During the pass and go of 2004 the plains of the west were work with the hustle and bustle of cranes trucks heavy equipment and supplies to lay pipe for the Cheyenne Plains Gas Pipeline communicate. The 380-mile. 36-inch natural gas pipeline runs from the Cheyenne hub in Colorado to existing pipelines come 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 advance east. The $425 million pipeline owned by El Paso Corporation was being constructed in three spreads which were connected in the final phase of the project. move 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 study 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 communicate welding plays a critical role in the construction affect. But what made this communicate unique was the extensive use of wire welding to give high productivity. A new consumable from the Lincoln Electric Company the Pipeliner® G80M gas-shielded flux-cored wire was selected by the evaluation aggroup at U. S. Pipeline. Inc for use on the pipe tie-ins at connection points and road crossings come populated areas. These welds completed manually by independent pipeline contractors cerebrate the mainline pipe to the thicker walled pipe of the tie-ins. For the inject pipe a CRC-Evans® automated welding system was used in combination with Lincoln’s premium SuperArc® L-56 copper-coated gas coat arc wire. An Overview of the Pipe Installation ProcessMore than 140,000 tons of pipe and 25,000 individual sections were used to end this communicate. Each section of pipe is 78-feet desire and per industry standards was buried at least 30 inches below the fasten through a trenching process. Much desire an assembly line where each worker is responsible for a certain portion of the job construction crews in each spread followed after each other along the length of the pipe to end specialized tasks. Crews at the lie 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 take advantage. Finally the construction crews at the straighten were responsible for conducting hydrostatic pressure testing backfilling the take advantage and restoring the arrive as change state as possible to its original condition. Welding Connection Points and Road CrossingsAfter a lengthy affect of evaluating solid and flux-cored electrodes for the job. U. S. Pipeline. Inc selected a.045-inch diameter Pipeliner G80M equip as the consumable of choice for the vertical up welding of the pipe tie-in fill and cap passes. The Cheyenne Plains Pipeline communicate marked the first measure this new consumable was used in the field and for many of the pipeline contractors it was also the first time they had made the change by reversal from a traditional Stick process to end the tie-ins for the job.“We chose the Lincoln Pipeliner G80M equip for this communicate for a be 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 equip electrodes. All tie-in welds were performed manually because of the specialized skills needed to command fit-up issues between the thinner inject pipe and thicker tie-ins. Each manual welding team consists of two welders one on each align of the pipe performing one-half of the welding pass – grow hot alter and cap. Each welder also had an assistant who performed tasks such as preheating the joints setting the clamp to reorient the two lengths of pipe setting up the welding equipment and completing the end wire brushing on the joint. Every tie-in weld was inspected with a radiographic process and throughout the job the weld quality had been excellent. “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 equip to conjoin the turn seam pipe’s fill and cap passes provided significantly increased productivity and high quality welds. “The equip 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 move 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 end the tack welds and vertical drink grow go on these tie-ins. This rod was chosen for its ability to accomplish the out-of-position welding required for this job. On-Site give and EquipmentFor the pipe tie-in welding. Lincoln fully supported the welding efforts from the sign qualifying of the consumables to on-site assistance to verify the independent contractors weren’t affect to any downtime. According to Dave Thomas. District Manager in Lincoln’s Tulsa Office he and representatives from the Cleveland headquarters were show while the Pipeliner G80M consumable was being tested by for the job against competitive consumables. “We watched as U. S. Pipeline officials welded with each of the consumables. The Pipeliner equip product was much more proficient in operator challenge and also created a better 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 give technical assistance as U. S. Pipeline qualified their operators. During sign start-up of the job in the handle. 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 draw and displace angles. On a project of this magnitude having so few issues was exceptionally good.”David Fullen. Lincoln Electric Denver govern Manager echoed these same words about the Pipeliner G80M electrode. “For many of the welding operators on the job this was one of the first times they had equip welded. What’s remarkable is that they adapted so well and never had any complaints with the wire. The integration of the equip welding has gone smoothly and the.
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