PIPING SPOOL
Piping Spool Fabrication by Computerized Automatic Welding

General Information

Position: 1G
Speed: 2~12mm/sec
1st Layer by GTAW / 2nd and over Layer by FCAW
Range of diameter: 2~52"
Range of thickness: Max. 70mm
Material
Carbon Steel / Stainless Steel / Low-Alloy Steel
Nickel Alloy / Titanium and etc.
Advantages

Automatic Welding

Welding time for 14"
19min
defect
1% below
Productivity : 30 Dia.Inch/hour

Hand-operated Welding

Welding time for 14"
66min
defect
3-5% below
Productivity : 6 Dia.Inch/hour
Welding Operator
Two(2) Months Training Period
Productivity and quality is stable regardless skill of welders
Size of piping : Min. 2”~ Max. 52”
Welder
Required at least 3 Years Experience
Productivity and quality depends on skill of welders
Size of piping : No Limit

Productivity Analysis


Size SettingTime Automatic Welding Manual Welding
Welding Time Finish Time Total Required Time Daily AVG. Welding Welding Time Finish Time Total Required Time Daily AVG. Welding
2"~3" 2M 30S 5M 2M 9M 30S 130" 20M 3M 23M 42"
4"~8" 3M 7M 2M 12M 200" 35M 4M 39M 50"
10"~14" 4M 13M 2M 19M 200" 60M 6M 66M 50"
16"~20" 7M 30M 3M 40M 190" 3H 30M 10M 3H 40M 44"
Productivity of Automatic Welding System is about three (3) times higher than manual welding

Quality Analysis (Radiographic Test Result Trend for 3 Months)


Section M1 M2 M3 Total
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
Reject Rate 0% 1.2% 0% 0.3% 0.3% 1.1% 1.4% 0.5% 0% 0.8% 0.5% 0.6% 0.53%
Reject Sheets 0 2 0 2 2 4 6 2 0 2 1 3 24
Shooting Sheets 6 168 609 764 612 376 425 366 235 234 207 445 4457

Welding Process


Section Welding Process Welding Position Welding Rod Range
Automatic Welding
Root Pass GMAW
- Mixed Gas (Ar+CO2)
- Metal Active Gas
1G Roll - Solid Wire
ER70S-6 (Spoolarc86)
- Φ0.9, Φ1.2
2" ~ 52"
Second and
Over Layer
FCAW
- Mixed Gas (Ar+CO2)
- Flux
- Metal Active Gas
1G Flux Cored Wire
E71T-9M (D.S7100SM)
- Φ1.2, Φ1.6
2" ~ 52"
Manual Welding
Normal Work
for Piping
Spool
Fabrication
GTAW All Position Solid TIG Wire
* ER70S-6
- Φ2.4, Φ3.2
BOSS and under 2"
SMAW All Position E7016 - Φ 2.6, Φ3.2, Φ4.0 No Limit
FCAW All Position Structure and Etc.