Circle (nozzle) welder

[CWEng]

Anybody out there using Cypress/Bug-o circle welders for nozzle welding and have any input as to their reliability, usability, setup, performance, etc? I haven't seen one used in a long time, but we have an upcoming job where they seem like they could be useful, and just thought I'd see if there are any users out there willing to share experiences. Can't find much online about them from users.

 

I haven't used this type of gear to weld for a long time, and never for nozzles, but I have seen how some shops do it. This equipment is what it is - somewhat clunky, a lot of modular parts to bolt together and adjust, and not as fast as they would have you believe. But if you have a technician and welder who are a bit handy you can do well with it.
If I were welding nozzles into large vessels day in and day out, I would prefer to home-build a more streamlined circle welder, possibly using some elements from Bug-o.
I think an equal challenge will be constructing a safe platform for elevated working, and all of the welding equipment location and cabling issues that come with that.

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

 

[racookpe1978]

Our company uses a complex but field-capable circular wire-fed TIG that is digitally controlled with a remote TV video of the weld arc and melt puddle for welding up deep valve seats in steam plant control valves.

Capable - a different manufacturer though. Hard to configure, align, and start welding for the first time for a newbie. Don't have any experience with your brand.

If you are considering buying it, make SURE you have the sales rep do the demonstration IN your plant (at YOUR field sites!) using YOUR sample problems and YOUR installations. Have him (her ?) DO THE WELDING on YOUR parts, never let them run a canned demo on their property! Setup, installation, adjustment, welding, completion, surface finish, removal, setup for the next valve. Force them to do it ALL. A canned demo in their site will only sell their product under their optiminimum conditions.

 

optiminimum

Don't know if that was intentional or a Freudian slip, but I love it. Can I have your permission to steal it?

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

 

[CWEng]

Thanks guys. You make some good points. I didn't really mention, but I'm not entirely set on that particular nozzle welder if there is a better one out there, but I know that one has been around a while, and it isn't over the top expensive. The other one that I've looked into is a bit pricier (about 5x more). Might have to wait for further justification. But it looks pretty slick.

https://welmax.no/product/portable-on-pipe-nozzle-welder/

 

You can get any custom-designed system you want, and automation shops are happy to do open-ended development (by 'open-ended' I mean 'running tab'). They seem to forget that vessel fabrication is a cut-throat, word-wide business, and that sweet technology comes with a price tag.

One of my guidelines for weld automation is that you should take advantage of the part geometry to guide the arc. Here you have a simple circle and a downhand welding position, so that you are free to use your optimum weld process.
Another one is 'use the minimum automation necessary to do the job successfully'.
Oh, and engage your workforce who will have to live with what you buy.

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

 

[racookpe1978]

Quote (racookpe1978)
optiminimum


Don't know if that was intentional or a Freudian slip, but I love it. Can I have your permission to steal it?

Feel free of course, but be careful. Once you start down a Freudian slope, you always accelerate past the breaking point.

 

[CWEng]

@IM- Funny thing, is that we have approached an welding automation vendor about a completely different custom automation project where we would pay them for development, and we can't get them to respond.

 

Once you start down a Freudian slope, you always accelerate past the breaking point.

No worries, I always check that my breaks are working.

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

 

[chicopee]

I have never seen this type of welder used in our heavy steel fabrication firm, however, I saw a YOUTUBE demonstration of a nozzle being welded on a flat plate and so I am thinking how will the welding tip adjust for elevation change when welding nozzles on curved surfaces?

 

[CWEng]

They have a cam or programmable motors that drive the head up and down to match the rise and fall of the pipe.

 

The fine tuning can be achieved with AVC height sensing. But with Bug-O type equipment that adds another bulky component to the stack.

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."