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Proposal and Trial for Welding Process Modification for

Circumferential seam welding
Date : 24-06-2016

Objective:
To avoid the GMAW process to weld the root run, by directly applying SAW on
circumferential seam welding of tower sections of more than 25mm thickness.

Current practice:
Joint configuration: Double-V with 60o included angle, Root face 2mm, Root
gap 2-3mm.
60o

2mm

2-3mm
Welding sequence:
1.
2.
3.
4.
5.
6.

Root run with GMAW at inner side.

2 or 3 layers of SAW upon root of it.
Back gauging 2-3 mm deep.
Dye penetrant test on gauged surface.
Fill up 2-3 layers of SAW at outer side.
Ultrasonic testing of entire circumferential seam.

Observations:
1. Defects are found almost at mid thickness of weld joint, mostly planar
defects.
2. Detailed study of defect yet to be carried out, but it may be because of
any of the following
i.
Fit ups not repeatable.
ii.
A broad root face, which does not melt the root face from
either side.
iii.
Back chipping didnt grind through sound weld metal.
iv.
Change in included angle.
v.
Operators skill.
vi.
Machine problem.

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Proposed trial:
Trial No: 1
Date: 24-06-2016
Trial test specimen size : 400mm x 300mm x 30mm
Joint configuration: Double-V with 70o included angle, Root face 4mm, Root
gap 0mm,
Plate thickness of 30mm.
70o

Inner side

18m
4mm
0mm

Outer side

Welding sequence:
1.
2.
3.
4.
5.
6.

Root run with SAW at inner side.

3 or 4 layers of SAW upon it.
Back gauging until sound weld metal is visible.
Dye penetrant test on gauged surface.
Fill up 1-2 layers of SAW at outer side.
Ultrasonic testing of entire circumferential seam.

Inference:
1. Slag removal was difficult.
2. UT is ok.
3. Visually not ok.
Further Action:
Repeat the trial with modification in weld edge geometry and welding
electrical parameters.

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Trial No: 2
Date: 28-06-2016
Trial test specimen size : 400mm x 300mm x 30mm
Joint configuration: Double-V with 60o included angle, Root face 2mm, Root
gap 0-1 mm.
60o

Inner side
2mm

0-1mm

Outer side

Welding sequence:
1. Root run with GMAW at inner side.
2. 2 or 3 layers of SAW upon it from inner side.
3. Back gauging 2-3 mm deep (Root of GMAW to be removed until we find
sound weld metal).
4. Fill up 2-3 layers of SAW at outer side.
5. Ultrasonic testing of entire circumferential seam.

Inference:
1. After root run using GMAW, it is found that penetration has not reached
the full thickness.
2. Back grinding of the root revealed that the entire length of weld has lack
of penetration to various depths, after completing one side welding.
3. Back grinding to depth upto 4mm required to reveal the sound weld metal.
4. UT is ok.
5. Visually ok.
Further Action:
Repeat the trial with modification in weld edge geometry and welding
electrical parameters.

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Trial No: 3
Date: 29-06-2016
Trial test specimen size : 400mm x 300mm x 30mm
Objective amendment: GMAW of root cannot be avoided as this is required for
fit up.
Joint configuration: Double-V with 60o included angle, Root face 2mm, Root
gap 2-3mm.
60o

Inner side
2mm

2-3mm

Outer side

Welding sequence:
1. Root run with GMAW at inner side.
2. 2 or 3 layers of SAW upon it from inner side.
3. Back gauging 2-3 mm deep (Root of GMAW to be removed until we find
sound weld metal).
4. Fill up 2-3 layers of SAW at outer side.
5. Ultrasonic testing of entire circumferential seam.