The oil and gas industry plays a very important role in the global energy supply as well as the world economy. Many technologies are crucial to the existence and functioning of this multi-billion dollar industry. One of these is welding.
The oil and gas industry utilizes various highly complex infrastructure such as rigs, pipelines, platforms, plants, and facilities. The majority of these infrastructures are created using welding technologies. Welding is critical in oil and gas operations both for the construction of new projects and for the maintenance of existing facilities.
Applications of Welding in Oil and Gas
The oil and gas industry is divided into three major stages of operation. These, which can be referred to as sectors, are Upstream, Midstream, and Downstream. Welding is widely used across all these sectors and its applications can be classified accordingly.
Benefits Of Dry Ice Blasting And Its Advantages Over Other Cleaning Methods
Dry ice blasting is an advanced cleaning and surface preparation process in which pressurized dry ice pellets (frozen CO2) are blasted at a very high speed and pressure at the surface to be cleaned. The extremely low temperature (109 F) of the pellets causes loose surface dirt and debris to dislodge due to thermal shock, while the kinetic energy of the pressurized jet knocks off the contaminants. Dry ice blasting is a highly effective cleaning method that is fast, effective, environmentally friendly, non-toxic, and non-abrasive. It is often preferred over other cleaning methods such as sandblasting, bead blasting, wet blasting, scraping, and chemical cleaning, due to its numerous superior characteristics and inherent advantages. This article explores the characteristics and benefits of dry ice blasting and its advantages over other cleaning methods.
Red-D-Wraps are customizable induction heating wraps that can be cinched up to give you a tight fit for induction heating of pipes and other workpieces. Red-D-Arc’s Orbital, Heating and Pipe Manager Lori Kuiper gives a brief overview of these innovative new induction heating accessories in the video below. Red-D-Wraps will be featured along with other new heat treatment equipment at our display at this year’s SEAA Tradeshow.
Welding automation has been around for a while, but recently its role has grown exponentially in manufacturing. For years, the welding industry has faced a skill gap, which is expected to grow wider in the coming years. To combat this, employers are adopting automated welding equipment to increase the efficiency of weld operations.
What Is the Skill Gap?
The “skill gap” describes a discrepancy between the skills held by job seekers and the skills employers need. This leads to a paradox where there’s a large pool of applicants, but companies aren’t able to hire workers with the appropriate knowledge and skill set. This has led to increasing welder salaries as manufacturing businesses compete to attract skilled workers, and even then, many positions are left unfilled.
The BotX robotic welder was featured on the Automation.com blog in April 2021. Automation expert Bill Lydon examines how some of the challenges faced by manufacturing firms can be met through the adoption of automation technologies like the BotX Welder. (more…)
Video: Watch how easy it is to set up the BotX Robotic Welder for a radial weld. Just over 2 minutes total.
This next generation welding robot is easy to learn and use and is operated via a mobile app.
Red-D-Arc Powerentals was called in to assist with the dewatering of a flooded area in Louisiana. Flooding in the region had been a problem for weeks leaving some residents with up to 3 feet of water in their homes. Our generator specialists are experienced in providing optimal emergency power solutions in a cost effective manner.
By booking your generator in advance you can be ready for blackouts, floods or other emergency situations. Thanks to generator specialist Michael Stevens for the photos. (more…)
Welding aluminum just got easier with the help of the Magnum SG spool gun from Lincoln Electric. The Magnum SG is a lightweight, semiautomatic spool gun designed to provide easy and reliable aluminum wire feeding. It works with a variety of CV power sources and engine-driven welders. Rated 250 amps @ 60%, the Magnum® SG features a 25 ft (7.5 m) gun cable and integrated wire feed speed control in the handle to reduce the need for walking back to the power source. (more…)
The Dual Maverick™ 200/200X is an advanced diesel engine driven welder with dual welding outputs. This best-in-class arc welding machine provides reliable power for multiple welding arcs, runs quietly, and promotes fuel savings with variable engine RPM and auto start/stop capabilities.
“This best-in-class arc welding machine provides reliable power for multiple welding arcs, runs quietly, and promotes fuel savings”
Miller’s ArcReach air-cooled induction heating system is designed for preheat and bake-out applications at temperatures up to 600 degrees Fahrenheit (315°C), without requiring cooler and coolant. Temperature control settings can be manually programmed or uploaded via USB stick. All heating data is recorded automatically and can be saved for quality control and documentation purposes.
“Achieve critical temperatures quickly and hold them steady over long periods of time”
Most of us are aware of industrial welding robots—those large, fast machines found on big assembly lines. But what about collaborative robots, also known as cobots? These compact machines can work safely alongside humans, but don’t let their size fool you; they’re the next big thing in welding automation.
If you can operate a smartphone, you can set up and operate the BotX welding cobot. Traditional industrial robots can take weeks to install and program. This same app offers a real-time cloud connection, which allows for 24/7 performance monitoring and troubleshooting support. (more…)
Collaborative robots like the BotX Welder are shaping the future of manufacturing. Rob Goldiez of Hirebotics joins robotics investor Marc Cuban and Enrico Krog Iverson of OnRobot to discuss the impact of collaborative automation technology.
Thisvirtual event will see the robotics thought leaders discuss their powerful visions of the future of manufacturing. The expert panel will share insights on how collaborative automation helps future-proof manufacturing companies, helping to build resilience and reduce risk as the world navigates unprecedented COVID-19 challenges where uncertainty is now the only constant.
Applications and Advantages in Tank Fabrication and Maintenance
In the fabrication of storage tanks, as in most other welding applications, there are two crucial processes that storage tank fabricators must carry out to ensure the final quality and durability of the tanks. They are weld preheating and post-weld heat treatment.
Pre-Heating
Preheating involves heating the material to be welded to a particular temperature before welding. This process reduces shrinkage by minimizing the temperature between the arc and the base material. It also removes moisture, lowers hydrogen, and slows the weld cooling rate. These reduce the risk of cracking, brittle welds, and failure of the welds. Preheating is crucial for storage tanks as they are to withstand high pressures during operation.
Power is out to more than 500,000 customers with an estimated 3 to 5 weeks to restore power. Generator-powered, air conditioned tents have been set up to provide power workers with meals; and we’ve also supplied generators for power requirements for restaurants, casinos, fabrication shops, etc.
Other members of our South West Region team are working tirelessly to mobilize generators for all segments of need. A big thanks goes to Michael Stevens and all our supporting personnel to be able to deliver more than 100 generators in a matter of hours.
Special thanks goes to Dave Kendrick and his team, for their outstanding efforts preparing our Lake Charles building prior to the hurricane landing. Dave worked late into the night to provide us with the best chance of weathering the storm. In the pictures below, you can see we sustained minimal damage compared to other buildings located down the road and we are very fortunate to have come out of this storm as well as we did.
TIG Welding is a cost-effective manufacturing process. However, several factors can significantly increase or reduce the cost-effectiveness and productivity of a welding project. These range from operational efficiency to the use of consumables.
In this article, we’ll go through 10 ways to significantly reduce welding costs and boost the productivity of welding projects.
1. Avoid Overwelding with TIG Welders
Overwelding occurs when a weld is larger than it needs to be. This is a common occurrence in the welding industry, especially with inexperienced welders. An overweld may result when there is no specified size in a design, when there is no fillet gauge, or when a big weld is created just to play it safe.
Overwelding is a significant resource drain; it uses more arc time, labor, shielding gas, and filler metal, which leads to higher costs. To put this waste into perspective, consider a 1/4″ overweld instead of a required 3/16″ weld: This results in a 78% increase in both weld metal deposition and arc-on time. This goes up to 177% when the overweld is 5/16″.
Increased cost and time are not the only negative implications of overwelding. Bigger-than-required welds tend to distort more because of the increased heat input. Also, excessive convexity may increase the likelihood of a weld failing due to fatigue. In groove joints, excessive reinforcements do not create stronger welds compared to welds that are flush (or just above) the base material surface.
To save resources and time, stick to weld specifications in designs, make use of a fillet weld gauge, and avoid excessive reinforcements on groove joints. A change in wire diameter may also be used to avoid overwelding.
2. Employ Weld Automation
Weld automation is the use of equipment that automates part or all of the welding process. Human operators, no matter how skilled, are susceptible to fatigue. They can also make errors during welding or other related activities (e.g., positioning and handling pieces of the weldment). These factors, coupled with safety concerns, can affect the productivity of welding.
There are numerous types of automation equipment that can greatly increase productivity and save cost. However, different levels of automation can be applied in welding, and the term automation doesn’t necessarily mean robotic welding. For example, hard automation is the use of weld positioners, manipulators, and turning rolls to keep a weldment in place. There are also fully automated setups in which the actual welding is carried out by robotic arms—this is known as robotic welding.
The use of automation makes welding safer, faster, more productive, and more cost-effective. Compared to humans, machines are quicker, more consistent, and less prone to errors. Machines are also easily programmable, thus reducing the cost of hiring, managing, and training human workers.
3. Use the Right Welding Process
Weld aesthetics To effectively boost productivity, it is important to review all these factors before selecting a welding technique. For example, welding is more precise than metal inert gas (MIG) welding but requires more skill. If aesthetics is an important consideration, a TIG Weldershould be used, as MIG would cause you to spend more time later on in finishing. There is no need to select the submerged arc welding (SAW) process, with its high deposition rate of, when your project only requires the 5 lb/hr deposition rate of stick welding.
To make sure that you are not consuming more resources than necessary you need to review all considerations. Also, selecting the wrong process may lead to the production of rejects.
4. Handle and Arrange Materials Properly
The proper handling of materials during welding is crucial to improving productivity. Valuable time is wasted when a welder has to stop a welding process, go somewhere else to look for (and procure) a needed welding accessory, return to the welding spot, and resume welding. Even more time is wasted when weldment pieces are scattered around the welding area. While these short interruptions may seem trivial, they add up to significant time-related costs.
Before welding begins, all consumables, welding accessories, and parts to be welded should be sorted out and arranged in proximity to the welder.
5. Properly Maintain All Welding Equipment
The importance of having equipment in excellent condition for productivity and cost savings can hardly be overemphasized, as faulty equipment may consume more resources while generating more waste. Frayed cables and faulty appliances can lead to voltage losses, wire feeding problems, and erratic arcs. Likewise, faulty gas systems can lead to gas leakage. All these contribute to the potential inefficiency of welding operations. There is also the problem of defective equipment producing poor-quality welds, which may lead to more rejects, compromised worker safety, and costly downtime. Investing in a comprehensive preventive maintenance program reduces costs in the long run.
6. Prepare Joints and Gaps Properly with TIG Welders
Adequate preparation of joints is required for a hitch-free welding process. To start, welding operators should carefully clean the surface of the base materials. This will help prevent contaminants, such as dirt and oil, from entering the weld puddle. Next, welding operators must ensure they have the right fit-up and no excessive gaps.
A poor fit-up can have numerous negative consequences. One example is the potential for distortion or burn-through, which compromises the strength of welds. Poor fit-up also leads to overwelding, as gaps increase the size of weld required to achieve the same load-bearing capacity. For example, a 1/4″ fillet is required for a joint when there is no gap. A gap of 1/8″ in that same joint would require a new fillet size of 3/8″ to achieve the same strength. That amounts to a 124% increase in filler metal consumption.
7. Control the Use of Consumables
Consumables such as shielding gas, filler metals, anti-splatter compounds, grinding wheels, back bars, and gun components account for a noteworthy portion of the total welding cost. As a result, their proper use is important in keeping costs low. Certain consumables should only be used when necessary.
Gas delivery systems should be checked regularly so that leaks can be identified and sealed off. Surge turbines and surge guards can be attached to the end of welding guns to measure gas surge and reduce pressure, respectively.
8. Boost Efficiency
Labor cost is the largest cost variable in any welding project. One way to reduce this cost and boost welding productivity is by ensuring efficiency in all operations. The following operations are all time-dependent activities that can be optimized:
Preparing the metal for welding
Preparing the joint
Assembling components
Preheating, if required
Tack welding components, if required
Positioning/repositioning, if required
Moving between welds
Interpass cooling, if applicable
Grinding spatter
Inspecting and testing for
Reworking/repairing of welds and subsequent
Post-weld heat treating, if applicable
It is evident that a lapse in one operation can have a domino effect on the operations that follow it. For example, poorly prepared joints can lead to overwelding, which in turn can lead to avoidable grinding and polishing. Likewise, poor positioning may lead to reworking and repairing of welds.
While inefficiencies in operations may be difficult to track and measure, the rewards are worth the effort. An effective way to spot inefficiencies is as follows: If step 2 is a required process for step 3, then all is in order. However, if step 2 is carried out to correct or optimize step 1, then there are inefficiencies inherent in step 1.
Another way of boosting productivity is by using technology that enhances efficiency. One of which is with cable length compensation (CLC™), adjust while welding (AWW™), Auto-Line, and SuitCase™ wire feeder which delivers smooth wire feeding with accurate, consistent speed. These boost productivity and reduce labor time and cost.
9. Minimize Rejects and Reworks
When a reject is produced, 100% of the filler material, shielding gas, electricity, labor, and time used is wasted. This is terrible for cost savings. Reworks also result in wasted time, resources, and labor. Ensure that through skill and efficiency, rejects and reworks are eliminated when using TIG welders.
10. Prioritize Welding Safety
While they do not directly contribute to welding costs, workplace accidents are never desirable nor do they contribute to the efficiency of any production environment. Worker safety should always be a top priority in any company, especially when working with TIG welders.
Ensure that you take all necessary precautions and follow the pertinent guidelinesand regulations to maintain the safety of welding operators throughout a welding project. High-quality safety gear and comprehensive safety plans help to prevent injuries and save costs in the long run.
Whether you’re working in the petrochemical, manufacturing, or food and beverage industry, plant shutdowns are inevitable. Plant maintenance is vital to optimizing the peak performance of a facility to ensure profitability, safety, and regulatory compliance.
From a routine plant shutdown and maintenance period, metrics such as quality, schedule, and cost can be measured and planned in advance. However, exceptions such as the global outbreak of the COVID-19 global pandemic can pave the way for unexpected maintenance opportunities. In a move to contain the virus spread, companies close up shop temporarily to follow government mandates, protect their employees and take advantage of the opportunity to perform deep-cleaning routines using technologies like dry ice blasting on their factories simultaneously.
Due to decreased market demand and socioeconomic factors, ramping up production won’t make sense in this time of crisis. Economically, increased future profits from plant maintenance might outweigh the revenue loss from operations and expenditures from the plant shutdown once all capital assets are calibrated to perform optimally. In this article, we discuss the crucial steps on how to manage a successful plant turnaround with welding factored in.
1. Planning and Scope Management
Plant shutdown or turnaround requires detailed project management. Managing complex layers of plant maintenance that revolve around three crucial standpoints of cost, time and quality can make or break the plant turnaround performance.
Stakeholder involvement also plays a part in setting the scope of work for the plant shutdown. Success should be measured from the business, operation, execution, and organizational perspectives. Hiring plant turnaround service providers can be beneficial in terms of shutdown expertise, while in-house skilled staff can provide the essential historical data from previous plant shutdowns to set the baseline metrics and benchmarks. These can include:
Calculation of labor hours and rates
Initial work packages
Equipment data records
One example of this client-contractor integration would be a defective pipeline weld requiring repair every few weeks. While a short-term solution by the client would be to weld over the cracks, in due time it will cost more in the long run if failure analysis is not performed by a competent welding engineer. It could be as simple as identifying the root cause, or as complex as examining fractured surfaces under an electron microscope and performing metallurgical tests.
2. Cost Management
Plant shutdowns can be very expensive, as any profits spread over the years can be slashed in a span of weeks to a few months’ time. Whether on a full-scale or segment basis, you need to factor in two direct costs on your estimates: maintenance fees from execution and profit loss.
As plant maintenance incurs costs, scheduled stoppage for plants is often moved from annual to 3-5 years due to upfront investment in quality machinery. However, any lack of routine maintenance on aging equipment can impede the productivity of a plant. Industries that rely heavily on welding can cause major headaches oncewelding equipmentbreaks down.
In three words, here’s one way where you can save up on costs: Preventable Cost Efficiency (PCE). Put actual numbers to the problem by dividing the cost of service per hour and the cost of production maintenance per hour. If a plant turnaround service provider charges $50/hour and downtime costs $500/hour, then PCE is 10%. You could pay $10 now for preventative maintenance of your welding equipment or pay $55 later for the repair of hard or soft failures.
3. Schedule Management
Since plant shutdowns have a direct cost-to-schedule ratio, there’s enormous pressure to finish the turnaround early or on time for potential savings. This requires efficient resource management: planning for risk mitigation, expert plant turnaround services, lead times on material and equipment procurement, labor availability, and duration of work packages. Maintenance systems are grouped into:
Routine
Predictive
Breakdown
Preventive
Turnaround managers schedule the scope of work on a critical path method (CPM) – achieving essential objectives in the shortest amount of time. Red-D-Arc provides two value-based solutions to this time-deficit problem: orbital welders produce quality pipe welds and minimize weld time by utilizing a gear-driven track ring system, while multi-process TIG welders combine 4-in-1 solutions (TIG welders, MIG welders, flux core and stick welding) providing a flexible versatile welding solution.
4. Inspection and Execution
For heavy-impact industries reliant on welding, inspection for plant shutdown should be done in an agile process with control points. Prior to procurement, welding engineers should perform material inspection alongside the planning phase to determine on a priority basis what needs removal, replacement, repair, or alteration.
To repair weld, knowing the material specification can’t be overstated. Welding engineers or turnaround managers should cross-reference construction drawings with the maintenance handbook and identify any grade markings that require regulatory compliance such as ASTM and AISI/SAE. Welding aluminum and steel on building structures require different welding procedures under AWS D1.2 and AWS D1.1, respectively.
Even far stricter under ASME B31 Code for Pressure Piping are boilers, vessels, and tanks with ASME marking stamped on nameplates. Stringent regulations impose that only contractors with “R” stamp issued by the National Board of Boiler and Pressure Vessel Inspectors are qualified to perform welding on these components.
For accuracy, cut the weld material for laboratory analysis and identify minimum requirements below:
Welding process used
Welding electrodes or filler metals to be used
Preheating and post-weld heat-treating requirements
Heat input control
Defect removal
Final inspection and non-destructive testing (NDT)
5. Quality Assurance / Quality Control (QA/QC) and Safety
Once plant shutdown is underway, perform safety regulationson-site for welded components per ANSI Z49.1 Safety in Cutting, Welding, and Allied Processes. Anytime a TIG welder enters a confined space for repair, local exhaust ventilation measures such as a downdraft bench and movable hood should be employed.
Existing building steel has external structural loads to be removed before weld repairs so consult AWS D1.7 Guide for Strengthening and Repairing Existing Structures. To minimize hydrogen-induced cracking and restore ductility, induction heaters can be employed for pre-heating and post-weld heat treatment, resulting in efficient weld quality of high-strength and low-alloy steels.
6. Restart
Plant shutdowns won’t be complete without final inspection for testing and commissioning. Once all systems are up and running with normal or improved performance levels, regulatory agencies will give you a green light for the startup. The final report will serve as baseline data for future plant turnarounds.
In welding, like in many other manufacturing and fabrication processes, the process is not complete until the necessary post-processing has been carried out. Post-weld operations are usually performed for reasons such as improving mechanical properties, relieving stress, and improving aesthetics. The two most common Post-weld operations are Post-Weld Heat Treatment (PWHT) and Finishing.
Post-Weld Heat Treatment
During welding, the welded materials are exposed to very high temperatures that can cause micro-structural changes in them. Also, residual stresses build up in welded materials when they are allowed to cool naturally. If left unaddressed, these stresses and structural changes can severely compromise the mechanical properties of a material and can lead to failure during use. To prevent this, PWHT is required for welded parts. There are two major types of Post-weld heat treatment and they are as follows. (more…)
Red-D-Arc’s dry ice blasting equipment was provided as part of the restoration effort for the prestigious Stephen F. Austin statue in Sugarland, Texas. Our team of dry ice blasting specialists delivered solutions to get the project completed with a package consisting of two Cold Jet dry ice blasting machines, two high volume after-cooled 375CFM air compressors, 2,500 lbs of blasting ice (CO2), and on-site operator/safety training. (more…)
Quality Assurance (QA) is a set of defined processes for systematic monitoring and evaluation to assure product quality.
Quality Control
Quality Control (QC) is the process of confirming that the product meets the specifications. It includes the checking and testing of manufacturing procedures as well as the final products. The results from these tests are compared with a set of defined acceptance criteria. By carrying out QC testing during manufacturing, defects can be identified in a timely manner, allowing for the product flaw to be rectified and if required, adjustments to be made in the manufacturing process to prevent further defective output.
In welding, QA/QC plays a vital role in ensuring sound and reliable welds are produced and in minimizing rework. (more…)
Dry Ice Blasting Solves Equipment Maintenance Challenges in the Coatings Industry
One of our customers – a powder pigment coating facility in Houston maintains one of the most extensive portfolios of powder technologies in the industry. When they encountered difficulties with their existing cleaning methods, they turned to Red-D-Arc for equipment cleaning alternatives. (more…)
Airgas, an Air Liquide company, is the nation's leading single-source supplier of gases, welding and safety products. Known locally nationwide, our distribution network serves more than one million customers of all sizes with a broad offering of top-quality products and unmatched expertise.
Welding aluminum just got easier with the help of the Magnum SG spool gun from Lincoln Electric. The Magnum SG is a lightweight, semiautomatic spool gun designed to provide easy and reliable aluminum wire feeding. It works with a variety of CV power sources and engine-driven welders. Rated 250 amps @ 60%, the Magnum® SG features a 25 ft (7.5 m) gun cable and integrated wire feed speed control in the handle to reduce the need for walking back to the power source. 
The Dual Maverick™ 200/200X is an advanced diesel engine driven welder with dual welding outputs. This best-in-class arc welding machine provides reliable power for multiple welding arcs, runs quietly, and promotes fuel savings with variable engine RPM and auto start/stop capabilities. 
Miller’s ArcReach air-cooled induction heating system is designed for preheat and bake-out applications at temperatures up to 600 degrees Fahrenheit (315°C), without requiring cooler and coolant. Temperature control settings can be manually programmed or uploaded via USB stick. All heating data is recorded automatically and can be saved for quality control and documentation purposes.
