HALDEN Long-Pipe Cladding Solution
TIG Overlay Pipe Cladding Station for Oil and Gas
A hot-wire TIG inner-wall cladding station for pipes up to 12.5 m long, using hollow-chuck workpiece rotation and a guided welding head to deposit corrosion-resistant overlay in the 1G position.
Overview
Oil and gas line pipe, forged tube and long-bore CRA overlay
A long-pipe inner-wall cladding workflow in which the workpiece rotates in a hollow chuck while a guided, water-cooled welding head travels through the bore. Final capacity must be confirmed from the finished internal diameter, pipe length, weight and required overlay procedure.
System
Long-bore cladding workflow
1. Load and align
Support the pipe on adjustable rollers and align it with the hollow-chuck rotation axis.
2. Position the head
The guided welding head enters the bore while the power-source carriage follows to limit cable length.
3. Rotate in 1G
The pipe rotates while the torch remains in a controlled welding position with AVC tracking.
4. Inspect each stage
Apply the buyer-approved WPS, layer inspection and final machining/chemistry checks.
Main source-listed subsystems
| Subsystem | Reference Configuration | Function |
|---|---|---|
| Workpiece handling | Hollow chuck, welding swing mechanism and adjustable roller frame | Rotates and supports long cylindrical workpieces |
| Welding-head guidance | Rail / wire-rope pull and guide arrangement | Positions the torch through the internal passage |
| Motion and control | PLC, servo control, HMI and AVC | Coordinates travel, rotation, arc length and recipes |
| Cooling | Forced circulating water-cooled torch | Supports extended welding cycles |
| Monitoring and protection | Real-time parameters plus source-listed fault detection | Supports operator response and machine interlocks |
Technical Parameters
Source data preserved for technical confirmation
Conflicting or ambiguous entries are retained instead of silently corrected.
| Item | Reference Specification | Technical Meaning |
|---|---|---|
| Model number | PCS-TT-I-D | Source identifier; final HALDEN model requires confirmation |
| Welding process | Automatic hot-wire TIG / GTAW | Internal corrosion-resistant weld overlay |
| Deposition rate | 1.3 kg/h listed in Basic Info. | Source-listed reference; actual rate is WPS- and geometry-dependent |
| Power-source type | DC inverter | Source-listed process power type |
| Welding-current range | 5–450 A | Main TIG current range |
| Main-source duty cycle at 40°C | 450 A at 80%; “420A 100A” also listed | Second entry is inconsistent and retained verbatim |
| Hot-wire current | 5–200 A | Hot-wire heating range |
| Hot-wire duty cycle at 40°C | 200 A at 60%; 100 A at 100% | Source-listed hot-wire loading |
| Open-circuit voltage | 80 V | Source-listed OCV |
| Input voltage | 3 × 400 V (-25% / +20%), 50/60 Hz | Plant electrical supply requirement |
| Input power | 80 kVA | Source-listed connected load |
| AVC accuracy | ±0.2 V | Reference arc-voltage-control accuracy |
| Recommended peak current | 150–280 A | Starting process window; WPS-dependent |
| Overlay diameter | φ130 mm after cladding to φ1000 mm | Confirm finished ID and torch clearance from drawing |
| Maximum overlay length | Up to / ≤12,500 mm | Reference long-bore working envelope |
| Loading capacity | 10 metric tons | Source-listed workpiece capacity |
| Wire diameter | 1.2 / 1.6 mm | Consumable-feed configuration |
| Tungsten diameter | 3.2 mm (4.0 mm optional) in Basic Info.; 4.0 mm (4.8 mm optional) in detailed table | Conflicting source entries; confirm against current range |
| Single-layer thickness | 1–3 mm | Source-listed deposited thickness per layer |
| Gas flow rate | 12–20 L/min | Reference shielding-gas flow |
| Arc starting | HF / contact | Source-listed ignition modes |
| TIG power source | EWM TETRIX 452 DC Ethernet/IP HF unit | Reference configuration; equivalent/current configuration to be contracted |
| Hot-wire source | EWM TETRIX 200 Hot Wire | Reference hot-wire configuration |
| Display | 5.7-inch Chinese/English display | Real-time parameters and operator control |
| Torch cooling | External constant-temperature circulating water cooling | Supports long-duration welding |
| Inverter cooling | Air cooling | Source-listed power-source cooling |
| Safety / fault detection | Short circuit, over-temperature, over-current, over-voltage, water shortage, gas shortage, power error, arc failure and servo error | Listed machine protection and diagnostics |
Materials and Applications
Source-listed pipe families
| Category | Listed Examples | Review Requirement |
|---|---|---|
| Line-pipe steels | 5L Gr.B, X52, X60, X65 | Confirm exact API grade, wall thickness and sour-service requirements |
| Stainless and CrMo pipe | Stainless steel and CrMo steel | Confirm grade, preheat, interpass and PWHT requirements |
| Workpiece forms | Hot-rolled pipe, seamless pipe and forged tube | Check straightness, bore access and surface condition |
| Overlay consumables | Buyer-specified CRA or wear-resistant wire | Select from service chemistry and WPS; do not infer alloy from pipe grade |
Quality and Inspection
Define acceptance before machine configuration
| Inspection Item | Reference / Buyer Input | Engineering Effect |
|---|---|---|
| Layer inspection | Source lists 100% UT by layer and 100% PT | Confirm code, method, coverage and acceptance criteria |
| Procedure qualification | Buyer-specified WPS/PQR/WPQ and governing code | Controls trials, heat input, records and documentation |
| Overlay chemistry | PMI or chemical analysis after machining when required | Controls deposited thickness, layers and dilution |
| Ferrite / hardness | Specify when applicable to alloy and service | Affects consumable choice and heat-input window |
| Final geometry | Finished ID, clad thickness, machining allowance and surface finish | Defines starting bore and total deposited metal |
Buyer-Critical Information Before Quotation
Send these details with the RFQ
| Information Needed | Examples | Why It Matters |
|---|---|---|
| Pipe or vessel drawing | ID/OD, length, straightness, end preparation, access openings | Defines torch reach, chuck, guide and roller arrangement |
| Workpiece weight | Maximum and minimum component weight | Confirms rotator and chuck loading |
| Base material | 5L Gr.B, X52, X60, X65, stainless or CrMo grade | Controls WPS, heat input and preheat requirement |
| Overlay alloy | ERNiCrMo-3, stainless, nickel alloy or specified wire | Defines wire feeder and procedure trials |
| Finished overlay | Thickness after machining, allowance and chemistry depth | Controls deposited layers and cycle time |
| Production target | Parts per shift, annual volume and changeover frequency | Sets automation and fixture requirements |
| Inspection standard | UT, PT, PMI, ferrite, acceptance criteria and governing code | Defines qualification and documentation scope |
| Plant utilities | Voltage, cooling water, shielding gas and ambient conditions | Confirms installation and auxiliary systems |
FAQ
Pipe-cladding selection questions
Is 12.5 m the guaranteed cladding length?
It is a source-listed reference. Confirm usable length against pipe ID, torch design, support arrangement and plant layout.
Is the minimum finished ID 125 or 130 mm?
The supplied pages list both values across related models. The applicable value is shown on this page, but the drawing and final torch configuration govern.
Does the station include preheating?
The source says the listed system is not configured with preheating. Add it to the RFQ if the WPS requires controlled preheat.
Can cycle time be quoted from deposition rate alone?
No. Pipe length, diameter, layer count, stops, inspection, end allowances and changeover all affect production time.
What must be confirmed before ordering?
Workpiece range, finished ID, weight, base and overlay materials, WPS, NDT, utilities, fixtures, monitoring and acceptance testing.
Request a Technical Review
Send your pipe or vessel drawing to HALDEN
Include ID, OD, length, weight, material, overlay alloy, finished thickness, production target and inspection standard.
