WELDING BOOK

For Stop-Log Works

Conveyor 800
 TABLE OF CONTENTS

1. Introduction .............................................................................................................................................................. 3
2. Scope and Purpose of Method Statement................................................................................................................ 3
3. References ................................................................................................................................................................ 3
4. Base Metals ............................................................................................................................................................... 3
5. Filler Metals............................................................................................................................................................... 3
5.1 Generalities ....................................................................................................................................................... 3
5.2 Products Designation ........................................................................................................................................ 3
6. Preparation of Base Metal ........................................................................................................................................ 4
7. Welding Map ............................................................................................................................................................. 4
8. Welding Procedure Specification .............................................................................................................................. 5

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1. Introduction

This method statement describes in details the welding processes for the Stop-Log Works of Channel in the Conveyor
800 project including the welding procedure specification.

2. Scope and Purpose of Method Statement

This method statement covers welding and related operations executed by PASS Company for Stop-Log works of
channel in conveyor 800 project in accordance with the project’s standards and specifications.

3. References

 ASME, section IX
 API 1104
 Project Specifications
 Client drawings

4. Base Metals

The base metal of the box beam (with dimensions 200 mm x150 mm x 5 mm) is: S 235 JR Steel.

5. Filler Metals

5.1 Generalities

 All filler metal shall be delivered in sealed containers that do not show evidence of damage and shall be stored
in warm and dry conditions and kept free from oil, grease and other matter once they have been removed from
their containers.
 All precautions will be taken to keep products in stock to protect from moisture.

5.2 Products Designation

 For root pass, we will be using: Electrode E 7018
- Tensile Strength As Welded 540 MPa
- Yield Strength As Welded 445 MPa
- Elongation Percent As Welded 29 %
- Welding current: DC+

 For fill and cap passes, we will be using: flux cored wire FCAW: E81T-Ni1M-JH4
Well established in the offshore sector, E81T-Ni1M-JH4 is alloyed with 0.9% Nickel and produces reliable
Charpy impact properties down to -60°C and CTOD performance to -10°C. The wire exhibits a smooth
stable arc with virtually no spatter.
Welding current: DC+
Typical mech. Properties: As welded FCAW 80%Ar / 20%CO2
Yield stress: 520 MPa
Tensile strength: 610 MPa
Elongation: % 22
Charpy V: Testing Temperature of -60°C: Impact values, 80J

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6. Preparation of Base Metal

The edges or surfaces of parts to be joined by welding shall be prepared by grinding. All surfaces and
edges shall be free from fins, tears, cracks or any other defects which would adversely affect the quality
of the weld.

All moisture, grease or other foreign material that would prevent proper welding or produce objectionable
fumes, shall be removed.
All surfaces to be welded shall be wire brushed prior to welding. In multi-pass welds the weld bead shall
be wire brushed between passes.

7. Welding Map

We will be welding three box beams together as sketched above to form a member. The box beams’
length is 3.2m and they shall be welded from both sides on the whole length of contact.

Then two plates shall be welded onto the box beams edges to close the gaps, as well as two lifting
pads for handling. The plates shall be welded in two stages: First stage, first plate on one side, and
second stage, the other plate on the other side after concrete pouring works are executed inside the
stop logs.

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8. Welding Procedure Specification

WPS NUMBER:1
PQR N°:

Joint type (QW-402):

Butt welding BW of box beam (one plate only)
Base material (QW-403)
Base metal characteristics: S 235 JR
P-No:1 Group N°:1
Preparation method and cleaning: grinding
Metal base thickness: 5 mm
Back welding (gouging, milling): NA

Filler material (QW-404)

Specification N° (SFA): A 5.1 A 5.29
Classification N° AWS: E 7018 E 81T1-Ni1M-JH4
F-N°: 4 6
A-Number: 1 10
Diameter of filler material 3.2 1.2
Flux N/A N/A
Gas (QW-408)
Welding position (QW-405) Flow
Gas Composition
Welding position: 1G / 2G / 3G (l/min)
Progression: Up hill Protection (FCAW) Argon - CO2 Argon 80 % - C02 20 % 18 - 22
Protection (SMAW) NA NA NA
Backing gas NA NA NA
Preheat (QW-406)
Heat Treatment (QW-407)
Preheat temperature: NA
Not Applicable
Interpass temperature:150°C max
Electric Parameter (QW-409): manual SMAW / semi-automatic FCAW
Filler Metal Welding Wire Energy
Current and Intensity Tension
Passes Process Classification Diameter speed speed Transfer
polarity (A) (V)
AWS (mm) (cm/min) (m/min) (KJ/cm)
1 SMAW E 7018 2.5 / 3.2 DC (+ on E) 65 - 140 15 - 20 5-8 NA 18 max
2 FCAW E 81T1-Ni1M-JH4 1.2 DC (+ on F) 220 - 250 22 - 24 14 - 16 7-9 35 max
3 FCAW E 81T1-Ni1M-JH4 1.2 DC (+ on F) 240 - 260 23 - 27 14 - 16 8 - 10 35 max
n FCAW E 81T1-Ni1M-JH4 1.2 DC (+ on F) 240 - 260 23 - 27 14 - 16 8 - 10 35 max
Transfer mode: Short circuit transfer
Technique (QW-410)
String or Weave Bead: Weave Bead
Nozzle size:16 - 20 mm (FCAW)
Initial and interpass cleaning: Brushing or grinding
Method of back gouging: grinding
Oscillation: Yes, only for FCAW
Contact tube to cork distance:10 to 15 mm (only for FCAW)
Multiple or single pass: Single root pass / 2-3 fill and cap passes

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WPS NUMBER: 2 PQR N°:
Joint type (QW-402):
Fillet welding FW of box beam with lifting pad
Base material (QW-403)
Base metal characteristics: S 235 JR
P-No: 1 Group N°: 1
Preparation method and cleaning: grinding
Metal base thickness: 5 mm
Back welding (gouging, milling): NA

Filler material (QW-404)

Specification N° (SFA): A 5.29
Classification N° AWS: E 81T1-Ni1M-JH4
F-N: 6
A-Number: 10
Diameter of filler material 1.2
Flux N/A
Gas (QW-408)
Welding position (QW-405) Debit
Gas Composition
(l/min)
Welding position: 2F / 3F
Progression: Up hill Protection (FCAW) Argon - CO2 Argon 80 % - C02 20 % 18 - 22
Protection (SMAW) NA NA NA
Backing gas NA NA NA
Preheat (QW-406)
Heat Treatment (QW-407)
Preheat temperature: NA
Not Applicable
Interpass temperature: 150°C max
Electric Parameter (QW-409): manual SMAW / semi-automatic FCAW
Filler Metal Welding Wire Energy
Current and Intensity Tension
Passes Process Classification Diameter speed speed Transfer
polarity (A) (V)
AWS (mm) (cm/min) (m/min) (KJ/cm)
1 FCAW E 81T1-Ni1M-JH4 1.2 DC (+ on F) 220 - 250 22 - 24 14 - 16 7-9 35 max
2 FCAW E 81T1-Ni1M-JH4 1.2 DC (+ on F) 220 - 250 22 - 24 14 - 16 7-9 35 max

Transfer mode: Short circuit transfer

Technique (QW-410)
String or Weave Bead: Weave Bead
Nozzle size: 16 - 20 mm (FCAW)
Initial and interpass cleaning: Brushing or grinding
Method of back gouging: grinding
Oscillation: Yes, for FCAW
Contact tube to cork distance: 10 to 15 mm (FCAW)
Multiple or single pass: Multiple for both side

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WPS NUMBER: 3 PQR N°:
Joint type (QW-402):
Fillet welding FW of box beam with plate

Base material (QW-403)

Base metal characteristics: S 235 JR
P-No: 1 Group N°: 1
Preparation method and cleaning: grinding
Metal base thickness: 5 mm
Back welding (gouging, milling): NA

Filler material (QW-404)

Specification N° (SFA): A 5.1
Classification N° AWS: E 7018
F-N°: 4
A-Number: 1
Diameter of filler material 3.2
Flux N/A
Gas (QW-408)
Welding position (QW-405) Flow
Gas Composition
(l/min)
Welding position: 2F / 3F
Progression: Up hill Protection (FCAW) Argon - CO2 Argon 80 % - C02 20 % 18 - 22
Protection (SMAW) NA NA NA
Backing gas NA NA NA
Preheat (QW-406)
Heat Treatment (QW-407)
Preheat temperature: NA
Not Applicable
Interpass temperature: 150°C max
Electric Parameter (QW-409): manual SMAW / semi-automatic FCAW
Filler Metal Welding Wire Energy
Current and Intensity Tension
Passes Process Classification Diameter speed speed Transfer
polarity (A) (V)
AWS (mm) (cm/min) (m/min) (KJ/cm)
1 SMAW E 7018 2.5 / 3.2 DC (+ on E) 65 - 140 15 - 20 5-8 NA 18 max
2 SMAW E 7018 3.2 DC (+ on E) 100 - 140 15 - 20 6-8 NA 18 max

Transfer mode: Short circuit transfer

Technique (QW-410)
String or Weave Bead: String Bead
Nozzle size: NA
Initial and interpass cleaning: Brushing or grinding
Method of back gouging: grinding
Oscillation: Yes
Contact tube to cork distance: NA
Multiple or single pass: Multiple for both side