Welding Question needed ASAP - welding engineer unavailable - overhaul taking place

[awhicker84]

Hi,

I really need some help. I have a WPS / PQR that requires a SMAW process defined as the following options (ASME IX Boiler Pressure Code):

Process: SMAW
Spec No (SFA): 5.5
AWS (Class): E-7015 CL2 / E7016-C2L / E8018-C2
F-No: 4
A-No: 10

I'm suspecting our weld engineer isn't so careful and told us that 8018 was 'probably a typo' and crossed it out and wrote 7018. He did not check to make sure we had 7018 on hand. I just drove all across Houston looking for 7018 and realized that we drove around to get 7018-1 (F4, A1, AWS 5.1). I don't think 8018 was a typo.

The base material: A352 LCB

Are we able to use E7018-1?

Sorry if these questions seem easy, but I am NOT a welding engineer.

Thanks!

Reason for edit: asked if we could use E7016-1. Meant 7018.

 

[DekDee]

awhicker84,
Would like to help but the question is very strange.
You have a WPS /PQR with three different types of SMAW electrodes ?
What is the electrode used on the PQR ?
Cheers,
DD

 

[awhicker84]

The PQR was made using E-7015 C2L for SMAW and ENi3 for GTAW

The WPS allows E-7015 C2L / E-7016-C2L / E-8018-C2 for SMAW and ENi3 for GTAW

 

[awhicker84]

I'm not sure what ENi3 is either. I've been trying to figure out what rod this is so that my guys can weld using TIG but I can't find anything. One of the welders came up with 308 as a substitute.

The TIG specs (per PQR) are:

SFA: 5.28 GTAW Rod
AWS: ENi3
F-No: F6
A-No: A10

Long story short, I'm thinking the 7018 was made in error and my welders aren't very helpful with figuring out what stick rods fall into the above AWS numbers and what TIG rod falls into the above AWS.

So right now, the plan is to move forward with the 7018 per the weld engineer's recommendation, but I'm still open for figuring out:
1) What TIG rod I can use
2) If other weld experts agree that 7018 is good.

I would also add that this casing is rated for -50 F

cheers,

 

[DekDee]

awhicker84,
There are still a lot of things that appear strange but an internet forum is not the place to discuss.
You really need to get your Welding Engineer involved.
What I can tell you is the A number is an essential variable (QW 404.5) so if your qualified electrodes are A 10 you cannot replace with electrodes which are A 1.
Cheers,
DD

 

[awhicker84]

I was thinking this would be the case.

You gave me good info though.

Thanks much.

 

[DekDee]

awhicker84,
I didn't see your second to last posting before I made my last reply.
You won't find an ENi 3 - as per SFA 5.28 it is ER Ni3.
The critical thing is what is your construction code ?
If impact testing is required by the construction code (and it seems highly likely) then you are restricted by the Supplementary Essential variables of ASME IX.
If that is the case then you cannot use E 7016-1 or E 7018-1 with the WPS you have.

I understand your concerns as you seem to be stuck without technical help but I would like to congratulate you for actually trying to do the right thing and not just carry on regardless,
Good luck,
Cheers,
DD

 

[awhicker84]

Thanks for the additional info. I just woke up to text messages / emails telling me that the casing wasn't welding properly. Not really sure what that meant. I don't think the welder we had was super confident with stick welding and he had a customer looking over his shoulder. Not a good combo.

I guess the weld engineering FINALLY answered his email or came to the shop. So now we have an alternate welding procedure approved by the customer. Completely lost a shift of work + another 3 hours.

oh well.

Thanks again for all your help. I'm going to ask for the above mentioned PQR / WPS to be updated for clarity.

Cheers,

 

[DekDee]

Here is a bit of additional info for you (maybe help clarify)

QW-404.12

When a filler metal conforms to a filler metal classification,
within an SFA specification, except for the “G” suffix
classification, requalification is not required if a change
is made in any of the following:
(c) for carbon, low alloy, and stainless steel filler metals
having the same minimum tensile strength and the same
nominal chemical composition, a change from one low hydrogen
coating type to another low hydrogen coating type
(i.e., a change among EXX15, 16, or 18 or EXXX15, 16, or
17 classifications)

So if the electrode used in the PQR qualification was E7015-C2L the same minimum tensile strength would be E70XX (This rules out the E8018-C2)
If the electrode used in the PQR was E7015-C2L the same nominal composition (3.00 to 3.75% Ni) belongs to E7016-C2L and E7018-C2L.

WPS should read E7015-C2L, E7016-C2L, E7018-C2L

If the construction code does not require impact testing then it is a whole different set of rules.
Hope that helps,
Cheers,
DD

 

[weldstan]

It is almost certain that the WPS must be impact test qualified if ASME VIII or B31.3 govern.

 

[awhicker84]

Thanks everyone for your help. It has been very helpful and instructive.

I learned a lot about the ASME code. Our weld engineer ended up using 8018 stick welding to weld repair. As I can see from this thread, that was not correct per ASME, but it was stated as an option on our WPS. We should update our WPS to show that 8018 isn't acceptable per ASME.

Anyway, thanks for bearing with me as I try to be a weld engineer in lieu of using our unusable weld engineer.

Now we're PWHT'ing and I've got to find out if A36 welded stands can withstand holding a 40,000 lb casing without first being heat treated themselves...