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SOLUTIONS C U S T O M E R I N F O R M AT I O N

Newsletter - Issue 2 - 2009

New CastoMIG welding equipment range

Messer World at Essen

Wear & Fusion Technology with Service and Quality

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Content >> R&D

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>> Industry

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>> Products

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>> Service

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>> News

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Modern R&D approach to remain the most Innovative

Oil & Gas: HARDFACING or WEARFACING for HARDBANDING ?

Power & Waste incineration: Boiler repairs specialist New CastoMIG range: The new step switch generation

Improve your welders skills with the best Castolin Eutectic technicians

Together with the Messer World at Schweissen & Schneiden 2009

Impressum Editor >> Dr. Gary Heath E-mail >> gheath@castolin.com Contributors for this edition >> Bengt Larsson, Dr. Gary Heath,Patricia Nigg, Tony Nogaredes For more information or contact addresses, please visit our websites www.castolin.com or www.eutectic.com

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Editorial The importance of INNOVATION for the future Dear Reader, As we all continue to witness one of the most severe economic downturns, we also see that certain companies and businesses continue to prosper through a focus on innovation, rather than just cost cutting.

Castolin Eutectic is an established repair and maintenance company with a global reputation for Service, Quality and Technical Innovation.

In this edition, the importance of Technical Innovation for Castolin Eutectic and its customers is underlined. Innovation is key to bringing new products and technology to our customers, to help them become more competitive and also ďŹ nd new markets. However, innovation can be implemented also in business processes, such as the Research & Development process itself. The traditional route for product development is the shiny Corporate R&D Central Laboratory, but even here, this can change due to the recent advances in networking and communication.

Castolin Eutectic is playing an innovative role here and has developed such a global decentralized R&D structure.

The new innovative products developed over the last few years are ďŹ nding success in the Oil, Power, Waste, Steel and Agricultural industries, dramatically improving wear performance and operational performance.

Castolin Eutectic is known as an expert in developing new materials and consumables. Ultimately, however, it is the deposited coating that gives the customer results and the coating performance is also dependant on using the optimal equipment parameters and having skilled and trained welders. Both aspects have also been a focus in our general

SOLUTIONS - Customer Information - Newsletter - Issue 2 - 2009

development programs. The results are the launch of a new generation of MIG/MAG welding machines, featuring not only the latest electronic innovations, but also the innovation of simple custom programming of parameters, tailored to individual customers business. The other innovation is in welder training, a tradition part of our service.

Innovation is recognised by most experts as a sure way to come out stronger from the recession, so take the time to talk to us and beneďŹ t from our innovations.

Good reading

Dr. Gary Heath VP Marketing and Product Management

Modern R&D approach to remain

the most Innovative

Thanks to their daily contact with customers, our technician experts encounter every year new parts subjected to wear phenomena at your plant. Our answer to customer problems consists of: Products, processes, applications, and production engineering 700 Sales staff with technical degrees Core team of 30 Development people employed in 12 countries 9 PhDs working on various projects 4-5 patent applications per year Our R&D is decentralized involving: Paris, Ireland, Italy, Poland, Austria, Switzerland, USA, Canada, Japan, India and Brazil. The advantage of this modern R&D structure and progressive communication is that excellent researchers around the globe can be fully utilized, without having to uproot them from a creative environment.

Germany

Poland

Ireland

R&D Corporate Headquarters

Customer

University France

Example of modern R&D organisation

>> R&D

Our goals through Development & Innovation are to bring new and INNOVATIVE SOLUTIONS to the market in order to respond to customer needs. The core development themes are: understanding wear, developing materials and optimal microstructures together with latest processes.

Stringent quality control

Bringing theory to reality: some new successful applications One of our innovations is in the field of nanotechnology. Although it is constantly being hailed as the driving force for the future, nanotechnology remains very expensive and is found mainly in the fields of biomedical, electronics, communications, etc. Castolin Eutectic have been able to convert this laboratory scale material into an affordable welding product and traditional industrial customers have been surprised that they can already benefit today from this new science with a NanoAlloy® range including: welding and brazing consumables, wearplate, CastoTube® and powders.

Hardbanding solutions for the Oil & Gas industry: Every year, extensive wear on casing and drilling tool joints costs the Oil & Gas Industry millions. Our answer to this growing problem is the development of the OTW-12 alloy. This alloy has been formulated to confer optimum hardbanding wear resistance in open hole drilling situations whilst retaining “casing friendly” proper-

ties. OTW-12 is a gas shielded fluxmetal cored welding wire specifically developed for Hardbanding drilling tool joint applications. Its peripheric arc characteristics ensure: lower heat input, reduced dilution, better bonding, shallow heat affected zone and minimal undercutting.

Industry proven Spray and Fuse alloys for boiler repair: Castolin Eutectic was amongst one of the first companies to recognise and offer nickel based self fluxing alloys as a wear and corrosion resistant coating for boiler tubes in the 1980s and have developed a considerable reputation and experience with these alloys. A novel high molybdenum, high silicon alloy was developed and patented for severe corrosive environments. This solution combined the inherent properties of such fused coatings (such as diffusion bonding, zero through porosity) with improved performance over even welded 625 type alloys.

For more information about these products, please visit the www.castolin.com website.

Wear & Fusion Technology with Service and Quality

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>> Industry

Oil & Gas: HARDFACING or WEARFACING for HARDBANDING ?

The world demand for energy is escalating. Two of the few major energy sources are Oil & Gas. In order to extract these energy resources drilling must be used to reach the underground reservoirs. Major oilfields are found on both land (onshore) and under the sea bed (offshore).

When drilling for Oil & Gas, a drill bit is used attached to a drill pipe tools with diameters from 1000 mm down to 100mm. The largest hole is at the top of the

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well which must be sealed as the steps get deeper. This is called well construction. The well is sealed from collapsing by using a steel tube with cement to fix it to the well formation. This steel tube is called the casing which has several functions. The major one is to seal off the well from its high pressure. In “open hole” drilling the tools are exposed to the severe wear from the formation, after setting the casing. The current depths of wells are from 3,000 m to 10,000 m deep.

Hardbanding is a very established name for the wearfacing welding process used in drilling to minimize wear on casing and drilling tool joints in order to reduce operational costs associated with Oil & Gas production. It involves the application of a wearfacing material on the drill tool joint.

The process is done by approved hardbanding applicators for OEM drill pipe producers and drilling companies. Trio OilTec Services have executed hardbanding in the Norwegian market for more than 8 years. Due to excellent cooperation between Trio OilTec Services and StatoilHydro, there has been a very successful devel-

SOLUTIONS - Customer Information - Newsletter - Issue 2 - 2009

opment and use of new, innovative alloys such as OTW-12, OTW16 wires and also special coating (MX5). Today Statoil- Hydro approves OTW-12, OTW-16 and the MX5 coating for drilling.

In the development of these products, TRIO, took this task very seriously, and uniquely in the industry constructed its own dedicated hardbanding Wear test Machine and also full scale automated Hardbanding welding facility.

With Trio’s integration into the global Castolin Eutectic organisation, there is an extension its product offer outside of Norway.

Casing

Critical zone Force Tool joint

Drill pipe

Drill sting tension

Schematic of wear sources

Power & Waste incineration:

Power generation boilers are large and expensive installations which can suffer enormously from wear caused by corrosion and erosion, aggravated by very high temperatures. The exact type of wear experienced varies from one part of a boiler to another and is influenced by the overall design of the boiler and the type of combustible fuel.

Castolin Eutectic’s protective coatings significantly extend the service life of worn boiler components making them last longer than uncoated new parts. Castolin Eutectic protective coatings are a more cost effective solution than replacement of the worn parts

>> Industry

Boiler Repairs Specialist

Arc wire spraying of boiler tube panels

with new ones and provide direct savings in materials and valuable reductions in downtime.

Additionally, Castolin Eutectic offers the widest range of coating products so protection can be tailored against the specific

combination of wear phenomena found in each part of every boiler.

This work can be achieved onsite or in our CastoLab® Services workshops.

Below some of the typical repairs for coal fire boilers:

Soot blow system

Stop valve repair

Raw coal feeding screw

Control valve repair

Slide valve

Separator

Boiler Tube panel

Wear & Fusion Technology with Service and Quality

Control valve repair

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New

CastoMIG range:

>> Products

The new step switch generation Our multi adaptable CastoMIG welding equipment range is used for applications which impose special requirements:

High welding capacity combined with outstanding bead quality High alloy steel with faster deposition rate wires (EnDOtec®) Specific welding parameter settings

Demonstrated at

program-controlled welding operations Tough conditions

Features: Welding parameters synergic adjustment for the CP version “CastoMized” synergic programs User-friendly selection of the parameters

Reliable wire drive system for precise and constant wire feeding

robust wheels, protected control panel, large handle and metallic structure

Precise and constant Arc ignition

Pre and post gas adjustments

Excellent arc stability

2 step and 4 step welding

Equipped for tough environment with :

Spot and intermittent weld ing for CastoMIG® 271, 381, 501

Smart details make working easier

Inn o Soluvative tion

The Unique «CastoMized programs» Solution Selecting the optimum Consumable and parameters have never been easier. In just 3 simple steps you can

We want to make your life easier for example with the ingenious four-roller drive unit with reproducible pressure settings and tool-free, changeable drive rollers. But also with the programme table fixed to each CastoMIG CP welding unit which helps you to select a suitable standard programme.

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SOLUTIONS - Customer Information - Newsletter - Issue 2 - 2009

achieve success: 1. Discuss your requirements with one of our Sales peple 2. Let us provide samples of what we can achieve 3. Have your machine delivered and pre programmed with the optimum settings

Improve your welders’ skills Our mission is to develop applications and solve customer problems. Depending on the customer’s request, we can perform the work for him in our approved CastoLab® Services workshops or transfer this knowledge to him.

Since the mid 1930’s Castolin Eutectic has offered industry a range of specialised training courses, which covers all aspects of the welding processes, e.g.

MMA, MIG, TIG, brazing, soldering and thermal spraying.

Spreading knowledge Our commitment to excellent customer service means providing first-class training available globally to customers and end-users. Castolin Eutectic has trained thousands of technicians from all over the world and training centres have been established in most countries with training programmes offered in a wide variety of languages.

We offer a wide range of courses starting from one-day welding courses to full week maintenance seminars. From welders to engineers, researchers to managing directors - there’s no limit to the range of technical and professional people trained by Castolin Eutectic in all aspects of industrial cost-savings, wear, repair and preventive maintenance.

Industrial seminars We provide solutions to all of the major companies operating in industry with global industrial programs for steel, cement, mining, power, oil, waste & recycling, etc.

Supporting maintenance technicians in their daily challenges is

>> Service

with the best Castolin Eutectic technicians

Coating training with SF-Lance

our routine so training courses in specific industries are also conducted where similar language groups can learn and exchange cost-saving solutions.

Depending on your requirements courses can comprise 100% practice or theory, or a mixture of both and are available in a written form for several product families and technologies.

For more information about training courses please contact your local Castolin Eutectic company. Contact information can be found on our website www.castolin.com

Diploma for MMA welding training

Industrial seminar in Paris specific for Cement plant

Wear & Fusion Technology with Service and Quality

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Together with the Messer World

at Schweissen & Schneiden:

>> News

14th - 19th of September 2009 in Essen

Messer World The world’s most important welding trade fair is taking place for the 17th time at Messe Essen from the 14th to the 19th September 2009.

Together with our sister companies of the Messer World, we will be presenting our latest welding technology innovations.

Our booth will be 772m² in size with live demonstrations, tombola, product presentations, etc. Our Motto “Joined in expertise” will be the guiding thread of the week.

Castolin Eutectic Our philosophy “Saving costs through innovation” will be illustrated with special live wearfacing

New CastoLab® Services video online Connect to the CastoLab® Services section on our website www.castolin.com or www.eutectic.com to discover our brand new CastoLab® video!

This video will show you the wide range of services offered by our workshops worldwide.

New name for UK: Castolin

In UK, 2009 started with many changes and investments. As you can see from the picture, the first investment was in the modernization of the offices and customer reception areas. But there was

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applications, demonstration of our new applications sharing software “TeroLink®” and presentation of our innovative approach.

Participating to: Fair Offshore Europe 2009 Aberdeen, UK 8th - 11th September 2009 Offshore Europe Oil & Gas Conference & Exhibition www.offshore-europe.co.uk

Eutectic Ltd

also made a strategic decision to change the company name from Eutectic Company Ltd to Castolin Eutectic Ltd in order to reinforce the strengthening links with the European and the Castolin entities and to enjoy more from the power of this brand name. Just for your information: due to historical reasons, the Eutectic brand name is stronger in NAFTA and Asia but Castolin is much stronger in Europe.

SOLUTIONS - Customer Information - Newsletter - Issue 2 - 2009

Fair Ecomondo Rimini, Italy 28th – 31th October 2009 Waste & Recycling Exhibition www.ecomondo.com