Innovative Welding Processes for Small to Medium Diameter Gas Transmission Pipelines

Overview

Fast Facts
Project No.	154
Contract No.	DTRS56-05-T-0001
Research Award Recipient	Edison Welding Institute, Inc. 1250 Arthur E. Adams Dr. Columbus, OH 43221-3560
AOTR	Anthony Rallis
Researcher 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
Peer Review	More than Effective

Technology and Commercialization
Technology Demonstrated	Yes
Commercialized (in whole/part)	Yes
Commercial Partner	CRC-Evans http://www.crc-evans.com/
Net Improvement	The project developed and demonstrated Root Pass Welding Techniques, Improved Root Pass Techniques, and Process Control Systems for Pipeline Girth Welding with the CRC-Evans pulsed gas metal arc welding (GMAW-P) technology (P-450 & P-260) as described below: (1) Communication software was developed to control a mechanized welding bug through RS232 communication. (2) Automated torch travel angle control hardware was developed and integrated with the mechanized bug system. (3) Automated torch travel angle control software was developed and integrated with the mechanized bug system. (4) Spin Arc (GMAW-RE) torch hardware was integrated with the mechanized bug system. (5) A control system was developed for the Spin Arc torch and integrated with the automated torch travel angle control. (6) A building block for real time quality measurement (RTQM) was developed and data gathered for future analysis with data acquisition from a cost-matched project. (7) An automatic control system was developed using the RTQM data acquisition system for measuring mean welding current and using this to maintain a user specified contact tip to work distance (CTWD) during welding. (8) The welding demonstration deployed the developed Spin Arc welding parameters.

Financial and Status Data
Project Status	Closed
Start Fiscal Year	2005 (11/01/2004)
End Fiscal Year	2006 (04/30/2006)
PHMSA $$ Budgeted	$399,989.00

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.