In my facility, I have noticed a recurring issue with weld leaks in the conical bottom vessels, particularly at the junction where the cone meets the boot. These vessels store slurry and are constantly in use as holding tanks, being pumped 24/7 with a turnaround cycle of 130 days. One potential root cause identified is the change in flow direction within the tank, leading to turbulence and erosion at the weld site. I am seeking recommendations for a welding rod specifically designed for these types of welds. Will using a stronger, more suitable rod help alleviate this problem and prevent future leaks?
What type of support does the vessel have? Can you please share a basic diagram?
Absolutely, there is a specialized hard-facing rod designed specifically for wear-resistant applications on 'A' series steel. Is it possible to incorporate additional metal during the welding process? And has a vortex breaker been considered to mitigate swirling effects?
Are you experiencing wear, erosion, or cracks in the weld? Is the weld leaking consistently around the circumference or just in patches? Are you wondering if TK refers to tank? What is the thickness of the tank's plate material, and is it constructed of carbon steel? Additionally, what type of electrode are you currently utilizing?
The plate is 1/2 inch thick with a weld that has eroded approximately 2.5 inches long by 1/8 inch wide. TK refers to tank, and the current electrodes being used are regular mild steel electrodes, such as the commonly used 6010. The weld encircles the boot's circumference, and one potential solution being considered is using a nickel electrode for a stronger weld.
The degradation of the weld is concentrated in one area and occurs repeatedly in the same location.
Absolutely, using a more suitable welding rod can greatly reduce the likelihood of future leaks. A combination of the right materials and technique is key in addressing this issue. For high-stress environments like yours, a rod designed for high yield strength and toughness would be beneficial - one that features high resistance to cracking and excellent ductility. I'd recommend rods compatible with Low Hydrogen welding processes, such as AWS E7018 or E6013, as they're known for their tensile strength, and they work well in wet conditions. Just remember, no matter how well-rated the rod is, the technique used, the cleanliness of the weld area, and the proper treatment and inspection post-welding are just as vital to durable, leak-free welds.
I've experienced similar issues in my own facility, so I can sympathize with your predicament. Constant erosion at the weld site can indeed cause leaks overtime. One possible solution could be to use a welding rod with a higher tensile strength, such as E7018 or E7024. These rods are known for creating more durable and robust welds. However, it's also worth considering other factors like your welding technique and the skill level of the welder. Sometimes, even the best welding rod won’t compensate for poor welding practice. You may also want to explore the possibility of internal lining or coating for added protection against the slurry. Ultimately, a combination of the right materials and proper welding practices can significantly reduce the occurrence of these leaks.
You're definitely on the right track by considering the impact of turbulence and erosion at the weld site. A stronger rod may help, but it's equally important is to ensure that the rod has sufficient corrosion resistance for the slurry being stored. Nickel-based rods, like the Inconel 625 or Hastelloy W, tend to have excellent resistance to erosion and corrosion, making them suitable for situations where the welds are exposed to harsh substances. However, remember to consider the overall metal composition of your vessel when choosing a welding rod, to avoid potential metal incompatibility. It might be worth bringing in a welding engineer to make a recommendation specific to your setup.
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Answer: - Weld leaks in conical bottom vessels can occur due to factors such as turbulence and erosion caused by the change in flow direction within the tank. This can weaken the weld site over time, leading to leaks.
Answer: - Weld leaks in vessels storing slurry can result in product loss, potential contamination, and operational downtime. It is essential to address these issues promptly to prevent further complications.
Answer: - Using a welding rod specifically designed for these types of welds can help improve the durability and integrity of the weld joints in conical bottom vessels. Selecting the right welding rod based on the vessel's operating conditions and material compatibility is crucial in preventing future leaks.
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