Our Client : M/s. RESULTS ENGINEERING PVT. LTD.

Chennai, Tamilnadu

Project : Integrated Development Services

for
The MBA Field RJ - 0N - 90 / 1 BLOCK

Document Title : BUTT WELD TEMPERATURE PROFILE ESTIMATION

Document No. : CAL – FPC – RE - 001

Revision Number : R0

Issue Date : Jan 2019

FOCUS PROJECTS AND CONSULTANTS

No. 54, Bajanai Koil Street, Sulochana Nagar, Mowlivakkam,
Chennai – 600 122. Tamilnadu. INDIA. www.focusengg.in
Email: vmani@focusengg.in | focusvelpandian@gmail.com | Mob. No.: +91 99404 32155

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 CONTENTS

1.0 INTRODUCTION: .................................................................................................................................................. 3

2.0 OBJECTIVE: ........................................................................................................................................................... 3
3.0 REFERENCE DOCUMENTS:.............................................................................................................................. 3
4.0 DETAILED CALCULATION & RESULTS INTERPRETATION:...................................................................... 4
4.1 INPUTS CONSIDERED: ........................................................................................................................ 4

4.2 CALCULATION: ......................................................................................................................................... 5

4.3 OUTPUT: .................................................................................................................................................. 15

4.4 RESULTS INTERPRETATION: ............................................................................................................ 15

5.0 APPENDICES: ..................................................................................................................................................... 16

5.1 WELD PARAMETERS ........................................................................................................................................ 17

Page 2 of 18
1.0 INTRODUCTION:

RESULTS ENGINEERING is planning to weld an internally and externally anti-corrosive coated pipeline
of size NB 12“ (OD 323.8 mm), Thickness 9.53 mm (Sch. Std) Pipe of Specification API 5l Gr. X65 using
Shielded Metal Arc Welding (SMAW) technique. Before burying this pipeline, it is anti-corrosion coated
internally using Fusion Bond Epoxy (FBE) Material and anti-corrosion coated externally and also
cathodically protected.

During welding, the Pipe material at the Heat Affected Zone (HAZ) is expected to be exposed to very
high temperature over 1,000°C. FBE can withstand a maximum temperature of 95°C only. Also after
welding it is possible to provide anti-corrosion coating on the external part of HAZ on the Pipeline before
burying. But it seems it is not possible to provide Anti-corrosion coating in the internal part due to human
or equipment inaccessibility (Smaller size of ID, Etc.). Hence it is judicial to provide the anti-corrosive
coating only on the non-Heat Affected Zone internally.

2.0 OBJECTIVE:

The objective of this study and calculation is to estimate the Temperature profile along the longitudinal
axis of the Pipeline from the Weld Point (even though the heat transfer would be uniform at all 360° at all
mutually perpendicular directions for the same Pipe material), so that the application of Anti-corrosion
coating can be stopped upto the point where the Pipe Material faces 90°C and less. Manual and Finite
Element Analysis methods will be employed to estimate the same.

3.0 REFERENCE DOCUMENTS:

S. Rev.
Document title Document no
No No.
1 Pipeline Overall Route Plan for Aishwariya Field. A303HAL–AISH–Y-DWG – 2002- 01 C1

Pipeline Alignment Sheet for 12” Mother Solution Pipeline

2 A303HAL–AISH–Y- DWG–2003-02 C1
from MCPF to well Pad - 06

3 Specification for field joint coating of line pipes CAIRN–TSG–Y–SP-0014 B1

Fusion Bond Epoxy Powder Coating for Internal Surface of
4 CAIRN–TSG–Y–SP-0027 A2
Carbon Steel Water Pipeline
THRU-KOTE Connection UBI4
5. Insert Sleeve with Backing Ring for U.B. Pipe OD 12 3050 – 621252 - 0312 -
3/4"x0,375 STD/SCH ID TOL.Accord. to API 5L

6. Thermal Insulation (PUF) Specification for Pipelines H214MMP RX -Y–SP-0022 B1

Pipeline Station Approach Drawing for Mangala Central

7. A303HAL–AISH–Y–DWG–2006-01 C1
Polymer Facility
Pipeline Station Approach Drawing for Mangala Central
8. A303HAL–AISH–Y–DWG–2006-02 C1
Polymer Facility
9. Specification for external coating of line pipes CAIRN-TSG –Y–SP-0013 B1

10. Record of Welder Approval Test G300HAL-RX–Q–IR–5028-1 A2

Page 3 of 18
4.0 DETAILED CALCULATION & RESULTS INTERPRETATION:

4.1 INPUTS CONSIDERED:

S.
Item Description Data
No.
1. Pipe Nominal Size, NB 300 mm (12”)
2. Pipe Outside Diameter 323.8 mm
3. Pipe Wall Thickness 9.53 mm (Sch. STD)
4. Pipe Material API 5l Gr. X65
5. Welding Method Employed SHIELDED METAL ARC WELDING
6. Edge Preparation ASME B16.25
7. Heat Input 52.74 to 60.61 KJ/ Inch
Maximum Allowable Exposure
8. 95°C
Temperature for FBE
9. Weld Speed 3.14 Inch / Minute
10. Pre-Heat Temperature 50°C
11. Inter-pass Temperature 50°C
12. Current,(A) 122 Amp
13. Volt,(V) 26 Volt
14. Arc Efficiency 1.0

Page 4 of 18
4.2 CALCULATION:

a. Peak Temperature Calculation:

Courtesy: http://www-it.jwes.or.jp/weld_simulator/en/cal2.jsp

From the above graph we interpret the Peak Temperature for the worst situation as

1500° C.

Page 5 of 18
b. Finite Element Thermal Analysis:

1. Results for peak Temperature = 2,000 ° C:

 Temp After 10 Sec- More than 60 °C shown as Red colour

 Temp After 20 Sec- More than 60 °C shown as Red colour

Page 6 of 18
 Temp After 30 Sec- More than 60° C shown as Red colour

 Temp After 60 Sec- Max Temperature = 47.23 °C only

Page 7 of 18
Page 8 of 18
2. Results for 1,800 ° C:

 Temp After 10 Sec- More than 60 °C shown as Red colour

 Temp After 20 Sec- More than 60 °C shown as Red colour

Page 9 of 18
 Temp After 30 Sec- More than 60 °C shown as Red colour

 Temp After 60 Sec- Max Temperature = 45.57 °C only

Page 10 of 18
Page 11 of 18
3. Results for 1600 °C:

 Temp After 10 Sec- More than 60 °C shown as Red colour

 Temp After 20 Sec- More than 60 °C shown as Red colour

Page 12 of 18
 Temp After 30 Sec- More than 60 °C shown as Red colour

 Temp After 60 Sec- Max Temperature = 43.73 °C only

Page 13 of 18
Page 14 of 18
4.3 OUTPUT:

Temperature w.r.t Distance tabulated below for various peak weld temperature

Distance in Temperature, ° C
No
mm 2,000 1,800 1,600
1 5 390.1 353.5 316.95
2 10 216.77 197.81 178.84
3 15 135.51 124.8 114.09
4 20 95.05 88.45 81.84
5 25 73.18 68.8 64.41
6 30 60.32 57.25 54.17
7 35 52.26 50 47.74
8 40 46.91 45.19 43.48
9 45 43.21 41.87 40.52
10 50 40.54 39.47 38.4
11 55 38.57 37.7 36.83
12 60 37.08 36.36 35.64
13 65 35.92 35.32 34.72
14 70 35.01 34.5 33.99
15 75 34.27 33.84 33.41
16 80 33.64 33.27 32.9
17 85 33.07 32.76 32.45
18 90 32.56 32.3 32.04
19 95 32.11 31.89 31.68
20 100 31.72 31.54 31.37

4.4 RESULTS INTERPRETATION:

From the above calculation results we infer that for a peak temperature of 1600° C the metal
temperature at 25 mm from the weld point is lesser than 95° C.

Hence FBE coating can be applied 25 mm measured from the Weld point.

Page 15 of 18
5.0 APPENDICES:

Page 16 of 18
5.1 WELD PARAMETERS

Page 17 of 18
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