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WELDING CODE, STANDARD& WELDING PROCEDURE

Drs. Ir. Toto Marnoto , M.Sc

Standard adalah kumpulan dokumen dokumen berisikan kode (codes), spesifikasi (specification), saran aplikasi (recommended practice), klasifikasi, dan petunjuk (guide) yang telah dipersiapkan oleh suatu institusi organisasi dan disahkan (Appraved) sesuai dengan prosedur yang ada (berlaku) :

"Codes" adalah suatu standard yang berisikan kondisi dan persyaratan yang berhubungan dengan bidang khusus (a particularly' subject) dan mengindikasikan bahwa prosedur yg digunakan telah sesuai dengan persyaratannya. Codes ini diikuti (mandatory) karena menyangkut kepentingan umum yang merefer kepada kebij akan otoritas pemerintahan (Codes is a body of laws arranged systimatically for easy reference)DEFINISI

WELDING AND JOINING

Specification (spesifikasi) adalah suatau standard yang berisikan penjelasan yang rinci dan akurat tentang persyaratan teknis dari material, produk, sistim atau jasa.Contoh Kode :Structural Welding Code-Steel (AWS D1.1) Boiler & Pressure Vessel Code (ASME)Welded Pipeline & Vessel (API)Contoh Specification :Filler Metal Specification (AWS A5.X)Material & Consumable of Welding (ASME sec. IIC)DEFINISI

WELDING AND JOININGAWS D1.1, Structural Welding Code-SteelAWS D1.2, Structural Welding Code-AluminumAWS D1.3, Structural Welding Code-Sheet Steel AWS D1.4, Structural Welding Code-Reinforcing SteelAWS D1.5, Bridge Welding CodeAWS D1.6, Structural Welding Code-Stainless Steel

AWS Structural Welding Code

WELDING AND JOINING(1) General Requirements(2) Design of Welded ConnectionsPart A-Common Requirements of No tubular and tubular ConnectionsPart B-Specific Requirements for No tubular Connection (statically or Cyclically Loaded)Part C-Specific Requirements for Cyclically Loaded No tubular ConnectionsPart D-Specific Requirements for Tubular connections(3) Prequalification of WPSs(4) QualificationsPart A-General RequirementsPart B-Welding Procedure Specifications (WPS) Part C-Performance QualificationWelding Code Steel (AWS D.1.1)

WELDING AND JOINING(5) Fabrication(6) InspectionPart A-General RequirementsPart B-Contractor ResponsibilitiesPart C-Acceptance CriteriaPart D-Nondestructive Testing Procedures Part E-Radiographic TestingPart F-Ultrasonic Testing of Groove Welds Far! G-Other Examination Methods(7) Stud WeldingStrengthening and Repairing Existing Structures Annexes-Mandatory Information Annexes-No mandatory Information CommentaryWelding Code Steel (AWS D.1.1)

WELDING AND JOININGTest Method Applicable Code References

Radiographic Section 6, Part EUltrasonic Section 6, Part FMagnetic Particle Section 6, ASTM E 709Liquid Section 6NDT Personnel Qualification 6.14.6.1 (SNT-TC-1A)

The acceptance criteria for both the visual inspection and nondestructive examination are found in the following code location, depending upon the type of structure being constructed.

Weld AcceptanceType of Structure Criteria Reference

Statically Loaded,Dynamically Loaded, and Section 6Tubular StructuresNondestructive TestingMethods-D1.1 Code Reference

WELDING AND JOININGASME SectionTopicIPower BoilerIIMaterial SpecificationPart A : Ferrous MaterialsPart B : Nonferrous MaterialsPart C : Welding Filler MaterialsPart D : PropertiesIIINo clear ComponentsIV Heating BoilersVNondesmetive ExaminationVI Care and Operation of Heating BoilersVIICare of Power BoilersVIIIUnifiers Pressure VesselsIX Welding and Brazing QualificationXFiberglass-Reinfereed Plastic Pressure VesselsXI In-service Inspection of No clear ComponentsASME Boiler and PressureVessel-Code Reference

WELDING AND JOINING Section Information Provided

II, Part A Description, including chemical and mechanical properties, of the steel base metals to be used. II, Part C Description, including chemical and mechanical properties, of the welding filler materials. II, Part DMaterial properties VMethods for performing various required nondestructive examinations. VIIIDesign, fabrication and inspection requirements for unfired pressure vessels. including weld acceptance criteria. IXRequirements for the qualification of welding procedures and welders.ASME STANDARD

WELDING AND JOININGAPI 1104, Standard for Welding Pipeline and Related FacilitiesAPI 620, Recommended Rules for Design and Construction of Large Welded low Pressure Storage TanksAPI 650, Standard for Welded Steel Tank for Oil StorageAPI STANDARD

WELDING AND JOININGEquipmentQuality of WeldsApprovedWelder(operator)Welding CoordinatorPersyaratan Dasar dalam MenentukanKualitas dalam Pengelasan

WELDING AND JOININGASME (American Society of Mechanical Engineers)EN (European Norm) /European StandardAWS (American Welding Society)Standar Eropa dan Amerikadalam mendukung kualitas Lasan

WELDING AND JOININGASME (Sec IX (Qualification Standard for Welding and Brazing Procedure, Welder, and Welding & Braze Operator.

ASME Sec II C Standard for Material and Consumable of Welding.ASME Standard untuk Welding

WELDING AND JOININGBASIC CONTRUCTION CODE / STANDARD : ASME Sec I, ASME B31.1, ASME B31.3 ASME Sec VIII Div 1 & 2Welding Material ASME II CExamination and Testing ASME VWelding Personnel And Welding Procedure ASME IXQuality of WeldsSTANDARD KUALITAS LAS dari ASME

WELDING AND JOININGEN 288 (Standard & Qualification Welding Procedure)EN 287 (Standard & Qualification of WelderEN 1418 (Standard & Qualification of Welding Operator)European Standard For Welding

WELDING AND JOINING Quality manual and certificate EN ISO 9000 Quality requirements For welding EN 729 (ISO 3834)Examination/Testinge.g. ISO 5817,ISO 30042,EN 970Safety in welding,e.g. EN 60974,EN 50078Materials0Parents metal, e.g. EN 10025Consumables, e.g. EN 440, EN 4990Quality of weldsWelding personnelEN 287 (ISO 9606)EN 1418 (ISO 14732)EN 719 (ISO 14731)Welding proceduresEN 288 (ISO 9956)[In Future EN ISO 15607-5614]STANDARD KUALITAS LAS dari EN

WELDING AND JOININGEN 288-1. General rules fusion welding.EN 288-2. WPS for Are Welding.EN 288-3. Welding Procedure Test for Are welding of steel.EN 288-4. Welding Procedure Test for Are welding of Aluminum and Its alloys.EN 288 - 5. Approval by using approved welding consumables for are weldingEN 288 - 6. Approval related to previous experience EN 288 - 7. Approval by a standard welding procedure for are welding.EN 288 - 8. Approval by a pre-production welding test.PROSEDUR LAS EN 288

WELDING AND JOININGEN 287-1. Approval testing of welders-Fusion welding part 1 : Steels.EN 287-2. Approval testing of welders-Fusion welding part 2 : Aluminum and aluminum Alloys.EN 287-3. Approval testing of welders- Fusion welding part 3 : Copper and Copper Alloys.EN 287-4. Approval testing of welders- Fusion welding part 4 : Nickel and Nickels alloysEN 287 - 5. Approval testing of welders- Fusion welding part 5 : Titanium and Titanium, Zirconium and Zirconiumalloys.EN 287 - 6. Approval related to previous experienceEN 287 - 7. Approval by a standard welding procedure for are weldingEN 287 - 8. Approval by a pre-production welding test.KUALIFIKASI WELDER - 287

WELDING AND JOININGApplicationApplicationCode/standardWelding StandardProcedureApprovalWelder Approval PressureVessels BS 5500 ASME VIIIBS EN 288 ASME IXBS EN 287 ASME IXProcess Pipe-workBS 2633BS 4677 ANSI/ASME B311ANSI/ASMEB31.3 BS 2971BS EN 288 (Part 3)BS EN 288 (Part 4)ASME IXASME IXBS EN 288 (Part 3) (if required)BS EN 287 (Part 1) BS EN 287 (Part 2)ASME IXASME IXBS 4872/BS EN 287

Structural FabricationAWS D1.1AWS D1.2BS 5135BS 8118AWS D1.1AWS D1.2BS EN 288 (Part 3)BS EN 288 (Part 4)AWS D1.1AWS D1.2BS EN 287BS EN 287BS 287StorageTanksBS 2654BS 2594API 620/650BS EN 288 (Parts 3 & 4)BS EN 288 (Parts 3 & 4ASME IXBS EN 287BS EN 287ASME IXTable 1 Example of application codes and standards and related welding procedure and welder approval standards

WELDING AND JOININGA weld cannot be checked to the full extent!

Strength, ductility and corrosion resistance can only be checked by destructive techniques.

Properties can only be guaranteed for the actual product when manufactured to exactly the same written procedure, and carefully controlled.Why a WPS

WELDING AND JOININGThe main objective of a WPS is to make a welding operation

Reproducible

Why a WPS

WELDING AND JOININGThe welding procedure is somewhatAnalogous to a cooks recipe.

It outlines the steps required to make a qualityWeld under specific conditions.

The WPS is a communication tool, and it is the primary means of communication to all the parties involved regarding how the welding is to be performed.It must therefore be readily available to foremen, inspectors and the welders.What is a WPS ?

WELDING AND JOININGAccording to QW-100.1 ASME Sec IX.Welding Procedure Specification (WPS).WPS is a written document that provides direction to the welder or welding operator for making production welds in accordance with Code requirements.

According to QW-200.2 ASME Sec IX.Procedure Qualification Record (PQR).A PQR is a record of the welding data used to weld a test coupon. The PQR is a record of variables recorded during the welding of the test coupons. It also contains the test results of the tested specimens. Recorded variables normally fall within a small range of the actual variables that will be used in production welding.What is a WPS ?

WELDING AND JOININGProcess(SMAW, FCAW, etc)Electrode specification(AWS A5.1, A5.20, etc)Electrode classification(E7018, E71T-1, etc)Electrode diameter (1/8 in., 5/32 in., etc)Electrical characteristics(AC, DC+, DC-)Base metal specification(A36, A572 Gr50, etc)Minimum preheat and interpassTemperatureWelding current (amperage)/wire feed speedAre voltageTravel speedPosition of weldingPost weld heat treatmentShielding gas type and flow rateJoint design detailsWhat is WPS Variables ?

WELDING AND JOININGEssential Variable :QW-401.1 Essential Variable (Procedure).A change in a welding condition which will affect the mechanical properties (other than notch toughness) of the well-meant (for example, change, in P-Number, welding process, filler metal, electrode, preheat or post weld heat treatment, etc.).

QW-401.2 Essential Variable (Performance).A change in a welding condition which will affect the ability of a welder to deposit sound weld metal (such as a change in welding process, deletion of backing, electrode, F-Number, technique, etc).What is Variables in WPS ?

WELDING AND JOININGSupplemental Essential Variable :QW-401.3 Supplemental Essential Variable (Procedure). A. Change in a welding condition which will affect the notch-toughness properties of a well-meant (for example, change in welding, heat input, preheat or PWHT, etc).When a procedure has been previously qualified to satisfy all requirements other than notch toughness, it is then necessary only to prepare an additional test coupon using the same procedure with the same essential variables, but additionally with all of the required supplementary essential variables, with the coupon long enough to provide the necessary notch-toughness specimens.What is Variables in WPS ?

WELDING AND JOININGNonessential Variable :

QW-401.4 Nonessential Variable (Procedure).

A Change in a welding condition which will not affect the mechanical properties of a well-meant (such as joint design, method of back gouging or cleaning etc.What is Variables in WPS ?

WELDING AND JOININGParagraphBrief of VariablesEssentialSupplementaryEssentialNonessentialQW-402Joints.1Groove DesignX.4-BackingX.10Root SpacingX.11RetainersXQW-403BaseMetals.5Group NumberX.6T Limits ImpactX.7T/t Limits > 8 in. (203 mm)X.8T QualifiedX.9t Pass > in. (13 mm)X.11P-No. qualifiedX.13P.No. 5/9/10XQW-404FillerMetals.4F.NumberX.5A. NumberX.6DiameterX.7Diam. > in. (6 mm)X.12AWS classX.30TX.33AWS classXQW-405Positions.1+PositionX.2PositionX.3Vertical weldingXQW-406Preheat.1Decrease > 100F (56)X.2Preheat maint.X.3Increase > 100 F (56) (IP)XQW-407PWHT.1PWHTX.2PWHT (T & T range)X.4T LimitsXQW-409ElectricalCharacteristic.1>Heat inputX.4Current or polarityXX.8I & E rangeXQW-410Technique.1String/weaveX.5Method cleaningX.6Method back gougeX.9Multi to single pass/sideXX.25Manual or automaticX.26PeeningX

Legend :+ Addition- Delection> Increase/greater than< Descrease/less than Uphill Downhill Forehand Backhand Chane

QW-253 WELDING VARIABLE PROCEDURE SPESIFICATION (WPS)Shielded Metal-ArC (SMAW)

WELDING AND JOINING28Application standardContractProject specificationDrawingsDevelopment of procedureP WPSPreliminary welding procedure specificationEN 288-3/4ASME IXAWS D1.1/2WPAR/PQRWelding procedure approval recordWelder approval certificate6 months prolongationFinalisation of procedureWelding procedure specificationWork instructionsParty involvedManufacturerExamining BodyApproval of prosedure2 years (EN 287) prolongationPlease for production Stages in Welding Procedures and Welder Approval

WELDING AND JOININGThe material group are based on comparable base material characteristics, such as composition, weld ability, braze-ability, and mechanical properties.Base MaterialWeldingBrazingSteel and steel alloysP No.1 through P No.11, includingP No.5A, 5B,and 5CP No.101 through P No.103 Aluminum and aluminum-based alloysP No.21 through P No.25P No.104 through P No.105 Copper and copper-based alloysP No.31 through P No.35P No.107 through P No.108 Nickel and nickel-based alloysP No.41 through P No.47P No.110 through P No.112 Titanium and titanium-based alloysP No.51 through P No.53P No.115 Zirconium and zirconium-based alloysP No.61 through P No.62P No.117ASME SECTION IX MATERIAL GROUPING P-NUMBERS

WELDING AND JOININGP No.EN-288Base Metal11Carbon Manganese Steels, 4 Sub GroupsGroup 1 up to approx 65ksiGroup 2 Approx 70ksiGroup 3 Approx 80ksiGroup 4 Special (e.g. SA-724 gr. A, B, C)2-Not Used34 3 Sub Groups:- Typically half moly and half chrome half moly452 Sub Groups:- Typically one and a quarter chrome half moly5A5Typically two and a quarter chrome one moly5B52 Sub Groups:- Typically five chrome half moly and nine chrome one moly5C65 Sub Groups:- Chrome moly vanadium686 Sub Groups:- Martensitic Stainless Steel Typically Grade 41078Ferritic Stainless Steels Typically Grade 40989Austenitic Stainless Steels, 4 Sub groupsGroup1 Typically Grades 304, 316, 347Group2 Typically Grades 309, 310Group3 High manganese gradesGroup4 Typically 254 SMO type steels9A, B, C7Typically two to four percent Nickel Steels10A,B,C,F,G?Mixed bag of low alloy steels, 10G 36 Nickel Steel10 H10Duplex and Super Duplex Grades 31803, 3275010 J?Typically 26 Chrome one moly11A Group 179 Nickel Steels11A Groups 2 to 5?Mixed bag of high strength low alloy steels11 B?10 Sub Groups:- Mixed bag of high strength low alloy steelsASME & EN MATERIAL P NUMBER

WELDING AND JOININGF No.General F Numbers1Heavy rutile coated iron powder electrodes : - A51 : E70242Most Rutile consumables such as : - A5.1 : E60133Cellulosic electrodes such as : A5.1 : E60114Basic coated electrodes such as : A5.1 : E7016 and E70185High alloy austenitic stainless steel and duplex : - A5.4 : E316L-166Any steel solid or cored wire (with flux or metal)2XAluminium and its alloys3XCopper and its alloys4XNickel alloys5XTitanium6XZirconium7XHard Facing OverlayNote : - X represents any number 0 to 9ASME F Numbers

WELDING AND JOININGWelding PositionTest PositionISO and ENFlat (Weld flat joint at 45 degrees)1FPAHorizontal2FPBHorizontal Rotated2FRPBVertical Upwards Progression3FPFVertical Downwards Progression3FPGOverhead4FPDPipe Fixed Horizontal5FPFWelding PositionTest PositionISO and ENFlat1GPAHorizontal2GPCVertical Upwards Progression3GPFVertical Downwards Progression3GPGOverhead4GPEPipe Fixed Horizontal5GPFPipe Fixed @ 45 degrees Upwards6GHL045Pipe Fixed @ 45 degrees Downwards6GJL045ASME Welding PositionsNote the welding progression, (vertically upwards or downwards), must always be stated and it is an essentialvariable for both procedures and performance qualifications.Welding Positions For Groove welds:-Welding Positions For Fillet Welds:-ASME Welding Positions

WELDING AND JOINING

PIPE HOTIZONTAL AND ROTATED.WELD FLAT (15). DEPOSITFILLER METAL OR NEAR THE TOP.

(A) TEST POSITION 1G ROTATED

PIPE OA TUBE VERTICAL ANDNOT ROTATED DURING WELDINGWELD HORIZONTAL (15_(B) TEST POSITION 2G

PIPE OR TUBE HOTIZONTAL FIXED (15)AND NOT ROTATEDDURING WELDING WELD FLAT, VERTICAL OVERHEAD.(C) TEST POSITION 3G

PIPE INCLINATION FIXED (45 a5)AND NOT ROTATED DURINGWELDING.(D) TEST POSITION 5GCONTOH TAHAPAN PROSESPENGELASAN PIPA

WELDING AND JOINING

ASME WELDING POSITION

WELDING AND JOINING

Additionally: only for butt welds on pipe - pipe sioped 45Pipe : fixedAxis : inclinedWeld : vertical upwardH-L045Pipe : fixedAxis : inclinedWeld : vertical upwardH-L045POSISI LAS-EN 288

WELDING AND JOINING

POSISI LAS

WELDING AND JOINING

POSISI LAS AWS

POSISI LAS AWS

WELDING AND JOININGProject EngWelding EngManufac turerWel derWelding InspectScience

Technology

StandardOperationRequirementMaterial SelectionFabrication of PipesWPQRWPSWelding ApplicationInspectionCONTOH TAHAPAN PROSESPENGELASAN PIPA

WELDING AND JOININGWELDING AND JOINING Kualifikasi Prosedur (Procedure Qualification)Sebelum mengelas komponen (pipa atau lainnya) umumnya prosedur pengelasan (welding procedure) hares dibuat dan dikualifikasi.

Dokumentasi (Record)Detail mengenai prosedur harus didokumentasi (record) yang berisi hasil lengkap tentang "procedure qualification test.

Kualifikasi Operator Las (Qualification of Welders)Setiap welder atau operator las harus dikualifikasi menurut prosedur buku sebelum melakukan pengelasan komponen (pya atau lainnya). Tujuannya adalah untuk menentukan kemampuan operator las (welder) dalam menghasilkan !assn yang baik tanpa cacat dengan menggunakan prosedur sebelumnya yang telah lulus qualifikasi.WELDING PROCEDURESWPQR AND WPS

WELDING AND JOININGProcess Manual, Semi-or automatic welding processPipe and Fitting Material API5L or ASTMDiameter and Wall ThicknessJoint DesignFiller Metal and Number of Bed The size and classificationnumber of the filler metal andminimum number and sequenceof beadElectrical Characteristics The range of voltage and amperagePosition Roll or fixDirection of Welding Uphill or downhillTime Between Passes Max time between completion of the root bed and start of the second and other bed.Type and Remove of Lineup ClampCleaning and or Grinding Pre and Post-Heat Treatment Methods, Temp. temp-control methods.Shielding Gas and Flow Rate Composition and range of flow rate.

Shielding Flux

Speed of Travel 4 in inch per minuteISI WELDING PROSEDURWPQR AND WPS

WELDING AND JOININGThe number of weld metal-layer (pass) In Welding of pipe depend on pipe wall thickness. Recommended number of layer as shown below.Range of pipe Wall ThicknessNumber of LayersCross section of WeldRemark3 / 8 to 5 / 8 in21 = Rott pass2 = Cover pass5 / 8 to 7 / 8 in31 = Root pass2 = Hott pass3 = Cover pass7 / 8 to 11 / 8 in41 = Root pass2 = Hott pass3 = Filler pass4 = Cover pass

CONTOH PENGELASAN PIPANUMBER OF WELD METAL - LAYER

WELDING AND JOININGFiller pass3/16 Electrode180-190 A DC +Cover pass3/16 Electrode180-190 A DC +Root/Stringer Bead5/32 Electrode135-175 A DC +Hot pass5/32 Electrode170-200 A DC +PIPE WELDING PROCEDURESTYPE OF PASS

WELDING AND JOININGLayerTravel Speed, Cm/MinuteRoot Pass7.5 20Hot Pass7.5 20Filler Pass12.5 25Cover Pass12.5 - 25PIPE WELDING PROCEDURESSPEED OF TRAVEL

WELDING AND JOININGFiller Metal GroupGroupAWS SpecificationElectrode1A5.1E6010.E6011A5.5E7010.E70112A5.5E8010, E80113A5.1 or 5.5E7015, E7016, E7018A5.5E7015, E7016, E70184A5.17EL8, EL8K, EL12, EM5KEM12K, EM13K, EM15KAWS E6010 AND E6011Electrode Dia, InCurrent AVotage, Arc Volt3/321/85/323/167/321/4 5/1640-8075-125110-170140-215170-250210-320275-42523-2524 2624-2626-3026-3028-34PIPE WELDING PROCEDURESFILLER METAL

WELDING AND JOININGPreheating shall be performing when:Carbon steel having a carbon content in excess of 0.32 % (ladle analysis) or a carbon equivalent (C + 1/4 ( Mn + Si )) in excess of 0.65 %(ladle analysis).Steel having lower carbon content or CE when the welding procedure indicates that chemical composition, ambient/or metal temperature, material thickness or weld geometry require such treatment to produce satisfactory welds (Source ASME B31.8)Preheating MethodFurnace Heat TreatmentInduction Heating Torch HeatingResistance Heating Exothermal HeatingPreheating Requirement Based on CECE %Preheating ReacquiredUp to 0.45Preheat optional0.45 to 0.60Preheat to 93-205 deg COver 0.60Preheat to 205 to 370 deg CPreheating Requirement Based on C ContentC Content, %Preheating Reacquired, CBelow 0.2Up to 930.20 - 0.30 93 1500.30 - 0.45 150 260 0.45 - 0.80 260 425 PIPE WELDING INSPECTIONPRE HEATING AND STRESS RELIEFING

WELDING AND JOININGStress RelievingTo eliminate or greatly reduce built up stress caused by welding.Required whenFollowing a welding operation on a bid work piece (wall thickness >)On that is likely to have large built up stress in it.Having trouble with work-piece warping out of shape.Methods of Stress RelievingHeat the complete structure as a unitHeat a complete section containing the weld to be stress reliefHeat a part of work by slowly heating a circumferential band containing the weld at the center.Branch or other welded attachmentEquipmentElectric inductionElectric resistanceFuel-fired ring burnerFuel-fired torchTemperature ControllerThermocouple pyrometerStress-Relief Time & Temperature for Carbon SteelMetal Temp-CTime per Inch of Section Thickness, h593565538510482123510PIPE WELDING INSPECTIONPRE HEATING AND STRESS RELIEFING

WELDING AND JOINING NDTVisualRadiographic TestingMagnetic Particle TestingLiquid Penetrate TestingUltrasonic TestingThe method used shall produce indications of defects that can be accurately interpreted and evaluated.Qualification of Inspection PersonnelWelding inspection personnel shall be qualified by experience and training for the specified inspection task they performed.Radiographic testing performed at least by Level I.Only Level II or III personnel shall interprete test results.Percentages of each day's field butt weld, at randomly by operatorsClass 1 location, except offshore, at least 10 %Class 2 location, at least 15 %Class 3, and class 4 location, at crossing or navigable river, offshore and rail road or public highway right of way, including tunnels, bridges and over head road crossing, 100 %, unless impracticable, at least 90 %.Pipelines tie-in, 100 %PIPE WELDING INSPECTIONMETHODS OF INSPECTION

PreparationRadiographicTestInterpretation and EvaluationAcceptanceWelding is PerfectRepairPIPE WELDING INSPECTIONBASIC CONCEPTWELDING AND JOINING

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