BASF 巴斯夫：

SPEC上未区分FCAW-S和FCAW-G

Gas shielded metal arc welding (GMAW) and fluxed core arc welding (FCAW) shall not be permitted for one-sided welded root layers of pressure-containing butt welds since they are prone to lack-of-fusion defects which are difficult to detect by conventional inspection methods. An exception to this would be the use of a mechanized welding process and when the lack of fusion can be detected definitely by an appropriate non destructive (NDE) method.

ExxonMobil美孚： 按API582

API 582要求

FCAW-S只能受限用于一些碳素钢结构件的焊接；

FCAW-G可以用于受压件或结构件的坡口焊缝或角焊缝焊接；

Shell壳牌：除API 582以外，额外增补的要求（DEP 30.10.60.18-Gen）

除了要满足API 582以外，壳牌DEP文件进一步限制了FCAW-S的适用范围，并对FCAW-G提出了额外的增补要求；

Add the following to 5.2.5:

Shops that will perform FCAW shall be approved individually, based on merits, experience and track record with FCAW.

Add the following to 5.2.5.1: 针对FCAW-S

Additionally, FCAW-S shall not be used for welding structural items to a pressure/containment boundary. It is not permitted for lifting lugs or similar lifting devices, or tank floor plates.

Add the following to 5.2.5.1(b): 针对FCAW-S

The electrode specified minimum impact requirements must be demonstrated by testing in the PQR.

Add new 5.2.5.6

a) Production welding consumables shall be limited to the same manufacturer brand/trade name as used in the procedure qualification record. The fabricator QC process shall demonstrate how welding consumables are controlled.

· Electrode types identified by the consumable Manufacturer for multipass application should be used.

· Electrodes of type T12 or T5 are preferred. T1 electrodes are acceptable, but only if required impact properties can be demonstrated. A maximum niobium (Nb) content of 0.02 % shall be specified (and reported) in consumable purchases when a T1 type electrode is selected to avoid low toughness properties.

· Type EXXTXXJ electrodes should be specified if the application specifies a toughness requirement 27 J (20 ftlbs) at 40 °C (40 °F).

b) For ferritic steels, all WPS/PQRs shall be qualified with impact testing. Impact testing of a minimum of three Charpy Vnotch specimens will be performed at 18 °C (0 °F) or lower or code required temperature for testing, whichever is lower, and must demonstrate an average impact energy of 40 J (30 ftlb), with no single specimen less than 27 J (20 ftlb).

c) For ferritic steels in nonsour service, in addition to code requirements the WPS/PQRs shall be qualified with a hardness traverse per API RP 582, paragraph 12.6 using Vickers hardness testing equipment (ASTM E92). The maximum permissible hardness for procedure qualification of P1 steels will be 275 HV10. For sour service, NACE MR0103 or ISO 15156 hardness requirements will apply. Other traverses may be submitted for consideration by the Principal.

d) Welder qualification – Each welder is to be qualified by mechanical testing. Mechanical testing shall also include Brinell hardness testing on each side of the welded coupon (root and cap surface) with an acceptance value of 200 HBW. Hardness results will not be accounted to pass/fail a welder but only to add data points on FCAW hardness. The Principal shall be informed if any hardness reading is greater than 200 HBW. Radiographic testing of welder coupons or production welds shall not be used in lieu of mechanical bending tests of coupons.

e) Production welding – Required hardness testing: For the FCAW process, the hardness limit for the carbon steel welds is 200 HBW. Weld metal hardness testing (HBW with Telebrineller) will be performed on the 0.5 m (1.5 ft) of the first five welds made by each welder. Welders with (excessive hardness) rejection rates higher than 2 welds should have additional training before continuing production welding. Also, the quality of the electrode and shielding gas should be reviewed. After satisfying this first testing requirement, random hardness readings will be taken on the remaining welds (measurements are done at least on 20 % of girth welds on piping or one measurement per seam on pressure vessels category A and B welds, spaced no more than 6 m (20 ft) apart). Welders with (excessive hardness) rejection rates higher than 10 % based on 20 readings (minimum) should have additional training before continuing production welding. Only one welder per section of weld seam may be tested. Production hardness testing of P8 base metal welds is not required.

f) The work area shall be shielded from excessive crosswind ventilation.

g) No vertical down progression is allowed.

h) FCAW is not permitted on root pass, except when root weld is back-gouged.

i) The use of short circuit transfer mode is not permitted.

j) FCAW wire shall be stored in a dry location while still in the original package according to the following table:

Ambient Temperature °C (°F)

Maximum relative humidity (%)

15-21 (60-70)

80

21-27 (70-80)

60

27-32 (80-90)

45

32-38 (90-100)

30

Only new FCAW coils in the original, undamaged packaging can be used for pressure retaining weld welding. The electrodes should be used within a shift after opening the package. Upon opening the spool, it should be marked with the date by when it should be spent or discarded. All wires having diffusible hydrogen “H” rating shall be treated in strict conformance with the Manufacturer’s instructions. Opened electrode mounted on wire feeders should be protected against condensation. Oxidised electrodes shall be discarded.

k) FCAW wire shall be clearly identified. The identification shall be in compliance with the relevant consumable standard. Unidentified or rusty wire shall not be used.

l) FCAW welds shall be subjected to NDE examination in accordance with the P.O. specifications/Construction Class rating of a given equipment. Absolute minimum NDE coverage of FCAWG pressure retaining welds shall correspond to the ASME/BPVC Sec VIII “spot RT” rules unless higher/more intensive examination is specified in the P.O. documents in which case such a specification shall govern.

m) When FCAWG is proposed for welding P1 through P5 and P15 materials on equipment with design temperatures over 350 °C (650 °F) or below 29 °C (20 °F), and when required by the Principal, special submission of evidence demonstrating prior experience and documented performance is required prior to acceptance by the Purchaser. This experience should include a list of past projects and number of completed welds and corresponding rejection rates.

n) Seamed fluxcored wires shall not be left on machines out of use for more than a shift.

BP：

文件未看到有针对FCAW焊接方法的限制或增补要求

COVESTRO科思创：（GP/ME 001e）

需要有外部保护气的FCAW（即FCAW-G），但针对不同材料的保护气要求不同

FLUOR福禄/SASOL萨索/UOP

只能使用FCAW-G

TECHNIP 德希尼布

只能使用FCAW-G

KBR（4-7TS）

FCAW-S只能焊接一些非重要的焊缝

3.5 Flux Cored Arc Welding (FCAW)

3.5.1 The use and application of FCAW shall be subject to the Purchaser's approval.

3.5.2 Flux cored arc welding without external shielding gas(FCAW-S) may only be used for welding non-pressure containing parts and non-pressure containing attachments to pressure containing parts.

3.5.3 When impact tests are required, procedure qualification impact tests shall be performed for each manufacturer and brand designation to be used for production welding.

3.5.4 The FCAW process shall not be used for root passes unless the backside of the root is ground or back gouged to sound metal and back welded.

TOYO Engineering东洋工程

FCAW-S禁止使用

文件1的要求：

Part II - API 582 Paragraph 5.2.5.1 – FCAW：

FCAW is not allowed for the following services and materials:

-When impact testing and PWHT are required either per code or contractual specifications,

- For low alloy steels and duplex stainless steel,

- Stainless steel exceeding 20 mm thickness.

文件2的要求：

13.7.1 Vendor shall submit a request for approval in writing at bid clarification stage, if it applies FCAW process to the following welds:

- Any weld between pressure retaining parts (It shall include welds of vacuum stiffening ring and reinforcement pad for opening.)

- Weld of non-pressure retaining part to pressure part, or between non-pressure retaining parts, which is subject to heavy load, such as head-to-skirt junction, pad attachment for support saddle / lug, lifting lug, trunnion, tailing lug, etc.

To adopt FCAW process for them, all of the following conditions shall be satisfied, in addition to the requirements of the applicable Code, Standard or Project specifications.

General requirements:

(1) FCAW shall be carried out under a roof and/or shelter for protecting against wind/rain.

(2) Shielding gas shall be CO2 or Ar+CO2. Self-shielded type shall not be used.

(3) Brand name of welding material on WPS shall be the same as that specified on PQR.

(4) FCAW shall not be applied to root pass of single-welded joints.

(5) Production impact test shall be performed per each WPS. The test shall be done for the weld of the largest thickness and in accordance with the applicable Code requirements for the production test.

Welding of carbon steel:

FCAW may be applied to carbon steel welding with all of the following conditions.

(1) The conditions specified in general requirements

(2) Carbon steel categorized in P No. 1 Group No. 1 or 2

(3) Not sour survive

(4) MDMT is -10 deg. C or higher (Note 1)

(5) Welding thickness “t” is 38 mm and less. (Note 2)

Note 1 When MDMT is less than -10 deg. C and up to -45 deg. C (inclusive), the following conditions shall also be satisfied.

(i) Weld consumable having guaranteed impact toughness at -45 deg. C or less, and shall be approved by Purchaser.

(ii) Vendor shall have enough experience to use the proposed weld consumable.

(iii) Charpy impact value (average and minimum value) on PQR shall be at least two times of Code-required value. If impact test results on PQR do not satisfy this requirement, Vendor shall carry out WPQT in order to meet it.

Note 2 When welding thickness “t” is over 38 mm and up to 50 mm (inclusive), the following conditions shall also be satisfied.

(i) Weld consumable having guaranteed impact toughness at -18 deg. C or less, and shall be approved by Purchaser.

(ii) Vendor shall have enough experience to use the proposed weld consumable for equipment having the subjected thickness and over.

(iii) Charpy impact value (average and minimum value) on PQR shall be at least two times of Code-required value. If impact test results on PQR do not satisfy this requirement, Vendor shall carry out WPQT in order to meet it.

(iv) Test pieces of PQR shall show no crack with 100% MT, 100% RT and 100%UT. If such test results are not available on PQR, Vendor shall carry out WPQT in order to meet it.

Welding of austenitic stainless steel:

FCAW may be applied to austenitic stainless steel with all of the following conditions.

(1) The conditions specified in general requirements

(2) Austenitic stainless steel categorized in P No. 8 group No. 1

(3) Operating temperature and temperature of heat treatment during fabrication shall be less than 550 deg. C.

(Note 1)

Note 1 When the temperature is 550 deg. C and over, the following conditions shall also be satisfied.

(i) Bi content of welding material shall be less than 0.001 %.

(ii) Vendor shall have enough experience to use the proposed weld consumable.

Welding of Cr-Mo steel：FCAW shall not be used.

Welding of other materials：FCAW shall not be used

UOP

The Flux Cored Arc Welding (FCAW) process shall utilize an external shielding gas and is not permitted for the root pass of joints made from one side. FCAW may be used for the root pass of joints made from both sides only if it is completely removed prior to welding from the reverse side.

只能用FCAW-G，且不能用于单面焊的打底焊，可以用于双面焊且背面清根的打底焊。

(注：UOP通用的焊接文件UOPP-400-00-ST未找到，请大家补充)

DOW

文件未看到有针对FCAW焊接方法的限制或增补要求