These are some other smaller projects I did for AZZ WSI.
The job was to apply a MIG welded overlay repair in an underground pipe at a refinery. My role was to design this grinding head to repair weld defects and smooth small sections for ultrasonic inspection. This unit attached to a delivery system which carried it down the pipe. Cameras and lighting provided the operator a view of the work area. The grinder (a standard 6" angle grinder), could be mounted to grind flat or use the edge to grind on the edge of the disc.
This is a single unit control station for a remote operated weld head. From this station outside containment, a welder could use a weld head mounted on a pipe to apply a weld overlay. This turned out really nice with a black powder coated finish.
Another large mockup. This one simulating the bottom array of heaters under a pressurizer vessel. The job was to replace all the heaters.
Looking up at the heater array. Most simulated heaters are dummies, but certain ones are weld coupons used to prove the weld process to the customer.
Sometimes, the heaters don't just slide out. In that case the core of the heater has to be drilled out. The interior of the heater is a ceramic like material. This is a dust collection unit I made to go between the drilling unit and the heater tube.
This is a welding "test bed" as we called it. It's a multi axis gantry allowing weld development to be performed in various positions relative to gravity.
A closer view of the business end of the weld head. The front end could pivots about the point of weld, so between that and the two axis of gantry motion, it was possible to weld along curved paths.
The subassembly used to rotate the weld front end was always a favorite of mine.
This is a mounting and alignment tool for a weld head used to make a butt-weld on a pipe. The curved portion on the left is in contact with the pipe. I made an improvement to the fine alignment of the cylinder. The base of the round portion is on a spherical bearing. The four bolts on the end can be used to make fine adjustments to get the weld head aligned with the root of the weld prep.