Indian Welding Journal
Chief Editor
Dr. T. K. Pal
Professor
Metallurgical and Material Engg. Department
Jadavpur University, Kolkata – 700032
Phone & Fax : 033-24146317 (O)
E-Mail :iwj.iiw@gmail.com
Joint Editors
Mr. Rahul Sengupta
Chairman
Meeting and Publication Commiittee
Indian Institute of Welding
Dr. Shaju Albert
Head, Materials Technology Division
Indira Gandhi Centre for Atomic Research,
Kalapakkam, Tamilnadu
Editorial Board
1.
Mr. P. K. Das, Immidiate past Chief Editor, IWJ and Vice president of IIW.
2.
Dr. A. K. Bhaduri, Associate Director, Indira Gandhi Centre for Atomic Research, Kalapakkam,
Tamilnadu - 603 102.
3.
Dr. G. Madhusudan Reddy, Scientist 'G', Group Head, Metal Joining Group, Solidification
Technology Division, Defence Metallurgical Research Laboratory (DMRL), Hyderabad,
Hyderabad – 500 058.
4.
Dr. Amitava De, Professor, Mechanical Engineering Department, In-Charge, Structural
Integrity Testing & Analysis Center (SITAC); Central Workshop, IIT Bombay, Powai - 400 076.
5.
Dr. V. Balasubramanian, Professor and Director, Centre for Materials Joining& Research,
Department of Manufacturing Engg., Annamalai University, Chennai.
6.
Dr. Santanu Das, Professor and Head, Mechanical Engg. Department, Kalyani Government
Engineering College, Kalyani, West Bengal.
7.
Dr. G. Padmanabham, Associate Director, International Advanced Research Centre for
Powder Metallurgy & New Materials (ARCI), Hyderabad.
8.
Dr. Mahadev Shome, Head, Material Characterization and Joining research group, R&D,
Tata Steel, Jamshedpur-831 001.
Special Invitees
1.
Dr. Stan David, Corporate Fellow and Group leader (Rtd.)
Oak Ridge National Laboratory, Consultant, USA.
2.
Professor W. Fricke, Hamburg University of Technology, Germany.
3.
Professor Dietrich Rehfeldt, Leibniz University, Hanover, PZH, IW, Joining of Materials.
Representing American Welding Society
Andrew Cullison & Jeffery Weber
11
EDITORIAL
EDITORIAL
First of all I would like to thank council members of The Indian Institute of Welding for giving me the opportunity to act
as Chief Editor of Indian Welding Journal from January issue.
You will agree that the economic growth of India over the period has changed her position and has involved changes in
her industrial structure. These changes greatly affect the status of welding engineering and technology in the present
industrial society. The Indian Institute of Welding has also decided to restructure itself to adopt to these new
environments.
We have come round an eventful year for the Indian Institute of Welding as well as Indian Welding Journal. Our
institute hosted the prestigious event “64th Annual Assembly & International Conference of the
International Institute of welding, Chennai, India, July 17-22, 2011”, being held for the first time in our
country and our annual assembly "NWS 2011" during December 16-18, 2011 at Bhilai.
IWJ provides a forum for the multidisciplinary subjects within joining of materials and helped to encourage
developments and information exchange of important work within the field. In this issue, there are three awarded
technical papers which would be of interest to both welding and material engineers.
We have the pleasure to put on records our compliments to Dr. R. S. Parmar, who made valuable contribution to
welding technology and the institute, for being chosen to receive the “Life time achievement award” and
Mr. P. K. Das, immediate past Chief Editor and Vice President of our institute, for being promoted the journal a new look
idea and making them available for advertisement and sponsorship.
IWJ is proud to welcome the new board members, who are recognized for their significant contribution towards the
growth of welding technology. It is my hope that the new editorial board will play an important role and with the
support from related organizations, contribute to the prosperity and welfare of human being and of global society.
The January issue of the journal is coming out during mid February. Late receipt of materials for publication has caused
this delay which we sincerely regret. The cooperation and ideas from all members shall continue to make the journal
more valuable in future.
Before we end, we from IWJ wish all our readers, home and abroad, a very Happy, Prosperous and eventful 2012.
T. K. Pal
Chief-Editor
Email: iwj.iiw@gmail.com
13
INDIAN WELDING JOURNAL Volume 45 No.1 January 2012
HONY. SECRETARY GENERAL'S DESK
Dear Members,
At the outset I must congratulate Bhilai Branch and the organising committee of NWS-2011 for the very successful way
they have organized our most prestigious annual event the National Welding Seminar-2011 in association with Bhilai
Steel Plant. In this connection I must acknowledge the generous and whole hearted support received from Shri Pankaj
Goutam, Chief Executive officer and other senior officials of Bhilai Steel without whose help and hospitality the
seminar would not have been such a success.
On an invitation from the International Institute of Welding a three member team comprising of M/s. R. Ravi, President
IIW-India, B. K. Mishra, Chairman, ANB-India and the undersigned, attended the IIW Intermediate meetings including
Working Group Regional Activities, Commission meetings and IAB meetings held in Paris during January 2012. During
the WG-RA Meeting majority of I1W Officials had highly appreciated the IIW-India for successful conduction of last
64th Annual Assembly & International Conference held at Chennai during July-2011.
I am pleased to inform that following our earlier application for holding IWC-2014 in India, the Governing Council of
IIW have awarded organization of the International Welding Congress 2014 to IIW India. This is scheduled to be held
at New Delhi from 6th to 8th March-2014. We have given a presentation in the WG -RA Meeting on IC-2014 regarding
the progress of the event. The members present appreciated the progress. Further the IAB Group B Committee has
extended the time for application for IWCP diplomas through Transition arrangements for IIW India up to 31st July
2012.
Our MES assessment activities have been progressing well. During the period from October to December-2011 out of
934 assessments received for various courses under fabrication sector, 781 candidates were assessed of which 765
candidates had passed.
Under IIW-India's National Welders Training and certification programme during October to December-2011, 3 new
Welder Training Institutes applied to us for becoming Authorised Training Institute for conducting NWTCS program.
I am also pleased to inform that our newly formed ANBCC has received preliminary approval from the IAB for operating
IIW's manufacturers Certification Scheme in India and that we have been able get our first client in Delhi for
conducting ISO 3824 audit.
Our ANB -India division from November-2011-January-2012 have organized a total of five Refresher Courses held at
Kolkata (2nos), Baroda, Chennai and Delhi. A total of 60 candidates had appeared in these courses and for award of
the International Welding Personnel Diplomas.
Best Regards.
Parimal Biswas
parimal.biswas@iiwindia.com
14
IIW NEWS
IIW NEWS
To commemorate the event a souvenir & CD, containing
NATIONAL WELDING SEMINAR – 2011
all the selected Technical Papers of NWS-2011, were
HELD AT BHILAI
released by the dignitaries.
REPORT FROM IIW BHILAI BRANCH
During Inaugural Session, various welding Awards,
The National Welding Seminar – 2011 (NWS-2011) was
institutionalized by IIW-India, were ceremoniously given
organized by the Bhilai Branch of the Indian Institute of
away for the papers presented during the last welding
welding in association with Bhilai Steel Plant (SAIL)
seminar by the IIW-India president Shri R. Ravi & Chief
during December 15th – 17th, 2011 and this was the
guest Shri Pankaj Goutam that also includes the best
third occasion the branch hosted this mega event after a
welding Engineer and best welders awards. The
gap of five years. The theme of the seminar was
prestigious Life Time Achievement Award for year 2010-
“Welding Science & Technology in Infrastructure
11 was given away to Dr. R. S. Paramar, Ex. Prof. of IIT,
Industries”. While the Inaugural session held at Kala
Delhi.
Mandir Auditorium, the technical sessions and
The two prominent memorial lectures viz Keith Hartley
concluding session were held at Bhilai Niwas, both within
Memorial lecture & Dr. Placid Rodriguez Memorial lecture
the Bhilai Steel Plant township. Around 225 delegates
were delivered by Dr. T. K. Pal, Prof. of Jadavpur
were drawn from a variety of fields like Educational
University & Dr. G. D. Janaki Ram, Prof. of IIT, Madras on
Institutions, R & D, Industrial Consumables,
topics 'Development of welding technology for
Manufacturer etc. Altogether 40 papers were accepted
auto-motive industries' & 'Emerging concepts in
and 36 papers were presented during the seminar on a
welding research, respectively.
wide range of topics.
Coming to Technical Sessions about 36 papers were
The Chief Guest Shri Pankaj Goutam, Chief Executive
presented in two parallel run sessions. The sessions
Officer of Bhilai Steel Plant and Chief Patron of Bhilai
were chaired by S/Shri N. K. Sarkar, V. S. Galgali, H. V.
Branch of IIW, underlined the rising importance of
Sharma, C. K. Datta, P. K. Das, Dr. G. L. Datta, A. B.
welding in the infrastructure Industry and stressed the
Purang, Dr. Madhusudan Reddy, H. K. Sethi & S. N. Singh
need for constant updation of knowledge related to all
all prominent persons in their chosen field of
aspects of welding. In the same vein Shri R. Ravi,
professions.
President (IIW-INDIA) while enumerating the role of
IIW in keeping the industry informed and guided in the
The papers covered the wide spectrum right from
latest development taking place in the field.
Research, New application, New developments,
Economy & Health concern related to various aspect of
Other speakers including President IIW – Bhilai Branch
welding.
Shri P.K. Singh, ED (Works) BSP and Secretary General of
The speakers were all experts in their particular areas
IIW-INDIA Shri Parimal Biswas also stressed the
importance of such events for better applicability of
and did a splendid job in compiling their thought &
welding as a Science & Technology.
research into their papers.
At the outset, Shri Debasish Thakur, Chairman (IIW-
Each paper was judged by 3 persons including the
Bhilai Branch) and GM (Utility) BSP, welcomed the
session chairman and 2 delegates from audience. These
dignitaries, distinguished guests & delegates and briefed
evaluation sheets have been handed over to Dr. Shaju
the gathering about the Seminar and the action role
Albert, Chairman, Technical Committee (IIW-INDIA) for
being played by the Bhilai Branch in spreading the
declaring the results.
objective of IIW-INDIA.
15
INDIAN WELDING JOURNAL Volume 45 No.1 January 2012
The sumptuous lunches & dinners assisted by cultural
Structural (Plate) Welding category and Mr. Vinod
programmes at night have only helped in assimilating
Kumar, R. Parmar of L&T, Baroda was declared as the
these technical contents easily.
Best Welder in the Pipe Welding category. Each of them
was given an Award of Rs.5000/- in cash and a
Valedictory function was presided over by Dr. R. S.
certificate.
Parmar and concluding remarks was summed up by Shri
Parimal Biswas on behalf of the council.
All the Awards sponsored by ELCA Laboratories, Thane,
Maharashtra were given to the winners during the
The proceedings of the entire activity were conducted by
Inauguration ceremony at the National Welding Seminar
Shri G. M. Arun Kumar, DGM (MARS); Mrs. Manju
held at Bhilai on 15th December, 2011.
Haridas, AGM (ERS); Shri V. K. Ogale, Sr. Mgr. (RMP-1)
IIW MES AB:
and Shri Umesh Malayath, Jr. Mgr. (CAS) while the vote
of thanks was proposed by Shri Ajay Bedi, Hony
A total number of 372 candidates assessed under this
Secretary (IIW-Bhilai Branch).
scheme at various ITI in Gujarat under the active
During the seminar, the 280th Council Meeting and
leadership of Mr. R. R. Vishawakarma, Gujarat State
Annual Members Assembly were also held.
Coordinator & Authorised Assessor
The work of various committees, formed to make the
event a grand success, was highly acknowledged that
also
BRANCH ACTIVITY REPORT
includes S/Shri S. K. Bansal, H. K. Sahu, R. K.
Bisare, M. R. K. Sariff and D. Anand.
REPORT FROM BANGALORE BRANCH
REPORT OF THE BWE & BW COMPETITIONS,
1.
jointly conducted on 17th Nov 2011 by Indian
2011
Society for Non-Destructive Testing [ISNT], Society
The National Level Competitions for the Best Welders
for Indian Aerospace SIATI Blr, where-in Padmashri
and Best Welding Engineer of the year, 2011-12 was held
Dr. C. G. Krishnadas Nair was facilitated; and the
at the Welding Reclamation Shop of the Bhilai Steel
Branch Chairman, Mr. N. Ramesh Rao delivered the
Plant, Bhilai on 13th December, 2011 and was conducted
Key-Note Address.
by Mr. N. K. Sarkar.
2.
Out of 11 branches, only 7 branches viz. Baroda, Bhilai,
Chennai,
Program on “Advances in Welding & Testing”
Jamshedpur,
Kolkata,
Mumbai
Program on “Copper Welding, Brazing &
Soldering” was conducted on 25th Nov 2011
and
jointly with Indian Copper Development Centre,
Visakhapatnam participated in this year's competition,
where-in the Branch Chairman Mr. N. Ramesh Rao
there were only five candidates in each category.
presented a paper on “Considerations in imple-
IIW Mumbai Branch assisted by Mr. S. C. Mitra and Mr. T.
menting Copper Welding Procedures” .
K. Mitra both from Kolkata branch and Mr. S. C. Tuteja
3.
from Bhilai.
The Branch Committee members visited Mysore &
Dharwad Regional Centres for Skill Development for
Mr. Biswajeet Paul of L&T Ltd., Mumbai was declared as
promoting Welding Training Programs; this was
the Best Welding Engineer. He was given an AWARD of
arranged by the Branch Hony Secry Mr SV Dilipan.
Rs. 7,000/- in cash and a certificate. He was registered as
4.
a free delegate for the NWS.
The Branch Committee members visited Advanced
Simulator Training Facility for Skill Development for
Mr. Roque Fernandes of Don Bosco Maritime Academy,
promoting Welding Training Programs; this was
Mumbai was declared as the Best Welder in the
arranged by the Branch Hony. Secy. Mr. S. V. Dilipan
16
IIW NEWS
REPORT FROM BARODA BRANCH
I.
Director, Selectarc Industries, France, on 14th
December 2011 at Hotel Surya Palace. 85
One-day Seminar
Participants attended.
Organised Seminar on "Welding in Pressure
3.
Vessels Industries" - as 13th Foundation Day
“Seam less flux/metal cored wires suitable
for pipe line, offshore & shipbuilding
Celebration, held on 15th October 2011 at Hotel
applications” Presented by Mr. Martin Schnirch,
Surya Palace.
Sales Director & Mr. Andreas Holzner, Head of
The Seminar was inaugurated by lighting the lamp
Quality and Application Management Drahtzug
by Chief Guest Mr. R. K. Batra & other dignitaries
Stein wire & welding (German Company).
present on dias. On this occasion, the Souvenir
III. Workshop Training :
covering technical papers, advertises & IIW
Following workshop training programmes were
informations etc., was released by Chief Guest.
The Chief Guest
conducted
Mr. R. K. Batra, Exe. Director
1.
(Project & Construction, Engineers India Ltd ) in his
WPS/PQR workshop from 17th to 18th December
inaugural speech emphasized on the need of
2011 at Hotel Sayaji, Vadodara. Total 26
welding knowledge sharing to various professionals
participants attended the workshop. The workshop
in the construction industries and training to the
conducted was to educate the welding engineers
welding inspectors as well as welders to improve
on the different aspects of preparing WPS/PQR as
upon the skill and performance to achieve the best
per ASME Section IX Code requirements. At the end
quality standards.
of the workshop participants were given case
studies to prepare the WPS on their own and
The Convenor of the seminar was Mr. D. C. Mehta
present it to all.
and the technical session was chaired by Mr. R. R.
Chhari. The Seminar received overwhelming
The Convenor of the programme was Mr. Kashyap
response from various advertisers & sponsors.
Bhatt, supported by Mr. Vijay Patel, Mr. R. R. Chhari
and Mr. B. S. Kandpal as faculties and evaluation
The Seminar was Sponsored by M/s Vijay Tanks and
team members.
Vessels (Baroda) and by M/s Satkul Enterprises Ltd,
(Ahmedabad).
2.
NDT Level II (Visual Testing) course from 23rd to
25th December 2011 at Hotel Nidra, Vadodara. The
II. Technical Lectures :
training for NDT Level II (Visual Testing) was
Following Technical Lectures were organized :
organized as per ASNT recommended Practice-SNT-
1.
“Comparison between ASME and EN
TC-1A : 2006. Total 18 Participants attended the
requirements for Welders and Welding
Training Programme.
Procedure Qualification” by Mr. Mahendra
The Convenor of the programme was Mr. Kashyap
Shiroya (QMOS-LeveIII Inspector) and Mr. Sunit
Bhatt.
Kumar (PED Inspector) from M/S. Bureau Veritas
3.
(India) Pvt. Ltd., Baroda, on 14th July 2011 at Hotel
Transition Route from 22nd to 26th November 2011
Revival Lords INN. near Sayaji Garden, Vadodara.
at GETRI, Baroda. 19 participants attended the
67 Participants attended.
2.
47th IWE/IWT Certification Programme through
programme.
“Welding of Nickel and High Alloy Steels”
Presented by Dr. K. Manfred Rostek, Technical
17
INDIAN WELDING JOURNAL Volume 45 No.1 January 2012
competition. Written Tests and Viva were conducted
IV. Awareness of IIW Activities (Promoting
for the Best Welding Engineers and for the welders
Welding Science & Technology)
category practical test coupon welding and viva
Presentation of IIW India activities (special
were conducted. The following candidates were
emphasis on AMIIW exam and Membership) were
declared winners after the evaluation procedure for
conducted by Dr. Vishvesh J. Badheka, Hon. Joint
the branch level competition :
Secretary of IIW Baroda Branch and in Industries
1.
by Mr. B. S. Kandpal at following academic and R &
Mr. Tushar Koradia - L&T Ranoli – Best welding
D institutes:
Engineer
Mechanical Eng Dept; U V Patel College of Eng &
Mr. Mukesh R Valand – Inox India – Best welder for
Technology, Ganpat University, Mehsana. More
structural Welding
than 80 students of Final & Pre final year
Mr. Vinodkumar R Parmar – L&T Ranoli – Best
Mechanical and M.Tech (Advance Mfg. Technology)
welder for Pipe Welding.
students were attended. Presentation was of about
The Winners of the branch level participated in the
1 hr. followed by 30 min. questions answers.
2.
National Level Competition held at Jamshedpur
ITER-INDIA, IPR, Gandhinagar; 20 Scientist/
from 13th to 15th December 2011. Results are very
Engineers of ITER India were attended. Mr. Mukesh
pleasing for Baroda Branch.
Jindal of ITER INDIA who is already member of IIW
Mr. Vinodkumar R. Parmar declared Winner of the
Baroda, is nodal person to promote IIW activities.
3.
Best Welder competition; while Mr. Tushar Koradia
Diploma Mechanical Engineering (Polytechnic) and
was declared as runner up of the Best welding
M.E (Welding Technology) of The M. S. University of
Engineer competition.
Baroda.
4.
5.
VI. Industrial Visits :
Diploma Fabrication Technology and Diploma
Mechanical Engineering at Government Poly-
Industrial Visit was made to M/s Hindustan Dorr
technic, Bhavnagar on 3rd December 2011
Oliver, Ahmedabad on 1st October 2011. A total 20
members visited the HDO.
Electrical Research and Development Association
(ERDA), on 14th December 2011.
REPORT FROM CHENNAI BRANCH
V. Best Welding Engineer And Best Welder
Competition -2011
I.
IWE/IWT ANB Programme during 11th to
Best Welder and Best welding Engineer competition
15th October 2011
was held at M/S Avadh Industries – Makarpura on
The forty fifth Certification Programme (IWE, IWT)
11th November 2011. The competition was
of International Institute of Welding was held from
conducted and examined
by Mr. Jayesh Patel,
11th to 15th October, 2011, at the lecture hall of the
Mr. Kashyap Bhatt, Mr. D. V. Acharya and Mr. B. S.
ISNT Chennai Chapter. Six participants attended the
Kandpal.
programme.
There were 4 participants from different industries
II. Best Welder/Best Welding Engineer Contests
for Best Welding Engineer Competition and 2
The contests for the Best Welder (Structural and
participants for Best Welder (Pipe & Plate)
Pipe Welding) and Best Welding Engineer were held
18
IIW NEWS
on 12th November, 2011, at the L&T - Construction
welder contests was held on Saturday, the 10th
Skills Training Institute, Kancheepuram, Chennai.
December, 2011 at Hotel Radha Regent, 171,
Nine participants for structural welder, 11 parti-
Jawaharlal Nehru Salai, Chennai. Mr. G. Ravindran,
cipants for pipe welder and 9 participants for weld-
JGM, Audco India Ltd, Maraimalainagar, Chennai
ing engineers participated in the contest. Shri. V.
was the Chief Guest and distributed the awards to
Sundaramurthy, Principal, L&T Construction Skills
the winners.
Training Institute inaugurated the contests.
V. Technical Lectures
Shri. R. Ravichandran, was convener of the BW &
BWE committee, and supported by Shri. S.
IIW-India, Chennai Branch organised two evening
Chandran, EC member.
technical lectures on 10th December, 2011 at Hotel
Radha Regent, Chennai on the following topics. The
Shri. R. Mekkavan of BARCF, Kalpakkam won the
programme was sponsored by FSH welding India
Best Structural Welder, Shri. Yesuraj, of TPPC
Pvt. Ltd.
Division, Larsen & Toubro Ltd, Vemagiri, AP won the
1.”Welding of nickel alloys & SS alloys
Best Pipe Welder and Sri. V. Mohanraj, of L&T HCP
Division; Manapakam, Chennai, won the Best
suitable
Welding Engineer contests respectively. The branch
applications” by Dr. K. Manfred Rostek,
level winners were nominated for national level
Technical Director - FSH Welding Group, France.
contest held in Bhilai on 13 & 14 December 2011.
for
High
temperature
2. “Seamless flux/metal cored wires suitable
for pipe line, offshore & shipbuilding
III. One Day WELDING Course in TAMIL
applications” by Mr. Martin Schnirch, Sales
A One day welding course in Tamil was held at hotel
Director & Mr. Andreas Holzner, Head, QC M/s
Radha Regent, 171, Jawaharlal Nehru Salai,
Drahtzug Stein wire & welding.
Chennai on November 19th, 2011. 107 participants
VI. IWE/IWT ANB Programme during 19th to
from Chennai and neighboring areas attended the
course. Sri. Joseph Amalraj, L&T/HCP division
23th December 2011
Chennai, inaugurated the course. Sri. V.
The forty eighth Certification Programme (IWE,
Muralidharan, Vice Chairman – IIW India Chennai
IWT) of International Institute of Welding was held
Branch was the course director.
from 19th to 23rd December, 2011, at the lecture
In the evening a weld quiz programme for the
hall of the ISNT Chennai Chapter. Thirteen
course participants was conducted by Sri R.
participants attended the programme.
Ravichandran, EC Member. Sri. R. Ravi, President,
VII. Half Day Technical Programme & Felicitation
IIW-India, distributed the prizes to the top three
to IIW EC Member.
winners. Sri. V. Muralidharan; Vice Chairman – IIW
A half day technical programme on “QA
India delivered a technical lecture on ISO
Experiences in Reprocessing Projects & J-
3834. At 19.00 hrs. the approved training body
Rod Campaign to DFRP – Experiences” was
(ATB) certificate was handed over to M/s
held at the Ramanna Auditorium, IGCAR
Cornerstone Academy Pvt. Ltd. Chennai, by the
Kalpakkam. The event was held on the 28th of
president, IIW - India.
December, 2011, (Wednesday ), from 14.00 hours
IV. BW & BWE awards function
to 17.00 hrs., to felicitate Shri P. Ram Kumar, Head,
RPSD, formerly the EC Member of IIW-India,
Awards function of the best welding engineer & best
19
INDIAN WELDING JOURNAL Volume 45 No.1 January 2012
REPORT FROM KOLKATA BRANCH
Chennai Branch, on the occasion of his
superannuation. Shri R. Natarajan, Director, RPG
inaugurated
the
programme.
Around
The branch will organise a one day Workshop on
60
"Advancement in Welding Technology" at The
participants attended the workshop and benefited.
Institution of Chemical Engineer's Hall, Jadavpur
Eminent speakers from IGCAR/Kalpakkam
University on 25th February, 2012. As a programme, the
delivered the technical lectures on following topics.
branch is planning to celebrate Foundation Day of the
Institute in a dignified manner on 21st February, 2012.
1. “QA Experiences in Reprocessing Projects”
by– Dr. B. Venkatraman
2. “J-Rod Campaign to DFRP – Experiences”
REPORT FROM VIZAG BRANCH
by Shri P. Ram Kumar
The Indian Institute of Welding, Visakhapatnam Branch
Sri. T. V. Prabhu Hony. Secretary, IIW Chennai
organized a lecture on “Advanced Welding
Branch co-ordinated the entire event.
Processes” and “Emerging Welding Processes”
held
the
Executive
Director
(Projects
&
Commissioning) Conference Hall on 19th December
REPORT FROM IIW DELHI BRANCH
I.
at
2011 from 10.30 am to 1.30 pm. The programme was
A one day workshop on “Advances in Arc
well attended by IIW members, Vizag Steel Engineers,
Welding Technology” was organized at
M. N. Dastur & Co. (P) Ltd., Engineers and other Industry
Northern India Engg. College, New Delhi on 16th
Engineers.
November, 2011. About 100 delegates from
Lecture was delivered by the Eminent Prof Dr. R. S.
various Engineering Colleges in the region
Paramar and started with welcome address by Sri A. K.
attended the program. The lectures were delivered
Bose, Vice Chairman.
by Dr. R. S. Paramar, Dr. C. K. Datta, Mr. J. R.
Mr. M. Saibabu, Hony. Secretary, Vizag Branch informed
Prasher and Mr. Vivek Vasudeva. A lively discussion
took place between the speakers and the delegates
the gathering about the IIW activities, particularly
at the end of the Technical Sessions. Certificate of
courses offered by ANB and the advantages of the
participation was given to all the attending
ANBCC.
delegates in the valedictory session.
Mr. Venkat R D, the Jt. Secretary of the IIW, Vizag
Branch, proposed a Vote of Thanks.
II. The Branch Seminar of IIW - Delhi Branch has been
announced to be held on 11th February, 2012 at
India International Center, Max Mueller Marg, New
Delhi. The theme of the seminar is “Emerging
Trends in Welding Industry.”
20
LIFETIME ACHIEVEMENT AWARD
LIFETIME ACHIEVEMENT AWARDS
Prof. R. S. Parmar was honoured by The Institute with the Lifetime Achievement Award
at the National Welding Seminar, Bhilai held in December 2011
Dr. R S Parmar is B.E. Mechanical Engineering from
He is a Life Fellow of the Indian Institute of Welding and
Punjab University; M.E.Hons. (Production Engg.) from
The Institution of Engineers (India) and a Life Member of
University of Roorkee, and Ph.D. (Welding) from IIT,
Indian Society of Mechanical Engineers and Indian
Kharagpur. He has an experience of more than 44 years
Society of Technical Education.
in Teaching and Research in different subjects of Mech.
He is a recipient of Gold Medal from University of
Engg. particularly related to Production Engineering. He
Roorkee, K. F. Antia Memorial Prize and Col. G. N. Bajpai
served at REC, Srinagar (Kashmir) for 14 years and at
Award (Twice) from the Institution of Engineers (India)
IIT, Delhi for 21 years. After retirement from IIT, Delhi he
and Keith Hartley Memorial Award (1996) of The Indian
Joined Netaji Subhas Institute of Technology, New Delhi,
Institute of Welding. He is also a Joint winner of McKAY-
where he served in the Department of Manufacturing
HELM AWARD (1998) of American Welding Society,
Processes and Automation Engineering till Sept., 2002
Miami, USA for their paper published in Welding Journal
and was also Dean Administration for 3 years (1999-
of Oct., 1997.
2002) there.
Dr. Parmar joined IIW in 1972 as a Member and is now a
He coordinated a Collaborative Project for 5 years on
LIFE FELLOW for the past about 15 years. He has been
Underwater Welding between IIT Delhi and Cranfield
very active with IIW Delhi Branch which he joined in
Institute of Technology, Cranfield (UK). He also served as
1978 as an EXECUTIVE COMMITTEE MEMBER. In its
a Visiting Professor for one year at Brunel University,
long association of about 27 years with IIW Delhi he has
Uxbridge, London (UK).
served in every capacity viz., Member, Treasurer,
Prof. Parmar has authored 2 books on Welding, and one
Secretary, Vice Chairman, and Chairman. He has been
book on Manufacturing viz.,
elected as Chairman 6 times and is still active in
1. WELDING PROCESSES AND TECHNOLOGY, and
2. WELDING ENGINEERING AND TECHNOLOGY
3. MANUFACTURING PROCESSES AND AUTOMATION
tenure as Chairman, IIW Delhi the Institute acquired its
organizing workshops and seminars in Delhi. During his
permanent premises at 705 A, Jaina Tower-I, Janakpuri
District Centre, Janakpuri, New Delhi - 110 058. He has
and has published more than 100 Technical Papers in the
been actively involved in organising Branch Seminars,
National and International Journals, conferences, and
Short Courses, and One Day Workshops at different
Seminars. He has guided 13 Ph.D. (2 Iranians and 11
venues in and around Delhi.
Indian Research Scholars), 27 M.Tech. and more than 50
B.Tech. Projects on Production Engineering in general
and Welding in Particular.
21
INDIAN WELDING JOURNAL Volume 45 No.1 January 2012
KEITH HARTLEY MEMORIAL AWARD 2011
Every alternate year an eminent welding professional of the country is selected for delivering the
Keith Hartley Memorial Award at the National Welding Seminar. IWJ compliments
Prof. T. K. Pal for being chosen to deliver the Prestigious Lecture this year at the NWS - 2011
Dr. T. K. Pal obtained his B. E. in Metallurgy from
going. He has guided 19 students for their Ph.D
Burdwan University in 1975 and subsequently
thesis and published about 110 papers in National
completed M.Tech in Mechanical Shaping and Heat
and International Journals and Proceedings. He is a
Treatment. After six month exposure in a private
founder of Welding Technology Centre at Jadavpur
foundry, he joined as a Senior Research Fellow at
University which was established in 2002. He is
Material Science Centre of I.I.T., Kharagpur. He
Course Director of Six module based Post Diploma
joined as Lecturer, Department of Metallurgical
Course in Welding Technology and Short term
Engineering, Jadavpur University in 1981 and
Course on "Welding Inspection and Testing".
completed his Ph.D (Engineering) from I.I.T.
He was Controller of Associate Membership
Kharagpur in 1987. He became Head, Metallurgical
examination of Indian Institute of Welding during
Engineering Department, Jadavpur University
the period from 1991 to 1999 and Chairman of IIW
during 1995 - 1997.
of Kolkata branch during 1999 - 2000. He has
During the last 30 years, he had been actively
received many awards for his contribution in the
engaged in Teaching, Research, Training Courses
field of welding Technology.
and Consultancy Services related to welding
He is a fellow member of the Indian Institute of
technology. He had already completed fifteen
Welding, life member of the Indian Institute of
research projects sponsored by different Central
Metals. The Institution of Engineers (India) and
Government funding authorities such as DST, CSIR,
The Indian Society for Non-Destructive Testing.
Ministry of Steel, Naval Research Board (NRB),
DRDO, UGC, AICTE and Private Industries like Tata
He is at present Professor and Coordinator, Welding
Steel and BOC Ltd. Two Research projects
Technology Centre, Metallurgical and Material
sponsored by Ministry of Steel and Tata Steel and
Engg. Department, Jadavpur University and also
one research project sponsored by CSIR are on-
Technical Advisor of two private industries.
22
PROF. PLACID RODRIGUES AWARD
PLACID RODRIGUES MEMORIAL AWARD 2011
Every year an eminent Welding Engineer and Scientist below 45 years of age is selected for delivering the
Prof. Placid Rodrigues Award. This year IWJ congratulates Dr. Janaki Ram for being selected to deliver
the prestigious lecture this year.
Dr. Janaki Ram obtained his masters and doctoral degrees in metallurgical engineering from IIT
Madras. He specializes in welding technology. From 1998 to 2005, he was in DRDO, working on
indigenous development and airworthiness certification of a number of aerospace materials and
components. In 2005, he went to Utah State University, USA, for his post-doctoral work in the field of
additive manufacturing technologies. In 2008, he returned to India to begin a faculty position in the
Department of Metallurgical and Materials Engineering, IIT Madras. Since then, Dr. Janaki Ram has been
teaching welding processes, welding metallurgy and additive manufacturing courses at IIT Madras. Dr.
Janaki Ram has been actively involved in welding research for more than a decade. His research
addresses both fundamental and applied aspects of welding. He has published more than 75 papers in
various international journals and conferences.
23
INDIAN WELDING JOURNAL Volume 45 No.1 January 2012
List of Award Holders for the year 2011
Sl.
No.
Award Name
1
2
Award
Amount
Sponsorers
Sponsors
Representative
If Attending
Awarded To
Life Time
Achievement
Award 2010-11
Silver
Salver
IIW
Head Office
Dr. R. S. Parmar
Keith Heartley
Memorial
Lecture-2011
Silver
Medalion
M/s.GEE Ltd
Mumbai
Dr. T. K. Pal
Subject Of The Award Paper
3
Prof. Placid
Rodriguez
Memorial
Lecture-2011
Rs.10,000/-
IIW-Chennai Branch
President-IIW
Dr.G.D.Janaki Ram,
Asst. Professor, Dept. of
Metallurgical and Materials
Engg. Indian Institute of
Technology, Chennai-600 036
4
Minati
Bhattacharjee
Memorial Award for
Excellence -2011
Trophy
Mr. R. R. Bhattacharjee,
Fellow Of The Institute
of India
President,
IIW-India
IIW-India
Kolkata Branch
Best Performing Branch
For The Year 2010-11
5.
Esab India Award
(Best Technical
paper across
all categories)
Rs.20,000/-
Esab India Ltd.
Chennai
Ms. Girish Kumar Padhy,
V. Ramasubbu, SK Albert
N. Murugesan and
C. Ramesh of Material
Joining Section,
IGCAR, Kalpakkam
Diffusible Hydrogen Measurement
in Steel Welds using an
Electrochemical Hydrogen
Sensor
6.
I.T. Mirchandani
Memorial Research
Award
Rs. 10,000/-
Ador Welding Ltd.
Mumbai
M/s. P. Venkataramana &
G. Madhusudan Reddy
of Mahatma Gandhi
Institute of Technology
Gandipet and Defence
Metallurgical Research
Laboratory, Kanchanbagh
Hyderabad
Dissimilar Metal Gas Tunsten
Arc Weldments of Maraging
Steel and Medium Alloy
Medium Carbon Steel effect
of Post weld head treatments
7.
H.D. Govindraj
Memorial Research
Award
Rs.10,000/-
Weldcraft Pvt. Ltd.
Bangalore
M/s. G. Madhusudhan Reddy
and P. Vankata Ramana of
Defence Metallurgical
Research Laboratory,
Kanchanbagh, Hyderabad
and Mahatma Gandhi Institute of Technology,
Gandipet, Hyderabad
Dissimilar Metal Friction
Welding of Maraging Steel
with Nickel as an inter
layer.
8.
Sharp Tools Award 1
(1st best paper in
Welding Fabrication
and Practices)
Rs.6,000/-
Sharp Tools Ltd.
Coimbatore
President - IIW
M/s. Aravinda Pai, T.K.Mitra
T. Loganathan & Prabhat
Kumar of Bharatiya Nabhikiya
Vidyut Nigam Limited (Bhavini)
Prototype Fast Breeder
Reactor (PFBR) Project
Dept. of Atomic Energy
Kalpakkam - 603 102
Challenges in Welding and
Fabrication of Shell Assemblies
of 500MWe Prototype Fast
Breeder Reactor Steam
Generators
9.
Sharp Tools Award 2
(2nd Best Paper in
Welding Fabrication
and Practices)
Rs. 4000/-
Sharp Tools Ltd.
Coimbatore
President - IIW
M/s. Satinder Pal Singh,
Amandeep Singh, Sunny
Soni, Manadar Gaddu,
Sanjeev Padvanda, Nishant
Shah, A.D. Bhathena,
L.S.Rao, Naresh Dhir and
H. T. Naik of Larsen &
Toubro Ltd., Modular Fabrication Facility, Hazira.
Optimization of Groove Design
& Backing Methods to enhance
the Productivity of Structural
Tubular Welds of Jacket
Legs and Piles
24
AWARDS
List of Award Holders for the year 2011 contd...
Sl.
No.
Award Name
Award
Amount
Sponsorers
10.
Panthaki Memorial
Award (Welding
of Non-ferrous
Metals)
Rs. 5,000/-
11.
EWAC Alloys
Award (Best Paper
in Reclamation and
12.
Awarded To
Subject Of The Award Paper
Bakshi Chempharma
Equipments Pvt. Ltd.
Mumbai
M/s. V.S.N. Venkata Ramana
K. Ratna Kumar, G. Madhusudhan Reddy & K. Srinivasa
Rao of Dept. of Mechanical
Engg., PVP Siddhartha Institute of Technology, Kanuru
Vijayawada, AP
Effect of Post Weld Heat
Treatment on Microstructure
and Corrosion behaviour of
Dissimilar AA 2024-AA6061
GTA Welds
Rs.10,000/-
EWAC Alloys Ltd.
Mumbai
M/s. Rajesh Sood and Alok
Jha, Reclamation Shop
Bhilai Steel Plant, Bhilai
Reclamation of Work Roll
of Plate Mill of Bhilai Steel
Plant
CEOBSP Award
(Best Paper in
Reclamation and
Repair Welding in
Steel Plant)
Rs.10,000/-
SAIL, Bhilai Steel Plant
Bhilai
M/s. Mahendra Pal, Mayank
Banjare and Susil Guria of
Indian Oil Corpn. Ltd.
Inspection Manager,
Root Cause Analysis of
Failure in Hot and Cold Mixing
Point in Hydrogen Generation
Unit (HGU) due to Thermal
Fatigue Phenomenon
13.
D&H Secheron
Award (Best
presented paper)
Rs.10,000/-
D&H Secheron Electrodes
Indore
M/s. G. Madhusudhan Reddy
& P. Venkata Ramana,
Defence Metallurgical
Research Laboratory,
Kanchanbagh, Hyderabad.
Friction Welding of Maraging
Steel to Low Alloy Steel
with Nickel as an interlayer
14.
Weldman Award
(Second best
presented paper)
Rs. 5,000/-
Weldman Synergic Pvt.
Ltd., Kolkata
M/s. B.P.C.Rao, C.Babu Rao,
S.Thirunavukkarasu, T.
Jayakumar, Baldev Raj
Aravinda Pai, T.K.Mitra &
Pandurang Jadhav of
Metallurgy & Materials
Group, Indira Gandhi Centre
for Atomic Research,
Kalpakkam
A New methodology for
Qualification of Welding Procedure
for Circumferential Shell
Welds of Steam Generators
of PFBR
15.
Best Welder
(Plate) Award
Rs.5,000/-
ELCA Laboratories
Thane
President - IIW
Mr. Roque Fernandez, Don
Bosco Maritime Academy,
Mumbai
16.
Best Welder (Pipe)
Award
Rs. 5,000/-
ELCA Laboratories
Thane
President - IIW
Mr. Vinod Kumar R. Parmar
Larsen & Toubro, Baroda
17.
Best Welding Engineer Rs.7,000/Award
ELCA Laboratories
Thane
President - IIW
Mr. Biswajit Paul,
Larsen & Toubro Ltd. Mumbai
18.
Associate Engineers
Rs.5,000/Award (Best M.Tech
thesis submitted for
award of degree in
the previous academic
year)
Associate Engineers
Baroda
President - IIW
Mr. Hrishikesh Das submitted
the best M.Tech thesis for the
year 2011 under the guidance
of Dr. T.K.Pal of Jadavpur
University, Kolkata
19.
Weldwell
Speciality Award
(Best thesis in the
field of welding
submitted for the
award of Ph.D)
Weldwell Speciality
Pvt. Ltd.
Mumbai
President - IIW
Dr. V. Venkateswara Rao
Mechanical and Metallurgical
submitted the best Ph.D
Characteriation of Maraging
thesis for the academic
Steel to Low Alloy Steel
year 2011 under the
Weldments
guidance of Dr. G. Madhusudhan Reddy of DMRL,
Hyderabad and Dr. A.V.Sitarama
Raju of JNTUH, Hyderabad
Rs.10,000/-
Sponsors
Representative
If Attending
25
Effects of Friction Stir Welding
parameters on mechanical
properties of 6063 aluminium
alloy and HIF GA steel
lap joint
INDIAN WELDING JOURNAL Volume 45 No.1 January 2012
List of New Members Elected during the 280th Council Meeting of
The Indian Institute of Welding
A. Industrial Corporate Member
BANG/ICM/R-522 ESI-India Sales & Technical Branch Office
MUM/ICM/R-523 John Deere India Pvt. Ltd.
MUM/ICM/R-524 Jitamitra Electro Engineering Pvt. Ltd.
Bangalore
Mumbai
Mumbai
B. Transfer from Life Member to Life Fellow
CHN/M/R-1956/L
R. Ravi
Chennai
C. Life Member
VIZ/M/R-10769/L
MUM/M/R-10771/L
CHN/M/R-10772/L
VIZ/M/R-10774/L
CHN/M/R-10776/L
CHN/M/R-10777/L
CHN/M/R-10778/L
JAM/M/R-10800/L
BAR/M/R-10810/L
CHN/M/R-10811/L
CHN/M/R-10812/L
MUM/M/R-10839/L
DEL/M/R-10840/L
DEL/M/R-10841/L
Kadaganchi Ramanjaneyulu
Ajaykumar Jadhav
K. Senthilmurugan
G. Mallaiah
S. Muthukumar
K. N. Mohan
A. Manickavasagam
Md. Murtuja Husain
Alap Mistry
Mariappan Annamalai
Kasi Athinamilagi
Dinesh Giri
Angamuthu Kandasamy
Pradeep Khanna
Visakhapatnam
Mumbai
Chennai
Visakhapatnam
Chennai
Chennai
Chennai
Jamshedpur
Baroda
Chennai
Chennai
Mumbai
Delhi
Delhi
D. Member
BAR/M/R-10792
CHN/M/R-10843
Vora Girishkumar
M. Ponsekar
Baroda
Chennai
E. Life Associate Member
KOL/AM/R-10773/L Nalin Karmakar
BHL/AM/R-10790/L Mandip Singh Bhogal
F. Associate Member
DEL/AM/R-10795
BAR/AM/R-10796
BAR/AM/R-10797
BAR/AM/R-10798
BAR/AM/R-10799
KOL/BBSR-10805
Deepak Gaba
Hardik Doshi
Hrushikesh H. Sangamnerkar
Rahul Chauhan
Yadunandan Das
Narendra Kumar Pal
BAR/AM/R-10806
BAR/AM/R-10807
BAR/AM/R-10808
BAR/AM/R-10809
Hardik Dineshbhai Vyas
Jaydeep Dineshkumar Patel
Mitesh S. Patel
Harshil Amruthlal Patel
G. Life Associate Professional Member
CHN/APM/R-10788/L B. Chandramohan
MUM/APM/R-10791/L Sanjeev Balan Nair
DEL/APM/R-10804/L Shalender Bisht
DEL/APM/R-10842/L Rajiv Kumar
H. Associate Professional Member
CHN/APM/R-10784
Sundaramurthi Perumal
CHN/APM/R-10785
M. Somnath
CHN/APM/R-10786
C. Jayanthi
CHN/APM/R-10787
M. Padmanathan
DEL/APM/R-10789
Ashok Kumar
VIZ/APM/R-10794
K. V. V. Srinivas Rao
VIZ/APM/R-10801
Md. Darbesh Baba
MUM/APM/R-10803 S. R. K. S. P. Kumar Akela
BAR/APM/R-10813
Rakesh Bhatt
Chennai
Chennai
Chennai
Chennai
Delhi
Visakhapatnam
Visakhapatnam
Mumbai
Baroda
I. Life Associate
BAR/AS/R-10815/L
Baroda
J. Associate
KOL/AS/R-10770
JAM/AS/R-10775
BAR/AS/R-10779
CHN/AS/R-10780
CHN/AS/R-10781
CHN/AS/R-10782
CHN/AS/R-10783
CHN/AS/R-10793
MUM/AS/R-10802
BAR/AS/R-10814
KOL/BBSR/AS/R-10816
KOL/BBSR/AS/R-10817
KOL/BBSR/AS/R-10818
KOL/BBSR/AS/R-10819
KOL/BBSR/AS/R-10820
KOL/BBSR/AS/R-10821
KOL/BBSR/AS/R-10822
KOL/BBSR/AS/R-10823
KOL/BBSR/AS/R-10824
KOL/BBSR/AS/R-10825
KOL/BBSR/AS/R-10826
KOL/BBSR/AS/R-10827
KOL/BBSR/AS/R-10828
KOL/BBSR/AS/R-10829
KOL/BBSR/AS/R-10830
KOL/BBSR/AS/R-10831
KOL/BBSR/AS/R-10832
KOL/BBSR/AS/R-10833
KOL/BBSR/AS/R-10834
KOL/BBSR/AS/R-10835
KOL/BBSR/AS/R-10836
KOL/BBSR/AS/R-10837
KOL/BBSR/AS/R-10838
Kolkata
Bhilai
Delhi
Baroda
Baroda
Baroda
Baroda
Kolkata
(Bhubaneswar)
Baroda
Baroda
Baroda
Baroda
Chennai
Mumbai
Delhi
Delhi
26
Sumit Kainthola
Nazmul Haque
Raj Kishore
Jaykumar H. K. Suthar
K. Hemnath
Joseph Prakash
Sankara M. Pandian
Lalith S. Eshwar
S. Udhayakumar
Sandeep T. Katkar
Akshay Mahesh Agrawal
Sujit Kumar Behera
Shambhu Kumar
Abhishek Kishor
B. Vinay Kumar
Bibhuti Bhusan Pattajoshi
S. Pragyan Prasad
Padmanav Reddy
Monalisa Patro
Santosh Kumar
Kunal Kumar
Siba Prasad Padhi
M. Naresh
Sudhansu Sekhar Gouda
Ananda Kishor Mishra
Chetan Kumar Shrivastav
Syed Ramijul Bari
Swastik Das
Manish Kumar Nayak
Rahul Kumar Singh
Abhishek
Manish Kumar Gupta
Mani Kant Ojha
Akhila Badatya
Kolkata
Jamshedpur
Baroda
Chennai
Chennai
Chennai
Chennai
Chennai
Mumbai
Baroda
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
Kolkata (Bhubaneswar)
REPORT ON MES-SDI SCHEME
REPORT ON MES-SDI SCHEME OF DGE&T, GOVT. OF INDIA
As an Assessing Body under DGE&T, Govt. of India, IIW-India MAB during the period
October to December 2011, received Assessment advises from various RDATs are as follows:
Sl. No.
Region
No. of advise
Course Name
Total
Candidates
1
RDAT-Chennai
3
Basic Welding Gas / Basic Welding Arc
110
2
RDAT-Faridabad
8
Basic Welding Gas / Basic Welding Arc / Basic Fitting Work
230
3
RDAT-Hyderabad
6
Basic Welding Gas / Basic Welding Arc / Basic Fitting Work
175
4
RDAT-Kanpur
1
Basic Welding Gas / Basic Fitting Work
55
5
RDAT-Kolkata
5
Basic Welding Gas / Basic Welding Arc / Basic Fitting Work / Gas Cutting
130
6
RDAT-Mumbai
8
Basic Welding Gas / Basic Welding Arc / Basic Fitting Work
234
934
Out of 934 assessment advise received for various courses under fabrication sector, 781 candidates were assessed
with 153 candidates remain absent. Out of these 781 candidates, 765 passed and 16 candidates failed.
Report on NWTCS programme (National Welders' Training and Certification Scheme)
During the period October to December, 2011 altogether 63 candidates had been certified by our Authorised
Examiners at the following ATIs.
Sl. No.
Module
Level
Name of the ATI
1.
MMAW
Standard (Radiographic)
Punj Lloyd, Banmore, MP
31
MMAW
Standard (Radiographic)
Technocon Trg. Inst., Rajarhat, W.B.
10
GTAW
Standard
WELDTECH (Rishi Laser), Vadodara, Gujarat
12
GTAW
Standard
Zanders Skill Dev. Centre, Mohali, Punjab
5
GMAW
Standard
Zanders Skill Dev. Centre, Mohali, Punjab
5
TOTAL
63
2
3
Total
Candidates
Under IIW-India's National Welders Training and Certification programme, during October to December 2011,
3-new Institutes had applied us for becoming IIW-India's Approved Training Institute for conducting NWTCS
programme. They are
1) Deshpande Inst. Of Vocational Training, Karnataka
2) The Indian Steel & Wire Products Ltd., Jamshedpur
3) J. K. Centre for Technician's Training, Kanpur
27
INDIAN WELDING JOURNAL Volume 45 No.1 January 2012
THE INDIAN INSTITUTE OF WELDING
(A Member Society of The International Institute of Welding)
Head Quarter & Regd. Office Address:
“MAYUR APARTMENTS”, Flat No. 4 B/ N, 3A, Dr. U. N. Brahmachari Streey, Kolkata - 700 017, INDIA
Phone: 91 33 2281 3208 | Telefax: 91 33 2287 1350
E-mail: indianwelding@vsnl.net | Website: http://www.iiwindia.com
AM - IIW Examinations : Summer Session, 2012
From June 11 to 14
SCHEDULE
Forenoon
10:00 A.M. - 1:00 P.M.
Date / Day
Afternoon
2:30 P.M. - 5:30 P.M
11.06.2012
(Monday)
1. AME - 01 : Elementary Mathematics
2. AME - 14 : Heat and Mass Transfer
3. AME - 19 : Testing and Quality Assurance
1. AME - 02 : Physics
2. AME - 15 : Welding and Allied Processes - I
3. AME - 21 : Welding Applications
12.06.2012
(Tuesday)
1. AME - 04 : General English
2. AME - 08 : Electrical Engineering and Electronics
3. AME - 17 : Computation Methods and Computer
Programming
1. AME - 06 : Industrial Sociology
2. AME - 09 : Material Science
3. AME - 18 : Weldment Design and Weld Procedure
13.06.2012
(Wednesday)
1. AME - 07 : Strength of Materials
2. AME - 11 : Engineering Drawing
3. AME - 23 : Welding Equipment and Consumables
1. AME - 05 : Applied Mechanics
2. AME - 13 : Welding Metallurgy - I
3. AME - 16 : Engineering Economics
1. AME - 03 : Chemistry
2. AME - 12 : Engineering Mathematics
3. AME - 20 : Welding Metallurgy - II
1. AME - 10 : Production Engineering
2. AME - 22 : Welding and Allied Processes - II
3. AME - 24 : Advanced Welding Technology
14.02.2012
(Thursday)
Last date for Receipt of Enrolment Forms : May 12, 2012
AM - IIW Examinations fees w.e.f. 01.06.2011
Sl. No
Type of Fee
(Rs.)
1.
Enrolment Fee
400.00
2.
Examination Fee per subject
350.00
3.
Examination Fee for Part ‘D’
1,500.00
WELDING - For Nation Biulding
28
AM - IIW
THE INDIAN INSTITUTE OF WELDING
(A Member Society of The International Institute of Welding)
Head Quarter & Regd. Office Address:
“MAYUR APARTMENTS”, Flat No. 4 B/ N, 3A, Dr. U. N. Brahmachari Streey, Kolkata - 700 017, INDIA
Phone: 91 33 2281 3208 | Telefax: 91 33 2287 1350
E-mail: indianwelding@vsnl.net | Website: http://www.iiwindia.com
ANNOUNCEMENT
Winter 2011 AM-IIW Examination will be held during June 11 to 14, 2012 (Monday to Thursday) at different Centres where I.I.W.
Branches are located subject to the availability of candidates. The examination schedule and other related information will be sent
to all the enrolled candidates individually as well as to the Branches for information.
The last date for submission of the Registration Form and Enrolment Form for appearing at the examination, which will be
available from the Prospectus, is May 12, 2012. Details of rules, regulations, subjects, course content etc are available in the
Prospectus, which can be obtained from the IIW Head Office on payment of Rs.150/- by a Demand Draft favouring “The Indian
Institute of Welding” payable at Kolkata. Bound copies of question papers of two previously held examinations at a price of
Rs.225/- by Demand Draft are also available from the Head Office.
EXEMPTION AVAILABLE IN THE REVISED SYSTEM OF COURSE
QUALIFICATION
SUBJECTS EXEMPTED
10+2: with Maths, Physics, Chemistry
NIL
Diploma in Engineering
AME – 1, AME – 2, AME – 3,
AME – 5*, AME – 7*, AME – 8*, AME – 11*
Bachelor of Science (B.Sc)
AME – 1, AME – 2, AME – 3
Degree in Engineering or equivalent
AME – 1 to AME – 6,
*Also AME – 7, 8, 9, 10, 11, 12, 16, 17
NOTE: * Provided the subject has been successfully completed during the Qualifying Examination (Column 1).
Exemption has to be claimed. In all claims, mark sheets must be produced to get exemption at the time of registration and
exemption would be given only, if all documents, to the satisfaction of the examination committee are received.
Prof. Joshi M. Das
Controller of Examination
SUBJECTS (REVISED SYLLABUS)
PART A
PART B
PART C
AME-1 : Elementary Mathematics
AME-7 : Strength of Materials
AME-16 : Engineering Economics
AME-2 : Physics
AME-8 : Electrical Engineering &
Electronics
AME-17 : Computation Methods &
Computer Programming
AME-3 : Chemistry
AME-9 : Material Science
AME-18 : Weldment Design & Weld
Procedure
AME-4 : General English
AME-10 : Production Engineering
AME-19 : Testing & Quality Assurance
AME-5 : Applied Mechanics
AME-11 : Engineering Drawing
AME-20 : Welding Metallurgy-II
AME-6 : Industrial Sociology
AME-12 : Engineering Mathematics
AME-21 : Welding Applications
AME-13 : Welding Metallurgy-I
AME-22 : Welding & Allied Processes-II
AME-14 : Heat & Mass Transfer
AME-23 : Welding Equipment &
Consumables
AME-15 : Welding & Allied Processes-I
AME-24 : Advanced Welding Technology
N. B. : Last Date for Enrolment : May 12, 2012.
WELDING - For Nation Biulding
29
INDIAN WELDING JOURNAL Volume 45 No.1 January 2012
ANB – India News
Transition Route for IWCP (IWE/IWT/IWS/IWP) Reopens:
IAB authorized period for qualification of International Welding Coordination Personnel (IWCP) through the
'Transition Route' had initially ended on 31st December 2010. However, during the IAB meeting at Chennai in July
2011 the same was extended up to 31st January 2012. We are informed that the IAB, during the meeting at Paris in
January 2012 has given further extension for International Welding Coordination Personnel till 31st July 2012.
However, it must be noted by all concerned that the qualification criteria remains frozen as on 31st
December 2010. That means all qualifications and experience prescribed must have been obtained by 31st
December 2010.
During the period from November 2011 - January 2012, there were a total of 5 refresher courses held at Kolkata (2
nos.), Baroda, Chennai and Delhi. A total of 60 candidates have appeared in the course.
International Welding Inspection Personnel (Basic / Standard / Comprehensive)
courses by the Transition Route:
The above course aims at integrating knowledge in Welding Technology and Welding Inspection and Organisations /
Candidates engaged in Welding Inspection activity will find it extremely useful for their skill development and
acceptance by various authorities. So, interested organizations / candidates may find it useful to visit our website
www.iiwindia.com or write to us at anb@iiwindia.com
Standard and Alternative Route for obtaining IWE / IWT qualifications:
Standard Route: IWE / IWT candidates can presently avail this route at our Approved Training Body (ATB) M/s.
Corner Stone Academy as per the access conditions. Qualified candidates without any experience subject to fulfilment
of all conditions may enroll. At present the second batch of candidates for IWE / IWT diploma are in the process of
completion of their stipulated course curriculum in preparation for appearing in the final examinations. .
Alternate Route: This route is extremely suitable for candidates who fulfill the access conditions for the Standard
Route and also have the minimum 4 years prescribed experience in the welding industry to avoid attending lessons in
an ATB and appear for the final examinations. A few candidates have already applied to qualify under this route and
are waiting to appear in the final examinations.
Welder Certification Activity:
Encouraging progress is made in the above activity. TELCON along with their vendors has entrusted ANB - India with
conducting certification tests for all their own and vendors welders in multiple units spread all over India. ANB - India
has also undertaken welder's certification, preparation of WPS, WPQR for many organizations that follow ISO, EN and
ASME Sec. IX standards. The recent formation of ANBCC for certification of companies under ISO 3834 has opened up
new area for certification of welders and the emerging market is being fully exploited.
All interested organizations / candidates are requested to visit our website under International
section www.iiwindia.com or write to anb@iiwindia.com to get the details of the qualification
required, fees and the course calendar.
30
GUIDELINES FOR AUTHORS
GUIDELINES FOR AUTHORS FOR SUBMISSION OF PAPERS
TO THE INDIAN WELDING JOURNAL
INTRODUCTION
Margins and Spacing
The Indian Welding Journal (IWJ) is the official journal of
The top, bottom, left, and right margins should be kept
the Indian Institute of Welding (IIW-India), and it is
one inch each, with justified format. Spacing should
published four times a year. Papers are invited in the
adhere to the following format:
areas of welding and allied processes for publication in
The body text of the paper should be single-spaced
l
the IWJ as per the following categories;
and fully justified in 11-point Arial font. Leave one line
a) Original papers
space between paragraphs, but do not indent the first
line of a new paragraph. Page numbers should be
b) Conference papers (For journal special issues, etc.)
centered at the bottom, and the first page should be
c) Critical assessments / Reviews
numbered.
d) Case studies / Application areas
Insert a line space after the final paragraph in a
l
section.
TITLE PAGE
First level heading should be consequently numbered
l
The title page should include:
like 1., 2., etc., left justified, all caps and bold. Insert
one line space before and after a first level heading.
The name(s) of the author(s)
l
Second level heading should be numbered
l
A concise and informative title
l
consequently like 1.1., 1.2., 2.1., 2.2., etc., left
The affiliation(s) and address(es) of the authors
l
justified, with running letter and bold, with one line
The e-mail address, telephone and fax numbers of
l
space above it.
the corresponding author
The heading of Abstract, Appendix and References
l
are to be all caps, 11-point, bold, and centered, with
ABSTRACT
two line spaces above, and one below.
An abstract should be of 150 to 250 words and it should
Figures and Tables
not contain any undefined abbreviations or unspecified
Figures and tables should appear close to their first
references
citation inside the text. Each table or figure should be
centered. Each table and each figure should have
KEYWORDS
centered titles that should be self explanatory. Table
Four (4) to six (6) keywords can be used for indexing
titles should go above the table and figure captions
purposes
below the figure. Leave one line space between the title
and the table or figure. Figures and tables are to be
numbered consequently. Refer these inside the text as
TEXT
Table 1 or Figure 1, etc. In addition, each figure should
Text Formatting
be given as separate file(s), naming the file as Fig 1, Fig
Manuscripts should be submitted either in PDF version or
2, etc. Figures (including photographs, line drawing,
in Word files.
etc.) must be clear and reproducible.
33
INDIAN WELDING JOURNAL Volume 45 No.1 January 2012
ensure the widest possible protection and dissemination
REFERENCES
of information under copyright laws.
Citation
The list of references should only include works that are
PEER REVIEW PROCESS
cited in the text and that have been published or
accepted for publication. Reference citations in the text
Manuscripts of contributed articles submitted under
should be identified by numbers in square brackets.
each category will be peer reviewed. Author(s) will be
Some examples :
communicated with the review results without revealing
the names of reviewers, and if needed, author(s) will be
1. The effect has been widely studied [5-9,12]
required to incorporate necessary changes in his/their
2. The same results has been observed by Reddy et al.
manuscript for final acceptance. Typically, there are four
[17].
review recommendations:
Example
a) Publish as it is (accept),b) Minor revisions (conditional
Badheka, V. J. and Albert, S. K. (2009); Improving the
acceptance), c) Major revisions (revise and resubmit), d)
weld penetration by application of oxide coating in GTAW
Reject.
of P91 steel, Proc. Nat. Weld. Sem., Kolkata, India, p.18.
Sabiruddin K., Das
For further information /clarification please
S. and Bhattacharya A. (2009);
contact
Application of the analytic hierarchy process for
The Chief Editor
Indian Welding Journal
The Indian Institute of Welding
3A, Dr. U. N. Brahmachari Street,
Kolkata- 700 017.
Email: iwj.iiw@gmail.com
Website: www.iiwindia.com
optimization of process parameters in GMAW, IWJ,
42(1), pp.38-46.
APPENDICES AND ACKNOWLEDGMENT
Appendices, if needed absolutely, should be placed after
references section. Uses of appendices are not
encouraged, in general. Acknowledgment, appendices,
etc., if any, may follow the References section.
COPYRIGHT
Authors will be asked to transfer copyright of the article
to the Indian Institute of Welding(IIW-India). This will
34
ESAB INDIA AWARD
Diffusible Hydrogen Measurement in Steel Welds
using an Electrochemical Hydrogen Sensor
Girish Kumar Padhy1, V. Ramasubbu1, N. Murugesan2, C. Remash2 and S.K. Albert*
1
Material Technology Division, 2Material Chemistry Division, Indira Gandhi Centre for Atomic Research,
Kalpakkam-603102, Tamilnadu, India.
ABSTRACT
Diffusible hydrogen (HD) measurement in steel welding consumables having cellulose, rutile and basic coating
has been carried out using a Proton Exchange Membrane Based Hydrogen Sensor (PEMHS). The sensor is an
electrochemical fuel cell based device which uses Nafion@117 as proton exchange membrane electrolyte. This
can detect hydrogen in an Ar+H2 mixture with detectable limit of 1 ppm. Further, HD measurements have also
been carried out on basic coated electrodes of modified 9Cr-1Mo steel, with very low levels of HD content.
Results obtained have been compared with those obtained from HD measurement using mercury manometer
as per standard ISO 3690. One to one correlation has been obtained between these two different methods of
measurements. This sensor has shown good sensitivity, accuracy and precision hence is reliable for HD
measurement. In addition to the above measurement, this method was used to study hydrogen evolution from
the weldments as a function of time. The paper presents and discusses the principles of HD measurement using
this sensor, its applications for HD measurements in weldment, the results obtained, its application to study the
hydrogen evolution from weldment as a function of time and the possibility of using this sensor for
measurement of hydrogen evolved from the weld specimens at high temperatures.
Keywords: Diffusible Hydrogen, Nafion Hydrogen Sensor, Hot Extraction, Hydrogen Diffusivity
1.0 INTRODUCTION
Hydrogen in the weldments of carbon
and alloyed steels when accompanied
with a crack susceptible microstructure
and tensile residual stress in the
weldment causes Hydrogen Assisted
Cracking (HAC) in the weld metal and in
the heat affected zone (HAZ). As these
cracks are not acceptable in weldments,
formation of these cracks should be
prevented. For predicting the susceptibility of weldment to HAC, amount of
diffusible hydrogen (HD) content in steel
weldment is used extensively (Yurioka
metal causes dissolution of large
and Suzuki, 1990). Though many
amount of hydrogen atoms present in
sources
the arc atmosphere in the weld pool
such as
shielding gas,
oil/grease, hydrocarbons on the surface
whereas oxygen atoms form oxides
to be welded and moisture in the
which become parts of the slag formed
surrounding atmosphere may contri-
during welding. In general, solubility of
bute to hydrogen in welds, the chief
hydrogen in ferritic steel is less than 2
source is the chemically bonded water in
ppm by weight at STP. However, the
the flux coated on the welding electrode
rapid cooling rate (80-150K/second) of
(IIW Doc.II-805-85, 1985) which disso-
the deposited metal during welding
ciate into hydrogen and oxygen atoms in
does not allow hydrogen to equilibrate
the arc during welding. Very high
with the deposited metal and results in
temperature (~1600°C) of the molten
supersaturation of hydrogen in the
* Corresponding author E-mail : shaju@igcar.gov.in
35
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
deposited metal, which starts diffusing
mercury (ANSI/AWS A4.3-86, DIN 8572,
attributed to the fact that hydrogen is
into the HAZ or out of the weld during
ISO 3690, IS-11802-1986, JIS Z3118-
partially soluble in glycerin. Many other
solidification and subsequent cooling.
1986) and gas chromatography (ANSI/
techniques such as determination of HD
During this diffusion, most of the
AWS A4.3-86, ISO 3690, JIS Z3118-
content using mass spectrometer
hydrogen is retained at various defects
1986, Ohtsubo et al., 1985, Quintana
[(Noble, 1985), (Pressouyre et al.,
called traps which are classified (Hirth,
and Dennecker, 1986) methods. A good
1988)], low frequency impedance based
1980) as reversible traps (e.g. grain
agreement between the results has
non contact diffusible hydrogen sensor
boundaries, lath boundaries, dis-
been reported with measurements
(Lasseigne, 2008), and computer aided
locations etc.) and irreversible traps
carried out using mercury and gas
determination of diffusible hydrogen
(e.g. vacancy, particle matrix, inclusions
chromatography methods (De Abreu et
(Karkhin and Levchenko, 2007) are also
etc.) in the weld and in the HAZ. At room
al., 1995). However, these methods are
reported.
temperature, irreversible traps have
not free from drawbacks. Limitations in
higher binding energies and release of
using the mercury method are the
hydrogen from these traps is difficult.
health and safety issues associated in
However, reversible traps, owing to their
the handling of mercury, the long
lower binding energies [(Iino, 1987),
durations of hydrogen collection (72
(Iino, 1998)] release hydrogen in
hours or longer after welding (Ravi and
subsequent times which is able to
Honavar, 1987)), non-applicability of
diffuse further. Hence, only a part of the
this method at higher temperature for
total trapped hydrogen tends to diffuse
hydrogen collection which would reduce
at or near room temperature (25-45°C)
the time of hydrogen collection. Also,
which is referred as diffusible hydrogen
this method provides no scope for
(HD). Cracking is caused by interaction of
studies such as the evolution of
HD with defects, which are locations of
hydrogen from the weld as a function of
stress concentration in the welds.
time from a single specimen, the
Hence, HD content in the weld metal
evolution of hydrogen at higher tempe-
shall be controlled and estimation of
ratures etc. For welding consumable
hydrogen by a suitable technique is the
manufacturers the test duration of 72
first step in the efforts to avoid cracking.
hours is quite long; but time cannot be
An understanding of the HD content is
shortened with this method as the
also useful to predict the minimum
measurement cannot be carried out at
preheat temperature to be employed
high temperatures. Gas chromato-
during welding of steels to avoid
graphy method permits heating of
cracking [(Suzuki and Terasaki, 1986),
samples up to a maximum of 400°C
(Ito and Bessyo, 1968)]. As one of the
reducing the test duration to 20-30
major sources of hydrogen is the
minutes. However, the equipment is
welding
costly. Another method, involved in
consumables,
they
are
classified based on the HD content in the
collection of HD over glycerin (JIS Z3113-
weld metal produced by them.
1975) is in limited use [(Quintana,
1984), (Siewert, 1986)] because it
Measurement of HD content from a weld
lacked accuracy and furnished lower HD
is carried out by measuring hydrogen
contents than those obtained using gas
evolved from the weld at a fixed
chromatography and mercury methods
temperature for a given duration.
(Kotecki and La Fave, 1985). The lower
Standards such as ISO, AWS, DIN, BIS
and IS have recommended procedures
for HD measurements which include
H D contents obtained using the
collection of hydrogen over glycerin is
36
HD measurement can also be carried out
using chemical sensors available for
detection
and
measurement
of
hydrogen in gas mixtures. These
sensors include pellistor sensors
[(Krawczyk, 2003), (http://www.
e2v.com)], semiconductor sensors (Lin
et al., 2003), thermal conductivity based
devices, electrochemical sensors etc.
Pellistor sensors require atmospheres
containing oxygen/air in explosive range
hence are not suitable for HD measurement. Semiconductor sensors are based
on conductivity changes caused by the
chemisorbed oxygen due to hydrogen
exposure. Hence oxygen is required
along with hydrogen. Thermal conductivity based devices are bulky and not
suitable for field applications. Electrochemical
sensors
for
hydrogen
measurement include both potentiometric [(Miura, 1983), (Miura and
Yamazoe 1988)] and amperometric
[(Miura,
1984),
(Miura,
1989)].
Potentiometric sensors are suitable at
low concentrations but are nonlinear in
response. Amperometric sensors are
linear in response and use of an amperometric sensor, H 2 /Pt//PVA//Pt/O2,
(comprising of a proton-conducting
polymer, Polyvinyl Alcohol (PVA) as its
electrolyte) for HD measurement has
been reported [(Albert et al., 1997),
(Albert, Ph.D Thesis, 1996)]. The results
obtained from the sensor agreed well
Girish Kumar Padhy - Diffusible Hydrogen Measurement in Steel Welds using an Electrochemical Hydrogen Sensor
Table 1: Chemical compositions in of mild steel
and modified 9Cr-1Mo in Wt%
with that of the standard Gas
Chromatography method. However, it
was seen that the PVA membrane
Elements
Mild steel
Modified 9Cr-1Mo
modest comparison of all the available
C
0.205
0.114
solid and liquid electrolytes showed that
Cr
-
8.838
Mo
-
0.860
(>60,000 hours), high chemical stability
Mn
0.551
0.403
and high ionic conductivity to opt for
Si
0.061
0.309
P
0.039
0.014
(Viswanathan and Helen, 2007)]. Nafion
Sr
0.047
based electrochemical cells, H2/Pt//
Nb
-
0.080
V
-
0.027
[(Sakthivel and Weppner, 2006),
Cu
0.321
(Velayuthamet al., 2004), (Ramesh et
Fe
Balance
suffers from poor long term stability. A
Nafion is the best available polymer
membrane because of its high longevity
PEM fuel cell applications [(Smitha et al.,
2005), (Neburchilov et al., 2005),
Nafion//Pt/O2, has been used for
measurement of hydrogen in Argon
Balance
al., 2008)]. The present study is involved
in the application of this Nafion based
electrochemical sensor for HD measurement in welding consumables.
2.0
EXPERIMENTAL
2.1
Materials used in the study
2.1.1 Test specimen
For HD measurement, the specimen was
All dimensions are in mm
prepared as per standard ISO 3690. A
Fig. 1 : Schematic of the Specimen assembly
triplicate set of specimen assembly
comprising of a specimen of dimension
30 mm x 15 mm x 10 mm, a run-on and a
assembly to the fixture. Beads were
run-off piece each of dimension 44 mm x
deposited with welding electrodes with
closed using a plug and the leak
15 mm x 10 mm were prepared from
different hydrogen levels on the
tightness of the plug is ensured with the
valves. The chamber can be opened or
mild steel and modified 9Cr-1Mo steel.
specimen assembly by manual metal arc
help of an O-ring. The chamber was
The chemical composition of steels used
welding (MMAW) process. A schematic
subjected to helium leak testing and it
is given in Table 1. The surfaces of the
diagram of the specimen assembly is
was found that the leak rate is less than
triplicate set were finished at right
shown in Fig. 1.
10-9 sccm. Fig. 2 shows the schematic of
angles to ensure good contact between
the adjacent pieces. The sample was
weighed to the nearest 0.01g prior to
2.1.2
Hydrogen
Collection
Chamber
the chamber along with plug. The
volume of the chamber is measured by
filling it with distilled water and draining
welding. The specimen assembly was
A hydrogen collection chamber (Lundin
the water completely into a measuring
clamped in a copper fixture. The
et al., 1986) was used to collect HD from
jar.
dimensions of the fixture was such that
the weld specimen. The chamber is
during welding, the heat is conducted
made of stainless steel and has an inlet
away immediately from the test
and an outlet connected to needle
37
2.1.3 Gas sampling valve
An 8-port gas sampling valve with a
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
sampling loop of known volume was used for sampling the gas
from the hydrogen collection chamber for analysis. The
sampling valve operates in two modes as shown in Fig. 3.
Mode 1 is the sampling mode and Mode 2 is injection mode. In
mode 1, as shown in Fig. 3, the inlet of the sampling loop is
connected to the specimen chamber (sample gas) through
port 7 and port 8 and the outlet is open to atmosphere through
port 4 and port 3. In this mode only the carrier gas which enters
O-Ring
Dia 40
through port 5, is passed onto the detector/sensor through
port 2 and port 1. In Mode 2, as shown in Fig. 4, the inlet of the
sampling loop is connected to the carrier gas line through ports
5 and port 4 and outlet to the detector/sensor through port 8
and port 1. In this process, the sample gas collected in the loop
while operating in Mode 1 is carried away to the sensor by the
carrier gas. While operating in this mode specimen chamber is
kept closed so that gas inside the specimen chamber is
conserved.
For analysis of the gas, initially the valve was operated at mode
1. The gas from the specimen chamber, which was filled at a
higher pressure than the ambient pressure, was used to flush
Flow
Control
Valve
the sampling loop while the carrier gas was flowing into the
sensor. At the end of flushing, the valve was switched over to
mode 2 operation and the carrier gas flowed through the
sampling loop to the sensor carrying the gas trapped in the
loop along with it. The sensor gives a signal corresponding to
concentration of hydrogen in the gas mixture.
2.1.4 Hydrogen Sensor
The hydrogen sensor used is an electro-chemical cell which has
All dimensions are in mm
Nafion, a proton conducting polymer, as its electrolyte. The
Fig. 2 : Schematic diagram of Hydrogen
Collection Chamber
polymer is cast as a film, coated with platinum black on the
sensing and counter electrode side. The sensing side of the
coated polymer is exposed to the hydrogen argon gas mixture
while the counter side is exposed to air. Thus the sensor
consists of hydrogen exposed inner platinum film and air
exposed outer platinum film with the conducting polymer
Nafion, sandwiched between them acts as a fuel cell. A
mechanical barrier limits the supply of hydrogen at the sensing
electrode. A schematic representation of the sensor with
conducting leads is shown in Fig. 5. Hydrogen present in the
Ar-H2 mixture gets chemisorbed at the sensing electrode and
loses its electron to form H+ which permeates through the
polymer to reach the counter electrode where it encounters
oxide ion (O2-, which is produced by taking up the electrons lost
by hydrogen and oxygen from the ambient) to form H2O.The
Fig. 3 : Valve in Mode 1 for sampling the
diffusible hydrogen gas
reactions taking place at the anode and at the cathode of the
38
Girish Kumar Padhy - Diffusible Hydrogen Measurement in Steel Welds using an Electrochemical Hydrogen Sensor
beads of the above mentioned
electrodes on mild steel specimen and
bead of the low hydrogen electrode,
P91M (with a composition modified from
that of E9015-B9), on modified 9Cr-1Mo
specimen. Table 2 give the electrode
details
and
welding
parameters
employed for preparation of specimens
for HD measurement. The specimen
assembly for HD measurement was
removed from the copper fixture
immediately after welding, quenched in
ice cold water followed by liquid
nitrogen. The test specimen was
separated from the run-on and run-off
pieces within 4-6 seconds. Any flux
remaining on the weld specimen was
Fig. 4 : Valve in Mode 2 for injection of sampled gas onto the sensor
removed within 20 seconds and was
stored in liquid nitrogen until its transfer
above electro-chemical cell are as
hydrogen in the hydrogen collection
into the hydrogen collection chamber for
follows:
chamber.
collection of HD.
At the anode
2.2 Diffusible Hydrogen
2.2.2 Collection and measurement
(Sensing side): H2 →2H+ + 2e-
Measurement
of diffusible hydrogen using the
At the cathode (Couneter
2.2.1 Preparation of specimen for
side): 2H+ + ½O2 + 2e- →H2O
the HD measurement
During the conduction of hydrogen ion
Five different classes of electrodes
weld specimen, it was cleaned with
through the polymer membrane, a short
which are known to have different levels
acetone to remove the ice/moisture,
circuit current is produced and a peak
of HD content were used for HD measure-
gently warmed to remove excess
corresponding to the short circuit
ment using the sensor. Prior to welding,
current was observed in the data
the specimen was degassed by holding
acquisition system which in turn is used
it at 650oC for 1 hour and the welding
to measure the concentration of
electrodes were baked as per the
requirement given in Table 2. Weld
specimens were prepared by depositing
sensor
For the collection of HD evolved from the
acetone and was transferred into the
collection chamber within one minute.
The chamber along with the specimen
was flushed and pressurized with argon
gas to a known pressure higher than the
ambient. After pressurizing, the weld
specimen was held in the chamber for
72 hrs for collection of HD as a mixture of
Diffusion barrier
hydrogen in argon (Ar-H2 gas mixture).
Volume of HD in the Ar-H2 gas mixture is
Pt (Sensing
Electrode)
measured by the sensor as described
below.
Nafion
Pt (Reference
Electrode)
Prior to the measurement of Volume of
HD in the chamber, sensor was calibrated
with different known concentrations of
hydrogen in the Ar-H2 gas mixture of by
injecting a fixed volume (this volume is
Fig. 5 : Schematic of Hydrogen Sensor
39
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
Table 2: Baking and Welding parameters of different electrodes
Electrodes
Baking
conditions
Welding
current (Amp)
Voltage (Volt)
E6010
Not Baked
110
25
E6013
125ºC/1h
110
27
E7016
250ºC/2h
110
28
E7018-1
250ºC/2h
110
27
P91M
300ºC/2h
90
28
further sizable hydrogen concentration
in the Ar-H2 mixture was obtained for a
subsequent time interval after 264 h of
HD measurement.
2.2.4 Measurement of diffusible
hydrogen at high temperature.
For collection of HD at high temperature,
a new chamber was designed (Fig. 6)
which has heating arrangements inside
it. Weld specimen was prepared as per
the
standard procedure already
equal to the volume of the sampling loop
concentration in the gas mixture,
of the valve shown in Figs. 3 and 4) of
pressure of the gas inside the chamber,
described and for HD measurement it
the gas mixture onto the sensor with the
weight of the deposited metal, volume
was transferred into heater inside the
help of the 8-port valve. Concentrations
of HD content was estimated and was
chamber. The chamber along with the
of hydrogen in the gas mixture were
reported in ml/100g of the deposited
weld
varied
specimen
is
flushed
and
metal. For each set of specimens, five
pressurized with argon; then the
controllers. Signal/response of the
separate measurements were carried
specimen is heated to 400°C for 0.5h
sensor corresponding to each concen-
out and the average values were
and hydrogen diffused out from the
tration of hydrogen in the Ar-H2 gas
reported.
by
standard
mass
flow
mixture was recorded as a peak height
of the peak is proportional to the
concentration of hydrogen in the gas
specimen is collected inside the
2.2.3 Measurement of diffusible
hydrogen with respect to time
chamber. It is cooled down to room
temperature and the concentration of
hydrogen is measured with the sensor.
mixture. After calibration, the inlet of
In addition to the standard 72 hour
sampling loop of the 8-port valve was
measurement, HD measurement from
connected to the chamber, the sampling
weld specimen was also carried out at
loop is flushed and filled with the gas in
different time intervals using the sensor.
Since the sensor method is a new
the chamber. Subsequently, by choosing
For feasibility of the measurements,
technique, all the HD measurements
the injection mode of the eight port
they were carried out at long time
carried out using this method were
valve, the gas mixture in the sampling
intervals after 72h. Apart from the
compared with similar measurements
loop was injected into the sensor. A
difference in the time duration of
using mercury method following
response
the
collection of HD, the procedures of
standard ISO 3690 procedure. The
concentration of hydrogen in the
specimen preparation and HD measure-
quenched and cleaned specimen was
chamber is recorded in the data
ment were the same as discussed in
acquisition system and compared with
sections 2.2.1 and 2.2.2. In this study,
the
the
HD was collected from a single weld
concentration of HD collected in the
specimen for time intervals of 0-24, 24-
obtain
chamber. As the specimen chamber is at
48, 48-72, 72-120, 120-192, 192-264 h
a higher pressure than the ambient, it
and was measured using the sensor.
was possible to repeat the measurement
After measuring the concentration of
at least thrice using the gas mixture
hydrogen evolved for a certain time
available in the chamber. After
interval, the chamber containing the
measuring HD concentration, the weld
same specimen was flushed and
specimen was taken out of the chamber,
pressurized again with argon to a known
cleaned, dried and weighed. From the
pressure and the measurement was
volume of the chamber, hydrogen
repeated for the next interval until no
40
the specimen inside was allowed for
hydrogen evolution for 72 hours.
Hydrogen evolved was collected in the
burette of the Y-tube. This volume is
subsequently converted to the volume
at STP and knowing the mass of the
specimen, HD content was normalized by
the following relationship:
HD =
-H
273
(273+T
( P760
(
(
to
transferred into the Y- tube filled with
mercury. The Y- tube was evacuated and
(
c a l i b ra t i o n
to
100
L2 - L1
(
corresponding
2.2.5 Measurement of diffusible
hydrogen by the mercury method
(V2 - V1) ml / 100g of weld deposit ..(1)
Girish Kumar Padhy - Diffusible Hydrogen Measurement in Steel Welds using an Electrochemical Hydrogen Sensor
Where,
HD
= Diffusible hydrogen at STP
(ml/100g)
T
= the room temperature (K)
P
= the barometric pressure (mm)
H
= (L2 - L1), the head of mercury
L1
= Height of mercury level in the
(mm)
graduated limb after 72 hours
(mm)
L2
=Height of mercury level in the
non-graduated limb after 72
hours (mm)
V1
= left over gas in the graduated
capillary of the closed limb
Fig. 6 : Hydrogen collection chamber
before evacuation (ml)
V2= the volume of hydrogen collected
in the graduated limb after 72 hrs
(ml)
3.0 RESULTS AND DISCUSSION
3.1 Diffusible Hydrogen content
A typical response of the sensor for
different concentrations of hydrogen in
the Ar-H2 mixture is shown in Fig. 7.
Fig. 8 shows the calibration of the
sensor which presents variation in peak
heights
Fig. 7 : Response of the hydrogen sensor against the
concentration of hydrogen
with
concentrations
of
hydrogen. The trend indicates a linear
relationship of peak height with the
concentration of hydrogen. Sensor was
calibrated prior to each set of
measurements.
Results of the HD measurements for
welding electrodes carried out using the
Nafion sensor and mercury method are
shown in Fig. 9. A good agreement for
the results obtained both from the
sensor and the mercury method for a
wide range of electrodes and levels HD
contents is obvious. In fact standard
deviation is less for measurements
Fig. 8 Calibration curve for hydrogen sensor obtained
using standard Ar-H 2 mixtures
41
made using the sensor than those made
by mercury method. Further, in Fig. 10,
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
a plot of HD contents obtained using
sensor method against HD contents
obtained using mercury method for
similar test sets was seen linearly
related with R2 = 0.9999. A mathematical correlation of HD contents
obtained for different test sets using
both these methods show one to one
correspondence between these two
methods as given below :
H Sensor Method = 0.99H Mercury Method -0.05 ...(2)
Hence, the results prove that the Nafion
based hydrogen sensor can be used for
HD measurements in the weld joints
Fig. 9 : Comparison of Mercury method and Sensor method
3.2 Accuracy of the Sensor Method
by t-Test
Following the recommendation of ISO
3690, t-Test has been carried out to
check the accuracy of the hot extraction
method as compared to mercury
method. In this test, the means of HD
contents of each electrode measured by
the mercury method (primary method)
and the mensor method (alternate
method) are compared statistically by
two-sided t-Test. The observed t value
(testimated) is estimated from equation (3).
The testimated for each electrode was
compared with the tstatistical obtained from
Fig. 10 : Relationship between mercury and sensor methods
the t-table of statistics for the number of
degrees of freedom, ?
=9 (Where, ?
=
nP+nR-2) at 95% confidence level (i.e.,
xP =
the level of significance, ?
= ±0.025 for
two-sided t-test) for each electrode. The
details are given in Table 3
t
estimated
=
(x
?
S
2
n
(Mercury)
sR =
R
R
+
S
n
2
P
....... (3)
sp =
Where,
nR =
testimated = the probability of difference in
means not due to chance
xR =
Mean of the sensor method
(Alternate)
nP=
± 0.025, 9
(at 95% confidence
Standard deviation of the rapid
From the Table 3, it is obvious that
method
testimated for all the set of measurements,
(Hot
extraction-
except one, fall within the interval of
Standard deviation of the
primary method (Mercury)
P
tstatistical = t
level in two sided test)
PEMHS)
- x P)
R
Mean of the primary method
t statistical = ±2.262 (Obtained from
statistical t-table (Beckwith et al., 2006).
The lone deviation observed is for the
Sample size in the rapid
E9015-B3 electrode deposited on mild
method
Extraction-
steel base metal; it may be noted that
PEMHS)
(Hot
composition of the base metal (mild
Sample size in the primary
steel) and weld metal (9Cr-1Mo steel)
method (Mercury)
are vastly different and this could be the
42
Girish Kumar Padhy - Diffusible Hydrogen Measurement in Steel Welds using an Electrochemical Hydrogen Sensor
reason for large value of testimated. Results
mentioned above, the new sensor
of evolution of hydrogen per hour within
prove that probability that good
method was successfully employed to
the time intervals of HD collection and
correlation obtained for HD content
study evolution of hydrogen as a
plotted against time in Fig. 12 which
measured by the sensor method and
function of time. In this study, hydrogen
shows rate of hydrogen evolution
the mercury method for different
concentration in the chamber was
decreases exponentially with time. Also,
electrode is by chance is less that 5%. In
measured for different time intervals
in Fig. 13, the cumulative total of HD
other words, with more than 95%
from weldment of modified 9Cr-1Mo
contents collected after different time
confidence level, it can be said that the
electrode (modified E9015-B9) on mild
periods clarifies that hydrogen evolution
results obtained for HD measurement
steel base metal up to 264 hours. This
is maximum within the first 24 hours
using sensor method is as accurate and
class of electrode was chosen because it
then it decreases exponentially with
as reliable as the results obtained from
is an alloy steel electrode and in the as
time. However, it should be noted that
the standard mercury method. The
welded condition, the microstructure of
total HD measured after 72 h (1.85 ml/
differences in means are only due to
the weld metal is fully martensitic and
100 g) is lower than HD obtained for the
random errors and not due to any
diffusion coefficient for hydrogen in this
single measurement carried out after 72
systematic errors. Hence, sensor
class of steel at ambient temperature is
h (2.1 ml/100 g). This could be because,
method can be used to measure HD
two orders magnitude lower than that in
the first 72 h measurement was divided
measurement as an alternative to the
mild steel (Albert et al., 2003). It was
into three 24h measure-ments and were
standard mercury method. This method
observed that evolution of hydrogen
carried out using a single sample and in
is environment friendly and possibly
continued even after 264 hours. HD
between two successive measurements,
emerges as a rapid method for HD
contents measured at various intervals
few hours are lost for measurement (gas
measurement. Once developed into a
for modified E9015-B9 deposited on
from the specimen chamber is sampled
commercial product, it is expected to be
mild steel is shown in Fig. 11. The
at least thrice for each measurement),
much cheaper than the Gas Chromato-
exponentially decreasing pattern of
flushing the chamber and refilling with
graphy method, another rapid method
diffusible hydrogen content with respect
Ar gas. Hence, gas evolved during these
currently available for HD measurement.
to succeeding time intervals was not
periods is not collected. However, the
observed from this data because the
results are sufficient to demonstrate
time intervals of measurement were not
that rate of hydrogen evolution
3.3
Hydrogen evolution as
function of time
equal. Hence, the data in Fig. 11 has
decreases with time and hydrogen
As per one of the applications
been normalized by estimating the rate
evolution continues much beyond 72 h.
Table 3: Comparison of means of HD obtained from both the methods by t-test
Standard
Deviation of HD
content (ml/100g)
Average HD
content (ml/100g)
Base Metal +
Electrodes
Mercury
Method
t-Value
Sensor
Method
Mercury
Method
Mild Steel +E6010
18.28
18.58
0.412
0.871
-0.7444
Mild Steel +E6013
9.37
9.56
0.338
0.438
-0.8352
Mild Steel + E7018-1
5.68
5.81
0.214
0.248
-0.9488
Mild Steel + E7016
4.19
4.26
0.102
0.124
-0.9449
Mild Steel + E9015-B9
2.11
2.19
0.0311
0.0588
-2.8317
9Cr-1Mo + E9015-B9
2.19
2.26
0.0711
0.117
-1.1950
Sensor
Method
testimated
tstatistical
(From
Table)
(tstatistical
= t±0.025,9)
±2.262
43
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
3.4 Diffusible hydrogen measurement by the sensor at high
temperatures
Measurement of diffusible hydrogen
was carried out at 400°C from the
weldment prepared by depositing P91M
welding electrodes on mild steel.
Hydrogen from weld metal was collected
in the chamber mentioned in section
2.2.4 and its concentration was
measured with the sensor. The results of
this measurement are given in Table 4.
These results are found to be in good
agreement with the results obtained by
Fig. 11 : Diffusible hydrogen measured at different intervals
the standard mercury method and with
the results obtained with the sensor
method at room temperature. Measurement of diffusible hydrogen in welding
electrodes with various levels of
hydrogen using the high temperature
method is in progress.
4.0
CONCLUSIONS
1. The Nafion based hydrogen sensor
has been successfully employed for
measuring diffusible hydrogen
content in the welding consumables.
2. Measurements were carried out for
five different classes of welding
consumables
with
Fig. 12 : Rate of hydrogen evolution with time
d i ffu s i b l e
hydrogen content in the range of 218 ml/100g of weld metal using the
sensor and the standard mercury
method. Results obtained correlate
well with those obtained by mercury
method.
3.
Statistical analysis of the results, as
recommended by ISO 3690 confirms
that confidence level on the accuracy
of the measurement of diffusible
hydrogen using the sensor is better
than 95%. Hence, this method can
be used as an alternate method for
diffusible hydrogen measurement
from the welding consumables.
Fig. 13 : Cumulative diffusible hydrogen Content
44
Girish Kumar Padhy - Diffusible Hydrogen Measurement in Steel Welds using an Electrochemical Hydrogen Sensor
Table 4 : Diffusible Hydrogen Measurements by Hot Extraction
4. One of the possible application of the
new method, hydrogen evolution
from the weld as a function of time
HD measured by
sensor method at
400°C (ml/100g)
Base Metal +
Electrodes
was also demonstrated by conducting measurement on a weld of
modified 9Cr-1Mo steel electrode
Mild Steel +
deposited on mild steel. It is shown
P91M (Baked)
that rate of hydrogen evolution
decreases exponentially with time
and it continues much beyond 72 h,
Average
the standard time of diffusible
HD measured by
sensor method at
room temperature
(ml/100g)
HD measured by
Mercury method
(ml/100g)
2.43
2.14
2.18
2.51
2.14
2.23
2.39
2.10
2.24
2.44
2.13
2.22
hydrogen measurement at ambient
temperatures.
Measurements, Fifth Edition, Pearson
5. A new method for measurement of
diffusible
hydrogen
at
high
temperature using the sensor with
considerable reduction of the
collection time of hydrogen from the
weld is demonstrated.
Education.
deposited weld metal from covered
De Abreu, L. C., Modenesi, P. J. and
Villani-Marques, P. (1995); Comparative
study of methods for determining the
Ito, Y. and Bessyo, K. (1968); Cracking
parameter of high strength steels
diffusible hydrogen in weld metal,
Deutsches Institut fur Normurg e.V.,
varthini, N. and Gill, T.P.S. (2003);
Berlin (1981).
assisted
cracking
and
diffusible
hydrogen content in Cr-Mo steel welds,
Sâdhanâ 28(3-4), pp. 383-393.
Albert, S. K., Ramesh, C., Murugesan,
N., Gill, T. P. S., Periaswami, G. and
Kulkarni, S. D. (1997); A New Method to
Measure Diffusible Hydrogen Content in
Hirth, J. P. (1980); Effects of hydrogen
Japanese Standards Association, 1986.
JIS Z3113-1975: Method for measurement of hydrogen evolved from
http://www.e2v.com/assets/media/files
/sensors_datasheets/Pellistors/pellistor
deposited metal.
Karkhin, V. A. and Levchenko, A. M.
_an1.pdf (Web Source: Pellistor Sensor
(2007); Computer-aided determination
Technology and Applications)
of diffusible hydrogen in deposited weld
trap binding enthalpy I, Metall. Trans. A,
Weld. J., 76(7), pp. 251s-255s.
18A (9), pp.1559-1564.
Albert, S. K., Studies on some aspects of
Iino, M. (1998); Evaluation of hydrogen
weldability of Cr-Mo Steels, Ph.D Thesis,
trap binding enthalpy II, Metall. Trans.
IIT-Bombay.
A, 29A (9), pp. 1017-1021.
ANSI/AWS A4.3 - 93: Standard methods
IIW
for determination of the diffusible
measurement of weld hydrogen levels,
hydrogen content of martensitic, bainitic
Welding in the World, 1985, 23 (3/4),
and ferritic steel weld metal produced by
pp. 50-62.
Beckwith, T. G., Maragoni, R.D.,
JIS Z3118-1986: Method of measure-
Metall. Trans. A, 11(6), pp.861-890.
Electrolyte Based Hydrogen Sensor,
Lienhard, J. H., (2006); Mechanical
IIW Doc.IX-576-68.
on the properties of iron and steel,
Iino, M. (1987); Evaluation of hydrogen
Miami, Florida (1986).
related to Heat-Affected-Zone cracking,
ment of hydrogen evolved from steel,
Steel Weldments Using a Polymer
arc welding, American Welding Society,
steels, Bureau of Indian standards, New
Delhi.
Welding International, 9(1), pp. 26-31.
Albert, S. K., Ramasubbu, V., ParvathaInfluence of alloying on Hydrogen
electrodes for welding mild and low alloy
diffusible hydrogen content in welds
DIN 8572 Part 1: Determination of
REFERENCES
ination of diffusible hydrogen content of
Doc.II-805-85
metal, IIW-Doc. II-1634-07 (II-A-18207).
Kotecki, D. J. and La Fave, R. A. (1985);
(1985);
The
AWS A5 Committee studies of weld
metal diffusible hydrogen, Weld. J., 64
(3): 31-37.
Krawczyk, M. and Namiesnik, J. (2003);
Application of a catalytic combustion
sensor (Pellistor) for the monitoring of
the explosiveness of a hydrogen-air
mixture in the upper explosive limit
ISO 3690: Determination of hydrogen
range, Journal of Automated Methods &
content in arc weld metal, II-E-586-10.
Management in Chemistry, 2003, 25(5),
IS-11802-1986: Methods of determ-
pp. 115-122.
45
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
Lasseigne, A., McColskey, D., Koenig, K.,
of proton conductor sensor sensitive to
Ravi, R. and Honavar, D. S. (1987);
Jackson, J., Olson, D. and Mishra, B.
H2 and CO at room temperature Chem.
Hydrogen in steel weldments - A review,
(2008);
Lett., 12(10), pp. 1573-1576
Advanced
Non-Contact
Diffusible Hydrogen Sensors for Steel
Weldments,
Trends
in
Welding
Research, Proc. 8th Inter.l Conf. 2-6
June, Pine Mountain, Georgia, USA,
pp.424-429.
Procs of Nat. Weld.Sem., 26-28
Neburchilov, V., Martin, J., Wang, H. and
Zhang, J. (2007); A review of polymer
Sakthivel, M. and Weppner, W. (2006);
electrolyte membranes for direct
Development of a hydrogen sensor
methanol fuel cells, Journal of Power
based on solid polymer electrolyte
Sources, 2007, 169(3); pp. 221-238.
Lin K. W., Chen H. I., Lu C. T., Tsai Y. Y.,
Chuang H. M., Chen C. Y. and Liu W. C.
(2003); A hydrogen sensing Pd/InGaP
metal-semiconductor (MS) Schottky
Noble, D. N. (1985); HAZ Hydrogen
Siewert, T. A. (1986); Testing of Welding
Met. Const., 17(11), pp. 754-757.
Electrodes for Diffusible Hydrogen and
Ohtsubo, T., Goto, S. and Amano, M.
Technol., 18 (7), pp. 615-619
(1985); Development of Apparatus for
and Richy, R. A., (1986), Advances in
Welding Science and Technology, ASM
International, Materials Park, Ohio: 585-
Determination of Diffusible Hydrogen in
Steel, Transactions ISIJ, 25(1), pp.2129.
Pressouyre, G. M., Lemoine, L., Dubois,
D. J. M., Leblonde, J. Saillard, P. R. and
596
Miura, N., and Yamazoe, N. (1988)
Development of a solid-state gas sensor
using proton conductor operative at
room temperature, Chemical Sensor
Faure, F.M. (1988); In situ measurement
of hydrogen in weld heat affected zones
through Mass Spectrometry and
computer analysis (Ref.6), pp. 219-237.
Technology, 1(2), Kodansha, Tokyo/
Quintana, M. A. and Dannecker, J. R.
Elsevier, Amsterdam, pp 123-139
(1986); Diffusible Hydrogen Testing by
Miura, N., Harada, T. and Yamazoe, N.
(1989); Sensing characteristics and
working mechanism of four-probe type
solid-state hydrogen sensor using
proton conductor, J. Electrochem. Soc.,
Gas Chromatography, Hydrogen Embri-
Miura, N., Kato, H., Ozawa, Y., Yamazoe,
N. and Seiyama, T. (1984); Ampero-
2005, 259 (1-2); pp. 10-26.
Suzuki, H. and Terasaki, T. (1986);
Estimating critical stress and preheat
temperature to avoid cold cracking, IIW
Doc. IX-1417-86.
G .,
Ramesh,
C .,
American Society for Testing of
Dhathathreyan K. S. and Periaswami G.
(2004); Nafion based amperometric
Evaluation of glycerin test, Weld. J.,
73(5), pp. 141s-149s.
(2008);
Chem. Lett., 17(2), pp. 1905-1908
amperometric sensor for hydrogen in
argon,
Improved
Journal
of
hydrogen sensor, Ionics, 10(1/2), pp.
63-67.
Viswanathan, B. and Helen, M. (2007);
Hydrogen In Air At Room Temperature,
Seiyama, T. (1983); An improved type
membranes for fuel cell applications-A
review, Journal of Membrane Science,
Materials, Philadelphia, pp. 247- 286.
M.V., Ganesan, V. and Periaswami, G.
Miura, N., Kato, H., Yamazoe, N., and
Smitha, B., Sridhar, S. and Khan, A. A.
(2005); Solid polymer electrolyte
Ve l a y u t h a m ,
Proton
To
Society for Testing of Materials,
Philadelphia, pp. 238- 246
Murugesan, N., Manivannan, V.,
Ramesh, C., Murugesan, N., Krishnaiah,
Sensitive
Control, ASTM STP 962, American
ttlement: Prevention and control and
metric Gas Sensor Using Solid State
Conductor
Coating Moisture, Hydrogen Embrittlement: Prevention and control and
Control, L. Raymond, ASTM STP 962,
Quintana, M. A. (1984); A critical
136, pp. 1215-1219.
membranes, Sensors and Actuators B,
113, pp. 998-1004.
Measurement during Weld Cladding,
diode hydrogen sensor, Semicond. Sci.
Lundin, C. D., Milton, R., Henning, J. A.
November, Bangalore, India.
Nafion-based
Solid
Is nafion, the only choice?, Bulletin of
the Catalysis Society of India, 6, pp. 5066.
Yurioka, N. and Suzuki, H. (1990);
State
Hydrogen assisted cracking in C-Mn and
Electrochemistry, 12(9), pp. 1109-1116.
low alloy steel weldments, Int. Mat.
Rev., 35(4), pp. 217-249.
46
I. T. MIRCHANDANI MEMORIAL RESEARCH AWARD
Dissimilar Metal Gas Tungsten Arc Weldments of
Maraging Steel and Medium Alloy Medium Carbon Steel –
Effect of Post-weld Heat Treatments
P. Venkata Ramana1 and G. Madhusudhan Reddy2
1
2
Mahatma Gandhi Institute of Technology, Gandipet, Hyderabad – 500 075
Defence Metallurgical Research Laboratory, Kanchanbagh, Hyderabad – 500 058
ABSTRACT
Maraging steel and medium alloy medium carbon steels exhibit their best mechanical properties such as tensile
strength and toughness in their respective heat treatment conditions. Gas tungsten arc welding of maraging
steel and medium alloy medium carbon steel was carried out taking both the steels in soft annealed condition.
Later the weldments were subjected independently to two post-weld heat treatments, one corresponding to
the maraging steel i.e. solutionising at 815oC/1 hr/air cooled & aging at 480oC/3 hrs/air cooled, and the other
corresponding to medium alloy medium carbon steel i.e. quenching at 925oC/35 min/air cooled & tempering at
295oC/45 min/air cooled. The effect of post-weld heat treatments on the microstructure and mechanical
properties such as hardness, tensile strength and impact toughness of the dissimilar metal welds of maraging
steel and medium alloy medium carbon steel was investigated. The influence of filler materials was also studied
by employing maraging steel and medium alloy medium carbon steel fillers. Maraging steel welds responded to
the solutionising and aging treatment whereas the medium alloy medium carbon steel welds responded to
quenching and tempering. Lowering of the hardness was observed at the interaction of maraging steel and
medium alloy medium carbon steel due to the diffusion of manganese. Medium alloy medium carbon steel filler
welds showed good strength and toughness properties.
Key words : Maraging steel, Medium alloy medium carbon steel, Gas tungsten arc welding and Post-weld heat
treatment.
1.0
INTRODUCTION
Structural steels with very high strength
levels are often referred to as ultrahighstrength steels. These steels with
ultrahigh strength coupled with fracture
toughness, in order to meet the
requirement of minimum weight while
ensuring high reliability, are widely used
defence applications. For many of the
iron-nickel alloys that gain strength
advanced applications, for both the
through age hardening of low carbon
technical and economic reasons,
martensite resulting in the precipitation
dissimilar combinations of ultrahigh
of strengthening intermetallic phases in
strength steels are necessary. For such
the martensitic matrix [5-13]. Medium
applications, maraging steel and
alloy medium carbon steels are ultrahigh
medium alloy medium carbon steels are
strength steels with reasonable ductility,
now being used.
considered to be inexpensive and
in light weight high-performance
Maraging steels are a class of very low
structural applications [1-4]. Because of
carbon high alloy martensitic steels with
these properties these steels are
ultra-high strength combined with good
extensively used in aerospace and
fracture toughness. These steels are
* Corresponding author E-mail : gmreddy_dmrl@yahoo.co.in
45
attractive substitute for maraging steel
[4]. These steels with good weldability
are important candidate materials for
critical applications such as rocket motor
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
cases, submarine hulls etc [4, 14].
the one of the heat treatments. The aim
thick sheets of 18% Ni (250 grade)
Though these steels are extensively
of the present study is to investigate the
maraging steel and medium alloy
used individually data are scarce about
influence of post-weld heat treatment
medium carbon steel. Gas tungsten arc
the dissimilar combination.
and influence of filler materials on the
welding of maraging steel and medium
Dissimilar materials' welding is qualitatively different from that of similar
materials welding because of many
differences in physical, chemical and
mechanical properties of parent
materials [15-20]. These differences
also complicate the selection of filler
metals compatible to both base metals.
mechanical
alloy medium carbon steel was carried
properties such as hardness, tensile
microstructure
and
out taking both the steels in soft
strength and impact toughness of
annealed condition. Later the weld-
dissimilar metal welds of maraging steel
ments were subjected independently to
and medium alloy medium carbon steel.
two post-weld heat treatments, one
The limited availability of the data on the
corresponding to the maraging steel i.e.
dissimilar welds of these steels makes
solutionising at 815OC/1 hr/air cooled &
this study significant.
aging at 480OC/3 hrs/air cooled, and the
other corresponding to medium alloy
Generally for better properties of the
dissimilar weld, filler metal selection is
medium carbon steel i.e. austenising at
2.0 EXPERIMENTAL PROCEDURE
925OC/35 min/air cooled & tempering at
dissimilar metals [21-24]. One of the
2.1 Parent materials, welding
295OC/45 min/air cooled. The details of
widely used fabrication process for
process and post-weld heat
weld coupon preparation and test plate
ultrahigh strength steels is fusion
treatments
welding in general and gas tungsten arc
The materials investigated are 5.2 mm
often compromised between the two
welding
p ro c e s s
in
assembly are shown in Fig.1. The para-
p a r t i c u l a r.
meters used for welding are given in
Table 1. Two fillers namely maraging
Consistency in weld quality, process
control, economy and weld joint
efficiencies exceeding 90% are the
features of gas tungsten arc welding
with respect to these steels.
Mechanical properties such as tensile
strength and impact toughness play an
important role in the design of
components. The adoption of dissimilarmetal combination provides possibilities
for the flexible design of the component
by using each material efficiently i.e.,
benefitting from the specific properties
Fig. 1 : Weld coupon design and test place assembly
of each material to meet functional
requirements.
Table 1 : Gas tungsten arc welding parameters
Maraging steel and medium alloy
Welding current
130 A
medium carbon steels, used in this
Welding speed
60mm/min
Electrode polarity
DCSP
ultrahigh strength after respective heat
Arc voltage
18-20 V
treatments. When used in similar metal
Filler wire diameter
1.6 mm
combination the materials will be
Electrode
2% Thoriated tungsten
subjected to their respective heat
No .of passes
2
Shielding gas
Argon, flow rate 35 CFH
Preheat
None
study, are generally supplied in soft
condition. These steels attain their
treatment schedules. But, when it
comes to dissimilar combination it
becomes important to choose between
46
P. Venkata Ramana - Dissimilar Metal Gas Tungsten Arc Weldments of........................ Effect of Post-weld Heat Treatments
Table 2 : Composition of parent materials and filler materials
Element (wt %)
Material
C
Ni
Co
Mo
Ti
Al
Cr
Si
Mn
Fe
Maraging steel
(parent material )
0.01
18.9
8.3
4.6
0.41
0.15
-
-
-
Bal.
Maraging steel filler
0.006
18.2
11.9
2.5
0.16
0.46
-
-
-
Bal.
Medium alloy medium
carbon steel (both
parent material & filler)
0.33
2.8
Max.
1.0
Max.
1.0
-
-
0.85
1.8
0.35
Bal.
steel filler, which was of similar
interval of 0.5 mm, employing Knoop
dissimilar metal welds of maraging steel
composition of the parent material but
micro-hardness testing machine. All the
and medium alloy medium carbon steel
with higher cobalt and aluminum and
hardness readings were obtained at a
with maraging steel filler and medium
lower molybdenum and titanium
load of 300gf.
alloy medium carbon steel filler, in the
contents and medium alloy medium
carbon steel filler with matching
2.4 Mechanical testing
as-welded and post-weld heat treated
conditions are shown in the Fig.2. From
The flat tensile specimens with
the figure it is evident that in the as-
used. Measured composition of the
geometry as per ASTM E8 (25mm gauge
welded (AW) condition of maraging
parent materials and filler materials is
length) and extracted from the
steel filler welds, the microstructure
given in Table 2. The dissimilar metal
transverse section of the weldment with
consists of dendritic structure with well
welds of maraging steel and medium
weld at centre of the specimen were
developed primary arms and clearly
alloy medium carbon steels were
tested on Instron 1185 universal testing
distinguishable short secondary arms.
subjected to post-weld heat treatments
machine at a cross head of 0.5 mm/min.
With the post-weld solutionising and
to study the influence of the same on
composition of the parent material were
Sub-size Charpy specimens (5mm x
aging (PWSTA) treatment, the dendritic
microstructure and mechanical prope-
10mm, notch depth-2mm) as per ASTM
features disappeared and the marten-
rties such as hardness, tensile strength
E23-28 specifications, sectioned from
site microstructure experienced coar-
and impact toughness.
the weldment with specimen axis
sening. Post-weld quenching and
2.2 Metallography
transverse to the weld joint and 'V' notch
tempering (PWQT) treatment did not
The weldment macro-microstructures of
dissimilar metal welds were studied by
at the weld centre were tested on Tinius
eliminate the light etching segregation
Oslon impact testing machine at room
features.
temperature.
The as-welded (AW) microstructure of
Leitz optical microscope. Modified Fry's
Both the above tests were also carried
medium alloy medium carbon steel filler
reagent (50ml HCl, 25ml HNO3, 1g CuCl2
out on the parent materials with the
weld consist fully dendritic structure in
same standard specifications. Scanning
addition to acicular product in the
electron microscopy was done to make
transgranular location (Fig.2). Post-
the fractographic analysis of both tensile
weld solutionising and aging (PWSTA)
and impact specimens. A minimum of
treat-ment at 815 O C resulted in
metallography of various regions using
and 150ml water) was used to etch
maraging steel weld and 2% nital (2ml
HNO3 and 98ml methanol) was used to
etch medium alloy medium carbon steel
weld. The respective etchants were also
used to etch fusion zone, heat affected
three tensile and impact tests were
development of acicular product and
carried out in each condition.
fine precipitates while transgranular
product and light etching phase persist.
zone and parent material regions.
When subjected to post-weld quenching
2.3 Hardness measurement
3.0 RESULTS AND DISCUSSION
Micro-hardness survey was carried out
3.1 Microstructure
across the cross section of the weld
The weld zone microstructures of
beads of all the weldments, with an
47
and tempering (PWQT) treatment the
dendritic features disappeared and
martensitic microstructure experienced
coarsening.
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
(a) Maraging steel filler
(b) Medium alloy medium carbon steel filler
Fig.2 : Optical microstructure of weld centre of dissimilar metal gas tungsten arc weldment of
maraging steel and medium alloy medium carbon steel with (a) maraging steel filler
(b) medium alloy medium carbon steel filler, in various post-weld heat treated conditions
3.2
Hardness
decreasing trend near the fusion
3.2.1 Dissimilar metal welds of
maraging steel to medium alloy
medium
carbon
steel
with
maraging steel filler
The hardness survey across the
transverse section of the dissimilar
metal weld of maraging steel and
medium alloy medium carbon steel in
the AW condition is shown in the Fig.3a.
The hardness in the fusion zone is
mostly same as that of the maraging
steel
parent
material
except
a
steel parent material and weld to rise to
boundary of medium alloy medium
550 HK from 350 HK in the as-welded
carbon steel. The reason for this being
condition. There is marginal decrease in
the presence of austenite formed due to
the hardness of medium alloy medium
diffusion of manganese [25].
carbon steel (Compare Fig. 3a and
Fig.3b shows the hardness survey
across the PWSTA dissimilar weldment
of maraging steel and medium alloy
medium carbon steel. It is known that
the maraging steel gains its strength
due to precipitation of intermetallic
compounds during aging treatment.
This made the hardness of the maraging
48
Fig. 3b) due to solutionising and aging
temperatures being more than the
quenching and tempering temperatures. There is a dip in the hardness
value in the weld very close to the fusion
boundary of medium alloy medium
carbon steel as the austenite present
due to the diffusion of manganese did
not respond to the solutionising and
P. Venkata Ramana - Dissimilar Metal Gas Tungsten Arc Weldments of........................ Effect of Post-weld Heat Treatments
Fig.3 : Hardness traverse across the dissimilar metal gas tungsten arc weldment of
maraging steel and medium alloy medium carbon steel with maraging steel filler in various
post-weld heat treated conditions (a) As-welded (b) Solutionised and Aged (c) Quenched and tempered
aging heat treatment.
alloy medium carbon steel filler
The hardness survey across the PWQT
Fig. 4a shows the dissimilar weld of
dissimilar weldment of maraging steel
maraging steel and medium alloy
and medium alloy medium carbon steel
medium carbon steel in the AW
is shown in the Fig. 3c. It is clear from
condition. The hardness of the fusion
the figure that the maraging steel parent
zone is high compared to that of the
material and maraging steel weld did
heat affected zone of maraging steel
not respond to the quenching and
whereas it is low compared to that of the
tempering, whereas the hardness of
heat affected zone of medium alloy
medium alloy medium carbon steel
medium carbon steel. It is noticed that
steel weld with low carbon martensite
from the maraging steel, diffusion of
manganese from medium alloy medium
carbon steel weld to the heat affected
zone of maraging steel and also may be
due to the coarse grain structure formed
near the fusion boundary of maraging
steel as it is exposed to high
temperature during the welding
process.
increased as compared to that in as-
the hardness showed considerable
Fig. 4b shows the hardness of the
welded condition(Fig. 3a) as it
decrease, partially along the fusion
dissimilar weld of maraging steel and
responded to the quenching and
boundary of maraging steel and
medium alloy medium carbon steel, in
tempering treatment.
adjacent region, in the heat affected
the PWSTA condition. From the figure it
zone of maraging steel. This decrease in
is observed that the hardness of
3.2.2 Dissimilar metal welds of
maraging steel to medium alloy
medium carbon steel with medium
the hardness can be attributed to the
maraging steel is higher than that of the
dilution medium alloy medium carbon
weld and medium alloy medium carbon
49
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
steel. The increase in the hardness of
filler weld and medium alloy medium
steels responded to their respective
the maraging steel is due precipitation
carbon steel parent material have
heat treatments with high hardness
hardening of maraging steel. The
responded to the quenching and
(Maraging steel - nearly 550 HK and
medium alloy medium carbon steel weld
tempering, with increase in the
Medium alloy medium carbon steel -
and parent material show low hardness
hardness as compared to the as-welded
nearly 650 HK). Maraging steel showed
due to the over tempering due to
condition (Fig. 4a). The maraging steel
slight decrease in the hardness due to
solutionising and aging temperatures.
did not respond to the quenching and
the quenching but did not respond to
In the fusion zone very close to the
tempering temperatures. In the fusion
the tempering temperature. Medium
fusion boundary of maraging steel is
zone it is observed that the hardness
alloy medium carbon steel showed
observed to the presence of austenite
decreased close to the fusion boundary
lower hardness, when subjected to
formed due to the diffusion pheno-
of maraging steel. This is due to the
solutionising and aging due to over
menon as mentioned earlier.
dilution of low carbon martensite and
tempering. In all the heat treatment
presence of austenite.
conditions, always there is a consider-
The hardness survey across the
In summary, it is observed that the in the
able decrease in the hardness along the
medium alloy medium carbon steel, in
as-welded condition the medium alloy
interface of maraging steel medium
the PWQT condition is shown in the
medium carbon steel displayed high
alloy medium carbon steel due to
Fig. 4c. It is clear from the figure that
hardness compared to that of maraging
dilution and diffusion effects.
the medium alloy medium carbon steel
steel in the same condition. Both the
dissimilar weld of maraging steel and
Fig.4 : Hardness traverse across the dissimilar metal gas tungsten arc weldment of maraging steel and
medium alloy medium carbon steel with medium alloy medium carbon steel filler in various
heat treated conditions (a) As-welded (b) Solutionised and Aged (c) Quenched and tempered
50
P. Venkata Ramana - Dissimilar Metal Gas Tungsten Arc Weldments of........................ Effect of Post-weld Heat Treatments
3.3 Tensile properties
The tensile properties of dissimilar metal
welds with maraging steel filler and
medium alloy medium carbon steel
fillers, in different heat treatment
conditions, are shown in Table 3.
Parent material properties are given
Table 4 for ready reference.
3.3.1 Dissimilar metal welds of
maraging steel to medium alloy
medium
carbon
steel
with
maraging steel filler
From the Table 3, it is evident that the
dissimilar metal welds of maraging steel
and medium alloy medium carbon steel
in PWSTA condition has high strength
and very low ductility compared to that
of the weld joints in AW and PWQT
conditions.
Fig.5 shows the fracture location of the
tensile samples. In the AW condition the
fracture occurred in heat affected zone
of maraging steel close to the fusion
boundary. This due to the low hardness
of the maraging steel (Fig. 3a).
In the weld joint in PWSTA condition the
fracture occurred in the weld close to the
fusion boundary of medium alloy
medium carbon steel. This is may be
attributed to the presence of low
hardness region in fusion zone (Fig.
3b).
In the PWQT weld joint the fracture
occurred in the maraging steel. This may
be attributed to the following: due to
quenching and tempering the medium
alloy medium carbon steel gains
strength whereas the maraging steel
remains unaffected with low strength.
Moreover the as the maraging steel is
exposed to higher temperatures during
the welding process the heat affected
zone close to the fusion boundary
inherits the low hardness coarse grain
structure.
The fractographs of the tensile samples
of dissimilar metal welds in AW, PWSTA
and PWQT shown in Fig.6 reveal that
the dimpled structure is in tune with
Table 3 : Tensile properties of dissimilar metal welds of maraging steel to medium alloy medium carbon steel
Medium alloy medium carbon
steel filler
Maraging Steel Filler
Material
YS
(MPa)
UTS
(MPa)
El.(%)
Loction of
Failure
YS
(MPa)
UTS
(MPa)
El.(%)
Loction of
Failure
As-welded
970
1045
11.4
Maraging
steel
942
1007
11.8
Close to FB
of Maraging
Steel
Wolutionised and
Aged
1307
1337
0.4
Weld
(close to
FB of
MAMCS)
0
719
0.02
Weld
Table 4 : Parent material properties in various heat treated conditions
Material
Maraging steel
Medium alloy medium
carbon steel
Condition
YS
(MPa)
UTS
(MPa)
El. (%)
Impact
Toughness (J)
Solutionised
950
1000
12
110
Solutionised
and aged
1600
1750
7.5
40
Quenched and
tempered
844
1015
18.6
156
Annealed
779
977
22.3
31
Solutionised and
aged
1564
1790
11
26
Quenched and
tempered
1458
1815
12
24
51
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
ductility of weld joints in AW and PWQT conditions, whereas
the brittle features of facets with cleavages are in tune with the
very low ductility of the weld joint in PWSTA condition.
Maraging Steel
Medium Alloy
Medium Carbon Steel
3.3.2 Dissimilar metal welds of maraging steel to
medium alloy medium carbon steel with medium alloy
medium carbon steel filler
Table 3 shows that the strength of dissimilar metal weld joint
in PWQT condition is marginally higher than that of the joint in
AW condition, whereas the ductility of the AW condition joint is
marginally higher than that of the joint in PWQT condition. It is
observed that the weld joint in PWSTA condition failed without
any yielding.
Fig.5 : Fracture location of tensile samples of
dissimilar metal gas tungsten arc weldment of
maraging steel and medium alloy medium
carbon steel with maraging steel filler in
various heat treated conditions
Fig.7 shows the fracture location of the dissimilar metal weld
joints. In the AW condition dissimilar metal weld joint, the
fracture occurred close to the fusion boundary of maraging
steel. This may be due the low hardness region at the fusion
boundary of maraging steel (Fig. 4a). In the PWSTA dissimilar
metal weld joint the fracture occurred in the fusion zone
though there is a low hardness region along the fusion
boundary of maraging steel (Fig. 4b). This may be attributed
to the temper embrittlement of the medium alloy medium
carbon steel weld. The fracture in the dissimilar metal weld in
PWQT condition occurred in the maraging steel. The weld and
medium alloy medium carbon steel respond to the quenching
and tempering treatment and gain strength and hardness
where as the maraging steel remain in the solutionised
condition with low hard-ness. This makes the joint to fail in the
maraging steel (Fig. 4c).
Fig.8 shows the fractographs of the tensile samples of
dissimilar metal weld joints. The fine dimpled structure of the
fracture surfaces in the weld joints in AW and PWQT conditions
are in tune with high ductility values compared to that of the
PWSTA condition weld joint. The brittle morphology with
cleavages sub-stantiates the failure of the weld joint, in PWSTA
condition, before yielding.
To summarize, in dissimilar metal welds, if the strength is the
criterion dissimilar metal weld of maraging steel and medium
alloy medium carbon steel with maraging steel filler in PWSTA
condition may be used. If the ductility is the criterion dissimilar
metal weld of maraging steel and medium alloy medium
carbon steel either with maraging steel filler or medium alloy
medium carbon steel filler may be used. If both strength and
ductility are the criterion dissimilar metal weld of maraging
steel and medium alloy medium carbon steel with medium
alloy medium carbon steel filler in PWQT condition may be
preferred.
Fig.6 : Fractographs of tensile samples of dissimilar
metal gas tungsten arc weldment of
maraging steel and medium alloy medium
carbon steel with maraging steel filler in
various heat treated conditions
52
P. Venkata Ramana - Dissimilar Metal Gas Tungsten Arc Weldments of........................ Effect of Post-weld Heat Treatments
3.4 Impact toughness
Maraging Steel
Medium Alloy
Medium Carbon Steel
Table 5 presents the Impact toughness of the dissimilar metal
weld joints, with maraging steel filler as well as medium alloy
medium carbon steel filler, in as-welded (AW), post-weld
solution treated and aged (PWSTA) and Post-weld quenched
and tempered (PWQT) conditions. Parent material impact
toughness properties are presented in Table 4.
3.4.1 Dissimilar metal welds of maraging steel and
medium alloy medium carbon steel with maraging
steel filler
Fig.7 : Fracture location of tensile samples of
dissimilar metal gas tungsten arc weldment of
maraging steel and medium alloy medium
carbon steel with medium alloy medium carbon
steel filler in various heat treated conditions
From Table 5 it is clear that the order of toughness in
dissimilar metal welds is that the impact toughness of weld
joint in PWQT condition is high compared to that of the weld
joint in AW condition which in turn is higher than that of the
weld joint in the PWSTA condition.
From Fig.9 which shows the impact samples, it is observed that
the crack path is in tune with the toughness values with longer
curved path for ductile welds and shorter straight path for
brittle weld.
Fig.10 shows the fracture features of the weldments. Fine
dimpled fracture surface is evident for the welds in AW and
PWQT conditions. This may be due presence of more low
carbon martensite in the maraging steel weld as one of the
adjacent parent materials is maraging steel. The weld in
PWSTA exhibited fracture surface with cracks. This may be due
to the precipitation hardening of low carbon martensite in
maraging steel weld and over tempering of the high carbon
martensite in the maraging steel weld diluted from medium
alloy medium carbon steel.
3.4.2 Dissimilar metal welds of maraging steel and
medium alloy medium carbon steel with medium alloy
medium carbon steel filler
From Table 7 it is evident that the toughness value of the
welds in AW and PWQT conditions is almost same. The weld in
PWSTA condition exhibit very low toughness compared all
other welds mentioned in the Table.
Both the welds in AW and PWQT conditions contain a mixture
of hard high carbon martensite of medium alloy medium
carbon steel and soft low carbon martensite. The marginal
difference in the toughness value of the weld in AW condition
can be attributed to the presence of untempered high carbon
Fig.8 : Fractographs of tensile samples of dissimilar
metal gas tungsten arc weldment of maraging steel
and medium alloy medium carbon steel with medium
alloy medium carbon steel filler in various
heat treated conditions
martensite. This untempered martensite when tempered
during PQWT process results in marginal increase in the
toughness value. The very low toughness in the PWSTA
53
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
Table 5 : Impact toughness of gas tungsten arc weldments in various post-weld heat treated conditions
Impact Toughness (J)
Weldment
Maraging steel filler
Medium alloy medium
carbon steel filler
Post-weld condition
Maraging steel
filler
Medium alloy medium
carbon steel filler
As-welded
32
34
Solutionised and aged
4
2
Quenched and tempered
40
35
condition can be attributed to the
1. Maraging steel responded to
temper embrittlement of the medium
solutionising and aging whereas
alloy medium carbon steel weld.
medium alloy medium carbon steel
The crack paths are similar for the welds
in AW and PWQT conditions as shown in
responded to quenching and
tempering treatment.
Fig.11. The weld in PWSTA exhibit
2. In the as-welded condition, medium
straight crack path showing low
alloy medium carbon steel displayed
toughness. From Fig.12 it is clear that
high hardness compared to that of
the welds in AW and PWQT exhibit high
maraging steel in the same
toughness with fine dimpled fracture
condition.
surface. The fracture surface of weld in
PWSTA exhibit fibrous structure with
macro cleavages. The fibrous structure
can be attributed to the presence of low
carbon martensite diluted from the
maraging steel to medium alloy medium
carbon steel weld.
In summary, it is observed that the
5. If the strength is the criterion
dissimilar metal weld of maraging
steel and medium alloy medium
carbon steel with maraging steel
filler in PWSTA condition may be
used.
6. If the ductility is the criterion
dissimilar metal weld of maraging
steel and medium alloy medium
3. Maraging steel showed slight
carbon steel either with maraging
decrease in the hardness due to the
steel filler or medium alloy medium
quenching but did not respond to
carbon steel filler may be used.
the tempering temperature.
7. If both strength and ductility are the
4. Medium alloy medium carbon steel
criterion dissimilar metal weld of
showed lower hardness, when
maraging steel and medium alloy
subjected to solutionising and aging
medium carbon steel with medium
dissimilar metal weld of maraging steel
and medium alloy medium carbon steel
due to over tempering.
Maraging Steel
Medium Alloy Medium
Carbon Steel
with maraging steel exhibited high
toughness compared to the other
weldments whereas the dissimilar metal
weld with medium alloy medium carbon
steel filler exhibited the lowest impact
toughness.
4.
CONCLUSIONS
Influence of post-weld heat treatments
on the microstructure and mechanical
properties of dissimilar metal welds of
maraging steel and medium alloy
medium carbon steels has been
investigated. Following observations are
made:
Fig.9: Impact test samples of dissimilar metal gas tungsten arc
weldment of maraging steel and medium alloy medium carbon steel
with maraging steel filler in various heat treated conditions
54
P. Venkata Ramana - Dissimilar Metal Gas Tungsten Arc Weldments of........................ Effect of Post-weld Heat Treatments
Fig.10: Fractographs of impact samples of dissimilar
metal gas tungsten arc weldment of maraging
steel and medium alloy medium carbon steel with
maraging steel filler in various heat treated conditions
Maraging Steel
Fig.12 : Fractographs of impact samples of dissimilar metal
gas tungsten arc weldment of maraging steel and medium
alloy medium carbon steel with medium alloy medium
carbon steel filler in various heat treated conditions
Medium Alloy Medium
Carbon Steel
alloy medium carbon steel filler in PWQT condition may be
preferred.
8. Dissimilar metal weld with maraging steel filler, in quenched
and tempered condition, exhibited
high toughness
compared to the other weldments whereas the weld with
medium alloy medium carbon steel filler, solutionised and
aged condition exhibited low toughness.
ACKNOWLEDGEMENTS
Financial assistance from Defence Research Development
Organization
Fig.11 : Impact test samples of dissimilar metal gas
tungsten arc weldment of maraging steel and medium
alloy medium carbon steel with medium alloy medium
carbon steel filler in various heat treated conditions
(DRDO)
is
gratefully
acknowledged.
The authors would like to thank Dr. G. Malakondaiah, Director,
Defence Metallurgical Research Laboratory, Hyderabad for his
continued encourage-ment and permission to publish this
55
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
work. The authors also thank Structural
6.
Failure Analysis Group and Metal
Decker R.F. and Floreen S.,
and Rodriguez P. Weld. J. (1997),
Maraging steels: Recent Develop-
76, p.135s.
Working Group for help in metallography
ments and Applications, in: Wilson
and heat treatment. One of the authors
R. K. (Ed.), TMS-AIME, Warrendale,
(P. Venkata Ramana) thanks the
PA, (1988), p.1.
manage-ment of Mahatma Gandhi
Institute of Technology, Hyderabad for
7.
Vasudevan V. K., Kim S. J. and
Wayman C. M., (1990), Metall.
permission and encouragement to carry
Trans. A, 21, p.2655.
out this work.
8.
Sha W., Cerezo A. and Smith G.D.W.,
(1993), Metall. Trans. A, 24, p.1221.
REFERENCES
1.
Philip T. V. and McCaffrey T. J. (ed),
(1993), ASM Handbook, vol.1,
p.1118.
2.
Olson G. B., "Overview: Science of
Steel," Innovations in Ultrahighstrength steel Technology, (ed) by
G. B. Olson, M. Azrin, and E. S.
4.
(1993), Metall. Trans. A, 24, p.1233.
10. Sha W., Cerezo A. and Smith G.D.W.,
(1993), Metall. Trans. A, 24, p.1241.
11. Sha W., Cerezo A. and Smith G.D.W.,
(1993), Metall. Trans. A, 24,
p.1251.
34th Sagamore Army Materials
(2003), Acta. Mater. 51, p.101.
13. Lang F. H. and Kenyon N., Bulletin
Tomita Y., (1991), Mat. Sci. and
159, Welding Research Council,
Technol. 7, p.81.
Engineering Foundation, New York,
Malakondaiah G., Srinivas M. and
Rama Rao P., (1995), Bull.Mater.Sci.
Floreen S. and Decker R. F., Source
Book on Maraging steels, Decker R.
F. (ed), ASM, Metals Park, OH,
(1979), p.20.
M. J., (1999), Weld. J. 78, p.329s
18. Nelson T. W., Lippold J. C. and Mills
M.J., (2000), Weld. J. 79, p.267s
19. Naffakh, H., Shamanian, M. and
Ashrafizadeh F., (2008), J. of Mater.
Sci., 43, p. 5300.
20. Bala Srinivasan P. and Satish Kumar
M. P., (2009),
Mater. Chem. and
Phys. 115, p.179.
21. Sireesha M., Shaju K. A., Shankar V.
and Sundaresan S.,(2000), J. of
Nucl. Mater279, p.65.
22. DuPont J. N. and Kusko C. S.,
(2000), Weld. J. . (2000), 86, p.
Wright, (1987), Proceedings of the
18, p.325.
5.
Sha W., Cerezo A. and Smith G.D.W.,
12. Guo Z., Sha W. and Vaumousse D.,
Research Conference, p.3.
3.
9.
17. Nelson T. W., Lippold J. C. and Mills
(1971).
51s.
23. Yang, Y. K. and Kou, S, (2008), Sci.
and Technol. of Weld. and Join. 13,
p. 318.
24. Das C. R., Bhaduri A. K., Srinivasan
G., Shankar V. and Mathew S.,
14. Garrison W. M. Jr., J. of Met. (1990),
42(5), p.20.
(2009), J. of Mater. Process.
Technol., 209, p.1428.
15. Barnhouse E. J. and Lippold J.C.,
Weld. J. (1988), 77, p.477s.
16. Albert, S. K., Gills, T. P. S., Tyagi, A.
K., Mannan, S. L., Kulkarni, S. D.,
56
25. Venkata Ramana P., Madhusudhan
Reddy G., Mohandas T., A.V.S.S.K.S.
Gupta, (2010),
31, p.749.
Mat. and design.
CEOBSP AWARD
Root Cause Analysis of Failure in Hot and Cold Mixing Point
in Hydrogen Generation Unit (HGU)due to Thermal Fatigue
Phenonmenon
Mahendra Pal*, Mayank Banjare
Indian Oil Corporation Limited, Guwahati Refinery, PO-Noonmati, Assam, Guwahati -781 020
ABSTRACT
In a Process unit there are several streams that are exchanging heat to optimize the unit operation. In the HGU
at IOCL, Guwahati refinery repetitive failures were observed in a 2” Ô, SS 304 pipe at this hot and cold mixing
point. The investigation revealed that the two streams were handling fluid at a temperature of 40oC and 160oC,
the difference being ?
120oC. These huge temperature differences lead to thermal gradient across the wall
thickness of the pipe and also along the length of the pipe surface in the flow direction. The inner surface of the
pipe seeing a higher temperature than the outer surface and therefore more expansion at inner surface. Due to
this thermal fatigue phenomenon and hindered expansion severe stresses were observed at the inner surface
of pipe leading to crack initiation and further propagation across the wall thickness. As a temporary measure
the joint was replaced with identical pipe with higher thickness (schedule), and as a permanent solution it was
suggested to replace the mixing point with an injection “Quill” design to avert the huge thermal gradient
Key words: Thermal gradient, thermal fatigue, Quill , process mixing point
1.0 INTRODUCTION
The reliability of a process unit operation
dependent units like Hydro treater unit
2.0
and MS-quality up gradation units.
DESCRIPTION OF HGU
BRIEF PROCESS
is to a large extent dependent on the
In a process plant where several
The HGU at Guwahati Refinery (GR) is a
reliability of its mechanical equipments.
streams are exchanging heat & mass, a
10000 TPA (1250 KG/HR) plant which
In this case, the reliability of the process
sound engineering design will help to
produces hydrogen of 99.9% purity.
equipments like column, vessels, heat
minimize, if not completely eliminate,
This hydrogen is primarily used in hydro-
exchangers, piping, pumps, compre-
the failures due to large variations in the
treater unit and MSQ unit for producing
ssors are of paramount importance for
temperature profiles of these process
diesel, ATF, MS and kerosene. The
safe and reliable operation and the
streams. This paper describes about the
process licensor is M/s KTI-BV,
profitability of the unit operation. The
repetitive failures experienced in the 2"
Netherlands. The feed is light Naphtha
outage of hydrogen generation unit due
Ô, SS 304 pipe at hot and cold mixing
and off gas.
to failures by leakage in the process
point. Temporary measures under taken
pipeline will not only lead to upset in the
and permanent solution suggested to
unit operation but also cause indirect
combat this chronic failure are also
throughput loss / shutdown of its
discussed in the paper.
* Corresponding author. E-mail : palm@iocl.co.in
63
The Hydrogen Unit is divided into the
following sections:
1)
Feed preheat.
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
2)
3)
Hydrogenation.
De-sulphurisation
CH4 + H2O
and
chlorination.
4)
Pre reforming.
5)
Reforming.
condensate separator) and exchangers
<=> CO + 3H2
de-
(Endothermic)
CO + H2O
(PSA) section for purifying the final
<=> CO2 + H2
(Exothermic)
Pre-reformer effluent goes to reformer
6)
Heat recovery.
section where it is mixed with additional
7)
High temperature shift conversion.
quantity of steam and then superheated
8)
9)
and further to pressure swing adsorber
o
hydrogen gas to 99.9 % purity.
2.1 Location of the failed mixing
point:
The dia. 2", SS-304 hot and cold mixing
point, is located in the down stream of
Low temperature shift conversion.
up to 630 C . This preheated feed then
Boiler feed water conditioning and
enters reformer furnace at top section
vessels V-07 (hot condensate vessel)
steam generation system.
through inlet pigtails connected to 36
and V-08 (cold condensate vessel). The
nos. of tubes. The reformer is operated
temperatures of the streams are 160oC
at steam to carbon ratio of 2.8 in design
and 40oC respectively. The isometric
feed case.
sketch below (Fig. 1) shows the layout
10) Pressure swing adsorption system
(PSA).
The feed light naphtha from CDU (crude
distillation unit) and off gas from LRU
(LPG recovery unit) is preheated to
250oC in the preheat section and sent to
hydrogenation section. LRU off gases
contain significant amount of olefins and
light naphtha contains mercaptans as
well as traces amount of heavy metals
such as arsenic, lead, vanadium, copper,
which are catalyst poison. In the hydrogenator, olefins are saturated. The
mecaptans are converted to hydrogen
The conversion of methane with steam
to CO and H2 is strongly favored by high
of the piping configuration and the
location of the failed mixing point.
temperature, low pressure and high
2.2 Material of construction (MOC)
steam ratios in the presence of nickel
and operating parameters:
based catalyst. Conversion reaction
Line size : dia. 2”
takes place in tubes in presence of the
catalyst. The normal reformer outlet
temperature is 850 oC.
CH4 + H2O <=> CO + 3H2
CO
+ H2O <=> CO2 +
H2
MOC of pipe : ASTM A-312 Gr, TP 304,
schedule 40S (originally)
Operating temperature : 40°C (cold
stream) , 160 °C (hot stream)
Operating pressure : 21.8 kg/cm2 & 21.2
sulfide. The impurities are absorbed on
The process gas is then sent to High
kg/cm2 in the hot & cold condensate
the hydrogenator catalyst. For hydro-
temperature (HT) and low temperature
lines respectively.
genation Co-Mo catalyst is used.
The feed is then sent to desulfurization
and de-chlorination section for chlorides
and sulfur removal in the sulfur
(LT) shift conversion section. In the LT
Service : Hot & cold condensates (From
section the process gas passes through
V-07 & V-08 vessels respectively).
a series of reactors, vessel V-07 (hot
condensate separator) and V-08(cold
Fluid velocities of the hot, cold & mixed
absorbers containing bed of zinc oxide
with top layer as chlorine guard. The
feed is then sent to pre-reformer section
V-07
where the de-sulfurised feed is mixed
Hot Stream
(160oC)
with controlled quantity of steam so as
to have feed to steam ratio of 2.5 kg/kg.
dia 2"
dia 2"
o
It is then heated to 450 C and routed to
pre-reformer. Hydrocarbons in the
presence of steam react over a nickel
Cold Stream
(40oC)
V-08
based catalyst to form an equilibrium
mixture of methane, carbon dioxide,
carbon monoxide and hydrogen.
C2H6 + 2H2O =>
2CO + 4H2
(Endothermic)
Fig. 1 : Isometric Sketch of Hot and Cold Mixing Point,
showing the failed location
64
Mahendra Pal - Root Cause Analysis of Failure in Hot and Cold Mix Point ................ (HGU) due to Thermal Fatigue Phenomenon
condensate streams are 0.33 m/s, 0.42 m/s & 0.75 m/s
respectively with flow of 2.44m3/hr, 3.09m3/hr and 5.53m3/hr
respectively.
2.3
Inspection history and repair jobs undertaken
The hydrogen generation unit (HGU) at IOCL, Guwahati
Refinery was commi-ssioned in the year 2002. In May 2006,
leakage was noticed for the first time since commissioning of
the unit at a mixing 'Tee' due to cracking of dia. 2” cold header
pipe located opposite to hot condensate entry point (at 90o).
Preliminary inspection of the leaked 'Tee' was carried out by
scanning with an ultrasonic thickness gauging meter of
“panametrics make” to identify loss in metal wall thickness of
the cold header pipe due to corrosion/erosion. There was no
Fig. 2 : Photograph of Replaced mixing point modified to
'Y' joint, DP tested after replacement in 2006
wall thickness loss in the Tee at any location. The external
surface of the cracked 'Tee' was also inspected by dyepenetrant testing (DP test). Surface cracks were noticed near
the leaked location.
Since this was the first incidence of cracking, the original angle
of 90º connection (Tee joint) was changed to 45º connection
('Y' joint) in June'06 turnaround (Fig.2). A reinforcing pad was
provided at the 'Y' joint for strengthening the weld joint. The
original dia. 2” Ô, schedule 40S (3.91mm thickness) pipe at
branch and main header was replaced with higher schedule
pipe, i.e. schedule 80S (5.54 mm thick). Thus by increasing the
weld area in a 45º connection along with reinforcement pad
than a 90º connection, the thermal stresses were minimized.
Welding of SS304 pipe and RF pad was carried out after joint
preparation with E-308 electrode. After completing the
replacement job of the failed 'Tee' joint with a 45o 'Y' joint, final
Fig. 3 : Photograph of Leaking portion of the mixing
'Y' joint at RF pad weld joint in 2008
DP-testing of the reinforcement (RF) pad weld joint and
radiographic inspection of butt joints (4 nos) was carried out.
The condition was found satisfactory. As an improve-ment in
the design it was recommended to change this welded 'Y' joint
at the mixing point, with a dia. 2” Ô, schedule 160 (8.74mm
thick), SS304 latrolet in the next opportunity. This forged
latrolet will reduce the stress concentration produced at the
mixing 'Y' joint.
In July 2008, the mixing 'Y' joint failed once again after staying
in operation for approximately 2 years. This time the leak was
noticed from the weld joint of reinforcement pad to the 2” dia
pipe in the hot and cold mixing point (see Figs. 3 & 4).
Thickness survey of the portion in and around the cracked
location did not reveal any corrosion/ metal loss.
As the recommended latrolet was not available, the cracked
Fig. 4 :Photograph of Hot & cold condensate mixing
Tee point after insulation removal
mixing 'Y' joint was replaced with an available equal Tee of dia.
65
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
2”, schedule 160 (8.72 mm thick)
(American
confirming to SS 304 material. The butt
committee reports and API standards
petroleum
institute)
joints were carried out to ensure weld
soundness.
welds (3 nos) were inspected using
were surveyed. Based on this an
radiography
found
"injection Quill" was recommended for
satisfactory. An RF pad was provided at
installation at the mixing point in Dec
3.0 DISCUSSION AND ANALYSIS
the 'Tee' portion for strengthening. The
2008. The design details of the quill
From the chronological sequence of
RF pad welding was DP tested, no
were worked out and the engineering
failures mentioned above, it is very clear
significant indications were observed.
design was approved through our
that the problematic zone is the mixing
and
were
The replaced failed 'Y' mixing joint was
engineering department in 2009.
Tee/'Y' point only. No leakages or
inspected using a remote visual
In Aug-2010 the unit was shut down for
failures were noticed in the straight pipe
inspection video scope (RVI) to see the
maintenance purpose. Seeing the
or elbows in either of the hot or cold
condition of the inner surface of the
criticality of this mixing point, weld joints
condensate circuit. This also confirms
pipe/'Y' weld joint. Multiple surface
and adjacent one feet region on all the
that there is no corrosion/failure
cracks were noticed in the weld joint
three sides of the Tee portion was
mechanism operating from process side
between the main header and branch
inspected by dye-penetrant test and
i.e from the condensate flowing inside
ultrasonic flaw detection (UFD). Linear
these pipes.
pipe ('Y' joint) and also on the pipe
surface upstream and down stream of
indications
were
In the first instance of failure i.e May
the flow direction. (See Figs. 5 & 6).
observed on the inner surface at the
2006 the hot condensate was entering
These cracks were both linear and
'Tee' point at reinforcement pad location
the cold condensate pipe at 90o (Tee
branched cracks.
The second time failure implies that the
'Y' joint design was not sufficient to
accommodate the thermal stresses
generated at the mixing point. This
mixing point was identified as "critical
injection point" for close monitoring
during operation and maintenance
shutdowns. For a permanent solution to
this
chronic
cracking
problem,
experiences of other refineries, API
(micro
cracks)
and inner pipe surface downstream of
configuration at the mixing point).
flow direction. As the 'Quill' was not
Therefore the hot condensate at 160oC
available, this 'Tee' joint was replaced
was directly impinging the cold
with SS304 schedule 160 pipe without
condensate pipe wall opposite to the
reinforcement pad. It was realized that
flow direction. A hot spot was formed at
the reinforcement pad was also adding
this localized impingement spot where
to the stress concentration instead of
the temperatures experienced were in
acting as strengthening to the 'Y'/Tee
the order of 120 -160o C. This caused
weld joint. Welding was carried out
localized thermal stresses causing
using E 308 electrode. D.P. testing of
leakage over a period of time. It was
'Tee' joint and radiography of butt weld
thought that changing the 90o flow to an
HOT CONDENSATE FROM
V-07 AT 160OC
COLD CONDENSATE
FROM V-08 AT 40OC
Fig. 5 : Photograph of Cracks noticed using remote visual
inspection (RVI) instrument on the inner pipe surface
at the mixing Tee location
Fig. 6 : Sketch showing portion cracked by thermal fatigue
66
Mahendra Pal - Root Cause Analysis of Failure in Hot and Cold Mix Point ................ (HGU) due to Thermal Fatigue Phenomenon
angular flow (45o to the cold condensate
coming from V-07 vessel at 160oC meet
inspection code. As per the survey
line) would eliminate the problem as
at the mixing point where differential
conducted by NACE, “NACE Inter-
there will be uniform mixing after the
thermal expansion is experienced due to
national publication 34101” majority of
design change. Also the weld area in a
this temperature difference of 120oC.
problems experienced in injection points
45o joint being greater than 90o would
The calculated differential expansion is
were associated
distribute the stresses over this area
of the order of 2 mm in 1metre length of
injection points followed by
thereby reducing the overall stress. An
the pipe. As the unit is in continuous
mixing points and the least with process
with wash water
process
additional RF pad was provided to
operation, this Tee/Y mixing joint is
chemical
further strengthen the 45o 'Y' joint.
subjected to continuous thermal cycling.
commonly faced problems at injection
However, in July 2008, leakage occurred
o
once again in this modified 45 design,
this time from the RF pad weld joint.
This indicates that the above design was
not adequate to handle the thermal
stresses generated at the mixing point.
It was also understood that the RF pad
was actually increasing the thermal
injection
points.
The
Thermal stresses are generated at this
points are localized corrosion, erosion,
mixing joint due to the hindered
SCC, thermal fatigue, mechanical
expansion of the pipe causing crack
rupture due to pressure surge/
generation. These cracks were noticed
vibration.
primarily at the weld joint between the
cold and hot line and in the inner surface
of the pipeline downstream of the flow
direction, as shown in Fig. 6.
The remedial measures taken to combat
the failure of injection points were:(a)
upgrading the material of construction,
(b) increasing inspection frequency, (c)
stress by acting as stress raiser point.
The 'Tee' weld joint and RF pad is a
upgrading the injection type i.e
The extensive surface cracks observed
stress raiser and the cracks were
providing an “quill” , (d) process change,
in the failed sample inner surface by RVI
initiated easily at the toe of the weld
(e) piping configuration change. Of the
instrument indicates that the expansion
causing leakage from this point. This
above measures the most popular ones
of the inner surface seeing high
crack had further propagated to the
are (a) and (c). Both these methods
temperatures of the order of 120-160 o C
main pipe also due to the thermal
have given successful results .Therefore
is being restricted in the longitudinal and
cycling. Therefore the combined effect
it was decided to go for a injection quill
thickness direction by the adjacent
of thermal cycling and stress caused
as it was tested at other locations will
metal
thermal fatigue of the mixing Tee joint
great success. The design of the quill
pipe
experiencing
lower
temperatures. The RF pad is further
leading to its failure. As per API RP 571,
was based on good engineering practice
restricting this free expansion and
section 4.2.9, cracking is suspected
with provision of an SS304 inner liner
increasing the thermal stresses.
when the temperature swing exceeds
and retainer rings as shown in Fig. 7.
o
Because of the small size of pipe line
(dia. 2") there was no benefit in changing the design from 90o 'Tee' to 45o 'Y'
o
about 200 F (93 C). In this case also the
The inner liner prevents direct contact
temperature swings are of the order of
of the hot fluid with the surface of the
120 oC.
pipe carrying cold fluid thereby
preventing thermal stresses. Inspe-
joint as there was no cushion w.r.t to
fluid volume once the hot fluid entered
4.0 CONCLUSION AND
the pipe carrying cold fluid to reduce the
RECOMMENDATIONS
ction, maintenance and repair of this
quill will be easy after its installation as it
can be easily dismantled. This will save
temperature of the mixed stream near
Refinery injection points are classified
the opposite pipe wall surface. It is to be
primarily into 3 types namely: a) Process
noted that fluid velocities of the hot and
chemical injection. eg. injection of
cold condensate streams are 0.33 m/s,
corrosion inhibitor in column overhead
Inspections of injection points shall be
0.42 m/s respectively with flow of 2.44
(b) Wash water injection; eg. to dissolve
carried out in accordance with API-570.
m3/hr and 3.09 m3/hr respectively. Had
salt deposits and wash out or dilute
Although process-mixing points do not
the cold pipe size been large say 4" or
time during shutdown and also increase
the unit run length.
corrosive components and (c) Process
fall under the ambit of API-570, still it
above then this modification would have
mixing point which in our case falls
shall be followed for inspection purpose
been successful.
under the category of process mixing
as it is very comprehensive. As per API-
The cold condensate coming from V-08
point. These are also referred to as
570, injection piping circuit covers 12”
vessel at 40o C and the hot condensate
“mixing Tee” in API 570 piping
length or 3D (3 times the nominal pipe
diameter) whichever is greater, in
67
INDIAN WELDING JOURNAL Volume 45 No. 1 January 2012
upstream direction from the injection
point, and upto a point downstream
from the injection point ending two
changes in flow direction or 25 ft (7.6 m)
beyond the first change of direction,
whichever is less.
REFERENCES
1. NACE International Publication
34101: Refinery injection and
process mixing points, NACE
international
2.) API 570-Piping Inspection code :
Inspection, Repair, Alteration and
Rerating of In-service piping system.
Second edition, Oct 1998, American
petroleum institute.
3. API
571-Damage
mechanism
Fig. 7: Sketch of Proposed “QUILL” design for hot and cold mixing point
affecting fixed equipment in refining
industry. First edition, Dec 2003,
Notes: -
American petroleum institute.
1. Both the liners may have perforations of 10 mm dia for reducing the thermal gradient on the
pipe.
4. Corrosion Manual, M&I Dept, Indian
Oil Corporation Ltd.
2. Length of the liner will be approx. 1000 mm with branch connection around 300 mm from the
inlet side to maintain the same velocities. The OD at inlet will be maintained as 2” and main
header dia will be increased to 3” to create annular space for minimizing thermal stresses.
LIST OF ADVERTISERS IN INDIAN WELDING JOURNAL
January 2012, VOL. 45, No. 1
1.
Ador Fontech Ltd.
13.
Koike Sanso Kogyo Co. Ltd.
2.
Ador Welding Ltd.
14.
Mailam India Ltd.
3.
Automation India Welding Technology
15.
MEMCO
4.
Bohler Welding Group
16.
Nederman India Pvt. Ltd.
5.
Cotmac Industrial Tdg. Pvt. Ltd.
17.
Orbitz Tours and Travels
6.
D & H Secheron
18.
Satkul Enterprises Ltd.
7.
Devidayal Chemical Inds. Pvt. Ltd.
19.
Spatter Cure Enterprises
8.
Don Bosco Maritime Academy
20.
Special Metals
9.
ESAB India Limited
21.
Sur Iron & Steel Co.
10.
Electronics Devices
22.
V Weld Equipment
11.
FSH Welding
23.
Weldwell Speciality Pvt. Ltd.
12.
GEE Limited
24.
Weldman Synergic Pvt. Ltd.
68