Breesh-Lock Heat Exchangers Weld overlay

[JASPAL SINGH]

Dear all,

I have query regarding the Weld Overlay in Breesh Lock Heat
Exchanger.

As per specifications it is required to give SS347 Weld- overlay with
3mm undiluted chemistry . It is written that weld overlay shall be
lined & Faced. does it mean Strip cladding First then Machining.

Secondly is it possible to offer single layer solution for the same.

IS it required to machine the overlay in Breesh Lock Heat Exchanger.

Thanks in advance

Jaspal Singh

[GERING, Erwin]

Hello Mr Singh,

Single layer strip cladding solution is possible for SS347 with ES and SA process.
Depending on dimensions and requirements selection to be made :

SA-strip:
OERLIKON AST 300 - SUPRASTRIP 24 13LNb
OERLIKON AST 347 - SUPRASTRIP 24 13LNb

ES strip:
OERLIKON ELT 300 - SUPRASTRIP 21 11LNb (low speed)
OERLIKON ELT 300S - SUPRASTRIP 24 13LNb (high speed)
OERLIKON ELT 347-1 - SUPRASTRIP 19 9LNb (low speed)
 
In general the ES-strip cladding process can not garantue zero defects (PT-check) after machining in the ovelap zone. SA strip cladding process should be chosen in that case.
 
With kind regards,
Erwin GERING
AIR LIQUIDE WELDING


-----Oorspronkelijk bericht-----
Van: material...@googlegroups.com [mailto:material...@googlegroups.com] Namens JASPAL SINGH
Verzonden: vrijdag 13 november 2009 6:03
Aan: Materials & Welding
Onderwerp: [MW:3644] Breesh-Lock Heat Exchangers Weld overlay

[Garry Hunt]

Hello
 
Have a look at this information from Soudokay. It gives chem for each layer.
 
Regards,

 
> Date: Thu, 12 Nov 2009 21:03:12 -0800
> Subject: [MW:3644] Breesh-Lock Heat Exchangers Weld overlay
> From: jaspa...@gmail.com
> To: material...@googlegroups.com

[PB HEGDE]

Hi
Single layer 347 weld overlay by ESSC is good solution and you can also try
with Soudokay/Sandvik strip with High speed flux You should be able to
achieve 4.5 thk weld clad with top 3 mm undiluted chemistry of 347 It is
established process with nil disbanding. However if you want final weld
thickness of 5mm after machining better to go for Double layer where you
should get w/o thk of 7 mm and at least 2 mm M/cing allowance to take care
of distortion during welding

Hope this will solve your problem

Regards

Hegde P.B.

[GERING, Erwin]

Hello mr Singh

Please be careful to chose ES-process if surface will be machined (indications at overlap).
Please be careful with ES high speed solution for 4,5 mm thickness in single layer : in this thickness cladding with a 24.12LNb strip the dilution will be relative low which will result in relative high ferrite contents which can be over 10%.

Please contact for accurate advise/solution directly a producer of strip cladding flux like OERLIKON / AIR LIQUIDE WELDING  

With kind regards,
Erwin GERING erwin....@airliquide.com
Corporate Product Manager SAW/ES wire/flux/strip

AIR LIQUIDE WELDING

-----Oorspronkelijk bericht-----

Van: material...@googlegroups.com [mailto:material...@googlegroups.com] Namens PB HEGDE
Verzonden: vrijdag 13 november 2009 13:17
Aan: material...@googlegroups.com
Onderwerp: [MW:3647] RE: 3645] RE: 3644] Breesh-Lock Heat Exchangers Weld overlay

[PB HEGDE]

Dear Mr Singh
I think Not to get panic with Single layer ESSC and With High speed Flux .
It has been established in almost all DHDS reactors where you can achieve
Undiluted chemistry for top 3 mm. with no problem at overlap. With Ferrite
about 6-7%
With disbanding test No defect at 482 C with fastest cooling rate.
You can use for SS w/o magnetic stirrer for 30, 60 width strip and 90mm with
magnetic stirrer
In fact now a days most of the consultants prefer single layer ESSC and not
SAW

Regards

Hegde p.B.

[Chaitanya Purohit]

I agree to comments of P B Hegde and I also have the same experience where I have used 60mm strip with single layer and achieved 6 to 7mm height where top 3mm you can get easily undiluted chemistry.

Ferrite is slight tricky issue where I was facing problem but again if you can ask supplier of consumable to give guarantee and demostration prior to start the job, which will help you to build confidence in your welding team.

C. K. Purohit
Eng-Tech Weld1
Sr Welding Inspector

2009/11/14 PB HEGDE <hegd...@isgec.com>

Dear Mr Singh
I think Not to get panic with Single layer ESSC and With High speed Flux .
It has been established in almost all DHDS reactors where you can achieve
Undiluted chemistry for top 3 mm.  with no problem  at overlap. With Ferrite
about 6-7%
With disbanding test No defect at 482 C with  fastest cooling rate.
You can use for SS w/o magnetic stirrer for 30, 60 width strip and 90mm with
magnetic stirrer
In fact now a days most of the consultants prefer single layer ESSC and not
SAW

Regards

Hegde p.B.

-----Original Message-----
From: material...@googlegroups.com
[mailto:material...@googlegroups.com] On Behalf Of GERING, Erwin

Sent: Saturday, November 14, 2009 2:15 PM
To: material...@googlegroups.com
Cc: GERING, Erwin

[pgos...@sympatico.ca]

Gents,

 

The subject is interesting.I had some chance to work at early part of my career.

Both SAW-SC & ESSC generates very high deposition high quality weld overlay. From a welding engineers perspective SAW-generates more base metal penetration and resultant more dilution, while in ESSC base metal dilution is minimized however the deposition is greatly increased over SAW-SC.

 

Looking  at the  problem I feel the following techniques would be appropriate:-

1. Deposition on the heat exchanges shell-- Single pass ESSC with magnetic stirring
2. Deposition on heat exchanger tube sheets-- Single or Multi pass ESSC with magnetic stirring, Single layer deposition would mean use of a high speed flux.
3. Deposition on heat exchanger tube sheets-- First layer by SAW-SC followed by next layer of ESSC to improve the bonding.
4. Deposition on heat exchanger tube sheets-- Both layers  by SAW-SC , which had been the proven technique in the industry for many years.

    Options 2 ,3 & 4 are proposed   with a bit of conservatism, considering :-

• Tube sheets as a rule are machined after application of over lay, in order to facilitate proper Tube to Tube sheet welds. Repair of  overlay defects after machining could mean additional work.
• Controlling distortion of tube sheets.

Controlling 3 mm of undiluted chemistry (say S.S 347) should not be a concern as the overlay thickness in breach lock exchanges generally tend to be usually 5/32" or more. However Ferrite is very easily affected by weld metal chemistry , which the consumable suppliers have to ensure at the supply and field mock up tests.

 

I have attached some article on SAW-SC & ESSC  so as to benefit all. The articles in ESABs Svetsaren on page 10 & 16 are quite appropriate to the present issue.

 

Thanks

 

Pradip Goswami,P.Eng

Senior Engineer/Specialist(Welding-Metallurgy)

Machine Dynamics & Component Integrity Dept.

Engineering & Training Services Division

ONTARIO POWER GENERATION Inc.

PO Box-2000, RR-55(South)

Nanticoke, Ontario,N0A1L0

Tel:-(519) 587-2201, Ext 3107--in Nanticoke

         (416) 231-4111, Ext 5925--in Kipling,Toronto

Fax: (519) 587-6814

Email-prad...@opg.com.

 

---

From: pgos...@sympatico.ca [mailto:pgos...@sympatico.ca]
Sent: Sunday, November 15, 2009 8:32 PM
To: pgos...@quickclic.net
Subject: FW: [MW:3658] Re: 3653] RE: 3647] RE: 3645] RE: 3644] Breesh-Lock Heat Exchangers Weld overlay

 

---

Date: Sun, 15 Nov 2009 08:33:06 +0400
Subject: [MW:3658] Re: 3653] RE: 3647] RE: 3645] RE: 3644] Breesh-Lock Heat Exchangers Weld overlay
From: chaitany...@yahoo.co.in
To: material...@googlegroups.com

I agree to comments of P B Hegde and I also have the same experience where I have used 60mm strip with single layer and achieved 6 to 7mm height where top 3mm you can get easily undiluted chemistry.

Ferrite is slight tricky issue where I was facing problem but again if you can ask supplier of consumable to give guarantee and demostration prior to start the job, which will help you to build confidence in your welding team.

C. K. Purohit
Eng-Tech Weld1
Sr Welding Inspector

2009/11/14 PB HEGDE <hegd...@isgec.com>

Dear Mr Singh
I think Not to get panic with Single layer ESSC and With High speed Flux .
It has been established in almost all DHDS reactors where you can achieve
Undiluted chemistry for top 3 mm.  with no problem  at overlap. With Ferrite   about 6-7%   With disbanding test No defect at 482 C with  fastest cooling rate.
You can use for SS w/o magnetic stirrer for 30, 60 width strip and 90mm with   magnetic stirrer
In fact now a days most of the consultants prefer single layer ESSC and not
SAW

Regards

Hegde p.B.



-----Original Message-----
From: material...@googlegroups.com
[mailto:material...@googlegroups.com] On Behalf Of GERING, Erwin
Sent: Saturday, November 14, 2009 2:15 PM
To: material...@googlegroups.com
Cc: GERING, Erwin

Subject: [MW:3653] RE: 3647] RE: 3645] RE: 3644] Breesh-Lock Heat Exchangers
Weld overlay

Hello mr Singh

Please be careful to chose ES-process if surface will be machined   (indications at overlap).
Please be careful with ES high speed solution for 4,5 mm thickness in single   layer : in this thickness cladding with a 24.12LNb strip the dilution will   be relative low which will result in relative high ferrite contents which   can be over 10%.

Please contact for accurate advise/solution directly a producer of strip
cladding flux like OERLIKON / AIR LIQUIDE WELDING  

With kind regards,

Erwin GERING erwin....@airliquide.com
Corporate Product Manager SAW/ES wire/flux/strip

AIR LIQUIDE WELDING

-----Oorspronkelijk bericht-----
Van: material...@googlegroups.com

[mailto:material...@googlegroups.com] Namens PB HEGDE
Verzonden: vrijdag 13 november 2009 13:17
Aan: material...@googlegroups.com

Onderwerp: [MW:3647] RE: 3645] RE: 3644] Breesh-Lock Heat Exchangers Weld
overlay

Hi
Single layer 347 weld overlay by ESSC is good solution and you can also try   with Soudokay/Sandvik strip with High speed flux You should be able to   achieve 4.5 thk weld clad with top 3 mm undiluted chemistry of 347 It is   established process with  nil  disbanding. However if you want final weld   thickness of 5mm after machining better to go for Double layer where you

hould  get w/o thk of 7 mm and at least 2 mm M/cing allowance to take care   of distortion during welding . 

Hope this will solve your problem

Regards

Hegde P.B.

-----Original Message-----
From: material...@googlegroups.com
[mailto:material...@googlegroups.com] On Behalf Of GERING, Erwin
Sent: Friday, November 13, 2009 2:50 PM
To: material...@googlegroups.com

[JASPAL SINGH]

Dear All,

Thank you very much for your valuable inputs.

I have finally decided to go with double layer.

Best Regards

Jaspal Singh
Assistant Manager-Welding Technology
Certified Welding Inspector
Pressure Vessel Division
ISGEC-Yamunanagar
Haryana-INDIA135001
www.isgec.com
jaspal...@isgec.com
919996624244

> Email-pradip.gosw...@opg.com.

>
> From: pgosw...@sympatico.ca [mailto:pgosw...@sympatico.ca]
> Sent: Sunday, November 15, 2009 8:32 PM
> To: pgosw...@quickclic.net
> Subject: FW: [MW:3658] Re: 3653] RE: 3647] RE: 3645] RE: 3644] Breesh-Lock Heat Exchangers Weld overlay
>

> Date: Sun, 15 Nov 2009 08:33:06 +0400
> Subject: [MW:3658] Re: 3653] RE: 3647] RE: 3645] RE: 3644] Breesh-Lock Heat Exchangers Weld overlay

> From: chaitanya_puro...@yahoo.co.in

> To: material...@googlegroups.com
>
> I agree to comments of P B Hegde and I also have the same experience where I have used 60mm strip with single layer and achieved 6 to 7mm height where top 3mm you can get easily undiluted chemistry.
>
> Ferrite is slight tricky issue where I was facing problem but again if you can ask supplier of consumable to give guarantee and demostration prior to start the job, which will help you to build confidence in your welding team.
>
> C. K. Purohit
> Eng-Tech Weld1
> Sr Welding Inspector
>

> 2009/11/14 PB HEGDE <hegde...@isgec.com>

>
> Dear Mr Singh
> I think Not to get panic with Single layer ESSC and With High speed Flux .
> It has been established in almost all DHDS reactors where you can achieve
> Undiluted chemistry for top 3 mm.  with no problem  at overlap. With Ferrite   about 6-7%   With disbanding test No defect at 482 C with  fastest cooling rate.
> You can use for SS w/o magnetic stirrer for 30, 60 width strip and 90mm with   magnetic stirrer
> In fact now a days most of the consultants prefer single layer ESSC and not
> SAW
>
> Regards
>
> Hegde p.B.
>
>
>
> -----Original Message-----
> From: material...@googlegroups.com
>
> [mailto:material...@googlegroups.com] On Behalf Of GERING, Erwin
> Sent: Saturday, November 14, 2009 2:15 PM
> To: material...@googlegroups.com
> Cc: GERING, Erwin
> Subject: [MW:3653] RE: 3647] RE: 3645] RE: 3644] Breesh-Lock Heat Exchangers
> Weld overlay
>
> Hello mr Singh
>
> Please be careful to chose ES-process if surface will be machined   (indications at overlap).
> Please be careful with ES high speed solution for 4,5 mm thickness in single   layer : in this thickness cladding with a 24.12LNb strip the dilution will   be relative low which will result in relative high ferrite contents which   can be over 10%.
>
> Please contact for accurate advise/solution directly a producer of strip
> cladding flux like OERLIKON / AIR LIQUIDE WELDING  
>
> With kind regards,

> Erwin GERING erwin.ger...@airliquide.com

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