CONSIDERING ORBITAL GMAW/FCAW PIPE WELDING?

A Primer for the Prospective First-time User Orbital GMAW/FCAW welding is increasingly being used in a wide variety of industries. It is being used to replace manual SMAW, semiautomatic GMAW/FCAW, and even orbital GTAW. The following is a brief introduction to this mechanized process and a discussion of many of the questions typically raised by the manufacturer or fabricator considering the first-time use of mechanized GMAW/FCAW pipe welding. Some of the common pitfalls to avoid are identified. There is a misconception that orbital GMAW/FCAW is a exotic new process, and today few companies can afford to be guinea pigs for product development. Orbital pipe welding systems using the GMAW process were first used for pipeline applications in 1969 and since that time in excess of 25,000 miles of pipeline have been welding using the process. Orbital FCAW was introduced 10 years ago and has been used successfully in industries ranging from ship building, power plant construction and maintenance, chemical plant/refinery construction and maintenance, as well as offshore gas production, to name just a few. The Electric Power Research Institute performs research and development for 800 of the nations Electric Utilities. Mr. David Gandy (Program Manager of Materials and Fossil Applications) states that Ait has been conclusively demonstrated to Utility members that current technology makes orbital GMAW/FCAW a valid option for maintenance applications in both nuclear and fossil power generation facilities. Equipment Configuration Equipment Configuration top

All of the equipment on the market essentially consists of: - a weld power supply - a weld Head which mounts the torch and manipulates it, similar to the motions a manual welder would use - a band or "guide ring" which clamps on the pipe and provides mounting for the Head and is involved in propulsion of the Head around the pipe - a filler wire feeder which may be mounted on the floor or on the rotating Head - a weld programmer/controller which may be integrated with the power supply or the weld Head. A remote control Pendant is usually provided.

Wire Feed on Head or Wire Feed on Floor?

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Weld Head models are available in Wire Feeder on Floor (WFOF) and Wire Feeder on Head (WFOH) configurations, allowing use for a wide variety of applications. Each version has advantages and disadvantages for specific applications. Wire Feeder on Floor systems use a conventional wire feeder mounting standard 15 kg (25 lb) spools, resulting in lower electrode costs. This version has advantages for fabrication shop use with smaller workpieces and when the wire feeder can be conveniently located near the weld Head. Torch cable lengths are limited to 4.6m (15') between weld Head and wire feeder however, which is a limitation for many applications. Future development of push-pull systems will possibly minimize these shortcomings. The lower weight of the weld Head makes it easier to move from joint to joint. Wire Feed on Head systems use a smaller 5 kg (10 lb) spool of wire mounted on the rotating Head with the feed mechanism. This configuration is frequently necessary for use on large workpieces or for field erection where the weld Head must be operated at a distance (50'/15m or more) from the power source and a floormounted feeder would be inconvenient.

Bevel Geometry

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One advantage of orbital GMAW is that the process allows use of conventional bevel geometries that are normally used for manual welding. A standard 30 or 37.5 bevel is used for pipe with wall thicknesses up to 19mm (3/4") and a compound bevel for heavier wall thicknesses to minimize the amount of wire that must be deposited. Electrode Considerations: Solid or Flux Core? top

Although it is possible to obtain significant productivity improvements with solid wire, there are even greater benefits using flux core wire when welding pipe out of position. The deposition rate is higher and the welding process is more forgiving, and thus less dependant on operator skill level. Flux core wires were first introduced in 1957. The evolution of filler wire technology is one of the principle ingredients making orbital FCAW a viable process today. Flux core electrodes are available today for virtually any grade of carbon steel, low alloy steel, and stainless pipe material. The proper handling of FCAW electrode, however, remains one of the most poorly understood subjects and is the most frequent cause of start up problems for the first-time user. Flux core electrode consists of a metal sheath which is filled with a core of various powder materials. These may include fluxing elements, de-oxidizers, denigrating compounds, and other alloying materials to variously increase hardness, strength, or improve corrosion resistance and arc stability. Virtually all of the flux core

wire on the market today does not have a continuous 360 sheath, but has either a butt or overlap joint. This interruption in the metal sheath can permit moisture into the flux. Flux core electrode is essentially stick electrode turned inside out. The seam along the entire length of the electrode can allow moisture to invade the flux. It is common practice to keep stick electrodes in a sealed container until ready for use and if they are not used that day, they are put in a "rod oven" to drive out the moisture. Yet customers often will improperly store or allow partially used spools of electrode to be exposed to moisture without realizing that they will experience the same problems. A frequent early complaint is "worm hole porosity" which is usually attributable to moisture in the flux. Flux-core electrode is frequently made in two formulations: a standard formulation and a "all position" formulation. The flux in the "all position" wire causes the puddle to freeze much faster which is required when welding "out of position" relative to gravity. "All position" versions of wire must be used for orbital pipe welding. An unfortunate fact is that FCAW electrodes from different manufacturers, which may have the identical specification, do not all perform the same. An electrode from one manufacturer may have very different welding characteristics than that from another despite the fact that they have the same specification. In addition, there has been so much consolidation in the industry that one manufacturer may operate many facilities, with electrodes marketed under their original labels. The wire from one factory may be a little different in formulation than another. Ask for advise from the orbital equipment manufacturer for a list of electrode brands with which their customers have had good results. Or evaluate electrodes from several manufacturers and form your own opinion before making a large purchase. When ordering electrode, be sure to specify: - Level Wound, regardless of spool size - Wire to be supplied in Sealed Bags with desiccant. (This is often available as an option.) Root pass top

With the equipment on the market today, the root pass is generally done manually using either manual GTAW, SMAW, or semiautomatic GMAW. The pipe ends will be gapped apart using pre-established procedures. Generally, two passes will be required - a root pass and

subsequent hot pass - before mechanized GMAW/FCAW welding can be used to complete the weld. A single pass is generally insufficient to avoid repenetration by the higher voltage/amperage FCAW parameters used for the fill passes. There are semiautomatic GMAW power sources on the market today, however, which will deposit a root pass sufficiently thick to eliminate the need for a subsequent hot pass. Can the root pass be done using a mechanized GMAW system? The answer is a qualified Yes, but with limitations which make it impractical for most users. Flux core wire cannot be used for doing the root pass because of the potential of slag entrapment. Therefore, solid wire must be used. If the fill pass procedures require flux core, which offers substantially higher deposition rates, the user will either have to exchange the filler wire spool, or have two systems, with one dedicated strictly to root pass welding. While the root pass can be done with orbital GMAW, it does require precise fit up including a very uniform gap around the 360 bevel as well as tight control over high/low mismatch. In addition to tight fit up tolerances, a greater amount of operator skill is required when doing the root pass. One company has developed an orbital pipe welding system specifically for making the root pass for pipeline applications. This system, however, requires an internal spacer clamp which precisely aligns the pipe ends and simultaneously creates a precise gap. While this system is practical for pipeline welding, the need for a very large internal clamp designed for a specific pipe size makes it impractical for most fabrication or field erection applications. Presently, it may be better to plan to do the root and hot pass manually or at least until welders have gained sufficient experienced with equipment. Orbital or Double-Up Welding? top

While the term orbital has become closely associated with mechanized GTAW welding, it is not totally appropriate when applied to mechanized FCAW welding. With the pipe in the horizontal (5G position), welding is done using a double up technique - 180 clockwise followed by 180 counterclockwise. An orbital technique is used only with the pipe vertical (2G position). A double-down welding technique can be used with GMAW. This technique is generally only used for cross-country or marine pipeline laying operations. Joints-per-day productivity of these operations mandate multiple weld stations with two or more weld Heads per

station used on a joint simultaneously. Each station is usually dedicated to one pass - for example, a Root Pass station followed by Hot Pass stations, two Fill Pass stations, and the final Cap Pass station. As each pass is completed, all the stations move forward to begin the same pass on the next joint in sequence. Because all stations must move-up in lockstep, the weld cycle time is dependant on the speed at the initial Root Pass station. While much higher rotational travel speeds can be used, less metal is deposited per pass. Great care must be taken by the operator to avoid sidewall fusion defects. When welding in the 5G position, a weave technique is generally used. Most of the systems available allow a programmable dwell or delay period at either end of the oscillation stroke which guarantees proper sidewall fusion. Oscillation dwell is programmed in tenths of a second. A useful feature is the ability to index the rotation of the torch around the pipe with the weave or oscillation motion of the torch. As the torch moves across the joint, forward motion of the torch (weld Head) is interrupted. When the torch reaches the end of its stroke and begins its programmable dwell period on the sidewall, the weld Head tractor moves the torch forward at the programmed speed. This approximates a technique used by many manual welders. Shielding Gas top

All of the equipment on the market today using either solid and flux core electrodes require an appropriate shielding gas. The gasless type wires, while excellent for many semi-automatic (manual) applications, still produce excessive spatter which would ultimately degrade the orbital equipment where the torch is mounted inches from the weld Head mechanisms. This is an important consideration that must be planned for if the equipment is to be used for field construction purposes. A contractor accustomed to welding with stick will have to consider erecting wind breaks, tarps, or tents over the equipment to prevent the shielding gas from being disrupted by wind, as well as to protect the equipment from the elements. He must consider the added cost of gas and the logistics of moving gas bottles around the job site and safely restraining them. Use the Correct Shielding Gas for the Electrode top

Particular attention should be paid to the manufacturer's recommendation for shielding gas composition for a particular filler wire type. Shielding gas not only affects the arc stability and general "weldability," but also the metallurgy of the deposited metal. Frequently, a manufacturer will recommend more than one gas, for example 100% CO2 or 75% Argon/25%CO2. The user should consider the trade offs when making the selection. For example, CO2 gas is least expensive, but argon/CO2 mixtures will produce a more stable arc with less spatter. Other factors will affect filler wire performance such as the characteristics of the power supply used and the metal transfer mode (short circuit, spray, pulse spray). Torch Oscillation (Weave) Straight Line or Pendular? top

Torch oscillation may be accomplished by a straight line linear motion or a pendular motion. Each technique has its proponents. Either technique will produce satisfactory results with FCAW. Several systems on the market provide the capability of both modes, which allows the customer to select the mode for a specific application. Fillet or socket welds are often best done using pendular oscillation. Typical Parameters top

Typical parameters for 5G fill passes with FCAW electrode: - Electrode Diameter: 0.045" (1.2mm) - Volts: 24 - 26 - Amps: 180 - 260 - Electrode Speed: 180 -300 ipm (4.6 - 7.6 mpm) - Head (Torch) Rotation Speed (Average): 6 ipm (15cm/min) - Deposition Rate: 4.6 - 6.8 lbs/hr (2.1 - 3.1 kg/hr) - Gas Usage: 40 - 50 cfh (15 - 20 liters/min) Consider Equipment and Process Suitability For Your top Application The potential user must consider whether his application will allow the productivity gains to justify the purchase of equipment and cost of qualifying new procedures. For example, a contractor with a job consisting primarily of smaller diameter thinner wall (Schedule 40) pipe may not be a logical candidate for mechanized FCAW. An application consisting of welding heavy wall CrMo piping with a preheat which must be maintained during the welding process is likely a very suitable candidate for mechanized FCAW.

Such applications which can take advantage of the high duty cycle of a machine are more obvious. Less obvious may be a limited welding requirement in a fabricated product, where the duration of the welding operation, subsequent inspection and repair proves to be a critical path item affecting delivery schedule. A major manufacturer of medical imaging devices uses orbital GMAW for a single-pass 84" diameter fillet weld which must undergo helium leakage testing. Many manufacturers have a rental program with purchase option which allows the customer to evaluate the equipment for his specific application using his personnel. This Atry before you buy@ approach may be a viable technique to evaluating the technology for those customers that are unsure about whether productivity improvements can be obtained for their specific application. Training top

All manufacturers of pipe welding equipment will offer training at the customer's facility. It is extremely important that management realize that training is required and there is a learning curve associate with any new equipment. Equipment marketed today is "mechanized," not "automatic." Too often there is an attempt to train welders "on the job." The manufacturer of the equipment will provide a structured training course, but time must still be allowed for the welder to practice, make the inevitable mistakes, and become confident before the equipment should be used in production. Weld Quality top

Orbital FCAW is capable of making welds meeting the same quality standards as SMAW, Submerged Arc Welding and in most cases GTAW. Many companies are already using semiautomatic GMAW/FCAW and the transition to mechanized orbital equipment for out of position pipe welding is a simple economic decision based upon pipe size, wall thickness and quantity of welds made. Other companies are hesitant through lack of experience with the process. However, numerous businesses and organizations have evaluated equipment, tested welds and approved the process for even some of the most demanding applications such as welding high-pressure piping in a power plant or Duplex stainless steel piping assemblies for offshore gas production and transportation. MULTIPASS GTAW ORBITAL WELDING OF A Primer for the Prospective First-time User PIPE

First developed 30 years ago by the aerospace and nuclear power industries, orbital mechanized pipe welding is now a mature industry widely used in virtually every industry that has any need to weld tubes and pipes. Despite its widespread acceptance and long-term use by many customers, each year many companies with no experience begin the evaluation process to see if mechanical welding makes sense for their specific application. This decision may be due to a lack of skilled manual welders; customer-mandated higher quality standards; the need to improve productivity and throughput; or the desire to reduce defects and rework. Most management and engineering individuals have the same concerns and questions, and this article will attempt to address some of these common considerations and basic issues. Although there are GMAW/FCAW process pipe welding systems commercially available, this article will focus on GTAW (Gas Tungsten Arc Welding) equipment. The relevant applications will be those where the pipe cannot be rotated, but must be welded in a fixed position, whether 5G, 2G or 6G (pipe horizontal, vertical or at an angle). There have been a great many articles published discussing the requirement for successful sanitary/sterile tube welding. Much of this welding can be done by simple autogenous tube welding systems in a single pass, and the equipment and requirement for success are quite different from pipe welding where the wall thickness dictates multiple weld passes to make root, fill, and cap passes. The focus then will be on multipass welding. Who Is Using Orbital Welding and Is it Suitable for My top Industry? Orbital mechanized welding is used in a broad spectrum of industries - from semiconductor manufacture to shipbuilding, power plant construction to marine gas pipelines, chemical plant maintenance to food processing. In summary, the technology is likely already being used by another company in your industry. Is Mechanized GTAW Pipe Welding Faster than Manual? top There is a misconception that a machine can make a weld faster than a man. This is not so. The process which involves a molten, fluid puddle of metal acted on by gravity and surface tension forces, is identical for manual and machine welding. Mechanized welding has the capability of higher deposition rates, higher torch travel speeds, etc., but ultimately the process limits any substantial

improvement in these factors over manual welding. Productivity with mechanized welding is primarily the result of duty cycle and reduced defect rates. A machine cannot tire, take coffee breaks, or make mistakes. The Importance of Duty Cycle for Cost Justification top

Is mechanized pipe welding guaranteed to increase productivity in your company? Not necessarily. Numerous considerations such as workflow and workpiece geometry may simply not make mechanized welding cost effective. For example, can workflow be arranged to allow welding of a number of similar size pipes in an uninterrupted succession? Or does your product require an assembly sequence where the pipe size is different for each subsequent weld, which will result in possible time lost to readjust the weld Head for pipe size. Given a suitable application, mechanized welding should achieve a 70% duty cycle, and a productivity improvement of 300% is realistically achievable as compared to manual welding. This productivity improvement will not be reached unless the workflow can be arranged to maximize arc-on time. If only one weld can be made followed by an hour of other processing before welding can resume, mechanized equipment will do little to improve productivity. This is sometimes the case in field fabrication, resulting from the time to move the equipment from one weld site to another weld site. Just the opposite is often true in field fabrication. For example, physical access to the weld may be a fundamental factor in productivity. Field pipe welds must frequently be made in power plants and chemical manufacturing facilities where a manual weld will take two hours that a machine can make in 10 minutes. In some cases, the manual welder is forced to make welds using a mirror, or with tight access preventing him from making the weld from one side. Quality and maintaining careful control of weld parameters may also override duty cycle considerations. If you don't have manual welders that can achieve the specified quality standards, duty cycle becomes a secondary issue. Many of today's alloys require tight control over weld parameters such as heat input, for example. Duplex stainless steel and Inconel alloys require tight regulation of heat input to maintain desired metallurgical properties in the weld deposit and heat affected zone or to avoid defects such as cracking.

The Importance of Required Weld Quality Standards

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If weld quality is not a major concern for your product or service, (you simply have to make sure the pipes are stuck together), there is unlikely to be a sufficient payback on equipment investments. If your application requires welding to rigorous codes such as ASME section IX, B31.1, B31.3, etc., you may achieve a rapid payback with reductions in weld defects and subsequent rework. Most companies can achieve sustained reductions in defect rates to well under 1%. Customers frequently benefit from relaxed QC mandates using mechanized welding. For example, 100% radiographic inspection may be relaxed to a 10% inspection sampling. What Are the Components of an Pipe Welding System top

The systems are on the market today generally have the following components: A weld Head which carries and manipulates the torch. A power source which provides both weld head control and programming, as well as current output. A remote pendant for system control at a distance from the power source. A water recirculator to provide torch and possibly weld head cooling. What Weld Head Features/functions Are Required for top Multipass Welding? The weld head should have the capability of the following: Torch rotation. Filler wire feed capability. Electronic control of arc length (Arc Voltage Control). Torch oscillation (weave) capability with programmable width, speed and independent end point (sidewall) dwell times. Selecting the Optimum Weld Head Type top

A variety of weld heads have been developed to meet specific application requirements and constraints. Weld heads fall into one of two categories: "full function-in-place"; or "orbital full function". Full Function in Place Heads

These Heads adjust to clamp on pipe of a specified o.d. range. An adjustable lever-actuated clamp holds the head on the pipe and remains stationary. A torch and other mechanisms mount on a rotating module. The filler wire feeder may be entirely mounted on the rotary portion of the head, or may be floor mounted with a conduit connected to the rotating module. These heads incorporate electronic arc-voltage control and electronic torch oscillation. (Some models may incorporate a mechanical follower to control arc length, but these technically are not "full function" and have limitations for multipass welding). Benefits include rapid installation on the pipe. Limitations of this type are that each head model can weld only a finite range of tube and pipe sizes and several models may be required to cover the necessary pipe size range. Radial clearance requirements depend on pipe OD. Head mechanisms cannot be water-cooled, limiting their use on alloys requiring preheat. Floormounted wire feeders allow the use of larger spools (lower wire costs), but may sacrifice wire feeding accuracy. Full Function Orbital Heads The Heads also incorporate torch rotation, filler-wire feed, electronic arc voltage control, and electronic torch oscillation. Unlike the "inplace type head", however, the entire weld head mechanism rotates around the work piece. The head attaches to the pipe using a metal band or guide ring fabricated to match the size of the tube or pipe. Generally, the guide ring attaches to the pipe, then the head installs on the ring, although some models retain the guide ring and both are installed simultaneously. One limitation is that they require slightly longer to install on the pipe than the "in-place" type Head. This type may also require a longer straight length of pipe for mounting. Benefits include the ability of one model to cover a broad pipe size range. Radial clearance remains constant on all pipe sizes. Head design permits water cooling of the body allowing use on alloys requiring preheat to work piece. Other Considerations in Weld Head Selection top

Other factors may dictate the type of equipment selected such as: Welding in tight clearance conditions with limited axial and radial clearance. Welding of alloys requiring preheat, requiring water-cooling of the weld head body. Applications dictating a very limited range of pipe sizes (for example, small diameter boiler tubing used in heat exchangers).

 Businesses such as fabrication job shops and mechanical contractors that require the capability of welding many sizes of pipe, which are determined by present and future contracts. Power Supply Considerations top

Consider the importance of power supply size to your application. Some systems are not very portable, but might be perfectly acceptable for a fabrication shop. For field use consider the need for portability. Many inverter-based power sources today can be moved by one or two men without equipment. Consider input voltage requirements for the power source. A fabricator will generally have access to any input voltage, but a field contractor may require a specific three-phase voltage at a job site. If a motor generator is to provide power, a single phase power source may be desirable. Some power sources operate on a specific input voltage only, while others can operate with a range of input voltages, single or three-phase. A power source output of 200-300 amps is generally sufficient for conventional mechanical welding. Frequently customers ask if they can use an existing commercial power source to operate the weld head. An orbital welding power source integrates the controls to both operate the various weld head functions and integrate them with the power source output in one "package". A standard power source can provide output power only and cannot be used. In addition, multipass welding requires multipass programing, which is usually done with an integrated microprocessor and custom software. Analog Versus Microprocessor-based Power Sources top

There are still analog power sources available. These are programmed by entering the desired speed, amperage, etc., on dials and enabling functions using mechanical switches. The units on the market today will allow only one pass (orbit of the pipe) to be programmed. With the requirement for multiple passes, the welder must stop the machine, reset the dials for the following pass, and restart the weld. The alternative is to change dial settings "on the fly" - a risky procedure at best. Analog power sources have advantages: easy to learn operation; tolerance of environmental extremes; simpler service. Unfortunately, their downside is greater: the need to stop between passes; welder error in setting dials ; no ability to "lock-out" unauthorized changes in critical parameters; no

program storage. With apologies to the computer haters out there, this is one place where the microprocessor-based power source offers significant advantages. Microprocessor Band Systems Offer the Following Advantages: Many levels of programming for all parameters. Multiple passes possible without stopping. Key switch or password authorized access to modify programs. Supervisor-defined override limits on each parameter provides process control. Weld program storage (most units store 100 programs internally). Integral printers provide hard copy of weld parameters, with ability to print weld number, date, etc. Solid state data cards allow program transfer between systems or "offline programming" on personal computers. Weld head selection allows calibrated readouts in proper engineering units. QC monitoring programs. Selectable language and inch/metric operation. Microprocessor-based units do have a longer learning curve. Evaluate models from various manufacturers on their ease of programming. The welder using the equipment does most weld programming, and the program should use simple "prompts" and not require computer literacy. Unlike the pro and con argument that can be made for analog programmable power sources for fusion welding, microprocessorbased systems offer clear advantages. Is it Necessary to Create New WPS/PQR's? top

There is a misconception by many people that the substitution of mechanized pipe welding for manual techniques requires that a new Procedure Qualification Record (PQR) be done (as well as the Weld Procedure Specification, which it supports). This is not the case. The ASME code, section IX, defines welding variables under section QW250. Nonessential variables are subsequently defined in section QW251.3. "Nonessential variables: Nonessentials variables are those in which a change, as described in the specific variables, may be made in the WPS without requalification."

Variables for gas tungsten arc welding (GTAW) are listed under QW256. Nonessential variables are listed under subheading 256.2. QW410.25 below is listed under 256.2 nonessential variables. QW410.25: A change from manual to semi-automatic to machine automatic welding and vice-versa". Joint design including bevel geometry and fit-up gap are nonessential variables for the GTAW weld process as defined under section QW-415 on welding variables. How Important Is Bevel Geometry? top

Very frequently customers will make the capital spending decision to purchase an orbital system, but will balk at spending the additional money to purchase pipe-prepping tools, to guarantee a repeatable, accurate bevel geometry. Although computerized, the pipe welding systems available are essentially "dumb" machine tools. They will unerringly repeat the programmed motions and precisely change functions such as current at the proper moment. They cannot, however, compensate for a changing bevel geometry and poor fitup. If a user is unwilling to spend the money on a pipe end-prep tool, they will not succeed in achieving code-acceptable machine welds. There are a large number of manufacturers of portable pipe prepping tools; with electric, pneumatic, and hydraulic drive options. It is important to think of mechanized welding as if you were installing a new multi-component system: Pipe beveling equipment to ensure repeatable pipe end geometry. Fit-up tools to ensure reasonable fit-up for tack welding. Mechanical pipe welders to ensure a repeatable weld process. top

What Bevel Geometry Should Be Used?

Pipes with wall thickness up to approximately .125" (3mm) can be welded in a single pass. Above this, a multipass technique will be required. For smaller pipes and boiler tubing, a standard V-bevel with a slight gap is adequate, if not optimal, for welding most materials. Generally, the most suitable prep for automatic welding is a J-prep with the pipes ends butted together. Is it not possible to use a standard v-bevel with an orbital head? Yes, it can be done with perfect fit -up and an extremely skilled and attentive welder. This

defeats the most common rationale for mechanized welding - lack of skilled welders. Equipment manufacturers will strongly recommend use of a J-prep. What Training Is Required and What Is the Typical top Learning Curve Duration? All manufacturers strongly recommend training. Typically three to five days of direct instructions, by a factory technical specialist is adequate. Welders will still need several weeks to reach full proficiency. One of the most common mistake is to purchase equipment as a "solution" to meet an ongoing contract deadline and to expect welders to become immediate experts. Recommendations top

Get "buy-in" from your welding staff. Invite welders to supplier demonstrations. They will be using the tool and can provide valuable input in equipment selection. Make them understand that this is a tool to make their job easier. (Often welders can feel threatened by mechanized equipment, and require reassurance that this is a tool to make them more productive and more valuable.) Make the cost/benefit decision the same way you would if buying a new computer system, or a new machine tool. Don't wait for the start of a big job as the impetus to evaluate mechanical welding. You cannot bypass the learning curve. Unfortunately, many first time users do not realize the importance of training and the length of the associated learning curve before welders can become proficient and achieve the productivity improvements possible with these welding tools.

RECENT DEVELOPMENTS IN ORBITAL-WELDING EQUIPMENT John G. Emmerson, Magnatech, East Granby, CT USA From its origins 30 years ago as a tool for aerospace and nuclear power plant construction, mechanized (GTAW) for tube and pipe joining has become an increasingly common process used in a number of industries. Orbital-welding applications include such unique uses as tubing runs in semiconductor clean rooms and hockey-arena cooling-pipe loops. Trends in power supplies and controls top

Just as inverter-power-supply technology sweeps through the ranks of manual welding-power supplies, it gains popularity by the tube-and pipewelding equipment manufacturers. Fabricators can now select among orbital-welding equipment that is smaller and lighter than ever, for portability at the job site and to fit into cramped working conditions. One worker can transport a miniaturized power source integrated with a watercooler package. A decade ago, a power supply suitable for pipe welding tipped the scale at 600 pounds for a welding output of 300 amps. Today, the equivalent power supply weighs in a svelte 100 pounds. Modern power supplies carry microprocessor-based controls that offer numerous benefits compared to older analog-based controls. For tubewelding, equipment with analog programming typically carried four preset levels. The equipment operator would record weld parameters on paper and carefully input them into the controller for each size of tube to be welded. By comparison, modern microprocessor-based controls can store up to 100 weld programs. The operator merely calls up the appropriate weld schedule and pushes the START-WELD switch. Rather than four levels of parameters per program, these programs frequently offer 100 levels, and allow changes in welding parameters as a function of rotational position. Has this increased programming capability actually led to better welds? Probably not for welders of tubing; analog units deposit welds equal in quality to the welds of microprocessor-based units. However, the microprocessor has led to many conveniences not previously available in analog tube-welding equipment. For example, automatic procedure generation allows the operator to enter basic parameters such as tube diameter, wall thickness, and travel speed. The program then automatically creates a near-perfect welding procedure, simplifying the weld-development process, with only one or two welds required to fine-tune the program. This capability eliminates the tedious requirement of depositing numerous test welds, and requires a minimal amount of welding expertise by the operator.

Microprocessor-based controls also carry software that automatically selects the appropriate weld head based on the application. Using an analog system, the operator needs to determine desires rotation speeds, convert them to RPM using a formula specific to each model of weld head, and enter an arbitrary speed setting based on a calibration curve provided with the equipment. Conversely, most modern systems immediately display actual RPM for the model of weld head selected. The operator selects a desired tungsten speed and the software calculates the RPM setting for the selected weld head. Moving up to pipe welding top

Unlike the pro-and-con argument that can be made for the fusion-only tube-welding industry, for multipass pipe welding microprocessor-based programming provides distinct advantages. Old analog machines required the operator to carefully enter the parameters for each weld pass using an array of switches and dials. Changing parameters during welding required the operator to turn the dials on a remote pendant control at precisely the right moment, demanding a high level of skill and attentiveness. Typically, the operator would terminate the welding process after each pass and reset the dials for the subsequent pass working from a setup sheet. Each dialspinning episode became a possible source of error. Although several companies offered analog programmers that allowed programming an entire weld on small sizes of pipe, these controllers consisted of a large number of conventional electrical components, including potentiometers, switches, and relays. This complexity ultimately effected reliability, since the relays were often required to operate in harsh environments for thousands of cycles. The introduction of the microprocessor allows programming a multipass weld from root pass through cap pass with an uninterrupted weld, eliminating mistakes in setting parameters. Microprocessors bring other advantages to pipe welders. For example, parameter-override lockouts set limits on each welding parameter; the operator can set variable override percentages from zero to 100 percent. A welding supervisor can limit the amount of changes an operator can make during a program, preventing him from accessing the override screen through the use of a key switch or password. Thus, the supervisor might set override limits at zero for a particularly critical on duplex stainless-steel tubing for example. Conversely, retubing a furnace at a chemical plant might require a greater degree of discretion or override capability by the welder, to compensate for imperfect fit up between the new tubes and existing tubes.

The multilevel capability within a "pass" or orbit around the pipe offers distinct advantages for certain applications. One such case is welding copper nickel or high copper content tube and piping. In this case, the high thermal conductivity of the material requires an initial high current that must be quickly tapered to maintain stable puddle size and uniform penetration for 360E welding. In addition to the ability to adjust parameters between weld passes, operators of microprocessor-based pipe-welding machines can also program changes to weld parameters during each pass or orbit around the pipe, which offers distinct advantages for certain applications. An example is welding on copper-nickel or high-copper-content tube and piping. The high thermal conductivity of these materials requires high current at arc start that tapers quickly to maintain stable puddle size and uniform penetration around the joint. Another example is the welding of high-nickel alloys, extremely sensitive to crater cracking at welding start and stop points. Microprocessor-based controls allow the operator to set initial and final current levels with precise control over the rate of upslope and downslope to minimize thermal shock. A software option allows the feeding of filler wire during part of the downslope period to further minimize thermal shock and the likelihood of cracking. As an added benefit, many microprocessor-based power sources can store programmed welding procedures on solid-state data cards. This allows the operator to easily transfer programs developed on one machine to other machines being used either in the same facility doing the same type of work. Data cards store 30 to 100 programs, created on a standard personal computer using software provided by the manufacturer. Data storage a boon to quality control top

Microprocessor-based machines can immediately alert the operator if weld parameters fall outside preselected limits, and can print-out records of preset and actual parameters. Parameters can be downloaded to PC data cares or directly to a quality-control computer program for storage or statistical analysis. This can eliminate time-consuming and expensive radiography in many applications. Audible alarms alert the operator to out-of-tolerance conditions, enabling him to perform timely functions and prevent the deposit of faulty welds. For example, an out-of-limit voltage signal might indicate that the tungsten electrode tip has deteriorated and requires replacement. To ensure equipment repeatability of older systems, users could only periodically

calibrate meters, and call on strip-chart recorders to monitor critical parameters for each weld, such as amperage, voltage, and rotation speed. The charts required skilled interpretation. If a user did not want to monitor parameters for every weld, he had to use radiography and destructive testing to determine if the equipment was operating correctly. Selecting the optimum weld head top

A variety of weld heads have been developed to meet specific application requirements and constraints. Weld heads fall into one of four categories: enclosed, or cassette, limited-function; full function-in-place; or orbital or guide-ring full-function. Enclosed head: This design works only for fusion-welding applications. It contains an internal rotor that holds the tungsten electrode and rotates around the work. Enclosed heads do not have a torch: the tungsten electrode inserts in a hole in a rotating gear or other component inside the enclosed chamber of the head body. The body straddles the weld joint and remains stationary. The enclosed chamber is flooded with shielding gas; arc length remains fixed. The clamping mechanism must be very precise to guarantee that the tube clamps concentric within the head. Applications for enclosed heads abound in the aerospace, pharmaceutical, nuclear, semiconductor, food processing and dairy, and medical and biotechnology industries. Enclosed heads offer superior gas shielding, as they enclose the entire joint. Also, the enclosed arc eliminates the need for weld-shield and eye-protection devices. They are the simplest type of head to operate. However, their high-temperature plastic bodies limit duty cycles on heavy-wall stainless-and carbon-steel tubes. Tube and pipe must be round to ensure a tight seal. The heads require periodic cleanings to avoid internal arcing. Each head model only covers a finite range of tube sizes, and radial clearance is dependent on tube o.d. In-place limited-function heads, of a relatively simple design, adjust to clamp to pipe or tube of a specified o.d. range. An adjustable leveractuated clamp holds the head on the work piece and remains stationary. A torch and wire feeder mount on a rotating disc; a torch-cable assembly delivers weld current, cooling water, and shielding gas to the head. Position of the tungsten electrode adjusts laterally relative to the joint. A mechanical follower device, using the pipe surface as reference, corrects arc length changes due to any out-of-roundness of the pipe. This head type enables use of filler-wire feeders positioned either on the floor or mounted on the rotating portion of the weld head.

Applications include aerospace, pharmaceutical, semiconductor and high purity, food process and dairy, process pipe, heat exchangers, chemical, and power generation. Benefits include clamping on only one side of the joint; uses for either autogenous welding or with filler wire; can weld outof-round pipe; all-metal construction tolerates heat well; and can be used with standard fittings purchased from the manufacturer. Limitations: each head covers a finite size range of diameters; shielding-gas coverage is inferior to that of enclosed heads; radial clearance depends on pipe o.d.; and multipass welding requires the use of the stringer-bead technique. Full-function in-place heads operate similarly to the limited-function heads, but can incorporate electronic arc-voltage control and electronic torch oscillation. These heads find work depositing multipass welds on pressure pipe. Applications include fossil- and nuclear-power plant construction and maintenance, steam-generation equipment, process piping, chemical and refinery plants construction and maintenance, and ship construction and maintenance. They allow clamping on one side of the joint, and are quickly installed. However, each head can weld only a finite range of tube and pipe sizes, radial clearance depends on pipe o.d., and the heads are not watercooled, limiting their use on alloys requiring preheat. Full-function orbital heads incorporate torch rotation, filler-wire feed, electronic arc-voltage control, and electronic torch oscillation. Unlike the in-place head, however, the entire orbital weld head rotates around the workpiece. The head attaches to the pipe using a metal band or guide ring fabricated to match the size of the tube or pipe. Generally, the guide ring attaches to the pipe, then the head installs on the ring. Applications include fossil-and nuclear-power plant construction and maintenance, steamgeneration equipment, process piping, chemical and refinery plant construction and maintenance, ship construction and maintenance. One model covers a broad size range, and fixed radial clearance remains constant on all sizes. These heads find use on the simplest fusion-welding jobs as well as on complex multipass welding of heavy-wall pipe. Head design permits water cooling of the head body for use on alloys requiring preheat. Trends in training top

Training operators in the use of orbital tube and pipe welding systems seems to follow the general trend in vocational training in the manufacturing sciences - inadequate, with too few courses in technical schools for welding in general, and few apprenticeship programs.

Unfortunately, too-few first-time users understand the amount of training required, and the length of the associated learning curve, before operators can become proficient at running orbital-welding equipment. Too often contractors will rent or purchase equipment on Friday and expect it to be productive on Monday morning. Even companies with long-term experience fail to properly train operators when new equipment comes on-board. A few bright spots appear on the horizon concerning training. Many firsttime operators come from a non-welding background and expect a morerealistic learning curve. Many union locals are purchasing equipment and conducting training programs for their members to support local companies. Many companies are finally realizing that there is a real payback in workertraining programs.

WELDING THE MAUI A-B PIPELINE Peter Butler, Heerema Engineering Service (UK) Ltd.,

London U.K., John G. Emmerson, Magnatech, E. Granby, CT USA Submarine pipelines have been installed all over then world, in diameters ranging from 76mm (3") up to 1270mm (50") or more and in water depths up to 500m (1600') using the S-lay method. This method is based on supporting the over bend by means of a mechanical structure known as a "stinger", and lowering the pipe to the sea bed at a typical horizontal inclination of 30 degrees. The pipe is prevented from buckling by tension maintained by the lay barge anchors which are periodically moved forward. On the S-lay barge deck pipe welding, NDT, and pipe joint coating work stations are sequentially positioned to allow use of standard 12 or 24m pipe lengths. Multiple work stations optimize the production rate. Most commercially interesting oil and gas fields located in shallow waters have already been developed, and new projects have focused on sites in increasingly deeper waters. With increasing water depth, the length and weight of the unsupported pipe span increases. At a certain depth limit, anchors and the S-lay method cannot be used. In 1989 Heerema, a Dutch Company, who operate a fleet of semisubmersible crane vessels (SSCV) which are used for the installation of offshore production platforms, decided to diversify into marine pipe laying. Realizing direct competition with established pipe lay contractors using S-lay barges could not be commercially competitive, an innovative J-lay system was designed which took advantage of the unique capabilities of the SSCV. With the J-lay technique the pipe is suspended near vertically from the lay barge, reducing the horizontal force required to prevent pipe buckling. The J-lay technique has obvious advantages for deep water applications where it is possible to eliminate the use of anchors by using dynamic positioning. The main drawback of the J-lay technique is that the near vertical pipe is difficult to handle and multiple work stations cannot be used. Only one length of pipe can be welded onto the pipeline at a time and subsequent inspection and coating must be done before the next weld can be made, resulting in low production rates compared to that achieved by S-lay barges. Heerema's solution to this limitation was to maximize the length of each piece of pipe added to the pipeline. By fabricating the pipe on shore into lengths up to 72 meters (240') and using the massive crane capacity, (some 4000 tons) of the SSCV to lift each pipe string

into position for welding, they could compensate for a lower productivity rate. J-Lay Project top

In 1990 Heerema was awarded a pipe lay contract from Shell Todd Oil Services of New Zealand to install 15km of pipeline between a new platform, the Maui B and an older platform, the Maui A. A 20" diameter pipeline was planned to carry untreated natural gas from this new platform, Maui B, to Maui A for treatment before transport to shore through the existing pipelines. The raw gas from the Maui field is extremely corrosive due to the high CO2 content which led to the selection of API 5LX grade X60 pipe internally clad with 316L stainless steel. The 20 inch diameter seam welded pipe had a nominal 3/4" (19mm) wall of API 5LX 60 and an internal cladding of type 316L stainless steel, 1/8" (3 mm) thick. The customer required that pipe welds meet a specification far more demanding than the traditional standard for pipelines (API 1104), with the requirement for 'no defects/no repairs' in the clad layer and the ability to make an acceptable root pass on pipes exhibiting the maximum permitted mismatch of 1.6mm (0.062"). The restrictive welding specification and the complexities of the clad pipe led to the decision to place the emphasis on making good welds-first time, and that weld deposition rate should be a secondary consideration. Magnatech orbital welding equipment was chosen for a welding development program based on the use of GTAW for all passes. The Magnatech Series 500 system consists of a track mounted orbital welding Head, a constant current power source and controls which integrate the operation of the welding Head and power source. The T Model welding Head incorporates torch rotation, filler wire feed, torch oscillation and arc voltage control functions. The welding Head mounts on the pipe using an appropriately sized guide ring, (a metal band which encircles the pipe O.D.) The Series 500 System was originally developed for welding pipe work in the steam generation and chemical industries. It has an established history of use for marine pipeline projects, including the welding of Duplex stainless steel pipeline and pipe clad internally with Inconel 825. The Maui pipeline was welded in the 6G position, with the pipe axis at a nominal 37 to the horizontal. Two weld Heads were used

simultaneously welding on one joint. A double-up (6 to 12 o'clock) welding technique was used to maximize deposition rate. All controls required during welding are located on a remote pendent although there are minimal requirements to make adjustments on the welding Head when in motion. Welding Procedure Development top

The welding procedure was established and various consumables were evaluated with the eventual selection of 309MOL alloy which met both mechanical and "weldability" criteria. Welding trials led to the selection of a 25 included angle J-groove geometry. Pipe alignment had to be tightly maintained to provide continuity of the clad layer. Production top

A local New Zealand company was awarded the contract to make the 72mm (240') pipe strings. This was done at a dock-side facility also using GTAW for the entire weld. A production line was set up using eight Magnatech Series 500 Systems to complete some 1,200 welds. The pipe strings were loaded in specially constructed racks, and transported to the SSCV Balder. Pipe laying operations began in December 1991. During production welding high levels of residual magnetism were experienced. A commercial degaussing unit and other techniques were used to counteract this problem. An integrated tool string was developed to combine an internal joint alignment clamp, complete with argon purge system and an X-ray system. These items were linked by a single umbilical cable to a winch at the top end of the pipe ramp. The umbilical cable provided all services to the tool string. All instrumentation and controls for the tools string were located in the welding station. Non-Destructive Testing top

The Maui project specification required both radiographic and ultrasonic inspection to very high standards. All NDT was conducted

in the welding station and it was essential to minimize both test time and interpretation. Radiography had to be performed by the panoramic X-ray technique due to both technical and safety requirements. Fine grain, high contrast film was used to provide the clarity needed to detect defects in the clad layer. It was decided to use mechanical ultrasonic inspection because of the speed and assured inspection coverage. Rontgen Technische Dienst b.v.(RTD), supplied their Rotoscan ultrasonic testing system and all NDT technicians required for the work offshore. The Rotoscan system produces a printout which was used directly for general acceptance purposes, with further investigation manually used to define areas for repairs. It was found that the stainless steel filler metal in carbon steel pipe, plus the influence of the clad layer gave rise to signals which required sophisticated interpretation techniques to be developed. Conclusion top

The Maui A-B pipeline was successfully completed and is the longest clad pipeline in the world. Pipelaying continued uninterrupted by the severe weather conditions of the Tasman Sea, where waves of 23' (7 metres) did not stop production. In laying the Maui A-B pipeline Heerema proved the operability of an innovative pipelay technique, enabling the laying of pipelines in deep waters and across sea bed of uneven topography.