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Automatic Pipe Welding In Australia
Bob Teale
President - TPWS Inc
Automatic Welding
Economics of
Automatic Welding
Automatic Welding
Background
Advantages and Disadvantages
Economic Factors
Rule of Thumb
Costs and Prices
Relevant Information
TPWS Role
Automatic Welding
Background
Original: CRC (Band & Bug System)
1968/1969
Automatic Welding
Offshore Alternatives: ETPM Rack (Four (4) Heads)
McDermott Rack (Four (4) Heads
PASSO Band & PASSO Band & Bug
Background
Automatic Welding
Premier AW Systems
Serimer Dual Head Band & Bug with
Remote/Computer Control and Wire Feed
Vermaat Single-Dual Head Band & Bug with
Remote/Computer Control and Wire Feed
CRC-Stanley IWM, Single-Dual Head Band & Bug with
Remote/Computer Control and Wire Feed
Background
Automatic Welding
RMS IWM, Single-Dual Head Band & Bug
Lone Star Single-Dual Head Band & Bug
Firefly Band & Bug – Second/Third Generation
SPA/Comet Band & Bug – Second/Third Generation
Magnatech Band & Bug – First/Second Generation
PWT Band & Bug – First/Second Generation
PASSO Band & Bug – First Generation
Background --- Other Systems
Automatic Welding
42 Years and Getting Better!
Background
WHY?
Automatic Welding
40 Years and Getting Better!
Offshore Pipelines even small diameter 100% GMAW
Most Offshore Contractors own equipment
Major land lines significant use of Automated GMAW
Most Land Contractors rent equipment, some own
“Second Generation” equipment
Background
Automatic Welding
High Weld Metal
Deposition
Fast Joint Fit Up
Less Weld Volume
Superior Mechanical
Properties
Higher Efficiency
Improved Weld Quality
Low Hydrogen Process
Less Manpower Required
QA/QC monitoring
available
X100-120 and CRA Pipe
Advantages over Manual Welding
Automatic Welding
Increased Productivity
Decreased Volume of Weld Metal
High Quality
Smaller HAZ
Higher Quality
Advantages over Manual Welding
Manual Automatic
Automatic Welding
Advantages
Faster root pass welding speed
Better tolerance to Hi/Lo
No copper contamination
Better Quality Root Profile
Better Corrosion Resistance
Disadvantages
Cost
Limited to 24” Ø and above
Maintenance
Misfire
Internal Welding Machine
Automatic Welding
Advantages
Cheaper than IWM
Available for Small Diameters
Disadvantages
Copper Contamination Risk
Slower Production Rates
Less tolerance to “High Low”
Weld Tent Required
Welders needed for Root Pass
Bug Needs CTWD Control
Copper Back-Up Clamps
Automatic Welding
Advantages
Cheaper than IWM or Copper
Available for Small Diameters
No Risk of Cu contamination
Disadvantages
Slower Production
Special Power Supply
Weld Tent Required
Skilled Welders needed for
Root Pass—Semi-Auto
Bug needs CTWD Control
No Backing Root
Automatic Welding
STT – Surface Tension Transfer
Automatic Welding
ROOT PASS WELD TIMES 42” Ø
5.33
3.56
1.6
0.78
0 1 2 3 4 5 6
Stick
STT
External
Internal
z
Automatic Welding
External Welder
Advantages Proven Reliability
Computer Control Option
“Thru the Arc” Tracking Option
Remote Pendant Option
Disadvantages Single Arc
Spare Parts and Maintenance
Not all Bugs are Equal
Automatic Welding
Advantages
Less Welders
Less Tractors
High Deposition
Lower Harness
Higher Production
Disadvantages
Increased Equip cost
More Equipment issues
Additional Welder
Training
More difficult WPQ
Additional
Maintenance/Spares
Dual Head
Automatic Welding
Dual Head
Single Head Orbital
Machine
Dual Head Orbital
Machines
40 - 50 % Increased Deposition
Fills 3 & 44322
1Fills 1 & 2
Fill 1
Fill 2
Fill 3
14 mm
Automatic Welding
Offshore Dual Head Bug
Automatic Welding
Narrow Gap Bevel
Less Weld Volume
Fewer Weld Passes
Faster travel Speed
Higher Arc Time Efficiency
Higher Arc Time %
No Wire/Rod Changes
Economic Factors
Automatic Welding
Offshore Pipelines
The Automatic Welding of
even short lengths of
small diameter projects
can be cost effective
offshore
Economic Factors
Automatic Welding
The length of the line has a major impact
on the cost effectiveness of Automatic
Welding
However, if the Contractor owns his own
equipment, short pipelines may be cost
effective
Economic Factors
Automatic Welding
Terrain
Climate
Schedule
Pipe Material
Mobilisation Time / Welders
Weld Properties
Quality Acceptance Criteria
Economic Factors
Automatic Welding
Rule of Thumb - Example
Pipe Diameter Wall Thickness Length AW Factor
36” x 0.500” ÷ 35 miles = 630
24” x 0.812” ÷ 60 miles = 1169
48” x 0.688” ÷ 100 miles = 3302
12” x 1.500” ÷ 30 miles = 540
Automatic Welding
Rule of Thumb – AW Factors
AW Factor
0-500 Not normally cost effective
501-1000 Difficult to complete
1001-1500 Possible AW Projects
1501-2000 Probable AW Projects
2001> Automatic the Only Real Option
Automatic Welding
Offshore
X80 - X100 and CRA Materials
Fast Track Projects
Labour Restrictions
Climate / Terrain
Mechanical Properties
Rule of Thumb - Exceptions
Automatic Welding
Land Auto Weld Production Rates 36”– 48” Ø
Internal Welder Pass 40’ Joints =
150 to 200 joints a day
External Copper Root Pass 40’ Joints =
80 to 120 joints a day
External No Backing Root Pass 40’ Joints =
40 to 50 joints a day
Consider 80’ Double Joints or Mini Spreads
Automatic Welding
Total Project Support
Field Welding Support / Engineering Support
Spare and Consumable Parts
Welding Wire ---- Use Bohler-Thyssen, ESAB or Lincoln
Equipment Package Tailored specific needs
International Service
Training / Consultant
Automatic Welding
The Future
Automatic Welding will continue to replace Manual
The Prospects for Growth in AW is significant
Computer Controls will increase Automation
Auto Weld will become more cost effective
Lower cost machines will be available
Automatic Welding
Advancing Technology
Automatic Welding
Advancing Technology – P-625
Automatic Welding
Advancing Technology – P-625
Automatic Welding
Enhanced Productivity
Multi-Welding Process
Computer Tracking
Computer CTWD
4 Synchronised bugs
Real-time QA/QC
Fume Extraction
Advancing Technology
SERIMAX S-XI
Automatic Welding
Advancing Technology
Automatic Welding
Concluding Remarks
Automatic Welding
Concluding Remarks
Bob Teale --- “The Automatic Choice”
That’s all folks!
Thank you for listening!
Questions Welcome
