What to Look for in a Tube Welding Machine

Any assembly industry project must ensure the attached or bonded system can withstand contingencies that could result in detachment or breakdown. Attachment methods such as riveting or the use of threaded fasteners may adequately meet this requirement for some metal-based projects; however, for many projects—including piping and/or tubing applications that carry fluids or gases through pressure vessels—these types of attachments can introduce unacceptable weaknesses into the system. 

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Pressure vessels are used in industrial facilities, such as industrial plants, biopharmaceutical and semiconductor manufacturing factories, and energy generation plants where welding is required for assemblies. In order to meet the increased strength and durability criteria for carrying transport through pipes or tubes under pressure, the tube welding machine should meet a range of basic requirements. As we turn to develop a list of core requirements for tube welding, you may also want to examine the types of welding used in pressure vessels. 

Welding Pressure Vessels

Pressure vessels are critical elements for many commercial and industrial operations. In industry, these vessels may contain chemical reactions, toxic fumes, or other contents under pressure. If released, these contents could be hazardous to employees, nearby populations, and/or the environment. Therefore, pressure vessels must maintain a high standard for strength and durability, and they can be classified as one of the following:

Heat Exchangers

Heat exchangers are common vessels used in many industries. As contents are typically under high or extreme heat, heat resistance is required for welded tubing in these systems. Additionally, the compression of gas or liquid for transport requires that the tubing must often be more pressure resistant than the vessel itself. 

Process Vessels

Process vessels are specialized to convert, combine, or extract contents. This equipment is most often used in conjunction with other common pressure vessel types.

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Storage Vessels

Storage vessels are the most commonly used types of pressure vessel. While liquid is regularly stored in them, storage vessels can also contain contents that require long-term housing. Due to extended exposure, vessel interior walls may be composed of a different material type than the surface, and this can lower costs. 

The movement of contents into, out of, or between vessels may be accomplished using pipe, tube, or tube to tubesheet connections. In order to determine the best tube welding machine, it is imperative that one consider pressure vessel requirements that include the type of connection(s), as well as their strength, durability, and content flow type. 

Pressure Vessel Tube Welding Machine Essentials

All welding projects are, to some extent, unique to a client’s demands. The specific tube welding machine falls under your purview, though, and it is necessary for you to determine the best process to use, as well as the machine requirements. Several types of welding are used in pressure vessels, including: SMAW, FCAW, SAW, GMAW, and GTAW. The latter two welding processes are often considered the best options, especially if resistance to high heat or thermal integrity is a priority.

Strength and durability of the weld joints are of high importance since failure for some applications could threaten personnel, local residents, or the environment surrounding the plant. To prevent potentially catastrophic failures from occurring, the equipment must be able to process high-quality, reliable welds and have the following attributes:

Welding pressure vessel tubing can be very difficult. Therefore, when looking for a tube welding machine, you’ll want to ensure that it has the attributes listed in the table above. An automated orbital GTAW welding machine meets these requirements and is a preferred method to weld pressure vessels, as well as the tube connections. 

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By js55 Date 03-12- 14:11 Shane,
Not sure about the present validity of an interpretation written in 83 (they do sometimes become invalid with changes in the code)and the date in which para QW-100.2 was written but QW-100.2 states that the "purpose of the performance qualification test for the welding operator is to determine the welding operator's mechanical ability to operate the welding equipment."
So, if QW-100.2 is valid, how do you do that with a manual or semi auto performance test? You can't.
If QW-100.2 existed when the interpretation was rendered I would have to say that care must be taken in interpreting the interpretation in that no, it is not an 'explicit' essential variable, but you must still comply with QW-100.2.
Note that the question didn't ask about requalification, it asked about an essential variable. Odd, to be sure. But IMO a requal is required due to QW-100.2.

Also, QW-300.3 states that the performance qualification test for welders and welding operators must be documented and 'certified'. How do you do this if the welding operator info wasn't certified at the time?
You can assume for example that there wasn't any 'automatic joint tracking' for example, but is assuming ligit?
How can you certify something you may not have witnessed?

But I do stand corrected on expressing it in terms of an Essential Variable. Good comment. I had to dig out the book on that one.