and point-of-use welding controls can reduce the need to travel to and from the power source. This optimizes arc-on time at the weld joint, reduces setup time and simplifi es process changeover, which in turn helps improve overall weld quality and productivity. The Miller PipeWorx FieldPro system offers these ad- vanced capabilities and technologies without the need for special control cables, instead using the standard weld cable. This eliminates the hassle and expense of special control cables and reduces clutter. The system offers a remote that basically allows welding operators to take the capabilities from the front panel of the power supply right to the area where they are welding. This makes process changeover easier, which eliminates the need to “get by” with less than optimal settings and helps reduce weld defects and associ- ated rework. Software in this advanced system also allows the creation of welding programs in all welding processes that are specifi - cally designed for welding pipe. Technologies are also available designed specifi cally for the shop environment, offering productivity, quality and safety benefi ts for pipe welding operations. Rolling induc- tion heating, available for preheating rolled pipe in a shop environment, leverages the benefi ts of rolled pipe welding while also addressing some of the concerns associated with other heating methods. Induction heating can bring the part to temperature quickly and hold the machine at a steady output, making it a good option for getting consistent tem- perature levels.
Optimizing the Process
Many factors come into play when choosing the appropri- ate welding process: the application, position of the weld, material type, welding procedure and possible job or contract requirements. With all the welding processes, selecting the right consumables and equipment can help optimize the arc for the best results.
While TIG and stick welding are familiar processes in the
fi eld that offer benefi ts for that environment, wire welding processes are another option that offer signifi cant productiv- ity benefi ts.
Switching to advanced welding processes, such as pulsed MIG or modifi ed short-circuit MIG, is another way pipe welding operations in the fi eld (and in the shop) can improve productivity. These processes offer a more forgiving weld to help reduce weld failures, and they can reduce the neces- sary training time and make it easier for a welding operator to complete an X-ray quality weld on the root pass.
Rolling induction heating, available for preheating rolled pipe in a shop environment, leverages the benefi ts of rolled pipe welding while also addressing some of the concerns associated with other heating methods.
Productivity gains can result from using a modifi ed short-
circuit MIG process for the root pass in pipe welding due to the potential that exists to eliminate the need for a hot pass. This advanced process (one example is RMD, or Regulated Metal Deposition, from Miller) provides the ability to create a thicker root pass of 3/16" (4.8 mm) or greater—enough to support the heat input of pulsed MIG or fl ux-cored welding for the fi ll pass.
The faster travel speeds and higher deposition rates of-
fered by advanced welding processes allow welding op- erators to complete code-quality welds in less time. A 24" (588-mm) Schedule 160 pipe that might take two days to stick weld with two operators can be completed in nine hours or less with one welding operator using advanced welding processes, for example. These advanced welding processes are available in sys- tems with remote control technologies, so welding operators can maximize productivity with the faster advanced pro- cesses while also taking advantage of the ability to change processes and parameters at the weld joint with the push of a button.
Addressing the Challenges Focusing on equipment, process and consumables solu- tions that offer ease of use, enhanced productivity and im- proved performance can help address the labor and timeline challenges facing many pipe welding operations today. Adapting to new technologies and processes can sepa-
rate the profi table from the unprofi table. These advance- ments help companies address critical industry challenges such as the shortage of skilled welders, shorter project turn- around times and the need to increase quality standards.
65 — Energy Manufacturing 2015
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