Graaf Welding Consumables For Girth Welding of Pipelines

Welding consumables
for girth welding of pipelines
Henk de Graaf
Industry segment manager - Pipeline
Brands; T-put & Bhler
We are the World of Welding Solutions.
Company introduction
High
Performance
Metals
Welding
Consumables
Precision
Strip
Special
Forgings
Long products
of Tool Steel
Electrodes, wires
and fluxes
Bimetal Strip
Aircraft
structural parts
High Speed
Steel
Soldering and
brazing materials
Nickel base
alloys
Finishing
Chemicals
Cutting and
creasing rules
Saw blade steel
Valve steel
Surgery knifes
Turbine blades
Special parts
Global Production and Sales Network
BWG Production Company (5 Europe, 2 Asia, 2 Americas)

BWG Sales Company (17 own sales offices)
Our own worldwide distribution network,

excluding local partners and agents.
Main brands for pipeline consumables
Production Hamm-Germany
* MIG/MAG solid wires (GMAW)

* TIG rods (GTAW)
* Wires & fluxes (SAW)
Production Kapfenberg-Austria
- Stick electrodes (SMAW)

- Flux cored wires (FCAW)
Trends in welding
Efficiency of welding processes

Manual welding
- stick electrodes
Root pass
Vertical down welding
(semi) automatic processes

MIG/MAG
FCAW
SAW
- solid wire
- flux cored wire
- wire & flux combinations
Reduce downtime
Slag removal
Changing of stick electrodes
Grinding activities
Stick electrodes
Basic vertical up
FOX 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 down

FOX 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 down

FOX 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
EV Pipe - time saving for root pass
Bhler FOX EV PIPE

3.2 x 350 (from 6 12 oclock)
Amperage 120 A
Tube S 355 N
330 x 10 mm
Root gap 2.5 mm
Root face 2.5 mm
12 h
6h
12 h
6h
Electrode AWS E 7018

2.5 x 350 (6-4 and 6-8 oclock)
3.2 x 350 (remainder)
Amperage
2.5... 70-75 A
3.2... 85-100 A
12 h
6h
12 h
6h
10,25
5G/PF
d.c. positive
5G/PF
d.c. negative
Root pass in 10.25 minutes

Time saving 46 %
19,08
Root pass in 19.08 minutes

Almost double the welding time
Deposition Rate [kg/h]
Efficiency by type of electrode (smaw)
Basic covered (up hill)

Basic covered (down hill)
Cellulose covered (down hill)
Welding current [A]

Time for root welding of 48 pipe by type of

electrode (according to Bruehl and Muesch)
4 Welders
Time in minutes
24
20
* Welding speed in mm/min

relation to one welder
Welding time
Non-productive time
65*
16
12
150*
8
4
320*
Coating:
cellulosic basic
basic
Electrode : 4,0 mm
3.25 mm 2,5 mm
vertical down vertical down vertical up
Position:
Hydrogen content ml/100g deposit
Avoiding hydrogen risk with cellulosic
60
50
40
30
20
10
cellulosic
rutile
basic
Type of coating
Appearance of hydrogen
inducted faults
preferred
area
In fracture recognizable
as brittle fracture spot
In longitudinal section
recognizable as cracks
Research for welded joints

by a bead bend test
1sheet (anchored on base plate)

2test joint
3specimen
4firm base plate
2
1
After welding and exposing for 24

hours (20oC) each trial plate will be
removed from the heavy plate section
Test plates
Completely hindered shrinkage
Bevel preparation (V-60)
Preheat temp. = interpass temp.
Investigation program:
wall thickness of welding joint
Interpass temperature
Strength level of CEL- electrodes
inspection scope:
30 joints per strength level (electrode)
4 strength levels
Bending of test specimen

After annealing
(250 C/16 hours) the test
specimen is bent, in order to
make micro cracks visible
Visual identifications
of the bended specimens
interpass
temperature
Bhler Fox CEL 90 (AWSE 9010/EN E50C), welding position: PG
wall
thickness
20C
80C
15 mm
120C
20C
80C
9 mm
120C
20C
80C
6 mm
120C
Relation between interpass

temperature and wall thickness
interpass temperature [oC]
160
E 9010
E 8010
E 7010
E 6010
140
120
100
80
60
40
20
0
5
10
15
wall thickness [mm]
20
25
Mechanical properties vertical down

Cellulosic Basic stick electrodes
Tensile strength
[N/mm]
900
800
700
600
500
cellulosic
rutile
basic
Type of coating
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
* contains <1% Ni
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)
Several possibilities for root pass
Electrodes that are tested under..
..all circumstances!
Schweipos.: steigend
Compare
of processes
Kontaktrohrabstand: 15 mm
FDR:
Thyssen TG 50 C
Thyssen RV 72
FCAWThyssen
metal cored
cored
TG 50 M-> rutile
Thyssen
RV 71
Einschaltdauer:
in
vertical up 100%
position!
4
bas. EL
4,0
3

Massivdraht
2
1,0
bas. EL
3,2
~
~
Abschmelzleistung, Schweigut [kg/h]
60
80
1,2

rut. EL
3,2

manueller
rut. EL
4,0
vollmasch.
Bereich
Bereich
100 120 140 160 180 200 220 240 260 280 300
Stromstrke [A]
Vergleich der Abschmelzleistung:

Stabelektrode, rutil- und basisch umhllt, Massiv- und Flldrahtelektrode
Changes over the last decades
Solid wire - narrow gap - vertical down
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 CO 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.
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
Flux cored wire compared to solid
Stable arc / less spattering
Difference & Benefits
All positions
Strip / Tube
Spray arc at low Amps. (180A)

Relative low heat input
Deposit rate / welding speed
Adding alloying elements

Core:
- Alloying elements
- Slag formers / metal powder
Less chances lack of fusion
Flux cored wires for higher strength

materials
NEW in our program!
Bhler TI 70 PIPE-FD
Bhler TI 80 PIPE-FD
Tubular wire, micro alloyed.
Tubular wire, micro alloyed.
Pipe steels:
Pipe steels:
L415MB - L485 MB (L555 MB)
L485 MB - L555 MB
X 60 - X 70 (X 80)
X70 - X80
Mechanical properties all weld metal
Mechanical properties all weld metal
Yield
>550 N/mm
Yield
>690 N/mm
Tensile
640-820 N/mm
Tensile
770-940 N/mm
Elongation
>18%
Elongation
>17%
Impact values
>47 Joule (-40C)
Impact values
>47 Joule (-40C)
Practical application TI 70 PIPE-FD
L 415 MB - 24 - 13.5mm
Mechanical properties welded joint
Strength properties
requirement
Yield
>525 N/mm
min. 469
Tensile
>600 N/mm
min. 572
Elongation >19 %
Impact values
(-20 C)
Centre weld >85 Joule
Hardness
min. 18
min. 40
(HV10)
Root area 190-180-190
max. 275
Cap area 190-220-200
max. 325
TI 70 PIPE-FD ; Properties reached on

X 70 (L480 MB) 48 15.9mm
Strength properties
Yield
>580 N/mm
Tensile
>670 N/mm
Elongation >20 %
Impact values
Cap
(-20 C)
>70 Joule
Hardness (weld)
(HV10)
Root area 214-211-211

Cap area 225-215-218
CTOD weld centre line
(-20 C)
0.11 - 0.12 - 0.13
SAW wire flux combinations

Prefab/double joint applications
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
Schematic overview
Possible SAW combinations

T-PUT
Base material
API
5 L-92
EN
10208-2
Submerged Arc - SAW

Wire
Flux
DIN 17172
AWS A5.17 / 5.23
AWS A5.17 / 5.23
Union S2 EM 12
Union S3 Si EH 12K
A -X52
L360MB
StE 360.7 (TM)
X56
L385MB
StE 385.7 (TM)
X60
L415MB
StE 415.7 (TM)
X65
L450MB
StE 445.7 (TM)
Union S3 Si EH 12K
Union S3 Si EH 12K
Union S2 NiMo 1 ENi1
Union S2 NiMo 1 ENi1
Union S3 NiMo 1
EG (EF 3 mod.)
X80
L555MB
StE 550.7 (TM)
Union S3 NiMo 1
EG (EF 3 mod.)
UV 421 TT F7A6-EM12
UV 421 TT F7A8-EH12K
UV 421 TT F8A8-ENi1-Ni1
UV 421 TT F8A8-ENi1-Ni1
UV 421 TT F9A8-EG-F3
UV 421 TT F9A8-EG-F3
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

Graaf Welding Consumables For Girth Welding of Pipelines

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Graaf Welding Consumables For Girth Welding of Pipelines

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Drepturi de autor:

Formate disponibile

Welding consumables

for girth welding of pipelines

We are the World of Welding Solutions.

We are the World of Welding Solutions.

Global Production and Sales Network

BWG Production Company (5 Europe, 2 Asia, 2 Americas)

Our own worldwide distribution network,

Main brands for pipeline consumables

* MIG/MAG solid wires (GMAW)

- Stick electrodes (SMAW)

We are the World of Welding Solutions.

Efficiency of welding processes

(semi) automatic processes

We are the World of Welding Solutions.

Cellulosic vertical down

Basic vertical down

We are the World of Welding Solutions.

EV Pipe - time saving for root pass

Bhler FOX EV PIPE

Electrode AWS E 7018

Root pass in 10.25 minutes

Root pass in 19.08 minutes

Deposition Rate [kg/h]

Efficiency by type of electrode (smaw)

Basic covered (up hill)

Welding current [A]

Time for root welding of 48 pipe by type of

* Welding speed in mm/min

Hydrogen content ml/100g deposit

Avoiding hydrogen risk with cellulosic

We are the World of Welding Solutions.

Research for welded joints

1sheet (anchored on base plate)

After welding and exposing for 24

We are the World of Welding Solutions.

We are the World of Welding Solutions.

Bending of test specimen

We are the World of Welding Solutions.

Bhler Fox CEL 90 (AWSE 9010/EN E50C), welding position: PG

Relation between interpass

interpass temperature [oC]

wall thickness [mm]

We are the World of Welding Solutions.

Mechanical properties vertical down

We are the World of Welding Solutions.

Application vertical down electrodes

Cellulosic vertical down / root-fill-cap

Basic vertical down / -fill-cap

FOX BVD 100

FOX BVD 110

FOX BVD 120

We are the World of Welding Solutions.

Several possibilities for root pass

Electrodes that are tested under..

We are the World of Welding Solutions.

Abschmelzleistung, Schweigut [kg/h]

Vergleich der Abschmelzleistung:

Changes over the last decades

We are the World of Welding Solutions.

Solid wire - narrow gap - vertical down

We are the World of Welding Solutions.

Wire types (T-put brand)

up to X 70 designed for pure CO shielding gas