Firefly Orbital Welding

Firefly used by Franklin Offshore Europe RDM Quayside Project

1 March 2016

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Fred Olsen Windcarrier Brave Tern vessel upgrade

Brave Tern was the first of Fred Olsen’s Tern vessels to undergo upgrade work by Franklin Offshore at their modification yard in Rotterdam. 

The upgrade included extending the jacking legs by 14m thus making the legs 92.4m long. The cranes will also be prepared for a boom extension of up to 20m. This will include both an insert piece for the crane boom and an extension of the A-frame.

Brave Tern Vessel Upgrade

Outline of the project

The project involved using the Firefly orbital welding machine to carry out the cutting, beveling/prepping and welding of the four leg extensions on the Brave Tern vessel.

Firefly Cutting

Video footage of Firefly being used with an oxy-acetylene cutting torch.

Firefly Bevelling

Video footage of Firefly machine being used in prepping / bevelling a work piece.

Firefly Welding

Firefly welding machine being used during the Brave Tern vessel upgrades.

Firefly Finished Welds

Finished welds on the Brave Tern vessel upgrades at Rotterdam docks.

Video Footage from the Brave Tern Vessel Project

Cutting – the standard Firefly track / ring was used for the cutting and welding processes. A specially adapted front end was fitted to the Firefly carriage to allow the fitting of the oxy-acetylene cutting torch.

Prepping / bevelling – special fittings were attached to the Firefly carriage to enable bevelling - an inner 30° bevel attachment and an outer 30° bevel attachment were used.

Alignment – manual alignment using internal jacking system consisting of 4x 300 jacks (up / down) and 4x 150 jacks (hi / lo).

Heat treatment – the Miller Pro Heat 35 heat induction system was used throughout the project.

Welding – was carried out using 4x Firefly welding machines with welders working in a set sequence as set out by the Weld Engineer.

Finished welds – finished welds were inspected by DNV and the client’s welding inspection team. All UT inspection carried out by a 3rd party.

Finished Welds –Brave Tern Project, Rotterdam

Equipment used

Firefly orbital welding machine with special cutting torch and bevel attachments; integrated data logger; Lincoln S350 inverter; STT module; robotic wire feed; water cooler; Miller Proheat 35 heat induction system and a specially built transit cube for the welding equipment.

Testing the legs

Before going to sea, the integrity of the Brave Tern’s legs are tested by Franklin Offshore.

Brave Tern Vessel Upgrade in Rotterdam Docks

Get smart – check out Firefly... the clever way to weld!

Firefly is available to purchase or systems can be rented with, or without, an operator. Help is also available with weld procedures and welder qualifications. Full installation, training and support is available.

If you would like to learn more about how Firefly can keep you ahead of the competition, please contact us.