19 Hours Faster Than the Competition
Texas – One of our customers was trying to heat 42” diameter pipe using pear burners so that welders could weld out the joints. Our team saw an opportunity to create a solution that would help our customer get the job done much more quickly. To make this in-the-field heating job go faster, we put together a package including a Miller ProHeat 35 induction heating system, a 60kVA generator and a DP25 power distribution panel.
Red-D-Arc provided a reliable RDA Induction heating solution to a pipeline construction and maintenance company in Houston who needed to maintain consistent temperatures for their welders to weld out joints from pipes. Our induction heating specialist supplied our customer with a portable induction heating package consisting of a 60 KVA generator, a Miller Pro-Heat 35 induction heating system, and a DP25 power distribution panel. As a cost-effective alternative to their existing propane burners, induction heaters allowed them a secure heating, consistent temperature control, increased weld time, and improved safety.
With this setup we were able to get the pipe up to 250 degrees in about 5 minutes. Our customer was able to beat the competition’s target time by over 19 hours and has been asked to quote on other pipeline work for their client. Needless to say they were pleased with the solution and the opportunity for extra work it created.
Plasma cutters are capable of cutting metals in simple and complex shapes including producing holes, bevel edges, gouging, and markings. Plasma is a cost effective and practical alternative to oxy-fuel, laser and water jet cutting processes and is used in industrial, trade and DIY applications. Plasma cutters are used in all types of industries including manufacturing, pharmaceutical, oil/gas and arms industries.
When gas is heated to extremely high temperatures, the electrons in the gas molecules break free from the nucleus, turning the gas into plasma. Plasma cutting is carried out by directing the plasma jet through the metal.
The advantages and disadvantages of plasma cutting as compared to the other cutting processes are as follows:
Pre-weld and post-weld heat treating is critical for many welding operations. Without proper thermal manipulation, welds and heat affected zones can have mechanical properties that are undesirable. Worse yet, inadequate heat treatment can result in cracks and devastating weld failures. While temperature and time are the primary concerns when heat treating a weld, the heating method should also be considered diligently when selecting a process. Induction heating is one of the most popular types of heat treating methods, and rightfully so. The benefits of induction heating are many, and Red-D-Arc has the equipment you need to successfully implement an induction heat treating operation for your projects.
Welding small diameter tubing can be difficult. The tight radii often require expert welders to deliver precise torch manipulation with finesse. If the welder is not skilled enough, the out of position areas are at risk of poor quality due to gravity affecting the weld pool and ineffective torch angles. If out of position welds cannot be completed satisfactorily, the part must be rotated. However, some assemblies can’t be rotated because of size constraints or they might rotate off of center. If a mechanized welding solution is desired for small diameter components, look no further than our Axxair Orbital Fusion Closed Welding Head Systems.
The method you select for welding pipe will depend on the location where the welding is taking place, materials and pipe size.
For welding steel pipes in the open (e.g. pipe installation in trenches), manual arc welding (SMAW) is most common. This technique used is downhill using cellulosic electrodes (also basic electrodes are used for higher strength steel applications). A root pass and a hot pass are followed by the fill passes. The weld is finalized by the top pass. Welding units optimised for downhill welding are utilised.
Welding Smaller Pipes
For small diameter and short length pipes which are free to rotate, the pipe is rotated while the welding torch is held stationary. The processes used are MIG (GMAW) and TIG (GTAW). In the case of TIG welding a wire feeder is necessary. A process cell is best for this type of welding.
Welding Large Pipes
In applications involving larger pipe sizes, welding is generally carried out using the orbital process. MIG is usually employed, but TIG with automatic feed of the filler wire can also be used. Orbital process using closed head welding units is also utilized for applications where smaller pipes cannot be rotated.
There are a number of advanced methods of depositing pipe welds currently in use. These include precisely controlled short circuit transfer for root pass (Miller – Regulated Metal Deposition), optimized pulsed welding (Miller – Pro-Pulse) and high frequency waveform control (Lincoln – Surface Tension Transfer) in order to speed up and improve the quality of the pipe welds.
Red-D-Arc has a wide range of pipe welding equipment for rent including the following:
- Closed head orbital welding units for small pipe diameter
- Orbital TIG welding system for larger pipe diameters
- Orbital MIG welding system
- Process pipe cell with oscillating open arc welding
- TIG and MIG welding power sources suitable for above
- Cutting and bevelling saws for up to 12.75” (325mm) pipe diameter
Have a look at our entire selection of pipe welding equipment which includes pipe cutters and bevelers.
Read more on orbital welding