Innovative Welding Processes for Small to Medium Diameter Gas Transmission Pipelines

Fast Facts
Technology and Commercialization
Research Entity:	Edison Welding Institute, Inc. 1250 Arthur E. Adams Dr. Columbus, OH 43221-3560
COTR:	Anthony Rallis, Anthony.rallis @ dot.gov, (713)272-2850
Contract #:	DTRS56-05-T-0001
Project #:	154
Contact Info:	Ian Harris Principal Engineer Edison Welding Institute, Inc. (EWI) 1250 Arthur E. Adams Drive, Columbus, OH 43221 Phone (614) 688-5131 Fax (614) 688-5001 Email ian_harris @ ewi.org
Partners:	EWI Cranfield University UK
Peer Review	Very Effective (PHP-1-2006, Feb 7-9, 2006)
Technology Demonstrated?	Yes
Commercialized (in whole/part)?	TBD
Financial and Status Data
Project Status:	Completed
Start Fiscal Year:	2005 (11/01/2004)
End Fiscal Year:	2006 (04/30/2006)
PHMSA $$ Budgeted:	$399,989.00
$$ Co-Funded:	$700,000.00
Total Project Cost:	$1,099,989.00

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Main Objective

The project aims to develop innovative welding processes and technologies for single-sided pipeline girth welding. Root pass welding techniques will be emphasized since they have the greatest potential to improve pipeline integrity and facilitate the use of new and existing GMAW fill pass techniques. Advanced automation techniques will be used to improve weld quality, process control, seam tracking, and robustness.

Public Abstract

A major challenge in high strength pipeline construction is producing small to medium diameter girth welds that have high quality and integrity. Manual shielded metal arc welding is currently used on these pipeline applications where the resulting weld deposit has marginal properties, high hydrogen content, and high defect propensity. This process is not suitable for higher strength materials used in high integrity applications. This proposed project will develop innovative gas metal arc welding (GMAW) and hybrid laser-GMAW processes and technologies for single-sided pipeline girth welding of small to medium diameter pipe (24-inch and less). A key requirement is the welding from a single-side with no internal backing tools or internal welding machine. The project team includes EWI, an internationally recognized leader in the development, evaluation and validation of pipeline welding, and materials joining technology; and Cranfield University, a leading provider of state-of-the-art automated pipeline welding technology.

Final Report

EWI Project No 47961GTH Technical Report Task 1