Example Column & Boom hire package

Spectrum is Europe’s biggest stockist of hire plant column & boom sub arc welding manipulators.

This is an example of the plant, support and service you would get.

The Request: a 3 x 3 column and boom

1. TO HIRE  3 x 3 column and boom STATIC BASE Lincoln Electric DC 1000 & NA-3 submerged arc welder package complete.

2. TO HIRE  ESAB OPC flux recovery system c/w 270ltr dedicated 415V 7.5HP 29CFM compressor, 20mtr air hose, fittings, attached to coom arm (we fit).

3. TO HIRE  Gullco GOV 200 110V sub arc flux oven

The Support

We can also offer install, commissioning, and training, to ensure all the operators are competent and certified to use automated SAW. We can also assist with getting you a weld procedure in place.

Is it 275 or 355 grade steel?

If for example a 60° V-prep for example (100% from one side), you will need to lay down a MIG root run, grind back to ensure no porosity, then weld on top of that. You may also need internal ceramic backing strips (these are not essential subject to procedure) and foil to weld onto to get full penetration for run number 1, or a steel strip ring on the inside behind the weld for the MIG run to blast onto for 100% penetration (subject to procedure). 35mm plate may need approx. 14 sub arc runs to fill (subject to prep and procedure).

To get the procedure verified, the below is a general rule of thumb:

1. Test welds on the same type of plate / same prep will need to be done.
2. Method written down for 10mm plate ie. 2 runs
3. Ultra Sonic tested to see if the welds passed.
4. Laboratory test done after (for DNV) to make sure there are no weak zones / Charpy test.
5. Get a NDT company to formally write that SAW weld procedure (inc. interpass temperature stipulations) into a document to follow.

1. Operators trained and certified to use automated SAW in accordance with DNV ISO 3834.
2. Parameters addressed to suit application ie. XXX amps / XXX volts / XXX cm per minute (subject to prep) will more than likely be the settings you end up using (these are the most common and best results for single 3.2mm wire when welding XXmm plate – interpass temperature is imperative to follow – you will need a digital thermometer gun to make sure the prep has gone down to approx. 60°C before putting in another weld – the WPS will state this).
3. With submerged arc, you don’t necessary need the operator to be coded (some clients do need the operator to be coded), as the automated SAW welding machine is classed as doing the weld.
4. The training and certificate Spectrum offer will make sure the operator is aware of all issues to note ie. interpass temperature, and the comprehensive guide to ensure full and proper understanding of the equipment and welding process to ensure consistent success.
5. Because every job is different ie. grade of steel, thickness, prep, process etc, the weld parameters will alter slightly, and to formally sign off on that PQR / WPS procedure before the weld goes into the job, you will need NDT / lab / metallurgist / weld procedure company such as an NDT specialist.

To put a formal and verified SAW weld procedure in place, you will to follow our step by step DNV guide.

NDT companies will get you the weld procedure in writing (if required), but they’ll suggest the below.

6. Weld test done in your workshop to a set of parameters, on a test piece.
7. NDT company to ultra sonic / x-ray / dye pen test piece (to ensure no cracking / verify structural integrity of steel / to show weld run layering and heat affected zones).
8. Laboratory Charpy test on the test piece to verify metallurgic integrity ie. tensile and yield strength.
9. Weld procedure (WPS) then formally written by an NDT company (after NDT and lab results comes back as a ‘PASS’) that stipulates consumables, parameters, and interpass temperatures stipulations.

Should you have any further questions, I’ll be happy to help.