Stainless "Monster Coupon" 625 wall 2" help

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I have a test in a day or so that is 2" stainless to stainless 625 extra heavy wall "monster coupon" and they are having us tig it with 309 filler... Any pointers on stainless to stainless with 309?? They say a lot of people fail it?
Reply:Destructive testing, non destructive? Just get a good root in the first time. Good purge, And let it cool down a lil every once in a while. 309 is a  stainless to carbon filler as im pretty sure u know. Strange they are making u test with it. Either way... keep it clean. Heavy wall tests are gravy. Sch 10... not so much. Good luck
Reply:Visual and X-ray, yea it is a weird test they even agreed it was weird.. The test is for Chevron Refinery.
Reply:I tested for conoco phillips last year... get this... 2" xx carbon steel. Tig stringer, hot, 7018 to flush, 309 stick cap. Restricted. Id say that has been one of the wierdest procedures ive tested to date. LolLast edited by Coaltrain; 01-23-2013 at 08:37 PM.
Reply:I'm working at the Chevron in Pascagoula for KBR, is that where you're going? Performance is doing a shutdown here paying better money, but too many hours for this old fart.and yes, they are busting out a ton of welders at the KBR test shop, but a lot of them are pretty green.How much experience do you have doing TIG on stainless?
Reply:I don't like 309 at all, it cracks for no apparent reason and flows/melts different then 308-316, make sure your purge is 100% and maybe use a gas lens if you are allowed .Careful with the end craters, x-ray is mostly about them.Good luck &have fun.--------------------------------------------------------------www.becmotors.nlyup, I quit welding.. joined welder anonymous
Reply:I've got a little bit of stainless under my belt I feel comfortable with it.. I have my test at 7am Monday morning if this doesn't work I'll just run over to Performance..
Reply:Best of luck bro, confidence is key, and sounds like you got it! I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Dont worry about those failing welders, it just means that they have not bothered to practice. Stainless Steel - now I cannot remember what sch. 0.625 wall is, but I am either assuming that it is 2 1/2" xxh test or else its the 2" sch. 160 test. Regardless, they should actually be testing welders on 6" pipe rather than 2" pipe because many welder can do a 2" pipe because it has far, far less root to weld in - and something that small, you can make a really nice looking root pass - whereas in comparison to a 6" coupon where you have to actually put in a fairly lengthy root pass, you wouldn't believe how much trouble many welders have. Now with stainless steel, you don't have to be welding all that hot - if the stainless is clean, it will still fuse quite nicely. If you are running too cold, then - and let me space my words out here, it    will   take    absoutely    forever    to    melt    the    filler    metal. But with stainless it doesn't really matter because you can hold the tig torch in the same spot all day long on it wont get porosity like carbon tig does. Carbon is actually a more difficult weld because if a welder is not careful, they will get that porosity and they will start carrying it through the weld. Anyways, here is a trick:On the test, you put in the root pass. Then after the root pass is in, you put in the hot pass - I like to put in 2 hot passes rather than one large hot pass because I like to have the bottom bevel soak up as much heat as possible while I splash some stainless onto the root pass - then I like to have the top bevel next soak up all the heat while I splash some on the root. Now you should find out why the welders are failing - whether they are burning throught the root pass, or whether they are getting drop through or suck back - just because its called a hotpass doesn't mean you can crank it up a whole bunch of amps and smolder it in there  After the hot pass is done - Take That pipe coupon - the carbon pipe with the stainless filler metal, or else its stainless pipe w/stainless filler metal, and you take the whole entire pipe and just drop it in a big bucket of water and you let it sit there. When its all nice and cold and the temperate is gone from the pipe, you take the pipe and you set it back up, you take the buffer and you buff the water off of your weld or you take a towel and wipe the water off, and then you take the electrode and put 1 pass up the left side and 1 pass up the right side, then you take it off and go back to dunking it in water and cooling it down. Just keep putting in 1 full pass then dunking - another 1 full pass, then dunking - Because why welders fail is because they are overheating the stainless' protective properties and I canont remember what exactly it was whether they were overheating the chromium or what alloy that stainless has - basically applying heat ontop of heat you will be depleting the stainless' properties. Now, 316 is less susceptible to cracking in comparison to 309 as I have been told. But it doesn't matter in this test, just keep dunking the pipe in water. When I renewed my stainless ticket, and even duplex ticket, I just kept dunking the pipe in water after every pass. Or you could blast it with air - its stainless. throw a wet rag on it, dunk it in water, it doesn't matter. I throw snow on the stainless. There is alot of procedures and alot of theories and many welders know a great deal about metallurgy - I am not one of those welders, but I ask questions, and knowledge is just a course away and some practical training and experience. If you don't dunk the pipe coupon in water after every pass it will and or may crack. If you dunk the pipe in water after every pass, it will be clean.46’ sae30047’ sa200 w/Wisconsin VF451’ shorthood56’ shorthood56’ shorthood68’ redface69 redface07’ ranger 305G13’ sae300Inconel/Hastelloy – SS – Duplex – Chrome/Carbon Tig – F3Downhand – STT/RMD – F3F4 – B Pressure
Reply:Originally Posted by justinTI have a test in a day or so that is 2" stainless to stainless 625 extra heavy wall "monster coupon" and they are having us tig it with 309 filler... Any pointers on stainless to stainless with 309?? They say a lot of people fail it?
Reply:He's not gonna get to dunk his  coupon to cool it off, once he tacks it to the stand, it stays there till he's finished. these guys are real serious about the welding on this job, it's the most anal job I've ever been on. Also, he's not going to be using a Lincoln, he's going to be on a Miller 8 bank.I had to take a 6 inch std wall TIG/Stick first, that's to weed out the worms before they spend the money on the monster coupon. After that you take a 2 inch monster carbon, TIG/stick, then you take the 2 inch monster stainless.they want a nice fat root in the pipe, don't even try to put it in flat. In addition, don't get more than a 1/8th buildup on the cap.Also, be prepared for about a 45 minute speech by the inspector before you even start welding.adding to the 6 inch test- they won't let you put a tack longer than 3/8ths, don't grind your tacks until you're ready to tie one in. I ground all mine beforehand and the gap closed way up on me, I barely got enough root in to get by,Last edited by TimmyTIG; 01-24-2013 at 10:00 PM.
Reply:Thanks Timmy!!
Reply:Justin, do NOT add water. The 309 is not like 316, it will show if you wet it up; the carbon feature in the filler will not like it. The test is SS to SS because you will likely wind up with some SS flanges to carbon pipe. I agree with Timmy; do a really solid root pass. I do lots of 309 lately, of all things welding on tools. It does not lay like butter the way 316 does. It's a touch sticky. But it does weld good, and does not cave in almost ever on me- and I am filling some big gaps where powerheads and hammer castings lost chunks that I am rebuilding, not just filling in. Heat for 309 is more akin to 70 s2, a bit hotter than 316ss.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:C'mon Justin! Splash it with water! The inspector will never know if you get the whole piece wet.. (Cause he'll have nothing to compare to) Just don't splash Magwi's.. They'll turn into gremlins and destroy the welding shop.. If he questions, just throw a naked supermodel infront of the weld coupon, he'll say it looks good and bend it anyways..46’ sae30047’ sa200 w/Wisconsin VF451’ shorthood56’ shorthood56’ shorthood68’ redface69 redface07’ ranger 305G13’ sae300Inconel/Hastelloy – SS – Duplex – Chrome/Carbon Tig – F3Downhand – STT/RMD – F3F4 – B Pressure
Reply:Some common practices in refineries are to weld carbon steel flanges to stainless pipe or to run carbon steel piping with stainless elbows or more frequently carpenter 20 elbows.  Reason being, fluid flow through sharp bend which cause turbulence tend to be more corrosive than fluid flows through straight runs.  Basically piping in refineries is designed to have a 10 year lifespan which is not very long so they will cut every corner to save money and still meet the 10 year limit.
Reply:Originally Posted by justinTThanks Timmy!!
Reply:We used 309 and Inconel on our High Pressure Steam coupons,which were black iron .Did the root with the 309 covered with inconel.
Reply:Yea I'm not dunking it hahah... I've never had to do that ever I'll just take my time and let my pipe cool to under 250 before each pass I think I'll do good, even if I fail this one I'll just head over to Performance, but I've never failed a test yet!!
Reply:I'm sure there testing you on 625wall carbon with 309 wire.If your using a miller 8 bank which is probably a 304xmt machine try to run the root in the mid 80s on that type of machine. Hot pass and fill around 100ish.There probably gonna want good penetration on the root so try to use a 5/32 gap and 1/8th wire. Feel the purge with the back of your hand or hold your breath and feel it with your lips. Could run it around 15-20 and 20-30 on your torch.On your last open quarter poke a hole in the tape on top of your coupon and run the last quarter.
Reply:2 of the 3 tests are carbon 1 is stainless I looked at some completed tests.
Reply:way past time for an update here, how did it go, Justin?