WeldingX80_100_ME_April_2011.pdf

1 | Manfred Höfer | Welding of X80/100 I April, 2011 1We are the World of Welding Solutions.

WELDING CONSUMABLES FORPIPELINE CONSTRUCTIONS WITHFOCUS ON LHVD ELECTRODESFOR X80 AND X100

MANFRED HOEFER, Technical Regional Manager

ME, April 2011

2 | Manfred Höfer | Welding of X80/100 I 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


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)







� Conclusion



Welding processes in pipeline girth welding

SMAW vertical up vertical down

GMAW vertical down

FCAW vertical up vertical down

SAW horizontal


� Trends in welding� Consumption of welding consumables





� Conclusion



0

500

1000

1500

2000

2500

China +

Hong K

ong

Europe

North A

merica

Japan

Asia +

Oceania

Russia+

CIS

Korea

India

Central+

Southam

erica

Middle E

ast

Africa

Taiw

an

China + Hong Kong EuropeNorth America JapanAsia + Oceania Russia+CISKorea IndiaCentral+Southamerica Middle EastAfrica Taiwan

Welding consumable consumption

The Japan Welding News for theWorld Issue 2007

1000

tonn

s


0

10

20

30

40

50

60

70

80

China +

Hong K

ong

Asia +

Oceania

Europe

Russia+

CIS

N. A

merica

Korea

Japan

India

C.-a.S

.Am

erica

Africa

Taiw

anSMAW GMAW FCAW SAW

Welding consumable consumption

%

The Japan Welding News for theWorld Issue 2007







� Conclusion



Development of pipe steel gradesover the last decades

*) M-TM

*) M-TM

*) M-TM

*) M-TM

*) N-M

*) N-M

*) N

690 / 760

552 / 621

482 / 565

413 / 537

413 / 537

386 / 517

386 / 517

X100

X80

X70

X60

X60

X56

X56

tensilerequirements

(mind.) YS/UTS [N/mm 2]

steel grade

acc. to

API 5L X

1990

1980

1970

1960

*) N = normalized

*) M = mikro alloyed

*) TM = thermomechanical treated




� Distinctive features of CEL vs. LHVD electrodes



� Conclusion



Cellulosic and basic coated vertical-down electrodes

Hydrogen

Mechanical properties

Economy

Distinctive features


Cellullosic and basic coated vertical-down electrodes

Mechanical properties

Strength Impact



cellulosic rutile basicType of coating

Ten

sile

stre

ngth

[N/m

m²]

900

800

700

600

500

Vertical down electrodes – tensile strength

Mechanical properties – tensile strength

X80

X100


TypicalTypical impactimpact valuesvalues of of thethe all weld metal of all weld metal of cellulosiccellulosic and and basicbasic coveredcovered electrodeselectrodes forfor thethe verticalvertical down weldingdown welding

Mechanical properties – impact values


5ml

Hyd

roge

nco

nten

tml/1

00g

depo

sit

cellulosic rutile basic

Hydrogen contents - Type of coatings

Coating system


HydrogenHydrogen -- risk potential when weldingrisk potential when weldingunalloyed high strength steels!!!unalloyed high strength steels!!!

Hydrogen contents


In fracture recognizable as brittle fracture spot

In longitudinal section recognizable as cracks

preferred area

Appearance of hydrogen inducted defects


Mode of experimental procedure for weld joints sampling for the bead bend test

1…sheet (anchored on base plate)

2…test joint

3…specimen

4…firm base plate

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

1 12

3

Bead bend test


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

Investigation program:Investigation program:�� wall thickness of welding jointwall thickness of welding joint�� InterpassInterpass temperaturetemperature�� Strength 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 (6010, 7010, 8010, 9010) 4 strength levels (6010, 7010, 8010, 9010)

Bead bend test


Test sheet before and after welding

Bead bend test


Mode of experimental procedure for weld joints sampling for the bead bend test

X…investigated wall thickness

Y…10 mm

gaining of the specimen from the welded plate

Bead bend test


Bend test equipment

Bead bend test


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

Bead bend test


Visual identification of the bended specimen

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

thicknessinterpass

temperature

20°C

15 mm80°C

120°C

9 mm

20°C

80°C

120°C

6 mm

20°C

80°C

120°C

Bead bend test


Relationship between interpass temperature and wal l thickness

0

20

40

60

80

100

120

140

160

5 10 15 20 25wall thickness [mm]

inte

rpas

s te

mpe

ratu

re [

oC

]

E 9010E 8010E 7010E 6010

Cracks possible

Crack free

Relationship between interpasstemperature and wall thickness


Hydrogen induced crack in E8010 weld metal

Transverse crack







� Conclusion



Cellullosic and basic coated vertical-down electrodes

Economy

Deposition rate Travel speed



Comparison of economical aspects betweencellulosic, basic coated vertical down and up

cellulosic coated basic coatedvertical down

basic coatedvertical up

Welding speed [mm/min]

Deposition rate [kg/h]

1,6Ø 5,0mm, 200A.

320Ø 4,0 mm,130A.

150Ø 3,2mm,130 A.

2,6Ø 4,5mm,240 A.

100Ø 3,2 mm,90 A.

1,3Ø 4,0mm,130 A.

Deposition rates vs. welding speeds


Time comparison between FOX CEL 85 (E 8010-P1), FOX BVD 85 (E 8045-P2 vert.down), FOX EV60 (8018-C3 v ert.up)

Pure arc burning time

Steel grade: X 65Dia of tube: 1225 mm (48“)Wall thickness: 18,3 mmLength of weld: Each electrode type was used

for half of the pipe.



Welding procedure

First SecondFOX CEL (E 6010) Ø 4,0 mm FOX CEL (E 6010) Ø 4,0 mmFOX CEL 85 (E 8010-P1) Ø 4,0 mm FOX CEL 85 (E 8010-P1) Ø 4,0 mmFOX BVD 85 (E 8045-P2) Ø 4,0 mm FOX CEL 85 (E 8010-P1) Ø 5,0 mmFOX BVD 85 (E 8045-P2) Ø 4,5 mm

Welding position 5 G, vertical down

FOX CEL (E6010) Ø 4,0 mmFOX CEL 85 (E 8010-P1) Ø 4,0 mmFOX EV 60 (E8018-C3) Ø 3,2 mmFOX EV 60 (E8018-C3) Ø 4,0 mm


Third


Results for the finished weld

FOX BVD (E8045-P2) sideArc burning time Σ 80 min

FOX CEL (E8010-P1) sideArc burning time Σ 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) sideArc burning time Σ 80 min

FOX EV 60 (E8018-C3) sideArc burning time Σ 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








� Conclusion



Specified strength forX80 pipe steel grade

Min.620Min.550EN 10208-2L 555 MB

Min.621Min.552API 5 LX80

TS

[MPa]

YS

[MPa]StandardSteel grade


V *1TiNb *1SPMnCX80

API 5 L

standard0,06

0,0150,0251,850,22

0,25>0,0150,0120,300,30

CuAlNCrNi

0,100,100,060,060,0200,0251,800,450,16L555 MB

EN ISO standard

MoV*2Ti*2Nb*2SPMnSiC

Chemical composition (%max.)Steel grade

*1 Niobium, vanadium or combinations thereof may be used at t he discretion of themanufacturer

*2 The sum of the niobium, vanadium and titanium contents sh all not exceed 0,15%.

Other chemical compositions from X80 may be furnished by ag reement betweenpurchaser and manufacturer

Specified chemical composition ofX80 pipe steel grade


FOX BVD 100 (10045-P2)FOX EV 70 Pipe (E9016-G)N/AFill & cap

FOX BVD RP (8045-P2)

FOX BVD 100 (10045-P2)

FOX Pipe (E7016-1)

FOX EV 70 Pipe (E9016-G)

FOX CEL (E6010) root pass

FOX CEL 90 (E9010-G) hot pass

Root

Hot pass552

Basic Vertical downBasic Vertical upCellulosic

MMA electrodesPart of weld

YS [MPa]

Welding consumable forX80 pipe steel grade


Pipeshield 81T8-FD

(E81T8-N2)

N.a.

Shelf shielded

Vertical down

Flux cored wire

Ti 80 Pipe-FD

(E111T1-G)

NiMo1-IG

(ER90S-G)Fill &

cap

3NiMo1-UP/BB 24

(F9A4-EF3 (mod.)-F3)

N.a.

NiMo1-IG

(ER90S-G)Root &

Hot pass552

Double JoiningGas shielded

Vertical up

Mechanised/

semi-automatic

Vertical down

SAW Solid wire &

Flux

Flux cored wireSolid wirePart of

weld

YS [MPa]

Welding consumable forX80 pipe steel grade


Coating types for vertical down welding

�CELLULOSIC

�BASICCombinedMethod


Basic electrodes for vertical down weldingBÖHLER BVD types

Classification acc. AWS 5.5-2006 E8045-P2, E9045-P2, E10045-P2(mod),

E11018-G, E12018-G


Reasons for the use ofbasic 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 withwall thickness > 25 mm


� High yield /tensile properties� High impact properties� Low hydrogen contents� Suitable in combination with cellulosic

coated electrodes� Easy to handle (striking and running

properties)

Requirements for basic LHVD electrodes


Testing of basic LHVD electrodesin respect of starting porosity

starting endFOX BVD 85 (E 8045-P2) Ø 3,2; 4,0; 4,5 mm

after rebaking of350°C/2 Std.

3 days storedat 30°C and 80 % rel.

humidity

starting porosityno starting porosity


Combined welding of X80 with cellulosic Combined welding of X80 with cellulosic and basic coated electrodesand basic coated electrodes

Layer sequence

Cellulosic electrodesPipe steel grade: STE 550.7 TM (X80)

Bead

Root passHot passFiller passCover pass

Electrode designationin accordance

with AWS

Diameter ofelectrodes

[mm]

45

4 and 4,54

E 6010 (FOX CEL)E 9010-G (FOX CEL 90)E 10045-P2* (FOX BVD 100)E 10045-P2*(FOX BVD 100)

*mod.


Cellulosic : Not expose to sun. Redrying is not permitted.Basic: After opening the tin the electrodes can be used fo r 9 hours without redrying. After that the electrod es have to be rebaked at 300-350 °C for 2 hours. Alternatively, after opening the electrode can be p ut in quivers where the temperature must be more tha n 120°C and used from there. Rebaking after 9 hours is in this c ase not necessary.

Electrode Storage:

In order to avoid welding defects caused by wind, r ain, snow the welding places should be protected by tents.Protection:

Slight weaving of maximum twice the core wire diame ter is recommended for basic electrode. Restriking of basic electrodes should be avoided.

Layer Sequence:

Root and hot pass in one heat. In case of interrupt ion after hot pass preheating min.100 °C.Welding:

Root and hot pass min.150-170 °C, (depends from the wall thickness) filler/cap min .100°C and max.250 °C.Interpasstemperature:

Minimum 150 °C.Preheating

Grinding and brushing.Cleaning:

Internal clamp -Removal of clamp after hot pass is recommended.Balancing:

2 or 4 -For root and hot pass 4 welders are recomme nded.No. of welders

Up to 20 mm Above 20 mm

Edge preparation

SMAWWelding process

56”For instance: 19,81 mm, 23,82 mm, 28,57 mm

Diameter:Wall thickness

X 80Base material:

Welding procedure specification cellulosic and basic welding X 80


Welding procedure specification cellulosic and basic welding X 80

200-300+ Pol.20-22180-2104,0FOX BVD 100 (E10045-P2 mod.)

5GCap

200-300+ Pol.20-22200-2404,5FOX BVD 100 (E10045-P2)

5GFiller p.

250-300+ Pol.28-32150-1804,0FOX CEL 90 (E9010-G)

5GHotpass

250-300- Pol.28-32120-1504,0FOX CEL (E 6010 )5GRoot

Rate ofTravel

mm/min

VoltageV

AmperageA

Electr.dia

Filler MaterialWeldingposition

Layer of beads


Mechanical properties in weld joint

61, 67, 5993, 84, 89126, 130, 12422701614

CVN@ -50°CCVN@ -30°CCVN@ 0°CElong.

[%]

UTS

[MPa]

YS

[MPa]

�Root pass: FOX CEL (E6010)

�Hot pass: FOX CEL 90 (E9010-G)

�Filler and

�cover passes: FOX BVD 100 (E10045-P2 mod.)

�Base material: X80

�Diameter: 48”

�Wall thickness: 18,2 mm

�Welding position: PG/ 5G


Some aspects by welding of API 5L X100 steels grades

Welding tests on X100 in cooperation with SHELL International


X 100 Welding tests – Properties of base material (X100)

0,0180,0520,00330,0050,2660,2330,035

TiNbNVMoNiCr

0,2220,0440,00090,011,960,2610,078

CuAlSPMnSiC

Chemical composition [wt-%]

Mechanical propertiesCE (IIW) = 0,496

17,5779696

Elongation[%]

Tensile strength[MPa]

Yield strength[MPa]


63

57

-20°C

45

46

-40°C

881785883212007134,5

9222873838598794Acc. AWS standard

+20°C

El.[%]

UTS[MPa]

YS[MPa]

Charpy V impact energy [J]

Mechanical propertiesLot

Nr.:ElectrodeDiameter

[mm]

Layersequence

Interpass temperature: 150 °C; Welding position: PG (vertical down)

X 100 Welding tests – Properties of FOX BVD 110 (E11018-G) all weld metal


Pipe material: API 5L X100; Pipe Nr. 10026 from Dillingerhütte

Wall thickness: 19,5 mm

Pipe diameter: 760 mm

Joint preparation: V- joint 60°

3883212404,5E11018-G3-17

264201804E11018-G2

458221102,5E8018-G1

Layersequence

Welding time [sec.]

WeldingVoltage [V]

WeldingCurrent [A]

Dia.[mm]

ElectrodeFOX

PassNr.

Procedure 1 (BVD - IPT:100°C)

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 Dillingerhütte

Wall thickness: 19,5 mm

Pipe diameter: 760 mm

Joint preparation: V- joint 60°

266251705E90102

3343232404,5E11018-G4-15

317212004E11018-G3

260281204E60101

Layersequence

Welding time [sec.]

WeldingVoltage [V]

WeldingCurrent [A]

Dia.[mm]

ElectrodeFOX

PassNr.

Procedure 3 (combined method- IPT:100°C)

Welding position: PG (vertical down); total welding time: 4186 sec. (69 min. 76 sec.)

X 100 Welding tests –welding parameters


Procedure 1 (BVD - IPT:100°C)

Charpy V toughness of the V joint

30

40

50

60

70

80

90

100

110

120

-50 -40 -30 -20 -10 0 10 20 30

temperature [°C]

impa

ct e

nerg

y [J

]

12 o'clock; center pos. 12 o'clock; root pos. 3 o' clock; center pos.

Center position

root position

X 100 Welding tests –mechanical properties of V- joint


Procedure 3 (combined method - IPT:100°C)

Charpy V toughness of the V joint

30

40

50

60

70

80

90

100

110

120

-50 -40 -30 -20 -10 0 10 20 30

temperature [°C]

impa

ct e

nerg

y [J

]

12 o'clock; center pos. 12 o'clock; root pos. 3 o' clock; center pos.

Center position

root position



YS/

IPT:

100°

C

UTS

/IPT:

100°

C

YS/

IPT:

200°

C

UTS

/IPT:

200°

C

all passes BVD

combined: CEL-BVD

700

720

740

760

780

800

820

840

860

880

900

stre

ngth

[MP

a]strength level

Strength level by using of different procedures and IPT



X 100, dia. 56”, wth. 19,1mm WELDING TESTS M/s SNAM - Italia


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°C0.10 / 0.11 / 0.07 at -20°C



Germany

Length 480 km

Pipegrade StE 480.7 TM

Wall thickness 8.7 - 10 mmDiameter 406 mm

Contractors� RAB� Südrohrbau� Nacab� Rienhard Rohrbau

Used welding consumablesBÖHLER FOX CEL (E6010)BÖHLER FOX CEL 90 (E9010-P1)BÖHLER FOX BVD 90 (E9045-P2)

Project welded with combination ofcellulosic and basic coated electrodes


� Length 72 km

� Pipegrade X 80

� Wall thickness 15.1 mm

� Diameter 48 ‘

� Contractor

– Nacap - Lawrence

� Used welding consumables

for Tie-in and crossings

BÖHLER FOX CEL (E6010) ø 4.0 mm

BÖHLER FOX CEL 90 (9010-P1) ø 4.0 mm

BÖHLER FOX BVD 100 (10045-P2) ø 4.0 mm

BÖHLER FOX BVD 100 (10045-P2) ø 4.5 mm

LONGSIDE pipeline, Scotland



SHAAN-JING Pipeline , China

Length: 918 kmPipegrade: X 60 API 5 LWall thickness: 8.3 mmDiameter: 660 mmContractor:China National Petroleum Corp.

Root pass: Böhler FOX CEL (E6010)Hot pass: Böhler FOX CEL 85 (E8010-P1)Filler&Cap: Böhler FOX BVD 85 (E8045-P2)



IKL-Project, Czech Republic 1995

Length 167,62 kmPipegrade StE 480.7 TM

Wall thickness 8 - 12,5 mm

Diameter 711 mmContractors

� Vodni Stavby 06� Vodni Stavby 01� IPS-Praha� Plynostav Pardubice

Used welding consumables� FOX BVD Rp (E8045-P2)� FOX BVD 90 (E9045-P2)



Laying ship: Lay barge Hyundai 289Laying area: Sumatra to Singapore appr. 300 kmBase metal: API 5L X 65 Ø 28“ x 12,7 mmElectrode type: Root: FOX BVD Rp (E8045-P2) Ø 3, 2 mm

Fill&Cap: FOX BVD 85 (E8045-P2) Ø 4,0 u. 4,5 mm



RUSSIASakhalin Oil and Gas Pipeline

Base material X 70 API 5LDiameter 48“Wall thickness 18.2 – 23,8 mmLength each 800 kmRoot pass EV Pipe typeFiller & cap FOX BVD 90

(E9045-P2)



E 6010 (root –polarity)E 6010 (root +polarity)E 6010 (root pass only vert. up)E 7010-A1E 7010-P1 (E 7010-G)E 8010-P1(E 8010-G)E 7010-P1E 8010-P1E 9010-P1

Böhler FOX CELBöhler FOX CEL+Böhler FOX CEL SBöhler FOX CEL MoBöhler FOX CEL 75 (G)Böhler FOX CEL 85 (G)Böhler FOX CEL 70-PBöhler FOX CEL 80-PBöhler FOX CEL 90

CELLULOSIC – COATED ELECTRODES

Welding consumables


E 8045-P2 root passE 8045-P2 vert. downE 9045-P2 (mod.)E 10045-P2 (mod.)E 11018-GE 12018-GE 7016 vert. upE 7016-1E 8016-GE 9016-G

Böhler FOX BVD RpBöhler FOX BVD 85Böhler FOX BVD 90Böhler FOX BVD 100Böhler FOX BVD 110Böhler FOX BVD 120Böhler FOX EV 50 WBöhler FOX EV PipeBöhler FOX EV60 PipeBöhler FOX EV70 Pipe

BASIC-COATED ELECTRODES

Welding consumables


ER 70S-6

ER 80S-G

ER 90S-G

ER 110S-G

ER 110S-G

ER 120S-G

SG3-P

K-Nova Ni

NiMo-IG

NiCrMo 2.5-IG

X 70-IG

X 90-IG

AUTOMATIC

GMAW-WIRE

E71T8-K6

E81T8-N2

Böhler Pipeshield 71 T8-FD

Böhler Pipeshield 81 T8-FD

SEMI-AUTOMATICFCAW-WIRE

Welding consumables


E71T-1

E81T-N1

E91T-1K2 M

E111T-1 G M

Ti 52-FD

Ti 60-FD

Ti 70 Pipe-FD

Ti 80 Pipe-FD

FCAW-WIRE

Welding consumables


Conclusion







When operators havesophisticated productsin their hands even welding, at least sometimes, can be enjoyable !


www.boehler-welding.com

Thank you very muchfor your kind attention

Manfred HoeferRegional Technical Manager

Böhler Schweißtechnik Austria GmbHKapfenberg – Austria

Member of theBohler Welding Group

WeldingX80_100_ME_April_2011.pdf

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