Scribd
Upload
103 views28 pages

Welding Processes

This document discusses welding consumables and welder qualification as per ASME Section IX. It provides information on welding processes, base and filler metals, weld thickness and diameter limits, backing types, and performance qualification requirements. The key points are: - It describes the various welding processes like SMAW, GTAW, FCAW used for performance qualification and lists the associated welding operators. - It lists the filler and base metal material specifications used for welder qualification and the maximum thickness qualified during testing. - It specifies limitations on pipe/tube diameters that can be welded based on the electrode and welding process qualified. - It outlines the requirements for backing types, preheat/post

Uploaded by

Jitendra Umaraliya
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
103 views28 pages

Welding Processes

This document discusses welding consumables and welder qualification as per ASME Section IX. It provides information on welding processes, base and filler metals, weld thickness and diameter limits, backing types, and performance qualification requirements. The key points are: - It describes the various welding processes like SMAW, GTAW, FCAW used for performance qualification and lists the associated welding operators. - It lists the filler and base metal material specifications used for welder qualification and the maximum thickness qualified during testing. - It specifies limitations on pipe/tube diameters that can be welded based on the electrode and welding process qualified. - It outlines the requirements for backing types, preheat/post

Uploaded by

Jitendra Umaraliya
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 28

1

ESSC - ADVANTAGES

SIMILAR EQPT. AS SAW

HIGHER DEPOSITION

VERY LOW DILUTION LEVEL

LESSER NO. OF LAYERS TO ACHIEVE


CHEMISTRY

STABLE PROCESS WITH LESS DEFECT

LOW FLUX CONSUMPTION (HALF OF WM)


2
I.D OVERLAY

FCAW GTAW PROCESS

OVERLAY ON SMALL DIAMETER


NO!!LE PIPES FORGINGS

DEVELOPED DOWN TO 2"## I.D


AFTER OVERLAY

MAX. LENGTH WELDED $ 2.% #&


'
PRODUCTIVITY
PROCESS MATERIAL DIA. AMP DEPOSITION NO. OF ELECTRODE
PER ARC-HR PER ARC-HR
(())
SMAW CS 2." *+ +., "-
'.2 1'+ 1.1 %%
%.+ 1*+ 1." '*
".+ 2%+ 2.% '%

SS 2." *+ +.- "2
'.2 1++ 1.+ ""
%.+ 1%+ 1.2 %2

FCAW CS 1.2 2++ '.'
SS 1.2 2++ '.%
%
PRODUCTIVITY
PROCESS MAT. DIA. AMP DEPOSITION PER
ARC-HR (Kg)

SAW CS 4.0 550 6.5
TWIN- CS 2.4X 2 550 6.6
WIRE SAW
TANDEM CS 4.0X 2 600 14
SAW
ESSC SS 60X0.5 1200 22
0X0.5 1!00 ""
120X0. 5 2200 42
"
-
FCAW
CONSUMABLE
C-Mn STEEL C- 1.6%Mn ER 70S-2 E 71T-1/ E70T-5 EH-14+TAPADA-!0/
"SA516 #R60/70$ S% + U&420TTR

C-M' LAS C- 0.5% M'/ E 701! A1 / ER !0S-D2 E70T-A1 / EA-% + OP41TT
"SA204-B$SA%02-B( C-Mn-M' E !01! D% E!1T1-A1 EA-4/EF-% + U&420TTR
1.25C)-0.5M' LAS 1*1.25C)-0.5M' E !01!B2 ER !0SB2 E !1T1-B2 EB2 + U&420TTR
"SA%!7#R11CL1/2(
2.25 C)-M' LAS 2.25C)-1M' E +01!B% ER +0SB% E+1T1-B% EB% + U&420TTR
"SA%!7 #R22CL2(
SS %04/ %04L 1!C) - !N, E %0!/ %0!L ER %0!/ %0!L E %0!LT-1 / E%0!LT0-1 ER%0!L + SS#R.1 / F--1
"SA240#R%04L(
SS %16/ %16L E %16/ %16L ER%16/ %16L E%16LT-1/ E%16LT0-1 ER%16L + SS#R.1 / F--1
"SA240#R%16L(
SS%21/ %47 E %47 ER%47 E%47T-1/ E%47T0-1 ER%47 + SS#R.1 / F--1
"SA240#R%21/ %21H(
SS-410S 1%%C)
E %0+LT-1/ E%0+LT0-
1
"SA240 T./0410S(
E %0+/ E%0+M'/
EN,C)F0%
ER%0+ / ER%0+M'/
ERN,CR%
BASE METAL - WELDN# CONSUMABLE SELECTON
SAW CONSUMABLE
E 701!/ 701!-1
1!C) - !N, -
2*%M'
1!C) - !N, -
N1+T2
MATERAL T3PE
NOMNAL
COMPOSTO
N
SMAW
CONSUMABLE
#TAW
CONSUMABLE
,
*
PREHEAT

ADVANTAGES

TO REMOVE OIL, MOISTURE ETC.

TO AVOID CRACKING

PREHEAT - MINIMUM 1 INCH. ON EITHER


SIDE OF JOINT.

USE ONLY LPG / ELECTRIC HEATING.

CARRY OUT UNIFORM PREHEAT

USE TEMPERATURE STICKS TO CHECK.


.
POSTHEATING

IF NOT DONE - CRACKS. FAILURE


IN
SERVICE.

HEATING AT 300 - 350 C FOR 3 /


HRS MIN. !EFORE ALLO"ING "ELD TO
COOL TO ROOM TEMPERATURE
FROM PREHEAT TEMPERATURE

AFTER POST HEATING COVER THE JOINT


"ITH AS!ESTOS FOR SLO" COOLING.
12
1'
CONSUMABLE PRICES

SMAW E#ECTRODE$ %TAW WIRE.)


TYPE COST() (R/)
E,+1* ""
E,+1*-1 -+
E*+1*B2 2,+
E'+*L %++
E'+.L "++
EN0C1F2' 12++
EN0C3, *++
1%
CONSUMABLE PRICES

SMAW E#ECTRODE$ %TAW WIRE(CONT.)


TYPE COST() (R/)
ER,+S-2 1.+
ER'+.L %*+
ER'+*L '"+
ERN0C1' 1+++
1"
CONSUMABLE PRICES

SAW$ &CAW WIRE


TYPE COSTSPOOL(R/)
S' 1*," (2" () SPOOL)
EH-1% 1'++ (2" () SPOOL)
ER'+*L '-2" (2" () SPOOL)
E,1T-1 1"++ (12." () SPOOL)
E'+.LT-1 "+++ (12." () SPOOL)
E'%,T-1 "+++ (12." () SPOOL)
E'+*LT-1 "+++ (12." () SPOOL)
1-
CONSUMABLE PRICES

&#UX
TYPE COST() (R/)
UV%2+TTR ,-
TAPADIA-*+ 2"
SS GR-1 1'+
F4-1 12"
', S 2++
1,
1*
In case fluxes are not used regularly,
oven temp. can be reduced to 100C.
However, the fluxes are to be baked at
00!"0C for # hrs m$n$mum pr$or to
$ssue.

% e.g.&'(#0))*, )apad$a +0 etc.,


00!"0C for # hrs
$mmed$ately before
use
SAW FLU4ES 00C m$n$mum.
-o t$me l$m$t
RE5UREMENTS FOR DR3N# OF WELDN# CONSUMABLES
# 1."!#00C for # hrs
m$n before use
100C m$n t$ll use
REMAR6S
/fter bak$ng the electrodes can be
stored $n hold$ng ovens % at 100C m$n t$ll
use ,
100C m$n t$ll use
BA6N# C3CLE
HOLDN# TME 7
TEMP.
SMAW
!do!
!0ow Hydrogen Carbon 1 0ow /lloy
2teel 3lectrodes % e.g. 3.01+,
3+01+ 4# etc. ,
#"0!00C for # hrs
m$n before use
SMAW
SL.
NO.
CONSUMABLES
!2ta$nless 2teel 3lectrodes,
! -on 5errous 3lectrodes
1
1.
2+
WE#DER '#&N. - ASME SEC.IX
ESSENTIA# VARIA(#ES

WELDING PROCESS

WELDING TYPE

BASE METAL (P N5.)

FILLER METAL N5. (F N5.)

WELD BASE METAL TH(. 6 DIAMETER LIMIT

BAC(ING

POSITIONS
21
WE#DIN% PROCESS

WE#DERS )
- SMAW
- GTAW
- FCAW GMAW

WE#DIN% OPERATORS )
- SAW
- ESSC
- MACHINE GTAW
WE#DER '#&N. - ASME SEC.IX
22
WE#DER '#&N. - ASME SEC.IX
WELDING TYPE

MANUAL SEMI-AUTOMATIC

MACHINE

AUTOMATIC
2'
WE#DER '#&N. - ASME SEC.IX
P N'.
P1
P%$4$5
P6$7
P!
P+
P10$11
P24
P%4
P44
P54
P64
T./0 '8 M290),2:
C2)1'n S900:
L'; A::'. S900:
F0)),9,< 2n= M2)90n>,9,< S92,n:0>> S900:
A?>90n,9,< S92,n:0>> S900:
N,<@0: S900: ":0>> 9A2n 4.5% N,(
5?0n<A0= 2n= T0B/0)0= S900:
A:?B,n,?B 2n= A::'.>
C'//0) 2n= A::'.> "C?/)'n,<@0:(
N,<@0: 2n= N,<@0: B2>0 A::'.>
T,92n,?B 2n= T,92n,?B B2>0 A::'.>
C,)<'n,?B 2n= C,)<'n,?B B2>0 A::'.>
2%
WE#DER '#&N. - ASME SEC.IX
Base Metals for Welder Qualifcation
P N# 1 $%&#'(% P N#. 11 )*+ P
N#. 3
#& P N#. ,
P N#. -1 $%&#'(% P N#. -5
P N#. 5, #& P N#. .,
Qualifed Production Base Metals
P N# 1 $%&#'(% P N#. 11 , P N#. 3,
P N#. , )*+ '*)//0(*1+ 21$)3/ #4 /0203)&
5%1205)3 5#26#/0$0#*
P N#. -1 $%&#'(% P N#. -5
P N#. 5, )*+ P N#. .,
2"
F- NUMBERS
F% - LOW H2 TYPE CS LAS - E,+1*7 E *+1*B2
F" - AUSTENITIC SS - E'+.'+*'%,
F- - GTAWSAWFCAW CSLAS -ER,+S2S'E,1T-1
ER'+*E'+*LT-1
F'X-C3 6 C3 BASE ALLOYS - ERN0C3, EN0C3,
F%X-N0 6 N0 BASE ALLOYS - EN0C1F2'ERN0C1'
F"X-T0 6 T0 BASE ALLOYS - ERT0-1
F,X-HARD FACING CONS. -STELLITE-1-
2-
WE#DER '#&N. - ASME SEC.IX
5?2:,8,0= ;,9A
F N' 4
F N' 5
An. F N' 6
An. F N' 21 9A)'?DA F N' 25
An. F N' %1$ F N' %2$ F N' %%$
F N' %5$ F N' %6 ') F N' %7
F N' %4 ') 2n. F N' 41 9A)'?DAF N' 45
2n. F N' 51 9A)'?DA F N' 54
An. F N' 61
An. F N' 71 9A)'?DA F N' 72
5?2:,8,0= 8')
F N' 1$ 2$ %$ 4
F N' 5
A:: F N' 6
A:: F N' 21 9A)'?DA 25
On:. 9A0 >2B0 F N?B10) 2> ;2> ?>0=
=?),nD 9A0 E?2:,8,<29,'n 90>9
F N' %4 2n= 2:: F N' 41 9A)'?DA F N' 45
A:: F N' 51 9A)'?DA F N' 54
A:: F N' 61
On:. 9A0 >2B0 F N?B10) 2> ;2> ?>0=
=?),nD 9A0 E?2:,8,<29,'n 90>9
A:90)n290 F N' 8') W0:=0) P0)8')B2n<0 5?2:,8,<29,'n
2,
WE#DER '#&N. - ASME SEC.IX
Weld Thickness in Qualification Test
[t in inch (mm)]
FG%/4 "1+.05(
H%/4 "1+.05(
#ROO&E
Maximum Qualified Weld Thickness
[inch (mm)]
An. TA,<@n0>>
29
O&ERLA3
Qualification Test Thickness
[T in inch (mm)]
Thickness Qualified
[inch (mm)]
U/9' 1 "25.4( T 9' ?n:,B,90=
F 1 "25.4( 1 "25.4( 9' ?n:,B,90=
2*
WE#DER '#&N. - ASME SEC.IX
#ROO&E AND O&ERLA3 WELDS - LMTATONS ON PPE / TUBE DAMETERS
OD inch (mm) NB inch Minimum Maximum
H1 "25.4( H%/4 S,I0 W0:=0= Un:,B,90=
1 9' 2 "7/!( ') 25.4 BB
9' 7%.0% BB
%/4 9' 2"1/2( 1 "25.4( Un:,B,90=
FG 2"7/!( ') 7%.0%BB 2"1/2( 2"7/!( ') 7%.0% Un:,B,90=
2.
- SN#LE SDED WELD - WELD WTHOUT BAC6N#/
FBRE TAPE
- DOUBLE SDED WELD - WELD WTH CHP BAC6/
BAC6N#
!ACKING
WE#DER '#&N. - ASME SEC.IX
QUALIFICATION WITH QUALIFIE
FO!
SINGLE SIDED SINGLE /
DOU!LE SIDED
DOU!LE SIDED DOU!LE SIDED
'+
PERFORMANCE 5UALFCATON- POSTON AND DAMETER
LMTATONS
NOTEJ
%1, 6$pe # o.d. and over. 7/8
17
#7
7
(7
7 and (7
#7,7,and (7

17
#7
"7
87
#7 and "7

P:290 2n= P,/0

OK0) 24 ,n.O.D.
P,/0
HG 24 ,n. O.D.
P:290 2n= P,/0
#)''K0 F,::09
P'>,9,'n 2n= T./0 W0:= 5?2:,8,0=
W0:= P'>,9,'n

6$pe!7roove
/00
/00
5
/00
/00
/00

5,H
5
5,H
5,H,'
5,H,9
/00


5,',9
5
5,H
/00

5
5,H
5 : -ote %1, ;
5,H : -ote %1, ;
5,',9
/00 /00
5 : -ote %1, ;
5 : -ote %1, ;
5 : -ote %1, ;
5,H : -ote %1, ;
5,9
5,',9
/00

5
5,H
5,'
5?2:,8,<29,'n T0>9
6late! 7roove

You might also like

pFad - Phonifier reborn

Pfad - The Proxy pFad of © 2024 Garber Painting. All rights reserved.

Note: This service is not intended for secure transactions such as banking, social media, email, or purchasing. Use at your own risk. We assume no liability whatsoever for broken pages.


Alternative Proxies:

Alternative Proxy

pFad Proxy

pFad v3 Proxy

pFad v4 Proxy