This website uses some cookies. If you continue navigation, you accept the use of cookies. Warning: blocking cookies prevents the proper operation of the site.

Guided search

Find your products

Kind of components to be machined ?

Which type of work is to be performed ?

What are the diameters/dimensions ?

What are the wall thicknesses to consider ?

Shall the equipment be driven?

Flange Diameter ?

Boring Depth?

Shall the machine be operated?

Search this site
Find a product
  • World Leading Machining Solutions

    Beveling - Pipe Facing - Orbital cutting - Counterboring - Surfacing - Boring
  • World Leading Machining Solutions

    Beveling - Pipe Facing - Orbital cutting - Counterboring - Surfacing - Boring
Read more

Orbital tube to tubesheet 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 with water cooling. Optional accessories for internal bore, back/double plate applications are available.

family-power-sources-orbital-welding.jpg

WELDING POWER SOURCES

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.
family-tube-to-tubesheet-welding-heads.jpg

TUBE TO TUBESHEET WELDING HEADS

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.

family-wire-feeders-tubesheet.jpg

WIRE FEEDERS FOR TUBE TO TUBESHEET WELDING

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.

family-customised-tubesheet-welding.jpg

CUSTOMISED EQUIPMENT AND TOOLS FOR ORBITAL TUBE TO TUBESHEET WELDING

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.

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.

Closed chamber welding head : TS

  • TS 8/75 Open welding head for welding of tube-to-tubesheet joints

    8 mm (0.31") ID
    75 mm (2.95") OD

  • TS 34-2 Closed chamber welding head for welding of tube-to-tubesheet joints

    10 mm (0.39") ID
    33.7 mm (1.33") OD