Consumers Energy Welding Procedures 2014 Michigan Pipeline Safety Conference Mitch M Loomis September 10 th, 2014
Welding Procedure Major Updates Previous GCD WPS family has been replaced with newly developed and qualified procedures. Qualified to API 1104 20 th Edition Official API 1104 interpretations PRCI Guidelines for Interpretation - Application of API 1104 Joint Detail Electrode selection/usage Diameter ranges Wall Thickness ranges Preheat/Inter-Pass requirements
API 1104 20 th Edition Essential Variables Changes requiring requalification Welding process or method of application Base material Joint design (ex. V groove to U groove) Position (Rolled to Fixed) Wall thickness Filler metal (Group Change) Electrical characteristics Time between passes Direction of welding Shielding gas and flow rate Shielding flux Speed of travel Decrease in the preheat temperature Post Weld Heat Treatment
Joint Design API 1104 20 th Edition 5.3.2.4 Joint Design The specification shall include a sketch or sketches of the joint that show the angle of bevel, the size of the root face, and the root opening or the space between abutting members. The shape and size of fillet welds shall be shown. If a backup is used, the type shall be designated. 5.4.2.3 Joint Design A major change in joint design (for example, from V groove to U groove) constitutes an essential variable. Minor changes in the angle of bevel or the land of the welding groove are not essential variables.
Joint Design Previous Version of WPS s: One procedure for each joint type Restrictive ranges on fit-up Multiple procedures for different diameters and wall thicknesses New Version of WPS s: One procedure for all joint types for each material group Applicable supporting PQR s. Realistic joint fit-up ranges allowing for field condition variances (i.e. beveling equipment not square, difficult tie-ins)
Joint Design IG Lap Joint (Socket Weld) Root Opening: 0 to 1/8 Insertion Gap: 1/16 min. Single V Groove (Butt Weld) Root Opening: 1/16 to 3/16 Root Face: 1/16 to 3/32 Groove Angle: 60 to 75 (bevel angle: 30 to 37.5 ) Single Bevel (Branch Weld) Root Opening: 1/16 to 3/16 Root Face: 1/16 to 3/32 Angle: 45 min.
Fillet Weld Size Fillet Weld Minimum Size for Sleeve Ends 45 minimum chamfer 1.4t max Effective weld throat = 0.7t to 1.0t Pipe Wall thickness = t Maximum gap of 1/8 inch Fillet weld leg size = 1.0t + gap to 1.4t + gap ASME B31.8
Fillet Weld Shape AWS D1.1
Filler Metal and Number of Beads API 1104 20 th Edition 5.3.2.5 Filler Metal and Number of Beads The sizes and classification number of the filler metal and the minimum number and sequence of beads shall be designated. 5.3.2.6 Electrical Characteristics The current and polarity shall be designated, and the range of voltage and amperage for each electrode, rod, or wire shall be shown.
Electrodes Selection Electrode Selection/Usage: Electrical Characteristics for each electrode Electrode diameter and Classification for each welding pass Travel Speed range for each electrode diameter *Verified through qualification process, documented on Coupon Test Record or PQR.
Electrode Selection Wall Thickness (inches) Electrode Classification Electrode Size (inches) Pass Number¹ Amps Volts Travel Speed² Heat Input (Joules).125 to <.219 E7016-H4 3/32 All 50-80 18-27 3-6 ipm 15-25 >.219 to.750 E7016-H4 3/32 Root/Temper Beads 70-100 18-27 3-7 ipm 22-39 >.219 to.750 E7016-H4 3/32 or Fill/Cap 70-100 18-27 3-7 ipm 22-39 >.219 to.750 E7016-H4 1/8 Fill/Cap 80-140 18-27 4-8 ipm 25-40 1. Tempering passes are applied to the pipe wall before joint is filled with additional weld passes. This allows for pipe wall tempering reducing hardness levels in the Heat Affected Zones. See Typical Welding Sequence for Full Encirclement Fittings. 2. Stringer or Weave passes are acceptable when applied within these ranges. Travel Speed is measured in the direction of welding progression. Weave motion perpendicular to the direction of travel is not included in the travel speed measurement. Example from GCD In-Service WPS
Minimum Number of Passes Horizontal Pipe Flat Seam Weld Vertical Pipe Incline Pipe Single V groove Weld Min. # Passes Min. # Passes Wall Thickness 1G & 5G 2G & 6G <.250 2 2 >.250 3 4 >.375 4 4 >.500 5 6 >.625 7 9.750 10 12 Addresses Multiple Fixed Positions
Diameter Ranges API 1104 20 th Edition and API Interpretations 5.3.2.3 Diameters and Wall Thicknesses The ranges of outside diameters and wall thicknesses over which the procedure is applicable shall be identified. Examples of suggested groupings are shown in 6.2.2, items d and e. Inquiry Number: 1104-I-01-96 The essential variable list in Section 5.4 for Weld Procedure Qualification does not cover diameter groupings although Welder Qualification Tests do have groupings. Is it correct in saying that qualifying a procedure on 2" diameter would qualify, say, a 40" diameter butt weld provided all other essential variables were met? API Official Response: Yes.
Diameter Ranges Previous version of WPS s: < 2.375 O.D. > 2.375 to < 12.750 O.D. > 12.750 O.D. *Mimics welder qualification ranges. Typical. New version of WPS s: No Restrictions Unlimited Why? Minimum Preheat requirements Inter-Pass temp control No significant changes from one diameter to the next
Wall Thickness API 1104 20 th Edition and API Interpretations 5.3.2.3 Diameters and Wall Thicknesses The ranges of outside diameters and wall thicknesses over which the procedure is applicable shall be identified. Examples of suggested groupings are shown in 6.2.2, items d and e. 5.4.2.5 Wall Thickness A change from one wall thickness group to another constitutes an essential variable. Inquiry Number: 1104-I-01-96 The section on essential variables for Weld Procedure Qualifications, Section 5.4.2.5, states a change from one group to another. However, this section does not specify which group. Is the first group specified in Table 2 which is <.500 inch and >.500 inch? Or is it the group specified under Welder Qualification Tests which is <.188 in,.188 in -.750 in, and >.750 inch? API Official Response: The groups are not specified in API-1104, they are to be selected by the user. See Para. 5.3.2.3.
Wall Thickness Previous versions of WPS s <.188 wall thickness >.188 to <.750 >.750 wall Thickness *Mimics welder qualification ranges. Typical. New wall thickness requirements Pipe & Fittings Unlimited Why? Wall Thickness/Electrode Chart Min. # of passes chart Minimum Preheat requirements Inter-Pass temp control
Pre-Heat API 1104 20 th Edition 5.4.2.13 Pre-heat A decrease in the specified minimum pre-heat temperature constitutes an essential variable. GCD 42 Preheat Conditions: When ambient temperature or material temperature is below 40 F or when moisture is present on/near welding joint. Required when wall thickness of pipe or fitting exceeds.500 inch. Temperature: 250 F minimum temperature. Maintain minimum temperature until weld is complete. Measure three to four inches away from each side of weld joint. GCD 65 & GCD 70 require preheat in all conditions
Pre-Heat Preheat = Material temperature at the time the welding arc is initiated. Procedures were qualified in winter December- February. Material temps were controlled approximately 40º F. GCD 42 & GCD 60 were qualified without application of additional heat. GCD 65 & GCD 70 were preheated to 300º F.
Inter-Pass Temperature Control Inter-pass Temperature: 500 F maximum temperature. Measure approximately one inch from each side of weld joint edge. Both Preheat and Inter-pass Temperatures were influenced by ASME design criteria.
Major Procedure Updates - Summary Qualified to API 1104 20 th Edition Incorporated Multiple Joint Designs More stringent electrode selection Diameters Electrical Characteristics Flexible Diameter ranges Flexible Wall Thickness ranges More stringent pre-heat requirements Inter-pass Temperature Control Updated PQR Form 670 Well organized and easy to follow procedures for field use Cross-functional team in place for reviewing, testing and approving final procedures (NDT, Materials Lab, CWI s, Engineering & Welding).
Procedure Replacement New GCD Welding Procedures: GCD 42 GCD 60 GCD 65 GCD 70 GCD Weld Repair GCD In-Service Replacing previous GCD procedure family: GCD 1 GCD 10 GCD 10A GCD 15 GCD 15A GCD 16 GCD 17 GCD 17R GCD 19 GCD 20 GCD 20A GCD 21 GCD 22 GCD23 GCD24 GCD 25 GCD 25B GCD 27 GCD 28 40TS-API 41TS-API 42TS-API SF-1 SF-2 SF-3 SF-4 SF-5 SF-6 SF-7 SGR1, 2, &3
Questions?