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Lonestar Welding Projects
Lonestar Automated Welding was sub-contracted to perform Automated Welding at Delta Electricity’s Munmorah Power station during installation of a gas fired turbine near existing coal fired turbines. The new turbine needed a substantial amount of peaking power gas to uphold maximum demand power consumption which in turn required Australia’s largest gas bottle to be installed alongside power station and surrounding areas. Jemena being the primary contractor used Diona as the desired sub-contractor to carry out construction works. Automated welding was the only solution for these 500 joins, given the small amount of time required, the wall thickness, and the engineering design used in which Lonestar Automated Welding provided labour and equipment to perform Automated Flux Cored Welding. Diona provided pipe movements & end preparation of 42 inch pipe. Manual Bead & hot pass was performed using an external clamp for 42inch pipe size. Lonestar Automated Welding was responsible for Auto Flux Cored Filling and Cap welding passes to weld specification AS2885. Welding bead width and welding heat input where closely monitored by Jemena Inspectors as part of the Quality management process. In order for this to be compliant, it was essential to reduce operator’s welding parameter control to avoid excessive parameter adjustment during welding. A failsafe feature supplied through Lonestar Automated Welding Systems allowed every weld on every join to be monitored every second of welding throughout project. Client: Diona Pty Ltd Location: Munmorah, Central Coast, NSW
Lonestar automated welding was sub-contracted to perform automated welding at Woodside’s Pluto LNG plant by The Ausclad Group. Automated Welding was required for two components of Ausclad’s welding scope including the main trunkline and the bulk separator (slug catcher). Specialised welding labour was introduced for the project through Lonestar which was used in conjunction with the existing welders through the Ausclad Group. The Ausclad group provided pipe movements & end preparation of 36 & 42 inch pipe. A tig bead & hot pass was performed using an external and internal clamp for both pipe sizes. Lonestar Automated Welding was responsible for Auto Flux Cored Filling and Cap welding passes to weld specification ASME and AS2885. Welding bead width and welding heat input where closely monitored by Woodside & Ausclad as part of the Quality management process. In order for this to be compliant, it was essential to reduce operator’s welding parameter control to avoid excessive parameter adjustment during welding. A failsafe feature supplied through Lonestar Automated Welding Systems allowed every weld on every join to be monitored every second of welding throughout project. Client: The Ausclad Group
International - List of active project and work currently being performed. Lonestar Automated Welding Systems and related pipe welding preparation equipment for purchase and rental to many clients world wide. To name few countries: Australia, USA, Indonesia, UK, Netherlands, Germany, Mexico, Brazil… Project September 2011 - Current Lonestar Australia provided sub-contract labour and equipment to perform welding on 12” x 33mm wall to ASMEIV using phase array. Also provided welding for 8” x 24mm wall to ASMEIV. Client: Lonestar Australia-
Monadelphous PNG/ Jacobs for Oil Search Limited Project - April 2009 - June 2010 Pluto LNG plant 36” x 29mm Main Trunkline Automated Welding. 42” x 32mm Slugcatcher Automated Welding with FCAW using 60 degree open bevel. Client: Lonestar Australia-
AGC/Foster Wheeler/Woodside- Karratha, Australia Project - 2009 Various cross country pipeline construction projects Dyna Torque Technologies Inc. provides automated welding equipment (LoneStar Automated Welding System) and together with Lastechniek Europa technical support for welding procedure development, welding qualification, training and production welding. Welding procedure qualification and training are performed and first project is scheduled to start in April 2009. Client: Bohlen Doyen – Germany Project - 2008-2009 Gascac Pipeline – Trecho IIA Pipeline Project 1200km 28-inch gas pipeline project on sections IIB and IIIB,
Pipeline Project; wall thicknesses 0.469", 0.562", 0.625" Dyna
Torque Technologies Inc. provides automated welding equipment (LoneStar
Automated Welding System) internal line-up clamps and pipe
facing equipment and technical support for production welding.
Dyna Torque Technologies Inc. had developed and qualified
welding procedure and trained and qualified local
welders/operators for production welding. Client: Conduto – Companhia
Nacional de Dutos, Rod. Washington Luiz, 4099, Duque de Caxias,
RJ 25065-007, Brasil Project - 2008-2009 Cross-Country Pipe Welding Projects Dyna Torque provides automated welding equipment (LoneStar Automated Welding System) for 6” to 24” Cross-Country Projects in Texas and Oklahoma with production ranging from 50 to 80 joints per shift, depending on the size of pipe. Dyna Torque Technologies Inc. provides automated welding equipment (LoneStar Automated Welding System). Dyna Torque Technologies Inc. had developed and qualified multiple welding procedures and trained and qualified local welders/operators and maintenance technicians for production welding. Multiple projects are ongoing. Yearly value for Dyna Torque Technology Inc. is over 2 million US$. Client: A-OK Construction, LLC, Tulsa Ok., USA Project - 2008 42-inch pipeline project, 24mm/30mm wall thickness. This project was the largest pipe diameter project in Australia today. NDE Method was UT. 500mm out of 10,000,000mm of Automated FCAW welding passes contained repairable defects. Client: Lonestar Automated Welding Australia – Jemena/Diona-
Central Coast, NSW, Australia. Project - 2007-2008 Cross-Country Pipe Welding Projects Dyna Torque provided automated welding equipment (LoneStar Automated Welding System) for 6” to 24” Cross-Country Projects in Texas and Oklahoma with production ranging from 50 to 80 joints per shift, depending on the size of pipe. Client: A-OK Construction, LLC Project - 2007-offshore 2G welding for EL Dorado/Will K Prospect/ Cameron Wellhead Dyna Torque provided automated welding equipment (LoneStar Automated Welding System), welding procedure and welding production for 2G welding on 30” pipe diameter pipe offshore in Gulf of Mexico. Client: Frank’s Casing. Inc / BP America Prod Co. Project - 2007 Research Weld Dyna Torque provided automated welding equipment (LoneStar Automated Welding System) for the benefit of Exxon Mobile in development of a welding procedure for X80 pipe to be used on onshore tie-in welds. Client: Acute Technological Services/Exxon Mobile Project - 2007 Attachment of sleeves to existing pipelines Dyna Torque and Lastechniek Europa B.V. provided procedures development services for and completed pipeline welding throughout Holland for onshore gas pipeline repairs. Scope of work included attaching sleeves to existing pipelines using flux core longitudinal and orbital welds with the Dyna Torque LoneStar Automated Welding System. Client: Dutch Gasunie/Lastechniek Europa Project - 2006 Coari Manaus Amazon Pipeline Project Dyna Torque provided procedures development services, which included procedures development and qualification, pipe facing, line-up clamps and Lonestar automated welding equipment and personnel. Dyna Torque utilized a GMAW process with a copper backed clamp for the root and fill/cap passes. Dyna Torque mobilized for welder training and qualifications in July 2007. Immediately thereafter, production of the 90 Km onshore pipeline located on the Amazon River was begun and the Dyna Torque welding systems and related equipment were used by a Brazilian subcontractor. Client: Petrobras/Andrade Gutierrez Project - 2006 Tahiti Welding project consisted of welding hold-off collars and spool pieces to pipe utilizing an RMD process for the root pass and the FCAW welding process for filing and capping welds. Dyna Torque provided welding services in their new facility including procedure development and qualification, pipe facing, Lonestar automated welding equipment and personnel. Client: Williams Companies Project - 2006 Tahiti Dyna Torque provided turnkey welding services including procedure development and qualification, pipe facing, Lonestar automated welding equipment and personnel. Dyna Torque utilized an open root RMD process for the root pass and the FCAW welding process for filling and capping the welds. Client: Williams Companies Project - 2006 Atlantis Dyna Torque provided turnkey welding services including procedure development and qualification, fatigue sample testing, pipe facing equipment, automated welding equipment and personnel. The root pass was completed by automatic GTAW and remaining passes were completed utilizing a pulsing GMAW weld process with the Dyna Torque LoneStar welding system. Client: BP p.l.c. 2005 - DP Vessel Midnight Express Dyna Torque Technologies successfully completed pipeline welding onboard the DP vessel Midnight Express. This was the first pipe lay project for the vessel. Dyna Torque provided turnkey welding services including procedure development and qualifications; pipe facing equipment, Lonestar automated welding equipment, and personnel on the project. Repair rate was less than 1% for the project utilizing the FCAW process for filling and capping. Client: Torch Offshore, Inc./Energy Partners Ltd. Project - 2004 Torch Offshore, Dulac Louisiana Dyna Torque successfully completed the Walter Oil pipeline welding project at the Torch, Inc. spool base in Dulac, Louisiana utilizing the FCAW welding process with a repair rate of less than 3%. Dyna Torque Technologies provided turnkey welding services including procedure development and qualification, pipe facing equipment, and manual and Lonestar automated welding equipment and personnel. Client: Torch Offshore, Inc./Walter Oil & Gas Company Dyna Torque Projects Project -2007-2008 Shell Perdido / Double Jointing Dyna Torque provided automated welding equipment that was used by Acute Technological Services for development of welding procedures and double jointing production. Client: Acute Technological Services/Shell Project - 2007 Inconel Procedures Development Dyna Torque provided procedures development services in developing a total weld by running a GTAW bead and hot pass and FCAW fills with Inconel 625 flux core wire. Additionally, Dyna Torque provided welding equipment for completion of the project by Kiewit Offshore. Client: Kiewit Offshore Services, Ltd./BP Project - 2004 Alba Project, Equatorial Guinea, Africa. This project involved both onshore and offshore welding. The offshore portion was completed on the pipe lay barge Midnight Brave with a repair rate of less than 1%, with a repair rate for the onshore portion of the project being less than 1% as well. Dyna Torque provided turnkey welding services including procedure development and qualification, pipe facing equipment, and manual and Lonestar automated welding equipment and personnel on the project. Client: Torch Offshore, Inc./Marathon Oil Company Project - 2004 Torch Offshore, Dulac Louisiana Dyna Torque successfully completed this pipeline welding project utilizing the FCAW welding process at the Torch, Inc. spool base in Dulac, Louisiana with a repair rate of less than 2%. Dyna Torque Technologies provided turnkey welding services including procedure development and qualification, pipe facing equipment, and manual and Lonestar automated welding equipment and personnel. Client: Torch Offshore, Inc./Ridgelake Energy Inc. Project - 2003 Thunderhorse Dyna Torque Technologies was involved with Bredero Shaw in procedure development for the BP Thunderhorse Project for flowline welds and provided fatigue samples for SCR welds. Client: Bredero Shaw/BP p.l.c. Project - 2003 Kizomba Platform Tendon Leg Project Dyna Torque provided procedure development services utilizing a GMAW root process with backing material; used 40’ joints of 32” pipe to make 240’ long tendon legs. Client: Bredero Shaw/BP p.l.c.
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COLONGRA
LATERAL PIPELINE- Automated Welding for Australia’s largest Gas
Storage Vessel.
PLUTO LNG
PROJECT - Site A 36inch Trunkline/ Site B 42inch Slug Catcher
