The Big Blue® 350 PipePro® System was designed to maintain steady, reliable arcs with stick welding, and enhanced MIG and flux-cored welding performance for working with high-strength steels.

Three affiliated welding equipment suppliers — Miller Electric Mfg. Co., Hobart Brothers, and Bernard — are introducing a fully integrated pipeline welding system. The Big Blue^® 350 PipePro^® System is a fully integrated pipeline welding system that was developed with input from welders experienced in the rugged, demanding process of pipeline welding.

“With the help of Local Union 798 we’ve built a system that sets a new standard for arc quality and consistency, gives pipeliners the flexibility to transition to flux-cored welding for high-strength steels, and substantially reduces operating costs in terms of fuel use,” according to Roger Hobrock, the director of North American pipelines for Miller Electric Mfg. Co. “The true end-to-end design of this system means that each component is optimized to work with the next, which will allow pipeline welders to excel the moment they put this system to work.”

The developers say their new package is designed to achieve steady, reliable arc characteristics with stick welding, while providing enhanced MIG and flux-cored welding performance for working with high-strength steels.

All three companies are wholly owned subsidiaries of Illinois Tool Works Inc., a multinational manufacturer of industrial products and equipment.

The components of the Big Blue 350 PipePro system include:

— Miller’s Big Blue 350 PipePro diesel engine-driven welder/AC generator supplies 20 to 400 amps for both DC stick (325 amps at 100 percent duty cycle) and DC TIG welding, 14 to 40 volts for MIG and flux-cored welding (350 amps at 100 percent duty cycle) and 12,000 watt peak/10,000 watts continuous auxiliary generator power for running tools on site. The machine meets all Tier 4i requirements, lowers RPM to 1,850 (compared to 3,600 RPM) and reduces noise and lowers fuel use by as much as 50 percent, compared to comparable welding machines.

— Hobart Brothers Fabshield 79T8 self-shielded, flux-cored tubular wire (E71T8-Ni1 J H8). It’s a product that requires no shielding gas, and forms a fast-freezing slag that is easy to remove. The wire performs well in all positions, notably for multi-pass welding on deep-groove pipe-weld butt joints. This wire is optimized within the system for welding on high-strength steel grades in demanding applications.

— Miller’s wireless remote hand control allows welders to change settings easily at the point of use. It extends the remote control range to 300 ft, eliminates remote cord failures, eliminates clutter for improved safety, and improves weld quality, with digital displays for precision control by operators.

— Miller’s SuitCase X-TREME^™ 8 HD voltage-sensing, heavy-duty wire feeder, with its high-torque motor for handling various diameters of wire, and dual scheduling capability. Its motor control allows enhanced precision and arc control, while the feeder’s polypropylene case protects it from other environmental challenges of pipeline construction.

— Bernard’s PipePro Dura-Flux^™ gun features a replaceable liner that simplifies power cable maintenance, along with a dual schedule switch that easily connects to the SuitCase X-TREME HD’s dual schedule feature for wire-feed speed adjustment while welding. Its handle and lightweight, rotatable Hi-Viz^™ neck reduces user fatigue and improves weld puddle visibility. Its internal trigger leads prevent the trigger cord from catching on surrounding impediments, and an advanced molded handle design protects the dual schedule switch from weld spatter.

“We’ve worked extensively with Miller on the development of this,” said Farron Hollabaugh, director of training for Pipeline Local Union 798. “It’s a strong machine that has good arc characteristics. You get the exact same amperage out of it every time you use it as opposed to a DC generator that varies with temperature. They can count on it being the same weld characteristics every time they strike an arc.”

The Big Blue 350 PipePro is available in an optional stainless steel package to withstand corrosive elements in demanding environments, and all models come standard with a LINE-X-coated top cover for added durability and reliability. Miller’s “Vault” — a sealed aluminum casing — protects the machine’s circuit board from dirt, moisture, and heat, to ensure consistent operation, including arc steadiness and generator power. It’s smaller than most models (56-in. depth) and is designed to operate for 10,000 hours before the first basic overhaul.

The Big Blue 350 PipePro System’s rated outputs are tested and verified at 104°F. Miller’s industrial engine drives are subjected to airborne dust and sand, humidity, corrosion, temperature extremes, shaking, vibration and continuous use as part of the rigorous testing process to ensure optimal performance in all conditions. Additional features include: an engine temperature gauge; digital fuel gauge/hour meter/maintenance meter; engine block heater; digital preset weld meters; output contactor control; automatic idle; and Miller’s Auto Remote Sense (ARS) that detects if a remote control is plugged into the 14-pin receptacle and eliminates confusion of a remote/panel switch.