1

ESSC - ADVANTAGES

SIMILAR EQPT. AS SAW

HIGHER DEPOSITION

VERY LOW DILUTION LEVEL

LESSER NO. OF LAYERS TO ACHIEVE

CHEMISTRY

STABLE PROCESS WITH LESS DEFECT

LOW FLUX CONSUMPTION (HALF OF WM)

2
I.D OVERLAY

FCAW GTAW PROCESS

OVERLAY ON SMALL DIAMETER

NO!!LE PIPES FORGINGS

DEVELOPED DOWN TO 2"## I.D

AFTER OVERLAY

MAX. LENGTH WELDED $ 2.% #&

'
PRODUCTIVITY
PROCESS MATERIAL DIA. AMP DEPOSITION NO. OF ELECTRODE
PER ARC-HR PER ARC-HR
(())
SMAW CS 2." *+ +., "-
'.2 1'+ 1.1 %%
%.+ 1*+ 1." '*
".+ 2%+ 2.% '%

SS 2." *+ +.- "2
'.2 1++ 1.+ ""
%.+ 1%+ 1.2 %2

FCAW CS 1.2 2++ '.'
SS 1.2 2++ '.%
%
PRODUCTIVITY
PROCESS MAT. DIA. AMP DEPOSITION PER
ARC-HR (Kg)

SAW CS 4.0 550 6.5
TWIN- CS 2.4X 2 550 6.6
WIRE SAW
TANDEM CS 4.0X 2 600 14
SAW
ESSC SS 60X0.5 1200 22
0X0.5 1!00 ""
120X0. 5 2200 42
"
-
FCAW
CONSUMABLE
C-Mn STEEL C- 1.6%Mn ER 70S-2 E 71T-1/ E70T-5 EH-14+TAPADA-!0/
"SA516 #R60/70$ S% + U&420TTR

C-M' LAS C- 0.5% M'/ E 701! A1 / ER !0S-D2 E70T-A1 / EA-% + OP41TT
"SA204-B$SA%02-B( C-Mn-M' E !01! D% E!1T1-A1 EA-4/EF-% + U&420TTR
1.25C)-0.5M' LAS 1*1.25C)-0.5M' E !01!B2 ER !0SB2 E !1T1-B2 EB2 + U&420TTR
"SA%!7#R11CL1/2(
2.25 C)-M' LAS 2.25C)-1M' E +01!B% ER +0SB% E+1T1-B% EB% + U&420TTR
"SA%!7 #R22CL2(
SS %04/ %04L 1!C) - !N, E %0!/ %0!L ER %0!/ %0!L E %0!LT-1 / E%0!LT0-1 ER%0!L + SS#R.1 / F--1
"SA240#R%04L(
SS %16/ %16L E %16/ %16L ER%16/ %16L E%16LT-1/ E%16LT0-1 ER%16L + SS#R.1 / F--1
"SA240#R%16L(
SS%21/ %47 E %47 ER%47 E%47T-1/ E%47T0-1 ER%47 + SS#R.1 / F--1
"SA240#R%21/ %21H(
SS-410S 1%%C)
E %0+LT-1/ E%0+LT0-
1
"SA240 T./0410S(
E %0+/ E%0+M'/
EN,C)F0%
ER%0+ / ER%0+M'/
ERN,CR%
BASE METAL - WELDN# CONSUMABLE SELECTON
SAW CONSUMABLE
E 701!/ 701!-1
1!C) - !N, -
2*%M'
1!C) - !N, -
N1+T2
MATERAL T3PE
NOMNAL
COMPOSTO
N
SMAW
CONSUMABLE
#TAW
CONSUMABLE
,
*
PREHEAT

ADVANTAGES

TO REMOVE OIL, MOISTURE ETC.

TO AVOID CRACKING

PREHEAT - MINIMUM 1 INCH. ON EITHER

SIDE OF JOINT.

USE ONLY LPG / ELECTRIC HEATING.

CARRY OUT UNIFORM PREHEAT

USE TEMPERATURE STICKS TO CHECK.

.
POSTHEATING

IF NOT DONE - CRACKS. FAILURE

IN
SERVICE.

HEATING AT 300 - 350 C FOR 3 /

HRS MIN. !EFORE ALLO"ING "ELD TO
COOL TO ROOM TEMPERATURE
FROM PREHEAT TEMPERATURE

AFTER POST HEATING COVER THE JOINT

"ITH AS!ESTOS FOR SLO" COOLING.
12
1'
CONSUMABLE PRICES

SMAW E#ECTRODE$ %TAW WIRE.)

TYPE COST() (R/)
E,+1* ""
E,+1*-1 -+
E*+1*B2 2,+
E'+*L %++
E'+.L "++
EN0C1F2' 12++
EN0C3, *++
1%
CONSUMABLE PRICES

SMAW E#ECTRODE$ %TAW WIRE(CONT.)

TYPE COST() (R/)
ER,+S-2 1.+
ER'+.L %*+
ER'+*L '"+
ERN0C1' 1+++
1"
CONSUMABLE PRICES

SAW$ &CAW WIRE

TYPE COSTSPOOL(R/)
S' 1*," (2" () SPOOL)
EH-1% 1'++ (2" () SPOOL)
ER'+*L '-2" (2" () SPOOL)
E,1T-1 1"++ (12." () SPOOL)
E'+.LT-1 "+++ (12." () SPOOL)
E'%,T-1 "+++ (12." () SPOOL)
E'+*LT-1 "+++ (12." () SPOOL)
1-
CONSUMABLE PRICES

&#UX
TYPE COST() (R/)
UV%2+TTR ,-
TAPADIA-*+ 2"
SS GR-1 1'+
F4-1 12"
', S 2++
1,
1*
In case fluxes are not used regularly,
oven temp. can be reduced to 100C.
However, the fluxes are to be baked at
00!"0C for # hrs m$n$mum pr$or to
$ssue.

% e.g.&'(#0))*, )apad$a +0 etc.,

00!"0C for # hrs
$mmed$ately before
use
SAW FLU4ES 00C m$n$mum.
-o t$me l$m$t
RE5UREMENTS FOR DR3N# OF WELDN# CONSUMABLES
# 1."!#00C for # hrs
m$n before use
100C m$n t$ll use
REMAR6S
/fter bak$ng the electrodes can be
stored $n hold$ng ovens % at 100C m$n t$ll
use ,
100C m$n t$ll use
BA6N# C3CLE
HOLDN# TME 7
TEMP.
SMAW
!do!
!0ow Hydrogen Carbon 1 0ow /lloy
2teel 3lectrodes % e.g. 3.01+,
3+01+ 4# etc. ,
#"0!00C for # hrs
m$n before use
SMAW
SL.
NO.
CONSUMABLES
!2ta$nless 2teel 3lectrodes,
! -on 5errous 3lectrodes
1
1.
2+
WE#DER '#&N. - ASME SEC.IX
ESSENTIA# VARIA(#ES

WELDING PROCESS

WELDING TYPE

BASE METAL (P N5.)

FILLER METAL N5. (F N5.)

WELD BASE METAL TH(. 6 DIAMETER LIMIT

BAC(ING

POSITIONS
21
WE#DIN% PROCESS

WE#DERS )
- SMAW
- GTAW
- FCAW GMAW

WE#DIN% OPERATORS )
- SAW
- ESSC
- MACHINE GTAW
WE#DER '#&N. - ASME SEC.IX
22
WE#DER '#&N. - ASME SEC.IX
WELDING TYPE

MANUAL SEMI-AUTOMATIC

MACHINE

AUTOMATIC
2'
WE#DER '#&N. - ASME SEC.IX
P N'.
P1
P%$4$5
P6$7
P!
P+
P10$11
P24
P%4
P44
P54
P64
T./0 '8 M290),2:
C2)1'n S900:
L'; A::'. S900:
F0)),9,< 2n= M2)90n>,9,< S92,n:0>> S900:
A?>90n,9,< S92,n:0>> S900:
N,<@0: S900: ":0>> 9A2n 4.5% N,(
5?0n<A0= 2n= T0B/0)0= S900:
A:?B,n,?B 2n= A::'.>
C'//0) 2n= A::'.> "C?/)'n,<@0:(
N,<@0: 2n= N,<@0: B2>0 A::'.>
T,92n,?B 2n= T,92n,?B B2>0 A::'.>
C,)<'n,?B 2n= C,)<'n,?B B2>0 A::'.>
2%
WE#DER '#&N. - ASME SEC.IX
Base Metals for Welder Qualifcation
P N# 1 $%&#'(% P N#. 11 )*+ P
N#. 3
#& P N#. ,
P N#. -1 $%&#'(% P N#. -5
P N#. 5, #& P N#. .,
Qualifed Production Base Metals
P N# 1 $%&#'(% P N#. 11 , P N#. 3,
P N#. , )*+ '*)//0(*1+ 21$)3/ #4 /0203)&
5%1205)3 5#26#/0$0#*
P N#. -1 $%&#'(% P N#. -5
P N#. 5, )*+ P N#. .,
2"
F- NUMBERS
F% - LOW H2 TYPE CS LAS - E,+1*7 E *+1*B2
F" - AUSTENITIC SS - E'+.'+*'%,
F- - GTAWSAWFCAW CSLAS -ER,+S2S'E,1T-1
ER'+*E'+*LT-1
F'X-C3 6 C3 BASE ALLOYS - ERN0C3, EN0C3,
F%X-N0 6 N0 BASE ALLOYS - EN0C1F2'ERN0C1'
F"X-T0 6 T0 BASE ALLOYS - ERT0-1
F,X-HARD FACING CONS. -STELLITE-1-
2-
WE#DER '#&N. - ASME SEC.IX
5?2:,8,0= ;,9A
F N' 4
F N' 5
An. F N' 6
An. F N' 21 9A)'?DA F N' 25
An. F N' %1$ F N' %2$ F N' %%$
F N' %5$ F N' %6 ') F N' %7
F N' %4 ') 2n. F N' 41 9A)'?DAF N' 45
2n. F N' 51 9A)'?DA F N' 54
An. F N' 61
An. F N' 71 9A)'?DA F N' 72
5?2:,8,0= 8')
F N' 1$ 2$ %$ 4
F N' 5
A:: F N' 6
A:: F N' 21 9A)'?DA 25
On:. 9A0 >2B0 F N?B10) 2> ;2> ?>0=
=?),nD 9A0 E?2:,8,<29,'n 90>9
F N' %4 2n= 2:: F N' 41 9A)'?DA F N' 45
A:: F N' 51 9A)'?DA F N' 54
A:: F N' 61
On:. 9A0 >2B0 F N?B10) 2> ;2> ?>0=
=?),nD 9A0 E?2:,8,<29,'n 90>9
A:90)n290 F N' 8') W0:=0) P0)8')B2n<0 5?2:,8,<29,'n
2,
WE#DER '#&N. - ASME SEC.IX
Weld Thickness in Qualification Test
[t in inch (mm)]
FG%/4 "1+.05(
H%/4 "1+.05(
#ROO&E
Maximum Qualified Weld Thickness
[inch (mm)]
An. TA,<@n0>>
29
O&ERLA3
Qualification Test Thickness
[T in inch (mm)]
Thickness Qualified
[inch (mm)]
U/9' 1 "25.4( T 9' ?n:,B,90=
F 1 "25.4( 1 "25.4( 9' ?n:,B,90=
2*
WE#DER '#&N. - ASME SEC.IX
#ROO&E AND O&ERLA3 WELDS - LMTATONS ON PPE / TUBE DAMETERS
OD inch (mm) NB inch Minimum Maximum
H1 "25.4( H%/4 S,I0 W0:=0= Un:,B,90=
1 9' 2 "7/!( ') 25.4 BB
9' 7%.0% BB
%/4 9' 2"1/2( 1 "25.4( Un:,B,90=
FG 2"7/!( ') 7%.0%BB 2"1/2( 2"7/!( ') 7%.0% Un:,B,90=
2.
- SN#LE SDED WELD - WELD WTHOUT BAC6N#/
FBRE TAPE
- DOUBLE SDED WELD - WELD WTH CHP BAC6/
BAC6N#
!ACKING
WE#DER '#&N. - ASME SEC.IX
QUALIFICATION WITH QUALIFIE
FO!
SINGLE SIDED SINGLE /
DOU!LE SIDED
DOU!LE SIDED DOU!LE SIDED
'+
PERFORMANCE 5UALFCATON- POSTON AND DAMETER
LMTATONS
NOTEJ
%1, 6$pe # o.d. and over. 7/8
17
#7
7
(7
7 and (7
#7,7,and (7

17
#7
"7
87
#7 and "7

P:290 2n= P,/0

OK0) 24 ,n.O.D.
P,/0
HG 24 ,n. O.D.
P:290 2n= P,/0
#)''K0 F,::09
P'>,9,'n 2n= T./0 W0:= 5?2:,8,0=
W0:= P'>,9,'n

6$pe!7roove
/00
/00
5
/00
/00
/00

5,H
5
5,H
5,H,'
5,H,9
/00


5,',9
5
5,H
/00

5
5,H
5 : -ote %1, ;
5,H : -ote %1, ;
5,',9
/00 /00
5 : -ote %1, ;
5 : -ote %1, ;
5 : -ote %1, ;
5,H : -ote %1, ;
5,9
5,',9
/00

5
5,H
5,'
5?2:,8,<29,'n T0>9
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