graaf welding consumables for girth welding of pipelines
DESCRIPTION
Technical presentation about Welding consumables suitable for girth pipe welding.TRANSCRIPT
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Welding consumables for girth welding of pipelines
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Henk de GraafIndustry segment manager - Pipeline
Brands; T-put & Böhler
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Company introduction
High Performance Metals
Welding Consumables
Precision Strip
Special Forgings
Electrodes, wires and fluxes
Soldering and brazing materials
Finishing Chemicals
Long products of Tool Steel
High Speed Steel
Nickel base alloys
Bimetal Strip
Cutting and creasing rules
Saw blade steel
Valve steel
Surgery knifes
Aircraft structural parts
Turbine blades
Special parts
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Global Production and Sales Network
Our own worldwide distribution network, excluding local partners and agents.
BWG Production Company (5 Europe, 2 Asia, 2 Americas)
BWG Sales Company (17 own sales offices)
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Main brands for pipeline consumables
Production Hamm-Germany
Production Kapfenberg-Austria
* MIG/MAG solid wires (GMAW)
* TIG rods (GTAW)
* Wires & fluxes (SAW)
- Stick electrodes (SMAW)
- Flux cored wires (FCAW)
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Trends in welding
Efficiency of welding processesManual welding - stick electrodes
Root passVertical down welding
(semi) automatic processesMIG/MAG - solid wireFCAW - flux cored wireSAW - wire & flux combinations
Reduce downtimeSlag removal
Changing of stick electrodes
Grinding activities
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Stick electrodes
Basic vertical upFOX EV PIPE, FOX EV 60 PIPE, FOX EV 70 PIPE
EV PIPE series are thin coated basic electrodes (no additional metal recovery) that allows the use of thicker diameters, specialty for root pass welding.
FOX EV 50, FOX EV 60, FOX EV 63, FOX EV 65, FOX EV 70
Basic coated stick electrodes with metal recovery 115-120% suitable for root pass, specially filling and cap layers.
Cellulosic vertical downFOX CEL, FOX CEL+, FOX CEL Mo, FOX CEL 70-P, FOX CEL 75, FOX CEL 80-P,
FOX CEL 85, FOX CEL 90
Basic vertical downFOX BVD RP, FOX BVD 85, FOX BVD 90, FOX BVD 100, FOX BVD 110, FOX BVD 120
Basic coated electrodes with metal recovery for vertical down welding
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Electrode AWS E 7018Böhler FOX EV PIPE ∅ 2.5 x 350 (6-4 and 6-8 o’clock)∅ 3.2 x 350 (from 6 – 12 o’clock) ∅ 3.2 x 350 (remainder) Amperage 120 A Amperage ∅ 2.5... 70-75 A
∅ 3.2... 85-100 A
Tube S 355 N∅ 330 x 10 mm
Root gap 2.5 mmRoot face 2.5 mm
19,08
12 h
6 h
5G/PFd.c. positive
12 h
6 h10,25
12 h
6 h12 h
6 h
5G/PFd.c. negative
Root pass in 10.25 minutes Root pass in 19.08 minutesTime saving 46 % Almost double the welding time
EV Pipe - time saving for root pass
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Efficiency by type of electrode (smaw)
Dep
ositi
on R
ate
[kg/
h]
Welding current [A]
Basic covered (up hill)Basic covered (down hill)Cellulose covered (down hill)
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Time for root welding of 48“ pipe by type of electrode (according to Bruehl and Muesch)
Tim
e in
min
utes
320*
150*
65*
Welding time
Non-productive time
24
20
16
12
8
4
4 Welders
Coating: cellulosic basic basicElectrode Ø: 4,0 mm 3.25 mm 2,5 mmPosition: vertical down vertical down vertical up
* Welding speed in mm/minrelation to one welder
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Avoiding hydrogen risk with cellulosic
cellulosic rutile basicType of coating
Hyd
roge
nco
nten
tml/1
00g
depo
sit
60
50
40
30
20
10
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In fracture recognizable as brittle fracture spot
In longitudinal section recognizable as cracks
preferred area
Appearance of hydrogen inducted faults
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1…sheet (anchored on base plate)
2…test joint
3…specimen
4…firm base plate
After welding and exposing for 24 hours (20oC) each trial plate will be removed from the heavy plate section
1 12
3
Research for welded joints by a bead bend test
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Completely hindered shrinkageCompletely hindered shrinkageBevel preparation (VBevel preparation (V--6060°°))Preheat temp. = Preheat temp. = interpassinterpass temptemp..
Investigation program:Investigation program:wall thickness of welding jointwall thickness of welding jointInterpassInterpass temperaturetemperatureStrength level of CELStrength level of CEL-- electrodeselectrodes
inspection scope:inspection scope:30 joints per strength level (electrode)30 joints per strength level (electrode)4 strength levels 4 strength levels
Test plates
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After annealing After annealing (250 (250 °°C/16 hours) the test C/16 hours) the test specimen is bent, in order to specimen is bent, in order to make micro cracks visiblemake micro cracks visible
Bending of test specimen
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Böhler Fox CEL 90 (AWSE 9010/EN E50C), welding position: PGwall
thicknessinterpass
temperature
20°C
15 mm80°C
120°C
9 mm
20°C
80°C
120°C
6 mm
20°C80°C120°C
Visual identifications of the bended specimens
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0
20
40
60
80
100
120
140
160
5 10 15 20 25wall thickness [mm]
inte
rpas
s te
mpe
ratu
re [o C
]
E 9010E 8010E 7010E 6010
Relation between interpasstemperature and wall thickness
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Mechanical properties vertical downCellulosic – Basic stick electrodes
cellulosic rutile basicType of coating
Tens
ilest
reng
th[N
/mm
²]
900
800
700
600
500
cellulosic rutile basicType of coating
Tens
ilest
reng
th[N
/mm
²]
900
800
700
600
500
Tens
ilest
reng
th[N
/mm
²]
900
800
700
600
500
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Application vertical down electrodes
Pipe grade Cellulosic vertical down / root-fill-cap Basic vertical down / …-fill-cap
FOX CEL FOX CEL 85 FOX CEL 90 FOX BVD 85 FOX BVD 90 FOX BVD 100 FOX BVD 110 FOX BVD 120
E6010 * E8010 * E9010 * E8045-P2 * E9018-G E10018-G E11018-G E12012-G
X42 / L290MB
X46 / L320M
X52 / L360MB
X56 / L385M
X60 / L415MB root pass
X65 / L450MB root pass
X70 / L485MB root pass
X80 / L555MB root pass
X100 / (L690)
(X110)
* contains <1% Ni Several possibilities for root pass
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Electrodes that are tested under…..
…..all circumstances!
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Vergleich der Abschmelzleistung:Stabelektrode, rutil- und basisch umhüllt, Massiv- und Fülldrahtelektrode
60 80 100 120 140 160 180 200 220 240 260 280 300
Stromstärke [A]
0
1
2
3
4
5
6
Abs
chm
elzl
e ist
ung,
Sch
wei
ßgut
[kg/
h]
Massivdraht
bas. ELø 3,2
rut. ELø 3,2
rut. ELø 4,0
bas. ELø 4,0
~ ~
FDR: Thyssen TG 50 C Thyssen RV 72Thyssen TG 50 M Thyssen RV 71
ø 1,2ø 1,0
manuellerBereich
vollmasch.Bereich
Schweißpos.: steigendKontaktrohrabstand: 15 mmEinschaltdauer: 100%
FCAW metal cored -> rutile cored
Compare of processes in vertical up position!
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Changes over the last decades
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Solid wire - narrow gap - vertical down
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Wire types (T-put brand)
Most of our pipeline wires are micro alloyed and designed for high quality automatic welding of pipelines. An optimum balanced alloying concept ensures good weld metal properties to fulfill the high requirements in the on- & offshore pipeline industry.
Union K 52 S up to X 65
Union K 56 S up to X 70
Union K Nova up to X 70 – designed for pure CO² shielding gas
Union K Nova Ni up to X 80 – 0,9% Ni for high toughness properties
Union NiMo 80 X 80 pipe material.
The wire selection is depending on several aspects - as;base material, bevel preparation, welding process and overmatching requirements.
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Main aspects with solid wire
Suitable for automatic welding.
Small bevel (narrow gap).
High traveling (welding) speed.
DC polarity or pulse.
Fast process for girth welding.
No moisture pick up from environment.
Main disadvantage is possible lack of fusion
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Flux cored wire compared to solid
Difference & Benefits Stable arc / less spattering
All positions
Spray arc at low Amps. (180A)
Relative low heat input
Deposit rate / welding speed
Adding alloying elements
Less chances lack of fusion
Strip / Tube
Core:- Alloying elements
- Slag formers / metal powder
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Flux cored wires for higher strength materials
Böhler TI 70 PIPE-FD
Tubular wire, micro alloyed.
Pipe steels:L415MB - L485 MB (L555 MB)
X 60 - X 70 (X 80)
Mechanical properties – all weld metal
Yield >550 N/mm²
Tensile 640-820 N/mm²
Elongation >18%
Impact values >47 Joule (-40°C)
Böhler TI 80 PIPE-FD
Tubular wire, micro alloyed.
Pipe steels:L485 MB - L555 MB
X70 - X80
Mechanical properties – all weld metal
Yield >690 N/mm²
Tensile 770-940 N/mm²
Elongation >17%
Impact values >47 Joule (-40°C)
NEW in our program!
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Practical application TI 70 PIPE-FD
L 415 MB - 24” - 13.5mm
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Mechanical properties welded joint
Strength properties requirement
Yield >525 N/mm² min. 469
Tensile >600 N/mm² min. 572
Elongation >19 % min. 18
Impact values (-20° C)
Centre weld >85 Joule min. 40
Hardness (HV10)
Root area 190-180-190 max. 275
Cap area 190-220-200 max. 325
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TI 70 PIPE-FD ; Properties reached onX 70 (L480 MB) 48” 15.9mm
Strength propertiesYield >580 N/mm²Tensile >670 N/mm²Elongation >20 %
Impact values (-20° C)
Cap >70 Joule
Hardness (weld) (HV10)
Root area 214-211-211Cap area 225-215-218
CTOD weld centre line (-20° C)
0.11 - 0.12 - 0.13
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SAW – wire flux combinations
Only horizontal position.
Deep penetration and fusion with base material. *
High deposit rate.*
Tandem process (2 wires)
Higher wall thickness.
Excellent mechanical properties.* Due to relative high parameters
Prefab/double joint applications
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Schematic overview
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Possible SAW combinations
T-PUT Submerged Arc - SAW
Wire FluxAPI 5 L-92
EN 10208-2 DIN 17172 AWS A5.17 / 5.23 AWS A5.17 / 5.23
A -X52 L360MB StE 360.7 (TM)Union S2 EM 12
Union S3 Si EH 12K UV 421 TT F7A6-EM12 UV 421 TT F7A8-EH12K
X56 L385MB StE 385.7 (TM)Union S3 Si EH 12K
UV 421 TT F7A8-EH12K
X60 L415MB StE 415.7 (TM) Union S3 Si EH 12KUnion S2 NiMo 1 ENi1
UV 421 TT F7A8-EH12K UV 421 TT F8A8-ENi1-Ni1
X65 L450MB StE 445.7 (TM)Union S2 NiMo 1 ENi1
Union S3 NiMo 1EG (EF 3 mod.)
UV 421 TT F8A8-ENi1-Ni1 UV 421 TT F9A8-EG-F3
X80 L555MB StE 550.7 (TM) Union S3 NiMo 1 EG (EF 3 mod.) UV 421 TT F9A8-EG-F3
Base material
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Thanks for your attention !
For information concerning our complete program and possibilities of welding consumables for pipeline or other applications, please feel free to contact us.
www.bohlerweldinggroup.com