Equipment Roundup

Revolutionary range of multi-option ESAB machines set to transform arc welding

The new Origo/Aristo range of CC/CV welding machines have been designed to give the high level flexibility required by such market sectors as energy and civil construction.

“The original Origo Tig 3000i machines were launched two years ago,” said Steve Purnell, marketing manager, Arc Equipment, ESAB UK. “The casework has been redesigned so that the water cooler now fits more neatly onto the machine”.

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All the new Origo and Aristo machines are supplied with proven ESAB control units that enable different weld types to be produced. The units also enable many process parameters to be set before welding starts. This facility also allows the parameters to be changed during welding.

The Origo Tig 3001i, which is a 300 Amp inverter power source that will produce a safe start and stable arc. All types of stainless and mild steel, together with a range of other materials with plate thicknesses of 0.5 mm and up, can be welded.

The TA24 control panel enables the heat input and the weld pool of pulsed TIG welding to be easily controlled. It also allows the Origo Tig 3001i to carry out MMA welding (handles all electrodes up to 5 mm).

The TA23 control panel has a function where the welder only needs to set the plate thickness and the control panel automatically sets the suitable welding parameters. It also allows the Origo Tig 3001i to carry out MMA welding (handles all electrodes up to 5 mm).

MMA welds are made using ESAB’s ArcPlus II with the Origo Tig 3001i. ArcPlus II gives a stable arc together with an even consumption of the welding electrode while providing improved weld quality with less need for after weld treatment.

When working with high-alloyed materials the ideal partners are the new Origo/Aristo Mig 4001i, A24 and Mig 4001iw. These Mig welding machines are compact 400 Amp power sources with a chassis made from galvanized steel, a material that withstands rough treatment. The power sources themselves are based on inverter IGBT technology.

These machines use a CAN bus communications and control system. This increases operational reliability because it reduces cabling.

ESAB LogicPump (ELP) automatically starts the cooling water pump in the machine when a water-cooled torch is connected.

The ELP eliminates the risk of overheating the welding torch. When a self-cooled torch is used the pump automatically shuts off. Doing this reduces noise and extends the life of the pump.

The Origo/Aristo Mig 4001i, A24 and Mig 4001iw use the TrueArcVoltage System. When used with an ESAB PSF torch the correct arc voltage is guaranteed independent of any voltage drop in the welding cables.

A set up with a short connection cable and a 3 m gun or one with a 35 m extended working radius will not affect the arc voltage or the quality of the weld.

Emerson enhances Ovation SCADA capabilities for more effective management of remote power generation assets

Emerson Process Management’s Bristol ControlWave remote terminal unit (RTU) technology has been fully integrated into its Ovation SCADA platform, translating into a number of benefits for power generators.

These benefits include better management of remote sites à‚— such as wind farms, solar farms, hydroelectric plants and other renewable energy resources à‚— and reduced operations and maintenance (O&M) costs.

Traditionally, SCADA systems poll RTUs for information either at specified time intervals or on demand. With the tight integration of the Bristol ControlWave RTU, the Ovation SCADA platform now features a configurable polling mechanism. This allows operators the option of having the RTUs send data directly to the SCADA server or central Ovation control system only when values change.

Not typically available from other SCADA suppliers, this ‘report by exception’ messaging scheme not only optimizes bandwidth but also provides real-time alarming of remote sites.

The Ovation SCADA system now also offers users access to more data than was available previously. If configured for periodic polling, the Ovation SCADA solution with ControlWave RTU technology has the capability to buffer and time stamp data à‚— including alarms à‚— then send it directly to the Ovation historian so that no data are ‘lost’ in the event of a communication failure.

Conversely, when most other SCADA systems are configured to transmit data during specific time intervals, only a ‘snapshot’ of information is relayed back to the SCADA server. This is less than optimal, as alarms or other abnormalities can be missed if they take place between polling intervals or during a communication outage.

The availability of better and more complete information through the integrated Ovation SCADA solution is advantageous for early detection of equipment failure, more efficient deployment of field crews and a higher degree of data integrity. It also offers unique enhanced reliability features.

These include fault-tolerant data transmission through redundant communication schemes, as well as an additional security mechanism that ensures the RTU is communicating only with the SCADA server or central Ovation control system and not being intercepted by an outside source.

ABB & GoalArt to find faults in power grids

ABB has agreed to integrate software from Sweden’s GoalArt into its systems for the management of power networks, to strengthen grid reliability by helping utilities improve their handling of alarms.

In a power grid, a fault typically triggers many others and each of these sets off an alarm. GoalArt’s software helps the operators of power networks, as well as industrial systems and complex technical products, to understand and manage faults in a timely, safe and efficient manner.

“ABB’s partnership with GoalArt will enhance the ability of our customers to respond quickly to faults in the system and maintain the reliability of their operations,” said Neela Mayur, Product Manager of Network Manager. “The new software automatically pinpoints the main cause of a disturbance so that operators can fix it rapidly.”

ABB has begun testing the software in a pilot project with the New York Independent System Operator, which has been using ABB’s Network Manager SCADA/EMS (Supervisory Control and Data Acquisition/Energy Management System) to control its power network since 2005.

Hayward Tyler completes overhaul of boiler circulation pumps in record time at Philippines coal fired power station

Hayward Tyler, a leading manufacturer of pumps and motors for the power generation and oil & gas industries, has completed the onsite overhaul of four Hayward Tyler Boiler Circulation Pumps (BCPs) at a coal fired power station in the Philippines à‚— in record time, minimizing plant downtime for the customer.

Hayward Tyler Service Division (HTS) completed the onsite mechanical and electrical overhaul (including stator rewind) of two BCPs in just 35 days.

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The prompt and professional approach shown by HTS sales and service engineers on these first two BCPs resulted in the customer requesting a further two BCPs to be overhauled.

The overhaul of these two additional BCPs was completed very recently in a 40-day period.

This is some achievement when you consider that a typical mechanical overhaul of one BCP, including electrical rewinding, normally takes 30 days to complete.

This type of onsite overhaul work depends heavily on the availability of spares at the site. The procurement of spares alone can take 10 to 14 weeks. Through excellent teamwork, spares were procured by HTS in just eight weeks, enabling onsite work to progress as planned.

The Masinloc coal fired power plant (Masinloc CPP) is a 600 MW power plant located in Masinloc, province of Zambales (Island of Luzon). Masinloc CPP installed BCPs from Hayward Tyler back in 1996. The power station, which is now owned by Masinloc Power Partners Co. Ltd (MPPC), a subsidiary of AES Corporation of the US, was originally a government-run facility. A lack of expenditure on planned maintenance prior to the takeover by AES meant that the BCPs had been poorly maintained.

On site, there are two boilers and seven Hayward Tyler BCPs, each boiler nominally requiring three BCPs, with an additional BCP as standby. Before HTS conducted the first overhaul and rewind work, the remaining BCPs had been running continuously for a number of years.

With a lack of any planned maintenance, the number of pumps in service was, in some cases, reduced to just two pumps per boiler, rather than the nominal three pumps.

The overall condition of the units had therefore deteriorated and had run into a state of disrepair.

According to Anil Patel, export sales engineer at HTS: “This, in effect, had reduced the output of the Masinloc power plant significantly, which in turn equated to lost revenue. Therefore, any attempt at scheduling in planned maintenance was given low priority and outages were deferred.”

“The AES takeover period was controlled but added a further period of time during the condition of suspension, which allowed a further degradation in the condition of the plant.

“However, provision and coordination with AES, the new owners, enabled the rapid release of orders and financing to initiate the supply of goods and services from HTS to support the extensive maintenance programme that followed the handover,” added Patel.

Paul Green, maintenance manager at AES commented: “AES was delighted by the prompt and professional approach demonstrated by HTS sales and service teams on the first overhaul, resulting in the overhaul of two further units more recently. We would like to thank HTS for the excellent job they have done in supporting our power station, which is now operating at increased output levels since the overhauls.”

Climax Portable Machine Tools in heaven after bagging Canadian deal for portable circular mill for wind turbine flanges

Climax Portable Machine Tools, a global provider of machining solutions based in Newberg and Duren, Germany, announces a contract from Hitachi Canadian Industries Limited (HCI) for its CM6000 portable circular mill for use in the precision machining of wind tower flanges.

The contract also includes the training of Hitachi machinists on the basic operation and maintenance of the equipment.

According to Climax Portable Tools, the metals removal capabilities, precision and portability of the Climax tool were key factors in HCI’s choice of the CM6000 circular mill.

The tool enables machinists to achieve a surface flatness tolerance of 0.051 mm, minimizing the likelihood of excess vibration and stress on the wind turbine and extending its operating lifetime. It also can create a 60 rms micro finish, far exceeding the requirements of the wind industry.

Furthermore, the circular mill cuts machining time up to 75 per cent, taking only two hours to machine large flanges compared to 12-14 hours when using single-point machining tools.

HCI is a power generation component manufacturing company headquartered in Saskatoon, Canada, and is owned by Hitachi Limited (headquartered in Tokyo, Japan). It is Hitachi’s only facility devoted to wind tower production, and supplies wind towers to wind farms throughout North America.

In addition to wind towers, HCI also manufactures pressure vessels and heat exchangers, and provides parts and services for the steam and gas turbine industry.

As the demand for alternative energy sources grows, it is driving the need for greater innovation and manufacturing capacity within the wind industry.

In response, HCI implemented a new equipment integration plan designed to accommodate the market’s growing demand for bigger towers for wind turbines.

The Canadian company said that is integrating the portable CM6000 into its manufacturing process so that flanges that are out of spec can be re-machined right on the assembly line, saving substantial time and labour. Training on the new circular mill has already taken place.

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