Wire off board version
Firefly Orbital Welding Machine
Overview
We have designed the firefly welding machine with the end user in mind – a range of innovative features combine to give you a smarter orbital welding machine:
- compact and lightweight design
- self adjusting legs
- intuitive and easy to use operators remote control
- choice in the degree of automation in a retro-fit modular format
- range of communications options to enable integration with all suitable inverters
- simple band clamping system
To find out more about the firefly orbital welding macine, click the drop downs below.
The firefly welding bug is full of innovative features to make your life easier:
- Firefly's self adjusting legs keep adjustment between pipe sizes to a minimum and allow a greater range of pipe sizes to be welded on one set of legs.
- Firefly uses an industry standard IPC controller to enable customisation of software.
- Firefly's state of the art operator's control is ergonomically designed for intuitive operation. Constructed from high impact composites and with military grade switches, firefly's 'workbox' offers a long life and reliability. A hi-visibility display allows ease of parameter identification and operator tolerance.
- Firefly uses a password protected, simple to use touchscreen HMI. Visual programming simplifies the parameter setup - 50 parameter memories come as standard.
- Firefly's lightweight design allows for ease of handling. Health and safety lifting related issues are reduced
- Firefly's simple band clamping system allows fast and effective clamping and removal of the machine to the weld band. A quick release system on the weld band means fast set up times are possible,
- Firefly can be used on a magnetic or vacuum mounted flat track.
- Firefly’s bi-directional capability eliminates the need for separate left and right hand bugs.
- Firefly has a root pass capability without the need for copper or ceramic backing shoes.
- Firefly's linear capability enables it to be used reliably over a greater range of welding applications without the need for modifications.
- Firefly's compact size keeps it close to the weld so that pipe coatings remain unaffected by fitting and removal of the guide band. Firefly's size means it can work in confined areas.
- Firefly has both hard wire and flux core welding capability due to the high torque motor installed, effective feed of both types of weld wire is possible. Firefly also has a TIG capability.
- Firefly's on board monitoring of service schedules enables accurate servicing schedules to be maintained.
- Firefly’s military specification connectors give rugged electrical and data connections prolonging the life of umbilical and remote connections.
- Firefly offers choice – a range of water cooled MIG or TIG torches; wire on board or wire off board models are also available.
- Firefly is compatible with suitable inverters from all manufacturers.
All this combines to give you an orbital welding machine that can fulfil your requirements in the most demanding situations.
| Minimum Weld Diameter* | 8 inches ( 203mm) |
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| Maximum Weld Diameter | Flat (∞) | |
| Maximum Wall Thickness* | 3 inches (75mm) | |
| Maximum Oscillation Width | 2 inches (51mm) Independently adjustable in 0.001 inch (0.01mm) increments | |
| Dwell Time | 0 - ∞. Independently adjustable in 0.01s increments | |
| Travel Speed* | 0 - 270 inches (0 - 6858mm) per minute | |
| Wire Capacity* | 0.8 - 1.0 -1.2 mm flux core or hard wire width | |
| 5kg spool | ||
| Machine Weight | 16kg gross, 11kg net | |
| * Denotes standard features. These can be changed subject to requirement. | ||
The Firefly system has been tested to comply with the following welding codes:
American Society of Mechanical Engineers (ASME)
ASME IX (ASME 9) – Process Pipework Code.
ASME B31.3 – 2010 Process Piping.
ASME B31.8 – 2010 Gas Transmission and Distribution Piping Systems.
British Standards
BS4515-1-2009 - Specification for Welding of Steel Pipelines on Land and Offshore.
BS2633:1987 - Specification for class I arc welding of ferritic steel pipework for carrying fluids.
BS2971:1991 - Specification for class II arc welding of carbon steel pipework for carrying fluids.
National Grid T/SP/P2 - Specification for process welding of steel pipelines on land and offshore.
National Grid T/SP/P1 - Specification for the welding of steel pipe for distribution systems and installations (operating at pressures below 7 bar).
American Petroleum Institute
API 1104 - Welding of pipelines and related facilities.
Australian Pipeline Standard
AS 2885-2 (2007) – Pipelines gas and liquid petroleum – Welding.
- The firefly orbital welding machine
- The operator remote control
- Starter kit – spares kit and operator tool kit
- High impact carry case
- Gas Box
- Service manual including recommended spares list
- Operator Manual
- Free access to our helpline for one month after delivery
- Free product familiarisation (two days) for up to one technician and one weld supervisor to take place at IPWL or on-site (subject to travel costs)
- HMI technician/programmer's remote (minimum of one required per customer)
- Memory Card for parameter backup
- Band system for all standard pipe sizes
- Custom band system for unusual pipe sizes
- Track based system for large vessel or custom welding projects
- Full spares kit
- Service manual on CD
- Service manual for HMI permanently stored in the technician’s remote for easy access by technician
- Tear-proof hardcopy service manual
- Custom modifications to the base model where applicable
- Annual inspection and service
Firefly offers choice in the degree of automation, from a semi-automatic machine to a fully automated system. Firefly is modular and scalable – a range of software and hardware options means Firefly can adapt to suit your changing requirements.
- The addition of a seam laser will enable automatic weld seam tracking, automatic torch height adjustment and the ability to profile scan the weld
- A spot laser will give a simple but accurate automatic torch height adjustment
- Varying degrees of control of inverter communications - from simple arc switching to full analogue or digital options
- Communication protocols can include RS232, RS485, DeviceNET, MODbus, PROFIbus, CANbus, ethernet or other fieldbus formats
- Sector control and job programming; customisable sectors to give the maximum flexibility and repeatability to parameters
- Data logging for enhanced traceability, analytical purposes, documentation or ISO compliance
- Enhanced security features
- Connectivity to allow downloadable software updates and remote assistance
- Vertical oscillation capability for fillet weld applications
- Blade style control system to facilitate fitting of enhancements
