TPT September 2011

W elding e quipment

A simple to operate, low cost orbital welder

AUSB port allow for software upgrades and updates

THE use of orbital tube welding equipment is mandated in a few select, global industries, such as semiconductor, bio-pharmaceutical (North America, Western Europe and Japan), nuclear, and aerospace. These industries, when applying the use of orbital welding, specify in their standards (for example, ASME/BPE 2002 & SEMI F78) not only a high degree of repeatable weld quality but, in addition, a high degree of documentation and verifiability of the orbital welding process. In the construction of a new pharmaceutical plant, tube welding quality control inspection records are an important part of the overall documentation required for validation of the completed facility before operating approval is granted by regulatory agencies. Every operator is required to make a test weld (coupon) at the beginning and end of each shift to ensure that the equipment is functioning properly. This has driven the development of QC software that monitors all weld parameters in real time. Boundary limits can be placed around each parameter: for example, rotation speed might be monitored for any deviations from programmed values by more than 1%. Weld data can be logged and printed out by an integral printer, or stored and downloaded to a USB flash drive for transfer to QC records. These features, which are critical to certain industries, come with a price, however. The features require hardware and software which drive up the cost. There is also the price in complexity. Numerous set-up screens are required to define the QC reporting and data storage/printout. The many options cannot be depicted with simple symbols and require text. Text requires multiple language selection, and so on. There are other industries that utilise a large volume of process piping (stainless steel in particular). The food processing, dairy, and beverage industries generally fall in this category. They do require a uniform

and completely penetrated weld at all times, no matter how these results are achieved (be it manual or mechanised weld processes). One development that has resulted in increased use of orbital welding are clean- in-place (CIP) systems. To allow cleaning of equipment without disassembly the weld surfaces must be smooth enough to avoid entrapment of product or cleaning residue. These industries require sanitary/hygienic tubing systems, but do not necessarily have to weld to a “code”. Although they do follow general guidelines and good manufacturing practices (The 3A Sanitary Standards; AWS D18.1 “Specification for Welding of Austenitic Stainless Steel Tube and Pipe Systems in Sanitary (Hygienic) Applications) for welding sanitary tube systems, worldwide few government agencies have adopted these as mandatory standards. Certain companies have adopted them, but there is no industry requirement. In the majority of cases, when asked what precludes the use of orbital tube welding as the primary joining process of their process lines, the perceived high cost of the equipment ends being the primary response. Surveys have shown that the price of an orbital welding system is 2-3 times higher than a fabricator or contractor, servicing these industries, is willing to pay. The complexity of controls for the welding systems on the market dictate on site training, adding further cost that may represent 10% of the system price. To offset this concern over equipment cost and simplify the orbital tube welding process, Magnatech has introduced an innovative solution to orbital tube welding with its modular, EZ Orbital Welding System. The Model 517 is a tube welding controller that integrates the operation of standard, commercial GTAW power source with the weld head. The customer can use his existing power source, allowing him to weld both manually and automatically. The controller has an intuitive symbol-based, touch screen user interface. Operation is as simple as selecting tube size and wall thickness, and pressing the Start switch on the head. The operator can adjust set parameters by a percentage override to accommodate tube lot variations. A USB port allows for software upgrades and updates. The Model 517 operates a new line of tube welding heads with digital control of rotation speed regulation, ensuring perfect repeatability. The heads use replaceable

360° contact tungsten holders, a moulded silicone switch panel, and incorporate flip- top viewing ports for convenience. The head is equipped for water-cooling and can be connected to a standard water circulator. However, it can be operated without one. If the head temperature exceeds a limit, the operator is notified that he has to reduce his duty cycle, or attach a water circulator. A training DVD provides all the instruction necessary for the simple-to-operate system. Magnatech – USA Website: www.magnatechllc.com

HDCT Slitting Line

Professional Chinese manufacturer of slitting lines, tube mills, tube toolings, etc., since 1980’s, the one-stop solution for the global market with efficient after-service. www.slittinglinelms.com info@lmsmachinery.com

The modular EZ Orbital Welding System

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S eptember 2011

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