Programmable SAW Nozzle Welder

Programmable SAW Nozzle Welder (Circle Welder) is an automated circumferential Submerged Arc Welding (SAW) system designed for welding nozzles/pipe with diameters ranging from 100 mm to 1,600 mm. Typical industries include pressure vessel fabrication, boiler and steam drum manufacturing, petrochemical equipment, heat exchangers, reactors, and other heavy process equipment.

Applications

• Pressure vessel shell-to-nozzle (pipe) welds
• Elliptical dished head-to-nozzle (pipe) welds
• Spherical dished head-to-nozzle (pipe) welds
• Centered / orthogonal nozzle connections
• Eccentric / off-center nozzle connections
• Internal and external nozzle welds
• Manway neck-to-shell and manway neck-to-head welds
• Multi-layer and multi-pass heavy-wall nozzle welds

Scope

• Included: SAW Nozzle Welder, CNC Controller &  Spare Parts
• Not included (available at additional cost):  Irizar Welding Manipulator, Lincoln Power Source, Lincoln Welding Head, Lincoln Welding Controller, Semi-Automatic Flux Delivery & Recovery System, and Cables (control, ground and power cables)

Model PNW-800

A compact, self-supporting SAW welding system designed to mount on the nozzle with a 3-jaw chuck. The PNW-800-NM does not require a welding manipulator, making it a practical solution for automated welding of small to medium diameter nozzles.

Nozzle Diameter Range: 200–800 mm
Nominal Pipe Size: NPS 8"–30"

Standard NPS Sizes:
8", 10", 12", 14", 16", 18", 20", 22", 24", 26", 28" and 30"

Specification:

Model PNW-1600

A heavy-duty SAW welding system designed for small to large diameter nozzles. The PNW-1600 can be mounted directly onto the nozzle with a 3-jaw chuck or A heavy-duty SAW welding system designed for small to large diameter nozzles. Desing to mount on the boom end of a Welding Manipulator.

Nozzle Diameter Range: 100–1,600 mm
Nominal Pipe Size: NPS 4"–60"

Standard NPS Sizes:
4", 5", 6", 8", 10", 12", 14", 16", 18", 20", 22", 24", 26", 28", 30", 32", 34", 36", 38", 40", 42", 44", 46", 48", 50", 52", 54", 56", 58" and 60"

Video

Specification:

Standard Features 

Advantages:

• Consistent, high-quality welds
• Increased welding speed and productivity
• Reduced dependence on manual welding skill
• Better control of distortion and heat input
• Improved repeatability for production work
• Reduced repair rates and lower fabrication costs

Features:

• The CNC Flange & Nozzle mounts directly onto a welding manipulator boom end.
• Automatic laser measurement, centring, and real-time tracking of the nozzle outside diameter throughout the welding process.
• Multi-axis motion control with an easy-to-use touchscreen interface.
• Teaching Function: Records reference points and compensates for groove-cutting and nozzle fit-up deviations by automatically correcting the welding path, helping maintain consistent weld quality and reduce defects.
• Automatic welding is performed by entering the vessel or dished-head dimensions, nozzle dimensions, and groove angle into the touchscreen.
• Segmented welding-speed control allows separate travel speeds for uphill and downhill welding, improving weld-bead consistency and quality.
• The arc start point, arc stop point, and welding direction can be changed at any location, allowing both forward and reverse welding.
• Performs nozzle welding from either inside or outside the vessel. Internal welding is possible when the vessel inside diameter exceeds 3,000 mm, and sufficient operating clearance is available.
• Wireless remote control allows real-time weld-path correction, torch positioning—including lift, retract, and jog functions—welding-speed adjustment, and remote arc start and stop.
• Performs submerged arc welding of eccentric nozzles on tanks and dished heads, when the weld-bead inclination is less than 12° from horizontal, and the vessel outside diameter-to-nozzle outside diameter ratio is more than 3:1

Initial Screen: 

Choose Workpiece: 

Pressure Vessels Parameters: 

Head Parameters:
 

Teaching Screen:

Monitoring Screen:

Parameters Screen:

Notes:

Our company recommends consulting a Certified Welding Engineer (CWEng) to design the welding procedure in accordance with the relevant national and provincial codes and standards. In Canada, CWEngs are certified by the Canadian Welding Bureau (CWB). In contrast, in the USA, they are accredited by the American Society of Mechanical Engineers (ASME), the American Welding Society (AWS), and the American Petroleum Institute (API), among other prestigious organizations worldwide. A CWEng is responsible for designing and selecting appropriate welding parameters, including plate beveling, wire and flux specifications, amperage, voltage, and welding speed, among other factors.

The CNC SAW Flange & Nozzle Welder must be operated by an experienced Submerged Arc Welding (SAW). Certification is required for this trade, meaning the operator holds a journeyperson certification. Irizar rental facility is available in Wetaskiwin, AB, Canada, where customer welder operators can familiarize themselves with the equipment and obtain coupons for qualifying Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), and Welder Qualification Tests (WQT). 

Delivery Time