Documents Governing Welding Inspection and Qualification
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This document discusses various types of documents that govern welding inspection and qualification, including purchase orders, codes, standards, specifications, drawings, and recommended practices. It provides examples of the information contained in fabrication drawings, welding codes and standards, material specifications, and discusses the requirements for procedure and welder qualification. Key points covered include essential welding variables, position and thickness limitations, and the difference between qualifying a welder versus certifying their qualifications.
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Documents Governing Welding Inspection and Qualification
- 1. DOCUMENTS GOVERNING WELDING INSPECTION AND QUALIFICATION
- 2. DOCUMENT TYPES • Purchase orders • Contract documents • Codes • Standards • Specifications • Recommended Practices • Drawings
- 3. DRAWINGS • Dimensions in U.S. Customary or S.I. • When both are used, second system is usually shown after the first in ( ) • Tolerances must be stated as a : + or -, maximum, minimum, or a range • All drawing notes must be reviewed • List of materials usually given
- 4. EXAMPLE OF FABRICATION DRAWING
- 5. DIMENSIONS
- 6. TOLERANCES
- 7. NOTES
- 8. WELDING DETAILS • Location • Size • Length • Joint configurations • Material call-outs • NDE requirements • Processing requirements
- 9. HOLD POINTS • Specific prearranged steps • Inspection required • Acceptance required • Fabrication continued
- 10. INSPECTION INFORMATION • Visual or other NDE • Test method • Test procedure • Location for testing • Extent of testing • Acceptance/rejection criteria • Personnel qualifications
- 11. CODE “A body of laws, as of a nation, city, etc., arranged systematically for easy reference”
- 12. TYPES OF CODES • Building codes • Electrical codes • Plumbing codes • Fabrication codes
- 13. CODES: • Have legal status • Use “Shall” and “Will” • Mandatory • Methods to determine compliance
- 14. CODE PRODUCERS • AWS • ASME • API • ABS • DOT • Others
- 15. STANDARD “Something established for use as a rule or basis of comparison in measuring or judging capacity, quantity, content, extent, value, quality, etc.”
- 16. WELDING CODES AND STANDARDS
- 17. ASME CODE BY SECTIONS • I - Const - Power Boilers • II - Materials • Part A - Ferrous • Part B - Nonferrous • Part C - Filler Metals • Part D - Properties • III - General Requirements • IV - Const - Heating Boilers • V - NDE • VI - Operations of Power B. • VII - Care of Power Boilers • VIII - Unfired Pres.Vessels • Divisions 1, 2, and 3 • IX - Welding Qualifications • X - FRP PressureVessels • XI - Nuclear Inspections
- 18. SPECIFICATION “A detailed description of the parts of a whole: statement or enumeration of particulars as to actual or required size, quality, performance, terms, etc.”
- 22. OTHER STANDARDS ORGANIZATIONS • ANSI • ASTM • ISO • IIW • NACE
- 23. CONTROL OF MATERIALS “The identification and traceability of materials”
- 24. MATERIAL TEST REPORT (MTR) The starting point for material control
- 25. MTR • Review: • Product Form • Heat Number • Chemistry • Mech. Properties
- 26. MATERIAL CONTROL SYSTEMS • Should be simple • Contain checks and balances • Specify marking methods
- 27. MATERIAL CONTROL METHODS • Segregation • Color coding • Alphanumeric • Bar coding • Tagging • Stamping
- 28. ALLOY IDENTIFICATION SYSTEMS • Industry associations • SAE • AISI • CDA • Castings • Tool steels • UNS • ASTM
- 29. ASTM STANDARDS
- 30. ASTM A514 “Standard specification for high yield strength, quenched and tempered alloy steel plate, suitable for welding”
- 31. TYPICAL ASTM SPECIFICATION • Scope • Applicable Documents • General Delivery Requirements • Process • Heat Treatment • Chemical Requirements • Mechanical Requirements • Hardness Requirements • Test Specimens • Number of tests • Retest • Marking • Supplemental Requirements
- 32. AWS A5.1 “Specification for covered carbon steel arc welding electrodes”
- 33. TYPICAL AWS FILLER SPECIFICATION • Scope • General Requirements • Classification • Acceptance • Certification • Retests • Method of manufacture • Marking • Packaging, Rounding-off • Required Tests, Methods • Manufacturing, Packaging, Identification • Details of Tests • Appendix
- 34. QUALIFICATION FABRICATORS’ RESPONSIBILITY • Procedures • Welders • Welding operators • Tack welders
- 35. PROCEDURE QUALIFICATION Determines compatibility of: • Base metal(s) • Filler metal(s) • Process(es) • Techniques
- 36. PROCEDURE QUALIFICATION Three methods: • Prequalified procedures • Procedure qualification testing • Mock-ups
- 37. PREQUALIFIED PROCEDURES • Used by AWS D1.1 & D1.5 • No need for testing • Saves time and money
- 38. PROCEDURE QUALIFICATION TESTING • ASME,API,AWS, & most Codes & Standards • Welding and brazing • Defines essential welding variables • Testing required
- 39. ESSENTIAL WELDINGVARIABLES “Those variables, that if changed beyond certain limits, require a new procedure qualification”
- 40. ASME QUALIFICATION • Section IX • Welding procedure specification (WPS) • Lists essential welding variables • Procedure qualification record (PQR) • Notes actual test conditions
- 41. MOCK-UPS “Used for special joint configurations”
- 42. REQUIRED SPECIMENS Prior to qualifying a procedure: • Determine test specimen requirements for selected Code • Make test weldment large enough to obtain proper number and type of samples • Consider making it large enough for an extra test specimen or two • Maintain test weldment and specimen orientation per Code
- 43. PROCEDURE QUALIFICATION STEPS - 1 OF 2 • Select welding variables • Check equipment and materials • Monitor fitup & welding - document! • Identify test specimens • Test and evaluate specimens
- 44. PROCEDURE QUALIFICATION STEPS - 2 OF 2 • Review results for compliance • Release approved procedure • Qualify other welders • Monitor production welding
- 45. WELDER QUALIFICATION “Determines if individual welders have sufficient skill to produce satisfactory welds using a qualified procedure”
- 46. WELDINGVARIABLES Examples of essential variables in some codes: • Welding position • Joint configuration • Electrode type and size • Base metal type, thickness • Welding techniques • Use of backing
- 47. TYPE & POSITION LIMITATIONS • Depends on Code used • Refer to Code for test weldment thickness requirements and limitations on welder qualification • Use Module 5, Figure 5.19, as example for review
- 48. WELD POSITION DESIGNATION Position Designations: • Different for Plate and Pipe • Different for Groove and Fillet welds • Must know positions and designations • See Module 5, Figures 5.20 - 5.23
- 49. THICKNESS RANGE QUALIFIED • Depends on Code used • Depends on test specimen thickness • See Figure 5.24 for D1.1 requirements
- 51. FILLET WELD TEST SPECIMEN
- 53. ELECTRODE CLASSIFICATION GROUPINGS Group Designation AWS Electrode Classification F4 EXX15, EXX16, EXX18, EXX15-X, EXX16-X EXX18-X F3 EXX10, EXX11, EXX10-X, EXX11-X F2 EXX12, EXX13, EXX14, EXX13-X F1 EXX20, EXX24, EXX27, EXX28, EXX20-X, EXX27-X
- 54. QUALIFYVS CERTIFY Qualify - Welder has skill to weld Certify - Documents support above
- 55. WELDING INSPECTION REQUIRES: • Availability of documents • Knowledge of documents • Use of documents • Materials control • Qualifications
- 56. QUALITY IS: ...conformance to specifications. so….. KnowYour Specifications!
Editor's Notes
- WIT Pg. 5-1 Instructor Should Explain: It Is Essential for the Welding Inspector to Study All Applicable Documents Before the Start of a Job. General Information Requirements Specifics Guidance
- WIT Pg. 5-1 Instructor Should Explain: These Are Documents the Inspector Needs or Should Have Access To.
- WIT Pg. 5-3, Fig. 5.2 Instructor Should Explain: Drawings Best Source for Fabrication Details: Graphic Detail of Part Dimensions Tolerances Assembly Needs Finishing Requirements
- WIT Pg. 5-1, Fig. 5.2 Instructor Should Explain: Dimensional Data Highlighted: Provides Sizes Shows Placement of Parts English or Metric
- WIT Pg. 5-2, Fig. 5.2 Instructor Should Explain: Tolerances Highlighted: A Variation Between Limits Design Size, Plus or Minus Design Size, One Tolerance Reference Fig. 5.1 Pg. 5-2
- WIT Pg. 5-3 Instructor Should Explain: Notes Block: Graphic Detail of Part Dimensions Tolerances Assembly Needs Finishing Requirements
- WIT Pg. 5-4 Instructor Should Explain: These Should Be Shown On A Welding Procedure Specification and Referenced to the Applicable Fabrication Drawings.
- WIT Pg. 5-4 Instructor Should Explain: Some Applicable Documents May Dictate “Hold Points” During The Fabrication Process. Hold Points Required to Avoid Case Where Subsequent Fabrication Will Cover up Previous Welds.
- WIT Pg. 5-4 Instructor Should Explain: Refer to Items The Welding Inspector Establishes Conformance or Otherwise With Reference to Specific Criteria. It Is Imperative That A Welding Inspector Be Able To Read A Blueprint.
- WIT Pg. 5-5 Instructor Should Explain: When Specified in a Purchase Document a Code Has Legal Status. Emphasize need to know definition
- WIT Pg. 5-5 Instructor Should Explain: Give Students Examples of Building Codes, Such As For Structures, Homes or Dwelling, Etc.
- WIT Pg. 5-5 Instructor Should: Briefly Discuss Each Item Listed
- WIT Pg. 5-5, 6 Instructor Should Explain: API - American Petroleum Institute ABS - American Bureau Of Shipping DOT - Department Of Transportation Refer Students to Table 5.1, Pg. 5-10, Standards Producing Organizations
- WIT Pg. 5-5, 6 Instructor Should Explain: Note: Student Should Know Definition Give Some Examples of Standards - Refer to Figures 5.6, 5.7, Page 5-8.
- WIT Pg. 5-7, 8 Figs. 5.4 - 5.8 Instructor Should Explain: Standards Can Become Codes When Adopted by State or City. These Are Photos of the Covers of Code and Standards Documents.
- WIT Pg. 5-9 Instructor Should Explain: Know Definition Give Examples of Specifications Such As: A5.1 - Filler Metal Specification for Covered Carbon Steel Electrodes
- WIT Pg. 5-14 Instructor Should Explain: AWS A5.1 - AWS A5.30 - Filler Metals Specifications for the several types of welding processes and metals used in welding
- WIT Pg. 5-15, Fig. 5.8 Instructor Should Explain: These Are Specifications for the Construction of the Indicated Items of Welded Equipment. D14.1Industrial and Mill Cranes D14.2Metal Cutting Machine Tools D14.3Construction Equipment D14.4Machinery and Equipment D14.5Welding Presses and Components D14.6Rotating Elements of Equipment
- WIT Pg. 5-9,14, Fig. 5.8 Instructor Should Explain: ANSI - American National Standards Institute ASTM - The American Society For Testing And Materials ISO - International Organization For Standardization IIW - International Institute Of Welding
- WIT Pg. 5-14 Instructor Should Explain: Give Example Showing the Importance of Material Control. Identification and Traceability of Materials Is an Important Aspect of Fabrication
- WIT Pg. 5-15 Instructor Should Explain: These Documents Are Usually Notarized Statements From the Manufacturer Tabulating the Chemical and Physical Properties for the Material. Specify on Purchase Order MTR Required
- WIT Pg. 5-16, Fig. 5.9 Instructor Should Explain: This is an example of an MT Report Alloy Type Chemistry Physical Properties Briefly Refer to Sections of the Sample Report in Fig. 5.9, Pg. 5-16
- WIT Pg. 5-15, 16 Instructor Should: Briefly Cover Each Point
- WIT Pg. 5-17 Instructor Should: Expound On Each Material Control Method
- WIT Pg. 5-18 Instructor Should Explain: SAE -Society Of Automotive Engineers AISI - American Iron And Steel Institute CDA - Copper Development Association UNS -Unified Number System (Widely Used in Metals Identification As Set Out in 5.11) ASTM -American Society for Testing and Material
- WIT Pg. 5-20 Instructor Should: Briefly Review Each of the Specification Headings Given on Page 5-20, 21. Filler Metals: - Electrode Designation - Chemistry - Mechanical Properties
- WIT Pg. 5-21 Instructor Should: Briefly Review Each of the Specification Headings Given on Page 5-21.
- WIT Pg. 5-22 Instructor Should: Review each item The Purpose of Qualification Is Shown on the Slides That Follow.
- WIT Pg. 5-22 Instructor Should: Discuss Each Item
- WIT Pg. 5-22 Instructor Should: Discuss The Three Methods
- WIT Pg. 5-22, 23 Instructor Should Explain: Prequalifies Several: Welding Processes Base Metals Filler Metals Thickness' (1/8” And Up) Joint Configurations Techniques
- WIT Pg. 5-25 Instructor Should: Discuss Each Item Involves the Welding of Test Coupons Which Are Subsequently Sectioned and Tested According to the Applicable Code Requirements.
- WIT Pg. 5-25 Instructor Should: Discuss The Essential Variables, Which Include, but Are Lot Limited to: Welding Process Base Metal Alloy Thickness Electrode Diameter
- WIT Pg. 5-25 Instructor Should Explain: Reference Figure 5.15, Pg. 5-26 Through Figure 5.18, Pg. 5-29.
- WIT Pg. 5-30 Instructor Should Explain: Used for Special Joint Configuration Such As a Number of Members Meeting at a Common Point. Give Examples, i.e. Tube-to-Tube Sheet Welds
- WIT Pg. 5-30 Instructor Should Explain: The Inspector Is Responsible to Ensure All Test Coupons Are Sectioned and the Individual Specimens Tested in Accordance With the Applicable Code Requirements.
- WIT Pg. 5-30 Instructor Should Explain: Part of the Welding Inspector’s Function Is to Ensure the Ongoing Suitability of All Welding Procedures Used in Production.
- WIT Pg. 5-31 Instructor Should Explain: Starting Point Is Having a Qualified Procedure Then, Test Welders.
- WIT Pg. 5-31 Instructor Should Explain: Variables Slightly Different for Welder Qualification i.e. - Position
- WIT Pg. 5-36, Fig. 5.25 Instructor Should: Differentiate Between: Backed Non-Backed
- WIT Pg. 5-36 Fig. 5.26 Instructor Should Point Out: Slide Shows - AWS Welder Qualification Test Plate for Fillet Welds
- WIT Pg. 5-37, Fig. 5.28 Instructor Should Explain: Discuss Role of the Restricting Ring in the 6GR Test Refer Students to Figure 5.28, Pg. 5-37
- WIT Pg. 5-37, Fig. 5.29 Instructor Should Explain: Review Each F Group, Noting Low H2 and Position #’s F1 - Iron Powder F2 - Routile F3 - CellulosicF4 - Low Hydrogen Note: F1 - EasiestF4 - Most Difficult
- WIT Pg. 5-38 Instructor Should Explain: Certification Denotes Paperwork
- WIT (Items Discussed Over a Range of Pages) Instructor Should Explain: Need for CWI to a Carry Copy of Code on the Job Site Inspector Is Responsible for Proper Material Usage
- WIT Pg. 5-42 Instructor Should Explain: Must Inspect to a Specification, Code or Standard