Q & A DURING L&T VISIT

Q-1 what is the function of copper coating in SAW filler wire?

Answer:

• to assure a good electric contact between wire and contact tip

• to assure a smooth feed of the wire through the guide tube, feed rolls and contact tip
(decrease contact tube wear)

• to provide protection against corrosion

Q-2 what are the functions of electrode covering in SMAW process?

Answer:

• To facilitate arc ignition and give arc stability.

• To generate gas for shielding the arc & molten metal from air contamination.

• To de-oxidise the weld metal and flux impurities into the slag.

• To form a protective slag blanket over the solidifying and cooling weld metal.

• To provide alloying elements to give the required weld metal properties.

• To aid positional welding (slag design to have suitable freezing temperature to

support the molten weld metal).

• To control hydrogen contents in the weld. (basic type)

Q-3 Write the energy distribution for different polarity?

Answer:

• DCEP – 67% at electrode and 33% at job.

• DCEN – 33 % at electrode and 67% at job.

• AC – 50 % at electrode and 50% job.

Q -4 what is the purpose of sodium, silicon and potassium in core element?

Answer:

• Silicon - deoxidize & form slag

 • Sodium - stabilize arc & form slag

• Potassium - stabilizes the arc & form slag

Q-5 what is the phenomena behind the overhead welding?

Answer:

In overhead welding during welding flux has more fluidity and comes on the surface when
the metal is deposited in the root gape. There are different freezing point metal and the
flux. so metal have low freezing point so its deposit in the root gape and flux have a high
freezing point so its deposit on the metal .

Q-6 which innovative welding technique is used by L & T in T joint welding?

Answer:

In T joint welding backing is required in other side while welding on one side. Flux goes on
another side from the root opening and that has to be removed before welding other side.
During the parallel welding, one side of the welder have to lead the position and other will
follow in other side. So flux which comes from a root opening is melt again by the welder
done welding leg to other side welder.

Preheating of the job is also not required by other sources since one side of welding serve
the purpose.

Q-7 during welding process, why sinusoidal wave form is converted in to the square
wave form?

Answer:

In sinusoidal wave, we get maximum energy at one point only. So for the more amount of
maximum energy we can get by converting the sinusoidal wave form in to the square wave
form, and more penetration and deposition rate is achieved due to maximum energy.

Q-8 which types of SAW process are used in Larsen and Toubro?

Answer:

Tandem SAW Narrow groove application

As the section thickness of vessel for nuclear and petroleum industry increase, the desire
for reduced weld time and material consumption has driven the joint on these vessels to
become narrower joint significantly reduce number of passes and material needed to
complete each joint. Whenever material and specification allow, SAW process ideally
Tandem with two torches are is preferred due to its ability to provide higher strength. It
prevents undercut, trapped slag and concave profile since there are maximum two passes
per layer. It is required to change mode of power supply from DC to AC when switching
from root pass to filler pass.

TWIN HEAD-SAW – In order to increase productivity of welding two wire or multi wire
SAW process is carried out. LNT practice that for many of high thickness nuclear pressure
vessel.

Q-9 how many electrodes are used in the TANDEM SAW? What is the polarity of the
both electrode?

Answer:

In TANDEM SAW process there are more than one electrode is used. But for first electrode
alternative current and for second electrode direct current shall be used.

Q-10 In TANDEM SAW process, why AC and DC both currents are used?

Answer:

AC will melt the base metal and make weld pool in the base metal and by DC it will fill the
weld metal in the weld pool.

Q-11 What is the purpose of dust free zone in LNT?

Special dust-free enclosures with temperature and humidity control enable the Company to
achieve manufacturing excellence in Class 1 nuclear island components. L&T manufactures
reactor vessels, steam generator, pressurizer, control rod drive mechanisms (CRDMs),
dummy fuel rod sub-assemblies, fuel transfer equipment, primary heat transfer systems,
heavy water upgrading columns and internals, high pressure safety heat exchangers, high
and low-level waste storage tanks, special equipment for in-service-inspection and thermal
insulation panels.

More precise job Dust free enclosure is used by LNT. L&T is associated with India's Fast
Breeder Technology Programme, having manufactured reactors and nuclear equipment for the
first 500 MW Prototype Fast Breeder Reactor (PFBR). The reactor vessels and other large
equipment - meeting tolerances that are among the world’s best were manufactured at a special
fabrication shop at the site. PFBR Steam Generators and Heat Exchangers are manufactured
within dust-free enclosures at L&T's workshops.

Q-12 which Testing is used in high thickness job in LNT?

Answer:

Ultrasonic Testing.