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Posts Tagged ‘Pipe’

Pipe welding is no easy task.After all, you are usually using it to join very large pieces of metal or plastic together–sometimes, so that very powerful chemicals and gases can pass through them.However, pipe welding is an incredibly popular way to manufacture things because it is the most cost-effective way to join pipes together.It can be done for a variety of projects, both big and small.

If you want to become a pipe welding pro, you will have to start by understanding the ins and outs of some of the basics, like:

1.Butt welding

If you need to join two piece of metal or plastic together, than you need to know about butt welding.In fact, butt welding has become a popular welding process because it is easy to do and it rarely requires any kind of post-welding work like other welding techniques do.

During this process, the two pieces are laid side-by-side and welded along a single seam.If your butt welding is done correctly, you will never see a seam, and you will never see any type of brittleness or corrosion develop.  Instead, it will just look like these two pieces naturally fit together!

2.CNC machining equipment

An abbreviation for “computer numerical control”, CNC machining equipment is vital to the pipe welding world.This equipment can be pre-programmed with a computer to do the work, instead of having an actual human being do it.CNC machining equipment can work faster than a person can, and it can simulate all of the movements that a human can make –by being able to move machines, equipment, and tools in virtually every direction.

As an added benefit, CNC machining equipment it never gets tired, like an actual person does.In fact, these machines can run 24/7 if you need them to! They will literally keep running until you tell them to stop.

3.High pressure fittings

Available in virtually any variety – from elbows, to couplings, to crosses, to tees, to filters – high pressure fittings are another important part of pipe welding.

By having fittings that can easily adapt to very high amounts of pressure, you can rest easy knowing that they will be able to hold their own against fast-moving fluids, oils, and chemicals.When you have weaker fittings, flowing fluids can break them down– leading to leaks and spills.  Instead, high pressure fittings can be used to connect pipes together in all sorts of situations.

Being a professional in any field is no easy task. It demands hard core and continuous smart work. Similarly, a professional welder needs to attain the certification for an adequate job. It is as difficult as passing a school test without preparation. There is equivalent nervousness and uncertainty involved in such tests.

If we get into the details of the kinds of tests for the pipe welding, we may get lost in it. Therefore, it is better to take an outline view of what is it all about? There are hundreds of pipe welding tests but two of them are more dominant. They are 2″ and 6″ schedule 80 pipes in the 6g position. The sad part is that these two joints need to be welded in various ways.

There are different ways for carbon steel pipe welding tests and stainless steel pipe welding certification tests. The former needs tig root pass with 7018 fill along with 6010 root pass having 7018 stick fill. The latter on the other hand requires tig throughout and it needs to be opened with stainless steel stick fill. Each of them has five different combinations. Once you complete all these operations, there are high chances that you will get Pipe welder certification get hired as a professional welder in paper mills, power plants, refineries, construction and maintenance sites.

Being a CWI Inspector implies that one needs to be aware of all the testing no matter what type it is. Since no one is perfect, it is good to go through some of the tips involved before you do any kind of welding. Before getting into the real deal of welding, one should weld a scrap metal first in order to get comfortable with the equipment and easy handling of further tasks of setting up the welding machine. Do follow the welding codes of getting arc strike within the range of the material to be welded.

Even after the welding activity has been performed, there are some finishing touches which must be taken into consideration. One should keep filing and brushing the finished product till the time all the stags are removed. To avoid any further mess, do all the starts and stops at one particular place. One should not chip around the hammer pecks all around. After everything is done, apply a little soapstone and then good power brushing which makes the welding shine brighter.

Let’s not escape it anymore. Each professional field in today’s times require certification and skills. The field of welding is no different. Even the field of welding and training requires certification of various kinds. Welding has its own types and certification varies according to that. For instance, pipe welding has different requirements to be fulfilled. This article aims at dealing with the detailing of pipe welding.

The organisation responsible for the pipe welding certification, the United Association of Plumbers and pipefitters (UA) has made a unique code for the same, i.e. UA-1, 2, 3, 4 etc. It goes on till the number 92 is reached. The common tests count up to 92 but there can be other possibilities as well.

There are several welding processes involved for the pipe welding like Gas Metal Arc (GMAW), Flex Core Arc (FCAW), Shielded Metal Arc (SMAW) and Gas Tungsten Arc (GTAW). If that was not enough, there are also different metal groups involved like carbon steel, stainless steel and aluminium. This is the reason that so many pipe welder certification exists for the varying sites.

You can refer to the ASME Section IX if you want to peep in to the certification requirements and qualification limitations. For the general purpose, we can assert that most common limitations are thickness, position and diameter of pipe. There are some limitations even after achieving the certification tests.

For instance, a welder who has passed the test of TIG on 2 inch schedule 80 pipe in a 6G position can weld 1 inch and grater diameter pipe. It can go up to 436” thick and then a welder can weld in all positions. Similarly, a welder having passed the test of 6” schedule 40 in a 6G position is qualified to weld till .560” thick and it can go down up to 2.875” pipe diameter.

The market welder qualification asks for a combo pipe welder. It is always beneficial to enhance your skill to make it to the best possible option. Obviously, if you carry both the skills of welding a TIG root as well as a hot pass followed by an E7018 stick fill and cap, it will be easy for you to get the job. The combo welders are able to weld with several welding processes. Companies choose TIG welding for the root and hot pass and stick welding for the rest of the pipe. Requirement can vary; therefore, your skills should be compatible enough to deal with the conditions.

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Pipe welding is the most cost-effective way to fuse pipes together.  It uses both heat and cold to turn multiple pieces of pipe into one flush pipe – without any fittings.

Why is that so important?

Fittings can slow down pipes from start to finish.  They take longer to install that simply welding the pipes together, so they make entire construction projects take longer.  And, fittings can get in the way once a pipe is installed – meaning that they can cause flow restrictions, which makes your pipes less effective.

Because it’s a faster and more effective way of manufacturing, pipe welding has become incredibly important to the manufacturing world.  In fact, it has become so important that it has turned into a huge industry that introduces new technology all the time.  A lot of that new technology focuses on

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.
What does that mean?

Post weld heat treatment is the work done after something has been welded.  It uses new heat to improve old welding work.  Post weld heat treatment can eliminate brittleness that has evolved on metal pipes over time, or it can be used to strengthen metal that has been weakened by lots of use.

Induction bending is the most common form of post weld heat treatment.  It uses an incredibly hot coil; as the pipe starts to get hot, the metal becomes pliable.  Induction bending is literally used to bend steel pipes. 
Induction bending is such a common form of pipe welding because it leaves the metal with a high quality finish.  All of the bends and curves are smooth, which makes the pipes themselves more effective.

However, as pipe welding tools and techniques get better and better, the need for post weld heat treatment diminishes a bit.  Butt welding is a great example of technology that isn’t completely dependent on post weld heat treatment.

Butt welding joins two pieces of metal or plastic together along a single edge.  The two pieces are laid side-by-side and welded together.  If it’s done correctly, you will never see a seam.  And, the work is so durable that you won’t need post weld heat treatment later to make any improvements.

Because it’s so effective, butt welding has become a common technique for manufacturing various machines, tools, and equipment.

A new addition to the ‘EZ’ Fit range is the ‘EZ’ Gold series, boasting an increased range of up to 14″ i/d and manufactured from forged steel for increased strength. Stainless steel roller balls are fitted as standard to the wing bolts. The “EZ” Gold Clamps can be used on stainless steel…
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The standard welding processes such as TIG, MIG, and stick can be used to weld carbon steel pipe to stainless steel pipe. Standard carbon E-class welding electrodes such as  E70 and 7018 can be used for MIG and stick welding respectively. However, using such welding electrodes on this type of welding, the welding quality may be compromised due to lack of chromium and nickel in the alloy. Hence, it is important to use high-carbon stainless steel electrodes to have a strong weld joint between the steel and stainless pipes. In particular, type 309 welding electrodes have the correct composition ensuring a proper weld with correct penetration and structural integrity. Similarly, the following steps must be used in this type of welding:

Step-1: Load or spool the MIG welding machine with the type 309 welding wire after removing already loaded welding wire used for other jobs.

Step-2: Replace the gas with the three part shielding gas mixture. It is necessary to mix the gas thoroughly before attaching the gas bottle to the MIG welder. The method used is to place the gas bottle on the floor horizontally roll it back and forth to mix the gas thoroughly. After that fix gas gauges to the three-part gas bottle.

Step-2: Now switch on the MIG welder and adjust the correct heat and wire speed levels. It is essential to note that the standard heat settings (used for carbon steel) will not be adequate for welding stainless steel as higher amount of heat is required to weld stainless steel. Best advise is to refer your welding guide to verify the initial test setting for your heat and wire speed. Once you adjust the heat levels, carry out a test pass with the welder to see that the settings are correct.

Step-3: Cut a piece of stainless steel pipe and a piece of carbon steel pipe with required lengths using a band saw. It is important to note that when cutting stainless steel using a band saw, reduce the speed and at the same time use cutting fluid to keep the band saw blade cool.

Step-4: You need to have 20-degree bevel on end of the cut pieces of pipe. This is done using a grinder by holding it at a constant 20 degrees to give you an even fill line. Make sure not to touch the grinding pipes because the pipe will get very hot during grinding.

Step-5: Once the pipe edges are grounded correctly, place one beveled end of the steel pipe against the beveled end of the stainless steel pipe allowing a welding gap about 1/16th of an inch between the two pieces of pipe. Then place a tack at the weld joint to keep the pipes together. Similarly, roll the pipes and provide a tack at one inch interval around the entire circumference of the pipe. ItÕs necessary to maintain the 1/16th inch weld gap right through out the circumference.

Step-6: Now start welding the pipes together. Start the weld from the stainless steel pipe and gradually pull the puddle onto the carbon steel pipe. Also, roll the MIG gun in a circle to flow the puddle to create good weld while watching the bottom of the weld to make sure proper penetration. During the welding process, if you note that the carbon pipe is under-cutting, it is necessary to reduce the heat on the MIG welder and repeat it.

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HDPE Pipes Repair Solution

High Density Polyethylene (HDPE) is a term that is used with pipes and linings. High density polyethylene pipes are more durable then A normal polyethylene pipe as it has low density. A number of people have started using HDPE pipes for its durability and long-lastingness in their home and offices. Modern pipe liner uses HDPE pipe repair and maintenance method with traditional resistance process as well. HDPE pipes have a thicker lining and last longer, and thus are getting popular everywhere.These pipes are light weight and can be installed easily at any place when needed.

HDPE pipe repair :

Even though they are durable but to protect HDPE pipes we must acquire knowledge on professional HDPE repair & installation as a pipe leak can happen anywhere, any time and without warning, and can threaten to shut down your entire operation, resulting in costly downtime and product ion loss.

(1) Instant Effective Pipe Repairs :

There’s no better solution for instant effective pipe repairs than Rapp-it Pipe Repair Bandages.Rapp-it is a roll of fibreglass bandage impregnated with water-activated polyurethane resin. Every pack of Rapp-it includes the bandage, a stick of epoxy putty and a pair of gloves. It’s simple to use with no mixing or measuring required, yet results in a strong, superior pipe repair. You simply immerse the bandage in water for 10 seconds, and then apply by wrapping around the damaged pipe area. A successful pipe repair can be achieved in only 30 minutes.

(2) Long Lasting OR Permanent Repair Method :

There are a number of methods to pipeline repair that include weld and non-weld, numerous non-exhaustive, external and internal replacement methods.

(1) Plastic extrusion is the most popular method Among all as it is the efficient and effective way to access pipelines without disturbing your premises. And,

(2) To prevent leakage you can use HDPE pipeline liners but these liners must be installed by Pipe Liner Specialists.

(3) The open-cut excavation method is also used for the pipeline repairing, however it is costly and requires loads of time.

(4) Another method of HDPE pipes repair is the trenchless pipe rehabilitation method. This procedure helps in to stop any kind of existing leakage and the further harm of the pipe lining system.

While selecting the method of repairing HDPE pipeline you must keep the safety issues in mind and make sure you go for Professional HDPE Repair & Installation for long lasting results. Ask for services of Pipe Liner Specialists for better results.

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HDPE pipes have a thicker lining and last longer, and thus are getting popular everywhere. Even though they are durable you must have an idea on HDPE pipe repair and acquire knowledge on how you can protect your HDPE pipes.

Now, with the trend of utilizing technology in every sector of life pipelines seem to get its fair share as High Density Polyethylene gets combined with the pipeline material. The result – is a pipeline that is durable and has highly resistant. In general specific dyes are used on a pipeline surface however a few sections are improperly coated. Now, these sections often get damaged due to constant heat, rust, dampness and other factor. To get away with such damage you must gather enough information on professional HDPE repair & installation.

Before going into the benefits of HDPE pipeline, know more on how you can install HDPE pipes in your facility. HDPE pipes are rather easy to install. These pipes are light weight and can be installed easily at any place when needed. While HDPE Repair & Installation make sure you are well aware of the area where the pipe is installed. Thus, most people suggest the plastic extrusion procedure. These high density pipes are growing popular with clients worldwide due to its low cost, light weight and durability. The HDPE pipe lines are generally known as more sophisticated with corrosion protection options since it is developed with pipeline coating.

The HDPE pipe repair methods are many, however, it is more important to stress on pipe maintenance rather than mending it. There are a number of methods to pipeline repair that include weld and non-weld, numerous non-exhaustive, external and internal replacement methods. Among all this it is the method plastic extrusion which is most popular as the efficient and effective way to access pipelines without disturbing your premises. In order to prevent infiltration and leakage you can use HDPE pipeline liners. These liners must be installed by Pipe Liner Specialists.

The pipeline repairing process is done through advanced technologies using the open-cut excavation method. The method is however costly and requires loads of time. While selecting the method of repairing HDPE pipeline you must keep the safety issues in mind. Another method of HDPE pipe repair is the trenchless pipe rehabilitation method. This procedure helps in to stop any kind of existing leakage and the further harm of the pipe lining system.

When should you look for Pipe Liner Specialists or else plan for Professional HDPE Repair? Here are some reasons:

1. Is there is any leakage? – Find out the existing leakage, in case there is a major one. In order to recognize a leakage which is rather small you must excavate.

2. Evaluate the reasons behind the damage, there should be one.

3. There are external or internal factors that lead to damage or repair or an HDPE pipe.

4. Once the leakage is discovered immediately go for repair.

Make sure you go for Professional HDPE Repair & Installation for long lasting results. Ask for services of Pipe Liner Specialists for better results.

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Sometimes a pipe is in such bad condition that modern sewer pipe lining is not possible. Examples would be when extensive sections of the pipe are partially collapsed which is common for Orangeburg pipe, or large sections of pipe are missing which is common for cast iron pipe, or a customer is unfamiliar with pipe re-lining, which is the more modern method used in trenchless pipe rehabilitation. In such cases pipe bursting technology is used.

The pipe bursting technology involves pulling a cone-shaped “head”, with a new high density polyethylene (HDPE) pipe attached, through an existing pipeline. As the head moves through, it breaks the old pipe and pushes the pieces back into the surrounding soil. The head also expands the bore diameter slightly larger than the outside diameter of the new pipe it is pulling in. This reduces friction, but it also makes it possible to replace an existing pipeline with one of a larger diameter. Of course very powerful winches and strong cables have to be used for this type of sewer pipe rehabilitation.

A bursting head with no other attachment is called a static head, and it depends entirely upon the power of a winch to pull it through an existing pipeline. In some cases, a bursting head is equipped with a cutting blade or an internal pneumatic hammer. The cutting blade concentrates all the pulling force into one area, making the initial opening of the pipe easier. In hard, dry soils, or when heavy pipe fittings are encountered, the driving force of a hammer aids penetration.

As the HDPE pipe is pulled into the old sewer pipe that requires replacement, new sections of HDPE pipe are fused together using a plastic welding technology. This makes a seamless pipe that will prevent root intrusion, water infiltration and exfiltration.

There are some limitations to using the pipe bursting process:

The first is the line has to be in good enough condition for the cable to be pulled through the line.

Pipe Bursting will not fix a sag, or, belly. The bursting head and new pipe follows the path of the old pipe.

Rocks, ledge and some other conditions may jam the bursting head preventing it from passing and still require excavation to complete the job.

Some bend configurations may not allow pipe bursting as the bursting head may exit the pipe and get stuck requiring excavation.

Each installation starts with excavation of a small pit (about two feet by three feet) at the property line and another where the service line enters the house. Vacuum excavation is used to open the pits because many utilities are clustered near the property lines. The soil is cut with a water jet, then vacuumed out by a Vactor truck with a 6-inch tube. Usually, the pits can be excavated in less than an hour.

City code in Sarasota requires that a cleanout be installed every 75 feet in new service laterals. For laterals over 75 feet long, pits are sometimes dug for the extra cleanouts, and the new pipe is pulled from one pit to the next. At other times, the entire length of the new line is pulled first and the cleanouts are installed later. We used small, modular equipment manufactured by Tric Tools, Inc. (www.trictrenchless.com) to install the new lateral lines. Normally, the pulling equipment is set up in the pit at the property line because it is deeper, and therefore offers more head wall surface to pull against. The Tric hydraulic puller can produce a pulling force of 60,000 pounds. The white, 4-inch SDR 17 HDPE (high density polyethylene) pipe is supplied on 800-foot reels. The color enhances video inspections, and the length greatly reduces the need for onsite pipe fusion.

When the pits are ready, a cable is strung through the existing service line from the property line to the house. There, the cable is attached to a 4-inch bursting head, which has a special blade to help crack or cut the old pipe. In turn, the bursting head is fused to the new pipe. In the pulling pit, the cable runs through a resistance plate and metal frame before it attaches to the hydraulic puller. A diesel-powered Vermeer high pressure pump supplies hydraulic power to the puller. Once the pull begins, the new HDPE pipe is pulled into place at 5 to 10 feet per minute, depending upon the power of the hydraulic pump.

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With the high price of plumbers it is understandable that so many people are now deciding that the do it yourself route is a far more affordable option. Plastic pipe is the perfect material for the job as even the lay man can manage to put together a piping system. Naturally plastic pipe is an umbrella term that covers a number of different plastics, usually of the thermo variety but still disparate enough to note the differences. Here are some of the most popular plastic pipe variants used.

PVC or polyvinyl chloride is an extremely popular plastic in the piping world; it is extremely rigid and is adept at resisting many chemicals. The main form of welding is though solvents and is predominantly used for applications such as sewers, drain pipes and cold water pressurised water piping. It comes in a variety of different colours.

ABS or acrylonitrile butadiene styrene is used for many of the same purposes as PVC although its chemical resistance is lower and it is normally produced with a black colouration.

CPVC or chlorinated polyvinyl chloride is like PVC but stands up to high temperatures more effectively and hence is used for hot and cold water supply applications.

The previous three plastic pipe variants are all rigid whereas PB (polybutylene) and PE (polyethylene) are flexible; the former being rigid and used for the same purposes as CPVC and the latter being low cost. Both of these types are not joined with solvents but are instead formed with mechanical and clamped couplings.

In terms of buying the pipe for your plumbing needs pipes normally come in sizes along two lines, these being pipe sizes and tubing sizes. Pipe sizes relate to the old steel pipes while tube sizes relate to copper tube. It is important to note that different plastic pipes should not be connected together, like for like connections are always advisable. Because the plastic pipe industry moves quickly it is important to recognise that building regulations should always be consulted before undertaking any work.

For instance regulations permit the use of CPVC and PB pipe for hot water applications. These two pipes are perfect for constructing in-home hot water systems as they are corrosion free and durable. It should be remembered however that this form of pipe should not be used for electrical grounding as it is non-conductive. PVC pressure pipes should predominantly be used for cold water movement in outdoor areas; such as water sprinkling systems in gardens. PE pipe is similar although it is flexible rather than rigid, and is perfectly suited to deep piping well purposes.

There are two major methods of fitting piping systems together; these are solvent welding and mechanical coupling. Solvent welding is simple enough although care should be taken to carry out the task effectively to prevent any leaks. The pipe must be cut squarely, cleaned thoroughly, coated with solvent and then joined with the fitting piece. It should be remembered however that cuts are final, there is no way back should you cut the pipe too short. Mechanical coupling however is used with plastic pipes that cannot be welded with solvents. Normally it requires a simple click into place as the fittings have barbs and clamps that prevent leaking.

Hopefully this information has given an idea on the types of plastic pipe out their and their uses. Additionally it is also hoped that the information on fitting will give DIY enthusiasts the knowledge that is needed to construct their own plumbing systems.

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Product Description
A standard reference for decades, this new edition of Pipe Welding Procedures continues to reinforce the welder’s understanding of procedures. Drawing on his extensive practical and teaching experience in the field, the author describes in detail the manipulating procedures used to weld pipe joints. Readers will find useful information on heat input and distribution, essentials of shielded metal-arc technology, distortion, pipe welding defects, welding safety, essentials of welding metallurgy, and qualification of the welding procedure and the welder.

NEW OR EXPANDED COVERAGE OF…

o Root Bead–Pulse Current–Gas Tungsten Arc Welding

o Shielded Metal Arc Welding—Electrode

o Welding Steel for Low Temperature (Cryogenic) Service

o Down Hill Welding—Heavywall and Large Diameter

o Welding Metallurgy

o Weld Repair

Pipe Welding Procedures