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RETAINED FOR INFORMATION UNTIL ALL PROJECT

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 SITE WELDING INSTRUCTION SHEET (SWIS) HANDBOOK
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THIS DOCUMENT IF PRINTED IS UNCONTROLLED AND FOR REFERENCE PURPOSES ONLY

SITE WELDING INSTRUCTION SHEET (SWIS)

HANDBOOK

November 2008

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GENERAL RULES FOR STRUCTURAL WELDING

This document outlines the general welding practice to be employed on jacket and module
structures. Currently this applies to all welding conducted in accordance with SWIS01 &
SWIS02. No deviation to these instructions is permitted unless specifically authorised by the
Welding Engineer.

1. GENERAL
1.1 Before starting welding, each welder should ensure that they have all necessary equipment,
including the correct SWIS card, consumables, temperature indicating crayons (Tempilsticks),
and a paint marker.
1.2 The values of Tempilstick required will vary according to the thickness of the material being
welded but as a minimum should include a 250°C (to monitor interpass temperature) and the
desired minimum preheat temperature (if 50°C or higher).
1.3 All butt welds should be welded from both sides unless otherwise directed.
1.4 Preheat temperature for gouging should be the same as the original weld requirement.

2. CONSUMABLES
2.1 The required consumables are shown on the appropriate SWIS card or WPS.
2.2 When using VacPac electrodes, the welders number and day of issue should be clearly marked
on the packet. Any partly used Vacpacs should be returned to the stores or consumable cabinet
return area.
2.3 Platers working in the vicinity of welders may request electrodes for tacking purposes. A plater is
permitted to retain a maximum of six electrodes at a time.
2.4 Any problems with consumables should be reported to the welding supervisor.

3. PREPARATION
3.1 The area to be welded +25mm either side should be free from scale, grease, or other foreign
material which could interfere with the welding process being used. Welding directly onto
approved weldable primer is permitted.
3.2 Primary steel joints need to be visually checked for fit-up prior to welding. Acceptable fit-up is
indicated by a blue triangle; do not weld if this triangle is missing.
3.3 The general tolerances for weld fit-up are as follows...

a. Butt Welds made from one side only without backing strip :- Root Gap 3-5mm, Root Face 1-2mm
Included Angle 40°min/60°max.
b. Butt Welds made from two sides :- Root gap 0-6mm, Root Face 0-4mm, Included Angle
40°min/60°max.
c. Fillet Welds should be set up with minimal gap. Gaps in excess of 0.5mm require the leg length
to be increased by the same amount as the overall gap. If the gap exceeds 2mm then the
preheat should be increased by a further 50°C
d. TKY connections may have an included angle less than 40°.
e. Single-sided welds made on top of a backing strip :- Root gap 6-10mm, Root Face 0.5-1.5mm.
f. Single sided closure butt weld root gaps of 12mm maximum up to 150mm in length may be
tolerated but should be avoided.

Do not attempt to weld any joint exceeding these tolerances - contact your supervisor or inspector
for advice on remedial action.

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4. PREHEATING
4.1 The relevant SWIS card includes a table of required preheat temperatures versus combined
thickness.
4.2 When the required preheat temperature is 50°C or above then the joint requires preheating.
Electrical resistance mats should be used for weld lengths over 300mm (1 foot). Shorter welds
may be preheated with a propane gas torch.
4.3 Welds that require preheat below 50°C need not be preheated under normal ambient conditions.
However, it is advisable to remove the chill in the plate with propane gas heating if the steel is
particularly cold (eg. when there has been overnight frost). This is mandatory if the steel
temperature is below 5°C or if the steel appears damp.
4.4 Where access is limited to one side of the joint, do not measure the preheat until the steel
temperature has been allowed to equalise. This takes 2min per 25mm thickness. If access to
both sides is possible, then the measurement should take place on the opposite side to that
heated and a mandatory equalisation delay is not required.
4.5 Preheat temperatures should be measured 75mm (3") away from the joint.
4.6 Check the (interpass) temperature immediately next to the joint or in the weld bevel before
starting each pass; if over 250°C then wait until the temperature has fallen before continuing.
4.7 If preheat of 50°C or higher is required then the weld may not be interrupted until one third of the
joint (or 15mm, whichever is greater) is completed, unless the preheat is maintained throughout
the interruption. If the temperature should fall below the required preheat level, satisfactory MPI
must be conducted before heating to the required preheat level and continuing.

5. WELD REPAIRS
5.1 Make sure the repair area is clearly marked and you are aware of the depth of the defect.
5.2 Preheat area +75mm radius prior to gouging.
5.3 Arc air gouge defect area + 50mm either side. For single-sided root repairs, 5mm of material
must be left ungouged and the final breakthrough performed by grinding or cold cutting.
5.4 Grind excavated area to bright metal to provide a smooth profile ready for rewelding. Root areas
should have feathered edges.
5.5 The excavated area requires satisfactory visual & MPI examination before rewelding.
5.6 Repair using 50°C higher preheat than original weld. Caution - the shorter weld length and
increased preheat may mean additional control to ensure that the maximum interpass
temperature does not exceed 250°C.

6. AFTER WELD COMPLETION

6.1 Grind off any temporary attachments until they can be broken off by hand (never hammer off).
Grind off any arc strikes or strongback tacks flush with the parent material.
6.2 For fillet and stitch welds, ensure ends are sealed with a return weld. This also applies to
permanent mouseholes.
6.3 Remove any spatter. Peening of caps (needle gun at 90° to weld) is not permitted.
6.4 Unless otherwise directed by your supervisor, mark your welders ID number next to the joint.

7. TACKWELDING
7.1 Tack-welding may be performed by approved welders using SWIS01 or SWIS02 or by approved
tack-welders using SWIS01.
7.2 The minimum length of tack welds should be four times the material thickness or 50mm -
whichever is less. Tackwelds will normally be single pass but in areas of high restraint, or critical
application such as cast padears, multipass tackwelds should be used.

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8. COMBINED THICKNESS CALCULATION (BS5135 / EN1011)

8.1 Combined thickness (CT) = the sum of the parent metal thicknesses averaged over a distance of
75mm from the weld.

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SWIS 01 - Rev 4
SMAW Welding Using Filarc 88S Electrodes on Structural Steels up to Grade 355EM/355EMZ,
repairs to SAW and GSFCAW welds where specified, and root runs for single-sided and
problematic double-sided welds completed using SWIS 02

Qualified WPSs : All 300 Series (plus dissimilar repair procedures 680.3, 801 & 804).

Use on DC-ve for root pass in single-sided butt welds and DC+ve for all other areas.
Use a stringer bead technique with maximum bead width of 3 times the electrode core wire diameter.
Keep arc length short.
Use grinder, wire brush, and needle-gun for interrun cleaning.

Apply preheat in accordance with 'General Rules for Structural Welding') item 4 and the following table
(See Section 8.1 for definitions of combined thickness) :-

Combined Thickness Preheat Temperature

Up to 50mm Ambient (but see General Rules' Item 4.3)
51mm to 75mm 50°C
Over 75mm 75°C

WELDING PARAMETERS (See ROL/Stub Length Charts)

Diameter Roots Hot Pass Fill Cap Single Pass Multipass

Fillet(*) Fillet
2.5mm 1.3-3.0 1.3-2.7 N/A N/A N/A N/A
3.2mm 1.3-3.0 1.4-2.6 1.2-2.5 1.0-1.8 1.9-3.3 1.0-2.7
4.0mm N/A N/A 1.3-2.8 1.1-1.8 1.9-3.3 1.1-2.8
5.0mm N/A N/A 1.7-2.8 N/A 1.9-3.3 1.7-2.8

* For a 6mm Leg Fillet, the heat input is approximately 2.0kJ/mm - the upper end of the single pass fillet
range therefore represents a 6mm fillet weld with 2mm root gap, ie. increased to 8mm leg. A 2mm fillet
root gap is the largest that should be attempted before switching to a multipass technique.

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SWIS 02 - Rev 8
GSFCAW Welding Using 1.2mm ESAB OK 15.11 / Murex Corofil R60 Ni2 on Structural Steels up
to Grade 355EM/355EMZ for all configurations (and on Grade 450EM/450EMZ in the range 10-
50mm for butt/TKY and multipass fillet welding)

Use on DC+ve Only. Shielding Gas is 20% CO2 / 2% O2 / 78% Ar @ 20litres/min. Nominal Stickout
20mm. Use a stringer bead technique with maximum bead width of 16mm. Use grinder, wire brush, and
needle-gun for interrun cleaning.
Where access to both sides exists, butt welds will normally be welded out entirely using the GSFCAW
process, back-gouged, ground, and the second side rewelded. Single-sided joints will be rooted with
SMAW to SWIS 01. The hot pass may also be made manually if desirable. The remainder of the weld
must then be performed using GSFCAW. A manual root may also be used for the first pass of double-
sided welds where there is poor fitup.

Apply preheat in accordance with 'General Rules for Structural Welding') item 4 and the following table
(See Section 8.1 for definitions of combined thickness) :-

Combined Preheat Temperature

Thickness
Up to 40mm Ambient (but see General
Rules' Item 4.3)
41mm to 55mm 50°C
Over 55mm 100°C

WELDING PARAMETERS (See Corofil R60 Ni2 - Heat Input Calculator)

Program Wire Feed Wire Potential Butt Weld Butt Weld Single Pass
No. [m/min] Feed [Volts] Fill & Capping Fillets
[in/min] Multipass Runs
Fillets
1 11.5 453 28 1G,2G/2F - 2F
2 6.5 256 24.5 3G/3F All 3F
4G/4F,3G
3 7.5 295 26.5 1G,4G 3F,4F
/3F
4 15 591 30 - - 2F
5 9 354 26.5 All 1G 3F,4F
6 10 394 27.5 1G,2G/2F 1G 4F
7 6 236 24.5 - All -

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SWIS 02 – Revised Settings for ESAB AristoFeed Wire Feeders

Program Wire Feed Preset Wire Nominal Preset Voltage Butt Weld Butt Weld Single Pass Fillets
No. [m/min] Feed Limits Potential Limits [Volts] Fill & Capping Runs
[m/min] [Volts] Multipass
Fillets
1 11.5 10.9 – 12.1 26.5 25.5 – 27.5 1G,2G/2F - 2F
2 6.5 6.2 – 6.8 23.5 22.5 – 24.5 3G/3F All 3F
4G/4F,3G/3
3 7.5 7.1 – 7.9 25.5 24.5 – 26.5 1G,4G 3F,4F
F
4 15 14.2 – 15.8 28.5 27.5 – 29.5 - - 2F
5 9 8.5 – 9.5 25.5 24.5 – 26.5 All 1G 3F,4F
6 10 9.5 – 10.5 26.2 25.2 – 27.2 1G,2G/2F 1G 4F
7 6 5.7 – 6.3 23.5 22.5 – 24.5 - All -

Permitted unfactored arc energy range is 0.7 – 2.2 kJ/mm

Explanatory Note
The ESAB Aristofeed wire feeders measure actual tip voltage whereas Miller, Kemppi, and other feeders measure the voltage supplied to the torch
euroconnector. Voltage drops in the torch current carrying cable on most feeders normally necessitate an increase at the euroconnector to compensate.
This is not required for the ESAB Aristo feeders, so they are preset with lower values.

This also has a minor impact on the maximum applied arc energy which is reduced accordingly from 2.3 kJ/mm to 2.2 kJ/mm

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Alternative SWIS02 Settings (4 program trigger-mode)

Program Replacing Wire Feed Voltage Butt Weld Fill Butt Weld Single Pass Fillets
No. Standard Speeds Range & Multipass Capping Runs
Programs [m/min] Fillets
1 2,3,7 5.7-7.9 23.5-27.5 3G/3F, 4G/4F All 3F, 4F
2 3,5 7.1-9.5 25.5-27.5 All 1G, 4G 3F, 4F
3 5,6,1 8.5-12.1 25.5-29.0 1G, 2G/2F n/a n/a
4 1,4 10.9-15.8 27.0-31.0 n/a n/a 2F

1 ALTERNATIVE SWIS02 SETTINGS (3 PROGRAM TRIGGER-MODE)

Program Replacing Wire Feed Voltage Butt Weld Fill Butt Weld Single Pass Fillets
No. Standard Speeds Range & Multipass Capping Runs
Programs [m/min] Fillets
1 2,3,7 5.7-7.9 23.5-27.5 3G/3F, 4G/4F All 3F, 4F
2 3,5 7.1-9.5 25.5-27.5 All 1G, 4G 3F, 4F
3 1,4,6 9.5-15.8 25.5-31.0 1G, 2G/2F n/a 2F

Wire feeders without remote control program units, but with the ability to preset wire feed speed and arc voltage may be used by setting the correct values
of programs 1-7 as required.

Equipment offering 3-way or 4-way programs controlled by the MIG torch trigger action should be preset as shown above.

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C o ro fil R 60 N i2 – H eat In p u t C alcu lato r

Heat Input
[k J/m m ] W ire Fe e d S pe e d [m /m in]
S pe e d
[m m /m in] 5.5 6 6.25 6.5 7 7.5 8 8.5 9 9.5 10 10.5 11 11.5 12 12.5 13 13.5 14 15 16
100 2.5 2.7 2.8 2.9 3.0 3.2 3.4 3.6 3.7 3.9 4.1 4.3 4.4 4.6 4.8 5.0 5.1 5.3 5.5 5.8 6.2
120 2.1 2.2 2.3 2.4 2.5 2.7 2.8 3.0 3.1 3.3 3.4 3.6 3.7 3.8 4.0 4.1 4.3 4.4 4.6 4.9 5.2
140 1.8 1.9 2.0 2.0 2.2 2.3 2.4 2.5 2.7 2.8 2.9 3.0 3.2 3.3 3.4 3.5 3.7 3.8 3.9 4.2 4.4
160 1.6 1.7 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 3.7 3.9
180 1.4 1.5 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.4
200 1.3 1.3 1.4 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.7 2.9 3.1
220 1.1 1.2 1.3 1.3 1.4 1.5 1.5 1.6 1.7 1.8 1.9 1.9 2.0 2.1 2.2 2.3 2.3 2.4 2.5 2.7 2.8
240 1.0 1.1 1.2 1.2 1.3 1.3 1.4 1.5 1.6 1.6 1.7 1.8 1.8 1.9 2.0 2.1 2.1 2.2 2.3 2.4 2.6
260 1.0 1.0 1.1 1.1 1.2 1.2 1.3 1.4 1.4 1.5 1.6 1.6 1.7 1.8 1.8 1.9 2.0 2.0 2.1 2.2 2.4
280 0.9 1.0 1.0 1.0 1.1 1.1 1.2 1.3 1.3 1.4 1.5 1.5 1.6 1.6 1.7 1.8 1.8 1.9 2.0 2.1 2.2
300 0.8 0.9 0.9 1.0 1.0 1.1 1.1 1.2 1.2 1.3 1.4 1.4 1.5 1.5 1.6 1.7 1.7 1.8 1.8 1.9 2.1
320 0.8 0.8 0.9 0.9 0.9 1.0 1.1 1.1 1.2 1.2 1.3 1.3 1.4 1.4 1.5 1.6 1.6 1.7 1.7 1.8 1.9
340 0.7 0.8 0.8 0.8 0.9 0.9 1.0 1.0 1.1 1.2 1.2 1.3 1.3 1.4 1.4 1.5 1.5 1.6 1.6 1.7 1.8
360 0.7 0.7 0.8 0.8 0.8 0.9 0.9 1.0 1.0 1.1 1.1 1.2 1.2 1.3 1.3 1.4 1.4 1.5 1.5 1.6 1.7
380 0.7 0.7 0.7 0.8 0.8 0.8 0.9 0.9 1.0 1.0 1.1 1.1 1.2 1.2 1.3 1.3 1.4 1.4 1.4 1.5 1.6
400 0.6 0.7 0.7 0.7 0.8 0.8 0.8 0.9 0.9 1.0 1.0 1.1 1.1 1.2 1.2 1.2 1.3 1.3 1.4 1.5 1.5
425 0.6 0.6 0.7 0.7 0.7 0.8 0.8 0.8 0.9 0.9 1.0 1.0 1.0 1.1 1.1 1.2 1.2 1.3 1.3 1.4 1.5
450 0.6 0.6 0.6 0.6 0.7 0.7 0.8 0.8 0.8 0.9 0.9 0.9 1.0 1.0 1.1 1.1 1.1 1.2 1.2 1.3 1.4
475 0.5 0.6 0.6 0.6 0.6 0.7 0.7 0.8 0.8 0.8 0.9 0.9 0.9 1.0 1.0 1.0 1.1 1.1 1.2 1.2 1.3
500 0.5 0.5 0.6 0.6 0.6 0.6 0.7 0.7 0.7 0.8 0.8 0.9 0.9 0.9 1.0 1.0 1.0 1.1 1.1 1.2 1.2
550 0.5 0.5 0.5 0.5 0.6 0.6 0.6 0.6 0.7 0.7 0.7 0.8 0.8 0.8 0.9 0.9 0.9 1.0 1.0 1.1 1.1
600 0.4 0.4 0.5 0.5 0.5 0.5 0.6 0.6 0.6 0.7 0.7 0.7 0.7 0.8 0.8 0.8 0.9 0.9 0.9 1.0 1.0
700 0.4 0.4 0.4 0.4 0.4 0.5 0.5 0.5 0.5 0.6 0.6 0.6 0.6 0.7 0.7 0.7 0.7 0.8 0.8 0.8 0.9
217 236 246 256 276 295 315 335 354 374 394 413 433 453 472 492 512 531 551 591 630
W ire Fe e d S pe e d [ipm ]

The above chart may also be used for ESAB OK 15.11 (NB: this is identical rebadged product)

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T ra v e l S p e e d C a lc u la to r
S peed
[m m /m in] Tim e Tak en to W eld Length [s ec onds ]
L e n gth [m m ] 10 12 15 17 20 22 25 30 35 40 45 50 55 60 70 80 90 100 110 120 130 140 150
25 150 125 100 88 75 68 60 50 43 38 33 30 27 25 21 19 17 15 14 13 12 11 10
30 180 150 120 106 90 82 72 60 51 45 40 36 33 30 26 23 20 18 16 15 14 13 12
35 210 175 140 124 105 95 84 70 60 53 47 42 38 35 30 26 23 21 19 18 16 15 14
40 240 200 160 141 120 109 96 80 69 60 53 48 44 40 34 30 27 24 22 20 18 17 16
45 270 225 180 159 135 123 108 90 77 68 60 54 49 45 39 34 30 27 25 23 21 19 18
50 300 250 200 176 150 136 120 100 86 75 67 60 55 50 43 38 33 30 27 25 23 21 20
60 360 300 240 212 180 164 144 120 103 90 80 72 65 60 51 45 40 36 33 30 28 26 24
70 420 350 280 247 210 191 168 140 120 105 93 84 76 70 60 53 47 42 38 35 32 30 28
80 480 400 320 282 240 218 192 160 137 120 107 96 87 80 69 60 53 48 44 40 37 34 32
90 540 450 360 318 270 245 216 180 154 135 120 108 98 90 77 68 60 54 49 45 42 39 36
100 600 500 400 353 300 273 240 200 171 150 133 120 109 100 86 75 67 60 55 50 46 43 40
110 660 550 440 388 330 300 264 220 189 165 147 132 120 110 94 83 73 66 60 55 51 47 44
120 720 600 480 424 360 327 288 240 206 180 160 144 131 120 103 90 80 72 65 60 55 51 48
130 780 650 520 459 390 355 312 260 223 195 173 156 142 130 111 98 87 78 71 65 60 56 52
140 840 700 560 494 420 382 336 280 240 210 187 168 153 140 120 105 93 84 76 70 65 60 56
150 900 750 600 529 450 409 360 300 257 225 200 180 164 150 129 113 100 90 82 75 69 64 60
160 960 800 640 565 480 436 384 320 274 240 213 192 175 160 137 120 107 96 87 80 74 69 64
180 1080 900 720 635 540 491 432 360 309 270 240 216 196 180 154 135 120 108 98 90 83 77 72
200 1200 1000 800 706 600 545 480 400 343 300 267 240 218 200 171 150 133 120 109 100 92 86 80
220 1320 1100 880 776 660 600 528 440 377 330 293 264 240 220 189 165 147 132 120 110 102 94 88
240 1440 1200 960 847 720 655 576 480 411 360 320 288 262 240 206 180 160 144 131 120 111 103 96
260 1560 1300 1040 918 780 709 624 520 446 390 347 312 284 260 223 195 173 156 142 130 120 111 104
280 1680 1400 1120 988 840 764 672 560 480 420 373 336 305 280 240 210 187 168 153 140 129 120 112
300 1800 1500 1200 1059 900 818 720 600 514 450 400 360 327 300 257 225 200 180 164 150 138 129 120
325 1950 1625 1300 1147 975 886 780 650 557 488 433 390 355 325 279 244 217 195 177 163 150 139 130
350 2100 1750 1400 1235 1050 955 840 700 600 525 467 420 382 350 300 263 233 210 191 175 162 150 140
375 2250 1875 1500 1324 1125 1023 900 750 643 563 500 450 409 375 321 281 250 225 205 188 173 161 150
400 2400 2000 1600 1412 1200 1091 960 800 686 600 533 480 436 400 343 300 267 240 218 200 185 171 160
450 2700 2250 1800 1588 1350 1227 1080 900 771 675 600 540 491 450 386 338 300 270 245 225 208 193 180
500 3000 2500 2000 1765 1500 1364 1200 1000 857 750 667 600 545 500 429 375 333 300 273 250 231 214 200
600 3600 3000 2400 2118 1800 1636 1440 1200 1029 900 800 720 655 600 514 450 400 360 327 300 277 257 240

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R O L /S tu b L e n g th H e a t In p u t C h a rt fo r 2 .5 m m F ila rc 8 8 S / 9 8 S E le c tro d e s
He a t In p u t S tu b L e n g th
[kJ/m m ] 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
0.6 203 197 191 184 178 171 165 159 152 146 140 133 127 121 114 108 102 95 89 83 76 70 64
0.7 174 169 163 158 152 147 142 136 131 125 120 114 109 103 98 93 87 82 76 71 65 60 54
0.8 152 148 143 138 133 129 124 119 114 110 105 100 95 91 86 81 76 71 67 62 57 52 48
0.9 136 131 127 123 119 114 110 106 102 97 93 89 85 80 76 72 68 64 59 55 51 47 42
1.0 122 118 114 111 107 103 99 95 91 88 84 80 76 72 69 65 61 57 53 50 46 42 38
1.1 111 107 104 100 97 94 90 87 83 80 76 73 69 66 62 59 55 52 49 45 42 38 35
1.2 102 98 95 92 89 86 83 79 76 73 70 67 64 60 57 54 51 48 44 41 38 35 32
1.3 94 91 88 85 82 79 76 73 70 67 64 62 59 56 53 50 47 44 41 38 35 32 29
1.4 87 84 82 79 76 73 71 68 65 63 60 57 54 52 49 46 44 41 38 35 33 30 27
1.5 81 79 76 74 71 69 66 64 61 58 56 53 51 48 46 43 41 38 36 33 30 28 25
1.6 76 74 71 69 67 64 62 60 57 55 52 50 48 45 43 40 38 36 33 31 29 26 24
1.7 72 69 67 65 63 61 58 56 54 52 49 47 45 43 40 38 36 34 31 29 27 25 22
1.8 68 66 64 61 59 57 55 53 51 49 47 44 42 40 38 36 34 32 30 28 25 23 21
1.9 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20
2.0 61 59 57 55 53 51 50 48 46 44 42 40 38 36 34 32 30 29 27 25 23 21 19
2.1 58 56 54 53 51 49 47 45 44 42 40 38 36 34 33 31 29 27 25 24 22 20 18
2.2 55 54 52 50 49 47 45 43 42 40 38 36 35 33 31 29 28 26 24 23 21 19 17
2.3 53 51 50 48 46 45 43 41 40 38 36 35 33 31 30 28 27 25 23 22 20 18 17
2.4 51 49 48 46 44 43 41 40 38 37 35 33 32 30 29 27 25 24 22 21 19 17 16
2.5 49 47 46 44 43 41 40 38 37 35 34 32 30 29 27 26 24 23 21 20 18 17 15
2.6 47 45 44 43 41 40 38 37 35 34 32 31 29 28 26 25 23 22 21 19 18 16 15
2.7 45 44 42 41 40 38 37 35 34 32 31 30 28 27 25 24 23 21 20 18 17 16 14
2.8 44 42 41 39 38 37 35 34 33 31 30 29 27 26 24 23 22 20 19 18 16 15 14
2.9 42 41 39 38 37 35 34 33 32 30 29 28 26 25 24 22 21 20 18 17 16 14 13
3.0 41 39 38 37 36 34 33 32 30 29 28 27 25 24 23 22 20 19 18 17 15 14 13
3.1 39 38 37 36 34 33 32 31 30 28 27 26 25 23 22 21 20 18 17 16 15 14 12
3.2 38 37 36 35 33 32 31 30 29 27 26 25 24 23 21 20 19 18 17 15 14 13 12
3.3 37 36 35 33 32 31 30 29 28 27 25 24 23 22 21 20 18 17 16 15 14 13 12
3.4 36 35 34 33 31 30 29 28 27 26 25 24 22 21 20 19 18 17 16 15 13 12 11
3.5 35 34 33 32 30 29 28 27 26 25 24 23 22 21 20 19 17 16 15 14 13 12 11

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R O L /S tu b L e n g th H e a t In p u t C h a rt fo r 3 .2 m m F ila rc 8 8 S / 9 8 S E le c tro d e s
H e a t In p u t S tu b L e n g th
[k J / m m ] 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
0.6 333 323 312 302 291 281 271 260 250 239 229 219 208 198 187 177 167 156 146 135 125 114 104
0.7 285 277 268 259 250 241 232 223 214 205 196 187 178 169 161 152 143 134 125 116 107 98 89
0.8 250 242 234 226 219 211 203 195 187 180 172 164 156 148 140 133 125 117 109 101 94 86 78
0.9 222 215 208 201 194 187 180 173 167 160 153 146 139 132 125 118 111 104 97 90 83 76 69
1.0 200 194 187 181 175 169 162 156 150 144 137 131 125 119 112 106 100 94 87 81 75 69 62
1.1 182 176 170 165 159 153 148 142 136 131 125 119 114 108 102 96 91 85 79 74 68 62 57
1.2 167 161 156 151 146 140 135 130 125 120 114 109 104 99 94 88 83 78 73 68 62 57 52
1.3 154 149 144 139 134 130 125 120 115 110 106 101 96 91 86 82 77 72 67 62 58 53 48
1.4 143 138 134 129 125 120 116 111 107 103 98 94 89 85 80 76 71 67 62 58 54 49 45
1.5 133 129 125 121 117 112 108 104 100 96 92 87 83 79 75 71 67 62 58 54 50 46 42
1.6 125 121 117 113 109 105 101 98 94 90 86 82 78 74 70 66 62 59 55 51 47 43 39
1.7 118 114 110 107 103 99 95 92 88 84 81 77 73 70 66 62 59 55 51 48 44 40 37
1.8 111 108 104 101 97 94 90 87 83 80 76 73 69 66 62 59 56 52 49 45 42 38 35
1.9 105 102 99 95 92 89 85 82 79 76 72 69 66 62 59 56 53 49 46 43 39 36 33
2.0 100 97 94 91 87 84 81 78 75 72 69 66 62 59 56 53 50 47 44 41 37 34 31
2.1 95 92 89 86 83 80 77 74 71 68 65 62 59 56 54 51 48 45 42 39 36 33 30
2.2 91 88 85 82 79 77 74 71 68 65 62 60 57 54 51 48 45 43 40 37 34 31 28
2.3 87 84 81 79 76 73 71 68 65 62 60 57 54 52 49 46 43 41 38 35 33 30 27
2.4 83 81 78 75 73 70 68 65 62 60 57 55 52 49 47 44 42 39 36 34 31 29 26
2.5 80 77 75 72 70 67 65 62 60 57 55 52 50 47 45 42 40 37 35 32 30 27 25
2.6 77 74 72 70 67 65 62 60 58 55 53 50 48 46 43 41 38 36 34 31 29 26 24
2.7 74 72 69 67 65 62 60 58 56 53 51 49 46 44 42 39 37 35 32 30 28 25 23
2.8 71 69 67 65 62 60 58 56 54 51 49 47 45 42 40 38 36 33 31 29 27 25 22
2.9 69 67 65 62 60 58 56 54 52 50 47 45 43 41 39 37 34 32 30 28 26 24 22
3.0 67 65 62 60 58 56 54 52 50 48 46 44 42 40 37 35 33 31 29 27 25 23 21
3.1 64 62 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20
3.2 62 60 59 57 55 53 51 49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 20
3.3 61 59 57 55 53 51 49 47 45 44 42 40 38 36 34 32 30 28 26 25 23 21 19
3.4 59 57 55 53 51 50 48 46 44 42 40 39 37 35 33 31 29 28 26 24 22 20 18
3.5 57 55 54 52 50 48 46 45 43 41 39 37 36 34 32 30 29 27 25 23 21 20 18

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R O L /S tu b L e n g th H e a t In p u t C h a rt fo r 4 m m F ila rc 8 8 S / 9 8 S E le c tro d e s
H e a t In p u t S tu b L e n g th
[kJ/m m ] 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
0.6 640 625 610 594 579 564 549 533 518 503 488 472 457 442 427 411 396 381 366 350 335 320 305
0.7 549 536 522 509 496 483 470 457 444 431 418 405 392 379 366 353 340 327 313 300 287 274 261
0.8 480 469 457 446 434 423 411 400 389 377 366 354 343 331 320 309 297 286 274 263 251 240 229
0.9 427 417 406 396 386 376 366 356 345 335 325 315 305 295 284 274 264 254 244 234 223 213 203
1.0 384 375 366 357 347 338 329 320 311 302 293 283 274 265 256 247 238 229 219 210 201 192 183
1.1 349 341 332 324 316 308 299 291 283 274 266 258 249 241 233 224 216 208 199 191 183 175 166
1.2 320 312 305 297 290 282 274 267 259 251 244 236 229 221 213 206 198 190 183 175 168 160 152
1.3 295 288 281 274 267 260 253 246 239 232 225 218 211 204 197 190 183 176 169 162 155 148 141
1.4 274 268 261 255 248 242 235 229 222 216 209 202 196 189 183 176 170 163 157 150 144 137 131
1.5 256 250 244 238 232 226 219 213 207 201 195 189 183 177 171 165 158 152 146 140 134 128 122
1.6 240 234 229 223 217 211 206 200 194 189 183 177 171 166 160 154 149 143 137 131 126 120 114
1.7 226 221 215 210 204 199 194 188 183 177 172 167 161 156 151 145 140 134 129 124 118 113 108
1.8 213 208 203 198 193 188 183 178 173 168 163 157 152 147 142 137 132 127 122 117 112 107 102
1.9 202 197 192 188 183 178 173 168 164 159 154 149 144 140 135 130 125 120 115 111 106 101 96
2.0 192 187 183 178 174 169 165 160 155 151 146 142 137 133 128 123 119 114 110 105 101 96 91
2.1 183 179 174 170 165 161 157 152 148 144 139 135 131 126 122 118 113 109 104 100 96 91 87
2.2 175 170 166 162 158 154 150 145 141 137 133 129 125 121 116 112 108 104 100 96 91 87 83
2.3 167 163 159 155 151 147 143 139 135 131 127 123 119 115 111 107 103 99 95 91 87 83 80
2.4 160 156 152 149 145 141 137 133 130 126 122 118 114 110 107 103 99 95 91 88 84 80 76
2.5 154 150 146 143 139 135 132 128 124 121 117 113 110 106 102 99 95 91 88 84 80 77 73
2.6 148 144 141 137 134 130 127 123 120 116 113 109 105 102 98 95 91 88 84 81 77 74 70
2.7 142 139 135 132 129 125 122 119 115 112 108 105 102 98 95 91 88 85 81 78 74 71 68
2.8 137 134 131 127 124 121 118 114 111 108 104 101 98 95 91 88 85 82 78 75 72 69 65
2.9 132 129 126 123 120 117 113 110 107 104 101 98 95 91 88 85 82 79 76 73 69 66 63
3.0 128 125 122 119 116 113 110 107 104 101 98 94 91 88 85 82 79 76 73 70 67 64 61
3.1 124 121 118 115 112 109 106 103 100 97 94 91 88 86 83 80 77 74 71 68 65 62 59
3.2 120 117 114 111 109 106 103 100 97 94 91 89 86 83 80 77 74 71 69 66 63 60 57
3.3 116 114 111 108 105 103 100 97 94 91 89 86 83 80 78 75 72 69 66 64 61 58 55
3.4 113 110 108 105 102 99 97 94 91 89 86 83 81 78 75 73 70 67 65 62 59 56 54
3.5 110 107 104 102 99 97 94 91 89 86 84 81 78 76 73 71 68 65 63 60 57 55 52

M:\0725\Doc Types\Procedure Page 14 of 36 Document No 0725-000-Q-PC-SLP-00002

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R OL /S tu b L en g th H ea t In p u t C h art fo r 5 m m F ila rc 8 8 S / 9 8 S E lec tro d es

He a t Input S tub Le ngth
[kJ/m m ] 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
0.6 967 944 921 898 875 852 829 806 783 760 737 714 691 668 645 622 599 576 552 529 506 483 460
0.7 829 809 789 770 750 730 710 691 671 651 631 612 592 572 552 533 513 493 474 454 434 414 395
0.8 725 708 691 673 656 639 622 604 587 570 552 535 518 501 483 466 449 432 414 397 380 363 345
0.9 645 629 614 599 583 568 552 537 522 506 491 476 460 445 430 414 399 384 368 353 338 322 307
1.0 580 566 552 539 525 511 497 483 470 456 442 428 414 401 387 373 359 345 331 318 304 290 276
1.1 527 515 502 490 477 465 452 439 427 414 402 389 377 364 352 339 326 314 301 289 276 264 251
1.2 483 472 460 449 437 426 414 403 391 380 368 357 345 334 322 311 299 288 276 265 253 242 230
1.3 446 436 425 414 404 393 382 372 361 351 340 329 319 308 297 287 276 266 255 244 234 223 212
1.4 414 404 395 385 375 365 355 345 335 326 316 306 296 286 276 266 257 247 237 227 217 207 197
1.5 387 378 368 359 350 341 331 322 313 304 295 285 276 267 258 249 239 230 221 212 203 193 184
1.6 363 354 345 337 328 319 311 302 294 285 276 268 259 250 242 233 224 216 207 199 190 181 173
1.7 341 333 325 317 309 301 292 284 276 268 260 252 244 236 227 219 211 203 195 187 179 171 162
1.8 322 315 307 299 292 284 276 269 261 253 246 238 230 223 215 207 200 192 184 176 169 161 153
1.9 305 298 291 284 276 269 262 254 247 240 233 225 218 211 204 196 189 182 174 167 160 153 145
2.0 290 283 276 269 262 256 249 242 235 228 221 214 207 200 193 186 180 173 166 159 152 145 138
2.1 276 270 263 257 250 243 237 230 224 217 210 204 197 191 184 178 171 164 158 151 145 138 132
2.2 264 257 251 245 239 232 226 220 213 207 201 195 188 182 176 170 163 157 151 144 138 132 126
2.3 252 246 240 234 228 222 216 210 204 198 192 186 180 174 168 162 156 150 144 138 132 126 120
2.4 242 236 230 224 219 213 207 201 196 190 184 178 173 167 161 155 150 144 138 132 127 121 115
2.5 232 227 221 215 210 204 199 193 188 182 177 171 166 160 155 149 144 138 133 127 122 116 110
2.6 223 218 212 207 202 197 191 186 181 175 170 165 159 154 149 143 138 133 127 122 117 112 106
2.7 215 210 205 200 194 189 184 179 174 169 164 159 153 148 143 138 133 128 123 118 113 107 102
2.8 207 202 197 192 187 183 178 173 168 163 158 153 148 143 138 133 128 123 118 113 109 104 99
2.9 200 195 191 186 181 176 171 167 162 157 152 148 143 138 133 129 124 119 114 110 105 100 95
3.0 193 189 184 180 175 170 166 161 157 152 147 143 138 134 129 124 120 115 110 106 101 97 92
3.1 187 183 178 174 169 165 160 156 151 147 143 138 134 129 125 120 116 111 107 102 98 94 89
3.2 181 177 173 168 164 160 155 151 147 142 138 134 129 125 121 117 112 108 104 99 95 91 86
3.3 176 172 167 163 159 155 151 146 142 138 134 130 126 121 117 113 109 105 100 96 92 88 84
3.4 171 167 162 158 154 150 146 142 138 134 130 126 122 118 114 110 106 102 97 93 89 85 81
3.5 166 162 158 154 150 146 142 138 134 130 126 122 118 114 110 107 103 99 95 91 87 83 79

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 SITE WELDING INSTRUCTION SHEET (SWIS) HANDBOOK
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Estimation of Purge Volume

Litres Distance Between Dams [m] (or total length of pipework needing purging)
Diameter [in.] 0.15 0.25 0.5 1 2 3 4 5 6 7 8 9 10
0.5 0.02 0.03 0.06 0.13 0.25 0.38 0.51 0.63 0.76 0.89 1.0 1.1 1.3
1 0.08 0.13 0.25 0.51 1.0 1.5 2.0 2.5 3.0 3.5 4.1 4.6 5.1
2 0.30 0.51 1.0 2.0 4.1 6.1 8.1 10 12 14 16 18 20
3 0.68 1.1 2.3 4.6 9.1 14 18 23 27 32 36 41 46
4 1.2 2.0 4.1 8.1 16 24 32 41 49 57 65 73 81
6 2.7 4.6 9.1 18 36 55 73 91 109 128 146 164 182
8 4.9 8.1 16 32 65 97 130 162 195 227 259 292 324
10 7.6 13 25 51 101 152 203 253 304 355 405 456 507
12 11 18 36 73 146 219 292 365 438 511 584 657 730
14 15 25 50 99 199 298 397 497 596 695 795 894 993
16 19 32 65 130 259 389 519 649 778 908 1038 1167 1297
18 25 41 82 164 328 493 657 821 985 1149 1313 1478 1642
20 30 51 101 203 405 608 811 1013 1216 1419 1621 1824 2027
22 37 61 123 245 490 736 981 1226 1471 1717 1962 2207 2452
24 44 73 146 292 584 876 1167 1459 1751 2043 2335 2627 2919

Use the above chart to estimate the volume of gas to be purged and the following chart to evaluate the
required purge rate for the calculated volume.

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E stim atio n o f Minimu m P urge Time by V o lu me and P urge R ate

Tim e [m in] P urge Ra te [litre s/m in] (se e note s 2 & 3)
Litre s 1 2 5 10 15 20 25 30 40 50 60 80 100
0.02 0.10 0.05 0.02 0.01 0.01 0.01 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.05 0.25 0.13 0.05 0.03 0.02 0.01 0.01 0.01 0.01 0.01 0.00 0.00 0.00
0.1 0.50 0.25 0.10 0.05 0.03 0.03 0.02 0.02 0.01 0.01 0.01 0.01 0.01
0.2 1.0 0.50 0.20 0.10 0.07 0.05 0.04 0.03 0.03 0.02 0.02 0.01 0.01
0.5 2.5 1.3 0.50 0.25 0.17 0.13 0.10 0.08 0.06 0.05 0.04 0.03 0.03
1 5.0 2.5 1.0 0.50 0.33 0.25 0.20 0.17 0.13 0.10 0.08 0.06 0.05
2 10.0 5.0 2.0 1.0 0.67 0.50 0.40 0.33 0.25 0.20 0.17 0.13 0.10
5 25 13 5.0 2.5 1.7 1.3 1.0 0.83 0.63 0.50 0.42 0.31 0.25
10 50 25 10.0 5.0 3.3 2.5 2.0 1.7 1.3 1.0 0.83 0.63 0.50
20 100 50 20 10.0 6.7 5.0 4.0 3.3 2.5 2.0 1.7 1.3 1.0
50 250 125 50 25 17 13 10.0 8.3 6.3 5.0 4.2 3.1 2.5
100 500 250 100 50 33 25 20 17 13 10.0 8.3 6.3 5.0
200 1000 500 200 100 67 50 40 33 25 20 17 13 10.0
500 2500 1250 500 250 167 125 100 83 63 50 42 31 25
1000 5000 2500 1000 500 333 250 200 167 125 100 83 63 50
2000 10000 5000 2000 1000 667 500 400 333 250 200 167 125 100
No te s :
1. Purge rates below 5 litres/min may not be sufficient to maintain effective purge due to air currents
2. At rates above 20 litres/min, it will be necessary to turn the level down just before root closure.

M:\0725\Doc Types\Procedure Page 17 of 36 Document No 0725-000-Q-PC-SLP-00002

 SITE WELDING INSTRUCTION SHEET (SWIS) HANDBOOK
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SWIS 05 - Rev 3
GTAW/SMAW/GSFCAW Welding of Low Temp & Utility Carbon Steel using Metrode 1Ni / Filarc
PZ6513 / Filarc 88S / Elga DWA 55 LSR in the thickness range 3-62mm on 0.75” diameter & over.

SETUP
Prepare by a. machining, or, b. flame-cutting followed by grinding to bright metal
Tackweld using GTAW or SMAW root/hot pass parameters at the same preheat temperature as
specified for the weld. Bullets must be used on pipe diameter 6" & over.

a = 60º-75º
a' = 45ºmin
g = 3mm +/- 1mm
f = 1mm +/- 0.5mm

PREHEAT
Preheat in accordance with the table shown below. Maximum interpass temperature : 250°C.
Check temperature with Tempilstick between each weld pass.
Thickness Min Preheat Method
Less than 12mm 20ºC Propane Gas
12mm to 25mm 50ºC Propane or Mats
Over 25mm 75ºC Electrical Mats

PROCESSES
Process Application Notes
GTAW All Diameters 1.6-2.4mm Metrode 1Ni or Filarc
Up to 15mm PZ6513. DC-ve. Max Weave 15mm
deposited thickness. Shielding : High Purity Argon at 10-15
litres/min. Argon purge for root pass
when practical – see charts.
SMAW 2.5” Diameter & Filarc 88S. DC-ve Root / DC+ve all
Over other passes. String / Weave : max
Up to 62mm WT width 3 x electrode core diameter.
GSFCAW Fill & Cap Only 1.2mm Elga DWA 55LSR. DC+ve.
3” Diameter & Over String / Weave : max width 25mm.
8.56mm - 62mm WT Shield Gas : 20% CO2 / 2% O2 / 78%
Ar at 20 litres/min. Stickout : 15-20mm

M:\0725\Doc Types\Procedure Page 18 of 36 Document No.: 0725-000-Q-PC-SLP-00002

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GTAW Welding Parameters

Weld Arc Current Speed Heat Input
Area Volts[volts] [amps] [mm/min] [kJ/mm]
Root 10-14 70-140 22-55 1.2-2.8
Fill & 10-14 90-155 30-70 1.2-2.8
Cap
SMAW Welding Parameters (Notes 1,2)
Weld Size Arc Current Speed Heat Input
Area [mm] Volts[volts] [amps] [mm/min] [kJ/mm]
Root 2.5 20-22 70-100 45-90 1.2-2.5
nd
2 Pass 2.5 22-24 80-110 55-100 1.3-2.4
3.2 22-24 100-140 60-110 1.5-2.7
Fill 2.5 22-24 80-110 85-145 0.9-1.5
3.2 20-24 100-150 70-165 1.0-2.4
4 21-25 140-200 95-180 1.3-2.5
Cap 2.5 21-23 70-100 85-140 0.8-1.3
3.2 21-25 100-140 90-165 1.0-1.8
GSFCAW Welding Parameters (Notes 3,4)
Weld Program Arc Current [amps] Speed Heat Input Wire Feed [m/min]
Area Numbers Volts[volts] [mm/min] [kJ/mm]
2G Fill 5 26.5 220-245 205-370 1.0-1.8 9
6 27.5 240-270 221-421 1.0-1.9 10
1 28 265-290 233-466 1.0-2.0 11.5
2G Cap 2 24.5 190-210 294-490 0.6-1.0 6.5
5G Fill 3 26.5 210-230 140-350 1.0-2.5 7.5
5 26.5 225-250 135-210 1.8-2.8 9
5G Cap 7 24.5 170-190 189-294 0.9-1.4 6
Parameter Notes:
1. Refer to standard ROL/Stub Length Charts
2. Only VacPac electrodes are to be used and opened packs must be used within one shift or returned to stores.
3. For material < 17mm WT, wire feed speeds down to 5.1m/min and voltage as low as 23V are acceptable.
Although this wire is all-positional, the 5G position is preferred for quality and productivity.

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GENERAL NOTES
• Interrun clean using a grinder and wire brush. Needle guns may be used for slag removal but must not be
used on the cap.
• This SWIS card may also be used for conducting weld repairs - refer to repair instruction chit.
• Individual projects may have restrictions on the use of some processes, eg. SMAW root passes or use of the
GSFCAW process may not be permitted - check with your supervisor.
• Carry out fillet welding to fill parameters within thickness/diameter range.
• PWHT is required for all thicknesses over 19mm or the project piping PWHT threshold – or as directed by the
Welding Engineer
• Temperbead application is permitted but not mandatory.
• Typical pass sequences are shown below.

a. Conventional root and 2nd pass.

b. Split hot pass.
c. Single pass cap (small pipes)
d. 2 run cap.
e. 3 run cap (natural temperbead).
f. Multirun Cap (without temperbead).

M:\0725\Doc Types\Procedure 20 of 36 Document No 0725-000-Q-PC-SLP-00002

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SWIS 06 – Corporate Version Rev 1

GTAW/SMAW Welding of Riser / BS8010 Carbon Steel using Metrode 1Ni / Filarc PZ6513 / Filarc
98S on 2”-24” diameters.

SETUP
Prepare by a. machining, or, b. flame-cutting followed by grinding to bright metal
Tackweld using GTAW or SMAW root/hot pass parameters at the same preheat temperature as
specified for the weld. Bullets must be used on pipe diameter 6" & over.

a = 60º-75º
a' = 45ºmin
g = 4mm +0.5mm/-1.0mm
f = 1.5mm +0.5mm/-1.0mm

PREHEAT
Preheat in accordance with the table shown below. Maximum interpass temperature : 200°C.
Check temperature with Tempilstick between each weld pass.

Diameter Min Preheat Method

2” to 4” 50ºC Propane Gas
6” to 10” 100ºC Propane Gas
12” & Over 100ºC Electrical Mats

PROCESSES
Process Application Notes
GTAW All Diameters : 1.6-2.4mm Metrode 1Ni or Filarc
Root & 2nd Pass PZ6513. DC-ve. Max Weave 15mm
2” to 4” : Fill & Cap Shielding : High Purity Argon at 10-15
litres/min. Argon purge for root pass
when practical – see charts.
SMAW 6” Diameter & Filarc 98S.
Over : Root and DC-ve Root / DC+ve all other passes.
2nd Pass (when String / Weave : max width 3 x electrode
project permits) core diameter.
Fill & Cap (all
projects)

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GTAW Welding Parameters

Weld Area Arc Current Speed [mm/min] Heat Input
Volts[volts] [amps] [kJ/mm]
Root 10-14 70-140 22-55 1.2-2.8
Fill & Cap 10-14 90-155 30-70 1.2-2.8
SMAW Welding Parameters (Notes 1,2)
Weld Area Size Arc Current Speed Heat Input
[mm] Volts[volts] [amps] [mm/min] [kJ/mm]
Root 2.5 18-22 65-85 28-55 1.3-3.0
nd
2 Pass 2.5 22-26 80-100 80-110 1.2-1.7
Fill 3.2 21-25 115-145 95-150 1.2-1.9
4 20-23 150-200 90-160 1.4-2.5
Cap 3.2 20-23 100-130 100-170 0.9-1.5

Parameter Notes:
1. Refer to standard ROL/Stub Length Charts
2. Only VacPac electrodes are to be used and opened packs must be used within one shift or returned to stores.
3. A modified procedure SWIS06B is employed on some projects and uses a 0.5% Mo wire (2.4mm ESAB
13.08) for root and 2nd pass. The parameters are shown below.

SWIS06B GTAW Welding Parameters (2.4mm ESAB 13.08)

Weld Area Arc Current Speed Heat Input
Volts[volts] [amps] [mm/min] [kJ/mm]
Root 11-15 100-180 30-50 2.4-3.6
nd
2 Pass 11-15 140-220 40-80 1.6-3.3

GENERAL NOTES
• Interrun clean using a grinder and wire brush. Needle guns may be used for slag removal but must not be
used on the cap.
• This SWIS card may also be used for conducting weld repairs - refer to repair instruction chit.
• Individual projects may have restrictions on the use of some processes, eg. SMAW root passes may not be
permitted - check with your supervisor.

M:\0725\Doc Types\Procedure 22 of 36 Document No 0725-000-Q-PC-SLP-00002

 SITE WELDING INSTRUCTION SHEET (SWIS) HANDBOOK
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• Carry out fillet welding to fill parameters within thickness/diameter range.

• PWHT is not normally required for this application.
• Typical pass sequences for 2” to 4” GTAW welds are shown below.

a. Conventional root and 2nd pass.

b. Split hot pass.
c. Single pass cap (small pipes)
d. 2 run cap.
e. 3 run cap (natural temperbead).
f. Multirun Cap (without temperbead).

• Natural temperbead technique is mandatory for 6” diameter & over – see required run sequence below.

M:\0725\Doc Types\Procedure 23 of 36 Document No 0725-000-Q-PC-SLP-00002

 SITE WELDING INSTRUCTION SHEET (SWIS) HANDBOOK
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SWIS 07 - Rev 1
GTAW/SMAW/GSFCAW Welding of 22% Duplex Stainless Steel using ESAB 16.88 (ER2509) /
Metrode ER329N / Metrode 2205XKS / ESAB 67.55 in the thickness range 2.87mm-38.1mm on
0.5” diameter & over.

SETUP
Prepare by machining and/or grinding.
Tackweld using GTAW root pass parameters. Bullets may be used on pipe diameter 6" & over.

a = 60º-75º
a' = 45ºmin
g = 2-4mm
f = 1mm +/- 0.5mm

PREHEAT
Preheat is not required unless the steel is below 5ºC (in which case propane gas may be used to raise the
temperature to room temperature.
Maximum interpass temperature : 150°C.
Check temperature with Tempilstick between each weld pass.

PROCESSES
Process Application Notes

GTAW All Diameters 1.6mm ESAB 16.88 (ER2509) for Root and 2nd Pass /
Up to 18mm Metrode ER329N for Fill and Cap. DC-ve. String /
deposited thickness. Weave max 10mm width.
Shielding : High Purity Argon at 10-15 litres/min. Argon
purge is mandatory for root, 2nd pass, and 3rd layers –
see charts.

SMAW Fill & Cap Only Metrode 2205XKS and/or ESAB 67.55. DC+ve. String /
3” Diameter & Over Weave : max width 2.5 x electrode core diameter.
8.56mm - 36.5mm
WT

GSFCAW Fill & Cap Only 1.2mm ESAB OK Tubrod 14.27. DC+ve.
3” Diameter & Over String / Weave : max width 12mm.
12.7mm – 38.1mm Shield Gas : 20% CO2 / 2% O2 / 78% Ar at 20
WT litres/min. Stickout : 15-20mm

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GTAW Welding Parameters (Notes 1,2)

Weld Arc Current Speed [mm/min] Heat Input
Area Volts[volts] [amps] [kJ/mm]
Root 9-14 40-120 20-60 0.6-2.1
Fill & 9-14 40-130 25-150 0.6-2.0
Cap
SMAW Welding Parameters (Notes 3,4)
Weld Size Arc Current Speed [mm/min] Heat Input
Area [mm] Volts[volts] [amps] [kJ/mm]
Fill 2.5 22-27 70-110 120-221 0.6-1.1
3.2 22-26 90-130 113-226 0.7-1.4
4 22-27 105-155 127-273 0.7-1.5
Cap 3.2 21-26 85-125 135-212 0.7-1.1
GSFCAW Welding Parameters (Notes 5,6)
Weld Arc Current Speed Heat Input Wire Feed [m/min]
Area Volts[volts] [amps] [mm/min] [kJ/mm]
5G Fill 24-26 135-195 160-270 0.8-1.6 7.0-9.0
5G 23-25 125-160 180-290 0.6-1.2 6.0-7.0
Cap

Parameter Notes:

1. Restrict heat input to 1.6kJ/mm max for pipe wall thickness up to 5mm
2. ESAB 16.88 (ER2509) filler wire must be used for rooting and may also be used for the 2nd pass.
3. Refer to standard duplex electrode ROL/Stub Length Charts
4. Metrode 2205XKS are preferred for 2.5mm and 3.2mm sizes and ESAB 67.55 are preferred for 4.0mm size.
However both consumables are qualified and one may be substituted for the other in the event of supply
problems or technical improvement in either.
5. GSFCAW may be used for the 4th weld layer onwards.
6. GSFCAW process is currently restricted to 1G, 3G, & 5G welding.

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GENERAL NOTES
• Interrun clean using a grinder and stainless steel wire brush.
• This SWIS card may also be used for conducting weld repairs - refer to repair instruction chit.
• Carry out fillet welding to fill parameters within thickness/diameter range.
• Typical pass sequences are shown below.

g. Conventional root and 2nd pass.

h. Split hot pass.
i. Single pass cap (small pipes)
j. 2 run cap.
k. 3 run cap.
l. Multirun cap.

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ROL/Stub Length Heat Input Chart for 2.5mm Metrode 2205XKS and ESAB OK 67.55 Basic Electrodes
Heat Input Stub Length
[kJ/mm] 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220
0.4 257 248 238 229 219 210 200 191 181 171 162 152 143 133 124 114 105 95 86 76
0.5 206 198 191 183 175 168 160 152 145 137 130 122 114 107 99 91 84 76 69 61
0.6 171 165 159 152 146 140 133 127 121 114 108 102 95 89 83 76 70 64 57 51
0.7 147 142 136 131 125 120 114 109 103 98 93 87 82 76 71 65 60 54 49 44
0.8 129 124 119 114 110 105 100 95 91 86 81 76 71 67 62 57 52 48 43 38
0.9 114 110 106 102 97 93 89 85 80 76 72 68 64 59 55 51 47 42 38 34
1.0 103 99 95 91 88 84 80 76 72 69 65 61 57 53 50 46 42 38 34 30
1.1 94 90 87 83 80 76 73 69 66 62 59 55 52 49 45 42 38 35 31 28
1.2 86 83 79 76 73 70 67 64 60 57 54 51 48 44 41 38 35 32 29 25
1.3 79 76 73 70 67 64 62 59 56 53 50 47 44 41 38 35 32 29 26 23
1.4 73 71 68 65 63 60 57 54 52 49 46 44 41 38 35 33 30 27 24 22
1.5 69 66 64 61 58 56 53 51 48 46 43 41 38 36 33 30 28 25 23 20
1.6 64 62 60 57 55 52 50 48 45 43 40 38 36 33 31 29 26 24 21 19
1.7 61 58 56 54 52 49 47 45 43 40 38 36 34 31 29 27 25 22 20 18
1.8 57 55 53 51 49 47 44 42 40 38 36 34 32 30 28 25 23 21 19 17
1.9 54 52 50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16
2.0 51 50 48 46 44 42 40 38 36 34 32 30 29 27 25 23 21 19 17 15
2.1 49 47 45 44 42 40 38 36 34 33 31 29 27 25 24 22 20 18 16 15
2.2 47 45 43 42 40 38 36 35 33 31 29 28 26 24 23 21 19 17 16 14
2.3 45 43 41 40 38 36 35 33 31 30 28 27 25 23 22 20 18 17 15 13

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ROL/Stub Length Heat Input Chart for 3.2mm Metrode 2205XKS and ESAB OK 67.55 Basic Electrodes
Heat Input Stub Length
[kJ/mm] 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220
0.4 479 464 449 434 419 404 389 374 359 344 329 314 299 284 269 255 240 225 210 195
0.5 383 371 359 347 335 323 311 299 287 275 263 252 240 228 216 204 192 180 168 156
0.6 319 309 299 289 279 269 259 250 240 230 220 210 200 190 180 170 160 150 140 130
0.7 274 265 257 248 240 231 222 214 205 197 188 180 171 163 154 145 137 128 120 111
0.8 240 232 225 217 210 202 195 187 180 172 165 157 150 142 135 127 120 112 105 97
0.9 213 206 200 193 186 180 173 166 160 153 146 140 133 126 120 113 106 100 93 86
1.0 192 186 180 174 168 162 156 150 144 138 132 126 120 114 108 102 96 90 84 78
1.1 174 169 163 158 152 147 142 136 131 125 120 114 109 103 98 93 87 82 76 71
1.2 160 155 150 145 140 135 130 125 120 115 110 105 100 95 90 85 80 75 70 65
1.3 147 143 138 134 129 124 120 115 111 106 101 97 92 88 83 78 74 69 64 60
1.4 137 133 128 124 120 115 111 107 103 98 94 90 86 81 77 73 68 64 60 56
1.5 128 124 120 116 112 108 104 100 96 92 88 84 80 76 72 68 64 60 56 52
1.6 120 116 112 109 105 101 97 94 90 86 82 79 75 71 67 64 60 56 52 49
1.7 113 109 106 102 99 95 92 88 85 81 77 74 70 67 63 60 56 53 49 46
1.8 106 103 100 96 93 90 86 83 80 77 73 70 67 63 60 57 53 50 47 43
1.9 101 98 95 91 88 85 82 79 76 72 69 66 63 60 57 54 50 47 44 41
2.0 96 93 90 87 84 81 78 75 72 69 66 63 60 57 54 51 48 45 42 39
2.1 91 88 86 83 80 77 74 71 68 66 63 60 57 54 51 48 46 43 40 37
2.2 87 84 82 79 76 73 71 68 65 63 60 57 54 52 49 46 44 41 38 35
2.3 83 81 78 76 73 70 68 65 62 60 57 55 52 49 47 44 42 39 36 34

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ROL/Stub Length Heat Input Chart for 4mm Metrode 2205XKS and ESAB OK 67.55 Basic Electrodes
Heat Input Stub Length
[kJ/mm] 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220
0.4 725 703 680 657 635 612 589 567 544 521 499 476 453 431 408 385 363 340 317 295
0.5 580 562 544 526 508 490 471 453 435 417 399 381 363 344 326 308 290 272 254 236
0.6 483 468 453 438 423 408 393 378 363 347 332 317 302 287 272 257 242 227 212 196
0.7 414 401 389 376 363 350 337 324 311 298 285 272 259 246 233 220 207 194 181 168
0.8 363 351 340 329 317 306 295 283 272 261 249 238 227 215 204 193 181 170 159 147
0.9 322 312 302 292 282 272 262 252 242 232 222 212 201 191 181 171 161 151 141 131
1.0 290 281 272 263 254 245 236 227 218 208 199 190 181 172 163 154 145 136 127 118
1.1 264 255 247 239 231 223 214 206 198 190 181 173 165 157 148 140 132 124 115 107
1.2 242 234 227 219 212 204 196 189 181 174 166 159 151 144 136 128 121 113 106 98
1.3 223 216 209 202 195 188 181 174 167 160 153 146 139 132 126 119 112 105 98 91
1.4 207 201 194 188 181 175 168 162 155 149 142 136 130 123 117 110 104 97 91 84
1.5 193 187 181 175 169 163 157 151 145 139 133 127 121 115 109 103 97 91 85 79
1.6 181 176 170 164 159 153 147 142 136 130 125 119 113 108 102 96 91 85 79 74
1.7 171 165 160 155 149 144 139 133 128 123 117 112 107 101 96 91 85 80 75 69
1.8 161 156 151 146 141 136 131 126 121 116 111 106 101 96 91 86 81 76 71 65
1.9 153 148 143 138 134 129 124 119 115 110 105 100 95 91 86 81 76 72 67 62
2.0 145 141 136 131 127 122 118 113 109 104 100 95 91 86 82 77 73 68 63 59
2.1 138 134 130 125 121 117 112 108 104 99 95 91 86 82 78 73 69 65 60 56
2.2 132 128 124 119 115 111 107 103 99 95 91 87 82 78 74 70 66 62 58 54
2.3 126 122 118 114 110 106 102 99 95 91 87 83 79 75 71 67 63 59 55 51

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SWIS 08 - Rev 1
GTAW/SMAW Welding of Austenitic Stainless Steel using BS2901 316S92 TIG wire and Rutile
E316L-16 Electrodes in the thickness range 2.87mm-30.5mm on 0.5” diameter & over.

SETUP
Prepare by machining and/or grinding.
Tackweld using GTAW root pass parameters.

a = 60º-75º
a' = 45ºmin
g = 2-4mm
f = 1mm +/- 0.5mm

PREHEAT
Preheat is not required unless the steel is below 5ºC (in which case propane gas may be used to raise the
temperature to room temperature.
Maximum interpass temperature : 175°C.
Check temperature with Tempilstick between each weld pass.

PROCESSES
Process Application Notes
GTAW All Diameters 1.6mm – 2.4mm 316S92 Wire.
Up to 30.5mm WT. DC-ve.
String / Weave max 10mm width.
Shielding : High Purity Argon at 10-15 litres/min. Argon
purge is mandatory for root, 2nd pass, and 3rd layers –
see charts.
SMAW Fill & Cap Only Rutile Electrodes (E316L-16).
3” Diameter & Over DC+ve. String / Weave : max width 10mm
7.6mm - 30.5mm WT

GTAW Welding Parameters

Weld Area Arc Volts[volts] Current Speed [mm/min] Heat Input
[amps] [kJ/mm]
Root 9-13 40-140 23-94 0.6-2.5
Fill & Cap 9-13 50-210 30-132 0.6-2.5

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SMAW Welding Parameters

Weld Area Size Arc Current Speed Heat Input ROL

[mm] Volts[volts] [amps] [mm/min] [kJ/mm] [mm]
Fill 2.5 19-23 70-110 71-170 0.7-1.5 60-85
3.2 22-26 95-145 70-169 1.0-2.4 110-140
Cap 2.5 20-24 70-100 70-140 0.8-1.6 60-85

GENERAL NOTES
• Interrun clean using a grinder and stainless steel wire brush.
• This SWIS card may also be used for conducting weld repairs - refer to repair instruction chit.
• This SWIS covers welding of 304/304L, 316/316L grade stainless steel (and also for 321/321H grades
provided the maximum design temperature is 600ºC or below).
• Carry out fillet welding to fill parameters within thickness/diameter range.
• Typical pass sequences are shown below.

a. Conventional root and 2nd pass.

b. Split hot pass.
c. Single pass cap (small pipes)
d. 2 run cap.
e. 3 run cap.
f. Multirun cap.

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SWIS 09 - Rev 1
GTAW Welding of 90/10 CuNi Alloy (“Kunifer”) using AWS A5.7 ER CuNi TIG wire in the
thickness range 1.5mm-9mm on all pipe diameters.

SETUP
Prepare by machining and/or grinding.
Tackweld using GTAW root pass parameters.

a = 60º-120º
a' = 45ºmin
g = 0-2.5mm
f = 0-0.5mm

PREHEAT
Preheat is not required.
Degrease with acetone and ensure it has evaporated completely before welding starts.
Maximum interpass temperature : 175°C.
Check temperature with Tempilstick between each weld pass.

PROCESS
Process Application Notes
GTAW All Diameters 1.6mm – 2.4mm A5.7 ER CuNi Wire.
1.5mm - 9.1mm WT. DC-ve.
String / Weave max 10mm width.
Shielding : High Purity Argon at 10-15
litres/min. Argon purge is mandatory for
root, 2nd pass, and 3rd layers – see charts.

GTAW Welding Parameters

Weld Area Arc Current [amps] Speed Heat Input
Volts[volts] [mm/min] [kJ/mm]
Root 10-14 60-125 53-99 0.6-1.4
Fill & Cap 10-14 60-140 49-113 0.6-1.6

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GENERAL NOTES
• Interrun clean using a grinder and stainless steel wire brush (segregated for CuNi use only).
• This SWIS card may also be used for conducting weld repairs - refer to repair instruction chit.
• Carry out fillet welding to fill parameters within thickness/diameter range.
• Typical pass sequences are shown below.

g. Conventional root and 2nd pass.

h. Split hot pass.
i. Single pass cap (small pipes)
j. 2 run cap.
k. 3 run cap.
l. Multirun cap.

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SWIS 10 - Rev 1
SMAW Welding of Austenitic & Duplex Stainless Steel Cladding Panels

APPLICATION RANGE
304, 316, 321, (including L Grades) & 22% Duplex Stainless Steel in the range 1.5mm to 8mm thickness to itself
and to non-primary CMn steel up to 12mm thickness.
This SWIS summarises WPS 901 & 902.

CONSUMABLES
Metrode Vertamet 309Mo in 2F, 3FD, 4F, and 3GD Positions using 2.5mm and 3.2mm Electrodes
Metrode Ultramet 309Mo or Supermet 309Mo may be substituted for 2F and 4F fillet applications.

TECHNIQUE
Use on DC+ve on low current (just sufficient to keep electrodes running). All vertical welding must be performed in
the vertical downwards direction using Vertamet type.

Restrict interpass temperature to 150°C maximum.

Electrodes run better when warm - poor operating characteristics or porosity imply that electrodes are damp -
bake at 250°C for 1 hour and use within 6 weeks if necessary.

SMAW Welding Parameters

Size Arc Current Speed [mm/min] Heat Input
[mm] Volts[volts] [amps] [kJ/mm]
2.5 20-24 80-100 170-440 0.3-0.8
3.2 20-24 110-140 155-500 0.3-1.1

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Arc Energy Calculations / Measurement

All SLP weld procedures and SWIS cards use unfactored arc energy rather than true heat input for
specification and monitoring purposes.

The calculation used is as follows :-

Arc Energy = Volts x Amps x Time[sec] / (Run-Out Length[mm] * 1000)

(Eqn. 1)

An easy way to remember this is “VAT/ROL divided by 1000”

(the division by 1000 is needed to convert from J/mm to kJ/mm).

If the welding travel speed can be read directly (eg. SAW welding) then these equations can be used :-

Arc Energy = Volts x Amps * 60 / (Travel Speed[mm/min] * 1000)

(Eqn. 2a)
or

Arc Energy = Volts x Amps * 6 / (Travel Speed[cm/min] * 1000)

(Eqn. 2b)

ROL v. Stub Length charts and estimates of heat input derived from wire feed speed are shown on the next few
pages. These may be used for welder parameter monitoring as indicated on the specific SWIS cards. However,
when using the ESAB AristoFeed equipment, direct calculations should be made using Eqn. 1 and the values
displayed on the feeder after completing the weld pass. The equations should also be used with other welding
plant that has calibrated readouts of voltage and current.

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Notes / Addenda

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