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Circle Technical Services are at the forefront of technology that has transformed one of the world's oldest methods of joining metal into a sophisticated and versatile technique known as friction welding.
Circle Technical Services design and manufacture a complete range of friction welding related equipment, including items specifically produced to meet particular application requirements.
As well as performing at an optimum level in both air and water (to depths of up to 1,000m) the Hydromarine range of equipment has been further enhanced to function safely and at maximum operating parameter in an explosive atmosphere.
All stages of the friction welding process, in whatever application, are subject to full quality control and quality assurance checks and verifications.
We continue to expand the boundaries of the friction welding process through our involvement with research and development bodies such as the Welding Institute and other academic establishments.
The application of friction welding has grown across a wide industrial front and its pedigree has been extended to include its use by all of the worlds leading aerospace and automotive manufacturers for crucial life dependent components.
FEATURES AND BENEFITS
- Environmentally sound - no smoke, slag, flux or filler metal.
- Remote operation up to 4km - safe operation in hazardous, potentially explosive environments
- PC/Laptop control station
- Welding similar and dissimilar metals, including many exotic materials
- Ergonomically designed for easy maneuverability topside or subsea
- Fine-grained forged welds - full cross-section
- Small heat affected zone
- Full range of clamping devices for wide range of applications
- Welding to live pipelines and fuel cells without shut-down or purging
- Safe for use in zoned areas to Zone 0 without risk of explosion
FRICTION WELDING APPLICATIONS
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FABRICATION YARDS
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CIVIL CONSTRUCTION
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· Installation of alloy cladding inside Process Vessels and tanks
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· Anchoring profiled steel deck/slab systems
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· Anode attachment to Process Vessels
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· Securing composite fire protection material
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· Blanking off damaged heat exchanger tubes Attachment of refractory material
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· Attachment of studs through galvanized sheeting and coatings
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· Fixing insulation pins to structural members, tanks, pressure vessels and ducting
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· Attaching anchor and sheet connectors
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· Welding in Hazardous zone zero areas
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· Attachment of scaffolding
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· Pipe supports
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· Bridge repairs / Reinforcements
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· Cable trays
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· Walkway grating tie-downs
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NUCLEAR INDUSTRY
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· Safety barriers
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· Encapsulation of spent fuel rods
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· Machinery guard attachments ·
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· Emergency repair and decommissioning
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Attachment of scaffolding
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· Remote salvage in contaminated areas
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· Electrical connections using dissimilar metals
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PETROCHEMICAL FACILITIES
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· Austenitic attachments
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· Hot Tapping
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· Blanking off damaged heat exchanger tubes
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· Installation of high point vents
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· Installation of alloy cladding
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· Installation of low point drains
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· Installation of sampling points
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OFFSHORE
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· Valve stem repair
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· Installing anodes to platforms and pipelines
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· Installation of gauges and meters
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· Repair of damaged jacket members
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· Installation of sealant injection points
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· Attachment of rigging points for tensioned cables and guide wires
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· Temporary Access attachments
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· Installation of protective sheathing such as monel
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· Permanent Access Points
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· Attaching pipe nipples for dewatering or grout and fluid injection into tubular members
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· Floor grating attachments
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· Fixing shear keys for grouted clamps
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· Installation of benchmarks for photo identification and measurements
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OFFSHORE STRUCTURES
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· Fully compatible with ROV and ADS systems
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· Securing winches, hose reels and safety equipment
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· Welding in extreme depths
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· Fixing insulation pins to structural members, tanks, pressure vessels and ducting
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· Welding to live gas lines
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· Attachment of scaffolding
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· Welding to live pressure vessels
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· Welding in hazardous explosive atmospheres
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SHIP/SEMI-SUBMERSIBLES
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MARINE CONSTRUCTION
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· Damage control/Salvage
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· Attaching ship fenders to jetty sheet pile
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· Patching holed vessels and tanks
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· Strengthening sheet pile inter-lock connections
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· Anode installation/retrofit
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· Attaching anodes to sheet and H pile
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· Blanking of seachests and penetrations
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· Patching holes and split sheets pile piers
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· Attaching Equipment arays to hulls
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· Dam penstock modifications
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· Deck Maintenance
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· Weir wall installations
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· Installation of watertight bulkheads
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Portable Hydraulic Friction Stud Welding Machine
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EQUIPMENT SPECIFICATION
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Designed to weld studs in the range 10 mm diameter to 25mm, this unit can be used underwater to 1000 metres. Its weight and size allow it to be handled by a diver, or it can be ROV mounted. The HMS 3000 can be used topside in hazardous environments to Zone 0
This machine has been approved by Lloyds, ABS and DNV.
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Weight
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Kg
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16
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Lb
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35
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Hydraulic flow
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Lt/min @ bar
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76@210
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GPM @ psi
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4@3500 l
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- Patented electronic control system enables welding of exotic material combinations
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- In-process proof tensile test displayed in real time with full data reording
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Max speed
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RPM
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6,000
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- Weld parameters displayed in real time with full data recording
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- Remote operation up to 4 km from weld site
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Max power
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Kw
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22
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HP
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30
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A range of standard clamps to react the forces exerted during the welding process are available for this unit.
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Stud range
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minimum
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10 mm dia
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maximum
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25mm dia
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Stud length
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minimum
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20 mm
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maximum
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300 mm
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Circle Technical Services Ltd. Can design and manufacture special clamps or jigs for special applications
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EXPLOSIVE ATMOSPHERES
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- This equipment will operate in Zone 0 explosive atmospheres without risk of ignition
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CIRCLE TECHNICAL SERVICES FRICTION WELDING CLIENT LIST
Hydro Marine Systems Friction Stud Welding Equipment is working or has previously worked with or for the following establishments and companies:
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ABB Seatec
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KCA Drilling
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APG/Salamis JV
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Magnox Nuclear Electric
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ARCO British
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Mar-vel Underwater Equipment Inc.
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Barrata Indonesia PT Persero
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Mod (Navy)
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BP Engineering
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MS90 (Engineering) Ltd (for BNFL)
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BP Exploration
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Norcoat A/S
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Briggs Marine
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NSL Norway
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Bruusgaard & Blindheim A/S
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Ocean Technical Services
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Cambridge University
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Qatar Subsea Services
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Chevron
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Salamis Marine and Industrial Ltd
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Coflexip Stena Offshore Limited
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Santa-Fe Drilling Co.
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Conoco (UK) Ltd
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Sheffield University
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Defence Research Agency
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Shell UK Exploration & Production
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Delray
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SLP (London) Ltd
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Diesbecq Diving BV
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Sonsub
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Elf Petroleum Norge
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Stolt Comex Seaway
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EMC
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Suruga Seiki Co Ltd, Japan
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Enterprise Oil PLC
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Textron
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Underwater Equipment Inc
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The Welding Institute (TWI)
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McDermotts
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UMC international
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GKN Defence
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US Navy
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GKSS
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Vickers Defence Systems Ltd
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Global Philips Cartner
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Wood Group
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Ian Murray Engineering
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WATER ABRASIVE COLD CUTTING
The Circle Jetcut system uses the latest water abrasive cold cutting techniques including direct injection of an abrasive material into the water stream.
Operating at 5,000 psi (345 Bar) or 10,000 psi (690 Bar) Jetcut is operated remotely (no hand held cutting).
The cutting head is controlled at the desired speed through a control panel by a fully qualified Circle technician.
The Circle Jetcut system is potentially the safest system available.
The cutting action is shock free, leaves no heat affected zones and is completely inert.
All that is required to operate the integrated package is water and air supply.
Circle Technical Services provide the key elements to successfully undertake any project:-
- · Site survey capability by experienced and qualified engineers.
- · Integrated package tailored to suit and engineering requirement.
- · Trained technicians to undertake set up, cutting and demobilization.
- · Full engineering and operation back-up service from our Aberdeen facility ideally located to support the North Sea Industry.
FEATURES AND BENEFITS
- Environmental and diver safety which negates the requirement of obtaining special permits to use explosives.
- Safe operation in hazardous areas without requirement to clean or degas where hydrocarbons are present.
- Complete cold cutting technology.
- Stand off by support vessels is not required during cutting.
- Clean cut for easier extraction from the seabed and later storage. Explosives tend to distort and flare out at cut location.
- Other work can continue without danger which eliminates downtime. Internal or external cutting operations which can be easily deployed from topside.
- Expensive diving teams, spreads and DSV's may not be required.
- Remote operation allowing operator safety and extended reach.
DIMENSIONS
For ease of mobilisation, storage and demobilisation the Jetcut system is supplied as containerised units:
Jetcut Skid Unit
- Length: 1.62m
- Width: 0.92m
- Height: 1.62m
- Dry Weight: 900kg
Jetcut Container
- Length: 3.05m
- Width: 2.44m
- Height: 2.59m
- Dry Weight: 7,000kg
Workshop/Grit Container
- Length: 3.05m
- Width: 2.44
- Height: 2.59m
- Dry Weight: 7,000kg
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