ACKNOWLEDGMENTS
Considerable data are presented in this Handbook, summarizing various Code
topics. If this Handbook results in the better training of welding inspection
personnel to the Code information presented herein, it will have served its
purpose.
As explained in the Commentary, portions of the referenced codes are verbatim
excerpts. Selected figures and tables have been reproduced in their entirety. In
each instance, the code paragraph or reference has been cited. The following
Codes granted permission to use their publications as they are presented in this
handbook for the original issue:
American Welding Society:
AWS D1.1, Structural Welding Code – Steel
AWS A3.0, Welding Terms and Definitions
American Society of Mechanical Engineers:
ASME Section III, Nuclear Power Plant Components, Division I
ASME Section IX, Welding and Brazing Qualificatibns
American National Standards Institute:
ASME B31.1, Power Piping Code
The pictures and photographs used in Section 9, “Defects,” were provided
through the courtesy of the Electric Power Research Institute (EPRI), Special
Report entitled “NDE Characteristics of Pipe Weld Defects.”
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Welding Inspection Handbook
ACK 1
DISCLAIMER NOTICE
It should be understood by all persons using this handbook, that neither
Bechtel Construction Operations, Inc, nor its related entities or their
employees, agents or officers, give any warranties, express or implied, nor
make any representations as to the accuracy, completeness or usefulness of
the information or conclusions contained herein, nor assume any responsibility
or liability of any nature from whatever cause including negligence resulting
from the use of this Welding Inspection Handbook.
Originally published as as noted:
“© Welding Inspection Handbook, Revision 0, Bechtel Power
Corporation, 1983, all rights reserved.”
“© Welding Inspection Handbook, Revision 1, Bechtel Power
Corporation, 1984, all rights reserved.”
Additional copies of this handbook may be obtained by writing or
telephoning
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Welding Inspection Handbook
Disclaimer 1
CONTENTS
Section
Subject
1
SOCKET WELDS
2
MEASUREMENT OF FILLET WELDS
3
USE OF INSPECTION GAGES
4
GROOVE WELDS, AWS D1.1 (PIPE AND PLATE)
5
WELDING SYMBOLS (AWS A2.4)
6
VISUAL AND NDE ACCEPTANCE CRITERIA (AWS D1.1)
7
VISUAL AND NDE ACCEPTANCE CRITERIA (ASME/ANSI)
8
CODE REQUIRED NDE
9
DEFECTS
10
REPAIR OF WELD DEFECTS
11
BASE METAL REPAIR BY WELDING
12
WELDING PROCESSES
13
PREHEAT/INTERPASS TEMPERATURES
14
POSTWELD HEAT TREATMENT (PWHT)
15
PREQUALIFIED WELD JOINTS (AWS D1.1)
16
SKEWED T-JOINTS
17
PROCEDURE/WELDER QUALIFICATION (AWS D1.1)
18
PROCEDURE/WELDER QUALIFICATION (ASME SECTION IX)
19
CHARTS
20
TERMS AND DEFINITIONS
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Welding Inspection Handbook
Contents 1
Section 1
Socket Welds
Page
1.1
ASME B31.1 .............................................................................................
1-1
1.1.1
Fittings.......................................................................................................
1-1
1.1.2
Flanges.......................................................................................................
1-2
1.2
ASME B31.3 .............................................................................................
1-2
1.3
ASME SECTION III .................................................................................
1-3
1.3.1
Welding Requirements ...............................................................................
1-3
1.4
AWS D1.1 .................................................................................................
1-3
1.4.1
No Requirements in AWS D1.1..................................................................
1-3
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Section 1
1.1
Socket Welds
ASME B31.1
In the assembly of the joint before welding, the pipe or tube shall be inserted into the socket to the
maximum depth and then withdrawn approximately 1/16 inch from contact between the end of the
pipe and the shoulder of the socket [See Figs 127.4.4 (B) and (C)]. In sleeve type joints without
internal shoulder, there shall be a distance of approximately 1/16 inch between the butting ends of
the pipe or tube.
The fit between the socket and the pipe shall conform to applicable standards for socket weld
fittings and in no case shall the inside diameter of the socket or sleeve exceed the outside diameter
of the pipe or tube by more than 0.080 in. [127.3 (E)]
1.1.1
Fittings
For socket welded fittings, the minimum welding dimensions are shown below.
Figure 127.4.4 (C) Minimum Welding Dimensions Required for
Socket Welding Components Other Then Flanges
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Section 1
1.1.2
Socket Welds
Flanges
Typical welding details for slip-on and socket-welding flanges are shown below.
Notes:
(1) Refer to Para. 122.1.1 (F) for limitations of use.
(2) Refer to Para. 122.1.1 (H) for limitations of use.
(3) Refer to Para. 104.5.1 for limitations of use.
Figure 127.4.4 (B) Welding Details for Slip-On and Socket-Welding Flanges;
Some Acceptable Types of Flange Attachment Welds
1.2
ASME B31.3
Typical weld details for slip-on and socket weld flanges are shown in Figure 328.5.2B; minimum
welding dimensions for other socket welding components are shown in Fig. 328.5.2C.
(328.5.2(a)
If slip-on flanges are single welded, the weld shall be at the hub. (328.5.2(b)
Figure 328.5.2B Typical Details for Double Welded Slip-On and
Socket Welding Flange Attachment Welds
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Welding Inspection Handbook
1-2
Section 1
Socket Welds
Figure 328.5.2C Minimum Welding Dimensions for Socket Welding Components
Other Than Flanges
1.3
1.3.1
ASME SECTION III
Welding Requirements
Illustrations concerning socket welds for ASME/ANSI-B31.1 and ASME Section III are the
same. Also, the method used for calculation for determining socket weld size is the same, except
that for flange-to-pipe socket weld requirements, the following apply. (NX-4427)
(Figure NX-4427-1)
1.4
1.4.1
AWS D.1.1
No Requirements in AWS D1.1
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Section 2
Measurement of Fillet Welds
Page
2.1
AWS D1.1 .................................................................................................
2-1
2.1.1
Effective Length.........................................................................................
2-1
2.1.2
Effective Throat .........................................................................................
2-1
2.1.3
Theoretical Throat .....................................................................................
2-2
2.1.4
Minimum Size............................................................................................
2-3
2.1.5
Maximum Size Along Edges ......................................................................
2-3
2.1.6
Minimum Length........................................................................................
2-3
2.1.7
Gaps Between Members.............................................................................
2-4
2.1.8
Faying Surfaces..........................................................................................
2-4
2.1.9
Fillet Weld Profiles (AWS 3.6)...................................................................
2-5
2.1.10
Gaps for Tubular Structures .......................................................................
2-6
2.1.11
Undersized Fillet Welds (Buildings)............................................................
2-6
2.1.12
Stud Welding (Manual) Fillet Weld Size.....................................................
2-6
2.1.13
Skewed T-Joints ........................................................................................
2-7
2.2
ASME/ANSI B31.1 ...................................................................................
2-7
2.2.1
Fillet Welds................................................................................................
2-7
2.2.2
Size of Fillet Welds ....................................................................................
2-7
2.3
ASME SECTION III .................................................................................
2-8
2.3.1
Fillet Weld Size..........................................................................................
2-8
2.3.2
Attachments to Piping after Hydro .............................................................
2-9
2.4
ASME/ANSI B31.3 ...................................................................................
2-9
2.4.1
Fillet Welds................................................................................................
2-9
2.4.2
Welded Branch Connections.......................................................................
2-11
2.4.3
Reinforcing Pad or Saddle..........................................................................
2-11
2.4.4
Nomenclature and Symbols ........................................................................
2-12
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Section 2
2.1
2.1.1
Measurement of Fillet Welds
AWS D1.1
Effective Length
The effective length of a fillet weld is the overall length of the full-size fillet, including end returns.
No reduction of weld length is necessary for starts or craters, provided the weld is full size
throughout its length, including craters. (AWS-2.3.2.1, 8.15.1.3)
2.1.2
Effective Throat
The effective throat is the shortest distance from the root of the joint to its face. (2.3.2.4)
For the purpose of measuring fillet welds, the
theoretical throat should be used.
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2-1
Section 2
2.1.3
Measurement of Fillet Welds
Theoretical Throat
The distance from the beginning of the root of the joint perpendicular to the hypotenuse of the
largest right triangle that can be inscribed within the fillet weld cross section. This dimension is
based on the assumption that the root opening is equal to zero. (AWS A3.0)
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Section 2
2.1.4
Measurement of Fillet Welds
Minimum Size
Minimum Fillet Weld Size (Prequalified Joints) (2.7.1.1).
A fillet weld in any single continuous weld shall be permitted to underrun the nominal fillet size
required by 1/16 in. without correction, provided that the undersize portion of the weld does not
exceed 10% of the length of the weld. On web-to-flange welds on girders, no underrun is
permitted at the ends for a length equal to twice the width of the flange. (8.15.1.7)
MINIMUM FILLET WELD SIZE FOR PREQUALIFIED JOINTS
Base Metal Thickness of Thicker Part Jointed (T)
in.
Minimum Size of Fillet Weld*
in.
1/8
3/16
1/4
5/16
T≤14
1/4<T≤1/2
1/2<T≤3/4
3/4<T
Single-pass
welds must
be used
* Except that the weld size need not exceed the thickness of the thinner part joined: For this
exception, particular care should be taken to provide sufficient preheat to ensure weld
soundness.
2.1.5
Maximum Size Along Edges
The maximum size fillet weld made on material less than 1/4 inch may be the thickness of the base
material. (A - below.) For base material 1/4 inch and thicker, the maximum fillet weld size is
1/16 inch less than the base metal thickness (B - below.), unless the weld is designated on the
drawing to be built out in order to obtain full throat thickness.
However, the distance between the edge of the base metal and toe of the weld may be less than
1/16 inch, provided the edge is clearly visible and the weld size clearly verifiable. (AWS 2.7.1.2)
The maximum fillet weld along edges of material shall be equal to the thickness of the base
material. (AWS 10.10.4)
2.1.6
Minimum Length
The minimum length of intermittent fillet welds shall be 1-1/2 inches. (AWS 2.7.1.5)
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Section 2
2.1.7
Measurement of Fillet Welds
Gaps Between Members
The parts to be joined by fillet welds shall be brought into as close contact as practicable. The
gap between parts shall not exceed 3/16 in. except in cases involving either shapes or plates 3 in.
greater in thickness if, after straightening and in assembly, the gap cannot be closed sufficiently to
meet this tolerance. In such cases, a maximum gap of 5/16 in. is acceptable provided a sealing
weld or suitable backing material is used to prevent melting through.
Note:
If the separation is 1/16 in. or greater, the leg of the fillet weld shall be increased by the amount of the
separation or the contractor shall demonstrate that the required effective throat has been obtained. (3.3.1)
2.1.8
Faying Surfaces
The separation of faying surfaces of lap joints, plug, slot welds, and butt welds using a backing
ring or bar shall not exceed 1/16 inch. (AWS 3.3.1)
Note:
Gaps greater than mentioned above should be brought
to the attention of the Engineer.
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Section 2
2.1.9
Measurement of Fillet Welds
Fillet Weld Profiles (AWS 3.6)
Desirable Fillet Weld Profiles
Note:
Convexity, C, of a weld or individual surface bead shall
not exceed 0.07 times the actual face width of the weld or
individual bead, respectively, plus 0.06 in. (1.5 mm).
Acceptable Fillet Weld Profiles
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Section 2
Measurement of Fillet Welds
Unacceptable Fillet Weld Profiles
2.1.10 Gaps for Tubular Structures
Parts to be fillet welded shall have a maximum gap of 3/16 inch. If the separation is 1/16 inch or
greater, the leg of the fillet weld shall be increased by the amount of the separation. Gaps greater
than 3/16 inch shall be subject to the approval of the Engineer. (AWS 10.14.1)
2.1.11 Undersized Fillet Welds (Buildings)
A fillet weld in any single continuous weld shall be permitted to underrun the nominal fillet size
required by 1/16 inch without correction, provided that the undersize portion of the weld does not
exceed 10% of the length of the weld. On web-to-flange welds on girders, no underrun is
permitted at the ends for a length equal to twice the width of the flange. (AWS 8.15.1.7)
2.1.12 Stud Welding (Manual) Fillet Weld Size
At the contractor’s option, studs may be fillet welded by the SMAW process, provided the
requirements of 7.5.5 through 7.5.5.6 of the AWS Code are met.
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Section 2
Measurement of Fillet Welds
MINIMUM FILLET WELD SIZE FOR SMALL DIAMETER STUDS
Stud Diameter
in.
1/4 thru 7/16
1/2
5/8, 3/4, 7/8
1
Minimum Size of Fillet
in.
3/16
1/4
5/16
3/8
Electrode Size. Welding shall be done with low hydrogen electrodes 5/32 or 3/16 in. in diameter
except that a smaller diameter electrode may be used on studs 7/16 in. or less in diameter or for
out-of-position welds. (7.5.5.2)
Preheat. The base metal to which studs are welded shall be preheated in accordance with the
requirements of Table 4.2 of Section 13 in -this handbook. (7.5.5.5)
2.1.13 Skewed T-Joints
Fillet welds may be used in skewed T-joints having a dihedral angle of not less than 60 degrees
nor more than 135 degrees. Angles smaller than 60 degrees are permitted; however, in such
cases, the weld is considered to be a partial penetration groove weld. (2.7.1.4) For additional
information concerning skewed T-joints, refer to Section 16 of this handbook.
2.2
2.2.1
ANSI B31.1
Fillet Welds
In making fillet welds, the weld metal shall be deposited in such a way as to secure adequate
penetration into the base metal at the root of the weld. (127.4.4)
2.2.2
Size of Fillet Welds
Fillet welds may vary from convex to concave. The size of a fillet is determined as shown below.
(127.4.4)
Note:
Excessive convexity of fillet welds is not a criterion for rejection.
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Section 2
Measurement of Fillet Welds
Figure 127.4.4(A)
Notes:
2.3
2.3.1
(1)
The “size” of an equal leg fillet weld is the leg length of the largest inscribed right
isosceles triangle. Theoretical throat = 0.7 x size.
(2)
For unequal leg fillet welds, the “size” of the weld shall be described using both leg
lengths and their location on the members being joined.
(3)
Fillet welds between members which lie at angles other than 90 degrees shall be
described as in Notes (1) and (2).
(4)
For all fillet welds the theoretical throat shall be determined by calculation based
on the angle between surfaces to be welded and the specified leg lengths.
(5)
For all fillet welds the leg dimensions and theoretical throat dimensions shall lie
within the cross section of the deposited weld metal as shown in the sketches.
ASME SECTION III
Fillet Weld Size
Shape and size of fillet welds may vary from convex to concave. The size of the weld shall be in
accordance with the figure below (NX-4427).
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Section 2
2.3.2
Measurement of Fillet Welds
Attachments to Piping after Hydro
Attachments may be made by fillet welds to a piping system after performance of a pressure test,
provided the welds do not exceed 3/8 inch throat thickness and do not exceed a total length of
24 inches (NX-4436)
2.4
ASME B31.3
2.4.1
Fillet Welds
Fillet welds (including socket welds) may vary from convex to concave. The size of a fillet weld
is determined as shown in Fig. 328.5.2A.
(a)
Typical weld details for slip on and socket welding flanges are shown in
Fig. 328.5.2B; minimum welding dimensions for other socket welding components
are shown in Fig. 328.5.2C.
(b)
If slip-on flanges are single welded, the weld shall be at the hub.
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Section 2
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Measurement of Fillet Welds
Welding Inspection Handbook
2-10
Section 2
2.4.2
Measurement of Fillet Welds
Welded Branch Connections
Welded branch connections (including integrally reinforced proprietary branch connection fittings)
which abut the outside of the run or which are inserted in an opening in the run shall be attached
by fully penetrated groove welds.
(a)
2.4.3
The welds shall be finished with cover fillet welds having a throat dimension not
less than tc. See Fig. 328.5.4D sketches (1) and (2).
Reinforcing Pad or Saddle
A reinforcing pad or saddle shall be attached to the branch pipe by either:
(1)
a fully penetrated groove weld finished with a cover fillet weld having a throat
dimension not less than tc
or
(2)
a fillet weld having a throat dimension not less than 0.7t min. See Fig. 328.5.4D
sketch (5).
(3)
The outer edge of a reinforcing pad or saddle shall be attached to the run pipe by a
fillet weld having a throat dimension not less than 0.5**Tr .. See Fig.328.5.4D
Sketches (3), (4), and (5).
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Section 2
2.4.4
Measurement of Fillet Welds
Nomenclature and Symbols
The nomenclature and symbols used herein and in Fig. 328.5.4D are:
tc
Tb
Th
Tr
tmin
=
=
=
=
=
lesser of 0.7 T or 1/4 in.
nominal thickness of branch
nominal thickness of header
nominal thickness of reinforcing pad or saddle
lesser of T or T
b
b
r
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Section 3
Use of Inspection Gages
Page
3.1
CAMBRIDGE INSPECTION GAGE ..............................................................................
3-1
3.1.1
Cambridge Inspection Gage.............................................................................................
3-1
3.1.2
Material Thickness ..........................................................................................................
3-1
3.1.3
Bevel Angle.....................................................................................................................
3-1
3.1.4
External Misalignment ....................................................................................................
3-2
3.1.5
Pit Gage...........................................................................................................................
3-2
3.1.6
Fillet Welds .....................................................................................................................
3-3
3.2
FIBRE METAL FILLET WELD GAGE ..........................................................................
3-4
3.2.1
Fibre Metal Weld Gage....................................................................................................
3-4
3.2.2
Leg Size ..........................................................................................................................
3-4
3.2.3
Theoretical Throat ...........................................................................................................
3-5
3.3
FILLET WELD GAGE....................................................................................................
3-6
3.3.1
Leg Size and Throat ........................................................................................................
3-6
3.3.2
Butt Weld Reinforcement.................................................................................................
3-7
3.4
G.A.L. HI LO GAGE.......................................................................................................
3-7
3.4.1
G.A.L. Hi Lo Gage ..........................................................................................................
3-7
3.4.2
Misalignment/Thickness..................................................................................................
3-7
3.4.3
Fillet Weld Leg Measurement/Butt Weld Reinforcement..................................................
3-8
3.5
OLD M&QS WELD GAGE.............................................................................................
3-8
3.5.1
Old M&QS Weld Gage....................................................................................................
3-8
3.5.2
Leg Size of Fillet at 90° Angle.........................................................................................
3-9
3.5.3
"W" Dimension for Skew T Fillets (Acute Side)...............................................................
3-9
3.5.4
"W" Dimension for Skew T Fillets (Obtuse Side).............................................................
3-9
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Section 3
3.1
3.1.1
Use of Inspection Gages
CAMBRIDGE INSPECTION GAGE
Cambridge Inspection Gage
The Cambridge Inspection Gage may be used for material thickness, bevel angle, misalignment, fillet weld
measurements, etc. The following illustrations show how this gage is used.
3.1.2
Material Thickness
Edge “A” slides inside the pipe or on the bottom of the plate, making sure good contact is made along its length.
Slide “B” is pushed down to make contact with the outside diameter of the pipe, or top of the plate, and the
thickness is read from Scale “C”.
3.1.3
Bevel Angle
Edge “A” lays along the top of the pipe or plate. Slide “B” is pushed down across the bevel, and Scale “C”
indicates the bevel angle.
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Section 3
3.1.4
Use of Inspection Gages
External Misalignment
Edge “A” lays flat on the high member. Slide “B” is pushed down to contact the low member and Scale “C”
indicates the amount of external misalignment.
3.1.5
Pit Gage
Edge “A” lays along the pipe or plate being checked. The point of Slide “B” is centered over the pit or undercut
and pushed in, making sure Edge “A” keeps in contact with plate or pipe. Scale “C” gives you the depth of the pits
or undercut.
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3-2
Section 3
3.1.6
Use of Inspection Gages
Fillet Welds
Fillet welds can be measured with this gage, but it is recommended that the Fibre Metal product gages be used for
fillet weld measurements. However, if Fibre Metal gages are not available, the Cambridge gage may be used as
shown below.
Leg Size
Theoretical Throat
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Section 3
3.2
3.2.1
Use of Inspection Gages
FIBRE METAL FILLET WELD GAGE
Fibre Metal Weld Gage
The following sketches illustrate the correct use of the Fibre Metal Product weld inspection gages used for fillet
weld inspection.
3.2.2
Leg Size
Acceptable Leg Size
Unacceptable Leg Size
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Section 3
3.2.3
Use of Inspection Gages
Theoretical Throat
Acceptable Throat
Unacceptable Throat
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Section 3
3.3
3.3.1
Use of Inspection Gages
FILLET WELD GAGE
Leg Size and Throat
This gage is used to measure leg size and throat size of convex or concave fillet welds, and the reinforcement of
butt welds. The following illustrations indicate how this gage is used.
Fillet Weld Leg Size
Throat of a Convex or Concave Fillet
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Section 3
3.3.2
3.4
3.4.1
Use of Inspection Gages
Reinforcement of Butt Welds
G.A.L. HI LO GAGE
G.A.L. Hi Lo Gage
The G.A.L. Hi Lo Gage may be used for material thickness, misalignment, included bevel angle, fillet weld leg,
measuring scribe lines on socket welds, etc. The illustrations below show some of the uses of this gage.
3.4.2
Misalignment/Thickness
For internal misalignment, the gage is turned 90° and Area A is inserted into the gap. When turned back 90°, the
handles (b) are pulled tight and the slide (C) is pushed down square against the outer surface. At this point, the set
screw (D) is set and the internal misalignment is read at Area B. Material thickness is read in the slide scale (E).
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Section 3
3.4.3
Use of Inspection Gages
Fillet Weld Leg Measurement/Butt Weld Reinforcement
For fillet leg measurement, one of the handles is placed against the flat surface and the other is raised to the top of
the fillet and the scale is read. Butt weld reinforcement is completed in the same manner.
3.5
3.5.1
OLD M&QS WELD GAGE
Old M&QS Weld Gage
The old M&QS gage(developed in 1983) may be used for measuring all types of fillet welds misalignment,
material thickness, etc. The gage is always read in the same manner. The bottom of the gage is placed on a flat
surface and the arm placed on the top of the article to be measured. For the thickness or size of the article, the
dimension is taken directly from the scale at the top of the arm. The following instructions show some of the ways
this gage is used.
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Section 3
Use of Inspection Gages
3.5.2
Leg Size of a Fillet at 90° Angle
3.5.3
“W” Dimension For Skew T Fillets (Acute Side)
3.5.4
“W” Dimension For Skew T Fillets (Obtuse Side)
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Section 4
Groove Welds
Page
4.1
AWS D1.1 (GENERAL .............................................................................
4-1
4.1.1
Effective Area ............................................................................................
4-1
4.1.2
Weld Size (Complete Penetration)..............................................................
4-1
4.1.3
Weld Size (Partial Penetration)...................................................................
4-1
4.1.4
Effective Weld Size (Flare Groove) ............................................................
4-1
4.1.5
Weld Size (Minimum) ................................................................................
4-2
4.1.6
Assembly Tolerances (Partial Penetration)..................................................
4-2
4.1.7
Alignment (Butt Joints) ..............................................................................
4-3
4.1.8
Assembly Tolerances..................................................................................
4-3
4.1.9
Wider Permitted Root Openings.................................................................
4-4
4.1.10
Tack Welds................................................................................................
4-5
4.1.11
Reinforcement............................................................................................
4-5
4.1.12
Flush or Less..............................................................................................
4-5
4.1.13
Ends of Butt Joints.....................................................................................
4-6
4.2
STATICALLY LOADED STRUCTURES ................................................
4-7
4.2.1
Transition Thickness “Unequal” .................................................................
4-7
4.2.2
Temporary Welds.......................................................................................
4-8
4.2.3
Backing Strips............................................................................................
4-8
4.2.4
Backing Material........................................................................................
4-8
4.3
TUBULAR STRUCTURES.......................................................................
4-9
4.3.1
Special Provisions ......................................................................................
4-9
4.3.2
Root Opening.............................................................................................
4-9
4.3.3
Temporary Welds.......................................................................................
4-9
4.4
ASME SECTION III .................................................................................
4-9
4.4.1
Alignment Requirements ............................................................................
4-9
4.4.2
Fairing of Offsets – Applicable Only to Joints Welded from Two Sides.......
4-11
4.4.3
Welding From One Side (Inside Inaccessible) .............................................
4-12
4.4.4
Fairing of Offsets – For Welds Made From One Side..................................
4-13
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Section 4
Groove Welds
Page
4.4.5
Longitudinal Joints – Tolerances ................................................................
4-13
4.4.6
Weld Joint Reinforcement for Vessels, Pumps, and Valves .........................
4-13
4.4.7
Reinforcement for Piping............................................................................
4-13
4.4.8
Weld Surfaces ............................................................................................
4-14
4.4.9
Welding End Transitions ............................................................................
4-14
4.4.10
Backing Rings – Piping ..............................................................................
4-15
4.5
ASME B31.1 .............................................................................................
4-17
4.5.1
Backing Rings............................................................................................
4-17
4.5.2
End Preparations........................................................................................
4-17
4.5.3
Girth Butt Welds........................................................................................
4-18
4.5.4
Longitudinal Butt Welds ............................................................................
4-20
4.6
ASME B31.3 .............................................................................................
4-22
4.6.1
Backing Rings............................................................................................
4-22
4.6.2
End Preparations........................................................................................
4-22
4.6.3
Alignment ..................................................................................................
4-23
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Section 4
4.1
Groove Welds
AWS D1.1 (GENERAL)
4.1.1
Effective Area
The effective area shall be the effective weld length multiplied by the weld size. (2.3.2)
4.1.2
Weld Size (Complete Penetration)
The weld size of a complete joint penetration groove weld shall be the thickness of the thinner
part joined. No increase in the effective area for design calculation is permitted for weld
reinforcement. (2.3.4.1)
4.1.3
Weld Size (Partial Penetration)
The weld size for partial penetration groove weld is that shown in Chapter 15 unless specifically
qualified otherwise.
4.1.4
Effective Weld Size (Flare Groove)
The effective weld size of flare bevel groove welds when-filled flush to the surface of a round bar,
a 90° bend in a formed section, or a rectangular tube shall be as shown in Table 2.1 unless a larger
size has been demonstrated by qualification as outlined below. (2.3.3.2)
Table 2.1
Effective Weld Sizes of Flare Groove Welds
Flare-Bevel Groove Welds
Flare-V-Groove Welds
5/16 R
1/2 R*
Note: R = radius of outside surface
*
Except 3/8 R for GMAW (except short circuiting
transfer) process when R is 1/2 in. or greater
1) When required by the Engineer, test sections shall be used to verify that the effective
throat is consistently obtained.
2) For a given set of WPS conditions, if the contractor has demonstrated consistent
production of larger effective weld sizes than those show in Table 2.1, the contractor
may establish such larger effective weld sizes by qualification.
3) Qualification required by (2) shall consist of sectioning the radiused member, normal
to its axis, at midlength and ends of the weld. Such sectioning shall be made on a
number of combinations of material sizes representative of the range used by the
contractor in construction or as required by the Engineer. (4.10.5)
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Section 4
4.1.5
Groove Welds
Weld Size (Minimum)
The minimum weld size of pre-qualified partial joint penetration single-, or double-V, bevel-, and
U-, groove welds shall be as in Table 3.4. The PJP square butt weld B-P1 and flare-bevel groove
weld BTC-P10 minimum weld sizes are to be calculated from the figures in Chapter 15.
(3.12.2.1)
Table 3.4
Minimum Prequalified Weld Sizes for Partial Joint Penetration Groove Welds
Base Metal Thickness of Thicker Part Joined
Minimum Effective Throat*
in.
in.
1/8 to 3/16 incl.
1/16
Over 3/16 to 1/4 incl.
1/8
Over 1/4 to 1/2 incl.
3/16
Over 1/2 to 3/4 incl.
1/4
Over 3/4 to 1-1/2 incl.
5/16
Over 1-1/2 to 2-1/4 incl.
3/8
Over 2-1/4 to 6 incl.
1/2
Over 6
5/8
* Except the effective throat need not exceed the thickness of the thinner part.
4.1.6
Assembly Tolerances (Partial Penetration)
The parts to be joined by partial joint penetration groove welds made parallel to the length of the
member shall be brought into as close contact as practicable. The root opening between parts
shall not exceed 3/16 in. except in cases involving rolled shapes or plates 3 inches or greater in
thickness if, after straightening and assembly, the root cannot be closed sufficiently to meet this
tolerance. In such cases, a maximum root opening of 5/16 inch is acceptable, provided suitable
backing material (see Note) is used and the final weld meets the requirements for weld size.
Tolerances for bearing joints shall be in accordance with the applicable contract specifications.
(5.22.2)
Note: Backing to prevent melting-through may be of copper, flux, glass tape, ceramic, iron powder, or
similar materials; by means of shielded metal arc welding root passes deposited with low hydrogen
electrodes, or other arc welding processes.
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Section 4
4.1.7
Groove Welds
Alignment (Butt Joints)
Parts to be joined at butt joints shall be carefully aligned. Where parts are effectively restrained
against bending due to eccentricity in alignment, an offset not exceeding 10 percent of the
thickness of the thinner part joined, but in no case is more than 1/8 inch, shall be permitted as a
departure from the theoretical alignment. See Figure 5.3. In correcting misalignment in such
cases, the parts shall not be drawn in to a greater slope than 1/2 in. in 12 in. Measurement of
offset shall be based upon the centerline of the parts unless otherwise shown on the drawings.
See Figure C5.4. (5.22.3)
Figure C5.3 – Permissible Offset in Abutting Members.
Figure C5.4
4.1.8
Assembly Tolerances
With the exclusion of electroslag and electrogas welding and with exception of 5.22.4.3 for root
openings in excess of those permitted in Figure 5.3, the dimensions of the cross section of the
groove welded joints which vary from those shown on the detail drawings by more than the
following tolerances shall be referred to the Engineer for approval or correction. (5.22.4.1)
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Section 4
Groove Welds
Root Not Gouged*
in.
Root Gouged
in.
(1)
Root face of joint
± 1/16
Not limited
(2)
Root opening of joints
without steel backing
Root opening of joints
with steel backing
± 1/16
+ 1/16
- 1/8
Not
applicable
(3)
+ 1/4
- 1/16
Groove angle of joint
+ 10°
+ 10°.
- 5°
- 5°
* See 5.2.4.2 for tolerances for complete joint penetration tubular groove welds made from one
side without backing.
Figure 5.3 – Workmanship Tolerances in Assembly of Groove Welded Butt Joints
4.1.9
Wider Permitted Root Openings
Root openings wider than those permitted in 5.22.4.1, but not greater than twice the thickness of
the thinner part or 3/4 in., whichever is less, may be corrected by welding to acceptable
dimensions prior to joining the parts by welding. (5.22.4.3)
Root openings larger than those shown in 5.22.4.1, may be corrected by welding only with the
approval of the Engineer. (5.22.4.4)
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Section 4
Groove Welds
4.1.10 Tack Welds
Tack welds shall be subject to the same requirements as the final welds except that:
(1)
Preheat is not mandatory for single-pass tack welds which are remelted and incorporated
into continuous submerged arc welds.
(2)
Discontinuities such as undercut, unfilled craters, and porosity need not be removed
before the final submerged arc welding. (5.18.2)
Tack welds which are incorporated into the final weld shall be made with electrodes meeting the
requirements of the final welds and shall be cleaned thoroughly. Multiple-pass tack welds shall
have cascaded ends. (5.18.2.1)
Tack welds not incorporated into final welds shall be removed, except that for statically loaded
structures, they need not be removed unless required by the Engineer. (5.18.2)
4.1.11 Reinforcement
Groove welds shall be made with minimum face reinforcement unless otherwise specified. In the
case of butt and corner joints, the reinforcement shall not exceed 1/8 inch in height. All welds
shall have a gradual transition to the plane of the base-meal surfaces with transition areas free of
undercut except as permitted by this code. Figure 5.4(D) shows typically acceptable groove weld
profiles in butt joints. Figure 5.4(E) shows typically unacceptable weld profiles for groove butt
joints. (5.24.4)
4.1.12 Flush or Less
Surfaces of butt joints required to be flush shall be finished so as not to reduce the thickness of the
thinner base metal or weld metal by more than 1/32 inch or 5% of the thickness, whichever is less.
Remaining reinforcement shall not exceed 1/32 inch in height. However, all reinforcement shall
be removed where the weld forms part of a faying or contact surface. All reinforcements shall
blend smoothly into the plate surfaces with transition areas free from undercut. (5.24.4.1)
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Section 4
Groove Welds
4.1.13 Ends of Butt Joints
Ends of butt joints required to be flush shall be finished so as not to reduce the width beyond the
detailed width or the actual width furnished, whichever is greater, by more than 1/8 inch or so as
not to leave reinforcement at each end that exceeds 1/8 inch. Ends of welded butt joints shall be
fared at a slope not to exceed 1 in 10. (5.31.4)
Figure 5.4 (D, E) Groove Weld Profiles
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Section 4
4.2
4.2.1
Groove Welds
STATICALLY LOADED STRUCTURES
Transition Thickness “Unequal”
See Figure 2.6.
Figure 2.6 – Transition of Butt Joints in Parts of Unequal Thickness (Nontubular)
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Section 4
4.2.2
Groove Welds
Temporary Welds
Temporary welds shall be subject to the same welding procedure requirements as the final weld.
These shall be removed, when required by the Engineer. When they are removed, the surface
shall be made flush with the original surface. (5.18.1)
4.2.3
Backing Strips
Steel backing of welds used in statically loaded structures need not be welded full length and need
not be removed, unless required by the Engineer. (5.10.5)
4.2.4
Backing Material
Roots of groove welds may be backed by copper, flux, glass tape, ceramic, iron powder, or
similar materials to prevent melting through. They may also may be sealed by means of root
passes deposited with low hydrogen electrodes if SMAW is used, or by other arc welding
processes. (5.10)
Groove welds made with the use of steel backing shall have the weld metal thoroughly fused with
the backing. (5.10.1)
Steel backing shall be made continuous for the full length of the weld. All necessary joints in the
steel backing shall be complete joint penetration welds in butt joints meeting all the requirements
of Section 5 of AWS Dl.l. (5.10.2)
Weld tabs used in welding shall conform to the following requirements:
(1)
When used in welding with an approved steel listed in Table 3.1 or Annex M, they may be
any of the steels listed in Table 3.1 or Annex M.
(2)
When used in welding with a steel qualified in accordance with 4.7.3 they may be
(a)
The steel qualified, or
(b)
Any steel listed in Table 3.1 or Annex M.
Steel for backing shall conform to the requirements of (1) and (2), except that 100 ksi minimum
yield strength steel as backing shall only be used with 100 ksi minimum yield strength steel.
Spacers used shall be of the same material as the base metal. (5.2.2)
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Section 4
4.3
4.3.1
Groove Welds
TUBULAR STRUCTURES
Special Provisions
Special provisions for joints, processes, procedures, and welder requirements are contained in
4.12, 4.13, and 4.26 of AWS D1.1. The details of the transition of thickness of tubular joint of
unequal thickness are shown in Figure 2.4.
4.3.2
Root Opening
Joint requirements for groove welds, from those shown on the detailed drawings, should be in
accordance with paragraph 4.1.8 (AWS 5.22.4). In addition, the following tolerances will apply
to complete joint penetration welds made from one side only without backing. (5.22.4)
Root Face
of Joint
in.
mm
Groove Angle
of Joint
deg.
SMAW
± 1/16
1.6
± 1/16
1.6
±5
GMAW
± 1/32
0.8
± 1/16
1.6
±5
FCAW
± 1/16
1.6
± 1/16
1.6
±5
*
4.3.3
Root Opening of Joints
Without Steel Backing*
in.
mm
Root openings wider than permitted by the above tolerances but not greater than the
thickness of the thinner part may be built up by welding to acceptable dimensions
prior to the joining of the parts by welding.
Temporary Welds
Temporary welds shall be subject to the same welding procedure requirements as the final weld.
These shall be removed, when required by the Engineer. When they are removed, the surface
shall be made flush with the original surface. (5.18.1)
4.4
4.4.1
ASME SECTION III
Alignment Requirements
Welding From Two Sides
(a)
Alignment of sections which are welded from two sides shall be such that the maximum
offset of the finished weld will not be greater than the applicable amount listed in Table
NB, NE-4232-1 or Table NC, ND, -4232(a)-1 as applicable, where t is the nominal
thickness of the thinner section at the joint.
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Section 4
Groove Welds
Figure 2.4 Transition of Thickness of Butt Joints in Parts of Unequal Thickness (Tubular)
(see 2.41)
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Section 4
Groove Welds
Table NB, NE-4232-1 and
Table NC, ND -4232(a)-1
Maximum Allowable Offset in Final Welded Joints
Direction of Joints
Section Thickness, in.
Longitudinal
Circumferential
Up to 1/2, incl.
1/4 t
1/4 t
Over 1/2 to 3/4, incl.
1/8 in.
1/4 t
Over 3/4 to 1-1/2, incl.
1/8 in.
3/16 in.
Over 1-1/2 to 2, incl.
1/8 in.
1/8 t
Over 2
Lesser of 1/16 t or 3/8 in.
Lesser of 1/8 t or 3/4 in.
For component supports (NF) the maximum allowable offset is given in Table NF-4232-1.
Table NF-4232-1
Maximum Allowable Offset in Final Butt Welded Joints
Section Thickness, in.
Maximum Allowable Offset
Up to 3/4, incl.
1/4 t
Over 3/4 to 1-1/2, incl.
3/16 in.
Over 1-1/2 to 2, incl.
1/8 t
Over 2
Lesser of 1/8 t or 3/4 in.
(b)
Joints in spherical vessels, joints within heads, and joints between cylindrical shells and
hemispherical heads shall meet the requirements for longitudinal joints.
4.4.2
Fairing of Offsets – Applicable Only to Joints Welded from Two Sides
(a)
Class 2 and 3
Any offset within the allowable tolerance provided above shall be faired to at least a 3:1 taper
over the width of the finished weld or, if necessary, by adding additional weld metal beyond what
would otherwise be the edge of the weld. (NB, NC, ND-4232.1)
(b)
Class 1 and MC
In addition to (a) above:
In addition, offsets greater than those stated in Table NB, NE-4232-1 are acceptable provided the
requirements of NB, NE-3200 are met. (NB, NE-4232.1)
(c)
Component Supports
Any offset within the allowable tolerance of Table NF-4232-1 shall be blended uniformly over the
width of the finished weld or, if necessary, by adding additional weld metal beyond what would
otherwise be the edge of the weld. (NF-4232.1)
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Section 4
4.4.3
Groove Welds
Welding From One Side (Inside Inaccessible)
Circumferential Joints - Tolerances
Class 1, 2 and 3
Figure NX-4233-1
Should tolerances on diameter, wall thickness, out-of-roundness, etc., result in inside diameter
variations which do not meet these limits, the inside diameters shall be counterbored, sized, or
ground to produce a bore within these limits provided the requirements of NX-4250 are met.
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Section 4
4.4.4
Groove Welds
Fairing of Offsets – For Welds Made From One Side
Offset of outside surfaces shall be faired to at least a 3:1 taper over the width of the finished weld
or, if necessary, by adding additional weld metal. (NB, NC, ND-4233)
4.4.5
Longitudinal Joints – Tolerances
For longitudinal joints the misalignment of inside surfaces shall not exceed 3/32 inch and the
offset of outside surfaces shall be faired to at least a 3:1 taper over the width of the finished weld
or, if necessary, by adding additional weld metal. (NB, NC, ND-4233)
4.4.6
Weld Joint Reinforcement for Vessels, Pumps, and Valves
The surface of the reinforcement of all butt welded joints in vessels, pumps, and valves may be
flush with the base material or may have uniform crowns. The height of reinforcement on each
face of the weld shall not exceed the thickness in the following tabulation. (NX-4426)
Nominal Thickness, in.
4.4.7
Maximum Reinforcement, in.
Up to 1, incl.
3/32
Over 1 to 2, incl.
1/8
Over 2 to 3, incl.
5/32
Over 3 to 4, incl.
7/32
Over 4 to 5, incl.
1/4
Over 5
5/16
Reinforcement for Piping
For double welded butt joints, the limitation on the reinforcement given in Column 1 of the
following tabulation shall apply separately to both inside and outside surfaces of the joint. For
single welded butt joints, the reinforcement given in Column 2 shall apply to the inside surface and
the reinforcement given in Column I shall apply to the outside surface. The reinforcement shall be
determined from the higher of the abutting surfaces involved. (NX-4426.2)
Material Nominal Thickness, in.
Maximum Reinforcement Thickness, in.
Column 1
Column 2
Up to 1/8, incl.
3/32
3/32
Over 1/8 to 3/16, incl.
1/8
3/32
Over 3/16 to 1/2, incl.
5/32
1/8
Over 1/2 to 1, incl.
3/16
5/32
Over 1 to 2, incl.
1/4
5/32
Over 2
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Greater of 1/4 in. or 1/8
times the width of the
weld, in inches
Welding Inspection Handbook
4-13
Section 4
4.4.8
Groove Welds
Weld Surfaces
The surface of the welds shall be sufficiently free from coarse ripples, grooves, overlaps, and
abrupt ridges and valleys to meet (a) through (e) below.
(a)
The surface condition of the finished weld shall be suitable for the proper interpretation of
radiographic and other required nondestructive examinations of the weld. In those cases
where there is a question regarding the surface condition of the weld on the interpretation
of a radiographic film, the film shall be compared to the actual weld surface for
interpretation and determination of acceptability.
(b)
Reinforcements shall be within the tolerances given above.
(c)
Undercuts shall not exceed 1/32 inch and shall not encroach on the required section
thickness.
(d)
Concavity on the root side of a single welded circumferential butt weld is permitted when
the resulting thickness of the weld meets the requirements of NX 3000. (NX-4424)
(e)
If grinding is required to meet the above criteria, care shall be taken to avoid reducing the
weld or base metal below the required thickness.
4.4.9
Welding End Transitions
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Section 4
Groove Welds
General Notes:
(a) Weld bevel is shown for illustration only
(b) The weld reinforcement permitted by NX-4426 may lie outside the maximum envelope
Notes:
(1) The value of t min. is whichever is applicable:
(a) the minimum ordered wall thickness of the pipe
(b) the 0.875 times the nominal wall thickness of pipe ordered to a pipe
schedule wall thickness which has an under tolerance of 12.5%
(c) the minimum ordered wall thickness of the cylindrical welding end of a
component or fitting (or the thinner of the two) when the joint is between
two components
(2) The maximum thickness at the end of the component is:
(a) the greater of (t min. +0.15 in.) or 1.15 t min. when ordered on a minimum
wall basis
(b) the greater of (t min. +0.15 in.) or 1.10 t nom. when ordered on a nominal
wall basis
The welding ends of items shall provide gradual change in thickness from the item to the adjoining
item. Any welding end transition which lies entirely within the envelope shown in Figure NX4250-1 is acceptable, provided that:
(a)
the wall thickness in the transition region is not less than the min. wall thickness of the
adjoining item; and
(b)
sharp reentrant angles and abrupt changes in slope in the transition region are avoided.
When the included angle between any two adjoining surfaces of a taper transition is less
than 150°, the intersection or corner (except for the weld reinforcement) shall be provided
with a radius of at least 0.05tmin.
4.4.10 Backing Rings – Piping
(a)
Class 1
When used in components other than piping, backing rings shall conform to the requirements of
NB-4240. Backing rings shall not be used in piping unless removed after welding and the inside
surfaces of the roots are examined by a magnetic particle or liquid penetrant method, in
accordance with NB-5110, and meeting the acceptance standards of NB-5340 or NB-5350. The
material for backing rings, when used, shall be compatible with the base metal. Permanent
backing rings, when permitted by NB-3352, shall be continuous, and any splices shall be made by
full penetration welds. Spacer pins shall not be incorporated into the welds. (NB-4421)
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Section 4
(b)
Groove Welds
Class 2
Backing rings which remain in place may be used for piping in accordance with the requirements
of NC-3661.2. The materials for backing rings shall be compatible with the base metal but spacer
pins shall not be incorporated into the weld. (NC-4421)
(c)
Class 3
Backup plates and backing rings which remain in place, and compression rings or stiffeners of
storage tanks such as angles, bars, and ring girders may be used. Their materials shall be
compatible with the base metal, but spacer pins shall not be incorporated into the welds.
(ND-4421)
(d)
Class MC
Backing rings shall conform to the requirements of NE-4240. The material for backing rings,
when used, shall be compatible with the base metal. Permanent backing rings, when permitted by
NE-4240, shall be continuous, and any splices shall be made by full penetration welds. Spacer
pins shall not be incorporated into the welds. (NE-4421)
(e)
Component Supports
The material for backing strips, when used, shall be compatible with the base metal. (NF-4421)
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Section 4
4.5
4.5.1
Groove Welds
ASME B31.1
Backing Rings
Backing rings, when used, shall conform to the following requirements:
(A)
Ferrous Rings. Ferrous metal backing rings which become a permanent part of the weld
shall be made from material of weldable quality, compatible with the base material and the
sulfur content shall not exceed 0.05%.
(A.1) Backing rings may be of the continuous machined or split band type.
(A.2) If two abutting surfaces are to be welded to a third member used as a backing ring
and one or two of the three members are ferritic and the other member or members
are austenitic, the satisfactory use of such materials shall be determined by the
welding procedure qualified as required in paragraph 127.5.
(A.3) Backing strips used at longitudinal welded joints shall be removed.
(B)
Nonferrous and Nonmetallic Rings. Backing rings of nonferrous or nonmetallic
materials may be used for backing provided they are included in a welding procedure
qualified as required in paragraph 127.5. Nonmetallic or nonfusing rings shall be
removed. (127.2.2)
4.5.2
End Preparations
(A.1) Oxygen or arc cutting is acceptable only if the cut is reasonably smooth and true, and all
slag is cleaned from the flame cut surfaces. Discoloration which may remain on the flame
cut surface is not considered to be detrimental oxidation.
(A.2) Butt-welding end preparation dimensions contained in ANSI B16.25 or any other end
preparation which meets the procedure qualification are acceptable.
(A.3) If piping component ends are bored, such boring shall not result in the finished wall
thickness after welding less than the minimum design thickness. Where necessary, weld
metal of the appropriate analysis may be deposited on the inside or outside of the piping
component to provide sufficient material for machining to insure satisfactory fitting of
rings.
(A.4) If the piping component ends are upset, they may be bored to allow for a completely
recessed backing ring, provided the remaining net thickness of the finished ends is not less
than-the minimum design thickness.
(B)
Cleaning. Surfaces for welding shall be clean and shall be free from paint, oil, rust, scale,
or other material which is detrimental to welding.
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Section 4
(C)
Groove Welds
Alignment. The inside diameters of piping components to be joined shall be aligned as
accurately as is practicable within existing commercial tolerances on diameters, wall
thicknesses, and out-of-roundness. Alignment shall be preserved during welding. The
internal misalignment shall not exceed 1/16 in. unless the piping design specifically states a
different allowable misalignment.
When the internal misalignment exceeds the allowable, it is preferred that the component
with the wall extending internally be internally trimmed per Figure 127.3.1. However,
trimming shall result in a piping component wall thickness not less than the minimum
design thickness and the change in contour shall not exceed 30 degrees.
(D)
Spacing. The root opening of the joint shall be as given in the Welding Procedure
Specifications. (127.3)
Figure 127.3.1 – Butt Welding of Piping Components with Internal Misalignment
4.5.3
Girth Butt Welds
(A)
Girth butt welds shall be complete penetration welds and shall be made with a single vee,
double vee, or other suitable type of groove, with or without backing rings or consumable
inserts The depth of the weld measured between the inside surface of the weld
preparation and the outside surface of the pipe shall not be less than the minimum
thickness required by Chapter II for the particular size and wall of pipe used.
(B)
In order to avoid abrupt transitions in the contour of the finished weld, the requirements of
(B.1 through (B.4) below shall be met.
(B.1) When components with different outside diameters are welded together, the
welding end of the larger diameter component shall fall within the envelope defined
by the solid lines in Figure 127.4.2. The weld shall form a gradual transitionnot
exceeding a slopre of 30°, from the smaller to the larger component. This
condition may be met by adding weld filler metal, if Necessary, beyond what would
otherwise be the edge of the weld.
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Groove Welds
(B.2) When both components to be welded have a transition from a thicker section to
the weld end preparation, the included angle between the surface of the weld and
the surface of either of the components shall not be less than 150°. Refer to Para.
119.3(B) for additional concerns related to this design.
(B.3) When welding pipe to pipe, the surface of the weld shall, as a minimum be flush
with the outer surface of the pipe, except as permitted in Para. 127.4.2(B4).
(B4)
(C)
For welds made without the addition of filler metal, concavity shall be limited to
1/32 in. below the outside surface of the pipe, but shall not encroach on minimum
required thickness.
As-welded surfaces are permitted; however, the surface of welds shall be sufficiently free
from coarse ripples, grooves, overlaps, abrupt ridges, and valleys to meet the following.
(C.1) The surface condition of the finished welds shall be suitable for the proper
interpretation of radiographic and other nondestructive examinations when
nondestructive examinations are required by Table 136.4. In those cases where
there is a question regarding the surface condition on the interpretation of a
radiographic film, the film shall be compared to the actual weld surface for
interpretation and determination of acceptability.
(C.2) Reinforcements are permitted in accordance with Table 127.4.2.
(C.3) Undercuts shall not exceed 1/32 in. and shall not encroach on the minimum
required thickness.
(C.4) If the surface of the weld requires grinding to meet the above criteria, care shall be
taken to avoid reducing the weld or base material below the required thickness.
(C.5) Concavity on the root side of a single welded circumferential butt weld is
permitted when the resulting thickness of the weld is at least equal to the thickness
of the thinner member of the two sections being joined and the contour of the
concavity is smooth without sharp edges. The internal condition of the root surface
of a girth weld, which has been examined by radiography, is acceptable only when
there is a gradual change in density, as indicated in the radiograph. If a girth weld
is not designated to be examined by radiography, a visual examination may be
performed at the welds which are readily accessible. (127.4.2)
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Section 4
4.5.4
Groove Welds
Longitudinal Butt Welds
Longitudinal butt welds not covered by the materials specification shall be the requirements for
girth butt welds. (127.4.3)
General Notes:
(a) The value of tm is whichever of the following is applicable:
(1) as defined in paragraph 104.1.2(A);
(2) the minimum ordered wall thickness of the cylindrical welding end of a
component or fitting (or the thinner of the two) when the joint is between
two components.
(b) The maximum envelope is defined by the solid lines.
Notes:
(1) Weld bevel is shown for illustration only.
(2) The weld transition and weld reinforcement shall comply with Paras.
127.4.2(B) and (C.2) may be outside maximum envelope.
(3) The maximum thickness at the end of the component is:
(a) The greater of (tm +0.15 in.) or 1.15tm when ordered on a minimum wall
basis;
(b) The greater of (tm + 0.15 in) or 1.10tnom when ordered on a nominal wall
basis.
Figure 127.4.2 – Welding End Transition - Maximum Envelope
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Section 4
Groove Welds
Table 127.4.2
Reinforcement of Girth and Longitudinal Butt Welds
Thickness of Base Metal,
in.
Maximum Thickness of Reinforcement for Design Temperature
>750°F
350-750°F
<350°F
in.
in.
in.
Up to 1/8, incl.
1/16
3/32
3/16
Over 1/8 to 3/16, incl.
1/16
1/8
3/16
Over 3/16 to 1/2, incl.
1/16
5/32
3/16
Over 1/2 to 1, incl.
3/32
3/16
3/16
Over 1 to 2, incl.
1/8
1/4
1/4
Over 2
5/32
The greater of 1/4 in. or 1/8 times
the width of the weld in inches
General Notes:
(a)
For double welded butt joints, this limitation on reinforcement given above shall apply separately to both
inside and outside surfaces of the joint.
(b)
For single welded butt joints, the reinforcement limits given above shall apply to the outside surface of the
joint only.
(c)
The thickness of weld reinforcement shall be based on the thickness of the thinner of the materials being
joined.
(d)
The weld reinforcement thicknesses shall be determined from the higher of the abutting surfaces involved.
(e)
Weld reinforcement may be removed is so desired.
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Section 4
4.6
4.6.1
Groove Welds
ASME B31.3
Backing Rings
Backing rings, when used, shall conform to the following.
(a)
Ferrous Metal Backing Rings. These shall be of weldable quality. Sulfur content shall
not exceed 0.05%.
(b)
If two abutting surfaces are to be welded to a third member used as a backing ring and one
or two of the three members are ferritic and the other member or members are austenitic,
the satisfactory use of such materials shall be determined by the welding procedure
qualified as required in paragraph 328.2.
Backing rings may be of the continuous machined or split band type.
(c)
Nonferrous and Nonmetallic Rings. Backing rings of nonferrous or nonmetallic
materials may be used for backing, provided the designer approves their use and the
welding procedure using they is qualified as required in paragraph 328.2. (328.3.2)
4.6.2
End Preparations
(a)
General
(b)
(1)
End preparation is acceptable only if the cut is reasonably smooth and true, and
slag from oxygen or arc cutting is cleaned from thermally cut surfaces.
Discoloration remaining on thermally cut surfaces is not considered to be
detrimental oxidation.
(2)
Butt-welding end preparation dimensions contained in ANSI B16.25 or any other
end preparation which meets the procedure qualification are acceptable.
Circumferential Welds
(1)
If component ends are trimmed as shown in Figure 328.3.2 sketch 9(a) or (b) to fit
backing rings or consumable inserts, or as shown in Figure 328.4.3 sketch (a) or
(b) to correct internal misalignment, such trimming shall not reduce the finished
wall thickness below the required minimum wall thickness tm.
(2)
Component ends may be bored to allow for a completely recessed backing ring,
provided the remaining net thickness of the finished end is not less than tm.
(3)
It is permissible to size the pipe ends of the same nominal pipe size to improve
alignment if wall thickness requirements are maintained.
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Section 4
Groove Welds
Figure 328.4.3 Trimming and Permitted Misalignment
(4)
Where necessary, weld metal may be deposited inside or outside of the component
to permit alignment or provide for machining to ensure satisfactory seating of rings
or inserts.
(5)
When a girth or miter groove weld joins components of unequal wall thickness and
one is more than 11/2 times the thickness of the other, end preparation and
geometry shall be in accordance with acceptable designs for unequal wall thickness
in ASME 16.25. (328.4.2)
4.6.3
Alignment
(a)
Circumferentail Welds
(b)
(1)
Inside surfaces of components at ends to be joined in girth or miter groove welds
shall be aligned within the dimensional limits in the WPS and the engineering
design.
(2)
If the external surfaces of the components are not aligned, the weld shall be taped
between them.
Longitudinal Welds. Alignment of longitudinal groove welds (not made in accidence
with a materials standard) shall meet the requirements for circumferential welds.
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Section 5
Welding Symbols
Page
5.1
AWS A2.4.......................................................................................................................
5-1
5.1.1
Introduction.....................................................................................................................
5-1
5.1.1.1
General............................................................................................................................
5-1
5.2.
AWS-AISC CONFLICTING REQUIREMENTS .............................................................
5-4
5.3
INTERMITTENT WELDS..............................................................................................
5-5
5.3.1.1
Intermittent Welds...........................................................................................................
5-5
5.3.1.2
Intermittent Fillet Welds..................................................................................................
5-6
5.3.1.3
Chain of Intermittent Fillet Welds ...................................................................................
5-6
5.3.1.4
Staggered Intermittent Fillet Welds .................................................................................
5-7
5.3.1.5
End Terminations ............................................................................................................
5-7
5.3.1.6
Depth of Preparation........................................................................................................
5-7
5.3.1.7
Effective Throat and Depth of Preparation .......................................................................
5-8
5.3.1.8
Back or Backing Weld Symbol Chart...............................................................................
5-8
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Section 5
5.1
5.1.1
Welding Symbols
AWS A2.4
Introduction
Symbols are an important part of the communications system used by the engineer to convey information from the
designer to the craftsmen. This method is a symbolic representation of weld requirements on engineering
drawings. it is consistent with the method used in the AWS A2.4 Standard (Symbols for Welding & NDE).
The welding symbol is an assembly of schematic weld outlines, joint dimensions, size limitations, contour
instructions and notes on a reference line, drawn with an arrow pointed to a specific weld location. The figure
below shows the standard location of various elements of the welding symbol.
5.1.1.1
General
There are eight basic points concerning the weld symbol. To completely understand how weld symbols are used by
the design engineer for shop and field installations, the information contained in 5.1.1.1 through 5.1.1.9 should be
used to properly interpret welding symbols.
5.1.1.2
The reference line is always horizontal, never vertical.
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Section 5
Welding Symbols
5.1.1.3
Information placed above or below the reference line always reads from left to right without regard to
which end of the reference line has the arrow.
5.1.1.4
The graphic weld symbol below the reference line (the letter “B”) refers to the arrow side of the joint,
and the graphic weld symbol above the reference line (the letter “A”) refers to the other side of the
joint.
5.1.1.5
For groove welds only, the broken arrow points to the specific member to be beveled. The weld
symbol shown is below the reference line; therefore, the bevel is on the arrow side of the joint. The
broken arrow points to the upper member, so the upper member is beveled and not the lower member.
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Section 5
Welding Symbols
5.1.1.6
When there is no break in the arrow, the bevel may be made in either member. Here the symbol is
shown below the reference line; therefore, the member is prepared and the weld made on the arrow
side of the joint.
5.1.1.7
The all-around symbol is the circle at the intersection of the reference line and arrow.
5.1.1.8
To convey additional information or special instructions concerning welding processes, NDE
requirements or specific joint details, a tail is placed at the opposite end of the reference line than that
of the arrow.
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Section 5
Welding Symbols
5.1.1.9
And finally, the field weld symbol, which is a flag placed on the reference line where the arrow and
reference line intersect, always points to the weld symbol. The “dot” should no longer be used to
indicate field weld.
5.1.1.10
Remembering these eight points regarding the weld symbol will make it much easier for you to
interpret engineering drawings and understand the weld symbol requirements.
5.2
AWS-AISC CONFLICTING SYMBOL REQUIREMENTS
5.2.1
AWS requires the size of welds to be placed on both sides of the reference line. AISC (American
Institute of Steel Construction) states, “Arrow and other side welds are of the same size unless
otherwise shown.”
5.2.1.1
To avoid confusion, Bechtel drawings should be interpreted in the following manner. In the case of
fillet welds, each side of the reference line should be dimensioned. If only one side is dimensioned,
the fillet weld symbol not dimensioned is considered continuous.
5.2.1.2
For multiple weld symbols, each symbol needs to be dimensioned which applies to both sides.
All other standard elements concerning weld symbols are the same for AWS and AISC.
The latest revision of AISC is now compatible with AWS in its entirety.
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Section 5
5.3
Welding Symbols
FILLET WELDS
Dimensions (size), which are always on the same side of the reference line as the weld symbol, and always shown
to the left of the symbol. Remember, the size shown on the welding symbol is always the minimum size required.
5.3.1.1
Intermittent Welds
The length of the weld is indicated to the right of the symbol if it is not continuous. If the weld is intermittent, the
first number is the length, followed by the pitch (center-to-center distance) of the weld as shown in Figure 7.
5.3.1.2
Intermittent Fillet Welds
Intermittent fillet welds. The first number gives the weld length required, and the second number indicates the
center-to-center spacing of the welds.
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Section 5
5.3.1.3
Welding Symbols
Chain Intermittent Fillet Welds
Chain intermittent welding is shown in figure below, with fillet welds shown directly opposite each other.
5.3.1.4
Staggered Intermittent Fillet Welds
Staggered intermittent welds by using staggered symbol arrangements.
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Section 5
5.3.1.5
Welding Symbols
End Terminations
If required by actual length of the joint, the length of the increment of the welds at the end of the joint should be
increased to terminate the weld at the end of the joint.
5.3.1.6
Depth of Preparation
5.3.1.7
Effective Throat and Depth of Preparation
The effective throat may be more or less than the depth of preparation depending on the joint design and welding
process used.
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Section 5
5.3.1.8
Welding Symbols
Back or Backing Symbol
The back or backing symbol when used indicates that back gouging, grinding, etc., and back welding is required.
The following pages contain the “Standard Welding Symbols” chart taken from AWS A2.4.
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Section 6
Acceptance Criteria
Page
6.1
SCOPE ......................................................................................................
6-1
6.2
VISUAL INSPECTION.............................................................................
6-1
6.3
LIQUID PENETRANT INSPECTION & MAGNETIC PARTICLE
INSPECTION............................................................................................
6-1
6.4
NONDESTRUCTIVE TESTING ..............................................................
6-1
6.4.1
Tubular Connection Requirements..............................................................
6-1
6.5
RADIOGRAPHIC INSPECTION..............................................................
6-1
6.5.1
Acceptance Criteria for Statically Loaded Nontubular Connections ............
6-3
6.5.2
Acceptance Criteria for Cyclically Loaded Nontubular Connections............
6-3
6.5.3
Acceptance Criteria for Tubular Connections .............................................
6-7
6.6
ULTRASONIC INSPECTION ..................................................................
6-14
6.6.1
Acceptance Criteria....................................................................................
6-14
6.7
PERSONNEL QUALIFICATIONS ...........................................................
6-15
6.7.1
ASNT Requirements ..................................................................................
6-15
6.7.2
Certification ...............................................................................................
6-15
6.7.3
Exemption of QCI Requirements................................................................
6-15
6.8
EXTENT OF TESTING ............................................................................
6-15
6.8.1
Full Testing................................................................................................
6-15
6.8.2
Partial Testing............................................................................................
6-15
6.8.3
Spot Testing...............................................................................................
6-15
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Section 6
6.1
Acceptance Criteria
SCOPE
Acceptance criteria for visual and nondestructive inspection of tubular connections and statically
and cyclically loaded nontubular connections are described in Part C. The extent of examination
and the acceptance criteria shall be specified in the contract documents on information furnished
to the bidder.
6.2
VISUAL INSPECTION
All welds shall be visually inspected and shall be acceptable if the criteria of Table 6.1 are
satisfied.
6.3
LIQUID PENETRANT AND MAGNETIC-PARTICLE TESTING
Welds that are subject to magnetic-particle and liquid penetrant testing, in addition to visual
inspection, shall be evaluated on the basis of the requirements for visual inspection. The testing
shall be performed in conformance with 6.7.5 or 6.7.6, whichever is applicable.
6.4
NONDESTRUCTIVE TESTING
All NDT methods including equipment requirements and qualifications, personnel qualifications,
and operating methods shall be in accordance with Section 6 of AWS D1.1, Inspection.
Acceptance criteria shall be as specified in this section. Welds subject to nondestructive testing
shall have been found acceptable by visual inspection in accordance with 6.2.
Acceptance criteria for ASTM A514 and A517 steels shall be based on nondestructive testing
performed not less than 48 hours after completion of the welds.
6.4.1
Tubular Connection Requirements
For complete Joint penetration groove butt welds welded from one side without backing, the
entire length of all completed tubular production welds shall be examined by either radiographic
or ultrasonic testing. The acceptance criteria shall conform to 6.5.3 or 6.6.3 as applicable.
6.5
RADIOGRAPHIC INSPECTION
Welds shown by radiographic testing that do not meet the requirements shall be repaired in
accordance with 5.26 of AWS D1.1. Discontinuities other than cracks shall be evaluated on the
basis of being either elongated or rounded.
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Section 6
Acceptance Criteria
Regardless of the type of discontinuity, an elongated discontinuity is one in which its length
exceeds three times its width. A rounded discontinuity is one in which its length is three times its
width or less and may be round or irregular and may have tails.
6.5.1
6.5.1.1
Acceptance Criteria for Statically Loaded Nontubular Connections
Discontinuities
Welds that are subject to radiographic testing in addition to visual inspection shall have no cracks
and shall be unacceptable if the radiographic testing show any discontinuities exceeding the
following limitations (E = weld size).
1. Elongated discontinuities exceeding the maximum size of Figure 6.1.
2. Discontinuities closer than the minimum clearance allowance of Figure 6.1.
3. Rounded discontinuities greater than a maximum of size of E/3, not to exceed 1/4 in.
However, when the thickness is greater than 2 in. (50 mm), the maximum rounded
indication may be 3/8 in.. The minimum clearance of this type of discontinuity
greater than or equal to 3/32 in. to an acceptable elongated or rounded discontinuity
or to an edge or end of an intersecting weld shall be three times the greatest
dimension of the larger of the discontinuities being considered.
4. Isolated discontinuities such as a cluster of rounded indications, having a sum of their
greatest dimensions exceeding the maximum size single discontinuity permitted in
Figure 6.1. The minimum clearance to another cluster or an elongated or rounded
discontinuity or to an edge or end of an intersecting weld shall be three times the
greatest dimension of the larger of the discontinuities being considered.
5. The sum of individual discontinuities each having a greater dimension of less than
3/32 in. shall not exceed 2E/3 or 3/8 in., whichever is less, in any linear 1 in. of weld.
This requirement is independent of (1), (2), and (3) above.
6. In-line discontinuities, where the sum of the greatest dimensions exceeds E in any
length of 6E. When the length of the weld being examined is less than 6E, the
permissible sum of the greatest dimensions shall be proportionally less.
6.5.1.2
Illustration of Requirements
Figure 6.2 and Figure 6.3 illustrate the application of the requirements given in 6.5.1.1.
6.5.2
Acceptance Criteria for Cyclically Loaded Nontubular Connections
Welds that are subject to radiographic testing in addition to visual inspection shall have no cracks
and shall be unacceptable if the radiographic testing shows any of the types of discontinuities
listed in 6.5.2.1, 6.5.2.2, 6.5.2.3, or 6.5.2.4.
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6.5.2.1
Acceptance Criteria
Tensile Stress Welds
For welds subject to tensile stress under any condition of loading, the greatest dimension of any
porosity or fusion-type discontinuity that is 1/16 in. or larger in greatest dimension shall not
exceed the size, B, indicated in Figure 6.4, for the weld size involved.
The distance from any porosity or fusion-type discontinuity described above to another such
discontinuity, to an edge, or to the toe or root of any intersecting flange-to-web weld shall be not
less than the minimum clearance allowed, C, indicated in Figure 6.4, for the size of discontinuity
under examination.
6.5.2.2
Compressive Stress Welds
For welds subject to compressive stress only and specifically indicated as such on the design
drawings, the greatest dimension of porosity or a fusion-type discontinuity that is 1/8 in. or larger
in greatest dimension shall not exceed the size, B, nor shall the space between adjacent discontinuities be less than the minimum clearance allowed, C, indicated by Figure 6.5 for the size of
discontinuity under examination.
6.5.2.3
Discontinuities Less Than 1/16 in
Independent of the requirements of 6.5.2.1 and 6.5.2.2, discontinuities having a greatest
dimension of less than 1/16 in. shall be unacceptable if the sum of their greatest dimensions
exceeds 3/8 in. (10 mm) in any linear inch of weld.
6.5.2.4
Limitations
The limitations given by Figures 6.4 and 6.5 for 1-1/2 in. weld size shall apply to all weld sizes
greater than 1-1/2 in. thickness.
6.5.2.5
Annex V Illustration
Annex V illustrates the application of the requirements given in 6.5.2.1.
6.5.3
6.5.3.1
Acceptance Criteria for Tubular Connections
Discontinuities
Welds that are subject to radiographic testing in addition to visual inspection shall have no cracks
and shall be unacceptable if the radiographic testing show any discontinuities exceeding the
following limitations (E = weld size).
1. Elongated discontinuities exceeding the maximum size of Figure 6.6.
2. Discontinuities closer than the minimum clearance allowance of Figure 6.6.
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Section 6
6.6
6.6.1
Acceptance Criteria
ULTRASONIC INSPECTION
Acceptance Criteria
Consult AWS D1.1 Section 6 for detailed acceptance criteria for Ultrasonic Examinations.
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Section 6
6.7
Personnel Qualification
6.7.1
ASNT Requirements
Acceptance Criteria
Personnel performing nondestructive testing other than visual shall be qualified in accordance with
the current edition of the American Society for Nondestructive Testing Recommended Practice
No. SNT-TC- I A.2 Only individuals qualified for NDT Level I and working under the NDT
Level II or individuals qualified for NDT Level II may perform nondestructive testing.
6.7.2
Certification
Certification of Level I and Level II individuals shall be performed by a Level III individual who
has been certified by (1) The American Society for Nondestructive Testing, or (2) has the
education, training, experience, and has successfully passed the written examination prescribed in
SNT-TC-lA.
6.7.3
Exemption of QC1 Requirements
Personnel performing nondestructive tests under the provisions of 6.7.7 need not be qualified and
certified under the provisions of AWS QC 1.
6.8
EXTENT OF TESTING
Information furnished to the bidders shall clearly identify the extent of nondestructive testing
(types, categories, or location) of welds to be tested.
6.8.1
Full Testing
Weld joints requiring testing by contract specification shall be tested for their full length, unless
partial or spot testing is specified.
6.8.2
Partial Testing
When partial testing is specified, the location and lengths of welds or categories of weld to be
tested shall be clearly designated in the contract documents.
6.8.3
Spot Testing
When spot testing is specified, the number of spots in each designated category of welded joint to
be tested in a stated length of weld or a designated segment of weld shall be included in the
information.
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Section 7
NDE Acceptance Standards ASME/ANSI
Page
7.1
ASME SECTION III .................................................................................
7-1
7.1.1
Visual Acceptance......................................................................................
7-1
7.1.2
General Acceptance Standards ...................................................................
7-1
7.1.3
Radiographic Acceptance Standards...........................................................
7-1
7.1.4
Ultrasonic Acceptance Standards ...............................................................
7-2
7.1.5
Magnetic Particle Acceptance Standards (NX 5340)...................................
7-3
7.1.6
Liquid Penetrant Acceptance Standards (NX-5350)....................................
7-3
7.2
ANSI B31.1...............................................................................................
7-3
7.2.1
Visual (136.4.2) .........................................................................................
7-3
7.2.2
Magnetic Particle (136.4.3) ........................................................................
7-4
7.2.3
Liquid Penetrant (136.4.4) .........................................................................
7-4
7.2.4
Radiographic (136.4.5)...............................................................................
7-4
7.3
ASME SECTION III WELD CATEGORIES ............................................
7-5
7.3.1
Category “A” .............................................................................................
7-5
7.3.2
Category “B” .............................................................................................
7-5
7.3.3
Category “C” .............................................................................................
7-5
7.3.4
Category “D” .............................................................................................
7-5
7.4
ASME/ANSI B31.3 ...................................................................................
7-6
7.4.1
Acceptance Criteria....................................................................................
7-7
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Welding Inspection Handbook
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Section 7
7.1
7.1.1
NDE Acceptance Standards ASME/ANSI
ASME SECTION III
Visual Acceptance
The surface of welds shall be sufficiently free from coarse ripples, grooves, overlaps, and abrupt
ridges and valleys to meet (a) through (e) below.
(a)
The surface condition of the finished weld shall be suitable for the proper interpretation
of radiographic and other required nondestructive examinations of the weld. In those
cases where there is a question regarding the surface condition of the weld on the
interpretation of a radiographic film, the film shall be compared to the actual weld
surface for interpretation and determination of acceptability.
(b)
Reinforcements are permitted in accordance with Section 4 of this handbook.
(c)
Undercuts shall not exceed 1/32 in. and shall not encroach on the required section
thickness.
(d)
Concavity on the root side of a single welded circumferential butt weld is permitted
when the resulting thickness of the weld is at least equal to the thickness of the thinner
member of the two sections being joined.
(e)
If-the surface of the weld requires grinding to meet the above criteria, care shall be
taken to avoid reducing the weld or base material below the required thickness.
(NX-4424)
7.1.2
General Acceptance Standards
Unacceptable weld defects shall be removed or reduced to an acceptable size, and when required
the weld shall be repaired and reexamined, in accordance with ND-4450. Acceptance standards
shall be as stated in the following paragraphs of this Subarticle, while the acceptance standard for
material adjacent to the weld shall be as stated in NB, NC, ND, NE-2500 as applicable. (NB, NC,
ND, NE-5310)
7.1.3
Radiographic Acceptance Standards
Welds that are shown by radiography to have any of the following types of indications are
unacceptable. (NX-5320)
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Section 7
NDE Acceptance Standards ASME/ANSI
Code Class
NB, NC, ND, NE, NF
(a) any type of crack or zone of incomplete fusion or penetration.
NB, NC, ND, NE, NF
(b) any other elongated indication which has a length greater than:
(1) 1/4 in. for t up to 3/4 in., inclusive;
(2) 1/3t for t from 3/4 in. to 2-1/4 in., inclusive;
(3) 3/4 in. for t over 2-1/4 in. where t is the thickness of the thinner portion of
the weld.
NB, NC, ND, NE, NF
(c)
internal root weld conditions are acceptable when the density change as
indicated in the radiograph is not abrupt; elongated indications on the
radiograph at either edge of such conditions shall be unacceptable as provided in
(b) above.
NB, NC, ND, NE, NF
(d)
any group of aligned indications having an aggregate length greater than t in a
length of 12t, unless the minimum distance between successive indications
exceeds 6L, in which case the aggregate length is unlimited, L being the length
of the largest indication.
NB, NC, ND, NE
(e)
rounded indications in excess of that shown as acceptable in Appendix VI of
ASME Section III, Division I.
NF
(e)
rounded indications are not a factor in the acceptability of welds that are
radiographed.
ND
(f)
when a Category B or C butt weld, partially radiographed as required in
ND-5221(b) or ND-5231(b), is acceptable in accordance with (a) through (e)
above, the entire weld length represented by this partial radiograph is
acceptable.
ND
For spot radiography refer to ND-5321(g).
7.1.4
Ultrasonic Acceptance Standards
All indications which produce a response greater than 20% of the reference level shall be
investigated to the extent that the operator can determine the shape, identity, and location of all
such reflectors and evaluate them in terms of the acceptance standards given in (a) and (b) below.
(NX-5330)
Code Class
NB, NC, ND, NE, NF
(a) Discontinuities are unacceptable if the amplitude exceeds the reference level, and
discontinuities have lengths which exceed:
(1) 1/4 in. for t up to 3/4 in., inclusive;
(2) 1/3t for t from 3/4 in. to 2-1/4 in., inclusive;
(3) 3/4 in. for t over 2-1/4 in.; where t is the thickness of the weld being
examined; if a weld joins two members having different thicknesses at the
weld, t is the thinner of these two thicknesses.
NB, NC, ND, NE, NF
(b) Where discontinuities are interpreted to be cracks, lack of fusion, or incomplete
penetration, they are unacceptable regardless of discontinuity or signal amplitude.
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Section 7
7.1.5
NDE Acceptance Standards ASME/ANSI
Magnetic Particle Acceptance Standards (NX 5340)
Code Class
NB, NC, ND, NE, NF
(a) Only indications with major dimensions greater than 1/16 in. shall be considered
relevant.
NB, NC, ND, NE, NF
(b) Unless otherwise specified in this Subsection, the following relevant indications
are unacceptable:
(1) any cracks and linear indications;
(2) rounded indications with dimensions greater than 3/16 in.;
(3) four or more rounded indications in a line separated by 1/16 in. or less edge
to edge;
7.1.6
Liquid Penetrant Acceptance Standards (NX-5350)
Code Class
NB, NC, ND, NE, NF
(a) Only indications with major dimensions greater than 1/16 in. shall be considered
relevant.
NB, NC, ND, NE, NF
(b) Unless otherwise specified in this Subsection, the following relevant indications
are unacceptable:
(1) any cracks and linear indications;
(2) rounded indications with dimensions greater than 3/16 in.;
(3) four or more rounded indications in a line separated by 1/16 in. or less edge
to edge;
(4) ten or more rounded indications in any 6 sq inches of surface with the major
dimension of this area not to exceed 6 in. with the area taken in the most
unfavorable location relative to the indications being evaluated.
7.2
7.2.1
ANSI B31.1
Visual (136.4.2)
Acceptance Standards. The following indications are unacceptable:
(1)
cracks – external surface;
(2)
undercut on surface which is greater than 1/32 in. deep;
(3)
weld reinforcement greater than specified in Section 4 of this handbook;
(4)
lack of fusion on surface;
(5)
incomplete penetration (applies only when inside surface is readily accessible).
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Section 7
7.2.2
NDE Acceptance Standards ASME/ANSI
Magnetic Particle (136.4.3)
Acceptance Standards. The following relevant indications are unacceptable:
(1)
any cracks or linear indications;
(2)
rounded indications with dimensions greater than 3/16 in.
(3)
four or more rounded indications in a line separated by 1/16 in. or less edge to edge;
(4)
ten or more rounded indications in any 6 sq inches of surface with the major dimension
of this area not to exceed 6 in. with the area taken in the most unfavorable location
relative to the indications being evaluated.
7.2.3
Liquid Penetrant (136.4.4)
Acceptance Standards. Indications whose major dimensions are greater than 1/16 in. shall be
considered relevant. The following relevant indications are unacceptable:
(1)
any cracks or linear indications;
(2)
rounded indications with dimensions greater than 1/16 in.;
(3)
four or more rounded indications in a line separated by 1/16 in. or less edge to edge;
(4)
ten or more rounded indications of any 6 sq inches of surface with the major dimension
of this area not to exceed 6 in. with the area taken in the most unfavorable location
relative to the indications being evaluated.
7.2.4
Radiographic (136.4.5)
Acceptance Standards. Welds that are shown by radiography to have any of the following types
of discontinuities are unacceptable:
(1)
any type of crack or zone of incomplete fusion or penetration;
(2)
any other elongated indication which has a length greater than:
(2.1)
1/4 in. for t up to 3/4 in., inclusive;
(2.2)
1/3t for t from 3/4 in. to 2-1/4 in., inclusive;
(2.3)
3/4 in. for t over 2-1/4 in. where t is the thickness of the thinner portion of the
weld.
Note:
t referred to in (A.2.1), (A.2.2), and (A.2.3) above pertains to the thickness of the weld being
examined; if a weld joins two members having different thicknesses at the weld, t is the
thinner of these two thicknesses.
(3)
any group of indications in line that have an aggregate length greater than t in a length
of 12t, except where the distance between the successive indications exceeds 6L where
L is the longest indication in the group;
(4)
porosity in excess of that shown as acceptable in Appendix A-250 of Section I of the
ASME Boiler and Pressure Vessel Code.
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Welding Inspection Handbook
7-4
Section 7
7.3
NDE Acceptance Standards ASME/ANSI
ASME SECTION III WELD CATEGORIES
Figure NX-3351-1 – Welded Joint Locations Typical of Categories A, B, C, and D
7.3.1
Category “A”
Category A comprises longitudinal welded joints within the main shell, communicating chambers,
transitions in diameter, or nozzles; any welded joint within a sphere, within a formed or flat head,
or within the side plates of a flat sided vessel; circumferential welded joints connecting
hemispherical heads to main shells, to transitions in diameters, to nozzles, or to communicating
chambers.
7.3.2
Category “B”
Category B comprises circumferential welded joints within the main shell, communicating
chambers, nozzles, or transitions in diameter including joints between the transition and a cylinder
at either the large or small end; circumferential welded joints connecting formed heads other than
hemispherical to main shells, to transitions in diameter, to nozzles, or to communicating
chambers.
7.3.3
Category “C”
Category C comprises welded joints connecting flanges, Van Stone laps, tube sheets, or flat heads
to main shell, to formed heads, to transitions in diameter, to nozzles or to communicating
chambers; any welded joint connecting one side plate to another side plate of a flat sided vessel.
7.3.4
Category “D”
Category D comprises welded joints connecting communicating chambers or nozzles to main
shells, to spheres, to transitions in diameter, to heads or to flat sided vessels and those joints
connecting nozzles to communicating chambers. For nozzles at the small end of a transition in
diameter, see Category B.
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Welding Inspection Handbook
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Section 7
7.4
7.4.1
NDE Acceptance Standards ASME/ANSI
ANSI B31.3
Acceptance Criteria for Welds: Shall be as stated in the engineering design and shall at least
meet the applicable requirements stated below, and in para. 344.6.2 for ultrasonic examination of
welds, and elsewhere in the code.
Table 341.3.2 states acceptance criteria (limits on imperfections A to M) for Types of Welds, for
Service Conditions, and for required Examination Methods, See Fig. 341.3.2 for typical weld
imperfections.
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Section 7
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NDE Acceptance Standards ASME/ANSI
Welding Inspection Handbook
7-7
Section 7
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NDE Acceptance Standards ASME/ANSI
Welding Inspection Handbook
7-8
Section 7
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Section 7
NDE Acceptance Standards ASME/ANSI
Figure 341.3.2 – Typical Weld Imperfections
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Section 8
Code Required NDE
Page
8.1
ASME B31.1 .............................................................................................
8-1
8.1.1
Nondestructive Examination.......................................................................
8-1
8.1.2
Visual Examination ....................................................................................
8-1
Table 136.4
Mandatory Minimum Nondestructive Examinations
for Pressure Welds or Welds to Pressure Retaining
Components........................................................................
8-2
Table 136.4.1 Weld Imperfections Indicated by Various Types
of Examination....................................................................
8-3
8.2
ASME B31.3 .............................................................................................
8-3
8.2.1
Examination Normally Required.................................................................
8-3
8.2.2
Examination – Category D Fluid Service ....................................................
8-4
8.2.3
Examination – Severe Cyclic Service..........................................................
8-4
8.2.4
Spot Radiography ......................................................................................
8-5
8.2.5
Hardness Tests...........................................................................................
8-6
8.3
ASME SECTION III .................................................................................
8-6
8.3.1
Requirements for Piping Welds ..................................................................
8-6
8.3.2
Requirements for Supports.........................................................................
8-6
8.3.2.1
Examination of Class 1 Support Welds.......................................................
8-6
8.3.2.2
Examination of Class 2 and Class MC Support Welds ................................
8-7
8.3.2.3
Examination of Class 3 Support Welds.......................................................
8-7
8.4
AWS D1.1 .................................................................................................
8-8
Table 8-1
Weld NDE Requirements – ASME Section III –
(Piping Welds Only)............................................................
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8-0
Section 8
8.1
Code Required NDE
ASME B31.1
8.1.1
Nondestructive Examination
Non destructive examinations shall be performed in accordance with the requirements of
Chapter IV of ASME B31.1. The types and extent of mandatory examinations for pressure welds
and welds to pressure retaining components are specified in Table 136.4. For welds other than
those covered by Table 136.4, only visual examination is required. Welds requiring
nondestructive examination shall comply with the limitations as to imperfections, within the
capabilities of the type of examination used, and for the type of imperfections to be evaluated as
shown in Table 136.4.1. Welds not requiring examination (i.e., RT, UT, PT, or MT) shall be
judged acceptable if they pass visual examination per General Note A of Table 136.4 and the
pressure test specified in Para. 137. (136.4.1)
8.1.2
Visual Examination
Visual examination as defined in Para. 100.2 shall be performed as necessary, during the
fabrication and erection of piping components to provide verification that the design and WPS
requirements are being met. In addition, visual examination shall be performed to verify that all
completed welds in pipe and piping components comply with the acceptance standards specified
in (A) below or with the limitations on imperfections specified in the material specification under
which the pipe or component was furnished.
(A)
Acceptance Sstandards. The following indications are unacceptable:
(A.1) cracks – external surface;
(A.2) undercut on the surface which is greater than 1/32 in. deep;
(A.3) weld reinforcement great than specified in Table 127.4.2;
(A-4) lack of fusion on surface;
(A-5) incomplete penetration (applies only when inside surface is readily accessible).
(136.4.2)
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Section 8
Code Required NDE
Table 136.4
Mandatory Minimum Nondestructive Examinations for
Pressure Welds or Welds to Pressure Retaining Components
Type Weld
Piping Service Conditions and Nondestructive Examination
Temperatures Between 350°F (175°C) and
750°F (400°C) Inclusive With All Pressures
Temperatures Over 750°F
over 1025 psig [7100 kPa (gage)]
(400°C) and At All Pressures
All Others
Buttwelds (girth and
longitudinal)[Note (1)]
RT for NPS over 2. MT or
PT for NPS 2 and less
[Notes (2) and (3)]
RT for over NPS 2 with thickness over
3/4 in. (19.0 mm) [Note (3). VT for all
sizes with thickness 3/4 in. (19.0 mm) or
less.
Visual for all sizes
and thicknesses
Welded branch connection
(size indicated is branch
size) [Notes (4) and (5)]
RT for over NPS 4 MT or
PT for NPS 4. and less
[Notes (2) and (3)]
RT for branch over NPS 4 and thickness
of branch over 3/4 in. (19.0 mm)
VT for all sizes and
thicknesses
MT or PT for branch NPS 4 and less with
thickness of branch over 3/4 in. (19 mm)
VT for all sizes with branch thickness 3/4
in. (19.0 mm) or less
Fillet, socket, attachment,
and seal welds
PT or MT for all sizes and
thicknesses [Note 6]
VT for all sizes and thicknesses
VTl for all sizes
and thicknesses
General Notes:
(A) All welds must be given a visual examination in addition to the type of specific nondestructive examination
specified.
(B) NPS – nominal pipe size.
(C) RT – radiographic examination; UT - ultrasonic examination; MT – magnetic particle examination; PT –
liquid penetrant examination; VT - visual examination.
(D) Temperatures and pressures shown are design.
(E) For nondestructive examinations of the pressure retaining component, refer to the standards listed in Table
126.1 or manufacturing specifications.
(F) Acceptance standards for NDT performed are as follows: MT - see Para. 136.4.3; PT - see Para. 136.4.4; VT See Para. 136.4.2; RT - see Para. 136.4.5; VT - see Para. 136.4.6.
Notes:
(1) The thickness of buttwelds is defined as the thicker of the two abutting ends after end preparation.
(2) RT may be used as an alternative to PT or MT when it is performed in accordance with Para. 136.4.5.
(3) UT may be used as an alternative to RT when it is impractical to use a combination of radiographic parameters
such that a geometric unsharpness of 0.07 in. (2.0 mm) cannot be obtained and provided the examination is
performed in accordance with Para. 136.4.6.
(4) RT or UT of branch connections shall be performed before any nonintegral material is applied.
(5) In lieu of volumetric examination (RT, UT) of welded branch connections when required above, surface
examination (PT, MT) is acceptable and, when used, shall be performed at the lesser of one-half of the weld
thickness or each 1/2 in. (12.5 mm) of weld thickness and all accessible final weld surfaces.
(6) Fillet welds not exceeding 1/4 in. (6 mm) throat thickness which are used for the permanent attachment of
nonpressure retaining parts are exempt from the PT or MT requirements of the above Table.
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Section 8
Code Required NDE
Table 136.4.1
Weld Imperfections Indicated by Various Types of Examination
Visual
Magnetic
Particle
Liquid
Penetrant
Radiography
Ultrasonic
Crack—surface
X [See Note (1)]
X [See Note (1)]
X [See Note (1)]
X]
X
Crack—internal
...
...
...
X
X
Undercut—on surface
X [See Note (1)]
X [See Note (1)]
X [See Note (1)]
X
...
Weld reinforcement
X [See Note (1)]
...
...
X
...
Porosity
X [Notes (1), (2)]
X [Notes (1), (2)]
X [Notes (1), (2)]
X
...
Slag inclusion
X [Note (2)]
X [Note (2)]
X [Note (2)]
X
X
Lack of fusion
(on surface)
X [Notes (1), (2)]
X [Notes (1), (2)]
X [Notes (1), (2)]
X
X
X [Note (3)]
X [Note (3)]
X [Note (3)]
X
X
Imperfection
Incomplete penetration
Notes:
(1)
Applies when the outside surface is accessible for examination and/or when the inside surface is readily
accessible.
(2)
Discontinuities are detectable when they are open to the surface.
(3)
Applies only when the inside surface is readily accessible.
8.2
8.2.1
ASME B31.3
Examination Normally Required
Piping in Normal Fluid Service shall be examined to the extent specified herein or to any greater
extent specified in the engineering design. Acceptance criteria are as stated in para. 341.3.2 and
in Table 341.3.2, for Normal Fluid Service unless otherwise specified.
(a)
Visual Examination. At least the following shall be examined in accordance with
para. 344.2:
(1)
sufficient materials an components, selected at random, to satisfy the examiner
that they conform to the specifications and are free from defects;
(2)
at least 5% of fabrication. For welds, each welder’s and each welding
operator’s work shall be represented.
(3)
100% of fabrication for longitudinal welds, except those in components made in
accordance with a listed specification. See para. 341.5.1(a) for examination of
longitudinal welds required to have a joint factor Ej of 0.90.
(4)
random examination of the assembly of threaded, bolted, and other joints to
satisfy the examiner that they conform to the applicable requirements of para.
35. When pneumatic testing is to be performed, all threaded, bolted and other
mechanical joints shall be examined.
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Section 8
(b)
(c)
8.2.2
Code Required NDE
(5)
random examination during erection of piping including checking of alignment,
support, and cold spring;
(6)
examination of erected piping for evidence of defects that would require repair
or replacement, and for other evident deviations from the intent of the design.
Other Examination
(1)
Not less than 5% of circumferential butt and miter groove welds shall be fully
examined by random radiography in accordance with para. 344.5 or by random
ultrasonic examination is accordance with para. 344.6. The welds to be
examined shall be selected to ensure that the work of each welds or welding
operator doing the production welding is included. They shall also be selected
to maximize the coverage of intersections with longitudinal joints. At least 11/2
in. (38 mm) of the longitudinal welds shall be examined. In-process
examination in accordance with para. 344.7 may be substituted for all or part of
the radiographic or ultrasonic examination on a weld-for-weld basis if specified
in the engineering design or specifically authorized by the inspector.
(2)
Not less than 5% of all brazed joints shall be examined by in-process
examination in accordance with para. 344.7, the joints being selected to ensure
that the work of each brazer doing production work is included.
Certification and Records. The examiner shall be assured by examination of
certifications, records, and other evidence, that the materials and components are of
the specified grades and that they have received the required heat treatment,
examination, and testing. The examiner shall provide the Inspector with certification
that all the quality control requirements of the Code and of the engineering design
have been carried out. (341.4.1)
Examination – Category D Fluid Service
Piping and piping elements for category d fluid service as designated in the engineering design
shall be visually examined in accordance with 344.2 to the extent necessary to satisfy the examiner
that the components, materials, and workmanship conform to the requirements of this Code and
the engineering design. Acceptance criteria are as stated in para. 341.3.2 and Table 341.3.2 for
Category D Fluid Service, unless otherwise specified. (341.4.2)
8.2.3
Examination – Severe Cyclic Service
Piping to be used under severe cyclic service shall be visually examined to the extent specified
herein or to any greater extent specified in the engineering design. Acceptance criteria are s
stated in para. 341.3.2 and in Table 341.3.2, for severe cyclic conditions unless otherwise
specified.
(a)
Visual Examination. The requirements of para. 341.4.1(a) apply with the following
exceptions.
(1)
All fabrication shall be examined.
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Code Required NDE
(2)
All threaded, bolted and other joints shall be examined.
(3)
All piping erection shall be examined to verify dimensions and alignment.
Supports, guides and points of cold spring shall be checked to ensure that the
movement of the piping under all conditions of startup, operation and shutdown
will be accommodated without binding or constraint.
(b)
Other Examination. All circumferential butt and miter groove welds and all
fabricated branch connection welds comparable to those shown in Figure 328.5.4E
shall be examined by 100% radiography in accordance with para. 344.5 or (if
specified in the engineering design) by 100% ultrasonic examination in accordance
with para. 344.6. Socket welds and branch connection welds, which are not
radiographed shall be examined by magnetic particle or liquid penetrant methods in
accordance with para. 344.3 or 344.4.
(c)
In-process examination in accordance with para. 344.7, supplemented by appropriate
nondestructive examination, may be substituted for the examination required in (b)
above on a weld-for-weld basis if specified in the engineering design or specifically
authorized by the Inspector.
(d)
Certifications and Records. The requirements of para. 341.1 (c) apply. (341.4.3)
8.2.4
Spot Radiography
(a)
Longitudinal Welds. Spot radiography for longitudinal groove welds required to
have a joint factor Ej of 0.90 requires examination by radiography in accordance with
para. 344.5 of at least 1 ft. (300 mm) in each 100 ft. (30 m) of weld for each welder
or welding operator. Acceptance criteria are those stated in Table 341.3.2 for
radiography under Normal Fluid Service.
(b)
Circumferential Butt Welds and Other Welds. It is recommended that the extent
of examination be not less than one shot on one in each 20 welds for each welder or
welding operator. Unless otherwise specified, acceptance criteria are as stated in
Table 341.3.2 for radiography under Normal Fluid Service for the type of joint
examined.
(c)
Progressive Sampling for Examination. The provisions of para. 341.3.4 are
applicable.
(d)
Welds to be Examined. The locations of welds and the points at which they re to
be examined by spot radiography shall be selected on approved by the Inspector.
(341.5.1)
8.2.5
Hardness Tests
The extent of hardness testing required shall be in accordance with para. 331.1.7 except as
otherwise specified in the engineering design. (341.5)
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8-5
Section 8
Code Required NDE
Hardness tests of production welds and of hot bent and hot formed piping are intended to verify
satisfactory heat treatment. The hardness limit applies to the weld and to the heat affected zone
(HAZ) tested as close as practicable to the edge of the weld.
(a)
Where a hardness limit is specified in Table 331.1.1 at least 10% of welds, hot bends
and hot formed components in each furnace heat treated batch and 100% of those
locally heat treated shall be tested.
(b)
When dissimilar metals are joined by welding, the hardness limits specified for the
base metal and welding materials in Table 331.1.1 shall be met for each material.
(331.1.7)
8.3
8.3.1
ASME SECTION III
Requirements for Piping Welds
See Table 8-1.
8.3.2
Requirements for Supports
8.3.2.1 Examination of Class 1 Support Welds
(1)
Primary Member Welded Joints
(a)
All full penetration butt welded joints in primary members shall be examined by
the radiographic method
(b)
All other welded joints in primary members shall be examined by the liquid
penetrant or magnetic particle method, except that the exposed ends of welds
need only be examined visually. (NF-5212)
(2)
Secondary Member Welded Joints. All welded joints in secondary members shall
be examined by the visual method. (NF-5213)
(3)
Special Requirements. For weldments that impose loads in the through thickness
direction of primary members 1 in. and greater in thickness, the base material beneath
the weld shall be ultrasonically examined, when required by NF-4400, over 100% of
the referenced area using the precede of SA-577 or SA-578 as detailed in Section V
to the acceptance standards of NF-5332, except that a calibration block
representative of the primary member shall be used. The block for straight beam
examination shall have 1/4 in. flat-bottomed holes at one-fourth, one-half, and
three-fourths of the thickness of the member being welded, from which a distance
amplitude curve shall be established. (NF-5214)
8.3.2.2 Examination of Class 2 and Class MC Support Welds
(1)
Primary Member Welded Joints
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Section 8
(2)
(3)
Code Required NDE
(a)
All butt welded joints in primary members shall be examined by the by the liquid
penetrant or magnetic particle method
(b)
All partial penetration or fillet welds in primary members that have a groove
depth or throat dimensions greater than 1 in. and T-welded joints welded with
throat dimensions of 1/2 in. or greater shall be examined by the liquid penetrant
or magnetic particle method, except that the exposed ends of welds need only
be examined visually. (NF-5221)
Secondary Member Welded Joints. All welded joints in secondary members shall
be examined by the visual method. (NF-5222)
Special Requirements. For weldments that impose loads in the through thickness
direction of primary members 1 in. and greater in thickness, the base material
beneath the weld shall be ultrasonically examined, when required by NF-4400, over
100% of the referenced area using the precede of SA-577 or SA-578 as detailed in
Section V to the acceptance standards of NF-5332, except that a calibration block
representative of the primary member shall be used. The block for straight beam
examination shall have 1/4 in. flat-bottomed holes at one-fourth, one-half, and
three-fourths of the thickness of the member being welded, from which a distance
amplitude curve shall be established. (NF-5224)
8.3.2.3 Examination of Class 3 Support Welds
(1)
Primary Member Welded Joints
(a)
Primary member welded joints that have a groove depth or throat dimension
greater than 1 in. shall be examined by the by the liquid penetrant or magnetic
particle method, except that the exposed ends of welds need only be examined
visually. (NF-5231)
(b)
Primary welded joint exclusive of those described in (a) above shall be
examined by the visual method. (NF-5232)
(2)
Secondary Member Welded Joints. All welded joints in secondary members shall
be examined by the visual method. (NF-5232)
(3)
Special Requirements. For weldments that impose loads in the through thickness
direction of primary members 1 in. and greater in thickness, the base material beneath
the weld shall be ultrasonically examined, when required by NF-4400, over 100% of
the referenced area using the precede of SA-577 or SA-578 as detailed in Section V
to the acceptance standards of NF-5332, except that a calibration block
representative of the primary member shall be used. The block for straight beam
examination shall have 1/4 in. flat-bottomed holes at one-fourth, one-half, and
three-fourths of the thickness of the member being welded, from which a distance
amplitude curve shall be established. (NF-5234)
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Section 8
8.4
8.3.1
Code Required NDE
AWS D1.1
General Requirements
When nondestructive testing other than visual is specified in the information furnished to the
bidders, it shall be the contrator’s responsibility to ensure that all specified welds meet the quality
requirements of section 6, Part C, whichever is applicable. (6.6.4)
When NDE is required by specification, refer to AWS D1.1, section 6, Part C for the
requirements.
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Welding Inspection Handbook
8-8
Table 8-1
Weld NDE Requirements – ASME Section III – (Piping Welds Only)
Circ. Butt
& Branch4
Nuclear
Class 1
Longitudinal
Butt
NB-5220
NB-5210
RT 100% + MT
or PT ext. &
accessible int.
surfaces adj.
base mtl. for at
least 1/2” either
side of weld
RT 100% + MT
or PT ext. &
accessible int.
surfaces adj.
base mtl. for at
least 1/2” either
side of weld
NC-5222
RT – 100%
NC-5212
RT – 100%
Partial
Penetration
& Sockets/
Fillets
NB-5260
MT or PT
100%
NC-5261
ND-5222
Nuclear
Class 3
NB-5243
OD >4” - RT or
UT 100% plus
MT or PT
OD ≤4” - MT or
PT all ext. and
accessible int. &
surfaces
NC-5242
MT or PT
100%
OD >4” - RT
100%
OD ≤4” - ext.
weld surface &
access. int. weld
surface – MT or
PT 100%
Not
Required
ND-5222 MT or
PT or RT 100%
for greater than 2”
NPS
Nuclear
Class 2
MT or PT or
RT 100% for
greater than 2”
NPS
Branch Conn.
Full Penet.
Corner Welds3
Structural
Permanent
Attachments1
Nonstructural
& Temporary
Attachments2
NB-5262
NB-5272
MT or PT 100%
for all perm.
attach. to pressure
retaining mat’l
PT 100%
None except
removal of same
req. 100% MT
or PT
NC-5262
NC-5272
MT or PT 100%
for permanent
attach. to pressure
retaining mat’l
PT 100%
None except
removal of same
req. 100% MT
or PT
ND-5212
For welds in
greater than 2”
NPS see
ND-2500
Weld Metal
Cladding
ND-5272
PT 100%
Not Required
Not Required
Hard
Surfacing
Special Welds
Tube to
Tubesheet
NB-5273
PT 100%
except: none
req. for valves
with inlet
connections ≤4”
NPS
NC-5273
PT 100%
except: none
req. for valves
with inlet
connections ≤4”
NPS
ND-5273
PT 100%
except: none
req. for valves
with inlet
connections ≤4”
NPS
NB-5274
PT 100%
NC-5274
PT 100%
Weld Edge
Preparations
NB-5130
Weld edge prep
surfaces in mat’l
2” or more in
thickness shall be
examined by MT
or PT 100%
NC-5130
Weld edge prep
surfaces in mat’l
2” or more in
thickness shall be
examined by MT
or PT 100%
ND-5274
(As shown in
NX-4436)
Attachments
to Piping
After Testing
Per NB-5000
rule as
applicable
Per NC-5000
rules as
applicable
Per ND-5000
PT 100%
rules as
applicable
Not Required
1
– Permanent Attachments – e.g., hangers
3
– Full penetration corner welds, e.g., weld-o-lets, half-couplings
2
– Nonstructural & temporary attachments – e.g., nameplates, lugs
4
– Full penetration butt welds; e.g., sweep-o-lets, sock-o-lets (NB-5242, NC-5242(a), ND-5242)
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Section 9
Defects
Page
9.1
GENERAL ................................................................................................
9-1
9.2
TYPE OF DEFECTS .................................................................................
9-1
9.2.1
Arc Strikes.................................................................................................
9-1
9.2.2
Undercut....................................................................................................
9-2
9.2.3
Porosity .....................................................................................................
9-3
9.2.4
Slag Inclusions ...........................................................................................
9-5
9.2.5
Tungsten....................................................................................................
9-7
9.2.6
Cracks........................................................................................................
9-8
9.2.7
Crater Cracks.............................................................................................
9-10
9.2.8
Incomplete Fusion......................................................................................
9-11
9.2.9
Inadequate Joint Penetration ......................................................................
9-13
9.2.10
Unconsumed Insert ....................................................................................
9-15
9.2.11
Concave Root Surface................................................................................
9-17
9.2.12
Drop-Through............................................................................................
9-18
9.2.13
Mismatch ...................................................................................................
9-19
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Welding Inspection Handbook
9-0
Section 9
9.1
Defects
GENERAL
Some discontinuities, or imperfections, that are small or insignificant are permitted by material
specifications, codes or standards. The evaluation of discontinuities is an important part of a
welding inspector’s job. The following pages cover various types of weld discontinuities, some of
their basic causes, their effects on various types of welds and the images they produce on a
radiograph.
Discontinuities are imperfections in materials. All metals and welds have imperfections that exist
in varying degrees. An imperfection which exceeds the acceptable limits is called a defect. Some
discontinuities have no effect on the base metal as long as they do not interfere with the welding
process, or become large enough to cause the item to fail when in service. The following four
items should be evaluated when judging whether an imperfection is to be regarded as an
acceptable discontinuity or a defect:
1. Type
2. Size
3. Location
4. Service
9.2
9.2.1
TYPE OF DEFECTS
Arc Strikes
Arc strikes are inadvertent changes in the contour of the finished weld or base material resulting
from an arc generated by the passage of electrical energy between the surface of the finished weld
or bare material and a current source, such as welding electrodes or magnetic inspection prods.
(ASME Section IX, QW-492)
Many codes and standards do not address arc strikes. Some codes impose specific requirements.
Arc strikes are not necessarily harmful. The significance of arc strikes is whether or not the
required material thickness is reduced below design requirements, and whether or not cracks have
resulted. Most of the engineering materials used for welded construction in power plants have
been selected because of their weldability. Because of their good weldability, they are resistant to
cracking induced by arc strikes. Most arc strikes are harmless. It should be noted that
nondestructive examination equipment may cause arc strikes. This examination method would
not be required by the various codes if arc strikes were a major concern. The greatest concern is
for arc strikes on the more hardenable, alloyed steel material with medium to high carbon content.
These materials are more susceptible to cracking. Austenitic stainless steels are relatively immune
to arc strike cracking.
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Welding Inspection Handbook
9-1
Section 9
Defects
Surface Arc Strike
9.2.2
Undercut
Undercut is another fairly common discontinuity, and is usually caused by the welder using improper
techniques, such as too much welding current, faulty electrode manipulation, incorrect electrode
size, or incorrect electrode angle. Undercut produces stress risers that can create problems under
impact, fatigue, or low temperature service. For non-impact, non-fatigue service, this may be an
innocuous discontinuity which can be evaluated on a simple strength of materials basis.
Photomacrograph of Undercut on the Outside Diameter
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Welding Inspection Handbook
9-2
Section 9
Defects
Depiction of Undercut on Fillet Weld
Undercut at Fillet Weld Toe
9.2.3
Porosity
Next to slag inclusions, porosity is probably the most commonly seen discontinuity. Porosity is
caused during the welding operation by trapped gas in the weld metal before it solidifies. It
usually appears round, but may also be cylindrical or elongated in shape. Porosity normally
suggests that the welding process is not being properly controlled or that welding consumables
are contaminated with gas producing elements. Some of the causes may be insufficient shielding,
excessive heat, excessive moisture in electrodes, damp flux, oil, rust, too long of an arc or
excessive air movement. On a radiograph, porosity appears as dark spots, or circles, which can
be uniformly scattered, in a cluster, or in a line as shown.
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Welding Inspection Handbook
9-3
Section 9
Defects
Scattered Porosity (Surface)
Radiographic Image of Scattered Porosity
Photomacrograph of Porosity
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Welding Inspection Handbook
9-4
Section 9
Defects
Radiographic Image of Porosity
9.2.4
Slag Inclusions
The most common cause of this type of discontinuity is due to the welding technique used by the
welder or failure to properly clean off the slag of previous weld beads. As an example, if a welder
does not manipulate his arc correctly, the slag may not float to the surface, and become trapped
between passes. Normally, slag entrapment is caused by improperly shaped weld beads. Slag
inclusions in a radiograph appear as irregularly shaped dark areas or lines.
Surface Slag Inclusion
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Welding Inspection Handbook
9-5
Section 9
Defects
Depiction of Slag Inclusions (Subsurface)
Photomacrograph of Slag Inclusion
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Welding Inspection Handbook
9-6
Section 9
Defects
Radiographic Image of Slag Inclusion
9.2.5
Tungsten
Tungsten inclusions occur from the gas tungsten arc welding process when the electrode
occasionally touches the work or the molten weld metal and transfers particles of tungsten into the
weld deposit. Since tungsten is a very high temperature melting element and is approximately twice
the density of steel, it normally is discovered by radiographic examination and is revealed as a very
low density (white) spot on the radiographic film. Typically round in nature, the tungsten represents
a weld discontinuity which is proper to evaluate by porosity acceptance standards.
Photomacrograph of Simulated Tungsten Inclusion
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Welding Inspection Handbook
9-7
Section 9
Defects
Radiographic Image of Tungsten Inclusion
9.2.6
Cracks
A crack is defined as a fracture-type discontinuity characterized by a sharp tip and a high-ratio
length- and height-to-opening displacement. Cracks are linear ruptures of metal under stress.
They are often very narrow separations in the weld or adjacent base metal, and usually little
deformation is apparent.
Weld metal cracks are the result of many factors. For example, cracking occurs when a joint is
highly restrained. Also, welds which are too small in size for the parts that are joined may crack
when the shrinkage strains during cooling fracture the least ductile location. Cracking also results
from poor welding practice, improper preparation of joints, and improper electrodes for matching
base material. Inadequate preheat during welding of low-alloy carbon-steel materials promotes
cracking of the weld metal or heat-affected zone (HAZ). Cracks in the HAZ are promoted by
high restraint of the joints and improper electrode control. (Low-hydrogen procedures are
necessary for most low-alloy steels.) High-alloy, austenitic materials such as stainless steel, are
more crack resistant than low-alloy carbon steel; however, contamination of the weldment with
compounds, such as sulphur, or the selection of the wrong filler material can produce
microfissuring and/or centerline cracking.
It must be recognized that other types of cracks can form during the service life of a component
or weldment. Cracks can be generated by overloading, metal fatigue, intergranular and
transgranular stress corrosion, and stress rupture mechanisms, to mention only a few. The
radiographic and ultrasonic examination response of such flaws is dependent upon the size and
orientation of the flaw.
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Welding Inspection Handbook
9-8
Section 9
Defects
Throat Crack
Photomacrograph of Crack
Radiographic Image of Crack
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Welding Inspection Handbook
9-9
Section 9
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Defects
Welding Inspection Handbook
9-10
Section 9
9.2.7
Defects
Crater Cracks
Crater cracks are shrinkage cracks which occur in the crater of a weld bead. This condition is
caused by improper filling of the crater before raising the electrode away from the weld puddle, or
by stopping the arc suddenly. Crater cracking is commonly called star cracking, but these cracks
can also take the form of centerline, or transverse cracking.
Depiction of Crater Cracks
Crater Crack
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Welding Inspection Handbook
9-10
Section 9
Defects
Longitudinal Crack Propagating From Crater Crack
9.2.8
Incomplete Fusion
Incomplete fusion, or “lack of fusion” as it is frequently termed, is described as fusion that is less
than complete. It is the failure of adjacent weld metal and base metal or weld metal and weld
metal to fuse together. This condition can be caused by improper weaving, low welding current,
or too fast a welding speed. Failure to obtain fusion may occur at any point in the weld.
Incomplete fusion results when base metal or previously deposited weld is not raised to the
melting temperature at the point of weld deposit-prior to weld metal solidification. Failure to
remove slag, mill scale and oxides from weld joint surfaces can also prevent the deposited metal
from fusing.
Incomplete fusion is usually elongated in the direction of welding and may have either rounded or
sharp edges, depending on how it is formed.
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Section 9
Defects
Photomacrograph of Incomplete Fusion at the Root
Depiction of Incomplete Fusion
Photomacrograph of Interbead Incomplete Fusion
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Section 9
Defects
Photomacrograph of Side Wall Incomplete Fusion
9.2.9
Inadequate Joint Penetration
Inadequate joint penetration is defined as joint penetration which is less than specified. Although
this is the preferred definition, the condition is often referred to as “lack of penetration.” The
condition is created when the penetration and fusion of the weld nugget into the joint cavity fail to
reach the specified depth within the base metal cross section. For full penetration joints, this can
be caused when insufficient root gap is provided during fitup operations or when weld shrinkage
causes the established gap to be closed. Another common cause is that an excessive root face or
land is provided during joint preparation which precludes penetration to the back side of the joint.
For joints welded from both sides, inadequate backgouging prior to welding the second side will
result in lack of penetration.
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Section 9
Defects
Depiction of Inadequate Joint Penetration
Photomacrograph of Inadequate Penetration
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9-14
Section 9
Defects
Radiographic Image of Inadequate Penetration
9.2.10 Unconsumed Insert
An unconsumed insert results from preplaced filler metal that is not completely melted and fused
in the root joint. This condition is caused by low welding current, improper weaving procedure,
improper joint design, and/or welding speed. Considerable welder technique and skill must be
developed to assure high quality root beads using inserts, with the gas tungsten arc welding
process. Proper welding variables and sufficient skill of the welder will produce melting and
fusion of the insert and the side walls of the joint preparation. This results in a satisfactory root
bead profile. The next figure shows one common insert shape which has not been fused. There
are other insert shapes, rectangular, round and Y, which are commonly used.
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Section 9
Defects
Photomacrograph of Unconsumed Insert
Radiographic Image of Unconsumed Insert
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Section 9
Defects
9.2.11 Concave Root Surface
A concave root surface, sometimes called “suck back,” is a defect caused by excessive shrinkage
of the weld deposited root bead. A concave root occurs when the molten weld solidifies without
sufficient filler metal being added to the molten zone to supply the volumetric shrinkage that takes
place during solidification. This condition is promoted by excessive amperage, excessive root
gaps, and out-of-position welding. It can be caused by improper welder technique, including too
slow travel speed, too high current or not adding sufficient filler material.
Photomacrograph of Concave Root Surface
Radiographic Image of Concave Root Surface
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9-17
Section 9
Defects
9.2.12 Drop-Through
Weld drop-through is an undesirable sagging or surface irregularity at the weld root. When the
molten weld puddle doesn’t solidify quickly enough, it will sag. Generally this condition is caused
by too wide a root gap, excessive heat, improper welding technique or a combination of these.
Photomacrograph of Drop-Through
Radiographic Image of Drop-Through
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Section 9
Defects
9.2.13 Mismatch
Mismatch refers to the amount of centerline offset of two members in a welded butt joint. Many
specifications put a limit on mismatch since it can be a stress raiser and can also cause difficulty in
welding. This condition is sometimes referred to as “high-low.” When the members are equal in
thickness, the mismatch is equal to the offset measured at the surface; but for differing
thicknesses, it is equal to the offset at the centerline and must be computed using the surface
offset and the two thicknesses. For pipe, mismatch refers to the internal alignment.
Photomacrograph of Mismatch
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Welding Inspection Handbook
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Section 10
Repair of Weld Defects
Page
10.1
ASME B31.1 .............................................................................................
10-1
10.1.1
Requirements .............................................................................................
10-1
10.2
ASME B31.3 .............................................................................................
10-1
10.2.1
Weld Repair ...............................................................................................
10-1
10.2.2
Defective Components and Workmanship ..................................................
10-1
10.3
ASME SECTION III .................................................................................
10-2
10.3.1
Defect Removal .........................................................................................
10-2
10.3.2
Requirements for Welding Material, Procedures and Welders .....................
10-2
10.3.3
Blending of Repaired Areas........................................................................
10-2
10.3.4
Examination of Repair Welds .....................................................................
10-2
10.3.4.1
Class 1 .......................................................................................................
10-2
10.2.4.2
Class 2, 3, MC & NF Supports...................................................................
10-2
10.3.4.3
Class 1, 2 and 3 Only..................................................................................
10-3
10.3.5
PWHT of Repaired Areas...........................................................................
10-3
10.3.6
Elimination of Surface Defects ...................................................................
10-3
10.4
AWS D1.1 .................................................................................................
10-4
10.4.1
Repair of Weld Defects ..............................................................................
10-4
10.4.2
Members Distorted by Welding ..................................................................
10-4
10.4.3
Prior Engineering Approval........................................................................
10-4
10.4.4
Inaccessibility of Unacceptable Welds.........................................................
10-5
10.4.5
Restoration of Unacceptable Holes by Welding ..........................................
10-5
10.4.6
Surface Finishes of Butt Welds...................................................................
10-6
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Welding Inspection Handbook
10-0
Section 10
10.1
Repair of Weld Defects
ASME B31.1
10.1.1 Requirements
(A)
Defect Removal. All defects in welds or base materials requiring repair shall be removed
by flame or arc gouging, grinding, chipping, or machining.
Preheating may be required for flame or arc gouging on certain alloy materials of the air
hardening type in order to prevent surface checking or cracking adjacent to the flame or
arc gouged surface
(B)
10.2
Repair Welds. Repair welds shall be made in accordance with qualified welding
procedures using qualified welders or welding operators (see Para. 127.5), recognizing
that the cavity to be repaired may differ in contour and dimension from a normal joint
preparation and may represent different restraint conditions. The types, extent, and
method of examination shall be in accordance with Table 136.4. For repairs to welds, the
minimum examination shall be the same method that revealed the defect in the in the
original weld. For repairs to base material, the minimum examination shall be the same as
required for butt welds. (127.4.11)
AMSE B31.3
10.2.1 Weld Repair
A weld defect to be repaired shall be removed to sound metal. Repair welds shall be made using a
welding procedure qualified in accordance with para. 328.2.1, recognizing that the cavity to be
repaired may differ in contour and dimensions from the original joint. Repair welds shall be made
by welders or welding operators qualified in accordance with para. 328.2.1. Preheating and heat
treatment shall be required for the original welding. See also para. 341.3.3. (328.6)
10.2.2 Defective Components and Workmanship
An examined item with one or more defects (imperfections of a type or magnitude exceeding the
acceptance criteria of this Code) shall be repaired or replaced; and the new work shall be
reexamined by the same methods, to the same extent, and by the same acceptance criteria as
required for the original work. (341.3.3)
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Welding Inspection Handbook
10-1
Section 10
10.3
Repair of Weld Defects
ASME SECTION III
10.3.1 Defect Removal
Defects may be removed by mechanical means or by thermal gouging processes. The area
prepared for repair shall be examined by a liquid penetrant or magnetic particle method in
accordance with NX-5110 and meet the acceptance standards of NX-5340 or NX-5350. This
examination is not required where defect removal essentially removes the full thickness of the
weld and where the backside of the weld joint is not accessible for removal of examination
materials. (NX-4453.1)
10.3.2 Requirements for Welding Material, Procedures and Welders
The weld repair shall be made using the welding material, welders, and welding procedures
qualified in accordance with NX-4125 and NX-4300. (NX-4453.2)
10.3.3 Blending of Repaired Areas
After repair, the surface shall be blended uniformly into the surrounding surface. (NX-4453.3)
10.3.4 Examination of Repair Welds
10.3.4.1
Class 1
The examination of a weld repair shall be repeated as required for the original weld except that
when the defect was originally detected by the liquid penetrant or magnetic particle method, and
when the repair cavity does not exceed the lesser of 3/8 in. or 10% of the thickness, it need only
be reexamined by the liquid penetrant or magnetic particle method. (NB-4453.3 (a))
10.2.4.2
Class 2, 3, MC & NF Supports
The examination of a weld repair shall be repeated as required for the original weld, except that it
need only be reexamined by the liquid penetrant or magnetic particle method when the
unacceptable indication was originally detected by the liquid penetrant or magnetic particle
method and when the repair cavity does not exceed the following:
(1)
1/3 t for tw ≤ 3/4 in.
(2)
1/4 in. for 3/4 in. < tw ≤ 2-1/2 in.
(3)
the lesser of 3/8 in. or 10%t for tw > 2-1/2 in.
Where tw equals the thickness of the weld. (NX-4453.4)
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Welding Inspection Handbook
10-2
Section 10
10.3.4.3
Repair of Weld Defects
Class 1, 2 and 3 Only
When repairs to welds joining P-No. 1 and P-No. 3 materials require examination by radiography,
but construction assembly-prevents meaningful radiographic examination, ultrasonic examination
may be substituted provided:
(a)
the weld had been previously radiographed and met the applicable acceptance
standards;
(b)
the ultrasonic examination is performed using a procedure in accordance with Article 5
of Section V to the acceptance standards of NB, NC, ND-5330 as applicable.
(c)
the substitution is limited to Category A and B welds in vessels and similar type welds
in other items.
The absence of suitable radiographic equipment is not justification for the substitution. (NB, NC,
ND-4453.4)
10.3.5 PWHT of Repaired Areas
The area shall be heat treated in accordance with NX-4620. (See Section 14 of this handbook for
PWHT requirements.) (NX-4453.5)
10.3.6 Elimination of Surface Defects
Weld metal surface defects may be removed by grinding or machining and need not be repaired by
welding, provided that the requirements of (a) through (c) below are met.
(a)
The remaining thickness of the section is not reduced below that required by
NX-3000.
(b)
The depression, after defect elimination, is blended uniformly into the surrounding
surface.
(c)
The area is examined by a magnetic particle or liquid penetrant method in accordance
with NX-5110 after blending and meets the acceptance standards of NX-5300 to
ensure that the defect has been removed or the indication reduced to an acceptable
limit. Defects detected by visual or volumetric method and located on an interior
surface need only be examined by the method which initially detected the defect when
the interior surface is inaccessible for surface examination. (NX-4452)
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Welding Inspection Handbook
10-3
Section 10
10.4
Repair of Weld Defects
AWS D1.1
10.4.1 Repair of Weld Defects
The removal of weld metal or portions of the base metal may be done by machining, grinding,
chipping, or gouging. It shall be done in such a manner that the remaining weld metal or base
metal is not nicked or undercut. Oxygen gouging shall not be used on quenched and tempered
steels. Unacceptable portions of the weld shall be removed without substantial removal of the
base metal. The surface shall be cleaned thoroughly before welding. Weld metal shall be
deposited to compensate for any deficiency in size. (5.26)
1a.
The contractor has the option of either repairing an unacceptable weld or removing
and replacing the entire weld, except as modified by 5.26.3. The repaired or
replaced weld shall be retested by the method originally used, and the same
technique and quality acceptance criteria shall be applied. If the contractor elects
to repair the weld, it shall be corrected as follows;
lb.
Overlap, Excessive Convexity or Excessive Reinforcement. Excessive weld metal
shall be removed.
1c.
Excessive Concavity of Weld or Crater, Undersize Welds, Undercutting. The
surfaces shall be prepared (see 5.30) and additional weld metal deposited.
1d
Incomplete Fusion, Excessive Weld Porosity, or Slag Inclusions, . Unacceptable
portions shall be removed (see 5.26) and rewelded.
1e.
Cracks in Weld or Base Metal. The extent of the crack shall be ascertained by use
of acid etching, magnetic particle inspection, dye penetrant inspection, or other equally
positive means; the crack and sound metal 2 in. beyond each end of the crack shall be
removed, and rewelded. (5.26.1)
10.4.2 Members Distorted by Welding
Members distorted by welding shall be straightened by mechanical means or by application of a
limited amount of localized heat. The temperature of heated areas as measured by approved
methods shall not exceed 1100°F for quenched and tempered steel nor 1200°F for other steels.
The part to be heated for straightening shall be substantially free of stress and from external
forces, except those stresses resulting from the mechanical straightening method used in
conjunction with the application of heat. (5.26.2)
10.4.3 Prior Engineering Approval
Prior approval of the Engineer shall be obtained for repairs to base metal (other than those
required by 5.15), repair of major or delayed cracks, repairs to electroslag and electrogas welds
with internal defects, or for a revised design to compensate for deficiencies. The Engineer shall
be notified before the welded members are cut apart. (5.26.3)
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Welding Inspection Handbook
10-4
Section 10
Repair of Weld Defects
10.4.4 Inaccessibility of Unacceptable Welds
If, after an unacceptable weld has been made, work is performed which has rendered that weld
inaccessible or has created new conditions that make correction of the unacceptable weld
dangerous on ineffectual, then the original conditions shall be restored by removing the welds or
members, or both, before the corrections are made. If this is not done, the deficiency shall be
compensated for by additional work performed according to an approved revised design. (5.26.4)
10.4.5 Restoration of Unacceptable Holes by Welding
Except where restoration by welding is necessary for structural or other reasons, punched or
drilled mislocated holes may be left open or filled with bolts. When the base metal with
mislocated holes is restored by welding, the following requirements apply:
(1)
Base metal not subjected to cyclic tensile stress may be restored by welding, provided
the contractor prepares and follows a repair WPS. The repair weld soundness shall be
verified by the appropriate nondestructive tests, when such tests are specified in the
contract documents for groove welds subject to compression or tension stress..
(2)
Base metal subject to cyclic tensile stress may be restored by welding provided:
(3)
(4)
(a)
The Engineer approves repair by welding and the repair WPS.
(b)
The repair WPS is followed in the work and the soundness of the restored base
metals is verified by the NDT method(s) specified in the contract documents for
examination of tension groove welds or as approved by the Engineer.
In addition to the requirements of (1) and (2), when holes in quench and tempered
base metals are restored by welding:
(a)
Appropriate filler metal, heat input, and postweld heat treatment (when PWHT)
is required shall be used.
(b)
Sample welds shall be made using the repair WPS.
(c)
Radiographic testing of the sample welds shall verify that weld soundness
conforms to the requirements of 6.12.2.1.
(d)
One reduced section tension test (weld metal); two side bend tests(weld metal);
and three Charpy V-notch (CVN) impact tests of the heat-affected zone (coarse
grained area) removed from the sample welds shall be used to demonstrate that
the mechanical properties of the repaired area conform to the specified
requirements of the base metal. See Annex III for Charpy testing requirements.
Weld surfaces shall be finished as specified in 5.24.4.1. (5.26.5)
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Welding Inspection Handbook
10-5
Section 10
Repair of Weld Defects
10.4.6 Surface Finishes of Butt Welds
(1)
Flush Surfaces. Butt welds required to be flush shall be finished so as not to reduce
the thickness of the thinner base metal or weld metal by more than 1/32 in. or 5% of
the thickness, whichever is less. Remaining reinforcement shall not exceeds 1/32 in. in
height. However, all reinforcement must be removed where the weld forms part of a
faying or contact surface. All reinforcement shall blend smoothly into the plate
surfaces with transition areas free from undercut. (5.24.4.1)
(2)
Finish Methods and Values. Chipping and gouging may be used provided these are
followed by grinding. Where surface finishing is required, roughness values (see ANSI
B46.1) shall not exceed 250 microinches. Surfaces finished to values of over 125
microinches through 250 microinches shall be finished parallel to the direction of
primary stress. Surfaces finished to values of 125 microinches or less may be finished
in any direction. (5.24.4.2)
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Welding Inspection Handbook
10-6
Section 11
Base Metal Repair by (Product Form)
Page
11.1
ASME SECTION III (CLASS 1, 2, 3 AND MC).......................................
11-1
11.1.1
General ......................................................................................................
11-1
11.1.2
Elimination and Repair of Defects ..............................................................
11-1
11.1.3
Defect Removal (All Product Forms) .........................................................
11-1
11.2
ASME/ANSI B31.1 ...................................................................................
11-1
11.2.1
Examination and Repair of Material Other Than Bolting.............................
11-1
11.3
ASME/ANSI B31.3 ...................................................................................
11-1
11.3.1
Examination and Repair of Material Other Than Bolting.............................
11-1
Table 11-1 Elimination of Surface Defects (By Mechanical Means)
ASME Section III..................................................................
11-2
Table 11-2 Repair By Welding (ASME Section III) .................................
11-5
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Welding Inspection Handbook
11-0
Section 11
11.1
Base Metal Repair by (Product Form)
ASME SECTION III (CLASS 1, 2, 3, AND MC)
11.1.1
General
ASME Section III contains the repair of base material by product form. Table 11-1 covers repair by mechanical
means, other than welding. Table 11-2 covers repair by welding.
Note:
The requirements in this section do not apply to materials manufacturers for the product forms listed.
11.1.2
Elimination and Repair of Defects
Material originally accepted on delivery in which defects exceeding the limits of NX-2500 are known or discovered
during the process of fabrication or installation is unacceptable. The material may be used provided the condition
is correct in accordance with the requirements of NX-2500 for the acceptable product form, except:
(a) the limitation on the depth of the weld repair does not apply;
(b) the time of examination of the weld repairs to weld edge preparation shall be in accordance with
NB, NC, ND, NE-5130, and NF-5120 (NX-4130).
11.1.3
Defect Removal (All Product Forms)
The defect shall be removed or reduced to an acceptable size by suitable mechanical or thermal cutting or gouging
methods and the cavity prepared for repair. (NX-4211.1) When thermal cutting is performed, consideration shall
be given to preheating the material using an appropriate preheat schedule such as given in ASME Boiler and
Pressure Vessel Code, Section III, Appendix D. (NX-2539-1)
11.2
11.2.1
ASME/ANSI B31.1
Examination and Repair of Material Other Than Bolting
Unacceptable defects may be repaired as permitted by the material specification.
11.3
11.3.1
ASME/ANSI B31.3
Examination and Repair of Material Other Than Bolting
Unacceptable defects may be repaired as permitted by the material specification.
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Welding Inspection Handbook
11-1
Section 11
Base Metal Repair by (Product Form)
Table 11-1
Elimination of Surface Defects (by Mechanical Means) ASME Section III
Code Class
Product Form
NB
Plate
(A)
(B)
NC, ND, NE
Unacceptable surface defects shall be removed by grinding or machining,
provided the requirements of (1) through (4) below are met.
(1) The remaining thickness of the section is not reduced below that required
by NB-3000.
(2) The depression, after defect elimination, is blended uniformly into the
surrounding surface.
(3) After defect elimination, the area is re-examined by the magnetic particle
method in accordance with NB-2545 or the liquid penetrant method in
accordance with NB-2546 to ensure that the defect has been removed or
the indication reduced to an acceptable size.
(4) Areas ground to remove oxide scale or other mechanically caused
impressions for appearance or to facilitate proper ultrasonic testing need
not be examined by the magnetic particle or liquid penetrant test method.
When the elimination of the defect reduces the thickness of the section below
the minimum required to satisfy NB-3000, the product shall be repaired in
accordance with NB-2539. (See Table 11-2) (NB-2538)
Plate
(A)
(B)
NB
Unacceptable surface defects may be removed by grinding or machining
provided the requirements of (1) and (2) below are met.
(1) The remaining thickness of the section is not reduced below the minimum
required by the design;
(2) the depression, after (continued) defect elimination, is blended uniformly
into the surrounding surface.
When the elimination of the defect reduces the thickness of the section below
the minimum required by the design, the material shall be repaired in
accordance with NX-2539. (See Table 11-2) (NX-2538)
Forgings
(A)
(B)
m:\temporary\welding inspection\chapter11.doc
Unacceptable surface defects shall be removed by grinding or machining,
provided the requirements of (1) through (4) below are met.
(1) The remaining thickness of the section is not reduced below that required
by NB-3000.
(2) The depression, after defect elimination, is blended uniformly into the
surrounding surface.
(3) After defect elimination, the area is re-examined by the magnetic particle
method in accordance with NB-2545 or the liquid penetrant method in
accordance with NB-2546 to ensure that the defect has been removed or
the indication reduced to an acceptable size.
(4) Areas ground to remove oxide scale or other mechanically caused
impressions for appearance or to facilitate proper ultrasonic testing need
not be examined by the magnetic particle or liquid penetrant test method.
When the elimination of the defect reduces the thickness of the section below
the minimum required to satisfy NB-3000, the product shall be repaired in
accordance with NB-2539. (See Table 11-2) (NB-2548)
Welding Inspection Handbook
11-2
Section 11
Base Metal Repair by (Product Form)
Table 11-1 (Cont’d)
Code Class
Product Form
NC, ND, NE
Forgings
(A)
(B)
Unacceptable surface defects may be removed by grinding or machining
provided the requirements of (1) and (2) below are met:
(1) the remaining thickness of the section is not reduced below the minimum
required by the design;
(2) the depression, after defect elimination, is blended uniformly into the
surrounding surface.
When the elimination of the defect reduces the thickness of the section below
the minimum required by the design-, the material shall be repaired in
accordance with NX-2539. (See Table 11-2) (NX-2548)
NB, NC, ND, NE
Pipe1
NX-2550 and NX-2560
1.0 Unacceptable surface defects may be removed by grinding or machining
provided that:
1.1 The remaining thickness is not reduced below that specified.
1.2 The depression, after defect elimination, shall be blended uniformly
into the surrounding surfaces.
1.3
1.4
NB, NC, ND, NE
After defect elimination, the area shall be re-examined by the method
which originally disclosed the defect to assure that the defect has been
removed or reduced to an acceptable size.
If the elimination of the defect reduces the wall thickness below the
minimum specified, the product may be repair welded in accordance
with ASME Section II, Part A, Section 8.RL. (See Table 11-2) (SA655, 9.RM)
Fittings2
NX-2553 and NX-2560
1.0 Surface defects may be removed by grinding or machining provided that:
1.1 The remaining thickness is not reduced below that specified.
1.2 The depression, after defect ..elimination, shall be blended uniformly
into the surrounding surfaces.
1.3 After defect elimination, the area shall be re-examined by the method
which originally disclosed the defect to assure that the defect has been
removed or reduced to an acceptable size.
1.4 If the elimination of the defect reduces the wall thickness below the
minimum specified, the product may be repair welded in accordance
with ASME Section II, Part A, Section 8.RL. (See Table 11-2)
(SA-652, 9.RM)
1
2
Includes seamless and welded without filler metal (NX-2550) and welded with filler metal (NX-2560).
Includes seamless and welded without filler metal (NX-2553) and welded with filler metal (NX-2560).
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Welding Inspection Handbook
11-3
Section 11
Base Metal Repair by (Product Form)
Table 11-1 (Cont’d)
Code Class
Product Form
NB, NC, ND, NE
Castings
NX-2570
15.1 Unacceptable surface defects shall be removed by grinding or machining
provided that:
15.1.1
The remaining thickness of the section is not reduced below that
required by the specification or drawing.
15.1.2 The depression, after defect elimination, is blended uniformly into
the surrounding surface.
15.1.3 After defect elimination, the area is re-examined by the magnetic
particle method in accordance with RW, or the liquid penetrant
method in accordance with RX to assure that the defect has been
removed or the indication has been reduced to an acceptable size.
15.1.4 If the elimination of the defect reduces the section thickness below
the minimum required by the specification or drawing, the casting
may be repaired in accordance with ASME Section II, Part A,
Sections 8 to 14 (RL). (See Table 11-2) (SA-613, 15.RM)
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Welding Inspection Handbook
11-4
Section 11
Base Metal Repair by (Product Form)
Table 11-2
Repair by Welding (ASME Section III)
Code Class
NB, NC, ND, NE
Product Form
Plate/Forgings
Defect Removal – The defect shall be removed or indication reduced to an acceptable size
by suitable mechanical or thermal cutting or gouging methods and the cavity prepared for
repair (NX-4211.1). (NX-2539.1)
Qualification of Welding Procedures and Welders – The welding procedures and welders
or welding operators shall be qualified in accordance with NX-4000 and Section IX. (NX2539.2)
Blending or Repaired Areas – After repair, the surface shall be blended uniformly into
the surrounding surface. (NX-2539.3)
Examination of Repair Welds – Each repair weld shall be examined by the magnetic
particle method (NX2545) or by the liquid penetrant method (NX-2546). In addition, when
the depth of the repair cavity exceeds the lesser of 3/8 in. or 10% of the section thickness,
the repair weld shall be radiographed after repair in accordance with NX-5000. The
penetrometer and the acceptance standards for radiographic examination of repair welds
shall be based on the section thickness at the repair area. (NX-2539.4)
Heat Treatment After Repairs – The product shall be heat treated after repair in
accordance with the heat treatment requirements of NX-4620 . (NX-2539.5)
NB
Material Report Describing Defects and Repairs – Each defect repair exceeding in
depth the lesser of 3/8 in. or 10% of the section thickness shall be described in the Certified
Material Test Report. The Certified Material Test report for each piece shall include a
chart which shows the location and size of the prepared cavity, the welding material
identification, the welding procedure, the heat treatment, and the examination results,
including radiographic film. (NB-2539.6)
NC, ND, NE
Material Report Describing Defects and Repairs – Each defect repair that is required to
be radiographed shall be described the Certified Material Test Report. The Certified
Material Test Report for each piece shall include a chart which shows the location and size
of the prepared cavity, the welding material identification, the welding procedure, the heat
treatment and a report of the results of the examinations, including radiographic film. (NX2539.6)
NB
Repair of Cladding by Welding – The Material Manufacturer may repair defects in
cladding by welding, provided the requirements of (a) through (d) below are met.
(NB-2539.7)
(a) Qualification of Welding Procedures and Welders. The welding procedure and the
welders or welding operators shall be qualified in accordance with NB-4000 and with
Section IX.
(b) Defect Removal and Examination of Cavity. The defect shall be removed, and the cavity
prepared for repair shall be examined by the liquid penetrant method (NB-2546).
(c) Examination of Repaired Areas. The repaired area shall be examined by a liquid
penetrant method (NB-2546).
(d) Report of Repairs. Each defect repair shall be described in the Certified Material Test
Report for ..each piece, including a chart which shows the location and size of the repair,
the welding material identification, welding procedure, heat treatment, and examination
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Welding Inspection Handbook
11-5
Section 11
Base Metal Repair by (Product Form)
results.
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Welding Inspection Handbook
11-6
Section 11
Base Metal Repair by (Product Form)
Table 11-2 (Cont’d)
Code Class
NB, NC, ND, NE
Product Form
Pipe1
Repair by Welding (NX-2551 or NX-2560)
When permitted by the basic material specification, repair by welding may be made
provided the requirements of the following subparagraphs are met:
Welding Qualification, Records and Identifying Stamps – The requirements of SA-655
Sections 5.2, 5.3, and 5.4 shall apply to weld repairs.
Welding Materials – The welding materials used for the repair shall be tested and
certified in accordance with SA-655 paragraph 5.8.
Blending, of Repaired Areas – After repair, the surface shall be blended uniformly into
the surrounding surface.
Examination of Repair Welds – Each repair weld shall be examined by the magnetic
particle method in accordance with the requirements of SA-655, Section 14.RW, or by the
liquid penetrant method in accordance with the requirements of SA-655 Section 15.RX. In
addition, repair cavities, the depth of which exceeds the lesser of 3/8 in. (9.5 mm) or 10%
of the nominal wall thickness, shall be radiographed after repair in accordance with SA655 Section 16.RY. The penetrometer for radiographic examination of repair welds shall
be based on the wall thickness at the repair area.
Heat Treatment After Repairs – The material shall be heat treated after repair in
accordance with the heat treatment requirements of SA-655, Section 5.7.
Material Report Describing Defects and Repairs – Each defect repair exceeding in
depth the lesser of 3/8 in. (9.5 mm) or 10% of the nominal wall thickness shall be
described in the Certified Materials Test Report. The Certified Materials Test Report for
each piece shall include a chart that shows the location and size of the prepared cavity, the
welding material identification, the welding procedure, the heat treatment, and the
examination results, including radiographic film. (SA-655, 8.RL ASME Section II, Part
A)
NB, NC, ND, NE
Fittings1
Repair by Welding (NX-2553 or NX-2560)
When permitted by the basic material specification, repair -by welding may be made
provided the requirements of the following subparagraphs are met:
Welding Qualifications, Records, and Identifying Stamps – The requirements of SA652, Sections 5.2 and 5.4 shall apply to weld repairs.
Welding Materials – The welding materials used for the repair shall be tested and
certified in accordance with SA-652, paragraph 5.8.
Blending of Repaired Areas – After repair, the surface shall be blended uniformly into the
surrounding surface.
Examination of Repair Welds – Each repair weld shall be examined by the magnetic
particle method in accordance with the requirements of SA-652, Section 14.RW or by the
liquid penetrant method in accordance with the requirements of SA-652, Section 15.R.X.
In addition, repair cavities, the depth of which exceeds the lesser of 3/8 in. (9.5 mm) or
10% of the nominal wall thickness, shall be radiographed after repair in accordance with
ASME Section V, Article 2, and the acceptance standards of SA-652, Section 16 RY. The
penetrometer for radiographic examination of repair welds shall be based on the wall
thickness at the repair area.
1
Includes seamless, seam welded, with and without filler metal.
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Welding Inspection Handbook
11-7
Section 11
Base Metal Repair by (Product Form)
Table 11-2 (Cont’d)
Code Class
NB, NC, ND, NE
Product Form
Fittings1
Heat Treatment After Repairs – The material shall be heat treated after repair in
accordance with the heat treatment requirements of SA-652, -paragraph 5.7.
Material Report Describing Defects and Repairs – Each defect repair exceeding the
lesser of 3/8 in. (9-5 mm) or 10% of the nominal wall thickness shall be described in the
Certified Materials Test Report. The Certified Materials Test Report for each piece shall
include a chart that shows the location and size of the prepared cavity, the welding
material identification, the welding procedure, the heat treatment, and the examination
results, including radiographic film. (SA-652, 8.RL, ASME Section VI, Part A)
NB, NC, ND, NE
Castings
Repair by Welding (NX-2570)
Repairs by welding may be made provided the requirements of the following
subparagraphs are met:
Welding Qualifications, Weld Materials, Records and Identifying Stamps – Shall be
in accordance with the requirements of SA-613, section 10.RL.
NB, NC,
Blending of Repaired Areas
After repair, the surface shall be blended uniformly into the surrounding surface.
Examination
When repair welds require examination, each repair weld shall be examined by the
magnetic particle method in accordance with the requirements of Section 19 (RW) or by
the liquid penetrant method in accordance with the requirements of Section 20 (RX). In
addition, when volumetric examination is specified in the order for the original casting,
repair cavities, the depth of which exceeds the lesser of 3/8 in. (9.5 mm) or 10% of the
nominal wall thickness, shall be radiographed after repair in accordance with Section 21
(RY) except that weld slag, including elongated slag, shall be considered as inclusions
under Category B of the applicable reference radiographs. The total area of all inclusions,
including slag inclusions, shall not exceed the limits of the applicable severity level of
Category B of the reference radiographs. The penetrometer and the acceptance standards
for radiographic examination of repair welds shall be based on the actual section thickness
at the repair area.
Examination of Repair Welds
Inlet Piping Connection of Two Inches and Less – Repair welds in pumps and valves
of P-No. I and P-No. 8 material require no examination. Other repair welds shall be
examined by the magnetic particle method (SA-613; 19RW) or by the liquid penetrant
method (SA-613; 20RX). In addition, repair welds in cavities the depth of which exceed
the lesser of 3/8 in. or 10% of the section thickness shall be radiographed in accordance
with (SA-613; 21RY).
Inlet Piping Connections Over Two Inches – Each repair weld shall be examined by
the magnetic particle method (SA-613; 19RW) or by the liquid penetrant method
(SA-613; 20RX). In addition, repair welds in cavities the depth of which exceed the
lesser of 3/8 in. or 10% of the section thickness shall be radiographed in accordance
with (SA-613; 21 RY).
1
Includes seamless, seam welded, with and without filler metal.
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Welding Inspection Handbook
11-8
Section 11
Base Metal Repair by (Product Form)
Table 11-2 (Cont’d)
Code Class
ND
Product Form
Castings
Examination of Repair Welds (All Sizes)
(a) When magnetic particle or liquid penetrant examination of the casting is required,
each repair shall be examined by the magnetic particle method (SA-613; 19RW) or
by the liquid penetrant method (SA-613; 20RY).
(b) When radiography of the casting is required, repair welds in cavities the depth of
which exceeds the lesser of 3/8 in. or 10% of the section thickness shall be
radiographed in accordance with (SA-613; 21RY).
(c) When partial radiography of a casting is required, repairs located in an area of the
casting which is not covered by radiography need only be examined by the
magnetic particle method (SA-613; 19RW) or by the liquid penetrant method
(SA-613; 20RX).
NB, NC, ND, NE
Heat Treatment After Repairs – The material shall be heat treated after repair in
accordance with the heat treatment requirements of Section III of the Code, Subsubarticle
NB-4620, except that the heating and cooling limitations of NB-4623 do not apply.
(13.RL SA-613, ASME Section II)
Material Report Describing Defects and Repairs – Each defect repair exceeding in
depth the lesser of 3/8 in. (9.5 mm) or 10% of the nominal wall thickness shall be
described in the Certified Materials Test Report for each piece shall include a chart
that shows the location and size of the prepared cavity, the welding material
identification, the welding procedure, the heat treatment, and the examination results,
including radiographic film, when radiographic is specified in the order for the
original casting.
NB, NC, ND, NE, NF
Bolts/Studs/Nuts
Repair by welding is not permitted. (NX-2580; SA-614 ASME Section II, Part A)
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Welding Inspection Handbook
11-9
Section 12
Welding Processes
Page
12.1
SHIELDED METAL ARC WELDING (SMAW).............................................................
12-1
12.1.1
Advantages......................................................................................................................
12-2
12.1.2
Disadvantages..................................................................................................................
12-2
12.2
GAS TUNGSTEN ARC WELDING (GTAW) .................................................................
12-1
12.2.1
Advantages......................................................................................................................
12-2
12.2.2
Disadvantages..................................................................................................................
12-2
12.3
GAS METAL ARC WELDING (GMAW).......................................................................
12-1
12.3.1
Advantages......................................................................................................................
12-2
12.3.2
Disadvantages..................................................................................................................
12-2
12.4
FLUX CORED ARC WELDING (FCAW) ......................................................................
12-1
12.4.1
Advantages......................................................................................................................
12-2
12.4.2
Disadvantages..................................................................................................................
12-2
12.5
SUBMERGED ARC WELDING (SAW) .........................................................................
12-1
12.5.1
Advantages......................................................................................................................
12-2
12.5.2
Disadvantages..................................................................................................................
12-2
12.6
STUD WELDING (SW) ..................................................................................................
12-1
12.6.1
Advantages......................................................................................................................
12-2
12.6.2
Disadvantages..................................................................................................................
12-2
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Welding Inspection Handbook
12-0
Section 12
12.1
Welding Processes
SHIELDED METAL ARC WELDING (SMAW)
Figure 12.1 – Shielded Metal Arc Welding
12.1.1
Advantages
1
The equipment is relatively simple, inexpensive and portable.
2 The shielding gas, provided by the burning flux, is less sensitive to wind and drafts when
compared to a process with an external shielding gas.
12.1.2
3
It is very versatile.
4
It can be used in limited access areas.
5
It is suitable for most common metals and alloys.
6
It is capable of producing X-ray quality welds.
7
Deposition rates are higher than the gas tungsten arc welding process.
Disadvantages
1 Deposition rate is low compared too GMAW or FCAW because of multiple stops, due to
electrode length.
2
The weld is covered by a layer of slag that must be removed.
m:\temporary\welding inspection\chapter12.doc
Welding Inspection Handbook
12-1
Section 12
12.2
Welding Processes
GAS TUNGSTEN ARC WELDING (GTAW)
Figure 12.2 – Gas Tungsten Arc Welding
12.2.1
Advantages
1
Capable of welding thin material.
2 Controls heat input extremely well because the heat source and the filler material are separately
controlled.
12.2.2
3
Welds can be made without adding filler material by fusing the base metals together.
4
Full penetration welds that are welded from one side only can be made.
5
Produces X-ray quality welds.
6
Recommended for materials which form refractory oxides, like aluminum and magnesium.
Disadvantages
1
Cost of equipment and shielding gas is high.
2
Deposition rate is slow.
3
A high degree of operator skill is required to produce quality welds.
4
Fitup tolerances are restrictive.
5 Exposure of hot filler material to the atmosphere through faulty technique, can cause weld metal
contamination.
m:\temporary\welding inspection\chapter12.doc
Welding Inspection Handbook
12-2
Section 12
12.3
Welding Processes
GAS METAL ARC WELDING (GMAW)
Figure 12.3 – Gas Metal Arc Welding (Globular Mode)
12.3.1
Advantages
1
Deposition rate is high.
2 Costs are low because there is less electrode waste, no slag removal and welder down-time due to
changing electrodes is less compared to SMAW.
12.3.2
3
Smoke and fumes are minimal.
4
Obtains deeper penetration than SMAW or GTAW.
5
It is very versatile. (All position process for carbon, low alloy and stainless steels.)
Disadvantages
1
Cost of machinery, shielding gas, and maintenance is high.
2
Accessibility to the welding joint is restrictive because of the size of the gun.
3
Shielding gas is sensitive to wind and drafts.
4
The length of the welding lead is restrictive.
5
The equipment is not as portable as SMAW.
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Welding Inspection Handbook
12-3
Section 12
12.4
Welding Processes
FLUX CORED ARC WELDING (FCAW)
Figure 12.4 – Flux Cored Arc Welding
12.4.1
Advantages
1
Deposition rate is high.
2 Costs are low because there is less electrode waste, welder down-time due to changing electrodes
is less, and one can utilize economical joint designs.
12.4.2
3
Compared to SMAW, distortion of the material is less.
4
Excellent profile for horizontal fillet welds.
Disadvantages
1
Cost of machinery and maintenance is high.
2
Electrode is more expensive than GMAW.
3
Length of welding lead is restrictive.
4
Not as portable as SMAW.
5
Produces more smoke and fumes than GMAW.
6
Slag covering that must be removed.
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Welding Inspection Handbook
12-4
Section 12
12.5
Welding Processes
SUBMERGED ARC WELDING (SAW)
Figure 12.5 – Submerged Arc Welding
12.5.1
12.5.2
12.6
Advantages
1
High deposition rate.
2
Easily automated.
3
High utilization of electrode wire.
4
Weld puddle is submerged, eliminating the need for protective clothing.
5
Little or no smoke.
Disadvantages
1
Limited welding positions (flat and horizontal).
2
High heat input that could be detrimental to some base metals.
3
Welding puddle not visible.
STUD WELDING
Stud welding is a two-step process. In the first step, a stud is placed in the gun with a ferrule, or arc shield, then
held against the workpiece until the arc heats the base metal and stud to the proper temperature. In the second
step, the heated surfaces are forced together under pressure.
When depressing the trigger on the stud gun, an automatic welding cycle begins and a solenoid lifts the stud off the
work, creating an arc between the stud and workpiece. A timer then shuts off the current, and a main spring in the
gun plunges to stud into the molten pool created by the arc.
Stud welding may be used in any position, and on all types of equipment and structures. AWS D1.1 requires
welded studs to show a full 360 degree flash around to stud base. Studs lacking this requirement usually must be
removed, or repaired by manual welding.
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Welding Inspection Handbook
12-5
Section 12
Welding Processes
Figure 12.6 – Stud Welding
12.6.1
12.6.2
Advantages
1
It is cost effective.
2
Welding time is low.
3
Cost of equipment is low.
4
Welds are made from one side only.
5
Distortion is minimal.
6
Heat input into the base metal is low.
7
Small studs can be welded on thin sections.
Disadvantages
1
Only one end of the stud can be stud welded.
2
Shape and size of the stud must be compatible with the chuck.
3
Stud size is limited by the base thickness and position.
4
Disposable ceramic ferrule is required for each stud.
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Welding Inspection Handbook
12-6
Section 13
Preheat and Interpass Temperatures
Page
13.1
ASME/ANSI B31.1 ...................................................................................
13-1
13.1.1
General Requirements ................................................................................
13-1
13.1.2
Requirements .............................................................................................
13-1
13.2
ASME/ANSI B31.3 ...................................................................................
13-1
13.2.1
Requirements & Recommendations ............................................................
13-1
13.3
ASME SECTION III .................................................................................
13-1
13.3.1
General ......................................................................................................
13-1
13.3.2
Requirements .............................................................................................
13-1
13.4
AWS D1.1 .................................................................................................
13-2
13.4.1
General Requirements ................................................................................
13-2
13.4.2
Requirements .............................................................................................
13-2
Table 13-1 Summary of Preheat Requirements.........................................
13-3
Table 13-2 Prequalified Minimum Preheat and Interpass
Temperature (Table 3.2).........................................................
13-4
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Welding Inspection Handbook
13-0
Section 13
13.1
Preheat and Interpass Temperatures
ASME/ANSI B31.1
13.1.1 General Requirements
1. The preheat requirements listed herein are mandatory minimum values. (131.1)
2. When welding two different P-Number materials, the minimum preheat temperature
required shall be the higher temperature for the material to be welded. (131.2)
3. The preheat temperature shall be checked by use of temperature-indicating crayons,
thermocouple pyrometers, or other suitable methods to assure that the required
preheat temperature is obtained prior to and uniformly maintained during the welding
operation. (131.3)
4. Thickness referred to is the greater of the nominal thicknesses at the weld for the
parts to be joined. The nominal thickness for branch welds is defined in Figure 14-1
of this handbook. (131.4.1)
13.1.2 Requirements
See Table 13-1.
13.2
ASME/ANSI B31.3
13.2.1 Requirements & Recommendations
Required and recommended minimum preheat temperatures for materials of various P-Numbers
are given in Table 13-1 (Table 330.1.1). If the ambient temperature is below 32°F, the
recommendations become requirements. The thickness is that of the thicker component measured
at the joint. (330.1.1)
13.3
ASME SECTION III
13.3.1 General
It is cautioned that the preheating suggested in Appendix D of Section III (Table 13-1), does not
necessarily ensure satisfactory completion of the welded joint and that the preheating
requirements for individual materials within the P-Number may be more or less restrictive.
Preheating may be required for the purpose of avoiding post-weld heat treatment. See PWHT
section of this handbook.
Interpass temperature for austenitic stainless steels is generally limited to 350’F. (Check
applicable technical specifications.)
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Welding Inspection Handbook
13-1
Section 13
Preheat and Interpass Temperatures
13.3.2 Requirements
See Table 13-1.
13.4
AWS D1.1
13.4.1 General
When the base metal temperature is below the temperature listed in Table 4.2 of AWS D1.1
(Table 13-2 of this section) for the welding process and filler material being used and the
thickness of material being welded, it shall be preheated (except as otherwise provided) in such
manner that the parts on which the weld metal is being deposited are above the specified minimum
temperature for a distance equal to the thickness of the part being welded but not less than 3 in.,
in all directions from the point of welding.
Welding shall not be done when the ambient temperature is lower than 0°F. (Zero°F does not
mean the ambient environmental temperature but the temperature in the immediate vicinity of the
weld. The ambient environmental temperature may be below 0°F but a heated structure or shelter
around the area being welded could maintain the temperature adjacent to the weldment at 0°F or
higher.)
Preheat and interpass temperatures must be sufficient to prevent crack formation, and
temperatures above the specified minimum may be required for highly restrained welds. In joints
involving combinations of base metals, preheat shall be as specified for the higher strength ,steel
being welded. (4.2)
Preheat interpass temperature and heat input for quenched and tempered steels shall be in
accordance with the steel manufacturer’s recommendations. (4.3)
13.4.2 Requirements
See AWS D1.1 Table 4.2 (Table 13-2).
m:\temporary\welding inspection\chapter13.doc
Welding Inspection Handbook
13-2
Section 13
Preheat and Interpass Temperatures
Table 13-1
Summary of Preheat Requirements*
P1
ASME/ANSI B31.1
ASME/ANSI B31.3
ASME Section III
(Mandatory Minimums)
(Required/Recommended)
(Non-mandatory Minimums)
175F for material with both carbon
over 0.30% and thickness over 1
inch
50F for all others
175F for material thickness
inch
P3
175F for material with greater than
70k tensile or thickness over 5/8
inch
50F for all others
P4
P6
250F for material with greater than
60k tensile or thickness over 1/2
inch
50F for all others
400F for material with greater than
60k tensile or material with both
over 6% Cr and thickness over 1/2
inch
300F for all others
400F for all material
175F for material thickness 1/2
inch
and 71k tensile
175F for all thickness of materal >
71k
50F for all others
300F for all thicknesses of
materials with 1/2% to 2% Cr
(Required)
P7
P5
1
50F for all others
Group 1
200F for C 0.30% and thickness >1-1/2
inches
250F for both over 0.30% C and 1 inch
thickness
50F for all others
Group 2
200F for 0.30% C or less and thickness
over 1 inch
250F for both over 0.30% C and 1 inch
thickness
50F for all others
Group 3
250F for either material >70k tensile or
thickness over 5/8 inch
50F for all others
250F for either material with over 70k
tensile or thickness over 5/8 inch
50F for all others
300F for material with greater than 60k
tensile or thickness over 1/2 inch
50F for all others
350F for all thicknesses of material
with 2-1/4% to 10% Cr
(Required)
400F for material with greater than 60k
tensile or material with both over 6% Cr
and thickness over 1/2 inch
300F for all others
300F for all material (600F
interpass)
400F for all material
50F for all material
50F for all material
No recommended minimum
P8
50F
50F for all material
No recommended minimum
P9
250F for P-No. 9A
300F for P-No. 9B
200F for all material
300F for all material
P10A
Not addressed
175F for all material
175F for all material
P10B
Not addressed
Not addressed
250F
P10D
Not addressed
Not addressed
300F with interpass at 300-450F
P10E
300F with maximum interpass of
450F
Not addressed
300F with interpass 350F-450F
300F with interpass at 300-450F
50F for all material
Not addressed
P11A
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Welding Inspection Handbook
13-3
Section 13
Preheat and Interpass Temperatures
Table 13-2
Prequalified Minimum Preheat and Interpass Temperature
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Welding Inspection Handbook
13-4
Section 13
Preheat and Interpass Temperatures
Table 13-2 (Cont’d)
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Welding Inspection Handbook
13-5
Section 14
Post Weld Heat Treatment (PWHT)
Page
14.1
ASME/ANSI B31.1 ...................................................................................
14-1
14.1.1
Code Required PWHT Tables ....................................................................
14-1
14.1.2
Different P-Number, PWHT Requirements.................................................
14-3
14.1.3
Definition of Thickness Governing PWHT..................................................
14-3
14.1.4
PWHT Heating and Cooling Requirements.................................................
14-4
14.2
ASME/ANSI B31.3 ...................................................................................
14-6
14.2.1
Code Required PWHT Tables ....................................................................
14-6
14.2.2
Different P-Number, PWHT Requirements.................................................
14-6
14.2.3
Definition of Thickness Governing PWHT..................................................
14-7
14.2.4
Hardness Tests...........................................................................................
14-8
14.3
ASME SECTION III .................................................................................
14-9
14.3.1
Code Required PWHT Requirements .........................................................
14-9
14.3.2
Code Exemptions to PWHT – All P-Numbers ............................................ 14-10
14.3.3
Different P-Numbers .................................................................................. 14-11
14.3.4
Definition of Thickness Governing PWHT.................................................. 14-11
14.4
AWS D1.1 ................................................................................................. 14-12
14.4.1
Code Required PWHT Requirements ......................................................... 14-12
14.4.2
Alternative PWHT Requirements ............................................................... 14-12
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Welding Inspection Handbook
14-0
Section 14
14.1
Post Weld Heat Treatment (PWHT)
ASME/ANSI B31.1
14.1.1 Code Required PWHT Tables
Table 132
Post Weld Heat Treatment
Holding Time Based on Nominal Thickness
P-Number from
Appendix A
P-No. 1
Gr. Nos. 1, 2, 3
Holding Temperature
Range, °F (°C)
1100 (600) to
1200 (650)
Up to 2 in.
(50 mm)
1 hr/in. (25mm)
15 min minimum
Over 2 in.
(50 mm)
2 hr plus 15 min for each additional
inch over 2 in. (50 mm)
Notes:
(I) PWHT of P-No. I materials is not mandatory under the following conditions:
(A) when the nominal thickness, as defined in Para. 132.4.1 is 3/4 in. (19.0 mm) or less; or
(B) for branch welds, fillet welds, and repair welds when the weld thickness, as defined in Para. 132.4.2 is
3/4 in. (19.0 mm) or less and a minimum preheat of 200°F (95°C) is applied when the base metal or the
thicker of the base metals to be welded exceeds 1 in. (25.0 mm).
(II) When it is impractical to PWHT at the temperature range specified in Table 132, it is permissible to perform
the PWHT of this material at lower temperatures for longer periods of time in accordance with Table 132.1.
Holding Time Based on Nominal Thickness
P-Number from
Appendix A
P-No. 3
Gr. Nos. 1, 2
Holding Temperature
Range, °F (°C)
1100 (600) to
1200 (650)
Up to 2 in.
(50 mm)
1 hr/in. (25mm)
15 min minimum
Over 2 in.
(50 mm)
2 hr plus 15 min for each additional
inch over 2 in. (50 mm)
Notes:
(I) PWHT of P-No. 3 materials with a specified carbon content of not more than 0.25%, is not mandatory under
the following conditions:
(A) when the nominal thickness, as defined in Para. 132.4.1, is 5/8 in. (16.0 mm) or less; or
(B) when the weld thickness, as defined in Para. 132.4.2, is 1/2 in. (13.0 mm) or less and a minimum
preheat of 200°F (95°C) is applied when the base metal or the thicker of the base metals to be welded
exceeds 5/8 in. (16.0 mm).
(II) When it is impractical to PWHT at the temperature range specified in Table 132, it is permissible to perform
the PWHT of this material at lower temperatures for longer periods of time in accordance with Table 132.1.
m:\temporary\welding inspection\chapter14.doc
Welding Inspection Handbook
14-1
Section 14
Post Weld Heat Treatment (PWHT)
Table 132 (Cont’d)
Holding Time Based on Nominal Thickness
P-Number from
Appendix A
P-No. 4
Gr. Nos. 1, 2
Holding Temperature
Range, °F (°C)
1300 (700) to
1375 (750)
Up to 2 in.
(50 mm)
1 hr/in. (25 mm)
15 min minimum
Over 2 in.
(50 mm)
2 hr plus 15 min for each additional
inch over 2 in. (50 mm)
Notes:
(I) PWHT is not mandatory for P-No. 4 material under the following conditions:
(A) welds in pipe or attachment welds to pipe complying with all of the following conditions:
(1) a maximum nominal pipe size of 4 in.;
(2) a maximum material thickness of 1/2 in. (13.0 mm);
(3) a maximum specified carbon content of the material to be welded of 0.15%;
(4) application of 250°F (120°C) minimum preheat during welding.
(B) for seal welding of threaded or other mechanical joints provided:
(1) the seal weld has a throat thickness of 1% in. (9.0 mm) or less;
(2) a minimum preheat of 250°F (120°C) during welding is applied.
Holding Time Based on Nominal Thickness
P-Number from
Appendix A
P-No. 5
Gr. Nos. 1, 2
Holding Temperature
Range, °F (°C)
1300 (700) to
1400 (760)
Up to 2 in.
(50 mm)
1 hr/in. (25 mm)
15 min minimum
Over 2 in.
(50 mm)
2 hr plus 15 min for each additional
inch over 2 in. (50 mm)
Notes:
(I) PWHT is not mandatory for P-No. 5 material under the following conditions:
(A) welds in pipe or attachment welds to pipe complying with all of the following conditions:
(1) a maximum nominal pipe size of 4 in.;
(2) a maximum material thickness of 1/2 in. (13.0 mm);
(3) a maximum specified chromium content of the material to be welded of 3.0%;
(4) a maximum specified carbon content of the material to be welded of 0.15%;
(5) application of 300°F (150°C) minimum preheat during welding.
Holding Time Based on Nominal Thickness
P-Number from
Appendix A
P-No. 6
Gr. Nos. 1, 2, 3
Holding Temperature
Range, °F (°C)
1400 (760) to
1475 (800)
Up to 2 in.
(50 mm)
1 hr/in. (25 mm)
15 min minimum
Over 2 in.
(50 mm)
2 hr plus 15 min for each additional
inch over 2 in. (50 mm)
Notes:
(I) PWHT is not mandatory for P-No. 6 material under the following conditions:
(A) for Type 410 material provided:
(1) the specified carbon content is not more than 0.08%;
(2) the maximum material thickness is 34 in. (10 mm);
(3) the weld is made with A-No. 8, A-No. 9, or F-No. 43 filler metal.
m:\temporary\welding inspection\chapter14.doc
Welding Inspection Handbook
14-2
Section 14
Post Weld Heat Treatment (PWHT)
Table 132 (Cont’d)
Holding Time Based on Nominal Thickness
P-Number from
Appendix A
P-No. 7
Gr. Nos. 1, 2
Holding Temperature
Range, °F (°C)
1350 (730) to
1425 (775)
Up to 2 in.
(50 mm)
1 hr/in. (25 mm)
15 min minimum
Over 2 in.
(50 mm)
2 hr plus 15 min for each additional
inch over 2 in. (50 mm)
Notes:
(I) In lieu of the cooling rate described in Para. 132.5, P-No. 7 material cooling rate shall be 100°F (55°C) per hr
maximum in the range above 1200°F (650°C) after which the cooling rate shall be sufficiently rapid to prevent
embrittlement.
(II) PWHT is not mandatory for P-No. 7 material under the following conditions:
(A) for Type 405 material provided:
(1) the specified carbon content is not more than 0.08%;
(2) the maximum material thickness is h in. (10 mm);
(3) the weld is made with A-No. 8, A-No. 9, or F-No. 43 filler metal.
14.1.2 Different P-Number, PWHT Requirements
When parts of two different P-Numbers are joined by welding, the post weld heat treatment shall
be that specified for the material requiring the higher PWHT temperature. When a nonpressure
part is welded to a pressure part and PWHT is required for either part, the maximum PWHT
temperature shall not exceed the maximum temperature acceptable for the pressure retaining part.
(132.2)
14.1.3 Definition of Thickness Governing PWHT
The term “Nominal Thickness” as used in Table 132 and Notes is the lesser thickness of (A) or
(B) as follows:
(A) the thickness of the weld;
(B) the thicker of the materials being joined at the weld. (132.4.1)
Thickness of the weld, which is a factor in determining the nominal thickness, is defined as
follows: (132.4.2)
(A) groove welds (girth and longitudinal) – the thicker of the two abutting ends after
weld preparation, including ID machining;
(B) fillet welds – the throat thickness of the weld;
(C) partial penetration welds – the depth of the weld groove;
(D) material repair welds – the depth of the cavity to be repaired;
(E) for branch welds, refer to Fig. 14.1 and calculate the weld thickness as follows:
(1)
for detail (a), weld thickness
= tb + tc
(2)
for detail (b), weld thickness
= th + tc
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Welding Inspection Handbook
14-3
Section 14
Post Weld Heat Treatment (PWHT)
(3)
for detail (c), weld thickness
= the greater of te + tc or tb + tc
(4)
for detail (d), weld thickness
= th + te + tc
(5)
for detail (e), weld thickness
t b + tc
Branch welds which have widely varying actual weld thicknesses shall be calculated in the same
manner using the wall thicknesses existing in the plane intersecting the longitudinal axis. For the
purpose of calculating weld thicknesses in (E.1) through (E.5) above,
tc = the smaller of 1/4 in. (6.0 mm) or 0.7 tn. (132.4)
14.1.4 PWHT Heating and Cooling Requirements
Above 600°F, the rate of heating and cooling shall not exceed 600°F per hour divided by 1/2 the
maximum thickness of material in inches at the weld but in no case shall the rate exceed 600°F per
hour. (See Table 132 for cooling rat requirements for P-Numbers 7 and 10E materials. (132.5)
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Welding Inspection Handbook
14-4
Section 14
Post Weld Heat Treatment (PWHT)
Figure 14-1 Branch Welds
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Welding Inspection Handbook
14-5
Section 14
14.2
Post Weld Heat Treatment (PWHT)
ASME/ANSI B31.3
14.2.1 Code Required PWHT Tables
Table 331.1.1
Requirements for Heat Treatment PWHT
P-No.
Base
Metal
Group
Nominal
Wall
Thick (in.)
Specified Min.
Tensile
Base Metal(ksi)
Metal
Temperature
Range(ºF)
1
Carbon steel
3/4
>3/4
All
All
None
1100-1200
--1
--1
-----
3
Alloy steels,
Cr 1/2%
--1
1
--1
1
--225
225
Alloy steels
1/2% < Cr 2%
71
All
>71
71
All
>71
None
1100-1325
1100-1325
4
3/4
>3/4
All
1/2
>1/2
All
None
1300-1375
1300-1375
--1
1
--2
2
--225
225
5
Alloy Steels, (2-14% Cr 10%)
1/2
>1/2
All
All
None
1300-1400
--1
--2
--241
All
All
All
All
All
All
1350-1450
1150-1225
None
None
None
100-1175
1
1
------1/2
2
2
------1
241
241
---------
All
1400-1500
1/2
1/2
---
None
---
---
---
3%Cr, and 0.15%C,and
>3%Cr, or >0.15%C
Holding Time
hr/in
Min.
Time
Brinell
Hardness
Max.
7
8
9A,B
High alloy steels,martensitic
A240 Gr. 429
High alloy steels,ferritic
High alloy steels,austenitic
Nickel alloy steels
10
Cr-Cu steel
All
All
All
All
3/4
>3/4
All
10A
Mn-V steel
3/4
71
>3/4
All
1100-1300
1
1
225
All
>71
1100-1300
1
1
225
6
10E
27Cr steel
All
All
1225-1300
1
1
---
10H
Duplex stainless steels
All
All
(per material
spec)
1/2
1/2
---
11A
5 Ni, 8Ni, 9Ni steel
2
All
None
---
---
---
>2
All
1025-1085
1
1
---
14.2.2 Different P-Number, PWHT Requirements
(A)
Heat treatment of welded joints between dissimilar ferritic metals or between ferritic
metals using dissimilarferritic filler metal shall be at the higher of the temperature ranges in
Table 331.1.1 for the materials in the joint.
(B)
Heat treatment of welded joints including both ferritic and austenitic components and filler
metals shall be as required for the ferritic material or materials unless otherwise specified
in the engineering design. (331.2.3)
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Welding Inspection Handbook
14-6
Section 14
Post Weld Heat Treatment (PWHT)
14.2.3 Definition of Thickness Governing PWHT
When components are joined by welding, the thickness to be used in applying the heat treatment
provisions of Table 331.1.1 shall be that of the thicker component measured at the joint, except as
follows.
(A) Branch connections;
Heat treatment is required when the thickness through the weld in any plane through the branch is
greater than twice the minimum material thickness requiring heat treatment, even though the
thickness of the components at the joint is less than the minimum thickness. Thickness through
the weld for the details shown in Figure 14-1 (Fig. 328.5.4D) shall be computed using the
following formulas:
(1)
(2)
(3)
(4)
(5)
for detail (a), weld thickness
for detail (b), weld thickness
for detail (c), weld thickness
for detail (d), weld thickness
for detail (e), weld thickness
= tb + tc
= th + tc
= the greater of te + tc or tb + tc
= th + te + tc
t b + tc
(B) Fillet welds;
In the case of fillet welds at slip-on and socket welding flanges and piping connections NPS 2 and
smaller, for seal welding of threaded joints in piping NPS 2 and smaller, and for attachment of
external nonpressure parts such as lugs in all pipe sizes, heat treatment is required when the
thickness through the weld in any plane is more than twice the minimum material thickness
requiring heat treatment (even though the thickness of the components at the joint is less than that
minimum thickness) except as follows:
(1)
(2)
(3)
not required for P-No.1 materials when weld throat thickness is 5/8 in. or less,
regardless of base metal thickness;
not required for P-No.3, 4, 5, or 10A materials when weld throat thickness is
1/2 in. or less, regardless of base metal thickness, provided that not less than the
recommended preheat is applied and the specified minimum tensile strength of the
base metal is less than 71 ksi.
not required for ferritic materials whenwelds are made with filler metal which does
not air harden.
14.2.3 PWHT Heating and Cooling Requirements
The heating method shall provide the required metal temperature, metal temperature uniformity,
and temperature control, and may include an enclosed furnace, local flame heating, electric
resistance, electric induction, or exothermic chemical reaction. The cooling method shall provide
the required or desired cooling rate and may include cooling in a furnace, in air, by application of
local heat or insulation, or by other suitable means.
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Welding Inspection Handbook
14-7
Section 14
Post Weld Heat Treatment (PWHT)
14.2.4 Hardness Tests
The hardness limits apply to the weld and heat affected zone tested as close as practicable to the
edge of the weld. Where a hardness limit is specified in Table 331.1.1, 100% of locally heat
treated welds shall be tested.
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Welding Inspection Handbook
14-8
Section 14
14.3
Post Weld Heat Treatment (PWHT)
ASME SECTION III
14.3.1 Code Required PWHT Requirements
Table NX-4622.1-1
Mandatory Requirements for Post Weld Heat Treatment of Welds1
P-No.
(QW-420
Section IX)
Holding
Temperature
Range °F
1/2 in. or less
1, 3
1100–1250
30 min
1 hr/in.
4
1100–1250
30 min
1 hr/in.
1 hr/in.
5, 6 (except
P-No. 6 Gr. 4)
1250–1400
30 min
1 hr/in.
1 hr/in.
6, Gr. 4
1100–1150
7
1300–1400
30 min
1 hr/in.
1 hr/in.
9A, Gr. 1
1100–1250
30 min
1 hr/in.
1 hr/in.
30 min
1 hr/in.
1 hr/in.
30 min
1 hr/in.
1 hr/in.
9B, Gr. 1
1100–1175
10F, Gr. 1
1100–1250
10I, Gr. 1
1300–1405
11A, Gr. 4
1000–1050
P-Nos. 8, 34, 42, 43,
45 & hard
surfacing on PNo. 1 base metal
whose reported
carbon content is
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Minimum Holding Time at Temperature
for Weld Thickness (Nominal)
Over 1/2 in to 2 in.
Over 2 in. to 5 in.
2 hr plus
15 min each
additional inch
over 2 in.
Over 5 in.
2 hr plus
15 min each
additional
inch over 2
in.
5 hr plus
15 min each
additional
inch over 5
in.
5 hr plus
15 min each
additional
inch over 5
in.
5 hr plus
15 min each
additional
inch over 5
in.
5 hr plus
15 min each
additional
inch over 5
in.
5 hr plus
15 min each
additional
inch over 5
in.
1 hr/in.
PWHT neither required nor prohibited
Welding Inspection Handbook
14-9
Section 14
Post Weld Heat Treatment (PWHT)
nor more than
0.30%
Notes:
(1) Exemptions to the mandatory requirements of this Table are defined in Table NX4622.7.
(2) All temperatures are metal temperatures.
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Welding Inspection Handbook
14-10
Section 14
Post Weld Heat Treatment (PWHT)
14.3.2 Code Exemptions to PWHT – All P-Numbers
Table NX-4622.7(b)-1
Exemptions to Mandatory PWHT
P-No.
QW-420
Sect. IX
1
Type of Weld
Vessel
(Note 1)
Other
components
3 except
Gr. 3
4
5
7
Circumferential butt and socket welds
connecting pipe and tubes to nozzles
Fillet welds
All welds, except repair welds, provided
welding procedure qualification is made in
equal or greater thickness than the
production weld
All welds, including repair welds, in material
1-1/2 in. and less
Fillet, partial penetration, and repair welds in
material over 1-1/2 in.
All welds, except repair welds in vessels,
provided welding procedure qualification
is made in equal or greater thickness than
production weld (Note 2)
Attachment welds joining nonpressureretaining material to pressure retaining
material
Circumferential butt welds or socket welds in
pipe and tubes
Circumferential butt welds in pipe and tubes
with nominal O.D. 4 in. or less and
attachment welds
Circumferential butt welds in pipe and tubes
with maximum reported chromium 3.00%
or less and nominal O.D. 4 in. or less and
attachment welds
Type 405 and 410 welded with A-No. 8,
A-No. 9, or F-No. 43 filler metal
Nominal
Thickness
(NX-4622.3)
Properties of
Pressure Retaining
Material Being Joined
Max.
Min.
Reported
Preheat
Carbon, %
Req’d, °F
1-1/4 in. and less
over 1-1/4 in. to
1-1/2 in.
3/4 in. or less
over 3/4 in. to
1-1/2 in.
3/4 in. or less
5/8 in. or less
0.30 or less
0.30 or less
–
200
over 0.30
over 0.30
–
299
–
0.25 or less
200
200
1-1/4 in. and less
0.30 or less
–
over 1-1/4 in. to
1-1/2 in.
3/4 in. or less
over 3/4 in. to
1-1/2 in.
3/4 in. or less
0.30 or less
200
over 0.30
over 0.30
–
299
–
200
5/8 in. or less
0.25 or less
200
1/2 in. or less
0.25 or less
200
1/2 in. or less
0.25 or less
200
1/2 in. or less
0.25 or less
250
1/2 in. or less
0.25 or less
300
3/8 in. or less
0.08 or less
–
Notes:
(1) Apply to Subsection NB only.
(2) Does not apply to Subsection NF Components.
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Welding Inspection Handbook
14-11
Section 14
Post Weld Heat Treatment (PWHT)
Table NX-4622.7(b)-1 (Cont’d)
P-No.
QW-420
Sect. IX
9A, Gr. 1
9B, Gr. 1
Type of Weld
All welds provided in procedure
qualification is made in thickness equal to
or greater than the production weld
Attachment welds joining nonpressureretaining material to pressure retaining
material over 5/8 in.
Circumferential butt welds or socket welds
in pipe and tubes with nominal O.D. 4 in.
or less and attachment welds
All welds provided the procedure
qualification is made in thickness equal
to or greater than the production weld
Attachment welds joining pressure-retaining
material to pressure retaining material
over 5/8 in.
Nominal
Thickness
(NX-4622.3)
Properties of
Pressure Retaining
Material Being Joined
Max.
Min.
Reported
Preheat
Carbon, %
Req’d, °F
5/8 in. or less
–
200
1/2 in. or less
–
200
1/2 in. or less
0.15 or less
250
5/8 in. or less
–
200
1/2 in. or less
–
200
Notes:
(1) Does not apply to Subsection NB Components.
(2) Applies to Subsection NF Components only.
14.3.3 Different P-Numbers
When materials of two different P-Number groups are joined by welding, the applicable post weld
heat treatment shall be that specified in Table NX-4622.1-1 for the material requiring the higher
PWHT temperature range. (NX-4622.5)
14.3.4 Definition of Thickness Governing PWHT
Nominal thickness in Table NX-4622.1-1 and Table NX-4622.7(b)-l is the thickness of the weld,
pressure retaining material, or the thinner of the sections being joined, whichever is least. For
fillet welds the nominal thickness is the throat thickness, and for partial penetration and material
repair welds the nominal thickness is the depth of the weld groove or preparation. (NX-4622.3)
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Welding Inspection Handbook
14-12
Section 14
14.4
Post Weld Heat Treatment (PWHT)
AWS D1.1
14.4.1 Code Required PWHT Requirements
The stress relief treatment shall conform to th following requirements:
(1)
(2)
(3)
(4)
The temperature of the furnace shall not exceed 600°F at the time the welded assembly
is placed in it.
Above 600°F, the rate of heating shall not be more than 400°F/hour divided by the
maximum metal thickness of the thicker part in inches, but in no case more than
400°F/hour During the heating period, variation in temperature throughout the portion
of the part being heated shall be no greater than 250°F within any 15 ft. interval of
length.
After a maximum temperature of 1100°F is reached on quenched and tempered steels, or
mean temperature range between 1100-1200°F is reached on other steels, the
temperature of the assembly shall be held within the specified limits for a time not less
than specified in Table 4.4.2, based on weld thickness. When the specified stress relief is
for dimensional stability, the holding time shall be not less than specified in Table 4.4.2,
based on the thickness of the thicker part. During the holding period there shall be no
difference greater than 150°F between the highest and lowest temperature throughout
the portion of the assembly being heated.
Above 600°F, cooling shall be at a rate no greater than 500°F per hour divided by the
maximum metal thickness of the thicker part in inches, but in no case more than 500°F
per hour. From 600°F, the assembly may be cooled in still air. (4.4.2)
14.4.2 Alternative PWHT Requirements
Alternatively, when it is impractical to post weld heat treat to the temperature limitations stated
in 4.4.2, welded assemblies may be stress-relieved at lower temperatures for longer periods of
time, as given in Table 4.4.3. (4.4.3)
Table 4.4.2
Minimum Holding Time
1/4 in. (6.4 mm) or Less
15 min
Over 1/4 in. (6.4 mm)
Through 2 in. (51 mm)
1 hr/in.
Over 2 in. (51 mm)
2 hrs plus 15 min for each
additional in. over 2 in. (51
mm)
Table 4.4.3
Alternative Stress-Relief Heat Treatment
Decrease in Temperature
Below Minimum Specified Temperature,
°F
°C
50
28
100
56
150
84
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Minimum Holding Time at Decreased
Temperature, Hours per Inch of Thickness
2
3
5
Welding Inspection Handbook
14-13
Section 14
Post Weld Heat Treatment (PWHT)
200
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112
Welding Inspection Handbook
10
14-14
Section 15
Prequalified Welded Joints AWS D1.1
Page
15.1
COMPLETE JOINT PENETRATION GROOVE WELDS (2.9) ...............
15-1
15.1.1
General ......................................................................................................
15-1
15.1.2
Dimensional Tolerances..............................................................................
15-1
15.1.3
Corner Joints..............................................................................................
15-2
15.1.4
Base Metal (8.2 and 10.2) ..........................................................................
15-2
15.1.5
Notes .........................................................................................................
15-2
Complete Joint Penetration Groove Weld Tables........................................
15-4
15.2
PARTIAL JOINT PENETRATION GROOVE WELDS (2.10) ................. 15-11
15.2.1
General ...................................................................................................... 15-11
15.2.2
Definition................................................................................................... 15-11
15.2.3
Dimensional Tolerances.............................................................................. 15-11
15.2.4
Corner Joints.............................................................................................. 15-12
15.2.5
Base Metal (8.2 and 10.2) .......................................................................... 15-12
15.2.6
Notes ......................................................................................................... 15-12
Partial Joint Penetration Groove Weld Tables............................................. 15-13
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Welding Inspection Handbook
15-0
Section 15
15.1
Prequalified Welded Joints AWS D1.1
COMPLETE JOINT PENETRATION GROOVE WELDS (2.9)
15.1.1 General
Complete joint penetration groove welds made by shielded metal arc, submerged arc, gas metal
arc (except short circuiting transfer), or flux cored arc welding in butt, corner, and T-joints which
may be used without performing the joint welding procedure qualification test prescribed in 5.2
are detailed in Figure 2.9.1 and are subject to the limitations specified in 2.9.2. (2.9.1)
2a.
All complete joint penetration groove welds made by short circuiting transfer gas metal
arc welding (see Appendix D) shall be qualified by the welding procedure qualification tests
prescribed in 5.2. (2.9.1.1)
15.1.2 Dimensional Tolerances
Dimensions of groove welds specified on design or detailed drawings may vary from the
dimensions shown in Figure 2.9.1 only within the following limits. (2.9.2)
3a. The specified thickness of base metal or weld effective throat is the maximum
nominal thickness that may be used. (2.9.2.1)
3b. The groove angle is minimum; it may be detailed to exceed the dimensions shown by
no more than-10 degrees. (2.9.2-2)
3c. The radius of J-grooves and U-grooves is minimum. It may be detailed to exceed the
dimensions shown by no more than 1/8 in. U-grooves may be prepared before or
after fitup. (2.9.2.3)
3d. Double-groove welds may have grooves of unequal depth, but the depth of the
shallower groove shall be no less than 1/4 of the thickness of the thinner part joined,
unless otherwise designated in Figure 2.9.1. (2.9.2.4)
3e. The root face of the joint shall be as dimensioned in Figure 2.9.1 with the following
variations permitted:
(1)
For SMAW, GKAW, or FCAW it may be detailed to exceed the specified dimension
by no more than 1/16 in. It may not be detailed less than the specified dimension.
(2)
For submerged arc welding the specified root face of the joint is-maximum. (2.9.2.5)
3f. The root opening of the joints is minimum. It may be detailed to exceed the specified
dimension by no more than 1/16 in., except that the root opening of closed joints for
submerged arc welding shall be detailed as zero (no variation). (2.9.2.6)
3g. Groove preparations detailed for prequalified shielded metal arc welded joints may be
used for prequalified gas metal arc or flux cored arc welding. (2.9.3)
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Welding Inspection Handbook
15-1
Section 15
Prequalified Welded Joints AWS D1.1
15.1.3 Corner Joints
For corner joints the outside groove preparation may be in either or both members, provided the
basic groove configuration is not changed and adequate edge distance is maintained to support the
welding operations without excessive melting. (2.9.4)
15.1.4 Base Metal (8.2 and 10.2)
Steel base metal to be welded to the requirements of AWS D1.1 shall conform to the
requirements of the latest edition of one of the specifications listed in 8.2 and 10.2 of the
AWS D1.1 Code. Combinations of any of the steel base metals specified in each section may
be welded together. (8.2.1 and 10.2.1)
15.1.5 Notes
The following Notes apply to the prequalified complete joint penetration groove welds. These
Notes only apply as indicated and are in the far right column for each welding process and joint
designation applicable to each illustration.
Note “A”
Not prequalified for gas metal arc welding using short circuiting transfer.
Refer to Appendix D.
Note “Br”
Bridge application limits the use of these joints to the horizontal position
(see 9.12.1.5).
Note “C”
Gouge root to sound metal before welding other side.
Note “D”
Welds must be centered on joint.
Note “J”
If fillet welds are used in building to reinforce groove welds in corner and
T-joints, they shall be equal to 1/4 T but need not exceed 3/8 in. Groove
welds in corner and T-joints of bridges shall be reinforced with fillet welds
equal to 1/4 T, but not more than 3/8 in.
Note “K”
Weld root after welding at least one pass on arrow side.
Note “M”
Double-groove welds may have grooves of unequal depth; but the depth
of the shallower groove shall be no less than one-fourth of the thickness of
the thinner part joined.
Note “N”
The orientation of the two members in the joints may vary from 135 deg
to 180 deg provided that the basic joint configuration (groove angle, root
face, root opening) remain the same and that the design throat thickness if
maintained.
Note “P”
Weld S2 first with gas metal arc (spray transfer), flux cored arc, or
shielded metal arc with low hydrogen electrodes. The root of this weld
shall be back gouged. Weld Sl with single- or multiple-pass submerged
arc welding in flat position after welding is complete on the other side.
Note “V”
For corner joints, the outside groove preparation may be in either or both
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Welding Inspection Handbook
15-2
Section 15
Prequalified Welded Joints AWS D1.1
members, provided the basic groove configuration is not change and
adequate edge distance is maintained to support the welding operations
without excessive edge melting.
Note “X”
It is permissible for the groove opening to vary from 0 - 1/8 in., in which
case, weld as follows: Seal weld the Sl groove first with shielded metal
arc using low hydrogen electrodes and completing the weld with
submerged arc welding. The root of the seal weld shall be back-gouged.
Weld the S2 groove with shielded metal arc using low hydrogen electrode
or by submerged arc welding.
Note “Y”
Shielded metal arc, submerged arc, gas metal arc (spray transfer), or flux
cored arc backing fillet weld required.
Note “Z”
When lower plate is beveled, make the first root pass on this side.
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Welding Inspection Handbook
15-3
Section 15
Prequalified Welded Joints AWS D1.1
Complete Joint Penetration Groove Weld Tables
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Welding Inspection Handbook
15-4
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-5
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-6
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-7
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-8
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-9
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-10
Section 15
15.2
Prequalified Welded Joints AWS D1.1
PARTIAL JOINT PENETRATION GROOVE WELDS (2.10)
15.2.1 General
Partial joint penetration groove welds made by shielded metal arc welding, submerged arc
welding, gas metal arc welding (except short circuiting transfer), or flux cored arc welding in butt,
corner, and T-joints which may be used without performing the joint welding procedure
qualification tests prescribed in 5.2 are detailed in Figure 2.10.1 and are subject to the limitations
specified in 2.10.2. (2.10.1)
15.2.2 Definition
Except as provided in 10.13.1.1, groove welds without steel backing, welded from one side, and
groove welds welded from both sides but without back gouging are considered partial joint
penetration groove welds. (2.10.1.1)
3a. All partial joint penetration groove welds made by short circuiting transfer gas metal
arc welding (see Appendix D) shall be qualified by the joint welding procedure
qualification test prescribed in 5.2. (2.10.1.1)
15.2.3 Dimensional Tolerances
Dimensions of groove welds specified on design or detailed drawings may vary from the
dimensions shown in Figure 2.10.1 only within the following limits: (2.10.2)
4a. The groove angle is minimum; it may be detailed to exceed the dimensions shown by
no more than 10 degrees.
4b. The radius of the J-grooves and U-grooves is minimum. It may be detailed to exceed
the dimensions shown by no more than 1/8 in. U-grooves may be prepared before or
after fit-up.
4c. Double-groove welds may have grooves of unequal depth, providing the weld
deposit on each side of the joint conforms to the limitations of Figure 2.10.1.
4d. The minimum root face of the joints shall be 1/8 in., except that the minimum root
face for joints to be welded by submerged arc welding shall be 1/4 in.
4e. The root opening of joints is minimum. It may be detailed to exceed the specified
dimensions by no more than 1/16 in., except that the root opening of closed joints for
submerged arc welding shall be detailed as 0 (no variation).
4f. The effective throat of partial joint penetration square-, single- or double-V, bevel-,
J-, and U-groove welds shall be as shown in Table 2.10.3. Section 4, page 4-2 of this
handbook.
4g. Shop or working drawings shall specify the groove depths (S) applicable for the
effective throat (E) required for the welding process and position of welding to be
used.
4h. Groove preparations detailed for prequalified shielded metal arc welded joints may be
used for prequalified gas metal arc or flux cored arc welding.
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Welding Inspection Handbook
15-11
Section 15
Prequalified Welded Joints AWS D1.1
15.2.4 Corner Joints
For corner joints, the outside groove preparation may be in either or both members, provided the
basic groove configuration is not changed and adequate edge distance is maintained to support the
welding operations without excessive melting. (2.10.5)
15.2.5 Base Metal (8.2 and 10.2)
For base metal requirements, refer to 15.1.1.
15.2.6 Notes
The following Notes apply to the prequalified complete joint penetration groove welds. These
Notes only apply as indicated and are in the far right column for each welding process and joint
designation applicable to each illustration.
Note “A”
Not prequalified for gas metal arc welding using short circuiting transfer.
Refer to Appendix D.
Note “B”
Joints welded from one side. These welds are not applicable to bridges.
Note “C”
Gouge root to sound metal before welding other side.
Note “C2”
Root need not be gouged before welding second side. This weld is not
applicable to bridges.
Note “E”
Minimum effective throat (E) as shown in Table 2.10.3; S as specified on
drawings.
Note “J”
If fillet welds are used in building to reinforce groove welds in corner and
T-joints, they shall be equal to 1/4 T but need not exceed 3/8 in. Groove
welds in corner and T-joints of bridges shall be reinforced with fillet welds
equal to 1/4 T but not more than 3/8 in.
Note “L”
Butt and T-joints are not prequalified for bridges.
Note “M”
Double-groove welds may have grooves of unequal depth, but the depth
of the shallower groove shall be no less than one-fourth of the thickness
of the thinner part joined.
Note “Mp”
Double-groove welds may have grooves of unequal depth, provided they
conform to the limitations of Note E. Also, the effective throat (E), less
any reduction, applies individually to each groove.
Note “V”
For corner joints, the outside groove preparation may be in either or both
members, provided the basic groove configuration is not changed and
adequate edge distance is maintained to support the welding operations
without excessive edge melting.
Note “W”
Unbeveled face is the lower edge for horizontal position.
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Welding Inspection Handbook
15-12
Section 15
Prequalified Welded Joints AWS D1.1
Partial Joint Penetration Groove Weld Tables
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Welding Inspection Handbook
15-13
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-14
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-15
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-16
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-17
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-18
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-19
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-20
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-21
Section 15
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Prequalified Welded Joints AWS D1.1
Welding Inspection Handbook
15-22
Section 16
Fillet Welds in Skewed Members
16.1
AWS D1.1 .................................................................................................
16-1
16.1.1
Prequalified Fillet Welds.............................................................................
16-1
16.1.2
Parts of a Fillet...........................................................................................
16-1
16.2
ASME III AND ASME/ANSI B31.1 .........................................................
16-2
16.2.1
Fillet Welds................................................................................................
16-2
16.3
GENERAL ................................................................................................
16-2
16.3.1
Measurement of Skewed Fillets ..................................................................
16-2
Table 1 (Obtuse Angle Relationships).........................................................
16-3
Table 2A (Acute Angle Relationships)........................................................
16-4
Table 2B (Acute Angle Relationships -continued).......................................
16-5
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Section 16
16.1
16.1.1
Fillet Welds in Skewed Members
AWS D1.1
Prequalified Fillet Welds
Fillet welds may be used in members having a dihedral angle not less than 60 degrees (acute side), nor more than
135 degrees (obtuse side), as shown below.
*Note: For AWS D1.1, fillet welds may be used in skewed members having dihedral angles less
than 60 degrees and greater than 135 degrees. However, they must be qualified by
procedure qualification. See AWS D1.1.
16.1.2
Parts of a Fillet
Note:
For relationships between L, W, te and Angle (0), see Tables 1, 2A, and 2B of this
section.
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Section 16
16.2
16.2.1
Fillet Welds in Skewed Members
ASME III AND ASME/ANSI B31.1
Fillet Welds
There are no dihedral angle restrictions for fillet welds in skewed members.
16.3
16.3.1
GENERAL
Measurement of Skewed Fillets
For measurements of skewed fillet welds, refer to Section 3, “Use of Inspection Gages,” page 3-11.
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Welding Inspection Handbook
16-2
Section 16
Fillet Welds in Skewed Members
Table 1
Obtuse Angle Relationships
θ
te
.088
.132
.177
.221
.265
.440
.354
95
L
W
3/16
3/16
1/4
1/4
5/16
5/16
3/8
3/8
7/16
7/16
1/2
1/2
9/16
9/16
100
L
W
3/16
3/16
1/4
1/4
5/16
5/16
3/8
3/8
7/16
7/16
9/16
9/16
9/16
9/16
105
L
W
3/16
3/16
1/4
1/4
5/16
5/16
3/8
3/8
7/16
7/16
9/16
9/16
5/8
5/8
110
L
W
3/16
3/16
1/4
1/4
5/16
5/16
7/16
7/16
1/2
1/2
5/8
5/8
5/8
5/8
115
L
W
3/16
3/16
1/4
1/4
3/8
3/8
7/16
7/16
1/2
1/2
5/8
5/8
11/16
5/8
120
L
W
3/16
3/16
5/16
5/16
3/8
3/8
1/2
7/16
9/16
1/2
11/16
5/8
3/4
11/16
125
L
W
1/4
1/4
5/16
5/16
7/16
3/8
1/2
7/16
5/8
9/16
3/4
5/8
13/16
11/16
130
L
W
1/4
1/4
5/16
1/4
7/16
3/8
9/16
7/16
11/16
9/16
13/16
5/8
7/8
11/16
135
L
W
1/4
3/16
3/8
5/16
1/2
3/8
5/8
1/2
3/4
9/16
7/8
5/8
15/16
11/16
140
L
W
5/16
1/4
7/16
5/16
9/16
3/8
145
L
W
5/16
3/16
1/2
5/16
5/8
3/8
150
L
W
3/8
3/16
9/16
5/16
11/16
3/8
Note:
.398
.442
.486
.530
.575
.619
.663
.707
See paragraph 16.1.2 for definitions of L, te, W, and Angle (θ).
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16-3
Section 16
Fillet Welds in Skewed Members
Table 2A
Acute Angle Relationships
θ
te
30
.221
.265
.440
.354
.398
.442
.486
.530
.575
.619
L
W
1/4
1/8
5/16
3/16
3/8
3/16
3/8
3/16
7/16
1/4
1/2
1/4
9/16
5/16
9/16
5/16
5/8
5/16
11/16
3/8
35
L
W
1/4
3/16
5/16
3/16
3/8
1/4
3/8
1/4
7/16
5/16
1/2
5/16
9/16
3/8
9/16
3/8
5/8
3/8
11/16
7/16
40
L
W
1/4
3/16
5/16
1/4
3/8
1/4
7/16
5/16
7/16
5/16
1/2
3/8
9/16
3/8
5/8
7/16
5/8
7/16
11/16
1/2
45
L
W
1/4
3/16
5/16
1/4
3/8
5/16
7/16
5/16
7/16
5/16
1/2
3/8
9/16
7/16
5/8
1/2
5/8
1/2
11/16
1/2
50
L
W
3/16
3/16
1/4
1/4
1/4
5/16
1/4
3/8
5/16
7/16
3/8
1/2
7/16
1/2
7/16
9/16
7/16
5/8
1/2
11/16
9/16
11/16
9/16
55
L
W
3/16
3/16
1/4
1/4
1/4
1/4
5/16
5/16
3/8
5/16
7/16
3/8
1/2
7/16
1/2
7/16
9/16
1/2
5/8
9/16
11/16
5/8
3/4
5/8
60
L
W
3/16
3/16
1/4
1/4
5/16
1/4
5/16
5/16
7/16
7/16
7/16
7/16
1/2
7/16
9/16
1/2
9/16
1/2
5/8
9/16
11/16
5/8
3/4
11/16
65
L
W
1/8
1/8
3/16
3/16
1/4
1/4
5/16
5/16
3/8
3/8
7/16
7/16
7/16
7/16
1/2
1/2
9/16
9/16
5/8
5/8
11/16
5/8
11/16
5/8
3/4
11/16
70
L
W
1/8
1/8
3/16
3/16
1/4
1/4
5/16
5/16
3/8
3/8
7/16
7/16
7/16
7/16
1/2
1/2
9/16
1/2
5/8
5/8
11/16
11/16
3/4
3/4
13/16
13/16
75
L
W
1/8
1/8
3/16
3/16
1/4
1/4
5/16
5/16
3/8
3/8
7/16
7/16
1/2
7/16
9/16
1/2
9/16
9/16
5/8
5/8
11/16
11/16
3/4
3/4
13/16
13/16
80
L
W
1/8
1/8
3/16
3/16
1/4
1/4
5/16
5/16
3/8
3/8
7/16
7/16
1/2
1/2
9/16
9/16
5/8
5/8
11/16
11/16
3/4
3/4
13/16
13/16
13/16
13/16
85
L
W
1/8
1/8
3/16
3/16
1/4
1/4
5/16
5/16
3/8
3/8
1/2
1/2
1/2
1/2
9/16
9/16
5/8
5/8
11/16
11/16
3/4
3/4
13/16
13/16
7/8
7/8
Note:
.088
.132
.177
See paragraph 16.1.2 for definitions of L, te, W, and Angle (θ).
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16-4
Section 16
Fillet Welds in Skewed Members
Table 2B
Acute Angle Relationships (Cont’d)
θ
te
.663
.707
.750
.795
.839
.884
.928
.972
1.017
1.061
1.105
1.149
30
L
W
11/16
3/8
3/4
3/8
13/16
7/16
7/8
7/16
7/8
7/16
15/16
1/2
1
1/2
1-1/16
9/16
1-1/16
9/16
1-1/8
9/16
1-3/16
5/8
1-1/4
5/8
35
L
W
3/4
7/16
3/4
7/16
13/16
1/2
7/8
9/16
15/16
9/16
15/16
9/16
1
5/8
1-1/16
5/8
1-1/16
11/16
1-1/16
11/16
1-3/16
11/16
1-1/4
3/4
40
L
W
3/4
1/2
13/16
9/16
13/16
9/16
7/8
9/16
15/16
5/8
1
11/16
1
11/16
1-1/16
11/16
1-1/8
3/4
1-3/16
13/16
1-3/16
13/16
1-1/4
13/16
45
L
W
3/4
9/16
13/16
5/8
13/16
5/8
7/8
5/8
15/16
11/16
1
3/4
1-1/16
13/16
1-1/6
13/16
1-1/8
13/16
1-3/16
7/8
1-1/4
15/16
1-1/4
15/16
50
L
W
3/4
5/8
13/16
5/8
7/8
11/16
15/16
3/4
15/16
3/4
1
13/16
1-1/16
13/16
1-1/8
7/8
1-1/8
7/8
1-3/16
15/16
1-1/4
1
1-5/16
1-1/16
55
L
W
3/4
5/8
13/16
11/16
7/8
3/4
15/16
13/16
1
7/8
1
7/8
1-3/16
7/8
1-1/8
16/16
1-3/16
1
1-1/4
1-1/16
1-1/4
1-1/16
1-5/16
1-1/16
60
L
W
13/16
3/4
7/8
13/16
7/8
13/16
15/16
13/16
1
7/8
1-1/16
15/16
1-1/8
1
1-1/8
1
1-3/16
1-1/16
1-1/4
1-1/8
1-5/16
1-6/16
1-3/8
1-1/4
65
L
W
13/16
3/4
7/8
13/16
15/16
15/16
1
15/16
1
15/16
1-1/16
1
1-1/8
1-1/16
1-3/16
1-1/8
1-1/4
1-3/16
1-5/16
1-1/4
1-5/16
1-1/4
1-3/8
1-1/4
70
L
W
13/16
13/16
7/8
7/8
15/16
15/16
1
1
1-1/16
1
1-1/8
1-1/16
1-3/16
1-1/8
1-3/16
1-3/16
1-1/4
1-3/16
1-5/16
1-1/4
1-3/8
1-5/16
1-7/16
1-3/8
75
L
W
7/8
13/16
15/16
7/8
1
1
1-1/16
1
1-1/16
1-1/16
1-1/8
1-1/8
1-3/16
1-1/8
1-1/4
1-1/4
1-5/16
1-5/16
1-3/8
1-3/8
1-7/16
1-7/16
1-1/2
1-1/2
80
L
W
7/8
7/8
15/16
15/16
1
1
1-1/16
1-1/16
1-1/8
1-1/8
1-3/16
1-3/16
1-1/4
1-1/4
1-5/16
1-5/16
1-3/8
1-3/8
1-7/16
1-7/16
1-1/2
1-1/2
1-1/2
1-1/2
85
L
W
15/16
15/16
1
1
1-1/16
1-1/16
1-1/8
1-1/8
1-3/16
1-3/16
1-1/4
1-1/4
1-5/16
1-5/16
1-3/8
1-3/8
1-7/16
1-7/16
1-1/2
1-1/2
1-1/2
1-1/2
1-9/16
1-9/16
Note:
See paragraph 16.1.2 for definitions of L, te, W, and Angle (θ).
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Section 17
Procedure/Welder Qualification AWS D1.1
Page
17.1
PROCEDURE QUALIFICATION.............................................................
17-1
17.1.1
Summary of Essential Variables..................................................................
17-1
Table 4.5
PQR Essential Variable Changes Requiring
WPS Requalification for SMAW, SAW, GMAW,
FCAW, and GTAW ............................................................
17-1
17.2
WELDER QUALIFICATION....................................................................
17-4
17.2.1
Limitations of Variables (4.22) ...................................................................
17-4
Table 4.10
Welding Personnel Essential Variable Changes
Requiring Requalification ....................................................
17-4
Table 4.11
Electrode Classification Groups...........................................
17-4
Table 4.8
Welder Qualification–Production Welding Positions
Qualified by Plate, Pipe, and Box Tube Tests ......................
17-5
Welder and Welding Operator Qualification–Number
and Type of Specimens and Range of Thickness and
Diameter Qualified (Dimensions in Inches) ..........................
17.6
Table 4.9
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Section 17
17.1
17.1.1
Procedure/Welder Qualification AWS D1.1
PROCEDURE QUALIFICATION
Summary of Essential Variables
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Section 17
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Welding Inspection Handbook
17-2
Section 17
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Welding Inspection Handbook
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Section 17
17.2
17.2.1
Procedure/Welder Qualification AWS D1.1
WELDER QUALIFICATION
Limitations of Variables (4.22)
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Section 17
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Welding Inspection Handbook
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Section 17
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Welding Inspection Handbook
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Section 17
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Welding Inspection Handbook
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Section 18
Procedure/Welder Qualification (ASME/ANSI)
Page
18.1
PROCEDURE QUALIFICATION.............................................................
18-1
18.2
WELDER QUALIFICATION....................................................................
18-1
Position Limitations – QW-461.9 ...............................................................
18-2
Bend Tests – QW-452.2.............................................................................
18-4
Thickness Limits – QW-452.1 ....................................................................
18-4
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Section 18
18.1
Procedure/Welder Qualification (ASME/ANSI)
PROCEDURE QUALIFICATION
18.1.1 WELDING PROCEDURE SPECIFICATION
Each manufacturer or contractor shall prepare written Welding Procedure Specifications, which
are defined as follows:
(a) Welding Procedure Specification (WPS). A WPS is a written qualified welding
procedure prepared to provide direction for making production welds to Code
requirements. The WPS or other documents [see (e) below] may used to provide
direction to the welder or welding operator to assure compliance with the Code
requirements.
(b) Contents of the WPS. The completed WPS shall describe all of the essential,
nonessential, and when required, supplementary essential variables for each welding
process used in the WPS. These variables are listed in QW-250 through QW-280
and are defined in Article IV, Welding Data.
The WPS shall reference the supporting Procedure Qualification Record(s) (PQR)
described in QW-200.2. The manufacturer or contractor may include any other
information in the WPS that may be helpful in making a Code weldment.
(c) Changes to the WPS. Changes maybe made in the nonessential variables of a WPS to
suit production requirements without requalification provided such changes are
documented with respect to the essential, nonessential, and when required,
supplementary essential variables for each process. This may be by amendment to the
WPS or by the use of a new WPS.
Changes in the essential or supplementary essential (when required) variables require
requalification of the WPS (new or additional PQRs to support the change in
essential or supplementary essential variables).
(d) Format of the WPS. The information required to be in the WPS may be in any
format, written or tabular, to fill the needs of each manufacturer or contractor, as
long as every essential, nonessential, and, when required, supplementary essential
variables outlined in QW-250 through QW-280 is included or referenced.
Form QW-282 (se Nonmandatory Appendix B) has been provided as guide for the
WPS. This Form includes the required data for the SMAW, SAW, GMAW, and
GTAW processes. It is only a guide and does not list all required data for other
processes. It also lists some variables that do not apply to all processes (e.g., listing
shielding gas which is not required for SAW). This guide does not easily lend itself
to multiple process procedure specification (e.g., GTAW root with SMAW fill).
(e) Availability of the WPS. A WPS used for Code production welding shall be available
for reference and review by the Authorized Inspector (AI) at the fabrication site.
(QW-200.1)
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Welding Inspection Handbook
18-1
Section 18
Procedure/Welder Qualification (ASME/ANSI)
18.1.2 PROCEDURE QUALIFICATION RECORD
Each manufacturer or contractor shall be required to prepare a procedure qualification record,
which is defined as follows:
(a) 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 the variables recorded during the
welding of test coupons. It also contains the test results of the tested coupons.
Recorded variable normally fall within a small range of the actual variables that will
be used in production welding.
(b) Contents of the PQR. The completed PQR shall document all essential and, when
required, supplementary essential variables of QW-250 through QW-280 for each
welding process used during the welding of the test coupon. Nonessential or other
variables used during the welding of the test coupon may be recorded at the
manufacturer’s or contractor’s option. All variables, if recorded, shall be the actual
variables (including ranges) used during the welding of the test coupon. If the
variables are not monitored during welding, they shall not be recorded. It is not
intended that the full range or the extreme range of the variable to be used in
production be used during qualification unless required due to a specific essential or,
when required, supplementary essential variable.
The PQR shall be certified accurate by the manufacturer or contractor. The
manufacturer or contractor may not subcontract the certification function. The
certification is intended to be the manufacturer’s or contractor’s verification that the
information in the PQR is a true record of the variables that were used during the
welding of the test coupon and that the resulting tensile, bend, or macro (as required)
test results are in compliance with Section IX.
When more than one welding process or filler metal is used to weld a test coupon,
the approximate deposit weld metal thickness of each welding process and filler metal
shall be recorded.
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Welding Inspection Handbook
18-2
Section 18
Procedure/Welder Qualification (ASME/ANSI)
(c) Changes in the PQR. Changes to the PQR are not permitted except as described
below. It is a record of what happened during a particular welding test. Editorial
corrections or addenda to the PQR are permitted. An example of an editorial
correction is an incorrect P-Number, F-Number, or A-Number that was assigned to a
particular base metal or filler metal. An example of an addendum would be a change
resulting from a Code change. For example, Section IX may assign a new F-Number
to a filler metal or adopt a new filler metal under an established F-Number. This may
permit, depending on the particular construction Code requirements, a manufacturer
or contractor to use other filler metals that fall within that particular F-Number
where, prior to the Code revision, the manufacturer or contractor was limited to the
particular electrode classification that was used during qualification. Additional
information can be incorporated can be incorporated into a PQR at a later date
provided that the information is substantiated as having been part of the original
qualification condition by lab record or similar data.
All changes to a PQR require recertification (including date) by the manufacturer or
contractor.
(d) Format of the PQR. Form QW-483 (see Nonmandatory Appendix B) has been
provided as a guide for the PQR. The information required to be in the PQR may be
in any format to fit the needs of each manufacturer or contractor, as long as every
essential variable and, when required, supplementary essential variable, required by
QW-250 through QW-280, is included. Also the type of tests, number of tests, and
test results shall be listed in the PQR.
The Form QW-483 guide does not easily lend itself to cover combinations of welding
processes or more than one F-Number filler metal in one coupon. Additional
sketches may be attached or referenced to record the required variables.
(e) Availability of the PQR. PQRs used to support WPSs shall be available, upon
request, for review by the Authorized Inspector (AI). The PQR need not be available
to the welder or welding operator.
(f) Multiple WPSs With One PQR/Multiple PQRs With One WPS. Several WPSs may
be prepared from the data on a single PQR (e.g., a 1G plate PQR may support WPSs
for the F, V, H, and O positions on plate or pipe within all other essential variables).
A single WPS may cover several essential variable changes as long as a supporting
PQR exists for each essential variable and, when required supplementary essential
variable (e.g., a single WPS may cover a thickness range from 1/16 in. through 11/4
in., if PQRs exist for both the 1/16 in. through 3/16 in. and 3/16 in. through 11/4 in.
thickness ranges). (QW-200.2)
18.2
WELDER QUALIFICATION
The requirements for ASME Section IX, Performance Qualification, are equally as complex as
Procedure Qualification requirements. However, to aid the user of this handbook in reviewing
welder qualification, the following charts and/or tables have been selected. They do not comprise
all the requirements of ASME Section IX, concerning Welder Qualification.
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Welding Inspection Handbook
18-3
Section 18
Procedure/Welder Qualification (ASME/ANSI)
QW-461.9
PERFORMANCE QUALIFICATION - POSITION LIMITATIONS
(Within the-Other Limitations of QW-303)
Weld
Qualification Test
Position
Plate -- Groove
1G
2G
F
F
[Note (2)]
F, H [Note (2)]
3G
F, V
F
[Note (2)]
F, H, V
4G
F, O
F
[Note (2)]
F, H, O
3G and 4G
F, V, O
F
[Note (2)]
All
2G, 3G, and 4G
All
F, H [Note (2)]
All
SP, F
SP, F
SP, F
F
[Note (2)]
2F
F, H
[Note (2)]
3F
F, H, V [Note (2)]
4F
F, H, O [Note (2)]
All
Special Positions (SP)
SP, F
[Note (2)]
[Note (2)]
1G
F
F
F
2G
F, H
F, H
F, H
5G
F, V, O
F, V, O
All
6G
All
All
All
2G and 5G
All
All
All
SP, F
SP, F
SP, F
Special Positions (SP)
Pipe -- Fillet [Note
(3)]
F, H
IF
3F and 4F
Pipe -- Groove
F
F, H
Special Positions (SP)
Plate -- Fillet
Position and Type Weld Qualified [Note (1)]
Groove
Fillet
Plate and Pipe
Over 24 in. O. D.
Pipe
Plate and Pipe
IF
F
2F
F, H
2FR
F, H
4F
F, H, O
5F
All
Special Positions (SP)
SP, F
Notes:
(1) Positions of welding as shown in QW-461.1 and QW-461.2.
F = Flat
V = Vertical
H.= Horizontal
O = Overhead
(2) Pipe 2-7/8 in O. D. and over.
(3) See diameter restrictions in QW-452.3, QW-452.4, and QW-452.6.
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Welding Inspection Handbook
18-4
Section 18
Procedure/Welder Qualification (ASME/ANSI)
QW-452.2
LONGITUDINAL BEND TESTS
Thickness
Test Coupon
Welded, in.
[Note (1)]
Groove
Groove
Type of Joint
Thickness t of Deposited Weld Metal
Qualified, in.
Type and Number of Tests
Required
(Guided Bend Tests)
[Note (2)]
Max.
Face Bend
[Note (3)]
QW-462.3(b)
Root Bend
[Note (3)]
QW-462.3(b)
Up to 3/8 incl.
2t
1
1
Over 3/8
2t
1
1
Notes:
(1) When using one, two, or more welders, the thickness t of the deposited weld metal for each welder with each
process shall be determined and used individually in the “Thickness” column.
(2) Thickness of test coupon of 3/4 in. or over shall be used for qualifying a combination of three or more welders,
each of which may use the same or different welding process.
(3) Face and root bend tests may be used to qualify a combination test of:
(a) one welder using two welding processes; or
(b) two welders using the same or a different welding process.
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Welding Inspection Handbook
18-5
Section 18
Procedure/Welder Qualification (ASME/ANSI)
QW-452
PERFORMANCE QUALIFICATION THICKNESS LIMITS AND TEST SPECIMENS
QW-452.1
TRANSVERSE BEND TESTS
Type of
Joint
Thickness of
Test Coupon
Welded, in.
[Note (1)]
Thickness t of
Deposited Weld Metal
Qualified, in.
[Note (2)
(see QW-310.1)
Max.
Type and Number of Tests Required
(Guided-Bend Tests)
[Notes (3), (4), (8)
Side Bend
Face Bend
Root Bend
[Note (5)]
QW-462.2 (a)
QW-462.3 (a)
QW-462.3 (a)
Groove
Up to 3/8 incl.
2t
Note (6)
1
1
Groove
Over 3/8 but less than 3/4
2t
Note (7)
1
1
Groove
3/4 and over
Max. to be welded
2
–
–
Notes:
(1) When using one, two, or more welders, the thickness t of the deposited weld metal for each welder with each
process shall be determined and used individually in the “Thickness” column.
(2) Two or more pipe test coupons of different thickness may be used to determine the deposited weld metal
thickness qualified and that thickness may be applied to production welds to the smallest diameter for which
the welder is qualified in accordance with QW-452.3.
(3) Thickness of test coupon of 3/4 in. or over shall be used for qualifying a combination of three or more welders,
each of which may use the same or a different welding process.
(4) To qualify for positions 5G and 6G, as prescribed in QW-302.3, two root and two face-bend specimens or four
side bend specimens, as applicable to the test coupon thickness are required..
(5) Face- and root-bend tests may be used to qualify a combination test of:
(a) one welder using two welding processes; or
(b) two welders using the same or a different welding process.
(6) For a 3/8 in. thick coupon, two side bend tests may be substituted for the required face- and root-bend tests.
(7) A side bend test may be substituted for each of the required face- and root-bend tests.
(8) Test coupons shall be visually examined per QW-302.4
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Welding Inspection Handbook
18-6
Section 19
Charts and Tables
Page
Table 19-1
Commercial Pipe Sizes and Wall Thicknesses .......................................
19-1
Table 19-2
Decimal Equivalents of Fractions..........................................................
19-2
Table 19-3
Hardness Conversion Numbers.............................................................
19-3
Table 19-4
Melting Points of Metals.......................................................................
19-4
Table 19-5
Thermal Expansion Data ......................................................................
19-5
Table 19-6(a)
Electrode Classification ........................................................................
19-6
Table 19-6(b)
Electrode Classification ........................................................................
19-7
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Welding Inspection Handbook
19-0
Section 19
Charts and Tables
Table 19-1
Commercial Pipe Sizes and Wall Thicknesses
m:\temporary\welding inspection\chapter19.doc
Welding Inspection Handbook
19-1
Section 19
Charts and Tables
Table 19-2
Decimal Equivalents of Fractions
Inches
Decimal of an Inch
Inches
Decimal of an Inch
1/64
1/32
3/64
1/20
1/16
1/13
5/64
1/12
1/11
3/32
1/10
7/64
1/9
1/8
9/64
1/7
5/32
1/6
11/64
3/16
1/5
13/64
7/32
15/64
1/4
17/64
9/32
19/64
5/16
21/64
1/3
11/32
23/64
3/8
25/64
13/32
27/64
0.015625
0.03125
0.046875
0.05
0.0625
0.0769
0.078125
0.0833
0.0909
0.09375
0.10
0.109375
0.111
0.125
0.140625
0.1429
0.15625
0.1667
0.171875
0.1875
0.2
0.203125
0.21875
0.234375
0.25
0.265625
0.28125
0.296875
0.3125
0.328125
0.333
0.34375
0.359375
0.375
0.390625
0.40625
0.421875
7/16
29/64
15/32
31/64
1/2
33/64
17/32
35/64
9/16
37/64
19/32
39/64
5/8
41/64
21/32
43/64
11/16
45/64
23/32
47/64
3/4
49/64
25/32
51/64
13/16
53/64
27/32
55/64
7/8
57/64
29/32
59/64
15/16
61/64
31/32
63/64
1
0.4375
0.453125
0.46875
0.484375
0.5
0.515625
0.53125
0.546875
0.5625
0.578125
0.59375
0.609375
0.625
0.640625
0.65625
0.671875
0.6875
0.703125
0.71875
0.734375
0.75
0.765625
0.78125
0.796875
0.8125
0.828125
0.84375
0.859375
0.875
0.890625
0.90625
0.921875
0.9375
0.953125
0.96875
0.984375
1.0
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Welding Inspection Handbook
19-2
Section 19
Charts and Tables
Table 19-3
Hardness Conversion Numbers
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Welding Inspection Handbook
19-3
Section 19
Charts and Tables
Table 19-4
Melting Points of Metals
Melting points of some metals and other temperatures of interest.
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Welding Inspection Handbook
19-4
Section 19
m:\temporary\welding inspection\chapter19.doc
Charts and Tables
Welding Inspection Handbook
19-5
Section 19
Charts and Tables
Table 19-6(a)
Electrode Classification
E60 Series – Minimum Tensile Strength of Deposited Metal in the As-Welded Condition
60,000 psi or Higher [see Table 19.6(b)]
AWS
Classification
Type of Covering
Capable of Producing
Satisfactory Welds in
Positions Shown*
Type of Current**
E6010
High cellulose, sodium
F, V, OH, H
dc, reverse polarity
E6011
High cellulose, potassium
F, V, OH, H
ac, or dc reverse polarity
E6012
High titania, sodium
F, V, OH, H
ac, or dc straight polarity
E6013
High titania, potassium
F, V, OH, H
ac, or dc either polarity
E6020
High iron-oxide
H-Fillets
ac, or dc straight polarity
F
ac, or dc either polarity
H-Fillets
ac, or dc straight polarity
F
ac, or dc either polarity
E6027
Iron powder, iron oxide
*The abbreviations F, V, OH, H, and H-Fillets indicate welding positions (Figures 1 and 2) as follows:
F
= Flat
H
= Horizontal
H-Fillets = Horizontal Fillets
OH
= Overhead
V
= Vertical
**Reverse polarity means electrode is positive; straight polarity means electrode is negative.
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Welding Inspection Handbook
19-6
Section 19
Charts and Tables
Table 19-6(b)
Electrode Classification
E70 Series – Minimum Tensile Strength of Deposited Metal in the As-Welded Condition
70,000 psi or Higher
AWS
Classification
Type of Covering
Capable of Producing
Satisfactory Welds in
Positions Shown*
Type of Current**
E7014
Iron powder, titania
F, V, OH, H
ac, or dc either polarity
E7015
Low hydrogen, sodium
F, V, OH, H
dc, reverse polarity
E7016
Low hydrogen, potassium
F, V, OH, H
ac, or dc reverse polarity
E7018
Iron powder, low hydrogen
F, V, OH, H
ac, or dc reverse polarity
E7024
Iron powder, titania
H-Fillets, F
ac, or dc either polarity
E7028
Iron powder, low hydrogen
H-Fillets, F
ac, or dc reverse polarity
*The abbreviations F, V, OH, H, and H-Fillets indicate welding positions (Figures 1 and 2) as follows:
F
= Flat
H
= Horizontal
H-Fillets = Horizontal Fillets
OH
= Overhead
V
= Vertical
**Reverse polarity means electrode is positive; straight polarity means electrode is negative.
m:\temporary\welding inspection\chapter19.doc
Welding Inspection Handbook
19-7
Section 20
Terms and Definitions
The terms and definitions used in this handbook are taken from AWS-A3.0-80. This was done as a convenience
only, and the authors assume no liability for any inaccuracy in these notations. Terms and definitions contained
herein taken from other codes or documents will be so indicated at the end of each notation, if not taken from
AWS.
A
acceptable weld
A weld that meets all the requirements and the acceptance criteria
prescribed by the welding specifications.
actual throat
See “throat of a fillet weld.”
arc strike
A discontinuity consisting of any localized remelted metal, heataffected metal, or change in the surface profile of any part of a weld
or base metal resulting from an arc.
as-welded
The condition of weld metal, welded joints, and weldments after
welding but prior to any subsequent thermal, mechanical, or
chemical treatments.
axis of a weld
A line through the length of a weld, perpendicular to and at the
geometric center of its cross section.
backhand welding
A welding technique in which the welding torch or gun is directed
opposite to the progress of welding. Sometimes referred to as the it
pull gun technique” in GMAW and FCAW.
backing
A material (base metal, weld metal, carbon, or granular material)
placed at the root of a weld joint for the purpose of supporting
molten weld metal.
backing bead
See preferred term “backing weld.”
backing ring
Backing in the form of a ring, generally used in the welding of
piping.
backing-split pipe
See “Split pipe backing.”
backing strap
See preferred term “backing strip.”
backing strip
Backing in the form of a strip.
backing weld
Backing in the form of a weld.
backstep sequence
A longitudinal sequence in which the weld bead increments are
deposited in the direction opposite to the progress of welding the
joint.
backup
(flash and upset welding)
A locator used to transmit all or a portion of the upsetting force to
the workpieces or to aid in preventing the workpieces from slipping
during upsetting.
B
m:\temporary\welding inspection\chapter20.doc
Welding Inspection Handbook
20-1
Section 20
Terms and Definitions
back weld
A weld deposited at the back of a single groove weld.
bare electrode
A filler metal electrode consisting of a single metal or alloy that
has been produced into a wire, strip, or bar form and that has had
no coating or covering applied to it other than that which was
incidental to its manufacture or preservation.
base material
The material to be welded, brazed, soldered, or cut. See also
“base metal” and “substrate.”
base metal
The metal to be welded, brazed, soldered, ,or cut. The use of this
term implies that materials other than metals are also referred to,
where this is appropriate. See also “base material” and “substrate.”
bead
See preferred term “weld bead.”
bead weld
See preferred term “surfacing weld.”
boxing
The continuation of a fillet weld around a corner of a member as an
extension of the principal weld.
chain intermittent welds
Intermittent welds on both sides of a joint in which the weld
increments on one side are approximately opposite those on the other
side.
complete fusion
Fusion which has occurred over the entire base material surfaces
intended for welding and between all layers and weld beads.
complete joint penetration
Joint penetration in which the weld metal completely fills the groove
and is fused to the base metal throughout its total thickness.
complete penetration
See preferred term “complete joint penetration.”
concave fillet weld
A fillet weld having a concave face.
concave root surface
A root surface which is concave.
concavity
The maximum distance from the face of a concave fillet weld
perpendicular to a line joining the toes.
continuous weld
A weld which extends continuously from one end of a joint to the
other. Where the joint is essentially circular, it extends completely
around the joint.
convex fillet weld
A fillet weld having a convex face.
convexity
The maximum distance from the face of a convex fillet weld
perpendicular to a line joining the toes.
crack
A fracture type discontinuity characterized by a sharp tip and
high ratio of length and width to opening displacement.
crater
In arc welding, a depression at the termination of a weld bead or in
the molten weld pool.
C
m:\temporary\welding inspection\chapter20.doc
Welding Inspection Handbook
20-2
Section 20
Terms and Definitions
crater crack
A crack in the crater of a weld bead.
defect
A discontinuity or discontinuities which by nature or
accumulated effect (for example, total crack length) render a
part or product unable to meet minimum applicable acceptance
standards or specifications. This term designates rejectability.
See “discontinuity” and “flaw.”
defective weld
A weld containing one or more defects.
depth of fusion
The distance that fusion extends into the base metal or previous pass
from the surface melted during welding.
discontinuity
An interruption of the typical structure of a weldment, such as a
lack of homogeneity in the mechanical, metallurgical, or physical
characteristics of the material or weldment. A discontinuity is not
necessarily a defect. See “defect,” “flaw.”
edge joint
A joint between the edges of two or more parallel or nearly parallel
members.
effective length of weld
The length of weld throughout which the correctly proportioned
cross section exists. In a curved weld, it shall be measured along the
axis of the weld.
effective throat
The minimum distance from the root of a weld to its face less any
reinforcement.
end return
See preferred term “boxing.”
face of weld
The exposed surface of a weld on the side from which welding was
done.
face reinforcement
Reinforcement of weld at the side of the joint from which welding
was done. See also “root reinforcement.”
faying surface
That mating surface of a member which is in contact or in close
proximity to another member to which it is to be joined.
fillet weld
A weld of approximately triangular cross section joining two
surfaces approximately at right angles to each other in a lap joint,
T-joint, or corner joint.
full fillet weld
A fillet weld whose size is equal to the thickness of the thinner
member joined.
D
E
F
m:\temporary\welding inspection\chapter20.doc
Welding Inspection Handbook
20-3
Section 20
Terms and Definitions
fusion
The melting together of filler metal and base metal (substrate), or of
base metal only, which results in coalescence. See “depth of fusion.”
inadequate joint penetration
Joint penetration which is less than that specified.
incomplete fusion
Fusion which is less than complete.
intermittent weld
A weld in which the continuity is broken by recurring unwelded
spaces.
joint design
The joint geometry together with the required dimensions of the
welded joint.
joint penetration
The minimum depth a groove or flange weld extends from its face
into a joint, exclusive of reinforcement. Joint penetration may
include root penetration. See also “complete joint penetration,”
“root penetration,” and “effective throat.”
kerf
The width of the cut produced during a cutting process.
lack of fusion
See preferred term “incomplete fusion.”
lap joint
A joint between two overlapping members.
overlap
The protrusion of weld metal beyond the toe, face, or root of the
weld; in resistance seam welding, the area in the preceding weld
remelted by the succeeding weld.
plug weld
A circular weld made through a hole in one member of a lap or Tjoint fusing that member to the other. The walls of the hole may or
may not be parallel and the hole may be partially or completely filled
with weld metal. (A fillet welded hole or a spot weld should not be
construed as conforming to this definition.)
porosity
Cavity type discontinuities formed by gas entrapment during
solidification.
I
J
K
L
O
P
m:\temporary\welding inspection\chapter20.doc
Welding Inspection Handbook
20-4
Section 20
Terms and Definitions
procedure
The detailed elements (with prescribed values or ranges of values)
of a process or method used to produce a specific result.
procedure qualification
The demonstration that welds made by a specific procedure can meet
prescribed standards.
procedure qualification
record (PQR)
A document providing the actual welding variables used to produce
an acceptable test weld and the results of tests conducted on the weld
for the purpose of qualifying a welding procedure specification.
random intermittent welds
Intermittent welds on one or both sides of a joint in which the
weld increments are deposited without regard to spacing.
reinforcement of weld
Weld metal in excess of the quantity required to fill a joint. See
“face reinforcement” and “root reinforcement.”
root crack
A crack in the weld or heat-affected zone occurring at the root of a
weld.
root of weld
The points, as shown in cross section, at which the back of the weld
intersects the base metal surfaces.
seal weld
Any weld designed primarily to provide a specific degree of
tightness against leakage.
R
S
size of weld
groove weld
The joint penetration (depth of bevel plus the root penetration when
specified). The size of a groove weld and its effective throat are one
and the same.
fillet weld
For equal leg fillet welds, the leg lengths of the largest isosceles
right triangle which can be inscribed within the fillet weld cross
section.
For unequal leg fillet welds, the leg lengths of the largest right
triangle which can be inscribed within the fillet weld cross section.
Note:
stud welding
m:\temporary\welding inspection\chapter20.doc
When one member makes an angle with the other member
greater than 105 degrees, the leg length (size) is of less
significance than the effective throat which is the
controlling factor for the strength of a weld.
A general term for the joining of a metal stud or similar part to a
workpiece. Welding may be accomplished by arc, resistance,
friction, or other suitable process with or without external gas
shielding.
Welding Inspection Handbook
20-5
Section 20
Terms and Definitions
T
throat of a fillet weld
theoretical throat
The distance from the beginning of the joint perpendicular to the
hypotenuse of the largest right triangle that can be inscribed within
the fillet weld cross section. This dimension is based on the
assumption that the root opening is equal to zero.
actual throat
The shortest distance from the root of weld to its face.
effective throat
The minimum distance minus any reinforcement from the root of
weld to its face.
T-joint
A joint between two members located approximately at right angles
to each other in the form of a T.
toe of weld
The junction between the face of a weld and the base metal.
underbead crack
A crack in the heat-affected zone generally not extending to the
surface of the base metal.
undercut
A groove melted into the base metal adjacent to the toe or root of a
weld and left unfilled by weld metal.
underfill
A depression on the face of the weld or root surface extending below
the surface of the adjacent base metal.
U
W
weld
A localized coalescence of metals or nonmetals produced either by
heating the materials to suitable temperatures, with or without the
application of pressure or by the application of pressure alone and
with or without the use of filler material.
welder
One who performs a manual or semiautomatic welding operation.
(Sometimes erroneously used to denote a welding machine.)
welder performance qualification
The demonstration of a welder’s ability to produce welds meeting
prescribed standards.
welder certification
Certification in writing that a welder has produced welds meeting
prescribed standards.
weld gage
A device designed for checking the shape and size of welds.
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Welding Inspection Handbook
20-6