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West–East Gas Pipeline Repair | Integrated | Case Study
> Cases > West–East Gas Pipeline Repair | Integrated Welding & Power for Greater Efficiency
West–East Gas Pipeline Repair | Integrated Welding & Power for Greater Efficiency
2024-12
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ES-5000PLUS Integrated Welding & Temporary Power in Real Pipeline Maintenance

Industry: Oil & Gas / Pipeline
Project: West–East Gas Pipeline

Application: Pipeline Welding, Grinding & Maintenance
Location: China
Equipment: SOFIMO ES-5000PLUS
Solution: Battery-Powered Welding + 5kW AC Power in one

01 Project Overview

This Repair Station supports maintenance and emergency repair operations for the West–East Gas Pipeline.

Traditionally, on-site welding and auxiliary electric tools were powered by large mobile power trucks or fuel generators, with temporary cables connecting separate welding machines and other equipment.

For this project, the SOFIMO ES-5000PLUS Welding Integrated Portable Power Station was deployed in an actual pipeline repair operation to demonstrate the practical use of mobile battery power for pipeline welding, grinding and temporary power during maintenance.

02 On-Site Requirements

The operation involved maintenance work around large-diameter pipe sections, requiring welding and auxiliary tasks to be carried out at different positions around the pipeline.

The main on-site power requirements included:

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Pipeline Welding & Weld Repair

🔧

Grinding & Surface Preparation

🔌

Welding + AC Tool Power

📍

Power Close to the Pipeline

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Relocation Between Work Points

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Sufficient Welding Endurance

03 The SOFIMO On-Site Solution

The project deployed the SOFIMO ES-5000PLUS Welding Integrated Portable Power Station →.

The ES-5000PLUS integrates:

13.69kWh Battery Storage + 10–200A Welding + 5kW AC Power

into one mobile industrial unit.

The unit was positioned directly beside the pipeline, providing welding output for pipe repair while simultaneously supplying AC power for angle grinders and other auxiliary electric tools.

Its industrial four-wheel design allowed the unit to be repositioned as the work location changed. When the repair crew moved from one pipe section to another, the power source could move with them.

Instead of organizing every task around a fixed centralized power source, power could be brought directly to where the work was taking place.

04 Welding Endurance per Charge

The ES-5000PLUS is equipped with a 13,690Wh battery system.

Rather than describing field capability only in kWh, the number of electrodes provides a more practical indication of how much welding work can be supported on a single charge.

Reference Welding Capacity per Full Charge

Electrode Size Approx. Welding Capacity
Φ2.5mm Approx. 486 rods
Φ3.2mm Approx. 242 rods
Φ4.0mm Approx. 143 rods
Φ5.0mm Approx. 87 rods

The unit can be charged in advance and moved directly to the repair area for immediate operation.

For faster turnaround between operations, the ES-5000PLUS supports AC380V charging in approximately 3–4 hours. Charging from AC220V takes approximately 5–6 hours.

Note: The figures above are reference values. Actual endurance varies depending on welding current, electrode type, duty cycle, operator technique and operating conditions.

05 On-Site Operation

SOFIMO ES-5000PLUS was deployed directly inside the pipeline maintenance area during the project.

Soldagem de tubulações

The unit was positioned close to the large-diameter pipe sections, providing 10–200A welding output for field welding and weld repair.

Grinding & Surface Preparation

Angle grinders were used for pipe preparation, grinding and post-weld finishing. The ES-5000PLUS supplied temporary AC power through its 5kW AC output.

Moving Between Work Points

As the repair crew worked around different pipe sections, the unit could be repositioned on site without keeping every operation tied to a single centralized power source.

Multiple Units for Distributed Work

Where different tasks or work points need to operate simultaneously, multiple mobile units can be positioned independently to provide distributed welding and temporary power.

07 Project Results

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Integrated Welding + AC Power Proven On Site

SOFIMO ES-5000PLUS supported both welding and auxiliary electric tools in an actual pipeline maintenance environment, allowing one platform to cover multiple stages of the repair process.

🚚

Mobile Deployment Proven On Site

The unit could be positioned directly beside large pipe sections and relocated between different work points, bringing the energy source closer to the actual point of use.

🔋

Welding Endurance for Field Operations

SOFIMO Welding Integrated Portable Power Stations provided stored energy for continuous field welding, with different electrode sizes allowing the system to support different workloads.

⚡

Distributed Power Deployment

Multiple units can be positioned at different work points, providing distributed welding and temporary power according to the requirements of each operation.

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Reduce On-Site Power Costs

Mobile battery power can be deployed directly at the work point, reducing long cable runs, fuel consumption and large power equipment deployment, helping lower the cost of emergency repair and maintenance operations.

From One Project to More Pipeline Work Sites

The West–East Gas Pipeline Repair project demonstrated the practical application of SOFIMO Welding Integrated Portable Power Stations in a real pipeline emergency repair and maintenance environment.

For pipeline welding, emergency repair, distributed maintenance and operations involving frequent relocation, SOFIMO can configure mobile energy solutions according to the welding process, required workload and auxiliary equipment.

ES-5000PLUS product imageES-5000PLUSSaída nominal de 10-200A/5000W/Capacidade de 13690Wh

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