Orbital and automated welding

Orbital tube to tubesheet welding

Automation for advanced productivity

Boilers and heat exchangers are used in all kinds of industries and are mostly found in the chemical and petrochemical industries, in refineries, as well as in electric power plants.

POLYSOUDE provides tube-to-tubesheet welding heads with or without filler wire and a continuous rotating torch. The high duty cycle is achieved due to water cooling. Optional accessories for internal bore, back/double plate applications are available.

Welding power sources

Polysoude - Welding Power Sources for orbital and automated welding See our products

High performance equipment for various applications

A welding power source for orbital welding is composed of several integrated subunits, each with specific functions:

  • One or two Power Inverters to supply both the welding current and, in the case of GTAW Hot Wire welding, the current to heat up the filler wire. Today, inverter sources are state of the art and POLYSOUDE’s unique high performance transistor power source PC-TR is cutting edge.
  • A programmable control unit, operated through an integrated micro- or PC-controller.
  • An integrated or external data acquisition system.
  • PS 164 Basic - Full Function, portable, “All Inclusive” power source + Contact us
    Complete and ready to use for all of the most common applications
  • P4 Advanced - Intelligent, portable 4-axis power source + Contact us
    Intuitive user interface, automatic weld procedure generation, built-in quality tools
  • P6 / P6 HW Advanced - Intelligent, 6-axis Cold and Hot Wire power source + Contact us
    Built-in Arc Voltage Control (AVC) and torch oscillation (OSC) / torch off-set, intuitive user interface
  • PC Unique - High power, multi-purpose, multi-axis, multi-process power source + Contact us
    Adaptable to all orbital, automated welding even cladding applications. A high performance power source with simply “no limits”
  • Data acquisition system Advanced - Productivity optimisation and follow-up for P6 and PC power sources + Contact us
    Process tracking, data-recording and archiving for total quality control

Tube to tubesheet welding heads

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The result of 60 years of continuous improvement

POLYSOUDE provides different configurations of tube-to-tubesheet equipment according to the application and special requirements:

A closed chamber welding head allows the execution of fusion welding without the addition of filler wire. - An open welding head without AVC configuration is particularly suitable for single layer welding. Two layers must be welded in two separate steps.
An open welding head with AVC configuration allows the use of multiple welding heads with filler wire by one operator. The electrode to workpiece distance can be programmed and is kept constant without interruption of the weld cycle.

  • TS 34 Precise and clean – Perfectly positioned and free of oxidation + Contact us
    Specially designed for the fusion welding of flush and slightly recessed titanium, inconel and all oxidation sensible materials
  • TS 8/75 “Top Gun” – One operator handles multiple welding heads + Contact us
    Designed for all weld joint configurations (protruding, flush, recessed, …). The welding head is equipped with a pneumatic clamping/centering system.

Wire feeders for tube to tubesheet welding

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Compatible with all series of power sources and welding heads

Generally, a wire feeding device can be directly mounted onto the orbital welding head or used as an external wire feeder. The choice of feeding device is dependent on the conditions of use, the constraints of the application, the requested mobility of the equipment and sometimes on the availability of the filler wire which must be on suitable spools.

  • Polyfil Floor mounted wire feeder + Contact us
    Multipurpose wire feeder for GTAW welding  for both Cold and Hot Wire
  • Polyfil-TS - On-board On-board wire feeder for tube-to tubesheet welding heads + Contact us
    “Twist-free” wire feeder for GTAW welding with rotating wire spool

Customised equipment and tools for orbital tube to tubesheet welding

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Proven solutions for unique applications

While the work piece is fixed, the welding torch follows a circular welding seam. For specific applications not covered by our range of modular standard welding heads, Polysoude has developed and is continually upgrading a range of generic tools adaptable for specific customer needs.

  • Welding lances and torches From the inside - For internal bore and reduced access + Contact us
    Special tools, torches and lances for tube to tubesheet welding heads
  • TP 60 Full control – For critical applications + Contact us
    For critical applications such as Urea reactors out of super duplex. Tube to tubesheet welding head with adaptive sensor and more…
  • TIG-20-160 Endless - X/Y programmable torch adjustment + Contact us
    Tube to tubesheet welding head for multilayer welding without interruption 
  • Robotic tube to tubesheet welding Never stops – Robot solution with offline programming and self positioning + Contact us
    Intelligent solution with laser sensor positioning and quality inspection system

Nearly all weldable metals and alloys are used in the field of tube-to-tubesheet applications, whereas the range of tube dimensions is relatively restricted. Most of the tube diameters measure between 19.05 mm (3/4″) and 50.8 mm (2″) with wall thicknesses between 1.65 mm and 4.5 mm.

In most cases, the welding equipment used for tube-to-tubesheet welding is strictly adapted to the kind of application and the desired level of automation:

1 – Welding equipment featuring three controlled axes (welding gas, welding current, torch rotation) is composed of a power source with integrated weld controller and a closed chamber welding head. This equipment allows the execution of fusion welding without the addition of filler wire.

2 – Welding equipment, including four controlled axes (welding gas, welding current, torch rotation, wire) is composed of a power source with integrated weld controller and an open welding head. The equipment is particularly suitable for single layer welding. Two layers must be welded in two separate steps.

3 – Welding equipment fitted with five controlled axes (welding gas, welding current, torch rotation, wire, AVC) is composed of a power source with integrated weld controller and a welding head with AVC configuration. The equipment allows the use of multiple welding heads by one operator, the electrode height is programmed and automatically adjusted without interruption of the weld cycle.

4 – Welding equipment furnished with six controlled axes, (welding gas, welding current, torch rotation, wire, AVC, torch offset) comprises a power source with integrated weld controller and a welding head with AVC and motorised torch offset configuration. The equipment allows the chaining of multi-layer welding (two or more layers). The torch height and gyration radius (offset) are programmable and automatically adjustable.