terms of performance rates for duty cycle, temperature resistance, shielding protection and camera transmission. In this way, Polysoude has created a complete catalogue for welding torches based on twelve different basic designs, which will be completed by the welding lances that perfectly suit the customer’s applications in terms of capacity and length.
But the final certification of this range of welding torches does not only rely on the experience: since for every torch, additional tests have been developed in order to optimize the final result. Jean-Pierre Barthoux, Head of Technological Department, explains: “Whilst developing a new type of torch, it has always been very difficult to examine the behavior of the different gases because of high luminosity and heat near to torch. Video transmissions helped us to understand the welding operation, but we lost a huge amount of time in order to obtain the perfect result for every new application.”
Each torch has been examined with specific tests in order to analyze the various gas flows and forms. This optical test by striae scope, (also called Schlieren's test, after the name of the inventor), reveals the density of the flows, or more precisely the refractive index by deviation of the light. The deviation is analysed with the help of compressed whirlwind, differences in temperature or chemical composition. With the introduction of this technology, the engineers of Polysoude are now able to foresee gas behaviour and its influence on the final welding result.
Hence, the experience and validation of this new technology enable Polysoude to propose a complete range of torches and accessories within a modular system, which can be adjusted for any customer’s request. The advantages are clear: less time needed for research and development, optimized torches in terms of energy and gas consumption. The torch is tested by striae scope before being constructed.
Kent Corporation – North Royalton, OH has supplied a second coil end welder to a large roll-former in India. This is one of over 58 Countries Kent has supplied machinery to for eliminating coil related down time. The Coil end welder eliminates rethreading the roll form, tube and stamping lines to reduce scrap, tooling wear and the down time spent rethreading the line. The coil end welder has been a huge improvement over the existing methods used by this customer, which has resulted in better, faster and more consistent end welds. The machine offers a three bladed crop shear that gives a distortion free cut. The higher quality sheared ends results in easier and better fit up for smoother end welds that will pass through tooling with no problems. New advances in the TIG welding technology allow for welding mild steels, aluminum, copper, and coated materials.
Kent Corporation has been providing quality entry equipment, strip end welders, accumulators, high speed cold saws and tube mill consumables to the strip processing, tube mill, roll forming and stamping industries for more than 40 years. Kent has delivered over 6,000 pieces of equipment that are currently running successfully, with applications that vary from .008”(.2mm) to .750” (19mm) thick and from strip widths of 0.5” (12.7mm) to over 80” (2032mm wide).
January 2014 Strong Hand Tools®, manufacturer of innovative Strong Hand Tools® Welding Clamps, Magnets, Pliers and BuildPro™ Welding Tables, is proud to introduce the New BuildPro Malleable Cast Iron Clamping Squares. The 4-face Heavy Duty Clamping Squares feature a total of 26 mounting holes over three surfaces for unlimited options in fixturing with the BuildPro Modular Welding Tables.
These new Heavy Duty Clamping Squares are compact, and easy to handle with a slim, space saving profile that saves valuable tabletop space. Use the 26 mounting holes to stop, locate, clamp, or square up stock at 90°. An extra long mounting slot allows for adjustable mounting, and can easily accommodate two mounting bolts for greater stability.
Insert BuildPro Clamps into the mounting holes on the two side walls or the top surface of the Clamping Squares for vertical or horizontal hold down clamping. The BuildPro Malleable Cast Iron Clamping Squares are available in left and right facing models.
BuildPro Modular Welding Tables feature a tabletop surface of CNC machined 5/8 holes in a 2” grid pattern on precision ground steel plates for fixturing at any point on the table.
Thick wall chrome steel pipe joints, as used in the power industry for high pressure high strength pipe work, need to be pre-heated for welding and probably need a post weld heat treatment too.
Weld joints of this nature need to be purged of oxygen and welded in an inert gas atmosphere, to prevent oxidation, slag formation etc., that leads to loss of corrosion resistance and undesirable change to the metallurgy.
With the high temperatures and length of time at temperature needed in the pre-heat, weld and post heat treat cycles, most weld purging systems are unsuitable.
However, Huntingdon Fusion Techniques, HFT®, has now developed “HotPurge™” Pipe Purging Systems, for use up to 300ºC (572ºF) for 24 hours. (The material used is rated up to 700ºC (1,292ºF)
HotPurge™ is based on the company’s world famous Quick Purge®II design that has been in wide use for many years, but adapted for use at high temperatures.
This system is available for pipe internal diameters (i.d.) from 4 – 96” (100 – 2,500 mm). Each Hotpurge™ is made to size and has a tolerance of +/- ½” (12 mm) because of the restrictions of heat proofing material.
Features of the HotPurge™
1.0 The central large collar that dramatically reduces the space to be purged and makes it easier to reach the lower oxygen levels faster.
2.0 Four pull handles are securely attached to each dam, secured with the Kevlar thread that will withstand a pulling force of 1.000 lbs on each handle.
3.0 The most stunning feature of the the HotPurge™ system is the PurgeGate® to prevent over inflation.
PurgeGate® is a clever, world wide patented invention that allows users to simply connect the Hotpurge™ system to any source of compressed inert gas and simply turn it on to whatever flow or pressure they wish.
PurgeGate® will protect the dams from over inflation or bursting and allow the user to deliver whatever flow they like, using the one gas source.
No matter how high the user raises the pressure in order to deliver more flow, PurgeGate® prevents the pressure going to the inflatable dams, but allows the increased flow to make a faster purge.
PurgeGate® is guaranteed for life.
HotPurge™ Pipe Purging Systems can be used over and over again for specialist weld purges on power industry piping, that will keep the oxygen levels below 100 parts per million throughout the welding cycle.
China's importance as a prospering market for international joining, cutting and surfacing technology is growing steadily: the BEIJING ESSEN WELDING & CUTTING, the leading trade fair of this industry in the Asian region, attracted more exhibitors and visitors in 2013 than ever before. "Impressive confirmation of our strategy to also anchor the world's leading fair SCHWEISSEN & SCHNEIDEN held in Essen in future markets through offshoot events and to develop new sales opportunities for our exhibitors," explains the Managing Director of Messe Essen, Egon Galinnis.
At the 18th BEIJING ESSEN WELDING & CUTTING, a total of 945 companies from 28 countries took the opportunity to show their latest technologies in the Chinese metropolis of Shanghai – once again 1% more than the record year of 2012. There was also growth in the number of guests at the fair: 24,284 trade visitors from all over the world use the fair as an information and ordering platform – over 8% more than a year ago.
The oldest foreign offshoot of the world's leading fair, SCHWEISSEN & SCHNEIDEN, which alternates every year between Beijing and Shanghai, once again offered exhibitors and visitors a comprehensive overview of the market in 2013. The varied offering, for which the fair yet again increased its area to over 96,000 m², ranged from ultramodern joining, cutting and surfacing technology, control systems and testing instruments to workplace equipment.
Exhibitors and visitors were extremely satisfied with the fair. Intensive contacts, important purchase deals and strong demand characterised the 18th BEIJING ESSEN WELDING & CUTTING, as the organisers Messe Essen, the German Welding Society (DVS – Deutscher Verband für Schweißen und verwandte Verfahren e.V.) and the Chinese Mechanical Engineering Society report. The reception at the German Consulate, which was attended by representatives from the Delegation of German Industry and Commerce (AHK) Greater China, in addition to German exhibitors and representatives of the organisers, was rated as very successful by the roughly 90 guests.
The BEIJING ESSEN WELDING & CUTTING was rounded off by an informative supporting programme. International researchers, manufacturers and users from the fields of joining, cutting and surfacing technology met in six conferences, congresses and forums to share and exchange knowledge and experience. Subjects were, for example, efficient welding technologies and automation processes.
Having been manufacturing Tube and Pipe Weld Purging Systems since 1975 Huntingdon Fusion Techniques® (HFT™) has evolved the science of Weld Purging to new levels.
Along with other recently announced scientific developments in its Weld Purge Monitor® series, the Company has now reached the Fifth version of its Tube and Pipe Weld Purge System designs by launching the new PurgElite® range of Tube and Pipe Weld Purging systems for diameters from 1” to 24” diameter inclusive.
These systems are suitable for all industries using tubes and pipes from the very highly specialist Biogas and Semiconductor fields, right along to other industries such as those where the pipework is less critical.
In particular, PurgElite® systems can be used in high quality tube and pipework where the internal surfaces may be polished to ensure minimum entrapment and low corrosion resistance. With the new Intacal® specially designed in line purge valve and the synthetic hose protection, there are no metal parts to scratch the tube or pipe surfaces.
IntaCal® needs no setting or controlling, but is precisely manufactured for the PurgElite® method of weld purging.
This new range comprises 15 models for tube and pipe sizes from just under 1” to 24”, each one overlapping the range of the other so that all internal diameters from 20 mm up to 610 mm are covered.
The new series has a number of major advantages over previous weld purging systems and has taken into account the evolving technology in all market places where much higher specifications of materials and work finish are available and expected.
The groundbreaking key feature is the development of an in line purge gas release valve that is required to purge the chamber between the two dams once they are inflated. Intacal®
This leads to the advantages mentioned above, namely:
1.0 The ability to manufacture a 1” system
2.0 Absence of protruding metal parts that scratch the insides of electro polished tubes and pipes
3.0 Elimination of the burst bladder problems that occur with other systems
4.0 Greater flexibility because the complicated valves still used by others, have been eliminated.
5.0 Faster purging using less of the expensive inert purging gas
6.0 No complicated valve to set and to mis-function and no loss of time at the start up of jobs.
7.0 Lower manufacturing cost
Other features of the PurgElite® system include:
B. High Tech, high temperature resistant, synthetic gas hose
C. Glow strip positioning band
D. Ease of pulling around bends and elbows in complex tube and pipework systems
E. Selection of Low Vapour Pressure Materials
Low Profile Valve:
1” diameter tube and pipe weld purging:
For the first time it is possible to locally purge 1” diameter tube and pipe welds with an inflatable tube and pipe weld purging system, instead of having to fill up complete systems with expensive inert weld purging gas.
The 1” PurgElite® Tube Weld Purging System will be a valuable welding accessory to manufacturers of many stainless steel, Titanium and Nickel Alloy tubular systems.
Absence of protruding Metal Parts:
No scratching: Particularly of expensive electro-polished tubes and pipes:
Weldpurging is mostly carried out on Stainless, Duplex and Chrome steels as well as Nickel and Titanium alloys.
When internal tube and pipe surfaces are scratched by metal parts on old fashioned weld purging systems, there will be a loss of corrosion resistance that cannot readily be repaired.
As well as negating one of the critical purposes for which the material was selected, scratches cause interruptions to the flow of the gases or liquids inside and leave resting places where bacteria can multiply.
The absence of protruding metal parts with the PurgElite® system completely minimises the risk of scratching and damaging the insides of valuable tube and pipe systems.
Manufacturers of High Purity Systems and those with some other critical applications will use internally electro-polished tubes and pipes making the PurgElite® system even more valuable and more essential to prevent scratching.
Elimination of burst bladder problems:
Other types of inflatable pipe purging systems have large valves that are often set incorrectly leading to frequent problems of burst bladders.
The new PurgElite® system completely overcomes that problem with a different type of system completely, for inflation and purging.
The PurgElite® system of Tube and Pipe weld purging systems, has eliminated the old style inflexible metal braided hose and substituted it for a new technology high temperature resistant, flexible gas hose protector connecting the two purge dams.
This special high temperature resistant weld purge hose protection material is heat resistant up to 700 degrees. In the event of hot liquid metal droplets falling on the hose protection, it’s intumescent properties make a heat barrier to prevent damage to the purge hose, thus avoiding the risk of loss of purge quality and the potential loss of a weld joint.
The greater flexibility of the systems with this non metal hose gives operators the freedom to pull PurgElite® systems around tight bends and through complex tube and pipe fabrications.
Faster Weld Purging:
With the smaller volume, simple gas release valve that uses mathematically calculated designs, the purge gas will be released faster and in greater quantities permitting fast purging of the volume below the weld, without creating the turbulence and long purge times associated with other devices.
When used with one of the PurgEye® Weld Purge Monitors® the PurgElite® systems provide the operator with the perfect combination to purge and monitor oxygen content to achieve the fastest and most ideal conditions for welding to begin.
The savings made by using less of the expensive inert purging gas, along with the savings achieved with shorter purging time, will help to pay for these products in just one weld.
No complicated valve to set and no loss of time at the start up of jobs.
The specially designed PurgElite® valve system allows operators to use their systems immediately without having to follow complicated valve setting procedures. Such work causes loss of production time and invariably leads to errors and failed systems.
The PurgElite® systems are totally and simply plug and play. Plug in the inert gas supply and purge the weld, more than halving set up time.
Lower Manufacturing Cost:
The new low profile, mathematically designed PurgElite® gas purge valve is a single in line item that replaces a costly valve with elbow fittings and other connectors that may even separate during welding.
In addition, the high temperature resistant flexible connection hose replaces and expensive metal braided hose with costly fittings.
Summed together, these savings allow HFT to bring the PurgElite® range to the market place for lower costs than ever before.
High Temperature resistant hose:
The heat build up in the welding cavity is such that the gas hose connecting the two dams has to have a high temperature resistance.
PurgElite® weld purge systems have a newly developed synthetic material capable of withstanding a temperature of 700 º C (c 1,300ºF) that will withstand even hot metal dropping on it by building an intumescent layer.
Replaceable Glo Strip band:
Once PurgElite® systems are inside a tube or pipe system, they can be pulled around from Joint to joint and positioned correctly and easily. This has been made possible by the fluorescent glo strip fitted to the centre of the purging system.
Welders can see through the pipe joint into the internal dark area, whether clamped or tacked ready for welding and view the purge system as it comes into place, with the replaceable glo strip immediately below the weld.
Low Vapour Pressure Materials:
Employing latest material developments (HFT) has selected lower vapour pressure materials to ensure that the outgassing rate into the weld zone will be reduced to the barest minimum during welding to protect the molten weld pool from oxidation and the problems arising.
For larger diameters of Pipes, Huntingdon Fusion Techniques Limited manufactures its rugged Argweld® Quick Purge® Systems to suit diameters from 8” to 80” (200 – 2000 mm
The design and manufacturing of welding equipment for nuclear power production is one activity among Polysoude’s wide range of applications. In this field, the company is involved from the first stage up to the very end.
Most of the piping must be installed and joined directly inside the plant under construction, which means restricted access to the welding areas and the necessity of all-position welding. These conditions are perfectly met by the orbital welding equipment. Mobile power sources are adapted to the harsh on-site conditions including humidity and unstable energy supply; with open orbital welding heads and low profile open carriage-type welding heads.
Nuclear fuel fabrication
The final processing of enriched solid uranium hexafluoride (UF6) is carried out in nuclear fuel fabrication facilities.
The thin-walled tubes which are used to produce these rods usually consist of a zirconium alloy. The extremities of the tubes are sealed gas-tight by means of welded end caps. The weld is carried out without the addition of filler wire.
Nuclear power plant
The components of the primary cooling circuit of a nuclear power plant belong to the Nuclear Island. The welding of the heavy components is carried out as far as possible during prefabrication in a workshop using stationary welding equipment. For example, the core barrel is placed on a turntable and rotates during the weld operation; two welding torches are installed opposite on column and boom devices and weld simultaneously. Narrow gap welding equipment and control devices for the synchronisation of the weld cycle and the different movements are designed and manufactured by Polysoude.
The inner surfaces of the reactor vessel and the steam generators are protected against the corrosive attack of the coolant by a resistant layer, the important surfaces are commonly coated in an economical manner by strip cladding.
Special attention needs to be paid to the construction of the reactor vessel head. In particular, the top and bottom parts are complex components with numerous nozzles for control instruments and the Control Rod Drive Mechanism (CRDM).
To connect one of the four CDRM tubes, in the first step carbon steel is welded on the outside of the vessel head until a flat circular surface is attained. During the second step a circular cladding operation with low alloy steel wire is carried out until the specified height of the stud is reached. During all operations none of the welds are in contact with the coolant and all carbon steel surfaces are protected.
The central element of modern steam turbines, the rotor with a length of up to 20 metres and a weight of up to 350 tons. To complete the heterogeneous joint, the rotor segments are super positioned and the buttered sides are then welded together using the TIG hot wire narrow gap technique.
Maintenance and repair
Preventive maintenance and professionally carried out repairs are essential for the safe and sustainable operation of nuclear power plants. The improved design of delicate constructions, helps to avoid unscheduled downtime. Mechanised, remotely operated welding equipment allows respect of the specified procedures and helps to maintain the man-rem exposure of the repair personnel at a low level.
Recycling of used fuel and sustainable nuclear waste disposal
Polysoude is involved in the development of methods to seal the huge transport canisters lastingly using specific welding procedures.
Pdf of the artcile can be download from the link below
Maintaining subsea pipeline integrity is absolutely vital for safety and commercial reasons – shutting down a defective pipeline could potentially cost millions of pounds a day – and this is where hyperbaric automatic orbital welding systems can be deployed.
Reducing the risk to divers must be part and parcel of any operational regime. Arc Machines Inc’s (AMI) automated orbital welding equipment can help minimise potential dangers divers face while they are undertaking subsea maintenance work on pipelines.
AMI, which offers the widest range of automated orbital welding products for subsea activities, has over three decades’ of experience in the offshore industry with its equipment being used in all parts of the world, including high pressure clad pipelines for Elf-Franklin, the Troll/Heidrun project in the North Sea and the Hondo firewater systems off the coast of California.
However safety conscious subsea contractors are, divers still have to be routinely deployed at depths of up to 180 meters of water to carry out repairs to ensure maximum uptime of pipeline flow, particularly where sour gas is concerned as it contains significant amounts of hydrogen sulphide (H2S) making it very corrosive to normal pipeline materials.
Automated orbital welding can minimise welder diver intervention as it can be used in dry hyperbaric conditions which are conducive for higher quality welding, while still maintaining the optimal weld requirements, something divers may find difficult to match due to the issues they face, such as the safety element of decompression sickness.
This remote welding application helps keep the risks associated with subsea pipeline activities closely controlled and as low as possible. Basically, deploying automated orbital welding equipment minimises the diver activity in the habitat where the weld is to be performed on the pipeline.
Typically oil and gas subsea pipelines are up to 36in in diameter, making them ideally suited for all-position, automated welding of pipe for hyperbaric GTAW process. The gas tungsten welding method gives a more refined weld in terms of quality for non-destructive testing and examination (NDT and NDE) pass standards. There is also less rework in terms of grinding out stop starts and cleaning out between passes.
AMI has adapted its M52 heavy duty and M15 weld heads, for subsea conditions. These weld heads are compatible with AMI’s versatile and easy to use M415 power supply. The AMI weld heads have high precision vision systems that can provide accurate monitoring of the welding operation and enable a remote post-weld visual check to determine weld acceptance.
Utilising automated orbital welding for work on subsea pipelines allows the welding to be performed with increased level of accuracy, when operating from a hyperbaric dry chamber. Typically the habitat would accommodate two diver welders and the weld head. The power supply is usually located in a chamber adjacent to the habitat to provide the welding power and control for the weld head. This frees up the diver welders present in the chamber to oversee the welding operation.
AMI’s Technical Sales Manager, John Morris, said: “Our welders are rugged, flexible and functional but above all extremely reliable. A remote automated weld head is far safer and more accurate for subsea welding. Additionally, weld integrity and the ability to adapt to exotic materials are critical.
“The accuracy and consistently high quality welds achieved by the AMI weld heads, power sources and control systems mean that the subsea industry does not have to rely on manual welders to complete the welding operation.”
Ensuring the safest method is used for sealing off any damage, or for connecting underwater piping systems in potentially hazardous conditions, is an essential part of the operational safety case for the offshore industry. If this can be done remotely it removes a lot of the risks divers face.
Messe Essen Will Bring International Joining Technology on to the South American Market
After the successful premiere in 2011: The BRAZIL WELDING SHOW will invite the specialist world of welding technology to São Paulo for the second time in the autumn. In the most important industrial centre in Brazil, Messe Essen will, with its Brazilian partner Aranda Eventos e Congressos and the ideal sponsor DVS - Deutscher Verband für Schweißen und verwandte Verfahren e. V. ("German Welding Society"), stage the foreign subsidiary of the world's premier SCHWEISSEN & SCHNEIDEN fair in the biennial rhythm. In the autumn of 2013, it will take place on October 1 - 4. A large number of trade visitors may be expected: Corte & Conformação de Metais, South America's largest trade fair for metal processing, will run at the same time. In 2011, both fairs attracted around 13,000 decision takers from international companies.
Brazil is a growing market with optimum prospects for joining technology. Bundesverband der Deutschen Industrie (BDI - "Federal Association of German Industry") is expecting that, by 2030, the BRIC state will invest more than Euro 2.8 trillion in infrastructure and construction projects - above all, in airports, roads, railways and waterways. According to BDI, the energy sector is also to be extended with the focus on gas and oil. With the BRAZIL WELDING SHOW, Messe Essen is opening up to the joining industry the opportunity to exploit a booming market.
Federal Government Will Promote German Cooperative Booth
Because of the good response to the premiere, Messe Essen and its joint venture partner Aranda Eventos e Congressos have considerably enlarged the BRAZIL WELDING SHOW 2013 - now to an exhibition area of 10,000 square metres. German companies which would like to introduce their welding technology innovations to the growth market of Latin America will also be able to present themselves together at the international trade fair. On the initiative of DVS, a cooperative booth will be set up at the BRAZIL WELDING SHOW 2013 and will be promoted by the Federal Ministry of Economic Affairs. Registrations will be possible until May 31, 2013.