Professional Documents
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A large quantity of pipe to flange joints has to be fabricated for a piping cont
ract. The pipe outer diameter is 245 mm with a wall thickness of 5.8 mm. The pip
e material is 316L stainless steel. The flange has a thickness of 25 mm; an oute
r diameter of 335 mm and is forged from 0.25% carbon steel.
Discuss the welding procedures that you would employ in the welding of these joi
nts.
Describe in detail, with reference to joint configuration, welding process, cons
umables and equipment, the steps that you would implement to mechanise (automate
) the fabrication process to ensure consistent weld quality. State all assumptio
ns made and motivate your decisions.
ADVANCED WELDING PROCESSES
PIPE: 316 L STAINLESS STEEL PIPE 5.8mm THICK
FLANGE: CARBON STEEL
In the welding of the above mentioned items, I would employ the following:
1 CARBON STEEL (P 1) TO STAINLESS STEEL (P 8) WPS/PQR
2 APPLICABLE WELDER QUALIFICATIONS
3 PREFERABLY A GTAW PROCESS
4 A QUALITY PLAN
1 WELDING PROCEDURE SPECIFICATION
A welding procedure specification (WPS) that addresses all the necessary essenti
al variables regarding the welding of these items should be set up so as to prov
e the contractorâ s competency in the successful execution of the job. The WPS should
be drawn up from a procedure qualification record (PQR). The welders should als
o be qualified to the WPS and be issued with a welder qualification record (WQR)
or welder performance qualification (WPQ). These terms are usually used interch
angeably. These documents are mostly drawn up using the variables outlined in a
code of construction such as ASME IX. Because the welding will be automated to
speed up fabrication and welding time, the WPS/PQR should be set up accordingly.
The WPS should in essence address the differences between manual and automatic
welding paying particular attention to the TECHNIQUE (QW-410), the ELECTRICAL CH
ARACTERISTICS (QW-409) and the JOINT DESIGN (QW-402), all of which could signifi
cantly change from a manual process. The choice of filler material would most pr
obably be a 309 L bare wire, which is mostly used for joining dissimilar metals.
The 309 L has a slightly higher % Cr at about 23-25% than 316 L, thus having a
slightly better corrosion resistance at high temperatures, although 316 L is per
fectly acceptable, itâ s just what I would choose in this instance.
The choice of a groove weld may be the better one mostly for the longevity of th
e WPS since according to ASME IX; groove welds range of qualification covers fil
let welds as well (QW-451). The joint design applicable for welding these flange
s to this pipe would probably be a fillet weld (assuming these are slip-on flang
es).
The automated orbital head can rotate to any angle required for access to the we
ld joint. Although it can be fixed to a chain or track around the pipe, it is ty
pically fixed to a flat position while the pipe can rotate to facilitate the wel
ding of the joint. One could use multiple heads and feeders to do multiple passe
s of weld metal depending on the thicknesses required.
Mostly, companies choose mechanisation over manual welding due to high productiv
ity rates and the â humanâ factor in that there are no industrial relations with machine
y. Therefore the initial setup costs soon start to become economical as the proc
ess implementation eases out.
Also, due to the 5.8mm thickness of pipe, huge deposition rates such as those pu
t down by SAW (Submerged Arc Welding) are not really necessary. GTAW can lay dow
n decent passes at a low heat input which is advisable for the joining of stainl
ess to carbon steels. Another factor would be the speed of the wire. This impact
s on the heat input and the amperage, depending on the machine used. Another imp
ortant factor in automation/mechanisation is the duty cycle. Given a duty cycle
of around 70%, this should increase productivity to around 300%, which is very s
ignificant when costing a job. Being that these items are mainly pipe to flange,
one can assume that there will few, if any, site welds to be made. This is impo
rtant because it may be very difficult to use this process in the field.
The systems are on the market today generally have the following components:
- A weld head which carries and manipulates the torch.
- A power source which provides weld head control and programming, as well as cu
rrent output.
- A remote pendant for system control at a distance from the power source.
- A water recirculation to provide torch and possibly weld head cooling.