a member of the IGM-group

Orbital welding of
heat exchangers

Z.I. du Bois Briand

2, rue Paul Beaupre
F 44300 NANTES
FRANCE

Heat exchanger rev 1

1
a member of the IGM-group

Summary
Main advantages of orbital welding
Different industry sectors
Different welding configurations
Welding time examples
Polysoude product range
Application examples with the standard products
Application example with special heads
Services proposed by POLYSOUDE
Heat exchanger rev 0
2
a member of the IGM-group

Main advantages of orbital welding

in heat exchanger manufacturing

Heat exchanger rev 0

3
 Main advantages of orbital welding
a member of the IGM-group

It permits as well to be more

flexible because...

You dont need to have skilled welders

You can at any time train your own operators in

order to increase rapidly your manpower potential

You can at any time re-start a previous

fabrication without having to train your
welders. Your know-how is capitalised once
for all !

4
 Main advantages of orbital welding
a member of the IGM-group

Orbital welding of heat exchanger

permits to...
Increase your productivity up to a factor of 2 to 3 by
having one operator for several welding heads: you
get more competitive !

Increase the welding quality at the best

affordable level
Decrease the number of non conformances because
the welding process is completely reproducible

Simplify and optimise your designs by including

configurations which are impossible to weld by hand

5
 Main advantages of orbital welding
a member of the IGM-group

Your products will have more value

Life time of your products will increase: you propose

the best affordable quality for the tube-sheet/tube
assembly
You can use new oncoming material which is
delicate to weld by hand
By recording welding parameters of each weld, you
can justify that all your welds comply with your
welding procedures

6
 Main advantages of orbital welding
a member of the IGM-group

And finally you save money

Your productivity increases very significantly

Operators are less expensive than welders

You can adopt less expensive designs

You reduce the number of repairs

You can reduce the amount of quality control

7
a member of the IGM-group

Industry sectors

Heat exchanger rev 0

8
a member of the IGM-group

Chemical and petrochemical

industry

Energy

Increase corrosion resistance

Increase mechanical strength
Increase abrasive resistance
Use new materials
Heat exchanger rev 0
9
a member of the IGM-group

Reduce contamination arising from the surface

Increase corrosion resistance

Food industry

Water distillation
equipment

Heat exchanger rev 0

10
a member of the IGM-group

Different welding configurations

Heat exchanger rev 0

11
 Different welding configurations
a member of the IGM-group

Depending on pipe diameter, all

1 Protruding tube welding
configurations can be welded with:
wire
Arc Voltage Control (AVC)
2
If necessary oscillation can be used Flush tube welding

3
Recessed tube welding

4 Back plate tube welding

5 Header box welding

6 Internal tube welding

12
 Different welding configurations
a member of the IGM-group

1 Protruding tube welding

Welding with
cladded tube-plate

Welding with an
open welding
head with wire

13
 Different welding configurations
a member of the IGM-group

2 Flush tube welding

Welding with an
Leak tight welding open welding
head with or
without wire

Resistance welding

Welding with a
Welding with
cladded tube-
closed welding
plate head (without wire)

14
 Different welding configurations
a member of the IGM-group

Welding with a
3 Recessed tube welding closed welding
head (without wire)

Welding with an open

welding head with or without
wire
15
 Different welding configurations
a member of the IGM-group

4 Back plate tube welding

Two pass welding with
filler metal

One pass welding

without filler metal

Several types
of tube/plate
preparation

Tooling for back plate

shield is necessary to
avoid oxidation

16
 Different welding configurations
a member of the IGM-group

5 Header box welding

6 Internal tube welding

12 mm - 25 mm

25 mm - 28 mm
Different Internal bore
welding torches with or
28 mm - 35 mm
without wire depending
on tube size
> 35 mm

17
a member of the IGM-group

Welding time examples

Heat exchanger rev 0

18
 Welding time examples
a member of the IGM-group

ORBITAL HAND
WELDING WELDING
Welding time Weld quantity per shift
Tube Quantity with pre-post 1 welding 2 welding 3 welding
of welding gas head per heads per heads per 1 welder
dimensions (minutes) operator operator operator
passes
One pass
25.4 x 2.11 mm with wire 1.3 143 258 80
One pass
38.1 x 2.4 mm with wire 2.3 102 184 266 60
One pass
50.8 x 2.7 mm with wire 3.2 80 145 209 48
Two passes
25.4 x 2.11 mm 2.7 90 162 234 48
with wire
Two passes
38.1 x 2.4 mm with wire 4.0 68 122 176 34

12.7 x 1.1 mm One pass 1.3 185 333 481 155

25.4 x 1.1mm One pass 1.6 145 195 281 120

19
a member of the IGM-group

Polysoude product range

Heat exchanger rev 0

20
 Product range
a member of the IGM-group

A very large range of equipment: for any type of application from the
simplest to the most complicated one

TS 2000 TIG 20-160

TS 25
tube-sheet version

Without filler metal With or without filler metal (internal

With filler metal (internal or
With front protection or external)
external)
chamber With or without AVC
With AVC
Protection chamber possible for
With oscillation
special applications
21
 Product range: welding diameters
a member of the IGM-group

STANDARD WELDING HEADS

Welding diameter
0 20 40 60 80 100
TS 2000 standard configuration 10.5 60.0

large diameter tooling 60.0 110.0

backplate welding tooling

with wire
35.0 110.0
AVC possible
plate thickness max 40 mm
Internal torch
Without wire 12.0 110.0

AVC possible
Internal torch 35.0 110.0
with wire
AVC possible

TS 25
standard configuration 7.0 25.4

22
 Product range
a member of the IGM-group

TS 25 Reliable shielding gas system with total gas protection of

the weld pool during the entire welding cycle for welding
for fusion welding materials that are extremely sensitive to oxidation
Small, light and very compact: 1.5 kg
Water cooled Very rapid clamping

No compressed air needed: manual lever for quick

clamping
Rigid, vibration-free mechanical system

Highly accurate speed and position controls due to a DC

gear drive with closed loop regulation

Weld current intensity of 100 A at a 20%

duty cycle
Weld current intensity of 70 A at a 50%
duty cycle
30 welds per hour on 25.4 mm O.D.
tubes with 1 mm wall thickness and Argon
shielding gas

23
 Product range
a member of the IGM-group

TS 2000 Integrated or external wire feeder (Polyfil)

With or without arc voltage control
With or without filler metal
Constant welding speed and torch
Water cooled torch prepositioning mechanism in relation to the
weld cycle
Robust welding head avoiding vibrations
during operation under critical applications
Welding head is centered into the tube via
a centering mandrel
Water cooled torch
Possibility to use pulsed current with
synchronised pulsed rotation
AVC height sensing or programmed
electrode / workpiece fixed height

Weld current intensity up to 200 A in the

standard version

24
 Product range
a member of the IGM-group

Pneumatic positioning
system for example
when several welding
heads are used by one
operator

It permits to maintain the

welding head in a stable
position during welding:
The ergonomics of the work
piece is greatly improved

25
 Product range
a member of the IGM-group

Excellent
visibility of
torch and wire
coming in the
welding pool
The
mechanism
permits to fit to
any type of
application

26

a member of the IGM-group
PS 254-2
4 programmable axes: rotation, current, gas, wire,
rotation, current, gas, wire
250 Amp at 100%
Product range: power sources
PS 406 PC 300 / PC 350 / PC 600 (DC)
PC 375 (AC-DC)
6 programmable axes:
6 programmable axes and more:
Programmable with the extremely
AVC, oscillation (for TIG
powerful welder oriented PO-Win
20/160 welding head)
software, for complex welding sequences
300 Amp to 600 Amp
400 Amp at 40%
300 Amp at 100%
27
 Product range: power sources
a member of the IGM-group

These power sources can be used with all the other

POLYSOUDE welding heads
Any type of power source with
the required number of axes

28
a member of the IGM-group

Application examples

Heat exchanger rev 0

29
 Tube sheet welding heads
a member of the IGM-group

Flush Titanium welding :

TS 25 equipped with front
protection chamber

30
 Tube sheet welding heads
a member of the IGM-group

TS 2000 for small heat exchangers tube welding

with a X-Y supporting device

Protruding small
stainless steel
tube welding
with the TS 2000
equipped with
AVC and an
integrated wire
feeder

31
 Tube sheet welding heads
a member of the IGM-group

Heat
exchanger for
chemical
industry

32
 Tube sheet welding heads
a member of the IGM-group

TS 2000 for heat exchanger manufacturing

Protruding
carbon steel
tubes welded
with the TS 2000
equipped with
AVC and an
integrated wire
feeder

33
 Tube sheet welding heads
a member of the IGM-group

Large diameter tube (up to

110 mm) welding with TS
200 welding heads

34
 Tube sheet welding heads
a member of the IGM-group

Large heat exchanger welding

with a TS 2000

35
 Tube sheet welding heads
a member of the IGM-group

Steam Condenser tube welding with protection

chamber

36
 Tube sheet welding heads
a member of the IGM-group

Compressor inlet air cooler for

natural gas

Header box
welding with
integrated
manifolds

TS 2000 with
wire and AVC

37
 Tube sheet welding heads
a member of the IGM-group

TIG 20-160 welding head

with AVC and oscillation

38
 Tube sheet welding heads
a member of the IGM-group

Titanium welding
with protection
chamber and wire

Special supporting
and positioning
device of the
welding head

39
 Special applications
a member of the IGM-group
Car industry application

Automated installation for welding of petrol tank

inlet nipples for AUDI and BMW cars

40
 The solution for high Quality
a member of the IGM-group Orbital MAG welding !
Many thanks for your attention !

New !
Orbital MIG-MAG welding
Up to 4 kg/hr deposit rate

41