WeldingX80 100 ME April 2011 PDF

WELDING CONSUMABLES FOR PIPELINE CONSTRUCTIONS WITH FOCUS ON LHVD ELECTRODES FOR X80 AND X100
MANFRED HOEFER, Technical Regional Manager
ME, April 2011
Manfred Hfer
Welding of X80/100
April, 2011
We are the World of Welding Solutions.
Content of presentation Trends in welding Applied welding processes Consumption of welding consumables Developments in pipe steel grades Distinctive features of CEL vs. LHVD Economical aspects Welding of X80 and X100 pipes with focus on LHVD Conclusion
Manfred Hfer
Welding of X80/100
April, 2011
Trends in welding Reduction of projects costs realized due to:

More efficient welding process
- MIG/MAG welding - Flux cored wire welding - Submerged arc welding - Vertical down welding instead of vertical up
Higher deposition rates

- Welding with Low Hydrogen Vertical Down instead of Cellulosic
Base metal
- High tensile steel
Automation - Increasing the effective arc on time Reduction of welding downtimes

- Slag removal - Spatter removal - Grinding activities - Less pickling work (Flux cored SS wires)
Manfred Hfer
Welding of X80/100
April, 2011
Content of presentation Trends in welding Applied welding processes Consumption of welding consumables Developments in pipe steel grades Distinctive features of CEL vs. LHVD Economical aspects Welding of X80 and X100 pipes with focus on LHVD Conclusion
Manfred Hfer
Welding of X80/100
April, 2011
Welding processes in pipeline girth welding
SMAW GMAW FCAW SAW
vertical up vertical up horizontal
vertical down vertical down vertical down
Manfred Hfer
Welding of X80/100
April, 2011
Content of presentation Trends in welding Consumption of welding consumables Developments in pipe steel grades Distinctive features of CEL vs. LHVD Economical aspects Welding of X80 and X100 pipes with focus on LHVD Conclusion
Manfred Hfer
Welding of X80/100
April, 2011
Welding consumable consumption

China + Hong Kong North America Asia + Oceania Korea Central+Southamerica Africa Europe Japan Russia+CIS India Middle East Taiwan
2500 2000
1000 tonns
1500 1000 500 0

China + Hong Kong Europe North America Japan Asia + Oceania Russia+CIS Korea India Central+Southamerica Middle East Africa Taiwan
The Japan Welding News for the World Issue 2007
Manfred Hfer
Welding of X80/100
April, 2011
Welding consumable consumption

SMAW 80 70 60 50 40 GMAW FCAW SAW
30 20 10 0
China + Hong Kong Asia + Oceania Europe Russia+CIS N. America Korea Japan India C.-a.S.America Africa Taiwan
The Japan Welding News for the World Issue 2007
Manfred Hfer
Welding of X80/100
April, 2011
Manfred Hfer
Welding of X80/100
April, 2011
Development of pipe steel grades over the last decades

steel grade acc. to API 5L X tensile requirements (mind.) YS/UTS [N/mm2]
X100 1990 X80 1980 X70 X60 1970 X60 1960 X56 X56
10 | Manfred Hfer | Welding of X80/100 I April, 2011
690 / 760 552 / 621 482 / 565 413 / 537 413 / 537 386 / 517 386 / 517
*) M-TM *) M-TM *) M-TM *) M-TM *) N-M *) N-M *) N
*) N = normalized *) M = mikro alloyed *) TM = thermo mechanical treated
Content of presentation Trends in welding Consumption of welding consumables Developments in pipe steel grades Distinctive features of CEL vs. LHVD electrodes Economical aspects Welding of X80 and X100 pipes with focus on LHVD Conclusion
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Manfred Hfer
Welding of X80/100
April, 2011
Distinctive features Cellulosic and basic coated vertical-down electrodes
Mechanical properties
Hydrogen
Economy
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Manfred Hfer
Welding of X80/100
April, 2011
Distinctive features
Cellullosic and basic coated vertical-down electrodes
Strength
Impact
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Manfred Hfer
Welding of X80/100
April, 2011
Mechanical properties tensile strength Vertical down electrodes tensile strength 900
Tensile strength [N/mm]
800
X100
700
X80
600 500
cellulosic rutile basic Type of coating
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Manfred Hfer
Welding of X80/100
April, 2011
Mechanical properties impact values

Typical impact values of the all weld metal of cellulosic and basic covered electrodes for the vertical down welding
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Manfred Hfer
Welding of X80/100
April, 2011
Hydrogen contents - Type of coatings
Hydrogen content ml/100g deposit
5ml
cellulosic rutile Coating system basic
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Manfred Hfer
Welding of X80/100
April, 2011
Hydrogen contents
Hydrogen- risk potential when welding unalloyed high strength steels!!!
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Manfred Hfer
Welding of X80/100
April, 2011
Appearance of hydrogen inducted defects
preferred area In fracture recognizable as brittle fracture spot In longitudinal section recognizable as cracks
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Manfred Hfer
Welding of X80/100
April, 2011
Bead bend test Mode of experimental procedure for weld joints sampling for the bead bend test
1sheet (anchored on base plate) 2test joint 3specimen 4firm base plate
2 1 3 1
After welding and exposing for 24 hours (20oC) each trial plate will be removed from the heavy plate section
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Manfred Hfer
Welding of X80/100
April, 2011
Bead bend test
Completely hindered shrinkage Bevel preparation (V-60) Preheat temp. = interpass temp. Investigation program: wall thickness of welding joint Interpass temperature Strength level of CEL- electrodes Inspection scope: 30 joints per strength level (electrode) 4 strength levels (6010, 7010, 8010, 9010)
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Manfred Hfer
Welding of X80/100
April, 2011
Bead bend test
Test sheet before and after welding
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Manfred Hfer
Welding of X80/100
April, 2011
Bead bend test Mode of experimental procedure for weld joints sampling for the bead bend test
gaining of the specimen from the welded plate
Xinvestigated wall thickness Y10 mm

Bead bend test Bend test equipment
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Manfred Hfer
Welding of X80/100
April, 2011
Bead bend test

After annealing (250 C/16 hours) the test specimen is bent, in order to make micro cracks visible
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Manfred Hfer
Welding of X80/100
April, 2011
Bead bend test

Visual identification of the bended specimen
interpass temperature 20 C 80 C 120 C 15 mm Bhler Fox CEL 90 (AWSE 9010/EN E50C), welding position: PG wall thickness
20 C 80 C 120 C 20 C 80 C 120 C 6 mm 9 mm
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Manfred Hfer
Welding of X80/100
April, 2011
Relationship between interpass temperature and wall thickness

Relationship between interpass temperature and wall thickness
160 E 9010 E 8010 E 7010 E 6010
interpass temperature [oC]
140 120 100 80 60 40 20 0 5
Crack free
Cracks possible
10
15
20
25
wall thickness [mm]
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Manfred Hfer
Welding of X80/100
April, 2011
Hydrogen induced crack in E8010 weld metal
Transverse crack
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Manfred Hfer
Welding of X80/100
April, 2011
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Manfred Hfer
Welding of X80/100
April, 2011
Distinctive features
Cellullosic and basic coated vertical-down electrodes
Economy
Deposition rate
Travel speed
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Manfred Hfer
Welding of X80/100
April, 2011
Deposition rates vs. welding speeds

Comparison of economical aspects between cellulosic, basic coated vertical down and up cellulosic coated basic coated vertical down basic coated vertical up
Welding speed [mm/min]

320 4,0 mm,130A. 150 3,2mm,130 A. 100 3,2 mm,90 A.
Deposition rate [kg/h]

1,6 5,0mm, 200A.
30 | Manfred Hfer | Welding of X80/100 I
2,6 4,5mm,240 A.
April, 2011
1,3 4,0mm,130 A.

Time comparison between FOX CEL 85 (E 8010-P1), FOX BVD 85 (E 8045-P2 vert.down), FOX EV60 (8018-C3 vert.up)
Pure arc burning time Steel grade: Dia of tube: Wall thickness: Length of weld: X 65 1225 mm (48) 18,3 mm Each electrode type was used for half of the pipe.
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Manfred Hfer
Welding of X80/100
April, 2011
Welding procedure
Welding position 5 G, vertical down First
FOX CEL (E 6010) FOX CEL 85 (E 8010-P1) FOX BVD 85 (E 8045-P2) FOX BVD 85 (E 8045-P2) 4,0 mm 4,0 mm 4,0 mm 4,5 mm
Second
FOX CEL (E 6010) 4,0 mm FOX CEL 85 (E 8010-P1) 4,0 mm FOX CEL 85 (E 8010-P1) 5,0 mm
Third
FOX CEL (E6010) 4,0 mm FOX CEL 85 (E 8010-P1) 4,0 mm FOX EV 60 (E8018-C3) 3,2 mm FOX EV 60 (E8018-C3) 4,0 mm
Results for the finished weld

FOX BVD (E8045-P2) side Arc burning time 80 min FOX CEL (E8010-P1) side Arc burning time 102 min
Arc time saving with BVD 22 %
The reasons of time saving with BVD are: Higher metal recovery of FOX BVD (appr. 120 %); FOX CEL (appr. 80 %) The possibility to use higher amperage
Results for the finished weld

FOX BVD (E8045-P2) side Arc burning time 80 min FOX EV 60 (E8018-C3) side Arc burning time 139 min
Arc time saving with BVD 43 %
The reasons of time saving with BVD are: Higher metal recovery of FOX BVD (appr. 120 %); FOX EV60 (appr. 115 %) The possibility to use higher amperage
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Manfred Hfer
Welding of X80/100
April, 2011
Specified strength for X80 pipe steel grade

Steel grade Standard YS [MPa] TS [MPa]
X80
API 5 L
Min.552
Min.621
L 555 MB
EN 10208-2
Min.550
Min.620
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Manfred Hfer
Welding of X80/100
April, 2011
Specified chemical composition of X80 pipe steel grade

Steel grade C L555 MB EN ISO standard X80 API 5 L standard 0,22 1,85 0,025 0,015 0,16 Ni 0,30 C Si 0,45 Cr 0,30 Mn Mn 1,80 N 0,012 P Chemical composition (%max.) P 0,025 Al >0,015 S S 0,020 Cu 0,25 Nb *1 Ti 0,06 V *1 Nb*2 0,06 Ti*2 0,06 V*2 0,10 Mo 0,10
*1 Niobium, vanadium or combinations thereof may be used at the discretion of the manufacturer *2 The sum of the niobium, vanadium and titanium contents shall not exceed 0,15%. Other chemical compositions from X80 may be furnished by agreement between purchaser and manufacturer
Welding consumable for X80 pipe steel grade

YS [MPa] Part of weld Cellulosic Root 552 Hot pass Fill & cap FOX CEL (E6010) root pass MMA electrodes
Basic Vertical up FOX Pipe (E7016-1)
Basic Vertical down FOX BVD RP (8045-P2)
FOX CEL 90 (E9010-G) hot pass FOX EV 70 Pipe (E9016-G) FOX BVD 100 (10045-P2) N/A FOX EV 70 Pipe (E9016-G) FOX BVD 100 (10045-P2)
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Manfred Hfer
Welding of X80/100
April, 2011
Welding consumable for X80 pipe steel grade

YS [MPa] Part of weld Mechanised/ semi-automatic Vertical down NiMo1-IG (ER90S-G) NiMo1-IG (ER90S-G) Shelf shielded Vertical down Gas shielded Vertical up Solid wire Flux cored wire Flux cored wire SAW Solid wire & Flux Double Joining
Root & Hot pass 552 Fill & cap
N.a.
N.a. 3NiMo1-UP/BB 24 (F9A4-EF3 (mod.)-F3)
Pipeshield 81T8-FD (E81T8-N2)
Ti 80 Pipe-FD (E111T1-G)
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Manfred Hfer
Welding of X80/100
April, 2011
Coating types for vertical down welding
CELLULOSIC BASIC
Combined Method
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Manfred Hfer
Welding of X80/100
April, 2011
Basic electrodes for vertical down welding BHLER BVD types Classification acc. AWS 5.5-2006
E8045-P2, E9045-P2, E10045-P2(mod), E11018-G, E12018-G
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Manfred Hfer
Welding of X80/100
April, 2011
Reasons for the use of basic LHVD electrodes
Use of pipe grade X 80 or higher High impact requirements Offshore welding of flow lines Pumping stations Welding of high tensile steel grades with wall thickness > 25 mm
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Manfred Hfer
Welding of X80/100
April, 2011
Requirements for basic LHVD electrodes
High yield/tensile properties High impact properties Low hydrogen contents Suitable in combination with cellulosic coated electrodes Easy to handle (striking and running properties)
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Manfred Hfer
Welding of X80/100
April, 2011
Testing of basic LHVD electrodes in respect of starting porosity
starting end
3 days stored after rebaking of at 30 C and 80 % rel. FOX BVD 85 (E 8045-P2) 3,2; 4,0; 4,5 mm 350 C/2 Std. humidity
starting porosity no starting porosity

Combined welding of X80 with cellulosic and basic coated electrodes

Layer sequence
Cellulosic electrodes
Pipe steel grade: STE 550.7 TM (X80) Bead Electrode designation in accordance with AWS E 6010 (FOX CEL) E 9010-G (FOX CEL 90) E 10045-P2* (FOX BVD 100) E 10045-P2*(FOX BVD 100) Diameter of electrodes [mm] 4 5 4 and 4,5 4
Root pass Hot pass Filler pass Cover pass *mod.

45 | Manfred Hfer | Welding of X80/100
April, 2011
Welding procedure specification cellulosic and basic welding X 80

Base material: Diameter: Wall thickness Welding process Edge preparation X 80 56 For instance: 19,81 mm, 23,82 mm, 28,57 mm SMAW
Up to 20 mm No. of welders Balancing: Cleaning: Preheating Interpass temperature: Welding: Layer Sequence: Protection: Electrode Storage:
Above 20 mm
2 or 4 -For root and hot pass 4 welders are recommended. Internal clamp -Removal of clamp after hot pass is recommended. Grinding and brushing. Minimum 150C. Root and hot pass min.150-170C, (depends from the wall thickness) filler/cap min.100C and max.250C. Root and hot pass in one heat. In case of interruption after hot pass preheating min.100C. Slight weaving of maximum twice the core wire diameter is recommended for basic electrode. Restriking of basic electrodes should be avoided. In order to avoid welding defects caused by wind, rain, snow the welding places should be protected by tents. Cellulosic: Not expose to sun. Redrying is not permitted. Basic: After opening the tin the electrodes can be used for 9 hours without redrying. After that the electrodes have to be rebaked at 300-350C for 2 hours. Alternatively, after opening the electrode can be put in quivers where the temperature must be more than 120C and used from there. Rebaking after 9 hours is in this case not necessary.
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Manfred Hfer
Welding of X80/100
April, 2011
Welding procedure specification cellulosic and basic welding X 80
Layer of beads Root Hot pass Filler p. Cap
Welding position 5G 5G 5G 5G
Filler Material
Electr. dia 4,0 4,0 4,5 4,0
Amperage A 120-150 150-180 200-240 180-210
Voltage V 28-32 28-32 20-22 20-22 - Pol. + Pol. + Pol. + Pol.
Rate of Travel mm/min 250-300 250-300 200-300 200-300
FOX CEL (E 6010 ) FOX CEL 90 (E9010-G) FOX BVD 100 (E10045-P2) FOX BVD 100 (E10045-P2 mod.)
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Manfred Hfer
Welding of X80/100
April, 2011
Mechanical properties in weld joint

YS [MPa] 614 UTS [MPa] 701 Elong. [%] 22 CVN@ 0 C 126, 130, 124 FOX CEL (E6010) FOX CEL 90 (E9010-G) FOX BVD 100 (E10045-P2 mod.) X80 48 18,2 mm CVN@ -30 C 93, 84, 89 CVN@ -50 C 61, 67, 59
Root pass: Hot pass: Filler and cover passes: Base material: Diameter: Wall thickness:
Welding position: PG/ 5G

Welding tests on X100 in cooperation with SHELL International
Some aspects by welding of API 5L X100 steels grades
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Manfred Hfer
Welding of X80/100
April, 2011
X 100 Welding tests Properties of base material (X100) Chemical composition [wt-%]
C 0,078 Cr 0,035 Si 0,261 Ni 0,233 Mn 1,96 Mo 0,266 P 0,01 V 0,005 S 0,0009 N 0,0033 Al 0,044 Nb 0,052 Cu 0,222 Ti 0,018
CE (IIW) = 0,496
Yield strength [MPa] 696
Tensile strength [MPa] 779
Elongation [%] 17,5
X 100 Welding tests Properties of FOX BVD 110 (E11018-G) all weld metal
Layer sequence
Electrode Diameter [mm] 4 4,5
Lot Nr.:
Mechanical properties YS [MPa] 838 832 UTS [MPa] 873 858 El. [%] 22 17
Charpy V impact energy [J] -40 C 46 45 -20 C 57 63 +20 C 92 88
Acc. AWS standard
59879 1200713
Interpass temperature: 150 C; Welding position: PG (vertical down)
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Manfred Hfer
Welding of X80/100
April, 2011
X 100 Welding tests welding parameters

Pipe material: API 5L X100; Pipe Nr. 10026 from Dillingerhtte Wall thickness: 19,5 mm Pipe diameter: 760 mm Joint preparation: V- joint 60
Procedure 1 (BVD- IPT:100 C)

Pass Nr. 1 2 3-17 Electrode FOX E8018-G E11018-G E11018-G Dia. [mm] 2,5 4 4,5 Welding Current [A] 110 180 240 Welding Voltage [V] 22 20 21 Welding time [sec.] 458 264 3883 Layer sequence
Welding position: PG (vertical down); total welding time: 4605 sec. (76 min. 75 sec.)
X 100 Welding tests welding parameters

Pipe material: API 5L X100; Pipe Nr. 10026 from Dillingerhtte Wall thickness: 19,5 mm Pipe diameter: 760 mm Joint preparation: V- joint 60
Procedure 3 (combined method- IPT:100 C)

Pass Nr. 1 2 3 4-15 Electrode FOX E6010 E9010 E11018-G E11018-G Dia. [mm] 4 5 4 4,5 Welding Current [A] 120 170 200 240 Welding Voltage [V] 28 25 21 23 Welding time [sec.] 260 266 317 3343 Layer sequence
Welding position: PG (vertical down); total welding time: 4186 sec. (69 min. 76 sec.)
X 100 Welding tests mechanical properties of V- joint Procedure 1 (BVD- IPT:100 C)

120 110
Charpy V toughness of the V joint

Center position
impact energy [J]
100 90 80 70 60 50 40 30 -50 -40 -30 -20 -10 0 10 20 30
root position
temperature [C]
12 o'clock; center pos.
12 o'clock; root pos.

April, 2011
3 o' clock; center pos.
X 100 Welding tests mechanical properties of V- joint Procedure 3 (combined method - IPT:100 C)
120 110
Charpy V toughness of the V joint

Center position
impact energy [J]
100 90 80 70 60 50 40 30 -50 -40 -30 -20 -10 0 10 20 30
root position
temperature [C]
12 o'clock; center pos.
12 o'clock; root pos.

April, 2011
3 o' clock; center pos.
X 100 Welding tests mechanical properties of V- joint Strength level by using of different procedures and IPT
strength level
900 880 860
strength [MPa]
840 820 800 780 760 740 720 700

C 0 C 00 C PT : 10 T:1 00 0 C
c omb in al l pa e d: CELBVD ss es BVD
YS / IP
UT S/I
YS /IP
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Manfred Hfer
Welding of X80/100
April, 2011
UT S/I
PT : 20
T:2
X 100, dia. 56, wth. 19,1mm WELDING TESTS M/s SNAM - Italia
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Manfred Hfer
Welding of X80/100
April, 2011
NIMO1-IG
0.9mm (ER90S-G) Yield Rp0,2 > 770 MPa Tensile Rm > 810 MPa A in % > 20 Impact (mid weld) > ~100 Joule at -10 C CTOD (mid weld) 0.11 / 0.10 / 0.11 at 0 C 0.09 / 0.12 / 0.12 at -10 C 0.10 / 0.11 / 0.07 at -20 C
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Manfred Hfer
Welding of X80/100
April, 2011
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Manfred Hfer
Welding of X80/100
April, 2011
Project welded with combination of cellulosic and basic coated electrodes

Germany
Length 480 km Pipegrade StE 480.7 TM Wall thickness 8.7 - 10 mm Diameter 406 mm Contractors RAB Sdrohrbau Nacab Rienhard Rohrbau Used welding consumables BHLER FOX CEL (E6010) BHLER FOX CEL 90 (E9010-P1) BHLER FOX BVD 90 (E9045-P2)
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Manfred Hfer
Welding of X80/100
April, 2011
LONGSIDE pipeline, Scotland

Length Pipegrade Wall thickness Diameter Contractor Nacap - Lawrence 72 km X 80 15.1 mm 48
Used welding consumables for Tie-in and crossings BHLER FOX CEL (E6010) BHLER FOX CEL 90 (9010-P1) 4.0 mm 4.0 mm
BHLER FOX BVD 100 (10045-P2) 4.0 mm BHLER FOX BVD 100 (10045-P2) 4.5 mm
SHAAN-JING Pipeline , China

Length: 918 km Pipegrade: X 60 API 5 L Wall thickness: 8.3 mm Diameter: 660 mm Contractor: China National Petroleum Corp. Root pass: Bhler FOX CEL (E6010) Hot pass: Bhler FOX CEL 85 (E8010-P1) Filler&Cap: Bhler FOX BVD 85 (E8045-P2)
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Welding of X80/100
April, 2011

IKL-Project, Czech Republic 1995
Length 167,62 km Pipegrade StE 480.7 TM Wall thickness 8 - 12,5 mm Diameter 711 mm Contractors Vodni Stavby 06 Vodni Stavby 01 IPS-Praha Plynostav Pardubice Used welding consumables FOX BVD Rp (E8045-P2) FOX BVD 90 (E9045-P2)
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Manfred Hfer
Welding of X80/100
April, 2011
Laying ship: Laying area: Base metal: Electrode type:

64 | Manfred Hfer |
Lay barge Hyundai 289 Sumatra to Singapore appr. 300 km API 5L X 65 28 x 12,7 mm Root: FOX BVD Rp (E8045-P2) 3,2 mm Fill&Cap: FOX BVD 85 (E8045-P2) 4,0 u. 4,5 mm
I April, 2011
Welding of X80/100
RUSSIA Sakhalin Oil and Gas Pipeline
Base material Diameter Wall thickness Length Root pass Filler & cap
X 70 API 5L 48 18.2 23,8 mm each 800 km EV Pipe type FOX BVD 90 (E9045-P2)
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Manfred Hfer
Welding of X80/100
April, 2011
Welding consumables
CELLULOSIC COATED ELECTRODES Bhler FOX CEL E 6010 (root polarity) Bhler FOX CEL+ E 6010 (root +polarity) Bhler FOX CEL S E 6010 (root pass only vert. up) Bhler FOX CEL Mo E 7010-A1 Bhler FOX CEL 75 (G) E 7010-P1 (E 7010-G) Bhler FOX CEL 85 (G) E 8010-P1(E 8010-G) Bhler FOX CEL 70-P E 7010-P1 Bhler FOX CEL 80-P E 8010-P1 Bhler FOX CEL 90 E 9010-P1
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Manfred Hfer
Welding of X80/100
April, 2011
Welding consumables BASIC-COATED ELECTRODES Bhler FOX BVD Rp Bhler FOX BVD 85 Bhler FOX BVD 90 Bhler FOX BVD 100 Bhler FOX BVD 110 Bhler FOX BVD 120 Bhler FOX EV 50 W Bhler FOX EV Pipe Bhler FOX EV60 Pipe Bhler FOX EV70 Pipe
E 8045-P2 root pass E 8045-P2 vert. down E 9045-P2 (mod.) E 10045-P2 (mod.) E 11018-G E 12018-G E 7016 vert. up E 7016-1 E 8016-G E 9016-G
Welding consumables AUTOMATIC SG3-P K-Nova Ni NiMo-IG NiCrMo 2.5-IG X 70-IG X 90-IG GMAW-WIRE ER 70S-6 ER 80S-G ER 90S-G ER 110S-G ER 110S-G ER 120S-G SEMI-AUTOMATIC FCAW-WIRE
Bhler Pipeshield 71 T8-FD Bhler Pipeshield 81 T8-FD
E71T8-K6 E81T8-N2
Welding consumables FCAW-WIRE Ti 52-FD Ti 60-FD Ti 70 Pipe-FD Ti 80 Pipe-FD E71T-1 E81T-N1 E91T-1K2 M E111T-1 G M
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Manfred Hfer
Welding of X80/100
April, 2011
Conclusion Trends in welding Applied welding processes Consumption of welding consumables Developments in pipe steel grades Distinctive features of CEL vs. LHVD Economical aspects Welding of X80 and X100 pipes with focus on LHVD
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Manfred Hfer
Welding of X80/100
April, 2011
When operators have sophisticated products in their hands even welding, at least sometimes, can be enjoyable!
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Manfred Hfer
Welding of X80/100
April, 2011
Thank you very much for your kind attention
Manfred Hoefer Regional Technical Manager Bhler Schweitechnik Austria GmbH Kapfenberg Austria Member of the Bohler Welding Group
www.boehler-welding.com
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April, 2011

WeldingX80 100 ME April 2011 PDF

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WELDING CONSUMABLES FOR PIPELINE CONSTRUCTIONS WITH FOCUS ON LHVD ELECTRODES FOR X80 AND X100

MANFRED HOEFER, Technical Regional Manager

ME, April 2011

We are the World of Welding Solutions.

Trends in welding Reduction of projects costs realized due to:

Higher deposition rates

Automation - Increasing the effective arc on time Reduction of welding downtimes

Welding processes in pipeline girth welding

SMAW GMAW FCAW SAW

vertical up vertical up horizontal

vertical down vertical down vertical down

Welding consumable consumption

1500 1000 500 0

The Japan Welding News for the World Issue 2007

Welding consumable consumption

The Japan Welding News for the World Issue 2007

Development of pipe steel grades over the last decades

*) M-TM *) M-TM *) M-TM *) M-TM *) N-M *) N-M *) N

*) N = normalized *) M = mikro alloyed *) TM = thermo mechanical treated

Distinctive features Cellulosic and basic coated vertical-down electrodes

Cellullosic and basic coated vertical-down electrodes

Mechanical properties impact values

Hydrogen contents - Type of coatings

Hydrogen content ml/100g deposit

Hydrogen- risk potential when welding unalloyed high strength steels!!!

Appearance of hydrogen inducted defects

Bead bend test

Bead bend test

Test sheet before and after welding

Xinvestigated wall thickness Y10 mm

Bead bend test Bend test equipment

Bead bend test

Bead bend test

Relationship between interpass temperature and wall thickness

interpass temperature [oC]

140 120 100 80 60 40 20 0 5

wall thickness [mm]

Hydrogen induced crack in E8010 weld metal

Cellullosic and basic coated vertical-down electrodes

Deposition rates vs. welding speeds

Welding speed [mm/min]

Deposition rate [kg/h]

Deposition rates vs. welding speeds

Deposition rates vs. welding speeds

Deposition rates vs. welding speeds

Results for the finished weld

Arc time saving with BVD 22 %

Deposition rates vs. welding speeds

Results for the finished weld

Arc time saving with BVD 43 %

Specified strength for X80 pipe steel grade

Specified chemical composition of X80 pipe steel grade

Welding consumable for X80 pipe steel grade

Basic Vertical up FOX Pipe (E7016-1)

Basic Vertical down FOX BVD RP (8045-P2)

Welding consumable for X80 pipe steel grade

Root & Hot pass 552 Fill & cap

N.a. 3NiMo1-UP/BB 24 (F9A4-EF3 (mod.)-F3)

Pipeshield 81T8-FD (E81T8-N2)

Coating types for vertical down welding

Reasons for the use of basic LHVD electrodes

Requirements for basic LHVD electrodes

Testing of basic LHVD electrodes in respect of starting porosity

) M-TM ) M-TM ) M-TM ) M-TM ) N-M ) N-M *) N

) N = normalized ) M = mikro alloyed *) TM = thermo mechanical treated