DOCUMENTS GOVERNING WELDING INSPECTIONAND QUALIFICATION DOCUMENT TYPES • Purchase orders • Contract documents • Codes • Standards • Specifications • Recommended Practices • Drawings DRAWINGS • Dimensions in U.S.Customary or S.I. • When both are used,second system is usually shown after the first in ( ) • Tolerances must be stated as a : minimum,or a range • All drawing notes must be reviewed • List of materials usually given + or -,maximum, EXAMPLE OF FABRICATION DRAWING DIMENSIONS TOLERANCES NOTES WELDING DETAILS • Location • Size • Length • Joint configurations • Material call-outs • NDE requirements • Processing requirements HOLD POINTS • Specific prearranged steps • Inspection required • Acceptance required • Fabrication continued INSPECTION INFORMATION • Visual or other NDE • Test method • Test procedure • Location for testing • Extent of testing • Acceptance/rejection criteria • Personnel qualifications CODE “A body of laws,as of a nation,city,etc.,arranged systematically for easy reference” TYPES OF CODES • Building codes • Electrical codes • Plumbing codes • Fabrication codes CODES: • Have legal status • Use“Shall” and“Will” • Mandatory • Methods to determine compliance CODE PRODUCERS • AWS • ASME • API • ABS • DOT • Others STANDARD “Something established for use as a rule or basis of comparison in measuring or judging capacity,quantity,content,extent,value,quality, etc.” WELDING CODESAND STANDARDS ASME CODE BY SECTIONS • I - Const - Power Boilers • V - NDE • II - Materials • VI - Operations of Power B. • PartA - Ferrous • VII - Care of Power Boilers • Part B - Nonferrous • VIII - Unfired Pres.Vessels • Part C - Filler Metals • Part D - Properties • III - General Requirements • IV - Const - Heating Boilers • Divisions 1, 2, and 3 • IX - Welding Qualifications • X - FRP Pressure Vessels • XI - Nuclear Inspections SPECIFICATION “A detailed description of the parts of a whole:statement or enumeration of particulars as to actual or required size,quality, performance,terms,etc.” AWS FILLER METAL SPECIFICATIONS AWSWELDING SPECIFICATIONS RECOMMENDED PRACTICE OTHER STANDARDS ORGANIZATIONS • ANSI • ASTM • ISO • IIW • NACE CONTROL OF MATERIALS “The identification and traceability of materials” MATERIALTEST REPORT (MTR) The starting point for material control MTR • Review: • Product Form • Heat Number • Chemistry • Mech.Properties MATERIAL CONTROL SYSTEMS • Should be simple • Contain checks and balances • Specify marking methods MATERIAL CONTROL METHODS • Segregation • Color coding • Alphanumeric • Bar coding • Tagging • Stamping ALLOY IDENTIFICATION SYSTEMS • Industry associations • SAE • AISI • CDA • Castings • Tool steels • UNS • ASTM ASTM STANDARDS ASTM A514 “Standard specification for high yield strength,quenched and tempered alloy steel plate,suitable for welding” TYPICAL ASTM SPECIFICATION • Scope • Applicable Documents • General Delivery Requirements • Process • HeatTreatment • Chemical Requirements • • • • • • • Mechanical Requirements Hardness Requirements Test Specimens Number of tests Retest Marking Supplemental Requirements AWSA5.1 “Specification for covered carbon steel arc welding electrodes” TYPICAL AWS FILLER SPECIFICATION • Scope • RequiredTests,Methods • General Requirements • Manufacturing,Packaging, Identification • • • • • • • Classification Acceptance Certification Retests Method of manufacture Marking Packaging, Rounding-off • Details ofTests • Appendix QUALIFICATION FABRICATORS’ RESPONSIBILITY • Procedures • Welders • Welding operators • Tack welders PROCEDURE QUALIFICATION Determines compatibility of: • Base metal(s) • Filler metal(s) • Process(es) • Techniques PROCEDURE QUALIFICATION Three methods: • Prequalified procedures • Procedure qualification testing • Mock-ups PREQUALIFIED PROCEDURES • Used byAWS D1.1 & D1.5 • No need for testing • Saves time and money PROCEDURE QUALIFICATION TESTING • ASME,API,AWS,& most Codes & Standards • Welding and brazing • Defines essential welding variables • Testing required ESSENTIAL WELDING VARIABLES “Those variables,that if changed beyond certain limits,require a new procedure qualification” ASME QUALIFICATION • Section IX • Welding procedure specification (WPS) • Lists essential welding variables • Procedure qualification record (PQR) • Notes actual test conditions MOCK-UPS “Used for special joint configurations” REQUIRED SPECIMENS Prior to qualifying a procedure: • Determine test specimen requirements for selected Code • Make test weldment large enough to obtain proper number and type of samples • Consider making it large enough for an extra test specimen or two • Maintain test weldment and specimen orientation per Code PROCEDURE QUALIFICATION STEPS - 1 OF 2 • Select welding variables • Check equipment and materials • Monitor fitup & welding - document! • Identify test specimens • Test and evaluate specimens PROCEDURE QUALIFICATION STEPS - 2 OF 2 • Review results for compliance • Release approved procedure • Qualify other welders • Monitor production welding WELDER QUALIFICATION “Determines if individual welders have sufficient skill to produce satisfactory welds using a qualified procedure” WELDING VARIABLES Examples of essential variables in some codes: • Welding position • Joint configuration • Electrode type and size • Base metal type,thickness • Welding techniques • Use of backing TYPE & POSITION LIMITATIONS • Depends on Code used • Refer to Code for test weldment thickness requirements and limitations on welder qualification • Use Module 5,Figure 5.19,as example for review WELD POSITION DESIGNATION Position Designations: • Different for Plate and Pipe • Different for Groove and Fillet welds • Must know positions and designations • See Module 5,Figures 5.20 - 5.23 THICKNESS RANGE QUALIFIED • Depends on Code used • Depends on test specimen thickness • See Figure 5.24 for D1.1 requirements BACKEDAND NON-BACKED JOINT FILLET WELD TEST SPECIMEN 6GR TEST WELDMENT ELECTRODE CLASSIFICATION GROUPINGS Group AWS Designation Electrode Classification EXX15, EXX16, EXX18, EXX15-X, F4 EXX16-X EXX18-X EXX10, EXX11, EXX10-X, EXX11-X F3 EXX12, EXX13, EXX14, EXX13-X F2 EXX20, EXX24, EXX27, EXX28, F1 EXX20-X, EXX27-X QUALIFY VS CERTIFY Qualify -Welder has skill to weld Certify - Documents support above WELDING INSPECTION REQUIRES: • Availability of documents • Knowledge of documents • Use of documents • Materials control • Qualifications QUALITY IS: ...conformance to specifications. so….. KnowYour Specifications!
