Weld Cleanup Poses Challenges for Oilfield Workers

Figure 1
Field welding applications can present additional challenges in weld cleaning because of the environment and out-of-position work.

Interpass and postweld surfacecleaning in field applications, suchas pipeline welding in an oil patch,sometimes requires out-of-positionwork in conditions that are less thanideal. A welding operator may haveto lie on his back in the mud, for example,to clean an overhead weld betweenpasses.

Obviously, field applications canpresent additional challenges in weldcleaning. New technologies that helpimprove safety and make it easier foroperators in the field to properly usepower wire brushes also may improvetheir comfort, productivity, and efficiency.

New brush technology specificallydesigned for pipeline constructionmakes flipping the accessory easierto help maximize wire life and safetyas the brush wears. The ability to easilyswitch the mounting position ofa weld cleaning brush can contributeto improved safety, productivity,and efficiency in demanding fieldapplications.

Challenges in FieldApplications

Industries such as pipeline welding oftenhave stringent code requirementsthat make surface cleaning to removethe slag and inclusions between eachwelding pass an important part ofcompleting high-quality welds. Attentionto proper weld cleaning is especiallycritical in field applications,given some of the difficulties thatwelding outdoors can pose.

An operator often needs to completethe weld cleaning out of position,perhaps lying down or evenstanding on a ladder. Because almostall pipeline welds must be cleaned,the brushes wear down naturally withuse, and some operators have a tendencyto push harder as the brushwears.

Applying too much pressure tothe brush is a common problem thatraises several concerns. With a dullbrush, the operator expends moreeffort and therefore becomes morefatigued, which in turn affects safetyand productivity. This is also an issueof wasted worker time for thecompany.

It can present additional safetyconcerns when an operator who isworking out of position tries to pushor force a tool harder than necessary,which creates an even more unfavorableor uncomfortable position forhim.

Too much pressure also can damagethe wires of the brush morequickly, reducing brush life.It’s important to remember thatpower brushes are designed to letthe wire tips do the work. Operatorsneed to apply only the weight of thetool, without leaning on the brush orpushing hard, for the best and safestresults.

Technology Designed for the Field

Figure 2
New technologies help improve safety and make proper use of weld cleaning brushes easier, which enhance productivity and efficiency.

A brush that can be easily flipped orreversed provides numerous advantagesfor operators and the company.Periodically switching the mountingposition of weld cleaning brushes enhancesthe speed and effectiveness ofthe brushes, which also improve operatorsafety.

Because a dull brush is less effective,the operator has to work harderto get results. Being able to flip thebrush easily improves the operator’sproductivity and thus has an impacton savings and the ROI of the tools.

Some newer weld cleaning brushesare designed with a dual-hex nut toallow for easy flipping of the wheeland elimination of interference issuesthat pose a safety hazard. The designof these types of brushes features ahex on each side of the wheel andadequate tool clearance, so the wheelposition can be changed without removingthe guard from the tool.

Because the grinder rotates in onedirection, the wire tips become dullin that direction over time. Flippingthe brush allows the operator to usethe other side of the tips, which becomerazor-sharp as the oppositesides wear.

Best Use

Operators shouldn’t wait to flip thetool until they notice a brush hasbecome dull or wires start to break.Flipping the brush periodically, beforedull wires make it necessary, willhelp keep the wires sharp and thetool most efficient and productive. Ifthe operator has to apply pressure toget the job done, it’s likely the brushneeds to be flipped or replaced.

A dull brush can lead to underbrushingof the weld joint. This problemcan lead to inclusions or defectsleft in the weld, which can adverselyaffect quality and possibly lead torework.

Flipping the brush too often is nota concern, so operators can make ahabit out of periodically changing themounting position. Regular inspectionstill is important, however, toknow when a brush has reached theend of its useful life.

Also, because the wire tips of powerbrushes are designed to do the work,operators should keep in mind theangle at which they are holding thebrush in relation to the work surface.The tips should be perpendicular tothe weld being cleaned to minimizethe amount of flex in the wires and reducethe likelihood of wire breakage.

Running a power wire wheel brushat an angle means the operator is usingthe sides of the wires rather thanthe tips. Therefore, the brush isn’t doingas much work and the operatorpushes harder, causing wire breakage.Holding the wire wheel brushperpendicular to the weld improvesperformance, cleaning results, andsafety, because the operator doesn’thave to work as hard to get results.

Proper brush storage is especiallyimportant in field applications,where weather and harsh conditionsmay be an issue. Clean, dry storagehelps keep wire brushes in safeworking condition, free from rust anddamage.

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