X 5 CRC-EVAIMS AUTOMATIC WELDING

Corporate Headquarters - Houston, Texas Manufacturing Facility - Tulsa, Oklahoma

P A G ECRC-EVANS AUTOMATIC WELDING is an operation of the world's

largest pipeline equipment company, CRC-EVANS Pipeline International, Inc.Tulsa, Oklahoma is the home of the manufacturing and engineering facilityfor the CRC-EVANS Pipeline Equipment and Automatic Welding divisions,while the corporate headquarters and field operations center are located inHouston, Texas. For over 60 years CRC-EVANS Pipeline International, Inc.has been the world's leading innovator and manufacturer of specialty pipelineequipment.

The CRC-EVANS automated pipe welding method was introduced in1968 and soon became the most cost efficient way of welding cross countryor offshore pipelines. These pipelines range in diameter from 4 to 60 inches,with wall thicknesses frequently exceeding 1 inch. Continuous improvementsin technology have enabled CRC-EVANS to provide equipment for welding awide variety of materials including X-52 to X-80 carbon steels, the duplexstainless steels and clad pipe materials.

Since 1968, the CRC-EVANS Automatic Welding System has beenused to weld many thousands of miles of pipeline around the world in everyenvironmental extreme, from below freezing in Canada, Alaska and Russia;to the subtropical climates of Mexico, South America and Southeast Asia; tothe deserts of Saudi Arabia, Algeria and Australia. Offshore, the CRC-EVANSsystem has been used successfully in tough environments such as the Gulfof Mexico, the North Sea, the Indian Ocean, the South China Sea and thePersian Gulf.

For over 25 years, CRC-EVANS Automatic Welding has been theAutomatic Choice.

Field Operations and R&D Center - Houston, Texas

P A G E

THE CRC-EVANS AUTOMATIC WELDING SYSTEM is a gas-metal-arcwelding (GMAW) system developed specifically for producing quality line pipe girthwelds at high production rates.

There are three major components of the system

• A pipe facing machine

• A combination internal welder/ line-up clamp

• External orbital welding machines

Another factor which contributes equally to the success of the system is amachined, narrow groove compound bevel as opposed to a standard API 30 degreebevel used for manual welding. This bevel design has several advantages over theconventional 30 degree bevel.

• The bevel is machined perfectly square with the axis of the pipe, assuringnearly perfect joint fit-up for every weld.

• The narrow gap bevel requires much less weld metal. (See Fig. 1)

• There is no root opening in the joint fit-up and the root pass is welded from theinside, which allows the hot pass to be welded almost simultaneously to speed thewelding process.

• The internal root pass tolerates high-low conditions very well. It alsoeliminates internal undercut and burn through.

The CRC-EVANS Automatic Advantage

• Reduced joint fit-up time

• Reduced weld metal volume

• Higher welding speed

• Improved weld quality

• Improved mechanical properties

VV ^

P A G E The features and benefits of the CRC-EVANS Automatic WeldingSystem are being utilized all over the world on land and offshore.

F e a t u r e s n e f i t s

Increased deposition rate

Narrow gap bevel design

More consistency in weld

strength, toughness and

NOT quality

Ability to weld high strength

steels and CRA materials

Reduces human error factor

Less physical strain on

welders

Less manpower/equipment

for heavy wall and large

diameter pipe

Documentation/traceability

Ease of training welders

Higher production rates

Less weld metal required

Fewer repairs

Consistent weld quality

Excellent root pass profile

Lower residual stress

High weld toughness

High weld strength

Lower cost per weld

Easily adaptable to QC/QAprograms

Less skill and experiencerequired

P A G EThe Pipe Facing Machine (PFM), is used to produce a precise, consistent

narrow gap bevel for the CRC-EVANS Automatic Welding System. Hydraulicallyoperated shoes secure the PFM to the pipe end perfectly square with the pipe axis.A rotating faceplate with as many as six carbide cutters is used to machine almostany bevel configuration.

Power for the PFM is supplied by a diesel engine or electric motor-drivenhydraulic power unit.

Two PFMs are normally used on a major pipeline project. Each machine issuspended by a sideboom tractor or A-frame with the power unit mounted on thetractor or near the A-frame. The pipe facing operation usually takes 2 to 5minutes, depending on the pipe wall thickness and the skill of the operator.PFMs are available for pipe diameters from 4 to 60 inches.

The CRC-EVANS Automatic Advantage

• Precision machined narrow gap bevels

• Rapid machining time

• Reduced fit-up time

• Improved weld quality

• Reduced weld volume

InternalWelder / Line-up Clamp andExternal RootBead Line-upClamp

P A G E

The CRC-EVANS combination internal welder/line-up clamp (IWM) travelsalong the inside of the pipe, aligns the two pipe ends with each other, clamps them intoplace and automatically welds the root bead on the inside of the joint. Multiple weldingheads are used for 24 to 60 inch pipe. For example, a four headed machine beginswelding with two heads at the 12 and 3 o'clock positions. These heads weld downhill to 3and 6 o'clock, respectively. Simultaneously, the other heads are moving into position at12 and 9 o'clock and then weld the other side of the pipe. On a 42 inch diameter pipe, theroot pass weld time is less than 1.5 minutes.

Typically, a different IWM is required for each 4 inch increment in pipe diameter.

The external root bead line-up clamp, shown above, is used for pipe sizes from16 to 22 inches. It allows the root pass to be deposited externally with a CRC-EVANSexternal welding machine. This clamp incorporates the use of a copper backing system toprovide support as the root pass is deposited.

The CRC-EVANS Automatic Advantage

• Quick, accurate pipe alignment

• High speed root bead deposition

• Repetitive root bead profile and quality

• Minimizes effect of high-low

• Ideal for sour service pipelines

Р АThe CRC-EVANS External Welding Machines (EWMs) are commonly called

"bugs". There are three basic configurations: hot pass, fill pass and cap pass bugs whichutilize the GMAW or pulsed GMAW welding process. The bugs travel on steel bands thatare attached to the pipe after the new bevel has been cut and before the pipe joint iswelded into the pipeline. The bugs are supplied in left and right hand versions to allowsimultaneous welding by two units on one pipe band. Each bug makes half a weld passfrom 12 to 6 o'clock, one in the clockwise (CW) direction and the other in thecounterclockwise (CCW) direction.

The latest versions of these bugs allow the same design to be used for both filland cap passes with closed loop control over welding parameters. New developments willincorporate state-of-the art features such as microprocessor control, side wall trackingand parameter monitoring among other technological advances.

The CRC-EVANS Automatic Advantage

• Consistent weld quality

• Higher production rates

• Quick, easy set-up

• Ease of training welders

• Less physical strain on welders

20

19

I 18-CLГЗ 1-

I 16H8 I 15

I 13

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CD 12

11

TYPICAL AVERAGEPRODUCTION RATES ON LAND

P A G E

24 36 42 48

PIPE DIAMETER (INCHES)

Fig. 1

Welding is the pivotal operation in pipeline construction, and the time tocomplete a pipeline depends directly on the speed at which the welding crew works.Welding production rates can be affected by other factors, such as trenching, pipestringing, pipe alignment, equipment move-up and inspection.

Projects on land

Move-up time is the time between the end of the root pass welding on one weldand the beginning of root pass welding on the next weld. Cycle time is the move-up timeplus the root pass arc time.

Welds per hour averages shown in Fig. 1 are based on the following assumptions:

• The IWM clamp is released and moved as soon as the root pass is complete.

• The move-up time is approximately 2 minutes.

• Two welding stations are used for each fill pass and as many as three stationsfor the cap pass so the back end weld stations will keep pace with the front end.

>- 220 -

| 200-

i 180-sS 160 -IS 140 -

Hi 120-

100 -

TYPICAL AVERAGEOFFSHORE LAY RATES

216

Projects offshore

24 30 36 42PIPE DIAMETER (INCHES)

Fig. 2

The offshore lay barge is by far the most effective vessel configuration in use foroffshore pipelining. In contrast to land based pipeline construction, lay barge applicationsdiffer in that they operate 24 hours a day and they have a fixed number of weld stations.The high cost of laying pipe in this environment allows no latitude for delay. The overridingconsideration in offshore work is to lay the pipe as rapidly as possible. The mainstay ofoffshore pipe joining is the automatic welding system.

Welds per 24 hour day shown in Fig. 2 are based on the following assumptions:• Pipe wall thickness is 0.688 in. (3 fill passes)• Lay barge has 5 weld stations• Pipe joints are single joints (40 ft.)• Barge efficiency (non-welding time) is 80%• Pipe alignment / pull time is 2.5 minutes• Repair rate is 4%

Typical Automal

Pipe End Preparation Stations Mobile Maintenance Wagon

P A G E 8

Listed below is an estimate of the manpower and equipment required for the welding operation on a typical automated weldingFor each fill pass, two back-end welding stations (4 welders) are required. M

END PREP CREW:2 sideboom tractor operators2 PFM operators2 helpers (on large pipe)

BANDING CREW:1 driver3 laborers/helpers

PIPE GANG:foremanor 2 set-or2 swaIWM opehot passhelperstack rig tihelpers сskid hustmechank

END PREP CREW:sideboom tractors

BANDING CREW:flat bed truck or tow tractorsled or wagon

CONTRACTOR'S EQUIPME

PIPE GANG:set-in sideboom tractortack rig tractormobile maintenance wagontow tractor for maintenance wagonwelding tent (optional)

1 or 21111

BACK-END WELDING CREW:welding tractorswelding tents (optional)repair welder's rig

441

Welding Spread

ne-up / Internal Root Passand Hot Pass Station* Fill Stations Cap Stations

* For higher productivity, the root pass and hot pass may be set up as separate stations.

)ject requiring a root pass, hot pass, one fill pass and a cap pass. The number of fipower and equipment requirements for specific projects are available on request.

passes is determined by the pipe wall thickness.

ractor operators>ersorilders

tor operatorgging leadss

BACK-END WELDING CREW:1 foreman8 fill and cap pass welders8 helpers4 welding tractor operators1 repair welder1 repair welder/helper2 laborers

END PREP CREW:PFMshydraulic power units

BANDING CREW:aligner bandswelding bands

RENTED FROM CRC-EVANS

22

3 (2 spare)75

PIPE GANG:Internal Root Applications

IWMsreach rods with controlshot pass bugs

External Root Applicationsexternal root bead line-up clampsroot pass bugs

BACK-END WELDING CREW:fill pass bugscap pass bugsspare parts container

2 (1 spare)3 (2 spare)4 (2 spare)

2 (1 spare)4 (2 spare)

6 (2 spare) Number of fill pass bugs is determined by wall thickness and number of fill passes.6 (2 spare)1

P A G E

Welding Procedures: The first step in preparing for welding on any pipelineconstruction project is welding procedure development.

CRC-EVANS strongly recommends that a sample (20 ft.) of project pipe andwelding specification be sent to the field operations center in Houston for proceduredevelopment and qualification. When the welding procedure is developed byCRC-EVANS in Houston, the pipeline-owning company and the contractor have thebenefit of all of CRC-EVANS' technical expertise to develop the optimum weldingprocedure to satisfy all project welding requirements.

Training: One of the advantages of the CRC-EVANS Automatic WeldingSystem is the short time in which most people can be trained to be competent weldingmachine operators.

To assist the contractor with training, CRC-EVANS has developed audio visualprograms that clearly and completely explain the operation of each piece of automatedwelding equipment. These programs have proven to be very beneficial when used inconjunction with hands-on training, and have been translated into many languages.

A CRC-EVANS training instructor is available to assist the contractor withtraining at the beginning of a project.

Field Service: CRC-EVANS Automatic Welding has a staff of highly qualifiedand experienced service technicians who maintain the automated welding equipment inthe field.

Their responsibilities are to set up and prepare the equipment for productionwelding after it arrives on the job, assist in the training of welders, and service andmaintain the equipment during production welding.

Spare Parts /Consumables

Research andDevelopment

P A G E 1 0 CRC-EVANS Automatic Welding maintains an extensive spare partsinventory for each and every piece of welding equipment it manufactures.From the smallest bearings to the most complex circuit, CRC-EVANS iscommitted to keeping your project running at maximum productivity.

CRC-EVANS Automatic Welding also keeps an extensive inventory ofwelding wire and other consumables. All the welding wire supplied byCRC-EVANS is manufactured to the highest standards. In addition, thewelding wire spools are "hand-level-wound", ensuring the correct cast andhelix for trouble free welding.

CRC-EVANS uses airtight containers to protect the wire spools inshipping and storage.

CRC-EVANS Automatic Welding has an ongoing commitment to researchand development. CRC-EVANS' in-house development capabilities consist of:

• Mechanical engineering - Complete design and drafting capability usingcomputerized techniques.

• Electrical engineering - Total capability for hardware and software design.Support laboratory for proof of design and prototype manufacture.

• NOT and metallurgical support - State-of-the-art facilities to perform X-rayand dye penetrant inspections. Complete metallurgical lab for specimen preparation,hardness survey, microstructural analysis, ferrite measurement, Ferric Chloride (G48)test and photography.

Our welding capabilities for procedure development include:

• Submerged arc welding for pipe double jointing

• Orbital mechanized gas tungsten arc welding (including pulsed)

• Orbital mechanized gas metal arc welding (including pulsed)

• Orbital mechanized flux core arc welding (including self-shielded)

• Manual shielded metal arc welding (cellulosic and low hydrogen)

P A G 1 1

CRC-Evans Automatic Welding manufactures the M-220 welding system, which isa portable, automated welding machine that is ideal for a variety of applications outside thetraditional pipeline construction environment. The M-220 features on-board control of allessential welding parameters for ease of set-up and adjustment during welding. Like theexternal welding bugs, the M-220 travels on a steel band which is sized for pipe diametersor can be provided in flexible or flat track configurations.

Welding processes

• Flux Core Arc Welding (FCAW)• Gas Metal Arc Welding (GMAW)• Pulsed Gas Metal Arc Welding (PGMAW)

Applications

' Tie-in welds • Large diameter waterlines • Shipbuilding • Storage tanks' Pressure vessels • Penstocks • Piling • Conductor casing • Pipe fabrication

Productivity

• The M-220 welding system is upto 3 times faster than manual out of positionwelding. In addition to higher depositionrates, the operator efficiency of the M-220system is improved from 30 percent formanual welding to 60 percent or higher forthe M-220.

The CRC-EVANS Automatic Advantage

• Consistent weld quality• Higher production rates• Quick, easy set-up• Ease of training welders• Less physical strain on welders

• Improved mechanical propgrties

ConResistant Alloy(CRA) Welding

P A G 1 2

CRC-EVANS Automatic Welding has over 10 years experience in welding corrosionresistant alloy (CRA) materials, both onshore and offshore, in the North Sea, Alaska, MobileBay and Southeast Asia.

The industry trend toward increased usage of corrosion resistant alloys for pipelinestransporting corrosive petroleum products requires that quality conscious, cost effectivemethods of welding these materials are available. CRC-EVANS has developed state-of-the-art techniques and manufactures the equipment to ensure the highest possible productivityfor welding CRA pipe materials.

Welding processes for CRA pipe materials

• Pulsed Gas Tungsten Arc Welding(PGTAW)

• Pulsed Gas Metal Arc Welding(PGM AW)

Welding process / Procedure techniques

• Automatic PGTAW for all passes

• Automatic PGTAW for root and hotpasses with automatic PGMAW for filland cap passes

• Automatic PGTAW for root pass only with automatic PGMAW for hot, fill and cappasses

• Automatic PGMAW for all passes

CRC-EVANS has developed proven techniques for reducing purge time and thenumber of weld passes required before purge removal which significantly increases theproductivity of CRA pipe welding.

CorrosionResistant Alloy(CRA) Welding

Automated equipment for CRA pipeline welding

Auto-PGTAW T-500 orbital welding system

• The CRC-EVANS T-500 system is anorbital GTAW pipe welding system. Its low profiledesign requires minimal radial clearance around theweld joint and its controls are easy to use with allnecessary functions and weld sequencing requiredfor automated GTAW pipe welding.

P A G 1 3 Purge d a m line-up clamp

• CRC-EVANS has developed twotypes of line-up clamps which incorporatepurge dams for CRA pipe welding. Both unitsserve as a conventional line-up clamp, butalso provide a back purge chamber into whichthe purge gas is fed through the clamp reachrod. Purge dam line-up clamps are availablefor many diameters 4 inches and up.

F

M-220 welding system

• PGMAW passes are deposited by theM-220 welding system featured on page 11.

PGTAW / PGMAW welding power sources

• For PGTAW passes, a conventionalPulsed-GTAW power source with weld sequencecontrol is used.

• CRC-EVANS uses a controlled droptransfer power supply with synergic closed loopcontrol for optimum arc characteristics with unique programs for each wire type anddiameter/gas type combination. These power sources have been field tested and proven tobe reliable in the pipeline construction environment.

Pipe Facing Machine (PFM)

• A modified J-bevel precision machined withthe CRC-EVANS pipe facing machine is used in mostapplications.

The CRC-EVANS Automatic Advantage

• High productivity

• High quality welds

• Consistent performance

P A G 1 4CRC-EVANS Automatic Welding equipment is rented on an individual project

basis. CRC-EVANS, with the contractor, determines how much and what kind ofequipment is needed for a pipeline project. The spread of automatic welding equipment isthen rented to the contractor.

The support equipment, such as generators and welding tractor kits, are normallyprovided by the customer.

The following information is needed to make a proposal:

• Name / location of project

• Pipe diameter (s)

• Pipe wall thickness

• Pipe grade

• Length of pipe joints (single or double joints)

• Total length of project

• Desired production rate

• Anticipated construction schedule

We would like the opportunity to present a proposal for your next project.

To our customers

We at CRC-EVANS Automatic Welding appreciate your interest in our companyand we are proud to present to you this brochure which outlines the products and serviceswe offer. We recognize that you may require more specific information, such as equipmentspecification sheets, technical papers, information on welding certain materials, ourautomatic welding video tape, or any new developments we may have.

If you require more detailed information regarding your project, call us. We lookforward to being of service to you and your company.

CRC-EVANS Automatic Welding

World headquarters: CRC-EVANS Automatic WeldingP.O. Box 3227, Houston, TX 77253-3227 • 713/460-2900 • Fax 713/460-9077

AN OPERATION OF CRC-EVANS PIPELINE INTERNATIONAL, INC. / AN COMPANY