INDUSTRY NEWS


Polysoude full attendance at conference event TIG weld overlay has undergone fresh changes


A


large panel of those working in the industry met at Polysoude in Nantes on the 12th


and 13th of December 2018 to find out about the latest changes with regards to weld overlay technologies. This event went a lot further than a simple theoretical presentation of new approaches, and this in several aspects. Of course, the production workshop allowed participants to have a close look at all the new aspects, with live demonstrations. But this was not the only goal of the event.


The event Partners from France and all around


the world, customers, component suppliers and prospects were able to freely exchange knowledge on the progress of this technology which has established itself over the course of the past decade. One of the first applications of this technology was the deposition welding of tubes in the petrol and gas industry sectors, where weld overlay technology is increasingly the most favoured solution.


Markets


International demand has accelerated to such an extent that equipment production was struggling to keep up. There is a large number of possible weld overlay configurations. Capitalising on years of research and development and equipment sales, Polysoude has found the solution: the standardisation of ready-to-assemble machines and subsets that has made it possible to reduce not only lead times but also purchasing costs for the end user.


Productivity By analysing the various applications


and customer feedback, specific developments have subsequently resulted in substantial improvements. The main aim with these developments was of course to improve productivity. The basic version of the TIG process is known for welding quality and not for productivity. However, since the demands of the market are increasingly towards reductions in costs and lead times, the question at hand was the level of deposit necessary to cover the inside of


a pipeline that can measure over 20 metres, so that it can operate 24/7. One of the solutions was to transpose the single arc with dual electrode and the hot wire welding principle to deposition welding techniques. Thanks to this configuration, a deposit level of up to 6 kg/hr can be reached. Needless to say, this deposit level will depend on the heat input provided to make the filler wire melt and on the characteristics of the part to be welded.


Configuration Two welding machines in master-


slave mode control the perfect synchronisation of the torches whilst the Polysoude Computer Numerical Control (CNC) synchronises all movements of the arm, positioner and head to control the electrode’s position at all times. Specific adjustable torches adapt to the part to be welded, whether it is a tube, a tank, a valve, a pump or any other component of a full installation. All this is overseen by a Wide Dynamic Range fibre optic camera system.


On site, once the deposition


Bureau Veritas commends HSE restrictions on hazardous welding fume


Bureau Veritas has applauded The Health and Safety Executive (HSE)’s action to increase awareness of the hazards posed by welding fume, following its recent safety alert enforcing greater restrictions and protection against exposure. The alert, which has


reclassified the status of all welding fume as a Group 1 carcinogen – cancer-causing to humans – is for all working people and employers who undertake welding activities, including mild steel. It follows new scientific evidence from the International Agency for Research on Cancer


2 IMT February 2019


linking exposure to lung cancer and potentially kidney cancer[1]. As such, the HSE will be enforcing tighter controls around exposure to welding fume, with immediate effect.


Simon Hodge, Consultancy


Group Manager at Bureau Veritas, comments: “Following this reclassification there is no known level of safe exposure to welding fume and businesses can expect greater scrutiny regarding the effectiveness of engineering controls. As of now, current control methods such as general ventilation, will not be deemed acceptable. It also means that


where controls are not adequate or not present – for example outside – that appropriate and effective respiratory protective equipment (RPE) is provided and used. This will include training for workers to ensure compliance. Welding activities can


generate various hazardous components including particles, gases and ultraviolet (UV) radiation; all of which present health risks. As well as welding fume being recognised as cancer- causing, other health effects of exposure have long been known to include metal fume fever, serious lung conditions


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welding cycle has been initiated, the welder can follow several production lines. For weld overlay applications of long tubes, the size of the filler wire coils is of ample dimensions to allow for uninterrupted performance of the task.


How can we deal with such


an increase in production? If a standard complete installation is not planned and after examining the customer’s specifications, the Polysoude project managers use the standard catalogue of electromechanical components to make a specific proposal. According to the various functions required for a specific task they advise on the optimal equipment to meet the customer’s requirements. In this way, all lead times are reduced, from the submission of the quote to the completion of the project itself. Since 2018 Polysoude has an additional production hall dedicated to the production of large scale equipment. Anticipating the increase in demand from the market also allows to meet all requirements. The future is bright for deposition welding.


and neurological effects linked to manganese, a chemical present in mild steel welding fume. As a global health and


safety and compliance expert, Bureau Veritas is ideally placed to provide a holistic support service to organisations undertaking welding activities. This includes assessment of welding qualifications, audit and assessment of welding processes, thorough examination and test of local exhaust ventilation (LEV) systems, measurement and monitoring of welding fume exposure, review and update of COSHH risk assessments and provision of advice on appropriate engineering controls. For further information, call 0345 600 1828 or visit www. bureauveritas.co.uk


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