Mip Bohler Pipeline

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WELDING CONSUMABLES FOR PIPELINE CONSTRUCTION
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Editorial
Since BHLER WELDING is one of the pioneer suppliers of arc welding consumables the dedication to sophisticated applications became apparent very soon. So when transport of oil and gas took a greater significance, BHLER WELDING started to engage and take interest in this business. Pipeline construction in different climatic zones and in territories with different conditions of the soil demand from the engineers inventiveness. BHLER WELDING faces this very challenge alongside the prominent pipelaying companies and consequently has achieved a
world leading position in this segment with cellulosic and basic electrodes and wires, with weld metal toughness for safety reasons in the focus of attention. BHLER WELDING consumables are world-famous both for onshore pipeline projects and for reeled offshore subsea pipeline laying from barges, because thousands of kilometres of linepipe have already been welded with them. A comprehensive worldwide sales network of well stocked partners ensures rapid and punctual deliveries in all countries. Your nearest sales partner can be found on the Internet www.boehler-welding.com
BHLER WELDING consumables are available in moisture resistant and hermetically sealed packs.
BSGA
Selection guide
Electrodes
Steel grades API EN CEL BVD Pipe
Wire
FCAW
Low strength pipe steels

API A, B FOX CEL FOX BVD RP FOX BVD 85 FOX BVD RP FOX BVD 85 FOX EV Pipe
X42 - X52
FOX CEL
FOX EV Pipe FOX EV 60 Pipe
SG 3-P SG 8-P
X56 - X60
FOX CEL FOX CEL Mo FOX CEL 70-P FOX CEL 75 FOX CEL 80-P FOX CEL 85 FOX CEL
FOX BVD RP FOX BVD 85
SG 3-P SG 8-P
EN
L210
FOX BVD RP FOX BVD 85 FOX BVD RP FOX BVD 85
FOX EV Pipe
L290MB-L360MB
FOX CEL
SG 3-P SG 8-P
L385M-L415MB
FOX CEL FOX CEL Mo FOX CEL 70-P FOX CEL 75 FOX CEL 80-P FOX CEL 85
SG 3-P SG 8-P
High strength pipe steels

API X65 FOX CEL FOX CEL 80-P FOX CEL 85 FOX CEL FOX CEL 80-P FOX CEL 85 FOX CEL 90 FOX CEL FOX CEL 90 FOX BVD RP FOX BVD 85 FOX EV 60 Pipe SG 3-P SG 8-P
X70
FOX EV 70 Pipe
SG 8-P NiMo 1-IG
Ti 70 Pipe-FD
X80
FOX BVD RP FOX BVD 90 FOX BVD 100 FOX BVD RP FOX BVD 110 FOX BVD 120
FOX EV 70 Pipe
NiMo 1-IG
Ti 80 Pipe-FD
X100-X110
EN
L450MB
FOX CEL FOX CEL 80-P FOX CEL 85 FOX CEL FOX CEL 80-P FOX CEL 85 FOX CEL 90 FOX CEL FOX CEL 90
FOX EV 60 Pipe
SG 3-P SG 8-P
L485MB
FOX EV 70 Pipe
SG 8-P NiMo 1-IG
L555MB
FOX BVD RP FOX BVD 90 FOX BVD 100
FOX EV 70 Pipe
NiMo 1-IG
Duplex steels
22Cr FOX CN 22/9 N FOX CN 22/9 N-B CN 22/9 N-IG CN 22/9 PW-FD
Selection depends on welding technology, see detailed recommendation for root pass, hot pass and filler layers on next pages. CEL BVD = Cellulosic electrodes = Basic electrodes for vertical down welding Pipe = Basic electrodes for vertical up welding FCAW = Flux cored welding wire
BHLER WELDING Consumables for pipeline construction
Overview
Page
Cellulosic electrodes for vertical down welding
Comparison table for pipe steels Recommendations for cellulosic electrodes BHLER BHLER BHLER BHLER BHLER BHLER BHLER BHLER BHLER BHLER FOX FOX FOX FOX FOX FOX FOX FOX FOX FOX CEL CEL+ CEL Mo CEL 70-P CEL 75 CEL 75 G CEL 80-P CEL 85 CEL 85 G CEL 90 (AWS (AWS (AWS (AWS (AWS (AWS (AWS (AWS (AWS (AWS E6010) E6010) E7010-A1) E7010-P1) E7010-P1) E7010-G) E8010-P1) E8010-P1) E8010-G) E9010-P1)
5 7 8 8 8 9 9 29 9 10 29 10 11 - 14 15 E8045-P2) E8045-P2) E9018-G) E10018-G) E11018-G) E12018-G) 16 16 16 17 17 17 18 - 22
Welding technology Basic electrodes for vertical down welding Recommendations for basic electrodes BHLER BHLER BHLER BHLER BHLER BHLER FOX FOX FOX FOX FOX FOX BVD BVD BVD BVD BVD BVD RP 85 90 100 110 120 (AWS (AWS (AWS (AWS (AWS (AWS
Welding technology
Basic electrodes for vertical up welding
Recommendations for basic vertical up electrodes BHLER FOX EV PIPE BHLER FOX EV 60 PIPE BHLER FOX EV 70 PIPE (AWS E7016-1) (AWS E8016-G) (AWS E9016-G)
24 25 25 25
Wires and flux cored wires for automatic and semiautomatic pipeline welding
Recommendations for automatic welding with solid wires BHLER BHLER BHLER BHLER BHLER SG 3-P SG 8-P NiMo 1-IG Ti 70 Pipe-FD Ti 80 Pipe-FD
26 27 27 28 28 28
Other consumables for pipeline welding
BHLER BHLER BHLER BHLER
FOX FOX FOX FOX
CEL S CEL 75 G CEL 85 G EV 50-W
29 29 29 29
Duplex steels
FOX CN 22/9 N FOX CN 22/9 N-B CN 22/9 N-IG CN 22/9 PW-FD
29 29 29 29
Comparison table for pipe steels
Steel classifications API 5 L-92 EN 10208-2 DIN 17172
Yield strength minimum ksi N/mm

2
Tensile strength minimum ksi N/mm

2
Elongation minimum %
A L210 StE 210.7 B L245MB StE 240.7 X 42 L290MB StE 290.7 StE 290.7 TM X 46 L320M StE 320.7 StE 320.7 TM X 52 L360MB StE 360.7 StE 360.7 TM X 56 L385M StE 385.7 StE 385.7 TM X 60 L415MB StE 415.7 StE 415.7 TM X 65 L450MB StE 445.7 TM X 70 L485MB StE 480.7 TM X 80 L555MB StE 550.7 TM
30.0 30.4 30.4 35.0 35.5 34.8 42.0 42.0 42.0
207 210 210 241 245 240 289 290 290
48.0 46.4 46.4 60.0 60.2 53.7 60.0 60.2 60.9
331 320 320 413 415 370 313 415 420
28 26 26 23 22 24 23 21 23
46.0 46.4 46.4
317 320 320
63.0 66.7 66.7
434 460 460
22 21 21
52.0 52.2 52.2
358 360 360
66.0 66.7 74.0
455 460 510
21 20 20
56.0 55.8 55.8
386 385 385
71.0 76.9 76.9
489 530 530
20 19 19
60.0 60.2 60.2
413 415 415
75.0 75.4 79.8
517 520 550
19 18 18
65.0 65.3 64.6 70.0 70.3 69.6 80.0 80.5 79.8
448 450 445 482 485 480 550 555 550
77.0 77.6 81.2 82.0 82.7 87.0 90.0 90.6 100.1
530 535 560 565 570 600 620 625 690
18 18 18 18 18 18 18 18 18
Vertical down welding using cellulosic electrodes, UAE
a.hak
Water Pipeline in Saudi Arabia
Recommendations for cellulosic electrodes
Cellulosic electrodes
Steel grades API
FOX CEL FOX CEL S E 6010 FOX CEL Mo E 7010-A1 FOX CEL 70-P FOX CEL 75 E 7010-P1 FOX CEL 80-P FOX CEL 85 E 8010-P1 FOX CEL 90 E 9010-G
A B X 42 X 46 X 52 X 56 X 60 X 65 X 70 X 80
Steel grades EN
L210 L245MB L290MB L320M L360MB L385M L415MB L450MB L485MB L555MB
for root pass welding only for root pass, hot pass, filler passes and capping. The application of FOX CEL or FOX CEL S for the root pass of the high strength steels X 60 / L415MB and upwards is very common however, their use depends upon the individual specifications and conditions. Please also note our remarks Combination technique and welding with one electrode grade on pages 8 and 9.
Due to their high economy cellulosic electrodes have been in use for decades for the welding of pipe girth welds for pipe steels up to API 5 L X 80. The high effectiveness originates from the both for root passes as well as filler layers and cover passes. Bigger electrode diameters in the vertical down position with high amperages and fast travel speeds. BHLER WELDING Consumables for pipeline construction
Although BHLER WELDING cellulosic electrodes are designed to produce joint welds with excellent integrity and impact strength, the high hydrogen content of the weld deposit may limit the application with regard to pipe wall thikkness and impact properties required.
BHLER Standard Operating data
Welding process
Typical Typical analysis mechanical properties %
Amperage
Approvals Characteristics and applications
Base metals Standard Classification
mm
A EN API
FOX CEL
EN ISO 2560-A:2005: E 38 3 C 2 1 AWS A5.1-04: E6010 AWS 5.1M-04: E4310
SMAW
C 0.12 Re Si 0.14 Rm Mn 0.5 A5
450 ( 390) N/mm2 520 ( 470-540) N/mm2 26 ( 22) %
2.5 3.2 4.0 5.0
50-90 80-130 120-180 160-210
Av +20C: 110 ( 70) J 0C: 105 J -20C: 95 J -30C: 65 ( 47) -40C: 45 J YS 65000 ( 57000) PSI TS 75000 ( 68000-78000) PSI Elongation on 4d 26 % Impact energy +68F: 81 ( 52) ft-lb +32F: 77 ft-lb -4F: 70 ( 35) ft-lb -22F: 48 ft-lb -40F: 34 ft-lb SMAW C 0.17 Re Si 0.15 Rm Mn 0.6 A5 450 ( 390) N/mm2 520 ( 470-540) N/mm2 26 ( 22) % 2.5 3.2 4.0 50-90 80-130 120-180
TV-D, TV-A, DNV, GdF, Statoil, SEPROZ, PDO, VNIIST, CE
Polarity negative or root pass. Re-drying: not allowed For preheating, interpass temperature and welding procedure note our recommendations on pages 10 and 11.
Cellulosic electrode for verticaldown welding of large diameter pipelines; suitable for root runs, hot passes, filler and cover layers. Especially recommended for root run welding. Highly economical compared with vertical-up welding. Apart from its excellent welding and gap bridging characteristics FOX CEL offers a weld deposit with outstanding impact strength values and thus offers the benefit of still more safety in field welding of pipelines. It can be used in sour gas applications (HIC-Test acc. NACE TM-02-84). Test values for SSC-test are available too.
S235JR, S275JR, S235J2G3, S275J2G3, S355J2G3, P235GH, P265GH, P355T1, P235T2-P355T2, L210NB-L415NB, L290MB-L415MB, P235G1TH, P255G1TH. Root pass up to L555NB, L555MB API Spec. 5 L: A, B, X 42, X 46, X 52, X 56. Root pass up to X 80. S235JR, S275JR, S235J2G3, S275J2G3, S355J2G3, P235GH, P265GH, P355T1, P235T2-P355T2, L210NB-L415NB, L290MB-L415MB, P235G1TH, P255G1TH. Root pass up to L555NB, L555MB API Spec. 5 L: A, B, X 42, X 46, X 52, X 56. Root pass up to X 80.
FOX CEL+
EN ISO 2560-A:2005: E 38 2 C 2 1 AWS A5.1-04: E6010 AWS A5.1M-04: E4310
Cellulosic electrode for verticaldown welding of large diameter pipelines. Especially recommended for root pass welding on D.C. positive polarity in the vertical down and vertical up welding positions. Apart from its good welding and gap bridging characteristics Bhler FOX CEL+ provides a powerful arc that deposites well penetrated, smooth root passes with high travel speeds as well as high safety against the formation of piping or hollow bead and undercut.
Av +20C: 105 ( 70) J 0C: 95 J -20C: 65 ( 47) J -30C: ( 27) J YS 65000 ( 57000) PSI TS 75000 ( 68000-78000) PSI Elongation on 4d 26 ( 22) % Impact energy +68F: 77 ( 52) ft-lb +32F: 70 ft-lb -4F: 48 ( 35) ft-lb -22F: ( 20) ft-lb
Re-drying: not allowed For preheating, interpass temperature and welding procedure note our recommendations on pages 10 and 11.
FOX CEL Mo
EN ISO 2560-A:2005: E 42 3 Mo C 2 5 AWS A5.5-06: E7010-A1
SMAW
C Si Mn Mo
0.1 Re 480 ( 420) N/mm2 0.14 Rm 550 ( 510-590) N/mm2 0.4 A5 23 ( 22) % 0.5 Av +20C: 100 ( 70) J 0C: 95 J -20C: 85 J -30C: 50 ( 47) J -40C: 42 J YS 70000 ( 61000) PSI TS 80000 ( 74000-85500) PSI Elongation on 4d 23 ( 22) % Impact energy +68F: 74 ( 52) ft-lb +32F: 70 ft-lb -4F: 63 ft-lb -22F: 37 ( 35) ft-lb -40F: 31 ft-lb
3.2 4.0 5.0
80-130 120-180 160-210
TV-D, TV-A, ABS, SEPROZ, VNIST, CE
Polarity negative for root pass. Re-drying: not allowed For preheating, interpass temperature and welding procedure note our recommendations on pages 10 and 11.
S235JR, S275JR, S235J2G3, S275J2G3, S355J2G3, P235GH, P265GH, Especially recommended for hot L210-L415NB, passes, filler and cover layers. L290MB-L415MB, Besides the excellent weld metal P355T1, toughness properties it offers easy operation, and a concentrated inten- P235T2-P355T2, P235G1TH, sive arc with deep penetration P255G1TH characteristics in order to ensure Root pass up to sound joint welds with good X-ray L555MB. quality. It can be used in sour gas applications (HIC-Test acc. NACE TM-02-84). Test values for SSC-test API Spec. 5 L: Grade A, B, X 42, are available too. X 46, X 52, X 56, X 60. Root pass up to X 80. Cellulosic electrode for verticaldown welding of high strength large diameter pipelines. Highly economical compared with conventional vertical-up welding.
Welding process
Amperage
mm
A EN API
FOX CEL 70-P

EN ISO 2560-A:2005: E 42 3 C 25 AWS A5.5-06: E7010-P1
SMAW
C Si Mn Ni
0.17 Re 475 ( 420) N/mm2 0.11 Rm 550 (510-610) N/mm2 0.6 A5 23 ( 22) % 0.17 Av +20C: 90 J -20C: 70 J -30C: 55 ( 47) J -40C: 45 J YS 69000 ( 61000) PSI TS 80000 ( 73000-93000) PSI Elongation on 4d 23 ( 22) % Impact work +68F: 66 ft-lb -4F: 51 ft-lb -22F: 40 ( 34) ft-lb -40F: 33 ft-lb
5.0
140-210
Cellulose electrode for vertical-down welding of high strength large diameter pipelines. Especially recommended for hot passes, filler and cover layers. Highly economical compared with conventional vertical-up welding. The BHLER FOX CEL 70-P provides a more intensive arc and a more fluid weld metal as compared to the well known BHLER FOX CEL 75.
S235JR, S275JR, S235J2G3, S275J2G3, S355J2G3, P235GH, P265GH, L210 - L415NB, L290MB - L415MB, P355T1, P235T2 - P355T2, P235G1TH, 255G1TH API Spec. 5 L: Grade A, B, X42, X 46, X 52, X 56, X 60
FOX CEL 75
EN ISO 2560-A:2005: E 42 3 C 2 5 AWS A5.5-06: E7010-P1
SMAW
C 0.14 Re Si 0.14 Rm Mn 0.7 A5
480 ( 420) N/mm2 550 (510-610) N/mm2 23 ( 22) %
3.2 4.0 5.0
80-130 120-180 160-210
TV-A
Av +20C: 100 ( 85) J 0C: 95 J -20C: 85 J -30C: 55 ( 47) J -40C: 45 ( 27) J YS 70000 ( 61000) PSI TS 80000 ( 74000-89000) PSI Elongation on 4d 23 ( 22) % Impact energy +68F: 74 ( 63) ft-lb +32F: 70 ft-lb -4F: 63 ft-lb -22F: 41 ( 35) ft-lb -40F: 33 ( 20) ft-lb
Polarity negative for root pass. Re-drying: not allowed For preheating, interpass temperature and welding procedure note our recommendations on pages 10 and 11.
Cellulosic electrode for verticaldown welding of high strength large diameter pipelines. Especially recommended for hot passes, filler and cover layers. Highly economical compared with conventional verticalup welding. The penetrating arc characteristics and the low slag formation allow good bead control and ensure best performance in all positions even with the larger diameter electrodes and high amperages. It can be used in sour gas applications (HIC-Test acc. NACE TM-02-84). Test values for SSC-test are available too.
S235JR, S275JR, S235J2G3, S275J2G3, S355J2G3, P235GH, P265GH, L210-L415NB, L290MB-L415MB, P355T1, P235T2-P355T2, P235G1TH, P255G1TH. Root pass up to L480MB. API Spec. 5 L: Grade A, B, X 42, X 46, X 52, X 56, X 60. Root pass up to X 70.
FOX CEL 80-P

EN ISO 2560-A:2005 E 46 3 1Ni C 25 AWS A5.5-06: E8010-P1
SMAW
C Si Mn Ni
0.15 Re 490 ( 460) N/mm2 0.15 Rm 570 (550-650) N/mm2 0.75 A5 23 ( 20) % 0.8 Av +20C: 90 J -20C: 80 J -30C: 60 ( 47) J -40C: 45 J YS 71000 ( 67000) PSI TS 83000 ( 80000-94000) PSI Elongation on 4d 23 ( 20) % Impact work +68F: 66 ft-lb -4F: 59 ft-lb -22F: 44 ( 34) ft-lb -40F: 33 ft-lb
5.0
140-210
Cellulose electrode for vertical-down welding of high strength, large diameter pipelines. Highly economical compared with conventional vertical-up welding. Especially recommended for hot pass, filler and cover layers. The BHLER FOX CEL 80-P provides a more intensive arc and a more fluid weld metal as compared to the well known BHLER FOX CEL 85.
L415NB - L485NB, L415MB - L485MB API Spec. 5 L: X 56, X 60, X 65, X 70
Welding process
Amperage
mm
A EN API
FOX CEL 85
EN ISO 2560-A:2005: E 46 4 1Ni C 2 5 AWS A5.5-06: E8010-P1
SMAW
C Si Mn Ni
0.14 Re 0.15 Rm 0.75 A5 0.7 Av +20C: 0C: -20C: -40C:
490 ( 460) N/mm2 570 (550-650) N/mm2 23 ( 20) % 110 105 100 70 ( 80) J J J ( 47) J
3.2 4.0 5.0
80-130 120-180 160-210
TV-D, TV-A, ABS, GdF, SEPROZ, PDO, CE
Cellulosic electrode for verticaldown welding of high strength large diameter pipelines. Highly economical compared with conventional vertical-up welding. Especially recommended for hot passes, filler and cover layers. Without doubt BHLER FOX CEL 85 is the most popular cellulosic electrode which meets all the exacting demands of the field welding of cross country pipelines extremely well. It ensures highest joint weld qualitydown to temperatures of -40 C. It can be used in sour gas applications (HIC-Test acc. NACE TM-02-84). Test values for SSC-test are available too.
L415NB-L485NB, L415MB-L485MB. API Spec. 5 L: X 56, X 60, X 65, X 70
YS 71000 ( 67000) PSI TS 82000 ( 80000-94000) PSI Elongation on 4d 23 ( 20) % Impact energy +68F: 81 ( 59) ft-lb +32F: 77 ft-lb -4F: 74 ft-lb -40F: 52 ( 35) ft-lb
FOX CEL 90
EN ISO 2560-A:2005: E 50 3 1Ni C 2 5 AWS A5.5-06: E9010-P1
SMAW
C Si Mn Ni
0.17 Re 610 ( 530) N/mm2 0.15 Rm 650 (620-720) N/mm2 0.9 A5 21 ( 18) % 0.8 Av +20C: 100 ( 80) J 0C: 90 J -20C: 75 J -30C: 65 ( 47) J -40C: 40 ( 27) J YS 89000 ( 77000) PSI TS 94000 ( 90000-104400) PSI Elongation on 4d 21 ( 18) % Impact energy +68F: 74 ( 59) ft-lb +32F: 66 ft-lb -4F: 55 ft-lb -22F: 48 ( 35) ft-lb -40F: 30 ( 35) ft-lb
4.0 5.0
120-180 160-210
TV-D, TV-A, GdF, Statoil, SEPROZ, VNIIST, CE
Cellulosic electrode for verticaldown welding of high strength large diameter pipelines. Highly economical compared with conventional vertical-up welding. Especially recommended for hot passes, filler and cover layers. The special design of the coating and the core wire guarantees the highest metallurgical quality and soundness of the weld metal deposit with excellent mechanical properties. The electrode allows good weld pool visability, and easy manipulation in all positions, as well as high safety margins against porosity and slag inclusions.
L450MB, L485MB, L555MB. API Spec. 5 L: X 65, X 70, X 80
10
Welding technology
Preheating and interpass temperature

In order to prevent hydrogen induced cracks it is neccessary to preheat the pipes before commencing welding and to maintain an interpass temperature during welding of the individual beads. In respect of the quite often difficult site conditions a preheating of 150 C (300 F) general is recommended. This covers all wall thicknesses up to 25 mm (1") and weld metals up to class E9010 (FOX CEL 90). When welding thin walled pipes be aware that lower preheating and interpass temperatures are applicable. The attached diagram features the lowest possible temperatures in dependence on the wall thickness and type of electrode.
minimum minimum in inC C 180 160 140 120 100 80 60 40 20 0 5 wall thickness in mm 10 wall thickness in mm 15 20 25 E9010 E8010 E7010 E6010 minimum in in F F minimum 356 320 284 248 212 176 140 104 68 32
Recommended joint preparation

60 1.5 - 2.0 1/16 - 5/64 inch) 2/3 1/3
Wall thicknesses 20 mm ( 3/4 inch)
1 - 1.5 (3/64 - 1/16 inch) 1.5 - 2. (1/16 - 5/64 inch)
10
30
Wall thicknesses > 20 mm (> 3/4 inch)
1.5 (1/16 inch)
Welding technique Stringer bead or root pass

With pipes positioned and held in true alignment with line-up clamps, the stringer bead or root pass is welded. For pipe diameters over 200 mm (8"), it has become general practice to have two welders work on opposite sides of the pipe. Even three or four welders may work simultaneously in order to reduce distortion and maintain uniform gap width. Three to four welders are employed for executing the root pass in pipe of more than 700 mm (28") diameter or on difficult ground. For this most important part of the weld which requires perfect penetration, electrode diameter, travel rate and amperage should be chosen to match pipe diameter and wall thickness. For pipe diameters up to about 250 mm (10") and wall thicknesses up to 8 mm (5/16"), we recommend to use 3.2 mm (1/8") diameter electrodes, for larger sizes, 4 mm (5/32") diameter electrodes. Welding proceeds vertical down, with the electrode being held to maintain good contact with the bevel faces. The procedure recommended is electrode negative. Electrode diameter: 2.5 mm (3/32") 3.2 mm (1/8") 4 mm (5/32")
Welding machines
Cellulosic electrodes can only be operated on direct current. Welding machines must have a drooping characteristic and high open circuit voltage. In manual arc welding, the distance between the electrode and the weld pool or joint faces, respectively, can hardly be kept constant, i.e. the length of the arc will vary and so will the amperage. The use of welding machines with drooping characteristics minimizes these variations. The open circuit voltage must exceed 70 V in order to provide the high ionization energy required for dissociation of the constituents making up the coating of the electrode. Generators used for welding with cellulosic pipeline electrodes usually have an open circuit voltage in the range of 80 to 100 V. Larger electrode diameters require high amperages as well as high voltages, which the generators must deliver during welding. These requirements must be fulfilled by welding machines in general; other details, such as type and mode of operation, may vary for different makes, and will be supplied by the manufacturer.
50 - 180 A 80 - 100 A 120 - 150 A
Line-up clamps should be removed only after completing the root pass over the whole circumference and, in welding larger diameter pipe, only after completing the hot pass. While executing this pass, do not move pipes in order to avoid the risk of crack formation.
80-90
root pass (stringer bead) welding root pass stringer bead 2.5, 3.2 or 4.0 mm 80-90 80-90
11
Cellulosic electrodes
avoid porosity. ln the cover pass, porosity is mostly due to overheating of the weld deposit or excessive weaving.
Hot pass
Slight grinding of the stringer bead surface with rotating steel wire brushes prevents lateral slag inclusions (showing up as waggon tracks in weld radiographs). For welding the hot pass, the electrode is held almost vertical, high amperage being used with the electrode connected to the positive terminal. Electrode sizes commonly used are: 4 mm (5/32") 5 mm (3/16") with 150 - 180 A with 170 - 210 A
80-90
filler passes
4.0, 5.0 or 5.5 mm
welding of filler and cover passes
60-70 cover pass (cap) 4.0, 5.0 mm 80-90
The high current causes deep penetration which will make any remaining slag inclusions float to the surface and ensure that the root pass is annealed thoroughly. The hot pass should be welded immediately following deposition of the stringer bead, but in no case more than 10 minutes later. This is of special importance for high strength line pipe grades to avoid under bead cracking in the base material.
80-90
Combination technique and welding with one electrode grade

The weld deposit of the root pass which has not been tempered by application of the hot pass may have a strength which is 100 to 150 N/mm2 (~18000 psi) above that of the finished joint. This, and the notch-sensitive shape of the stringer bead may, in case of uncontrolled pipe movement during the welding operation, cause mechanical crack formation before the hot pass is deposited. The combination weld technique which has been recommended and practised successfully for years is an excellent method of avoiding this risk. The combination technique involves welding the stringer bead in higher carbon, higher strength steels with an electrode of lower strength compared to that of the base metal, but giving better ductility (FOX CEL). A comparatively soft and tough stringer bead will absorb mechanical stresses better while it is being welded and before the hot pass is applied. The combination technique has proved highly satisfactory for higher carbon steels, in particular. In spite of its lower strength level, the electrode used for stringer bead welding is compensated in strength due to about 50 % dilution with the base metal. In welding low carbon, reduced pearlite steels, however, the high dilution of the root pass will reduce the strength in this part of the joint. In thin wall pipe, the stringer bead cross section constitutes a larger percentage of the overall pipe cross section than in heavy wall pipe. This may account for additional reduction in strength over the whole cross section. Therefore, we recommend using one electrode grade for all passes, from stringer bead to cap, in line pipe from reduced pearlite steels with less than 0.10 % carbon, having wall thickness below 10 mm (13/32"). Mechanical properties of this electrode grade should equal those of the base metal.
hot pass welding hot pass 2.5, 3.2 or 4.0 mm 80-90 40-50
Filler layers
Beads will be sufficiently flat, and free from undercut and slag inclusions, if the electrode is applied with a slight circular or stepping motion, especially in positions 12 to 2 o'clock, 12 to 10 o'clock, 4 to 6 o'clock and 8 to 6 oclock. Weaving is recommended for all other positions. Rotating steel wire brushes are used to remove slag carefully after each pass. Selection of electrode diameter depends on pipe diameter and wall thickness. Electrode sizes and amperages recommended for filler pass welding on positive (+) polarity: 4 mm (5/32") 120 - 150 A 5 mm (3/16") 160 - 210 A 5.5 mm (7/32") 200 - 260 A Vertical down welding will yield bead thicknesses varying for different pipe welding positions. Therefore, prior to welding the cover pass, it is usually necessary to apply stripper passes on those parts of the pipe circumference where thickness must be corrected. Stripper passes are applied in a relatively fast movement, in positions 2 to 4 o'clock and 10 to 8 o'clock.
Storage
The coating of cellulosic electrodes has a relatively high content of moisture which is necessary for the welding characteristics and metallurgical properties of the deposit. In open, unprotected storage, air humidity and/or temperature may reduce or increase the moisture content considerably. Therefore, BHLER cellulosic electrodes are packed in cans. Electrodes should be kept in closed storage where prolonged exposure to solar radiation and excessive variations in temperature can be avoided. Once a can has been opened, the electrodes should be used up as soon as possible. Rebaking of cellulosic electrodes is not permitted.
Cover pass (cap)

The cover pass is executed with a slight weaving of the electrode. The weld should not overlap the groove edge by more than 1.5 mm (1/16"). If the cover pass is applied correctly, weld reinforcement is about 1 to 2 mm (1/16"). For this pass, electrode diameter usually is 5 mm (3/16"), with amperage slightly lower than for filler passes (150-200 A) in order to 12
Welding technology
Trouble shooting
Defects
Causes
How to avoid defects
Porosity visible on the surface
excessive and uncontrolled weaving base metal overheated (increased risk in thin wall pipe) moisture content of electrode coating too low delayed deoxidation process in weld deposit moisture content in electrode coating too low or too high
weaving not to exceed 2 X electrode dia. choose electrode dia. and amperage as a function of pipe wall thickness keep electrodes in closed containers see Chapter on page 13 storage avoid excessive upsetting of metal deposited see Chapter on page 13 storage
Pinholes not visible on the surface
Piping or hollow beat almost exclusively in the reinforcement of stringer bead - therefore, practically no reduction of cross section
root gap too narrow: degassing hindered by excessive dilution chemical composition of base metal: high Al levels usually favour piping formation insufficient cleaning in between passes stringer bead poorly ground incorrect electrode manipulation amperage too low
root gap width not less than 1 mm the optimum root gap width of 1.5 mm should be observed for 0.040 % Al steels in particular. If trouble continues, use smaller electrode dia. clean each layer with rotary wire brush grind stringer bead sufficiently before applying hot pass improve electrode manipulation increase amperage choose amperage to match electrode dia. and welding position clean groove faces properly
Slag inclusions generally occuring in groove faces and in stringer bead area (waggon tracks)
Lack of fusion (cold shuts)
insufficient melting of groove faces amperage too low groove faces contaminated and/or oxidized
Underbead cracks almost exclusively in the hardened HAZ
combined action of hydrogen, stresses, hardened structure
preheat pipe material to favour hydrogen effusion, increase of heat input is also advantageous avoid moving pipe string considerable hardening is to be expected during welding of the stringer bead, therefore the hot pass must be applied immediately after its completion avoid moving pipe particularly during welding of stringer bead refer to relevant standards and specifications for maximum offset which, however, should be kept to a minimum
Cracks caused by mechanical stresses usually in the stringer bead region
moving of pipe string during welding of stringer bead and/or before applying hot pass edge offset too great, resulting in reduced root cross section and incrcased risk of crack formation
Undercut in the region of stringer bead and cover passes
amperage too high incorrect manipulation
selection of correct amperage to match electrode size
Excess reinforcement
Incorrect manipulation
select amperage to match joint width allowance for desired cover pass weld reinforcement is to be made already when applying last filler pass (e.g. by additional layers or grinding of filler layers that are too high)
Sagging stringer bead
amperage too high poor joint preparation, root gap too large
select correct amperage to match joint preparation for stringer bead
Striking marks
striking right or left of the joint causes local hardening risk of hardening cracks
strike arc in the groove
13
Consumption rate
Wall thickness [inch; mm]
0,25 inch 0,312 inch 0,432 inch 6,35 mm 7,92 mm 10,97 mm
0,5 inch 0,562 inch 0,625 inch 0,719 inch 0,812 inch 0,938 inch 12,7 mm 14,27 mm 15,88 mm 18,26 mm 20,62 mm 23,83 mm
1.0 inch 1,062 inch 1,188 inch 25,4 mm 26,97 mm 30,15 mm
Pipe
Electr. [mm]
Weight [kg]
9,5* 8,9* 25* 11* 10,6* 28,3* 12,5* 11,7* 31,3* 14,3* 13,4* 36,3* 16,2* 15,1* 39,8* 18* 16,9* 44,8* 19,9* 18,6* 49,9* 21,7* 20,3* 53,3* 23,6* 22,1* 58,3* 25,4* 23,8* 61,7* 27,3* 25,5* 68,6* 29,1* 27,2* 71,9* 31* 29* 75,2* 32,8* 30,7* 80,3* 9,1 8,8 42,6 11 10,5 51,2 12,1 11,6 55,8 13,9 13,3 62,6 15,7 15 71,2 17,5 16,8 78,1 19,3 18,5 86,6 21,1 20,2 95,1 22,9 22 102 24,7 23,7 110,5 26,5 25,4 117,3 28,3 27,1 125,9 30,1 28,9 134,5 32 30,6 141,3 33,8 32,3 149,9 35,6 34 156,7 37,4 35,8 165,2 39,2 37,5 172 41 39,2 180,6 42,8 41 189,1 44,6 42,7 196 50 47,9 219,9 53,6 51,3 221,4 8,9 8,5 86,3 10,7 10,3 103,6 11,9 11,4 113,5 13,7 13,1 129 15,5 14,8 146,3 17,3 16,5 161,7 19,1 18,3 179 20,9 20 194,4 22,7 21,8 211,7 24,5 23,5 227,2 26,3 25,2 242,7 29,1 26,9 259,9 29,9 28,7 275,4 31,7 30,4 292,6 33,5 32,1 308,1 35,3 33,8 325,4 37,2 35,6 340,8 39 37,3 356,3 40,8 39 372,6 42,6 40,8 389,1 44,4 42,5 406,3 49,8 47,7 454,5 53,4 51,1 471,7 8,8 8,4 114,4 10,6 10,2 138,5 11,7 11,2 153,6 13,5 13 174,3 15,4 14,7 196,8 17,2 16,4 219,2 19 18,2 241,7 20,8 19,9 264,1 22,6 21,6 284,8 24,4 23,3 307,2 26,2 25,1 329,7 28 26,8 352,1 29,8 28,5 374,6 31,6 30,3 395,3 33,4 32 417,7 35,2 33,7 440,1 37 35,5 462,6 38,8 37,2 483,3 40,6 38,9 505,7 42,4 40,6 528,1 44,3 42,4 550,6 49,7 47,6 616,1 53,3 51 643,7 8,7 8,3 147,6 10,5 10,1 175,2 11,6 11,1 193,8 13,4 12,9 221,4 15,2 14,6 249 17 16,3 276,7 18,9 18,1 306,1 20,7 19,8 333,7 22,5 21,5 361,3 24,3 23,2 388,9 26,1 25 418,3 27,9 26,7 446 29,7 28,4 473,7 31,5 30,2 501,3 33,3 31,9 527,2 35,1 33,6 558,3 36,9 35,3 585,9 38,7 37,1 613,6 40,5 38,8 641,2 42,3 40,5 670,6 44,1 42,3 698,3 49,6 47,5 781,1 53,2 50,9 817,4 8,6 8,2 182,5 10,4 9,9 217,1 11,5 11 239,1 13,3 12,8 273,6 15,1 14,5 308,3 16,9 16,2 342,8 18,7 17,9 377,4 20,5 19,7 412 22,4 21,4 448,2 24,2 23,1 482 26 24,9 517,5 27,8 26,6 552,1 29,6 28,3 586,6 31,4 30 621,2 33,2 31,8 655,8 35 33,5 690,4 36,8 35,2 725 38,6 37 759,5 40,4 38,7 794,1 42,2 40,4 830,4 44 42,2 865,1 49,4 47,3 968,8 53,1 50,8 1015,3 8,4 8,1 240,1 10,2 9,8 284,7 11,3 10,9 314 13,2 12,6 360,4 15 14,3 405,8 16,8 16,1 452,4 18,6 17,8 497,5 20,4 19,5 544,2 22,2 21,3 589,1 24 23 635,9 25,8 24,7 680,8 27,6 26,4 727,6 29,4 28,2 772,6 31,2 29,9 819,3 33 31,6 864,3 34,8 33,3 911 36,6 35,1 956 38,4 36,8 1002,8 40,2 38,5 1047,7 42,1 40,3 1094,5 43,9 42 1141,1 49,3 47,2 1277,9 52,9 50,6 1341,8 8,3 7,9 171 10,1 9,6 210,8 11,2 10,7 232,8 13 12,5 267,4 14,8 14,2 291,6 16,8 15,9 324,3 18,4 17,6 357,2 20,2 19,4 391,8 22,1 21,1 424,6 23,8 22,8 457,5 25,7 24,6 490,4 27,5 26,3 524,9 29,3 28 557,8 31,1 29,7 590,6 32,9 31,5 623,5 34,7 33,2 656,3 36,5 34,9 690,8 37 35,4 723,2 10,1 38,4 756,6 41,9 40,1 1001,1 43,7 41,9 1042,6 49,1 47 1168,9 52,7 50,5 1229,4 8 7,7 230,5 9,8 9,4 350 10,9 10,5 386 12,8 12,2 443,1 14,6 13,9 500,2 16,4 15,7 557,4 17,6 16,8 594 20 19,1 671,6 21,8 20,9 730,4 23,6 22,6 785,8 25,4 24,3 843 27,2 26 901,9 29 27,8 959 30,8 29,5 1016,1 32,6 31,2 1073,3 34,4 33 1130,4 36,2 34,7 1187,5 38 36,4 1244,7 39,9 38,2 1301,9 41,7 39,9 1359 43,5 41,6 1417,8 48,9 46,8 1589,2 52,5 50,3 1674
10 60 1.5 (1/16 inch) 30
10 3/4" 273 mm 12 3/4" 323,8 mm 14" 355,6 mm 16" 406,4 mm 18" 457,2 mm 20" 508 mm 22" 558,8 mm 24" 609,6 mm 26" 660,9 mm 28" 711,2 mm 30" 762 mm 32" 812,8 mm 34" 863,6 mm 36" 914,4 mm 38" 965,2 mm 40" 1016 mm 42" 1066,8 mm 44" 1117,6 mm 46" 1168,4 mm 48" 1219,2 mm 50" 1270 mm 56" 1422,4 mm 60" 1524 mm * Exception:
Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap Root pass Hot pass Filler + Cap
4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0 4.0 4.0 5.0
7,9 7,6 258,5 9,7 9,3 391,8 10,5 10 418,6 12,2 11,7 480,5 14 13,4 544,1 15,7 15 606,1 17,5 16,7 669,7 19,2 18,4 731,6 21 20,1 795,2 22,7 21,7 857,1 24,4 23,4 919,1 26,2 25,1 981,1 27,9 26,7 1044,7 29,7 28,4 1106,6 31,4 30,1 1170,2 33,2 31,8 1232,1 34,9 33,4 1294 37,9 36,3 1404,5 38,4 36,8 1419,6 41,5 39,8 1532,7 43,4 41,5 1598,4 48,8 46,7 1792,4 52,4 50,2 1887,6
1.5 - 2 (1/16 - 5/64 inch)
7,8 7,5 289,8 9,6 9,2 438,9 10,7 10,3 483,6 12,5 12 556,3 14,3 13,7 629 16,1 15,5 701,8 18 17,2 774,6 19,9 18,9 847,3 21,6 20,7 919,9 23,4 22,4 991,1 25,2 24,1 1063,8 27 25,8 1136,6 28,8 27,6 1209,3 30,6 29,3 1282 32,4 31 1354,8 34,2 32,8 1427,5 36 34,5 1500,3 37,8 36,2 1572,9 39,6 37,9 1591,8 41,4 39,7 1718,5 43,2 41,4 1789,5 48,7 46,6 2007,8 52,3 50 2115,1
7,6 7,2 354,5 9,4 9 538,3 10,2 9,7 586,9 11,9 11,4 675,6 13,6 13,1 747,6 15,4 14,7 834,8 17,1 16,4 921,9 18,9 18,1 1003,3 20,6 19,8 1096,1 22,4 21,4 1181,5 24,1 23,1 1269,9 25,9 24,8 1347,9 27,6 26,4 1434,4 29,4 28,1 1519,8 31,1 29,8 1606,8 32,8 31,5 1692,3 34,6 33,1 1779,3 37,6 36 1939,5 38,1 36,5 1962 41,2 39,5 2119,7 43 41,2 2209,8 48,4 46,4 2478,4 52 49,8 2613,5
Root pass 3.2 Hot pass 4.0 Filler + Cap 4.0
Electrode consumption in kg Electrode weight for cellulosic electrodes. Calculation for 100 joints without wastage. Stub end loss 50 mm (2 inches).
1.5 (1/16 inch)
1.5 (1/16 inch)
14
1/3
2/3
Recommendations for basic electrodes
Basic electrodes
Steel grades API FOX BVD E 8018-G FOX BVD 85 E 8018-G FOX BVD 90 E 9018-G FOX BVD 100 E 10018-G FOX BVD 110 E 11018-G
A B X 42 X 46 X 52 X 56 X 60 X 65 X 70 X 80 X 100
Steel grades EN
L210 L245MB L290MB L320M L360MB L385M L415MB L450MB L485MB L555MB
for root pass welding only for filler passes and capping
Basic vertical down electrodes are characterized by their favourable mechanical and technological features and by their low hydrogen contents. Welding time is the same in comparison with filler and cover passes as for welding using cellulosic electrodes. However, there are losses in economy when welding root passes. It is therefore recommended that root and hot passes be welded with cellulosic electrodes and the filler and cover passes with basic vertical down electrodes. BHLER WELDING Consumables for pipeline construction
Low hydrogen vertical down electrodes are used in the welding of thick walled joints and for the welding of steels like API X 80 or X 100 as well as for the welding of joints with high impact strength requirements. A further field of application is in above ground installation (AGI) and pipe laying tasks (e.g. Iandfall sections), where the use of cellulosic electrodes is prohibited. 15
Basic electrodes for vertical down welding
Welding process
Amperage
mm
A EN API
FOX BVD RP
EN ISO 2560-A:2005: E 46 3 B 4 1 AWS A5.5-06: E8045-P2
SMAW
C 0.05 Re Si 0.3 Rm Mn 1.0 A5
510 ( 460) N/mm2 560 (550-650) N/mm2 26 ( 22) %
2.5 3.2
80-110 100-160
TV-D, SEPROZ, CE
Av +20C: 170 ( 130) J 0C: 150 J -20C: 120 J -30C: 60 ( 47) J YS 74000 ( 67000) PSI TS 81200 ( 80000-94000) PSI Elongation on 4d 26 ( 22) % Impact energy +68F: 125 ( 96) ft-lb +32F: 111 ft-lb -4F: 89 ft-lb -22F: 44 ( 35) ft-lb
Basic electrode for vertical-down welding of root passes in pipeline construction and structural work. Also suitable for vertical-up welding of root passes. The deposit is extremely crack resistant and features high toughness and a very low hydrogen content. Highly economical compared with conventional verticalup welding. It can be used in sour gas applications (HIC-Test acc. NACE TM-02-84). Test values for SSC-test are available too.
Root passes for following steels: S235J2G3 up to S355J2G3, L290NB up to L415NB, L290MB up to L555MB, P235GH up to P310GH API Spec. 5 L: Root passes for following steels: X 42, X 46, X 52, X 56, X 60, X 70, X 80
Re-drying if necessary: 300-350 C, min. 2 h. Note our recommendations on pages 18 and 22.
FOX BVD 85
EN ISO 2560-A:2005: E 46 5 1Ni B 45 AWS A5.5-06: E8045-P2
SMAW
C Si Mn Ni
0.05 Re 0.4 Rm 1.1 A5 0.9 Av +20C: 0C: -20C: -40C: -50C:
510 ( 460) N/mm2 560 (550-650) N/mm2 27 ( 22) % 170 150 120 85 65 ( 130) J J J ( 60) J ( 47) J
3.2 4.0 4.5
110-160 180-210 200-240
TV-D, GdF, SEPROZ, CE
YS 74000 ( 67000) PSI TS 81200 ( 80000-94000) PSI Elongation on 4d 27 ( 22) % Impact energy +68F: 125 ( 96) ft-lb +32F: 111 ft-lb -4F: 89 ft-lb -40F: 63 ( 45) ft-lb -58F: 48 ( 35) ft-lb
Basic electrodes for vertical-down welds of large diameter pipelines and for structural work. Suitable for filler and cover pass welding in pipeline construction. Deposit is extremely crack resistant, and features high toughness and a very low hydrogen content. Deposition rate is 80-100 % higher than for vertical up welding. The weld deposit of BHLER FOX BVD 85 shows an ideal combination between high strength and cryogenic toughness down to -50 C (-58 F). Special design and development work has enabled this electrode to provide exceptional striking characteristics and the avoidance of start porosity on cover (cap) passes. Due to this and the good welding characteristics this special basic electrode offers easy handling even under field conditions. It can be used in sour gas applications (HIC-Test acc. NACE TM-02-84). Test values for SSC-test are available too.
S235J2G3 up to S355J2G3, L290NB up to L450NB, L290MB up to L450MB, P235GH up to P295GH API Spec. 5 L: A, B, X 42, X46, X 52, X 56, X 60, X 65
FOX BVD 90
EN 757:1997 E 55 5 Z2Ni B 45 AWS A5.5-06: E9018-G
SMAW
C Si Mn Ni
0.05 Re 0.3 Rm 1.2 A5 2.2 Av +20C: 0C: -20C: -40C: -50C:
600 ( 550) N/mm2 650 (620-720) N/mm2 27 ( 20) % 170 145 130 110 80 ( 120) J J J J ( 47) J
3.2 4.0 4.5
110-160 180-210 200-240
TV-D, Statoil, GdF, SEPROZ, NAKS, CE
YS 87000 ( 80000) PSI TS 94000 ( 90000-104000) PSI Elongation on 4d 27 ( 20) % Impact energy +68F: 127 ( 89) ft-lb +32F: 107 ft-lb -4F: 96 ft-lb -40F: 82 ft-lb -58F: 60 ( 35) ft-lb
Basic electrodes for vertical-down welds of large diameter pipelines and for structural work. Suitable for filler and cover pass welding in pipeline construction. Deposit is extremely crack resistant, and features high toughness and a very low hydrogen content. Special design and development work has enabled this electrode to provide exceptional striking characteristics and the avoidance of start porosity on cover (cap) passes. Due to this and the good welding characteristics this special basic electrode offers easy handling even under field conditions. Deposition rate is 80-100 % higher than for vertical up welding.
L485MB, L555MB API Spec. 5 L: X 70, X 80
16
Basic electrodes for vertical down welding
Welding process
Amperage
mm
A EN API
FOX BVD 100

EN 757:1997 E 62 5 Z2Ni B 45 AWS A5.5-06: E10018-G
SMAW
C Si Mn Ni
0.07 Re 0.4 Rm 1.2 A5 2.3 Av +20C: 0C: -20C: -50C:
670 ( 620) N/mm2 730 (690-810) N/mm2 24 ( 18) % 150 125 120 70 ( 110) J J J ( 47) J
4.0 4.5
180-210 200-240
TV-D, SEPROZ, CE
Re-drying if necessary: 300-350 C, min. 2 h. Recommended interpass temperature > 100 C. Note our recommendations on pages 18 and 22.
YS 97000 ( 90000) PSI TS 105800 (100000-117000) PSI Elongation on 4d 24 ( 18) % Impact energy +68F: 111 ( 81) ft-lb 32F: 92 ft-lb -4F: 89 ft-lb -58F: 52 ( 35) ft-lb
Basic electrodes for vertical-down L555MB welds of large diameter pipelines and for structural work. Suitable for filler API Spec. 5 L: and cover pass welding in pipeline X 80 construction. Deposit is extremely crack resistant, and features high toughness and a very low hydrogen content. Special design and development work has enabled this electrode to provide exceptional striking characteristics and the avoidance of start porosity on cover (cap) passes. Due to this and the good welding characteristics this special basic electrode offers easy handling even under field conditions. Deposition rate is 80-100 % higher than for vertical up welding.
FOX BVD 110

EN 757:1997 E 69 3 Mn2NiMo B 45 AWS A5.5-06: E11018-G
SMAW
C Si Mn Ni Mo
0.07 0.4 1.5 2.2 0.4
Re Rm A5 Av +20C: -20C: -40C:
720 ( 690) N/mm2 810 ( 760) N/mm2 20 ( 17) % 90 ( 80) J 70 ( 50) J 50 ( 40) J
4.0 4.5
180-210 200-240
SEPROZ
YS 104000 ( 100000) PSI TS 117000 ( 110000) PSI Elongation on 4d 20 ( 17) % Impact energy +68F: 66 ( 60) ft-lb -4F: 52 ( 37) ft-lb -40F: 37 ( 30) ft-lb
L6901) Basic electrodes for vertical-down welds of large diameter pipelines and for structural work. Suitable for filler API Spec. 5 L: X1001) and cover pass welding in pipeline construction. Deposit is extremely 1) not standardised yet crack resistant, and features high toughness and a very low hydrogen content. Special design and development work has enabled this electrode to provide exceptional striking characteristics and the avoidance of start porosity on cover (cap) passes. Due to this and the good welding characteristics this special basic electrode offers easy handling even under field conditions. Deposition rate is 80-100 % higher than for vertical up welding.
FOX BVD 120

EN 757:1997 E 69 3 Mn2NiMo B 45 AWS A5.5-06: E12018-G
SMAW
C Si Mn Ni Mo
0.07 0.4 1.85 2.25 0.35
Re Rm A5 Av +20C: -20C: -40C:
815 ( 740) N/mm2 870 ( 830) N/mm2 18 ( 17) % 80 ( 80) J 60 ( 50) J 50 ( 40) J
3.2 4.0
110-160 180-220
L6901) Basic electrodes for vertical-down welds of large diameter pipelines and for structural work. Suitable for filler API Spec. 5 L: and cover pass welding in pipeline X1001), X1101) construction. Deposit is extremely 1) crack resistant, and features high not standardised yet toughness and a very low hydrogen content. Deposition rate is 80-100 % higher than for vertical up welding. This covered electrode is optimised for best striking properties and for avoiding start porosity in the cap layer. With its excellent welding properties the electrode offers easy handling also under difficult conditions.
YS 118000 ( 107300) PSI TS 126000 ( 120300) PSI Elongation on 4d 18 ( 17) % Impact energy +68F: 60 ( 60) ft-lb -4F: 44 ( 37) ft-lb -40F: 37 ( 30) ft-lb
17
Welding technology
Interpass Temperature
The interpass temperature influences the metallurgical processes that take place in the deposit during solidification and cooling and thus to a certain extent also the mechanical properties of the weld metal. It is thus generally recommended that the interpass temperature be maintained at approx. 100 C 30 C (210 F 86 F) throughout welding.
Welding machines
For welding pipe girth welds in pipeline construction, the basic vertical down electrodes can only be operated on direct current and positive polarity. Practical experience has shown that welding machines usually used for the welding of cellulosic electrodes in pipeline construction are also suitable for the welding of basic vertical down electrodes. The welding machines should have a drooping characteristic and a high open circuit voltage.
60 30 0-1 (3/64 inch)
0 - 1 (3/64 inch)
Recommended joint preparation

10
2/3
2 - 3 mm (5/64 - 1/8 inch)
2 - 3 mm (5/64 - 1/8 inch)
Preheating
Welding with basic electrodes with their relatively low hydrogen content involves less risk of hydrogen induced underbead cracking than if cellulosic electrodes are used. Still, preheating to a temperature of approx. 100 C (210 F) is recommended, particularly for welding heavy wall pipe from steels that are susceptible to hardening. The diagram illustrates those cases for which preheating is recommended.
0.20 Preheating Carbon content (%)
0.10 No preheating or only for the purpose to eliminate condensed water (mm) 5 (inch) 3/16 Wall thickness 10 3/8 15 19/32 20 25/32 25 1
Preheating depending upon wall thickness and carbon content.
18
1/3
Basic electrodes
In cases where extra high toughness is required, extreme climatic conditions, heavy wall pipes ( 25 mm / 1 inch) e.g. Iandfall sections or the highest strength pipe steels StE 550.7 TM/X 80, X 100 there is a demand for low hydrogen vertical down electrodes. BHLER WELDING offers four different grades matching all of the important requirements including the practical and economical demands in field welding large diameter pipelines.
Comparison of impact strength

Diagram no. 1 indicates the impact strenght behaviour of vertical down welded joints and shows that the basic deposit is clearly tougher. The fact that the weld metal toughness of our of cellulosic electrodes has improved considerable is shown with the example of FOX CEL 85 (E8010-P1). Diagram no. 2 gives an overview about the excellent economical benefits when welding filler and cover passes with basic vertical down electrodes.
Iow hydrogen vertical down electrodes have approximately the same deposition rate as 5.5 mm (7/32") diameter cellulosic electrodes. Therefore the time required for the welding of filler and cover passes is similar using cellulosic or basic vertical down electrodes. However, there are losses in economy when welding the root pass with basic vertical down electrodes. It is therefore recommended and widely practiced, that root and hot passes be welded with cellulosic electrodes, and filler and cover passes with basic vertical down electrodes. It is thus possible to combine high economy with good mechanical-technological values in the joint weld. A great deal of experience has been gained already using this technology with very positive results. Should you require further details please contact our Technical Department.
Diagram no. 2 2.6
Combined technology with cellulosic and basic electrodes

Due to the high iron powder content of the basic coating and the ability to weld with high currents, 4 mm (5/32") diameter
Diagram no. 1 Single V butt joint, API X 60, 20 mm vertical down Basic AWS E8018-G
160 140 120 100 Charpy V impact energy in Joule 80 60 40 20 0
2.4 2.2 2.0 1.8 cellulosic 5G down 5 mm
Basic 5G down 4.5 mm
New gereration AWS E8010
1.6 1.4 Basic 5G up 1.2 4 mm 1.0 Deposition rate in kg/h 0.8 0.6 0.4 0.2 0 140 160 Welding current in A
-60 -40 -20 Test temperature in C
+20
180
200
220
240
19
Welding technology
D.C. positive 2.5 mm (3/32) 70 - 90 A In welding position 10 - 14 oclock 60 - 70 A 3.2 mm (1/8) 90 - 150 A In welding position 10 - 14 oclock 90 - 100 A
Stringer bead or root pass

All available grades of line pipe steels can be welded with BHLER FOX BVD RP if root pass welding with cellulosic electrodes is not permitted. It has become general practice to have two or more welders work simultaneously in order to reduce distortion and maintain uniform gap width. The recommended electrode diameter is 2.5 mm (3/32") or in the case of heavy walled large diameter pipes also 3.2 mm (1/8"). Maintain direct contact with the bevel faces. Grinding of the end crater should be carried out. In order to avoid a change in the slag viscosity and to maintain excellent control of the slag, groove faces must be free from foreign matter such as scale or rust.
Start: 12 oclock
80 - 90
Stop: 7 oclock
Short arc! Keep direct contact!
To prevent any porosity it is necessary to avoid any keyhole formation during welding. Too high a current could cause this problem. One should never finish root passes welded from two sides in 6 o'clock position. Termination of the runs should be approximately in the 7 o'clock position only. It is recommended to operate the electrode with a short arc. Remove slag from each bead by grinding. A clean slag-free bead assures excellent slag control when welding the subsequent layers with basic electrodes.
Avoid: keyhole formation
Correct: no keyhole
Filler passes
These passes are executed with 3.2 mm, 4 mm and 4.5 mm dia electrodes, depending upon plate thickness.
3.2 mm 4 mm 4.5 mm
(1/8") (5/32") (3/16")
110 - 160 A 180 - 210 A 200 - 240 A
Grind end craters
The high amperage ensures sufficient penetration and satisfac tory economy of the process. Avoid welding without weaving, as this would cause the pool to move faster than the electrode, short-circuiting the arc for a considerable time and making the electrode stick. This has a negative effect on the deoxidation process and favours porosity. Experienced welders will know which weave width and weld speed to choose, also taking into account the slag flow. In the overhead position, width of weaving is limited by manipulation. For welding heavy wall pipe we recommend to deposit 2 to 3 beads side by side, removing all slag before applying a new
Grind root pass
20
Basic electrodes
bead. If slag residuals are covered by a new bead, in 3 o'clock position in particular, the whole slag pool will flow ahead of the arc. Keep the arc as short as possible. To avoid any hardening peaks it is recommended that the last filler pass should be flush with the pipe surface so that the edges of the joint preparation are melted. This is to ensure that the capping pass when deposited tempers the heat affected zone.
Start: 12 oclock
80 - 90 80 - 90 11 to 1 oclock + 5 to 7 oclock 60 - 80 for other positions
Cap
The cap is deposited with a slight weaving technique, with a maximum weave of twice the electrode diameter.
Stop: 6 oclock
Recommended amperages: 3.2 mm 4 mm (1/8") (5/32") 110 - 160 A 180 - 210 A

Keep the arc short!
Rules for storage and rebaking of basic electrodes

Electrodes which have been stored in sealed cans do not need to be rebaked.
Weave width max. 2 x
Once a can has been opened, the electrodes it contains should be kept in a closed electrode container, until they are used for welding. Electrodes which are taken from unsealed, damaged cans or those which have been kept in open storage for several hours should be rebaked at 300 - 350 C (570 - 660 F) for 2 hours minimum and 10 hours maximum. In the event of rel. air humitity of more than 70 % it is recommended to use heated quivers maintaining a temperature of 100 - 200 C (210 - 400 F) prior to use.
Electrode Stopping the arc
Avoid: direct lifting of electrode
Correct: move downwards and then lift
Avoid: narrow gaps
Correct: Flat beat contours
Leads to slag inclusions
Grind if necessary
21
Welding technology Basic electrodes
Wall thickness
inch mm
Electrode consumption (kg)

2.5 mm 3/32 inch 0.30 0.20 0.20 0.20 3.2 mm 1/8 inch 4 mm 5/32 inch Total
Wall thickness
inch mm
Electrode consumption (kg)

3.2 mm 1/8 inch 0.20 0.20 0.20 0.20 4 mm 5/32 inch 2.60 3.00 3.40 3.90 Total
11/64 13/64 1/4 5/16 3/8 1/2 5/8 11/16 3/4 13/16 7/8 15/16 1
14.36 15.16 16.35 17.93 19.52 12.70 15.88 17.46 19.04 20.63 22.22 23.81 25.40
0.20 0.35 0.65 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20
0.90 1.55 2.45 2.95 3.50 4.00 4.75 5.40 6.00
0.30 0.40 0.55 0.85 1.10 1.75 2.65 3.15 3.70 4.20 4.95 5.60 6.20
13/16 7/8 15/16 1
20.63 22.22 23.81 25.40
2.80 3.20 3.60 4.10
60
10
30 1/3 2/3
Trouble shooting
Defects
Causes
How to avoid defects
Start porosity
use of damp electrodes drawing a long arc after ignition use of electrodes with damaged striking tips welding over slag residues insufficient grinding of undercut amperage too low
use only dry (rebaked) electrodes keep the arc short use undamaged electrodes use ignition active BHLER electrodes precise inter run cleaning by grinding or brushing grind sufficiently any undercut increase the amperage
Lack of fusion
Sagging stringer bead
amperage too high electrode diameter too large poor joint preparation root gap too narrow
set a lower amperage use of smaller electrode diameter joint preparation according to recommendation
Striking marks
stray arcing outside joint preparation causes local hardening
strike arc in the groove only
Slag inclusions
insufficient cleaning between passes
clean each layer with rotating wire brush
Scattered porisity
use of damp electrodes prolonged short circuit due to use of welding machines with poor welding characteristics poor electrode manipulation e.g. arc too long, angle incorrect
use only dry (rebaked) electrodes check the welding machine (open circuit voltage etc) handle the electrode correctly e.g. keep the arc short, keep the angle of 80 - 90
22
Gas pipeline X-70, Malaysia
23
Recommendations for basic vertical up electrodes
Basic electrodes
Steel grades API FOX EV Pipe E 7016-1 FOX EV 60 Pipe E 8016-G FOX EV 70 Pipe E 9016-G
A B X 42 X 46 X 52 X 56 X 60 X 65 X 70 X 80
Steel grades EN
L210 L245 L290MB L320M L360MB L385M L415MB L450MB L485MB L555MB
for root pass, hot pass and filler passes and capping for root pass welding only
Compared to root pass welding with cellulosic vertical-down electrodes the welder has to face a welding speed reduction of 60-70 % when welding the same root pass with basic verticalup electrodes. Nevertheless new product developments show a welding behaviour which allows the economic production of joints. BHLER FOX EV Pipe products guarantees significant advantages in positional welding: Usability of a diameter 4.0 mm up to a wall thicknesses equal or above 12 mm. 24
Better
and easier operating properties compared to a standard E7018-type. Obvious economic advantages for cap layers. Reduced grinding work compared to E7018 electrodes.
Furthermore these products exhibit high mechanical load capacity, lowest hydrogen contents in deposit, good air gap bridgeability, best thoughness values and highest tensile strength properties (if required).
Basic electrodes for vertical up welding
Welding process
Amperage
mm
A EN API
FOX EV PIPE
EN ISO 2560-A:2005: E 42 4 B 1 2 H5 AWS A5.1-04: E7016-1 H4 R AWS A5.1M-04: E4916-1 H4 R
SMAW
C 0.06 Re Si 0.60 Rm Mn 0.9 A5
470 ( 420) N/mm2 560 ( 520-640) N/mm2 29 ( 22) %
2.0 2.5 3.2 4.0
30-60 40-90 60-130 110-180
Av +20C: 170 ( 120) J -20C: 100 J -40C: 60 ( 47) J -46C: 55 ( 27) J YS 68000 ( 61000) PSI TS 81200 ( 74000-92800) PSI Elongation on 4d 29 ( 22) % Impact energy +68F: 125 ( 89) ft-lb -4F: 74 ft-lb -40F: 44 ( 35) ft-lb -51F: 40 ( 20) ft-lb
TV-D, LTSS, SEPROZ, VNIIST, VNIGAZ, DB, CE
Polarity negative for root pass. Preheat and interpass temperature as required by the base material. The optimum gap width for root passes is 2-3mm, the root face should be in the range 2-2.5 mm. The electrodes are ready for use straight from the hermetically sealed tins. Re-drying if necessary: 300-350 C, min. 2 h.
BHLER FOX EV PIPE is a basic electrode with some additions of rutile and silicates. It is excellent suited for positional welding of root passes using D. C. negative polarity as well as for filler and cover passes of pipes, tubes and plates on D. C. positive polarity, or even AC. BHLER FOX EV PIPE offers considerable time savings against AWS E7018 type electrodes when welding root passes due to increased travel speeds. Also the use of dia. 3.2 mm is possible for root passes in case of wall thicknesses of 8 mm and more. It is user friendly and provides a good gap bridging ability together with easy slag removal to ensure minimum grinding. Weld metal toughness is available down to -46C; very low hydrogen content (HD < 5 ml/100 g).
P235GH, P265GH, P295GH, P235T1, P275T1, P235G2TH, P255G1TH, S255N-S420N1), S255NL1 up to S420NL1, L290NB up to L360NB, L290MB up to L415MB, L450MB2) up to L555MB2) API Spec. 5 L: A, B, X42, X46, X52, X56, X60, X65-X802) ASTM: A53 Gr.A-B, A106 Gr.A-C, A179, A192, A210 Gr.A-1
stress relieved up to S380N / S380NL1
2) 1)
only for root pass
FOX EV 60 PIPE
EN ISO 2560-A:2005: E 50 4 1 Ni B 1 2 H5 AWS A5.5-06: E8016-G H4 R
SMAW
C Si Mn Ni
0.07 Re 0.60 Rm 1.2 A5 0.9 Av +20C: 0C: -20C: -40C: -46C:
550 ( 500) N/mm2 590 (560-720) N/mm2 29 ( 22) % 170 150 140 110 60 ( 130) J J J ( 47) J J
2.5 3.2 4.0 5.0
40-90 60-130 110-180 180-230
VNIIGAZ
Polarity negative for root pass. Preheat and interpass temperature as required by the base material. The optimum gap width for root passes is 2-3 mm, the root face should be in the range 2-2.5 mm. The electrodes are ready for use straight from the hermetically sealed tins. Re-drying if necessary: 300-350 C, min. 2 h.
YS 80000 ( 72500) PSI TS 85600 ( 81200-104400) PSI Elongation on 4d 29 ( 22) % Impact energy +68F: 125 ( 96) ft-lb +32F: 111 ft-lb -4F: 103 ft-lb -40F: 81 ( 35) ft-lb
Basic electrode excellent suited for positional welding of root passes using D.C. negative polarity as well as for filler and cover passes for pipes, tubes and plates on D.C. positive polarity, or even A.C. BHLER FOX EV 60 PIPE offers considerable time savings against AWS E8018 type electrodes when welding root passes due to increased travel speeds. Also the use of dia. 3.2 mm is possible for root passes in case of wall thicknesses of 8 mm and more. Good impact properties down to -40 C, low hydrogen content (HD < 5 ml/100 g), as well as packaging in hermetically sealed tins are further features for the user.
S235J2G3-S355J2G3, L210NB-L450NB, L210MB-L450MB, P235GH-P295GH, E295, E335, S355J2G3, C35-C45, P310GH, S380N-S460N, P380NH-P460NH, S380NL-S460NL, S380NL1-S460NL2, GE260-GE300 API Spec. 5 L: X42, X46, X52, X56, X60, X65 ASTM: A516 Gr.65, A572 Gr.55,60,65, A633 Gr.E, A612, A618 GrI, A537 Gr.1-3
FOX EV 70 PIPE
EN 757:1997
E 55 4 Z (Mn2NiMo) B 1 2 H5
SMAW
C Si Mn Ni Mo
0.06 0.50 1.7 2.2 0.3
Re Rm A5
620 ( 550) N/mm2 680 (630-780) N/mm2 20 ( 18) %
2.5 3.2 4.0
40-90 60-130 110-180
AWS A5.5-06: E9016-G H4 R
Av +20C: 140 ( 90) J -20C: 80 J -40C: 70 ( 47) J -46C: 55 J YS 90000 ( 80000) PSI TS 98600 ( 91300-113100) PSI Elongation on 4d 20 ( 18) % Impact energy +68F: 103 ( 66) ft-lb -4F: 59 ft-lb -40F: 52 ft-lb
BHLER FOX EV 70 PIPE is a high strength basic electrode. It is excellent suited for positional welding of root passes using D. C. negative polarity as well as for filler and cover passes of pipes, tubes and plates on D. C. positive polarity, or even AC. BHLER FOX EV 70 PIPE offers considerable time savings against AWS E9018 type electrodes when welding root passes due to increased travel speeds. Also the use of dia. 3.2 mm is possible for root passes in case of wall thicknesses of 8 mm and more. It is user friendly and provides a good gap bridging ability together with easy slag removal to ensure minimum grinding. Good impact properties down to -40 C, low hydrogen content (HD < 5 ml / 100 g), as well as packaging in hermetically sealed tins are further features for the user.
L450MB, L485MB, L555MB API Spec. 5 L: X65, X70, X80
Polarity negative for root pass. Preheat and interpass temperature as required by the base material. The optimum gap width for root passes is 2-3 mm, the root face should be in the range 2-2.5 mm. The electrodes are ready for use straight from the hermetically sealed tins. Re-drying if necessary: 300-350 C, min. 2 h.
25
Recommendations for automatic welding with solid wires
Solid wires
Steel grades API SG 3-P ER 70S-6 SG 8-P ER 80S-G NiMo 1-IG ER 90S-G
Flux cored wires

Ti 70 Pipe-FD E91T1-K2MH4
X 42 X 46 X 52 X 56 X 60 X 65 X 70 X 80
Steel grades EN
L290MB L320M L360MB L385M L415MB L450MB L485MB L555MB
for root pass, hot pass and filler passes and capping
BHLER wire for Pipeline welding are especially intended for the needs of semiautomatic and automatic root, hot, fill and cap passes welding on cross-country pipelines. They show on excellent mechanical properties, clean weld deposit, and uniform bead shape. The wires are suited for use on API 5L X42 through X80 pipes.
26
Wires for automatic pipeline welding
Welding process
Amperage
mm
A EN API
SG 3-P
EN ISO 14341-A:2008 G3Si1 G 46 5 M G3Si1 G 42 4 C G3Si1 AWS A5.18-05: ER70S-G AWS A5.18M-05: ER485S-G
GMAW
C Si Mn Ti
0.05 as welded Ar +15-25 % CO2 0.75 510 ( 470) N/mm2 1.55 Re Rm 640 (600-680) N/mm2 + A5 25 ( 24) %2 Av +20C: 120 ( 100) J -40C: 75 ( 65) J -50C: 55 ( 47) J YS 74000 ( 68000) PSI TS 92800 ( 87000-98600) PSI Elongation on 4d 25 ( 24) %
0.9
TV-D, CE BHLER SG 3-P is a micro alloyed GMAW solid wire designed for high quality automatic welding of pipelines. An optimum balanced alloying concept ensures good weld metal properties to fulfil the high requirements in the OnOffshore-Pipeline Industry. Deposit is extremely crack resistant and the weld metal toughness is available down to -50 C. The very important quality aspects, prerequisite for uninterrupted feedability of the solid wire e.g. helix of the wire, copper coating, close wire diameter tolerance and precision layer wound spooling are taken into account during the production.
L290MB-L485MB API Spec. 5 L: X42, X46, X52, X56, X60, X65
Shielding gases: Ar +15-25 % CO2 100 % CO2 Preheating and interpass temperature as required by the base metal.
Impact energy +68F: 89 ( 74) ft-lb -40F: 55 ( 48) ft-lb -58F: 40 ( 35) ft-lb as welded 100 % CO2 Re Rm A5 470 ( 440) N/mm2 610 (570-640) N/mm2 26 ( 25) %
Av +20C: 100 ( 95) -40C: 60 ( 47) YS 68000 ( 63800) PSI TS 88400 ( 82600-92800) PSI Elongation on 4d 26 ( 25) % Impact energy +68F: 74 ( 70) ft-lb -40F: 44 ( 35) ft-lb
BHLER SG 8-P
EN ISO: 14341-A:2003 G3Ni1 G 42 5 M G3Ni1 AWS A5.28-05: ER80S-G
GMAW
C Si Mn Ni Ti
0.06 0.70 1.50 0.90 +
as welded Ar +15-25 % CO2 Re Rm A5 Av +20C: -50C: 500 ( 420) N/mm2 590 ( 550) N/mm2 24 ( 20) % 150 ( 47) J 80 J
0.9 1.0 1.2
DNV
Shielding gases:
Ar +15-25 % CO2 Ar +0-5 % CO2 + 3-10 % O2 100 % CO2
YS 72000 ( 61000) PSI TS 85000 ( 80000) PSI Elongation on 4d 24 (20) % Impact energy +68F: 110 ft-lb -58F: 58 ft-lb as welded 100 % CO2 Re Rm A5 Av +20C: -50C: 470 ( 420) N/mm2 560 ( 500) N/mm2 25 ( 20) % 110 J 45 J
Micro alloyed GMAW wire designed for high quality automatic welding of pipelines. An optimum balanced alloying concept ensures good weld metal properties to fulfil the high requirements in the OnOffshore pipeline industry. The deposit is extremely crack resistant and the weld metal offers high impact values down to -50 C.
L290MB-L485MB API Spec. 5 L: X42, X46, X52, X56, X60, X65, X70
Preheating and interpass temperature as required by the base metal.
YS 68000 ( 61000) PSI TS 81000 ( 72500) PSI Elongation on 4d 25 (20) % Impact energy +68F: 81 ft-lb -58F: 35 ft-lb
27
Wire for automatic pipeline welding
Welding process
Amperage
mm
A EN API
NiMo 1-IG
EN ISO 16834-A G Mn3Ni1Mo (for wire) EN ISO 16834-A G 55 6 M Mn3Ni1Mo G 55 4 C Mn3Ni1Mo AWS A5.28-05: ER90S-G
GMAW
C Si Mn Mo Ni
0.08 0.6 1.8 0.3 0.9
as welded Ar +15-25 % CO2 Re Rm A5 620 ( 550) N/mm2 700 (650-800) N/mm2 23 ( 20) %
(0.9) 1.0 1.2
DB, BB, GL, SEPROZ, CE
Copper GMAW wire for high strength, quenched and tempered fine-grained constructional steels. The wire is suited for joint welding in boiler, pressure vessel, pipeline, and crane construction as well as in structural steel engineering. The typical composition of the wire fulfils the requirements of the NORSOK regulation for water injection systems. Due to the precise addition of micro alloying elements NiMo 1-IG wire features excellent ductility and crack resistance in spite of its high strength. Good cryogenic impact energy down to -60 C, low hydrogen contents in the deposit, best feedability and low copper contents are other advantages of this wire.
Pipe steels and fine grained steels, quenched and tempered finegrained steels. S380N-S500N, S380NL-S500NL, S500NC-S550NC, N-A-XTRA 56-70, BHV 70, PAS 600, HSM 600, 20MnMoNi5-5 ASTM: A517 Gr.A,B,C,E,F, H,J,K,M,P; A225 Gr.C, A633 Gr.E, A572 Gr.65 API Spec. 5 L: X70, X80
Av +20C: 140 ( 120) J -40C: 110 ( 90) J -60C: ( 47) J YS 89900 ( 80000) PSI TS 101500 ( 94000-116000) PSI Elongation on 4d 23 ( 20) %
Shielding gases: Ar +15-25 % CO2 Ar +0-5 % CO2 +3-10 % O2 100 % CO2 Preheating and interpass temperature as required by the base metal.
Impact energy +68F: 103 ( 89) ft-lb -40F: 82 ( 66) ft-lb -94F: ( 35) ft-lb as welded 100 % CO2 Re Rm A5 590 ( 550) N/mm2 680 (620-770) N/mm2 22 ( 20) %
Av +20C: 120 ( 100) -40C: ( 47) YS 85500 ( 63800) PSI TS 98600 ( 89900) PSI Elongation on 4d 22 ( 25) % Impact energy +68F: 89 ( 74) ft-lb -40F: ( 35) ft-lb
Ti 70 Pipe-FD
EN ISO 18276-A:2006: T 55 4 Mn1Ni P M 1 H5 AWS A5.29-05: E91T1-K2MH4
FCAW
C Si Mn Ni
0.07 Re 550 N/mm2 0.4 Rm 640-820 N/mm2 1.5 A5 18 % 1.0 Av -40C: 47 J YS 80000 PSI TS 93000-119000 PSI Elongation on 4d 18 % Impact work -40F: 34 ft-lb
1.2
180-280
TV-D, CE Tubular rutile micro alloyed flux cored wire for single or multipass welding of carbonmanganese steels and high strength steels with Ar-CO2 shielding gas. Main features: excellent weldability in all positions, excellent bead appearance, no spatter; fast freezing and easy removable slag. The exceptional mechanical properties of this wire even at the low temperature (-40C) as well as the low content of diffusible hydrogen make it especially suitable for pipeline applications. Further applications are to be seen in the off-shore industry, ship building and structures built with high strength steels.
Pipe steels and fine-grained steels S460 S500N, S460NL S500NL, S500NC S550NC, L450MB L485MB (L555MB) API Spec: 5L: X65, X70, (X80)
re-drying: possible 150C/24h but in general not necessary
Ti 80 Pipe-FD
EN ISO 18276-A:2006 T 69 4 Z P M 1 H5 AWS A5.29-05: E111T1-GMH4
FCAW
C Si Mn Ni
0.07 Re ( 690) N/mm2 0.3 Rm 770-940 N/mm2 1.7 A5 (17) % 2.5 ISO V -40C: ( 47) J YS 80000 PSI TS 111700-136000 PSI Elongation on 4d 17 % Impact work -40F: 34 ft-lb
1.2
180-280
TV-D, CE Tubular rutile Ni-Mo alloyed flux cored wire for single or multipass welding of high strength steels with Ar-CO2 shielding gas. Main features: excellent weldability in all positions, excellent bead appearance, no spatter; fast freezing and easy removable slag. The exceptional mechanical properties of this wire even at the low temperature (-40C) as well as the low content of diffusible hydrogen make it especially suitable for pipeline applications. Further applications are to be seen in the offshore industry, ship building and structures built with high strength steels.
Pipe steels and fine-grained steels L485MB, L555MB API Spec: 5L: X70, X80
28
Other consumables for pipeline welding
BHLER
Welding process
Typical analysis %
Typical mechanical properties N/mm2 (KSI)
Amperage
AWS EN
mm A
FOX CEL S
E6010
SMAW
C 0.10 Si 0.20 Mn 0.50
Re Rm A5 Av
480 550 23 110
(70) (80) % J
2.5 3.2 4.0
Cellulosic electrode especially designed for vertical up welding of root passes on D.C. positive polarity. Can be used however, also vertical down and on negative polarity. Ideally suited for the Dolly Mix technique. It shows a forceful arc and good operating characteristics.
FOX CEL 75 G
E7010-G
SMAW
C 0.14 Si 0.10 Mn 0.7 Ni 0.6
Re Rm A5 Av -40C
460 (68) 550 (80) 24 % 110 J 65 J
3.2 4.0 5.0
TV-D, CE Bhler FOX CEL 75 G is an AWS E7010-G cellulosic electrode for welding the pipe grades X 56, X 60 and X 65 or the EN steels L385M, L415MB and L450MB. The electrode provides consistently high quality as well as outstanding low temperature toughness values together with superior operating characteristics.
FOX CEL 85 G
E8010-G
SMAW
C Si Mn Ni
0.16 0.4 0.7 0.7
Re Rm A5 Av -40C
490 570 23 105 70
(71) (82) % J J
3.2 4.0 5.0
Bhler FOX CEL 85 G is an AWS E8010-G cellulosic electrode for welding the pipe grades X 60 through X 70 or the EN steels, L415MB, L450MB and L485MB. The electrode provides consistently high quality as well as outstanding low temperature toughness values together with superior operating characteristics.
FOX EV 50-W
E7016-1 H4 R E 42 5 B 1 2 H5
SMAW
C 0.07 Si 0.5 Mn 1.1
Re Rm A5 Av
460 560 28 200
(67) (81) % J
2.5 3.2 4.0
40-60 55-85 80-140 110-180 180-230
TV-D, GL, LTSS, PDO, SEPROZ
Low hydrogen electrode for compressor station or pressure reduction construction. Excellent for root passes in the vertical up position. It has a very stable penetration arc and gives good X-ray quality welds. Best root welding characteristics on D.C. negative polarity. HD < 5 ml/100 g.
FOX CN 22/9 N
E2209-17 E 22 9 3 N L R 3 2
SMAW
C 0.03 Si 0.8 Mn 0.9 Cr 22.6 Ni 9.0 Mo 3.1 N 0.17 PREN 35
Re 650 Rm 820 A5 25 Av 55 -20C 32
(94) (118) % J J
2.5 3.2 4.0 5.0
40-75 70-120 110-150 150-200
TV-D, TV-A, ABS, DNV, GL, LR, RINA, Statoli, SEPROZ, CE
Rutile basic alloyed-core wire electrode for the welding of ferritic-austenitic duplex steels e.g. 1.4462, UNS 31803. Highly recommended for vertical up welding of tubes and pipes (electrode diameter 2.5 mm; D.C., electrode negative). Good weldability on A.C.
FOX CN 22/9 N-B

E2209-15 E 22 9 3 N L B 2 2
SMAW
C 0.03 Si 0.3 Mn 1.1 Cr 22.6 Ni 8.8 Mo 3.1 N 0.16 PREN 35
Re Rm A5 Av -60C
630 830 27 110 40
(92) (121) % J J
2.5 3.2 4.0 5.0
50-75 80-110 100-145 140-180
TV-D, CE Basic DUPLEX electrode for UNS S31803. The weld deposit shows excellent impact properties down to -60 C and assures safe welding of heavy wall thicknesses under high requirements. The Pitting Resistance Equivalent is 35 (PREN = % Cr + 3,3 x % Mo + 16 x % N) the ferrite content of the weld deposit is 30 FN.
CN 22/9 N-IG
ER2209 W 22 9 3 N L G 22 9 3 N L
GTAW GMAW
C 0.015 Si 0.4 Mn 1.7 Cr 22.5 Mo 3.2 Ni 8.8 N 0.15 PREN 35
Re Rm A5
GTAW: 600 (87) N/mm2 1.6 800 (116) N/mm2 2.0 2.4 33 % 3.2 Av 150 J -60C 32 J Re Rm A5 GMAW: 660 (95) N/mm2 1.0 830 (120) N/mm2 1.2 28 %
TV-D, TV-A, ABS, DNV, GL, LR, Statoil, CE TV-D, TV-A, DNV, GL, Statoil, DB, SEPROZ, CE
TIG welding rod and GMAW wire highly suitable for welding ferriticaustenitic duplex steels, e.g. 1.4462, UNS 31803. The metallurgical design of CN 22/9 N-IG with an optimum alloying composition and closest tolerance limits ensure particularly good weld metal properties & resistance to stress corrosion cracking and pitting. it is ideally suited for the high quality requirements in pipeline welding. Best results can also be obtained with our SAW wire CN 22/9 N-UP and flux BB 202.
Av 85 J -40C 32 J
CN 22/9 PW-FD
E2209T1-4 E2209T1-1 T 22 9 3 N L P M 1 T 22 9 3 N L P C 1
FCAW
C 0.03 Si 0.8 Mn 0.9 Cr 22.7 Mo 3.2 Ni 9.0 N 0.13 PREN 35
Re Rm A5
600 (87) N/mm2 800 (116) N/mm2 27 %
1.2
100-220
Av 80 J -46C 45 J
TV-D, DNV, ABS, LR, GL, RINA, CWB, SEPROZ, CE
Flux cored wire for positional welding. Easy to operate in all weld positions with one single parameter setting using Argon mixtures or CO2. Powerful penetrating arc, spray transfer, minimum spatter formation, self releasing slag, excellent wetting behaviour, flat and smooth bead profile. Fast travel speeds and a wide range of operating parameters offer highest productivity. Suitable for service temperatures from -46 C to +250 C.
29
Additional brochures on welding consumables made by BHLER WELDING for selected industries are available in several language versions.
Further information can be obtained from BHLER WELDING sales partners or in the Internet under www.boehler-welding.com
WELDING CONSUMABLES FOR HYDRO POWER STATIONS
WELDING CONSUMABLES FOR THERMAL POWER STATIONS
FLUX CORED WELDING WIRES FOR STAINLESS STEELS
BHLER DRY SYSTEM GUARANTEED DRY ELECTRODES
METAL POWDER AND CASTING RODS
WELDING CONSUMABLES FOR THE OFFSHORE INDUSTRY
WELDING CONSUMABLES FOR STEEL CONSTRUCTION
Details regarding the nature and application purposes of our products are intended for the information of the user. The data concerning the mechanical properties always refers to the all weld metal deposit in accordance with the applicable standards. In the area of the weld joint, the weld metal properties are influenced by the base metal, the welding position and the welding parameters. A guarantee of the suitability for a specific type of application requires in each individual case an implicit agreement in writing. Subject to change without notice.
Published by BHLER WELDING
Bhler Schweitechnik Austria GmbH Bhler-Welding-St. 1 8605 Kapfenberg / AUSTRIA +43 (0) 3862-301-0 +43 (0) 3862-301-95193 [email protected] www.boehler-welding.com
BSGA 04/2009 ENG1500 Cover picture: HAK
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WELDING CONSUMABLES FOR PIPELINE CONSTRUCTION

Low strength pipe steels

FOX EV Pipe FOX EV 60 Pipe

FOX BVD RP FOX BVD 85

FOX EV Pipe FOX EV 60 Pipe

FOX BVD RP FOX BVD 85 FOX BVD RP FOX BVD 85

FOX EV Pipe FOX EV 60 Pipe

FOX BVD RP FOX BVD 85

FOX EV Pipe FOX EV 60 Pipe

High strength pipe steels

FOX BVD RP FOX BVD 90

SG 8-P NiMo 1-IG

FOX BVD RP FOX BVD 85

FOX BVD RP FOX BVD 90

SG 8-P NiMo 1-IG

FOX BVD RP FOX BVD 90 FOX BVD 100

BHLER WELDING Consumables for pipeline construction

Cellulosic electrodes for vertical down welding

5 7 8 8 8 9 9 29 9 10 29 10 11 - 14 15 E8045-P2) E8045-P2) E9018-G) E10018-G) E11018-G) E12018-G) 16 16 16 17 17 17 18 - 22

Basic electrodes for vertical up welding

Other consumables for pipeline welding

BHLER BHLER BHLER BHLER

FOX FOX FOX FOX

CEL S CEL 75 G CEL 85 G EV 50-W

FOX CN 22/9 N FOX CN 22/9 N-B CN 22/9 N-IG CN 22/9 PW-FD

Comparison table for pipe steels

Steel classifications API 5 L-92 EN 10208-2 DIN 17172

Yield strength minimum ksi N/mm

Tensile strength minimum ksi N/mm

30.0 30.4 30.4 35.0 35.5 34.8 42.0 42.0 42.0

207 210 210 241 245 240 289 290 290

48.0 46.4 46.4 60.0 60.2 53.7 60.0 60.2 60.9

331 320 320 413 415 370 313 415 420

46.0 46.4 46.4

317 320 320

63.0 66.7 66.7

434 460 460

52.0 52.2 52.2

358 360 360

66.0 66.7 74.0

455 460 510

56.0 55.8 55.8

386 385 385

71.0 76.9 76.9

489 530 530

60.0 60.2 60.2

413 415 415

75.0 75.4 79.8

517 520 550

65.0 65.3 64.6 70.0 70.3 69.6 80.0 80.5 79.8

448 450 445 482 485 480 550 555 550

77.0 77.6 81.2 82.0 82.7 87.0 90.0 90.6 100.1

530 535 560 565 570 600 620 625 690

BHLER WELDING Consumables for pipeline construction

Vertical down welding using cellulosic electrodes, UAE

Water Pipeline in Saudi Arabia

Recommendations for cellulosic electrodes

Cellulosic electrodes for vertical down welding

BHLER Standard Operating data