THIS STANDARD IS: STD NO : 50-83-02

Updated INDEX : 9.1.9

DESIGN STANDARD DATE : 21 DEC 1999
OWNER : 9814
PAGE : 1 OF 6

SUBJECT : SPECIFICATION FOR ARC WELDING AND CAPACITOR DISCHARGE

WELDING OF STUDS AND PINS TO NON-PRESSURE PARTS AND/OR
PRESSURE PARTS

PURPOSE : To provide arc welding and capacitor discharge welding procedures,

welder qualifications equipment sources and quality control procedures.

REMARKS: This Standard to be effective immediately.

NOTES: 1. See Page 2 for Versions.

2. Changes to the text are indicated by vertical bars.

DESIGN PRODUCT ENGINEER

REVIEWED BY: H. SCHORTMAN
APPROVED FOR CONTENT: D. PALMER
APPROVED FOR DISTRIBUTION: T. MISKELL
NON-PRESSURE PARTS ENGINEERING - 9814
MANAGER
NON-PRESSURE PARTS ENGINEERING - 9814
PROGRAM MANAGER
STANDARDS ENGINEERING - 8126

This document contains proprietary data and shall not be reproduced

or disclosed without the permission of ALSTOM Power Inc.
SUBJECT: Specification for Arc Welding and Capacitor STD NO. : 50-83-02
Discharge Welding of Studs and Pins to INDEX : 9.1.9
Non-Pressure Parts and/or Pressure Parts DATE : 21 DEC 1999
OWNER : 9814
PAGE : 2 of 6
______________________________________________________________________________________________________

UNITS: o ENGLISH; o METRIC; n BOTH; o NONE

PRODUCT LINES: CHECK THE PRODUCT LINES THAT THE STANDARD IS APPLICABLE TO

o ALL; n A = CONTROLLED CIRC. BOILERS n B = SUPERCRITICAL BOILERS

n C = VU40 AND VU60 BOILERS o D = STANDARD BOILERS (D AND VP)
o E = FLUIDIZED BED BOILERS (CFB) n F = NATURAL CIRC. BOILERS (UTILITY)
o P = BOWL MILLS (PULVERIZERS) o R = CHEMICAL RECOVERY BOILERS
o H = HEAT RECOVERY STEAM GENERATORS (HRSG)
o S = SERVICES (AFTER MARKET USE)

Versions

Ver. 1 – Added Paragraphs 1.3 and 3.1;

renumbered Paragraphs 3.2 through 3.11;
added Paragraphs 7.0 and 8.0.

Ver. 2 – Updated Standard format; added

Metric; deleted Paragraph 2.0 and renumbered
subsequent Paragraphs; revised Table.
SUBJECT: Specification for Arc Welding and Capacitor
Discharge Welding of Studs and Pins to
Non-Pressure Parts and/or Pressure Parts
______________________________________________________________________________________________________
1.0 Scope
1.1 This specification covers the method
of qualifying the procedure and the welders for
Capacitor Discharge (CD) or Stored Arc (SA) and
arc welding of studs and pins to non-pressure
parts and pressure parts.
1.2 This specification also covers the
procedure to be followed to insure minimum
requirements for adequate quality control.
1.3 Do not arc weld pins or studs to
pressure parts.
2.0 Procedure and Procedure
Qualification for Arc Welding
2.1 Do not arc weld pins or studs to
pressure parts.
2.2 Required current ranges listed in
Table 1 are for mild steel and stainless steel pins
or standard studs with normal conditions of
primary power can cable lengths.
2.3 Lift
ô The gun lift should be approximately
0.080” (2 mm) for diameters of 1/2” (12.7 mm)
and smaller and 0.100” (2.5 mm) for larger
diameters.
2.4 Plunge
ô Set the adjustable leg so that the pin
or stud protrudes approximately 1/8” (3.2 mm)
beyond the arc shields on pins or studs up to 1/2”
(12.7 mm) in diameters, and 3/16” (4.8 mm)
beyond the arc shields for larger diameters.
2.5 Fluxing
ô Studs or pins with diameters of 5/16”
(7.9 mm) and over are solid fluxed. Below 5/16”
(7.9 mm) diameter, flux is available on request.
STD NO. : 50-83-02
INDEX : 9.1.9
DATE : 21 DEC 1999
OWNER : 9814
PAGE : 3 of 6
Unfluxed studs or pins will require slightly more
welding power than shown in Table 1.
2.6 Base Metal Preparation
The base metal in the area of
welding shall be sufficiently clean to provide an
electric ground. This may be accomplished in
several ways, including wire brushing, grinding,
etc.
2.7 For each different pin or stud
diameter to be welded, weld a pin or stud to a
scrap plate, sheet or bar of the same material to
which the pin or stud is to be welded.
ô 2.8 Place a pipe of sufficient size and
length over the pin or stud to within 1” (25.4 mm)
of the material and apply lateral pressure or force
to the pipe at a point 12” (304.8 mm) (24”
(609.6 mm) from the plate in order to reduce the
force in half on the larger diameter pins or studs)
from the material. Refer to Table 1 for the force
to be applied. If the pin or stud breaks off at the
weld, adjust the setting on the voltage control.
2.9 After the settings are considered
satisfactory, weld 10 pins or studs in succession
without changing the machine settings. Check all
pins or studs as per Paragraph 2.7. All pins or
studs should withstand the force applied without
breaking at the weld.
2.10 Record the settings for use on the
job.
ô 2.11 Do not weld when metal temperature
is below 320 F (00 C).
3.0 Welder Qualification for Arc Welding
of Studs and Pins to Non-Pressure
Parts
Follow the procedure in Paragraph 2.8 to
qualify the welders.
SUBJECT: Specification for Arc Welding and Capacitor
Discharge Welding of Studs and Pins to
Non-Pressure Parts and/or Pressure Parts
______________________________________________________________________________________________________
4.0 Procedure and Procedure
Qualification Capacitor Discharge
Welding
4.1 Connect the welding cables and
control cables between the gun and the welding
unit. When welding mild steel and stainless steel
pins or studs, the welding is always done on
straight polarity (the gun cable being connected
to the negative terminal while the ground cable is
connected to the positive terminal).
4.2 Set the voltage control rheostat to the
minimum position (turn counter-clockwise).
4.3 Plug the unit into any 115 volt AC
outlet of suitable capacity and turn the machine
on.
4.4 Set the voltage control rheostat at
approximately mid-range.
4.5 Insert a pin or stud in the welding
gun (the size and type for which machine settings
are required).
4.6 Prepare a piece of scrap plate, sheet,
bar or tubing of the same material to which the
pin or stud is to be welded. This preparation
consists of cleaning the area where the pin or
stud is to be welded to bare metal by grinding
lightly or powered wire brushing using a stiff wire
wheel.
4.7 Weld the pin or stud to the clean
piece of scrap material making sure the pin or
stud is straight up and down and not tilted.
4.8 Examine the weld area and check for
a complete weld of the head of the pin or stud to
the test piece. There should be a “burnt” mark
around 3600 of the pin or stud head.
4.8.1 If the “burnt” mark is not all the
way around the head, the weld is probably too
cold and the voltage control rheostat should be
increased by 5 volts and another pin or stud
welded.
STD NO. : 50-83-02
INDEX : 9.1.9
DATE : 21 DEC 1999
OWNER : 9814
PAGE : 4 of 6
4.8.2 If the head of the pin or stud has
caused a crater to be formed in the test piece as if
it were pushed into the metal surface or if there is
metal splashed out of the weld area, the weld is
probably too hot and the voltage should be
reduced and another pin or stud welded.
4.8.3 If the weld looks good (having a
“burnt” mark all around the weld), bend the pin
or study until the end touches the test piece. This
should be accomplished with a sharp bend as
near to the welded pin or stud head as possible.
4.8.4 If the pin or stud bends without
breaking off and the weld is still tight, the settings
are to be considered satisfactory.
4.9 After the settings are considered
satisfactory, weld 10 pins or studs in succession to
clean scrap metal as per Paragraph 4.6, welding
as per Paragraph 4.7.
4.9.1 All pins or studs should withstand
the visual and bend test per Paragraph 4.8.4,
without breaking at the weld.
4.9.2 Record the settings for use on the
job.
4.10 Do not weld when metal temperature
is below 320 F (00 C).
5.0 Welder Qualification
Follow the procedure in Paragraph 4.9.1
and 4.9.2.
SUBJECT: Specification for Arc Welding and Capacitor STD NO. : 50-83-02
Discharge Welding of Studs and Pins to INDEX : 9.1.9
Non-Pressure Parts and/or Pressure Parts DATE : 21 DEC 1999
OWNER : 9814
PAGE : 5 of 6
______________________________________________________________________________________________________

6.0 Quality Control (Pressure and Non- 7.2.2 Capacitor Discharge Welded
Pressure Parts Pins or Studs

6.1 Welders are to be specifically If the weld looks good (having a

instructed that they are not, under any
circumstances unless approved by the ALSTOM
Power Inc. Erector in the field, or welding
foreman in the shop, to change machine settings,
cable lengths, or any other condition that could
adversely affect welding.
6.2 The Erector, shop welding Foreman
or a person designated by either, should check
the machine settings before work is started in the
morning and several times during the day. Any
sign of tampering with the equipment or settings
is cause for appropriate action.
7.0 Quality Control (Pressure Parts Only)
”burnt” mark all around the head), bend the pin
or stud until the end touches the material. All
pins or studs should bend without breaking and
the weld should be tight.
7.3 The Erector should notify the
Customer’s Inspector the night before ALSTOM
pin or stud welding is to be done so that the
Inspector will be available without delaying the
job.
7.4 Conducting the test in the presence
of the Customer’s Inspector may be waived only
upon the Customer’s specific request.

7.1 Before work starts in the morning,

the machines should be set and 5 pins or studs
welded to material, the same as that to be welded
during the day. This test shall be done in the
presence of the Customer’s Inspector, in the case
of field welding, and shall be continued as
required to satisfy the Customer that the process
is dependable and satisfactory.

7.2 All of the pins or studs shall be tested

as follows:

7.2.1 Arc Welded Pins or Studs

ô Place a pipe of sufficient size and

length over the pin or stud to within 1”
(25.4 mm) of the material and apply lateral
pressure or force to the pipe at a point 12”
(304.8 mm) (24” (609.6 mm) from the material
to reduce the force by half for the larger diameter
pins or studs) from the material. All pins or studs
should withstand the force applied without
breaking at the weld.
SUBJECT: Specification for Arc Welding and Capacitor STD NO. : 50-83-02
Discharge Welding of Studs and Pins to INDEX : 9.1.9
Non-Pressure Parts and/or Pressure Parts DATE : 21 DEC 1999
OWNER : 9814
PAGE : 6 of 6
_____________________________________________________________________________________________________________________________________________

Table 1

Weld Metal Base Equivalent Pin or Stud Current Range Test Force
Diameter Diameter
Mild Steel Stainless Steel Mild Steel Pins & Studs Stainless Steel
Pins & Studs Pins & Studs Pins & Studs
in. mm in. mm Amps Amps Lbs - Force Newtons Lbs - Force Newtons
0.875 22.2 1 Stud 25.4 1800 - 2200 1975 - 2425 295 1312.2 170 756.2
0.750 19.1 7/8 Stud 22.2 1600 - 1800 1750 - 1975 200 889.6 115 511.5
0.625 15.9 3/4 Stud 19.1 1000 - 1200 1100 - 1325 125 556.0 70 311.4
0.500 12.7 5/8 Stud 15.9 750 - 1050 825 - 1150 70 311.4 40 177.9
0.437 11.1 1/2 Stud 12.7 650 - 750 725 - 825 35 155.7 20 89.0
0.375 9.5 7/16 Stud 11.1 525 - 650 575 - 725 25 111.2 15 66.7
0.312 7.9 3/8 Stud 9.5 450 - 525 500 - 575 15 66.7 10 44.5
0.275 7.0 5/16 Stud 7.9 375 - 500 425 - 550 10 44.5 5 22.2
0.250 6.4 1/4 Pin 6.4 350 - 450 400 - 500 5 22.2 3 13.3
0.217 5.5 1/4 Stud 6.4 325 - 400 350 - 450 5 22.2 3 13.3
0.187 4.7 3/16 Pin 4.8 275 - 350 300 - 400 2 8.9 1 4.4
0.134 3.4 10 Gauge Pin 3.4 200 - 250 225 - 275 1 4.4 0.5 2.2