Tremco Pipeline Equipment ran the demonstration on three consecutive days in late June with each full demonstration taking a day. The demonstrations attracted a large attendance, with representatives from CRC Evans saying that it was one of the most successful and well attended demonstrations worldwide in recent years.
On show at the demonstration from CRC Evans were its automatic welding systems – including the pipe facing machine, automatic internal welding and external welding machines – while PIH showcased its automated joint coating units. Tremco Pipeline Equipment is the Australian distributor for CRC Evans and PIH, with PIH a division of CRC Evans.
With the rise of large diameter pipeline projects in Australia, especially those in the 40 inch plus range, automatic welding is set to become an integral part of the Australian pipeline scene.
Automated coating application is increasingly being considered and used as an option that ensures consistency of application for field joint coatings.
Tremco Pipeline Equipment secured additional factory space in Acacia Ridge to allow them to set-up the equipment on show with ample space for visitors.
Automatic welding success with CRC
The demonstration commenced with an overview of CRC Evans and the company’s products and services. CRC Evans explained that their systems are fully digital. This means that all components communicate digitally without the need for analog conversions, which increases speed and precision, eliminates errors and ensures quality. It is the only company to offer three product lines of automatic welding systems to allow customers to choose the system that meets the specific production and budget requirements of the project.
CRC Evans uses a combination of Internal Welding Machine (IWM) and External Welding Machine for faster, more accurate welds in the field. The CRC Evans IWM combines line-up mechanisms that clamp the pipe ends into alignment and an internal pipe welder, which automatically deposits the root bead in a 42 inch pipeline in approximately 1.25 minutes. The machine then quickly travels down the pipe, ready to weld the next section. The entire process is controlled by a single operator using one control panel. The IWMs utilise four to eight weld heads depending on the desired productivity rate and the pipe diameter to be welded, which can range from 24 inch to 60 inch. Eight-head systems typically complete each weld in less than a minute.
The external welding machines are available in single torch, dual torch, and tandem systems – a full range of welding units including the M300, P260, P450, P600 and the recently released P625, which was designed for smaller diameter pipe, were discussed. The ability to weld corrosion resistant alloys in addition to carbon steel was highlighted as a benefit of the units.
Better productivity, consistent quality and “˜cleaner’ welds were outlined as reasons for adopting automatic welding technology on pipeline projects. In 2009, CRC Evans automatic welding machines completed 290,000 welds worldwide.
When asked what makes automatic welding suitable for the Australian industry and conditions, CRC Evans said that it is very similar to what makes it valuable elsewhere around the world – productivity and lower repair rates.
CRC Evans outlined that the welding machines are always operated by qualified welders. The company said that training welders to use the equipment was cheap and easy to achieve.
Different situations require some slightly different selection and set-up of the automatic welding equipment – for example, water pipelines require different equipment selection compared to petrochemical pipelines, and different contractors can have specific requirements.
Equipment rental is the preferred method for most clients, with around 95 per cent choosing to rent. With some machines, such as the smaller flux-core machines, CRC Evans sells approximately 250 units a year. Larger, more complex units, such as the dual torch P600 are usually rented.
CRC Evans prides itself on being a one stop shop, with a range of ancillary equipment provided by them. For some clients, especially newer ones, this one-stop-shop element is vital, saving them the need to run around to gather all the equipment. CRC Evans said that other clients take a more al a carte approach, choosing the elements they need to compliment the ones they already have.
When discussing how Australian contractors will adjust, CRC Evans says it will be very similar to what they are doing, and that “we’re just making it easier for them.”
The personal savings for auto welding over manual welding can be quite significant, and up to the order of 50percent for the welding crew – but CRC Evans stressed that it does depend on the exact set-up and nature of the project. The company said that it is available to discuss how it can best work for clients in more detail at any time.
PIH automates the coating procedure
PIH manufactures and operates automated coating units, used for the application of field joint coating in pipeline construction. It is a full service provider and can apply project proponents’ coating of choice, with PIH having worked with a wide range of field joint coating systems over many years.
Outlining the services and history of PIH, Technical Sales Manager David Bell outlined that PIH can provide a range of options to suit the needs of clients for the effective installation of the selected field joint coating system, from surface preparation and application services to complete turnkey field joint coating services.
The automated coating process is primarily pre-programmed, which ensures repeatable quality and high daily production rates.
When applying liquid field joint coating systems there are some environmental and climatic conditions that lend themselves to the use of pre-heat.
The PIH pre-heat method involves the use of induction coils, which give uniform pre-heat around 360 degrees of the pipe. Pre-heat is predominately used to pre-condition the substrate and take away any moisture, but also to improve the cure rate of the applied liquid coating system.
PIH demonstrated the application of both liquid epoxy and polyurethane field joint coating systems by use of their automated, pre-programmable, rotating on-pipe equipment. The polyurethane formulation was supplied by TIB Chemicals and was applied to 42 inch diameter HPCC coated pipe and the epoxy formulation, which was supplied by Speciality Polymer Coatings, was applied to the 18 inch FBE coated pipe.
To date there has not been a widespread use of automated coating in Australia, but Mr Bell said that PIH was here to demonstrate the most up-to-date methods and he highlighted that the process is primarily about quality and importantly, repeatable quality.
The Tremco Pipeline Equipment automatic welding and automated coating demonstration gave the Australian industry a glimpse of the developments now available. Tremco Pipeline Equipment believes these options offer excellent opportunities for the Australian industry to continue enhance the great tradition of pipeline construction.