According to Mr Barker, pipe end preparation is a commonly overlooked process which is just as important as the welding process itself. “Your company concentrates on welding speeds, travel speeds, how many welds-per-day can we achieve,” he says.
Without the next pipe ready for welding, these advantages gained from the above points, can be shattered with the welding catching up to the pipe preparation.
“As most companies have seen this take place when the welding is going well, a solution has been provided based on numerous requests from potential clients over the past five years.”
Mr Barker says that, due to the large shipping transit times for this equipment, most clients turn away as they usually need it now. To overcome this, Lonestar Welds has purchased a few units to hold in stock and make available to urgent requirements.
“Most companies use oxy/acetylene to cut pipe ends to length and prepare a bevel for welding. A majority of end clients do not like the idea of placing large amounts of heat into their weld area prior to welding.”Oxy/acetylene uses extreme temperatures beyond welding temperatures to cut through steel placing avoidable stress on the metals properties; a common component used to combat this is a clamshell lathe which is more suitable as it is a cold cutting process – however, it is quite slow,” says Mr Barker.
Another major benefit that Lonestar Welds has found for heavy-walled pipe, according to Mr Barker, is to reduce the weld area by altering the face angle to 20 degrees.
“This method reduces the weld area, greatly allowing reduced welding time, less welding fill area, and less welding passes, which all leads to quicker welding times. They are also highly suited to flux-cored welding wire and the manual root method can still be achieved. A machined bevel also provides an even fit up around the entire pipe face, and there is no matching required to fit the square ends together.”
Mr Barker says that in general, numerous articles have asserted that the fastest weld is produced when using pipe-facing machines, automated welding systems and internal line up clamps with copper. “Using all the above components normally suggested, the project is a long straight pipeline of large diameter and heavy wall. Some projects are not suited to using internal clamps due to bends and fittings, nor are they suited for automated welding due to the diameter, minor wall thickness, pipe quality, or process required.
“It can be suggested that pipe-facing machines suit most projects whether used for automated or manual welding – the fit-ups provided eliminate nearly all fit up complications,” he says.
The initial outlay when acquiring this equipment is a common drawback for companies seeking this advantage. By offering a short-term lease, Lonestar Welds is looking to provide this equipment to bevel large amounts of pipe ends in a very short time.
“Whether it be in a laydown area or on a pipeline spread, this equipment is built for producing the same bevel in quick time, eliminating numerous man hours normally required to complete the same task with slower methods,” Mr Barker says.
Lonestar Welds’ operating range for pipe diameters is from 152-1,524 mm and up to 50 mm wall thickness.
For more information visit www.lonestarwelds.com.au
