ORBITAL WELDING

PROCEDURE
FOR
PHARMACEUTICAL PIPING PROCES
(Guide for operator and technician)
 Preparation
Some issue to be check and verify before
installation:
- Submit all the data equipment to be use for
installation process.
- Submit All the document information for
equipment especially calibration certificate for
orbital welding machine, operator certificate,gas
certificate etc.
- Always get all the approval from clien for all
machine and material to be use for installation.
-Get all the detail information for Power
supply ( capacity and stability )
-Require a clean room for Orbital machine
installation .
(no dust, water splash, and dirt surround
welding machine and weld head area)
- Check and verify all tube and fittings to be
use for installation.
( material std ASME BPE SFT 4 (EP) or
SFT 1 (MP) )
- Chek and verifiy all the equipment to be
used based on client URS.
- Chek all detail Mill cert ( heat no, and job
number for all piping and fitting)
-Machine and equipment check list:
1. power source : AMI 307 or
Orbimatic 300 CB
2. Weld head : AMI type 8 or
OW76s orbimatic.
3.Tube clamp insert: inch 2 inch for
AMI type 8 Weld head
inch 3 inch for
OW76s orbimatic.
4.Tungsten and spare part.
 5.Tungsten Grinder and tungsten length
cart.
6.Tube cutter and tube squaring machine.
( Spare part for cutter and squaring)
7.Purging equipment ( Orbipurge)
8.Oxygen analyzer
9.Magnehelic gauge
10.Pure Argon and regulator ( 2 unit )
( Complete with certificate )
11.Supporting Equipment:
- TIG weld machine ( caddy type with
portable argon tank) for pre tacking &
supporting pipes.
- Flash light ( visual inspection)
- Dye Penetrant chemicals ( for 100%
NDT visual inspection of the outside of
the weld)
- Video bores cope for 20% of total joint weld.
- Alcohol solution ( for cleaning tube
and fitting before weld ) if needed
- Safety device ( helmet, eye glasses,
safety shoes, fire fighting,etc)
- Working table
- Grinder and polisher machine.
- Plastic wrapping
- Spare printing paper
- etc.
Install Machine:
1.Chek and make sure all the power supply
are correct.
2.Always use power stabilizer to avoid power
supply problem.
3.Chek water cooling volume at the water cooling
tank machine.
4.Chek and make sure all the cable connector for
weld head and gas supply are correct and no
leak.
5.Turn on the machine.
Installation procedure
1. Weld procedure,welders and equipment
certified prior to start of job.
2. Verify correct power supply for power source.
3. Always use stabilizer for power supply
4. Verify weld head, calibration weld head
tube clamp inserts, electrodes/ tungsten
5.Verify all the material tube and fitting to be
use for installation ( check and store all the
mill cert document)
6.Verify the tungsten length,and performa.
7.Verify and set up gas supply for machine
and for purging.
Before start working:
1.Always do the machine calibration, by using auto
calibration mode for machine and weld head
perform.
( when start working or changing size of tube)

2.Input all the data of the tube or fitting to be weld

( heat no, sized of tube, project name etc)
3.Opening coupon ( when starting the job )
Daily.
Make a sample welding coupon by using
the same material to be weld.
During installation Process:
1.Tube preparation:
make sure all the tube and fitting are the same size, and flat facing.
Always doing the data transferable after cutting process
2.Try to avoid pre tacking weld as much as possible.
3.Make sure no oxygen gas in the tube or fitting before doing the welding to avoid
discolourization
4.Apply the Oxygen analyzer before start welding.
5.Apply the Magnahelic gauge for balancing the purging pressure at inlet and outlet.
6.Apply the Dye penetrant test after welding ( NDT procedure)
7.Cleaning and polishing outer tube ( after qc inspection on NDT test)
8.Slooping and supporting pipes installation.
9.Tagging process.
10.IQ process documentation.
11.20% Borescope test from total joint welding.
12.Pressure test after finish all the welding process ( oiless pneumatic air test, and Hydro
test ( use product water) )
13.Chemical Passivation process.
Noted:
Use the plastic wrapping for wrap the weld
head cable for cleaning and no
contamination issue.
Always change the plastic wrapping when
working in the different type of room (
sterille room etc)