This document discusses the TiP TiG welding technology and its benefits for piping applications. It summarizes that the TiP TiG process provides higher deposition rates, no slag cleaning needed, lowest heat input, highest quality welds, and can be used from root to cap. It then discusses specific projects where TiP TiG has been used successfully for large diameter stainless steel pipe at nuclear and oil/gas facilities.

1. TiP TiG Technology being used in the Piping Industry
All in One
Combo 500 DC
Suitcase / Confined Space

2. TiP TiG Technology feeder rolls
All in One
Combo 500 DC

3. TiP TiG Technology 18 SC Jumbo Torch
TW 20 Flex Neck
TW 20 Mini

4. TiP TiG Technology Change Neck
Configurations

5. TiP TiG Technology being used in the
Piping Industry running on any Power Source water cooled with HF and min.
recommend 275 Amps (2-6mm)

6. Total Benefit from TIP TIG on PIPE Applications
 Highest deposition rates for any TIG process available on the market.
 No Slag, No Inter pass cleaning = increased Arc on time and weld quality
 Lowest possible heat input of any weld process resulting in lowest HAZ and
significantly reduced distortion.
 Highest quality with the best Metallurgical and Mechanical properties on all
alloys.
 One single process from root to cap
 Simple to Learn, Simple to Use, Simple to Teach.

7. Benefits of New Technology vs Older Processes and Equipment
TIP TIG Hotwire vs Conventional GTAW
 TiP TiG’s Wire Feed Speeds and Amperage are constant and stable, allowing for greater control of the
Weld Process.
 The TiP TiG Process Improves Weld Uniformity and Repeatability
 The TiP TiG Wire Feed process is consistently directed to the “Sweet Spot” of the Arc in any Position.
 Reduced Skill Level Required for all Position, all alloy Welding.

8. Open Root OD Open Root ID
The TiP TiG Process, 6” SCH 80
Weld performed by David Hintz Welding Director Pipe Fitters LU 597 UA Weld Program

9. The TiP TiG Process, 6” SCH 80
Root Pass CS welding Hot Pass CS welding

10. In southeastern Washington state, Bechtel National, Inc. is designing, constructing and commissioning the world’s largest
radioactive waste treatment plant for the U.S. Department of Energy (DOE). When complete, the Hanford Tank Waste
Treatment and Immobilization Plant (WTP) will process and stabilize 56 million gallons of radioactive and chemical waste
currently stored at the Hanford Site.
Bechtel's subcontractor Intermech. Inc. is using the new TIP TIG process to weld it's 42 - 60 inch diameter stainless piping,
both in their shop and in the field. The pipe is utilized as an HVAC duct in a nuclear air-duct application.
BCOI Welding and NDE Services have recognized the potential of the Tip Tig GTAW process and are evaluating the
application of this process. Bechtel Welding and NDE Services will be working with the project to utilize available
equipment in order to evaluate the processes potential and perform R&D. At this present time Bechtel has a number of
projects which will require installation of large quantities of large bore stainless steel piping. Based on preliminary
evolution the Tip Tig GTAW and equipment may add value by increasing productivity, maintaining or perhaps increasing
the quality while reducing hexavalent chromium exposure to craft welders.
Major Project Reference / Customers

11. DoyonAssociated,LLC ALASKA625InconelPipe/TiPTiGPipeWeldingCrew

12. Mechanical Contractor Doyon Associated
ALASKA Pipeline 625 Inconel
Alaska Local 375 recruited UA members from around the US to produce x-
ray quality welds on the Inconel pipeline using the Tip-Tig process.
Major Project Reference / Customers

13. Doyon Associated, LLC ALASKA 625 Inconel Pipe
Operating conditions - 50F
Major Project Reference / Customers

14. Doyon Associated, LLC ALASKA 625 Inconel Pipe
Major Project Reference / Customers

15. DoyonAssociated,LLC ALASKA625InconelPipe
Major Project Reference / Customers

16. New Technology Portable Field Unit
For Coils 10LB / 33LB
Compatible Power Supplies
Miller Maxstar / Dynasty
Lincoln Aspect 375
Up to 75’ Extension for hard to reach
applications

17. TiP TiG AUTOMATION
TiP TiG ORBITAL
All of our automation systems incorporate the use of our patented wire feed technology
Simple to use touch screen programmable interface
Average 4lb / 2kg to 6lbs / 3kg per hour
Arc Voltage Control (AVC)
Auto Electrode Adjustment (AEA) for setting the tungsten to work distance.

18. Customer Benefits
 Up to four times increase in production
 Significantly reduced weld defects which cost companies time and money
 Flexible system configurations based on specific welding needs
New Technology Robo TIP TIG
Product Overview
Unique to ABB, this revolutionary new, patent pending technology
integrates user-friendly robotics with the
TiPTiG process, enhancing its higher travel speed,
lower heat input, and better quality welding advantages.
The process combines proprietary Robo-TiPTiG torch
technology and a fully integrated robotic interface to create the new
function package.

19. TiP TiG Automated Work Station with AVC / Oscillation

20. Material Types for Piping welded with TiP TiG
Inconel 625 Carbon Steel
Stainless Steel
P91

21. CRA Pipe Lined Inconel 625 SCH 160

22. Exotics “Copper to Stainless”
Stainless
Copper

23. Caterpillar’s Safety and Cost Saving Benefit from TIP TIG on Hexavalent Chromium
• Research & Experiment – Caterpillar’s goal is to Identified potential solutions to mitigate Cr(VI) exposure while still maintaining AWS
code quality welds.
• OSHA’s Standard – (29 CFR 1910.1026), the PEL for Cr(VI) is an 8-hr time weighted average (TWA) of 5 micrograms per cubic meter
of air (5ug/m3).
• Current Process – Caterpillar performs Quarterly monitoring with their Cr(VI) Program costing $300K yearly because exposure
monitoring were well above OSHA’s permissible exposure limit (PEL). Even with the introduction of local fume exhaust extractors,
Caterpillar’s stainless steel welders’ exposure limits remained quite high.
• Current Analysis – The team focused on additional Personal Protective Equipment, work practice controls, engineering controls, and
ultimately reducing or eliminating the hazard all together. Benchmarking included weld equipment suppliers, tradeshows, the CAT Tech
Center, OSHA resources and publications, and Ohio State’s Welding program. It became apparent to Caterpillar that NO DIRECTLY
APPLICABLE INDUSTRY SOLUTION EXISTED to mitigate the source of Cr(VI) in the application.
• Process Improvement – Cr(VI) exposure fell drastically to .50ug/m3 from the TIP TIG process and welder exposure was reduced to
levels below OSHA/s PEL and its action level (AL) of 2.5ug/m3.
• Benefits to Caterpillar– The efforts of the enterprise team at Caterpillar over the course of this study will allow Caterpillar to cease its
$300K Cr(VI) program. Flux core welding on stainless steel has been eliminated in many tasks. As a result, hexavalent chromium
emissions are being drastically reduced from all operations as TIP TIG is fully implemented.

24. Thank you!
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