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2
PRODUCTIVITY
PROCESS MATERIAL DIA. AMP DEPOSITION NO. OF ELECTRODE
PER ARC-HR PER ARC-HR
(Kg)
SMAW CS 2.5 80 0.7 56
3.2 130 1.1 44
4.0 180 1.5 38
5.0 240 2.4 34
SS 2.5 80 0.6 52
3.2 100 1.0 55
4.0 140 1.2 42
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PRODUCTIVITY
PROCESS MAT. DIA. AMP DEPOSITION PER
ARC-HR (Kg)
4
5
BASE METAL - WELDING CONSUMABLE SELECTION
• ADVANTAGES
• TO REMOVE OIL, MOISTURE ETC.
• TO AVOID CRACKING
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POSTHEATING
13
CONSUMABLE PRICES
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CONSUMABLE PRICES
• SAW/ FCAW WIRE
TYPE COST/SPOOL(Rs)
S3 1875 (25 Kg SPOOL)
EH-14 1300 (25 Kg SPOOL)
ER308L 3625 (25 Kg SPOOL)
E71T-1 1500 (12.5 Kg SPOOL)
E309LT-1 5000 (12.5 Kg SPOOL)
E347T-1 5000 (12.5 Kg SPOOL)
E308LT-1 5000 (12.5 Kg SPOOL)
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CONSUMABLE PRICES
• FLUX
TYPE COST/Kg (Rs)
UV420TTR 76
TAPADIA-80 25
SS GR-1 130
FJ-1 125
37 S 200
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REQUIREMENTS FOR DRYING OF WELDING CONSUMABLES
SL. HOLDING TIME &
CONSUMABLES BAKING CYCLE REMARKS
NO. TEMP.
1 SMAW 250-300°C for 2 hrs 100°C min till use After baking the electrodes can be
-Low Hydrogen Carbon & Low Alloy min before use stored in holding ovens ( at 100°C min till
Steel Electrodes ( e.g. E7018, use )
E8018 B2 etc. )
3 SAW FLUXES 300-350°C for 2 hrs 300°C minimum. In case fluxes are not used regularly,
( e.g.UV420TTR, Tapadia 80 etc.) immediately before No time limit oven temp. can be reduced to 100°C.
use However, the fluxes are to be baked at
300-350°C for 2 hrs minimum prior to
issue. 18
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WELDER QLFN. - ASME SEC.IX
ESSENTIAL VARIABLES
• WELDING PROCESS
• WELDING TYPE
• BASE METAL (P No.)
• FILLER METAL No. (F No.)
• WELD/ BASE METAL THK. & DIAMETER LIMIT
• BACKING
• POSITIONS
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WELDER QLFN. - ASME SEC.IX
WELDING PROCESS
• WELDERS :
- SMAW
- GTAW
- FCAW / GMAW
• WELDING OPERATORS :
- SAW
- ESSC
- MACHINE GTAW 21
WELDER QLFN. - ASME SEC.IX
WELDING TYPE
• MANUAL / SEMI-AUTOMATIC
• MACHINE
• AUTOMATIC
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WELDER QLFN. - ASME SEC.IX
P1 Carbon Steel
P3,4,5 Low Alloy Steel
P6,7 Ferritic and Martensitic Stainless Steel
P8 Austenitic Stainless Steel
P9 Nickel Steel (less than 4.5% Ni)
P10,11 Quenched and Tempered Steel
P2X Aluminium and Alloys
P3X Copper and Alloys (Cupronickel)
P4X Nickel and Nickel Base Alloys
P5X Titanium and Titanium Base Alloys
P6X Zirconium and Zirconium Base Alloys
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WELDER QLFN. - ASME SEC.IX
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F- NUMBERS
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WELDER QLFN. - ASME SEC.IX
F No 4 F No 1, 2, 3, 4
F No 5 F No 5
Any F No 6 All F No 6
Any F No 31, F No 32, F No 33, Only the same F Number as was used
F No 35, F No 36 or F No 37 during the qualification test
Any F No 61 All F No 61
Any F No 71 through F No 72
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Only the same F Number as was used
during the qualification test
WELDER QLFN. - ASME SEC.IX
GROOVE
<3/4 (19.05) 2t
OVERLAY
Qualification Test Thickness Thickness Qualified
[T in inch (mm)] [inch (mm)]
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WELDER QLFN. - ASME SEC.IX
BACKING
- SINGLE SIDED WELD - WELD WITHOUT BACKING/
FIBRE TAPE
Pipe-Groove 1G F F F
2G F,H F,H F,H
5G F,V,O F,V,O ALL
6G ALL ALL ALL
2G and 5G ALL ALL ALL