Flux-Core Welding in Refinery Service

Abstract While its reputation has been stigmatized by early quality problems in the 1980’s, Flux-Core Arc Welding (FCAW) has evolved into a process by which experienced fabricators can obtain radiographic quality welds in many alloy systems. Research and development, modem manufacturing techniques, and improvement in sensor and inspection technologies have produced consumables for gas-shielded procedures that can meet many petroleum refinery industry specifications. During the last decade there has been increased pressure exerted by fabricators on buyers to utilize Flux-Core Arc Welding (FCAW) where possible. In spite of the fact that there is reluctance on the part of process industry to accept the FCAW process, today’s competitive market has enabled fabricators to persuade segments of the power, chemical, and petroleum processing industry to accept FCAW for pressure vessel, heat exchanger, and piping fabrication applications in order to reduce both cost and schedule. Even though many refinery owner/operators' specifications prohibit the use of FCAW for radiograph quality welds, there has been a growing trend to rethink the restriction, and allow the controlled use of FCAW (gas shielded) for petroleum refinery pressure retaining welds. This paper discusses the author's experiences with the increasing use and ongoing limitations of FCAW(G).