Core Responsibilities
- Multi-Wire SAW Operation: Operate automated Inside (ID) and Outside (OD) welding stations utilizing tandem, triple, or quadruple wire configurations.
- Parameter Management: Monitor and adjust welding variables (Amperage, Voltage, Travel Speed, and Wire Feed) according to the approved Welding Procedure Specification (WPS).
- Consumable Oversight: Ensure the correct grade of welding wire and flux is used. Manage flux recovery systems and ensure flux is pre-heated and moisture-free to prevent hydrogen cracking.
- Weld Quality Monitoring: Conduct real-time visual monitoring of the weld pool via laser-tracking systems or cameras to ensure proper penetration, bead profile, and overlap.
- Tack Weld Integration: Ensure the final SAW pass successfully consumes and integrates with the initial tack weld without creating slag inclusions or porosity.
- Machine Maintenance: Perform daily cleaning of welding nozzles, contact tips, and wire feeders. Monitor the health of the cooling system and flux delivery hoses.
Technical Skill Set
- Equipment Proficiency: Experience with high-end power sources and controllers from Lincoln Electric (Power Wave), ESAB (A6 systems), or Miller.
- Laser Tracking Systems: Proficiency in using automated seam tracking systems to maintain the arc exactly on the seam.
- Blueprint & WPS Literacy: Ability to read technical drawings and strictly follow WPS charts for various steel grades (API X52 through X80).
- Defect Recognition: Ability to identify common SAW defects such as undercut, porosity, slag inclusion, and burn-through in real-time.
Key Qualifications
- Education: ITI (Welder/Mechanical) or a Diploma in Mechanical Engineering.
- Experience: 3-10 years of hands-on experience in Inside or Outside SAW within an LSAW or HSAW pipe mill.
- Certification: Valid Welder Performance Qualification (WPQ) as per ASME Section IX or API 5L is mandatory.
- Industry Background: Candidates from similar industries are highly valued for their experience with high-pressure, export-quality welding standards.
Preferred Attributes
- Understanding that weld repairs are costly and impact the pipe's fatigue life.
- Safety Vigilance: Strict adherence to PPE (welding hoods, respirators) and awareness of the hazards related to UV radiation, fumes, and high-voltage electricity.
- Data Accuracy: Operators must ensure that heat inputs for every pipe are logged digitally and correctly into the MES for quality traceability.
Employer-Specific Expectations
- Strict adherence to specified Welding Requirements.
- Focus on maintaining high travel speeds and productivity without compromising the mechanical properties of the Heat Affected Zone (HAZ).
