Comparison for FCAW & GMAW

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Lakshman Kumar. B

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Oct 26, 2016, 12:43:53 AM10/26/16
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Hi friends,

 

We have a big pipe line job in water segment.

We are planning to implement FCAW or GMAW technique to expedite the welding activity…

Please suggest me that which technique is most favorable for IS2062 material (equivalent to Pno 1) at site for 5G or 6G position…..

Your detail explanation will be more helpful on selecting the process….

Also in terms of cost – which will be economical for the project ….

 

Thanks & Regards,

Lakshman Kumar B,

Project Manager.

 

Navayuga Engineering Company LTD

Corp Off: Plot no 379, Road No 10,

Jubileehills, Hyderabad.500033 India.

Tel -  +91 -40-2333 9990/91/92 – Ext 398

Fax: +91-40-2333 7789

Mob - +91 9440031459.

Email –lakshma...@navayuga.com

http://www.necltd.com/

cid:image001.jpg@01D1CBAD.24B27170

 

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Kannayeram Gnanapandithan

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Oct 26, 2016, 2:19:17 AM10/26/16
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it is better to go with FCAW because consumable is suitable for all position welding

THANKS & BEST REGARDS,
KG.PANDITHAN, IWE,  AWS-CWI, CSWIP 3.1,
CONSULTANT-WELDING & QUALITY
Mobile no: +919940739349

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dilintas

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Oct 26, 2016, 2:38:17 AM10/26/16
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GMAW is prone to lack of fusion



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Neilashkumar

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Oct 26, 2016, 7:03:08 AM10/26/16
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Dear Lakshman,

Can you please tell us the size of the pipe and thickness in order to choose the suitable weld process? It's like need to be automated in terms of orbital type.

I will be able to give more input on hearing the above queries .

P.NEILASHKUMAR 
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aslab khan

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Oct 26, 2016, 7:03:14 AM10/26/16
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Flux-cored wire is considered to have some advantages for outdoor welding on-site, as the shielding gas plume is less likely to be blown away in a wind than shield gas from a conventional nozzle. A slight drawback is that, like SMAW (stick) welding, there may be some flux deposited over the weld bead, requiring more of a cleaning process between passes.

consider FCAW better in your case.




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Aslab Ahmad Khan
QA/QC Inspector
Samsung Engineering Co.Ltd.Takreer CBDC PRJ(abudhabi)
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Lakshman Kumar. B

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Oct 26, 2016, 10:35:38 PM10/26/16
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Hi Mr. Neilash Kumar,

 

It is 120 Inch (3000Mm Dia) with 20 mm thick for a water transmission project.

 

Thanks & Regards,

Lakshman Kumar B,

prem_nautiyal26

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Oct 26, 2016, 10:36:48 PM10/26/16
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It will be better to go for FCAW in order to have much better quality Welds and productivity.
Also E71T1 can be welded in any position with radiographic quality.

Also how come you will be getting IS 2062 material in pipe form??

Your pipes may be A 106 GrB or IS 1239 or API 5L.


Regards

Prem Nautiyal 
Cell 9769316004




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-------- Original message --------
From: "Lakshman Kumar. B" <lakshma...@gmail.com>
Date: 26/10/2016 09:56 (GMT+05:30)
Subject: [MW:25601] Comparison for FCAW & GMAW

Hi friends,

 

We have a big pipe line job in water segment.

We are planning to implement FCAW or GMAW technique to expedite the welding activity…

Please suggest me that which technique is most favorable for IS2062 material (equivalent to Pno 1) at site for 5G or 6G position…..

Your detail explanation will be more helpful on selecting the process….

Also in terms of cost – which will be economical for the project ….

 

Thanks & Regards,

Lakshman Kumar B,

Project Manager.

 

Navayuga Engineering Company LTD

Corp Off: Plot no 379, Road No 10,

Jubileehills, Hyderabad.500033 India.

Tel -  +91 -40-2333 9990/91/92 – Ext 398

Fax: +91-40-2333 7789

Mob - +91 9440031459.

Email –lakshma...@navayuga.com

http://www.necltd.com/

cid:image001.jpg@01D1CBAD.24B27170

 

Alan Denney

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Oct 26, 2016, 10:36:48 PM10/26/16
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pgoswami

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Oct 26, 2016, 11:43:39 PM10/26/16
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Hi Lakhsman,

 

Both the processes are popular choices for pipeline welding. Mechanization  is the key. In general controlled surface transfer process e.g. STT or RMD are very conveniently used for long pipeline welding projects to cut down the production time and defect rates.

 

The attached documents provide some insights to such projects. Use the info at your discretion.

 

Thanks.

 

 

 

Pradip Goswami, P.Eng,IWE
 Welding & Metallurgical Engineering Specialist ,

ca.linkedin.com/pub/pradip-goswami/5/985/299

pgos...@quickclic.net

pradip....@gmail.com

 

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Mechanized-Pipeline-Welding-Magnatec.pdf

Neilashkumar

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Oct 27, 2016, 2:16:17 AM10/27/16
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Dear Lakshman,

Good morning, as told by Pradip sir it's has to be root weld by GMAW-STT, followed by  SAW -Machine Welding column and boom with roller bed both in site or shop.
Since 3meter OD little bit difficult with Mechanisation process, and I have practical experience with Magna tech and lone star machine up to 48 inch only.
I don't see any external band for 3meter OD.
Even in machine welding in order to increase productivity you can choose Twin wire SAW process.
Further any clarification let me know to clarify.

P.NEILASHKUMAR 
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<Mechanized-Pipeline-Welding-Magnatec.pdf>

Kannayeram Gnanapandithan

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Oct 27, 2016, 2:50:09 AM10/27/16
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go with Bug O System with multiple torches

THANKS & BEST REGARDS,
KG.PANDITHAN, IWE,  AWS-CWI, CSWIP 3.1,
CONSULTANT-WELDING & QUALITY
Mobile no: +919940739349

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Dear Lakshman,

Good morning, as told by Pradip sir it's has to be root weld by GMAW-STT, followed by  SAW -Machine Welding column and boom with roller bed both in site or shop.
Since 3meter OD little bit difficult with Mechanisation process, and I have practical experience with Magna tech and lone star machine up to 48 inch only.
I don't see any external band for 3meter OD.
Even in machine welding in order to increase productivity you can choose Twin wire SAW process.
Further any clarification let me know to clarify.
P.NEILASHKUMAR 
Sent from my iPad
MOB : 966 551094590
             +91 9952110791
On 27-Oct-2016, at 6:40 AM, pgoswami <pgos...@quickclic.net> wrote:

Hi Lakhsman,

 

Both the processes are popular choices for pipeline welding. Mechanization  is the key. In general controlled surface transfer process e.g. STT or RMD are very conveniently used for long pipeline welding projects to cut down the production time and defect rates.

 

The attached documents provide some insights to such projects. Use the info at your discretion.

 

Thanks.

 

 

 

Pradip Goswami, P.Eng,IWE
 Welding & Metallurgical Engineering Specialist ,

ca.linkedin.com/pub/pradip-goswami/5/985/299

pgos...@quickclic.net

pradip....@gmail.com

 

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<Mechanized-Pipeline-Welding-Magnatec.pdf>

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Lakshman Kumar. B

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Oct 27, 2016, 6:24:30 AM10/27/16
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Dear Mr. Pradip And all friends…

 

Thanks a lot for sharing your valuable inputs, and really it’s a great learning and good understanding also….

 

Further I would like to bring to your notice for the following key parameters…

(please see the images also and pls be informed that it is of water pipe line and cant able to correlate with Oil & Gas Cross country pipe lines) the following limitations we have …

 

1.       Pipe are not in exact round shape and most of the time pipes internal will be supported by spider pipes (bracings) to retain its shape, however those will be removed during execution time. Here 120 Inch dia (3000Mtr dia) with a thickness of 16/18 mm – D/T is almost 190…

 

Hence internal / external fitup clamps are not possible.

Edge preparation at site is not feasible, and we have a limitation to restrict to factory made bevel or bevel preparation by free hand ( not that much accurate)

 

 

2.       Pipe will be laid in the trench one after one – (like as O&G it is not welded outside the trench and lowering the pipe line with side booms) – after completing one pipe welding another pipe will be laid and will continue further…

3.       Hence pipe are directly laying in the trench, we didn’t have much clearance under the pipe

 

Hence big weld heads are not possible to use.

We can’t able to go for full automation like as CRC Evans and all (earlier I worked in Reliance and in CRC welding)

 

4.       Like as O&G – alignments are not too much straight, and didn’t have free ROU clearances –

O&G lines has to laid far from villages and dense areas, where as Water lines have to laid near to villages and cities by connecting all the areas.

Like as in O&G or for full automation – we can’t provide the clear work front.

 

Water lines have the above limitations and so only we should be particular about the process…

Any way I understood Any of  the process can be implemented.

 

Thanks & Regards,

Lakshman Kumar B,

+91 9440031459.

 

pipe laying.jpg
Pipes with spiders.jpg
laid pipe line.jpg
pipe line welding.jpg
Laying of pipe.jpg 2.jpg
Laying of pipe.jpg
Big dia pipe.jpg

Hemant W Joshi

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Nov 2, 2016, 6:18:26 AM11/2/16
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The issue of using IS 2062 plate for the pipes as has being enquired rihghty so by mr. Nautiyal remains unanswered. Can we get an idea about it?


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Gopi Krishna Banerjee

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Nov 3, 2016, 6:42:32 AM11/3/16
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Sir 

It is possible that if you use Pulsed MIG for Root Run only and Subsequent Run by FCAW Process for this Projects. 

G. K. Banerjee.

NAGPUR.


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