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Pipe Welding Handbook PDF
Pipe Welding Handbook PDF
Pipe Welding
Handbook
Protect yourself and others from injury read and follow these precautions.
WELDING can cause fire or explosion. D Wear approved ear protection if noise level is
high.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot CYLINDERS can explode if damaged.
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause Shielding gas cylinders contain gas under high
sparks, explosion, overheating, or fire. Check and be sure the area is pressure. If damaged, a cylinder can explode. Since
safe before doing any welding. gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers. D Protect compressed gas cylinders from excessive heat, mechani-
D Do not weld where flying sparks can strike flammable material. cal shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
D Protect yourself and others from flying sparks and hot metal.
support or cylinder rack to prevent falling or tipping.
D Be alert that welding sparks and hot materials from welding can D Keep cylinders away from any welding or other electrical circuits.
easily go through small cracks and openings to adjacent areas.
D Never drape a welding torch over a gas cylinder.
D Watch for fire, and keep a fire extinguisher nearby. D Never allow a welding electrode to touch any cylinder.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can D Never weld on a pressurized cylinder explosion will result.
cause fire on the hidden side. D Use only correct shielding gas cylinders, regulators, hoses, and fit-
D Do not weld on closed containers such as tanks, drums, or pipes, tings designed for the specific application; maintain them and
unless they are properly prepared according to AWS F4.1 (see associated parts in good condition.
Safety Standards). D Turn face away from valve outlet when opening cylinder valve.
D Do not weld where the atmosphere may contain flammable dust, D Keep protective cap in place over valve except when cylinder is in
gas, or liquid vapors (such as gasoline). use or connected for use.
D Connect work cable to the work as close to the welding area as D Use the right equipment, correct procedures, and sufficient num-
practical to prevent welding current from traveling long, possibly ber of persons to lift and move cylinders.
unknown paths and causing electric shock, sparks, and fire D Read and follow instructions on compressed gas cylinders,
hazards. associated equipment, and Compressed Gas Association (CGA)
D Do not use welder to thaw frozen pipes. publication P-1 listed in Safety Standards.
M-247 250 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other Diesel engine exhaust and some of its constituents are
reproductive harm. Wash hands after handling. known to the State of California to cause cancer, birth
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
Se protger et protger les autres contre le risque de blessure lire et respecter ces consignes.
DANGER! Indique une situation dangereuse qui si on . Indique des instructions spcifiques.
lvite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrs par les symboles
joints ou sont expliqus dans le texte.
Indique une situation dangereuse qui si on lvite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrs par les symboles joints ou Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqus dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
NOTE Indique des dclarations pas en relation avec des blessures affrant pour les actions ncessaires afin dviter le danger.
personnelles.
LES RAYONS DE LARC peuvent D Utiliser exclusivement des fusibles ou coupecircuits appropris.
Ne pas augmenter leur puissance; ne pas les ponter.
provoquer des brlures dans les
yeux et sur la peau. D Une fois le travail achev, assurezvous quil ne reste aucune
trace dtincelles incandescentes ni de flammes.
Le rayonnement de larc du procd de soudage
D Utiliser exclusivement des fusibles ou coupecircuits appropris.
gnre des rayons visibles et invisibles intense
Ne pas augmenter leur puissance; ne pas les ponter.
(ultraviolets et infrarouges) susceptibles de provoquer des brlure
dans les yeux et sur la peau. Des tincelles sont projetes pendant le D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
soudage. NFPA 51B pour les travaux chaud et avoir de la surveillance et un
extincteur proximit.
D Porter un casque de soudage approuv muni de verres filtrants
appropri pour protger visage et yeux pour protger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 numr dans les normes de scurit). DES PIECES DE METAL ou DES
D Porter des lunettes de scurit avec crans latraux mme sous
SALETES peuvent provoquer des
votre casque. blessures dans les yeux.
D Avoir recours des crans protecteurs ou des rideaux pour
D Le soudage, lcaillement, le passage de la pice la brosse en
protger les autres contre les rayonnements les blouissements
fil de fer, et le meulage gnrent des tincelles et des particules
et les tincelles ; prvenir toute personne sur les lieux de ne pas mtalliques volantes. Pendant la priode de refroidissement des
regarder larc.
soudures, elles risquent de projeter du laitier.
D Porter des vtements confectionns avec des matires rsistan- D Porter des lunettes de scurit avec crans latraux ou un cran
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de facial.
protection.
M-247 250 Page 6
LES ACCUMULATIONS DE GAZ LES BOUTEILLES peuvent exploser
risquent de provoquer des blessures si elles sont endommages.
ou mme la mort.
Des bouteilles de gaz protecteur contiennent du gaz
D Fermer lalimentation du gaz protecteur en cas sous haute pression. Si une bouteille est endom-
de non-utilisation. mage, elle peut exploser. Du fait que les bouteilles
de gaz font normalement partie du procd de
D Veiller toujours bien arer les espaces confi- soudage, les manipuler avec prcaution.
ns ou se servir dun respirateur dadduction
dair homologu. D Protger les bouteilles de gaz comprim dune chaleur excessive,
des chocs mcaniques, des dommages physiques, du laitier, des
flammes ouvertes, des tincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support station-
naire ou dans un porte-bouteilles pour les empcher de tomber ou
Les CHAMPS LECTROMAGNTIQUES (CEM) de se renverser.
peuvent affecter les implants mdicaux.
D Tenir les bouteilles loignes des circuits de soudage ou autres
circuits lectriques.
D Les porteurs de stimulateurs cardiaques
et autres implants mdicaux doivent rester D Ne jamais placer une torche de soudage sur une bouteille gaz.
distance. D Une lectrode de soudage ne doit jamais entrer en contact avec
D Les porteurs dimplants mdicaux doivent consulter une bouteille.
leur mdecin et le fabricant du dispositif avant de sapprocher D Ne jamais souder une bouteille pressurise risque dexplosion.
de la zone o se droule du soudage larc, du soudage
D Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,
par points, du gougeage, de la dcoupe plasma
tuyaux et raccords convenables pour cette application spcifique ;
ou une opration de chauffage par induction.
les maintenir ainsi que les lments associs en bon tat.
D Dtourner votre visage du dtendeur-rgulateur lorsque vous
ouvrez la soupape de la bouteille.
D Le couvercle du dtendeur doit toujours tre en place, sauf lorsque
LE BRUIT peut endommager loue. la bouteille est utilise ou quelle est relie pour usage ultrieur.
D Utiliser les quipements corrects, les bonnes procdures et suffi-
Le bruit des processus et des quipements peut samment de personnes pour soulever et dplacer les bouteilles.
affecter loue.
D Lire et suivre les instructions sur les bouteilles de gaz comprim,
D Porter des protections approuves pour les lquipement connexe et le dpliant P-1 de la CGA (Compressed
oreilles si le niveau sonore est trop lev. Gas Association) mentionn dans les principales normes de scu-
rit.
In short circuit transfer, the wire short circuits to the workpiece and weld wire is transferred with each short circuit.
Short circuit transfer uses smaller wire diameters at lower arc voltages and higher slope settings. See Figure 3-1.
A B C D E F
WORK
S-0568
In spray transfer, a steady stream of small droplets of weld wire are transferred into the weld. Spray transfer uses
larger diameter wires at higher arc voltages and lower slope settings. See Figure 3-2.
Steady
State
WORK
S-0567
For short circuit transfer, a constant voltage welding power source is required. Adjustable slope and inductance
are desirable. Slope slows the response rate of the welding power source and lowers maximum short circuit
current. A constant speed wire feeder is recommended for short circuit transfer.
For spray transfer, either a constant voltage or constant current welding power source can be used. A voltage
sensing wire feeder is recommended for spray transfer.
The values in the following tables are a starting point for setting up a weld. Most settings can be varied while
welding to fine tune the arc.
M-247 250 Page 11
Table 3-1. Short Circuit Transfer For Mild And Low Alloy Steel*
Electrode Amperage Load
Power Source
Diameter Range DCEP Voltage
.030 in. 70-130 15-21 CV
.035 in. 80-190 16-22 CV
.045 in. 100-225 17-22 CV
*Using CO2 shielding gas for mild steel and Argon-CO2 for low alloy steel.
Table 3-2. Spray Transfer For Mild And Low Alloy Steel*
Electrode Amperage Load Power
Diameter Range DCEP Voltage Source
.030 in. 150-265 24-28 CV or CC
.035 in. 175-290 24-28 CV or CC
.045 in. 200-315 24-30 CV or CC
1/16 in. 275-500 24-32 CV or CC
3/32 in. 350-600 24-33 CV or CC
*Using Argon - 5% Oxygen shielding gas or
C10 - 90% Argon - 10% Oxygen shielding gas for mild and low alloy steel.
Table 3-3. Short Circuit Transfer For Stainless Steel 300 Series*
Electrode Amperage Load Power
Diameter Range DCEP Voltage Source
.030 in. 50-145 17-22 CV power source with
.035 in. 65-175 17-22 characteristics for short
.045 in. 100-210 17-22 circuiting transfer.
*Using tri-gas mixture 90% He; 7-1/2% A; 2-1/2% CO2 and flow rates of approximately 20 CFH.
*Using CO2 as the shielding gas. Flow rates depend on nozzle diameter, surrounding air movement, and electrode extension.
Welding in still air generally requires flow rates from 30 to 40 CFH. Drafty conditions or longer electrode extension may require
higher flow rates.
Most manufacturers recommend an extension of 3/4 to 1-1/2 in. for gas shielded electrodes. Follow the electrode
manufacturers recommendations.
M-247 250 Page 12
B. Advanced Process: RMD And Pro-Pulse
RMD (Regulated Metal Deposition)
Current
Waveform
S Shorter arc lengths and narrow arc cone for out-of-position welding
S Less heat input reduces interpass cooling time and improves weld cycle time
15
15
5G Fixed
1G Rotating
45 5
11
10
3
6
5
804 097-B / Ref. 804 374-C
! Do not mount feeder on top of power 2 Negative Volt Sense Cable 10 14-Pin Feeder Control Cable
source. 3 Positive (+) Weld Cable 11 Interconnect Cable
! Do not put feeder where welding 4 Negative () Weld Cable Connect 14-pin socket into wire feeder
wire hits cylinder. control cable or optional extension cable.
5 Workpiece Connect 72-pin connector to I/O receptacle
! Do not move or operate equipment RC72 on rear of power source. Connect
when it could tip. 6 Welding Gun
10-pin connector into receptacle RC8 on
1 Welding Power Source 7 Wire Feeder rear of power source.
8 Gas Hose
. Attach volt sense lead as close to arc . Maximum cable length not to exceed
as possible. 9 Gas Cylinder 150 feet.
2 4
5
3
11
8
10
805 144-B
! Do not put feeder where welding 6 Gas Hose of gas hose to gas solenoid connector on
wire hits cylinder. rear of feeder or Y-hose for dual wire feeder.
7 Gas Cylinder
! Do not move or operate equipment 8 Work () Weld Cable
when it could tip. Connect 14-pin plug to rear of power . Attach volt sense lead to work clamp
1 Welding Power Source source, and connect 14-socket plug to rear and attach work clamp as close to arc
of wire feeder. Connect one end of weld as possible.
2 Wire Feeder cable to weld terminal on rear of power
3 MIG Connection source. Connect remaining end of weld 9 Volt Sense Cable
cable to wire feeder drive housing. Connect 10 Workpiece
4 Positive (+) Weld Cable
one end of gas hose to regulator/flowmeter
5 Feeder Control Cable Connection on gas cylinder and connect remaining end 11 Welding Gun
8
1
7
13
5
2
6
10
13
10
9
12
11
805 317-B
! Do not put feeder where welding 8 Gas Cylinder connect remaining end of gas hose to gas
wire hits cylinder. Locate end of composite cable where gas solenoid connector on rear of feeder or
hose extends out of sleeve approximately Y-hose for dual wire feeder.
! Do not move or operate equipment 50 inches (1270 mm). This end of the
when it could tip. 9 Work () Weld Cable (2/0 minimum)
composite cable connects to the power
1 Welding Power Source source. Connect 14-pin plug to rear of . Attach volt sense lead to work clamp
power source, and connect 14-socket plug
2 Wire Feeder to rear of wire feeder. Connect one end of and attach work clamp as close to arc
as possible.
3 Feeder Cart weld cable to weld terminal on rear of power
source and secure cable in clamp block on 10 Volt Sense Cable
4 Composite Cable rear panel. Connect remaining end of weld
5 MIG Connection cable to wire feeder drive housing and 11 Workpiece
secure cable in clamp block on feeder 12 Welding Gun
6 Positive (+) Weld Cable
base. Connect one end of gas hose to
7 Gas Hose regulator/flowmeter on gas cylinder and 13 Strain Relief Clamp
General Terms:
Arc Control The adjustment of arc cone width and arc characteristics in the RMD and Pulse processes. Increasing Arc
Control value increases the arc cone width and subsequently effects the arc length (end of electrode to
workpiece).
Arc Length Distance from end of wire electrode to workpiece. This term is also used to represent arc length adjustments in
RMD and Pulse processes. Increasing Arc Length increases the actual arc length; likewise, decreasing Arc
Length shortens actual arc length.
Inductance Control Allows setting inductance in MIG and FCAW. In short circuit GMAW welding, an increase in inductance will
decrease the number of short circuit transfers per second (provided no other changes are made) and increase
the arc-on time. The increased arc-on time makes the welding puddle more fluid.
Notes
1/16-3/32 in.
(1.6-2.4 mm)
LAND
1 in.
(25.4 mm)
9 3
6 O CLOCK
MAINTAIN
DRAG
ANGLE
805 024-A
MAINTAIN
DRAG
ANGLE
805 026-A
805 027-A
9 3
805 028-A
9 3
6 O CLOCK
PIPE
ROTATING
MAINTAIN
DRAG
ANGLE
805 024-A
MAINTAIN
DRAG
ANGLE
PIPE
ROTATING
PIPE
ROTATING
PIPE
ROTATING
PIPE
ROTATING
PIPE
ROTATING
PIPE
ROTATING
Steel
Wire Size Wire Feed Speed Arc Adjust/Trim Arc Control Shielding Gas
Process
in (mm) IPM (mpm)
.035 (0.9) 120-780 w/250 Nominal 52-57 w/56 Nominal 30-35 85/15
3.0-19.8 w/6.4 Nominal
Steel
Wire Size Wire Feed Speed Arc Adjust/Trim Arc Control Shielding Gas
Process
in (mm) IPM (mpm)
.035 (0.9) 120-780 w/200 Nominal 52-57 w/54 Nominal 30-35 85/15
(3.0-19.8 w/5.1 Nominal)
Stainless Steel
Wire Size Wire Feed Speed Arc Adjust/Trim Arc Control Shielding Gas
Process
in (mm) IPM (mpm)
.040 (1.0) 120-275 w/200 Nominal 48-52 w/50 Nominal 25 98/2 CO2
RMD Stainless Steel (3.0-7.4 w/5.1 Nominal)
Stainless Steel
Wire Size Wire Feed Speed Arc Adjust/Trim Arc Control Shielding Gas
Process
in (mm) IPM (mpm)
.035 (0.9) 150-780 w/175 Nominal 48-54 w/53 Nominal 18 98/2 CO2
(3.8-19.8 w/4.4 Nominal)
ProPulse
Stainless Steel Using .035 (0.9) 150-780 w/175 Nominal 48-52 w/51 Nominal 18 98/2 Ox
A Positioner (3.8-19.8 w/4.4 Nominal)
(Rolling The Pipe)
.045 (1.1) 140-450 w/200 Nominal 52-55 w/55 Nominal 25 Tri-H
(3.6-11.4 w/5.1 Nominal)
.045 (1.1) 120-525 w/200 Nominal 53-57 w/55 Nominal 16 98/2 CO2
(3.0-13.3 w/5.1 Nominal)
.035 (0.9) 150-780 w/175 Nominal 48-52 w/50 Nominal 18 98/2 CO2
(3.8-19.8 w/4.4 Nominal)
.045 (1.1) 120-525 w/140 Nominal 50-55 w/53 Nominal 16 98/2 CO2
(3.0-13.3 w/3.6 Nominal)
Flux Core
Note: Arc Control is arc width and Arc Adjust/Trim is arc length. Wire feed speed and voltage are synergic for the
RMD and ProPulse processes. Therefore, when adjusting wire feed speed, the voltage is automatically adjusted so it
is not necessary to adjust Arc Adjust/Trim. These are only starting parameters, the operator must make final
adjustments depending on material and conditions.
*See wire manufacturer for recommended wire feed speed and gas mixture.
Steel
Stainless Steel
Stainless Steel
Flux Core
Note: Arc Length Length of arc from end of wire to weld puddle. Wire feed speed and voltage are synergic for the
RMD and ProPulse processes. This means when adjusting wire feed speed, the voltage is automatically adjusted so
it is not necessary to adjust the Arc Length.
*See wire manufacturer for recommended wire feed speed and gas mixture.
B. Root Pass
The first weld pass is referred to as the root pass and is used to fill the gap between two sections of pipe. When
using the GMAW process, the root pass is usually with an open root weld (no backing ring). Generally, a manual
weld root pass is continuous all the way around and through the tack welds.
C. Hot Pass
The hot pass is usually a single weld that joins the root weld and both groove faces together. A split hot pass is
generally an acceptable procedure for 2G welding and when the root opening is larger than normal.
D. Fill Pass
The fill pass should nearly fill the groove. If a bead sequence is necessary, an alternating pattern should be used
from face to face of the joint. The location of each bead should have an adequate, uniform lap for each
subsequent weld bead. If a narrow cavity should develop between weld beads or between the face of the joint
and the weld bead it may result in a lack of fusion or contamination (slag). If possible, grind the area to eliminate
the cavity and improve the lap weld before making the next weld.
E. Cap Pass
The cap weld should completely fill the top of the joint with the least amount of excessive build-up beyond the top
surface of the pipe. Grinding may be necessary to improve the weld bead shape and remove any contamination
before making the final cap pass.
A. Process Issues
Gas in contaminated/leaky connections Check fittings, hoses and shielding gas connections
Workpiece contamination Remove paint, mill scale, rust, oil, and oxide
Excessive contact tube to work distance 3/8 to 5/8 in. (10 to 16 mm) stick-out for RMD or pulse
3/4 to 1 in (19 to 25 mm) stick-out for FCAW
Incomplete fusion Weld zone surfaces not free of film or excessive oxide Grind or sand to clean off surface
Too large of a weld puddle Increase travel speed or decrease wire feed speed
Excessive travel speed Decrease travel speed or increase wire feed speed
Humping and crowning Excessive travel speed Slow down travel speed or weave electrode
unmelted electrode on root Improper welding technique Focus electrode back further on weld puddle
side (whiskers)
Excessive melt through Excessive heat input Reduce wire feed speed
Other issues Unable to resolve problem Contact factory pipe welding products service
(9207354001)
B. Parameter Issues
Change Required Arc Voltage Welding Current Travel Speed
Deeper penetration Increase
Shallower penetration Decrease
Larger bead Increase Decrease
Smaller bead Decrease Increase
Higher, narrower bead Decrease
Flatter, wider bead Increase
Faster deposition Increase
Slower deposition Decrease
WELD JOINT
TYPES
GROOVE FILLET
WELD POSITION:
FLAT
BUTT
1G
TJOINT
1F
HORIZONTAL
BUTT
2G
TJOINT
2F
VERTICAL
BUTT
3G
TJOINT
3F
OVERHEAD
BUTT
4G
TJOINT
4F
39
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International HeadquartersUSA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
For International Locations Visit
www.MillerWelds.com
ORIGINAL INSTRUCTIONS PRINTED IN USA 2010 Miller Electric Mfg. Co. 201001