welding inspection on welding
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Find out the Welding techniqueTRANSCRIPT
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ASME SEC-IX
QUALIFICATION STANDARD FOR WELDING & BRAZING
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CODES & PURPOSEAPI-1104 CROSS COUNTRY WELDING PIPELINE
API-650- ABOVE GROUND WELDED STORAGE TANKS
ASMEB31.3- PROCESS PIPING
AWS D1.1 STRUCTURAL WELDING OF STEEL
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CODES & PURPOSEASME-SEC-VIII- BOILERS & PRESSURE VESSELS CODE
ASME SEC-IX WELDING & BRAZING QUALIFICATIONS
ASME SEC-III RULES FOR CONSTRUCTION OF NUCLEAR POWER PLANT COMPONENTS
ASME SEC-II (PART-C ) SPECIFICATION OF WELDING RODS , ELECTRODES & FILLER METALS
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QUALIFICATION OF WELDINGARTICLE -1 Welding General Requirements.
ARTICLE -2 Welding Procedure Qualifications
ARTICLE 3- Welding Performance Qualifications
ARTICLE -4 Welding Data
ARTICLE -5 Standard Welding procedure Specification
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ARTICLE-1 WELDING GENERAL REQUIREMENTS
GeneralWeld orientation (Test positions for Groove & Fillet Welds)Types & Purposes of Tests & Examination
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WPS Welding Procedure Specifications
This is a written document that provides direction to the welder or welding operator for making production welds in accordance with Code requirements
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WPS Welding Procedure Specifications The Purpose for qualification of a WPS is to determine that the Weldment proposed for construction is capable of providing the required properties for its intended application
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WPQ- Welding Procedure Qualification
This establishes the properties of the Weldment not the skill of the welder
(or) welding operator
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PQR Procedure Qualification Record
PQR documents what occurred during welding the test coupon & the results of testing of the coupon
PQR shall document all essential variables
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WELD ORIENTATION
PLATE POSITIONS (GROOVE WELDS)
1G( Flat Position) : Plate in a horizontal plate with the weld metal deposited from the above
2G ( Horizontal Position) : Plate in a Vertical plane with the axis of the weld horizontal
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WELD ORIENTATION
PLATE POSITIONS( GROOVE WELDS)
3G( Vertical Position) : Plate in a vertical plane with the axis of the weld Vertical
4G ( Overhead Position) : Plate in a horizontal plane with the weld metal deposited from underneath.
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WELD ORIENTATION PIPE POSITIONS(GROOVE WELDS)
1G ( Flat Position ) : Pipe with its axis horizontal & rolled during welding so that the weld metal is deposited from the above
2G ( Horizontal Position) : Pipe with its axis Vertical and the axis of the weld in a horizontal plane. Pipe shall not be rotated during welding
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WELD ORIENTATION PIPE POSITIONS(GROOVE WELDS)
5G ( Multiple Position ) : Pipe with its axis horizontal and with the welding groove in a vertical plane. Welding shall be done without rotating the pipe
6G ( Multiple Position) : Pipe with its axis inclined at 45 degree to the horizontal . Welding shall be done without rotating pipe.
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ANGULAR DEVIATION OF GROOVE WELDS
An Angular deviation of +/- 15degree from the specified horizontal and vertical planes, and an angular deviation of +/- 5 degree from the specified inclined plane are permitted during welding
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WELD ORIENTATIONPIPE POSITIONS ( FILLET WELDS)
1F ( Flat Position) : Pipe with its axis inclined at 45 degree to horizontal and rotated during welding so that the weld metal is deposited from above and at the point of deposition the axis of the weld is horizontal & the throat vertical.
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WELD ORIENTATIONPIPE POSITIONS ( FILLET WELDS)
2F ( Horizontal position) : Pipe with its axis vertical so that the weld is deposited on the upper side of the horizontal surface & against the vertical surface. The axis of the weld will be horizontal & the pipe is not rotated during welding2FR ( Horizontal Position) : Pipe with its axis horizontal and the axis of the deposited weld in the vertical plane. The pipe is rotated during welding.
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WELD ORIENTATIONPIPE POSITIONS ( FILLET WELDS)
4F ( Overhead Position) : Pipe with its axis vertical so that the weld is deposited on the underside of the horizontal surface & against the vertical surface. The axis of the weld will be horizontal & the pipe is not to be rotated during welding
5F ( Multiple Position) : Pipe with its axis horizontal & the axis of the deposited weld in the vertical plane. The pipe is not to be rotated during welding
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TYPES & PURPOSES OF TESTS & EXAMINATIONSMECHANICAL TESTS
Tension Tests : Used to determine the ultimate strength of groove welded jointsGuided Bend Tests : Used to determine the degree of soundness & ductility of groove welded jointsFillet Weld Tests : Used to determine the size, contour & degree of soundness of fillet welds.Notch Toughness Tests : Used to determine notch toughness of weldments
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SPECIAL EXAMINATION FOR WELDERS
RADIOGRAPHIC EXAMINATION
This may be substituted for mechanical testing for Groove weld performance qualifications to prove the ability of welders to make sound welds.
VISUAL EXAMINATION
This is used to determine that the final weld surfaces meet specified quality conditions.
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ARTICLE- 2
WELDING PROCEDURE QUALIFICATIONS
GeneralPreparation of Test CouponWelding Variables
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WELDING PROCEDURE SPECIFICATIONSWPS This is a written qualified welding procedure prepared to provide direction for making production welds to code requirements.
CONTENTS This shall describe all essential & non-essential variables . WPS shall reference the supporting procedure qualification record.
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WELDING PROCEDURE SPECIFICATIONS
CHANGES TO WPS
1) Changes may be made in non-essential variables of a WPS to suit production requirements without requalification provided such changes are documented. 2) Changes in essential variables need requalification
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WELDING PROCEDURE SPECIFICATIONS
FORMAT OF WPS
This may be in any format ( Written or tabular) to fit the needs of each manufacturer or contractor.
The format includes the required data of SMAW,SAW,GMAW & GTAW . This is only a guide.
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WELDING PROCEDURE SPECIFICATIONS
AVAILIABILITY OF THE WPS
This shall be available for reference & review by the Authorized inspector
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PROCEDURE QUALIFICATION RECORD
PQR This is a record of the welding data used to weld a test coupon.
CONTENTS This shall document all essential variables. Non-essential variables may be recorded at the manufacturer (or) contractors option
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PROCEDURE QUALIFICATION RECORD
PQR shall be certified by the manufacturer or contractor. The manufacturer or contractor may not subcontract the certification function.
CHANGES TO PQR IS NOT PERMITTED Except Editorial corrections ( Incorrect P-Number, F-Number, A-Number) All changes to PQR need recertification by manufacturer or contractor
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PROCEDURE QUALIFICATION RECORD
FORMAT OF PQR This may be in any format to fit the needs of manufacturer or contractor. The format also cover the type of tests, number of tests & tests results.
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PROCEDURE QUALIFICATION RECORD
AVAILIABILITY OF THE PQR
PQR used to support WPS, shall be available, upon request for review by the authorized inspector PQR need not be availiable to the welder or welding operator.
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PREPARATION OF TEST COUPONS
BASE METALBase metal may consists of plate, pipe or other product form
Qualification in plate also qualifies for pipe welding & vice versa.
The dimensions of the test coupon shall be sufficient to provide the required test specimens
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PREPARATION OF TEST COUPONS
TYPE & DIMENSION OF GROOVE WELDS
The type & dimensions of the welding groove are not essential variables
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WELDING VARIABLES IN GENERAL
ESSENTIAL VARIABLES
SUPPLEMENTARY ESSENTIAL VARIABLES
NON-ESSENTIAL VARAIBLES
NOTE : VARY FROM WELDING PROCESS TO PROCESS
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WELDING VARIABLES ESSENTIAL VARIABLES
Essential variables are those in which a change as described in the specific variables is considered to affect the mechanical properties of weldment & shall require requalification of the WPS
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WELDING VARIABLESSUPPLEMENTARY ESSENTIAL VARIABLES
These are the variables in which a change as described in the specific variables is considered may affect the mechanical properties of weldment, if affect shall require requalification or other wise specified may follow manufacturer or contractors discretion for requalification
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WELDING VARIABLESNON ESSENTIAL VARIABLES
Non essential variables are those in which a change, as describes in the specific variables, may be made in the WPS without requalification.
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WELDING VARIABLESESSENTIAL VARIABLES ( GENERAL)
P-Number, P- Number (5/9/10), Max Thickness qualified, F-Number, A-Number, Alloy, Flux, AWS Class,PWHT, Type of Fuel Gas, Alloying elements, Flux type
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WELDING VARIABLES
SUPPLEMENTARY ESSENTIAL VARIABLES ( GENERAL )
Group Number, T limits, AWS class , Multi to single pass, Heat input, Position, Current or polarity
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WELDING VARIABLES
NON ESSENTIAL VARIABLES
Groove design, Backing, Backing composition, Root spacing, Size , Position, Technique, Method cleaning, Preheat, Flux designation, Wire class , Electrode spacing, Flow rate.
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ARTICLE-3
WELDING PERFORMANCE QUALIFICATIONS
GeneralQualification of Test couponsRetests & Renewal of QualificationWelding variables for weldersWelding variables for Welding operators
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WELDING PERFORMANCE QUALIFICATION
GENERAL
The welder qualification is limited by the essential variables given for each welding process
A welder /welding operator may be qualified by radiography of a test coupon, radiography of his initial production welding, or by bend tests taken from a test coupon
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WELDING PERFORMANCE QUALIFICATIONGENERAL
The Purpose of WPQ is to ensure that the manufacturer or contractor has determined that his welders and welding operators using his procedures are capable of developing the minimum requirements specified for an acceptable weldment
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WELDING PERFORMANCE QUALIFICATIONGENERALWhen a welder/welding operator changes employer organizations, the employing organization shall verify that the welders continuity of qualifications has been maintained.Each manufacturer or contractor shall qualify each welder or welding operator for each welding process to be used in production welding
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WELDING PERFORMANCE QUALIFICATIONGENERALThe performance qualification test shall be welded in accordance with qualified welding procedure specifications
Each qualified welder/welding operator shall be assigned by an identifying number, letter or symbol by the manufacturer or contractor which shall be used to identify the work of the welder/welding operator
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WELDING PERFORMANCE QUALIFICATIONGENERAL
The record of welder/ welding operator of WPQ shall include the essential variables, type of tests & test results.
The type of test results include (Mechanical test, Radiography Examination, Visual Examination )
CODE FOR WELDING & BRAZING QUALIFICATIONS