TPT May 2013

Technology News

Arc Machines automated orbital welding equipment improves heat exchanger production

cooled heat exchanger. Because restricted access to the air cooler tubes limited the amount of manual welding that could be used during the manufacturing process, GEA ordered two of AMI’s Tube Welding Model 207 power supplies, together with the M9-2500 and M9BT-1500 weld heads, helping the company to complete the contract a month ahead of schedule.  GEA’s international welding engineer, Angel Krustev, said: “The quality of the welds is outstanding. We welded more than 1,000 welds on 1" tubes in space with very restricted access. It reduced the manufacturing time by up to 75 per cent and has tremendously increased our productivity.” Meanwhile, Wellman Hunt-Graham, the UK’s largest manufacturer of shell and tube heat exchangers, installed four of AMI’s M227 power supplies and M6 weld heads, following the securing of a major contract from one of Britain’s biggest petroleum companies. Wellman Hunt-Graham identified AMI’s tube-to-tube sheet equipment for the job after its client specified automated welding. Following rigorous testing and pre-purchase welding trials, all four automatic systems were deployed welding 1.000"x0.065" Duplex tubes in 22Cr for one of the biggest refineries operating in Scotland.   Pipework in petrochemical plants and power stations can consist of a wide range of materials, including

EFFICIENTand accurate welding of heat exchangers in the power generation, oil and gas and process industries are crucial for ensuring safe operation, which must always be a priority, but for also keeping downtime to a minimum, while maximising productivity. High performance automated orbital welding systems will boost productivity as well as assure proficient and cost- effective arc time in welding industrial heating and cooling equipment, which must be fabricated to a very high standard to meet safety and operational requirements. Arc Machines Inc (AMI) has a long history of developing automated orbital welding applications for use in the manufacture of heat exchangers. AMI’s tube-to-tubesheet weld heads have performed millions of welds on a range of materials, enabling manufacturers to meet tight deadlines and stringent quality requirements. By deploying automated orbital welding, the biggest supplier of air- cooled heat exchangers in South Africa reduced manufacturing times at its plant in Johannesburg by up to three quarters, winning the company more orders and helping it receive a global innovation award. GEA Aircooled Systems turned to Arc Machines for automated orbital welding equipment after winning a major contract from a South African petrochemical giant to supply an Incoloy 825 alloy air-

chromium, stainless steels, duplex and low alloy steel; it thereforemakes sense to implement and utilise automated orbital welding technology that enables heat exchanger manufacturers to guarantee a safe, methodical and efficient welding operation on any TIG weldable material. AMI’s Model 96 tube-to-tubesheet weld heads are capable of fusion welding a range of materials including stainless steel, through to reactive grades such as titanium which requires 100% gas shielding during the weld cycle. The Model 6 weld head, which includes radial action AVC and on- board wire feed, is used for heavier applications where additional filler wire is required to create strength fillet welds to meet the requirements of higher in- service pressures. Arc Machines – UK Email: john@arcmachines.co.uk 
 Website: www.arcmachines.com

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M ay 2013