Pipe-Manufacturing

A glance at Pipe Manufacturing Industry..

Contents
This will be discussed under following Major headings:Types of Pipe Manufacturing Process. Manufacturing Parameters. Inspection-Raw material inspection. Requirement & End usage. Production,Quality & End Customers.

Types of Pipe Manufacturing Process

HSAW PIPES(Helical Submerged arc Welded Pipes). LSAW PIPES. ERW PIPES. SEAMLESS PIPES.

HSAW PIPES

Manufacturing Process for Seamless Pipes

Seamless pipe

ERW PIPES

Raw material required for Manufacturing Seamless,ERW,LSAW,HSAW PIPES

Steel round billets are required to manufacture Seamless pipes.Billets are procured both from Indigenous Suppliers & from abroad. HR Coils are required to manufacture ERW pipes,HSAW pipes which are Sourced from POSCO,ESSAR,TATA,JSW,HADEED & Other International & domestic mills from Europe,Canada & Far East of China. For LSAW pipes HR-Plates are required ,source from domestic & International-Mills.

Difference betn SeamlessPipes,ERW & SAW pipes

In Seamless pipe,there are no welding or joints & is manufactured from solid round billets.It is mainly used for High-Pressure applications such as Oil & Gas Exploration & Drilling,Oil & Gas Transportation,Hydrocarbon Industries & Refineries,Air & Hydraulic Cylinders,Bearings,Boilers,Automobiles etc ERW pipes are welded longitudinally manufactured from Strip/Coil & can be manufactured up to 20-inches mainly used for low/medium pressure applications such as transportation of Water/Oil. SAW Pipes are either longitudinally or Spiral welded manufactured from Plate & Coil ,can be manufactured up to 100-inches OD.It is used for transportation of large volume of liquid/gases. Seamless Pipes cannot be substituted for others.Only ERW & SAW Pipes can be substituted.

 Seamless Pipe is a high-end Product & used only in the high Pressure application areas & Other Steel-Pipes Viz. Spiral & ERW Pipes Cannot be used as a substitute .Hence Seamless Pipe industries has a bright future ahead.

Does Pipe industry forsee any threat from substitution of Other types of Pipes

Technologies for Production of Seamless & ERW Pipes

CPE Technology used for Seamless Pipes & Tubes Production up to 7-inches OD is the world renowned Technology. Plug Mill Technology used for Higher Dia. Seamless Pipes & Tubes Production from 7-inches to 14-inches,is the most reliable technology,in higher dia. Segment. High frequency Induction Welding Technology is used for ERW Pipes &Tubes upto 21-inchesOD.

Major Customers of Seamless Pipes,ERW Pipes

Oil & Gas Sectors Companies:-ONGC,Oil India,GAIL etc. Automation Sector Companies:-Bajaj Auto,LML,M&M,TELCO,etc Bearing Industry-:FAG,NEI,etc. Boiler & Heat Exchanger(ABB,BHEL,ISGEC,Thermax etc). Indian Railways etc. Export Segment viz. USA,Europe,Middle-East & Far East Countries. Hydraulic-Cylinders Salzgitter Hydraulic Ltd.

PipeMills registered Vendors with domestic Oil & Gas Players,refineries

ONGC,OIL,GAIL,RIL,Indraprastha Gas,Cairnenergy,Mahanagar Gas Ltd,British Gas etc,KOC,Saudiaramco,KNPC,PETRONAS,SHELL,EXXON. Exploration & Production of Crude Oil is going up,this will lead to increasing demand of Seamless Pipes mainly for Oil Companies & Tabular Goods(OCTG).Globally Exploration & Production activities which will lead to increase in demand of Seamless Pipe World-over.

LSAW-Pipe Manufacturing
Edge milling Machine. Roll bending machine. Post bending machine. Continous root welding machine. Internal welding station. External welding station. X-ray Station. Hydrotester. End facing machine. Expanded area External welding station. Ultrasonic testing station

Picture depicting LSAW-Pipe Manufacturing

a) Edge milling machine

b)Roll bending machine

The forming in the pipe mill is accomplished through the use of a Hydraulic 3-Roll bending machine type with prestressed top roll. With only 2-3 passes a plate is bent into an open seam pipe.

c)Post bending machine

In the post bending machine,which works by an innovative roll/die process the remaining flat ends are formed to the proper pipe diameter.

Continous welding machine

The finished formed slot pipe is finally adjusted & tack welded with a continous root in the tack-welding machine under gas shielded arc.The root weld also serves as backing for the inside welding of the pipe.

Internal welding station

The internal welding station consists of a height-adjustable welding boom including SAW equipment.The pipe moves on a pipe transport carriage.A video system helps the operator to control the process.

External welding station

The external welding station consists of a pipe transport carriage & outside heigt-adjustable welding boom equipped with SAW equipment.The pipe is transported through the station on the carriage.Following the weld seam is extremely visually inspected.The end taps are removed & the overstand of welding on both pipe ends is manually smoothed following the test procedure.

Pic.-External Welding Station

X-ray Station
In the second X-ray station both pipe ends of the weld seam are filmed accprding to the required standard.Eventual suspected defects observed in the ultrasonic defects observed in the ultrasonic station are also filmed. The equipment can also be extended for a realtime X-ray over the full pipe length.Afterwards a visual inspection covers the complete pipe surface in order to detect & remove any visual defects.

Pic-Showing LSAW Pipes

Pic-For XRAY-Station

Hydrotester
The hydrostatic pipe tester,necessary for all quality standards,tests each pipe by internal water pressure.Each length of pipe must withstand without leakage a hydrostatic test to at least the pressure specified in the standards.

Pic-For Hydrostation

End facing machine

The pipe-end bevelling machine chamfers simultaneously both ends to the requirement. By bevelling both ends simultaneously their parallelism is guaranteed.The bevel is concentric with the pipe inside the diameter.

Pic-For End facing Station

Internal welding station

The internal welding station consists of a height-adjustable welding boom including SAW equipment.The pipe moves on a pipe transport carriage.A video system helps the operator to control the process.

Pic.-For Internal Welding Station

Expanded area
The pre-washing station serves to remove all remaining flux,slags & milling scale by water. In the mechanical expander the pipe is sized to tighter tolerances of diameter & straightened according to any international standards or Customer requirements.Beside the sizing process for closer tolerances the expanding process increases the material yield of about 5-8%. The post-washing station removes the expander lubrication oil from the internal pipe body by high water pressure.

External welding station

The external welding station consists of a pipe transport carriage & outside height-adjustable welding boom equipped with SAW equipment.The pipe is transported through the station on the carriage. Following the weld seam is extremely visually inspected.The end taps are removed & the overstand of welding on both pipe ends is manually smoothed for the following testingprocedure. At the visual inside weld inspection,the pipe is cleaned from flux & slag & visually inspected by a video camera or an operator(depending on the pipe diameter).

Ultrasonic testing station

In the first ultrasonic testing station the weld seam is tested for any defects.Satisfactory pipes are transported to the pre-washing station while pipes with defects are diverted to the repair x-ray station where the defects are documented and repaired.

Pic For Ultrasonic test Station

API Pipe Grades

Different API-Grades:API Pipe Grades
Grade B, X42, X52, X60, X65, X70, X80

API Pipe Grades

Grade B, X42, X52, X60, X65, X70, X80

And Two Product Specification Levels

API Pipe Grades

Grade B, X42, X52, X60, X65, X70, X80

And Two Product Specification Levels

PSL 1 and PSL 2

API Grade X60, PSL 2 Yield Strength Range 60.2 81.9 ksi
API Grade X65, PSL 2 Yield Strength Range 65.3 87 ksi API Grade X70, PSL 2 Yield Strength Range 70.3 92.1 ksi

60

62

64

66

68

70

72

74

76

78

80

82

84

86

88

90

92

94

Yield Strength in ksi

Historically, it has been a common practice to apply dual-grade markings at the lower end of the grade spectrum

The most common dual grade product has always been Grade B/X42
Other common dual-grade items are: -X42/X46 -B/X42/X46 -X42/X52

API Specification 5L Provides Only Minimal Guidelines regarding dual markings for Line Pipe:
- Pipe manufactured as Grade X60 (415) or higher shall not be substituted for pipe ordered as Grade X52 (360), or a lower grade, without the purchaser's approval. - API Spec 5L, Annex N specifically allows marking pipe with comparable specifications. This allows pipe to have API markings as well as CSA or ISO designations

In the last few years, pipe mills have seen an increased number of requests for application of dual-grade markings in upper grades.
- X60 / X65 -X65 / X70 - X60 / X65 / X70 -X70 / X80

API Grade X52, PSL 1 Yield Strength Minimum 52.6 (no maximum for PSL 1)
API Grade X60, PSL 1 Yield Strength Minimum 60.2 (no maximum for PSL 1) API Grade X65, PSL 1 Yield Strength Minimum 65.3 (no maximum for PSL 1) API Grade X70, PSL 2 Yield Strength Range 70.3 92.1 ksi API Grade X80, PSL 2 Yield Strength Range 80.5 102.3 ksi

60

62

64

66

68

70

72

74

76

78

80

82 84

86

88

90

92

94

96

98 100 102 104

Yield Strength in ksi

There have been reports of pipe being stenciled and certified as follows:
X52 PSL 1, X60 PSL1, X65 PSL 1, X70 PSL 2, X80 PSL 2

API 1104 for Field Welding of Line Pipe contains the following restrictions on welding procedure qualification:

Welding Procedures shall be qualified within the following grade ranges: < X42 X46, X52, X56 (including intermediate grades) For X60 & above, each grade is qualified individually

One pipeline operator reported that they were laying a line of X65 PSL 2 pipe. They were using X65 / X70 dual grade pipe in the line. They were audited by the pipeline regulatory agency (PHMSA) and all of their welding documentation referenced qualification of API Grade X65, PSL 2. Since the pipe was X65 / X70 and each grade is required to be qualified separately, the auditor would not accept the X65 documentation.

Proposal Issued for Vote to the API Membership for requirements to be added to API Spec 5L:

The results of the ballot were surprising. Overall, the votes were for acceptance of the new requirement. However, as expected, there were a number of negative votes. The biggest objection was that the current proposal restricts dual-grading of X42 / X52, which has been a common industry practice.

API requires that negative ballots must be resolved before the item can go forward.

The work on this item is currently on-going. A new edition of API Specification 5L will probably be issued early 2011. It is the intent of the work group to have this item finalized and ready for publication in the next edition of the Specification. Before that can happen, all negative votes have to be resolved and the exact wording of the requirement will need to be finalized. The final version will be reviewed by members of the API 1104 group as well as the API Quality group to assure compliance with those requirements.

Marking of Pipe to Multiple Grades: Marking of pipe to multiple grades is permitted only by agreement between the purchaser and the manufacturer within the following guidelines:
- Pipe may have multiple markings within the following grade ranges: < X42 X46, X52, X56 (including intermediate grades) For X60 & above, marking of multiple grades is prohibited - The manufacturer is responsible to assure that the pipe conforms to all requirements of each of the certified grades. This allows pipe to be used as any of the grades individually. - Pipe shall be marked to only one PSL level. - Where pipe is marked to multiple grades, a single certification document shall be issued referencing the grade combination as marked on the pipe. The certification document may contain a specific statement that pipe conforms to each grade individually. - Pipe shall only be re-graded and re-marked under the manufacturers control. Certificates for re-graded pipe may only be issued by the pipe manufacturer.

While designing the pipeline, following needs to be considered.

The type of material and properties, Manufacturing methods, Time required for pipe laying, Tolerance controls on dimensions of pipes, Welding processes and techniques, Inspection methods and techniques, Acceptance limits of defects, etc.

SPECIFICATION FOR LINE PIPE

API 5L/2007 ISO 3183/2007 NACE MR 0175/ ISO15156

TYPES OF PIPE
SEAMLESS PIPE CONTINUOS WELDED PIPE ELECTRIC WELDED PIPE - PSL 1 Electric Welded Pipe: For grades higher than X42, heat treatment of weld seam and entire HAZ - PSL 2 Electric Welded Pipe: Welding with a minimum welder frequency of 100 kHz. LONGTITUDINAL SEAM SUBMERGED-ARC WELDED PIPE One longitudinal seam produced by automatic submerged arc welding process GAS METAL-ARC WELDED PIPE One longitudinal seam produced by continuous gas metal arc welding process HELICAL SEAM SUBMERGED ARC WELDED PIPE Making of one helical seam

PSL 2
PSL 2 has mandatory requirements for Carbon equivalent , Notch toughness, Max. yield strength and Max. tensile strength

 Chemical Composition Different grades of steel must contain certain amount of iron and alloying elements (Mn, Cu, Ni, Si, Al etc.) to attain desired mechanical properties. Mechanical Properties - For cold expanded pipe, ratio of body yield strength and body UTS shall not exceed 0.90. -The YS shall be the tensile stress required to produce a total elongation of 0.5% of the gage length as determined by extensometer.

MATERIAL REQUIREMENTS

 When Carbon content <= 0.12%, CE=C+Si/30+Mn/20+Cu/20+Ni/60+Cr/20+Mo/15+V/10+5B Max. CE =0.25% When Carbon content >= 0.12%, CE=C+Mn/6+(Cr+Mo+V)/5+(Ni+Cu)/15 Max. CE =0.43%

CARBON EQUIVALENT FOR PSL 2

TYPICAL COMPOSITION AND MECH. PROPERTIES (PSL2)

Composition: GRADE C (Wt%) max Mn (Wt%) max P (Wt%) max S (Wt%) Max Ti (Wt%) Max

X46, X52
X65 X70

0.22
0.22 0.22

1.40
1.45 1.65

0.025
0.025 0.025

0.015
0.015 0.015

0.04
0.06 0.06

Mechanical Properties: GRADE X52 X70 YS (psi), min 52000 70000 YS (psi), max 77000 90000 UTS (psi), min 66000 82000 UTS (psi), max 110000 110000

 Traditionally, C-Mn steels similar to API 5L grades- X46, X52, X56, X60 and X65 were used.

MATERIALS USED

Use of X 70 and X80 and higher grades are gaining momentum to reduce the wall thickness and cost.
Special steel grades are used for more corrosive environments such as sour service and for highly corrosive field production pipelines.

New higher strength grades require special production methods and controls on chemical composition and toughness properties.

MATERIALS RELATED CONSIDERATIONS

Newer materials are to be produced through advanced steel melting, tertiary refining and controlled rolling processes to obtain highest quality levels. Typically, Basic open hearth furnace or an LD convertor process in used with special ladle fluxing and vacuum degassing would be required to achieve low levels of C, S, P, Mn, Si and dissolved gases and non-metallic inclusions. Additional steps such as Calcium treatment are to be utilized for inclusion shape control for sour services.

 Recently, bainitic steels with ultra low carbon and additions of alloying elements such as Mn, Nb, B, Ti, with special online accelerated cooling and controlled rolling steps, are being increasingly used.
The need to use faster laying techniques require faster welding techniques which by itself put many restrictions on the material quality, welding processes and manufacturing tolerances, NDT etc. Newer materials such as Duplex stainless steels, High Nickel alloy clad carbon steels, heat traced pipelines etc. are being introduced to tackle corrosive fluids.

 For all materials used for pipelines, the upper limit of the UTS must be specified in order to restrict the spring back and residual stresses. The ratio yield strength/ UTS must not exceed 0.90, in order to ensure ductile behavior. The residual stress levels should be controlled in order to derive full utility of the strength of the material. The weld metal chosen should have mechanical properties matching the base metal Base metal and weld metal should have sufficiently high impact properties to ensure freedom from brittle fracture in service. For sour service, compliance to NACE requirements must be ensured by testing.

INSPECTION & TESTING

TESTING OF CHEMICAL COMPOSITION Heat analyses and Sampling methods TESTING OF MECHANICAL PROPERTIES - Tensile tests - Flattening tests - Bend tests - Fracture toughness tests - Hydrostatic tests DIMENSIONAL TESTING SURFACE INSPECTION NONDESTRUCTIVE TESTING

COATINGS

DESIRABLE CHARACTERISTICS OF COATING

EFFECTIVE ELECTRICAL INSULATOR EFFECTIVE MOISTURE BARRIER ABILITY TO RESIST DEVELOPMENT OF HOLIDAYS GOOD ADHESION TO PIPE SURFACE RESISTANCE TO DISBONDING EASE OF REPAIR NONTOXIC INTERACTION WITH ENVIRONMENT GOOD HARDNESS/ABRASION RESISTANCE GOOD PENETRATION RESISTANCE GOOD SOIL STRESSING RESISTANCE APPLICABILITY

COATING STANDARDS
CSAZ 245.20-06 External fusion bond epoxy coating for steel pipe (double layer) ISO/FDIS 21809-2:2007(E) External coatings for buried or submerged pipelines used in pipeline transportation systems- Fusion bonded epoxy coatings (single layer) DIN 30670 Polyethylene coatings for steel pipes and fittings NACE RP 0169-96 SECTION 5 AWWA C203-02 Coal tar protective coatings and linings for steel water pipelines

TYPES OF PIPELINE COATINGS

COAL TAR ENAMEL (CTE) FUSION BONDED EPOXY (FBE), SINGLE AND DUAL LAYER 3 LAYER POLYETHELYNE (3LPE) 3 LAYER POLYPROPYLENE (3LPP)

COATING CHARACTERISTICS & LIMITATIONS LIMITATIONS PIPE COATING CHARACTERICTICS

CTE -Low current requirement -Good resistance to cathodic disbondment - Good adhesion to steel - Low current requirement -Excellent resistance to cathodic disbondment - Excellent adhesion to steel -Excellent resistance to hydrocarbons -Lowest current requirement -Highest resistance to cathodic disbondment -Excellent adhesion to steel -Excellent resistance to hydrocarbons -High impact and abrasion -Limited manufacturers -Limited applicators -Health and air quality concerns -High moisture absorption -Lower impact and abrasion resistance -High application temp

FBE

3LPE

-Limited applicators -Higher initial cost -Possible shielding of CP current

HARDNESS COMPARISON CURVE

IMPACT RESISTANCE COMPARISON CURVE AT 20 DEGREE CENTIGRATE

IMPACT RESISTANCE COMPARISON CURVE AT 20 DEGREE CENTIGRATE

CATHODIC DISBONDMENT COMPARISON CURVE

PENETRATION COMPARISON CURVE

WATER ABSORPTION COMPARISON CURVE

5.Submerged Arc Welding

Inside welding process As the arc is completely covered by the flux layer, heat loss is extremely low. This produces a thermal efficiency as high as 60% (compared with 25% for manual metal arc). There is no visible arc light, welding is spatter-free and there is no need for fume extraction Operating characteristics SAW is usually operated as a fully-mechanised or automatic process, but it can be semi-automatic. Welding parameters: current, arc voltage and travel speed all affect bead shape, depth of penetration and chemical composition of the deposited weld metal. Because the operator cannot see the weld pool, greater reliance must be placed on parameter settings.

5.Submerged Arc Welding

Outside Welding Process

Process features SAW involves formation of an arc between a continuously-fed bare wire electrode and the work piece.

The process uses a flux to generate protective gases and slag, and to add alloying elements to the weld pool. thin layer of flux powder is placed on the workpiece surface. excess flux is recycled via a hopper. Remaining fused slag layers can be easily removed after welding.

7.Welding defects
Porosity : Causes:

Poor steel (high sulfur content)

Organic contamination - oil Rusty joint or wire ( moisture bond in the rust) Contaminants in the flux (moisture, dirt and mil scale) Electrode contamination under unusual storage Insufficient flux Tack welds

Arc blow
Trapped flux

7.Welding defects
Slag:

a) Poor (convex) weld bead profile resulted in pockets of slag being trapped between the weld runs Causes The slag becomes trapped in the weld when two adjacent weld beads are deposited with inadequate overlap and a void is formed. When the next layer is deposited, the entrapped slag is not melted out. As slag is the residue of the flux coating in MMA welding, it is principally a deoxidation product from the reaction between the flux, air and surface oxide. Slag may also become entrapped in cavities in multi-pass welds through excessive undercut in the weld toe or the uneven surface profile of the preceding weld runs,

7. Welding Defects
Lack of penetration:

Causes Low current, High welding speed, Low voltage, Poor welding technique

7. Welding Defects
Undercut: Causes High welding speed, Improper electrode angle, High welding current, Improper manipulation of electrodes

7. Welding defects
Weld Reinforcement:

Correct reinforcement Minimum cost Good joint strength

Excess reinforcement High cost Poor joint strength

Under reinforcement

Poor joint strength

Topics
1. Introduction 2. Welding Processes 3. Welding Position & Joints 4. SMAW Process 5. SAW Process 6. Main variables effect 7. Welding defects 8. Welding Consumables 9. Flux Management 10. Welding Procedure and performance qualification 11. Remainder

8.Welding consumables

8.Welding consumables
SAW is a combination of two consumables. It can be confusing, and result of that is a lack of your product. confidence in

8.Welding consumables
How to choose the proper filler metal ? Flux choice will be driven by : Base metal (stainless/non or low alloy) Single pass or multiple passes (non and low alloyed steels only) Mechanical properties (impacts) Dedicated to one job or universal product in the workshop (optimisation)

8.Welding consumables
Flux Normally Used in Pipe Industries: Multipass & / or single pass: 995N = Specific application with LNS 140TB P223 = Good impact and because of his slag freezing viscosity very good in spiral pipe mills 960 = Slow speed, large puddles, impact @ 20C. 25mm and up 980 = Impact @-0C, good with contaminated higher than 960 . Thin gauge plates plates. point and Plates thickness from Welding speed can be

8.Welding consumables
Electrode Normally Used in Pipe Industries: Single, Multiple or Combination of these - LNS 140TB - EM12K - EA2 (S2Mo)

8.Welding consumables
Non & low alloyed steels:

1)Single pass / two run :

What is it ?

Two different kind of application

High tech :2 passes (pipes) Low tech : one or 2 passes (sound weld at low cost)

8.Welding consumables
Basicity of flux : Basi. Index
Acid <0,9 Neutral 0,9<BI<1,2 Basic 1,2<BI<2 Highly basic <2

Melting range
1100c /1300c 1300c/ 1500c >1500c >1500c

8.Welding consumables
Why not a fully basic flux for high quality in single or two run technique ?

Topics
1. Introduction 2. Welding Processes 3. Welding Position & Joints 4. SMAW Process 5. SAW Process 6. Main variables effect 7. Welding defects 8. Welding Consumables 9. Flux Management 10. Welding Procedure and performance qualification 11. Remainder

9. Flux Management

9.Requirement
Why flux management is important?

Flux shields weld from outside atmosphere Facilitates welding, covers arc Flux is made of materials which produce slag of specific viscosity which allows entrapped gases to come out but provides effective shielding Hygroscopic in nature, absorbs moisture Melts due to weld arc, gets converted to slag, rises to top If contaminated with foreign materials, can produce weld defects

9.Requirement
Bake for 3500C, hold at 80-1000C Baking cycle 2 hours, holding time till issue Data: Flux name / number Each bag contains 25 kg Cost Consumption per meter of welding Administration: 2 ovens ID, 2 ovens OD 4 welding stations for ID, 4 for OD

9.Administration-ID welding station

2 ovens Each oven has 7 trays Fresh flux & recycled flux within closed loop is used Unique system for handling is used System comprises of hoppers, holding tanks, dry air inlet, recovery Temperature for holding can be set

9.Administration-Operating procedure
Oven is loaded with trays filled for 2 height Oven is set for 3500C Time of loading is recorded Batch number is recorded After 3500C temperature is reached, time is recorded

Flux is held for 2 hours

After 2 hours, time is recorded & 1. Either flux is removed & fed to hopper or 2. Temperature is reduced to 80-1000C Unloading time is recorded Next loading starts

9.Administration-OD welding station

2 ovens Each oven has 7 trays collected by suction, fed to feeding tank

Recycling
Recycling is done to reduce cost without effecting quality All foreign material to be separated This is ensured by sieving, passing thru separators Collected & re-baked

9.Administration-ID welding station

2 ovens Each oven has 7 trays Fresh flux & recycled flux within closed loop is used Unique system for handling is used System comprises of hoppers, holding tanks, dry air inlet, recovery Temperature for holding can be set

Topics
1. Introduction 2. Welding Processes 3. Welding Position & Joints 4. SMAW Process 5. SAW Process 6. Main variables effect 7. Welding defects 8. Welding Consumables 9. Flux Management 10. Welding Procedure and performance qualification 11. Remainder

10. Welding Procedure and Performance Qualification

Edge Preparation - Need

Poor penetration

Poor access at root

Poor strength Good penetration

Good access at root

Good joint strength

Basic Joint Types

butt tee
lap

corner
edge

Applicable Welds for Butt joint

Square Groove weld V Groove weld

Bevel Groove weld

U Groove weld

J Groove weld

Applicable Welds for Butt joint

Double V Groove weld Double Bevel Groove weld

Double U Groove weld

Double J Groove weld

Butt joint
Single V Groove weld
Groove angle

Root face Root gap Double V Groove weld

Groove angle

Single U Groove weld Root gap

Root radius

Root face

Weld Reinforcement

Correct reinforcement Minimum cost Good joint strength

Excess reinforcement High cost

Under reinforcement

Poor joint strength Poor joint strength

Butt joint Complete Joint penetration

Weld from face side

Backing weld from root side

Back gouging

Back gouging from face side

Back weld

Weld from face side

Welding Position Groove

1G

3G

2G 4G

Welding Position Groove

1G 2G

5G

6G

45

Area A

Dilution

Area B
Dilution is the amount of base metal present in the weld metal and given by (Area B / (Area A + Area B)) Dilution depends on the welding process and heat input. High dilution alters the chemical composition of weld metal

Weld Metal Requirements

Matching strength with the parent metal Good notch toughness at the operating temperature

Corrosion resistance
Creep resistance for elevated temperature application Resistance to wear, erosion etc

Filler Metal Selection

Mechanical / chemical properties required Welding process

Type of electrode, current, power range

Metal to be joined and its thickness Weld joint design and welding position Shop or Field weld / surface condition Number of passes / amount of weld metal

Welding Procedure Specification

It is a written document that provides direction to the welder for making production welds in accordance with code requirements. Any WPS must be qualified by the manufacturer. WPS specifies the condition (ranges) under which welding must be performed called variables. WPS addresses essential, supplementary essential and non essential variables

Purpose of WPS Qualification

To determine that the weldment is capable of providing the required properties for the intended application.
WPS establishes the properties of the weldment and not the skill of the welder.

Procedure Qualification
PQR is a record of welding data to weld a test coupon. It also contains test results. Completed PQR shall document all essential variables including ranges. PQR to be certified accurate and shall not be subcontracted. If more than one process is employed then weld deposit thickness for each process and filler metal to be recorded.

Base Metal Classification

Base metals classified into various P Nos depending on composition, weldability & mechanical properties. P1 - P11 P21 - P25 Steel Al alloys etc.

Group nos. within P nos classify metals for procedure qualification where notch toughness requirements are specified.

Filler Metal Classification

F Numbers are based on usability characteristics i.e ability of welders to make satisfactory welds with given filler e.g. F1 - E XX20, F2 - E XX12, F3 - E XX10, F4 - E XX18 etc. A Numbers are based on chemical composition e.g. A1 - Mild steel A2 - C - Mo steel etc.

WPS for SMAW

Essential variables

Change in qualified Thickness Change in P no Change in F no of filler metal Change in A no of filler metal Change in deposited metal thickness Decrease of more than 100 F in preheat Change in PWHT

Procedure Qualification Thickness limits

T (mm) <1.6 1.6 10 10 - 19 19 - 38 >38 Range of T T - 2T 1.6 - 2T 4.8 - 2T 4.8 - 2T 4.8 - 203 max t 2t 2t 2t 2t if t<19 2T if t>19 2t if t<19 203 if t>19 Tests 2T, 2 FB, 2 RB -do-do2T, 4 SB -do-

Welding Performance Qualification

The performance qualification tests are intended to determine the ability of welders to make sound welds A welder is qualified by radiography of a test coupon or by radiography of initial production welding or by bend tests taken from a test coupon

Welding Performance Qualification

The performance qualification tests are intended to determine the ability of welders to make sound welds A welder is qualified by radiography of a test coupon or by radiography of initial production welding or by bend tests taken from a test coupon

Welding Performance Qualification Variables for SMAW

Removal of backing Change in Pipe diameter Change in P number Change in F Number Change in thickness of weld deposit Change in welding position Change in vertical welding

Topics
1. Introduction 2. Welding Processes 3. Welding Position & Joints 4. SMAW Process 5. SAW Process 6. Main variables effect 7. Welding defects 8. Welding Consumables 9. Flux Management 10. Welding Procedure and performance qualification 11. Remainder

11.Reminder

11.Reminder
Possibilities for Welding-Seam Monitoring by Personnel in Submerged-Arc Welding Plants
A) Visual Assessment of the Pipe to be Final-Welded

One prerequisite for a high-quality submerged-arc welding seam is proper preparation of the inside and outside seam area.

The seam area must be free from rust and scale. It is imperative that the surface is free from oil, grease and water. The tack-welded seam must be uniform. Both the strip edges must have the same contour from the miller. If these points are not complied with, this results in contamination of the welding seam by slag and pores and in irregularities in the arc and thus poorer seam geometry and penetration notches.

11.Reminder
B) Checking of Specified Production Data In principle, every operator must convince himself at the start of the shift that the production data specified for the order in question (current intensity, voltage, welding speed and welding-wire position) has been set correctly. If welding-seam faults are found as a result of the micrographs or nondestructive testing or if there are any irregularities in the production sequence which have a negative influence on the welding seam, then the production data must be checked immediately, including checking of the welding-wire feed and of the flux supply.

11.Reminder
C) Observation of Production Sequence

Attention must always be paid to the constancy of the measuring-instrument displays for the electrical welding data. The regularity and temperature of glowing-through during the welding process must be observed. The flux feed must be adequate, regular and symmetrical to the centre of the seam. Constant wire discharge is shown by steady welding data, uniform glowing through and a stable position of the inside arm. Surrounding influences, such as shocks to the installations as a result of pipe transport, sticking of control elements, wearing of parts of the installation, jerking of the pipe etc., must be observed and eliminated immediately.

11.Reminder
D) External Assessment of Welding Seam External inspection and measurement of the seam is often sufficient to provide information about the quality of the welding seam. It is thus possible to assess the regularity and dimensions (height and width) of the seam shape. In most cases, impermissible faults, such as notches, external pores, seam protuberances, seam offset and seam interruptions, are obvious. E) Metallographic Micrograph Assessment The metallographic micrograph of the submerged-arc welding seam primarily serves to assess the seam geometry, the seam shape and the heat influence in the seam area. It also enables information to be given about the purity of the welding seam and about the material properties. During ongoing operational testing, the following data is determined and registered on the basis of the micrographs: excess seam height, seam width, seam offset, width / transition zone, penetration figure and normalization. If faults are included in the welding deposit or in the base material, special marking is applied.

Process route for Hot finished Product

Process route for Casing & Tubing

Process route for anti-corrosion coating

Process route for Cold-finished Product

Survey of API-leveller information format data

PIPE MILLS INCLUDED ARE:WELSPUN GUJARAT. JINDAL SAW LTD. PSL LIMITED. RATNAMANI LTD. MAN INDUSTRIES LIMITED.

No.1 leveller -1

No.2 leveller

-2

-1
-1 -2

-2

-1 work roll diameter

-2

pitch between the center of upper 1st roll and the center of upper 2nd roll the distance between the center of upper roll and the center of bottom roll = intermesh (roll gap)

maximum motor power of each leveller.

wheather or not the back up roll is exist. (if back up roll is exist, then it needs of back up rolls information like work roll.)

Leveller information format

1st leveller Tube making line No
Upper/ Lower No of roll
Work Roll Diameter Motor pressure Max Have a Back-up roll?

2nd leveller
Upper/ Lower No of roll
Work Roll Diameter Motor pressure Max Have a Back-up roll?

Spiral no.1

2/1

300mm

100bar

No

3/2

250mm

150bar

Yes

Spiral no.2

2/1

250mm

80bar

Yes

2/1

200mm

100bar

Yes

LEVELLER INFORMATION
1st leveller (Non drive) 2- pitch 3- center of Tube making 1- Work Upper/Low between upper roll and line No Roll st nd er No of roll upper 1 & 2 the center of Diameter roll bottom roll 2nd leveller (Non drive) Motor power/ 2- pitch 3- center of Have a Upper/Lo 1- Work pressure Max for between upper roll and Back-up wer No of Roll st nd work roll up upper 1 & 2 the center of roll? roll Diameter down roll bottom roll 23.6kw / screw jack hyd. Cylinder / 100 bar hyd. Cylinder / 100 bar Motor power/ Have a pressure Max Back-up for work roll up roll? down

4- intermesh (roll gap)

4- intermesh (roll gap)

Spiral no.-1

3/4

340mm

360mm

440mm

80mm

No

No 2.2kw/ screw jack 2.2kw/ screw jack

Spiral no.-2

2/1

340mm

350mm

400mm

60mm

No

2/3

340mm

360mm

340mm

00mm

Yes

Spiral no.-3

2/1

340mm

350mm

400mm

60mm

No

2/3

340mm

360mm

340mm

00mm

Yes

1st leveller back up roll

2nd leveller back up roll

2- pitch Upper wrok 3- center of back up between roll & bottom work roll bottom work bottom roll & back up Diameter roll & back up back up roll roll roll

4- intermesh (roll gap)

Remarks

Upper wrok roll back up & bottom roll back up Diameter roll

2- pitch 3- center of between bottom work bottom work roll & back up roll & back up roll roll

4- intermesh (roll gap)

Remarks

Spiral no.-1 Spiral no.-2 Spiral no.-3

No No No 1/2 1/2 190mm 190mm 240mm 240mm

No 236.27mm 236.27mm -