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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)
1
I.D OVERLAY

• FCAW / GTAW PROCESS


• OVERLAY ON SMALL DIAMETER
NOZZLE PIPES/ FORGINGS
• DEVELOPED DOWN TO 25mm I.D
AFTER OVERLAY
• MAX. LENGTH WELDED = 2.4 mt

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

FCAW CS 1.2 200 3.3


SS 1.2 200 3.4

3
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


90X0.5 1800 33
120X0. 5 2200 42

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5
BASE METAL - WELDING CONSUMABLE SELECTION

NOMINAL SMAW FCAW


GTAW
MATERIAL TYPE COMPOSITIO CONSUMABLE CONSUMABLE SAW CONSUMABLE
CONSUMABLE
N
C-Mn STEEL C- 1.6%Mn ER 70S-2 E 71T-1/ E70T-5 EH-14+TAPADIA-80/
(SA516 GR60/70, E 7018/ 7018-1 S3 + UV420TTR

C-Mo LAS C- 0.5% Mo/ E 7018 A1 / ER 80S-D2 E70T-A1 / EA-3 + OP41TT


(SA204-B,SA302-B) C-Mn-Mo E 8018 D3 E81T1-A1 EA-4/EF-3 + UV420TTR
1.25Cr-0.5Mo LAS 1~1.25Cr-0.5Mo E 8018B2 ER 80SB2 E 81T1-B2 EB2 + UV420TTR
(SA387GR11CL1/2)
2.25 Cr-Mo LAS 2.25Cr-1Mo E 9018B3 ER 90SB3 E91T1-B3 EB3 + UV420TTR
(SA387 GR22CL2)
SS 304/ 304L 18Cr - 8Ni E 308/ 308L ER 308/ 308L E 308LT-1 / E308LT0-1 ER308L + SSGR.1 / FJ-1
(SA240GR304L)
SS 316/ 316L 18Cr - 8Ni - E 316/ 316L ER316/ 316L E316LT-1/ E316LT0-1 ER316L + SSGR.1 / FJ-1
(SA240GR316L) 2~3Mo
SS321/ 347 18Cr - 8Ni - E 347 ER347 E347T-1/ E347T0-1 ER347 + SSGR.1 / FJ-1
(SA240GR321/ 321H) Nb+Ta
E 309LT-1/ E309LT0-
E 309/ E309Mo/ ER309 / ER309Mo/
SS-410S 13%Cr 1
ENiCrFe3 ERNiCR3
(SA240 Type410S)
6
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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.

8
POSTHEATING

• HEATING AT 300 - 350 °C FOR 3 / 4


HRS MIN. BEFORE ALLOWING WELD TO
COOL TO ROOM TEMPERATURE
FROM PREHEAT TEMPERATURE

• AFTER POST HEATING COVER THE JOINT


WITH ASBESTOS FOR SLOW COOLING.

• IF NOT DONE - CRACKS. FAILURE


IN
SERVICE. 9
12
CONSUMABLE PRICES
• SMAW ELECTRODE/ GTAW WIRE.)
TYPE COST/Kg (Rs)
E7018 55
E7018-1 60
E8018B2 270
E308L 400
E309L 500
ENiCrFe3 1200
ENiCu7 800

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CONSUMABLE PRICES

• SMAW ELECTRODE/ GTAW WIRE(CONT.)


TYPE COST/Kg (Rs)
ER70S-2 190
ER309L 480
ER308L 350
ERNiCr3 1000

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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
16
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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. )

2 SMAW 175-200°C for 2 hrs 100°C min till use -do-


-Stainless Steel Electrodes, min before use
- Non Ferrous Electrodes

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
19
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

20
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

22
WELDER QLFN. - ASME SEC.IX

P No. Type of Material

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
23
WELDER QLFN. - ASME SEC.IX

Base Metals for Welder Qualification


Qualified Production Base Metals

P No 1 through P No. 11 and P P No 1 through P No. 11 , P No. 34,


No. 34 P No. 4X and unassigned metals of similar
or P No. 4X chemical composition

P No. 21 through P No. 25 P No. 21 through P No. 25

P No. 5X or P No. 6X P No. 5X and P No. 6X

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F- NUMBERS

F4 - LOW H2 TYPE CS / LAS - E7018, E 8018B2


F5 - AUSTENITIC SS - E309/308/347
F6 - GTAW/SAW/FCAW CS/LAS -ER70S2/S3/E71T-1/
ER308//E308LT-1
F3X-Cu & Cu BASE ALLOYS - ERNiCu7/ ENiCu7
F4X-Ni & Ni BASE ALLOYS - ENiCrFe3/ERNiCr3
F5X-Ti & Ti BASE ALLOYS - ERTi-1
F7X-HARD FACING CONS. -STELLITE-1/6

25
WELDER QLFN. - ASME SEC.IX

Alternate F No for Welder Performance Qualification

Qualified with Qualified for

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 21 through F No 25 All F No 21 through 25

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

F No 34 or any F No 41 throughF No 45 F No 34 and all F No 41 through F No 45

any F No 51 through F No 54 All F No 51 through F No 54

Any F No 61 All F No 61

Any F No 71 through F No 72
26
Only the same F Number as was used
during the qualification test
WELDER QLFN. - ASME SEC.IX

GROOVE

Weld Thickness in Qualification Test Maximum Qualified Weld Thickness


[t in inch (mm)] [inch (mm)]

>=3/4 (19.05) Any Thickness

<3/4 (19.05) 2t

OVERLAY
Qualification Test Thickness Thickness Qualified
[T in inch (mm)] [inch (mm)]

Upto 1 (25.4) T to unlimited

> 1 (25.4) 1 (25.4) to unlimited


27
WELDER QLFN. - ASME SEC.IX

GROOVE AND OVERLAY WELDS - LIMITATIONS ON PIPE / TUBE DIAMETERS

OD inch (mm) NB inch Minimum Maximum

<1 (25.4) <3/4 Size Welded Unlimited

1 to 2 (7/8) or 25.4 mm 3/4 to 2(1/2) 1 (25.4) Unlimited


to 73.03 mm

>= 2(7/8) or 73.03mm 2(1/2) 2(7/8) or 73.03 Unlimited

28
WELDER QLFN. - ASME SEC.IX
BACKING
- SINGLE SIDED WELD - WELD WITHOUT BACKING/
FIBRE TAPE

- DOUBLE SIDED WELD - WELD WITH CHIP BACK/


BACKING

QUALIFICATION WITH QUALIFIED


FOR

SINGLE SIDED SINGLE /


DOUBLE SIDED

DOUBLE SIDED DOUBLE SIDED


29
PERFORMANCE QUALIFICATION- POSITION AND DIAMETER
LIMITATIONS

Position and Type Weld Qualified

Qualification Test Groove Fillet

Plate and Pipe Pipe


Weld Position Plate and Pipe
Over 24 in.O.D. <= 24 in. O.D.

Plate- Groove 1G F F [ Note (1) ] F


2G F,H F,H [ Note (1) ] F,H
3G F,V F [ Note (1) ] F,H,V
4G F,O F [ Note (1) ] F,H,O
3G and 4G F,V,O F [ Note (1) ] ALL
2G,3G,and 4G ALL F,H [ Note (1) ] ALL

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

NOTE: (1) Pipe 2 7/8o.d. and over. 30

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