An oilfield equipment and vessel manufacturer in the United Arab Emirates approached Red-D-Arc for assistance with a large project. It was awarded to them at the last minute and was not their primary area of expertise. The requirement was to manufacture 25 large tanks with a timeframe of only one year. Each of the tanks was to be 5 meters in diameter by 25 meters long, manufactured using 16 millimeter thick material at a weight of approximately 45 tonnes.
The experienced Red-D-Arc Weld Automation team was able to immediately address all of the customer’s challenges. While other suppliers where insistent that the customer purchase the equipment, Red-D-Arc determined that long term rental would be their best option. This would avoid the time consuming process of acquiring CAPEX approval to purchase such a large amount of equipment and would further increase the profitability of the project. The manufacturer also had questions on how to avoid ovality and transverse movement of the sub-assemblies. Red-D-Arc experts were on-hand to provide the right advice and the right equipment to address these challenges.
The rental equipment included:
• 6x 10 tonne rotator sets
• 10x 60 tonne drive rolls
• 47x 30 tonne and 60 tonne idler rolls
• 7x submerged arc packages with LT7 tractors and D600 power sources
Red-D-Arc worked very closely with the company to ensure their success, providing comprehensive training and on-site assistance. After the successful completion of this project the company has become recognized in their market and are receiving new orders from similar customers in the industry. Furthermore, they anticipate being awarded “phase 2” of this project which is scheduled to begin in 2018.
A metal fabrication company located in Charlotte, North Carolina received an order for 300 small I.D. vessels for titanium molds. At the time they were using FCAW and back gouging the inside and outside of the vessels to achieve 100% penetration. On average they were producing 2 vessels per hour with 2 welders.
They reached out to Red-D-Arc to find a faster and more efficient way to produce these vessels. After discussions with Red-D-Arc the fabricator decided to purchase a bespoke submerged arc system.The custom designed system came complete with a small I.D. sub arc welding head mounted on a 9’x9′ column and boom, flux recovery system, NA5R automatic wire feeder, DC600 multi-process welder and 5 ton rotators. The system also included a laser and camera for precise control and monitoring of the submerged arc welding process.
The submerged arc system increased productivity by 250%. They were able to produce 5 cans per hour with half the labor cost. The safety of the work place was also significantly increased for a number of reasons:
• Back gouging was eliminated which in turn reduced the risk of fire
• Rotators replaced manual rotation of the vessels on tables
• Welders no longer had to weld inside the confined space of the vessels
The customer and the Red-D-Arc team were beyond pleased with the results. The customer plans to purchase two more of these systems for future projects.
Submerged arc welding can increase the efficiency and quality of many industrial welding projects regardless of the size or complexity. Red-D-Arc has all the equipment, expertise and experience to provide you with a submerged arc system to fit your needs – available for sale, lease and rent.
Red-D-Arc recently supplied a variety of equipment to a UAE based company that is fabricating pile piping and jackets for the largest offshore wind farm project in the world. The company had to meet a strict time line of only 6 months, and would require a massive amount of welding and weld automation equipment immediately. Through consultation with Red-D-Arc, the customer determined that renting the majority of the equipment would be the most economical option. Red-D-Arc was able to fulfil the customers equipment needs immediately thanks to our vast and diverse fleet of equipment.
This massive order involved equipment and support from Red-D-Arc North America, Red-D-Arc UK and Red-D-Arc Middle East. The order consisted of a variety of welding and weld automation equipment including:
• 23 column and booms with single and tandem submerged arc welders
• 20 submerged arc tractors
• 200 rotators
• 167 jack-up rotators
• 400 CC/CV inverter welders
• 200 FCAW wirefeeders
• 10 Induction Heating Systems
By renting the majority of the equipment the fabrication company avoided the need to invest heavily in specialized equipment and ensured they would meet their deadline. Red-D-Arc works with customers to address their unique challenges and develops specialized solutions. Learn more about customized turnkey packages here.
Red-D-Arc UK recently supplied 20x Fronius TransSteel 5000’s to a customer in the South of England through our WelderLogistics operating lease program. Red-D-Arc’s operating lease program provides all of the benefits of equipment ownership while delivering additional cost and operational advantages. A cost effective option to acquire your core fleet of welding equipment.
Benefits of the Red-D-Arc lease plan:
• No budget constraints and acquisition delays
• 100% write-off for tax purposes
• No interest charges and other carrying costs
• Fully factory warranty during the lease term
• Only the latest equipment
• Replacement of the equipment every three years with optional mid-term equipment upgrades
• Reduced operating costs
• Improved quality
Please call Red-D-Arc for further details on our WelderLogistics operating lease program at +971 (4) 885 8577 or Contact Sales.
A customer involved in the rebuilding of a hydroelectric power generation station came to Red-D-Arc with a unique challenge: Use induction heat to help separate a massive rotor from its center shaft assembly. A traditional approach is to use a combination of open flame along with dry ice which would have taken several weeks to set up and also ran the risk of being ineffective due to the scale and complexity of the project.
Sil Nonis, an induction heating specialist at Red-D-Arc, suggested using 6 induction heating units activated in sequence to provide thermal growth in a uniform pattern; releasing the interference from the center shaft before lifting the rotor. The 6 Miller ProHeat 35 Induction Heating Systems powered two half circle assemblies, positioned at the bottom of the locking ring which was 5′ in diameter as well as two half circle assemblies positioned on a top locking ring which was 4′ in diameter. Massive rotor arms also had 4 pads attached to them, positioned in sequence.
Setup took approximately 2 days and removal of the rotor was completed in a single day. The same process will be used to reinstall the rotor after it has been rebuilt. Over the next few years two additional rotor assemblies will be removed, rebuilt and reinstalled using the same process.
Red-D-Arc delivered three submerged arc systems to a construction company from Willebroek (Belgium) which has acquired a record contract for the construction of foundation structures to be used in an offshore wind farm close to the German-Dutch border. The Red-D-Arc column and booms are 7 m x 7 m and are equipped with a double wire system powered by the ESAB 1250 for welding 4 mm cored wire. In addition, each of the column and booms included a seam tracking system and flux recovery unit. Thanks to the advanced electronics and touch screen interface controls the turnkey systems each require only a single operator.
Red-D-Arc designed and built a custom made column and boom with a boom length of over 9 meters for a leading tank manufacturing company in the Netherlands. The Red-D-Arc facility had to be customized with a raised roof section to accommodate the height of the large column. The raised roof was later opened, allowing for a crane to hoist the manipulator out of the manufacturing facility and then shipped to the customer.
The column and boom was part of a welding system provided by Red-D-Arc. The system featured a compact welding head designed for welding in narrow spaces, touch screen controls and a high resolution weld monitoring system to allow the operator to monitor the welding process from a safe distance.
The decision to rent, lease or own welding equipment often depends on utilization rates, amount of equipment required and necessary process capabilities. If equipment will be used more than 60-70% you should consider buying or leasing equipment. If utilization rates are lower than 60%, renting may be the way to go. Renting provides you with immediate access to professionally maintained welding equipment when and where you need it. Red-D-Arc has the most up to date, diverse fleet of rental welding equipment available to accommodate any process or technological requirement.
We are a rental company after all, so let’s look at the welder rental option a little further. When renting a welder you pay for actual use, not equipment ownership. Renting minimizes costs associated with maintenance, repair, storage, handling and freight and can provide you with an opportunity to try out new equipment before deciding to purchase. Contractors, maintenance and repair companies, owner-operators and other welding professionals rent from Red-D-Arc because of our fleet size, equipment diversity, expert advice and equipment performance.
Many companies prefer to own their core fleet of equipment and rent additional equipment as required. Red-D-Arc’s WelderLogistics Lease Program program is a low cost, flexible option to obtain your core fleet, allowing you to conserve capital and avoid investing in depreciating assests. The WelderLogistics lease program is 100% write-off for tax purposes and the equipment remains under full factory warranty during the lease term. If you already have an existing fleet, simply trade it in for new equipment.
Red-D-Arc provided ProHeat 35 induction heating systems during the construction of The Wilshire Grand Centre in Los Angeles. Large box columns of various sizes and weights needed to be pre-heated during the fabricating and erecting process. Red-D-Arc suggested the use of Pro Heat 35 induction heating systems and helped design fixtures for the heating cables so the box columns could be pre-heated safely and effectively. The 73 story, 1100 foot tower is planned to be completed in 2017 and will become the tallest tower in California!
Red-D-Arc contributed several Growing Line Systems to be used during the production of wind tower foundations for a wind farm in the Adriatic Sea. In addition to the Growing Line Systems, Submerged Arc Welders were supplied along with camera systems that are equipped with a monitor and touch screen for optimal control of functions. Red-D-Arc equipment was used because the foundations must be long and strong to withstand the depth of the Adriatic Sea.
To learn more about Red-D-Arc Growing Lines and Fit Up Stations watch our video: reddarc.ae/videos