1 | Manfred Höfer | Welding of X80/100 I April, 2011 1 We are the World of Welding Solutions. WELDING CONSUMABLES FOR PIPELINE CONSTRUCTIONS WITH FOCUS ON LHVD ELECTRODES FOR X80 AND X100 MANFRED HOEFER, Technical Regional Manager ME, April 2011
Nov 08, 2014
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
3 | Manfred Höfer | Welding of X80/100 I 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)
4 | Manfred Höfer | Welding of X80/100 I April, 2011
� 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
Content of presentation
5 | Manfred Höfer | Welding of X80/100 I April, 2011
Welding processes in pipeline girth welding
SMAW vertical up vertical down
GMAW vertical down
FCAW vertical up vertical down
SAW horizontal
6 | Manfred Höfer | Welding of X80/100 I April, 2011
� 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
Content of presentation
7 | Manfred Höfer | Welding of X80/100 I April, 2011
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
8 | Manfred Höfer | Welding of X80/100 I April, 2011
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
9 | Manfred Höfer | Welding of X80/100 I April, 2011
� 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
Content of presentation
10 | Manfred Höfer | Welding of X80/100 I April, 2011
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
11 | Manfred Höfer | Welding of X80/100 I April, 2011
� 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
Content of presentation
12 | Manfred Höfer | Welding of X80/100 I April, 2011
Cellulosic and basic coated vertical-down electrodes
Hydrogen
Mechanical properties
Economy
Distinctive features
13 | Manfred Höfer | Welding of X80/100 I April, 2011
Cellullosic and basic coated vertical-down electrodes
Mechanical properties
Strength Impact
Distinctive features
14 | Manfred Höfer | Welding of X80/100 I April, 2011
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
15 | Manfred Höfer | Welding of X80/100 I April, 2011
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
16 | Manfred Höfer | Welding of X80/100 I April, 2011
5ml
Hyd
roge
nco
nten
tml/1
00g
depo
sit
cellulosic rutile basic
Hydrogen contents - Type of coatings
Coating system
17 | Manfred Höfer | Welding of X80/100 I April, 2011
HydrogenHydrogen -- risk potential when weldingrisk potential when weldingunalloyed high strength steels!!!unalloyed high strength steels!!!
Hydrogen contents
18 | Manfred Höfer | Welding of X80/100 I April, 2011
In fracture recognizable as brittle fracture spot
In longitudinal section recognizable as cracks
preferred area
Appearance of hydrogen inducted defects
19 | Manfred Höfer | Welding of X80/100 I April, 2011
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
20 | Manfred Höfer | Welding of X80/100 I April, 2011
�� 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
21 | Manfred Höfer | Welding of X80/100 I April, 2011
Test sheet before and after welding
Bead bend test
22 | Manfred Höfer | Welding of X80/100 I April, 2011
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
23 | Manfred Höfer | Welding of X80/100 I April, 2011
Bend test equipment
Bead bend test
24 | Manfred Höfer | Welding of X80/100 I April, 2011
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
25 | Manfred Höfer | Welding of X80/100 I April, 2011
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
26 | Manfred Höfer | Welding of X80/100 I April, 2011
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
27 | Manfred Höfer | Welding of X80/100 I April, 2011
Hydrogen induced crack in E8010 weld metal
Transverse crack
28 | Manfred Höfer | Welding of X80/100 I April, 2011
� 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
Content of presentation
29 | Manfred Höfer | Welding of X80/100 I April, 2011
Cellullosic and basic coated vertical-down electrodes
Economy
Deposition rate Travel speed
Distinctive features
30 | Manfred Höfer | Welding of X80/100 I April, 2011
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
31 | Manfred Höfer | Welding of X80/100 I April, 2011
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.
Deposition rates vs. welding speeds
32 | Manfred Höfer | Welding of X80/100 I April, 2011
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
Deposition rates vs. welding speeds
Third
33 | Manfred Höfer | Welding of X80/100 I April, 2011
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
Deposition rates vs. welding speeds
34 | Manfred Höfer | Welding of X80/100 I April, 2011
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
Deposition rates vs. welding speeds
35 | Manfred Höfer | Welding of X80/100 I April, 2011
� 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
Content of presentation
36 | Manfred Höfer | Welding of X80/100 I April, 2011
Specified strength forX80 pipe steel grade
Min.620Min.550EN 10208-2L 555 MB
Min.621Min.552API 5 LX80
TS
[MPa]
YS
[MPa]StandardSteel grade
37 | Manfred Höfer | Welding of X80/100 I April, 2011
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
38 | Manfred Höfer | Welding of X80/100 I April, 2011
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
39 | Manfred Höfer | Welding of X80/100 I April, 2011
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
40 | Manfred Höfer | Welding of X80/100 I April, 2011
Coating types for vertical down welding
�CELLULOSIC
�BASICCombinedMethod
41 | Manfred Höfer | Welding of X80/100 I April, 2011
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
42 | Manfred Höfer | Welding of X80/100 I April, 2011
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
43 | Manfred Höfer | Welding of X80/100 I April, 2011
� 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
44 | Manfred Höfer | Welding of X80/100 I April, 2011
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
45 | Manfred Höfer | Welding of X80/100 I April, 2011
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.
46 | Manfred Höfer | Welding of X80/100 I April, 2011
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
47 | Manfred Höfer | Welding of X80/100 I April, 2011
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
48 | Manfred Höfer | Welding of X80/100 I April, 2011
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
49 | Manfred Höfer | Welding of X80/100 I April, 2011
Some aspects by welding of API 5L X100 steels grades
Welding tests on X100 in cooperation with SHELL International
50 | Manfred Höfer | Welding of X80/100 I April, 2011
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]
51 | Manfred Höfer | Welding of X80/100 I April, 2011
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
52 | Manfred Höfer | Welding of X80/100 I April, 2011
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
53 | Manfred Höfer | Welding of X80/100 I April, 2011
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
54 | Manfred Höfer | Welding of X80/100 I April, 2011
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
55 | Manfred Höfer | Welding of X80/100 I April, 2011
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
X 100 Welding tests –mechanical properties of V- joint
56 | Manfred Höfer | Welding of X80/100 I April, 2011
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 Welding tests –mechanical properties of V- joint
57 | Manfred Höfer | Welding of X80/100 I April, 2011
X 100, dia. 56”, wth. 19,1mm WELDING TESTS M/s SNAM - Italia
58 | Manfred Höfer | Welding of X80/100 I 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°C0.10 / 0.11 / 0.07 at -20°C
X 100, dia. 56”, wth. 19,1mm WELDING TESTS M/s SNAM - Italia
59 | Manfred Höfer | Welding of X80/100 I April, 2011
X 100, dia. 56”, wth. 19,1mm WELDING TESTS M/s SNAM - Italia
60 | Manfred Höfer | Welding of X80/100 I April, 2011
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
61 | Manfred Höfer | Welding of X80/100 I April, 2011
� 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
Project welded with combination ofcellulosic and basic coated electrodes
62 | Manfred Höfer | Welding of X80/100 I April, 2011
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)
Project welded with combination ofcellulosic and basic coated electrodes
63 | Manfred Höfer | Welding of X80/100 I April, 2011
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)
Project welded with combination ofcellulosic and basic coated electrodes
64 | Manfred Höfer | Welding of X80/100 I April, 2011
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
Project welded with combination ofcellulosic and basic coated electrodes
65 | Manfred Höfer | Welding of X80/100 I April, 2011
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)
Project welded with combination ofcellulosic and basic coated electrodes
66 | Manfred Höfer | Welding of X80/100 I April, 2011
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
67 | Manfred Höfer | Welding of X80/100 I April, 2011
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
68 | Manfred Höfer | Welding of X80/100 I April, 2011
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
69 | Manfred Höfer | Welding of X80/100 I April, 2011
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
70 | Manfred Höfer | Welding of X80/100 I 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
71 | Manfred Höfer | Welding of X80/100 I April, 2011
When operators havesophisticated productsin their hands even welding, at least sometimes, can be enjoyable !
72 | Manfred Höfer | Welding of X80/100 I April, 2011
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