Power generators are crucial to numerous kinds of projects that require electricity. These include onsite work, events, emergency operations, and many others. Industrial generators serve as a reliable source of electricity for projects carried out in remote locations where there is no access to grid power. They are also an excellent alternative for projects that might put too much strain on the grid. For sectors such as oil and gas, manufacturing and construction , and others that require a continuous power supply, power generators provide a steady stream of reliable power during potentially damaging seasonal fluctuations in the grid electricity supply. They can also provide backup power in emergency and recovery situations.
Whether as prime, backup, or supplementary power supply, power generators have to be in good working condition to function correctly and deliver on all their benefits. Power generators are made up of numerous constantly moving components operating at very high temperatures and pressures. The key to keeping them working optimally throughout their life cycle, despite these operating conditions, is proper maintenance.
The construction industry is responsible for the creation of all kinds of structures with varying sizes, levels of complexity, and uses. From simple, small structures such as family homes to large, complex ones like bridges, dams, and manufacturing plants.
Structural integrity and durability are the most important considerations in this industry. This is why the construction industry employs a very large quantity of metals. In the United States alone, more than 40 million tons of steel are used annually in the construction industry. The majority of this quantity is used to create structural frameworks. This is where welding plays an indispensable role in construction.
Welding technologies are widely usedin the construction industry, mainly for the fabrication of structurally sound metal frameworks for by fusing various metals components. It also used to create and maintain non-structural components. Some of the welding used for construction is on pre-fabricated in a shop environment while other parts of the welding process are done on-site.
Applications of Welding in Construction
Construction comprises numerous industries, including transportation, oil and gas, telecommunication, power, manufacturing, many others. The construction industry is very broad & diverse and is divided into three major sectors which differ by the type of structures they create. These sectors are Building, Infrastructure, and Industrial.
The application of welding, is crucial to all three sectors.
EX360 FieldPro Multi-process Welder
ArcReach® technology is an investment that results in a lot of time saved during welding operations. With most welding equipment the operator needs to walk back and forth to adjust output voltage – sometimes over hundreds of feet – multiple times during a job. This results in hundreds of wasted hours and thousands of lost dollars over the course of a large project.
ArcReach technology enables welders to adjust the voltage settings right at the point of welding
ArcReach technology enables welders to adjust the voltage settings right at the point of welding instead of walking all the way to the power source and back. Even worse, if the voltage settings are “just good enough”, the operator might not bother making the trip, resulting in lower quality welds.
19 Hours Faster Than the Competition
Texas – One of our customers was trying to heat 42” diameter pipe using pear burners so that welders could weld out the joints. Our team saw an opportunity to create a solution that would help our customer get the job done much more quickly. To make this in-the-field heating job go faster, we put together a package including a Miller ProHeat 35 induction heating system, a 60kVA generator and a DP25 power distribution panel.
Red-D-Arc provided a reliable RDA Induction heating solution to a pipeline construction and maintenance company in Houston who needed to maintain consistent temperatures for their welders to weld out joints from pipes. Our induction heating specialist supplied our customer with a portable induction heating package consisting of a 60 KVA generator, a Miller Pro-Heat 35 induction heating system, and a DP25 power distribution panel. As a cost-effective alternative to their existing propane burners, induction heaters allowed them a secure heating, consistent temperature control, increased weld time, and improved safety.
With this setup we were able to get the pipe up to 250 degrees in about 5 minutes. Our customer was able to beat the competition’s target time by over 19 hours and has been asked to quote on other pipeline work for their client. Needless to say they were pleased with the solution and the opportunity for extra work it created.
Some of the most difficult welds to make are those that require the welding of a small diameter to a plate. Gas tungsten arc welding or gas metal arc welding joints such as these require a high degree of operator skill, take a great deal of time, and can be a quality nightmare. These factors become even more troublesome when the material with the small radius being welded is in the vertical or overhead position. Fortunately, Red-D-Arc provides stud welding equipment that increases productivity, decreases the required operator skill immensely relative to other welding processes, and allows for consistent, repeatable weld quality on materials with small radii.
What is Stud Welding?
Stud welding is a fusion welding process that is commonly used for the joining of small round stock to plate. The process requires a power source, a stud welding gun, a ground clamp, and the materials that are to be welded. To carry out the stud welding process, a solid, round piece of metal, also known as a stud, is placed into the stud welding gun.
To begin, let’s establish what exactly we’re talking about when we say “biodiesel.” ASTM (American Society for Testing and Materials) has published a standard, D6751-07b, that defines what biodiesel is. We’re not talking about used cooking grease, or even commercially produced biodiesel, if it doesn’t meet this standard.
Also, the word “biodiesel” is often used to describe what is actually a blend of biodiesel and diesel fuel. (The diesel fuel sold for on-road use in the U.S. is Ultra Low Sulfur Diesel fuel, or ULSD.) The term “BX” designates the blend ratio, where “X” stands for the percentage of biodiesel in the blend. So B100 means 100%, or pure, biodiesel, while B20 means 20% biodiesel mixed with 80% ULSD.
Additionally, this article doesn’t address OEM recommendations or warranty limitations. We’re simply looking at the question from a mechanical standpoint.
So now, with all that out of the way, what’s the bottom line?
Red-D-Arc was featured in the December/January issue of Tank Storage Magazine in an editorial titled “Rental welding equipment for storage tank fabricators”. Tank Storage Magazine is an industry leading publication, reporting exclusively on the bulk liquid storage tank and terminal sector.
The storage tank construction industry is highly competitive and fabricators gain a significant advantage by leveraging Red-D-Arc’s rental fleet of automatic tank welding equipment. Red-D-Arc supplies specialized automatic storage tank welding equipment to companies in the tank fabrication industry for projects all over the world.
Along with our specialized tank welding equipment comes a highly knowledgeable and experienced team of Red-D-Arc technicians. Sayer Hendricks – storage tank welding equipment specialist at Red-D-Arc is quoted in the article: “A fabrication company without prior knowledge of the equipment, is able to rent a turn-key tank welding automation system and increase their welding productivity by 40-50%. With on-site training, service and support, our customers are up and running quickly and making 100% x-ray quality welds without fail”
The full article is available here: Rental welding equipment for storage tank fabricators
Nevada – The Tesla Gigafactory, which produces lithium-ion batteries for Tesla Motors, will be the second-largest facility (by usable space) in the world, once all construction phases are completed. Staff from our Branch in Sacramento have been on site since ground was first broken in 2014. Red-D-Arc has been working closely with contractors on the project, providing a fleet of welders and generators, expert advice, and ensuring equipment performance and availability.
Our experts regularly consult on large scale construction projects and help solve the challenges around equipment procurement and maintenance faced by engineering project managers. Contact an expert for insights and advice on your next construction project.
Scheduled for completion in July 2016, U.S. Bank Stadium, the new home of the Minnesota Vikings, is a fixed roof structure that will be nearly 30 stories tall at its highest point. During construction, the base plates of some of the structural support columns needed to be pre-heated to 400o prior to welding. Traditional heating by flame proved to be difficult. It was determined that induction heating was the right solution to safely and efficiently heat the steel to an exact temperature. Induction heating is the preferred method to address challenges associated with the pre-heating of structural steel because it provides a safe and accurate method of heating the metal to a precise temperature.
Red-D-Arc offers Miller ProHeat 35 Induction Heating Systems (IHS) available for rent, lease and sale. This highly efficient technology uses non-contact heating to induce heat electromagnetically rather than using a heating element in contact with the part.
UPDATE: This project was completed ahead of schedule.
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!
Walsh Construction, a nation-wide contractor based out of Chicago, was encountering delays on some repair work that they were performing on bridges on the Chicago River in downtown Chicago. They had been using the stick welding process (SMAW) to weld ¾” studs onto piles which were then driven into the riverbed. A quality assurance (QA) technician requested the use of a stud welder to ensure greater placement accuracy and an increase in speed of the welding cycle.
Red-D-Arc supplied a 150 kVA generator and an ARC1850 stud welder – used to attach the studs using the stud welding process which sped up the whole process. The generator/stud-welding package was loaded onto a barge which enabled them to move from bridge to bridge, commencing with the Clark Street Bridge (shown). One of the largest and most impressive of the pony truss bascule bridges in downtown Chicago.