Welding World - Issue 4 - September 2020

ISSUE 04 £8.99

SEPTEMBER 2020 WHEN SOLD

IN THIS ISSUE:

JOBS BOOST

IN THE FIGHTBACK AGAINST THE CORONAVIRUS FACTORY OPENINGS AND 75TH ANNIVERSARY CELEBRATIONS FOR FRONIUS

CLICK HERE

TO JOIN NOW!

PLUS: PRODUCT REVIEWS • WELDING NEWS • AND MUCH MORE

Welding technology from Germany connects around the world

Premium welding technology from EWM is used by customers around the world.

Our complete system solutions include welding machines and torches, welding consumables, welding accessories, services and solutions for automated welding.

www.ewm-group.com/uk info@ewm-morpeth.co.uk

W ELCOM E

INSIDE

NEWS 4 Coronavirus update: Advice for our members 5 Calendar: An update on global events 6 New guidelines: Gas supply and

distribution systems 7 New facility: Cheshire site opens 8 Hinckley Point C: Jobs boost 10 Production line: EWM teams up with Bell 12 Happy 75th: Celebration for Fronius

EDITOR ’ S L E TTE R There is a call to arms in the air and a sense that the fightback has well and truly begun.

Our economic hopes and fears of the past few years may have been sent into overdrive with the effects of the coronavirus in 2020, but it’s clear that both in the UK and globally there is a determination to get industry back on track - and quickly!

We may be living in a different world at the moment, one of sudden lockdowns coupled with an inability to travel across the continents, but despite this the mood is positive, it’s clear what needs to be done.

The reassessment has been huge and old ways of working, many of which were on their way out, have been swiftly shown the exit. But all the bathwater hasn’t been thrown out, at the same time we are understanding that old values such as customer service, aftercare and providing full and clear information are still key.

Welding World has grasped the nettle, we are delighted to issue our second interactive digital title, still a first for this sector and one which is already attracting keen interest across other areas as well.

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Sculpture: Frontline inspiration New factory: Sub-assembly facility Hot work: Facing the risks President’s message Cutting World Extraction World

NEW PRODUCTS 24 A guide to some of the latest technologies

And a look at this edition will show that new products are still being released, there is an appetite to do business and that all of our members and the products and services which they offer are as relevant as ever.

DARREN ISTED Editor, Welding World editor@welding-world.com

J OIN T HE CO N VE RS ATI O N @WeldingWorld1 Welding World @ WeldingWorld1 Stepping up: @Tusker_UK manufacture supplies for the COVID-19 effort

REGULARS 30 SifTips 31 And Finally

Welding World @ WeldingWorld1 An extremely heavy duty, large diameter pipe bevelling system from GBC

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COR ON AV IRUS UPDAT E

POSITIVE THOUGHTS

A psychologist walked around a room while teaching stress management to an audience. As she raised a glass of water, everyone expected they’d be asked the “half empty or half full” question. Instead, with a smile on her face, she inquired: “How heavy is this glass of water?”

Answers called out ranged from 8 oz. to 20 oz.

She replied, “The absolute weight doesn’t matter. It depends on how long I hold it. If I hold it for a minute, it’s not a problem. If I hold it for an hour, I’ll have an ache in my arm. If I hold it for a day, my arm will feel numb and paralysed. In each case, the weight of the glass doesn’t change, but the longer I hold it, the heavier it becomes.”

She continued, “The stresses and worries in life are like that glass of water. Think about them for a while and nothing happens. Think about them a bit longer and they begin to hurt. And if you think about them all day long, you will feel paralysed – incapable of doing anything.”

Remember to put the glass down.

Anon

“Positive thinking”- How many times have you heard people saying- “If I could do this all over again, I would but I would do it differently.” Well here is a once in a lifetime chance. You open the business and do it different. Add in all those knowledge, time-learnt ideas, stop all the roadblocks in your business that you know about or which during furlough became obvious to you. This is your chance to have a change in your business. To come out of the lockdown a more effective, efficient and well run business. Make your furlough time away work for you.

Dave Ellwood

HSE Coronavirus Below are three pages from the HSE on coronavirus and getting back to work. Click on the images below to view:

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COR ONAV IR US UPDAT E

EuroBLECH postponed to 2021

CALENDAR JUNE GLOBAL INDUSTRIE

23 - 26 June 2020 Paris Nord Villepinte Focus on the industry of the future

POSTPONED TO MARCH 16/19 2021

Eurexpo, Lyon www.global-industrie.com/en

SEPTEMBER METALMADRID ’20

30 September - 1 October 2020 IFEMA, Madrid, Spain The leading annual industrial show.

Jointly with NittiGritty. www.metalmadrid.com/en/

TRAVEL INFO

VISITOR INFO

Mack Brooks Exhibitions has postponed EuroBLECH, which was scheduled to take place at the Hanover Exhibition Grounds in Germany from 27 to 30 October 2020.

The new dates for the next EuroBLECH, 26th International Sheet Metal Working Technology Exhibition, are 9 -12 March 2021. This decision was taken after extensive conversations with all exhibitors and partners over recent weeks and months who have expressed their preference not to hold the show in October, in light of the ongoing Covid-19 crisis. Uncertainties around travel restrictions in order to maintain the truly international character of the EuroBLECH event were also a concern to many participants.

Speaking about the announcement, Nicola Hamann, Managing Director of Mack Brooks Exhibitions said: “The past months have been challenging, in particular for the sheet metal working industry and its related industry sectors.

We have seen a decrease in orders of capital goods and many companies are telling us about their challenges in dealing with the impact of the Covid-19 pandemic. Although we have recently received authority approval for our Safety and Security concept to hold EuroBLECH

EXIBITOR LIST

STAND COSTS

in October this year, we have decided to postpone EuroBLECH to Spring 2021”.

As part of a recent series of industry surveys, the participants of EuroBLECH indicated their requirement to network and conduct business in order to pave the way for the recovery of the industry following the Covid-19 pandemic. EuroBLECH will therefore offer a virtual hub for the global sheet metal working industry in October: “Following feedback from our exhibitors and visitors indicating the need to participate in an event, even if not in a physical form, we will organise a Digital Innovation Summit taking place from 27 to 30 October, our planned event slot. This Digital Innovation Summit will provide our exhibitors with a platform to demonstrate their latest machines and solutions and arrange virtual meetings with international visitors. We believe it is our duty to assist the industry through these extraordinary times by offering a market place this year as a platform for innovations and a starting point for the recovery of the industry”, continued Nicola Hamann. ■ For updates and further information, click on the licks above or visit the event website: www.euroblech.com

OCTOBER WELDING BRNO 2020 5 - 9 October 2020 Brno, Czech Republic International Welding Engineering Fair www.bvv.cz/en/welding/ welding-2020/

METAVAK

6 - 8 October 2020 Evenementenhal Gorinchem, Netherlands Annual trade event for the metalworking industry https://metavak.nl

EXPO WELDING

13 - 15 October 2020 Sosnowiec, Poland 7th International Welding Fair https://old.exposilesia.pl/uk/

EUROBLECH

27 - 30 October 2020

POSTPONED TO MARCH 9-12 2021

Hanover, Germany 26th International Sheet Metal Working Technology Exhibition www.euroblech.com/2020/ english/

CLICK HERE for more

events and news updates

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N EWS

BCGA issues new guidance for gas supply and distribution systems for welding sector National trade body The British Compressed Gases Association (BCGA) has rewritten one of its most frequently referenced codes of practice, which is used across the welding industry.

‘Code of Practice 4 - Gas supply and distribution systems (excluding acetylene),’ referred to by the BCGA as CP4 has been completely revised, with experts from across the Association’s membership contributing to the new document.

CP4 provides the minimum safety practices and principles for the selection and assembly of pressure equipment to control and distribute gases, covering the design, construction, installation, testing, commissioning and handover of a pressure system, before it is put into use.

It provides information on three key roles - the designer, installer and the user - with clarification of these being one of the main focuses in the 2020 revision.

Ellen Daniels, Chief Executive of the BCGA, said: “CP4 is wide-recognised as a valuable resource in manufacturing operations where there is a gas supply which needs to be distributed and controlled into a building.

“The revision has been a significant undertaking, which has drawn on a bank of expertise both in BCGA membership and other industry specialists.”

The code of practice is intended for use in conjunction with current guidance and information produced by the Health and Safety Executive (HSE) and other related bodies and trade associations.

Other significant changes in the code include the section on testing, with three specific tests now detailed, a standard pressure test, a proof pressure test and a final leak test.

There is also detailed information on the requirements for commissioning the pressure system and the handover once commissioned - to the user, in a condition where it can be put into service.

The code also now includes details on the use of a variety of different jointing techniques, providing information on venting exhaust gases and recommendations for a system of identification of pipework and components.

This is the fifth revision of the 96-page code of practice, which was last updated in 2012. ■ BRITISH COMPRESSED GASES ASSOCIATION Registered office: 4a Mallard Way, Pride Park, Derby, UK. DE24 8GX Company Number: 71798, England

www.bcga.co.uk

TECHNICAL INFORMATION SHEET 30

WORKING IN REDUCED OXYGEN ATMOSPHERES

Background The air that we breathe is primarily composed of two gases; nitrogen at 78 % and oxygen at 21 %. Oxygen is absolutely vital to life and breathing a lower concentration of oxygen may have fatal consequences.

Oxygen also plays a vital part in combustion mechanisms. Oxygen is not in itself flammable, but increasing the oxygen content in an atmosphere will dramatically reduce the ignition resistance and increase the combustion rate of materials and substances. Conversely, reducing the oxygen content in an atmosphere markedly reduces the combustion rate of materials.

Cellulose, for example, in the form of paper, is extremely hard to ignite at a 15 % oxygen level.

An atmosphere controlled to this level therefore becomes very useful, to reduce fire risks, in places such as document stores, library archives, museums etc. This is sometimes usefully exploited in so called ‘hypoxic air’ fire suppression systems, in which the oxygen content in the local atmosphere may be taken down to circa 15 % or even lower. This is usually achieved by either the injection of extra nitrogen into the atmosphere to dilute oxygen or the use of a mechanical device (for example, a Pressure Swing Adsorber) to remove oxygen. In addition to fire suppression, hypoxic environments are becoming more common in other areas, such as in food preparation, for preservation to help deter oxidation and extend shelf-life.

However, at 15 % oxygen level, such an atmosphere can also be a significant threat to human life due to the risk of asphyxiation (from hypoxia), therefore the use of hypoxic atmospheres shall be risk assessed and safeguards may need to be put in place. How well a person can cope with these environments is dependent on the health and fitness levels of the individuals exposed, the strenuousness of the task being undertaken and the time spent in such atmospheres. For further information refer to BCGA GN 11, The management of risk when using gases in enclosed workplaces.

The BCGA is concerned at the increased use of ‘hypoxic air’ fire suppression systems and the safety of people within these areas. BSI Publicly Available Specification (PAS) 95 and the Health and Safety Executive (HSE) Research Report RR1137 provide guidance but this should not be taken to infer that such systems are therefore safe.

Use in reduced oxygen atmospheres BCGA strongly recommends that installers of such systems, and indeed premise owners with, or who are considering having, such systems installed in their buildings, should comply with the following requirements: 

A space containing a reduced oxygen atmosphere meets the criteria of a confined space within the meaning of the Confined Spaces Regulations 1997; These Regulations require that employers shall carry out an adequate risk assessment and put in place appropriate

BCGA TIS 30

Revision 2

1 of 3 Published: 24/09/2019

Produced by: BCGA TSC 6

ISSN 2398-9386

CLICK HERE to visit the BCGA publications area

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LONG SERVICE CELEBRATIONS FOR FSP Fabweld Steel Products are celebrating a landmark year with eight members of staff totting up a total of 140 years in the business.

Operations Director Wayne Carter (pictured) is celebrating 30 years with FSP after joining as an apprentice.

Team leader Kevan Knight, despatch coordinator Birige Lal Kanith, technical estimator and responsible welding co-ordinator Craig Williams and Pete Edmunds, a team leader and health and safety officer, are all celebrating 20 years this year.

Sales manager Christopher Corbett, credit controller Tori Hinde and Molly Peters, the firm’s HR and data protection officer, will also each mark 10 years of service in 2020.

FSP was founded by Managing Director Richard Hilton in 1988 and now employs more than 40 staff.

He said that the 140-year milestone was testament to their determination to invest in and support the development of the team.

“More than two thirds of our current workforce started with us as either a trainee or an apprentice,” he said. “We continually strive to develop and enhance the skills of all our employees and, with a staff retention rate of over 90 per cent, we have built an experienced and talented workforce.

“That reaps the benefits for our clients as the combined knowledge and skills of our staff enables us to deliver the highest level of service and quality products. I’d like to thank them all for their contribution into making FSP the successful business it is today.”

Wayne, who started his career at FSP as a trainee welder on a YTS scheme earning £35 a week, said he was delighted to be celebrating his 30th anniversary.

“When I began as an apprentice I wasn’t expecting to rise to the level that I have and I am very grateful for the opportunities that have enabled me to become a director.

“Our apprenticeship and training programme is very much shaped at helping individuals achieve their full potential and develop the upcoming leaders and directors of FSP to give the business a sustainable foundation for the future.” ■

NEWS

A new UK fabrication facility in Cheshire has officially opened As part of a global growth journey, the doors have been opened on a new 13,500 sq.ft. welding and fabrication site at Ellesmere Port’s Rossmore Trading Estate from where a new division will deliver pressure part welding and fabrication site services, throughout the UK and beyond.

This new arm of the company will add a range of synergistic products and services to the existing portfolio, including pressure part fabrication and welding; component fabrication; fabrication and site services and mechanical support services.

Commenting on the Ellesmere Port facility opening, Fortress Energy Founder and MD Martin Atkinson said: “Our exponential growth in key markets is as a result of our ability to compose and develop innovative techniques and solutions, backed by team expertise totalling more than 70 years.

This new facility will provide an important springboard from which we will be able to broaden our service offering in both UK and overseas pressure part markets.

“We are excited that integration between our machining and pressure parts division will come in-house, thus minimising the point of contact responsibility to our

clients and facilitating an even more streamlined, responsive service.”

Head of the engineering, fabrication, welding and construction division Craig Gerrard added: “By creating this new facet to what we do, we will be able to augment

relationships with existing clients and seek to grow our client base with new customers. The scope of this new base will allow us to do that in an organic way which marries with our distinctive approach to developing our business.” ■

AWD Zoom Meetings Welding World is offering regular face to face meeting opportunities via Zoom. We held our first seminar on the COVID19 pandemic under the title “Life after Lockdown”, where Croner the Employment law specialist, presented advice to Employers on enabling the safe return to work of their staff.

For those that missed the presentation, this advice can be viewed again below:

We are planning a number of these Welding World Virtual Meetings, via Zoom sessions over the coming months and would appreciate hearing from members and organisations that wish to sponsor these events or support them with content, presentations or subject matter.

The dates for each event are as follows and each seminar will run from 10am until 12 noon.

2020 NOVEMBER 11TH 2021 FEBRUARY 10TH 2021 APRIL 14TH Please contact us at admin@welding-world.com to confirm your interest in supporting these events or reserving your place.

The world may be in turmoil, but it is slowly rebuilding its strength. The Welding Industry has always been strong and will continue to be so. Let’s work together to develop the right image of the Industry, the people and the products and build a brighter future to compensate us all for the recent past. ■

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NEW JOBS AT HINKLEY POINT C Staffordshire-based Capula and Exyte Hargreaves from Lancashire are the latest British engineering companies to create new jobs to support the next phase of construction at the Hinkley Point C nuclear power station. Their 80 new engineering posts are a small part of the expected 1,200 new jobs and 300 apprentices who will become part of the 4,000 strong workforce who will fit electrical systems, cables and pipes at the nuclear power station.

The work is being delivered by an innovative joint venture – the “MEH Alliance” formed by EDF and its major contractors Altrad, Balfour Beatty Bailey, Cavendish Nuclear and Doosan Babcock. (MEH stands for Mechanical, Electrical and HVAC - heating, ventilation and air conditioning). Its new forecast predicts 1,200 new posts and 300 apprenticeships will be created. The fitting of the first five out of 156 storage tanks has marked the beginning of major MEH work on site.

Capula’s new contract to design and build instrument and control cabinets will create 50 new jobs. Bury based Excite Hargreaves will create 30 new jobs to design manufacture and commission ventilation systems. Their success follows the recent

announcement by Warrington-based Bilfinger UK that it is creating 350 British jobs to design and manufacture specialist pipework for Hinkley Point C. Hinkley Point C will deliver a long-term socio-economic legacy for the UK helping to overcome critical national skills shortages whilst opening up new, sustainable, career opportunities for people throughout the country. Many of the new workers will be making use of new locally based training facilities such as a welding and electrical centre of excellence.

A new welding centre in Bridgwater is supported by the MEH Alliance, the Engineering Construction Industry Training Board (ECITB), the Weldability SiF Foundation and South West Institute

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of Technology and Bridgwater & Taunton College. The centre plans to train and qualify 350-500 welders a year, benefitting people and industries across the SouthWest of England and beyond.

Simon Parsons, Hinkley Point C MEH Programme Director, said: “In this next major chapter for our project, the MEH phase will join together hundreds of small and large companies from across Britain, creating 1,200 new jobs and 300 apprenticeships. Together we are delivering on our promise to build Britain’s industrial capability by creating new jobs and skills. Development of a near identical power station at Sizewell C will bring further opportunities for our extensive and experienced British supply chain.”

The Member of Parliament for Stone, Sir Bill Cash, said: “I’m very pleased to see Stone-based Capula create 50 new local engineering roles. It is great to see how Staffordshire and the wider West Midlands still leads the way for great British highquality manufacturing for major projects such as nuclear power stations. Nuclear power not only creates jobs and supports the economy across the entire nation but it is also a vital part of meeting the country’s climate targets.” ■

N EWS

Bell establishes own welding production line with EWM Articulated dump trucks (ADTs) made

by South African heavy equipment manufacturer Bell Equipment are built to carry huge loads over challenging terrain. The production of these large vehicles can be challenging too. It requires specialist welding machines and accessories able to withstand long weld seams and high duty cycles at high currents in a two-shift operation. During 2019, Bell Equipment’s German factory in Eisenach-Kindel moved from an assembly operation to one that now also produces the requisite components itself. To help with the planning and implementation of their own welding product line, Bell Germany enlisted the country’s largest and one of the most important worldwide manufacturers of arc welding technology, EWM AG. Bell Equipment’s German operation was established in Alsfeld, in the German state of Hesse, in 2000. An assembly facility followed in 2003 in Hörselberg-Hainich near Eisenach, which today supplies 22 European countries and North America with Bell dump trucks and associated spare parts. Individual components come predominantly from European suppliers while the core assemblies are delivered from the South African parent plant. This was also the case for the bins up until 2018. To manufacture these, the company shipped plates from European production

Bell Equipment Deutschland supplies the European and North American markets with articulated dump trucks – pictured here is the smallest of the series – and other construction machinery. The bin previously came from the parent plant in South Africa but, as of 2019, are now made by an internal production line

Bins are welded both manually and automatically with mechanised robots across seven stations in the 12,000-square-metre hall

lines to South Africa, where they were cut, milled, edged, and welded and then shipped back to Germany as finished bins.

Bin production and shipping to Germany typically took four to six months after receiving the order. There clearly was room to streamline this process to bring it in line with the environmental ideas rooted in the company’s principles, including a more sustainable and economical bin production, explains Steffen Zitter, a member of the strategic purchasing team responsible for carrying out global projects at Bell Equipment.

Internal welding production line started in 2019 As a solution, Bell Germany started its own welding production line near Eisenach-Kindel in 2019 and has been mass producing bins for ADTs for Europe and North America for six months. Bins to fit ADTs with 20- to 50-ton load capacities are now welded at various stations in the new, modern 12,000-square metre hall.

The hall hosts both fully mechanised, automated stations and manual welders.

Manual welders are required primarily for the harder-to-reach seams. The dimensions of these vehicles are immense, so are the weld seams, with the smallest bin measuring 4.70 metres long and the largest, built in Thuringia, measuring 5.30 metres.

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EWM already involved in planning When Bell Equipment finally decided to take the leap and establish their own welding production line at their site in Eisenach-Kindel, EWM AG, Germany’s largest manufacturer and global leader in arc welding technology, was right there. To start the ball rolling, Stephan Giese, Technical Director at Bell Germany, gathered information about the possibility of an internal welding production line.

During his research he got to know Ralf Rauh, the Site Manager for EWM in Nossen, who was already involved in the initial planning phase. As part of EWM maXsolution, the extensive consultation service, Rauh worked on a complete custom solution for the company. With EWM maXsolution, the customer’s entire production process chain is optimised in a way that saves the company energy, resources, and time. To do so, he became familiar with Bell Germany, its production site in Eisenach and its users and learned all about the required specific needs. The specifications from the parent company played a huge role in creating a suitable solution. “Processes set by South Africa are reflected in our work,” explains Steve Rudolph, head of assembly production and quality control.

Preparing for the EU Ecodesign Directive Robust machines with a high duty cycle

NEWS that can withstand long seams and welding times are needed for metre-long metal plates made from wear-resistant steel in thicknesses from 6 to 32mm. For this, the production line in South Africa uses step switch controlled machines that require the user to find and set their own operating point. This means that the same machines needed to be purchased in Germany too. However, despite his endeavours to take all the customer’s wishes and specifications into account when creating his solution, Rauh intervened on this requirement. “In the coming year, the Europe-wide Ecodesign Directive will come into effect, including for welding machines. From 2023, power sources will have to use no more than 50 watts of power in open circuit.” Rauh therefore offered the Taurus Basic instead, a welding machine with energy and resource-efficient inverter technology.

As the customer wanted one type of welding machine for the entire production line, and indeed one that allowed the user to manually set the operating point, all production employees now weld using the Taurus 505 Basic. This power source is like a step switch controlled machine in its operation, yet, thanks to digital technology and the EWM quality, it saves a lot of energy. The decision maker in South Africa ultimately gave the greenlight for the EWM complete solution which, as well as the welding machines, also included wire feeders, hose packages, drum connection, welding consumables and work safety equipment such as welding helmets.

Non-stop welding time in two shifts per bin The close attention EWM pays to quality, performance, high power reserves and mains voltage tolerance, makes its welding machines perfect for the seams measuring up to 6 metres long. So EWM offers a full three-year guarantee in three-shift operation, all without a limitation on operation hours, for good reason. The company even offers a five-year material guarantee on its main transformers, output chokes and secondary rectifiers.

Even when it comes to the duty cycle, EWM has its own measures in place that go beyond the legal regulations. The Taurus Basic 505, for example, has a duty cycle of 100% at 430 amperes. “Welding bins require high currents of around 290

Wire feeders flexibly attached at the height of the bins give the welder mobility and save on the tedious back-and-forth and climbing as welding parameters can be set directly on the wire feeder control

Metre-long weld seams are welded at high currents and high duty cycles. EWM welding machines are perfect for the job

Ralf Rauh (left), Site Manager for EWM in Nossen, assisted (2nd from left) Steve Rudolph, (Head of assembly production and quality control) Gert Van Zyl (Head of bin production) and Steffen Zitter (Procurement Engineer) in planning and implementing welding production at Bell Germany

amperes over a long period of time. One bin takes at least two shifts of non-stop welding. The EWM machines are perfectly equipped for this,” confirms Zitter.

As part of his complete solution, Rauh planned various improvements for users and optimisations for the company, which are different to those in South Africa. As a result, welders work with decompact systems with separated power sources and wire feeders. Intermediate hose packages from 10 to 15 metres increase the working radius. This makes it easier to work on large components and hardto-reach seam positions. The switchover to a drum connection for the weld wire saves around 17 spool changes per workplace. As part of internal solutions, Bell flexibly attached wire feeders to the metre-high manipulators, on which the bin components are conveniently positioned.

The welder can change the welding parameters directly on the wire feeder control instead of having to set them on the power source. This increases mobility and saves any long back-and-forth and unnecessary climbing.

Short delivery time and great service

The fact that all 22 machines were delivered in just three weeks was yet another reason to work with EWM. “The time factor and pricing played a role, but also the personal contact and great service,” explains Zitter. All this meant that production could start quickly, with mass production being ready in just a few months. Together with EWM, the aim is to continue to improve the production process in the coming years.

“All experience relating to machine technology or welding consumables is shared intensively with South Africa. If we find that something could be improved, it is discussed and improved,” he adds. To find such areas for improvement, Rauh regularly visits the welding production, having welders test an EWM welding torch or answering any questions. The results speak for themselves. “With the EWM welding torches we only needed five EWM contact tips in two and a half weeks,” Steve Rudolph responds to Ralf Rauh’s enquiry. “Working with EWM, in particular in the area of torch technology, in no time we were able to save up to 30% on consumables and wear materials, depending on the use and workplace.” ■

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FAMILY BUSINESS WITH TRADITION:

Fronius celebrates its seventy-fifth birthday

In 1945, Günter Fronius laid the foundations for Fronius International GmbH, which today ranks among the world’s leading innovators in the fields of welding technology, photovoltaics, and battery charging technology

What began in 1945 as a one-man business based on a simple idea is now part of the industrial landscape: we’re talking about the Austrian family-owned company Fronius, which has grown over the past three quarters of a century from a regional repair shop to a global player in the fields of welding technology, photovoltaics, and battery charging technology.

And it all started 75 years ago on June 20.

Günter Fronius set the ball rolling in 1945 when he started a radio and electrical repair workshop, beginning a story of success that continues to this day under the stewardship of the third generation of the founding family. The business was born in the market town of Pettenbach, Upper Austria, where Fronius’s headquarters are still located. This is where Günter Fronius lived and worked after being given an old military barracks in exchange for carrying out some repair work.

In those days, charging vehicle batteries was not a simple matter – something

which he felt ought to change. A trained electrical engineer, he developed a solution which meant that batteries could be used for longer. “So what we are and what we stand for is based on a sustainable idea that my grandfather had,” says Fronius CEO Elisabeth Engelbrechtsmüller-Strauß, who has been managing the family business since 2012.

In 1950, Günter Fronius expanded the company’s product range to include welding transformers. Building on this technological basis, over the following decades Fronius grew into a substantial medium-sized company, which the electrical engineer handed over to his children, Brigitte Strauss and Klaus Fronius, in 1980. They launched a programme of growth and international expansion that led to the founding of subsidiaries all over the world. In 1992, it was also decided to focus on solar energy as a “technology of the future”. And so, today, Fronius stands on three pillars: welding technology, photovoltaics, and

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battery charging technology.

The Business Unit Perfect Charging is as old as the firm itself. Company founder Günter Fronius started charging lead accumulator batteries in the early years of the business. After numerous further developments, in the early 1990s the company switched from 50 Hz chargers to high-frequency technology for the first time. Further research lead to a real milestone in 2007 – the Ri charging process which charges the battery according to its effective inner resistance. Since then, Fronius products have automatically adapted themselves to the batteries being charged and their properties, making every charge unique. Perfect Charging is currently taking the next step into the future with lithium-ion technology, incorporating new ideas about digitalisation and device networking The Business Unit Perfect Welding has been in existence since 1950, when company founder Günter Fronius

From the archive: one of the first battery chargers

NEWS discovered that he could melt a rod electrode with the technology used in the battery chargers. Research made great progress in the mid-1970s, culminating in a real revolution with the Fronius Transarc 500. This was the world’s first transistorbased primary switched inverter welding system, and Fronius suddenly gained major partners outside Austria. In 1998 the Transarc was replaced by the digital TransPuls Synergic (TPS), the first welding system capable of being updated. At the time, the company was also researching a new type of welding process, which would go down in history under the name of “cold metal transfer” (CMT) in 2005. Since then, it has been possible to join extremely thin materials, as well as materials such as aluminum and steel. Today, Fronius is setting a new trend with TPS/i (Trans Process Solution / intelligent revolution).

This high-performance welding computer is the company’s answer to Industry 4.0 and comes into its own when used in conjunction with the data management system provided by the WeldCube Premium software solution.

The Business Unit Solar Energy has been part of Fronius since 1992. The Fronius Sunrise inverter was launched on the

Above: Fronius Transarc 500: the world’s first transistor-based primary switched inverter welding syste

Left: Fronius Sunrise: the first inverter

market in 1995 and achieved international success within a very short time. A genuine revolution came about in 2001 with the launch of Fronius IG. This was the first inverter with a high-frequency transformer, which allows technicians to replace the PC board on site. In recent years, the business has developed from a pure inverter manufacturer to becoming a provider of solutions for the efficient and intelligent generation, storage, distribution, and consumption of energy.

The product range extends from tailormade storage solutions to photovoltaics for water heating and solar e-mobility, hydrogen production and storage, and H2 refueling infrastructure. ■

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DORSET LEP INVESTS OVER £700,000 IN BOURNEMOUTH & POOLE COLLEGE Dorset LEP is investing £712,800 into three facility upgrade projects at Bournemouth & Poole College in an effort to close Dorset’s skill gap.

And a push towards virtual welding is top of the list of new projects.

New construction, design and digital media facilities will be introduced.

Construction, engineering and digital hubs will be created to focus on employability and enterprise skills, ensuring students are work-ready before they enter industry.

Dorset LEP Chair, Jim Stewart, said: “We are delighted to be able to allocate this government Local Growth Fund allocation to Bournemouth & Poole College.

“These new facilities and equipment will help the college meet the local skill gaps that have been identified by local employers and shown in the results of our Dorset 2020 Employer Skills Survey.

“These three projects will help young people more easily find work and stay in the area, which will boost Dorset’s economy. Dorset LEP are committed to investing in local young people and unlocking the area’s talent, making Dorset not only a great place to learn but to also work.”

The ‘Construction and Engineering Project’ will see an existing workshop refurbished to further increase

construction and engineering teaching capabilities for BCP College’s North Road campus. This project has received £610,000 of funding to place all construction wet trades onto one campus while upgrading engineering equipment to extend the level of training offered. For example, investment into the engineering and electronics curriculum will see the introduction of virtual welding systems.

Bringing together plastering, painting, decorating and brickwork will enable the college to increase the number of courses it offers and support the delivery of new T-levels.

Apprentices will acquire an enhanced range of skills in line with the requirements of the majority of Dorset employers, which will impact positively on productivity within local businesses. This formula for success is expected to increase the number of employers the college will work with, subsequently increasing the future number of local apprenticeships.

Inspirational sculpture for frontline workers A welder has produced a remarkable sculpture using engraved keys in order to honour our frontline workers during the coronavirus crisis.

John Gillespie produced the sculpture, which measures in at three metres long, using stainless steel and it now has pride of place in his back garden.

Entitled Unity, the sculpture is of a figure of a nurse and the keys which comprise it have essential roles such as healthcare worker engraved on them.

The 41-year-old from Chichester, West Sussex, designed the sculpture so that the nurse has her head in her hands, reflecting the pressure and the stress faced by all key workers during the crisis. It took more than 300 hours to create.

This project started in February and aims to be completed by November 2020.

Secondly, Dorset LEP has awarded £85,928 to the college so it can open a ‘Digital and Enterprise Innovation Hub’ at both its campuses.

The two new hubs, expected to be open to students from October 2020, will focus on developing employability and enterprise skills for more than 4,000 full-time students and apprentices per year. Therefore, Dorset can expect more productive employees from the onset of employment, reducing the training and mentoring time required Finally, a further £16,800 of funding will contribute towards the purchase of graphic pen-to-screen tablets for the college’s ‘Digital Design’ students. These, in-line-with-industry standard tablets, will improve the skills of 256 students every year. The equipment is expected to be available for student use from October 2020. ■

John said: “I’ve managed to get most of her together now. The bench is assembled but still needs welding and I’ve lots of little bits to still do.

“Well done to all our key workers it’s your unity that is helping us through this.” ■

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Lotus announces all new sub-assembly manufacturing facility in Norwich Lotus Cars has announced that its steel fabrication (currently situated at Vulcan Road, Norwich) and lightweight structures (located in Worcester) businesses will be brought together in to one new, larger facility at Hurricane Way in Norwich with the creation of up to 125 new jobs.

The investment from Lotus, which has its headquarters and sports car manufacturing in Hethel, Norfolk, further demonstrates its commitment to the region and to Norwich.

The 12,300 m2 Hurricane Way factory will be converted to a new high tech subassembly facility to house manufacturing of the award-winning aluminium extruded and bonded aluminium chassis for the Evora, Exige and Elise Lotus sportscars, along with manufacturing of aluminium components for other global car companies. The facility will also house the steel welding and fabrication of subframes, suspension components and other key parts for Lotus cars.

As Lotus Cars’ expansion continues under new ownership since 2017, the company has outgrown existing facilities in Worcester and Norwich, and by moving into one, combined new location, the

company will take the opportunity to further upgrade machinery and tooling in readiness for new Lotus sportscars to be launched in the coming years.

David Hewitt, Executive Director of Operations, Lotus Cars said: “By bringing the aluminium chassis and steel subassembly manufacturing businesses together into one facility, we can further improve upon efficiencies and productivity for Lotus manufacturing. Being located close to Lotus’ HQ in Hethel, Norfolk where all Lotus cars are assembled, will also benefit the business as we expand further into the future.”

New Anglia Local Enterprise Partnership (which works with businesses, local authority partners and education institutions in Norfolk and Suffolk) and

Norwich City Council helped secure the move.

Chris Starkie, Chief Executive of New Anglia Local Enterprise Partnership, said: “We are delighted to have helped Lotus complete this deal to develop a new production facility in Norwich. It underlines the commitment of this globally-recognised brand to the county with which it is synonymous, and reinforces our region as a centre of excellence in low volume, hightech manufacturing.

“The New Anglia Local Enterprise Partnership will also be supporting a training programme aimed at upskilling existing staff and providing technical apprenticeships, ensuring this region has the skills that are needed in its key sectors.” ■

NEW GUIDANCE ON LOCAL EXHAUST VENTILATION The Institute of Local Exhaust Ventilation Engineers (ILEVE), together with the Building Engineering Services Association (BESA), have published new guidance on local exhaust ventilation. TR40 – A Guide to Good Practice for Local Exhaust Ventilation, is a comprehensive guide for all those who design, commission, operate and maintain LEV systems, and includes LEV commissioning engineers.

The guide has been produced to support the ILEVE aims of reducing ill health and death resulting from workplace exposure to hazardous substances, improving competence and providing members and the wider public with first class information and criteria for best practice.

TR40 includes information on the different roles and responsibilities, and associated legal and statutory responsibilities, providing guidance on what to do and

when to ensure the LEV process provides effective solutions to control exposure to hazardous substances.

It includes guidance on identifying LEV competency skills, experience and knowledge, training (to be used in conjunction with the industry LEV Competency Matrix), the importance of keeping records, what to look for, what to ask when evaluating LEV tenders and quotations, and the installation and commissioning

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process through to handover.

“TR40 will help give the consistent approach we have all been working towards. The guide is designed to ensure that we have bespoke systems being designed and installed to protect the health of all those in the working environment.” Dean Greer, chair of ILEVE. It supports the principles of the government’s ‘Helping Great Britain Work Well’ strategy by providing simple, accessible and relevant advice to facilitate proportionate, appropriate and effective risk management, encouraging all those in the system to take much greater ownership of health and safety. ■ TR40 is available for CIBSE members to download on the CIBSE Knowledge Portal at cibse.org/knowledge, for all others visit www.thebesa.com to purchase.

The new siaramic ceramic fibre disc for maximum performance Its regular, triangular shape differentiates the new generation of siaramic ceramic abrasive grit from conventional grit. The ceramic abrasive grit used in siaramic fibre discs (series 4581 / 4582 siaramic) makes it possible to achieve an uncompromisingly fast and clean cut through steel and stainless steel. This allows for an extraordinarily high removal rate, thereby reducing the duration of the respective processing steps and saving the user time.

The key to the high performance of the new 4581 siaramic and 4582 siaramic fibre discs from sia Abrasives is the regular, triangular shape of the ceramic grit. In conventional abrasive discs, the ceramic grit has more of an irregular block shape, which leads to a ploughing effect during material removal and creates unwelcome excess heat.

In contrast, the new generation of siaramic ceramic grit cuts cleanly through metal and achieves a high removal rate. This significantly speeds up grinding work. In comparison with conventional ceramic abrasives, users of the siaramic fibre discs can grind welded seams up to 40% faster.

In addition, a–cooling additive has been applied to the fibre discs inhigh the siaramic Ceramic fibre disc with extra speed and maximum lifetime 4582 siaramic series. This counteracts any unwanted discolouration of the workpiece as a result of heat development while grinding stainless steel. The lower grinding temperature also increases disc lifetime.

siaramic Technology The special structure of the siaramic grit provides an outstanding selfThe ceramic grain makes a difference sharpening effect that allows the user tothat achieve a continuous grinding result throughout the whole service life of the disc.

The new siaramic discs are best suited for typical angle grinder applications such as welded seam preparation or removing welded seams, scale and mill scale. They are available in four different diameters: 100, 115, 125 and 180 mm. You can also use the innovative X-LOCK quick change system with the 115 mm and 125 mm discs.

The special X-LOCK hole pattern of the discs allows the user to use the siaramic discs on standard angle grinders as well as on X-LOCK angle grinders. Fibre discs in the 4581 series are available in grits 36+, 60+ and 80+; discs in the 4582 series are available in grits 36+, 60+, 80+ and 120+.

Conventional, crushed ceramic grain

EXT SPE HIGH RA ED

siaramic technology, shaped ceramic grain

Conventional (crushed) grain is irregular and blocky in shape which The optimal triangular shape of the siaramic technology grain enables a results in a "ploughing" action and generates unwanted heat when clean cutting action, delivering fast stock removal and a cooler grinding grinding.For any enquiries contact sales.gb@sia-abrasives.com temperature, which increases the lifetime – all of this offers an ordisc call 01422 313319 optimal grinding experience.

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HOT WORK:

FIRES AND INJURIES IN THE CONSTRUCTION SECTOR AND HOW TO REDUCE THE RISK WHAT IS HOT WORK? Hot work refers to any task that requires using open flames or applying heat or friction which may generate sparks or heat.

More specifically, it is defined by the British Standards Institution (BSI) in BS 9999 as: “Any procedure that might involve or have the potential to generate sufficient heat, sparks or flame to cause a fire.”

Examples of hot work includes welding, flame cutting, soldering, brazing, grinding and the use of other equipment incorporating a flame.

Hot work poses a particular threat within the construction sector as the cause of multiple fires in buildings.

For example, according to figures from the Scottish Fire & Rescue Service, who were contacted with a Freedom Information Request, there were 180 fires in the construction industry in 2018/19, a staggering 143 (79 per cent) of which were the result of hot work.

Fifty-one fires during this period were caused by welding or cutting equipment, 22 by manufacturing equipment and 23 by kilns or other services. These fires resulted in 21 casualties.

The most common examples of hot work and those that can pose significant risks without proper safety precautions are for example: • Brazing and soldering • Gas/electric welding cutting apparatus • Grinding wheels and cutting discs • Thawing pipes • Open flames, blow lamps and blow torches • Bitumen and tar boilers • Hot air blowers and lead heaters.

A variety of industries, construction in particular, may require hot work to be carried out in their premises as part of routine work activities. It is also frequently carried out as part of contractual work, which is common in construction.

However, no matter who does it, they must know what kind of hazards hot

work presents and how to prevent it from causing harm.

Flying sparks are the principal risk posed by hot work and they can easily get trapped in cracks, pipes, gaps, holes and other small opening, where they could potentially smoulder and cause a fire to break out.

The debris and residue which hot work creates, such as flammable swarf, molten metals, slag, cinder and filings, are often combustible.

Hot work can cause pipes to substantially heat up and easily transfer, through the process of conduction, to another flammable surface and cause a fire.

Failure to remove flammable materials or substances from a surface before commencing work means that they could easily become hot and cause a fire.

In certain environments, there may be potentially explosive vapours or gases in the air which are highly combustible and could ignite if exposed to hot work.

In a similar vein, hot work could generate fumes which, in turn, create an explosive atmosphere.

CONTROL MEASURES TO MINIMISE THE RISK OF HOT WORK FIRES Due to the high risk nature of hot work, the BS 9999 and the Health & Safety Executive (HSE) outline various safety procedures which organisations must adhere to. Their aim is to protect workers from dangerous aspects of hot work and to prevent fires from breaking out.

Measures to make hot work safer BS 9999 states that “hot work should only be undertaken if no satisfactory alternative method is feasible.” Therefore, it is important to consider every possible alternative for completing a task before deciding to proceed with hot work.

In some situations, hot work is unavoidable. If this is the case, a permit must be created before the work starts. A permit is crucial as it sets out the safety measures which everyone must follow to

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minimise the risks associated with the work.

CREATING A HOT WORK PERMIT Due to the level of risk posed by hot work, preparing a hot work permit is mandatory.

According to BS 9999 “a hot work permit procedure, which may be part of an overarching safe system of work/hot work permit procedure, should be followed before any hot work is allowed in or near a building. This is to ensure that correct actions are taken before hot work commences, during the operation and afterwards.”

To fulfil this requirement, people need to know how to create a hot work permit.

Sections include: • Details of the work. What type of hot work needs carrying out?

• Hazards and risks. What are the associated risks of the hot work?

• Precautions and procedures. What steps will be put in place and apply before and during the work?

• Personal protective equipment. Do people need to wear protective goggles, face masks and gloves?

• Reference to isolation certificates. Does any nearby equipment need isolating before work can start?

• Authorisation and acceptance. This includes those involved in creating, implementing, and following the permit.

• Training and competence. Do people need any training before they can carry out the hot work?

• Handover procedures. If the people doing the work swap shifts, what procedure will the workplace follow to ensure they change over safely?

• Hand back and cancellation procedures.

Once the work is completed or needs cancelling, who is in charge of managing this?

Understanding the tasks and knowing precisely who is involved makes a permit fairly straightforward to prepare. A competent person who is not directly

NEWS

involved in the hot work must prepare and authorise the plan but the input and commitment from everyone taking part is essential.

to cover them completely and monitor the area closely.

HOUSEKEEPING One of the most crucial ways to prevent fire hazards posed by hot work is by clearing the area before starting. This involves removing flammable and combustible materials and liquids within a five-metre radius of the work. If overhead hot work needs carrying out, then site managers may need to extend this radius.

It is also vital to ensure that the atmosphere does not contain flammable or explosive vapours, gas or dust. If there could be an issue, gas or vapour monitoring should be carried out.

DESIGNATED AREAS It is vital that hot work takes place in an area designed specifically for it, but some areas will understandably not be specifically built to withstand it. For example, if a contractor needs to carry out welding work on a pipe in a staff room kitchen, this is not an area of the building specifically designed to minimise hot work risks.

However, it is perfectly possible to assess an area and prepare it for hot work, such as by applying protective covers as discussed above. This applies equally to five-minute jobs just as much as it does to a task that takes longer.

PROTECTING AREAS Hot work often produces sparks that can easily get into holes or gaps in floors, walls, and ceilings or smoulder on combustible materials. Therefore, take the time to cover these areas with suitable flameproof sheeting, purpose-made blankets, drapes or screens before commencing work.

Combustible floors can also be covered with damp sand to prevent ignition.

Where unable to fully clear the area of combustible materials, use appropriate flameproof covers on them but make sure

FIRE SAFETY SYSTEMS Those carrying out and supervising hot work must understand the fire safety procedures that are in place.

In particular, they should be aware of: •W hether the area has a sprinkler system and whether or not it is active.

•H ow to activate the alarm, where to evacuate during an emergency and how to contact assistance or the fire authorities.

•H ow to prevent false alarms. Do certain detectors need temporarily deactivating?

If so, these must be reactivated as soon as the work finishes.

• Which fire extinguishers are necessary.

At the very least, the person in charge of supervising should receive fire extinguisher training. Furthermore, the site should have at least two appropriate extinguishers available, based on the type of hot work being carried out.

FINISHING THE WORK Once hot work activities cease, workers must properly deal with the materials used.

For example, people are required to: • Fully extinguish LPG blow lamps and torches and allow them to cool after use. Remember to also let them cool down before changing cylinders and to fully remove the gas cylinders upon completion of the work.

• Properly switch off, unplug and cool down electrically-powered hot air blowers before returning them to storage.

• Submerge stub ends of welding rods in water before safely and appropriately removing and disposing of them from the site.

• Clear up the area if the hot work produced flammable materials, such as metal filings. ■

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Hitachi Rail begins new phase of manufacturing at UK factory with East Coast Trains order Manufacturing of five 100% electric East Coast Trains has marked the start of a new phase of train building at Hitachi Rail’s Newton Aycliffe factory.

The construction of the new intercity trains for East Coast Trains Limited incorporates a more extensive manufacturing programme than previous fleets. The increased scope will see the highly skilled workforce create a new state-of-art fleet from empty aluminium shells.

Despite the impact of Covid-19, Hitachi Rail has continued to work diligently and safely in preparing the factory and is now ready to start manufacturing the East Coast Trains order.

The five fully electric East Coast Trains – known in the rail industry as Class 803s – will begin carrying passengers between Edinburgh and London from autumn 2021, offering passengers a high quality, cost effective and more sustainable alternative

to flying between two of the UK’s capital cities.

East Coast Trains are focused on delighting passengers. They will have the first service of the day from London to Edinburgh, making it an attractive alternative to flying. The trains will also travel entirely in electric mode, resulting in zero-emission intercity travel.

NEOPULSE MIGSRANGE MULTI PROCESS MIG/TIG/MMA TRACEABILITY - weld data capture PORTABILITY - share weld parameters and jobs across multiple machines CONNECTIVITY - Automation and robotic connection - Software updates - easy updates of machine evolution SINGLE PHASE - 220A 3 PHASE - 320A / 400A / 500A NO.1 MANUFACTURER OF INVERTER WELDING EQUIPMENT IN EUROPE WORLD LEADER IN CAR BODY WELDING EQUIPMENT

01926 338 609 uk@gys.fr www.gys-welding.com

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These trains are part of the award winning Class 800 series, which are currently some of the UK’s most reliable new train fleets and improving passenger satisfaction.

Hitachi Rail are due to build more intercity orders this year, which will benefit from their £8.5m investment in welding and painting at the factory.

Ross Nagle, COO Rolling Stock UK at Hitachi Rail: “Building these East Coast Trains signifies a new and exciting chapter for Hitachi Rail’s UK factory.

“It is an important step as we increase our manufacturing capabilities and upskill our workforce at Newton Aycliffe, which includes a £8.5m investment in new welding and painting facilities.

“The increased skills of our workforce makes us well placed to deliver a number of highly significant orders over the next 12 months, and consolidate our place as a strategic North East manufacturing hub.” ■

B OA R D M EM B ERS

PRESIDENT’S MESSAGE Hi Everyone, how are you all feeling? Nervous, relieved or a bit of both?

So the last few weeks have again, been a mixture of emotions for me with restrictions easing but then our city was put back into lockdown. As many of you know I am a true Leicester lad who grew up in the very centre where we have the issues in the textiles factories. I was so sad for local businesses who’d put so much effort and expense into opening up, only to be told they had to wait another 2 weeks, which in reality turned into 3. Even our local pub featured on the BBC news with #releaseglenfield.

Finally, village by village in Leicestershire we are opening up.

I’m sure you will agree it’s so important to try to support the local businesses around you so that together we can help build the country and economy back up. Reshoring is the new buzz word. We have to start heading out and spending money to keep the wheels turning in what is going to be a very tough year for everyone. I send my fellow business owners a massive well done for making it through these dark, hard times. Good Luck with your new “normal” and count your blessings for being in the welding industry and not hospitality.

I am very pleased to say that I finally got my haircut, my granddaughter made a great attempt but it’s nice to be back in the barber’s chair.

In contrast to the world uncertainty, in the last few months I have been reassured as to how our company will run with my son and daughter, Craig and Claire, in the driving seat with me imprisoned at home. I am pleased to report that Westermans International will continue to thrive with the support of a brilliant team behind them. I am not planning on retirement yet and someday I might like a holiday, but that’s a way off yet!! The main thing is I know you can all contact anyone within the company and I know you will get the advice you need.

I am ready and raring to go but I need your help!! I need to buy more equipment for Craig to sell as he’s always on my case. So, I need heavy industrial, three phase equipment such as CNC plasma cutters, diesel welders, seam welders, rotators, orbital equipment and so on. If your customer’s have something to sell, please email me some photos peter@westermans.com and we can start chatting again. We’ll pay a Finder’s Fee of between 20-30% on successful deals.

Brought to you by:

Welding World Ltd on behalf of the Association of Welding Distribution Gavin Pearson, 5 Parsons Street, Dudley, West Midlands, DY1 1JJ. + 44 (0)1952 290 036 + 44 (0)1952 290 037 secretariat@awd.org.uk www.awd.org.uk Adrian Hawkins Managing Director Telephone: 01462 482200 07793 220800 E-mail: adrian@welding-world.com Dave P. Ellwood Director & Company Secretary Telephone: 01252 333661 07860 258309 E-mail: dave@welding-world.com Lee Darton Finance Director Telephone: 01462 482200 07734 857044 E-mail: lee@welding-world.com

Editor: Darren Isted editor@welding-world.com Design: David Walters Published on behalf of Welding World by: Tel: 07539 782979 Email: hdmdigitalsales@gmail.com www.hashtagdigitalmedia.co.uk While every effort is made to ensure the accuracy of this publication, the AWD, the editor and the publisher, Hashtag Digital Media, cannot accept liability for any statement or error, or for any claims made by the advertisers, contained herein ©Welding World 2020. They cannot be held responsible for the failure to use, or for the poor depiction of use of environmental, personal or other equipment, such as Personal Protective Equipment (PPE) and Local Exhaust Ventilation (LEV) equipment in photographs received from editorial contributors or advertisers. Best practice in the use of the correct and appropriate equipment is advocated and strongly recommended by the AWD. Hashtag Digital Media ensures that the paper used for printing this publication has been sourced from sustainably managed forests.

PETER WESTERMAN President AWD

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CU TT ING WO RLD

Hypertherm ProNest® 2021 Hypertherm, specialist manufacturer of industrial cutting systems and software, have announced the release of ProNest® 2021, a major version update of its advanced CAD/CAM nesting software for automated cutting. This release contains new features and enhancements designed to make customers more efficient and profitable.

These features include: • Redesigned 2D CAD package provides improved font support, ability to shape text, and other new features that are especially popular among sign makers.

• CAD editor preference users to set a default CAD program for edits to parts in the ProNest part list. Select the embedded ProNest CAD software or choose a third-party software such as AutoCAD. • Part report quickly opened from the part list so users can add individual part reports with an image of the part, plus dimensions, size, material, class,

process, costing information, and more.

• I nterior bridge cutting to add bridges to text and other interior geometry so that pieces don’t drop when cut. This helps minimize interior cutouts on parts for aesthetic purposes and reduces tip-ups.

“ProNest 2021 builds on the strong foundation of ProNest 2019 to make the programming process more efficient,” said Tom Stillwell, Marketing Project Manager for Hypertherm CAD/CAM software products.

“Whether using plasma, waterjet, laser, or oxyfuel cutting, this new version provides the powerful tools fabricators and manufacturers need to increase material savings, boost productivity, lower operating costs, and improve part quality.”

In addition, Hypertherm is releasing upgrades to its ProNest LT software for lighter production environments.

Users with an active subscription, and customers with an active maintenance plan can upgrade to the new version of

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their respective product at no additional charge and continue to receive unlimited technical support, and other benefits.

More information is available at www. hypertherm.com/CAM. Hypertherm designs and manufactures industrial cutting products for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair. Its product line includes cutting systems, in addition to CNC motion and height controls, CAM nesting software, robotic software and consumables. Hypertherm systems are trusted for performance and reliability that result in increased productivity and profitability for hundreds of thousands of businesses. The company’s reputation for cutting innovation dates back 50 years to 1968, with Hypertherm’s invention of water injection plasma cutting.

The 100 percent associate owned company has more than 1,400 associates along with operations and partner representation worldwide. ■

EXT RACT ION WOR L D

CUTTING OUT MIST EXTRACTION IS FALSE ECONOMY SAYS FILTERMIST Telford based industrial air cleaning expert Filtermist Systems Limited is urging companies investing in CNC machine tools to think carefully about leaving mist extraction off the order to cut costs.

The company, which works with many of the country’s leading machine tool distributors as well as end users, has noticed a marked increase in customers investing in ‘bare bones machines’ and not including bar feeders, high pressure or mist extraction in a bid to reduce spend.

“Whilst taking a cautious approach is understandable in the current climate, it’s false economy,” states Filtermist’s Director of Group UK Sales, Andy Hives. “Although there is an initial capital investment, effective extraction can actually help to lower running costs in the longer term.a “Cost reductions can include lower heating bills in colder months as the air exhausted back into the facility is warm;

lower cleaning bills as there’s less oily residue on floors, ceilings and work surfaces; less days lost to ill-health as a result of exposure to contaminated air; and last but not least, there’s a far lower chance of employers being hit with chargeable enforcement and improvement notices from the HSE, or hefty fines for failing to comply with COSHH (Control of Substances Hazardous to Health) regulations.”

Prior to the outbreak of COVID-19, the HSE completed its Q4 inspection programme which targeted metal fabricating premises in a bid to reduce exposure to metalworking fluids and welding fume: reducing occupational lung disease is a key focus in the HSE’s current workplan. Both COSHH (Control of Substances Hazardous to Health) regulations and the UKLA/ HSE Good Practice Guide for Safe

Handling and Disposal of Metalworking Fluids recommend using Local Exhaust Ventilation (LEV) on CNC machines to control exposure to airborne mist particles.

Whilst the COVID crisis has hit most areas of the UK economy including manufacturing, it has also resulted in lots of discussions about the value of reshoring the manufacture of critical components back to the UK, which, if it transpires could potentially result in a boost to the industry.

A poll in May reported that 59% of respondents thought the crisis should trigger a UK wide reshoring strategy and many of the trade associations Filtermist is a member of, including the GTMA, BTMA and the EIA, are involved in Reshoring UK – an initiative designed to connect OEMs and Tier 1 companies with local suppliers to fill gaps in their supply chains. ■

CAN YOU PROVE YOUR FUME EXTRACTION IS WORKING? THE HSE WANTS TO KNOW Just as the flurry of fume extraction seemed to settle slightly, the HSE has expedited its search and has been actively looking for infractions. Many companies have rightly taken the time to research and invest in fume extraction equipment to help safeguard their employees from imminent and future health complications and ensuring this equipment is correctly LEV tested. The HSE, however, has become more astute in its attempts at catching businesses out.

Two points for you to consider, as the HSE certainly is, are whether or not you can prove your LEV systems are sufficient enough to provide constant and consistent protection and that some insurers will fail systems that cannot prove a clean air return.

It is imperative that you ensure your systems are LEV tested regularly, but unfortunately this may no longer be enough.

Can you prove that the fume levels in your workshop did not exceed safe limits at any point? Unlike a three-day air monitoring service, a permanent or rented environmental detection instrument (EDI) places constant and live data in your hands and produces annual records that can be saved and kept. This can be used to prove to the HSE that your extraction equipment is sufficient and means that any

employee that returns with claims that fume levels have been a contributor to an emerging illness can be instantly discredited. Extractability’s Protectoscan EDI will even switch your extraction units on when fume levels are breached in case your employees have forgotten.

If you are still stuck on the daunting task of choosing suitable fume extraction for your workplace, consider watching the free webinar series that Extractability have put together on choosing the correct fume extraction. ■ As always, if you require assistance or would like to discuss how a Protectoscan EDI might benefit your company, contact the experts on 08458 622620 or email sales@extractability.eu.

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P R ODUCT N E WS

EWM TAURUS STEEL SAVES ELECTRICITY AND COSTS With welding machines from the Taurus Steel series, EWM AG customers are already meeting the requirements of the EU Ecodesign Directive. These MIG/MAG welding machines by EWM, Germany’s leading manufacturer of arc welding technology and one of the world’s leaders in technology, have been designed for working with steel. Thanks to state-ofthe-art inverter technology, the machines are resource-efficient and, true to EWM quality, extremely durable and powerful, saving companies real money. This makes welding machines from the Taurus Steel series a veritable alternative to step switch-controlled machines.

Comparison calculations show that through the low power consumption alone, companies using an EWM Taurus Steel machine save more than 3000 kWh per year in comparison to a step switchcontrolled welding machine. That translates to almost two tonnes less CO2 and, with an electricity price of 20 cents per kWh, around 600 euros worth of cost savings a year – and that’s just one, single machine. For steel and metal-working industries and shipyards, as well as for steel construction companies, there is huge potential for savings with initial procurement costs being paid off in no time.

Thanks to their large power reserves and renowned EWM quality, machines in the Taurus Steel series are suitable for continuous use in three-shift operation.

The machine controls are easy to operate and the welding task can be quickly set up with 100% reproducibility. EWM now offers the Taurus Steel in three power variants. In addition to the Taurus Steel 400 A and 500 A models, EWM now also offers the brand-new Taurus Steel 355 with 350 A output. All three products have an incredible duty cycle. The 350 and 500 variants boast a duty cycle of 60% at maximum current, while the 400 variant offers a 100% duty cycle for easy welding with full penetration. This is all down to state-of-the-art EWM inverter technology that saves electricity while significantly reducing the weight.

The Taurus Steel Synergic is an inverter welding machine with a synergic control concept and optimised characteristics for steel. Thanks to the synergic function, parameters adapt automatically to the specified settings. The inverter-pulse welding machine, the Taurus Steel puls, also offers an additional, convenient pulse function. This ensures less weld spatter, reducing the need for finishing work.

Last but not least, the Taurus Basic S is an inverter welding machine with nonsynergic twin-knob operation, perfect for the more traditional welders out there.

With their modular system and associated wire feeders, the Taurus Steel machines are incredibly flexible and – depending on the assembly of intermediate hose packages and welding torches – also have a large working radius. The EWM

With welding machines from the Taurus Steel series, EWM AG customers are already meeting the requirements of the EU Ecodesign Directive. These MIG/MAG welding machines by EWM have been designed for working with steel.

The welding machines in the Taurus Steel series from EWM are equipped with stateof-the-art inverter technology and are extremely durable and powerful thanks to the EWM quality.

welding machines are robust and perfect for use in demanding work environments.

This makes all three variants perfect alternatives to the step switch-controlled welding machines still widely used throughout Germany. Their power sources are significantly lighter than machines with transformers and they are easy to transport thanks to their modular casing. ■

Comparison calculations show that through the low power consumption alone, companies using an EWM Taurus Steel machine save more than 3000 kWh per year in comparison to a step switchcontrolled welding machine.

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P R ODUCT N E WS

LIMITED EDITION AT THE START:

KEMPER optimises CleanAirTower and increases its performance With the comprehensive relaunch of the CleanAirTower, KEMPER is bringing its established general ventilation system to a higher level of protection. The extraction technology specialist has optimised the filter tower in terms of extraction capacity, plant safety, service life and design.

Thanks to a completely redesigned internal construction, the extraction capacity increases by 10 percent compared to the previous model. The newly developed pinball method prevents sparks and coarse particles from penetrating the filter and damaging it. Because they collide with special sheet steel elements on the inside, their energy is automatically extracted. Thanks to the innovative air flow, the filter life is extended by 20 percent compared to the previous model.

In the new CleanAirTower, KEMPER has completely redesigned the head of the filter tower. Extraction openings are no longer located circumferentially on the side, but in the cover of the general ventilation system. A new tornado principle at the head of the filter tower ensures that the contaminated air is drawn in with a very high degree of efficiency.

The optimisation also changes the design of the filter tower head. The element can be retrofitted in existing systems.

As part of a mix of measures for effective occupational safety, the CleanAirTower is the ideal supplement to source extraction.

Especially for welding processes with high to very high potential risk, the general ventilation system helps to comply with limit values and ensure a high level of occupational safety. This means the CleanAirTower also ensures that employees at surrounding workplaces are effectively protected from welding fumes.

It separates more than 99.9 percent of alveolar dust particles that could enter the bloodstream.

The general ventilation system from

KEMPER operates according to the recommended principle of layer ventilation. Automatic dust removal means that operation is uninterrupted. Welders dispose of the hazardous substances completely free of contamination. The optimised internal construction also reduces the cleaning effort.

Since the general ventilation system feeds the cleaned and heated air back into the hall, companies can save up to 70

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percent of their heating costs. Instead of

a one-off investment, the CleanAirTower is also available as a leasing model at attractive monthly instalments. For the market launch, KEMPER is bringing out a #nextlevel edition: The first 150 CleanAirTowers are being delivered by the manufacturer completely in black. â–

CLICK HERE for more information

PR ODUCT NEWS

QUICKPURGE® FOR WELD PURGING LARGE DIAMETER PIPEWORK

Weld Purging large diameter pipework made from stainless, duplex and chrome steels, titanium or zirconium can be expensive, with requirements to have the oxygen level well below 100 ppm during the welding cycle.

As it is not cost effective to completely fill pipework with expensive inert gas, Huntingdon Fusion Techniques HFT® have developed QuickPurge® Systems to dramatically reduce the space that needs to be purged.

Ron Sewell, Chairman for HFT® said: “Welders can often spend up to half a day purging pipes, which will cost a considerable amount in time and gas costs. With the help of QuickPurge®, large diameter pipes can be purged down to 100 ppm ready for welding in just a short time. The dramatic savings in time and argon pay for the system in just one weld!”

Huntingdon Fusion Techniques, HFT®’s innovative design of the reusable QuickPurge® Systems means that zero colour welds will be achieved and there will be no loss of corrosion resistance caused by oxidation.

QuickPurge® has an additional gas input line, which means extra purge gas can be introduced for applications such as this, thereby achieving a much faster purge, down to the lowest oxygen levels, which is perfect for larger diameter pipes where quality welds are required.

All systems are manufactured as standard with a hose for connecting a Weld Purge Monitor® to, which can read oxygen levels down to as low as 10 ppm depending on the model.

For pre-heated chrome steel and high strength stainless steel pipe joints, HFT® design and manufactures the HotPurge® range for a higher and longer temperature exposure. ■ Huntingdon Fusion Techniques HFT® have a worldwide Exclusive Distributor network. Please visit www.huntingdonfusion.com.

Made in Wales ‘Manufacturer of the Year’ and Welsh Business Awards – Exporter of the Year.

PurgEye®

Welders often face weld purging difficulties when working under the conditions experienced on-site including exposure to extremes of heat and cold, harmful sand and dust and even hazardous fumes, where an expensive Weld Purge Monitor® may not always be ideal.

Huntingdon Fusion Techniques HFT® have designed and developed the PurgEye® Site, which is manufactured inside a protected secure, safe, waterproof and dustproof, tough carry case, perfect for on-site welding.

The PurgEye® Site has a fast response, long life sensor and it is equipped with PurgeNet™, allowing the monitor to connect to a variety of accessories.

One of the accessories, an automatic welding machine interface, allows controls to be based upon the oxygen level, to prevent welding if that level is too high. Other accessories include a traffic light visual indication system and a temperature gauge.

With the housing case open, the PurgEye® Site is IP65 rated and IP68 rated with the lid closed.

The PurgEye® Site measures oxygen levels very accurately from 1,000 ppm, right down to 1 ppm (accurate to 10 ppm) with readings in parts per million (ppm) or percentage, depending on the users preference.

The small, low volume, almost indestructible case, can be carried anywhere and the PurgEye® Site used either with its internal battery, which lasts up to 10 hours or connected to mains electricity from 90 – 250V, single phase A.C. The large, bright, OLED display allows the data to be easily read and is mainly symbol based, rather than text. The display does not need a backlight and can be viewed from greater angles than LED screens. ■

www. awd.org . u k

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P R ODUCT N E WS

ELIMINATE UP TO 99.99% OF SURFACE BOUND AND AIRBORNE VIRUSES, BACTERIA, ODOURS AND ALLERGENS New and exclusive in the UK from Wilkinson Star is the Viro Tech range of Professional Ozone/ UV Sanitising Systems which can eliminate up to 99.99% of surface bound and airborne viruses, bacteria, odours and allergens.

These systems offer maximum workplace protection and provide a product which is safe in order to get people back working and businesses to operate during the Coronavirus pandemic.

For commercial use, both large and small offices, call centres, gyms, hotelsrestaurants-bars-cafes, health care settings, retail, hospitality, property services, schools, colleges, universities.

Also ideal for large sports venues, arenas…..the list is endless.

There are products to suit all budgets and facilities. All products are filterless, offering low maintenance and are chemical free. Both systems offer NCC and ozone generation technology.

The Viro Tech Mini can cover up to 279m2 and offers effective cleaning for living spaces, small offices and small shops.

The Viro Tech SO range offers 3 models offering coverage of up to 800m2 in just 4 hours. This range allows offers an overnight boost control for air purification covering all those hard to reach places in just 2 hours.

The units operate with NCC & Ozone Generation Technology. Natural catalytic conversion is a process that uses UV light to create the same oxidation and ionization as natural sunlight.

As with any powerful oxidant, disinfectant, disinfectant fogger machine, or bleach, Ozone should be used in accordance with the manufacturer’s directions. When used correctly Ozone is much safer than alternative methods of cleaning Most businesses have to rely on cleaning using chemicals in some way to remove bacteria, viruses and odours. Often the process can be expensive and susceptible to misuse of products. It relies on a cleaner (operator) to use the right chemicals for the application. Some cleaners can cause

damage or tainting of products. The Viro Tech product can overcome these issues at the flick of a switch.

Viro Tech has CE Approval. The Viro-Tech range has endured vigorous testing to Bureau Veritas accreditation. (Industry and Facilities Division) Inspection sites include leading global hotel chains, global banking institutes and the training and medical facilities at an

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Italian Champions League winning Serie A football club. As well as medical clinics in Italy. Inspection certification available on request. ■ Want to find out more about this revolutionary new product available this summer?

Please visit www.viro-tech.info or email viro@wilkinsonstar.com, 0161 793 8127

PR ODUCT NEWS

GYS upgrade Pulse MIG and TIG software with advanced traceability and user management THE GYS NEOPULSE PULSE MIG RANGE AND TITANIUM TIG RANGE HAVE JUST RECEIVED A MAJOR SOFTWARE UPGRADE ENABLING A POWERFUL ARRAY OF FUNCTIONALITY TRACEABILITY FUNCTION This enables trace/record of all welding values including Amps, Volts, Wire-feed speed, temperature and energy usage during each welding operation. This facilitates post-production analysis, evaluation, reporting and documentation of the recorded welding parameters and storage of the data requested under EN ISO 3834. Data can be accessed by exporting to a USB stick and displaying on any computer.

USER MANAGEMENT The User management function enables a series of parameters to be set and then locked off in order to disable users from altering the predetermined values. In a production environment, consistency of manufactured parts is essential, therefore having the ability to lock-in optimised is valuable. Each user can create their own Avatar and passcode so that multiple users can use the same machine on alternating

shifts. Allowance for tolerance can also be set, giving individual users a window of tolerance to alter the parameters to better suit their welding style whilst obtaining the same integrity and appearance of the required welds.

JOB SAVE After finding that perfect weld setting this mode allows you to create, save, recall and delete JOBs. Each Job can be saved as a Full Text format, allowing the personalisation of each user and the JOB saved i.e. John Smith Aluminium bracket 6 mm AlSi5 1.2. 100 JOBs can be stored in the memory of the machine, current

settings are also saved and automatically recalled the next time the machine is used.

QUICK LOAD The Quick Load is a JOB recall mode that allows the user to switch from Job-to-Job with the simple use of the torch trigger.

Previously stored jobs are added into a Quick load list in whichever order needed and sequentially recalled by briefly pulling on the trigger. All trigger modes (2T/4T) and welding modes (SPOT/ STD/PLS) are supported. This features then allows for continuous welding, even when the welding position or material thickness changes. â–

www. awd.org . u k

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SI F T I PS In their latest webinar series, Extractability teach you how to go through the process of choosing the right extraction system, from start to finish.

You’ve probably heard by now that welding fume was recently reclassified as carcinogenic in February of last year.

There’s now a legal requirement for all fume and dust (not just from welding) considered to be a contaminate to be extracted before it goes into the breathing zone of your employees.

What are the risks not acting or choosing the wrong products?

You’re liable to get fines from the HSE. If they find you haven’t got extraction or that your extraction isn’t suitable, they’ll issue you a breech notice, which can mean a partial or full closure of your business, especially if they find a large number of breeches or an immediate danger to your workers. By way of longer-term risks, if any of your workers develop health complications, in 10-30 years’ time, and they can directly attribute their condition to one of your work processes and prove that you didn’t have suitable LEV at the time for them then you would be liable for a lawsuit. On the smaller end of the spectrum, you may buy the wrong product, wasting your time and money. If you have any concerns or are due an HSE visit, you can always call Extractability, who will be happy to walk through the whole process with you. They can also tell you what kind of things they will be looking out for and what they might pick you up on.

In order to protect against lawsuits, Extractability offer ProtectoScan EDI that provides constant, year-long air monitoring so that you can both keep on top of your fume extraction and produce solid, data-driven, proof that your workplace has been compliant with Government advice.

To begin the process of choosing you fume

extraction you need to consider: • What are the processes in your workplace that produce contaminant?

A few of your work processes might require extraction under HSE guidelines that you haven’t previously considered.

• What are my constraints? Consider your workshop size, for example if you have a low ceiling you may not be able to fit fixed extraction or if you struggle for floor space it might not be suitable to have mobile units wheeled around. You will also need to take into consideration your workers’ physical ability, are they able to push/pull a mobile unit into position? At times, your location can dictate certain environmental laws meaning that you may not be allowed to use a vent to atmosphere system • How much of it do I do? You may not need to go all out on a fitted extraction system if you only use a welder occasionally for maintenance. If you are welding for less than 200 hours a year, you may be able to use a small, cost-effective, disposable filter unit that would grant your LEV conformity without having to spend much money.

If you are doing more than 200 hours a year of welding you will need a unit with cleanable filters to save you a significant amount of money.

• What are my ongoing costs? There

will always be an on-going cost with LEV units, eg, filters, maintenance, and your annual LEV testing.

•R equirement for annual TExT? A Thorough Examination and Test report is a legal requirement that needs to be carried out every 14 months, though most people choose to get it done annually.

• Training? Your welders need to be trained on their LEV systems. The HSE inspectors may ask workers using LEV equipment if they have been trained, if they haven’t, the HSE will pick you up on it.

Extractability is more than happy to cover these points with you, including the training of your staff and will issue you with a certificate as proof.

What type of system would suit your needs?

If you’re doing off site work and need a mobile system or something to extract from an on-torch set-up like the SifGun Evolution, then you would look at vacuum systems. If you needed a mobile or a several mobile units to position in different spots in your workshop, particularly if you are working on a large project, you might look at a large mobile unit like the ProtectoXtra or ProtectoXtract.

Alternatively, for multiple welders working in booths, a fixed system will be the most efficient form of protection.

It is important to also consider what materials you are looking to extract. If you need to extract flammable or explosive dusts you will need to look at systems designed to reduce the risk of fire.

If you are unsure or unable to find a system to suit you, Extractability can advise or even build a bespoke system to suit your needs. ■

CLICK HERE to view

Extratability’s full webinar series

Technical advice in the original SifTips style was started in 1932. ‘Sifbronzing’ is an almost universally recognised way of describing the low temperature bronze welding of sheet steel, cast iron and other metals. This explains why Sifbronze, the company which first developed and promoted the technique, is generally considered to be a supplier of high quality welding rods, wires, fluxes and equipment.

‘Will the Welder’ was a SifTips magazine that was produced in the early 1930s. The aim was to provide users with ideas and tips on how to get the most out of their welding equipment.

Sif is renowned for its UK manufacturing heritage as well as its complete range of quality welding consumables used globally for almost a century.

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A ND FINA L LY

AND FINALLY...

We have all been through some difficult times in recent months and our Government has done well to create and maintain the furlough scheme in support of society at this difficult time.

Copper’s surge from its spring lows to a three-year high at around $6,500 a tonne is an eye-catching development and one that will quicken the pulse of investors and hearten anyone seeking evidence of a rebuild in confidence that worldwide trade is on the increase again.

The metal is malleable, ductile and a terrific conductor. As such, it has many industrial uses, ranging from construction to automotive production to wiring to integrated circuits and as a result the metal is nicknamed ‘Doctor Copper’, because it is often seen as a good guide to the globe’s economic health.

On a wider basis, commodity prices more generally have rallied from the lows plumbed in the spring. The Bloomberg Commodity index, which tracks the ‘spot’ price of 24 raw materials ranging from copper to aluminium, gold to silver, hogs

to crops and oil to gas, is up by almost a third since late March.

All of this is evidence of a worldwide recovery in general activity and it is hoped that we can look forward from the gloom of this pandemic to a brighter future for all.

Kind Regards,

Adrian Hawkins Managing Director, Welding World Ltd managing.director@welding-world.com

www. awd.org . u k

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NEW

When it comes to pulse welding, we understand the importance of generating a consistent and precise arc for achieving optimal results.

The key lies in merging inverter welding technology with advance MCU circuitry. With this in mind, we give you the JASIC MIG350P and MIG500P.

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