The history of pipe and tube production dates back to the 1900s when a process like hot-rolling was used for large-scale manufacturing. Since then, technologies like welding and seamless manufacturing have allowed the production of a much larger scale of pipes and tubes. Welding accounts for over half of all steel tubes and pipe production worldwide.
The welding approach provides greater strength than any other pipe and tube system fabrication approach. However, cost, quality, and fabrication timeline are all equally important in production welding. Orbital welding is the solution to large-scale pipe and tube production issues.
The Different Pipe And Tube Welding Needs
Critical industries including oil and gas, biopharmaceuticals, food and beverage, and nuclear, all require large-scale production and installation of pipes, tubes, and tube to tubesheet connections for process fluid transfer. To meet strict industry standards, these pipe and tube components must be fabricated to high specifications. Generally, industries seek the following requirements in their pipe and tube systems.
| High strength | The pipes and tube system must withstand stresses due to extreme temperature and pressure conditions |
| Corrosion resistance | To prevent material degradation due to harsh chemicals and environmental conditions |
| Tight tolerance | Tight tolerance of pipe and tubes meet the exact dimensional specification with minimal distortion |
| Durability | Pipe and tube system must be strong enough to endure heavy external loads (common in the construction industry), thus, improving durability |
| Cleanliness | Smooth surface finish and ideal material use reduce the chances of bacteria or contamination buildup for sanitary welding applications |
Welding offers the most high-quality results in comparison to other pipe and tube fabrication processes. With precise techniques, advanced equipment, and skilled personnel, the welding process prioritizes the consistency and integrity of the final product.
Regarding large-scale manufacturing, the pipes, tubes, and tubes to tubesheet producers also emphasize productivity and cost in addition to quality. For production welding, orbital technology can provide these advantages.
Advantages of Production Welding With Orbital
For large-scale production welding, manufacturers seek qualities such as repeatability, speed, and efficiency in their process. This ensures integrity and consistency so that the entire batch meets the quality standards.
Orbital welding is automated and uses a specialized machine to arc weld tubes and pipes. The advantages of using orbital welding for large-scale production include the following:
- Quality — The machine can set the weld parameters depending on the material being used while the automated machine implements the uniform process. The monitoring system can also be set up to check if the process requires optimization. The consistent travel speed, torch angle, and heat input produce welds with minimal defects.
- Repeatability — The computer-controlled welding allows for the set input to produce the same output for the entire batch. The consistent and uniform input produces repeatable output.
- Productivity — Automated production welding is much faster and efficient when compared to manual welding. Moreover, with a reduced chance of defect, there is also less material waste. In large-scale production, these advantages mean huge savings in terms of cost and material and an increase in productivity.
- Safety — Orbital welding keeps the manual operators in a remote, supervisory position, reducing their exposure to hazardous gases and radiation and minimizing workplace accidents.
The repeatable and consistent results from orbital welding make it easier to ensure quality control during production welding.
Production Welding Efficiency With Orbital
Welding of the tube to tubesheet equipment, pipelines, and tubing systems requires adherence to high-specification standards. It is also important to note the need to achieve clean and consistent weld results at a greater speed in large-scale production welding.
Orbital welding closely controls and implements the weld parameters to produce a defect-free result with high strength and purity. Simultaneously, the automated system provides speed and efficiency, increasing productivity and making the process safer.
With orbital welding, you can achieve your productivity benchmark without compromising on quality.
Arc Machines, Inc. offers a variety of orbital welding equipment to help in the production welding of your pipe and tube welding projects. For inquiries regarding products, contact sales@arcmachines.com. For service inquiries contact service@arcmachines.com. Arc Machines welcomes the opportunity to discuss your specific needs. Contact us to arrange a meeting.
