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    Welding Procedures

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    Andis
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    Welding Procedures

    Uploaded by

    Andis
    89 views8 pages
    Study

    Copyright

    © © All Rights Reserved

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    Copyright:

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    Download as docx, pdf, or txt
    89 views8 pages

    Welding Procedures

    Uploaded by

    Andis
    Study

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    of 8

    Welding

    Procedure
    s
    (overview)

    The cost impact of not being able to control the quality of


    welding and repair rates can be substantial. This will and
    can cost the contractor considerable delay in the
    completion of the project. Thereafter invoking contractual
    penalties. Resulting in the loss of profit margins and later
    arbitration.

    Approvals prior to the commencement of welding


    operations.

    Welding Procedure Specifications.


    Procedure Qualification Reports.
    Welder Certification Certificates.
    Welding Consumables.
    NDT Company.
    NDT Operators.
    NDT Procedures.
    Radiation Safety.
    Post Weld Heat Treatment Company.
    Post Weld Heat Treatment Procedure.
    Welding Inspection Personnel.
    Welding Repair Procedure.

    Method Statement
    Welding of Piping and Structural Components

    1) Welders shall only work within the


    limit of their qualification range.

    2) Welding supervisor/welders shall


    ensure that Welding Procedure
    Specification (WPS) selection is taken
    from the approved matrix for each
    specific line class/application
    accompanying each WPS.

    3) Withdraw consumables only from


    designated welding stores and
    endorse initials on the Welding
    Consumables Distribution Form
    maintained by the issue clerk.

    4) Withdraw only sufficient quantities


    of welding consumable for a four (4)
    hour period of work.

    5) All low-hydrogen welding electrodes


    shall be maintained in heated
    portable rod caddies. The lid of the
    caddie should be closed following the
    withdrawal of each withdrawal
    electrodes.

    6) Low-hydrogen electrodes shall only


    be conveyed to the job site in heated
    portable rod caddies.

    7) At shift change, all rod caddies


    must be returned to the originating
    welding store for checking. All issued
    and unused low-hydrogen electrodes
    shall be scrapped.

    Welding Defects Defined

    DEFECT

    CAUSE

    Pipe off set mismatch

    Pipe misalignment

    Lack of root penetration

    Welding technique

    Insufficient root fill

    Welding technique

    Excessive penetration

    Welding technique

    External undercut

    Excessive amps/volts

    Internal undercut

    Excessive amps/volts

    Internal concavity

    Welding technique

    Root burn through

    Welding technique

    Lack of root penetration

    Weld joint set up

    Interpass slag inclusions

    Weld technique, grinding,


    cleaning

    Elongated slag inclusions

    Weld technique, grinding,


    cleaning

    lack of side wall fusion

    Weld technique, amps/volts


    to low

    Interpass cold lap

    Weld technique

    Scattered porosity

    Weld technique

    Cluster porosity

    Weld technique, insufficient


    wind cover

    Root pass aligned porosity

    Weld technique, insufficient


    wind cover

    Transverse crack

    Insufficient wind cover, lack


    of pre-heating & post weld
    heat treatment of weld joint.
    Material problem.

    Longitudinal crack

    Insufficient wind cover, lack


    of pre-heating & post weld
    heat treatment of weld joint.
    Material problem.

    Longitudinal root crack

    Insufficient wind cover, lack


    of pre-heating & post weld
    heat treatment of weld joint.
    Material problem.

    Tungsten inclusions

    Weld technique

    8) The technical requirements of the


    Welding Procedure Specification
    (WPS) must be followed at all times.

    9) Pre-heat and interpass


    temperatures shall be monitored using
    Tempil Stiks or calibrated digital
    temperature by pyrometers. greater
    than the nominal wall thickness. ii) For
    flanges, use the thickness
    corresponding to two (2) higher wall
    thickness ranges greater than the
    nominal wall thickness.

    10) Pre-heat values shall be taken


    calculated and WPS assuming a value
    of 0.42 CE (Carbon Equivalent). Wall
    thickness values shall be selected as
    follows:
    a) For pipe-pipe, use the actual wall
    thickness.
    b) For pipe-to-fitting or fitting-tofitting.
    c) For fittings (other than flanges),
    use the next higher wall thickness
    range a sufficient period of time to
    ensure an Oxygen content of less tan
    0.5%. When available, purge
    monitoring devices shall be used.
    d) Backpurge shall be maintained for
    a minimum of four (4) passes. Pipe
    bungs (purge dams) shall be left in
    place until completion of the joint.
    e) The end of partly used filler wire
    shall be snipped off prior to use.
    f) Maintain the tip of the filler rod
    within the gas shroud during welding
    to avoid contamination.
    g) Interpass temperatures for these
    materials is critical. The welder shall
    check the temperature prior to the next
    pass. All austenitic stainless welds on
    this project will be tested for Ferrite
    content therefore, cleanliness during
    fabrication and monitoring of interpass
    temperatures will have a direct effect
    on test results.
    h) Only approved iron-free cutting
    and grinding disks shall be used.
    i) Only approved marking materials
    (sulphur, chlorine free etc.) are to be
    used.
    j) All material handling devices and
    equipment shall be adequately
    protected/lined, to prevent the
    possibility of carbon pick-up (i.e.
    workbench, transport trucks, supports
    etc.).
    k) Wherever possible, tools shall be
    colour coded to prevent cross-use with
    other material types.

    11) Pre-head shall be applied through


    the full thickness of the joint and
    checked from the opposite side
    wherever possible.

    Welding Process Metology

    Welding Procedures to avoid hydrogen induced cracking.

    To control cracking when completing the welding


    procedure the following factors must be considered.

    12) For repair welds, the pre-heating


    temperature shall be 500 C (1220 F)
    above that used for the original weld.
    Maximum pre-heat for repair welding
    is 1500 C (3020 F).

    13) All tack welds shall be in


    accordance with an approved WPS.
    Internal misalignment for butt joints
    shall not exceed 1.5 mm (1/16).

    14) Deposit the root pass and six (6)


    successive passes or 1/3 of the weld
    volume prior to interruption (allowing
    to cool to ambient temperature).

    15) Buttering (build-up) is permitted as


    follows:
    a) Buttering shall not exceed the
    lesser of 10 mm or 1/3 base metal
    thickness.
    b) If buttering will exceed 10 mm or
    1/3 base metal thickness then this
    shall be witnessed by the customer
    and the area shall be tested by PT/MT
    following completion of buttering but
    before final welding of the joint.

    16) Backwelding is permissible for all


    applications, so long as the same
    electrodes and process is used as for
    the fill pass.

    17) The following points shall be


    observed when fabricating/welding
    stainless and non-ferrous materials:
    a) Weld preps and filler materials
    shall be degreased using an
    appropriate solvent.
    b) Weld prep surfaces shall be
    buffered using flapper wheels.
    c) Argon hoses shall be checked for
    any loose connections or leakage etc.
    d) Fit up geometry shall be in
    accordance with the applicable,
    approved WPS.
    e) Bridge tacks to be used. Avoid
    tacking directly on to the adjacent pipe
    wall. Bridge tack within the fusion
    faces of the joint wherever possible.
    f) Prior to welding, the backpurge
    shall be set up in accordance with the
    approved WPS for a sufficient period
    of time to ensure an Oxygen content
    of less tan 0.5%. When available,
    purge monitoring devices shall be
    used.
    g) Backpurge shall be maintained for
    a minimum of four (4) passes. Pipe
    bungs (purge dams) shall be left in
    place until completion of the joint.
    h) The end of partly used filler wire
    shall be snipped off prior to use.
    i) Maintain the tip of the filler rod
    within the gas shroud during welding

    - Combined thickness of the material to be welded


    - Carbon equivalent values
    - Hydrogen scales
    - Welding arc energy

    Codes and Standards That are most Commonly Used on


    Construction Projects

    Codes and Standards That are most Commonly Used on


    Construction Projects

    ASME Boiler and Pressure Vessel Code


    Clause

    Section

    Power boilers
    Pressure vessels
    Pressure vessels
    Heating Boilers
    Nondestructive Ex
    Welding & brazing
    qualifications

    I
    VIII, DIVISION 1
    VIII, DIVISION 2
    IV
    V
    IX

    American Pipeline Institute


    API

    1104

    Welding Pipelines & related facilities

    API

    650

    Welded Steel Tanks for Oil Storage

    AWS

    D1.1

    American Welding Society

    ANSI

    American National Standards Institute

    B31.1 Power Piping


    B31.2 Industrial Gas & Air Piping
    B31.3 Petrolium Refinery Piping
    B31.4 Oil Transportation Piping
    B31.5 Refrigeration Piping
    B31.6 Chemical Industrial Piping
    B31.7 Nuclear Power Piping
    B31.8 Gas Transmission & Distribution Piping Systems

    to avoid contamination.
    j) Interpass temperatures for these
    materials is critical. The welder shall
    check the temperature prior to the next
    pass. All austenitic stainless welds on
    this project will be tested for Ferrite
    content therefore, cleanliness during
    fabrication and monitoring of interpass
    temperatures will have a direct effect
    on test results.
    k) Only approved iron-free cutting
    and grinding disks shall be used.
    l) Only approved marking materials
    (sulphur, chlorine free etc.) are to be
    used.
    m) All material handling devices and
    equipment shall be adequately
    protected/lined, to prevent the
    possibility of carbon pick-up (i.e.
    workbench, transport trucks, supports
    etc.).
    n) Wherever possible, tools shall be
    colour-coded to prevent cross-use with
    other material types.

    NDT
    Technique

    Materials
    applicable

    Detection
    capability

    Depth
    Sizing

    Orientation
    Evaluation

    Access
    problem

    Remote
    Detection

    Automated
    detection

    Liquid
    penetrant

    All

    Surface

    No

    No

    Yes

    No

    No

    Ultrasonic

    All

    Volumetric

    Yes

    Yes

    Limited

    Yes

    Yes

    Radiography

    All

    Volumetric

    Yes

    Yes

    Yes

    No

    Yes

    Magnetic
    Particle

    Magnetic

    Surface,
    No
    near-surface

    No

    Yes

    No

    No

    Magnetic
    Fluxleakage

    Magnetic

    Surface,
    Yes
    near-surface

    Yes

    No

    Yes

    Yes

    Eddy current

    Conducting

    Surface,
    Yes
    near-surface

    yes

    Yes

    Yes

    yes

    Acoustic
    Emission

    All

    Volumetric

    No

    No

    Yes

    Yes

    Yes

    Thermo-graphy All

    Surface,
    No
    near-surface

    Yes

    No

    Yes

    Yes

    Visual

    All

    Surface

    No

    No

    Limited

    Yes

    Yes

    XRD

    Conducting

    Suface
    Stresses

    Yes

    No

    Yes

    No

    No

    Surface

    Yes

    No

    Yes

    No

    Yes

    Potential drop Conducting

    Engineering and Construction Codes and Standards


    ASME IX - American Society of Mechanical Engineers
    ASME IX - B 31.3 PROCESS PIPING
    ASME IX - B 31.1 POWER PIPING
    Material (P numbers) will assist the Welding Engineer to complete the Welding Procedure Specification prior to
    the mechanical testing of the Procedure Qualification Report.

    P-numbers
    1
    3
    4
    5A
    5B
    5C
    6
    7
    8
    9
    10
    11
    21
    22
    23
    25
    31
    32
    33
    34
    41
    51
    61

    Material Composition
    Carbon Steel
    Up to 1/2% Cr and up to 1/2% Mo
    1 to 2% Cr, 1% Mo Alloy Steel
    2 to 3% Cr, 1% Mo Alloy Steel
    5 to 10% Cr, 1% Mo Alloy Steel
    All 5A and 5B Materials heat treated to 85ksi+
    Martensitic Stainless Steel
    Ferritic Stainless Steel
    Austenitic Stainless Steel
    2 to 5% Ni Alloy Steel
    Mn-V, Cr-V, 9%Ni, High Cr Alloy Steels
    Low Alloy Steel, Quenched and Tempered to 95ksi+
    1.2% Mg or Mn alloy Aluminium
    1.2% Mn, 2.5% Mg, 0.25% Cu Aluminium
    1.3% Mg, 0.7% Si, 0.25% Cr Aluminium
    1.5% Mg, 0.8% Mn, 0.15 Cr Aluminium
    Copper
    Admirally, Naval, Aluminium brass, Muntz Metals
    Cu-Si Alloys
    Cu-Ni Alloys
    Nickel
    Titanium
    Zirconnium
    WELDING DEFECTS

    Cold Lap

    Porosity

    Cluster Porosity

    Slag inclusion

    Incomplete Penetration (IP) or lack of penetration (LOP)

    Incomplete fusion

    Internal Concavity or Suck Back

    Internal or Root Undercut

    External or Crown Undercut

    Offset or Mismatch

    Inadequate Weld Reinforcement

    Excess Weld Reinforcement

    Cracks

    Discontinuities in TIG Welds


    Tungsten Inclusion

    Oxide inclusions

    Discontinuities in Gas Metal Arc Welds (GMAW)


    Whiskers are short lengths of weld electrode wire, visible on the top or bottom su6rface of the weld or contained within the weld. On a
    Burn Through

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