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Flux-Cored (FCAW-G) Welding

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Welding on Pipe

Cheyenne Plains Pipeline

 

 

 

 

“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.”

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.

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Lincoln Electric FCAW-G manual An Overview of the Pipe Installation Process, Welding Connection Points and Road Crossings
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FCAW-G specifications

Lincoln Electric FCAW-G (Flux-Cored Arc Welding – Gas Shielded) is an innovative welding process that combines the versatility of flux-cored wires with the advantages of a gas shielding mechanism. This process is designed to enhance productivity, improve weld quality, and offer greater flexibility in various welding applications.

One of the main features of Lincoln Electric FCAW-G is its ability to provide superior penetration and weld quality on thicker materials. This is achieved through the use of tubular wires that contain flux and metal powder, which generates a protective gas shield during the welding process. This feature allows welders to produce high-quality welds with a lower likelihood of contamination and defects, making it ideal for both indoor and outdoor applications.

Additionally, Lincoln Electric's FCAW-G technology is known for its ability to traverse a wide range of operating conditions. The process works effectively on dirty or rusty surfaces, significantly reducing the need for extensive surface preparation. This characteristic makes it highly advantageous in construction and maintenance scenarios, where time and efficiency are critical.

Another notable aspect of Lincoln Electric FCAW-G is its versatility. It can be employed in a variety of welding positions, including flat, horizontal, vertical, and overhead, which allows for greater flexibility in fieldwork and fabrication projects. The process can also be used with a variety of base materials, including mild steel, stainless steel, and even some high-strength alloys.

From a technological standpoint, Lincoln Electric has integrated advanced arc control features into its FCAW-G equipment. These technologies allow for precise control over the welding arc, ensuring consistent results across different applications. The welders are equipped with user-friendly interfaces that enhance the operational experience, enabling quick adjustments and settings tailored to specific welding environments.

In summary, Lincoln Electric FCAW-G combines the robust features of flux-cored welding with the superiority of gas shielding, making it a highly effective solution for professional welders. Its ability to operate under various conditions, produce high-quality welds, and adapt to different materials and positions makes it an essential tool in the welding industry, driving efficiency and reliability in every project. As a result, it stands out as a preferred choice for contractors and fabricators seeking to elevate their welding capabilities.
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