Welspun Group ||Welspun

WelspunCorp Ltd.| |Pipe

CorpLtd. Division| L-SAW
PipeDivision | L-SAW
Plant
Plant
Anjar
Anjar

COMPARISON OF THREE & FOUR TANDEM WIRES USED FOR SUBMERGED ARC
WELDING OF HEAVY WALL THICK AND LARGE DIAMETER LSAW PIPES

Date :
Welspun Corp. Ltd-India Tuesday, July 07, 2020
 Welspun Group | Welspun Corp Ltd. | Pipe Division | L-SAW Plant Anjar

Content
• LSAW Pipe process flow
• Weld Configuration
• Welding Parameters at Internal SAW
• Welding Parameters at External SAW
• External SAW Chemical Composition
• Comparison of bead profile and Macrostructure of 3 Wire & 4 Wire
• Comparison of Mechanical Properties for 3 and 4 wire external SAW
• CVN - Impact Toughness @ -20°C
• Transverse weld tensile of 3 and 4 wire
• Hardness profile variation across the weld
• Impact variation in 3 and 4 wire at weld profile of external SAW
• Conclusion

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 Welspun Group | Welspun Corp Ltd. | Pipe Division | L-SAW Plant Anjar

LSAW-PIPES
• Use of multiple-arc technology, increase in the deposition rate. This lead to higher
welding speeds.
• To set optimum process parameters in multiple-arc technology is a prerequisite to
comply with the stringent quality demands.

Forming Welding Finishing

Tack Welding Internal SAW External SAW

GMAW Tandem SAW Tandem SAW

• Material : API 5L X-65M PSL 2 having 1219 mm OD x 38.1 mm WT

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 Welspun Group | Welspun Corp Ltd. | Pipe Division | L-SAW Plant Anjar

Weld Configuration - Double V Groove Butt Joint

tQ (Thickness) = 38.10mm, 1 = GMAW;

h1 = 13.0mm, 2 = SAW Internal;
C = 13.0 mm,
h2 = 12.1mm, 3 = SAW External
α 1 = 70°,
α 2 = 70°

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 Welspun Group | Welspun Corp Ltd. | Pipe Division | L-SAW Plant Anjar

Welding Parameter at Internal SAW

Parameter Head 1 (DC) Head 2 (AC 1) Head 3 (AC 2)

Current (A) 1100 975 875

Voltage (V) 34 37 38

Stick Out (mm) 34 36 38

Angle (Deg) -15 0 15

Travel Speed (m/min) 0.7

Filler Metal EG EG EG

Wire Diameter (mm) 4 4 4

3.21 3.09 2.85

Heat Input (kJ/mm)
9.14 (Summation)

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 Welspun Group | Welspun Corp Ltd. | Pipe Division | L-SAW Plant Anjar
Welding Parameter at External SAW

3 Wire 4 Wire

Head1 Head2 Head3 Head1 Head2 Head3 Head4

Parameter
(DC) (AC 1) (AC 2) (DC) (AC1) (AC 2) (AC 2)

Current (A) 1225 950 850 1400 950 800 700

Voltage (V) 34 36 38 34 36 37 39
Stick Out (mm) 34 36 38 40 41 42 43
Angle (Deg) -10 0 12 -10 0 10 20

Travel Speed
0.7 1.0
(m/min)

Filler Metal EG EG EG EG EG EG EG
Wire Diameter
4 4 4 4 4 4 4
(mm)
3.57 2.93 2.77 2.856 2.052 1.776 1.638
Heat Input (kJ/mm)
9.27 8.32

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 Welspun Group | Welspun Corp Ltd. | Pipe Division | L-SAW Plant Anjar

External SAW Chemical Composition

Elements 3 Wire 4 Wire
%C 0.05 0.05
% Si 0.43 0.43
% Mn 1.54 1.60
%P 0.015 0.016
%S 0.003 0.003
% Cu 0.14 0.15
% Ni 0.23 0.24
% Cr 0.05 0.06
% Mo 0.22 0.24
%V 0.005 0.005
% Ti 0.031 0.031
% Nb 0.02 0.02
%B 0.0052 0.0054
% Al 0.026 0.02
%Ca 0.0005 0.0004
%N 0.001 0.001

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 Welspun Group | Welspun Corp Ltd. | Pipe Division | L-SAW Plant Anjar

Comparison of bead profile and Macrostructure of 3 Wire & 4 Wire

Wire Classification 3 Wire 4 Wire

Designation Description 3 Wire 4 Wire

A OD Bead Height (mm) 2.7 2.4
B OD Penetration (mm) 23 22
C ID Bead Height (mm) 1.7 1.7
D ID Penetration (mm) 20 20
E Overlapping (mm) 5–6 4–5
F OD Bead Width (mm) 35 – 36 34 – 35
G ID Bead Width (mm) 33 – 34 33 – 34

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 Welspun Group | Welspun Corp Ltd. | Pipe Division | L-SAW Plant Anjar

Comparison of Mechanical Properties for 3 and 4 wire external SAW

Properties 3 Wire 4 Wire

UTS (Mpa) 632.1 – 644.42 615.46 – 626.38

HV10 - WELD HAZ BASE WELD HAZ BASE

250 Max. 224-232 208-216 192-195 218-224 204-211 188-198

CVN@ WELD HAZ WELD HAZ

-20°
(Avg.) 114 413 160 438
(J)

CVN@
-20° 412, 410, 440, 445,
121, 116, 104 153,154,174
(Ind.) 418 430
(J)

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 Welspun Group | Welspun Corp Ltd. | Pipe Division | L-SAW Plant Anjar
CVN - Impact Toughness @ -20°C

Base HAZ Weld

4 Wire 3 Wire 4 Wire 3 Wire 4 Wire 3 Wire

463 462 440 412 153 121

454 450 445 410 154 116

458 456 430 418 174 104

462 455 438 413 160 114

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 Welspun Group | Welspun Corp Ltd. | Pipe Division | L-SAW Plant Anjar

Transverse weld tensile of 3 and 4 wire

650

640
TW T (M Pa)

630

620

610

600

3 Wire 4 Wire

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 Welspun Group | Welspun Corp Ltd. | Pipe Division | L-SAW Plant Anjar

Hardness profile variation across the weld

232
4 Wire 3 Wire

230

228
A vg. H v 10 kgF

226

224

222

220

218

L C R L C R L C R
Outer Diameter Inter Penetration Inner Diameter

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 Welspun Group | Welspun Corp Ltd. | Pipe Division | L-SAW Plant Anjar

Impact variation in 3 and 4 wire at weld profile of external SAW

500 Ind. 1 Ind. 2 Ind. 3
Avg.

450

400
C VN @ -20C
o

350

150

100

4 Wire 3 Wire 4 Wire 3 Wire 4 Wire 3 Wire

Base HAZ Weld

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 Welspun Group | Welspun Corp Ltd. | Pipe Division | L-SAW Plant Anjar

Conclusion
• About 30% increase in welding productivity due to welding speed in four wire
system w.r.t. three wire.

• Overall weld profile is much better - with lesser bead height and width; in case of
four wires.

• Resultant almost 10 % low heat input, has led to improved toughness of the weld
with optimized weld tensile strength and low hardness in weld a better option for
the low temperature.

• Optimizing the welding parameter in case of 4 wire with similar weld deposition
rate helped in attaining similar weld chemical composition and enhanced weld
toughness.

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 Welspun Group | Welspun Corp Ltd. | Pipe Division | L-SAW Plant Anjar

L-SAW Plant – Anjar Unit

Tuesday, July 07, 2020 Welding Consumable Selection Flow Chart 15