Proceedings of the ASME 2017 Pressure Vessels and Piping Conference
PVP2017
IMPROVEMENTS IN THE WELDING TECHNOLOGY FOR HEAVY WALL
PRESSURE VESSELS 2 ¼ CR 1MO ¼ V LOW ALLOY STEELS
Fausto Fusari
Belleli Energy CPE
Mantova, Italy
fausto.fusari@belleli.it
Michele Musti
Belleli Energy CPE
Mantova, Italy
michele.musti@belleli.it
ABSTRACT
The standard practice recommended for high pressure vessels,
having heavy walls, requires the implementation of weld joint
preparation with narrow gap technique; this generally calls for
a ‘two beads per layer’ sequence alongside the use of the
submerged arc welding process. This process provides a high
quality and uniformed weld joint whilst also reducing the
residual stresses after welding.
In refinery equipment that are subjected to high pressures and
are exposed to hydrogen environment, high strength materials
such as 2 1/4 Cr 1 Mo 1/4 V are commonly used.
A recent study conducted on this material, and the process of
submerged arc welding with narrow gap technique ‘two beads
per layer,’ had identified a potential issue in complying with
ASME Code specified creep resistance properties. In another
setting, with regards to the properties of toughness in weld
joints, other possible inconsistencies, in the narrow gap weld
joint, between the weld centerline and center bead, were
found.
In order to overcome the deficiencies stated above, an
innovative welding technology is presented in this paper which
is based on the preparation of a narrower groove than the
commonly used narrow gap technique. Such groove has been
designed to implement the 'single bead per layer' approach.
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July 16-20, 2017, Waikoloa, Hawaii, USA
PVP2017-65663
Paolo Marangoni
Belleli Energy CPE
Mantova, Italy
paolo.marangoni@belleli.it
Stefano Alberini
Belleli Energy CPE
Mantova, Italy
stefano.alberini@belleli.it
This paper illustrates that the use of this new technique results
in improved quality of weld seams as applied in heavy wall
high pressure vessels used in creep regime. The welding
process considered is that of tandem submerged arc welding
with two wires. The mechanical characteristics and results
obtained by comparing the two techniques ‘two beads per
layer’, and the new innovative one ‘single bead per layer’ will
be evidenced and discussed.
INTRODUCTION
Vanadium modified 2 ¼ Cr 1Mo alloy used for the fabrication
of high pressure hydro-processing reactors is known to give
several advantages over the conventional 2 ¼ Cr 1 Mo alloys.
The advantages include the following:
1. Improved resistance to hydrogen attack.
2. Limited embrittlement and higher strengths.
Since the 2009 Addenda of ASME Sec. VIII Div. 2 Code, the
temperature at which the stress-rupture tests need to be
performed has been lowered from 875°F (470°C) to 825°F
(440°C). That is, a majority of reactors in the refinery industry
now require stress-rupture tests performed on critical welds.
As indicated in Fig. 1, the stress – rupture tests must be made
on all the welding joints in category ‘A’.
 Figure 1. ASME requirements for Stress Rupture Test

In a research setting conducted on the use of these materials, a

potential critical zone in the ‘two beads per layer’ sequence
weld joints was identified, in particular, when obtaining the
required characteristics for creep resistance. As shown in Fig.
2, the combined effect of tempering, produced by successive Figure 2. Weld joint type “A” in detail
beads (multipass) and the arrangement of beads in the 'two
beads per layer' results in localized central zone with a
potentially large fine grained structure which is not desirable
for creep resistance.
One possible solution to this problem could be to adopt a
larger bevel that would allow the execution of three or more
weld beads per layer, as indicated in Fig. 3, Type B. Such a
solution though would result in an increase of the weld beads
with potential consequences in increasing residual weld
stresses.
The aim of this research, therefore, is to reduce the width of
the bevel to allow the implementation of a ‘one weld bead per
layer’ sequence that would eliminate the formation of a critical
zone.
Specifically the objectives of this study are:
• To eliminate the potential critical zone at the center
of the weld joint
• To reduce the quantity of welding (and/or not
increase it) contributing to a potential reduction of
the weld residual stresses.
Other than the stress rupture tests, ‘toughness tests’ have also
been carried out due to, in the case of the narrow gap weld
joint with ‘two beads per layer’, a warning with possible
inconsistencies in results in differing zones of the weld joints
Figure 3. Different weld joint types
(weld centerline and center bead).

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 COUPON
The base material and the welding consumables used for the
tests were those normally employed and recognized in the
industry.
The chemical analysis is indicated in Table 1.

Table 1. Base and weld material typical chemical analysis

Base Material Weld Material
(mass %) (mass %)
C 0,12 0,10
Mn 0,45 1,00
Si 0,1 0,18
Cr 2,30 2,35
Mo 0,95 1,00
V 0,28 0,24
P 0,005 0,005
S 0,002 0,003
Nb(Cb) + Ta 0,003 0,02
As -- 0,002
Sb -- 0,001
Sn 0,008 0,002
Ti 0,002 0,004 Figure 4. Test coupon under welding
Cu 0,15 0,04 Table 2 shows the main welding condition adopted for the test
Ni 0,15 0,14 coupon

A significant number of tests were deemed necessary for the Table 2. Welding condition
developed welding technology which is based on a “one bead Base material SA336M F22V
per layer” welding sequence. Welding process SAW Tandem
The primary tasks involved in the development of the Current/Polarity AC/AC
proposed technique are: Amperage 500÷600 A
• Weld bevel design Voltage 28÷34 V
• Selection of the proper welding parameters Travel speed 70÷85 cm/min
• Welding torch design Preheat Temperature 350°F(177°C)
The welding torch has been specifically designed for its use Interpass Temperature 480°F (250°C)
for the single bead per layer technique. The torch, as designed, Stick-Out 25÷35 mm
also provides control of the position of the wire with regards DHT 660°F (350°C) x 4 h
to the joint side walls. Fig. 4 shows the coupon during the NDE MT/UT
execution of the final welding procedure qualification.
Stress rupture tests were performed according to the ASME
code Sect. VIII Div. 2 par. 3.4.4.5 at the following conditions:
• PWHT (Post Weld Heat Treatment): 1310 °F (710°C)
per 26 h and 32 h
• Load value: 30 ksi
• Test temperature: 1000°F (540°C)
• All weld metal longitudinal and transversal
specimens
• Gage length specimens diameter Ø 13 mm
(According to ASTM E139 standard)

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 The reasons for carrying out the tests after 32 h were due to
the fact that in some cases pressure vessel can face problems
of unavailability of a furnace and/or the need for specific
manufacturing sequences (internals assembly) to carry out a
local post weld heat treatment. In these cases, the execution of
two heat treatments during manufacturing (one in a furnace
and one local for the final closing) is needed. Generally, two
heat treatment cycles, for eventual repair (at shop and at site),
are also required.
It can be noted that, according to the ASME Code Sec. VIII
Div. 2 paragraph 3.4.31 (a), we may have an allowance to
apply at least 80% of the total thermal history expected for the
vessel, but sometimes final users do not accept such an
allowance and therefore 32 h becomes the target PWHT cycle
to be considered for all tests.
Whilst the temperature of post weld heat treatment is
commonly considered for this material to be 1300°F (705°C),
we preferred to use a temperature of 1310°F (710°C) both for
further flexibility on the design of the heat treatment
temperature, and to have further confirmation on the
properties of hardness and toughness.
Impact tests were carried out on test coupon subjected to a
minimum PWHT condition of 1310°F (710°C) per 8 h, as
these are considered to be the worst condition for such tests.
Tests were done at the required -20°F (-29°C) temperature
with a target result of 54 J minimum. In the case of the narrow
gap weld joint with ‘two beads per layer’ technique, as a
comparison, impact tests with notch, both at the centre of the
weld centerline and at the center bead, were made.
Figure 5. Weld macro-section “one bead per layer”
welding Sequence
TEST RESULTS AND DISCUSSION

Weld appearance and macrostructure

Figure 5 shows the macro-section of the new welding
technology with “one bead per layer “welding sequence. As
can be seen, the weld beads’ shape and dimensions are
uniform and regularly distributed. In this way, as shown in
Fig. 6,there are no large concentrated fine-grained zones nor
are there notable differences in the subdivisions of coarse-
grained zones, both in the thickness and the cross-section of
the weld joint. Figure 7 shows the 'two beads per layer' which
results in the undesirable fine grained microstructure. Figure 6. Weld macro-section detail “one bead per layer”
welding Sequence

Figure 7. Typical narrow gap macro section detail

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 Figure 8 shows the typical weld microstructure with coarse The stress rupture test results seem to confirm a former
and fine grain structures obtained from the overlapped weld investigation [1] where for narrow gap weld “two beads per
passes. layer “the inherent larger portion of fine grained
microstructure in the weld centerline was indicated as a
potential cause that could have led to a faster creep rate.
Coarse grain Figure 9 shows a typical macro section of a stress rupture test
sample taken by a test coupon welded with the “one bead per
layer” sequence , while Fig.10 shows a similar section taken
by a test coupon welded with a narrow gap “two beads per
layer” sequence.

Fine grain

Figure 8. Typical multipass microstructure

Stress Rupture Tests

Table 3 shows the tests performed and inherent results

obtained. It can be observed that the stress rupture test results,
carried out on the test coupon welded with the new technology
“one bead per layer” sequence, are well above the ASME Figure 9. Typical macro section taken by a test coupon
requirements even after a longer PWHT conditions. In done with “one bead per layer” sequence.
accordance with the ASME code, transversal stress rupture
tests were also carried out and, based on the statistical data
found, there were no significant differences seen in the
longitudinal and transversal tests for the weld section itself.
However, such differences have been found mostly caused by
the poor base material creep properties since the majority of
tests were broken out of weld.

Table 3. Stress rupture test results

Figure 10. Typical macro section taken by a test coupon

welded with narrow gap ‘two beads per layer’ sequence.

It should also be pointed out that whilst the creep results

obtained with narrow gap ‘two beads per layer’ technique
satisfy the minimum limits of the ASME code, they still result
in being inferior to those obtained with the new ‘single bead
per layer’ technique. This difference is deemed important
(B) = broken in base material; (W) = broken in weld
inasmuch this new technique is able to pass the creep tests

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 even when under difficult conditions, such as, when the
materials are not of good quality and/or when cycles of heat
treatments are very severe. Therefore, it is concluded that this
new welding technique will result in better service life for
pressure vessels that work in creep regime.

Toughness test
Toughness tests have been carried out at different temperatures
to understand better the performances of different welding
sequences and Charpy V notch impact position. As can be seen
in Fig. 11, the weld joint executed by the new ‘single bead per
layer’ technology complies completely with all standard
toughness requirements. Also the tests carried out applying
narrow gap ‘two beads per layer’ sequence go beyond the
minimum toughness standards required. It's also evident that,
even if notch in weld center line tests show slightly better
results than notch in bead center ones, the difference is not as
relevant as to require more tests on both the welding joint
positions while qualifying the welding process.
Figure 12. Tandem Submerged Arc Welding system
“one bead per layer” sequence

Circumferential weld joint-thickness 284 mm and longitudinal

weld joints thickness 140 mm were carried out as shown in
pictures 1, 2, 3, 4. These welds were subjected to the required
examinations including ultrasonic examination both manual
and mechanized TOFD (Time of Flight Diffraction ) according
to the ASME Code Sect. VIII Div. 2, paragraph 7.5.5, with
fully satisfactory results. A further examination was carried out
according to API RP 934 A, Annex A, with no defects
detected.

Figure 11. Weld toughness comparison chart for NG

(Narrow Gap two beads per layer), NT (New Technology
one bead per layer)

PRODUCTION WELDS
Several production welds were carried out to validate the new
welding technology that has been developed; dedicated
devices were designed to assist such a demanding technology.
An assisted automatic self-adjusting anti drift system was
developed to obtain the correct weld torch position. Moreover,
a device was duly designed to facilitate the slag removal Picture 1. Circumferential weld seam 284 mm thickness
operation. The complete welding system is shown in Fig.12. (before welding)

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 CONCLUSIONS
• A new welding technology, based on a submerged arc
welding process and a “one weld bead per layer”
welding technique, has been developed and
investigated.
• This new technology has been proven to meet the
overall quality normally required for the welding of 2
¼ Cr 1 Mo ¼ V low alloy steel.
• More specifically, the creep resistance behavior has
been improved, in comparison with the standard
narrow gap “two weld beads per layer” welding
technique. The reason for this improvement should be
attributed to the peculiarity of the ‘single bead per
layer’ welding technology where the potential “weak
zone”, previously investigated [1] for narrow gap
welds, is no longer present.
Picture 2. Circumferential weld seam 284 mm thickness
• Weld toughness values have been found in line with
(during welding)
the standard narrow gap welding technique for which
no significant differences have been noted among
different notch impact location (weld centerline and
weld bead center).
• With the adoption of this new welding technology,
the amount of weld passes has been significantly
reduced. The associated potential beneficial impact
on the level of the weld residual stresses can be
expected.
• Several production welds with, thicknesses from
140mm to 284mm, have been carried out adopting
the newly developed welding technology involving
both circumferential and longitudinal weld seams.
Picture 3. Longitudinal weld seam 140 mm thickness
(before welding)

REFERENCES
[1] C. Lundin, M. Prager, D. Osage – Property and
microstructural changes associated with long-term service
of pressure vessel and piping steels at elevated
temperatures and their detection and effects on remaining
Picture 4. Longitudinal weld seam 140 mm thickness (after life – ESOPE 2016, Paris.
welding)

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