Stub- In September of last year, ESAB
Asia/Pacific managed to obtain an
order for duplex consumables for
the building of chemical carriers.
The customer is the Qingshan
Shipyard, in the city of Wuhan, 750
km east of Shanghai. The city is
built on both sides of the large
Yangtsekiang river, where another
river, the Han Shui, also joins the
Railtrac was the only option The order is from a European
shipowner and the size of the ship is
complete the job, which required
~ 6.800dwt, indicating that the
520 kg of consumables. Stringer
amount of duplex consumables will
beads were deposited to control
be about 35MT. The plate material
heat input. The wire OK Tubrod
is standard 2205 from CLI. ESAB
15.13 was set at 33 V and 240 amps
will supply the following
with a stickout of 18 mm. The travel
consumables: OK 67.62, OK 67.50,
speed was 55 cm/min to 70 cm/min,
OK 67.60, OK 14.27, OK 14.22, OK
depending on the desired build-up.
16.86 and flux 10.93. The ship is
The interpass temperature was
being built according to GL rules.
maintained at 300°C. The weld
The project team, consisting of
deposit was checked continuously
people from different countries, is
by UT for cracks and so on
running extensive support activities
At Petron Emirates, an oil and gas Railtrac once again proved its
for the yard. The programme
industry in Dubai, there was an efficiency and it was a great
consists of assisting with pWPSs,
urgent need to restore the walls of a experience to bring the project to a
training personnel - both engineers
regenerator. The regenerator successful conclusion as man and
and welders, engineering support,
converts sulphur into sulphur machine raced against time during
production start-up support, 24-
dioxide, So2, at a temperature of the shut-down.
hour telephone support and a six-
500°C, which is then used in the
month schedule to make visits to
processing of crude oil. The inside
Facts about Railtrac assist.
lining of ceramic is supposed to
Railtrac is a modular system with This is a very good example of
maintain the So2 in gas form, but,
many different components that practical work according to the
due to temperature differences, the can be used to create suitable ”local to global” way of utilising
lining sometimes cracks and the gas systems and solutions for ESAB’s resources. So far in the
comes in contact with the base mechanised welding and cutting.
above-mentioned schedule, the
metal where it initiates corrosion. Four basic versions are available as
standard: engineer and welder training has
Railtrac F1000 Flexi been completed. It took place last
Railtrac FW1000 Flexi Weaver year with support from Singapore,
In this case, the metal wall thickness
Railtrac FR1000 Flexi Return the Netherlands and Sweden.
had been reduced from 28.5mm to Railtrac FWR1000 Flexi Weaver The project team is looking
11.0mm and it was therefore Return forward to the progress of this
essential to restore the area. Due to
project and will use the experience
space restrictions, the only method The Railtrac tractor runs on a
universal rail, which can also be that is acquired in other similar
available was welding. ESAB
used on bent surfaces. The projects in this region.
Middle East recommended
operator controls the welding from
cladding using OK Tubrod 15.13,
a digital programming box, which
1.2mm. Using two Railtrac F1000 can store as many as five different
and LAX 380+MEK2+PSF 400, the welding programs. Functions
entire area, with a length of 8 m include interval welding, weaving
and a height of 1.5 m, was built up and backfill.
to a thickness of 29.00mm. ESABs welding guns, wire-feed
units and power sources can be
Round-the-clock work connected to Railtrac 1000.
Railtrac 1000 weighs six or seven
The machines were in use 24 hours
kilograms, depending on the
a day with six welders working in model.
shifts. It took eight days to From the welder training
Svetsaren nr 1 • 2001 • 13
Hydro Power Repair and maintenance electrodes in new
Generation PZ 6166 VacPac wrapper
goes Latin American
The hydro-power turbine ESAB brand coated electrodes for
fabricator IMPSA in Argentina repair and maintenance that are
acclaims the PZ 6166 metal-cored manufactured at our plant in
wire from ESAB. Perstorp, Sweden, will only be
PZ 6166 is designed for welding available in the new VacPac
the 410NiMo martensitic stainless wrapper from now on. This type of
steel, which is widely used for pack offers a remarkable way of
hydro-turbine components like storing electrodes on the shelf in
runners. PZ 6166 is without doubt your stores for up to three years, if
the ESAB leading-edge product in they are kept unopened. An
this segment. excellent reason for any customer
The very good all-positional to take a closer look at ESAB
operability combined with the R&M quality electrodes.
resulting defect-free welds are the This is a real benefit because the
features the company praises in this ageing of the electrodes is inhibited For repair and maintenance
product. as they are protected from harmful electrodes, the full-pack 1/1 type of
IMPSA is also using other atmospheric content. plastic container is now being
welding consumables from ESAB The new VacPac is available in discontinued.
Europe for its hydro-turbine three different sizes. 1/4, 1/2 and 3/4 The smaller dimensions of the
fabrication. In fact, the company packs. most sophisticated types of
has successfully used most of the 1. Quarter packs contain the electrode in the R&M range
products ESAB offers for this smallest number of electrodes. namely nickel-based electrodes,
application in its production There are nine 1/4 packs to one electrodes for welding dissimilar
operations. For submerged arc carton. The approximate weight steels and copper-based electrodes
welding, it uses our combination of of a 1/4 pack is between 0.7 and are available in the 1/4 packs. A
OK Flux 10.63/OK Autrod 16.79, 1.0 kg and the number of positive factor for a purchaser as
the metal-cored PZ 6166 wire for electrodes varies according to this eliminates the need to purchase
semi-automatic welding and the the diameter. more electrodes than are necessary.
stainless, low-hydrogen OK 68.25 2. The half pack is the next size up Coated electrodes for
covered electrode. In addition, and there are six so-called 1/2 aluminium welding will still be
IMPSA has tested various types of packs to one carton. supplied in the older similar type of
ceramic backing for one-sided 3. The largest VacPac is the 3/4 size VacPac including the plastic
welding. and there are four of these to a container.
The hardfacing electrode dedicated to the sugar cane processing industry
Enormous rollers like the one seen with OK 84·76 is very easy and the 450 mm. The welding current can
here are used in the sugar cane welding characteristics are superb range between 140 and 220 amps.
crushing process and are subjected in the environment to which the The weld metal hardness, as
to excessive wear during the electrodes are exposed. welded, is 55 to 60 HRC.
season. They have to be OK 84.76 is a high chromium- The welding positions are:
continuously welded, even when carbide type and contains
the process is in full swing. No approximately 4-5% carbon and as
stopping the presses here! This much as 35% chromium. The
means that a welder must be electrode deposits a dispersion of
present on a three-shift basis to be small, hard and very wear-resistant
able to work the roller surface. The globules that fasten to the side walls This electrode is tried and tested
roller, which is located near the end of the ridges of the roller. and it appeals to welders in the
of the crushing process, is It is used on positive current for DC cane industry.
smothered in crushed, sludgy cane power sources, whereas it needs an For further information, please
and its surface is therefore wet. The open circuit voltage of at least 65 contact:
characteristics of our electrode volts for AC transformers. ESAB AB, Jeff Ramsay at
must be able to accommodate OK 84·76 is available with a e-mail: email@example.com
these conditions. Striking an arc diameter of 4 mm and a length of or fax +46 31 50 91 70
14 • Svetsaren nr 1 • 2001
arc markers and two triple-torch
head units. The initial target of
30% has been more than met! The
machine is used on three shifts,
seven days a week!
Today, the new target is once
again to increase productivity by
30% compared with the existing
machine. This target can be realised
by increasing the cutting speed
using plasma instead of flame
The new TXB 25000 machine
will be equipped with a grinding
unit, two arc markers, one triple-
torch head and a dry VBA plasma
head. In order completely to extract
the fumes that are generated, an
The most sophisticated panel cutting machine! exhaust table measuring 20 m x 20
Chantiers de L’Atlantique is the Systems designed a panel machine m will be installed. This is a brand-
largest shipyard in France. Its order with an integrated grinding device. new concept and all the equipment
book is full until 2004-2005. The The grinding head removes paint should be installed within three
company specialises in passenger from the surface (50 mm grinding weeks and commissioned at the end
cruise liners and, as such, it has just width) where the stiffeners will of August. ESAB, always a cut
received an order for the largest subsequently be welded, at a speed above the rest!
passenger ship ever built and called of 15 m/min instead of 3 m/min with
the Queen Mary 2. a “normal” shot-blasting device. For more information, please
Three years ago, the target was This speed guarantees that less than contact Arnaud Paque at
to increase productivity on the 5 microns of paint will remain after e-mail: firstname.lastname@example.org
panel line by 30%. In order to grinding. The machine was or fax +33 (0) 1 30 75 55 20
achieve this target, Esab Cutting equipped with a grinding unit, two
Continued success for ESAB Super Stir™
Interest in the Friction Stir Welding machine is of the same gantry-type
(FSW) technique for aluminium design as the one for TWI, but it is
continues to grow. Even if the cost designed for a welding area of 3 x 5
of the investment is substantial, metres and is equipped with one
experience acquired from the welding head.
systems that have been installed so The third contract was signed
far indicates that good profitability with EADS/Institute de Soudure in
is possible. France and involved a basic
The FSW process offers many longitudinal FSW machine. This
benefits. The strength and quality machine is also equipped with a
are superior to those provided by unit for circumferential welding
other welding methods and the and, furthermore, the welding head
process requires no special surface is designed not only for normal
treatment prior to welding. tools but also for retractable pin-
Another of the advantages of FSW SuperStir™ equipment will now be tool and bobbin-tool techniques.
is the opportunity to join alloys that installed where the entire process All three systems will initially
could not previously be welded. was invented and where Friction start with test welding and
During the latter part of 2000, Stir Welding actually began. The laboratory operations.
ESAB’s FSW team in Laxå, equipment has a gantry-type design ESAB has previously delivered
Sweden,signed three new contracts with a welding area of 5 x 8 metres some ten sets of Super Stir™
involving deliveries of the ESAB and it is equipped with two heads equipment to companies in the
Super Stir™ system. of different sizes. marine sector and the aerospace
The first contract was signed The second contract was signed and automotive industries.
with TWI in the UK. ESAB with DanStir ApS in Denmark. This
Svetsaren nr 1 • 2001 • 15
Repairing cement kilns
North-west of Sofia lies the small village of Vratsa. it was fixed in place. The joint was filled with OK 92.26,
When the Holderbank Company of Switzerland a nickel-based electrode with high strength properties
purchased the cement works there, the plant was in at high temperatures.
great need of repair. In the past, a total of seven kilns Picture 2 shows the plate in position and welding
produced cement at this plant, but today only two completed on the outside of the kiln. Two teams of two
remain. The things that needed repairing included one welders worked two shifts for four days to complete the
of the kilns. welding. The welding team was a Sofia-based company
which had been commissioned to carry out the work on
The finishing touches
The joint was X-rayed and passed 100%. Before
assembling the fire bricks, the joint on the inside of the
kiln was ground, Picture 3. The new fire bricks were
then carefully re-assembled and the kiln was fired up
once again. It is now back in production.
Another part of the plant, the ball mill, was also in
need of repair. Longitudinal cracks had occurred
between the fixing bolts in the 25-year-old mill and they
had to be completely eliminated by repairing. Dye
penetrant was used to define the extent of the cracks,
which were then drilled or gouged out using the OK
21.03 gouging electrode. After thoroughly checking the
Figure 1. The kiln with a two by four metre opening. joints for remaining cracks, they were welded with OK
55.00. This repair work required 37 hours of non-stop
welding to complete.
Figure 2. The replacement plate after welding.
The diameter of this kiln is a little over six metres.
On a circumferential section in the middle of the above Figure 3. Grinding of the joint on the inside of the kiln.
picture, the shell was badly damaged because the
fireproof bricks on the inside had collapsed, rupturing
the 40 mm thick shell. A two by four metre opening was
made in which a new 40 millimetre thick replacement
plate would be fitted, see Figure 1.
The plate was cut, bevelled and prepared in the
workshop on site at the plant. The joint preparation was
an asymmetrical X type with a 3 mm root face and a 60°
bevel on each side. The corners of the plate and, later,
the opening were rounded. A mobile crane lifted the
eight square metre plate 25 metres into position, where
16 • Svetsaren nr 1 • 2001