TOPICS TO BE COVERED

• WELDING PROCESSES
• SPECIAL WELDING TECHNIQUES
• PRODUCTIVITY
• WELDING CONSUMABLE SELECTION
• BAKING REQUIREMENT
• SWP / WPS / TP
• CONSUMABLE PRICES
• WELDER QLFN. AS PER ASME SEC IX
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 WELDING PROCESSES

FUSION WELDING
• GAS WELDING PROCESS
- OXYACETYLENE WELDING
• ARC WELDING PROCESS
- SMAW, GTAW ( TIG ) , SAW, GMAW
( MIG ), PAW, ESW,
• HIGH ENERGY BEAM WELDING
- EBW, LBW

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ARC WELDING PROCESSES

• HEAT SOURCE
- ARC

• SHIELDING OF LIQUID METAL

1. FLUX - SLAG SYSTEM :

SiO2, Al2O3, TiO2, CaO, MnO,
CaF2, MgO

2. GAS SHIELDING

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 FUNCTIONS OF SHIELDING

• PROTECTS WELD POOL FROM OXIDATION

• DEOXIDATION

• ALTERS METALLURGICAL PROPERTIES

• IMPROVE BEAD PROFILE

• ALLOYING ADDITIONS
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SPECIAL TECHNIQUES OF SUBMERGED
ARC WELDING

• THIN WIRE SAW 0.8 DIA --1.6 MM

DIA, SOME TIMES WITH OSCILLATION
FOR WELD OVERLAYS.

• STRIP CLADDING USING ELECTRODE IN

FORM OF STRIP (50 - 75 MM WIDE X 0.4 -
0.5 THK ) .

• NARROW GAP SAW FOR JOINT WITH

THICKNESS>75 MM.
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SPECIAL TECHNIQUES OF SUBMERGED
ARC WELDING

• TANDEM SAW USING TWO WELDING

HEADS ( LEADING DCEP -- TRAILING
AC ) HAVING COMMON WELD POOL .

• TWIN HEAD SAW --- T - JOINTS .

• TWIN WIRE SAW.

• LONG STICK OUT SAW ETC .

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NARROW GAP SUBMERGED ARC WELDING - LONG. SEAM
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DC-AC TANDEM SAW - NUB BUILD-UP IN DHDS REACTORS
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DC-AC TANDEM SAW - NUB BUILD-UP IN DHDS REACTORS

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CIRC. SEAM WELDING IN
TANDEM (E.O. REACTOR)

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TWIN HEAD SAW T-FRAME
WELDING

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SAW NOZZLE WELDER

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SAW NOZZLE WELDER IN DHDS
REACTORS

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2G SAW WELDING STATION
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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)
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ESSC USING 120 X 0.5MM STRIP - DHDS
REACTORS

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BEAD OVERLAP IN ESSC USING 120 X 0.5MM STRIP

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ESSC ON DHDS REACTOR D. END
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FCAW I.D. OVERLAY AT LFS

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 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

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FCAW I.D.
OVERLAY

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GTAW PIPE I.D. OVERLAY

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END SHIELD OUTER ASSLY.-SUPPORT RIB # BASE
PLATE JOINTS

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END SHIELD OUTER ASSLY. SUPPORT RIB # BASE PLATE JOINTS
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 40
END SHIELD OUTER ASSLY. - SUPPORT RIB # BASE PLATE JOINTS
PULSE-GTAW ARRANGEMENT FOR SUPPORT RIB # BASE PLATE JOINTS
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PULSE GTAW IN PROGRESS - END SHIELD SUPPORT RIB # BASE PLATE WELDING42
END SHIELD CSTS # LATTICE TUBE BI-JUNCTION WELDING

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END SHIELD CSTS # LATTICE TUBE BI-JUNCTION WELDING

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INNERSHIELD WELDING

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THIN WIRE SAW OVERLAY WITH OSCILLATION
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THIN WIRE SAW OVERLAY WITH OSCILLATION

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SMAW DOUBLE WELDER TECHNIQUE

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FCAW IN VERTICAL
POSITION (3G)

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SEMI0AUTOMATIC GTAW TORCH ARRANGEMENT FOR LINER WELDING
ON UREA REACTOR

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SEMI-AUTOMATIC GTAW LINER WELDING ON UREA REACTOR 51
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 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
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 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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 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) 56
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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.

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 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.
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 PREHEAT
MATERIAL THICKNESS PREHEAT TEMPERATURE
( mm ) ( Deg. C )
(A) CARBON STEEL UP TO 25 10
SA 516 GR60 / 70 26 - 50 75
SA 106 GRB 51 - 75 100
SA 537 CL1 76 - 100 125
100 AND ABOVE 150
(B) LOW ALLOY STEEL UP TO 25 100
( P3 GR1,2 ) 26 - 50 125
SA 335 P1 51 - 75 150
SA 182 F1 76 - 100 175
SA 204 GRB 100 AND ABOVE 200
(C) LOW ALLOY STEEL UP TO 25 125
( P4 GR1 ) 26 - 50 150
SA 182 GRF11 51 - 75 175
SA 335 P11 76 - 100 200
SA 387GR12 CL2 100 AND ABOVE 225
(D) LOW ALLOY STEEL UP TO 25 150
( P5A GR1 ) 26 - 50 175
SA 182 GRF22 51 - 75 200
SA 213 T22 75 AND ABOVE 225
SA 387GR22 CL2
SA 335 P22
REFER SHOP WELDING PLAN / WPS FOR ACTUAL PREHEAT
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 IMPACT WPS

IMPORTANT POINTS
• INTERPASS TEMPERATURE ( MAX. )
• MIN. BEAD LENGTH PER ELECTRODE
DIA . LENGTH MIN. BEAD LENGTH
(mm) (mm) (mm) (Inch.)
2 .5 350 50 (2)
3.2 450 75 (3)
4.0 450 125 (5)
5.0 450 275 (11)
• WEAVING MAX. 3.0 TIMES OF ELECTRODE DIA..
• 3G POSITION - MOST IMPORTANT
• CLEANING JOINTS BEFORE WELDING
• COMPLETE RUST REMOVAL
• INTERPASS CLEANING.
• UNIFORM PREHEATING TO AVOID CRACKS. 65
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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
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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. 72
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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 75
 WELDER QLFN. - ASME SEC.IX

WELDING TYPE
• MANUAL / SEMI-AUTOMATIC
• MACHINE
• AUTOMATIC

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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
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 WELDER QLFN. - ASME SEC.IX

Base Metals for Welder Qualification Qualified Production Base Metals

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

or P No. 4X P No. 4X and unassigned metals of similar
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

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 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 Only the same F Number as was used 80

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 81

 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

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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

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 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 7/8 o.d. and over. 84

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