Noreast Services & Pipelines

Introduce
The Autoweld System


Corporate Presentation
Presentation outline
Introduction to the Autoweld System
Pipe Facing machine
Internal welding machine
External welding machine
Future developments
Procedure for Automatic Welding using fully mechanised system
Technical Support services
Suggested welding procedure (pWPS)
Conclusions of The Autoweld System
History and experience
Autoweld System Approval List
Pictures of system in use on the WEPP project China


Introduction
The Autoweld System is a Fully Mechanised Gas Metal Arc Welding
(GMAW) System, Designed and developed to Weld Linepipe Girth Welds
for both Onshore and Offshore Pipelines.

It utilises Internal and External Welding Machines for speed of production.
It is designed and manufactured by Autoweld Systems, exclusively for
Noreast Services & Pipelines

Available to rent, short and long term lease and / or buy.
Pipe Facing Machines
Diameter ranges, with expander sections

Joint geometry

Facing procedure

Inspection of bevels
Diameter Ranges
From 28 to 36 inch diameter, expander required for 36 inch.

From 40 to 48 inch diameter, expander required for 48 inch.

From 56 to 60 inch; no expander required.



Pipe Facing Machine & Hydraulic Power Unit

Pipe facing machine

Expander Unit

Compound Narrow Gap Bevel

5
45
37.5
0.110"
0.210"
0.045" 0.055"
Macro Section ( smooth root profile)

Facing Procedure
Tool holders set correctly
Cutting tools replaced accordingly
1 operator only required
Inspection of bevel
Critical to welding procedure
Check with bevel gauge
Production of weld prep approx. 100 welds ahead of
mainline
Protect ends from mechanical damage and weather
conditions
Internal Welding Machine
Diameter ranges vary upon wall thickness but
generally in accordance with API requirements.
24 to 28 inch OD
30 to 32 inch OD
34 to 36 inch OD
40 to 42 inch OD
46 to 48 inch OD
56 to 60 inch OD
Advantages with the Autoweld Internal Welding
Machine
Front end welding speed
Minimising of misfires due to modified wire drive gear box
Standard size spools for both Internal & External machines
4WD drive for maximum drive through pipe
Eliminates the need for Cu backing shoes
Parameters need to be set only once during production
Minimal on site maintenance
Only 1 operator required to produce Root Pass
Increases weld root quality
Cost reductions of welding large diameter pipes with thick wall
The Autoweld System is one of only two fully automatic systems
available

Internal Welding Speeds
OD in Inches Arc times in mins
24 1.20
28 1.50
30 1.57
32 1.68
36 1.10
40 1.20
42 1.25
48 1.50
56 1.90
42 inch Front Section

42 inch Middle Section

42 inch End Section

Reach Rod control box

External Welding Machine
Weld diameter range from 12 inches to unlimited
Robust and cost effective
Autoweld/97-1 version already being used worldwide
User friendly equipment and software
Proven world-wide on pipeline projects
Autoweld/97-1 external welding machine

Autoweld/97-1 external welding machine

Future developments
Dual welding torch system, for thick wall pipe.
Modified electronics
Internal welding machine
External welding machine
Upgrades available ( appox. 2 years)
Dual torch

Dual torch

Technical support services
Training by Noreast
Very experienced team consisting of:
Lead Technicians
Service Technicians
Welding Engineers
Welding Supervisors
Structured training program in one location by our technicians and
welders
Numbers to be agreed to develop the best training program.
Technical support services
For training client personnel, Noreast would supply the following:
2 Welding supervisors
1 PFM operator
1 Welding Engineer
I Lead Service Technician

The above personnel will carry out training for:
PFM operators
Internal welding machine operators
External welding machine operators
Service Technicians
Technical considerations for Welding procedure
Materials used in pipeline construction
Consumables
Welding procedure
Typical mechanical results
Materials used in pipeline construction

The Autoweld System is Capable of Welding
Linepipe Grades from X42 Through to X80
Spiral and Longitudinal Seam Welded Pipe
Light and Heavy Wall Thickness'
To Sour and Non-Sour Specifications
Onshore and Offshore
Consumable Selection (GMAW)
ER 70 S-6 (AWS) Solid
Filler Wire
Triple Deoxidised
Si Mn Ti
Up To API 5L X80
Grade Pipe (Min. TS
620MPa)
ER 90 S-G (AWS)
Solid Filler Wire
Triple Deoxidised
Ni Mo Variant
For StE 550.7 TM
Grade Pipe (Min. TS
690MPa)
Welding Procedures
Narrow Gap Bevel Configuration
Filler Wire Type
Shielding Gases
Process Parameters

Autoweld Systems - Preliminary Welding Procedure Specification
Procedures For Exclusive Use With Autoweld Mechanised Welding System
Pipe to Pipe Mechanised GMA Girth Weld

Client: IIW

Project: Gas Pipeline

Specification: API 1104

WPS No.: AWS/IIW/001A

Rev. No.: 0 Date: 6
th
March 2002

Page 1 of 2
Material Specification : API 5L
Grade/Type : TBA
Diameter : O.D. 56"
Wall Thickness : 0.78"
Dia. Range Qualified :
Th. Range Qualified :
Joint Design
5 0.110"



45
0.045"
Weld Process :AUTOWELD (GMAW)
Filler Manufacturer : Bohler
Trade Name :SG-Pipe (All Passes)
Classification : ER70S-6
Heat No. :TBA

Weld Position : 5G (Vertical Down)
0.210"

37.5 0.055"
Pass Sequence


Preheat Temp. :Min C TBA
Interpass Temp. :Min/Max C TBA
Application Method :Propane Gas/Induction
Measurement By :Tempilstick/Thermometer

Type of Line-up Clamp :INTERNAL WELDER
No. of Weld Heads : 6 Internal 2 External
No. Of Welders :1 Internal 2 External
Clamp Removed After :*100 Root
Lower Off After :100 Root
Cleaning Method :Power Grinder/Brush
Maximum time lapse between the completion of the Root
Bead to the start of the Hot Pass = TBC

Minimum No. of passes before the joint is allowed to
cool.....3......
Maximum time between commencement and completion of
weld....48hrs.......
Pass CTWD
10%
mm
Gas Shield
%Ar/CO
2

Flow
Rate10%
L/min
Voltage

V
Current

A
Weld5%
Speed
ipm/mm
WFS 5%

ipm / M
Oscillation
5%
No/min
Heat
Input
kJ/mm
Root
Hot
Fill 1
Fill 2
Fill 3
Fill 4

Cap

9.0
8.0
12.5
12.5
12.5
12.5

8.0
80/20
100 CO
2
100 CO
2
100 CO
2

100 CO
2
100 CO
2


80/20
33
42
42
42
42
42

33
19-21
24-26
23-25
23-25
23-25
22-24

19-21
180-220
240-280
220-260
220-260
220-260
210-250

180-220
30 762
50 1270
16 406
16 406
16 406
16 406

12 305

380 9.6
500 12.7
500 12.7
500 12.7
500 12.7
500 12.7

380 9.6

-
-
160
160
160
160

110

0.27-0.36
0.27-0.34
0.75-0.96
0.75-0.96
0.75-0.96
0.68-0.89

0.67-0.91
Notes:
1) Polarity DCEP 4) Last Fill Nominal Weld Speed 20% 7) Bevel Tolerance 0.005", 0.5
2) Head Angle 5 - 10 5) Cap Nominal Weld Speed 20% 8) *Except in the case of a Misfire
3) Filler Wire Diameter 0.9mm 6) Stripper Run Where Required
Autoweld Systems Ltd:

SIGNED:

NAME:
TITLE:


Date:
CONTRACTOR:

SIGNED:

NAME:
TITLE:


Date:
CLIENT:

SIGNED:





Date:

* Summary of
parameters
Used for
Proposed Welding
procedure
Typical Weld Bead Sequence for W.T. 16mm
Typical Weld Bead Sequence for W.T. 16mm
Typical Weld Bead Sequence for W.T. 16mm
Typical Weld Bead Sequence for W.T. 16mm
Typical Weld Bead Sequence for W.T. 16mm
Typical Weld Bead Sequence for W.T. 16mm
Filler Wire Type
ER 70 S-6
Autoweld SG3-P
(Bohler)
ER 90 S-G
NiMo1-IG (Bohler)
Shielding Gases
Root & Cap Passes
80% Ar / 20% CO
2
Flow Rates 75cfh
Hot & Fill Passes
100% CO
2

Flow Rates 100cfh
Typical Process Parameters
Root & Hot Passes
Travel Speeds
30ipm & 50ipm
Fill & Cap Passes
Travel Speeds
18ipm & 13ipm
Typical Process Parameters
Root & Hot Passes
Wire Speeds
380ipm & 500ipm
Fill & Cap Passes
Wire Speeds
600ipm & 400ipm
Typical Process Parameters
Root & Hot Passes
(Stringer Beads)
None
Fill & Cap Passes
Oscillation Rates
180b/min & 120b/min
Typical Process Parameters
Root & Hot Passes
Heat Inputs 0.3 kJ/mm
Fill & Cap Passes
Heat Inputs 0.8kJ/mm
Chemical Analyses (Weld Body)
SG3-P (ER70S-6)
%wt C 0.09
%wt Si 0.62
%wt Mn 1.34
%wt Cu 0.06
%wt Ti 0.02
NiMo1-IG (ER90S-G)
%wt C 0.08
%wt Si 0.45
%wt Mn 1.46
%wt Cu 0.08
%wt Ti 0.02
%wt Ni 0.80
%wt Mo 0.24
Mechanical Properties
Weld Metal Yield & Tensile Strength
Weld Metal Hardness
Weld Metal Toughness
Fracture Toughness (CTOD)
Impact Toughness (CvN)
All Weld Tensile Results
SG3-P
YS 663 MPa
TS 713 MPa
%EL 25%
NiMo1-IG
YS 703MPa
TS 765MPa
%EL 20%
All Weld Tensile Results
SG3-P
SMYS (X70)
Overmatching 38%
Min. TS (X70)
Overmatching 19%
NiMo1-IG
SMYS (X70)
Overmatching 46%
Min. TS (X70)
Overmatching 35%
Overmatching API 5L X80
SG3-P
SMYS (550MPa)
Overmatching
Capability 20%
Min.TS (620MPa)
Overmatching
Capability 15%
NiMo1-IG
SMYS (550MPa)
Overmatching
Capability 28%
Min. TS (620MPa)
Overmatching
Capability 23%
Weld Metal Hardness (HV10)
SG3-P
Min. 228 HV10
Max. 272 HV10
Mean 245 HV10
NiMo1-IG
Min. 247 HV10
Max. 280 HV10
Ave. 262 HV10
Weld Metal Toughness (CTOD)
SG3-P @ -10C
Min. 0.201mm
Max. 0.286mm
Mean 0.256mm
NiMo1-IG @ -10C
Min. 0.182mm
Max. 0.332mm
Mean 0.233mm
Weld Metal Toughness (CvN)
SG3-P WM
Centre Line 2mm From
Root
Upper Shelf 115J
@ 20C
Lower Shelf 18J
@ -80C
50% FATT -35C
NiMo1-IG WM
Centre Line 2mm From
Root
Upper Shelf 100J @
20C
Lower Shelf 30J @
-80J
50% FATT -40C
Weld Metal Transition Curve for SG3-P
HT. No. 812443
0
20
40
60
80
100
120
140
-100 -80 -60 -40 -20 0 20 40
TEST TEMPERATURE C

E
N
E
R
G
Y

A
B
S
O
R
B
E
D


J




Comparison of Weld Metal Transition Curves
0
20
40
60
80
100
120
140
-100 -80 -60 -40 -20 0 20 40
TEST TEMPERATURE C

E
N
E
R
G
Y

A
B
S
O
R
B
E
D


J


NiMo1-IG SG-Pipe
Conclusions of The Autoweld System - 01
The Autoweld System has been shown to be Capable of
Producing Consistent Quality Multi-run Girth Welds which
Possess High Weld Metal Mechanical Properties, in Terms of
Overmatching Weld Metal Strength and Low Temperature Weld
Metal Toughness.

The Internally Applied Root Bead Minimises the Effect of High-
Low and Offers the Inherent Advantage of Producing a Consistent
Weld Metal Profile, Often a Requirement for Sour Service
Pipelines.

Due to the fact that The Autoweld System uses a Low Hydrogen
Welding Process it Possesses Particular Technical, as well as
Economical, Advantages when Welding High Strength and/or
Heavy Wall Thickness Linepipe and is therefore Capable of
Fulfilling the Technical Demands of Current Trends in Linepipe
Materials.


Conclusions of The Autoweld System - 02
Used extensively on a world wide stage
Significant reductions in weld volumes, thereby increasing
production
Full Welding Engineering support when requested
Exclusive agreement for the Indian market
Can weld 24 to 60 inch with Internal welding machine
Fast front end production
Reduction in the amount of personnel required compared to
manual welding
Significant cost reduction on large diameter, long section
pipelines

Highly experienced training and site support personnel

High weld quality, both NDT and mechanical properties

Bohler welding wires are the best in the world for these pipelines,
acquired from Noreast.

Conclusions of The Autoweld System - 03
History and experience
Noreast projects
( See List as attached to handout )
Approval List for Noreast Autoweld System
Transco ( British Gas)
Pemex, Mexico
Gaz De France
CNPC, CPEC, China
TransCanada Pipelines
Nova Corporation
PTT, Thailand
Alliance Pipelines
Courtesy of No.2 Company

Courtesy of No.2 Company

Courtesy of No.2 Company

Thank you for your attention
Noreast wish you
success on your
forthcoming pipeline
project