Customised equipment and tools for orbital tube to tubesheet welding
Orbital tube to tubesheet welding as versatile solution
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 with water cooling. Optional accessories for internal bore, back/double plate applications are available.
Smart Welding Station - Power sources
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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 TIG 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.
P3 UHP
Designed for demanding environments, ultra-compact portable 3-axis Smart Welding Station +Contact us
Lightweight design and highly accurate, with ergonomic features: WiFi, digital flowmeters, OPC-UA ready...
P4
Advanced - Intelligent, portable 4-axis Smart Welding Station +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
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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.
Multipurpose wire feeder for TIG 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 TIG 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.
SPX Compact
Endless - X/Y programmable torch adjustment +Contact us
Tube to tubesheet welding head for multilayer welding without interruption
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…
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.
