A metal fabrication company located in Charlotte, North Carolina received an order for 300 small I.D. vessels for titanium molds. At the time they were using FCAW and back gouging the inside and outside of the vessels to achieve 100% penetration. On average they were producing 2 vessels per hour with 2 welders.
They reached out to Red-D-Arc to find a faster and more efficient way to produce these vessels. After discussions with Red-D-Arc the fabricator decided to purchase a bespoke submerged arc system.The custom designed system came complete with a small I.D. sub arc welding head mounted on a 9’x9′ column and boom, flux recovery system, NA5R automatic wire feeder, DC600 multi-process welder and 5 ton rotators. The system also included a laser and camera for precise control and monitoring of the submerged arc welding process.
The submerged arc system increased productivity by 250%. They were able to produce 5 cans per hour with half the labor cost. The safety of the work place was also significantly increased for a number of reasons:
• Back gouging was eliminated which in turn reduced the risk of fire
• Rotators replaced manual rotation of the vessels on tables
• Welders no longer had to weld inside the confined space of the vessels
The customer and the Red-D-Arc team were beyond pleased with the results. The customer plans to purchase two more of these systems for future projects.
Submerged arc welding can increase the efficiency and quality of many industrial welding projects regardless of the size or complexity. Red-D-Arc has all the equipment, expertise and experience to provide you with a submerged arc system to fit your needs – available for sale, lease and rent.
Red-D-Arc recently supplied a variety of equipment to a UAE based company that is fabricating pile piping and jackets for the largest offshore wind farm project in the world. The company had to meet a strict time line of only 6 months, and would require a massive amount of welding and weld automation equipment immediately. Through consultation with Red-D-Arc, the customer determined that renting the majority of the equipment would be the most economical option. Red-D-Arc was able to fulfil the customers equipment needs immediately thanks to our vast and diverse fleet of equipment.
This massive order involved equipment and support from Red-D-Arc North America, Red-D-Arc UK and Red-D-Arc Middle East. The order consisted of a variety of welding and weld automation equipment including:
• 23 column and booms with single and tandem submerged arc welders
• 20 submerged arc tractors
• 200 rotators
• 167 jack-up rotators
• 400 CC/CV inverter welders
• 200 FCAW wirefeeders
• 10 Induction Heating Systems
By renting the majority of the equipment the fabrication company avoided the need to invest heavily in specialized equipment and ensured they would meet their deadline. Red-D-Arc works with customers to address their unique challenges and develops specialized solutions. Learn more about customized turnkey packages here.
A Red-D-Arc customer shared some interesting photos which document the process of extending the legs of a large seabound work platform and also feature several Red-D-Arc rotators. The platform is used for cleanup activities on the seabed and in order to work at greater depths; the legs of the work platform needed to be extended. The massive cylindrical legs were placed on Red-D-Arc rotators and rotated while the cutting and welding processes were carried out. Once the extensions were completed the legs were then returned to the platform.
Red-D-Arc contributed several Growing Line Systems to be used in the production of wind tower foundations for a wind farm in the Adriatic Sea. In addition to the Growing Line Systems, Submerged Arc Welders were supplied along with camera systems that are equipped with a monitor and touch screen for optimal control of functions. Red-D-Arc equipment was used because the foundations must be long and strong to withstand the depth of the Adriatic Sea.
To learn more about Red-D-Arc Growing Lines and Fit Up Stations watch our video: reddarc.uk/videos
Red-D-Arc delivered three submerged arc systems to a construction company from Willebroek (Belgium) which has acquired a record contract for the construction of foundation structures to be used in an offshore wind farm close to the German-Dutch border. The Red-D-Arc column and booms are 7 m x 7 m and are equipped with a double wire system powered by the ESAB 1250 for welding 4 mm cored wire. In addition, each of the column and booms included a seam tracking system and flux recovery unit. Thanks to the advanced electronics and touch screen interface controls the turnkey systems each require only a single operator.
Red-D-Arc designed and built a custom made column and boom with a boom length of over 9 meters for a leading tank manufacturing company in the Netherlands. The Red-D-Arc facility had to be customized with a raised roof section to accommodate the height of the large column. The raised roof was later opened, allowing for a crane to hoist the manipulator out of the manufacturing facility and then shipped to the customer.
The column and boom was part of a welding system provided by Red-D-Arc. The system featured a compact welding head designed for welding in narrow spaces, touch screen controls and a high resolution weld monitoring system to allow the operator to monitor the welding process from a safe distance.
Red-D-Arc supplied equipment and installation services for a new weld overlay cladding facility in the west of Scotland for one of the leading global distributors of raw material for wellhead and completion equipment to the oil and gas industry. After discussions with the client, Red-D-Arc designed a solution to meet the specific needs of their project. It was determined that the new cladding facility would consist of six Compact Cladding Cells and four Butt Welding Stations.
“We regularly develop specialized solutions alongside our customers…”
Layout of the facility began with our experienced engineers installing the six Red-D-Arc Compact Cladding Cells. Each Compact Cladding Cell consists of an automated system controller, 2m x 1m cross slide, 3 tonne turntable with built-in slip ring for preheating, and a Miller power source. Next, the four Red-D-Arc Butt Welding Stations were installed. Each station consists of an automated system controller; 3m x 3m travelling column and boom; 300mm x 300mm oscillation slide; 3 tonne headstock, 2 travelling support pipe idlers and a Miller power source.
The Red-D-Arc Weld Automation team has extensive experience across diverse sectors of industry. We regularly provide weld process recommendations and develop specialized solutions alongside our customers to address their unique challenges. Red-D-Arc Weld Automation Systems are designed for optimized reliability and productivity, and come complete with installation, onsite training, services and support.
Red-D-Arc UK delivered and installed a new vertical cladding facility for a manufacturing facility in Doha, Qatar. Red-D-Arc’s logistics team arranged for the equipment to be air-freighted to the new manufacturing facility in Qatar where Engineers awaited the arrival to begin installation.
The installation consisted of a Red-D-Arc automation controller, 4×4 column and booms, 2×1 cross-sides and a 20 ton floor turntable. This took Red-D-Arc engineers only three days to fully install and weld test. They were able to begin on-site training shortly after.
MacAljon, a industrial general contracting firm in the US, has increased the productivity of its thin-wall tank manufacturing operation by more than 50% using the Red-D-Arc RDA MFUB-TW (fit-up bed for thin-wall cans). Fit-up time has been decreased by 20% and the use of spider bracing is no longer required. With no spider bracing to get in the way, a manipulator is now used to perform SAW ID circumference welding which has increased productivity by 30%.
The RDA MFUB-TW system is specially designed for the construction of thin-wall vessels ranging in size from 3 m to 4.7 m in diameter (custom sizes are available). Our patented system is fitted with independently-adjustable vertical-rolls to support, align and compensate for tank non-concentricity when assembling multiple thin-wall sections which eliminates the need for spider bracing.
If you work with vessels that require the use of spider bracing or that have a wall thickness of between 4.8 mm – 9.5 mm contact the Red-D-Arc sales team to learn more about the RDA MFUB-TW and how it can increase the productivity of your thin-wall tank manufacturing operation.
Red-D-Arc UK was recently awarded the contract to supply a fully-automated welding system to the Nuclear Advanced Manufacturing Research Centre (NAMRC), a UK-government funded organization sponsored by several global companies including Rolls-Royce (the lead industrial partner), Areva, Westinghouse, Sheffield Forgemasters and Tata Steel.
The UK government’s Low Carbon Industrial Strategy, initiated in July, 2009, was a commitment to “establish a Nuclear Advanced Manufacturing Research Centre that combines the knowledge, practices and expertise of manufacturing companies with the capability of universities.” Following bids from some of the UK’s leading universities to develop the centre, it was announced in December, 2009 that the NAMRC would be managed by the University of Sheffield and The University of Manchester in conjunction with the industrial partners.
NAMRC took possession of its facility in the Advanced Manufacturing Park in October 2011, with an official launch in May 2012. The refurbished Manufacturing Technology Research Laboratory in Manchester also opened in October 2011.
Red-D-Arc supplied and installed a sophisticated, fully-automated system (pictured above) consisting of a 4m x 4m column and boom, a 15-ton positioner complete with slip-rings for heating, a Miller tandem sub-arc head, and a Miller strip-cladding head capable of welding a 90mm strip. All this equipment is controlled and programmed through a touch-screen PLC control system that Red-D-Arc supplied. All the equipment (except for the Miller welding equipment ) was manufactured by Key Plant, our new partner for PMT/Weld Automation products and services. The successful fulfillment of this order puts Red-D-Arc in a strong position to offer additional weld-automation equipment packages to other companies who will be investing in the UK nuclear-build programme. If you would like further information about this project, please contact Ross McCrorie at firstname.lastname@example.org