Graaf Welding Consumables for Girth Welding of Pipelines

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Welding consumables for girth welding of pipelines


Henk de GraafIndustry segment manager - Pipeline

Brands; T-put & Böhler


Company introduction

High Performance Metals

Welding Consumables

Precision Strip

Special Forgings

Electrodes, wires and fluxes

Soldering and brazing materials

Finishing Chemicals

Long products of Tool Steel

High Speed Steel

Nickel base alloys

Bimetal Strip

Cutting and creasing rules

Saw blade steel

Valve steel

Surgery knifes

Aircraft structural parts

Turbine blades

Special parts


Global Production and Sales Network

Our own worldwide distribution network, excluding local partners and agents.

BWG Production Company (5 Europe, 2 Asia, 2 Americas)

BWG Sales Company (17 own sales offices)


Main brands for pipeline consumables

Production Hamm-Germany

Production Kapfenberg-Austria

* MIG/MAG solid wires (GMAW)

* TIG rods (GTAW)

* Wires & fluxes (SAW)

- Stick electrodes (SMAW)

- Flux cored wires (FCAW)


Trends in welding

Efficiency of welding processesManual welding - stick electrodes

Root passVertical down welding

(semi) automatic processesMIG/MAG - solid wireFCAW - flux cored wireSAW - wire & flux combinations

Reduce downtimeSlag removal

Changing of stick electrodes

Grinding activities


Stick electrodes

Basic vertical upFOX EV PIPE, FOX EV 60 PIPE, FOX EV 70 PIPE

EV PIPE series are thin coated basic electrodes (no additional metal recovery) that allows the use of thicker diameters, specialty for root pass welding.

FOX EV 50, FOX EV 60, FOX EV 63, FOX EV 65, FOX EV 70

Basic coated stick electrodes with metal recovery 115-120% suitable for root pass, specially filling and cap layers.

Cellulosic vertical downFOX CEL, FOX CEL+, FOX CEL Mo, FOX CEL 70-P, FOX CEL 75, FOX CEL 80-P,

FOX CEL 85, FOX CEL 90

Basic vertical downFOX BVD RP, FOX BVD 85, FOX BVD 90, FOX BVD 100, FOX BVD 110, FOX BVD 120

Basic coated electrodes with metal recovery for vertical down welding


Electrode AWS E 7018Böhler FOX EV PIPE ∅ 2.5 x 350 (6-4 and 6-8 o’clock)∅ 3.2 x 350 (from 6 – 12 o’clock) ∅ 3.2 x 350 (remainder) Amperage 120 A Amperage ∅ 2.5... 70-75 A

∅ 3.2... 85-100 A

Tube S 355 N∅ 330 x 10 mm

Root gap 2.5 mmRoot face 2.5 mm

19,08

12 h

6 h

5G/PFd.c. positive

12 h

6 h10,25

12 h

6 h12 h

6 h

5G/PFd.c. negative

Root pass in 10.25 minutes Root pass in 19.08 minutesTime saving 46 % Almost double the welding time

EV Pipe - time saving for root pass


Efficiency by type of electrode (smaw)

Dep

ositi

on R

ate

[kg/

h]

Welding current [A]

Basic covered (up hill)Basic covered (down hill)Cellulose covered (down hill)


Time for root welding of 48“ pipe by type of electrode (according to Bruehl and Muesch)

Tim

e in

min

utes

320*

150*

65*

Welding time

Non-productive time

24

20

16

12

8

4

4 Welders

Coating: cellulosic basic basicElectrode Ø: 4,0 mm 3.25 mm 2,5 mmPosition: vertical down vertical down vertical up

* Welding speed in mm/minrelation to one welder


Avoiding hydrogen risk with cellulosic

cellulosic rutile basicType of coating

Hyd

roge

nco

nten

tml/1

00g

depo

sit

60

50

40

30

20

10


In fracture recognizable as brittle fracture spot

In longitudinal section recognizable as cracks

preferred area

Appearance of hydrogen inducted faults


1…sheet (anchored on base plate)

2…test joint

3…specimen

4…firm base plate

After welding and exposing for 24 hours (20oC) each trial plate will be removed from the heavy plate section

1 12

3

Research for welded joints by a bead bend test


Completely hindered shrinkageCompletely hindered shrinkageBevel preparation (VBevel preparation (V--6060°°))Preheat temp. = Preheat temp. = interpassinterpass temptemp..

Investigation program:Investigation program:wall thickness of welding jointwall thickness of welding jointInterpassInterpass temperaturetemperatureStrength level of CELStrength level of CEL-- electrodeselectrodes

inspection scope:inspection scope:30 joints per strength level (electrode)30 joints per strength level (electrode)4 strength levels 4 strength levels

Test plates


After annealing After annealing (250 (250 °°C/16 hours) the test C/16 hours) the test specimen is bent, in order to specimen is bent, in order to make micro cracks visiblemake micro cracks visible

Bending of test specimen


Böhler Fox CEL 90 (AWSE 9010/EN E50C), welding position: PGwall

thicknessinterpass

temperature

20°C

15 mm80°C

120°C

9 mm

20°C

80°C

120°C

6 mm

20°C80°C120°C

Visual identifications of the bended specimens


0

20

40

60

80

100

120

140

160

5 10 15 20 25wall thickness [mm]

inte

rpas

s te

mpe

ratu

re [o C

]

E 9010E 8010E 7010E 6010

Relation between interpasstemperature and wall thickness


Mechanical properties vertical downCellulosic – Basic stick electrodes


Tens

ilest

reng

th[N

/mm

²]

900

800

700

600

500


Tens

ilest

reng

th[N

/mm

²]

900

800

700

600

500

Tens

ilest

reng

th[N

/mm

²]

900

800

700

600

500


Application vertical down electrodes

Pipe grade Cellulosic vertical down / root-fill-cap Basic vertical down / …-fill-cap

FOX CEL FOX CEL 85 FOX CEL 90 FOX BVD 85 FOX BVD 90 FOX BVD 100 FOX BVD 110 FOX BVD 120

E6010 * E8010 * E9010 * E8045-P2 * E9018-G E10018-G E11018-G E12012-G

X42 / L290MB

X46 / L320M

X52 / L360MB

X56 / L385M

X60 / L415MB root pass




X100 / (L690)

(X110)

* contains <1% Ni Several possibilities for root pass


Electrodes that are tested under…..

…..all circumstances!


Vergleich der Abschmelzleistung:Stabelektrode, rutil- und basisch umhüllt, Massiv- und Fülldrahtelektrode

60 80 100 120 140 160 180 200 220 240 260 280 300

Stromstärke [A]

0

1

2

3

4

5

6

Abs

chm

elzl

e ist

ung,

Sch

wei

ßgut

[kg/

h]

Massivdraht

bas. ELø 3,2

rut. ELø 3,2

rut. ELø 4,0

bas. ELø 4,0

~ ~

FDR: Thyssen TG 50 C Thyssen RV 72Thyssen TG 50 M Thyssen RV 71

ø 1,2ø 1,0

manuellerBereich

vollmasch.Bereich

Schweißpos.: steigendKontaktrohrabstand: 15 mmEinschaltdauer: 100%

FCAW metal cored -> rutile cored

Compare of processes in vertical up position!


Changes over the last decades


Solid wire - narrow gap - vertical down


Wire types (T-put brand)

Most of our pipeline wires are micro alloyed and designed for high quality automatic welding of pipelines. An optimum balanced alloying concept ensures good weld metal properties to fulfill the high requirements in the on- & offshore pipeline industry.

Union K 52 S up to X 65

Union K 56 S up to X 70

Union K Nova up to X 70 – designed for pure CO² shielding gas

Union K Nova Ni up to X 80 – 0,9% Ni for high toughness properties

Union NiMo 80 X 80 pipe material.

The wire selection is depending on several aspects - as;base material, bevel preparation, welding process and overmatching requirements.


Main aspects with solid wire

Suitable for automatic welding.

Small bevel (narrow gap).

High traveling (welding) speed.

DC polarity or pulse.

Fast process for girth welding.

No moisture pick up from environment.

Main disadvantage is possible lack of fusion


Flux cored wire compared to solid

Difference & Benefits Stable arc / less spattering

All positions

Spray arc at low Amps. (180A)

Relative low heat input

Deposit rate / welding speed

Adding alloying elements

Less chances lack of fusion

Strip / Tube

Core:- Alloying elements

- Slag formers / metal powder


Flux cored wires for higher strength materials

Böhler TI 70 PIPE-FD

Tubular wire, micro alloyed.

Pipe steels:L415MB - L485 MB (L555 MB)

X 60 - X 70 (X 80)

Mechanical properties – all weld metal

Yield >550 N/mm²

Tensile 640-820 N/mm²

Elongation >18%

Impact values >47 Joule (-40°C)

Böhler TI 80 PIPE-FD

Tubular wire, micro alloyed.

Pipe steels:L485 MB - L555 MB

X70 - X80

Mechanical properties – all weld metal

Yield >690 N/mm²

Tensile 770-940 N/mm²

Elongation >17%

Impact values >47 Joule (-40°C)

NEW in our program!


Practical application TI 70 PIPE-FD

L 415 MB - 24” - 13.5mm


Mechanical properties welded joint

Strength properties requirement

Yield >525 N/mm² min. 469

Tensile >600 N/mm² min. 572

Elongation >19 % min. 18

Impact values (-20° C)

Centre weld >85 Joule min. 40

Hardness (HV10)

Root area 190-180-190 max. 275

Cap area 190-220-200 max. 325


TI 70 PIPE-FD ; Properties reached onX 70 (L480 MB) 48” 15.9mm

Strength propertiesYield >580 N/mm²Tensile >670 N/mm²Elongation >20 %

Impact values (-20° C)

Cap >70 Joule

Hardness (weld) (HV10)

Root area 214-211-211Cap area 225-215-218

CTOD weld centre line (-20° C)

0.11 - 0.12 - 0.13


SAW – wire flux combinations

Only horizontal position.

Deep penetration and fusion with base material. *

High deposit rate.*

Tandem process (2 wires)

Higher wall thickness.

Excellent mechanical properties.* Due to relative high parameters

Prefab/double joint applications


Schematic overview


Possible SAW combinations

T-PUT Submerged Arc - SAW

Wire FluxAPI 5 L-92

EN 10208-2 DIN 17172 AWS A5.17 / 5.23 AWS A5.17 / 5.23

A -X52 L360MB StE 360.7 (TM)Union S2 EM 12

Union S3 Si EH 12K UV 421 TT F7A6-EM12 UV 421 TT F7A8-EH12K

X56 L385MB StE 385.7 (TM)Union S3 Si EH 12K

UV 421 TT F7A8-EH12K

X60 L415MB StE 415.7 (TM) Union S3 Si EH 12KUnion S2 NiMo 1 ENi1

UV 421 TT F7A8-EH12K UV 421 TT F8A8-ENi1-Ni1

X65 L450MB StE 445.7 (TM)Union S2 NiMo 1 ENi1

Union S3 NiMo 1EG (EF 3 mod.)

UV 421 TT F8A8-ENi1-Ni1 UV 421 TT F9A8-EG-F3

X80 L555MB StE 550.7 (TM) Union S3 NiMo 1 EG (EF 3 mod.) UV 421 TT F9A8-EG-F3

Base material


Thanks for your attention !

For information concerning our complete program and possibilities of welding consumables for pipeline or other applications, please feel free to contact us.

www.bohlerweldinggroup.com

http://www.bohlerweldinggroup.com/

Graaf Welding Consumables for Girth Welding of Pipelines

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