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Some key aspects of writing welding procedure specifications. A good learning point for people who have no experience in the field, and a good reference for seasoned engineers
How to write a Welding Procedure Specification (ISO 15614-1Tiago Pereira
Some key aspects of writing welding procedure specifications. A good learning point for people who have no experience in the field, and a good reference for seasoned engineers
Welding Procedure Specification and Welder approval based on
AWS D.1.1: Structural Steel Welding Code
ASME IX: Welding and Brazing Qualifications
API 1104: Welding of Pipelines
Welding Procedure Specification and Welder approval based on
AWS D.1.1: Structural Steel Welding Code
ASME IX: Welding and Brazing Qualifications
API 1104: Welding of Pipelines
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This presentation is intended to give a clear guidance to the reader on AWS D1.1. That is on Structural Welding and its legitimacy in the industry. This would be more helpful for MEP engineers and well as Structural engineers in practice. More over, those who are in the process of learning could be benefited using this.
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R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
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Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Democratizing Fuzzing at Scale by Abhishek Aryaabh.arya
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In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
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Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
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Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
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Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
2. 08/25/17 ASME Section-IX 2
WELDING QUALIFICATIONS ANDWELDING QUALIFICATIONS AND
ESTABLISHING WPS.ESTABLISHING WPS.
• ASME Section IX relates to qualification of
welders, welding operators, brazers and
brazing operators and the procedures that they
employ in welding and brazing.
• It is divided in two parts, part QW gives
requirements for welding and part QB contains
requirements for brazing. We shall deal only
with part QW.
3. 08/25/17 ASME Section-IX 3
WPS & PQRWPS & PQR
• The purpose of welding procedure specification
(WPS) and procedure qualification records (PQR)
is to determine that the weldment proposed for
construction is capable of providing the required
properties for its intended application.
• WPS is intended to provide direction for the
welder and lists the variables, both essential and
non essential and the acceptable ranges of these
variables when using the WPS.
4. 08/25/17 ASME Section-IX 4
WPS & PQRWPS & PQR
• It is presumed that welder or welding operator
performing the welding procedure qualification
test is skilled workman so that welding
procedure qualification test establishes the
properties of weldment and not the skill of the
welder.
• The purpose of performance qualification is to
determine if the welder is able to deposit sound
metal or the welding operator is able to operate
welding equipment properly.
5. 08/25/17 ASME Section-IX 5
Part QWPart QW
Part QW is divided into 4 articles.
• Article I -Welding general requirements
• Article II-Welding procedure qualifications
• Article III-Welding performance qualifications
• Article IV-Welding data
6. 08/25/17 ASME Section-IX 6
Test PositionTest Position
Before we proceed let us first understand various
test position in groove welds in plates, groove welds
in pipes and fillet weld in plates etc.
In general,
• 1G or 1F is called flat positions
• 2G or 2F is called horizontal and circumferential
• 3G or 3F is called vertical position
• 4G or4F is called overhead position
8. 08/25/17 ASME Section-IX 8
Test PositionTest Position
• Position 5G is only in welds in pipes. It is a
position when pipe axis is held horizontal and
circumferential seam is welded without rotating.
In a way it is combination of 1G, 3G & 4G.
• Position 6G is also for the pipes when pipe axis is
at 45 deg. to horizontal plane and circumferential
seam is welded without rotating the pipe. It is
combination of all positions.
9. 08/25/17 ASME Section-IX 9
Position for groove & fillet weldPosition for groove & fillet weld
• Fig. 461.1- is the diagram defining the position
for groove welds depending on the inclination
of the axis of the weld and the angle of rotation
of the face of the weld.
• There is similar fig. 461.2 giving position for
fillet welds.
12. 08/25/17 ASME Section-IX 12
• Fig. 451.1 gives the thickness limits and the type and
number of the test specimen required for procedure
qualification of groove
13. 08/25/17 ASME Section-IX 13
• In case of weld between dissimilar materials where it is difficult to
carry out bending so that weld is at the center of convex position,
transverse bends are replaced by longitudinal bends and the fig. look
like (Refer fig. 463.1 c)
14. 08/25/17 ASME Section-IX 14
• Fig.451.3 & 451.4 Give the test required to fillet test and fig.462.4 a,d
(it is similar except that instead of bend there is macro examination of
2 section of ¼ section)
18. 08/25/17 ASME Section-IX 18
• Refer fig.452.1,that gives performance qualification limits and type and number
of the test specimen required table. Fig 452.3 gives the diameter limits. It is
worth noting that one, two or more welders can be qualified on just one test
coupon. Each may be using even different processes.
27. 08/25/17 ASME Section-IX 27
Welding VariablesWelding Variables
• Article (IV) gives data about various types of
welding variables. It also gives tables for various
welding processes showing essential variables,
supplementary essential variables and non
essential variables for procedures qualification;
and essential variables for performance
qualification.
28. 08/25/17 ASME Section-IX 28
Cont.Cont.
• Essential variables for procedure are
those welding variables whose change
will affect the mechanical properties
(other than notch-toughness) of the
weldment (ex. Change in P-number, filler
metal, electrode type, preheat post heat
etc.)
29. 08/25/17 ASME Section-IX 29
Cont.Cont.
• Supplementary essential variables for
procedure are those welding variables
whose change will affect the notch
toughness properties of weldment (ex.
Uphill or down hill vertical welding, heat
input, preheat or PWHT)
30. 08/25/17 ASME Section-IX 30
Cont.Cont.
• Non essential variables for performance are
those welding variables which will not affect
the mechanical properties of weldment (ex.
Joint design, method of back gauging or
cleaning etc.)
31. 08/25/17 ASME Section-IX 31
Cont.Cont.
• Essential variables for performance are
those welding variables which will affect
the ability of welder to deposit sound
weld (e.g. position, deletion of backing F-
number etc.
• Change in process is essential variable
for procedure as well as performance.
34. 08/25/17 ASME Section-IX 34
Let us understand the term P-number
A-number and F-number.
• All those materials are divided into various P-
numbers depending on their nominal
composition and further divided into groups
depending on the type of refinement / min.
specified UTS etc. QW-422 gives the full
details.
35. 08/25/17 ASME Section-IX 35
Cont.
• Plain carbon steels, C-Si, Cr-Mn & C-Mn-Si
are grouped as P-1 materials and austenitic
stainless steel as P-8 material. Ferrous welding
consumable are classified under various A-
numbers based on their weld metal chemical
composition (table 442) and all welding
electrodes and welding rods are grouped in
different F-number depending on their AWS
classification which is based on type of flux and
chemical composition (table 432)
36. 08/25/17 ASME Section-IX 36
QW-120 - TEST POSITIONS FOR GROOVEQW-120 - TEST POSITIONS FOR GROOVE
WELDSWELDS
• Angular deviation of ±15 deg from the
specified horizontal and vertical planes,
and an angular deviation of ±5 deg from
the specified inclined plane are permitted
during welding.
37. 08/25/17 ASME Section-IX 37
QW-140 – TYPES AND PURPOSES OF TESTSQW-140 – TYPES AND PURPOSES OF TESTS
AND EXAMINATIONSAND EXAMINATIONS
• Tension tests are used to determine the ultimate
strength of groove-weld joints.
• Guided-bend tests are used to determine the
degree of soundness and ductility of groove-
weld joints.
• Toughness Tests are used to determine the
notch toughness of the weldment.
38. 08/25/17 ASME Section-IX 38
QW-144 – VISUAL EXAMINATION
Visual examination is used to determine
that the final weld surfaces meet
specified quality conditions.
39. 08/25/17 ASME Section-IX 39
QW-150 – TENSION TESTSQW-150 – TENSION TESTS
• Thicknesses up to and including 1 in. (25
mm), a full thickness specimen shall be
used for each required tension test.
• Cold straightening of the test coupon is
permitted prior to removal of weld
reinforcement
40. 08/25/17 ASME Section-IX 40
QW-153 – ACCEPTANCE CRITERIA,QW-153 – ACCEPTANCE CRITERIA,
TENSION TESTTENSION TEST
• If the specimen breaks in the base metal
outside of the weld or weld interface, the
test shall be accepted as meeting the
requirements, provided the strength is
not more than 5% below the minimum
specified tensile strength of the base
metal.
41. 08/25/17 ASME Section-IX 41
QW-163 – ACCEPTANCE CRITERIA, BEND
TEST
• Open discontinuity in the weld or heat-affected
zone exceeding 1/8 in. (3 mm), measured in any
direction on the convex surface of the specimen
after bending. Open discontinuities occurring on
the corners of the specimen during testing shall
not be considered unless there is definite evidence
that they result from lack of fusion, slag
inclusions, or other internal discontinuities. For
corrosion-resistant weld overlay cladding, no open
discontinuity exceeding 1/16 in. (1.5 mm),
measured in any direction, shall be permitted in
the cladding, and no open discontinuity exceeding
1/8 in. (3 mm) shall be permitted along the
approximate weld interface.
42. 08/25/17 ASME Section-IX 42
QW-184 MACRO-EXAMINATION,QW-184 MACRO-EXAMINATION,
PERFORMANCE SPECIMENSPERFORMANCE SPECIMENS
• Visual examination of the cross section of the
weld metal and heat-affected zone shall show
complete fusion and freedom from cracks,
except that linear indications at the root not
exceeding 1/32 in. (0.8 mm) shall be acceptable.
• The weld shall not have a concavity or
convexity greater than 1/16 in. (1.5 mm)
• There shall be not more than 1/8 in. (3 mm)
difference in the lengths of the legs of the fillet
43. 08/25/17 ASME Section-IX 43
QW-201 MANUFACTURER’S ORQW-201 MANUFACTURER’S OR
CONTRACTOR’S RESPONSIBILITYCONTRACTOR’S RESPONSIBILITY
• Each manufacturer shall qualify the
WPS by the welding of test coupons and
the testing of specimens (as required in
this Code), and the recording of the
welding data and test results in a
document known as a Procedure
Qualification Record (PQR).
44. 08/25/17 ASME Section-IX 44
QW-251.2 Essential Variables
• Essential variables are those in which a
change, as described in the specific variables, is
considered to affect the mechanical properties
of the weldment, and shall require
requalification of the WPS.
• Supplementary essential variables are required
for metals for which other Sections specify
notch-toughness tests and are in addition to the
essential variables for each welding process.
45. 08/25/17 ASME Section-IX 45
QW-251.3 Nonessential VariablesQW-251.3 Nonessential Variables
Nonessential variables are those in which a
change, as described in the specific
variables, may be made in the WPS
without requalification.
46. 08/25/17 ASME Section-IX 46
Tables to be referredTables to be referred
1 QW461.3 Groove welds in test position
2 QW461.4 Fillet welds in plates test position
3 QW461.5 Fillet welds in pipe test position
4 QW462.1
A,b,c,d & e
Method of taking out test specimen
5 QW463.1
A,b,c,d,e,f
Method of taking out test specimen
6 QW451 Procedure qualification thk.limits
7 QW452 Performance qualification & test specimen
8 QW461.9 Performance qualification & diameter
limits