Pipe Misalignment in Pipe Welding

Pipe Misalignment in Pipe Welding

Achieving precise pipe welding alignment is vital to the integrity of the final structure. Pipe misalignment is a fault that occurs when two sections of pipes are improperly aligned during the fit-up process and show up during welding. There are a number of ways this can happen, all of which pose challenges to strong, structurally sound welds. 

Although this is a frustration and significant concern, fixing the misalignment to secure the pipes' operational efficiency is possible. Understanding the nuances of pipe misalignment, its potential causes and what tools can benefit corrective procedures, can all help to produce robust, reliably welded pipelines.

Pipe Misalignment

Misalignment can show up in various forms to present challenges for welders tasked with creating strong and structurally sound joints. These misalignments are identified as hi-lo misalignment, lateral misalignment, angular misalignment or vertical offset. Inaccurate cutting, inadequate support, handling issues and poor fit-up are all factors that can be significant contributors to pipe misalignment that can lead to welding defects. 

Lack of penetration, weld discontinuities and incomplete fusion compromise the weld's structural integrity and increase the odds of failure. Addressing the cause of these defects requires proper preparation, accurate measurement and skilled welding technique execution. Sources of pipe misalignment can include:

  • Pipe damage: With age, alignment issues increase, potentially causing leaks as corrosion and other factors strain misaligned connections.
  • Construction tolerance: Incorrect or imprecise sizing of pipe ends, resulting in misalignment during pipe fit-up.
  • Heavy equipment: Heavy loads on a pipeline add pressure to the structure and can amplify even minor misalignment on an established weld.

Hi-Lo Misalignment

The result of variation in pipe dimensions, improper fit-up or inaccurate cutting, hi-lo misalignment shows a noticeable height discrepancy or ridge between two pipes, which can lead to component corrosion and bacteria and sediment collection. These differing dimensional tolerances affect both the internal and external connections, indicating a weak weld that may not be able to withstand high demands.

Welders can use shims and alignment tools to elevate the pipes equally, resulting in a uniform, structurally sound weld. Where there is a suspicion of hi-lo misalignment, it is common to see tack welding, a temporary weld that helps address the issue before completing the weld. To help compensate for joint geometry variations, you can use welding techniques like oscillating or weaving the weld bead.

Alignment Tolerance in Pipe Welding

There is a limit to how sharp a ridge angle between two welded, misaligned pipes can be — this is known as alignment or standard tolerances. An on-site quality control (QC) manager can determine the exact tolerance based on various factors unique to the pipes in question. Key points to know about this subject include:

  • Types of alignment: Alignment tolerance accounts for the different types of misalignments — angular misalignment is where the angle between pipes is unbalanced, and parallel misalignment refers to the horizontal offset.
  • Industry standards: Welding codes specify alignment tolerances for various industries like oil and gas, and even sewage, to ensure consistent quality and clarity around acceptable misalignments. Deviations beyond the acceptable alignment tolerances negatively impact the weld integrity. 
  • Safety: Poor welds can cause considerable damage to immediate and surrounding ecosystems, people and environments. For example, a bad weld could result in massive oil discharge into the ocean or harmful chemicals being sprayed onto workers.

Measuring Pipe Joint Alignment 

The first step in achieving a structurally sound weld is to measure accurately. Understanding the types of misalignment and accompanying tolerance standards can impact the results of pipe measurements and predict how accurately pipes will align. It is also essential to determine if the pipe ends' shape can carry the stress of the substance the pipes carry. There are four measurements to take:

  • Outer diameter (OD): Measuring across a continuous axis, the OD indicates the total distance from one outer edge of the pipe to the opposite outer edge.
  • Inner diameter (ID): The ID measurement starts from an inside point of the pipe to the opposite inside edge, running through the center axis of the pipe. 
  • Wall thickness (WT): WT measures the radial distance between the outer and inner surfaces of the pipe.
  • Angular or linear offset: If there is an angular offset, the pipes will misalign at an angle to one another. A linear offset refers to a vertical or horizontal misalignment.

Combatting Pipe Misalignment

Ideally, prevention strategies are in place to avoid pipe welding misalignment issues. Accurate measurements, adherence to welding specifications, proper planning and the right pipe alignment tools are all elements that can contribute to this risk mitigation. However, errors may occur and each misalignment may be unique, calling for solutions specific to the joints at hand. In misalignments that are fixable, there are a few processes that can assist in amending the problem:

  • Beveling: Beveling is a standard solution for alleviating pipe joints' hi-lo. This process removes material from the tube end through counterboring. The goal is to create a landing that aligns for a smooth fit-up by removing material through a Compound Bevel, J-bevel, V-bevel, Counterbore or Face.
  • Orbital welding: Orbital pipe fabrication using an open head adjusts the arc gap through automatic gap control, called AGC or AVC. 

Using Alignment Tools for Zero Misalignment

Specialized equipment and tools can prevent misalignment before it even happens. Walhonde Tools offers a range of tools that assist in accurate axial spacing and radial alignment by orienting pipes for a better fit-up. Whether you are installing a new pipeline system, conducting upgrades or repairing existing structures, these tools will aid you in alignment and safety during the weld processes: 



Get Proper Pipe Alignment Tools From Walhonde

Recognizing and addressing pipe misalignment is essential in any industry that uses pipelines. A primary determinant of weld quality is precise alignment. It safeguards against structural vulnerabilities to ensure the reliability and longevity of welded pipes. When you take a proactive approach with attention to detail and adherence to industry standards as a driving force, you can ensure that the welding process produces durable, defect-free joints.

For over 30 years, Walhonde Tools has developed and manufactured patented precision tube and pipe alignment tools. You can learn more about our alignment products here or contact us for a quote.

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