Depliant PWT ok 2015 9 - PWT - Automatic pipe welding ... · Depliant PWT ok 2015 9.indd 4 23/04/15 18.28. ... It’s the base solution for Contractors looking for a reliable and

PRODUCTS&SERVICESDepliant PWT ok 2015 9.indd 3 23/04/15 18.28

Our Vision

We create Customer successin pipeline welding around the world

By responding to the lifecycle pipeline integrity

requirements, we will be recognized as the

global partner for providing innovative, effi cient,

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.

Depliant PWT ok 2015 9.indd 4 23/04/15 18.28



• PWT – Service

• MILLER PIPEPRO® AUTO XCS Platform

• MILLER PIPEPRO® AUTO XCS Light

• MILLER PIPEPRO® AUTO XCS

• PWT – WELDING ARC CONTROL FEATURES

• PWT – DEDICATED WELDING WIRES

• PWT – ICA (Internal Clamp Automatic)

• PWT - HBM (Hydraulic Beveling Machine)

• ACCESSORIES


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 specifi cation

• Technical Support during discussions with Final Clients

• Site or in-house Welding Procedures Qualifi cation Tests

• Site Welding Supervisions support and site Equipment Maintenance

• Contractor’s welding operators and technicians training

• Site refurbishing and upgrading of Contractor owned fl eet

• 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.

PWT - SERVICE


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 or right side.

Flexible: • Deeply integrated and cutting edge technology to maximize operational productivity• Smart and light to minimize safety risks, environmental impact and costs.


MILLER PIPEPRO® AUTO XCS PLATFORM

Miller PipePro® Auto XCS Welding head

Miller PipePro® Auto XCS Platform is the PWT scalable bug and band solution for pipeline welding: from the Light version for tie-ins to the Fully equipped version for the most demanding main lines, contractors can benefi t from the best solution fi tting their needs.

The new XCS family has been designed to be Easy, Effective and Flexible : three milestones in pipeline construction where an advanced equipment with high effi ciency and low O&M costs at site can make the difference.


MILLER PIPEPRO® AUTO XCS PLATFORM

The scalability of the platform allows contractors to upgrade the system adding additional features and enabling the Miller Advanced Pulse, a newly developed welding process for pipeline automatic welding.

TECHNICAL FEATURE ADVANTAGE FOR CONTRACTORNo right\left head and self-contained

Bespoke, modern design of electronics and mechanics using proven technologies

No water cooling of the torch, no air conditioning of electronics

Datalog of welding parameters and pre-heat temperature

Root to cap with the same equipmentMultiprocess Power source

Just 25 cm overall heightJust 16 kg each head including all electronics and wire feeder motor

Wire feeder system onboard the head, pulling wire from external spool

Less and faster bolting and connections

All standard processes: RMD® for root, MIG, FCAW, Pulsed

WiFi enabled

Wireless control operator remote

Touch screen monitor on each side of the weld inside the cabin

Miller Advanced Pulse

Contact Tip Work Distance and Burn Through prevention bespoke algorithms

Seam Tracking algorithm

Torch tilting system

V bevel welding up to 12 mm

Less spare parts, more reliability and easier maintenance

Fast mobilization and turnaround. Extended range of use down to 6’’

Reliability and simplicity. Temperature range from -40°C to + 50°C

Quality and performance traceability, gathering of evidence to prove fi tness for service

Flexible operation and use both downhill or uphill

Less wooden skids, less “boxes” to be connected together, less connectors prone to breakdowns.

Standard 15 kg spools of wire located in a very simple feeder box with no electronics at all.

Quick and easy installation

Well known and fi eld proven solutions to deliver high quality welds from the beginning using standard V bevels or site made J bevels

Easy and fl exible system settings and parameter editing. Can be controlled and updated through the internet

Operator “ownership” of the machine, no cable, ease of use

In cabin – PC free – parameters monitoring, changes on the fl y and upload download

High performance (up to 150 cm/min) with less welding units without copper shoes.High fl exibility: 3+ mm high-low and 0,5+ mm gap. Root thickness is 4.5+ mm

Better quality of the weld, low sensitivity to welding operator skills

Lower sensitivity to welding operator skills

More welding arc motion control possibilities

Suitable for short projects and waterlines

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It’s the base solution for Contractors looking for a reliable and fl exible welding system with RMD for root, MIG, FCAW, and Pulsed welding processes ready to use. It can be upgraded at any time to the full version.

The system includes:

• No. 2 Self contained Welding head and integrated data logger• No. 2 Wired remote control with onboard display• No. 2 External spool holders 15 Kg

• No. 2 PipePro® 400 XC complete of interface• No. 1 Transformer• No. Manual gas mixer with high and low pressure hoses and regulators• No. 1 Assembly box to host gas mixer, transformer and welding inverters • No. 1 Set of power and control cables

• RMD® for root, MIG, FCAW and Pulse welding process

• Burn through prevention for RMD® and automatic stick-out control.

Options• Wireless remote control and WiFi connection for PC• Torch Tilting system• Welding Tent Monitors enabling In cabin – PC free – parameters monitoring, changes

on the fl y and upload download.

MILLER PIPEPRO® AUTO XCS LIGHT


MILLER PIPEPRO® AUTO XCS

This system is conceived for Contractors looking for higher performances and advanced welding arc control features.

The system includes in addition to the Light version:

• Miller Advanced Pulse• Seam Tracking• Torch Tilting system• CTWD automatic control for burn through & lack of penetration prevention• Electronic Gas Mixer• Wireless upload of welding parameters• External display for welding inspector to monitor actual parameters• Torch Tilting system

Options

• Wireless remote control with onboard display• Welding Tent Monitors enabling In cabin – PC free – parameters monitoring,

changes on the fl y and upload download.


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 specifi cations, based on years of experience on automatic pipeline welding across the planet in many various cultures, terrain, weather and other constraint confi gurations.

The resulting welding arc regime is classifi ed 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 0.5+ mm

• 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, fl exibility and effectiveness.

To achieve these amazing results, a current shape specifi c 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.

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

• Specifi c 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.

PWT WELDING ARC CONTROL FEATURES

PASS

NO COPPER with Miller Advanced

Pulse(cm/min)

NO COPPER with RMD®

Process (cm/min)

COPPER with MIG Process

(cm/min)

ROOT 120 40 100

HOT 70 60 60

FILL 60 40 40

CAP 50 40 40

Root pass layer thickness 4.5-5 mm


PWT DEDICATED WELDING WIRES

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 Hobart consumables for automatic welding.

Testing and issuing the specifi cation our aims were:

- Consistency from batch to batch in terms of quality (mechanical property tests), operability and productivity

- Minimize inter-pass grinding

- Robust fi t for purpose packaging

- Using not only standard solid and folded fl ux core wires but also bespoke seamless metal cored and fl ux cored wires

- Commercial availability in large batch and short delay with actual 3.1b certifi cates


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 fi rm position of each pipe during the alignment of the bevels in order to have the perfect conditions for a reliable root pass welding.

According to the diameter, the expander crown has to up 24 pistons, on 48”, for the best fi t 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.

PWT-ICA PNEUMATIC INTERNAL CLAMP


PWT-ICA PNEUMATIC INTERNAL CLAMP

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 modifi cations 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 specifi c 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.


The PWT Hydraulic Beveling Machine is the right equipment to get a perfect bevel profi le 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.

The facing operation is made by specifi c 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 fi t 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 fl exible 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.

HBM DHPUPIPE FACINGMACHINE

DIESEL HYDRAULIC POWER UNIT


HBM DIESEL HYDRAULIC POWER UNIT

DHPU Diesel Hydraulic Power unit


WELDING CABINS

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 specifi cally 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).

ACCESSORIES

Light cabin

An optimized cabin holder allows to transport up to 4 cabins in a 20 feet standard sea container.


BANDS

• 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 ProHeat® induction heating is a competitive solution for light wall pipes pre-heating or for joint temperature control. One or more fl exible blankets can be used to optimize heating time on each pipe end.

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 specifi cally for the pipeline market by AEC Technology, a Company of ITW.

INDUCTION HEATING

The 35 KW Miller ProHeata competitive solution for light wall pipes pre-heating or for joint temperature control. One or more fl exible blankets can be used to optimize heating time on each pipe end.


PWTVia Salvo d’Acquisto, 1 - 26862 Guardamiglio – (Lodi) Italy

Phone: +39 0377 451228 Fax: +39 0377 451094

E-mail: [email protected] site: www.pwtsrl.com


Documents

Depliant PWT ok 2015 9 - PWT - Automatic pipe welding ... · Depliant PWT ok 2015 9.indd 4 23/04/15 18.28. ... It’s the base solution for Contractors looking for a reliable and