An orbital welding system and methods of operation controllably and safely weld a first metal tubing to a second metal tubing. A weld head includes interlocking clamping jaws for clamping the tubing. An alignment mechanism aligns the second tubing with the first tubing. The interlocking clamping jaws clamp the second tubing following the aligning of the second tubing with the first tubing. An alignment measurement mechanism measures relative alignment between the first tubing and the second tubing. A weld environment mechanism establishes a gaseous environment for orbitally welding the first tubing to the second tubing. The weld environment mechanism includes a weld environment sealing mechanism for sealing the gaseous environment and an electrode for gas arc welding. The weld environment mechanism orbits the first tubing and second tubing during the orbitally welding. Interface circuitry interfaces a power supply with the weld head and controls parameters associated with said weld head.