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    Pipeline Welding

    Uploaded by

    Rajnish Bajaj
    This document provides information about various pipeline welding techniques. It discusses different pipe laying methods like reel-lay, S-lay and J-lay which are used depending on water depth and pipe rigidity. It also describes the conveyor production system used for welding pipelines and some key characteristics like maintaining an even work load and addressing bottlenecks. Furthermore, it outlines the work sequence of pipeline welding including tasks like transportation, cleaning, welding, testing and cooling. Specific welding processes used are also summarized like SMAW, FCAW, GMAW and SAW.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Pipeline Welding

    Uploaded by

    Rajnish Bajaj
    408 views61 pages
    This document provides information about various pipeline welding techniques. It discusses different pipe laying methods like reel-lay, S-lay and J-lay which are used depending on water depth and pipe rigidity. It also describes the conveyor production system used for welding pipelines and some key characteristics like maintaining an even work load and addressing bottlenecks. Furthermore, it outlines the work sequence of pipeline welding including tasks like transportation, cleaning, welding, testing and cooling. Specific welding processes used are also summarized like SMAW, FCAW, GMAW and SAW.

    Original Description:

    This presentation discussed various pipeline welding practices for off-shore pipelines.

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    This document provides information about various pipeline welding techniques. It discusses different pipe laying methods like reel-lay, S-lay and J-lay which are used depending on water depth and pipe rigidity. It also describes the conveyor production system used for welding pipelines and some key characteristics like maintaining an even work load and addressing bottlenecks. Furthermore, it outlines the work sequence of pipeline welding including tasks like transportation, cleaning, welding, testing and cooling. Specific welding processes used are also summarized like SMAW, FCAW, GMAW and SAW.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    408 views61 pages

    Pipeline Welding

    Uploaded by

    Rajnish Bajaj
    This document provides information about various pipeline welding techniques. It discusses different pipe laying methods like reel-lay, S-lay and J-lay which are used depending on water depth and pipe rigidity. It also describes the conveyor production system used for welding pipelines and some key characteristics like maintaining an even work load and addressing bottlenecks. Furthermore, it outlines the work sequence of pipeline welding including tasks like transportation, cleaning, welding, testing and cooling. Specific welding processes used are also summarized like SMAW, FCAW, GMAW and SAW.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 61
    At a glance
    Powered by AI
    The key takeaways are the different types of pipeline laying systems like J-lay, S-lay and Reel-lay and their applications based on water depth and pipe type.

    The different types of pipeline laying systems described are J-lay for deep sea with rigid pipes, S-lay for shallow sea with rigid pipes and Reel-lay for flexible and cable pipes.

    Some of the characteristics of pipeline welding mentioned are high cost, need for even work load and productivity, team work required, downtime due to repairs, mechanical issues or weather, and station #1 often being the bottleneck.

    PIPELINE WELDING

    Pipe-lay System

    Reel-lay
    Flexible and cable

    Reel

    S-lay

    J-lay

    Shallow Sea
    Rigid pipe

    Deep Sea
    Rigid pipe

    Stinger

    J-lay tower

    S-laying

    Water Depth 200M


    S shaped Pipeline
    Maintain Tension

    HD-60

    HD-2500

    HD-423

    HD-289

    HD-2500

    Conveyor Production System

    Characteristics of Pipeline Welding

    Conveyor Production System

    Even Work Load


    Team Work

    High Cost Production


    Daily 100,000~350,000 USD
    Productivity Cycle Time

    Downtime : Repair, Mechanical,


    Operational, and Weather

    Station #1 is the bottleneck

    Work Sequence

    Pipe Transportation

    Edge Beveling

    Unloading Pipe

    Pipe inside cleaning

    Line-up

    Welding(Station #2~#4)

    Welding(Station #1)

    Welding(Station #2~#4)

    NDT

    HSS

    Passing Tensioner

    Dope

    Cooling

    Entering sea

    Stinger

    Riser

    J-Lay

    Reel-Lay

    Flexible pipe
    Cable
    Rigid pipe(small diameter)

    Welding of Clad pipe

    316L clad
    Inconel 625 clad
    (S)DSS

    Untreated crude oil


    Interfield ( 15Km)

    LONGI. WELDING

    C/S SAW

    Auto G/G

    Clad W/D-Auto-TIG

    C/S SAW

    Pipe Manufacturer

    Welding of Clad Pipeline

    Welding consumables for dissimilar materials (ER309,


    Inconel 625)
    Quick Argon Purging and maintenance of purging up to
    3rd layer.
    Open-root repair not possible Interim X-ray after 3rd
    layer

    Aux Equipments
    Induction Heater

    Preheating Equipment
    Heating Temp : Minimum Preheat Temp+50C

    Demagnetizer

    50 Gauss
    3

    Liquified Gas Tank

    Ar50+CO250

    Evaporator and Mixer

    Pipe Facing Machine(PFM)


    Beveling pipe edge (Pursuit Out-ofRoundness)

    Internal Clamp

    Line-up (No Tack)


    For manual welding
    For automatic welding(Copper shoe)

    Pneumatic

    Internal Clamp/Welder

    Line-up and Welding

    Compensate big Hi-Lo(Large


    diameter pipes)
    Mechanized internal GMAW
    Single wire 6 Torch
    Mixed Gas (Argon/CO2 = 75:25)
    1st Half circle welding and then
    2nd half welding

    INTERNAL WELDER WORK SEQUENCE

    Welding Processes

    1. SMAW : Cellulosic electrodes


    2. FCAW : Innershield

    3. Auto-GMAW : Tandem-GMAW(Pulse)
    4. SAW(Double Joint) : DC or AC
    5. GTAW + GMAW(V-up) : For Clad pipe

    SMAW

    Cellulosic Electrodes
    Vertical-Down

    Electrodes
    AWS A5.1 and A5.5.
    E-6010
    E-7010P1
    E-8010P1

    Vertical-down welding

    V-up

    V-down

    Number of Passes

    10

    Time for Root Pass

    30 Min.

    5Min.

    Time for Balance

    30Min.

    45Min.

    Total Time

    60Min.

    50Min.

    Cycle Time

    30Min.

    12.5Min.

    AVG Current

    140A

    180A

    Electrode Dia

    3.2/4.0

    4.0/5.0

    Electrodes

    * Cellulosic Electrode

    - DC
    - V-Down or Up
    - Deep penetration
    - Small Slag and Fast Freezing
    - Gas former(CO, CO2, H2, and H2O)
    - High Hydrogen
    Low Hydrogen Electrodes(Basic type)
    - DC/AC
    - V-down Not possible
    - Medium penetration
    - Much slag quantity and slow freezing
    - Small Gas former(High resolution temp)
    - Low Hydrogen

    * Low Hydrogen V-down Electrode

    - Low Hydrogen
    - E7018-G/E8018-G/E7048
    - Not very good bead formation.
    - X65 or higher grade pipes

    Electrode Manipulation

    Drag technique : Slag shall not go faster than arc.

    Current changing during welding

    ROOT PASS
    1. E6010, 4.0mm
    2. ROOT GAP : 1.5mm
    3. DC(-)

    4. Best welders

    HOT PASS (2nd Pass)


    1. High current for deep penetration
    (remelt the wagon track)
    2. 4.0mm dia.

    3. DC(+)
    4. 140~180 Amp

    5. Pipe movement after hot pass


    FILL PASSES

    CAP PASS(ES)

    1. 5.0mm .

    1. 4.0mm /(5.0mm)

    2. DC(+)

    2. DC(+)

    3. 160~220 Amp

    3. 140~180 Amp

    Pass Sequence

    T=9.5mm

    T=12.7mm
    9

    T=14.3mm

    10
    8(STRIP)
    7
    6
    5
    4
    3
    2
    1

    6
    4
    3
    2
    1

    T=15.9mm

    1
    T=17.5mm

    T=23.8mm

    Cf. V-up, T=15.9mm

    Welding Machine
    1. DC-CC
    2. Remote control
    3. Output control

    1. DC-CC/CV
    2. Remote control
    3. Output control

    Double Joint

    24M pipe manufacturing by joining two single joints.


    Longer Barge length.
    150~160% efficiency comparing with single joint

    Line-up

    Internal Clamp

    Outside Welding : Twin wire Submerged Arc Welding

    Welding & Pipe rotating

    Inside welding Single wire Submerged Arc Welding

    Manipulator

    Monitoring during Welding

    Monitor

    Grinding

    Process
    Tiny Twin Wire SAW
    Wire : 2.0mm x 2(Outside), 3.2mm(Inside)
    Power source/control : DC1500/NA5
    4 passes best !!
    Slag detachability is important

    OUTSIDE

    15.9mm

    INSIDE

    MAINLINE
    WELDING

    Mechanized GMAW
    Tandem wire (Individual Power
    source) : ER70S-6, 1.0mm
    Mixed Gas (Argon/CO2 = 50:50)
    Bug & Band
    Programmed welding
    parameters for each layer
    Adjustment during welding
    (Weave width and speed)
    Automatic adjustment of torch
    height
    Monitoring welding parameters

    Control System

    Characteristics

    R=2.4mm, a=5 (Narrow gap)


    Target : 4 passes
    Concave bead by capillarity
    Irregular bead by mis-centering

    Parameters

    Oscillation
    Centering
    Gas Flow
    Slow WFS for Start-up
    Crater Treatment
    Welding parameters per arc location
    (Angle sensor)
    WFS, Amp, Volt, Weaving width,
    Weaving frequency, Dwell time, and
    Travel speed

    Travel speed too high


    Lack of fusion
    Weaving frequency
    too high Overload
    on weaver

    Coating contact tube


    with ceramic for root
    welding

    Root Welding

    Fill & Cap

    Fill pass
    Contact tube outside groove

    For Cap pass

    Multi-Torch Welder

    Mechanized external
    GMAW
    Single wire 6 Torch
    Torch on Frame

    Pulsed Arc

    Repeat High / Low current/Voltage


    Digital control(Programming)
    High : Spray arc (One pulse one drop),
    No spatter.
    Low : Arc maintenance
    Achievement of spray arc and deep
    penetration with same average current.

    Seam Tracking
    Arc sensor (Voltage sensing)
    Algorithm

    25V

    22V

    18V

    SPECIFICATIONS

    - API (American Petroleum Institute)


    API 1104 (Welding of Pipelines and related facilities)
    API 5L (Specification for Line pipe)
    - DNV
    DNV-OS-F101 (Submarine Pipeline Systems)

    - BS
    BS4515 (Specification for welding of steel pipelines on land and offshore)
    Part 1(Carbon and carbon manganese steel pipelines)

    API STD 1104

    - Qualification (Procedure, Welder)


    - Production Welding (Alignment, Line-up, Bevel, Weather, Preheat..)
    - Inspection (Method, Acceptance standards)
    - Repair
    - NDT procedure (Workmanship, or alternative acceptance standard)
    - Mechanized Welding with Filler Metal Additions
    - Automatic Welding without Filler metal Additions
    - In-service welding

    Qualification

    WPQT
    - Welding
    - Visual Inspection
    - NDT
    - Mechanical testing (Tensile, Bend, Nick Break, Macro, Hardness,
    Charpy v-notch Impact)
    - Records (WPQR)
    WQT
    - Welding
    - Visual Inspection
    - NDT
    - (or) Mechanical testing (Tensile, Bend, Nick Break)
    - Records (WQR)

    Qualification

    INSPECTION

    RT, UT, MPI Procedure


    Personnel Certification
    Equipment Calibration
    Acceptance Standard

    Alternative Acceptance Standard

    Workmanship criteria

    Judge based on length.


    Based on experiences,
    Service independent.

    Judge based on Height and length.


    Fracture mechanic analysis
    Fitness for Purpose
    Additional WPQT(CTOD test)
    Stress Analysis
    Inspection (Depth, height & length)

    Alternative Acceptance Standard

    Stress Analysis
    CTOD test
    AUT Validation

    NDT

    Radiography

    AUT

    Radiography(X-ray)
    Crawler

    Aligning Source with joint


    Panoramic shooting

    Film attachment, shooting, print-out and Interpretation : Abt 5 Min.

    Auto UT

    Zone
    discrimination

    Phased Array

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