Lincoln Electric LN-15 Manuel utilisateur

SUCCESS

Flux-Cored (FCAW-G) Welding

The Cheyenne Plains Gas Pipeline

project was the first major pipeline in

the U.S. to use high strength X-80

grade pipe. The contractor, U.S.

Pipeline, was looking for ways to

increase productivity while still creating

high quality welds that could pass

radiographic inspection.

Lincoln Electric Pipeliner®G80M

gas-shielded flux-cored wire for

use on the pipe tie-ins at connection

points and railroad crossings near

populated areas.

Using a wire process yielded results

that were three to five times faster

than the stick welding typically used

for pipeline welding. The Pipeliner

G80M provided high quality and

flawless operation with its smooth

arc and low spatter levels.

-SOLUTION-

-RESULTS-

Contractor U.S. Pipeline

turned to new Lincoln Electric

Pipeliner®G80M gas-shielded

flux-cored wire to weld the

pipe tie-ins for the 380-mile

Cheyenne Plains Gas Pipeline

project, which used X-80

grade pipe.

-CHALLENGE-

During 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 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.

MC05-114 7/05

WELDING CONSUMABLES

Cheyenne Plains Pipeline

Welding on Pipe

www.lincolnelectric.com

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

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-

tion.

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 consists of

two welders, one on each side of

the pipe performing one-half of

the welding pass – root, hot, fill

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.

“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 Bratcher.

“In addition, we felt that the

Lincoln product flowed better

and was more suitable for

outdoor use.”

SUCCESS

2/4

Flux-Cored (FCAW-G) Welding

WELDING CONSUMABLES

Cheyenne Plains Pipeline

Welding on Pipe

www.lincolnelectric.com

SUCCESS

3/4

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.

According to Dave Thomas, District

Manager in Lincoln’s Tulsa Office, he

and representatives from the Cleveland

headquarters were present while the

Pipeliner G80M 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.

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 flawlessly

on the job with great operator appeal

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

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 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 I received

great service from Lincoln,” explained

Bratcher. “With a phone call, I would

have what I 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

“Every tie-in weld was

inspected with a radiographic

process and throughout

the job the weld quality had

been excellent.”

“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.”

Flux-Cored (FCAW-G) Welding

WELDING CONSUMABLES

Cheyenne Plains Pipeline

Welding on Pipe

www.lincolnelectric.com

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. I 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 weld 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-

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 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.

SUCCESS

4/4

AWS Class:

E71T-1MJH8

& E71T-9MJH8

ADVANTAGES

• Smooth, spray type arc transfer and low spatter level.

• Slag system provides excellent puddle support, good

wetting and good bead shape in all positions.

• Manufactured to actual lot control. Actual certificates of

conformance are available upon request.

Featured Lincoln Products

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.

LN-15 Semiautomatic Wire Feeder

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.

Flux-Cored (FCAW-G) Welding

WELDING CONSUMABLES

Cheyenne Plains Pipeline

Welding on Pipe

www.lincolnelectric.com

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