Tobias Finndin, Chalmers 21 Jan 2010

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Your Partner in Wind Tower Production

Chalmers, 21 January

Tobias Finndin,

Global Wind Energy Segment Manager

([email protected])


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A Century ofInnovation

rom e company s oun a on n we en n an

the development of the worlds first welding electrode,

ESAB has grown into a global leader with sales exceeding

1.3 billion annually.

~9300 em lo ees

Oscar Kjellberg, Founder


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A Global Presence

Perstorp

Gothenburg St PetersburgLax

Dalsbruk

Changwon

MrVamberk

a ow ce po e

HanoverAshtabula

Traverse City

FlorenceShanghai (Malu)

Karben

Zhangjiagang (2)

IthimanMesero

Taratala

Weihei

Wuxi (Romar)

Terni

on erreyKhardah, Calcutta

Ambattur, ChennaiNagpur

Jakarta

Irungattukotai

Singapore (Romar)

Belo Horizonte

ChascomusSt Luis

Pompeya

e ng consuma es ac oe ng consuma es ac or esr es

CuttingCutting systems factoriessystems factories

Cutting and welding equipment factoryCutting and welding equipment factory

Welding equipment factoriesWelding equipment factories* Includes manufacturing facilities of ESAB North America. A wholly owned

Welding equipment & consumables factoryWelding equipment & consumables factory

Consumables and cutting factoryConsumables and cutting factory

.


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ESABs Sales

ESABs worldwide sales reached 1 260 million in 2008

South AmericaChina

3%

Rest of world

15%Europe

North America*

19%

* Includes sales of ESAB equipment and supplies through ESAB North America. A

wholly owned subsidiary of Anderson Group Inc.


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- -

YOUR PARTNER EQUIPMENT CONSUMABLESPROCESSESCUTTINGSTEP- BY- STEP PARAMETERS TRAINING RETROFIT

The Tower segment Design Production


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a wind tower. (Click on icons/button for more info)

-

Cutting Rolling Tack Longitudinal Flanges Fit-up Circumferential Door Blasting

u ng o ng Tack

welding

Longitudinal

seams

anges Circumferential

seams

Door

frame

Blasting

& painting

YOUR PARTNER EQUIPMENT CONSUMABLESPROCESSESCUTTINGSTEP-BY-STEP PARAMETERS TRAINING RETROFIT


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is the most productive arc welding

process for heavy plates welded

The arc between welding wire

and work iece is shielded from

the atmosphere by a layer ofgranulated minerals the welding

The flux influences the weld metal

composition

There is no visible arc,

no spatter and no fume


SAW Process variants Cored wires


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The SAW flux feeds through the hopper tube and continuously distributes

itself over the seam a short distance ahead of the welding zone

The wire feed mechanism begins to feed the welding wire into the joint at a

controlled rate

An electric arc is established as the current flows between the electrode and

the work

The carriage is started (manually or automatically) to travel along the seam

A self-releasing glass like slag is formed protecting the weld metal until it has

cooled down


SAW Process variants Cored wires


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segments is limited by external factors,

such as transportation to the factory

A typical size and shape before rolling

is shown below



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thickness to obtain optimal

strength at the lowest weld.



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bevelled for the coming joint

With ESAB cutting machines,

process



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rolled into conical shapes and

tack-welded

ESAB can advise on the choice

of rolling equipment



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on the rollerbed with crane lifting

with shells standing on top of

each otherRollerbed TA and crane hook lifting

on the rollerbed with fit-upequipment

Vertical arrangement for GMAW

ESAB offers a wide range of tackwelding equipment


Rollerbeds and Column and Boom


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handling equipment to position

welding equipment (power sources,

, , .

consumables handling equipment

equipment to position welding heads



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shells to form a tower

longitudinal welds due to length

of the joint

High quality welds require perfectsynchronisation between welding

Superb operator control and



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2 1

23 1

3 2 14



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2 1 2 1 4 3

4 3

6 5 8 7 2 1 4 3

6 5 6 5 8 7


8 7


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that copes with high pressure forces

for quality tower door frames



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Availability What to retrofit? Cases Flexibility


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SUPRAREX machine

e ui ed with two tri le-torch-

VBAs, working on one or two

plates simultaneously


Sequences Processes Tools Machines Software Tables and filters


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The LAF and TAF power source

series are among the most popular

in the industry, offering excellentwelding characteristics.

TAF series (AC)

LAF series (DC)


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Challenge Competence Cutting Welding Welding consumables Support Research Partner


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,

* *

Area 660 m2 440 m2 220 m2

Construction 1 000 660 000 440 000 220 000

Maintenance for 10 year 2 500 485 000 350 000 135 000

Construction + Maintenance for 10 years 1 145 000 790 000 355 000

(Note, above figures may vary and shall only be considered as indicative)


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Process Variants - Deposition Rates

the deposition rate, but

also:

heat input

handling equipment

SAW Variant Single Wire Twin Wire Tandem Tandem Twin Multi Wire

Number of Wires 1 2 2 4 3 6

Number of Power Sources 1 1 2 2 3 6

Wire Diameter Range (mm) 1.6 - 5.0 1.2 3-0 3.0 5.0 2.5 3.0 3.0 5.0

Current Range (A) total 200 1000 400 1200 1500 2400 1500 2200 2000 5500

Current type DC+ DC+ DC+, AC DC+, AC DC+, AC, AC,,,

Voltage (V) per wire 25 38 26 38 28 38 26 38 30 - 42

Max. total deposition rate solid wire (kg/h) up to 12 up to 15 up to 25 up to 38 up to 90


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Challenge Competence Cutting Welding Welding consumables Support Research Partner

Documents

Tobias Finndin, Chalmers 21 Jan 2010