1Wear & Fusion Technology with Service and Quality

SOLUTIONSNewsletter - Issue 2 - 2009

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

New CastoMIG welding equipment range

Messer World at Essen

SOLUTIONS - Customer Information - Newsletter - Issue 2 - 2009SOLUTIONS - Customer Information - Newsletter - Issue 2 - 2009

development programs. The results are the launch of a new generation of MIG/MAG welding machines, fea-turing not only the latest electronic innovations, but also the innovation of simple custom programming of parameters, tailored to individual customers business. The other inno-vation is in welder training, a tradi-tion part of our service. Innovation is recognised by most experts as a sure way to come out stronger from the recession, so take the time to talk to us and benefit from our innovations.

Good reading

Dr. Gary HeathVP Marketing and Product Management

2 SOLUTIONS - Customer Information - Newsletter - Issue 2 - 2009

EditorialContent>>

R&

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Modern R&D approach to remain the most Innovative

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Oil & Gas: HARDFACING or WEARFACING for HARDBANDING ?

Power & Waste incineration: Boiler repairs specialist

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Impressum Editor >> Dr. Gary Heath

E-mail >> gheath@castolin.com

Contributors for this edition >> Bengt Larsson, Dr. Gary

Heath,Patricia Nigg, Tony Nogaredes

For more information or contact addresses, please visit

our websites www.castolin.com or www.eutectic.com

Together with the Messer World at Schweissen & Schneiden 2009

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6 New CastoMIG range:The new step switch generation

Dear Reader,

As we all continue to witness one of the most severe economic down-turns, we also see that certain com-panies and businesses continue to prosper through a focus on innova-tion, rather than just cost cutting. Castolin Eutectic is an established repair and maintenance company with a global reputation for Service, Quality and Technical Innovation.In this edition, the importance of Technical Innovation for Castolin Eutectic and its customers is under-lined. Innovation is key to bringing new products and technology to our customers, to help them become more competitive and also find new markets. However, innovation can be implemented also in business proc-esses, such as the Research & Devel-opment process itself. The tradition-al route for product development is the shiny Corporate R&D Central Laboratory, but even here, this can change due to the recent advances in networking and communication. Castolin Eutectic is playing an inno-vative role here and has developed such a global decentralized R&D structure.The new innovative products devel-oped over the last few years are find-ing success in the Oil, Power, Waste, Steel and Agricultural industries, dramatically improving wear per-formance and operational perform-ance.Castolin Eutectic is known as an expert in developing new materials and consumables. Ultimately, how-ever, it is the deposited coating that gives the customer results and the coating performance is also depend-ant on using the optimal equipment parameters and having skilled and trained welders. Both aspects have also been a focus in our general

Improve your welders skills with the best Castolin Eutectic technicians

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The importance of INNOVATION for the future

3Wear & Fusion Technology with Service and Quality

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Modern R&D approach to remain the most Innovative

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

Thanks to their daily contact with customers, our technician experts encounter every year new parts sub-jected to wear phenomena at your plant. Our answer to customer prob-lems consists of: Products, processes, applications,

and production engineering 700 Sales staff with technical

degrees Core team of 30 Development

people employed in 12 countries 9 PhDs working on various

projects 4-5 patent applications per year

Our R&D is decentralized involving: Paris, Ireland, Italy, Poland, Austria, Switzerland, USA, Canada, Japan, In-dia and Brazil. The advantage of this modern R&D structure and progres-sive communication is that excellent researchers around the globe can be fully utilized, without having to up-root them from a creative environ-ment.

Bringing theory to reality: some new successful applications One of our innovations is in the

field of nanotechnology. Although it is constantly being hailed as the driving force for the future, nanote-chnology remains very expensive and is found mainly in the fields of biomedical, electronics, communi-cations, etc. Castolin Eutectic have been able to convert this laboratory scale material into an affordable welding product and traditional in-dustrial customers have been sur-prised that they can already benefit today from this new science with a NanoAlloy® range including: weld-ing and brazing consumables, wear-plate, CastoTube® and powders. Hardbanding solutions for the Oil

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

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

alloys for boiler repair: Castolin Eu-tectic was amongst one of the first companies to recognise and offer nickel based self fluxing alloys as a wear and corrosion resistant coat-ing for boiler tubes in the 1980s and have developed a considerable repu-tation and experience with these al-loys. A novel high molybdenum, high silicon alloy was developed and pat-ented for severe corrosive environ-ments. This solution combined the inherent properties of such fused coatings (such as diffusion bond-ing, zero through porosity) with improved performance over even welded 625 type alloys. For more information about these products, please visit the www.castolin.com website.

Example of modern R&D organisation

Stringent quality control

France

CustomerUniversity

Ireland

Corporate

Headquarters

R&D

Poland

Germany

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The world demand for energy is escalating. Two of the few major energy sources are Oil & Gas.In order to extract these energy resources drilling must be used to reach the underground reser-voirs. Major oilfields are found on both land (onshore) and under the sea bed (offshore).When drilling for Oil & Gas, a drill bit is used attached to a drill pipe tools with diameters from 1000 mm down to 100mm. The largest hole is at the top of the

well which must be sealed as the steps get deeper. This is called well construction. The well is sealed from collapsing by using a steel tube with cement to fix it to the well formation. This steel tube is called the casing which has several functions. The major one is to seal off the well from its high pressure. In “open hole” drilling the tools are exposed to the severe wear from the forma-tion, after setting the casing. The current depths of wells are from 3,000 m to 10,000 m deep.Hardbanding is a very established name for the wearfacing welding process used in drilling to mini-mize wear on casing and drilling tool joints in order to reduce op-erational costs associated with Oil & Gas production. It involves the application of a wearfacing material on the drill tool joint. The process is done by approved hardbanding applicators for OEM drill pipe producers and drilling companies. Trio OilTec Services have executed hardbanding in the Norwegian market for more than 8 years. Due to excellent co-operation between Trio OilTec Services and StatoilHydro, there has been a very successful devel-

Oil & Gas: HARDFACING or WEARFACING for HARDBANDING ?

opment and use of new, innova-tive alloys such as OTW-12, OTW-16 wires and also special coating (MX5). Today Statoil- Hydro ap-proves OTW-12, OTW-16 and the MX5 coating for drilling. In the development of these prod-ucts, TRIO, took this task very seri-ously, and uniquely in the indus-try constructed its own dedicated hardbanding Wear test Machine and also full scale automated Hardbanding welding facility.With Trio’s integration into the global Castolin Eutectic organi-sation, there is an extension its product offer outside of Norway.

Schematic of wear sources

Force

Drillpipe

Casing

Drill stingtension

Tooljoint

Critical zone

Wear & Fusion Technology with Service and Quality

Power generation boilers are large and expensive installations which can suffer enormously from wear caused by corrosion and erosion, aggravated by very high tempera-tures. The exact type of wear ex-perienced varies from one part of a boiler to another and is influ-enced by the overall design of the boiler and the type of combusti-ble fuel. Castolin Eutectic’s protective coatings significantly extend the service life of worn boiler compo-nents making them last longer than uncoated new parts. Castolin Eutectic protective coatings are a more cost effective solution than replacement of the worn parts

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with new ones and provide direct savings in materials and valuable reductions in downtime. Additionally, Castolin Eutectic offers the widest range of coat-ing products so protection can be tailored against the specific

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Soot blow system

Separator

Control valve repairStop valve repair Boiler Tube panel

Control valve repairRaw coal feeding screw

Slide valve

Power & Waste incineration: Boiler Repairs Specialist

combination of wear phenomena found in each part of every boiler. This work can be achieved on-site or in our CastoLab® Services workshops.

Below some of the typical repairs for coal fire boilers:

Arc wire spraying of boiler tube panels

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New CastoMIG range:

The new step switch generation

Our multi adaptable CastoMIG welding equipment range is used for applications which impose special requirements:

We want to make your life easier for example with the ingenious four-roller drive unit with repro-ducible pressure settings and tool-free, changeable drive roll-ers. But also with the programme table fi xed to each CastoMIG CP welding unit which helps you to select a suitable standard pro-gramme.

Smart details make working easier

Features: Welding parameters synergic

adjustment

for the CP version

“CastoMized” synergic programs

User-friendly selectionof the parameters

Reliable wire drive system for precise and constant wire feeding

Precise and constant Arc ignition

Excellent arc stability

Equipped for tough environment with :

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

Pre and post gas adjustments

2 step and 4 step welding

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

Demonstrated at

High welding capacity com-bined with outstanding bead quality

High alloy steel with faster deposition rate wires (EnDOtec®)

Specific welding parameter settings

program-controlled welding operations

Tough conditions

The Unique «CastoMized programs» Solution

Selecting the optimum

Consumable and parameters

have never been easier. In

just 3 simple steps you can

achieve success:

1. Discuss your requirements

with one of our Sales peple

2. Let us provide samples of

what we can achieve

3. Have your machine deliv-

ered and pre programmed

with the optimum settings

The Unique «CastoMized programs» Solution

Selecting the optimum

Consumable and parameters

Innovative Solution

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ceOur mission is to develop ap-plications and solve customer problems. Depending on the cus-tomer’s request, we can perform the work for him in our approved CastoLab® Services workshops or transfer this knowledge to him.Since the mid 1930’s Castolin Eutectic has offered industry a range of specialised training courses, which covers all aspects of the welding processes, e.g. MMA, MIG, TIG, brazing, solder-ing and thermal spraying.

Spreading knowledgeOur commitment to excellent customer service means provid-ing first-class training available globally to customers and end-us-ers. Castolin Eutectic has trained thousands of technicians from all over the world and training centres have been established in most countries with training programmes offered in a wide variety of languages. We offer a wide range of courses starting from one-day welding courses to full week maintenance seminars. From welders to engi-neers, researchers to managing directors - there’s no limit to the range of technical and profes-sional people trained by Castolin Eutectic in all aspects of indus-trial cost-savings, wear, repair and preventive maintenance.

Industrial seminarsWe provide solutions to all of the major companies operating in in-dustry with global industrial pro-grams for steel, cement, mining, power, oil, waste & recycling, etc. Supporting maintenance techni-cians in their daily challenges is

Improve your welders’ skills with the best Castolin Eutectic technicians

our routine so training courses in specific industries are also con-ducted where similar language groups can learn and exchange cost-saving solutions.Depending on your requirements courses can comprise 100% prac-tice or theory, or a mixture of both and are available in a writ-ten form for several product fam-ilies and technologies.

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

Coating training with SF-Lance

Diploma for MMA welding training

Industrial seminar in Paris specific for Cement plant

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Together with the Messer World at Schweissen & Schneiden: 14th - 19th of September 2009 in Essen

SOLUTIONS - Customer Information - Newsletter - Issue 2 - 2009

Participating to:

Fair

Offshore Europe 2009 Aberdeen, UK8th - 11th September 2009Offshore Europe Oil & Gas Conference & Exhibition

www.offshore-europe.co.uk

Messer World

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

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

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

Fair

EcomondoRimini, Italy28th – 31th October 2009Waste & Recycling Exhibition

www.ecomondo.com

Castolin Eutectic

Our philosophy “Saving costs through innovation” will be illus-trated with special live wearfacing

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

Connect to the CastoLab® Services section on our website www.castolin.com or www.eu-tectic.com to discover our brand new CastoLab® video!

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

New CastoLab® Services video onlineConnect to the CastoLab® Services section on our website www.castolin.com or www.eu-tectic.com to discover our brand new CastoLab® video!

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

In UK, 2009 started with many changes and investments. As you can see from the picture, the fi rst investment was in the moderniza-tion of the offi ces and customer reception areas. But there was

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