Pipeline Welding Explained: One of the Toughest Welding Jobs

Pipeline welding is a profession that has been around for over a century and is held in high regard. It provides a vital element of infrastructure all over the world but is most commonly associated with land-based oil-producing locations such as North America and the Far East.

What Is Pipeline Welding

Put simply, pipeline welding is the process of joining steel tube sections to one another to create the infrastructure used to carry liquid products long distances, usually pipeline welding is referring specifically to the pipes carrying oil and oil products.

Pipelines are needed to carry oil from the source; oilfields to the refineries for processing, this is usually far more efficient than overground vehicular transportation, depending on the distances to be covered.

Where Pipeline Welding is Used

Any product or liquid that is carried by steel pipe over large distances is likely to utilize pipeline welding for the creation of the transport system.

The vast distances over which the material is moved often call for hundreds or thousands of joints, meaning a strong, maintenance free solution is needed.

Why Pipeline Welding Is One of the Most Demanding Welding Jobs

Pipeline welding is a tough and demanding job, for a number of reasons:

• Weather: Almost all pipeline welding is done at the mercy of the weather, be that freezing temperatures in the north, or near-desert conditions in the south
• Working in the dirt: Because pipelines are laid on the ground, much of the work involves lying or crouching on the ground
• Long work days: They are needed as the worksites are often many miles from civilization, meaning its most efficient to work as long as possible per trip, 12 hour shifts are typical, but they can be longer
• Isolation: Time away from home is tough for some, because the worksite is constantly moving, welders often spend months away from home

Common Pipeline Welding Techniques and Positions

Efficiency and speed will dictate the weld type used, for this reason most companies will use automated welding wherever possible. When not possible or economical, SMAW is generally the preferred method, although faster methods such as flux core MIG welding are being trialed.

Automated Pipeline Welding

Mechanized welding offers efficient and consistent joints by utilizing tightly monitored speed and process controls. Automated pipe welding is often done using FCAW, GMAW and sometimes submerged arc welding.

SMAW Pipeline Welding

Sometimes the old ways are the best, and on many pipeline projects SMAW or stick welding is still the go-to. It creates an incredibly versatile and strong joint, as long as the welder is sufficiently skilled.

The most common electrodes tend to be some form of cellulosic for the root runs, such as E6010, and a low hydrogen cap run such as E7018.

Welding Positions on Pipeline

In almost all cases, pipeline welds are done entirely “in-position”, meaning no manipulation or rotating of the pipe is done. This speeds up the overall process but means welders need to be confident welding in every position imaginable.

Materials Used in Pipeline Welding and Their Challenges

Pipe Materials

In most cases, low carbon steel will be used for pipeline sections. It offers sufficient strength and is cost-effective. In specialized situations, nickel alloys or stainless steels will be used, particularly if the material to be carried is out of the normal chemical parameters.

While carbon steel is cheap, it does necessitate painting or coating to prevent rust. This is something that is done before the tubes are delivered, with the joints post-treated after welding to provide a seamless finish.

Welding Materials

All welding consumables need to be handled and stored with care, but SMAW rods in particular are susceptible to moisture and temperature. Most welding rigs will have a dedicated storage solution to keep them dry between jobs.

Quality Standards, Safety Requirements, and Certifications

Ensuring weld and installation quality is naturally a key requirement, as repairing after the job is done can be costly and time-consuming. Pipeline welding is most commonly covered by API 1104 in North America.

Alongside API 1104, ASME Section IX will be frequently referenced as the governing standard for welding procedures, consumables, and qualifications.

Pipeline Safety Requirements

While site specific, pipeline crews need to adhere strictly to all relevant OSHA guidelines and rulings. Most personnel will require at minimum the OSHA 10 certification, with persons in charge holding OSHA 30.

In Summary

Pipeline welding is a vital but grueling branch of welding as a career. Whilst requiring long stints away from home and working in harsh conditions, it does offer a solid career with good pay and job security.