Our Vision. We create Customer success in pipeline welding around the world

Transcription

1 PWT Via Salvo d Acquisto, Guardamiglio (Lodi) Italy Phone: Fax: info@pwtsrl.com Web site: PRODUCTS&SERVICES

2 Our Vision We create Customer success in pipeline welding around the world By responding to the lifecycle pipeline integrity requirements, we will be recognized as the global partner for providing innovative, efficient, scalable welding solutions to the pipeline industry, facilitating long-term customer success in the most challenging environments. Our global network shall deliver and support simple and reliable solutions that are based on advanced technologies, unique multi-discipline knowledge, in-depth pipeline construction experience, and will ensure consistent weld integrity.

3 PWT Service MILLER PIPEPRO XCS Light MILLER PIPEPRO XCS PWT WELDING ARC CONTROL FEATURES PWT DEDICATED WELDING WIRES PWT ICA (Internal Clamp Automatic) PWT - HBM (Hydraulic Beveling Machine) ACCESSORIES

4 PWT - SERVICE Together with a full range of products and services for an integral execution of automatic welding activities, PWT approach is to work as a Partner to the Customer for the successful achievement of each project. Early stage review and comments of the project welding specification Technical Support during discussions with Final Clients Site or in-house Welding Procedures Qualification Tests Site Welding Supervisions support and site Equipment Maintenance Contractor s welding operators and technicians training Site refurbishing and upgrading of Contractor owned fleet We rent, lease, sell and support all our pipeline automatic welding related equipment We have a project support focused internal organization to match Contractors work structure. Our equipment associated welding solutions are: Easy: Simple remote High reliability, easy to maintain Welder friendly advanced regulations leveraging unique one proprietary team approach from bespoke invertor welding arc control algorithms to bug control features Effective: Being user friendly it enables operators to focus on making it right over and over enhancing quality The same machine from root to cap with onboard quality control system Each head (bug) can be use either on left and right side Flexible: Deeply integrated and cutting edge technology to maximize operational productivity Smart and light to minimize safety risks, environmental impact and costs

5 MILLER PIPEPRO XCS LIGHT The Miller PipePro XCS Light is the right solution to complete girth welds with V shape bevels using the Miller RMD process in root pass and flux core arc welding in fill and cap passes with the exact same machine. It makes it the perfect solution to complete tie-ins welds after completion of the root and hot passes using the very same invertor by only switching the Miller standard wire feeder and the XCS Light bug communication cable. This reliable and performing solution based on the classic MIG/MAG welding process (with or without copper backing), benefits of brand new designed welding heads and advanced electronic components to increase reliability, reduce spare parts and minimize site maintenance. The Miller PipePro XCS Light is offered with the cutting edge inverter Miller PipePro 400XC that enables the following welding process: - MIG/MAG - PULSED - FCAW - RMD - MCAW The system includes: No. 2 Welding head units with onboard control PC boards, wire feed pull motor and all required drivers Wired remote control with onboard display No. 2 External spool holders 15 Kg No. 1 Manual gas mixer with high and low pressure hoses and regulators No. 2 PipePro 400 XC complete of interface No. 1 Transformer No. 1 Assembly box to host gas mixer, transformer and welding sources No. 1 Set of power and control cables PipePro 400 XC Gas Mixer The main features of Miller PipePro XCS Light are: - Light, self- contained welding heads to reduce cabling, plugs and spare parts, to optimize site maintenance - Fully integrated electronics - No right and left bug: each head can be configured for each side via the remote control - Upload and download of welding parameters, data logs and setting of the system via USB pen drive or USB cable connected to a PC - No need of A/C system. Even the torch the air cooled - No need of specific diesel generators: just a commercial diesel set 60 KVA - Quick installation and connection/disconnection - Operation in slope and bends for maximum flexibility at site - Data Logging of actual welding parameters - Optional K thermocouple slot for pipeline pre-heating temperature measurement and logging - Up to 2 pass less using metal cored wires vs. solid wires starting at 18 mm thickness. Miller PiePro XCS Light Welding head This advanced welding source is designed for the pipeline market and can manage up to 6 different welding process: from the standard ones to the most specialized developed for auto pipe welding. The Miller PipePro XCS Light can also weld without copper backing using the Miller RMD process for the root pass. Use of metal core wires is also possible to improve deposition rates and quality. PASS COPPER (cm/mm) NO COPPER (cm/mm) THICKNESS (mm) ROOT (using RMD process) 4,5 HOT ,5 FILL ,5 CAP ,5 MIG process using solid or seamless metal core wires of 1.2 mm

6 MILLER PIPEPRO XCS The Miller PipePro XCS is the new generation of welding systems best representing the state of the art of the easy, effective and flexible philosophy. It is designed to out-perform the heavy and complicated dualtorch systems on main line jobs. The heart of this top notch solution is the bespoke Miller Advanced Pulse, a specially engineered pulse algorithm optimized for automatic pipeline welding which is inclusive of true live Contact Tip Work Distance control, penetration control and seam tracking systems. Beside the integrated data logging capability, including gas flow and pre-heat temperature, a torch tilting feature is enabled to extend the range of possibilities improving safety, quality and productivity. There is no need of copper backing to reach excellent performances: PASS NO COPPER (cm/mm) THICKNESS (mm) ROOT 120 4,5 HOT 100 3,5 FILL 70 2,5 CAP 50 0,5 Miller Advanced Pulse process enabled typical travel speed and layer thickness Thanks to a new bevel design the process can manage high-low of 3 mm and local gap of 1 mm while the number of passes and welding wire consumption are reduced thanks to its 3 vertical angle. The system is designed to be compact, self contained and to have performances similar to double torch solutions, despite keeping the simplicity of an air cooled, single torch system. The head is 3D engineered to reach an operating weight of 16 Kg including onboard pull wire feeder system and a height of just 25 cm (including cables and tubing). Each welding head can be programmed, as left or right hand side, in order to reduce the specific spare parts and consumables. Also the space on the paywelder platform has been optimized with just 1 cubic meter needed for the shelter box and the 2 power sources Miller Pipepro 400XC. The system includes: No. 2 Welding head units with onboard control PC boards, wire feed pull motor and all required drivers Wireless remote control with onboard display No. 2 External spools holder (15 Kg) No. 2 Welding cabin color displays allowing on the fly parameters change and monitoring without any PC No. 1 Electronic gas mixer fully integrated allowing gas mix program for each pass and angular sector plus data logging No. 2 Pipe-Pro 400 XC complete of interface and Miller Advanced Pulse bespoke algorithm No. 1 Transformer No. 1 Assembly box to host gas mixer, transformer, welding sources and network connection with external color display for parameters monitoring No. 1 Wireless connectivity to upload/download parameters, data logs and system configuration from even outside the welding cabin No. 1 Set of power and control cables. Main features of Miller XCS are: - Light, self- contained welding heads to reduce cabling, plugs and spare parts, to optimize site maintenance - Fully integrated electronics - No right and left bug: each head can be configured for each side via the remote control - Upload and download of welding parameters, data logs and setting of the system via wireless (even from the inside of the QC vehicle in case of poor weather) or USB pen drive or USD cable connected to a PC - No A/C needed - No need of specific diesel generators: just a commercial diesel set 60 KVA - Quick installation and connection/disconnection - No need of beveling machines using standard V bevels on pipes with less than 12 mm thickness - Miller Advanced Pulse welding process ensuring root pass high welding speed and deposition rates without copper backing - 3 mm high-low and 1 mm gap, operation in slope and bends for maximum flexibility at site - For the root, prevention of burn through and lack of penetration thanks to the Contact Tip Work Distance and additional penetration control regulation, for fill and cap better control of the heat input via continuous control of the CTWD - Precise and automatic additional torch movement controls thanks to the embedded seam tracking and torch inclination features - Optional K thermocouple slot for pipeline preheating temperature measurement and logging - Welding Tent Monitors allow technicians to change parameters on the fly directly from the touch screen monitor while standing next to the welder.

7 PWT WELDING ARC CONTROL FEATURES PWT DEDICATED WELDING WIRES Thanks to ITW full ownership of the complete supply chain, PWT combined together a unique group of welding wire, welding power sources and motion control specialists to answer to our technical specifications, based on years of experience on automatic pipeline welding across the planet in many various cultures, terrain, weather and other constraint configurations. The resulting welding arc regime is classified as Advanced Pulse, runs lower heat input, is synergic and self-adaptive to overcome simultaneously: Root pass without copper backing Root average travel speed from 110 to 140 cm/min with peaks at 150 cm/min Accepted high-low (or mismatch) of 3 mm Accepted local gap of 1mm Root pass deposited thickness is 4.5 to 5 mm in a single layer The same welding algorithm is used for all passes root to cap insuring simplicity, flexibility and effectiveness. To achieve these amazing results, a current shape specific to pipeline automatic welding has been created: it is self-adaptive to smartly control the penetration root preventing both the burn through and lack of penetration. Welding head onboard sensors are mainly dedicated to: Close regulation loops to insure consistency Log all system data including welding parameters of course - at selectable frequencies to enable troubleshooting, development of WPS, regular quality control monitoring and trends identification Steer the welding torch in between the 2 walls of the bevel providing effective seam tracking. In summary, thanks to true integration of hardware and software from the power source to the welding head controls the new welding process becomes a component of the overall system enabling: Torch Contact Tip to Work Distance and seam tracking Specific synergic pipeline automatic welding current shapes Root pass penetration control through self-adaptive management of the welding current shapes Onboard sensing to insure reliable data logging of all welding and system parameters. One of the most critical components participating to the successful completion of the joint is the welding consumable, the wire itself. Just like the welding arc, the wire has impact on the quality, operability and productivity. Welding arc control algorithms and parameters are optimized to get the most out of those high quality welding wires. Thanks to the ITW group integration, PWT has been able to select and optimize, specifically for downhill automatic welding in narrow groove, optimal consumables. Testing and issuing the specification our aims were: - Consistency from batch to batch in terms of quality (mechanical property tests), operability and productivity - Avoid of inter-pass grinding - Robust fit for purpose packaging - Less than 1% Nickel to comply with NACE base criteria in case of slightly sour or sour service - Commercial availability in large batch and short delay with batch actual 3.1b certificates Based on the above criteria we decided to use mainly existing products but only selected batches as per PWT specification. Hobart solid wires on 16 Kg spools: - Up to X70: Quantum arc 6 PWT - X80: Quantum arc 8 PWT Hobart- Megafil specific pipeline family of seamless metal core wires on 16 Kg spools: - Up to X70: Megafil X70M - Up to X80: Megafil X80M - Up to X90-X100: Megafil X100M Regarding the application of flux core wires, mainly on V shape bevels, heavier wall thicknesses, we selected a range of Hobart Megafil family of rutile flux core wires: - Up to X70: 821R - X80: 610RPAG-14/15

8 PWT - ICA PNEUMATIC INTERNAL CLAMP The PWT pneumatic Internal line up clamp is designed to ensure a perfect line up of the pipes during the welding of the root pass. The internal arrangement of the mechanic and pneumatic components provides a firm position of each pipe during the alignment of the bevels in order to have the perfect conditions for a reliable root pass welding. If the choice to use copper shoes internal support is done a patented copper backing system is included: thanks to this technology, remarkable welding speeds are achievable in favor of high production rates. Few and easy modifications can quickly convert the clamps for no copper root pass both by stick rod and automatic welding using RMD with Miller Advanced Pulse process. The PWT Internal pneumatic clamp can be proposed with specific features such as: - Dedicated set up for slopes, particular ground conditions and use with double joint pipes. - High power clamp for heavy wall pipes or out of roundness pipe. It provides 50% more output strength than the standard product with a limited price increase. According to the diameter, the expander crown has to up 24 pistons, on 48, for the best fit of the internal diameter. The clamps are designed to properly operate on all wall thickness by adding calibrating shims: in this way the clamp can be calibrated within a span of 2 inches.

9 HBM PIPE FACING MACHINE DHPU DIESEL HYDRAULIC POWER UNIT The PWT Hydraulic Beveling Machine is the right equipment to get a perfect bevel profile on each pipe end to be welded. Simply changing the cutting tool position it is possible to obtain J bevel, V bevel, composite bevel and tapering. DHPU Diesel Hydraulic Power unit The facing operation is made by specific designed cutting tips (carbide inserts) held by tool holders locked to a rotating faceplate; this system allows making chamfers up to 40 mm thickness in less than 1 minute. The PWT HBM has been designed to fit large ranges of pipe diameters by calibration on replacement of the expander. This, joined to a robust construction, high torque due to the double hydraulic motor and minimized vibrations makes it a flexible and reliable equipment for pipeline projects. PWT HBM is fed by a dedicated Diesel Hydraulic Power unit with a power up to 100 HP and a range of operation from -40 C up to +50 C or can be directly coupled to the hydraulic outlet of an excavator boom.

10 ACCESSORIES WELDING CABINS BANDS In order to provide the proper environment for welding, PWT propose two models of welding cabins both equipped with fume extractor, tool holders drawers and 240 V or 110 V power supply with an electric board complete of all the safety features. Light welding cabins are only 450 Kg weight, for 48 (as reference) and are equipped with manual opening specifically sized for the pipe diameter. As an alternative we propose the automatic door opening with an overall weight of 750 Kgs for 48 (as reference). Treated special iron coil Toothing on one side Gripping system with compensation spring Fine regulation device thanks to a 1 mm pace thread INDUCTION HEATING The 35 KW Miller Pro-Heat induction heating is a competitive solution for light wall pipes preheating or for joint temperature control. One or more flexible blankets can be used to optimize heating time on each pipe end. Light cabin An optimized cabin holder allows to transport up to 4 cabins in a 20 feet standard sea container. For faster preheating in pipeline projects with high productivity the Pegaso Plus induction heating machine is the best solution. Able of 70 kw power, fully automatic and easy to operate thanks to the remote control the Pegaso Plus has been designed specifically for the pipeline market by A&C Technology, a Company of ITW.

11