Mohsen Barfmal’s Post

𝐇𝐨𝐥𝐥𝐨𝐰 𝐁𝐞𝐚𝐝 (𝐇𝐁) 𝐃𝐞𝐟𝐞𝐜𝐭 𝐢𝐧 𝐏𝐢𝐩𝐞𝐥𝐢𝐧𝐞 𝐖𝐞𝐥𝐝𝐬 ￫ Elongated pore or void located in the root pass of a girth weld in pipelines ￫ Oriented linearly along the weld direction  ￫ Oil and gas pipelines are commonly welded using a manual metal arc welding technique using cellulosic electrodes. ￫ Cellulosic electrodes provide good penetration and high travel speeds and hence high productivity. 𝙀𝙭𝙘𝙚𝙨𝙨𝙞𝙫𝙚𝙡𝙮 𝙝𝙞𝙜𝙝 𝙬𝙚𝙡𝙙𝙞𝙣𝙜 𝙨𝙥𝙚𝙚𝙙 𝙖𝙣𝙙 𝙘𝙪𝙧𝙧𝙚𝙣𝙩 𝙘𝙖𝙣 𝙘𝙖𝙪𝙨𝙚: ￫ Inadequate gas escape from weld pool, trapping bubbles 𝗠𝗲𝗰𝗵𝗮𝗻𝗶𝘀𝗺: ￫ High speed welding doesn't allow time for gas bubbles to escape ￫ Bubbles trapped as gas pores during solidification - Liquid metal ahead of solidification front gets supersaturated with gas pores, making elongated pore along with weld direction 𝙃𝙤𝙡𝙡𝙤𝙬 𝘽𝙚𝙖𝙙 (𝙃𝘽). #HollowBead #pipeline #radiography #weldingdefects #WPS #ITP #inspection #PipingDesign #ASMECode #EngineeringExcellence #QualityAssurance #QualityControl #QualityManagement #ContinuousImprovement #CustomerSatisfaction #OperationalExcellence #EngineeringExcellence #Innovation #MaterialScience #IndustryAdvancements #QAQC #QA #QC #asme #welding #weldinginspection #weldingengineer #weldinginspector #engineering #construction #fabrication #piping #steel #api #aws #data #code #standard #quality #qualitycontrol #qualityassurance #pressurevessels #tanks #oilandgas #powerindustry

The manual Gas Metal Arc Welding (GMAW) process also known as Metal Inert Gas (MIG) welding. When performing this process it is important to use the correct weld voltage and wire feed speed settings for the thickness and type of material you are welding as well as gas considerations. However that is the easy part of the manual process. Utilizing correct techniques to control factors such as work angle, travel angle, travel speed and contact tip to work distance (CTWD) play crucial roles in making sound welds. Work and travel angles can affect penetration and appearance. Possibly causing undercut, cold lap, and uneven weld legs. Travel speed affects penetration and heat input. Faster speeds will have lower penetration while slower speeds will have more penetration but also higher heat input and broaden the heat affected zone around the weld. CTWD controls arc length which directly affects amperage and penetration. A longer CTWD will have lower amperage and penetration. Alternatively a shorter CTWD will have higher amperage and thus greater penetration. Control of all these factors come together with weld settings and gas selection to make the manual GMAW process a highly skilled endeavor. #fabrication #manufacturing #gmaw #welding #weldingtechnology #production #welder #mig #engineering

The effect of polarity on penetration welding In welding, polarity refers to the direction of flow of electrical current between the electrode and the workpiece. There are two main types of polarity used in welding: direct current (DC) and alternating current (AC). The effect of polarity on penetration welding depends on the type of welding process being used. Direct Current (DC): DCEN (Direct Current Electrode Negative): In this polarity, the electrode is connected to the negative terminal of the power source, and the workpiece is connected to the positive terminal. DCEN is commonly used in welding processes such as Shielded Metal Arc Welding (SMAW) and Gas Tungsten Arc Welding (GTAW/TIG). DCEP (Direct Current Electrode Positive): In this polarity, the electrode is connected to the positive terminal of the power source, and the workpiece is connected to the negative terminal. DCEP is commonly used in processes like Gas Metal Arc Welding (GMAW/MIG) and Flux-Cored Arc Welding (FCAW) Alternating Current (AC): In AC welding, the direction of current flow alternates between positive and negative cycles. This alternating current allows for a balance between the advantages of both DCEN and DCEP. AC welding can provide good penetration while maintaining arc stability and control. AC welding is commonly used in processes like Gas Tungsten Arc Welding (GTAW/TIG) and Shielded Metal Arc Welding (SMAW) Typically, electrode-positive (reversed polarity) welding results in deeper penetration. Electrode-negative (straight polarity) welding results in faster melt-off of the electrode, and therefore a faster deposition rate. Deposition rate refers to the amount of filler metal melted into the weld joint #knowledge #welding #inspector #engineer #oilandgas #offshore #onshore #subsea #marine #pipeline #piping #structure #jobs #inspection #quality #qaqc #weldinginspector #coating #painting

𝐄𝐥𝐢𝐦𝐢𝐧𝐚𝐭𝐢𝐧𝐠 𝐁𝐚𝐜𝐤𝐬𝐢𝐝𝐞 𝐆𝐚𝐬 𝐏𝐮𝐫𝐠𝐢𝐧𝐠 𝐰𝐢𝐭𝐡 𝐓𝐆𝐗 𝐄𝐥𝐞𝐜𝐭𝐫𝐨𝐝𝐞𝐬 𝗖𝗼𝗻𝘃𝗲𝗻𝘁𝗶𝗼𝗻𝗮𝗹 𝗕𝗮𝗰𝗸𝘀𝗶𝗱𝗲 𝗚𝗮𝘀 𝗣𝘂𝗿𝗴𝗶𝗻𝗴: ￫ For stainless GTAW, backside shielding is required to prevent oxidation and enable full penetration.  ￫ Argon gas is commonly used to locally purge the root side. ￫ Drawbacks include high gas usage, complex purge setups, and increased welding time. 𝗨𝘀𝗶𝗻𝗴 𝗧𝗚𝗫 𝗘𝗹𝗲𝗰𝘁𝗿𝗼𝗱𝗲𝘀 Ex: 𝙏𝙂-𝙓308𝙇 (𝘼𝙒𝙎 𝘼5.22 𝙍308𝙇𝙏1-5) 𝙁𝙡𝙪𝙭-𝘾𝙤𝙧𝙚𝙙 𝙀𝙡𝙚𝙘𝙩𝙧𝙤𝙙𝙚 ￫ This designates a welding rod (R), with composition similar to 308L stainless (308L), (T) tubular rod, (1) all positions and (5) Type of shielding gas 100% Ar . ￫ TGX tubular electrodes contain flux that forms protective molten slag during welding. ￫ Slag flows to root side of joint, shielding it from the atmosphere.  ￫ 𝘽𝙪𝙞𝙡𝙩-𝙞𝙣 𝙛𝙡𝙪𝙭 𝙚𝙡𝙞𝙢𝙞𝙣𝙖𝙩𝙚𝙨 𝙣𝙚𝙚𝙙 𝙛𝙤𝙧 𝙚𝙭𝙩𝙚𝙧𝙣𝙖𝙡 𝙗𝙖𝙘𝙠𝙨𝙞𝙙𝙚 𝙜𝙖𝙨 𝙥𝙪𝙧𝙜𝙞𝙣𝙜. ￫ Slag absorbs nitrogen, preventing porosity in the weld metal. 𝗕𝗲𝗻𝗲𝗳𝗶𝘁𝘀 𝗼𝗳 𝗨𝘀𝗶𝗻𝗴 𝗧𝗚𝗫 𝗘𝗹𝗲𝗰𝘁𝗿𝗼𝗱𝗲𝘀: ￫ Dramatically reduces inert gas consumption and costs. ￫ Eliminates complex gas purge arrangements.   ￫ Speeds up welding by removing purging operations. ￫ Produces high quality welds without root side oxidation. ￫ Allows full penetration and control in all positions. #BackPurging #stainlesssteel #tublar #FCAW #GTAW #WPS #ITP #inspection #PipingDesign #ASMECode #EngineeringExcellence #QualityAssurance #QualityControl #QualityManagement #ContinuousImprovement #CustomerSatisfaction #OperationalExcellence #EngineeringExcellence #Innovation #MaterialScience #IndustryAdvancements #QAQC #QA #QC #asme #welding #weldinginspection #weldingengineer #weldinginspector #engineering #construction #fabrication #piping #steel #api #aws #data #code #standard #quality #qualitycontrol #qualityassurance #pressurevessels #tanks #oilandgas #powerindustry Photo Credits: 1- https://lnkd.in/dUW_bsRC 2- KOBELCO Welding Today

Pipe welding involves joining two pieces of metal tubing or pipes together. This process is crucial in various industries, such as oil and gas, construction, and manufacturing, because it ensures the integrity and strength of the piping systems that transport fluids, gases, and sometimes solids under varying pressures and temperatures. The quality of pipe welding is paramount for safety, efficiency, and compliance with industry standards and regulations. There are several techniques and methods used in pipe welding, each suited to different types of materials, pipe sizes, and project requirements. Some of the most common pipe welding methods include: 📍 Shielded Metal Arc Welding (SMAW): Also known as stick welding, it uses a consumable electrode coated in flux to lay the weld. This method is versatile and widely used for its simplicity and effectiveness in outdoor conditions. 📍 Gas Tungsten Arc Welding (GTAW), or TIG welding: This method uses a non-consumable tungsten electrode to produce the weld. It is highly valued for its ability to produce high-quality, precise welds on a variety of metals, including thin materials. 📍 Gas Metal Arc Welding (GMAW), or MIG welding: This uses a continuous, consumable wire electrode fed through a welding gun. It's popular for its speed and ease of use, especially on thicker materials. 📍 Flux-Cored Arc Welding (FCAW): Similar to MIG welding, but it uses a special tubular wire filled with flux. It can be more effective than MIG in outdoor applications or when welding thicker materials. 📍 Submerged Arc Welding (SAW): This method uses a consumable electrode under a blanket of flux. It's known for high deposition rates and deep weld penetration, often used in industrial applications requiring heavy-duty welding. Each of these methods has its advantages, limitations, and suitability for specific applications. The choice of welding technique depends on factors such as the type of pipes (material, thickness, diameter), the working environment (indoors, outdoors, underwater), and the specific requirements of the piping system (pressure, temperature, fluid type). Which technique do you use commonly in your industry? Share it in the comments. Here's a guide on different pipe welding procedures. Do check it out. For more such insightful content, follow Jefy Jean A #welding #safety #mechanical engineering #mechanicaldesign #chemicalengineering #chemicalengineer #processsafety #civilengineering

Seeing these things up close really gives you a good perspective of how discontinuities affect the structural integrity of assemblies.

𝐖𝐡𝐚𝐭 𝐀𝐫𝐞 𝐇𝐲𝐝𝐫𝐨𝐭𝐞𝐬𝐭𝐬 𝐚𝐧𝐝 𝐖𝐡𝐲 𝐚𝐧𝐝 𝐖𝐡𝐞𝐧 𝐒𝐡𝐨𝐮𝐥𝐝 𝐓𝐡𝐞𝐲 𝐁𝐞 𝐏𝐞𝐫𝐟𝐨𝐫𝐦𝐞𝐝? Hydrotests (otherwise known as Hydrostatic or Pneumatic Tests) are used to measure the rate of expansion of the unit (pipeline or pressurized vessel such as tank, etc…) to determine if they can safely hold the amount of pressure the vessel is rated for. It ensures that the weld joints and flanges are fitted properly and confirms that the material used has the required strength to sustain the specified pressure. They are often used:   𝑭𝒐𝒓 𝑵𝒆𝒘 𝑷𝒊𝒑𝒆𝒍𝒊𝒏𝒆 𝑪𝒐𝒏𝒔𝒕𝒓𝒖𝒄𝒕𝒊𝒐𝒏: -      to test the structural integrity of a pipeline or segment of pipeline (or pressurized vessel such as a tank) following construction (or installation in the case of a tank) before commissioning to verify the safety and readiness for service.   𝑭𝒐𝒓 𝑳𝒆𝒂𝒌 𝑫𝒆𝒕𝒆𝒄𝒕𝒊𝒐𝒏: -      To test for a visible, measurable leak over a specified period of time. Bear in mind, for successful leak detection, we must inject our tracer gas at the beginning of the fill.   𝑾𝒉𝒆𝒏 𝒓𝒆𝒕𝒖𝒓𝒏𝒊𝒏𝒈 𝒂 𝒑𝒊𝒑𝒆𝒍𝒊𝒏𝒆 𝒐𝒓 𝒂𝒔𝒔𝒆𝒕 𝒕𝒐 𝒔𝒆𝒓𝒗𝒊𝒄𝒆 -      When returning a pipeline or asset to service after being dormant for a period of time   𝑺𝒐𝒎𝒆 𝑬𝒏𝒗𝒊𝒓𝒐𝒏𝒎𝒆𝒏𝒕𝒂𝒍 𝑪𝒐𝒏𝒅𝒊𝒕𝒊𝒐𝒏𝒔 -      When warranted under some environmental conditions, to help  prevent potential damage resulting from leaks using water in a hydrotest minimizes damage resulting from leaks or ruptures.   𝐋𝐞𝐠𝐚𝐜𝐲 𝐏𝐢𝐩𝐞𝐥𝐢𝐧𝐞𝐬 𝐨𝐫 𝐀𝐬𝐬𝐞𝐭𝐬 - For pipe sections manufactured before 1970 using low-frequency electric resistance welding (LFERW) and lap welding (LW), hydrotesting is a valuable tool. Some factory-welded seams in these pipes have shown susceptibility to failure.   #hydrotesting #hydrostatictest #hydropressure #pneumatictesting #pipelineleakdetection #pipelineintegrity

Friction welding of drill pipe is an advanced welding technology used in the manufacture of drilling equipment in the oil and gas industry. It is mainly used to connect pipe sections of drill pipe to form a continuous drill pipe column. Friction welding (FW) is a solid-state welding method that does not involve filler materials or shielding gases. The friction heat generated by the rotational motion makes the two metal surfaces reach a plastic state, and then welds under pressure. The drill pipe after welding is subjected to necessary mechanical processing, such as turning the end face, to ensure dimensional accuracy and surface finish. Non-destructive testing (NDT), ultrasonic testing (UT) or radiographic testing (RT) are also required to verify the welding quality. The application of friction welding technology in drill pipe manufacturing can improve welding efficiency, reduce energy consumption, and the welded joint has high strength and good reliability. It is particularly suitable for drill pipes that need to withstand high pressure, high temperature and complex underground conditions. In addition, since the metal does not melt during the welding process, the possibility of welding defects is reduced, and the overall performance and service life of the drill pipe are improved. #drillpipe #pipe #drawworks #BOP #topdrive #TDS #usedrig #drillingrig #mudpump #pump #workoverrig #750hp #industrialpower #bop #Reliability #PrecisionPerformance #OilDrilling #QualityProducts #OilandGas #Engineering #workover #workoverrig #oilindustry #oilfield #drilling #oildrilling #energyindependence #oil

Pipe welding involves joining two pieces of metal tubing or pipes together. This process is crucial in various industries, such as oil and gas, construction, and manufacturing, because it ensures the integrity and strength of the piping systems that transport fluids, gases, and sometimes solids under varying pressures and temperatures. The quality of pipe welding is paramount for safety, efficiency, and compliance with industry standards and regulations. There are several techniques and methods used in pipe welding, each suited to different types of materials, pipe sizes, and project requirements. Some of the most common pipe welding methods include: 📍 Shielded Metal Arc Welding (SMAW): Also known as stick welding, it uses a consumable electrode coated in flux to lay the weld. This method is versatile and widely used for its simplicity and effectiveness in outdoor conditions. 📍 Gas Tungsten Arc Welding (GTAW), or TIG welding: This method uses a non-consumable tungsten electrode to produce the weld. It is highly valued for its ability to produce high-quality, precise welds on a variety of metals, including thin materials. 📍 Gas Metal Arc Welding (GMAW), or MIG welding: This uses a continuous, consumable wire electrode fed through a welding gun. It's popular for its speed and ease of use, especially on thicker materials. 📍 Flux-Cored Arc Welding (FCAW): Similar to MIG welding, but it uses a special tubular wire filled with flux. It can be more effective than MIG in outdoor applications or when welding thicker materials. 📍 Submerged Arc Welding (SAW): This method uses a consumable electrode under a blanket of flux. It's known for high deposition rates and deep weld penetration, often used in industrial applications requiring heavy-duty welding. Each of these methods has its advantages, limitations, and suitability for specific applications. The choice of welding technique depends on factors such as the type of pipes (material, thickness, diameter), the working environment (indoors, outdoors, underwater), and the specific requirements of the piping system (pressure, temperature, fluid type). Which technique do you use commonly in your industry? Share it in the comments. Here's a guide on different pipe welding procedures. Do check it out. For more such insightful content, follow Jefy Jean A

𝗛𝗲𝗮𝘁 𝗔𝗳𝗳𝗲𝗰𝘁𝗲𝗱 𝗭𝗼𝗻𝗲 𝗖𝗿𝗮𝗰𝗸 The heat affected zone (hashtag #HAZ) of a weld is not limited to the weld itself but to the immediate area of parent material surrounding the weld. A HAZ crack can originate at the toes of the weld or a few millimeters from the weld altogether. The most common causes for this type of crack are: excess hydrogen, high residual stress levels on the weld, and high carbon content on the base material. 𝑻𝒐 𝒎𝒊𝒏𝒊𝒎𝒊𝒛𝒆 𝒕𝒉𝒆 𝒔𝒖𝒔𝒄𝒆𝒑𝒕𝒊𝒃𝒊𝒍𝒊𝒕𝒚 𝒐𝒓 𝒑𝒓𝒆𝒗𝒆𝒏𝒕 𝑯𝑨𝒁 𝒄𝒓𝒂𝒄𝒌𝒔 𝒄𝒐𝒏𝒔𝒊𝒅𝒆𝒓: 1. using low hydrogen electrodes 2. pre-heating the base material 3. slow cooling the base material after welding 𝑻𝒉𝒆 𝒇𝒊𝒈𝒖𝒓𝒆 𝒔𝒉𝒐𝒘𝒔 𝑯𝒆𝒂𝒕 𝒂𝒇𝒇𝒆𝒄𝒕𝒆𝒅 𝒛𝒐𝒏𝒆 𝒄𝒓𝒂𝒄𝒌 𝒊𝒏𝒅𝒖𝒄𝒆𝒅 𝒃𝒚 𝒉𝒚𝒅𝒓𝒐𝒈𝒆𝒏. 𝑻𝒉𝒆 𝒄𝒓𝒂𝒄𝒌 𝒐𝒓𝒊𝒈𝒊𝒏𝒂𝒕𝒆𝒔 𝒂𝒕 𝒑𝒐𝒊𝒏𝒕 𝒐𝒇 𝒉𝒊𝒈𝒉 𝒔𝒕𝒓𝒆𝒔𝒔 𝒂𝒔 𝒉𝒚𝒅𝒓𝒐𝒈𝒆𝒏 𝒅𝒊𝒇𝒇𝒖𝒔𝒆𝒔 𝒐𝒖𝒕 𝒐𝒇 𝒕𝒉𝒆 𝒘𝒆𝒍𝒅 𝒂𝒏𝒅 𝒉𝒆𝒂𝒕 𝒂𝒇𝒇𝒆𝒄𝒕𝒆𝒅 𝒛𝒐𝒏𝒆. #Welding #HAZ #Metallurgy #Quality #Inspection #Crack #Construction #OilandGas #Piping #Mechanical #Projects #Preheating #Inspector #Inspection #welding_imperfections