Large Pipe Fabrication
Welding large pipes using either Submerged Arc or Open Arc welding processes may pose a number of problems, such as:
- poor alignment of torch to seam
- improper levels or placement of shielding gas or flux
- improper joint preparation
- jammed wire feeders
- wrong welding power levels
to name just a few.
In order to avoid these problems and ensure the highest possible quality, welding processes must be monitored closely. When automated welding processes were first introduced, fabricators stationed an operator in a chair atop a welding machine, such as a column and boom welder, to visually monitor the welding process directly. Surprisingly, this is still a widely used approach to weld monitoring!
An empty chair waiting for the operator….
Even today, there are fabricators who are unfamiliar with automated inspection process and are forced to place an operator on a chair high above the welded pipe to monitor the welding process. This is a health and safety problem waiting to happen! Not only does the operator face fume inhalation, they risk injury from moving equipment, inadequate protection and dangerous heights.
Can you see the Operator monitoring the process?
In addition to the safety concerns, work breaks are a major drain on productivity. Just think of the production time lost while moving the gantry robot or hoisting equipment down so that the operator can safely exit the equipment at ground level, not to mention the idle time until the operator returns to their position.
A Better Solution
The better solution is to use a remote monitoring weld camera installed at the weld head that can be viewed from as far as 100 m away. Operators are on the production floor, removed from the welding process but still able to see all the details of a welding process. Watch the video below, created by LJ Welding in Edmonton, Alberta, Canada, for an excellent demonstration of how weld cameras are being used in the field:
You can visit our
for dozens of examples of the camera in action.
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