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    Gen - Importance of Welding in L & T PDF

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    Gen - Importance of Welding in L & T PDF

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    172 views30 pages

    Gen - Importance of Welding in L & T PDF

    Uploaded by

    Siva

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    © All Rights Reserved
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    of 30

    Importance of welding in L&T

    • All fabrication consists of Forming and


    Joining (welding).
    • It is finally the quality of welding that
    decides whether L&T gets an order,
    executes it on time and books a profit.
    • What is special about welding in L&T?
    Welding in L&T

    • Fabrication of equipment for a wide range


    of industries like Food, Cement, Chemical,
    Petrochemical, Fertilizer, Man-made Fibres,
    Oil & Gas, Nuclear, Defence and
    Aerospace. Each of these applications has
    its specific requirements.
    • Use of a wide range of materials like
    Ferrous (CS, LAS, SS) & Non-ferrous (Ni,
    Cu, Al, Ti, Zr & Alloys).
    Welding in L&T

    • Variety of design and fabrication codes like


    ASME, BS, AD-Merkblatter.
    • Emphasis on mechanized welding processes
    like SAW with many variations like
    Tandem, Strip cladding etc.
    • Wide range of Thickness: 0.5 to 500 mm.
    • Large number of highly skilled welders.
    FUNCTIONS OF
    WELDING ENGG.

    PLANNING EXECUTION DEVELOPMENT MATERIALS TRAINING &


    QUALIFICATIONS
    Planning Cell

    • Study drawings, specifications.


    • Decide welding process/wep.
    • Deciding consumable type.
    • Calculating consumable and indenting.
    • Availability of welding procedures.
    • Deciding NDE and destructive testing.
    • Documentation.
    Execution Cell

    • Ensure sound welding practices.


    • Minimise rework.
    • Suggest high productivity techniques.
    • Identify need for training and qualification.
    • Trouble shooting.
    Development Cell

    • Literature survey and analysis.


    • New materials.
    • New processes/techniques.
    • Special applications/configurations.
    • Updating know-how.
    • Failure analysis.
    Materials Cell

    • Identifying quality vendors.


    • Setting standards for consumables.
    • Procuring local consumables.
    • Maintaining Inventory.
    Training & Qualifications

    • Training welders for various processes.


    • Qualification tests for welders.
    • Qualification of welding procedures.
    Information from Welding Engg.

    • Shop Welding Plan (SWP)


    • Test Plan (TP)
    • Provisional Weld Plan (PWP)
    • Shop Weld Repair Plan (SWRP)
    • Welding Procedure Specification (WPS)
    • Welder Master List
    Why Preheat?

    • Drive out moisture.


    • Hydrogen diffuses out faster at higher temp.
    • Lower cooling rate & lower hardness.
    • Lower shrinkage & residual stresses.
    • Prevent cold cracking in ferritic steels.
    • Reduces chances of porosity.
    How to Preheat? (1)

    • Low intensity burners with shrouds are best.


    • Avoid hot spots.
    • From opposite side where feasible.
    • From inside for multi-wall vessels.
    • Extra care for clad vessels.
    • Width of preheat- higher of 75mm on either
    side or thickness.
    How to Preheat? (2)

    • Uniform preheat with a moderate heating


    rate. Uneven heating in a restrained joint
    can lead to weld cracking.
    • Soot formation on vessel to be avoided.
    • Temperature to be measured on the opposite
    side of heat source. Otherwise remove heat
    source and wait for 1minute/inch before
    measuring.
    Why Interpass?

    • Reduces overheating and grain coarsening


    thus controlling drop in impact toughness.
    • Reduces the susceptibility to IGC.
    Why Postheating?

    • Generic term is DHT (Dehydrogenation


    treatment).
    • Provides more time for hydrogen to diffuse
    out from the weldment.
    • Diffusion of hydrogen is faster as the
    temperature is higher (300-350°C)
    • Prevent cold cracking.
    Why portable ovens?

    • Keep electrodes hot and maintain lower


    moisture levels.
    • All our consumables are procured with low
    hydrogen coating.
    • Another preventive measure for cold
    cracking.
    • Worldwide standard.
    • Reduces chances of porosity.
    Why temper bead?

    • A weld layer heat treats (tempers) the


    previously laid weld and improves
    toughness. This beneficial action is not
    available to the last layer so a temper bead.
    • In materials where the impact toughness is
    very critical (difficult to obtain) or when
    there is no PWHT.
    Why buttering?

    • Dissimilar materials being joined.


    • Materials with different PWHT
    requirements being joined.
    • Reduces the risk of Lamellar tearing.
    • Preferred option for critical applications.
    Why depth charts?

    • Improve accountability for weld quality.


    • Necessary for analysis in case of repairs.
    • Productivity monitoring?
    Importance of good set-ups

    • Excess gap can lead to solidification


    cracking. It also increases the weld metal
    requirement.
    • Higher root face leads to less penetration
    and deeper chip back.
    • Improperly tacked backing strips lead to
    cracking.
    Temporary attachments

    • More critical than the “permanent welds”.


    • Preheating more important.
    • Material identification.
    • Removal equally critical.
    Miscellaneous (1)

    • Fans for welder or job?


    • Earthing clamp or arcing clamp?
    • Electrode holder condition.
    • Does post-heat begin when burners are put
    on? Or when the required temperature is
    achieved?
    • Clean surfaces to be welded.
    Miscellaneous (2)

    • Local purging is more effective.


    • Set through nozzle to shell joints are highly
    restrained. Weld a sufficient thickness
    before cooling from preheat. Best is “Don’t
    stop till joint is filled up.”
    • Preheating is also required for arc air
    gouging.
    Miscellaneous (3)

    • Run-in and run-out plates.


    • Gas heaters for CO2 welding.
    Cold cracking

    • Occurs due to hydrogen in the presence of


    stresses. Hard microstructures are more
    susceptible.
    • Can take place uptill 48 hours after welding
    is completed and hence the name.
    • Generally transverse to the weld.
    • Mostly in HAZ.
    Impact toughness

    • Resistance to crack initiation and growth.


    • Prevent brittle failures which are sudden
    and hence more damaging.
    • Depends upon material composition,
    microstructure, geometry(notch effect).
    • Microstructure depends on the heat input
    (current, voltage, travel speed & weaving)
    Hot cracking

    • a.k.a Solidification cracking.


    • Takes place during cooling.
    • Concave profiles (very thin and wide bead).
    • Segregation of low melting compounds at
    the centre of weld bead.
    • Most common form is crater crack.
    • Impurities like S, Si increase tendency.
    IGC

    • Inter granular corrosion. a.k.a Sensitization.


    • Is a problem when materials (like SS) are
    used for their corrosion resistance.
    • Chromium provides the resistance by
    forming an adherent film on surface.
    • When heated the carbon ties up chromium
    and film cannot form (insufficient).
    Why qualified welder?

    • Quality system requirement.


    • Lowering the possibility of weld defects.
    Productivity
    • Powai’s best SAW deposition for a circ. seam =
    37kg/shift.
    • We expect 7.17 hours and get about 5.9 hours in
    first shift.
    • At 550A & 40mm ESO actual deposition rate is
    155gm/min.
    • If 5.9 hours then 55kg or at least 50kg assuming
    0.5hr for spool change.
    • 37kg/shift indicates 4hours of arcing.

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