THIS SHEET IS ONLY A PLACE HOLDER.
PLEASE REPLACE IT WITH
THE SWRMC COVER SHEET.
-1[Revised November 26, 2012]
PROCESS CONTROL PROCEDURE FOR
CG-47 CLASS SUPERSTRUCTURE CRACK REPAIR
(INCLUDING SHIPALTS)
TABLE OF CONTENTS
SECTION
1.1
1.2
1.3
1.4
2.1
2.2
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
3.21
3.22
3.23
3.24
3.25
3.26
3.27
3.28
3.29
4.1
5.1
PAGE
SCOPE.…………………………………………………………………........
PURPOSE…………………………………………………………..….........
REFERENCES……………………………………………………..….…….
ENCLOSURES………………………………………………………...........
QUALIFICATION REQUIREMENTS………………………………….......
DIRECT KNOWLEDGE….…………………………………………..……..
MATERIAL/EQUIPMENT………………………………….………..……...
SAFETY EQUIPMENT……………..………………………………..……...
SAFETY PRECAUTIONS…………..………………………………………
PREPARATION…….…..………………...…………………….…………...
START OF PROCEDURE………………………………………………….
ENVIRONMENTAL CONTROL…….…………………..………................
JOINT PREPARATION………..…..………………………………...………
JOINT DESIGN AND FITUP REQUIREMENTS…………..………..…….
CRACK REPAIR METHODS…………………………………………........
WELDING EQUIPMENT AND SUPPLIES ……….………………...…….
WELDING REQUIREMENTS……………….….……….……….………….
PREHEATING AND INTERPASS TEMPERATURE…………………......
DISTORTION CONTROL/WELD BALANCING………………………......
TACK WELDS………………………………………………………………...
BUTT WELDS AND JOINTS………………………………………………..
BUTT JOINTS WELDED FROM ONE SIDE………………………………
BUTT JOINTS WELDED FROM BOTH SIDES…………………………..
BIMETALLIC STRIP…………………………………………………………
CRITICAL ATTACHMENT (FILLET) WELDS…………………………….
SURFACE FINISHING OF WELDS……………………………………….
WELD NDT INSPECTION REQUIREMENTS……………………………
IN-PROCESS NDT INSPECTION…………………………………………
FINAL ACCEPTANCE NDT INSPECTION……………………………….
INSPECTION ACCEPTANCE CRITERIA………………………………...
REPAIR OF WELD DEFECTS……………………………………………..
IDENTIFICATION OF DEFECT AREAS…………………………………..
INSPECTION/DOCUMENTATION FORMS………………………………
OBJECTIVE QUALITY EVIDENCE………………………………………..
CONTROL OF THE PROCEDURE………………………………………..
HAZARDOUS MATERIAL……………………………………………………
LOCAL REGIONAL AND STATE REQUIREMENTS……………………..
-2[Revised November 26, 2012]
4
4
4
5
5
5
6
6
6
7
7
8
8
9
10
10
11
12
12
13
13
13
14
14
14
15
16
16
17
18
18
18
19
19
19
19
20
TABLE OF CONTENTS (CONTINUED)
APPENDICES
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
PAGE
PCP Direct Knowledge Attendance Form……………………………….
Weld Technique Sheet……………………………...……………….…….
Weld In-Process Control/NDT Record …………………………………..
Weld Defect Repair Record ………………………………………………
Acceptable Groove/Fillet Weld Profiles……………………………….....
Definition of Critical/Non-Critical Fillet Welds……………………………
Cleanliness Record……………………….………………………………..
Shielding Gas Dew Point Record…………………………………………
Preheat/Interpass Temperature Record………………………………….
ShipAlt Accountability Record……………………………………………..
-3[Revised November 26, 2012]
21
22
23
24
25
26
27
28
29
30
1 SECTION 1 IDENTIFICATION
1.1
SCOPE
1.1.1 This procedure applies to critical welds as defined by References (h) for the
repair of Aluminum Superstructure Cracking. This procedure meets the specific
requirements of paragraphs 5-9.6 thru 5-9.6.2 of Reference (g) Technical
Manual for CG-47 Class Superstructure Cracking Repair S9CGO-BP-SRM010/CG-47 CL. This procedure furthermore meets the requirements of
References (a) through (h) and Enclosure (1).
1.1.2 While the scope of Reference (g) is for the repair of CG-47 class superstructure
cracking it may also be invoked for Ship Alterations installed to reinforce CG-47
class superstructure and preclude further cracking. When this PCP is used in
way of accomplishing Ship Alterations (S/A), the requirements of the S/A apply
and not the Crack Repair Methods identified in Section 3.9.
NOTE:
Process Control Procedures (PCPs) are SWRMC Code 200 approved documents for contractor
execution of a specific repair item. PCPs are to be followed as written. However there may be
circumstances where the PCP needs to be revised to meet field conditions. Revisions that in the
opinion of the SWRMC Onsite Rep and the SWRMC Code 200 signatory are minor and do not
degrade the overall performance of the process, require contract modifications, or significantly
alter the scope of the work may be made onsite by the SWRMC Onsite Rep with concurrence of
the SWRMC Code 200 PCP signatory. Changes will be noted with name, time, date and
signature of SWRMC Code 200/Onsite Rep making the change on the KTR's copy of the PCP
as pen-and-ink changes. The KTR will submit a formal revision to SWRMCENG.PCP@navy.mil
(SWRMC PCP Inbox) within 3 working days of the pen-and-ink change. The PCP revision policy
is stated in SWRMC SOP-225-002
1.2
PURPOSE
1.2.1 The purpose of this procedure is to correct and/or minimize fatigue cracking that
has occurred in the aluminum superstructure of the CG 47 Class ships. In order
to achieve satisfactory performance, high quality welding is imperative. The goal
is to obtain welds which contain no rejectable defects while minimizing weld
repair cycles.
1.2.2 NOTE: Aluminum Plate and sheet material shall be procured to ASTM B928/B
928 M Standard Specification for High Magnesium Aluminum-Alloy Sheet and
Plate for Marine Service and Similar Environments and shall be procured,
inspected, handled and stored per paragraph 3.1, 3.2 and 3.3 respectively of
Reference (h).
1.3
REFERENCES
a)
NAVSEA Standard Items
b)
MIL-STD-1689A (SH) Fabrication, Welding, and Inspection of Ships structure
c)
MIL-STD-22D Welded Joint Design
d)
T9074-AS-GIB-010/271 Requirements for Nondestructive (NDT) Testing Methods
-4[Revised November 26, 2012]
1.4
e)
MIL-STD-2035A (SH) Nondestructive Testing Acceptance Criteria
f)
S9074-AQ-GIB-010/248 Requirements for Welding and Brazing Procedure and
Performance Qualification
g)
S9CGO-BP-SRM-010/CG-47 Class Superstructure Cracking Repair
h)
SERMC DM 10-623 Rev B
ENCLOSURES
1
Work Item/ MOD
2
Welder Qualifications
3
NDT Inspector Qualifications
4
Joint Design
5
Location of Work (Sketches)
6
Weld sequencing and Fixturing Plan
7
Material Certification Index
8
Nondestructive Inspection Report
2 SECTION 2 PERSONNEL QUALIFICATION
2.1
QUALIFICATION REQUIREMENTS
2.1.1 Welders will be currently qualified in accordance with Reference (f). Welder
qualifications shall be identified in Enclosure (2). Additions to Enclosure 2 shall
be made by “Pen and Ink” and shall be initialed by the Welding Supervisor.
2.1.2 NDT Inspectors will be qualified in accordance with Reference (d). NDT
Inspector qualifications shall be identified in Enclosure (3). Additions to
Enclosure 3 shall be made by “Pen and Ink” and shall be initialed by the
appropriate NDT Level III Inspector (i.e. Inspec Testing will change Inspec
Testing; BAE will change BAE, etc.).
2.2
DIRECT KNOWLEDGE
2.2.1 A briefing will be conducted prior to beginning work to ensure personnel
accomplishing this procedure have direct knowledge of the requirements of this
procedure and the safety requirements of the job. Accomplishment of the
briefing will be documented on Appendix 1.
2.2.2 Method utilized to ensure complete knowledge of the job:
2.2.2.1 All personnel shall have a thorough knowledge of this procedure and
complete understanding of the system being worked, prior to starting
work.
2.2.2.2 All personnel shall have the ability to foresee and resolve potential
problem areas, and to complete the job in a timely yet efficient manner.
3
SECTION 3 PROCESS DESCRIPTION
-5-
[Revised November 26, 2012]
3.1
MATERIAL/EQUIPMENT
3.1.1 Fabrication Equipment: Welding Machine properly grounded per 009-12
(Welding, Fabrication, and Inspection Requirements; accomplish) of Reference
(a), Welding Leads, Torch, Stinger, Portable Rod Oven/Rod Pouch, Pre/Post
heat devices.
3.1.2 Welding equipment shall be of the specified type, in good repair, and properly
adjusted. The equipment shall correspond to the type used for qualification of the
weld procedure. For conventional GMAW, a constant voltage power source with
constant wire feed speed is recommended. A constant voltage power source
compensates for changes in arc length by varying the current, which affects the
heat input and varies weld penetration.
3.1.3 Consumables: Weld Rod/filler material, Shielding Gasses, Torch Gas
3.1.4 Temperature Measuring Devices suitable for aluminum (Preheat and Interpass),
digital thermometer, dewpoint indicator, all with current calibration
3.1.5 Cleaning Tools: White cleaning cloth, Carbide burr, Stainless steel wire brush,
Aluminum oxide coated fiber wheels, and abrasive disks
3.1.6 Cleaning solvent: Denatured alcohol, Acetone, isopropyl alcohol or Met-L-Chek
E-59A
3.1.7 Only manually operated, electric drive, or rear exhausted pneumatic tools shall
be used for cleaning
3.1.8 Temporary enclosure materials
3.1.9 General Hand Tools as Required
3.2
SAFETY EQUIPMENT
3.2.1 Ventilation (as required by Marine Chemist Certification)
3.2.2 Respiratory Protection: (When required)
3.2.3 Safety Clothing (PPE)
3.2.4 Welding Hood with Flash Burn Protection
3.2.5 Eye Protection
3.2.6 Gloves/long sleeve shirt (recommended)
3.2.7 Proper fire extinguishing agent
3.2.8 Fire Protection Covering
3.3
SAFETY PRECAUTIONS
3.3.1 Accomplish the requirements of NSSI 009-07, (Confined Space Entry,
Certification, Fire Prevention and Housekeeping; accomplish) Reference (a).
-6[Revised November 26, 2012]
WARNING: To prevent build up of fumes, sufficient time shall be given for
evaporation and ventilation of any solvent used for cleaning prior to hot
work.
3.3.2 When required, accomplish the requirements of NSSI 009-24 (Tag out, Isolation,
Blanking, and Tagging Requirements; accomplish) Reference (a). Work
authorization (WAF) shall be obtained.
3.3.3 When required, accomplish the requirements of 009-112 of Reference (a). for
Radiographic Testing (RT), this shall include the submission of Attachment “A”
no later than 5 working days prior to the scheduled test date.
3.4
PREPARATION
3.4.1 Stage all required Materials for verification at the Start of Procedure Checkpoint.
3.5
START OF PROCEDURE
CHECKPOINT (I) (G) "START OF PROCEDURE"
3.5.1 Start of this procedure is a CHECKPOINT IAW Paragraph 3.4 of NAVSEA
Standard Item 009-09 Process Control Procedure (PCP) Reference (a). Notify
the QA office 4 hours prior to starting this procedure.
3.5.2 SWRMC.NDTCHECKPOINT@navy.mil shall be Included when notifying the
government of required NDT “G” Check Points.
3.5.3 Identification of material shall be visually verified at the point of initial fabrication
as being the same material identification or an approved alternate material
identification as required by the installation plan or work item in accordance with
paragraph 6.2.1 of Reference (b).
3.5.3.1 Aluminum plate, sheet metal and filler material shall be listed in Enclosure (7). All aluminum
plate and sheet metal shall conform to ASTM-B928/B928M in accordance with paragraph 3.1
of Reference (h), unless otherwise directed by NAVSEA or Code 200.
3.5.3.2 All filler material shall conform to AWS A5.10 with Schedule J lot conformance testing in
accordance with paragraph 3.1 of Reference (h).
3.5.3.3 Additions to Enclosure (7) will be made by “Pen and Ink” and signed by the Welding
Supervisor or Quality Assurance Inspector.
3.5.4 Paragraph 5-9.6.1 of Reference (h) requires written sign-off of Key Fabrication
Steps. Key Fabrication Step sign-offs will be accomplished as (I) or (I)(G)
checkpoints in accordance with NAVSEA Standard Item 009-04 of Reference
(a). The minimum Key Fabrication Steps required by Reference (h) are as
follows:
3.5.4.1 (I)(G) Section 3.6 Protective Enclosure Installation
3.5.4.2 (I)(G) Section 3.7 Joint Prep
3.5.4.3 (I)(G) Section 3.8 Fit-Up
3.5.4.4 (I) Section 3.22 5X Visual Inspection of Root Welds
3.5.4.5 (I) Section 3.22 5X Visual Inspection of Back Gouge (When Required)
3.5.4.6 (I) Section 3.22 5X Visual Inspection of the Final Weld Surface
3.5.4.7 (I)(G) Section 3.23 PT and UT of Final Weld Surface
-7[Revised November 26, 2012]
3.5.4.8 (I)(G) Sections 3.25 and 3.26 Any re-work/repair resulting from final NDT or after two weld
repair cycles of a completed weld as defined in MIL-STD-1689 are accomplished and
involves repair welding1
Note 1:
The contractor will be allowed two repair cycles to accomplish the weld prior to mandatory government oversight. If
the weld does not pass final NDT after two repair cycles, the remaining work shall be accomplished at the discretion of
NSA Code 200. If additional weld repair cycles are determined to be necessary, checkpoints 3.5.4.5 – 3.5.4.6 (and 3.5.4.7
as required) will become (I)(G) checkpoints through the completion of that specific weld sequence.
3.6
ENVIRONMENTAL CONTROL - Section 4.0 of Reference (h)
(I)(G) “Protective Enclosure Installation” (Key Fabrication Step Sign-Off
IAW Para. 3.5.4)
3.6.1 For welding in outside or exposed locations a taut or rigid, draft free protective
enclosure shall be erected around area to be welded in such a manner as to
ensure that shield gas will not be disturbed.
3.6.2 Enclosures shall provide adequate protection from the elements to prevent rain
or other precipitation from contaminating the weld with moisture and to provide a
still atmosphere (draft free) to ensure stability of the shield gas.
NOTE: High levels of moisture in the weld atmosphere are a major contributor to
porosity in the weld. Even momentary interruption of the shield gas will adversely
affect weld quality.
WARNING: To prevent build up of fumes, sufficient time shall be given for
evaporation and ventilation of any solvent used for cleaning prior to hot work.
3.6.3 Protection provided by the enclosure shall be such that a common paper match
will burn without interference. The match test shall be accomplished when
containment is erected and whenever the containment has been repaired due to
damage.
3.7
JOINT PREPARATION - Section 6 of Reference (h)
Note: It is noted that PT inspection requirements cited in Reference (h) shall not be
substituted with 5X VT inspections
(I)(G) “PT INSPECTION OF BASE METAL”
3.7.1 The surfaces to be welded and adjacent surfaces shall be inspected 100 percent
a minimum of 1/2 inch on both sides from the expected weld area using
penetrant inspection (PT) prior to fit-up and repair welding.
3.7.2 For pre-existing material in the exterior of the deckhouse and sensitized material
in the interior of the deckhouse, the 100 percent surface PT inspection shall be
expanded to the 4 inches from the weld joint.
-8[Revised November 26, 2012]
3.7.3 For pre-existing non-sensitized material in the interior of the deckhouse, a
minimum of 1/2 inch on both sides from the expected weld area shall be PT
inspected. The PT inspected surfaces shall be free of discontinuities such as
linear indications or defects that may affect weld quality or the condition of the
base material.
3.7.4 The purpose of the PT inspection is to ensure that weld repair is made to sound
base material. If discontinuities exist, a Condition Found Report (CFR) or similar
reporting document shall be submitted, which document recommendations
discussed between the contractor and the NSA. NSA Code 200 shall judge
severity of discontinuities and determine which defects shall be repaired prior to
fit-up and welding.
3.7.5 Once the above PT inspection is satisfactory, it shall be documented on
Enclosure (8).
3.7.6 The surfaces to be welded and adjacent surfaces, including faying surfaces of
attachment (fillet) welds, shall be thoroughly cleaned no less than a minimum of
4 inches on both sides from the expected weld area prior to fit-up and welding.
3.7.7 Surfaces shall be cleaned and solvent wiped with an approved ship board
solvent and shall have the oxide film removed to bright metal by an approved
mechanical or chemical means.
WARNING: To prevent build up of fumes, sufficient time shall be given for
evaporation and ventilation of any solvent used for cleaning prior to hot
work.
NOTE: Welding shall take place within six (6) hours after oxide film removal
or the joint surface is to be re-cleaned. Date and Time of Inspection shall be
documented on Appendix 7.
3.7.8 Solvent wipe to remove oil coating prior to use. Any items used for joint
preparation which become contaminated shall be discarded and removed from
the site.
3.7.9 Only manually operated, electric drive or rear exhaust pneumatic tools shall be
used for cleaning. Tools being used shall be of low R.P.M.’s. All Starts and stops
in the welding process shall be cleaned by approved mechanical means
immediately prior to welding.
NOTE: Experience has shown that contamination of the surface to be
welded is a major contributor to porosity and other critical weld defects.
Care in selection of materials, good work habits, and attention to detail are
essential to obtaining high quality welds and avoiding unnecessary and
detrimental re-work.
3.7.10 Interpass Cleaning. After each weld pass, the weld shall be manually brushed
with a clean stainless steel wire brush. Wire brushing after each pass removes
any residual soot that may have deposited on the weld bead and adjacent base
metal. Removing the soot will help prevent the formation of porosity and lack of
fusion in the subsequent weld passes.
-9[Revised November 26, 2012]
3.8
JOINT DESIGN AND FIT-UP REQUIREMENTS - Section 6.3 of Reference (h)
(I)(G) “Fit Up Inspection” (Key Fabrication Step Sign-Off IAW Para. 3.5.4)
3.8.1 Welded joint design and fit-up shall be in accordance with Reference (c) and the
following additional requirements:
3.8.1.1 When new plating is used to facilitate crack repairs, the new plate shall be
1/8” inch thicker than the existing plate per Section 4 of Reference (g).
3.8.1.2 Appendix 2 shall be documented to reflect the existing (A) and new (B)
plating thicknesses.
3.8.1.3 The edges of the thicker plate will be tapered to a four to one (4:1) slope
to conform to the thickness of the thinner plate.
Note: New plate 1/8 in. requirement is not applicable to SHIPALT’s. Work
accomplished by ShipALT’s shall be in accordance with NAVSEA design
drawings.
3.8.2 Weld joints and faying surfaces shall be prepared by sawing or routing using no
lubricants.
3.8.3 Alignment tolerances and maximum allowable deviation shall be in accordance
with the requirements of Reference (b) paragraph 12.3.1 and TABLE XIX.
3.8.4 Fairness shall be in accordance with the requirements of Reference (b).
3.8.5 Existing welds which are intersected by welds accomplished for this repair shall
be cutback and re-welded for a distance of six (6) inches from the weld
intersection.
3.9
CRACK REPAIR METHODS - Section 4-8 of Reference (g)
3.9.1 Temporary ceramic backing strips shall be used for crack and insert repairs if
feasible. Use of ceramic backing strips has historically resulted in improved weld
quality and cost savings through reduced NDT.
3.9.2 Table 1 below identifies typical crack repair methods which are found in
Reference (g). Check the box of the applicable method(s) and add a copy of
the applicable repair process paragraph(s) (including figure(s)) to this Process
Control Procedure as part of Enclosure (4). The Paragraphs and Figures
identifying repairs not part of the scope of work this PCP shall be left out when
submitting for approval. NDT shall be accomplished in accordance with
Paragraphs 3.21 thru 3.24 of this PCP.
- 10 [Revised November 26, 2012]
TABLE 1
Para.
No.
Typical Crack Repair Methods
4-8.1
4-8.2
4-8.3
4-8.4
4-8.5
4-8.6
4-8.7
4-8.8
4-8.9
4-8.10
4-8.11
Applicable
to this PCP
Base Metal Repair
Repair of Cracks in a Flat Plate
Repair of Crack in a Flat Plate That Extends Across a Structural
Member
Repair of a Crack by a Plate Insert That Does Not Cross a
Structural Member
Repair of a Crack by a Plate Insert Which Crosses a Structural
Member
Repair of a Cracked Tee Beam to Plate Weld
Repair of a Cracked and Tripped Tee Beam Frame
Repair of Cracked Welds Intersection of Bulkhead with
Deck/Bulkhead
Repair of Cracks Around Structural Openings (Hatchways,
Doors, Arches, Ventilation Cuts, Etc.)
Repair of Mast Leg Bracing Member
Repair of Damaged Mast Foundation Structure
Repair of Structural Damaged Fashion Plates
3.10
WELDING EQUIPMENT AND SUPPLIES - Section 5-8 of Reference (g), Section 7 of
Reference (h)
3.10.1 Gas tungsten arc welding (GTAW) may be used for installation of pipe that is less
than or equal to 2 inches in diameter and to repair isolated defects no more than
6 inches in length when there is no other rejectable area in the weld for a
distance of not less than 24 inches in either direction measured along the weld
axis in accordance with Reference (g).
NOTE: An isolated defect is a single rejectable area less than six inches in length
such that there is no other rejectable area in the weld for a distance of not less
than 24 inches in either direction when measured along the weld axis.
3.10.2 Shielding gases shall be checked and verified for acceptable dew point prior to
welding. Any traces of air or moisture in the shielding gas will affect weld quality.
3.10.3 The gas delivery system and/or welding equipment shall be checked for leaks to
avoid contaminating the shielding gas. Non-rubber hoses shall be used.
3.10.4 Hoses shall be a maximum of 100 feet in length and shall be limited to one midlength connection to minimize the distance between the gas bottle and work
area. Deviation from the maximum 100 foot inert gas hose requirement is
allowed with local NSA, C200 approval.
3.10.5 The shielding gas dew point shall be checked as follows in accordance with
Reference (h):
3.10.5.1 Shielding gas dew point shall be -40º F or less when measured at the
welding torch head.
- 11 [Revised November 26, 2012]
3.10.5.2 Shielding gas dew point shall be verified to be -40º F or less at the torch
3.10.5.3
3.10.5.4
3.10.5.5
3.10.5.6
3.10.5.7
head prior to commencing welding on any shift.
The welding apparatus shall be pre-purged with shielding gas for a
minimum of 10 seconds prior to welding. The rationale for this
requirement is that there has been a downward trend in porosity levels
since this requirement was employed.
The welding apparatus shall be purged and the shielding gas dew point
shall be verified to be -40º F or less at the torch head each time there is
a change in gas source or supply connection (e.g. gas bottle change or
hose connection to manifold change).
Inert gas shall be water pumped or liquid pumped, not oil pumped.
Quality Conformance Certification documentation shall be maintained for
procured shielding gas.
Shielding gas dew point readings shall be documented on Appendix 8.
3.11 WELDING REQUIREMENTS - Section 5-4 of Reference (g), Section 7.0 of Reference (h)
3.11.1 Aluminum Structural components shall be fabricated in accordance with the
workmanship requirements References (b), (g) and (h).
3.11.2 Appendix 2 shall be used to document weld procedure parameters and base /
filler material information.
3.11.3 Ship alterations (SHIPALT’s) shall be indentified on Appendix 10 and weld joints
documented on Appendix 3.
3.11.4 Cracks repaired by welding or by insert shall be identified on Enclosure (5) and
documented on Appendix 3.
3.11.5 All weld/NDT inspections shall be documented on Appendix 3 except that UT
inspection reports shall be provided by NDT Inspector on Enclosure (8).
3.11.6 All defect repairs shall be documented on Appendix 4.
3.11.7 Weld rework is time consuming, expensive and rapidly becomes
counterproductive to the basic intent of the repair. Repeated welding in a single
area enlarges the heat affected zone and adversely affects the base metal.
Satisfactory weld quality can be achieved with a minimum of rework if there is a
consistent high level emphasis on preparation, maintenance of cleanliness,
exclusion of moisture, enforcement of process control, and correct welding
techniques.
3.11.8 A primary requirement for quality aluminum welding is that the welding torch be
angled in the direction of the welding. Use of either a vertical or drag torch angle
inhibits the cleaning action of the welding arc. This in turn results in entrapment
of oxide and welding smut, leading to lack of fusion and porosity defects. A
welder can observe if proper cleaning is taking place by watching the edges of
the weld puddle.
- 12 [Revised November 26, 2012]
3.12 PRE-HEATING and INTERPASS TEMPERATURE
3.12.1 The welding surface shall be moisture free.
3.12.2 If required, preheating temperature shall be to a minimum of 60º F and maximum
of 150º F and shall not be applied for longer than 30 minutes.
3.12.3 In accordance with MIL-STD-1689, preheating of 5XXX series aluminum alloys
between 150º F to 450º F shall be avoided. Heating 5XXX series aluminum
alloys between 150º F and 450º F for a prolonged period of time can result in the
metal becoming sensitized and susceptible to stress corrosion cracking.
3.12.4 The maximum interpass temperature shall be 150º F. It is noted that 110º F
interpass temperature is considered optimal. A high interpass temperature can
result in slower cooling rates in the weld metal and heat affected zone (HAZ).
3.12.5 Temperature shall be checked by surface contact pyrometers or other
temperature measuring devices suitable for aluminum. Temperature indicating
crayons shall not be used. Document pre-heat and interpass temperature
readings on Appendix 9.
3.13 DISTORTION CONTROL / WELD BALANCING AND SEQUENCING
3.13.1 Structural fit-up methods and alignment procedures shall conform to 1689A for
guidance, and Chapter 4 through 5 of Reference (g); (Superstructure Cracking
Repair Manual) Joint designs requirements to Mil-STD-22D.
3.13.2 Temporary Fitting aids fixtures utilized to maintain proper fit-up shall consist of
strong backs, along with a series of dog and wedges to maintain proper fit-up
alignment and tolerances during welding and/or control contraction during
cooling.
3.13.3 After the fixtures are removed, the surface shall be flush with the adjacent metal
and shall be inspected with 100 % PT. The PT inspected surfaces shall be free of
discontinuities such as cracks and other rejectable defects as specified in
Section 3.23 and shall be documented on Enclosure (8).
3.13.4 The order of fit-up and adjustment will be determined as a condition of ship fitting
the adjacent surface.
3.13.5 Weld-out Balancing and Sequencing shall be accomplished in segments to
minimize distortion and residual stress through utilizing such methods as balance
welding around, (i.e., weld 2 or 3 inches, skip 3 or 4 inches and weld another 2 to
3 inches).
3.13.6 In addition, positioning welds near to the neutral axis of the weld structure, along
with utilizing weld sequencing or back step welding to minimize distortion. When
accomplishing the sequencing plan, weld sequence direction shall be maintained
as indicated on the enclosures.
NOTE: Surfaces shall be wiped down with clean solvent soaked rags
immediately prior to welding. All Starts and stops in the welding process
shall be cleaned by approved mechanical means immediately prior to
welding.
- 13 [Revised November 26, 2012]
WARNING: To prevent build up of fumes, sufficient time shall be given for
evaporation and ventilation of any solvent used for cleaning prior to hot
work.
3.14 TACK WELDS
3.14.1 Tack welds shall be made using qualified procedures and by qualified personnel
in accordance with Reference (f).
3.14.2 Tack welds may be incorporated into the final weld provided the tack welds are
visually inspected by 5X VT and defects such as cracks, excessive undercut,
entrapped slag, and excessive surface roughness shall be corrected to the extent
necessary to assure that the final weld quality requirements will be met.
3.14.3 For tack welds that are not incorporated into the final weld, the tack welds shall
be cleaned after tacking.
3.14.4 Prior to welding the final weld, tack welds shall be removed by grinding and the
surface area to be welded shall be cleaned as described in Section 3.7.
3.14.5 After removal of tack weld, the surface of the plating in way of the tack weld shall
be ground flush. The ground surface shall be inspected by 5X VT and shall be
free of surface discontinuities that may affect weld quality.
3.15 BUTT WELDS AND JOINTS
3.15.1 For butt welds, only full penetration, 100 percent efficient welds in accordance
with Reference (b) Table XVII and Reference (h) are acceptable.
3.16 BUTT JOINTS WELDED FROM ONE SIDE
3.16.1 Welding from one side is preferred.
3.16.2 New temporary ceramic backing strips should be used instead of temporary or
permanent aluminum backing strips.
3.16.3 Non-ceramic backing strips may be used only when the far (back) side of the
weld is inaccessible or with minor DFS approval.
3.16.4 Butt joints welded from one side shall comply with the following:
3.16.4.1 Surfaces shall be cleaned in accordance with Section 3.7.
3.16.4.2 Backing strips shall be installed just prior to welding. If six or more hours elapse between
installation of backing strips and start of welding, the backing strip shall be removed and the
surface cleaned again.
3.16.4.3 Weld the Root Pass.
3.16.4.4 Accomplish the NDT inspection of the Root Pass in accordance with Section 3.22, when
required repair defects and re-inspect until satisfactory.
3.16.4.5 Complete the welding of the Final Pass.
3.16.4.6 Remove temporary backing, clean, grind, and perform visual inspection of the back side.
When required Remove defects, repair, re-inspect until satisfactory.
3.16.4.7 Finish surface by contour grinding all welds in accordance with Section 3.20.
3.16.4.8 Perform visual inspection of surface, when required repair defects and re-inspect.
3.16.4.9 Perform final PT and RT/UT in accordance with Section 3.23. When required correct defects
- 14 [Revised November 26, 2012]
and re-inspect until satisfactory.
3.17 BUTT JOINTS WELDED FROM BOTH SIDES
3.17.1 Butt joints welded from two sides shall comply with the following:
3.17.1.1 Surfaces shall be cleaned in accordance with Section 3.7.
3.17.1.2 Weld the Root Pass.
3.17.1.3 Accomplish the Root Pass NDT in accordance with Section 3.22, repair defects and reinspect until satisfactory.
3.17.1.4 Complete the welding of the Final Pass.
3.17.1.5 Back gouge the Root Pass.
3.17.1.6 Accomplish the Back Gouge NDT in accordance with Section 3.22.
3.17.1.7 Remove all defects by back gouging prior to welding from the second side. Re-inspect to
verify defect removal with the inspection method that was utilized to identify the defect.
3.17.1.8 Weld the second side.
3.17.1.9 Finish surface by contour grinding all welds in accordance with Section 3.20.
3.17.1.10 Perform visual inspection of finished surfaces, repair defects and reinspect.
3.17.1.11 Perform final PT and RT/UT in accordance with Section 3.23. Correct
defects and re-inspect until satisfactory.
3.18 BIMETALLIC STRIP
3.18.1 Welds made to a bimetallic strip shall be done at an interpass temperature of
400°F degrees Fahrenheit or below.
3.18.2 Bimetallic butt welds above and below shall be staggered to minimize distortion.
3.19 CRITICAL ATTACHMENT (FILLET) WELDS
3.19.1 The following attachment (fillet) welds are designated as CRITICAL because the
deck house side toes of these welds which connect backup structure and
attachments to the house side are susceptible to fatigue cracking. The geometry
and the weld quality of these CRITICAL fillet welds must be controlled to
minimize the potential for fatigue cracking:
3.19.1.1 Welds joining the 02 or 03 levels with the deckhouse side or the fashion plates in way of the
deckhouse side transition.
3.19.1.2 Welds joining the deckhouse side stiffeners and secondary structural members (i.e.,
foundations, framing for false deck, etc.) to the deckhouse side in way of the deckhouse side
transition.
3.19.1.3 Welds joining transverse frames or transverse bulkheads to the deckhouse side only in the
transition area (necking down).
NOTE: These attachment welds shall receive the additional surface
finishing (contour grinding) in accordance with Section 3.20 and NDT
inspection in accordance with Section 3.22. Acceptance standards shall
meet the requirements of Reference (g) paragraphs 5-9.5.3 through 5-9.5.4.
- 15 [Revised November 26, 2012]
3.20 SURFACE FINISHING OF WELDS - Section 7.11 of Reference (h)
NOTE: Aluminum welds are prone to fatigue cracking at the weld toes due
to geometric discontinuities such as undercut and weld crown re-entry
angle. Proper welding techniques can produce the required weld toe
contour. In most cases, however, manual welding leads to some undercut
and/or non-smooth weld re-entry angle. In such cases contour grinding is
required to achieve the required weld toe contour.
3.20.1 Butt Welds
3.20.1.1 After welding and prior to performing final NDT, all butt welds which do not meet the weld toe
contour requirements identified on Appendix 6 (Acceptable Groove Weld Profiles In Butt
Joints sketch) shall be ground smooth and tapered gradually into the weld base metal.
3.20.1.2 The toes of welds shall have a smooth re-entry angle into the base plate of 180° degrees.
3.20.1.3 The contoured surface shall not reduce the thickness of the thinner base metal by more than
10% or 1/64” inch, whichever is less.
NOTE: When contour grinding is used the final grinding marks should be
perpendicular to the weld axis to maximize fatigue improvement. Grinding
is not required if an acceptable weld profile exists at the completion of
welding.
3.20.2 Critical Attachment (Fillet) Welds
3.20.2.1 After welding and prior to performing final NDT, the attached (fillet) welds identified as critical
(see paragraph 3.19 above) which do not meet the weld toe requirements of Appendix 6
shall have their toes contour ground to provide an acceptable contour for their full length and
to within 3 inches of any interfering attachment welds.
3.20.2.2 The contoured surface shall not reduce the thickness of the thinner base metal by more than
10% or 1/64” inch, whichever is less.
3.20.2.3 In no case shall the shorter leg of an attachment (fillet) weld be less than the minimum
thickness of the member being joined. The throat of the fillet welds shall not be reduced to a
size less than that required for the fillet leg size specified.
NOTE: Grinding of attachment (fillet) welds is not required if an
acceptable weld profile exists at the completion of welding.
3.20.2.4 In order to minimize the amount of grinding required and eliminate over-grinding of weld
throats, fillet welds may be initially welded so as to be non-symmetric about the weld root,
with the longer legs being on the continuous member as identified on Appendix 6 resulting in
only the critical weld and toe region requiring grinding.
3.21 WELD NDT INSPECTION REQUIREMENTS - Section 5-9 of Reference (g) and Section 8
Reference (h)
Note: It shall be noted that PT inspection requirements cited in this
document shall not be substituted with 5X VT inspections.
3.21.1 SWRMC.NDTCHECKPOINT@navy.mil shall be Included when notifying the
government of required NDT “G” Check Points.
- 16 [Revised November 26, 2012]
3.21.2 Visual inspection and nondestructive inspection of critical welds associated with
SHIPALT’s or repairs shall be performed in accordance with the requirements of
MIL-STD-1689, NAVSEA Technical Publication T9074-AS-GIB-010/271, and the
additional requirements below.
3.21.2.1 All acceptance criteria for nondestructive inspection shall be in accordance with MIL-STD2035A except for instances in which MIL-STD-1689 explicitly specifies acceptance criteria.
3.21.2.2 NDT shall be accomplished in accordance with this section, the requirements of Reference
(g), (d) and (h) and as indicated. All NDT inspections shall be documented on Appendix 3
and when applicable Enclosure (8).
3.21.2.3 All RT/UT inspection reports shall be included with the completed documentation of this PCP.
Acceptance standards shall be in accordance with the requirements of Reference (e).
3.21.2.4 Repair of defects found shall be documented on Appendix 4.
3.22 IN-PROCESS NDT INSPECTION: In-process inspection of welds shall be made using 5X VT.
The following in-process inspections shall be required in accordance with NAVSEA Technical
Manual S9CG0-BP-SRM-010/CG-47 CL. The inspection of non-critical attachment (fillet) welds
shall be in accordance with MIL-STD-1689.
3.22.1 Critical Butt Welds (Including Seam Welds)
(I) VISUAL INSPECTION OF ROOT WELDS (Key Fabrication Step Sign-Off
IAW Para. 3.5.4)
3.22.1.1 Inspect 100% of the weld side of the root pass & 100% of subsequent weld passes by 5X VT.
Document the inspection results on Appendix 3 and when applicable Enclosure (8).
3.22.1.2 If a temporary backing strip is utilized, after completion of welding and removal of the
temporary backing strips, grind the surface flush, and inspect 100 percent of the backside of
the weld by 5X VT.
3.22.1.3 When back-gouging is performed, 100 percent of the back-gouge side shall be inspected by
5X VT.
3.22.1.4 After completion of welding and prior to surface finishing (contour grinding), inspect 100
percent of the weld side by 5X VT.
3.22.2 Critical Attachment (Fillet) Welds
(I) VISUAL INSPECTION OF ROOT WELDS (Key Fabrication Step Sign-Off
IAW Para. 3.5.4)
3.22.2.1 Inspect 100 percent of the root pass by 5X VT shall be documented on Appendix 3 and
when applicable Enclosure (8).
3.22.2.2 Inspect 100 percent of the weld surface using 5X VT. The inspection shall be used to both
identify defects, if present, and to establish the necessity for surface finishing by contour
grinding in accordance with Section 7.11 of Reference (h).
3.22.2.3 Upon completion of contour grinding, where required, and prior to the final acceptance PT
inspection as described in Section 8.3 of Reference (h) conduct a 100 percent 5X VT
inspection of the ground surface. Where weld contours are satisfactory without surface
finishing, only one satisfactory 5X VT inspection shall be required.
NOTE: Wherever Radiography Inspection (RT) is required for Final NDT
Inspection, Ultrasonic Inspection (UT) may be substituted in accordance
with the requirements of Reference (g) paragraph 5-9.1.4.
- 17 [Revised November 26, 2012]
3.23 FINAL ACCEPTANCE NDT INSPECTION
3.23.1 The final acceptance inspection of welds shall be made in the final surface
condition after any surface modifications, grinding, or brushing is required to
meet final acceptance criteria. For butt welds and seams, both PT and UT shall
be required in accordance with Reference (g) and this document. Where PT
inspection is utilized, the weld shall be thoroughly cleaned with a solvent after
inspection in accordance with Reference (d). NDT Inspections shall be
documented on Appendix 3 and Enclosure (8).
3.23.2 Critical Butt Welds (Including Seam Welds)
(I) (G) NDT INSPECTION OF FINAL SURFACE (Key Fabrication Step SignOff IAW Para. 3.5.4)
3.23.2.1 Final PT inspection shall be perform on 100% of critical butt welds (including seam welds)
including a minimum of 4 inches on either side of the weld bead adjacent to pre-existing
material and ½ inch on either side of the weld bead adjacent to new material to ensure that
the entire HAZ is inspected. This inspection shall be identified and documented on
Appendix 3 and Enclosure (8).
3.23.2.2 Final UT shall be performed on 100% of the length of butt weld and seams. This inspection
shall be identified and documented on Appendix 3 and Enclosure (8).
3.23.3 Critical attachment (FILLET) Welds
(I) (G) NDT INSPECTION OF FINAL SURFACE (Key Fabrication Step SignOff IAW Para. 3.5.4)
3.23.3.1 For critical attachment (fillet) welds, both 5X VT and PT shall be required.
3.23.3.2 Final 5X VT shall be performed on 100 percent of the weld and toe region. 5X VT shall be
performed prior to final PT. All rejectable defects identified by 5X VT shall be corrected prior
to final PT.
3.23.3.3 Final PT shall be performed on 100 percent of the length of the fillet weld. This inspection
shall be identified and documented on Appendix 3 and Enclosure (8).
3.24 INSPECTION ACCEPTANCE CRITERIA
3.24.1 Acceptance criteria for 5X VT and PT shall be in accordance with MIL-STD2035A Reference (e), Class 3 and acceptance criteria for UT inspection shall be
in accordance with MIL-STD-2035A, Class 1 except as described below:
3.24.1.1 Butt welds (including seam welds) shall not be below the adjacent base material surface,
except for localized weld surface areas.
3.24.1.2 Welds and adjacent base material shall be free of arc strikes. Where arc strikes are removed,
the resulting cavities shall not exceed 1/64 inch in depth or 10% percent of the adjacent base
metal thickness, whichever is less, and shall be blended smoothly into the base metal (VT,
Class 1 requirement).
3.24.1.3 Butt welds (including seam welds) and critical attachment (fillet) welds and toe regions shall
have no allowable undercut, linear indications, or aligned porosity. Any porosity greater than
1/16 inch in diameter shall be rejectable.
3.24.1.4 Toes for all butt welds (including seam welds) shall have a smooth 180° degree re-entry
angle (VT, Class 1 requirement).
3.24.1.5 Toes for critical fillet (attachment) welds shall have a re-entry angle not less than 90° degrees
to the plating, which is continuous under the attachment.
- 18 [Revised November 26, 2012]
3.24.1.6 All welds and at a minimum of 4 inches of the adjacent pre-existing base material and ½ inch
of the new material shall be free of linear indications greater than 1/16 inch in length.
Indications 1/16 inch and less shall be considered non-linear.
3.24.1.7 Expansion UT of existing welds shall be evaluated in accordance with the original fabrication
acceptance criteria.
3.25 REPAIR OF WELD DEFECTS - Section 8 of Reference (h)
Note: The weld is considered completed when all weld material is deposited,
the weld has cooled to ambient temperature and is visually accepted
and is ready for other NDT inspection, this starts the repair cycle.
3.25.1 Repair of weld defects shall be documented on Appendix 4.
3.25.2 When Visual and NDT inspections accomplished require repair of weld defects,
no more than two (2) weld repair cycles shall be permitted. If satisfactory
inspections cannot be accomplished with two or fewer repair attempts, then the
requirements of Reference (h), paragraph 8.4.1 shall be accomplished.
NOTE: Where in-process or final Visual and NDT Inspections reveal
rejectable defects, the defect shall be completely removed by exploring to
ensure that the full extent of the defective weld is identified and removed
while, at the same time, removing only the minimum material necessary to
ensure satisfactory repair.
3.26 IDENTIFICATION OF DEFECT AREAS
3.26.1 Where in-process or final NDT inspection reveal rejectable defects, the defect
shall be completely removed by exploring to ensure that the full extent of the
defective weld is identified and removed while, at the same time, removing only
the minimum material satisfactory repair.
3.26.2 After repair of a defect identified by final PT or UT, the entire weld repair length
plus 6 inches on both sides along the length of the weld repair shall be reinspected by either PT or UT, which ever inspection method was utilized to
identify the defect.
3.26.3 Re-welding shall be limited to two times. If rejectable defects remain after two
repair cycles, report the conditions to the NSA via CFR for evaluation and
determination of further repair procedures.
(I)(G) NDT RE-INSPECTION OF REPAIRS (As Required) (Key Fabrication
Step Sign-Off IAW Para. 3.5.4)
3.26.4 Repairs shall be re-inspected in accordance with the requirements of Section
3.24. Repair of weld defects shall be documented on Appendix 4.
3.27 INSPECTION/DOCUMENTATION FORMS
3.27.1 This Process Control Procedure and Completed Appendices and Enclosures
3.27.2 NDT Reports
3.27.3 Checkpoint/Inspection Notification Forms (Contractor Provided)
3.27.4 Associated CFR’s, DFS and Waivers
- 19 [Revised November 26, 2012]
3.28 OBJECTIVE QUALITY EVIDENCE
3.28.1 This procedure along with the material certifications (new aluminum plate,
sheet metal and filler material only) and all completed documentation
(installations and inspections) forms comprise Objective Quality Evidence and
traceability of materials and components. This OQE is a formal contract
deliverable and shall be delivered to Quality Assurance for review and further
disposition, per paragraph 3.5 of 009-09 of Reference (a).
3.29 CONTROL OF PROCEDURE
3.29.1 A copy of the approved procedure shall be at the work site in the possession of
the project manager, foreman and/or lead man, during the performance of the
work.
4 SECTION 4 HAZARDOUS MATERIAL
4.1
HAZARDOUS MATERIALS
4.1.1 Hazardous material (HAZMAT):
4.1.1.1 Cleaning Solvent (Isopropyl Alcohol, Acetone)
4.1.2 Hazardous waste:
4.1.2.1 Solvent soaked rags
4.1.3 Hazardous waste disposal
4.1.3.1 All waste generated will be disposed in accordance with local, state and federal regulations.
4.1.3.2 Every effort will be made to limit the quantity of hazardous waste generated, i.e. the re-use of
wiping rags, etc.
5
5.1
SECTION 5 LOCAL, REGIONAL, AND STATE REQUIREMENTS
No local, regional or state regulations require controls to achieve the required technical results
of the work item.
- 20 [Revised November 26, 2012]
PCP DIRECT KNOWLEDGE ATTENDANCE FORM
Description of Briefing:
Ship / Hull:
Date:
PCP No:
Job #:
Item No:
Instructors; Please retain with completed PCP
No.
Attendee Name
(Print or type)
Dept #
Attendee Signature/Excused Absence
(Ink only)
Badge #
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Print Instructors Name (Company Name):
Instructor Signature:
APPENDIX 1
- 21 [Revised November 26, 2012]
WELD TECHNIQUE SHEET
SHIP:
SYSTEM/DESCRIPTION
HULL#
ITEM#
JOB#
PCP#
Weld Procedure(s)
Procedure #
Process
Thickness Range
Amps
Volts
Polarity
Shielding gas / flow rate
Purge gas / flow rate
Preheat / interpass temp
Joint #’s welded with this
procedure.
Joint designs applicable
to this procedure
Base Material
Component
Letter # / size
Class or type
Component A: (Existing Structure)
Component B: ( New material )
Component C:
Component D:
Component E:
Filler Material & Weld Procedure
Filler A:
Filler B:
COMMENTS: *Use Torch to Pre-heat base metal plate until warm to the touch.
APPENDIX 2
- 22 [Revised November 26, 2012]
Applicable Document
WELDING IN-PROCESS CONTROL/NONDESTRUCTIVE TEST RECORD (STRUCTURAL)
(TO DOCUMENT WELDING IN-PROCESS AND NDT INSPECTION RESULT)
1. Ship/Hull:
4. Brief Description (PCP Title):
2. Item/MOD #:
3. PCP #:
5. Job #:
6. Contract #:
REFERENCES: MIL-STD-1689A(SH), MIL-STD-22D, MIL-STD 2035 [Acceptance Class:  1  2  3 ]
7. JOINT INFORMATION
8. ROOT PASS
9. BACK GOUGE
10. FINAL PASS
Weld Identification (i.e. Joint I Number.)
Component (A)
Component (B)
Size or
Thickness
Size or
Thickness
Welder Name
Fit-Up
Joint [SAT]
Design [Un-Sat]
4/
Date Welded
NDT Inspector
Root
Insp
Acc /
Rej
Inspect Date
Back
Gouge
Insp
ACC
REJ
1/
NDT Inspector
Welder Name
Final
Insp 3/
Inspect Date
Date Welded
NDT Inspector
ACC
REJ
1/ 2/
Inspect Date
WELD IDENTIFICATION:
 SAT
 U/Sat
Init____
 VT
 VT5X  ACC
 PT
 REJ
 VT
 VT5X  ACC
 PT
 REJ
 VT
 VT5X  ACC
 PT
 REJ
 VT
 VT5X  ACC
 PT
 REJ
 VT
 VT5X  ACC
 PT
 REJ
 VT
 VT5X  ACC
 PT
 REJ
 VT
 VT5X  ACC
 PT
 REJ
 VT
 VT5X  ACC
 PT
 REJ
 VT
 PT
 UT
 ACC
 REJ
 VT
 PT
 UT
 ACC
 REJ
 VT
 PT
 UT
 ACC
 REJ
 VT
 PT
 UT
 ACC
 REJ
WELD IDENTIFICATION:
 SAT
 U/Sat
Init____
WELD IDENTIFICATION:
 SAT
 U/Sat
Init____
WELD IDENTIFICATION:
 SAT
 U/Sat
Init____
11. VT INSPECTION
12. PT TECHNIQUE
 VT5X
 DIMENSIONAL
PENETRANT TYPE II
MANUFACTURER
 MAGNAFLUX  OTHER:
PT INSPECTION PROCEDURE:
VT INSPECTION PROCEDURE:
13. SIGNATURE VALIDATION
WELDER NO. 1
WELDER NO. 2
WELDER NO. 3
PRINTED NAME
SIGNATURE
PRINTED NAME
SIGNATURE
NDT INSPECTOR NO. 1
NDT INSPECTOR NO. 2
NDT INSPECTOR NO. 3
NOTES: 1. REJECTED WELD JOINTS SHALL BE REPAIRED AND DOCUMENTED ON WELD DEFECT REPAIR FORM (APPENDIX 4).
2. THE INSPECTOR ACCEPTING WELDS CERTIFIES BY PERSONAL OBSERVATION THAT THE WELD FILLET SIZE IS SATISFACTORY AS APPLICABLE.
3. SEE RADIOGRAPHIC TEST (RT) OR ULTRASONIC TEST (UT) REPORT FOR INSPECTION RESULTS AS APPLICABLE.
4. THE PERSON INITIALING FOR THIS BLOCK IS ALSO SIGNING IN ACKNOWLEDGEMENT THAT THE MATERIAL HAS BEEN VERIFIED PER PARAGRAPH 3.6.3
OF THIS PCP.
APPENDIX 3
- 23 [Revised November 26, 2012]
WELD DEFECT REPAIR RECORD1
(TO DOCUMENT WELD JOINT REPAIR AS APPLICABLE)
3. ITEM#
1. SHIP:
2. HULL:
4. MOD#
9. DEFECT DESCRIPTION (CHECK ALL THAT APPLY)
CRACK
SLAG
POROSITY
UNDERCUT
INCOMP INSERT FUSION
CRATER PIT
INTERNAL CONCAVITY
INTERNAL CONVEXITY
OXIDATION
CENTERLINE CREASE
5. PCP#
6. CONTRACT#:
7. JOINT WELDED:
INCOMPLETE FUSION
BURN THRU
MELT THRU
TUNGSTEN
INCOMPLETE
PENETRATION
10. DEFECT LOCATION(S) AND EXTENT
SEE SKETCH IN REMARKS
ARC STRIKE
WELD SPLATTER
ROOT EDGE FUSION COND
LINEAR
LINEAR DISPOSED
11. INSPECTOR (SIGNATURE/DATE)
12. DEFECT REPAIR.
REPAIR CYCLES
13. TYPE OF REPAIR
GRIND ONLY
GRIND AND WELD
WELD ONLY
OTHER (SEE
REMARKS)
18. LAYER
T/R/I/F
ROUNDED
SHORT LEG SIZE
OTHER: (ENTER BELOW
14. REPAIR LOCATION(S)
AND EXTENT
SEE SKETCH IN REMARKS
19. FILLER
TYPE
15. WELD PROC AND
REV/CH
NA
SAME AS
ORIGINAL
20. PREHEAT/
INTERPASS TEMP
16. EXCAV NDT
REQUIRED
Y (MARK REQD
INSP BLK 23/24)
N
1
2
17. ROOT PASS INSP REQUIRED
Y (MARK REQD INSP
BLK 23/24)
N
21 WELDER (SIGNATURE/DATE)2
SAT
SAT
SAT
22. REPAIR NDT INSPECTIONS
REPAIR WELD REQUIRES THE SAME INSPECTIONS AS THE ORIGINAL WELD. (R) ROOT (I) INTERMEDIATE (F) FINAL (T) TACKS
23. INSPECTION
24 INSPECTION TYPE
25. PROCEDURE
26. INSPECTOR (SIGNATURE/DATE)
USED
EXCAV
5X
PT TYPE IIC
SAT
NA
REJ
ROOT
NA
VT
BACKGOUGE
NA
5X
VT ( I )
NA
5X
VT (F)
NA
VT
PT(F)
NA
RT(F)
NA
FILLET SIZE (F)
N/A
5X
SAT
REJ
SAT
REJ
SAT
REJ
SAT
REJ
5X
PT TYPE IIC
60O
360O
SAT
REJ
SAT
REJ
SAT
REJ
100%
27. REMARKS (SKETCHES)
NOTE: 1. USE ONE SHEET PER WELD JOINT.
2. WELDER’S SIGNATURE INDICATES THAT ALL WELD PARAMETERS OF APPENDIX 2 HAVE BEEN VERIFIED.
APPENDIX 4
- 24 -
[Revised November 26, 2012]
Acceptable Groove/Fillet Weld Profiles
Figure 1. Example of Unacceptable and Acceptable Butt Weld Profiles
APPENDIX 5
- 25 [Revised November 26, 2012]
Definition of Critical/Non-Critical Portions of Fillet Welds
Figure 2. Critical and Non-critical Weld and Toe Regions for Symmetric and
Non-symmetric Attachment (fillet) welds
APPENDIX 6
- 26 [Revised November 26, 2012]
Ship Hull:
PCP #:
Joint ID:
Item/Mod:
Job#:
Contract#:
CLEANLINESS RECORD (OXIDE REMOVAL)
DATE
TIME
LOCATION SAT/UNSAT
INSPECTED BY:
NOTE:
1. Welding must commence within 6 hours of completion of cleanliness requirements. If welding
has not commenced, joints must be re-cleaned and inspected.
2. Shielding gas dew point shall be minus forty degrees Fahrenheit (-400F) or less when measured
at the welding torch head and shall be verified prior to commencing welding on any shift.
3. The welding apparatus shall be purged and the shielding gas dew point shall be verified to be
minus forty degrees Fahrenheit (-400F) or less at the torch head each time gas supply bottles reconnected.
APPENDIX 7
4. A copy of this record shall be maintained at each worksite at all times.
APPENDIX 7
- 27 [Revised November 26, 2012]
Ship Hull:
Item/Mod:
PCP #:
Job#:
Calibrated Equipment:
DATE
TIME
Joint ID:
Contract#:
SHIELDING GAS DEW POINT RECORD
ID#.
Cal Due Date
LOCATION DEW POINT
TEMP (oF)
SAT/UNSAT Verified By:
NOTE:
1. Welding must commence within 6 hours of completion of cleanliness requirements. If welding has
not commenced, joints must be re-cleaned and inspected.
2. Shielding gas dew point shall be minus forty degrees Fahrenheit (-400F) or less when measured at
the welding torch head and shall be verified prior to commencing welding on any shift and after a bottle
change.
3. The welding apparatus shall be pre-purged with shielding gas for a minimum of 10 seconds prior to
welding.
4. The welding apparatus shall be purged and the shielding gas dew point shall be verified to be minus
forty degrees Fahrenheit (-400F) or less at the torch head each time gas supply bottles re-connected.
5. A copy of this record shall be maintained at each worksite at all times.
APPENDIX 8
APPENDIX 8
- 28 [Revised November 26, 2012]
PRE-HEAT / INTERPASS TEMPERATURE RECORD1
Ship Hull:
PCP #:
Joint ID:
Job#:
Work Item/Mod:
Contract#:
Calibrated Equipment:
P=Preheat
I= Interpass
(Circle one)
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
P
I
DATE
ID#:
TIME
Cal Due Date:
TEMP
(600F MIN – 150 0F
MAX)
COMMENTS:
NOTE: 1. USE ONE SHEET PER WELD JOINT.
APPENDIX 9
- 29 [Revised November 26, 2012]
SAT/UNSAT
Verified By:
ShipALT #:
Sheet / Elevation / Detail / Section
[Revised November 26, 2012]
- 30 -
APPENDIX 10
Rev #:
Item/Mod:
Job #:
Contract #:
Page
NDT Re-Inspection
of Repairs
PCP #:
NDT of Final
Hull:
5X Visual Inspection
of Final
Ship:
NDT of Back-Gouge
5X Visual Inspection
of Back-Gouge
NDT of Root Pass
5X Visual Inspection
of Root Pass
Fit-Up Inspection
Joint Preparation
DWG #:
Protective
Enclosure
Installation
ShipAlt Accountability Record
Initial Upon Completion or Mark “N/A”
of
Material Certification Index
Ship /Hull Number:
PCP Number:
Date:
Contract Number:
Job Number:
Work Item:
Lot No. & Description
Signature And Badge Number of
Receipt Inspector 1/ 2/ 3/
Invoice No.
1
2
3
4
5
6
7
8
9
10
NOTE 1: To be signed by the Welding Supervisor. Additions may be signed by the Welding Supervisor or Quality Assurance Inspector
NOTE 2: Signature indicates verification of procurement to ASTM-B928/B928M Standard Specification IAW Para 3.1 of Ref (h).
NOTE 3: Signature indicates verification of procurement of Filler Material to AWS A5.10 with Schedule J lot conformance testing
IAW Para 3.1 of Ref (h).
ENCLOSURE 7
1
[Revised November 26, 2012]