1. WELDING CODE, STANDARD
& WELDING PROCEDURE
Dr. Ir. Winarto, M.Sc.
DEPARTEMEN METALURGI & MATERIAL
FAKULTAS TEKNIK UNIVERISTAS INDONESIA
DEFINISI
n
“Standard ” adalah kumpulan dokumen- dokumen berisikan
Standard”
dokumenkode (codes), spesifikasi (specification), Saran aplikasi
(recommended practice), klasifikasi, dan petunjuk (guide)
klasifikasi,
yang telah dipersiapkan oleh suatu institusi organisasi dan di
sahkan (approved) sesuai dengan prosedur yang ada
(berlaku).
berlaku).
n
“Codes ” adalah suatu standard yang berisikan kondisi dan
Codes”
persyaratan yang berhubungan dengan bidang khusus (a
particularly subject) dan mengindikasikan bahwa prosedur
yg digunakan telah sesuai dengan persyaratannya . Codes ini
persyaratannya.
HARUS diikuti (mandatory) karena menyangkut
kepentingan umum yang merefer kepada kebijakan otoritas
pemerintahan. (Codes
pemerintahan. (Codes is a body of laws arranged
systimatically for easy reference)
1
2. DEFINISI
n
“Specification” (spesifikasi) adalah suatu
Specification” spesifikasi)
standard yang berisikan penjelasan yang rinci
dan akurat tentang persyaratan teknis dari
material, produk, sistim atau jasa .
produk,
jasa.
n Contoh Kode :
– Structural Welding Code-Steel (AWS D1.1)
Code– Boiler & Pressure Vessel Code (ASME)
– Welded Pipeline & Vessel (API)
n
Contoh Specification :
– Filler Metal Specification (AWS A5.X)
– Material & Consumable of Welding (ASME sec. IIC)
AWS – Structural Welding Code
n
n
n
n
n
n
AWS D l.1, Structural Welding Code—Steel
Code—
AWS D l.2, Structural Welding Code—Aluminum
Code—
AWS D l.3, Structural Welding Code—Sheet Steel
Code—
AWS D l.4, Structural Welding Code—Reinforcing Steel
Code—
AWS D l.5, Bridge Welding Code
AWS D l.6, Structural Welding Code—Stainless Steel
Code—
2
5. ASME STANDARD
API - STANDARD
n
API 1104, Standard for Welding Pipeline
and Related Facilities
n API 620, Recommended Rules for Design
and Construction of Large Welded LowLowPressure Storage Tanks
n API 650, Standard for Welded Steel Tank
for Oil Storage
5
6. Persyaratan Dasar dalam Menentukan
Kualitas dalam Pengelasan
Standar Eropa dan Amerika
dalam mendukung Kualitas Lasan
n
ASME (American Society of Mechanical
Engineers)
n EN (European Norm) / European Standard
n AWS (American Welding Society )
6
7. ASME Standard untuk Welding
n
ASME Sec IX (Qualification Standard for
Welding and Brazing Procedure, Welder,
and Welding & Braze Operator.
n ASME Sec II C Standard for Material and
Consumable of Welding.
STANDARD KUALITAS LAS dari ASME
Basic Construction Code //Standard ::
Basic Construction Code Standard
•ASME Sec I, ASME B31.1 ,,ASME B31.3
•ASME Sec I, ASME B31.1 ASME B31.3
•ASME Sec VIII Div II& 2
•ASME Sec VIII Div & 2
Examination and
Examination and
Testing
Testing
••ASME V
ASME V
Quality of
Welds
Welding Personnel
Welding Personnel
And Welding
And Welding
Procedure
Procedure
••ASME IX
ASME IX
Welding Material
Welding Material
••ASME II C
ASME II C
7
8. European Standard For Welding
n
EN 288 (Standard & Qualification Welding
Procedure)
n EN 287 ( Standard & Qualification of
Welder)
n EN 1418 ( Standard & Qualification of
Welding Operator )
STANDARD KUALITAS LAS dari EN
8
9. PROSEDUR LAS - EN 288
n
n
n
n
n
n
n
n
EN 288 - 1 . General rules fusion welding.
EN 288 - 2. WPS for Arc Welding
EN 288 - 3. Welding procedure test for Arc welding of
steel.
EN 288 - 4. Welding Procedure Test for Arc welding
of Aluminum and It’ s alloys
It’
EN 288 - 5. Approval by using approved welding
consumables for arc welding
EN 288 - 6. Approval related to previous experience
EN 288 - 7. Approval by a standard welding procedure
for arc welding
EN 288 - 8. Approval by a pre-production welding test.
pre-
KUALIFIKASI WELDER - EN 287
n
n
n
n
n
n
n
n
EN 287 - 1 . Approval testing of welders – Fusion welding
part 1 : Steels.
EN 287 - 2. Approval testing of welders – Fusion welding
part 2 : Aluminum and aluminum Alloys.
EN 287 - 3. Approval testing of welders – Fusion welding
part 3 : Copper and Copper Alloys.
EN 287 - 4. Approval testing of welders – Fusion welding
part 4 : Nickel and Nickels alloys
EN 287 - 5. Approval testing of welders – Fusion welding
part 5 : Titanium and Titanium, Zirconium and Zirconium
alloys
EN 288 - 6. Approval related to previous experience
EN 288 - 7. Approval by a standard welding procedure for arc
welding
EN 288 - 8. Approval by a pre-production welding test.
pre-
9
10. Table 1 Examples of application codes and standards and related welding procedure and welder approval standards
Application
Application
code/standard
Welding Standard
Procedure
Welder
approval
approval
BS 5500
ASME VIII
BS EN 288
ASME IX
BS EN 287
ASME IX
BS 2633
BS 4677
ANSI/ASME B311
ANSI/ASME
B31.3
BS 2971
BS EN 288 (Part 3)
BS EN 288 (Part 4)
ASME IX
ASME IX
BS EN 288 (Part 3)
(if required)
BS EN 287 (Part 1)
BS EN 287 (Part 2)
ASME IX
ASME IX
BS 4872/BS EN 287
Structural
Fabrication
AWS D1.1
AWS D1.2
BS 5135
BS 8118
AWS D1.1
AWS D1.2
BS EN 288 (Part 3)
BS EN 288 (Part 4)
AWS D1.1
AWS D1.2
BS EN 287
BS EN 287
BS 4872
Storage
Tanks
BS 2654
BS 2594
API 620/650
BS EN 288 (Parts 3 & 4)
BS EN 288 (Parts 3 & 4)
ASME IX
BS EN 287
BS EN 287
ASME IX
Pressure
Vessels
Process
Pipe-work
Why a WPS
A weld cannot be checked to the full extent !
strength, ductility and corrosion resistance can
only be checked by destructive techniques.
properties can only be guaranteed for the
actual product when manufactured to
exactly the same written procedure,
and carefully controlled.
10
11. Why a WPS
The main objective of a
WPS is to make a
welding operation
reproducable
What is a WPS ?
The welding procedure is somewhat
analogous to a cook's recipe.
It outlines the steps required to make a quality
weld under specific conditions.
The WPS is a communication tool, and it is the
primary means of communication to all the
parties involved regarding how the welding is
to be performed.
It must therefore be readily available to
foremen, inspectors and the welders.
11
12. What is a WPS ?
According to QW-100.1 ASME Sec IX.
Welding Procedure Specification (WPS).
WPS is a written document that provides direction to the
welder or welding operator for making production welds
in accordance with Code requirements.
According to QW-200.2 ASME Sec IX.
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 variables recorded
during the welding of the test coupons. It also contains
the test results of the tested specimens. Recorded
variables normally fall within a small range of the actual
variables that will be used in production welding.
What is WPS Variables ?
Process
(SMAW, FCAW, etc.)
Electrode specification
(AWS A5.1, A5.20, etc.)
Electrode classification
(E7018, E71T-1, etc.)
Electrode diameter
(1/8 in., 5/32 in., etc.)
Electrical characteristics
(AC, DC+, DC-)
Base metal specification
(A36, A572 Gr50, etc.)
Minimum preheat and interpass
temperature
Welding current (amperage)/wire feed speed
Arc voltage
Travel speed
Position of welding
Post weld heat treatment
Shielding gas type and flow rate
Joint design details
12
13. What is Variales in WPS ?
1. Essential Variable :
QW-401.1 Essential Variable (Procedure).
A change in a welding condition which will affect the
mechanical properties (other than notch toughness) of the
weldment (for example, change in P-Number, welding
process, filler metal, electrode, preheat or postweld heat
treatment, etc.).
QW-401.2 Essential Variable (Performance).
A change in a welding condition which will affect the
ability of a welder to deposit sound weld metal (such as a
change in welding process, deletion of backing, electrode,
F-Number, technique, etc.).
What is Variales in WPS ?
2. Supplemental Essential Variable :
QW-401.3 Supplemental Essential Variable (Procedure).
A change in a welding condition which will affect the notchtoughness properties of a weldment (for example, change in
welding process, uphill or down vertical welding, heat input,
preheat or PWHT, etc.).
When a procedure has been previously qualified to satisfy all
requirements other than notch toughness, it is then necessary
only to prepare an additional test coupon using the same
procedure with the same essential variables, but additionally
with all of the required
supplementary essential variables, with the coupon long
enough to provide the necessary notch-toughness specimens.
13
14. What is Variales in WPS ?
3. Nonessential Variable :
QW-401.4 Nonessential Variable (Procedure).
A change in a welding condition which will not affect the
mechanical properties of a weldment (such as joint design,
method of back gouging or cleaning, etc.)
14
15. ASME SECTION IX MATERIAL GROUPING P-NUMBERS
The material group are based on comparable base material
characteristics, such as composition, weldability, braze-ability,
and mechanical properties.
15
16. P No.
EN-288
Base Metal
Carbon Manganese Steels, 4 Sub Groups
Group 1 up to approx 65 ksi
1
1
Group 2 Approx 70ksi
Group 3 Approx 80ksi
Group 4 Special (e.g. SA-724 gr. A, B, C)
2
3 Sub Groups:- Typically half moly and half chrome half moly
5
2 Sub Groups:- Typically one and a quarter chrome half moly
5A
5
Typically two and a quarter chrome one moly
5B
5
2 Sub Groups:- Typically five chrome half moly and nine chrome
one moly
5C
6
5 Sub Groups:-Chrome moly vanadium
6
8
6 Sub Groups:-Martensitic Stainless Steels Typically Grade 410
7
P NUMBER
4
4
MATERIAL
Not Used
3
ASME & EN
-
8
Ferritic Stainless Steels Typically Grade 409
Austenitic Stainless Steels, 4 Sub groups
Group1 Typically Grades 304, 316, 347
8
9
Group 2 Typically Grades 309, 310
Group 3 High manganese grades
Group 4 Typically 254 SMO type steels
9A, B, C
7
Typically two to four percent Nickel Steels
10A,B,C,F,G
?
Mixed bag of low alloy steels, 10G 36 Nickel Steel
10 H
10
Duplex and Super Duplex Grades 31803, 32750
10J
?
Typically 26 Chrome one moly
11A Group 1
11 A Groups 2 to
5
11B
7
9 Nickel Steels
?
Mixed bag of high strength low alloy steels.
?
10 Sub Groups:- Mixed bag of high strength low alloy steels.
ASME F Numbers
F No.
General Description
1
Heavy rutile coated iron powder electrodes :- A5.1 : E7024
2
Most Rutile consumables such as :- A5.1 : E6013
3
Cellulosic electrodes such as :- A5.1 : E6011
4
Basic coated electrodes such as : A5.1 : E7016 and E7018
5
High alloy austenitic stainless steel and duplex :- A5.4 : E316L-16
6
Any steel solid or cored wire (with flux or metal)
2X
Aluminium and its alloys
3X
Copper and its alloys
4X
Nickel alloys
5X
Titanium
6X
Zirconium
7X
Hard Facing Overlay
Note:- X represents any number 0 to 9
16
17. ASME Welding Positions
Note the welding progression, (vertically upwards or downwards), must always be stated and it is an essential variable for
both procedures and performance qualifications.
Welding Positions For Groove welds:Welding Position
Test Position
ISO and EN
Flat
1G
PA
Horizontal
2G
PC
Vertical Upwards Progression
3G
PF
Vertical Downwards Progression
3G
PG
Overhead
4G
PE
Pipe Fixed Horizontal
5G
PF
Pipe Fixed @ 45 degrees Upwards
6G
HL045
Pipe Fixed @ 45 degrees Downwards
6G
JL045
Welding Positions For Fillet welds:Welding Position
Test Position
ISO and EN
Flat (Weld flat joint at 45 degrees)
1F
PA
Horizontal
2F
PB
2FR
PB
Horizontal Rotated
Vertical Upwards Progression
3F
PF
Vertical Downwards Progression
3F
PG
Overhead
4F
PD
Pipe Fixed Horizontal
5F
PF
POSISI LAS - ASME IX
17
20. CONTOH TAHAPAN PROSES
PENGELASAN PIPA
.
Project Eng
Operation
Operation
Requirement
Requirement
Material
Material
Selection
Selection
Science
WPS
WPS
Welding
Eng
Fabrication
Fabrication
of Pipes
of Pipes
Technology
Manufac
turer
WPQR
WPQR
Welding Application
Welding Application
Inspection
Inspection
Wel
der
Standard
Welding
Inspect
WELDING AND JOINING
.
WELDING PROCEDURES
WELDING AND JOINING
WPQR AND WPS
n
Kualifikasi Prosedur (Procedure Qualification)
Ä Sebelum mengelas komponen (pipa atau lainnya) umumnya
prosedur pengelasan (welding procedure) harus dibuat dan
dikualifikasi.
n
Dokumentasi (Record)
Ä Detail mengenai prosedur harus didokumentasi (record) yang berisi
hasil lengkap tentang “procedure qualification test”.
n
Kualifikasi Operator Las (Qualification of Welders)
Ä Setiap welder atau operator las harus dikualifikasi menurut
prosedur baku sebelum melakukan pengelasan komponen (pipa
atau lainnya). Tujuannya adalah untuk menentukan kemampuan
operator las (welder) dalam menghasilkan lasan yang baik tanpa
cacat dengan menggunakan prosedur sebelumnya yang telah lulus
qualifikasi.
20
21. ISI WELDING PROSEDUR
WELDING AND JOINING
WPQR AND WPS
¥ Process è Manual, Semi-or
automatic welding process
¥ Pipe and Fitting Material è API
5L or ASTM
¥ Diameter and Wall Thickness
¥ Joint Design
¥ Filler Metal and Number of Bed
è The size and classification
number of the filler metal and
minimum number and sequence
of bead
¥ Electrical Characteristics è The
range of voltage and amperage
¥ Position è Roll or fix
¥ Direction of Welding è Uphill or
downhill
¥ Time Between Passes è Max
time between completion of the
root bed and start of the second
and other bed
¥ Type and Remove of Lineup
Clamp
¥ Cleaning and or Grinding
¥ Pre and Post-Heat Treatment è
Methods, Temp. temp-control
methods
¥ Shielding Gas and Flow Rate è
Composition and range of flow
rate
¥ Shielding Flux
¥ Speed of Travel è in inch per
minute
CONTOH PENGELASAN PIPA
WELDING AND JOINING
NUMBER OF WELD METAL-LAYER
n The number of weld metal-layer (pass) in welding of pipe depend on
pipe wall thickness. Recommended number of layer as shown below.
Range of Pipe
Wall Thickness
Number
of Layers
3/8 to 5/8 in
2
5/8 to 7/8 in
3
7/8 to 1 1/8
in
4
Cross Section of Weld
2
1
3
2
1
4
3
2
1
Remark
1 = Rott pass
2 = Cover pass
1 = Root pass
2 = Hott pass
3 = Cover pass
1 = Root pass
2 = Hott pass
3 = Filler pass
4 = Cover pass
21
22. PIPE WELDING PROCEDURES
WELDING AND JOINING
TYPE OF PASS
.
Filler Pass
3/16 Electrode
180 - 190 A DC +
Cover Pass
3/16 Electrode
160 - 190 A DC +
Base Metal
Hot Pass
5/32 Electrode
170 - 200 A DC +
Root/Stringer Bead
5/32 Electrode
135 - 175 A DC +
PIPE WELDING PROCEDURES
WELDING AND JOINING
SPEED OF TRAVEL
.
Layer
Travel Speed,
Cm/Minute
Root Pass
7.5 - 20
Hot Pass
7.5 - 20
Filler Pass
12.5 - 25
Cover Pass
12.5 - 25
22
23. PIPE WELDING PROCEDURES
WELDING AND JOINING
FILLER METAL
.
Filler Metal Group
AWS E6010 AND E6011
3
E7010, E7011
1/8
75 - 125
A5.5
E8010, E8011
5/32
110 - 170
26
E7015, E7016, E7018
3/16
140 - 215
24 - 26
A5.5
E8015, E8016, E8018
7/32
170 - 250
26 - 30
A5.17
2
E6010, E6011
A5.1 or 5.5
1
AWS
Specificatio
n
A5.1
A5.5
EL8, EL8K, EL12, EM5K
1/4
210 - 320
26 - 30
EM12K, EM13K, EM15K
Group
5/16
275 - 425
28 - 34
4
Electrode
Dia, In
Current
A
Votage,
Arc Volt
3/32
Electrode
40 - 80
23 - 25
24 -
28 - 34
PIPE WELDING PROCEDURES
WELDING AND JOINING
PRE HEATING AND STRESS RELIEF
n
Preheating shall be performing when:
Ä Carbon steel having a carbon content in
excess of 0.32 % (ladle analysis) or a
carbon equivalent (C + 1/4 ( Mn + Si ) )
in excess of 0.65 % (ladle analysis).
Ä Steel having lower carbon content or CE
when the welding procedure indicates
that chemical composition, ambient/or
metal temperature, material thickness
.
Preheating Requirement Based on CE
CE
%
Preheating Reaquired
Up to 0.45
Preheat optional
0.45 to 0.60
Preheat to 93 - 205 deg C
Over 0.60
Preheat to 205 to 370 deg C
or
weld
geometry
require
such
treatment to produce satisfactory welds
(Source ASME B31.8)
n
Preheating Method
Ä Furnace Heat Treatment
Preheating Requirement Based on C Content
C Content, %
Preheating Temperatur, oC
Ä Induction Heating
Below 0.2
Ä Torch Heating
0.20 - 0.30
Up to 93
93 - 150
Ä Resistance Heating
0.30 - 0.45
150 - 260
Ä Exothermal Heating
0.45 - 0.80
260 - 425
23
24. PIPE WELDING PROCEDURES
WELDING AND JOINING
PRE HEATING AND STRESS RELIEFING
Stress - Reliefing
Ä Equipment
Ä To eliminate or greatly reduce built
up stress caused by welding.
§ Electric induction
Ä Required when
§ Fuel-fired ring burner
§ Electric resistance
§ Following a welding operation on a big
work piece (wall thickness >)
§ Fuel-fired torch
Ä Temperature Controller
§ On that is likely to have large built up
stress in it,
§ Having
trouble
with
warping out of shape.
work -piece
§ Thermocouple pyrometer
Stress-Relief Time & Temperature for Carbon
Steel
Ä Methods of Stress Relieving
Metal Temp.
o
C
§ Heat the complete structure as a unit
Time per Inch of Section
Thickness, h
§ Heat a complete section containing the
weld to be stress relief
593
1
§ Heat a part of work by slowly heating a
circumferential band containing the
weld at the center.
565
2
538
3
510
5
482
10
§ Branch or other welded attachment
PIPE WELDING INSPECTION
WELDING AND JOINING
METHODS OF INSPECTION
þ NDT
þ
n Visual
weld, at randomly by operators
n Radiographic Testing
n Class 1 location, except offshore,
n Magnetic Particle Testing
at least 10 %
n Liquid Penetrant Testing
n Class 2 location, at least 15 %
n Ultrasonic Testing
þ The method used shall produce
indications of defects that can be
accurately interpreted and evaluated.
þ Qualification of Inspection Personnel
n Welding inspection personnel shall
be qualified by experience and
training
for
the
specified
inspection task they performed.
þ Radiographic testing
least by Level I
Percentages of each day’s field butt
performed
at
n Class 3, and class 4 location, at
crossing
or
navigable
river,
offshore and rail road or public
highway right of way, including
tunnels, bridges and over head
road crossing, 100 %, unless
impracticable, at least 90 %.
n Pipelines tie-in, 100 %
þ Only Level II or III personnel shall
interprete test results.
24
25. PIPE WELDING INSPECTION
WELDING AND JOINING
BASIC CONCEPT
Preparation
Preparation
Radiographic
Radiographic
Test
Test
Interpretation
Interpretation
and Evaluation
and Evaluation
Acceptance
Acceptance
Yes
Welding is Perfect
Welding is Perfect
No
Repair
Repair
WELDING AND JOINING
Terima Kasih
.
25
