ORBITALTIGWELDINGMACHINE(PIPEtoPIPE) ESABRef:NPRJ/KAPL/OT/2012/06 Date:12/04/2012

TECHNICAL SPECIFICATIONS OF ORBITAL TIG WELDING MACHINE FOR PIPE WELDING Sl. NO 1 1.1 FEATURE UNIT SPECIFICATION Butt Welding of Extraction Pipes in Extraction Pipes Boiler Piping (L01, (Condenser) L10, L11, L12) L01: 120 to 528, L10: 21.34 to 2136.0 L11: 21.34 to 219.1 500 to 1020 OPTION Machine for Butt welding quoted FEASIBILI TY REMARKS

PURPOSE & WORK PIECE MATERIAL Purpose: Job details:

Pipe OD Range:

mm

The quoted tool is suitable for OD range 160 and above upto 1020 mm L01: 11 to 59, L10: 3.73 to 31.0 L11: 2.77 to 3.9

Different Racks are required for different pipe ranges. The same are specified in the attached catalogue Joint configuration needs to be provided by the buyer for our Confirmation For Stainless Steel inside purging equipment if necessary is not included in the scope Please also inform the preheating of pipes before welding Handling equipment is not in our product range, hence not quoted

1.2

Pipe Thk. Range:

mm

10

The welding package quoted is suitable for 10 mm thickness. Buyer has to provide the joint details for confirmation

Pipe Material

CS: SA516Gr70 L01, L10, L12: Carbon (Pipes shall be Steel rolled from plates) L11: Stainless Steel Noted, the equipment is suitable for Carbon Steel and Stainless Steel welding Quoted Power Source, Weld Programming Unit, Pipe Welding Head & Welding Head Positioning

2 3

SCOPE OF SUPPLY: POWER SOURCE & CONTROLLER

Power Source, Weld Programming Unit, Pipe Welding Head & Welding Head Positioning / Handling Unit

3.1

Type of Power Source:

Microprocessor controlled programmable (invertor based) constant / pulsed current GTAW Welding power source - DC Straight polarity with controlled heat input and weld penetration.

Microprocessor controlled programmable (invertor based) constant / pulsed current GTAW Welding power source - DC Straight polarity with controlled heat input (Pulsing). Weld penetration is dependant on welding parameters

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ORBITALTIGWELDINGMACHINE(PIPEtoPIPE) ESABRef:NPRJ/KAPL/OT/2012/06 Date:12/04/2012

TECHNICAL SPECIFICATIONS OF ORBITAL TIG WELDING MACHINE FOR PIPE WELDING Sl. NO Model: 3.2 Vendor to specify FEATURE UNIT SPECIFICATION OPTION Welding Tool: PRD 160 Power Source: AristoMechtig 4000i with inbuilt water cooling unit Controller: AristoMech-4 Controller 4 ~ 400 A 250 A @ 100 % duty cycle 1 % max. It more accurate at maximum current 60 Volts 20 to 26 Volts 99 Programs FEASIBILI TY REMARKS

3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11

Output current range Current Duty cycle Welding Current precision Open Circuit Voltage Welding Voltage Range Maximum Number of Data Log Files in Memory TIG Arc Ignition Power Rating Auto Tripping

A A V V

3 ~ 300 A 250 A @ 100 % duty cycle 1 % max. 60 Volts (Minimum) (Vendor to Specify) Vendor to specify

KW

By means of an in-built high frequency unit By means of an in-built high frequency unit Energy save mode (400V), W 60, KVA Rating: 12 Vendor to specify KVA Tripping facility by means of an automatic Overload protection - tripping facility by means of an circuit breaker, in case of electrical short automatic circuit breaker - overloading, over heating etc. citcuit, overloading, over heating etc. A digital display unit to indicate all the working parameters (Voltage, Current, Pulsing time, Wire feed, Speed etc.) Built-in and suitable closed loop water cooling system with flow safety valve. Vendor to Specify 1% regulation 0.5 Amp / 0.1 Sec. Programmable limits (Vendor to specify range) Length to suit long travel on cable festoon 10" colour monitor for digital display unit (Please refer the catalogue) to indicate all the working & for Setting of parameters (Voltage, Current, Pulsing time, Wire feed, Speed etc.) Built-in closed loop water cooling system with over flow flow guard. 2-12 mm/s 1% regulation Program increments for 1 Amp / 0.1 sec Available only in manual mode. 8 m Gas hose length has been considered suitable for connecting the gas cylinder with the power source. Other necessary essential connectors are also included. Yes it is included Water flow guard, Gas flow low level error display.

3.12

Display Unit

3.13 3.14 3.15 3.16 3.17

Cooling unit Torch Oscillation speed AVC Function Programming increments for welding current & time parameters Welding parameter override during welding Gas hose with end fittings Gas cylinder to power source

3.18

3.19 4

Fault Protection Sensors WELD PROGRAMMING UNIT:

For gas & cooling water flow

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ORBITALTIGWELDINGMACHINE(PIPEtoPIPE) ESABRef:NPRJ/KAPL/OT/2012/06 Date:12/04/2012

TECHNICAL SPECIFICATIONS OF ORBITAL TIG WELDING MACHINE FOR PIPE WELDING Sl. NO FEATURE UNIT SPECIFICATION A microprocessor based weld program control unit with digital display unit, keyboard etc. OPTION Yes it a is microprocessor based controlled, with programming facility with 10" colour monitor for digital display. Menu buttons are with selection knobs are provided for setting parameters and ajustments FEASIBILI TY REMARKS

4.1

Type:

Key board not required The online data is printed on a inbuilt printer. For online waveform print, accessories like industrial PC and printer is required which reduces the mobility of the entire machine.

4.2

Weld Report Generation

Weld Programming Unit to facilitate easy output generation and online plotting of wave form through the external Chart Recorder.

Weld Programming Unit facilitates easy output generation. The plotting or graphical representation is seen on the monitor while data is printed on the online printer. For online wave form generation on external Chart Recorder, this requires a requires an industrial PC and printer - which is not in ESAB's scope.

4.3 4.4 5 5.1

Auto-diagnostic System Safety Lock ORBITAL TIG WELDING HEAD Type

Built-in fault check for system status. Key lockable switch-Programming / Low profile tube orbital welding head of rugged construction 250A, 100% duty cycle Vendor to Confirm

Built-in fault check for system status - Display in the form of Error codes User Level password protection is standard feature Orbital welding head of rugged construction - Model PRD 160, please refer to the attached leaflets Maximum welding current (100% duty cycle) DC 315 A - Continuous DC 400 A - Pulsed DC Spool and feeder is integral part of welding head

5.2 5.3

Current Rating Wire Spool & Feeder Location shall be integral part of the welding head

5.4

No.of passes of welding without interrruption

Vendor to Specify

As the cable is wound first and then it is unwound during welding. There is no specific data available on this, the less number of turns is to be used to provide unintrupped wire feeding to weld pool. Electrode size: 1.6 - 3.2 mm Filler Wire sise: 0.8 - 0.9 mm Water cooled Clamping details are enclosed separately

Please specify your requirement

5.5 5.6 5.7

Consumable Wire size Cooling for Torch & Body Clamping Type / Weld Head Mounting on Pipe - For easy mounting / dismounting of head

Vendor to Specify Water cooled Vendor to Provide complete details on clamping system of Orbital Weld Head on the Pipe

Attached

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ORBITALTIGWELDINGMACHINE(PIPEtoPIPE) ESABRef:NPRJ/KAPL/OT/2012/06 Date:12/04/2012

TECHNICAL SPECIFICATIONS OF ORBITAL TIG WELDING MACHINE FOR PIPE WELDING Sl. NO 5.8 5.9 FEATURE Wire Nozzle Adjustment (Manual) Torch Tilt In / Out UNIT SPECIFICATION Vertical, horizontal & angular Vendor to Specify OPTION angular adjustment = - 30 to + 45 (15 per division ) The contact tip is adjustable in Vertical and Horizontal direction Torch Tilt is possible Please refer to the attached information Pipe diameters between the specified range are required to quote the Standard Racks FEASIBILI TY REMARKS

5.10

Locator and Collet Assembly shall form part of supply and shall be suitable for above tube size.

Vendor to Confirm

There is no collets for this kind of tool. Standard size of Racks are avilable as per the list enclosed, Buyer to inform the rack sizes so as to quote The flow is regulated by Regulator mounted on gas bottle with flow measurement. The Power source / controller provides the flow and pre, post weld flow timing can be preset The minimum set value of flow rate is 4l/min and if it falls below this rate, the machine stops and gives an error

5.11

Built-in programmable mass flow meter with flow safety valve for shielding gas.

Vendor to Confirm

5.12

5.13

Motion controls: Torch Rotation: Constant or pulsed, Wire feeding: Constant or pulsed, AVC: Arc Voltage Control with provision for Torch oscillation. Tungsten Electrode Size

Vendor to Specify

Torch Rotation: Constant or pulsed, Wire feeding: Constant or pulsed. AVC and Torch oscillation is controlled through Mech4 controller Electrode size: 1.6 - 3.2 mm The cable and hose package for the welding head is sheathed with heat and abrasion resistant material. Note AVC cable & Weaving connection cables sensitive cables and winding dia is to be made as big as possible

Vendor to Specify The cable and hose package for the welding head shall be adequately sheathed with heat and abrasion resistant material. It shall withstand repeated winding / rewinding while in operation.

5.14

Cable and Hose Package

6 6.1 6.2 7

ELECTRICAL & ELECTRONIC SYSTEM Drive Motors All control cabinets and panels should be dust proof REMOTE OPERATOR PENDANT

Vendor to Specify Vendor to Confirm

Servo Motor driven Cabinets are with IP 23 protections

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ORBITALTIGWELDINGMACHINE(PIPEtoPIPE) ESABRef:NPRJ/KAPL/OT/2012/06 Date:12/04/2012

TECHNICAL SPECIFICATIONS OF ORBITAL TIG WELDING MACHINE FOR PIPE WELDING Sl. NO FEATURE Features: Pendant shall contain the following controls: a. Selector Switch: Weld / Setting b. Welding Program Access & Selection c. Display screen for welding parameters d. Emergency stop e. Sequence Start / Stop f. Gas flow switch g. Inching operation (by toggle switch control or joystick control) for the following functions: i) AVC function ii) Torch oscillation amplitude iii) Torch Centering iv) Wire feed speed v) Head travel speed vi) Welding current up/down (manual override) PIPE BUTT JOINT FIT-UP FIXTURE / JOB CLAMPING UNIT Type Clamping Pipe clamping range Axial Alignment Make & Model UNIT SPECIFICATION OPTION FEASIBILI TY REMARKS

7.1

Vendor to Confirm

Following are available for controls: a) Selector Switch: Weld / Setting b. Welding Program Access & Selection c. Display screen for welding parameters d. Emergency stop e. Start / Stop f. Gas flow switch g. Following are preset from the controller: i) AVC ON/OFF ii) Torch oscillation amplitude iii) Torch Centering iv) Wire feed speed v) Head travel speed vi) Welding current up/down

8 8.1 8.2 8.3 8.4 8.5 9

mm

Portable Manually operated Clamping on Outer diameter 500 ~ 1020 No mismatch at the root for welding Vendor to provide details

Note quoted, as the data not available

Note quoted, as the data not available

AMBIENT CONDITION & THERMAL STABILITY Total machine should work trouble free and efficiently under following operating conditions: Temperature: 5 ~ 50 Degree Relative humidity: 95% max. Total machine is suitable for to work trouble free and efficiently under following operating conditions: Temperature: 5 ~ 40 Degree Relative humidity: 95% max. But both not occuring at the same time

9.1

Vendor to confirm

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ORBITALTIGWELDINGMACHINE(PIPEtoPIPE) ESABRef:NPRJ/KAPL/OT/2012/06 Date:12/04/2012

TECHNICAL SPECIFICATIONS OF ORBITAL TIG WELDING MACHINE FOR PIPE WELDING Sl. NO FEATURE Training: For KAPL personnel at KAPL works after commissioning and prove out by Supplier. 10 Vendor to confirm UNIT SPECIFICATION OPTION Training on programming, usage of tool shall be provided by our engineers to KAPL. The WPS / Welding Parameter Generation is not in ESAB Scope. The criteria of prove out is to be defined by KAPL to ESAB to confirm in writing before finalisation of contract or if not available to be discussed mutually and accepted by ESAB. FEASIBILI TY REMARKS

EQUIPMENT INSPECTION & ACCEPTANCE Noted: Buyer to specify the NDT requirements. These tests shall be performed by ESAB at buyer's premises 1. Welding trials have to be conducted on on arrival of equipment.at Mundra Plant short length sample pipes, in presence of 1) Welding trials shall be conducted on short length KAPL Engineer, for a minimum of 10 Joints sample pipes, in presence of KAPL Engineer, for a of Carbon Steel Pipe OD ranging from 550 ~ minimum of 10 Joints of Carbon Steel Pipe of any one 1020 mm. OD ranging from 550 ~ 1020 mm. (ESAB will perform 2. Raw material and welding consumables welding on one type of pipe diameter) for above test shall be in vendor's scope. 2). Raw material and welding consumables for above 3. The Vendor to program the welding test shall be buyer's scope parameters for the above joints and weld 3). The welding parameters for the above joints and samples. weld samples shall be provided by buyer. 4. NDT: a) Visual / PT, b) UT or RT 4) These NDT test shall be qualified subject to receipt of NDT requirements

11

Welding on one size (diameter & thickness) of pipe (as per the buyers's choice will be performed, the size is to be informed in advance to arrange the pipes.

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ORBITALTIGWELDINGMACHINE(PIPEtoPIPE) ESABRef:NPRJ/KAPL/OT/2012/06 Date:12/04/2012

TECHNICAL SPECIFICATIONS OF ORBITAL TIG WELDING MACHINE FOR PIPE WELDING Sl. NO FEATURE MACHINE ERECTION & COMMISSIONING The quoted machine is standard machine and does not require specialised supervision. However, ESAB will Vendor to take full responsibility for supervise the erection, start up, test the machine , its supervision of the erection, vendor shall start control & all types of other supplied equipment, for the up, test the machine, its control & all types specified period in the price part, additional days shall of other supplied equipment, carrying out be charged as per the rates given. welding of test pieces etc. Service For carrying out welding of test pieces buyer has to requirement like power, air & water shall be provide WPS provided by KAPL. We have noted the srvice requirement like power, air & water shall be provided by KAPL. UNIT SPECIFICATION OPTION FEASIBILI TY REMARKS

12

Conducting trials on all ranges is not in ESAB Scope. The WPS in any case needs to be provided by buyer.

13 14 15

SAFETY WARRANTY SERVICE ON SITE IN INDIA Months

Machine should have adequate and reliable safety interlocks/ devices, to protect Operator, Machine, Work Piece during

24 hr / 6 days a week.

Machine has adequate and reliable safety interlocks/ devices, to protect Operator, Machine, Work Piece during Machine Operation 12 from the date of acceptance or 18 months from the 24 date of supply whichever occurs earlier Within 72 Hrs and 6 days a week, Working days only, through Phone / In person / or by other communication modes, whichever is most suitable

16

SPARES REQUIREMENT

Itemized break-up of mechanical, electrical and electronic spares used in the machine in sufficient quantity as per recommendation of Vendor for 2 years of trouble free operation Spare parts list is quoted shall be offered by vendor. The list is to include following, in addition to other recommended spares: (Unit Price for each item of spare shall be offered)

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