Lincoln Electric FCAW-G User's Manual
Contents
1. dis trict office Six months prior to the start of pipeline construction consumables were tested in the Houston office to ensure the weld procedures with the consumable com plied with the strict industry standards for this job Lincoln engineers worked closely with CRC Evans personnel to ensure the right consumable for the job was selected said Nicholson LN 15 Semiautomatic Wire Feeder The LN 15 is one of the smallest and most maneuverable wire feeders for the construction shipbuilding and pipeline industries available on the market today Through the use of a high temperature abrasion resistant plastic case aluminum alloy roll cage and fully encapsulated PC boards the LN 15 is perhaps the most rugged portable wire feeder in the world The LN 15 is available in both Across The Arc and Control Cable versions Both offer outstanding welding performance including pulse welding on a wide variety of steel stainless steel aluminum and alloy materials WWW PIPELINER Pipeliner G80M is designed to deliver high deposition rates for low hydrogen semiautomatic fill and cap pass welding of high strength pipe up to X80 AWS Class E71T 1MJH8 amp E71T 9MJH8 ADVANTAGES e Smooth spray type arc transfer and low spatter level e Slag system provides excellent puddle support good wetting and good bead shape in all positions e Manufactured to actual lot control Actual certificates of conformance are available2. the evaluation team at U S Pipeline Inc for use on the pipe tie ins at connection points and road crossings near populated areas These welds completed manually by inde pendent pipeline contractors connect the mainline pipe to the thicker walled pipe of the tie ins For the mainline pipe a CRC Evans automated welding system was used in combination with Lincoln s premium SuperArc L 56 copper coated gas metal arc wire MCO05 114 7 05 WELDING CONSUMABLES Flux Cored FCAW G Welding Welding on Pipe An Overview of the Pipe Installation Process More than 140 000 tons of pipe and 25 000 individual sections were used to complete this project Each section of pipe is 78 feet long and per industry standards was buried at least 30 inches below the ground through a trenching process Much like an assembly line where each worker is responsible for a certain por tion of the job construction crews in each spread followed after each other along the length of the pipe to complete specialized tasks Crews at the front staked the area and prepared the right of way Those following behind aligned the pipe welded and inspected the pipe www lincolnelectric Cheyenne Plains Pipeline and then lowered it into the trench Finally the construction crews at the rear were responsible for conducting hydrostatic pressure testing backfilling the trench and restoring the land as close as possible to its original condi t
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4. LINCOLN amp THE WELDING EXPERTSsu WELDING CONSUMABLES Flux Cored FCAW G Welding Welding on Pipe Cheyenne Plains Pipeline RESULTS uring the summer and fall of 2004 the plains of the west were busy with the hustle and bustle of cranes trucks heavy equip ment and supplies to lay pipe for the Cheyenne Plains Gas Pipeline Project The 380 mile 36 inch natural gas pipeline runs from the Cheyenne hub in Colorado to existing pipelines near Greensburg Kan Once operational in early 2005 the pipeline will export 560 million cubic feet of natural gas per day from Wyoming to growing markets in the mid continental U S and further east The 425 million pipeline owned by El Paso Corporation was being con structed in three spreads which were connected in the final phase of the project Spread one was contracted to Associated Pipelines while spreads two and three were handled by U S Pipeline Inc The Cheyenne Plains Gas Pipeline Project was the first major pipeline in the U S to use X 80 grade pipe Already a standard in other parts of the world the X 80 pipe provides higher strength with a thinner wall As on any pipeline project welding plays a critical role in the construction process But what made this project unique was the extensive use of wire welding to provide high productivity A new consumable from the Lincoln Electric Company the Pipeliner G80M gas shielded flux cored wire was selected by
5. W G Welding Welding on Pipe On Site Support and Equipment For the pipe tie in welding Lincoln fully supported the welding efforts from the initial qualifying of the consumables to on site assistance to ensure the inde pendent contractors weren t subject to any downtime Every tie in weld was inspected with a radiographic process and throughout the job the weld quality had been excellent According to Dave Thomas District Manager in Lincoln s Tulsa Office he and representatives from the Cleveland headquarters were present while the Pipeliner GBOM consumable was being tested for the job against competitive consumables We watched as U S Pipeline officials welded with each of the consumables The Pipeliner wire product was much more proficient in operator appeal and also created a bet ter looking weld In addition it also came out on top after destructive tests on the plate in the lab said Thomas Cheyenne Plains Pipeline Thomas also described how once the G80M product was selected Lincoln representatives qualified the procedures for the wire and were close at hand to answer questions and provide technical assistance as U S Pipeline qualified their operators During initial start up of the job in the field Lincoln representatives were at the site three to four days per week and at least one day a week on an ongoing basis throughout the project s duration The Lincoln consumables ran flaw
6. d the circumference of the pipe using a gas metal arc process for high productivity The system was used in combination with Lincoln s premium SuperArc L 56 copper coated gas metal arc wire for welding the pipe s outside diameter consisting of hot fill and split cap passes This 040 inch diameter wire provided specifically for this project offers superior feedability and excellent arc characteris tics a result of Lincoln s manufacturing which uses a strictly controlled chemistry process All mainline welds are inspected using automatic ultrasonic tests From a business perspective it was a good decision for us to work with a domestic consumable supplier such as Lincoln Electric said Brian Laing President of CRC Evans From a techni cal standpoint the mechanical property requirements for the project were easily met by the SuperArc L 56 wire Our direct customers the construction con Featured Lincoln Products SUCCESS tractors and ultimately the pipeline owner were satisfied with the overall quality of the welding and productivity achieved thanks in part to the Lincoln electrode selected According to Peter Nicholson Manager of Pipeline Products at The Lincoln Electric Company providing consumables for the Cheyenne Plains Gas Pipeline required a coordinated effort between many Lincoln entities including its International Division the Cleveland headquarters and Lincoln s Houston
7. field said Fullen We sent Lincoln LN 15 wire feeders with accompanying Magnum welding guns to the job which remedied the situation We also spent time on site providing technical assis tance setting up the equipment and installing wire feed CV modules We were dedicated to keeping the customer up and running Throughout this project received great service from Lincoln explained Bratcher With a phone call would have what needed either hand deliv ered or on site the next day For this project Lincoln Electric partnered with distributor Airgas Intermountain to supply select consum ables and equipment to the site as well as an 85 percent 15 percent argon blend shielding gas According to Flux Cored FCAW G Welding Mark Duncan General Manager East for Airgas Intermountain Airgas provided additional on site support to augment Lincoln s efforts We have a strong relationship with the Lincoln Denver office and worked as a team couldn t have asked for better support from them said Duncan I also tip my hat to our field person Tom McClelland who did a fantastic job providing technical assistance process help and service for the equipment when necessary Welding Pipe Mainline For welding the mainline pipe of the Cheyenne Plains Gas Pipeline Lincoln consumables also played a prominent role A CRC Evans automated pipe welding system was utilized to automati cally wel
8. ion Welding Connection Points and Road Crossings After a lengthy process of evaluating solid and flux cored electrodes for the job U S Pipeline Inc selected a 045 inch diameter Pipeliner G80M wire as the consumable of choice for the vertical up welding of the pipe tie in fill and cap passes The Cheyenne Plains Pipeline Project marked the first time this new consumable was used in the field and for many of the pipeline con tractors it was also the first time they had made the switch from a traditional Stick process to complete the tie ins for the job We chose the Lincoln Pipeliner G80M wire for this project for a number of reasons First it met the mechanical requirements of the job and also offered a crisper arc said Dana Bratcher Welding Foreman U S Pipeline Inc In addition we felt that the Lincoln product flowed better and was more durable for outdoor use We also were attracted to the fact that the pipe supplied from the manufacturer was welded using a Lincoln consumable This electrode specifically designed for pipeline welding is easier for the operator to use and provides a smooth arc lower spatter levels and less frequent clogging of gun nozzles when compared to other flux cored wire electrodes All tie in welds were performed manually because of the special ized skills needed to handle fit up issues between the thinner main line pipe and thicker tie ins Each manual welding team c
9. lessly on the job with great operator appeal The wire is about three to five times faster than stick welding said Edwards The same length of weld bead that would take up to five minutes with stick welding is now taking me about one minute and ease of use commented Steve Duren Technical Sales Representative from Lincoln Electric s Denver office The only issues we addressed with consumables were questions about techniques and proper drag and push www lincolnelectric Cc SUCCESS angles On a project of this magnitude having so few issues was exceptionally good David Fullen Lincoln Electric Denver District Manager echoed these same words about the Pipeliner G80M elec trode For many of the welding opera tors on the job this was one of the first times they had wire welded What s remarkable is that they adapted so well and never had any complaints with the wire The integration of the wire welding has gone smoothly and the job finished ahead of schedule Most of our time spent on the job site was addressing equipment issues Although a competitive brand of welding equipment was specified for the job its alarming failure rate and resulting downtime prompted Lincoln to step in and provide equipment We received an urgent call about equipment when the contractors were struggling with the competitive wire feeders We were able to answer the call and overnight equipment to the
10. onsists of two welders one on each side of the pipe performing one half of the welding pass root hot fill Cc and cap Each welder also had an assistant who performed tasks such as preheating the joints setting the clamp to align the two lengths of pipe setting up the welding equipment and complet ing the finish wire brushing on the joint Every tie in weld was inspected with a radiographic process and throughout the job the weld quality had been excel lent We had a low repair rate with the Lincoln wire It was consistent and worked wonderfully noted Bratcher Our welding operators liked the fact that they were able to see how the puddle flowed The use of Pipeliner G80M wire to weld the spiral seam pipe s fill and cap pass es provided significantly increased productivity and high quality welds The wire is about three to five times faster than stick welding said Ray Edwards an independent pipeline welder from the Pipeliners Union 798 and one of the welders on Spread Two of the project The same length of weld bead that would take up to five minutes with stick welding is now taking me about one minute In addition Lincoln s Shield Arc 70 stick electrode was used to complete the tack welds and vertical down root pass on these tie ins This rod was cho sen for its ability to accomplish the out of position welding required for this job om WELDING CONSUMABLES Flux Cored FCA
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