Kemppi MIG/MAG System Welds The Gap Faster At Spirax Sarco

18th October 2010
Posted By : ES Admin
Kemppi MIG/MAG System Welds The Gap Faster At Spirax Sarco
Spirax Sarco Limited, is part of the Spirax Sarco Engineering group, based in Cheltenham, England employing around 4,500 people in 7 strategic manufacturing plants around the world. The company provides steam users across a wide range of industries with knowledge, service and products to improve and maintain steam heating and process plants of all types and is a world leader in the control and efficient use of steam and other industrial fluids.
At their Engineered Systems Manufacturing unit in Cheltenham, Kemppi welding equipment plays a pivotal role in the fabrication of bespoke steam systems and heat exchanger systems. The Company has a large fabrication shop where flash steam and blowdown vessel components are prepared for welding.

John Edmonds, Spirax Sarco Production Manager (RRE) explains: “Our manufacturing is very customer driven both for the UK and overseas, we manufacture individual systems to meet customer requirements and because we are dealing with equipment using very high temperature steam and water at pressure, our welding operations are designed to meet precise standards. In this plant, welding is used to fuse two end caps to a pre-formed shell, this then form vessels ranging from 150mm to 1.5m in diameter in carbon steel up to 6.4mm thick. Our welding operations mainly comprise MIG and TIG welding and occasionally MMA, plus we have a submerged arc capability. We employ 14 coded welders and two apprentice welders creating a fine balance between the welders and the number of welding machines we have.”

The Company has a number of Kemppi welding systems including two recently delivered FastMig™ Synergic water cooled MIG/MAG welding systems comprising KMS400 power sources and MSF57 wire feed units and both with WiseRoot™ for root pass welding.

These two systems were purchased specifically to carry out root pass welding on their blow down vessels to speed up the operation. Before Spirax Sarco was putting a root run in using TIG welding equipment, which is a slow, time consuming process. Now they are putting the root in on a 3mm gap using 1.mm A18 MIG wire with a mixed gas at a much faster rate and then filling using submerged arc welding as before. After welding, a visual inspection laid out in a standard operating procedure is carried out and then each unit is hydrostatically tested to ensure its integrity.

John continued: “We have been purchasing Kemppi equipment for in excess of twenty years. All our welders are very familiar with the equipment, which is reliable and is worked very hard during day and nightshifts seven days a week. We were introduced to the FastMig™ welding system and FastRoot™ by our local Kemppi dealer, Kingsley Welding Alloys, Gloucester, who subsequently arranged a product demonstration by Mike Summers, Kemppi’s Regional Sales Manager. He was very knowledgeable and was easily able to anwser all our questions. All in all the demonstration was very impressive, we could see that by using MIG welding and WiseRoot™ that our root filling operations would be much faster than by TIG welding. In fact, our productivity has definitley improved, the weld quality is just what we need and our welders like welding with their FastMig™ Synergic water cooled MIG/MAG welding systems finding them easy to use”

Overall Spirax-Sarco Ltd is pleased with its Kemppi equipment plus the service it gets from both Kemppi and their local distributor.

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