L&T Construction

Metallurgical & Material Handling SBG

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 Topics to Discuss

Types of Pipe Material

Types of Welding Process
Types of Welding Consumable
Types of Welding Positions
Types of common Weld defects
Types of basic Non-Destructive Testing
Post weld heatreatment
on-Destructive Testing

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SEAM PIPE

ERW-ELECTRIC RESISTANCE ARC WELDING

EFSW-ELECTRIC FUSION SUBMERGED ARC WELDIN

SPRIAL WELDED PIPE

GI COATED PIPE
It is used in low pressure line like water, air etc.

SEAMLESS PIPE

It is defined by “SCHEDULE NO” according to wall

thickness. Used in high pressure line like steam ,oil,
gas, service line.
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Pipe Material Specification for UAIL Project

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ASME SEC-II PART-A

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PSL stands for Product Specification Levels.

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Welding Process

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Manual metal arc welding process (MMAW)
or
Shielded Metal arc welding (SMAW)

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 Limitations of SMAW Process

 Less metal deposition – Cannot be used for heavy fabrication

welding
 Requires more number of welders
 Control of distortion is difficult
 Continuous & automatic Welding is not possible
 More strain to the welders

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 Shieling

Covering the electrode

RESULT
> Hydrogen and carbon di-oxide are released.
> Slag forms a protective covering.

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Gas Tungsten arc welding process (GTAW)

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 Limitations of GTAW Process
 Higher equipment cost as compared to SMAW .
 Higher operating cost due to costly shielding gas like Ar, He
etc.
 Lower deposition rates and welding speeds than GMAW,
SAW etc.
 Requirement of skilled welder
 Less economical than consumable electrode arc welding for
thick sections greater than 3 mm
 Problematic in drafty environments because of difficulty in
shielding the weld zone properly

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 TIG WELDING ELECTRODES
Size of Electrodes
Dia. - 0.3, 0.5, 1.0, 1.6, 2.0, 2.4, 3.0, 3.2, 4.0, 4.8, 5.0, 6.4, 8.0 mm
Length - 50, 75, 150, 175, 305, 455, 610 mm
Types of Electrodes and Color Code

AWS Colour * Alloying Alloying Weight ( % ) of

Classification Element Oxides Alloying Oxide
EWP Green ---- ---- ----
EWCe-2 Orange Cerium CeO2 1.8 – 2. 2
EWla-1 Black Lanthanum La2O3 0.8 – 1. 2
EWla-1.5 Gold Lanthanum La2O3 1.3 – 1. 7
EWla-2 Blue Lanthanum La2O3 1.8 – 2. 2
EWTh-1 Yellow Thorium ThO2 0.8 – 1. 2
EWTh-2 Red Thorium ThO2 1.7 – 2. 2
EWZr-1 Brown Zirconium ZrO2 0.15 – 0.4 0

Tungsten melting point : 3422°C

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Shielding Gases for TIG Welding

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 Welding Consumable
All those things used up in the production of a weld

Though generally, we refer to those element that are used in a

specific welding process

Electrodes, Wires, Fluxes and Gases

 Covered electrode

Three Generic Types of Electrode Covering:

Rutile

Cellulosic

Basic
 Covered electrode treatment

Keep dry. May be dried up to

Rutile. General purpose electrodes. 120°C- No baking!

Cellulosic: Developed for positional Use straight from the box – Do Not
welding in the vertical down position. require baking or drying!
Stove pipe welding.

May require baking to achieve low

Basic. Low hydrogen electrodes. hydrogen content! Vacuum packed
Used for high quality welds. used straight from box within 4
hours.
 BAKING PROCEDURE
Basic electrodes (E-7018) Baking in oven 1- 2 hours at 250-
300°C (As per Manufacture
Recommendation)

Limited number of rebakes! After baking, maintain in

oven at 120-150°C

If not used within 4

Use from quivers at Weld
hours, return to oven
120-100°C
and rebake!
Unidentified / damaged / improperly maintained electrodes shall be
removed from all working areas and disposed for temporary purpose
 AWS A5.1 Electrodes
E 70 1 8
Covered Electrode

Tensile Strength (p.s.i)

Welding Position

Flux Covering
 AWS A5.18 Filler Material
ER 70 S 2
Designate an electrode/rod (ER)
or only an electrode (E)
Minimum UTS of weld metal (ksi)

Solid (S)

Chemical composition of
the solid wire or of the
weld metal in case of
composite electrodes
 Welding Consumable (UAIL Project)

Material Electrodes / Filler Tungsten Shielding Gas Backing /Purging

ASTM A 53 GR.B ER-70S2/E-7018 EWth2 99.9% Argon NA

ASTM A 106 GR.B ER-70S2/E-7018 EWth2 99.9% Argon NA

API5L GR-B ER-70S2/E-7018 EWth2 99.9% Argon NA

A312TP316 ER-316L EWth2 99.9% Argon 99.9% Argon

A312TP304 ER-308L/316L EWth2 99.9% Argon 99.9% Argon

DUPLEX (UNS S31803) ER-2209 EWth2 99.9% Argon 99.9% Argon

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Welding Positions

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Pipe Welding Positions

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Plate Welding Positions

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Essential Variables

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Thickness Qualification Range

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Welding Defects

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What is Defect ?

• Defect is nothing but the presence of

certain unwanted characteristics which may
affect the desired performance of the
product

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 Common welding Defects

1. Cracks 2. Lack Of Fusion.

3. Slag 4. Porosity.
5. Pinhole 6. Piping .
7. Undercut 8. Overlap.
9. Lack Of Penetration 10. Excess Penetration.
11. Spatters 12. Suck Back.
13. Burn Through 14. Uneven Bead.

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 Crack
Cause Remedy
1) Wrong Consumable 1) Use Right Electrode
2) Wrong Procedure 2) Qualify Procedure
3) Improper Preheat 3) Preheat Uniformly

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 Slag
Cause Remedy
1) Inadequate Cleaning 1) Clean each bead
2) Inadequate Current 2) Use Right Current
3) Wrong Electrode angle 3) Train / Qualify welder
4) Improper bead placement 4) Train / Qualify Welder

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 Porosity
Cause Remedy
1) Damp Electrode. 1) Bake the electrodes
2) Damaged coating. 2) Replace the electrodes
3) Wet surface of BM. 3) Clean & warm the BM
4) Rusted core wire. 4) Replace the electrodes

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Undercut
Cause
1) Excess Current
2) Excess Voltage
3) Improper Electrode angle
4) Eccentric Coating
Remedy
1) Reduce the Current
2) Reduce Arc length
3) Train & Qualify the Welder
4) Replace the electrode
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 Excess Penetration*
Cause Remedy
1) Excess root opening 1) Reduce root gap
2) Excess Current 2) Reduce Current
3) Inadequate root face 3) Increase Root face
4) Wrong Electrode angle 4) Train / Qualify Welder

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 Spatters
Cause Remedy
1) Excess Current 1) Reduce to Right Current
2) Excess Voltage 2) Reduce Arc length
3) Wrong Polarity 3) Correct the polarity
4) Wet Electrodes 4) Use Baked electrodes
5) Rusted BM surface 5) Clean BM surface
6) Rusted Core wire 6) Replace the electrodes
7) Eccentrics coating 7) Replace the electrodes

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Non-Destructive Testing

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 Non-Destructive Testing

Four basic NDT methods

Magnetic particle inspection (MT)
Dye penetrant inspection (PT)
Radiographic inspection (RT)
Ultrasonic inspection (UT)
Penetrant Testing

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 Penetrant Testing
Advantages Disadvantages
 Simple to use  Surface breaking defect only
 Inexpensive  little indication of depths
 Quick results  Penetrant may contaminate
 Can be used on any non- component
porous material  Surface preparation critical
 Portability  Post cleaning required
 Low operator skill required  Potentially hazardous
chemicals
 DPT Requirement as per piping specification

Dry Penetrant testing

 Dry Penetrant testing
Controlling Documents:
Acceptance Criteria of
ASME Sec-VIII Div-1 Carbon steel (Branch
Stainless steel
Joints)

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Magnetic particle inspection (MT)

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Collection of ink
particles due to
leakage field

Electro-magnet (yoke) DC or AC

Prods DC or AC
 Magnetic Particle Testing

Advantages Disadvantages
• Simple to use • Surface or slight sub-surface
• Inexpensive detection only
• Magnetic materials only
• Rapid results
• No indication of defects depths
• Little surface preparation
required • Only suitable for linear defects
• Possible to inspect through • Detection is required in two
thin coatings directions
Radiographic Testing

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 Radiographic Testing

X – Rays Gamma Rays

Electrically generated Generated by the decay of
unstable atoms
 Radiographic Testing
Source

Image quality indicator

Radiation beam

10fe16

Radiographic film Test specimen

 Radiographic Techniques
Single Wall Single Image (SWSI)
• film inside, source outside
Single Wall Single Image (SWSI) panoramic
• film outside, source inside (internal exposure)
Double Wall Single Image (DWSI)
• film outside, source outside (external exposure)
Double Wall Double Image (DWDI)
• film outside, source outside (elliptical exposure)
 Single Wall Single Image (SWSI)

Film

Film

IQI’s should be placed source side

 Single Wall Single Image Panoramic

Film

• IQI’s are placed on the film side

• Source inside film outside (single exposure)
 Double Wall Single Image (DWSI)

Film

• IQI’s are placed on the film side

• Source outside film outside (multiple exposure)
• This technique is intended for pipe diameters over 100mm
 Double Wall Double Image (DWDI)

Film

• IQI’s are placed on the source or film side

• Source outside film outside (multiple exposure)
• A minimum of two exposures
• This technique is intended for pipe diameters less than 100mm
 Radiography

GAMMA SOURCES
Isotope Typical Thickness Range
• Iridium 192 10 to 50 mm (mostly used)
• Cobalt 60 > 50 mm
• Ytterbium < 10 mm
• Thulium < 10 mm
• Caesium < 10 mm

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 Radiography
Advantages
• Permanent record
• Little surface preparation
• Defect identification
• No material type limitation
• Not so reliant upon operator
skill
• Thin materials
Disadvantages
• Expensive consumables
• Bulky equipment
• Harmful radiation
• Defect require significant
depth in relation to the
radiation beam
• Slow results
• Very little indication of depths
• Access to both sides required
Post weld heatreatment

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 purpose of post weld heat treatment

In order to ensure the material strength of a part is

retained after welding, a process known as Post
Weld Heat Treatment (PWHT) is regularly
performed. PWHT can be used to reduce residual
stresses, as a method of hardness control, or even to
enhance material strength.

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 150°c per Hours

300°c

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 Post weld heatreatment Requirement as per piping specification

 Post Weld PWHT

Heatreatment
Controlling Documents:
Piping specification & Piping Class-K Piping Class-H Piping Class-L
B31.3

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Post weld heatreatment

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Thank you

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