Although automated pipe welding is a niche industry, there are many different types, styles and features of automated pipe welding machines on the market today. In this article we will discuss how to chose the right style of machine for your needs and application, how to select a machine once you know the type of machine you need and finally important considerations when selecting a partner to purchase the machine from and have support your equipment post-sale.
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How to Chose the right Type of Automated Pipe Welding Machine
The first thing to think about is what do you need this automated pipe welding machine to do? Are you primarily wanting to automate your pipe welding in the shop or out in the field? Often times the biggest gains in production can be had in the pre-fabrication phase or in the shop before the piping is taken out to do the field to be welded in place. This is where you can make some serious ground by automating your spool welding in the shop with an automated pipe spool welding machine. These welds are typically elbows, straight runs, flanges and some T-joints. In the past even a straight run pipe weld could be challenging to automated because everything was program-based. That meant that you would manually program a welding schedule into the automated pipe welding machine, make a weld and test your results. You would then make welding parameter adjustments based on your welding results. Once you had a program that worked you could repeat the process. The challenge we always ran into was that pipe is never perfectly round, especially the larger bore pipe and no two fitters ever beveled and tacked the pipe together the exact same way. This created problems with these automated pipe welding machines that were program based because any new variable (like uneven alignment gaps due to out of round pipe not lining up evenly) would cause the same welding program to fail since the machine had no way of adjusting to these varying alignment gaps. Then the next innovation was to incorporate a joystick to manually move the torch around. This was good for coving an uneven gap but what about uneven bevels that create an uneven wall thickness or just a variation in the pipe wall thickness as most pipe is not perfect on wall thickness? Well then you need to adjust amperage, travel speed and oscillation speed not just move the torch around. There also was the problem of operator skills. It became a whole other skill set for operators to learn and get skilled at using the joystick on these automated pipe welding machines. Not only that, the operator had to be paying close attention to the screen all day everyday which many operators are not going to do consistently. What is the result? They make mistakes and welds fail costing you a ton of time and money.
In comes the advent and development of Ai. Ai is a new form of computing in which the computer can essentially make decisions, reach conclusions and scan and process information faster than ever before. The Rotoweld automated pipe welding machine uses a proprietary in-house Ai software to allow the machine to constantly analyze the weld puddle, bevel and fitup gap and make real-time weld parameter adjustments simultaneously to ensure that a perfect weld is made even with inconsistencies in gap alignment, material, bevel quality and environment. This is the ultimate solution if you want to automate your in-shop pipe welding for pre-fabrication. For more info on this machine click here. This automated pipe welding machine will undoubedly boost your produciton and weld quality if you are looking for gains for your inshop welding. This way your skilled welders can spend their time making the more challenging in-position welds that can not be welded on a roll out system like the Rotoweld. The Rotoweld uses a chuck and welds in 1G, so some of your welds that require welding in position will still need to be done by a skilled welder. We are not trying to put welders out of a job rather we are filling a gap in the skilled labor market so that the skilled welders that we do have can spend their time making the welds that cannot be automated easily.
But what if you are looking to automate your field welding operation? We have solutions for this too and this will take us to our orbital welding machines from Magnatech. These orbital welding machines perform both MIG and TIG depending on the machine and can make position welds. However, unlike the Rotoweld, these machines will require a precise bevel and fitup in order to consistently produce x-ray quality welds. Fortunately we have best practices and now some new technology to help you achieve consistency with your orbital welding operations. First off for pipe welding we more often than not will recommend the Magantech brand. Magnatech has been a leader in the US orbital welding market for decades and their programming software is bar-none. Magnatech features an auto-programming mode for TIG wire-fed pipe welding. This is no easy feat, TIG welding is a very precise welding process and the welding parameters needs to be accurately controlled and adjusted. Magantech has done the hard work to allow their orbital pipe welding machine to automatically create welding schedules in minutes. This saves the operator hours and hours of manual programming and testing welds. Just plug in the pipe OD, wall thickness and material and the Magnatech Pipemaster 515 or 516 will produce a base weld schedule.
Most of the time especially on small bore pipe the base program will work perfectly on the first run. There will be materials and pipe sizes that will still require some fine tune adjustments to be made to the base program that the orbital welding machine generates in order to get the weld to look how you want it to. This is a great solution for in-position and welding in the field if you want to automate this process. While slower and more program intensive than the Rotoweld you can still see very significant gains in production and weld quality if you are willing to commit to the orbital welding process. In order to create a repeatable orbital pipe welding process you will need to incorporate a precise beveling process like the tool in the below picture which we offer for rent and sale. These are simple beveling tools that will create a consistent and precise machined bevel for your orbital welding machine.
Important Considerations when Selecting an OEM or Distributor to Purchase From
Many OEMs use a distributor network nowadays to distribute and support their equipment locally. This can be a great thing to allow you more hands-on local service and support for your new equipment. It is important to consider however the service capabilities of the OEM that you are selecting. Local service providers can be helpful but often for warranty repairs and quality work and know-how the OEM technicians are the best to have service your new equipment. A local distributor being available 24/7 for emergency support is critical. Be sure to ask your distributor or OEM if the price you were quoted includes installation and training? Often times they will not quote the installation and training because it is very expensive and they want to appear to be cheaper than their competitors who quote all-in costs. Anytime GSI quotes a new machine we include the installation and training so you are not going get any surprise bills after the machine is sold and installed. Another question to ask is are there ongoing software subscription fees? These can often cost you thousands per month, GSI does not charge any ongoing subscription fees for our machines. Also be sure to ask if you need emergency support does your local distributor charge call out and travel fees? GSI will never charge you a call out or travel fee for training or support 24/7. If you are purchasing or renting orbital welding equipment is your provider available 24/7 for emergency support and will they help you with weld schedule development free of charge? These are all important considerations when renting or purchasing automated pipe welding equipment.
We hope this helps you make a sound decision on your automated pipe welding or orbital welding equipment, as always reach out to GSI Machinery 24/7 for questions, demos, rentals, training or help.
The welding equipment used in pipeline welding is highly varied, as different types of pipelines require different welding techniques. Due to the specific challenges posed by this type of welding and its crucial role in global infrastructure and economy, pipeline welding is considered a distinct profession within the welding industry. Consequently, it necessitates the use of a wide range of specialized tools and equipment to facilitate the safe and efficient joining and repair of pipelines.
Pipeline Welding Challenges
Pipelines are like the veins of our planet, and each region has its own pipeline structures transporting natural gas, oil, water, and other vital infrastructure. Like veins in our bodies, pipelines are scattered everywhere. And very often, they are laid in uninhabited terrain with harsh environments, which makes a pipeline welder's job a challenge on its own.
Any pipeline failure can lead to dramatic economic and environmental consequences. So, weld quality is crucial for pipeline integrity and environmental safety. Pipe welding is sometimes done manually but often employs automated welding equipment to improve weld quality.
Unlike horizontal plate welding, pipe welding requires making circumferential welds around the joint line. The welding process is far more challenging because you must keep the torch/electrode angle consistent as you travel along the joint. In addition, operators must reposition themselves as they travel around the pipe, which takes time and can put welders in uncomfortable welding positions out in the field. Welder fatigue, harsh environmental conditions, the challenge of maintaining the same arc travel angle, keeping an even joint gap, and many other challenges make pipe welding a complex job that requires specialized welding equipment.
Different Types Of Pipelines
The oil and gas industry primarily relies on pipelines for gathering, processing, and distribution. However, many different pipeline types are involved in these processes, and they all have unique challenges during their production.
There are five main types of pipelines:
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- Gathering Pipelines
- Transmission Pipelines
- Distribution Pipelines
- Flowlines
- Feeder Pipelines
These pipelines vary in size, primary material, internal pressures, and the types of chemicals and aggressive agents the inside and outside of the pipes are exposed to. As a result, there are varying welding needs depending on the pipeline type you are working with. For example, joining a service distribution pipeline made of copper with a pressure of 6 psi has completely different welding equipment requirements than joining a carbon steel transmission pipeline of up to 42-in diameter with pressures up to 1,200 psi.
Pipeline Welding Equipment
Pipeline welding equipment is highly diverse and specialized for welding pipes of various materials and diameters. In addition, many advanced automated pipe welding solutions exist for different pipe materials and sizes. While manual pipe welding plays a significant role in the pipeline industry, automated equipment provides consistent arc manipulation patterns, speed, voltage, amperage, and work angles.
Besides the welding equipment, joining pipes also requires external and internal clamps, pipe stands, pipe lifting devices, pipe bending equipment, weld testing machines, and various auxiliary equipment. The need for these additional tools depends on the pipeline types and the location where the pipes are joined.
Welders also need to use personal protective equipment (PPE). Besides welding apparel, pipe welders use pancake-style welding helmets to prevent backlight exposure and ensure maximum eye protection from arc radiation, sparks, and spatter. In addition, pancake-style welding helmets are lighter than standard flip-up welding hoods, which reduces fatigue during days with extended hours under the hood.
Welding Power Sources
While a lot of the manual pipe welding is done with the well known E and E stick welding electrodes, the TIG, MIG, and Flux-cored welding processes are also often applied, depending on the pipeline type, material, pipe diameter, and other variables.
Joining pipelines in remote locations is not only challenging for your welding crew but for your equipment as well. Besides exceptional arc stability and built-in features, your welding power source must be made to perform in harsh environments.
For example, the diesel-powered Big Blue Air Pak from Miller is designed for heavy industrial applications and built to be one of the most reliable high-output welders in the world. This powerful unit can output 500A at 100% duty cycle or 600A at 60% duty cycle, allowing your welders to join the thickest of pipes efficiently and with little to no downtime. Its 'Arc-Drive' automatically enhances stick welding, especially when welding pipe, by improving arc stability and preventing it from going out. Besides excellent stick welding capabilities, the Big Blue Air Pak includes MIG, FCAW, DC TIG, and submerged arc welding processes. As a result, you can join pipes in the most optimal way for your current job.
Another option is to use dual-output diesel-powered welders like the Dual Maverick 200/200X from Lincoln Electric. This workhorse of a welder can output up to 450A in a single mode or up to 225A in dual mode ' it combines two welding machines into one, allowing your pipe welders to work simultaneously on the same pipe. Besides its support for MIG, DC TIG, and stick welding, it also supports arc gouging at up to 450A, allowing you to gouge bad welds quickly. In addition, its Downhill Pipe (CC) mode allows your operators to weld the pipes 'downhill' with a more forceful digging arc during the root and hot passes and a softer arc when 'stacking the iron' during the fill and cap passes.
Pipe Bevelers and Cutters
Cutting and beveling the pipe remains one of the most challenging aspects of pipe preparation. No matter how skilled your operators are, achieving a consistent bevel angle on the pipe is nearly impossible when manually severing with the torch. On the other hand, pipe fit-up and cut precision must be almost perfect for maximum joint quality and for the weld to pass the inspection.
Pipe bevelers and cutters allow you to accurately prepare the pipe joint quickly and consistently. Depending on the system, they are mounted inside or outside the pipe. An operator can easily position the beveler or a cutter in about five minutes or less and achieve clean cuts and bevel angles, making pipe welding far easier and with a lower chance of weld failure.
Pipe Heating Equipment
Preheating and post-welding heat treatment are often crucial to establishing a sound weld. Pipes made from various high-strength steel grades and alloys have specific preheating temperatures and often must undergo a process of stress relieving through post-welding heat treatment. In addition, the interpass temperature between each consecutive weld is usually provided in the welding specification sheet.
If the pipe joint is not appropriately preheated or the interpass temperature is incorrect, there are higher chances of weld cracking due to brittleness and hydrogen diffusion. Therefore, pipe heating equipment is vital for successful pipe joining.
There are various pipe heating technologies on the market, but most of them are based on induction heating, open flame heating, and ceramic resistance pads. High-quality systems not only provide sufficient pipe heating, but can also log the data and offer very accurate and uniform pipe heating. Unlike traditional open flame heating systems, induction heating systems like the Miller ProHeat 35 don't cause water vapor condensation and won't contribute to additional hydrogen buildup in the weld.
Rent Or Lease Pipe Welding Equipment From Red-D-Arc
Pipeline welding is a very diverse field and depending on the types of pipes you need to join, your equipment selection can vary significantly. For example, if you are a fabricator who joins pipes in the shop for your client, you may require completely different equipment than a contractor working on large transmission pipelines in the open and across the states.
Red-D-Arc has a massive fleet of pipeline welding equipment at your disposal. You can rent the necessary tools and avoid purchasing, storage, and maintenance costs. Investing in heavy-duty pipe welding equipment is costly and often doesn't make financial sense. Many contractors move from job to job. So, it's more cost-effective to rent and scale in and out with your equipment on an 'as-needed basis.'
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