McDermott Automatic Welding Systems, Multi-joint Welding and Tendon Fabrication Facilities

McDermotts welding technology, capability and proven performance for both shallow and deepwater pipelay, is world-class. Welding research, development and support are centered at McDermotts three main Automatic Welding facilities at Morgan City, Louisiana, Batam, Indonesia and Dubai, UAE, where equipment is assembled, tested and refurbished, procedures are developed and welders are trained and qualified to support regional offshore pipelay projects. Welds made with our Automatic Welding equipment meet requirements of API 1104 section 6 9, API 1104 Appendix A and DNV OS-F101 with non-destructive testing (NDT) of our welds by radiography (RT), manual ultrasonic testing (MUT) and automated ultrasonic testing (AUT).

McDermotts Automatic Welding System (JAWS)

McDermotts Automatic Welding System (JAWS) combines state-of-the-art technologies in welding, servo systems and computerized controls. Comprising six welding heads, a patented laser tracking system and Pulsed Gas Metal Arc Welding (GMAWP), multiple successful pipelay projects have proven the systems high quality welds and excellent production rates for S-Lay installation. Six welding torches at each station provide exceptional production rates and programmed welding parameters eliminate operator adjustments. The system is easily maintained and reliable with very little equipment downtime producing welds with excellent mechanical properties. The benefits of JAWS: improved penetration reduced potential for lack of fusion-type defects reduced weld spatter and porosity increased deposition efficiency

McDermotts Automatic Bug and Band Welding System (JBBS)

McDermotts state-of-the-art system incorporates the latest developments in pipeline welding technology and supplements JAWS which is used primarily on larger diameter and longer pipelines. JBBS is based on Vermaat Technics Veraweld system, and through technical collaboration with Vermaat, McDermott welding engineers developed the dual-torch welding system. Each welding station utilizes dual-torch bugs to produce repeatable, high quality welds with exceptional mechanical properties and high production rates for both S-Lay and J-Lay installation.

McDermotts JBBS equipment typically utilizes Pulsed Gas Metal Arc Welding (GMAW-P) but also operates in the conventional Short Circuit Gas Metal Arc Welding (GMAW-SC) process, as well as the Surface Tension Transfer (STT) mode. JBBS equipment can be used on Corrosion Resistant Alloy (CRA) pipe including 316 stainless steel and 825 inconel (either metallurgically or mechanically bonded pipe). The JBBS system has also been upgraded with Lincoln Electrics PowerWave weld power supplies to further enhance weld quality. The benefits of JBBS: automatic control of all welding parameters programmable parameters can be changed as a function of radial location reduced lack of sidewall fusion (pulsed mode) production flexibility - each station can complete an entire weld

Multi-Joint Welding Capabilities Stringent welding criteria for deepwater systems are met through our advanced Automatic Welding Systems (AWS), which produce high-quality welding and excellent production rates. Welding is complemented by our worldwide welding development centers and a dedicated Multi-Joint Welding facility (MJWF) in Morgan City, Louisiana. At the core of MJWF is the advanced technology of our Bug and Band Welding System (JBBS), an updated dual-torch version of the Vermaat Technics Veraweld system. Together MJWF and JBBS produce a time- and cost-efficient process for quad joint production that meets the strictest welding criteria. Incorporating the latest in cutting-edge PowerWave technology from Lincoln Electric, system improvements are significant in arc control, start-stop points, and diagnostic tools. The MJWF delivers double- and quad-joint line pipe, heavy-wall Steel Catenary Riser (SCR) systems and fatigue-sensitive flowlines for deepwater projects. First used on a challenging subsea project reaching water depths of more than 4,000 feet and reservoirs 28,000 feet below sea level, the MJWF successfully completed thousands of SCR, standard flowline and fatigue-sensitive welds to the stringent criteria required by the extreme conditions. A tendon fabrication product line also comprises part of the facility. While technology like MJF and PowerWave effectively raise work quality levels, the everyday, neverending efforts of our people developing and using the technology are the real keys to its success. Developing better ways to weld is not just about the latest machinery, it is about improving all aspects of the job from material flow to welder competency, shift patterns, safety, training, quality standards and means of repair. By focusing on the entire process, identifying issues, and sharing knowledge, we continuously improve our welding practices, becoming safer, more effective and more efficient.

The Multi-Joint Welding Facility (MJWF) McDermotts 29,700 square-foot, undercover facility contains four welding stations, non-destructive evaluation, testing, profiling and coating stations to handle quad-joint pipe for: flowlines - from 3 to 30 inches outside diameter, up to 160 feet, with two firing lines tendons - from 28 to 48 inches outside diameter, with two firing lines continuous reel pipe - up to 12 inches outside diameter jumpers PLET piping Equipped with conveyors, gantry cranes and mobile transporters the quad joints are welded, coated / painted and stored. The maximum length of pipe that can be conveyed through the covered facility is 300 feet.