WELDING MACHINES

Andelko Marusic
Objectives

To give an idea about:

the SAIPEM fleet

S-Lay and J-Lay barges configuration

Standard welding equipment installed on barges

Technical information about welding equipment

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 Configuration of the Saipem fleet

S-LAY BARGES J-LAY BARGES

NO NO
DOUBLE JOINT QUAD JOINT
DOUBLE JOINT QUAD JOINT
FACILITY FACILITY
FACILITY FACILITY

CASTORO 6 CASTORO 2 FDS S7000

SEMAC 1 CASTORO 8

CASTORO 10

CRAWLER

S 355

BOS 270

BOS 230

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S- LAY BARGE CONCEPT
(Castoro 6)

LINE UP
DOUBLE BEVELLING
JOINT STATION

NDT THIRD SECOND FIRST

COATING
STATION WELDING WELDING WELDING
STATION STATION STATION

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S-LAY Barge: PLE and Welding
Equipment (Castoro 6)
Bevelling station: 4 bevelling machines (Pipe Facing Machine)
(2 for SAW bevel preparaton, 2 for FL bevel peparation)
Double joint
4 SAW welding station: 2 internal Lincoln head NA3 and
NA5 on the 12m long boom , 4 esternal Lincoln head NA3
2 Internal Line Up Clamp (ILUC)
Welding stations
First station: welding system PASSO,PRESTO
S-Type ILUC for fit up, PFM for beveling of main pipe string
in case of cut out
Second and third welding station: welding system PASSO
(If using two bands on one joint it is possible to use 4
welding hads at the same time)
NDT station: NDT and repair if needed
Field joint: coating

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Castoro 6 bevelling station

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Castoro 6 firing line configuration (1)

CLOSED INDUCTION
COIL

Line up used to aline the pipe Induction heating provided by

to be weld on the main line pipe two induction coils. Two types:
string. open is applied on the main
line pipe string;
close is applied on the
stand-by pipe.

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Castoro 6 firing line configuration (2)

The open induction coil must ILUC in the first welding

be used to allow ILUC station as it is positioned
ombelical cable to pass before fitting up.
through.

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Castoro 6 firing line configuration (3)

Welding with PASSO system Central magnetic ground

in first station between first and second
welding station.

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BOS 230 firing line

Two welding stations and line up

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S355 firing line

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J-LAY BARGE CONCEPT (S7000)

WELDING STATION

BEVELING STATION
NDT STATION

J-LAY TOWER

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J-LAY Barge PLE and Welding
Equipment (S7000)
Bevelling station: 4 bevelling machines
Pipe movement phases
Conveyor: pipe is linearly moved from the bevelling station to
the tower
Loader: pipe is turned in the vertical position
Elevator: pipe is elevated to the level of the upper welding
station
Transfer: pipe is transfered to the stand by position where it
is pre-heated
Welding station
Welding carusel: 3 presto double torch systems, 6 ESAB
welding machines LRA 400, separate gas system (Argon,
CO2 bottles on the welding carusel, gas reducers, gas
mixers)
J-Lay ILUC
NDT station: NDT, repair, coating

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J-LAY Barge PLE and Welding
Equipment (S7000)

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S7000 J-lay ILUC

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FDS Firing Line (1)

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FDS Firing Line (2)

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TECHNICAL INFORMATION ABOUT
WELDING MACHINES
Introduction

Scope of this seminar is to get theoretical knowledge about

welding machines used by Saipem. Important is to understand
how welding machines are integrated in welding system and in
case of problems which is the way to act during
troubleshooting. Sometimes welding system is complex and is
not very simple to understand at first sight where to look for the
problem. You are not electrical engineers but on the barge or
onshore you will be the only person who should understand all
about welding system. It doesn’t mean that you have to repair a
welding machine but you have to be able to understand if
something is wrong with it. Technical documentation will be also
delivered (user and service manuals) so in the future if you need
you can deepen your knowledge.

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 Clasification of Welding Machines (1)

DC Welding Machines

DIRECT
CURRENT WELDING
MACHINES (DC)

STATIC ROTATIVE

WELDING RECTIFIER INVERTER DYNAMO ALTERNATOR AND

WELDING RECTIFIER

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Clasification of Welding Machines (2)

AC Welding Machines

ALTERNATIVE
CURRENT
MACHINES (AC)

STATIC ROTATIVE

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DC Rotative Welding Machines

In general this are dynamo (DC generators) which are coupled

with one diesel motor or with three phase asynchronous motor.
They are used for SMAW and air gouging. There have two
regulations. First one is Open Circuit Voltage (OCV) that is
regulated by changing excitation current of the stator winding.
OCV also depends on RPM of the rotor. Change of OCV
translates the static characteristic without changing a slope. For
another regulation additional winding has been added and this
one reduces the excitation field in function of the amount of
welding current. Dynamo has a collector which together with
brushes practically forms mechanical rectifier. Brushes are
positioned in neutral zone. If they are moved from this position
you change short circuit current and with this also a slope. The
position of brushes is changed mechanically by rotating a lever.
This welding machines has optimal performance. Problem is
that are very heavy and request periodical maintenance of
collector and brushes. Even they are not in production any more
they are still frequently used in on shore pipe lines.

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DC Rotative Welding Machines -Dynamo

SDL 400 Amp

a) Short circuit and slope adjustment
b) OCV adjustment

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DC Static Welding Machines
Transformer and welding rectifier -1

This machines consist of three phase welding transformer which

one on the secondary winding supply three phase rectifier.
Semiconductor electronic components that are used as rectifiers
are called thyristor which in fact are ignition controlled diode.
Diode consist of two electrode (anode and cathode) and has a PN
junction. When diode is direct polarised, which means ANODE is
on potential more positive then CATHOD she can conduct current.
When diode is reverse polarised (negative on ANODE and
positive on CATHOD) it can not conduct current and it behaves as
open circuit. Thyristor in adition to ANODE and CATHODE
connection also have third control input called GATE. Thyristor
even direct polarised cannot conduct until it is not piloted on gate.
In that way by changing angle of ignition of the thyristor, different
voltage can be obtained on the output of rectifier and output
welding current can be controlled.

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DC Static Welding Machines
Transformer and welding rectifier -2

Welding rectifier principle: maximum output voltage

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DC Static Welding Machines
Transformer and welding rectifier -3

Welding rectifier principle: reduced output voltage

dew to decrease of angle of driving pulse on thyristors 1-3

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DC Static Welding Machines
Transformer and welding rectifier -4

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DC Static Welding Machines
Transformer and welding rectifier -5

Intermittance factor: indicates how long welding can be carried out at

the specified welding data, expressed as a percentage of a 5 - minute
period.

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DC Static Welding Machines
Transformer and welding rectifier - 6

Characteristic:
More sophisticated in comparison with rotative welding machine.
Not requested special maintenance because they do not have
peaces in movement.
Very heavy because transformers implemented work on mains
frequency (50 or 60 Hz).

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DC Rotative Welding Machines
Alternator and welding rectifier

Alternator and welding rectifier machines are similar to the

transformer and welding rectifier type mentioned before. The
difference is that instad of thansformer they have three phase
alternator (asynchronous generator) which, on the secondary
winding, supply three phase rectifier.
In Saipem this type of equipment we use on Pay Welders and
onshore production
Onshore motor generator Miller Big Blue 500XCC

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Rotative DC welding machines
Stick Mode -1

Static characteristic of stick

mode (constant current)
Two controls
Ampere range switch (step
control)
Amperage Adjust Control
(fine control, can be also
remoted)
The arc drive circuit
provides additional
amperage during low
voltage (short arc length
conditions) to prevent
“sticking” electrodes

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 Rotative DC welding machines
Stick Mode - 2

Demonstration how the same change of stick out (arc length) can
result in different welding current change (first case 20A, second one
70A where welder can control better molten puddle and deposition rate

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Rotative DC welding machines
TIG Mode

Static characteristic of TIG mode (constant current )

Similar to stick characteristic but not the same
OCV is optimised for stick and is lowered for scratch start TIG
welding (HF start or lift arc option )

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Rotative DC welding machines
MIG Mode

Static characteristic of MIG mode (constant voltage)

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DC Rotative Welding Machines
Alternator and welding rectifier

On shore pay welders use MOSA MS 2x400 MIG welding

machine

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DC Static Welding Machines – Inverter
Principle of operation 1

By development of fast semiconductor switches new type of the

welding machines has been introduced. They are called inverters
and they are based on static conversion of direct current to the
alternate current.
The first part of the machine is single or three phase rectifier which
rectifies input AC into DC voltage. This voltage then is filtered
(smoothed) and is supplied to the semiconductor switch. This part
consist of fast transistor (Insulated Gate Bipolar Transistor or
Metal Oxide Semiconductor Field Effect Transistor) which is
interrupting DC voltage with very high frequency (20-50kHz).
The AC voltage created can be transformed to secondary voltage
by means of power switching transformer. This one reduces high
input voltage to the low secondary voltage. This AC voltage is than
rectified by diodes and filter by inductance.

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DC Static Welding Machines – Inverter
Principle of operation 2

Inverter principle:
Fig1-2, output voltage on TM1-TM2.
Fig 3, resulting output voltage from two transistor pairs
together.
Fig 4, output current

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DC Static Welding Machines - Inverter
PWM Concept

Pulse Width Modulation concept

Switchig frequency is constant
By changing of width of control signal changes the time
during transistor in power unit conduct.

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DC Static Welding Machines Inverter
Principle of Process Regulator -1

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DC Static Welding Machines Inverter
Principle of Process Regulator - 2

For MIG-MAG process welding machine needs voltage

reference (constant voltage characteristic)
For SMAW process welding machine needs current reference
(constant current characteristic)
Process regulator is measuring output voltage and current, and
comparing them with requested values comming from internaly
memorised characteristic.
Resulting signal is driving power unit maintaning ouput voltage
or current on requested level

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DC Static Welding Machines Inverter
External voltage sense

Optional external sense of arc voltage – dashed lines

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DC Static Welding Machines –Inverter
Advantages - Disadvantages

Because of high switching frequency dimension and weight of power

transformer is reduced. Transformer is realized by ferrite cores, not
by ferrous sheet as in case of welding rectifiers. For this reason
complex weight of welding machine is reduced. Dew to the high
switching frequency dimension of the output inductance is also
reduced.
Different welding characteristic and processes can be easy
incorporated because they are part of software algorithm that are
incorporated in machine (SMAW, TIG, MIG, MIG-PULSED). For new
models upgrade of the machine is related to the modification of the
software and does not request hardware modification. It means that
equipment can be improved constantly and personal requirements
can be implemented.
Very complex. For complicated repairs they have to be send to the
factory.

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DC Static Welding Machines - Inverter
LUC 400 on Crawler

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DC Static Welding Machines - Inverter
LUC 400 or LUC 500

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DC Static Welding Machines - Inverter
LUC 400 Setting Box

Communication between
power source and the
welding setting controll is
throught 5m long
bidirectional optical cable.
This cable also consist of
two cooper conductors that
supply the unit.
LUC 400 is used with Passo
system only, or with MED 44
unit for FCAW repair

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DC Static Welding Machines - Inverter
LUD 450W (1)

ESAB welding machines

LUD 450W: standard inverters
used for production in firing
line.
For semiautomatic welding
(repair station) used with wire
feeder unit MEK44.
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DC Static Welding Machines - Inverter
LUD 450W (2)

More frequently used on Saipem barges

Specially modified for Saipem
Saipem interface to Passo and Presto
welding system
Personalized voltage drop characteristic
PUA 1 programming unit
Possibility to be use with different mains input
(autotransformer option )
Standard 3 phase 400Vac 50-60Hz
3 phase 440Vac 60Hz on Castoro 6
3 phase 480Vac 60Hz on Semac 1

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DC Static Welding Machines - Inverter
LUD 450W (3)

Possible mains voltages 3 phase 50-60Hz:

208V,230V,400V,460V,475V,480V

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DC Static Welding Machines - Inverter
Welding machine to Passo interface

Welding machine needs sequent elettrical input signals to be

provided from Passo welding system:
Start
Welding program
Increment / Decrement of welding voltage
Arc welding voltage sensing (optional)
Older version of Passo cabinet was only able to give start and
Increment / Decrement command
Remote control Esab was developed to change program directly
from welding station and also to have possibility to visualize
welding parameter (voltage and current)

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DC Static Welding Machines - Inverter
Remote control Esab (1)

It is installed between welding machine and Passo cabinet

Takes power suppply from welding machine, additional cables
and shunt have to be instaled to provide input signals for
ampermeter and voltmeter

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DC Static Welding Machines - Inverter
Remote control Esab (2)

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DC Static Welding Machines - Inverter
Remote control Esab (3)
Signals connected to the welding machine
A and B - 42Vac (power supply)
F - Start (must be short circuited to B to give start signal)
V - positive external sensing voltage
E - negative external sensing voltage
L - common for Programs and INC/DEC comands
W – INCREMENT (must be short circuited to L to increment
output voltage in step of 0,25V)
X - DECREMENT (must be short circuited to L to
decrement output voltage in step of 0,25V)
N,P,R,S – program inputs (one at the time must be short
circuited to L to choose repectivly programs 1,2,3,4 saved in
PUA 1 programing unit)
Welding machine (PUA 1) must be in REMOTE mode to respond
to commands mentioned before.

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DC Static Welding Machines - Inverter
Remote control Esab (4)

New version of Passo cabinet have possibility to change welding

programs directly from welding head.
If programming unit PUA 1 is installed in welding station it is
posible to use it to visualise welding voltage and current. In this
case it is not necessary to install Remote control Esab any more.

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DC Static Welding Machines - Inverter
LUD 450W schematic diagram

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DC Static Welding Machines - Inverter
LUD 450 and MEK 44 interface (1)

Additional PC board MEK 44 is istalled in welding machine

It is used as interface between LUD 450 and Passo or Presto
welding system through 23 pin Burndy connector
The same PC board is used in MEK 44 Wire feeder unit
On the back side of LUD 450 there is a switch AUTOMATIC/
MANUAL which decides if internal or external PC board is
interfaced to the welding machine.
MANUAL selection – external wire feeder MEK 44 enable
AUTOMATIC selection – internal MEC 44 board anabled
On the latest model no switch is installed. Function is carried out
by software
Internal/ External switch for enabling of the sensing on the
negative pole

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DC Static Welding Machines - Inverter
LUD 450 and MEK 44 interface (2)

If switched to External, and pin E (23 pin Burndy connector) is

connected on the potential of the pipe, voltage drop on negative
welding cable is compensated by welding machine.

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DC Static Welding Machines - Inverter
Welding system to Presto interface (1)

Welding machine needs sequent elettrical input signals to be

provided from Presto welding system:
Start ( pin B,F)
Welding program (pin N,P,R with reference to pin L)
Analog voltage reference (0-10V) (Pin K with reference
to pin L)
V - positive external sensing voltage
E - negative external sensing voltage
Signals on program pins must be binary coded

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DC Static Welding Machines - Inverter
Welding system to Presto interface (2)

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DC Static Welding Machines - Inverter
PUA1 Programming unit concept

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DC Static Welding Machines - Inverter
PUA1 Programming unit – Main menu

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DC Static Welding Machines - Inverter
PUA1 Programming unit – Configuration

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DC Static Welding Machines - Inverter
PUA1 Programming unit – 5 PROG

Passo setup (Forget override - Disabled)

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DC Static Welding Machines - Inverter
PUA1 Programming unit – Analog voltage

Presto setup (DIGITAL OP: Binari coded)

Analog MAX: 50V

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DC Static Welding Machines - Inverter
PUA1 Programming unit – Memory card

System software PCMCI memory card used for new sofware

instalation every time new machine is instaled or PC board
substituted
Software version for Saipem machines
Boot software 1.12A
Power source 2.51A
Wire Feeder 2.74A
Weld Data Unit 3.00Z
Program memory card for welding data transfer

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Castoro 6 SAW configuration (1)

DJ FACILITY INTERNAL SAW HEAD

INTERNAL HEAD
WITH CAMERA
AND LASER POINTER

SAW ILUC GARAGE

LINCOLN DC1500
WELDING MACHINES

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Castoro 6 SAW configuration (2)

SAW EXTERNAL HEAD

LINCOLN

SAW
DJ FACILITY
EXTERNAL HEAD INTERNAL SAW HEAD
LINCOLN

LINCOLN
SAWNA3
ILUC GARAGE
LINCOLN DC1500 LINCOLN NA5
CONTROL UNIT
WELDING MACHINES CONTROL UNIT

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Castoro 6 SAW configuration (3)

Welding machines for SAW – Lincoln DC1500

- 67 -
Castoro 6 gas distribution system

SAIP/02 gas reduction system SAIP/04 gas mixer

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S355 welding equipment

- 69 -
BOS 230 welding equipment (1)

AristoMig U500:
new generation ESAB
welding machine
it is the evolution of LUC
400, Aristo 500, and LUD
450W
it has been personalized
for SAIPEM and can be
interfaced with PASSO
and PRESTO.

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BOS 230 welding equipment (2)

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BOS 230 welding equipment (3)

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Other welding equipments

Lincoln STT 2 (Surface

Tension Transfer)
used for root pass
welding where ILUC with
copper shoes is not
allowed or possible
can be used stand-alone,
with PRESTO or PASSO,
or with the wire feeder
unit S10.

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