WELDINGS

The oil and gas industry places a demanding requirement on the quality of materials as well as technology. As the industry is spread over some of the most inhospitable places on earth, it becomes imperative that all the equipment performs optimally. In this sector, crude/refined oil or gases are transported from the gas field of oil refinery to the consumers. Weld Technology is the answer to the transport of crude or gases done through the pipes. The welding process used in the oil and gas industry is the most sophisticated as it has to maintain the strength and offer corrosion resistance even in extreme climatic conditions. Our welding solution is that makes us different to achieve such challenges.

Automated Welding (GTAW/GMAW/PTA)

Automatic ID/OD Cladding GTAW

In this process, the TIG welding technique is automated to get the high-quality welding application of the TIG process along with greater speed. Through this process, the deposition rates can be increased significantly compared to the manual TIG welding process. The independent control of the arc and wire feed variables allows setting different parameters that give greater flexibility in this process. This process is generally used in high-density steel, which is widely used in the oil and gas industry. The use of automated TIG with addition to hotwire improves the corrosion resistance of the weldment thereby making it more favourable and affecting the material performance and its service.

  • The technique allows welding the internal diameter of 55mm plus and a length of 1000mm.
  • On OD, the maximum diameter of 1200mm and a maximum length of 7 meters can be welded.

Automated OD cladding GMAW

Using cladding is an accepted practice in the oil and gas industry to mitigate corrosion in the sub sea valves and other sub sea components. Cladding is also widely used in offshore operations to make the component resistant to corrosion thereby improving their life. During the automated cladding GMAW process, all the welding parameters are controlled. In this process, manual adjustment can be made in between the operations, but during the welding process, it is fully automated. This is very important for the oil and gas industry as it allows them to rapidly provide the cladding to their pipes and other equipment to increase their durability by covering them with more resistant materials. It allows you to provide a cladding approximately 2-4mm thick.

PTA Cladding

Plasma transferred arc (PTA) cladding is a versatile method of depositing high-quality metallurgic ally fused deposits on relatively low cost surfaces. Soft alloys, medium and high hardness materials, and carbide composites can be deposited on a variety of substrates to achieve diverse properties including wear and corrosion resistance at ambient or elevated temperatures.

PTA parameters can be adjusted to provide a variety of deposits in thicknesses from 1.2 to 2.5 mm

Weld deposits are characterized by very low levels of inclusions, oxides, and discontinuities.

Manual Welding (GTAW/GMAW/Micro TIG)

Manual OD/ID Cladding GTAW

After completing the welding process, clad material is welded over the joint using high alloy filler metals. The cladding is provided as corrosion resistant to the welded point or even the entire surface. It is sometimes as thin as 1.5 mm. During the TIG cladding process, high-energy impulse creates an explosive charge that drives together the surfaces of the metal to be bonded.

Manual OD Cladding GMAW (Gas Metal Arc Welding)

During the GMAW cladding process, corrosion-resistant alloy wires are fed across to a molten soup that is shielded with inert gas. During the process, the wire feed speed regulates the deposition rate. Any increase in the speed of the alloy wire results in creating more heat which helps the weld molten soup to penetrate deeper into the base metal. This allows the welder to create a corrosive-resistant material layer over the welded material to improve its corrosion resistance property.

Micro Tig welding

Micro TIG welding (micro tungsten inert gas), also known as pulse arc welding process that uses a non-consumable tungsten electrode to produce an arc which creates the weld

It produces high quality welds with minimal heat affected zones by generating arcs between the work piece and the tungsten electrode,

Precision in micro welding (TIG and plasma) from 0.1 to 80 amps

Very stable and soft arc, soft arc will not damage small or delicate parts.

Robotic laser welding

In the oil and gas industry, laser welding is also widely used due to its advantages some of which are given below for your ready reference.

  • Laser welding provides the ultimate precision welding solution and is therefore preferred while handling complicated joints. The precision of laser welding is essential to weld very small parts without damaging them.
  • Laser welding welds dissimilar materials. Additionally, it welds those areas which are very hard to reach using the traditional welding process.
  • Laser technology also uses very low heat during the welding process. This is excellent for minimizing any distortion to the parent material. This reason makes laser welding the preferred choice for the oil and gas industry where any underlying damage to the parent material during the welding process, in the long run, can damage that part.
  • Laser welding can be done even when the tools (like Electronic Sub) are in the electrically wired condition.
  • Laser welding makes a consistent and repeatable weld resulting in uniform quality of weld throughout the system. Laser welding is also faster compared to traditional methods and is much more versatile.
  • Laser welding makes high-strength welds. The reason being there is no need for filler material and laser provides an excellent weld quality which is essential in the oil and gas industry where the safety of the welded joints is paramount.

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Hard Facing

Automated Hard facing with PTA Process

The automated hard facing with PTA (plasma transferred arc system) is actually a thermal spray process using high-energy and inert gas. In this process, Argon is used for the plasma supply and the coating material is fed into the plasma arc through powder. The process welds the PTA deposit over the parent material.

This technique can create a new layer that can be as thin as 0.5mm and as thick as 50 to 60mm. Through this process, the parent material can be coated with any industrial metal or alloy. This allows companies in the oil and gas industry to use the best alloy material to provide a durable coating over the surface of their equipment and improve their corrosion resistance.

Manual hard facing

Hard facing is about creating a thick coating of hard; wear-resistant material over other component surface to ensure its longevity. For hard facing, welders use thermal spraying, spray fuse, and additional welding processes. During this process, hard facing materials such as powders are sprayed over the metal surface and then subsequently fused with the underlying layer by using an oxyacetylene torch. Such a coating is metallurgically bonded to the parent material and is free of porosity.

Stub Welding

Automated Narrow groove stub welding

This kind of welding method was developed so that thicker joints can be welded more conveniently. This type of welding process has important advantages for the oil and gas industry, some of which are mentioned below.

  • It is convenient for welding thick materials.
  • There are very little angular distortions as the joint preparation is done almost parallel-sided.
  • It reduces the weld volume significantly compared to the traditional welding process.
  • Reduces the heat-affected zone.
  • Minimizes residual stresses and material distortion.

Manual stub welding

In this technique, the entire welding process is continuously monitored to ensure that only the purest weld is applied by using the GTAW process. It allows the welder to join large cross-sections without losing the tensile strength of the material in any significant form. This allows the weld strength to remain strong, which is very important in the oil and gas industry. To ensure the integrity of welding, the experts of Raysun Techno Industries LLP use a non-destructive and testing method that includes visual, radiographic testing, liquid penetrant testing, ultrasound testing as well as hardness inspection of the welded joints.