Welding Procedure Establishment for Tubular Joints Welded by Single Station, Solid State Welding Machine

2010 ◽  
Author(s):  
Ganesan S. Marimuthu ◽  
Per Thomas Moe ◽  
Bjarne Salberg ◽  
Junyan Liu ◽  
Henry Valberg ◽  
...  
Keyword(s):  
Solid State ◽  
Oil And Gas ◽  
Welding Process ◽  
High Strength ◽  
Pipe Material ◽  
Tubular Joints ◽  
Welding Machine ◽  
Single Station ◽  
Welding Procedure ◽  
Treatment Procedures

Forge welding is an efficient welding method for tubular joints applicable in oil and gas industries due to its simplicity in carrying out the welding, absence of molten metal and filler metals, small heat-affected zone and high process flexibility. Prior to forging, the ends (bevels) of the joining tubes can be heated by torch or electromagnetic (EM) techniques, such as induction or high frequency resistance heating. The hot bevels are subsequently pressed together to establish the weld. The entire welding process can be completed within seconds and consistently produces superior quality joints of very high strength and adequate ductility. Industrial forge welding of tubes in the field is relatively expensive compared to laboratory testing. Moreover, at the initial stages of a new project sufficient quantities of pipe material may not be available for weldability testing. For these and several other reasons we have developed a highly efficient single station, solid state welding machine that carefully replicates the thermomechanical conditions of full-scale Shielded Active Gas Forge Welding Machines (SAG-FWM) for pipeline and casing applications. This representative laboratory machine can be used to weld tubular goods, perform material characterization and/or simulate welding and heat treatment procedures. The bevel shapes at mating ends of the tubes are optimized by ABAQUS® simulations to fine tune temperature distribution. The main aim of this paper is to establish a welding procedure for welding the tubular joints by the representative laboratory machine. The quality of the welded tubular joint was analyzed by macro/micro analyses, as well as hardness and bend tests. The challenges in optimizing the bevel shape and process parameters to weld high quality tubular joints are thoroughly discussed. Finally a welding procedure specification was established to weld the tubular joints in the representative laboratory machine.

Development of an Effective ASME IX Welding Procedure Qualification Program for Pipeline Facility and Fabrication Welding

2016 ◽  
Author(s):  
Junfang Lu ◽  
Bob Huntley ◽  
Luke Ludwig
Keyword(s):  
Oil And Gas ◽  
Material Selection ◽  
Base Material ◽  
Welding Process ◽  
Notch Toughness ◽  
Essential Variable ◽  
Performance Qualification ◽  
Pipeline Welding ◽  
Welding Consumable ◽  
Welding Procedure

For cross country pipeline welding in Canada, welding procedures shall be qualified in accordance with the requirements of CSA Z662 Oil and Gas Pipeline Systems. For pipeline facility and fabrication welding on systems designed in accordance with CSA Z662 or ASME B31.4, welding procedures qualified in accordance with the requirements of ASME Boiler & Pressure Vessel Code Section IX are permitted and generally preferred. Welding procedures qualified in accordance with ASME IX provide advantages for pipeline facility and fabrication applications as a result of the flexibility achieved through the larger essential variable ranges. The resulting welding procedures have broader coverage on material thickness, diameter, joint configuration and welding positions. Similarly, ASME IX is more flexible on welder performance qualification requirements and accordingly a welder will have wider range of performance qualifications. When applied correctly, the use of ASME IX welding procedures often means significantly fewer welding procedures and welder performance qualifications are required for a given scope of work. Even though ASME IX qualified welding procedures have been widely used in pipeline facility and fabrication welding, it is not well understood on how to qualify the welding procedures in accordance with ASME IX and meet the additional requirements of the governing code or standard such as CSA Z662 in Canada. One significant consideration is that ASME IX refers to the construction code for the applicability of notch toughness requirements for welding procedure qualification, yet CSA Z662 and ASME B31.4 are both silent on notch toughness requirements for welding procedure qualification. This paper explains one preferred method to establish and develop an effective ASME IX welding procedure qualification program for pipeline facility and fabrication welding while ensuring suitability for use and appropriate notch toughness requirements. The paper discusses topics such as base material selection, welding process, welding consumable consideration and weld test acceptance criteria.

Alloying Concept for High-Strength Seamless Heavy-Wall Line Pipe Suitable for Sour Service Applications

2004 ◽  
Author(s):  
K. Biermann ◽  
C. Kaucke ◽  
M. Probst-Hein ◽  
B. Koschlig
Keyword(s):  
Heat Treatment ◽  
Wall Thickness ◽  
Oil And Gas ◽  
High Strength ◽  
Gas Production ◽  
Pipe Material ◽  
Low Carbon ◽  
Line Pipe ◽  
Oil And Gas Production ◽  
Sour Service

Offshore oil and gas production worldwide is conducted in increasingly deep waters, leading to more and more stringent demands on line pipes. Higher grades and heavier wall thicknesses in combination with deep temperature toughness properties, good weldability and suitability for sour service applications are among the characteristics called for. It is necessary that pipe manufacturers develop materials to meet these at times conflicting requirements. An alloying concept based on steel with very low carbon content is presented. This type of material provides excellent toughness properties at deep temperatures in line pipe with a wall thickness of up to 70 mm, produced by hot rolling followed by QT heat treatment. Pipes from industrial production of identical chemical composition and heat treatment achieved grades X65 to X80, depending on wall thickness. The properties of the steel used in pipes are presented. The resistance of the pipe material to the influence of sour gas was assessed by standard tests. To demonstrate weldability, test welds were performed and examined.

Solid-state joining of aluminum to titanium: A review

2021 ◽  
pp. 146442072110108
Author(s):  
Vijay S Gadakh ◽  
Vishvesh J Badheka ◽  
Amrut S Mulay
Keyword(s):  
Mechanical Properties ◽  
Solid State ◽  
Titanium Alloys ◽  
Intermetallic Compounds ◽  
Welding Process ◽  
High Strength ◽  
Weld Interface ◽  
Fusion Welding ◽  
Cp Ti ◽  
Welding Processes

The dissimilar material joining of aluminum and titanium alloys is recognized as a challenge due to the significant differences in the physical, chemical, and metallurgical properties of these alloys, where the increasing demands for high strength and lightweight alloys in aerospace, defense, and automotive industries. Joining these two alloys using the conventional fusion techniques produces commercially unacceptable sound joints due to irregular, complex weld pool shapes, cracking and low strength, high residual stresses, cracks, and microporosity, and the brittle intermetallic compounds formation leads to poor formability or inferior mechanical properties. The formation of intermetallic compounds is inevitable but it is less severe in solid-state than in the fusion welding process. Hence, this article reviews on aluminum–titanium joining using different solid-state and hybrid joining processes with emphasis on the effect of process parameters of the different processes on the weld microstructure, mechanical properties along with the type of intermetallic compounds and defects formed at the weld interface. Among the various solid-state welding processes for aluminum–titanium joining, the following grades of aluminum and titanium alloys were employed such as cp Ti, Ti6Al4V, cp Al, AA1xxx, AA 2xxx, AA5xxx, AA6xxx, AA7xxx, out of which Ti6Al4V and AA6xxx alloys are the most common combination.

Development of Welding Procedures for X90-Grade Seamless Pipes for Riser Applications

2012 ◽  
Author(s):  
Hiroyuki Nagayama ◽  
Masahiko Hamada ◽  
Mark F. Mruczek ◽  
Mark Vickers ◽  
Nobuyuki Hisamune ◽  
...  
Keyword(s):  
Weld Metal ◽  
Arc Welding ◽  
Mechanical Test ◽  
Welding Process ◽  
High Strength ◽  
Submerged Arc Welding ◽  
Welding Parameters ◽  
Flux Cored Arc Welding ◽  
Welding Procedure ◽  
Submerged Arc

Ultra-high strength seamless pipes of X90 and X100 grades have been developed for deepwater or ultra-deepwater applications. Girth welding procedure specifications (WPSs) should be developed for the ultra-high strength pipes. However, there is little information for double jointing welding procedure by using submerged arc welding process for high strength line pipes. This paper describes mechanical test results of submerged arc welding (SAW) and gas shielded flux cored arc welding (GSFCAW) trials with various welding consumables procured from commercial markets. Welds were then made with typical welding parameters for riser productions using high strength X90 seamless pipes. The submerged arc weld metal strength could increase by increasing alloy elements in weld metal. The weld metal with CE (IIW) value of 0.74 mass% achieved fully overmatching for the X90 pipe. The weld metal yield strength (0.2% offset) was 694 MPa, and the ultimate tensile strength was 833 MPa. It was also confirmed that the reduction of boron in weld metal can improve low temperature toughness of high strength weld metal. Furthermore, it was confirmed that the HAZ has excellent mechanical properties and toughness for riser applications. In this study GSFCAW procedures were also developed. GSFCAW can be used for joining pipe and connector material for riser production welding. The weld metal with a CE (IIW) value of 0.54 mass% could meet the required strength level for X90-grade pipe as specified in ISO 3183. Cross weld tensile testing showed that fractures were achieved in the base metal. Good Charpy impact properties in weld metal and HAZ were also confirmed.

scholarly journals Fatigue Life Enhancement of Transverse and Longitudinal T-Joint on Offshore Steel Structure HSLAS460G2+M using Semi-automated GMAW and HFMI/PIT

2019 ◽  
Vol 269 ◽  
pp. 06001 ◽  
Author(s):  
Dahia Andud ◽  
Muhd Faiz Mat ◽  
Yupiter HP Manurung ◽  
Salina Saidin ◽  
Noridzwan Nordin ◽  
...  
Keyword(s):  
Fatigue Life ◽  
Oil And Gas ◽  
Welding Process ◽  
Steel Structure ◽  
Raw Material ◽  
Welding Parameters ◽  
Weld Toe ◽  
Life Enhancement ◽  
Welding Procedure ◽  
Fatigue Life Enhancement

This research deals with a method and procedure for enhancing the structural life of the commonly used steel structure in oil and gas industries HSLA S460G2+M with a thickness of 10 mm. The type of joint and welding process is T-joint with transverse and longitudinal attachment welded using semi-automated GMAW. Filler wire ER80S-Ni1 and mixed shielding gas (80% Ar / 20% CO2) is used as material consumables. At first, the best suitable welding parameters are comprehensively investigated, prepared, tested and qualified according to welding procedure specification (WPS) qualification requirements. Further, the weld toe is treated by using HFMI/PIT with a frequency of 90Hz, 2 mm pin radius and air pressure of 6 bars. In accordance with the recommendation of the International Welding Institute (IIW), fatigue test is conducted using constant amplitude loading with the stress ratio of 0.1 and loading stresses from 55% to 75% of the yield strength of the material. Finally, the results of the fatigue experimental are compared with the fatigue recommendation of as-welded and HFMI/PIT of IIW as well as the untreated raw material. As a conclusion, it is observed that the fatigue life is increased up to 300% compared to IIW and 70% to as-welded. It is also obvious that treated transverse T-joint shows significant improvement than the longitudinal attachment.

New Low Alloy High Strength Steel Welding Procedure Evaluation

2019 ◽  
Vol 814 ◽  
pp. 238-241
Author(s):  
Wen Juan Li
Keyword(s):  
High Strength Steel ◽  
Welded Joint ◽  
Welding Process ◽  
High Strength ◽  
Hardness Test ◽  
Ultrahigh Strength Steel ◽  
New Type ◽  
Welding Procedure ◽  
Test Result ◽  
Reliable Basis

In order to determine the weldability of a new type of low alloy high strength steel, the feasibility of the proposed welding process was examined and the welding procedure qualification of a new type of ultrahigh strength steel WELDOX 1100 was carried out through the weldability test of the welded joint, the small iron research and the highest hardness test. . The test result satisfies the specification requirements and proves that the proposed welding process plan is correct and feasible. It provides a reliable basis for the preparation of welding process documents and ensures the smooth development of the company's new products.

Development of a Welding Sequence Optimized for the Fatigue Resistance of Tubular Joints With a Novel Representative Welded Sample

2018 ◽  
Author(s):  
Philippe Thibaux ◽  
Eric Van Pottelberg
Keyword(s):  
Fatigue Resistance ◽  
Fatigue Testing ◽  
Welding Process ◽  
Offshore Structures ◽  
Fatigue Tests ◽  
Complex Geometries ◽  
Tubular Joints ◽  
Welding Sequence ◽  
Welding Procedure ◽  
Welding Position

Tubular joints are complex geometries present in many offshore structures. Fatigue testing of tubular joints requires either downsizing of the dimensions of the joints or the use of a simplified geometry, to avoid prohibitive costs. For the development of a welding process optimized for the fatigue performance of tubular joints, one needs to use a representative sample: same material, same thickness, use of similar welding positions, same level of restraint as in a real structure, combined with the supplementary requirement of ease of manufacturing and testing. A novel geometry was developed to fulfil all these requirements. Then, different welds were produced using robot and manual welding in different positions. The fatigue tests proved to be very reproducible, and indicate a strong influence of the welding position on the fatigue resistance. For that reason, an optimized welding procedure and sequence was developed, in which the welds in the most fatigue sensitive locations are produced first in optimum condition, while the less sensitive parts are produced by subsequent welding in position.

Full Scale Fatigue Performance of Pre-Strained SCR Girth Welds: Comparison of Different Reeling Frames

2010 ◽  
Author(s):  
Philippe P. Darcis ◽  
Israel Marines-Garcia ◽  
Eduardo A. Ruiz ◽  
Elsa C. Marques ◽  
Mariano Armengol ◽  
...  
Keyword(s):  
Arc Welding ◽  
Oil And Gas ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Full Scale ◽  
Strain History ◽  
Oil And Gas Development ◽  
Arc Welding Process ◽  
Girth Welds ◽  
Welding Procedure

The current work aims to point out the influence of plastic strain history, due to reel-lay installation, on the fatigue resistance of welded SMLS (seamless) steel pipes used for fabrication of Steel Catenary Risers (SCRs) for oil and gas development. A C-Mn steel X65 pipe 10.75″ (273.1 mm) outside diameter (OD) and 25.4 mm wall thickness (WT) was chosen for this program. The Welding Procedure designed for girth welds manufacturing involved the use of Lincoln STT-GMAW™ (Surface Tension Transfer–Gas Metal Arc Welding) process for the root pass and SAW (Submerged Arc Welding) process with twin wire configuration for the fill and cap passes. This welding procedure presents a special post-weld finishing treatment, which consists in flapping the inner and outer weld overfills to produce a flush profile between weld metal and outer/inner pipe surfaces. The experimental approach was focused on quantifying the effect of accumulated plastic deformation using two different reeling frames simulating the same laying vessel: the Technip’s Apache. In this program, two reeling trials were performed at Heriot Watt University, Edinburgh, U.K., and two other trials at Stress Engineering Services, Houston, U.S.A. Then, the strained specimens were full scale fatigue tested at TenarisTamsa R&D facilities. Those results have been compared with fatigue results obtained on unstrained specimens. Post-tests fractographic investigations were systematically performed on all samples to identify the causes for fatigue initiation. The results were statistically analyzed to determine which standard fatigue design curves best represent the measured S-N fatigue endurance. Finally, the results were also compared with the available literature.

Susceptibility Study to Hydrogen Embrittlement of Welded Joints of API 5L X52 Steel in Sulphide Media

2020 ◽  
Vol 1158 ◽  
pp. 27-42
Author(s):  
Daniel Kohls ◽  
Enori Gemelli ◽  
Laercio da Silva Filho ◽  
Majorie Anacleto Bernardo
Keyword(s):  
Hydrogen Embrittlement ◽  
Base Metal ◽  
Welded Joints ◽  
Oil And Gas ◽  
Welded Joint ◽  
Welding Process ◽  
High Strength ◽  
Tensile Tests ◽  
Low Alloy Steels ◽  
X52 Steel

Pipelines for oil and gas, manufactured in high-strength low-alloy steels (HSLA), such API pipes, promote high levels of strength and fracture toughness. Therefore, it is important to ensure this high level of toughness in the welded joint. When the pipelines are exposed for many years to wet H2S environments, they can fail due to hydrogen embrittlement. Thus, it is important to evaluate the influence of different weld specifications in the susceptibility to hydrogen embrittlement. In this case, the aim of this work was to study the susceptibility to hydrogen embrittlement of API 5L X52 steel and in the welded region in wet environments. The welding was performed in the circumferential direction by GMAW process in two different specifications (with lower and higher thermal input). The susceptibility to hydrogen embrittlement was carried out according to NACE TM0177 and SSRT (slow strain rate tensile tests) test, performed according to ASTM G 129 standard. All welded joints and base metal did not show any signal of cracks and susceptibility to hydrogen embrittlement, according to the requirements of the NACE TM0177 test. According to SSRT tensile test, the results showed that the welded joints and base metal are susceptible to hydrogen embrittlement. The tensile tests exhibited a drop in the strain and necking, and higher values of yield stress. The welded joint with the lowest heat inputs employed in the welding process presented the highest susceptibility to hydrogen embrittlement.

Establishment of Cold Wire Addition Technology® in Multiwire Submerged Arc Welding for Line Pipe Manufacturing to Improve the Weldment Quality

2015 ◽  
Author(s):  
Ramakrishnan Mannarsamy ◽  
S. K. Shrivastava ◽  
Piyush Thakor ◽  
Gautam Chauhan ◽  
S. K. Joshi ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Weld Metal ◽  
Arc Welding ◽  
Welding Process ◽  
High Strength ◽  
Submerged Arc Welding ◽  
Line Pipe ◽  
Cold Wire ◽  
Welding Procedure ◽  
Submerged Arc

For achieving high productivity multiple wire submerged arc welding such as tandem wire, three wires and five wires submerged arc welding was introduced in recent past years. Due to adding of additional wires in a pipe mill faced process difficulties such as controlling the current supply to each wire and further challenges for consumable design in order to give effective slag characteristics and bead shape control at these higher welding speeds and heat inputs. To gain maximum productivity, welding speed must be as fast as possible (in excess of 2 m/min) consistent with reliable high speed wire feeding and the characteristics of the SAW flux considering these factors in determining the balance of heat input, penetration, bead shape, dilution, weld metal chemistry and mechanical properties such as toughness. Steels containing high strength low alloying elements like Manganese, Molybdenum, Titanium and boron have favorable physical properties such as higher subzero toughness, resistance to improve the mechanical properties because of which there is substantial saving in the material. High strength low alloy steels materials are utilized in offshore and onshore at critical services. However, such benefits can be exploited provided these steels can be welded with appropriate development of welding process such as cold wire addition® in multi wires with process controller using WINCC programmer, Z5 version to give better weldments, which will not compromise the integrity, and operating condition. To obtain higher productivity and quality, it is necessary to develop a welding procedure for butt joint of line pipe steels. This paper describes the recent work carried out by Welspun, in this regard to establish the welding procedure using GMAW and submerged arc welding process and evaluation of mechanical properties. Macro and micro structural analysis were also made to characterize the weld metal properties.

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