Sample Magazine - US Edition by gasworld

MARKETS – INTELLIGENCE – TECHNOLOGY

ISSN 1052-0139 www.gasworld.com Volume 58, No. 1 January 2020

US EDITION

AUTOMATION, WELDING Cobots, labor shortage, e-commerce, training, additive manufacturing

Indiana Oxygen Company reveals its e-commerce strategy

How cobots can transform your business

NorTECH sells, trains, builds relationships

INSIDE THIS ISSUE: OXY-FUEL CUTTING • WELDING FUMES

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CONTENTS

24 Indiana Oxygen Company MARKETS – INTELLIGENCE – TECHNOLOGY

ISSN 1052-0139 www.gasworld.com Volume 58, No. 1 January 2020

6-15

News

16-19 Distributor Zone 16 IWDC Annual PurityPlus® Meeting preview 18 NorTECH not only sells, but educates 20

The era of the cobot is here Automation has potential to ease labor shortage

Making a success of online retail Indiana Oxygen Company’s e-commerce business

AUTOMATION, WELDING

Forerunner of the future The USS Albacore’s place in naval and welding history

Cobots, labor shortage, e-commerce, training, additive manufacturing

Adopting additive manufacturing Linde Gases

Who likes a lousy, leaking pump seal? Part 2 Keith Hall, Applied Cryogenic Technologies

Market Report The Mountains

Controlling gas surge Curt Rocha, ESAB

Company Profile WeldPro

Clearing the air for tank manufacturers Adam Pfeiffer, RoboVent

Community Events and tweets

Oxy-fuel cutting process automation Martin Roubicek, GCE Group

US EDITION

Indiana Oxygen Company reveals its e-commerce strategy

How cobots can transform your business

NorTECH sells, trains, builds relationships

INSIDE THIS ISSUE: OXY-FUEL CUTTING • WELDING FUMES

On the cover this issue Cobots like this one from Vectis Automation are being hailed as a solution to the skilled labor crisis. How can cobots help businesses struggling to find skilled welders, and will they take the jobs of humans? Read our report on page 20.

GASWORLD US EDITORIAL ADVISORY BOARD MAURA GARVEY Director of Market Research, Intelligas Consulting

RAY BORZIO

Managing Partner, Global Calibration Gases, LLC.

PHIL KORNBLUTH

President, Kornbluth Helium Consulting, LLC

SAM A. RUSHING

KEITH HALL

VP of LNG Sales and Product Development, Applied Cryogenic Technologies

President, Advanced Cryogenics, Ltd

January 2020 • gasworld US Edition | 03

THE FUTURE OF OXY-FUEL CUTTING

WOULD YOU LIKE TO SAVE ON COST, MAKE YOUR LIFE EASIER AND GET A NEW VIEW ON TRADITIONAL TECHNOLOGY THAT MEETS THE LATEST INDUSTRY TRENDS? An innovative oxy-fuel solution you find by every valuable cutting machine supplier.

HIGH PRODUCTIVITY AND QUALITY

COST EFFECTIVE PROCESS

SAFETY OF THE CUTTING OPERATION

WELCOME

US Editor

Nick Parkinson Automation and e-commerce cannot be ignored

obots are no longer something that belong in the future, sci-fi movies or comic books – they are here today transforming businesses, making industry more efficient and even working alongside humans. Many companies will utilize automation more to grow their businesses in 2020, increase productivity and overcome challenges. Hector Villarreal, President of Weldcoa, told gasworld recently, “In my budgeting for 2020, I’m looking at automation to load the robots and the lasers because I can’t find people to work my second shift. I’m buying robots, to run my robots. How insane is that?” Identifying the right product, and what jobs to use it for, is key and, for some, it is also about overcoming a nervous reluctance to adopt the technology. We focus on automation this month and look at the potential it has for your business, and take a close look at new cobots on the market as more of you adopt or sell automation. “Companies are automating everything,” a President of a leading US industrial gas distributor told me recently, and it is one solution to the skilled labor shortage in the US. But is there a conflict between these progressive initiatives and skilled welding jobs threatened by changing technology? One recent example was the news the Port of Los Angeles shipping terminal is planning to replace diesel trucks and human workers with robots. To be competitive, companies

have to move towards automation as it lowers operating costs, boosts efficiency and solves labor shortage with the press of a button. But then what jobs will be left for humans to do? Find out how cobots can help businesses with a shortage of labor and an ageing workforce, and why it might not necessarily be bad news for welding jobs from page 20. As well as utilizing the latest technology like automation, it pays to have a good website as more and more people choose to buy goods online as opposed to walking into a bricks and mortar store. Indiana Oxygen Company (IOC) is a trailblazer among the industrial gas and welding supplies community when it comes to e-commerce. IOC might be North America’s oldest industrial gas distributor, but it has moved with the times and its online store weldingsuppliesfromioc.com was recently ranked No. 5 in the category of “DIY, Tools, Supplies,” above any other welding supply only store, by weekly magazine Newsweek. IOC tells us how they got it right with its online welding supplies site from page 24. We also have some great advice from ESAB on controlling gas surge, RoboVent provides tips on weld fume mitigation for tank manufacturers, GCE gives us some insight on oxyfuel cutting and Linde Gases explains the value of adopting additive manufacturing. Please keep us updated with your news in 2020, and get in touch with anything you would like to see featured in gasworld US. Happy new year!

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gasworld (US Edition) (ISSN-1052-0139) is published monthly by gasworld Publishing LLC., 239 South Street, Hopkinton MA 01748, USA; TEL: 781-862-0624; E-mail: usedition@gasworld.com. Postmaster: Please send address changes to: gasworld Publishing LLC, 239 South Street, Hopkinton MA 01748, or nick.parkinson@gasworld.com. Unauthorized reproduction is illegal. For permission to photocopy articles, contact the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, USA; Tel: 978-750-8400. For reprints, contact publisher directly. ©2020 by gasworld Publishing LLC.

January 2020 • gasworld US Edition | 05

NEWS

All Safe Global acquires Thunderbird Cylinder All Safe Global (ASG) has expanded its geographic footprint in the US with the acquisition of Thunderbird Cylinder, Inc. Minneapolis, Minnesotabased ASG is a distributor of equipment and accessories for compressed gas delivery, beverage production, and fire suppression. The acquisition of Phoenix, Arizona-based Thunderbird Cylinder expands ASG’s geographic

Thunderbird Cylinder has been providing compressed gas cylinder services for over 70 years

footprint and provides additional scale to the company’s growing business. “All Safe Global’s acquisition of Thunderbird expands our presence in the Western US and is an important step toward realizing our vision of building a national network of cylinder requalification centers” said Matt Boettner, ASG President and CEO. “Thunderbird’s core values and strong reputation for compliance, safety and service bolsters ASG’s long tradition of providing our customers with industry leading products and services.” Thunderbird Cylinder has

Cryomech breaks ground on new manufacturing facility, New York Cryocooler designer and manufacturer Cryomech has broken ground on its new 76,000 square foot facility in DeWitt, New York. The custom-designed building will provide space for continued growth and innovation in the cryogenics industry and includes space for future expansion plans. It is located just blocks away from Cryomech’s current location at 6682 Moore Road. In a speech at the groundbreaking ceremony, Chief Business Officer Kelly Wypych said, “Today stands for more than simply putting shovels into the ground. Today represents our commitment to our customers in over 50 countries on all seven

continents, most of whom are pioneering groundbreakers in ultra-low temperature technology and research.” “Today represents our commitment to this region, which has always been our home and is the ground that we want to stand on.” Cryomech said it plans to grow staff in both manufacturing and administration. According to the current build schedule, the US company hopes to be in the new facility by the end of 2020.

06 | gasworld US Edition • January 2020

been providing compressed gas cylinder requalification, refurbishment and maintenance services for over 70 years. “Both companies come to the table with a wealth of experience and a shared vision of compliance and service,” said Thunderbird Cylinder owner Fred Nachman. “Together, we look forward to blending our expertise, bringing exceptional and standardized

services on a national scale to the compressed gas industry.” ASG believes the combination will enhance its ability “to provide new and current customers with exceptional service, quality products, and fast turnaround times”. ASG’s customers include industry leaders in welding gas, specialty gas, craft beer, cold brewed coffee, cylinder waste disposal and alternative fuels.

Linde plc appoints Opfermann as Executive Vice-President Americas Linde plc has named Andreas Opfermann as Executive Vice-President of Americas, effective November 1 (2019). Formerly in the role of Regional Business Unit leader for Europe North, Opfermann replaced Bernd Eulitz, who left Linde on October 1 (2019). Opfermann joined Linde in 2005 and has held a variety © Linde | Andreas Opfermann

of management positions in technology, innovation and clean energy. Prior to his roles at Linde, Opfermann worked at McKinsey & Company. He has an undergraduate degree in Physics from the University of Heidelberg and a Ph.D. in Physics and Mathematics from the University of Cambridge. Opfermann will report directly to Linde’s CEO Steve Angel and serve as a member of the industrial gas giant’s Management Committee.

RELATED ARTICLE Linde announces price increases gasworld.com/2018080.article gasworld.com/northamerica

NEWS

Central McGowan acquires Jasons, expands footprint Central McGowan, a St. Cloud, Minnesota-based distributor of gases and state-of-the-art equipment/ technology, has expanded its carbon dioxide (CO2) business with the acquisition of St. Paul, Minnesota-based Jasons Beverage Carbonation Company. The deal more than doubles Central McGowan’s beverage carbonation and dry ice customer base – started in 2006 – and expands it to nearly 3,000 customers in Minnesota, North Dakota, South Dakota, Wisconsin and Iowa. The combined business will deliver CO2, nitrogen, beer gas, and dry ice to bars, breweries, and some of the Midwest’s most successful restaurant chains in the fine

dining, fast casual and fast food categories. Jasons will continue to operate under the Jasons name, and all of its current employees, building, fleet and assets will be a part of the Central McGowan family. Joe Francis, CEO/President of Central McGowan, believes the acquisition complements a core business of Central McGowan and expands not only its footprint and buying power but also its experience in the CO2 Solutions business. “Like us, Jasons is an expert in beverage carbonation, which is both the art and science behind delivering the precise gas mix to achieve a perfect pour and the right amount of bubbles in carbonated

Sulzer opens its new regional headquarters for pump services Sulzer has opened a new regional headquarters for pump services in Pasadena, Texas, to increase repair capacity for the Americas. Located adjacent to the company’s electromechanical services center, the new service center features a large pump repair shop that is equipped with lift capacity, enhanced repair technologies and equipment. “We have structured our

new repair facility to ensure maximum efficiency in delivering high-quality repairs with minimal downtime,” said Scott McPherson, Service Centre Manager. “Coupled with our onsite engineer, balancing and hydro-testing capabilities, we offer a comprehensive range of services that can improve reliability and performance of pumping systems.” “The new Houston Service Center will strengthen Sulzer’s overall capabilities in pump services and ensure we continue to deliver cutting-edge solutions for our customers,” said Glenn Doerksen, President of Pump Service, North America.

beverages,” Francis said. “Our on-staff beverage carbonation specialists and bulk beverage systems offer a highly efficient, cost-effective and safe method to carbonating soda and beer while making gas outages and changing out high-pressure cylinders a thing of the past.” The addition of Jasons will also grow distribution

of ColdZERO™– Central McGowan’s own brand of dry ice that is manufactured daily at its St. Cloud location using Cold Jet’s newest technology for the highest density dry ice rice available. Bob Crew, formerly the company’s Vice-President of Distribution Operations which included beverage carbonation, has been named Vice-President & General Manager of Jasons and Central McGowan’s existing CO2 Solutions business. He is charged with leading the successful integration of sales and operations and will lean on his extensive experience and expertise along with that of his existing managers, specialists, and teams in St. Cloud, Fargo and St. Paul.

RegO to expand North Carolina facility, upgrade several work centers RegO, a manufacturer of gas control products, has announced plans for a multimillion-dollar expansion of its US manufacturing capacity. The expansion will take place at the company’s Whitsett, North Carolina facility, where RegO will upgrade several of its machining work centers with state-of-the-art equipment. Mike Lucas, RegO CEO, said, “By replacing existing machinery with the new automated CNC machining cells, we’re able to double our throughput capacity for the parts made on that manufacturing line with a 60% increase in efficiency.” “With the new transfer

machining stations for the high-volume brass product line, we can increase production to more than five million parts per year with optimum overall equipment efficiency.” Four new machines will be installed over the next eight months as part of the upgrade – two automated gantry CNC lathe/saw/washer combination cells, and two automated rotary transfer machines.

January 2020 • gasworld US Edition | 07

NEWS

Linde reports sales of $7bn, raises product prices Linde plc reported sales of $7bn in its third quarter 2019 results, and a strong operating cash flow of $1.9bn increased 86% sequentially. The industrial gas giant reported third-quarter income from continuing operations of $728m. Excluding Linde AG purchase accounting impacts and other charges, adjusted pro forma income from continuing operations was $1,052m, up 24% versus prior year and 5% sequentially. Linde’s sales for the third quarter were $7bn. Pro forma sales were $6.9bn, 1% higher than the prior year. Excluding unfavorable currency translation effects, sales increased 4% driven by volume and price each growing 2%. Sequentially, sales decreased 3% driven primarily by lower

engineering sales, unfavorable currency and lower cost pass-through. Third-quarter operating profit of $1,000m was 49% above the prior-year quarter mainly due to the merger, including a gain from a merger related divestiture. Americas sales of $2,771m were 5% higher versus prior-year quarter and flat sequentially. Compared to second quarter 2019, price increased 1%, offset by negative cost pass-through. Operating profit of $671m was 24.2% of sales Commenting on the financial results, CEO Steve Angel said, “The Linde team delivered another quarter of strong financial results with operating margins expanding 270 basis points, operating cash flow reaching $1.9bn and

earnings per share growing 26%. These results reflect our employees’ relentless focus on operational excellence and delivering value for our shareholders. For the remainder of the year we anticipate continued softening of the global economy, however, we are raising our full-year EPS guidance given the opportunities we see to continue to improve the quality of our business.” Third-quarter operating cash flow of $1,872m increased $867m versus the second quarter primarily driven by higher net income and improved working capital. During the quarter Linde invested $959m in capital expenditures, mostly for new production plants under longterm contracts.

Price rises Linde and its affiliates, including Praxair, Inc., increased the prices of product and equipment rentals in North America, from December 1 (2019), or as contacts permit. Linde announced the following increases: up to 15% for nitrogen and oxygen; up to 20% for carbon dioxide, argon and hydrogen; up to 15% for facility fees or equipment rentals. Helium prices will also be increased as contracts permit.

Anova merges with Silicon Controls Linde expands Indiana skills pipeline to support LPG and propane industry workforce development program Anova, a New Jersey-based provider of industrial Internet of Things (IoT) solutions, has announced a merger with Silicon Controls. The new partnership will allow Anova to enhance its role in supporting the LPG and propane industry globally. Through the merger, Anova will also increase its presence, offer relevant business models to an expanding Asian and South American market, and support the rapidly growing use of technology across North America. The companies’ combined capabilities will enable Anova to help its customer

base transform logistics and redefine consumer services. “Our customers need a dependable partner that is heavily invested in developing next-generation technology solutions that will not only provide the lowest cost of ownership, but, quite simply, make their lives easier,” said Chet Reshamwala, CEO of Anova. “The new Anova team has over 90 years of LPG and propane experience and intends to build on that, ensuring our customers have access to the best technology, equipment, partners and people support our customers’ needs.”

08 | gasworld US Edition • January 2020

Linde has expanded its Indiana-based Skills Workforce Development Program in order to help address the increased demand for skilled workers. Funded by a $200,000 contribution from Linde’s Global Giving Program, and in collaboration with Ivy Tech Community College, the Skills Pipeline program will train students for careers in production and maintenance technology. “Many students face barriers as they transition from high school to college. This program helps students invest in their futures and

allows us to help promote a more capable workforce long term,” said Dr. Anne Roby, Executive Vice-President of Linde plc. The new program is the first in the Skills Pipeline family to offer formal training to dual-credit students finishing high school in Northwest Indiana and aligns with the state's next level jobs workforce initiative. The Skills Pipeline program features strong collaborations between industry, government and educators, providing students with a strong platform for success. gasworld.com/northamerica

NEWS

Air Liquide: +2.0% for Gas and Services in Americas

Air Liquide reported group revenue of €5.5bn (approximately $6,095bn), up 3.5% on a comparable basis, in its 2019 third quarter (Q3) results. The French industrial gas giant, which has US headquarters in Houston, said its Gas and Services posted sales growth up 3.5% in spite of a softening economic environment. Gas and Services revenue in the Americas amounted to €2,137m (approximately $2,37m), an increase of +2.0%

during the third quarter of 2019. In Engineering and Construction, sales to third-party customers were stable compared with the second quarter, with resources mainly attributed to internal Large Industries and Electronics projects. Within its Large Industries business, Air Liquide highlighted the signature of three long-term contracts in Q3, in the US Gulf Coast with Methanex, in Canada with Shell Chemicals and in the Philippines with Pilipinas

Shell. Large Industries sales were up +0.6%, affected by customer maintenance turnarounds in the US. Industrial Merchant revenue posted resilient growth of +1.1%, mainly driven by higher pricing. Electronics growth stood at +1.5% and Healthcare continued to improve markedly (+11.1%). Commenting on the Q3 results of 2019, Benoît Potier, Chairman and CEO of Air Liquide, said, “Sales growth continued this quarter, with Group revenue amounting to €5.5bn, up 3.5%. Growth was driven by all Gas and Services activities, which represent 96% of the Group’s sales, as well as our Global Markets and Technologies business. Positive currency and significant scope impacts offset lower energy prices.” Potier continued, “All Gas and Services activities grew on a comparable basis, despite a more moderate

global growth. Healthcare and Electronics were particularly dynamic, and Industrial Merchant and Large Industries remained solid. Assuming a comparable environment, Air Liquide is confident in its ability to deliver net profit growth in 2019, at constant exchange rates.” In a softening economic environment, growth in Industrial Merchant stood at +2.4%, driven mainly by successful pricing management, growth in consumer-related markets and a favorable number of working days. Sales growth was high in Healthcare, in particular in Home Healthcare in Europe and in Latin America, and in Medical Gases in the US.

3.5%

Air Liquide group revenue was up 3.5% on a comparable basis

Air Products: GAAP net income of $1.8m, up 18% In Air Products ’s fiscal year 2019 results, it reported GAAP diluted EPS from continuing operations of $7.94, up 20%; GAAP net income of $1,809m, up 18%, primarily driven by higher pricing, volumes and tax reform impacts; and GAAP net income margin of 20.3%, up 310 basis points, each versus prior year. Full-year sales of $8.9bn were flat versus last year on 2% volume growth and 3% higher pricing, offset 3% by

unfavorable currency and 2% from a contract modification to a tolling agreement in India, which impacts sales but not profits. The US industrial gas company reported sales of $2.3bn, for its fourth quarter (Q4) ended September 30 (2019). GAAP diluted EPS from continuing operations of $2.27 was up 11%. GAAP net income of $519m was up 13%, primarily driven by higher pricing volumes, and prioryear tax reform and pension

settlement impacts. Commenting on the results, Seifi Ghasemi, Chairman, President and CEO, said, “We are pursuing our strategic FivePoint Plan, including a focus on sustainability that is driving significant global growth opportunities in gasification, carbon capture, and hydrogen for mobility.” Industrial gases Americas sales of $937m decreased 5%, as 3% higher pricing was more than offset by 5% lower energy pass-through,

2% lower volumes, and 1% unfavorable currency. Operating income of $261m increased 4%, primarily driven by higher pricing, and operating margin of 27.8% increased 230 basis points. Adjusted EBITDA of $412m increased 3%, primarily driven by higher pricing, and adjusted EBITDA margin of 43.9% increased 350 basis points. Air Products expects capital expenditures of approximately $4bn to $4.5bn for full-year fiscal 2020.

January 2020 • gasworld US Edition | 09

NEWS

Qatar to raise LNG production, helium potential

State-owned Qatar Petroleum will raise Qatar’s liquefied natural gas (LNG) production capacity to 126 million tons per annum (mtpa) by 2027, an increase of 64% from the current 77 mtpa. Saad Sherida Al-Kaabi, the Minister of State for Energy Affairs, the President and

CEO of Qatar Petroleum, also announced that new studies have revealed that the North Field’s productive layers extend well into Qatari land in Ras Laffan, paving the way for a new LNG production project in the north of Qatar. Minister Al-Kaabi confirmed gas reserves of

the North Field exceed 1760 trillion cubic feet, in addition to more than 70 billion barrels of condensates, and massive quantities of LPG, ethane, and helium. Qatar’s expansion plans, with four new production facilities, known as LNG trains, is potentially a boost for future worldwide helium supplies which would help ease the current shortage, and is potentially a new Qatar 4. “During the past two years, Qatar Petroleum worked diligently to determine the degree to which the North Field extends towards the south west, as well as the possibility of production from Qatar’s northern coastal

onshore areas,” Minister AlKaabi said. “I am pleased to announce that our appraisal efforts have borne fruit, and that we have confirmation that the productive layers of the North Field extend well into Qatari land in Ras Laffan. Studies and well tests have also confirmed the ability to produce large quantities of gas from this new sector of the North Field. These are very important findings, which will have a great positive impact on Qatar’s gas industry, and which will move it forward into bigger and wider horizons.” MORE ONLINE gasworld.com/2018117.article

CAER receives funding from DOE to develop carbon capture innovations

Atlas Copco acquires Accurate Air Engineering, Compressed Air, WestRon

The University of Kentucky Centre (CAER) for Applied Energy Research has received a grant from the Department of Energy (DOE) to advance its carbon capture system. The funding marks the second phase of a threephase program launched by the DOE to support largescale, fossil fuel research and development. “Our CO2 capture research has made giant leaps over the past decade,” said Principle Investigator Kunlei Liu. “And this phase two grant will allow our team to take necessary steps to lead this research forward and commercialize our processorientated, post-combination CO2 capture technology.” According to Liu, the

Atlas Copco has acquired the assets of Accurate Air Engineering and Compressed Air of California. The two sister companies are located south of Los Angeles, California, and have a sales and service network covering the majority of the state. Together the companies have 52 employees. “This acquisition will complement our existing footprint in the region,” said Vagner Rego, Business Area President of Compressor Technique. “The companies have a strong reputation of being agile and staying close to the customer base.” The business acquired from Accurate Air Engineering and Compressed

second phase of the project will allow CAER to move forward with its fourpronged CO2 capture system, taking the next step toward demonstrating its technology to a ten-megawatt electric equivalent scale. The center’s postcombustion system features modular equipment and free-standing columns with built-in advanced controls to continually minimize the CO2 capture energy penalty while responding to a dynamic external demand. If CAER is successful in phase two of the program and it receives funding to support phase three, the center will increase the scale of the Burgin facility by more than ten times.

10 | gasworld US Edition • January 2020

“This acquisition will complement our existing footprint in the region” Air of California will operationally become part of the Compressor Technique service division. The purchase price was not disclosed. Atlas Copco has also acquired WestRon, a Canadian company focused on sales, installations and service of small industrial compressors and blowers. Located in Calgary, Alberta, WestRon currently has 26 employees. The Group also has facilities in Ontario and British Columbia. gasworld.com/northamerica

NEWS

Datacor acquires TrackAbout, increases resources TrackAbout has been acquired by Datacor, a leading provider of software for process manufacturers and chemical distributors. The new allegiance will enable more resources to continuously improve TrackAbout’s software and provide greater value to its customers, the Pittsburghbased company explained in a statement. “Nineteen years ago, we set out to change the way the world tracks and manages portable, physical assets,” Tim Fusco, TrackAbout’s CEO and co-founder, said. “Through continuous collaboration with our customer base, including

world-class organizations in over 30 countries, TrackAbout has become the best solution for tracking, managing, maintaining and renting portable, physical assets. TrackAbout is committed to continuing to service and support our integrations with a wide variety of ERP packages.” “In addition, we can now offer a comprehensive ERP solution (Datacor ERP, formerly Chempax) tightly

integrated with TrackAbout’s industry-leading asset management system.” “While TrackAbout was already profitable before the acquisition, we now will be part of a financially stronger parent company.” “The acquisition will lead to faster growth for TrackAbout. More resources means more investment in TrackAbout’s platform. This benefits all TrackAbout customers. If you are

interested in upgrading your ERP system, we have a very robust and tightly-integrated option for you.” Datacor and TrackAbout are technology providers serving similar industries with little overlap in functionality. Each solves a comprehensive set of problems for its customers. Florham Park, NJ-based Datacor saw that acquiring TrackAbout would allow it to: (1) enter the packaged gas market with comprehensive ERP, CRM and asset tracking services, and (2) provide asset tracking services to its existing customers in process manufacturing and chemical distribution.

SoCalGas and PNNL land $300,000 DOE funding for ICCCM process

Svante Inc. partners with Cross River on indstrial scale carbon capture

Southern California Gas Co. (SoCalGas) and the Pacific Northwest National Laboratory (PNNL) have received $300,000 in funding from the US Department of Energy (DOE) to advance an integrated carbon capture and conversion to methanol (ICCCM) process. The funding will be used to design, fabricate and demonstrate a modular ICCCM prototype for the combined capture and conversion of carbon dioxide (CO2) into methanol. The unit will be designed for installation at an industrial CO2 source. “As we look for ways to reduce greenhouse gas emissions in support of the

Svante Inc., a Canadian carbon capture technology company formerly known as Inventys, has signed a collaboration agreement with Cross River Infrastructure Partners LCC to develop industrial scale carbon capture projects in North America. Connecticut-based Cross River will be responsible for project origination and financing the carbon capture and storage projects using Svante’s technology, as well as operating facilities that deliver captured carbon dioxide (CO2) to end-users. “We provide capital and commercialization solutions to technology providers such as Svante to develop pipelines of small to mid-size projects

state’s climate goals, we will need to develop cost-effective technologies that can capture and use CO2 to prevent it from reaching the atmosphere,” said Yuri Freedman, Senior Director of Business Development for SoCalGas. “The goal of this project is to determine whether ICCM technology can be a cost-effective way to reduce emissions and it is our hope the results will show that it is.” In the last three years, Los Angeles-based SoCalGas has spent more than $10m on the research and development of low or zero carbon technologies, illustrating its commitment in helping California achieve its decarbonization goals.

with similar risk profiles,” said Andrew Wilder CEO of Cross River. “Our goal is to help unlock significant investment capital to accelerate the deployment of low-carbon technologies such as Svante’s.” The partnership will focus on the Permian Basin in the US and in Canada’s western provinces, both of which have large CO2 storage potential, a wide range of commercial CO2 users, and a significant number of industrial sources of CO2, such as cement and hydrogen production. RELATED ARTICLE Inventys receives $26m for carbon capture technology

gasworld.com/2017431.article

January 2020 • gasworld US Edition | 11

NEWS

Hyundai reveals concept for nitrogen-cooled trailer As well as showcasing the HDC-6 NEPTUNE Concept, a hydrogen-powered Class 8 heavy duty truck, at the North American Commercial Vehicle Show in Atlanta, Hyundai Motor Company also revealed its new, clean energy refrigerated concept trailer, the HT Nitro ThermoTech®. The HT Nitro ThermoTech concept trailer provides a response to the rising challenges of clean transportation, according to Hyundai. The HT Nitro ThermoTech will be one of the first trailer manufacturers in North America to introduce a refrigerated trailer using a cryogenic nitrogen

refrigeration technology system. The concept trailer, developed in collaboration with Air Liquide, is changing the way Hyundai Translead provides refrigerated transportation. The HT Nitro ThermoTech concept trailer’s carbon footprint is up to 90% less than a traditional unit. The HT Nitro ThermoTech concept trailer is optimal for transporting cold chain products. Temperatures are reduced more quickly than a traditional refrigeration unit and maintained with precise control of desired temperatures. The intelligent control system and independent cooling power maximize thermal efficiency.

The HT Nitro ThermoTech concept trailer cooling unit is also virtually noiseless which significantly reduces noise pollution for drivers as well as at the point of deliveries, making it ideal for night-time deliveries in urban areas. “This refrigerated trailer concept represents a

significant advancement in our continued commitment to corporate social responsibility”, Bongjae Lee, CEO of Hyundai Translead. “The HT Nitro ThermoTech reduces pollutants and emissions while providing reliable and effective cold chain food transportation.”

British Columbia Government backs Integrity Energy Services continues expansion in nitrogen services market proposal for LNG ship-refueling facility OFS Energy Fund has announced that Houston, Texas-based Integrity Energy Services, LLC, has completed the acquisition of Vanguard Energy Services LLC. Illinois-based Vanguard offers nitrogen pumping and delivery services to the upstream, midstream and downstream energy markets. The acquisition will allow Integrity to continue its growth in the nitrogen services market. “Integrity is positioned to continue its growth in the nitrogen services market and build relationships across all upstream to downstream markets,” said Bruce Ross, OFS Managing Partner. “The acquisition of Vanguard provides Integrity

with additional assets and management breadth at a time when the company is further expanding its foothold into the downstream market,” said Robert Whilden, OFS Managing Director. “Over the course of the past 12 months, Integrity has completed several large LNG projects, which has provided Integrity with a solid market presence in the downstream market.” Integrity was formed in July 2016 as a wholly owned subsidiary of Conquest Completions Services, LLC, a portfolio company of OFS that was sold in July 2017. In conjunction with the sale, Integrity was spun off from Conquest into a standalone entity and a new platform company for OFS.

12 | gasworld US Edition • January 2020

The British Columbia (BC) Government has joined Vancouver Fraser Port Authority and FortisBC to establish the first ship-to-ship LNG marine refueling – or bunkering – facility on the west coast of North America. The new project will develop ship-to-ship bunkering enabling large vessels to be fueled from a fueling vessel which fills up at an on-shore jetty at Tilbury Island on the Fraser River. “We are confident in BC’s ability to join the global network of ports that deliver clean-burning LNG direct to the ships of the future,” British Columbia’s Premier John Horgan. “This will allow BC to have a direct impact on global emissions by reducing

“Working together, we can meet the increasing global demand for energy solutions that reduce air pollution...” the amount of greenhouse gas emissions from visiting vessels. Working together, we can meet the increasing global demand for energy solutions that reduce air pollution and protect our climate, while creating more jobs and opportunities for everyone in BC.” RELATED ARTICLE New LNG terminal for BC

gasworld.com/2017635.article gasworld.com/northamerica

PERSONNEL

Weldship appoints Kowey as Vice-President of Business Development Weldship, a Pennsylvaniabased manufacturer of tube trailers, ISO containers and ground storage equipment, has appointed Rick Kowey as Vice-President of Business Development. Kowey has over 36 years of experience in the industrial and specialty gas industry

and has served in multiple senior leadership positions within MATHESON TriGas, Inc. and Scott Specialty Gases, Inc. (now Air Liquide). Throughout his years in business, Kowey has gained experience in strategic marketing, commercial

leadership, operations, general management, business development and mergers and acquisitions. Kowey also holds a Bachelor of Science in Chemistry from Ursinus College and an MBA in Marketing from Drexel University.

Acme Cryogenics hires Daly as new Sales Engineer Acme Cryogenics, a Pennsylvania-based manufacturer of cryogenic gas equipment and systems, has appointed Jim Daly as its new Cryogenic Sales Engineer. Based in San Diego, California, Daly will be responsible for supporting the company’s existing

customer base on the West Coast and adding new customers to the vacuum jacketed piping business. Daly has experience working as a Technical Sales Engineer at Diakont, FLW, Inc., and most recently at Mersen USA. Daly also holds a Mechanical Engineering degree from

Virginia Tech University. Established in 1969, Acme Cryogenics provides engineering design, fabrication, installation, and repair services to the food packaging, pharmaceutical, semi-conductor, aerospace, medical gas and industrial gas industries.

Van Slyke joins ILMO’s Specialty Gas Division, brings 20+ years experience ILMO Products Company has appointed Peter Van Slyke as Specialty Gas Program Director at the Jacksonville, Illinois-based company. Van Slyke brings over 20 years in sales, financial, and management experience in specialty gases and will be responsible for directing the sales functions for ILMO’s

Specialty Gas Division. He began his career in Charlotte, North Carolina for National Welders Supply as a Specialty Gas Sales Rep, and has since spent the last 20 years working in the Specialty Gas industry. Before joining ILMO, Van Slyke worked as Specialty Gas Products Manager for Scott-Gross Company and

then assumed the role of VP of Specialty Gases for AWG – both located in Kentucky. “ILMO offers true specialty gas value and innovation to our current and future specialty gas customers,” Van Slyke said. “I’m enthusiastic to apply my industry-specific knowledge to ILMO’s Specialty Gas Division.”

TOMCO2 names Schmoeckel as new Vice-President of CryoSystems TOMCO2, the carbon dioxide (CO2) equipment manufacturer, has appointed Chris Schmoeckel as its new Vice-President of CryoSystems. Schmoeckel joins TOMCO2 with 18 years of experience working for

Chart Industries, where he most recently served as President-Americas following a variety of management roles involving engineering, product management, and manufacturing. “We continue to focus on customer solutions and

applications to further our growth,” said Luke Bradshaw, President at TOMCO2. “Chris’s experience in applications, commercializing products and operations management will enable us to support turnkey systems that

incorporate vaporizers and vacuum-insulated pipe.” Schmoeckel graduated from the University of MinnesotaTwin Cities, with a Bachelor of Science and Mechanical Engineering. He also holds a Master of Science in Management of Technology.

January 2020 • gasworld US Edition | 13

EQUIPMENT

RoboVent redesigns popular weld fume extractor RoboVent has re-designed one of its most popular weld fume extraction systems as the first part of a new wave of product launches and organizational updates leading into 2020 from the Michigan-based company. Each Spire unit provides filtration for up to two robotic weld cells for effective source capture filtration or easily converted to an ambient unit for area-wide filtration when a hooded enclosure is not possible. RoboVent President Rick Kreczmer said, “We’ve retained the name of the unit and the 3’x3’ footprint that our customers love about the Spire. However, we completely re-engineered the Spire for better pulsing, longer lasting filters and easy maintenance features

our customers requested. We made substantial improvements to make filter changes and dust disposal easy and upgraded our touchscreen controls to a huge 7” screen–customers that liked the old Spire will love the new Spire.” The new Spire has a 7” full color HMI Touchscreen, for easier user operation; variable speed drive, to save energy and extend filter life; 3ft x 3ft footprint; moveable control panel, to make installation and access easier; upgraded dust containment, which means production can run longer and dust removal is simple; RoboVent PleatLock Filters, for longer filter life and easier change-outs, and improved filter pulsing to minimize filter pressure build up, extending filter life.

Mike Meyer, EVP of Engineering & Technical Services at RoboVent, said, “This is one of the best product launches I’ve been part of. The new Spire was produced with a collaborative effort of end users, specifying engineers, industry influencers and consultants and every part of our organization. Together we took everything we knew, challenged it and created the next generation of dust collectors for welding operations.” This latest innovation through Spire is the first of several new and enhanced products RoboVent will be launching in 2020. ©

RELATED ARTICLE Clearing the air

Ro bo

Ve n

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FumeVac launches new weld fume capture system FumeVac, a Wisconsinbased manufacturer of high pressure/high capacity systems to protect welders, has released a new weld fume source capture system. The new FV-500-20 with Ergomax fume guns present a versatile solution for dust and fume control when welding. The new innovation from FumeVac meets the ACGIH guidelines, as well as OSHA standards for mitigating harmful weld fumes, including manganese and hexavalent chromium. Both models – 400A and 500A – come with lowfriction liners to provide wire

feeding performance that leads to consistent arc starts and weld stability. A polished nickel-plated metallic outer neck tube provides additional heat dissipation for super cool operation, and a simple, high-strength

14 | gasworld US Edition • January 2020

stainless steel trigger provides additional durability. The gun works in conjunction with the FV-500-20 high-vacuum extractor to provide optimal filtration – as high as 99.97%. Multiple configurations are available, including a four-gun

continuous duty unit. “We see this new ErgoMax gun as a real game changer,” said Chris Bailey, President of FumeVac. “Welders who have previously tried fume extraction guns will definitely see and feel the improvements we’ve made. This is like nothing else on the market when it comes to ease of use and maximum source capture capability. The gun can only reach peak performance when used as part of the entire FumeVac system. The beforeafter images we’ve captured from manufacturers that have tested out the system say it all.” gasworld.com/northamerica

NEWS

Lincoln launches multi-process welder products Lincoln Electric®, a Cleveland based manufacturer of arc welding products, has introduced its latest innovation, the POWER MIG® 140 MP® multi-process welder. The POWER MIG 140 MP welder providers versatility with MIG, TIG and Stick welding capabilities, allowing for a MIG weld at 30-140 amps, a DC TIG weld at 10120 amps and a stick weld at 35-90 amps. “The POWER MIG 140 MP welder will allow our customers to work efficiently have one tool to satisfy a variety of projects,” said Joseph Keipert, Associate

Product Manager of Commercial Equipment at Lincoln Electric. The machine comes with a Magnum® PRO 100L gun and 10ft cable assembly with brass connection and 8-pin trigger connector, a Harris® gas regulator and a 25 inch hose for use with argon/carbon dioxide blended gases, sample spools of Innershield® NR®211-MP flux-corded wire and SuperArc® L-56® premium MIG wire, a work clamp and cable and an electrode holder with 10ft cable for stick welding. The product is available in two variants, the POWER MIG 140MP multi-process welder, and the POWER MIG 140 MP TIG One-Pak®, which comes with a foot pedal and ready to weld PTA-9 TIG torch. Lincoln has also recently introduced its new Flextec® 350X PowerConnect® with CrossLinc® technology. The Flextec® is Lincoln’s

new multi-process electric welder that automatically connects to any power input globally from 200600V, allowing the welder to be plugged in and used worldwide. Compatible with acrossthe-wire portable wire feeders, analogue wire feeders, digital wire feeders and CrossLinc wire feeders, the Flextec 350X offers maximum flexibility to customers. The Flextec® has basic pulsed MIG capabilities for smoother, more consistent welds; and is equipped with

CrossLinc technology to allow for weld output control at the wire feeder without additional control cables or having to change output levels at the power source. Additional features of the Flextec® include: 1/3-phase, 50/60HZ input, IP23 rated for outdoor use and use in harsh environments, lightweight and portable, and built on Lincoln Electric industry proven design elements. RELATED ARTICLE FABTECH 2019 event recap

gasworld.com/2018066.article

CO2Meter partners with GrowFlux for new sensor CO2 enrichment which can boost yields by 30%+. “Our business development team had the opportunity to meet with and discuss a collaboration with the GrowFlux team at the 2018 MJBIZ Conference in Las

CO2Meter, a Florida-based manufacturer of gas detection and monitoring devices, has partnered with GrowFlux to develop a new and improved “wireless and cloud connected” carbon dioxide (CO2) sensor for indoor agricultural environments. The new GrowFlux Wireless and Cloud Connected CO2 Sensor will allow growers to access data via the “GrowFlux app”, enabling them to monitor their crops anytime and anywhere, while optimizing

Vegas,” said Travis Lenader, CEO at CO2Meter. “We were quickly able to identify the opportunity for a collaboration, work on design and device specifications, and create a business partnership that allows the

two organizations to offer a superior product in the marketplace.” “We were drawn to partner with GrowFlux because of their mission on advancing energy efficiency while building advanced cultivation technologies for the future.” The new partnership creates a unique opportunity in the indoor agriculture space to promote the long term economic and environmental viability of controlled environments for growers.

January 2020 • gasworld US Edition | 15

DISTRIBUTOR ZONE

Distributor Zone IWDC Annual PurityPlus® Annual Meeting preview By Erica Janas, Director of Marketing, IWDC

embers, industry experts and approved vendors of the IWDC PurityPlus® program will converge at the Wild Dunes Resort in beautiful Isle of Palms, South Carolina for the Annual PurityPlus® Meeting on February 4-6. Leading industry authorities will provide market insights that guides in sales and distribution while vendors will outline the newest features and innovations to enhance the work performance. Assets vendors will also be on hand to discuss products and maintenance. Members of PurityPlus® program will leave the meeting knowing many more ways to meet the needs of today’s specialty gas customers. But it won’t be all work. IWDC has some fun in store as well, because collaboration does not just happen during the meeting, attendees will get the opportunity to connect with one another during our planned group events. These are an invaluable part of the PurityPlus® meeting because it gives the opportunity for engagement with others in your field. Group activities provide time to informally ask questions and learn new ways to think and respond to the markets we serve outside of the formal training environment. This year’s speakers will discuss carbon dioxide and helium. Industry experts will provide insight into its shortage and potential impacts to healthcare, scientific research, food and beverage, and industrial manufacturing. The program is meant to develop attendee knowledge in the broader geopolitical environment that effects the cost of doing business. It will also improve understanding of emerging applications. Operations and product quality are 16 | gasworld US Edition • January 2020

also on the agenda. IWDC’s PurityPlus IWDC Member companies collectively program has a unique position in represent over $2.7bn in sales, serving a the markets because of the rigorous wide range of industries. The common quality management system and denominator is that these industries local service. Customers look to them for industrial, receive the products specialty, and medical gases they need with the high as well as related equipment, standards of excellence welding hardgoods, and IWDC Member companies they expect from vendors consumables. collectively represent of their research and End-use customers served over $2.7bn in sales by IWDC Members benefit manufacturing processes. The combination of the from having the unparalleled highest quality and service is a expertise of a local Member perfect mixture and the 2020 Annual distributor who has access to nationalPurityPlus® Meeting will guide in scale purchasing and marketing driving that value. programs. The IWDC is a cooperative, formed You can learn more about IWDC in 1994, which leverages the strengths at www.iwdc.coop. You can learn of its independent welding distributor more about the PurityPlus program at Members across North America. www.purityplusgases.com. gw

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January 2020 • gasworld US Edition | 17

DISTRIBUTOR ZONE

NorTECH not only sells, but educates Norco looks to foster relationships at center for latest robotic and welding equipment By Nick Parkinson

orco’s NorTECH facility is serving a few roles for North America’s largest independent distributor. The state-of-the-art NorTECH training and automation center is not only a place for students and customers’ employees to train and use the latest automation, productivity and safety enhancing equipment. NorTECH, which is in the Salt Lake City area, is also a selling tool, a place where customers can come and try the equipment for themselves before purchasing. “NorTECH is our window to the market for that high-end equipment,” Robert Mohr Gerry, Executive Vice President, Industrial Division, at Norco Inc., told gasworld. “The center is designed to accomplish a couple different things, one of them is the community connection and education, and we bring in the institutions. The high schools can’t afford any equipment like this, some of the tech schools can’t afford a robot or a $200,000 cutting table. We can bring those people through and give them experience of this type of equipment, expose the student and faculty to what is out there. “The center is also a selling tool. There’s nothing like it – you probably have to get past the Rockies east, and the Chicago marketplace where Praxair has one, so we wanted to have this place where we could

18 | gasworld US Edition • January 2020

“Instead of pushing merchandise, we try to sell them on the concept of changing their business” bring customers and sell them on things to make their business more productive and equipment they haven’t seen operated, get them out of their day-to-day firefighting, see a better process. In a labor-constrained America, which is what we are in today with low unemployment, businesses need to adapt to that and they need to look to ways which doesn’t rely on labor. America has decided we’re not going to ship everything to China, so fabricators have to be very productive and we’re trying to help them get there.” Norco, a Northwest-based independent distributor of welding and safety gases and supplies with 70+ locations and 1300+ employees, as well as two air separation units, hopes to gain the trust and loyalty of some of its younger visitors to the twoyear-old, 13,000 square foot NorTECH. For over 70 years, Norco’s motto has been the same ‘Serving You Better’ and as an Employee Owned company we embrace change and are excited about these market

opportunities. “In the old industrial selling program you have a guy pounding the streets and he shakes hands with someone on a floor level of a business and maybe become friends, and then sells them goods, maybe for 20 years, and typically you sell them the same goods,” Gerry said. “Part of what NorTECH is trying to do is to get communication at a higher level of the organization so we can have an executive conversation. Instead of pushing merchandise, we try to sell them on the concept of changing their business and what it might mean to them. Then we have stronger relationships inside the company. You’re talking about selling higher in the stream on the customer side. It just creates a massive amount of stickiness with us inside that customer base when they rely on us for knowledge, updated equipment and how the future might look with their business.” Norco sees its hands-on training as a valuable tool to increase knowledge and employee retention while giving students the opportunity to learn new skills in real world conditions, from experienced industry professionals. This includes individualized attention and valuable feedback from subject matter experts who are ready to answer questions and provide practical help. Delivering immediate feedback, augmented reality welding systems at NorTECH allow the user to experience the most realistic multiprocess welding simulation available, and build a more skilled workforce. “Automation is no longer the future, it’s arrived,” Elias Margonis, Norco Inc. President, told gasworld. “It’s just a matter of customers, fabricators, having the service level and the support in the change process. A lot of people want this but don’t know how to do it. It’s about people, and that has been Norco’s strength. It’s not just sales of the equipment, it’s the support of the change gasworld.com/distributorzone

DISTRIBUTOR ZONE

and the recommendations and building a partnership. It’s about helping our existing customers with that change process.” High-end equipment NorTECH has the latest in robotic welding solutions, large scale welding manipulators, advanced process submerged arc welding assembly stations, leading edge high definition plasma cutting equipment, weld fume extraction and dust collection equipment, as well as a very specific set of safety offerings. “In the center at any moment in time we have from $20,000 high definition plasma cutting tables up to a $200,0000 high definition plasma cutting tables,” Gerry said. “We have another partner that is Irco Automation sub arc system, which is really high definition, you can maneuver the boom around, that’s up to $200,000 piece of equipment as well, then we have ALM Positioners for jigs, turning and rolling, we have three distinct air filtration systems from the more manual to the ones that are bolted into the ceiling, we have the Miller robotic cell, we have the whole range of Miller’s digital weld equipment. We also have another area dedicated to safety and we have a beverage center with all the mixers and blenders. We also have our vending offering and specialty gas displays.” As for the education on offer, classes can be designed around a specific vendor. “Sometimes we build specific classes around a particular vendor, for example Hypertherm, and we might do a seminar on how to get maximum use out of your consumables and how to maximize the equipment you have purchased,” Gerry

said. “It’s education at a higher level than just selling a customer equipment and then telling them to go and play with it. We try to position Norco as the knowledge expert and that puts us in a good place with the customer – they buy from us because we provide something more than just a product. We have a classroom set up there and we do certifications for other things that we might not even be selling, like the safety side of the business.” Norco, along with Miller Electric, is also in a partnership with Roosevelt, Utah-based UBTech. Norco allows students to learn how to use machines and equipment at NorTECH. The partnership allows students to work on their welding skills and experience, readying them for the workplace. “The students get a certain amount of time inside of our NorTECH center and can play for the day,” Gerry said. “We also give them access to our staff at the NorTECH facility so access to NorTECH is part of the partnership offering. The value to Norco is serving the community and partnerships. The technical colleges

are getting more funding in the last couple years because of this resurgence of bluecollar work and we have helped feed that. “It’s also a branding thing. If the students that are going to go into welding see Norco and Miller and see us doing good work for them and the community, that’s a great association and we only hope it sticks with them for a lifetime. Those students might go from welders, to managers, and to owners who run fab shops. If they are our friends when they are 18 they should be our friends when they are 50. For folks that stay in our market, that’s a ton of brand recognition.” As well as students, NorTECH is also used by Norco’s own employees. “If you are just in a branch in a small town and you work for Norco for five years, as an individual we can tell you our capabilities but until you see them and get a chance to run a robot you don’t get a sense of our scope and size and capabilities,” Gerry said. Norco plans to keep its equipment portfolio refreshed, and to increasingly use it to drive business. “NorTECH does not happen by accident,” Margonis said. “It’s a strategic program for Norco’s industrial business and it’s all about customers, people, and service. We monitor the cadence of activities in the facility on a monthly basis and we target developments. We also learn from these customer experiences to make future ones better. We do our best to generate success for our customers and further develop our employees to continue delivering on ‘serving you better’.” gw

January 2020 • gasworld US Edition | 19

SPECIAL FEATURE | COBOTS

The era of the cobot is here Automation can ease labor shortage, attract younger workers – but will it also take jobs? By Nick Parkinson

obots are increasingly being utilized in the manufacturing industry, but there are plenty who are still cautious about deploying robot coworkers, concerned that automation will displace jobs as well as posing a safety risk in the workplace. Had those doubters been at FABTECH 2019 in November, they would have been able to see first-hand the potential of cobots which include the collaborative robot arms from Universal Robots (UR) that are being utilized by BotX Welder from Hirebotics, Red-D-Arc and Airgas; Vectis Automation’s Cobot Welding Tool; and SnapCut from ARC Specialties. One potential, big benefit to these 20 | gasworld US Edition • January 2020

collaborative robots (known as cobots), which are robots engineered to work alongside humans, is how they can help address a labor shortage and an aging working force. The American Welding Society (AWS) estimates there will be a deficit of 200,000 welders this year, and double that by 2024. But cobots can fill some of those vacancies, especially for repetitive jobs, according to those in the cobot market. Mitch Dupon, Application Development Engineer, Universal Robots USA, Inc., told gasworld, “Industry is desperate to find a solution to the lack of skilled welders for the current demand, looking forward to the future

is even scarier as the old guard retires and there isn’t anyone to replace them. There is a market unserved by traditional automation that is being served by collaborative automation and they are seeing the benefits, the future looks bright for those willing to embrace the collaborative future. “The robots enable a company to quote more work, control consumable costs and increase quality. This leads to a more secure work environment. They give opportunity for skill development and promotion opportunities for workers and for the company to hire easier to find workers to backfill those positions. Most important, cobotic welders are gasworld.com/specialfeatures

SPECIAL FEATURE

tools in the hands of the skilled welder. The skilled welder can employ the cobot welder to do mundane welding tasks while the manual welder focuses on the value added welding tasks.” Cobot vendors and manufacturers argue the machines can create new roles, rather than eliminating jobs from the welding industry. Josh Pawley, director of business development and co-founder of Fort Collins, Colorado-based Vectis Automation, told gasworld, “I don’t see cobots taking any jobs. I think we’ll continue to see the ‘Now Hiring Welders’ sign in front of each shop that a cobot goes in to. Key to this is that cobots can’t weld every application – there are many applications that are not fit for a cobot but are well-suited for the manual welder. The idea behind collaborative welding is to have the cobot handle the repetitive, boring parts so the skilled welder can focus on the skilled weldments.” What cobots will do, if adopted, is transform the nature of jobs a skilled welder does. “Automation has shown that for decades we’ve been treating human workers like robots,” Rob Goldiez, cofounder of Nashville, Tennessee-based Hirebotics, told gasworld. “When we ask humans to do the same work day after day, week after week, without error and as efficiently as possible… we’re describing work best suited for automation but we’re asking humans to perform it. This treatment of human workers can easily lead to mistakes, burnout, turnover, safety issues, animosity towards management,

“The idea behind collaborative welding is to have the cobot handle the repetitive, boring parts so the skilled welder can focus on the skilled weldments”

and more. By unlocking robotics for more applications, BotX is allowing manufacturers, managers, and employees to break this trend. Let the BotX work on the repetitive work while your human workers are working on the unique parts, preparing new parts, or doing other high value tasks instead of the repetitive work.” Goldiez believes cobots can build trust between humans and workers on the shop floor, to avoid feelings of humans versus robots, like something from The Terminator. “Cobot welders like BotX fill a void in the market between large, complex traditional robots that are best suited for extremely large volume where cycle time is critical and human workers who have the highest levels of job satisfaction when using their problem-solving skills,” Goldiez told gasworld. “Cobots free up human workers to spend their valuable time solving problems and doing unique work instead of working like a robot on lower volume, but still repetitive, parts. “Traditional robots require expert programmers and large safety cages which creates distance between the human and the robot. These spatial barriers can easily create animosity between human workers and robots. Even worse, if your trusted human workers are not integral to your automation strategy you are creating gaps in understanding and capabilities of automation with your workforce. The BotX Welder is designed to empower the human welder. Your skilled welder will work side-by-side with BotX teaching

new parts and letting the BotX Welder do what it does best – repetitive work.” Other benefits Other reasons to invest in cobots include ease-of-use, versatility, portability, safety, lower costs, and increased capacity. New tax incentives to encourage more spending on automation, as well as the latest automation software, has also led to a wider deployment of robotics, including small job shops. Higher quality parts and more repeatable processes produce increased efficiencies in product development, as labor and time spent fitting up inconsistent parts decreases, along with waste from over-welding, like excess filler metal and shielding gas. Vectis Automation’s Cobot Welding Tool – which is powered by Universal Robots’ UR10e and was launched at FABTECH 2019 – is commonly 25-40% less expensive than the all-in cost of a small traditional robot welder. Vectis’ Let’s Weld TogetherTM intuitive programming interface is accessible directly through the UR cobot’s own teach pendant. Programs can be created, saved, and later recalled in order to handle the numerous part numbers typical for high mix/low volume shops. At FABTECH, gasworld was given the opportunity to make its own welding program using Vectis Automation’s Cobot Welding Tool, and to experience its ease-of-use. Vectis recommends the most efficient deployment of automation to be on the smaller, simpler, repetitive parts. “The Vectis Cobot Welding Tool is helpful for automating small parts, subassemblies, or even sections of larger January 2020 • gasworld US Edition | 21

SPECIAL FEATURE | COBOTS

parts since it is portable,” Pawley said. “Oftentimes, the temptation is to automate the large or complex weldment, but cobots are best suited for handling the ‘boring’ smaller parts and allowing the skilled welders to work on the skilled weldments. This also generates buy-in from the shop floor as well, as most welders hate welding those pallets of piece parts or subassemblies.” The BotX Welder – developed by Hirebotics, Red-D-Arc, and Airgas – offers the opportunity to hire a robot welder by the hour and utilizes a UR10e cobot for simplicity of programming with cloud monitoring while avoiding the cost of ownership. Manufacturers pay only for the hours the system actually welds, which is ideal for seasonal work or

22 | gasworld US Edition • January 2020

sudden loss of business. “Our software empowers companies with short run production needs to quickly improve quality, consistency and output by leveraging their existing skilled welders,” Goldiez said. Cobots also have a smaller footprint compared to traditional, large industrial robots in a welding application which are rigidly mounted to a workcell purposed with one task only and are often isolated from workers for safety by barriers or a cage. A cobot, however, can flexibly be applied to several tasks on the same day in a low-volume, high-mix job shop. Goldiez said, “The fact that they’re collaborative and don’t require safety fencing like traditional industrial robots means a smaller footprint for

“The fact that they’re collaborative and don’t require safety fencing like traditional industrial robots means a smaller footprint for the equivalent working space, less floor space to produce same size part” the equivalent working space, less floor space to produce same size part. In many cases less than half the floor space of traditional automation.” Customers can teach BotX the required welds simply via an app on any smartphone or tablet utilizing a library of welding recipes contained in the BotX software developed specifically for the BotX and optimized to work with Airgas’ ARCAL shielding gas. The Hirebotics mobile app allows the welder instead of a programmer to set up new parts in an easy-to-use, friendly interface. Users can monitor their BotX Welder from anywhere in the world via realtime charts and dashboards, monitor consumables, and track live progress of the current weld sequence. “One of the key benefits of building the BotX Welder on the Universal Robots platform is kinetic teaching,” Goldiez said. “Also, customers can use the mobile app to engage with Hirebotics automation experts as well as Red-D-Arc, Airgas, and Air Liquide welding experts. The Hirebotics mobile app gives customers immediate access to help and support, at any time of the day or night.” Bridging the generation gap There is also the theory that cobots can contribute to closing the generation gap. The average age of today’s welder in the US is 55, with less than 20% under the age of 35, according to the AWS. gasworld.com/specialfeatures

SPECIAL FEATURE

“We absolutely believe that cobots will entice younger generations to get involved in and excited about manufacturing,” Pawley said. “At the same time, the cobot welding tool can provide a conduit for experienced welders to pass on their immense welding knowledge. Combined, these two facts will allow different generations to work together to solve a common issue – boosting productivity. This exact scenario actually happened recently at one of our customers. The owner said he came back from a meeting to see his most experienced welder working together with a new-hire recent college graduate. The college graduate was leading the programming effort and she was excited about fixturing/layout/sequencing, etc – while the welder with 40 years of experience under the hood was guiding the weld parameter development. It was inspiring to hear a piece of equipment bringing two generations together for a common goal.” Attitudes are changing towards automation, and more companies are making the jump to automation. Hector Villarreal, President of Illinois-based Weldcoa, a manufacturer of products that store, transport, fill or analyze compressed gas cylinders or cryogenic liquids, told gasworld, “It’s funny, for the first half of my 25 years in this industry I traveled the world telling people, automation is affordable, reliable and can help you grow your business. And then one day, about 10 years ago, people started to call me asking me what kind of automation they should invest in. The changing mindset towards automation has really been amazing. “About eight years ago I added two slides to my presentations on automation, and one was on Rethink Robotics. At that time, they had come out with the first ever commercially available co-operative robot. Up to that point I’d never seen a robot that was designed to work with people. The concept made sense to me, so I added a short video of the robot at work with people to my presentation. “The other slide was on IBM’s Watson AI. I found it remarkable that Watson

had beat humans on the TV Gameshow Jeopardy! So, I added five minutes on AI technology. At the time people thought I was kidding about the commercial potential for both technologies. Which today is funny but back then was unimaginable for most people. That’s when I realized that the problem wasn’t the complexity that came with the technology. The problem is that most people can’t imagine how to use the technology until someone shows them how it can be applied to their business.” And cobots received a lot of interest at FABTECH in Chicago a couple months ago as more consider it an option for 2020. “At FABTECH, we continually heard ‘I can’t find skilled labor’,” Pawley said. “Many of those manufacturers have been stuck between a rock and a hard place – unable to find skilled labor while simultaneously unable to justify, hire programmers for, or take the leap into traditional automation. With the UR-powered Vectis Cobot Welding Tool, those manufacturers now have an affordable, versatile, and compact robotic welding option with a quick lead time, DIY setup and programming, and a 30-

day return policy to minimize their risk.” Challenges ahead More metal fabricating companies might be making the jump to automation – but it comes with its own challenges. Gaining the customer’s trust when it comes to robots, or cobots, is a big one. “The main challenge will be changing how people react to the word robot,” Dupon said. “Using cobot helps this task, however, people still approach the conversation about cobots from a traditional robot mindset. This is a different way of thinking and it takes a fresh approach.” Goldiez said, “Automation has an allure to manufacturers struggling to find and retain skilled employees, dealing with quality issues, or trying to reduce costs. But automation brings new challenges for many companies. Someone at the company must deal with robot programming, integration to other equipment, gripper design, part presentation, and more.” First, though, is the challenge to convince industry to embrace the rise of the cobots. gw January 2020 • gasworld US Edition | 23

SPECIAL FEATURE | INDIANA OXYGEN COMPANY

Making a success of online retail Indiana Oxygen Company’s e-commerce business is thriving. Here’s how they do it… By Nick Parkinson

ndiana Oxygen Company (IOC) is an old company with a modern-day vision. When it comes to selling welding equipment and supplies online, no one is doing it better than IOC. The Indianapolis-based company is the oldest gas and welding supply distributor in the US and its 13 branches serve a five-state region, but its online store weldingsuppliesfromioc.com serves customers further afield, and even overseas. As well as gaining customers, it also received recognition last year (2019). Newsweek, the weekly magazine, ranked IOC’s welding supplies site fifth in the category of “DIY, Tools, Supplies,” above any other welding supply only store, in a survey of more than 9,500 online shops in the US, compiled by Statista, Inc., the global data-research firm, published in the September 27th issue. IOC received a score higher than the likes of Amazon, Costco, and Walmart in the Newsweek poll. The ease and convenience of shopping online means e-commerce will continue to grow. Wally Brant, CEO of Indiana Oxygen Company and grandson of founder Walter Brant, has seen many twists and turns after 40 years in the industry and believes online stores can co-exist with traditional bricks and mortar store, rather than put them out of business. “Very definitely, the future has a place for selling welding equipment online, but at the same time it does not spell the end of the brick and mortars,” Brant told gasworld.

24 | gasworld US Edition • January 2020

“I feel there will be a healthy future for both. The initial trajectory which spelt doom and gloom for all the brick and mortars has been redefined. My view is that all of retail is broken down into two categories: there are things that you want, and things that you have to have. For example, if you are looking for a new pair of shoes, or book, you want those, you don’t have to have them. The chances are you will go online for those because of convenience and selection. But if you are a contractor in the middle of a welding job and you run out of welding rod, you have to have it now. There will always be a place for brick and mortar stores like ours, hardware stores and drugs stores. We just happen to fall into that category that covers both the ‘have to have it’ and ‘want to have it’ buyers.”

Despite more and more people opting to do their shopping online, there are still advantages to buying in a store. Brant explained, “We say that if you want the online deal you have to get the product on the internet, and if you want the one that is on the floor you have to pay the price that is on the floor because we are going to help you set it up, we’re going to help you learn how to use it, tell you the right type of wire and gases, and there’s a price for that. When you go online, even though you are getting a lot of expertise from the people answering the phone, it still comes down to a brown box at the end of the driveway.” Taking on Amazon The personal touch and expertise in the sector are what sets apart IOC from its gasworld.com/specialfeatures

SPECIAL FEATURE

“You’re never going to compete with Amazon on their terms, our industry can’t, but we can beat them on customer service and expert knowledge” rivals, according to Brant and Justin Yoder, IOC’s Chief Digital Officer. “We have that customer service element – we strive to ensure that everyone that calls gets a live person with knowledge of the products we sell. You’re never going to compete with Amazon on their terms, our industry can’t, but we can beat them on customer service and expert knowledge. Those things are central to our wellbeing,” Yoder told gasworld. “Amazon is big enough to shape what the customer expects the online experience to be, so that is our starting point. We have to have a site that is easy to navigate, people have to know stores, and they think they know what if something is in stock and we have to they want. It comes down to our online or ship it quickly. It has to be easy to check brick and mortar businesses to add some out, we have to communicate when it is shipped, it has to be trackable, and returns value to their visit and maybe steer them in a slightly different direction if they are a have to be easy. Once we’ve accomplished somewhat misinformed. The goal of both that, we have to take the next step and those buying experiences is to add some add those customer service components additional value they can’t get with that you can’t get at Amazon. It’s easy the competition. Companies to buy a product at Amazon that succeed in this next but if you want to know phase of retail, whether it’s about it before you buy it or online or in a branch, will need some personal help Online sales account be those who can add some afterward, Amazon can’t for approximately complimentary experience to compete with us on that. a third of IOC’s sales the sale.” “One of the things we have IOC has a full-time, fourseen in the last few years is a person team ready to answer lot of consumers are starting their search online now. Walking into a welding customers’ telephone calls, emails, or live chats about products, orders, or any other supply shop is intimidating for people questions they have. This personal touch who don’t know what they want, so we has been crucial to the success of IOC’s have seen a huge amount of research e-commerce channel. starting on YouTube. Buyers arrive at our “Anyone can throw up a website and virtual store, or our brick and mortar

⅓

work on price,” Brant said. “One of our successes is that we have knowledgeable people, real live human beings, on the other end of the phone who can answer questions from people/ customers who may not know what they are looking for. If I order a book on Amazon, their algorithm might suggest a few similar options. But what’s missing is the chance to have someone listen to me and make a recommendation based on our conversation. That’s what we can offer that Amazon can’t.” Challenges Online sales account for approximately a third of IOC’s business, which is nationwide and also ships to “to about a dozen different countries”. But there are challenges, one being margin preservation. “As more and more retailers come into the market, price or freebees like helmets, jackets, or gloves becomes the easiest way January 2020 • gasworld US Edition | 25

SPECIAL FEATURE | INDIANA OXYGEN COMPANY

to get a sale,” Yoder said. “Margin preservation is one of our biggest challenges because we have to keep the lights on, we have to pay our people, and we run it like a stand-alone business rather than this novelty of moving product just because it’s online.” For Brant, maintaining a successful presence online in a crowded marketplace is like the video parlor

26 | gasworld US Edition • January 2020

game Whac-A-Mole; new challenges constantly pop up and you have to be ready to quickly respond. “Every day is a new challenge where a competitor or manufacturer will throw a twist and we have to counter that immediately,” Brant said. “One of the things, for example, is MAP pricing (minimum advertised pricing). We are very big proponents of MAP and we get a little upset when some of the other online companies try to go around on the rule by offering a discount or freebees in addition to what you are selling at minimum advertised pricing. When the price drops once you add an item to your cart or you get a whole bunch of accessories for free, we feel like that’s cheating. We are big proponents of MAP pricing because we feel a responsibility to the market and to be able to have margins in there so we can continue to offer a premier level of service.” Another mole to pop up, or challenge, is sales tax on out-of-state online sellers. “Having to navigate the tax codes of something like 39 states where we remit was a big burden for us this year [2019],” Yoder said.

“We are big proponents of MAP pricing because we feel a responsibility to the market and to be able to have margins...” “You could have a full-time tax specialist on hand to make sure you are collecting and remitting the right amount.” IOC plans to open up its e-commerce business to its existing customers. “Our plans to expand include moving into the business to business (B2B) realm,” Yoder said. “We’re trying take the experience from the business to consumer (B2C) side to the B2B so that our existing customers can have this rich shopping experience with all the things they have come to expect from their online experience, like their own pricing, cylinder balances, paying bills, viewing past orders. The expansion to the business to business (B2B) will be new to us. We’re trying to make this an attractive thing for all of our customers,” Brant added. gw gasworld.com/specialfeatures

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SPECIAL FEATURE | ESAB

Controlling gas surge By Curt Rocha, Global Product and Business Director – Gas Control Equipment, ESAB

Found money The rate of waste varies widely, but on average, most operations could realize a gas savings of 20 to 40% by controlling gas surges using two common solutions. One solution is a surge limiting regulator (North American term) or a “gas economiser” (EU term). These devices connect to the shielding gas inlet (see Figure 2). Using a fixed or adjustable orifice, they limit the maximum gas flow rate at the end of the 28 | gasworld US Edition • January 2020

Figure 1: Surge Flow Chart TYPICAL OF SHIELDING GAS SAVED USING SURGE LIMITING REGULATOR

CUBIC FEET PER HOUR

s that “whoooshhhh” sound the start of gas shielding pre-flow, or is it the sound of flushing money down the drain? Unfortunately, it’s probably the latter, as gas surges during arc start are a common – yet accepted – problem in many welding operations. After the solenoid valve on the welding machine or wire feeder closes, gas pressure in the hose continues to build up until back pressure stops the flow of gas. The gas hose may even expand a fraction of an inch. Like pinched fingers releasing a swollen balloon, the next opening of the solenoid valve allows a blast of compressed gas to exit the MIG gun or TIG torch at 80 to 120 CFH (2265 to 3398 l3/min) or more (Figure 1). As we’ll discuss later in this article, more is not better when it comes to gas flow. Operations that require short intervals between arc starts will experience less surge, but even a few minutes of idle time will allow the pressure to build back up. Those operations using larger diameter and longer gas hoses have more potential for waste.

TIME IN SECONDS AFTER EACH TRIGGERING

Gas surge flow rates can easily reach three to six times the recommended flow rates for TIG welding or MIG/flux cored welding. Source: ESAB

“Spot welding applications tend to save more gas (an average of 40 to 45%), where seam welding operations save about 20%...” gas line, such as to 50 CFH. These are “install it and forget it” devices because they are extremely durable (Figure 3). Another solution is a “cylinder regulator ecosaver,” which combines the surge limiting regulator principle into

an adjustable flow meter with a pressure gauge to ensure a consistent flow rate (also Figure 3). They make more sense when operators want to adjust gas flow, such as when switching between solid and cored wires. Ecosavers can reduce gas waste by 0.018 cu. ft. (0.5 l3) per weld. Spot welding applications tend to save more gas (an average of 40 to 45%), where seam welding operations save about 20%. ESAB recently worked with a large transportation equipment manufacturer using 100% CO2 shielding gas for their flux cored welding operation that spent approximately $250,000 annually on CO2 at one location. By investing $27,500 to install surge limiting regulators, the manufacturer reduced gasworld.com/specialfeatures

SPECIAL FEATURE

Figure 2: Connection Diagram

A surge limiting regulators connected to the inlet port of a welder. Source: ESAB

annual shielding gas costs by $75,000, a savings of 30%. While a 30% savings might not mean that much to a shop with just a few welding stations, the hassle of fewer cylinder swap-outs — especially annoying when gas runs out in the middle of a project — will be well worth the small investment for a surge limiting device. By optimizing gas use, fabricators may also be able to reduce the number of spare cylinders in stock, reduce rental charges and reduce the frequency of cylinder delivery. Quality control As noted earlier, more is not better when it comes to gas flow. Yes, a welding system can have restrictions in the gas flow (e.g., damaged or clogged torch cables), need a bit of overpressure to compensate for a long line or need a little more or less gas flow depending on © ESAB | Surge limiting regulators are available with and without pressure gauges

consumable choice (as a cautionary side note, always re-evaluate gas flow rates when changing consumable types). Increasing gas flow beyond the recommended rate, whether intentionally or due to a gas surge, is almost guaranteed to cause weld quality issues. Worse, these issues may be hard to diagnose. For example, one California structural steel fabricator had switched to a different brand of E71T-1 gas shielded flux cored wire. After the switch, they began experiencing gas marks (commonly called “worm tracks”) at the beginning of their welds, and it was a painful source of rework. After trying the typical cures for eliminating worm tracks without success (adjusting voltage, electrical stickout, changing cylinders, changing torch angle, etc.), the fabricator believed they had received a pallet of wire that had either moisture absorption issues or a manufacturing defect. Fortunately, the welding supply distributor and filler metal manufacturer team were able to diagnose the real problem as gas surges. The new filler metal had a faster-freezing slag system that trapped excess gas between the weld puddle and the slag, creating worm tracks. Installing surge limiting regulators

solved the problem, and eliminating the time spent repairing welding defects provided an instant savings. Gas surges commonly cause porosity when MIG welding, as the turbulent, swirling gas flow pulls in outside atmospheric contaminates. Thinking poor gas coverage caused porosity, operators increase flow rates to a point where they compound contamination problems: gas surges during arc start create porosity at the beginning of the weld and then turbulent flow during welding causes random porosity. As one aerospace fabricator learned, gas surges may also cause burn-though issues when TIG welding an extremely thin part at low amperage. At the time, their welding power source had a minimum output current of 10 amps, and the fabricator thought it would need to purchase a power source with an output of 5 amps or less to complete the project. Fortunately, a low-cost surge limiting regulator solved the problem, which was actually caused by excess volume of ionized gas. For any fabricator who now suspects they might have an issue related to gas surges, ask your manufacturer’s representative or welding supply distributor to conduct a flow test. The procedure is simple, and the solutions are easy to apply. © ESAB

January 2020 • gasworld US Edition | 29

SPECIAL FEATURE | ESAB

ESAB STRENGTHENS GLOBAL GAS PRESENCE Since Maryland-based ESAB Welding & Cutting Products completed its acquisition of Sweden-based Gas Control Equipment in October 2018, the company has focused on aligning its global product offerings and innovations into four focus areas: cutting and welding, central gas systems, cylinder valves and healthcare. “We now have the industry’s broadest portfolio of products, as well as the broadest range of products within those portfolios,” said Christophe de Fitte, CEO of the GCE Group since January 2014. “With respect to the European and North American markets, we’ve been working to identify gaps and see how our combined resources can best meet the needs of our distribution partners and end users.” ESAB employs more than 8,700 people and operates in the EU, Middle East and Africa, Asia-Pacific and North and South America. Specialty gas and healthcare North American distributors now have full access to GCE products, notably the GCE Druva and GCE Valves product lines. Specialty gas products within the line include regulators, manifolds, valves and accessories for high-purity © gasworld | ESAB’s exhibition at FABTECH in November

30 | gasworld US Edition • January 2020

© ESAB | Innovative products include the Victor EDGE 2.0. Launched in North America and coming soon to the EU, unique benefits include a design that enables operators to more easily set and see delivery and cylinder pressures while offering unmatched safety benefits

and ultra-high-purity applications found in laboratories, petrochemical and semiconductor manufacturing. Curt Rocha, Global Product and Business Director Gas Equipment for ESAB adds that, “GCE medical and healthcare products coming to North America include the Zen-O™ portable oxygen concentrators (POCs), which deliver up to two liters of oxygen per minute to support people with respiratory disorders.” The US market size for POCs will reach $1.051bn by 2026, according to Zion Market Research. ESAB will support distributors with specialists for the specialty gas, valves, and healthcare lines. Other activities for 2020 include upgrading the clean room at ESAB’s Denton, Texas, facility. “Distributors know Denton for

its heritage with Victor cutting and welding products, but it also has a separate specialty gas lab where we’ll add more assembly and testing equipment and make other enhancements to support our expanded North American portfolio,” said Rocha. Innovation Prior to the GCE acquisition, ESAB’s main strength in its gas equipment portfolio especially came from the Victor® brand, which has served the industrial cutting and welding markets since 1913, and the company’s EU portfolio now reflects that strength. “Starting in Q2 2020, we will offer the innovative Victor EDGE™ 2.0 regulators in Europe,” said Rocha. “No other regulator on the market offers its combination of safety, durability, performance and usability.” Designed for controlling the flow of oxygen, acetylene, argon, air, nitrogen and other industrial gases, EDGE 2.0 features the Patented SLAM™ (Shock Limitation and Absorption Mechanism) technology built into the adjusting knob. SLAM permits the knob to absorb the impact in the event of a cylinder fall, helping prevent catastrophic failure. “GCE and ESAB share a history of new product introductions and innovations such as the Zen-O and EDGE 2.0, and we will retain this focus moving forward,” said de Fitte. gw gasworld.com/specialfeatures

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January 2020 • gasworld US Edition | 31

SPECIAL FEATURE | WELD FUME MITIGATION

Clearing the air for tank manufacturers By Adam Pfeiffer, Field Solutions Director for RoboVent

egardless of industry, manufacturers that depend on high volume welding production agree on one thing: weld fumes are bad news. The toxic elements in weld smoke threaten employee health. When inhaled, weld fumes may cause upper respiratory ailments and greatly increase the risk of serious diseases including COPD and cancer. Weld fumes produce some of the most dangerous airborne contaminants found in manufacturing facilities today. The high temperatures needed for welding create fumes containing exceedingly small particulates. While most of these particulates come from the weld wire, some are from the base materials. Particulates from base metals such as manganese and hexavalent chromium are extremely toxic and very dangerous when inhaled. Manganese is a trace element found in many kinds of welding. Breathing its particulates can cause “manganism”, a neurological condition similar to Parkinson’s disease. Hexavalent chromium is found in fumes coming from welded metals that include chromium, such as stainless steel. These particulates can be highly irritating to the eyes, nose and throat. Hexavalent chromium is also a known carcinogen. Light metals in weld fumes, such as beryllium and aluminum, can also cause health problems when inhaled, including the risk of lung cancer. Every manufacturer that utilizes high volume welding is vulnerable to the dangers of weld fumes. Fume mitigation and air quality control are a necessity. Fortunately, today’s air filtration systems are powerful, efficient and customizable 32 | gasworld US Edition • January 2020

“Customization is important, particularly for tank manufacturing and other industries where clearing the air poses some special challenges” for any welding environment. Customization is important, particularly for tank manufacturing and other industries where clearing the air poses some special challenges. The key is finding the best solution for a specific welding application.

Ambient air capture provides total-plant solution Tank manufacturers fabricate storage tanks, cylinders and pressure vessels for many industries including oil and gas, transportation, food and beverage, and chemicals. Every industry has its own requirements, and while the volume and composition of weld fumes depends on the material and processes used, toxic elements such as hexavalent chromium, manganese, nickel and beryllium are often present. Storage tanks for the oil and gas industry, for example, are massive weldments. They are too large to be contained under a fume hood and may require the use of overhead cranes. As a result, capturing weld fumes at their source, which is usually the most economical and effective method of air gasworld.com/specialfeatures

quality control, presents an extremely difficult challenge. Also, large storage tanks, valves and other components are often made of stainless steel which produces especially toxic weld fumes including hexavalent chromium. In this situation, one of the more common solutions for protecting welders and anyone else working in the vicinity of the work is ambient air capture and filtration combined perhaps with some Powered Air Purifying Respirators (PAPRs). Ambient systems will not immediately remove the fumes from the breathing zone as a source capture, backdraft-type design could. While effective at clearing the air in a facility and reducing the overall particles in the air, ambient solutions clean the air in the general vicinity of the welding operation. There are typically three types of configurations that are used most widely: 1) A ducted push-pull system; 2) A ductless floor system, and/or 3) A ductless ceiling/wall-mounted system. Each have their own distinct advantages. A ducted push-pull system is the most traditional method. Ductwork is installed down one side of the room or space being addressed. Collection points installed in the ductwork at regular intervals where the fume stratifies carry the particulates to a filtration unit. Clean air is then pushed in through ductwork and registers on the other side of the room creating a laminar air flow pattern across the space. A ducted system uses centralized collectors which help save space. The filtration unit can even sit outside the building. In comparison, a ductless push-pull system positions a standalone filtration unit – or array of units – near welding stations and collects fumes. The unit then returns cleaned air through strong

jets back into the facility. These filtration units are easy to install and can be moved around if needed. The Spire360, the Fusion Vortex and Vista360 are all examples of free-standing ductless dust collectors. The Spire sits on the floor and is placed strategically near key collection points and the Fusion and Vista can be suspended from the ceiling or wall mounted around the process to create an effective air flow pattern. Ambient filtration systems provide total-plant solution for indoor ambient air quality. When source capture isn’t possible due to large custom components or overhead cranes, these systems can clean and recirculate the air in the entire plant without conflicting with these obstructions. By filtering and recirculating clean air, ambient systems also help avoid the costly energy bills associated with replacing the warm air that other systems simply exhaust from the building. These filtration solutions are both environmentally responsible and cost effective. No ductwork is required for freestanding, ductless filtration equipment which eliminates interference with overhead cranes or other obstructions while lowering installation cost as well..

Source capture safely extracts weld fumes in confined spaces The most effective capture method for weld fumes is source capture filtration. If a process is automated or can be placed under or near a hood, a source capture solution is ideal – especially for welds happening on the exterior of the tank. Fabricating large storage tanks often requires manual welding

inside enclosed spaces. Weld fumes can rapidly collect to dangerous levels in these conditions, greatly increasing the risk of toxic exposure. Weld smoke haze also accumulates quickly in confined spaces, affecting productivity and work quality. Fortunately, source capture – collecting fumes at the point of welding – is a proven way to reduce weld fumes where it is needed most. Welding guns with integrated fume extraction at the tip, such as the RoboVent Extractor™, provide a versatile solution for welding in confined spaces. Combining these guns with a type of hi-vac extraction unit has proven to be an effective solution for capturing welding fumes generated at the source and help reduce the welder’s exposure to the fumes by up to 95%. The gun can be connected to a centrally placed extraction system, such as standalone hi-vac collection systems or to more portable fume extraction systems, like the MiniCube™. With this type of flexibility, the Extractor can be used in many different work environments including large tanks. Today, tank manufacturers have many fume extraction and air filtration options for their welding operations. Selecting the right solution for their specific applications will ensure a constant flow of clean, breathable air throughout their facility. gw ABOUT THE AUTHOR Adam Pfeiffer, Field Solutions Director for RoboVent, has been in welding and fume extraction industry for nearly 20 years and has designed hundreds of solutions for manufacturers in the US. January 2020 • gasworld US Edition | 33

SPECIAL FEATURE | OXY-FUEL CUTTING

Oxy-fuel cutting process automation By Martin Roubicek, Ph.D., Business Development Manager CWT at GCE Group

here is still significant potential for increasing the efficiency of oxy-fuel cutting technology. The higher level of process automation is a prerequisite. Today’s cutting machines are automated systems, controlled by CNC with software, often ready for integration into production lines and units as Industry 4.0. We often see machines employing two or more different technologies, such as plasma, oxy-fuel, drilling, beveling, marking, etc. The machine is a carrier of individual technologies that are automated in certain degree and require varying levels of operator experience. Of course, here too,

34 | gasworld US Edition • January 2020

the higher the degree of automation of the technological process, the less demands are placed on the equipment operator. A comparison of plasma and oxy-fuel cutting technologies shows us a different approach to automation. Plasma cutting technologies are delivered in most cases as package containing all parts necessary for the operation of the process: hardware, software and process parameters. They are supplied to virtually all manufacturers of cutting machines by a couple of premium suppliers, specialized in the plasma process. That is, considerably simplified, the machine manufacturer buys complete plasma technology from

a specialized supplier and installs it on his machine. It is a really simplified view and the machine manufacturer shall invest substantial knowledge and effort to make the whole unit functioning according to the wishes of the user. But most conventional cutting machines can work with plasma technology in practice automatic mode. In the case of oxy-fuel cutting it is much more demanding on the machine manufacturer. So far there has been no specialized supplier of the whole process on the market; there are only vendors of individual components such as torches, cutting nozzles, safety elements, hoses, valves, height sensors, lighters. The machine manufacturer thus relies on own resources and knowledge in the design of oxy-fuel technology, component selection, finding and optimizing process parameters, etc. The result is then very different in different machine manufacturers, both in the level of automation of the cutting process and in the level of utilization of the technology in terms of cutting quality, cutting speed, sheet metal piercing ability. Not every cutting machine manufacturer has an oxy-fuel cutting process so well managed that the machine can work alone, automatically, without significant intervention of the operator. The issue is also dependent on the finances that the user is willing to invest in each technology. Often, we hear the sentence: “Everybody knows oxy-fuel cutting, it must be cheap”. But today’s reality is different. Given the general gasworld.com/specialfeatures

SPECIAL FEATURE

APC is arranged modularly for flexible assembly on the machine. The main components are:

Advantages for users: • High-speed oxygen cutting with cutting quality corresponding to the highest criteria of ISO 9013 • System integration minimizes the distance between two adjacent torches • It allows cutting near sheet metal edge or cutting kerf • Best-in-class height sensor for drytable cutting • Flashback detection to increase torch life • Slag detection on sheet metal surface • Automatic flame ignition is integrated into the torch

• Flame ignition detection • Tool-free replacement of consumables High productivity and production quality with APC The low operating costs per unit of cut length ensure the fastest return on investment. Automation is one of the decisive factors for this when using the optimum cutting machine and balanced components. Cutting speed is the key for economic success. The latest design of cutting nozzles increases cutting speed. ASF and PSF high speed nozzles are among the best available on the market. Results can be even improved by using ARC and PRC nozzles which are the fastest in class. All types of cutting and heating nozzles are connected to the torch by the Tool-Free system manually, without tools. They ensure also the best possible cutting quality according to ISO 9013. The perpendicularity of the cut is guaranteed for the full range of sheet thickness from 3mm to 300mm on both sides of the cutting kerf. This is an indisputable advantage of oxygen cutting compared to other methods of thermal cutting of materials. Incorrect type or low-quality cutting or heating nozzle leads to a slower return on investment.

Figure 1: Cutting Processes Comparison

a sm Pla

ch 1 tor uel F y s Ox rche 3 to

La se

Automatic Process Control (APC) APC is the first generation of technological system for the oxy-fuel cutting, developed in collaboration of GCE Group and IHT Automation. It is the only complete system available on the market so far for use by all cutting machine manufacturers. APC contains all the technological components optimized for unalloyed and low-alloy steel cutting, including process control software and a database of the cutting parameters. APC features innovative FIT+ three cutting torch and nozzle technology with many other functions, carefully selected components, always the best in its class. Areas of application: • Oxy-fuel cutting machines and combined machines of all types for cutting steel from 3 up to 300 mm sheet thickness • One or more torch machines with individual control of gas parameters for each individual torch • Solutions for new machines and machine retrofits • Automatic cutting height control up to 300 mm, piercing up to 100 mm sheet thickness

• Intelligent cutting torch with builtin height sensor, flame ignition, flashback detection, etc. • Torch height control including lifter • Control system, software with database of process parameters for flame ignition, preheating, piercing and cutting • Gas controller with optimization of gas pressures for each torch • Internal gas distribution • Safety elements, flashback arrestors • Electrical components and cabling • Communication route with CNCs of the machine • Operating terminal

€($)/Meter

downward trend in user’s specialized process knowledge, it is becoming increasingly difficult to find right operators. Then the user, along with strong marketing pressures, demands for him easier plasma technology even where oxygen would be more economical. An approximate comparison of the cost level of individual methods of thermal cutting of materials is shown in the graph, see Figure 1. The higher degree of automation of the oxy-fuel cutting process and the elimination of dependence on operating personnel is thus a step towards better utilization of the process capabilities and its application in the areas of both economic and technological advantage.

Sheet Metal Thickness 0

100

300 mm

12 inch

Source: GCE Group January 2020 • gasworld US Edition | 35

SPECIAL FEATURE | OXY-FUEL CUTTING

Costs can be calculated in different ways, but ultimately the total cost per unit of cut length is significant rather than the amount of initial investment in equipment. The total costs include more components such as energy and gas consumption, consumables, labor, setting time, additional rework, etc. When counting all together, oxy-fuel cutting is economically competitive with other cutting methods already from 25mm sheet thickness and should therefore be considered as the primary cutting technology there. The latest statistics confirm this. The area of greatest use for mechanized oxy-fuel cutting of unalloyed steels are thicknesses 20mm–60mm. The fully automatic process brings additional benefits Integrated flame ignition: Automatic flame ignition speeds up the process and reduces gas consumption costs. The flame can always be stopped automatically when the cut is finished and then easily reignited to start next cut. Such a start/stop system saves more energy and emissions than similar systems in cars when stopped at a traffic light. The ignition integrated in the torch guarantees reliability even when cutting thicker sheet metal, while being safely protected from the effects of molten slag. Manual flame ignition operations are not safe and efficient. Slag detection: The slag always remains on the surface of the metal sheet after the previous piercing. So, there are two options: thorough slag removal by a designated operator manually, which

“Oxy-fuel cutting is economically competitive with other cutting methods already from 25mm sheet thickness...” 36 | gasworld US Edition • January 2020

is costly, or the use APC with slag detection and automatic adjustment of cutting parameters. Lifetime of consumables: Solid design of durable materials and the use of Coolex® system is an advantage. Coolex® lowers equipment temperature by controlled cooling oxygen flow throughout the operating cycle. This increases both the lifetime of the cutting and heating nozzles and service life of the torch. A cooled equipment is more resistant to the effects of backfire. Safe system: Knowing the right behavior and safety rules is very important when cutting. It is a whole set of knowledge in connection with technical gases, intense flame, high temperature, electrical energy, etc. One of APC’s advantages is that it contains a few integrated safety features and minimizes the risk behavior of the cutting machine operator. E.g. carefully selected types of the flashback arrestors are part of the APC system. Flashback detection: Early detection of any risk is a prevention of material and equipment damage and, more importantly, a risk to personnel health. The detection of the sustained backfire minimizes the risk of endangering situations.

Conclusion The current APC is the first generation of a system that is constantly being developed and improved in cooperation with end-users, cutting machine producers, CNC and software companies, universities and innovation centers. The end goal is to give the chance to user for optimal cutting process selection for his application. The target is a cutting machine working without a qualified operator with adequate efficiency and repeatable quality of products. Such machine could then be integrated into Smart factories. gw gasworld.com/specialfeatures

Â®

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SPECIAL FEATURE | WELDING APPLICATIONS

Forerunner of the future The USS Albacore’s place in naval and welding history By Agnes H. Baker

ith the motto Praenuntius Futuri (Forerunner of the Future), the USS Albacore was commissioned in 1953 as an experimental vessel to test submarine hydrodynamics and ended up revolutionizing submarine design. The pioneering shape of her hull, when combined with the nuclear power technology of the USS Nautilus resulted in the USS Skipjack, the first submarine capable of sustained underwater high performance. Today, the USS Albacore is a National Historic Landmark and the centerpiece of Albacore Park in Portsmouth, NH, not far from the shipyard where she was built. This month, as part of gasworld’s examination of welding and automation applications, we take a look at how © USS Albacore Park | The USS Albacore Park

38 | gasworld US Edition • January 2020

this historic welded structure was instrumental in the introduction of new materials and the development of welding applications still in use today. To learn more about what makes this submarine so significant, particularly from a fabrication perspective, gasworld met with Ken Herrick, President of the Portsmouth Submarine Memorial Association, Jim Arsenault, retired Superintendent of the Welding, Shipfitter and Sheet Metal Group at the Portsmouth Naval Shipyard, and Patti Violette, Executive Director/Curator of Albacore Park. The need for speed Historically, US submarines were surface ships that occasionally dropped beneath the waves. They were slow and

difficult to maneuver. Ken Herrick, who worked as a Naval Architect Technician at the Portsmouth Naval Shipyard from 1959 until his retirement in 1998, explained that at the end of World War II, the US realized that German submarine technology had surpassed its own. Subsequently, a commission was established, the Committee on Undersea Warfare (CUW), to study submarine performance. CUW’s final report issued in 1949 strongly suggested that the Navy build a high-speed research submarine capable of exceeding 20 knots submerged. Herrick related, “At this time, there were two very influential Admirals running the submarine side of Naval Ship Design Operations, Admiral Hyman G. Rickover and Admiral Charles Monson – both of whom had very different priorities about submarine design. Rickover was after a new, air independent, propulsion system, and was uninterested in redesigning the characteristics of the ship itself.” The nuclear-powered USS Nautilus was the result of Rickover’s efforts. “Momsen wanted to improve capability,” said Herrick. “His goal was to build a submarine hull with underwater speed as the prime requirement. At the end of WWII, our subs could not keep up with a German destroyer or maneuver around them. They needed greater underwater speed and agility and these were Momsen goals.” Momsen had a long history of forward thinking. A Navy expert on diving, he had invented the Momsen lung that enabled people to escape from submarines and was instrumental in gasworld.com/specialfeatures

SPECIAL FEATURE

“After more than 25 scale models were produced, the final version of the sub was shaped like a fish with a cod’s head and a mackerel’s tail” the design of the McCann Submarine Rescue Chamber. He also led the diving team that developed tables of helium and oxygen mixtures, which permitted divers to safely operate at depths greater than 300 feet. In addition to be being a skilled designer, Momsen was an astute politician. In a carrier-focused Navy, he recognized the need to justify his ideas based on the defense of the fleet. From his WWII experience he knew submarines were feared by carrier Admirals so he proposed building a target for submarine hunter-killer groups to practice on. That target was to become the Albacore.

Reverse engineering Some work on speed and maneuverability had already been done. According to Herrick, the Germans had developed a high speed class of submarine during WWII, known as the Type XXI U-Boat. After the War, the US brought over two Type XXI subs from Germany. “The Portsmouth Naval Shipyard reverse engineered one sub down to the last bolt and with the other the Navy formed and qualified a crew to conduct numerous, performance related, Sea Trials. We still have one of those crew members with us today,” said Herrick. Six copies of the Type XXI sub were built, and while they were an improvement over the US’ WWII GUPPYs, tests showed only marginal increase in performance and capability. According to Herrick, this was unacceptable to Momsen and he called for a 20-plus knot submarine. This represented a lofty goal. Subs at the end of WWII only could travel at 8-10 kts submerged and 10-15 kt on the surface. Hull design Herrick described the three important elements of submarine hull design: (1) the shape of the nose, which pokes a

hole in the water; (2) the maximum diameter of the ship, which is the point at which the hole in the water stops getting any bigger; and (3) the shape of the stern, which determines the dynamics of the water’s collapse into the path of the propeller. Determining the submarine’s shape was a huge concern to Momsen. He began the quest for speed by testing new hull designs in the huge Tow Tanks available at the Navy’s David Taylor Model Basin in Carderock, Maryland. There the optimum hydrodynamic shape for underwater speed and maneuverability could be defined. The team looked at successful aerospace designs for shape ideas. A form based on the British Experimental Airship R-101 became the model of choice and it was among the first shapes tested in the Langley Air Force Base’s wind tunnels in Hampton, Virginia. There the resistance equations for the R-101 Airship, first developed by American scientist Hilda Lyon in 1929, were tested and confirmed. In the end, after more than 25 scale models were produced, the final version of the sub was shaped like a fish with a cod’s head and a mackerel’s tail. Getting the sub built In an effort to gain as much freedom to design speed and maneuverability into the Albacore, Momsen decided that it would contain no ordinance. Without the Bureaus of Ordinance, Engineering, Navigation and Construction and Repair, Momsen remarked, the submarine would not end up like a “stuffed turkey.” His instructions to the designers, according to Albacore Park History, were: “Forget about surface performance. Think only about submerged capability which will provide the utmost speed with a minimum of power. When in doubt, think speed.” As Deputy Chief of Naval Operations (Submarines) Momsen oversaw the building of the ship at the Portsmouth Naval Shipyard, the preeminent ship building facility in the county and one January 2020 • gasworld US Edition | 39

SPECIAL FEATURE | WELDING APPLICATIONS

owned by the US government. “I was at the shipyard during Albacore’s Phase II, and we were made aware that there would be lots of changes to this boat,” said Herrick. “When we were instructed to make changes, we did. At a private shipyard you couldn’t do that. It would take weeks to get contracts settled. In all, the Albacore went through five building and design phases and the end product was everything everyone thought it would be,” said Herrick. “It was quieter, faster, and it could turn inside the turning radius of a destroyer, the most maneuverable ship in the squadron. The destroyer’s job is to defend the squadron from outside threat so it was critical that the sub could maneuver within its range.” Making history According to the American Society of Mechanical Engineers (ASME) (asme.org), which has designated the USS Albacore as a Historic Mechanical Engineering Landmark, the Albacore represented a radical change in submarine design. It was “the first Navy-designed vessel with a true submarine hull form in which the surface characteristics were subordinated to requirements of underwater performance. Its design innovations were adopted for all US Navy submarines that followed.” “In recognition and triumph of this time-tested experimental submarine to serve as a prototype for the development

of contemporary Navy vessels, and in appreciation of its valuable contribution to the welding industry, symbolizing for all generations a continued vision into the future,” the USS Albacore also received the designation of Historic Welded Structure from the American Welding Society (aws.org). According to Herrick, the construction of the Albacore using newly developed HY-80 steel gave it its historic significance from a fabrication perspective. Herrick said, “As defined in Archimedes’ Principal, the weight of the hull factors into how deep a sub can go. Previous subs had been built with Mild steel, which has a pressure rating of 33,000 psi and High Tensile steel, which is rated at 55,000 psi. The Navy was looking for something stronger. HY-80, rated at 80,000 psi, was developed by Lukens Steel, among other steel companies, for use in building submarines.” “Different types of steel weigh about

“It was quieter, faster, and it could turn inside the turning radius of a destroyer, the most maneuverable ship in the squadron”

the same: 1/8-inch-thick steel weighs around 5.1 pounds per sq. ft. and 1-inch-thick steel around 40.8 pounds per sq. ft. We needed to make the hull more pressure resistant but not heavier,” continued Herrick. “To go deeper using Mild or High Tensile steel in the hull, you had to increase the thickness of the hull and therefore the weight of the ship. HY-80, with a psi of 80,000, would allow the Navy to build subs that went deeper yet could retain the same underwater capability.” Jim Arsenault, Retired Superintendent of Welding, Shipfitter and Sheet Metal at the Portsmouth Naval Shipyard, grew up working with HY-80, which is commonly used today, but explained that it represented a big change for welders used to working with Mild Steel in the late 1950s. “The Albacore welding team had to figure out a lot of things. They were pioneers in HY-80 fabrication,” Arsenault said. “For example, Mild Steel has a much larger temperature band to work within than does HY-80. Also, with HY-80 welds it takes longer for the hydrogen to migrate out of the metal and this requires longer times between weld inspections, seven days with HY-80 versus one day with Mild Steel.” “It was a challenging transition, and the Albacore is a Historic Welded Structure because its fabrication

40 | gasworld US Edition • January 2020

gasworld.com/specialfeatures

SPECIAL FEATURE

“The Albacore welding team had to figure out a lot of things. They were pioneers in HY-80 fabrication” represents the basis for using HY-80 today,” said Herrick. The Albacore comes home The Albacore was decommissioned in 1972 and was moved from Philadelphia to its present location in Portsmouth, NH, in 1985. “This community has a huge sense of pride in the Albacore,” said Patti Violette, Executive Director /Curator. “The people who worked on this vessel, and their decedents, were behind the effort to create this museum and park, which opens up the story of the Albacore

to the wider world.” Herrick added, “While the Navy ‘gave’ us the sub, it came with a donation contract that includes many stipulations. For example, each year the Navy inspects the sub to insure that everything is up to spec. We are responsible for making whatever repairs the Navy dictates and for the associated costs of those repairs.” Averaging over 32,000 visitors a year, the museum is in an enviable position of being self-supporting from an operations standpoint. Herrick explained, “However, extraordinary repairs have become necessary with time. To this end we have formed the Portsmouth Submarine Memorial Association (PSMA) to focus on fundraising for these expenses.” The museum is currently working on Phase 3 of the Albacore Preservation/ Restoration Project. Phase 1 consisted of renovating the Albacore’s dry berth basin to eliminate the ship’s hull exposure to the existing corrosive environmental conditions. Phase 2 involved the repair of

The Albacore was in service for 19 years, and revolutionized how submarines operate today

a series of deteriorated and/or damaged outer hull sections. Phased 3 of the project will entail the complete re-preservation (painting) of Albacore’s outer hull and superstructure, which is estimated to cost up to $500,000. The PSMA welcomes your contributions to this effort. To learn how you can help contact Albacore Park at (603) 436-3680 or email albacoremailcall@gmail.com. The Albacore was in service for 19 years. During that time the men and women who worked on the ship helped revolutionize the way submarines operate today. For the opportunity to climb aboard the Albacore and experience the fruits of their dedication we are grateful to Albacore Museum and Park. For more information, or to virtually board the sub, visit ussalbacore.org. gw January 2020 • gasworld US Edition | 41

SPECIAL FEATURE | ADDITIVE MANUFACTURING

Adopting additive manufacturing As much a mindset change as it is technological By Linde Gases

ompanies putting manufacturing at the heart of their business are under mounting pressure, both from global competition and the rapid rise in technological advancements that are changing the way goods are manufactured. With mass production having largely shifted to developing economies, Western companies are moving towards lower volume production of high-added value, innovative, customizable and more sustainable products. They also continue to seek out ways to improve cycle times, reduce waste and maximize work flow. To compete in this new environment, manufacturers have sought new fabrication approaches to support economic low volume production. One such emerging technology is Additive Manufacturing (AM). Capable of producing fully dense components layer by layer from computer aided 3D modeling, the technology removes many of the limitations of manufacturing techniques based on traditional subtractive methods. AM consists of various technologies to process versatile materials – from laser powder-bed fusion, directed energy deposition (using a laser or an arc), electron beam melting, to binder and material jetting – and once destined primarily for prototyping, AM is now employed increasingly for the development of spare parts, small series production and tooling. Adoption of AM has seen the greatest uptake in industries where its 42 | gasworld US Edition • January 2020

relatively higher production costs can be outweighed by the advantages AM can deliver, particularly in highly innovative, leading-edge industries such as aerospace, defense, medical and automotive. Such advantages include greater design freedom and customization, removal of tooling requirements, improved product strength and functionality, reduced assembly time for complex components, localized production, rapid time to market, mitigation of wastage, reduced obsolescence, decreased reliance on traditional suppliers, and even the creation of new materials with unique mechanical and behavioral properties. As a disruptive technology, it challenges the foundations upon which much of

“... the technology removes many of the limitations of manufacturing techniques based on traditional subtractive methods” traditional manufacturing understanding, practices and experience is based. From design, quality inspection and even supply chain operations, AM confronts generally accepted notions of manufacturing for the production engineers involved, presenting considerable needed changes in mindset.

For many, overcoming resistance has as much to do with change management as it does with overcoming the unfamiliar technical landscape. Linde is a leader in pioneering gas technology to optimize the additive manufacturing process, overcoming the challenge posed by atmospheric impurities in order to give manufacturers optimal printing conditions. Through leveraging its own technologies and expertise in the area, Linde recently embarked on a research project to advance manufacturing techniques of industrial burners using AM. However, its lessons were far from limited to the actual AM process itself, resulting in an appreciation of the mindset adaptation needed to successfully transition from traditional manufacturing to AM. The burners in question Burners are made from multiple metal components typically produced by subtractive manufacturing methods in which the parts are machined from large masses of premium grade brass or steel. Added to this process is milling the many multi-directional holes to be drilled and brazed, the cutting of threads, nozzle tips to be screwed and welding of other connections. The use of burners is a critical operation for various process industries and they are often tailor-made for the specific application, requiring up to 20 components or more. The burners must also ensure an even, homogeneous gasworld.com/specialfeatures

flame distribution, requiring highly skilled manufacturing. Such customization and specialist proficiency can make the end-to-end process of manufacture complex, expensive and lengthy. For the Linde AM research project, the burners in question were Linde’s own LINDOFLAMM® acetylene burners for pre and post-treatment of welded components, though theoretically the process steps and learnings could be applied to other burners for varying applications and industries. While reduced labor costs, production time and wastage were key goals, it was recognized that the AM process could enable additional, highly valuable functionality to the burners – for example, facilitating a cooling layer to protect the burner in order to reduce thermal stress. However, this is very challenging to incorporate through traditional manufacturing techniques – and for cooling over curved surfaces, almost impossible. The project The project initially arose out of a goal within Linde to promote AM methods

across its own manufacturing product portfolio. Linde undertook an ideation workshop to understand how it could benefit from the technology – and what adjustments would be needed in order to undertake successful prototyping. One of the most significant adjustments was the idea of a complete redesign of the burner for production in a printing chamber. While the engineering team undertook basic AM training and had the support of Linde’s AM specialists, a key learning was that there is no replacement for direct experience. Adopting a ‘fail fast and learn’ approach, the team operated a series of learning ‘loops’: component modeling via computer aided design

(CAD); component printing; sub-optimal results; back to the drawing board; redesign; try again. One of the early challenges – but also an important learning from the project – was that the original component design was not precise enough and showed microgaps in the model, leading to poor contours and issues with porosity, resulting in leakage of the burner. Through trial and error and further collaboration with the AM team, the engineers learned what specifications and factors needed to be prioritized in AM. Change management While the excitement over AM continues January 2020 • gasworld US Edition | 43

SPECIAL FEATURE | ADDITIVE MANUFACTURING

unabated, on initiating AM production many manufacturers find their early efforts less than optimal. Sometimes it is a lack of understanding of the technology: the wrong AM process or material selected, sub-optimized atmospheric conditions within the print chamber, incorrect positioning or inappropriate post processing treatments. Or that the specific component design was more suited to a conventional technology and not adapted sufficiently to AM capabilities. While there are enormous benefits to be gained from AM, expectations need to be set in terms of the many potential snags and challenges a company may experience to create the perfect part. As manufacturers begin to adopt AM technology, companies need to consider the human challenges beyond the strategic and technical ones. These can include how to develop know-how within manufacturing engineering teams and, perhaps more fundamentally, how to overcome resistance to this innovative technology. AM necessitates a change of mindset on the part of those involved. Until very recently, designers and engineers have been taught to think in subtractional terms. In the voice of one key engineer at Linde, “Our university education to learn engineering via subtractive methods needs to be essentially eradicated from our brains. We need to re-educate ourselves in terms of design.” Engineers now need to take into consideration the limitations of old technical feasibilities and the potential – and also restrictions – of new AMenabled ones. For example, instead of internal geometries of components being created with complex individual parts through intensive assembly processes, engineers can now produce almost all geometries in a single print phase, enabling design of parts according to their function. However, this recalibration in thinking – even among the most experienced and lauded engineers – can take time. As such, it is equally a case of change management as it is about 44 | gasworld US Edition • January 2020

“Engineers need to take into consideration the limitations of old technical feasibilities and the potential – and also restrictions – of new AM-enabled ones” learning new models and approaches to manufacturing engineering. According to one of Linde’s lead engineers, “One of the targets of the project was to make this new way of thinking second nature.” Conclusion Linde has successfully developed an

additive manufactured prototype of its market-leading LINDOFLAMM burners, with the value-added capability of delivering an excellent cooling layer to burner. Next phases of the project include testing of the new prototype burners with customers to ensure they meet exact requirements and reliability, and then scaled-up production for product launch in 2020. Implemented properly, AM can encourage manufacturing engineers to think beyond the boundaries of traditional manufacturing methods to reduce the number of production steps, material wastage, inventory held, and the overall parts needed to be manufactured for assembly. But an implementation framework covering both technical education and change management strategies are needed to make it work. gw

ADDITIVE MANUFACTURING: A SPECIALTY GAS SNAPSHOT As a technology, AM has existed for more than 30 years. But, the explosion in its industrial application has intensified in the past five years. According to Linde, it sees the market development at between 25-30% per year with all main geographic regions participating in the uptake of the process, and the usage of gases being equally important in the powder production, AM machine and post treatment processes. From the very outset of the additive manufacturing process, industrial gases and their enabling technologies play a fundamental role. High pressure argon or nitrogen is used to atomize highalloyed metals into small, uniform spheres of powder particles to create the 'raw' material from which finished parts will be formed. Gases are also vital for

the various laser-based layering processes to 'bind' the powdered metal alloys.Oxygen, and oxygen detection is also used in controlling the chamber environment. Once a component has been produced, it must go through a final step of cleaning to ensure it is ready for market. Parts that have been printed have some rough surfacing and flashing that require smoothing before they are ready for use, and technology to solve this is integral to the entire AM process. Linde’s CRYOCLEAN® Snow, for example, has been designed specifically for industrial surface finishing and produces dry ice particles on demand for cleaning. Solid dry ice particles are created and shot onto a component surface using compressed air for an effective cleaning process to smooth out edges of a finished piece. gasworld.com/specialfeatures

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SPECIAL FEATURE | CRYOGENIC CENTRIFUGAL PUMP SEAL

Who likes a low-down, lousy, leaking pump seal? Part two: How to extend the life of your cryogenic centrifugal pump seal By Keith Hall, Applied Cryogenic Technologies (ACT)

ast month, in part one of this article, we discussed the first three of five simple, yet critical things operators can do to extend the life of the pump seals on the external cryogenic centrifugal pumps they operate: 1. Properly prechill the pump before starting it; 2. Before starting the pump and throughout the delivery, build and maintain sufficient net-positive suction head (NPSH)/sub-cool pressures; 3. Maintain back pressure on the pump throughout the pumping operation. In this second part and final instalment we will discuss: 4. Never let the pump run dry; 5. Keep the pumping system free of moisture, before some advice from experts and some final thoughts. © CS&P | A sealess pump

46 | gasworld US Edition • January 2020

4. Never let the pump run dry The fastest way to ruin a pump seal is to run a pump dry. An operator should never attempt to start a pump when it is dry, nor even while it is cooling down. Not even for a quick instant. And a maintenance person should never “bump” a dry pump, ie., to verify rotational direction (such as when you are connecting up the three legs of power on a 440-volt, 3-phase supply and you want to make sure the electric motor driven pump is rotating in the correct direction to make the pump discharge product). Under any circumstances, before operating, a pump must be cold and the seal lubricated with the cryogenic liquid, or serious damage to the pump seal will instantly occur. Even during normal offload operations, damage to the pump’s seal is caused, for example, when a pump is permitted to run dry at the end of offloading an entire load of product. If the operator is not paying attention, the pump, running at full speed, will lose prime and cavitate as the supply tank nears empty, leaving the seal dry while rotating at high speed. Never, ever, under any circumstance run a cryogenic pump warm or dry, not even for a quick instant! If the operator is paying attention, he will notice the pump discharge pressure gauge needle begin to flicker when the liquid level gauge is showing only

“Before operating, a pump must be cold and the seal lubricated with the cryogenic liquid, or serious damage to the pump seal will instantly occur” a few inches of water column on the differential pressure liquid level gauge. The operator may choke back the discharge valve, open the forced feed pressure build valve, and slow the pump, and be able to off-load a bit more product. But this is done at the risk of running the pump dry – spinning the pump seal dry at high speed, will cause significant wear and can even destroy the seal. The best course of action for the operator is to note the minimum liquid level at which he or she should stop the pump – and do so. The operator may simply slow and stop the pumps, or may partially open the recirculation valve while closing the discharge valve, and then slow the pump to a complete stop. Leaving a small heel of product in the transport trailer or bulk storage supply tank serves to help keep the tank cold until it is filled again. And by so doing the risk of running gasworld.com/specialfeatures

SPECIAL FEATURE

DID YOU KNOW? Did you know that the units of measure for pressure head is “feet of water column” pressure? One foot water column, 1-inch wide by 1-inch across by 1-foot tall, weighs 0.4334 pounds. Thus a one-foot tall column of water, no matter its lateral dimensions exerts a downward force of 0.433 pounds per square inch (psi). The table below shows the respective column heights of water and common cryogens to produce 5 psi.

Regarding the 5-psi sub-cool rule, when converted to head pressure, 5 psi is the same force exerted by a column of water 11.5 feet tall. Since it is less dense than water, a taller column of nitrogen, over 14-feet tall, is required to produce the same 5 psi force an 11.5-foot tall column of water produces. Argon is denser than water and only requires a column 8.6 feet tall to produce the same 5 psi force. At 3.54 pounds per gallon, LNG is very light and would require a column over 27-feet tall to produce the same 5 psi! For your reference a table showing the densities of various common cryogens compared to water is provided below.

THE 5 PSI RULE FEET HEAD PRESSURE EQIVALENTS

COMMON PRODUCT DENSITIES

Pump manufacturers provide pump curves for their various model pumps. Unique head pressure versus flow rate curves are generated for each cryogen at the pump speed necessary to produce the required discharge pressure range and corresponding flow rate range; and given an assumed pump suction pressure (tank pressure is additive to the pump’s discharge pressure capability). From the table below, you gain an understanding that a pump used to discharge different density cryogens at the same head pressure will product vastly different PSI pressure values. 500-feet of head pressure when pumping water results is almost 217 psi. The pump discharge pressure is only 91.9 psi when pumping less dense LNG. In contrast, 500-feet head pressure of argon equals 302 psi! PUMP DISCHARGE PRESSURE EXAMPLE

HEAD (feet)

POUNDS

GALLONS

PRODUCT

WATER

11,547

WATER

8.345

WATER

216.8

LIN

14.366

LIN

6.745

LIN

175.2

LOX

10.132

LOX

9.528

LOX

247.5

8.619

LAR

11.630

LAR

27.189

LNG

3.540

LNG

ETHANE

21.210

ETHANE

4.538

ETHANE

117.9

ETHYLENE

20.327

ETHYLENE

4.735

ETHYLENE

123.0

NITROUS-OXIDE

9.372

NITROUS-OXIDE

10.270

NITROUS-OXIDE

266.8

PRODUCT

LAR LNG

PSI

the pump dry is eliminated. Consistently waiting for the pump to lose prime when the supply tank empties before shutting down the pump takes significant life from the seal. 5. Keep the pumping system free of moisture Ice crystals do great damage to pump seals. All cryogenic tanks and piping circuits, including the pump recirculation and discharge circuits must be kept dry. A dewpoint of -40F/C is recommended (-40F & C is the same temperature). Guard again the entrance of moisture into the pump piping circuit.

When you cool down the pump and when you are pumping, frost forms on the outside of the pump and all associated cold piping. After a delivery operation, as the piping warms the frost melts into water. It is very important to install the caps back over the fill hose connections immediately upon removal of the hose. Avoid letting frost form inside piping circuits. The least obvious, but perhaps the most frequent means for the ingress of moisture into piping circuits occurs when an operator leaves the purge/bleed valve open, for example, when venting down and draining the discharge hose.

HEAD (FEET)

500

PSI

302.1 91.9

Just as frost has formed on the outside of the hose and piping, once exposed to the atmosphere, humid air enters the circuit and frost forms inside the piping during the first few minutes after the off-load operation. As the piping warms, like the external frost, the frost that was formed on the internal piping walls melts into water. And then when the Purge/Bleed valve is finally closed, the moisture is trapped inside. For this reason, bleed valves must be closed as soon as all liquid and pressure have been purged from the circuit. Always immediately cap the discharge hose connection piping at January 2020 • gasworld US Edition | 47

SPECIAL FEATURE | CRYOGENIC CENTRIFUGAL PUMP SEAL

the end of a delivery, and vent and drain the circuit. Note that these circuits are protected with thermal line reliefs which will prevent over-pressurization of the piping. Additionally, an understanding of how this internal moisture issue occurs illustrates the importance of a thorough purge of not only the piping, but of the dispense hose, before commencing the next delivery operation. When you purge the hose before a fill, you are not just purging air or debris from the hose and discharge piping connection circuit, but also any moisture. Ice crystals do great damage to pump seals. Guard again the entrance of moisture into the pump piping circuit. For many permanent ground-mounted installations, a slight positive pressure dry nitrogen gas purge is applied to the pump seal before the pump cool down sequence is initiated. And the slight purge remains on the seal throughout the off-load operation, and as the pump 48 | gasworld US Edition • January 2020

“The operator needs to keep the pump on the operating curve to avoid cavitation abuse which will damage the pump’s seal”

attentive operator control.” Dilling states that during initial installation of the pump, “the pump needs to be cooled down with liquid before completely tightening the mounts and flanges to avoid piping strain which could cock the seal and cause a premature leak.” Although the pumps have flexible hose vibration dampener sections before the inlet (suction) and after the discharge warms up. If a slight positive pressure ports, these are not meant to compensate of dry nitrogen gas is emitting from a for misalignment. pump seal, it is impossible for moisture to Fit up alignment of the pump in the enter. Purging of the pump’s seal aids in relaxed, chilled down position must extending its useful life. achieved before the pump bolts are tightened down. Advice from the experts Finally, Dilling concludes, “The operator needs to keep the pump on the Shane Dilling, with Cryogenic Industries operating curve to avoid cavitation abuse Houston, a Nikkiso ACD pump service company, says there are several factors that which will damage the pump’s seal.” Sean Hardy, Sales Manager for contribute to extending pump seal life, but in his opinion the most critical are “proper Cryostar USA, points out that “Across our industry, it is widely recognized that pump installation, religiously following mechanical seals represent the largest a thorough cool down procedure, and gasworld.com/specialfeatures

SPECIAL FEATURE

“When any of the installation and operational guidelines are relaxed or omitted, premature wear and damage occurs to the mechanical seal” investment for pump maintenance – in addition to the inconvenience caused due to seal failures.” Hardy also laments that “when pump seals fail prematurely due to incorrect operation, an inaccurate reflection is cast on the reliability and reputation of our equipment. For this reason, we strongly support the good practices highlighted in this article.” Finally, Brannon K. Baskin, Director of Operations for CS&P Technologies agrees that, “Strictly adhering to the industry accepted practices outlined in this article will ensure maximum service life of your cryogenic pump. When any of the installation and operational guidelines are relaxed or omitted, premature wear and damage occurs to the mechanical seal. Continued operation of a cryogenic centrifugal pump with a leaking seal results in accelerated mechanical damage to the pump. Consequently, the customer incurs a repair cost that is triple to that of a standard repair.”

Note, ACD and Cryostar also offer seal-less pumps that are submerged in the cryogenic tank or vacuum-jacketed sump. These pumps are expected to last up to ten times longer than the seal on an external centrifugal pump. But not all applications lend themselves to submerged pumps. CS&P Technologies manufactures patented seal-less magnetic drive cryogenic centrifugal external pumps that eliminate the need for the mechanical seal and feature a pump service life of five times that of conventional pumps. Final thoughts A Pump Cool Down Timer, which locks out the pump, preventing it from being started before it has cooled down for the manufacturer’s prescribed time period, is a strongly recommended feature to have with each cryogenic pump. It may also be worth your time to investigate computerized pump monitoring and control systems which not only assist the operator and perform such functions as auto-stopping when filling certain liquid cylinders and minibulk tanks, but which also monitor the pump to protect it. Such systems monitor key pump parameters, and take action when needed, to protect the pump. Such parameters include controlling proper pump cool down; controlling the 5-psi NPSH/Sub-Cool pressure; monitoring differential pressure to detect the on-set of cavitation; detecting high and low flow

rates; and detecting high and low pump discharge pressures conditions; etc. Making deliveries to fill mini-bulk tanks and liquid cylinders using an externally mounted cryogenic centrifugal pump is perhaps the worst-case service environment for such a pump. Instead of being cooled down once and then off-loading an entire load (a bulk delivery, for example), these systems are cooled down and make deliveries at one stop, then the pump is shut down and warms back up as the bobtail or trailer travels to the next customer, then the pump is cooled down again and the delivery process is repeated many times a day. With trained, conscientious operators, and using computer-controlled systems, the author knows of multiple pump seals that have lasted over seven years in minibulk service. However, a competent operator, trained with a basic understanding of cryogenic principles and the rules described in this article, can do what the computer does... and probably much more. One important asset the operator has that a computer does not, is ears – to listen to the pump to make sure it “sounds” happy. And if the pump sounds happy the boss will sound happy too! gw

ABOUT THE AUTHOR Keith Hall is a member of the gasworld editorial board and VicePresident of Product Development and LNG Sales at Applied Cryogenic Technologies in Houston, TX. ACT designs and manufactures cryogenic transport trailers and other cryogenic transportation and vaporization equipment. The views expressed in this article are those of the author and do not necessarily express the views of his employer. Hall would also like to recognize the contributions to this article by Sean Hardy - Cryostar USA, LLC; Shane Dilling, Nikkiso ACD’s Houston Cryogenic Industries; and Brannon Baskin - CS&P Technologies. Hall can be reached at (281) 888-3884 or keith.hall@appliedcryotech.com. January 2020 • gasworld US Edition | 49

REGIONAL MARKETS | THE MOUNTAINS REPORT

The Mountains Report Incorporating: Colorado, Idaho, Montana, Utah and Wyoming

he Mountains region is the smallest industrial gas market in the US, however it contains the US’ largest independent distributor as well as some growing market segments. The region’s industrial gas market generated revenues of approximately $644m in 2018, up from $555m in 2008, indicating an average annual growth rate of 2% p.a. for the decade. In 2018, the largest industrial gas

50 | gasworld US Edition • January 2020

company in the Mountains region – Colorado, Idaho, Montana, Utah and Wyoming – was Praxair, which accounted for $216m in revenue. The company operated a relatively large number of onsite ASUs in the region, with the largest of these facilities being a 1,400 tpd facility commissioned in Utah. The second largest company was Air Liquide, which commanded a 18% market share, with Linde accounting for revenues

of just over $89m. The rest of the market was made up of Air Products, which commanded a market share of 3%. The remaining 32% of the market ($205.8m) was made up of independent producers and distributors in the region. The sale of packaged gas accounted for the majority of revenues in the region, with 17.8% of commercial sales being generated through this supply method. Bulk liquid sales generated $179m in revenue, with a further $141m being contributed by supply scheme contracts. The majority of industrial gas revenues in the Mountains were accounted for through the sale of carbon dioxide (CO2). Nitrogen sales generated roughly $196m for industrial gas companies, with a further $131m being accounted for through oxygen sales. The rest of the commercial gases market is fragmented, with helium, hydrogen and argon sales being more marginal. The food and beverage industry accounted for the largest value of gas sales in the Mountains, with 25% of commercial sales being generated in this sector. The metallurgical sector accounted for $104m in revenue, with the manufacturing and healthcare industries generating $113m gasworld.com/regionalmarkets

REGIONAL MARKETS

and $67m in sales respectively. The rest of the end-user market is fragment, with no other sector accounting for revenues in excess of $50m. New developments Norco is the dominant distributor in the region, with facilities in Idaho (10), Montana (5), Utah (4) and Wyoming (11). Norco’s NorTECH facility, in the Salt Lake City area, is featured in depth on pages 18-19, and is a state-of-the-art technical and automation center used for training and driving sales. The Northwest’s biggest distributor is looking to keep its automation at the center refreshed and updated in the future, and presents an opportunity for local students and customers to try the latest technology. Norco, which has its headquarters in Boise, Idaho, is the US’s largest privately owned medical, welding, safety and gas supplier. It operates four Utah branches in Vernal, Ogden, Salt Lake City, and a new location in Orem, along with more than 65 other branches in Washington, Idaho, Oregon, Montana, Nevada, and Wyoming. It has two ASUs and a specialty gas lab. Computers Unlimited, developers of TIMS Software for industrial gas and welding supply distributors, last year launched TIMS Contract Campaign Manager, designed to simplify contract price updates for gases, cylinder rent, and hardgoods. The Billings, Montanabased company also unveiled a new application to complement its existing ERP software product, which provides the means to streamline and unify all bulk gas operations. TIMS Bulk Gas Manager is fully integrated with the core TIMS system and streamlines the processes of bulk gas tank installations, forecasting, ordering, scheduling, delivery, billing, and payments. Helena, Montana-based McDantim, Inc. blends gases for beers and other industries across the country. McDantim’s blenders are used to keep beer carbonated and to push it from a keg. McDantim recently introduced the Secondary Tru Regs, intended to solve issues that create concern in beer dispensing.

Commercial Gases Value

Market Share by Gas Company based on a market total of $644m

14%

31%

18% 31%

4% 32%

34%

11%

17%

Nitrogen

Helium

Air Liquide

Air Products

Medical Oxygen

Hydrogen

Praxair

Linde

Industrial Oxygen

Carbon Dioxide

Other

Argon

Others

In Colorado, the booming legalized cannabis industry is a big driver for CO2 and nitrogen, even for companies outside the state. Marijuana legalization revenue now accounts for roughly 3% of the state’s $30bn budget, and in June last year the state announced that it surpassed $1bn in total cannabis-related revenue. Also in June, it was reported Colorado had nearly 3,000 licensed marijuana businesses and just over 41,000 people working in the industry. Fort Collins, Colorado-based Green CO2 Systems supplies, installs, and maintains CO2, nitrogen, blended gas, and equipment systems to restaurants, bars, swimming pools, indoor cultivation facilities, and convenience stores. Green CO2 serves five primary markets: bars and restaurants, microbreweries, indoor cannabis cultivation facilities, convenience stores, and commercial swimming pools. Green CO2 Systems’ safety and storage solutions also work with most cannabis extraction technology and can provide extractors with a reliable CO2 source and safe, compliant working environment. Mitsubishi Hitachi Power Systems and Magnum Development have announced plans for the ‘world’s largest renewable energy storage project’, to be located

in Utah. The Advanced Clean Energy Storage initiative will develop 1,000 megawatts of completely clean energy storage for technologies and strategies in the quest to decarbonize the power grid of the Western US. The consortium plans to hold hydrogen or compressed air in a huge salt cavern in central Utah, which reportedly is roughly one mile deep and three miles across. With five salt caverns already in operation for liquid fuels storage, Utah-based Magnum is continuing to develop Compressed Air Energy Storage and renewable hydrogen storage options. The Future gasworld Business Intelligence forecast models predict growth from 3.4% p.a. in a low scenario to 4.9% p.a. in a high scenario within the 2018-2023 timeframe. Accordingly, the industry in the Mountains is expected to achieve revenues of between $760m to $819m by 2023. gw

MORE INFORMATION For more information on The Rocky Mountains region, and any of the other regional industrial gas markets in the US, or any other markets around the world, contact: intelligence@gasworldcom January 2020 • gasworld US Edition | 51

COMPANY PROFILE | WELDPRO

WeldPro Welding equipment research and development, production and sales service

eveloped and wholly owned by Linlong Limited, Minnesota-based WeldPro holds its focus on the US light industrial welding products market. Launched in February 2017 as a US brand of welding equipment, WeldPro set out with an aim to complement the distribution of the “private label” products that the company provides in the US. Exclusive to the US, WeldPro’s products are developed, delivered and supported by a team of professionals who are experts in the needs of customers. WeldPro’s professionals work alongside customers to deliver productions and solutions for DIY, ranch and farm, construction and the light industrial markets. Linlong Limited holds a history spanning more than 15 years and employs more than 300 individuals globally. Within its first ten years of business Linlong achieved strategic cooperation with customers globally, with demand coming from the US, Australia, South Africa, Russia, and more. It was this increased demand from worldwide clients that meant Linlong had to expand and create new business ventures, such as WeldPro for its US customer base. Although still in its infancy as a standalone brand, WeldPro has already gained a significant foothold in the US. Products The company is currently focused on the “light industrial” welding equipment market (under 250 amps). Serving that market, the company has introduced multi-voltage welding equipment and plasma cutting equipment that accepts both 110v and 220v single phase input. The company is focused on inverter technology in four welding applications:

52 | gasworld US Edition • January 2020

• SMAW (MMA) – offering four machines for 120 amps to 200 amps • MAW (MIG) – offering three machines from 100 amps to 200 amps • GTAW (TIG) – offering a 200 amp ACDC machine which are well suited for Lift Arc TIG • PLASMA – offering two cutting machines at 40 amps and 60 amps Increasing the company’s product recognition, WeldPro has attended multiple trade shows throughout the year. The company was present at FABTECH Mexico, GAWDA Regional, GAWDA National, and most recently FABTECH 2019 in Chicago where they offered live welding demonstrations. Future Even in its short time as a standalone company, WeldPro has recognized a need for expansion in order to both quickly and efficiently serve its customers. To encourage and serve

company growth, WeldPro purchased a large plot of land in Wenling City, China, for a new facility in May 2018. A ground-breaking ceremony took place in December 2018 with completion expected in the second quarter of 2021. The company’s new and modern manufacturing facility will allow for much faster response times to market changes. The “time to market”, generally described as the time from the moment an opportunity is recognized to having products on the shelves and available will be compressed from months to weeks and in some cases days. Speaking to gasworld, during the FABTECH Chicago event, WeldPro said, “The company recognizes that welding has been, is, and will likely remain the most efficient method for joining metals. And though this metal joining technology is a likely constant, the market trends, manufacturing efficiencies, logistics, communications technologies and business practices can change at dizzying speeds.” gw gasworld.com/specialfeatures

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