Codes and QA & QC in Welding

QualityDegree to which a set of inherent characteristics fulfils requirements

BByDr. Khalid Mohamed Hafez

Welding & Material [email protected]

Tel.: 0125784166

MAJOR QUALITY PROBLEMSMAJOR QUALITY PROBLEMS(RESULTS SURVEY OF ENGINEERING INDUSTRIES IN BRITAIN IN 1970)

IHuman Error.. 12%IBad Inspection Method. 10%I pILack of and/or wrong specification. 16%ILack of Proving (new design, materials, manufacturing I processes) . 36%IPoor Planning. 14%IU f bl & h 12%IUnforeseeable & other.. 12%

Dr. Khalid Mohamed HafezWelding & Material [email protected].: 0125784166

Codes & Standards


Types of Standardsyp[Codes are generally applicable to processes

d i di t th d t f t i l Shall/willand indicate the mandatory use of materials or actions

[Specifications are generally associated with i[Specifications are generally associated with a product and indicate the mandatory use of materials or actions

Shall/will

[Recommended practices and guides are offered primarily as aids to the user

Should/may

[Classifications and methods provide lists of established practices or categories for processes or products


Code Writing Agencies

This Tableis in theis in the Welding Handbook

Wh t i C d b St d dWhat is Covered by Standards[Productsoduc s

l Piping - American Petroleum Institutel Filler metals - American Welding Societyl Filler metals American Welding Societyl Ships - American Bureau of Shippingl Pressure vessels and boilers - American Societyl Pressure vessels and boilers American Society

of Mechanical Engineersl Bridges - American Institute of Steel Constructiong

[Health & Safety[Terminology[Terminology[Testing Procedures


American National Standards Institute (ANSI)[Coordinating organization for the U S voluntary[Coordinating organization for the U.S. voluntary

standards system[There are approximately 10 000 American National[There are approximately 10,000 American National

Standards, which encompass nearly every field and disciplinep

[ANSI standards are developed and used voluntarily; they become mandatory when adopted or referenced by a governmental body

International Organization for Standardization (ISO)g ( ) Establishment of Uniform Standards for International Trade


International Organization for gStandards (ISO)[ 80 countries, 4000+ standards, ANSI is the U.S. representative[ ISO 9000-9004 (ANSI/ASQC Q90) is a series of quality

management and assurance standards in manufacturingmanagement and assurance standards in manufacturingl Designed for manufacturing sectorl EC has adopted ISO 9000 and prefers US suppliers p p pp

that are ISO 9000 certifiedl DoD, DuPont, 3M, AT&T are asking suppliers to comply

with ISO 9000with ISO 9000[ ISO 3834 - Factors to be Considered When Assessing Firms

Using Welding as a Prime Means of Fabrication


Health & Safety

[ANSI/ASC Z49.1-1988 Safety in Welding and CuttingCuttingl Included in the General Industry Standards of

OSHAOSHAl Specifically covers arc, oxyfuel gas, resistance

weldingwelding[Health and Safety in Welding and Allied Processes

4th edition, ed. N.C. Balchin and H. R. Castner, , ,McGraw-Hill Inc. 1993


American Welding Society (AWS) g y ( )Standards

[Definitions and Symbols (A)Fill M t l (A5)[Filler Metals (A5)

[Qualification and Testing (B, C, and D)W ldi P (C)[Welding Processes (C)

[Welding Applications (D)


Definitions and Symbols

[ ANSI/AWS A2.4 Symbols for Welding, Brazing, and Nondestructive ExaminationNondestructive Examinationl Communication between designers and fabricatorsl Joint geometry, weld contour, surface finish

[ ANSI/AWS A3.0 Standard Welding Terms and Definitionsl Standard terms for use in written and oral communication

conveying materials joining informationconveying materials joining informationl Non-standard terms


ANSI/AWS D1.1 Structural Welding gCode: Steel

[Guidelines for design of welded joints as well as prequalified joint geometriesprequalified joint geometriesl Statically loaded structures

Dynamically loaded structuresl Dynamically loaded structuresl Tubular sections

[Details the processes used with particular joints[Details the processes used with particular joints[How to qualify welding procedures and personnel

O tli lit d i ti i ld d t ti[Outlines quality and inspection in welded construction[Filler metal recommendations


ASTM (American Society for TestingASTM (American Society for Testing and Materials)

[ Specifications cover virtually all materials used in industry and commerce, but not welding consumablescommerce, but not welding consumables

[ Annual Book of ASTM Standards, 15 sections (65 volumes)l 1 - Iron and Steell 2 - Non-ferrousl 3 - Metal test methods and analytical procedures

[ Specification of groups of similar steel (A)[ Specification of groups of similar steel (A)l A36 - general construction steelsl A387 - chromium-molybdenum steel for elevated-y

temperature service in piping and pressure vessel systems


American Society of Mechanical Engineers (ASME)Mechanical Engineers (ASME)[ Boiler and Pressure Vessel Code has 11 sections and is

referenced by most states, major cities in the U.S., Canadian provinces, a number of federal agencies

[ Before fabricating a boiler or pressure vessel a company must[ Before fabricating a boiler or pressure vessel, a company must have a quality control system and a manual describing itl ASME issues a Certificate of Authorization and a code

symbol stamp[ Unique in that it required 3rd party inspection independent of

fabricator and userab ca o a d use[ Uses same steel designations as ASTM


Boiler and Pressure Vessel Code[ Section II- Materials Specifications for base metals, filler

metals fluxesmetals, fluxes[ Section V - Nondestructive Examination[ Section IX - Welding and Brazing Qualifications for[ Section IX Welding and Brazing Qualifications for

personnel and proceduresl Delineates a P number grouping of steels for the

purpose of welding qualificationl P1 - carbon-manganese steels with a minimum UTS of

45 90 ksi45-90 ksil P5 - alloy steels with 2.25-9% chromium,

Oth St d dOther Standards

[American Petroleum Institute (API) Standard 1104 Welding of Pipelines and Related Facilities

Q lifi ti f W ldi P d d W ldl Qualifications of Welding Procedures and Weldersl Inspection and nondestructive testingl Repair and removal of defects

[Unified Numbering System (UNS)l Cross references the numbering systems from

different countriesO 3500 t l ll d fill t ll Over 3500 metals, alloys, and filler metals

l Designated SAE HSJ1086 / ASTM DS56


Qualification & Certification


W ldi P d S ifi ti (WPS)Welding Procedure Specification (WPS)A document that provides in detail required welding conditions for a specific application.

Procedure Qualification Record (PQR)A record of actual welding conditions used to produce an acceptable test joint and the results of the qualification tests.

Welder Performance Qualification-CertificationA record of a welders or welding operators ability to produce welded joints that meet prescribed standards


W ldi d (WPS)Welding procedure (WPS)

[Process instructionl Details joint and materials to be welded, l Process, method and equipment to be , q p

used[Subject to review revision or withdrawal[Subject to review, revision or withdrawal[Approval by technical authority

Vi ibl b th ld[Visible by the welderl Understand it?


Common to all Processes[ Procedure number [ Process type [ Consumable Size Type and full Codification[ Consumable Size, Type and full Codification. [ Consumable Baking Requirement if applicable [ Parent material grade and spec. [ Thickness range. [ Plate or Pipe, Diameter range [ Welding Position [ Joint Fit Up, Preparation, Cleaning, Dimensions etc. [ Backing Strip Back Gouging information[ Backing Strip, Back Gouging information.[ Pre-Heat (Min Temp and Method) [ Interpass If Required (Maximum Temperature recorded ) [ Post Weld Heat Treatment. If Required (Time and Temp) [ Welding Technique (weaving,max run width etc.) [ Arc Energy Limits should be stated if impact tests are required or if the material

being welded is sensitive to heat input.


Specific To Welding Processes MMA TIGMIG MAG FCAW

SUB ARCFCAW

Welding current yes yes yes yes

Type of Welding current AC/DC Polarity yes yes yes yes

Arc voltage If Auto yes yesArc voltage If Auto yes yes

Pulse parameters (Pulse time and peak & backgound current)

If Used If Used

Welding Speed If Mechanised yes yes yesWelding Speed If Mechanised yes yes yes

Wire configuration yes

Shielding gas (comp,flow rate) yes yes

P ( & fl t ) If U d If U dPurge gas (comp & flow rate) If Used If Used

Tungsten electode Diameter and type. yes

Nozzle diameter yes yes

Type of Flux Codification & Brand Name yes

Nozzle Stand Off Distance (Distance from tip of nozzle to workpiece).

yes


WPS


Procedure qualification

[Proves that the procedure meets statutory i trequirements

[Demonstrates that a test weld has the required mechanical properties (and sometimes soundness)[Demonstrates fabricators capability[Documented by a welding procedure[Documented by a welding procedure

qualification test record (WPQR or PQR)


WPS qualification tests

[WPQR test plate or pipeAt l t 300 l ith 150 f bl At least 300mm long with 150mm of base material either side of weld

[Tested to contract or specification[Tested to contract or specification requirements l NDT and mechanical testsl NDT and mechanical tests

[Strength, ductility, toughness[Welding is witnessed and parameters[Welding is witnessed and parameters

recorded


Basic Steps in Qualification of a Procedure

[Prepare a preliminary WPS[Prepare and weld a suitable test weldment

using WPS[Conduct required NDT and Destructive Tests[ Evaluate Results of prep welding testing[ Evaluate Results of prep, welding, testing[Document results on PQR

I d PQR[Issue approved PQR[Issue approved WPS


PQR - WPS Variables Considered

Tack Weld/Grind Off?W ldi D t il Base Metal

Welding Process Filler Metal Type of Current/Range

Welding Details Electrode Size PassesWeaveType of Current/Range

Voltage Heat Input Travel Speed

Position * Preheat and Interpass Peening

S d Sid P Joint Design and Tolerances Joint and Surface Prep

Second Side Prep Post Weld Heat Treat Records (If Required)

Check Specific Code for List of Essential Variables(Essential Variable Must Be Included in the WPS)


PQRPage 1


PQRP 2Page 2


Typical qualification testsyp q[NDT (often not required)[Transverse tensile test

l Demonstrates that weld has strength equivalent to the base t i lmaterial

[Bend testsDemonstrate that weld has sufficient ductility and is free ofl Demonstrate that weld has sufficient ductility and is free of defects

[Charpy impact tests py pl Notch position in weld metal and often in HAZ

[Macro examination[Hardness tests[Other tests


Qualification test piece300

Bends

Discard

Bends

Tensiles

WeldRoot

HAZ

450 CharpysMacro

HAZ

Charpy notch positionsHardness

Retests

Charpy notch positions

Discard


WPS approval

[Review and acceptance of the WPS and l t WPQR b th l t th itrelevant WPQR by the relevant authority

[Required by standards


WPS variables

[Essential variables-l If changed beyond the allowed tolerances the

procedure is not valid[Non-essential variables-

l Changes to these may be made, but the parameters must be documented


Pre-qualified procedures

[Procedures that do not require qualification t ttests[AS1554.1, AS3992, AWS D1.1

l Deemed to be a low risk of test failurel Limited range of

Materials and consumables Joint geometry (specific bevel angle, gap, etc)

W ldi Welding processes

l Technique must follow standard


Pre-Qualified Procedures(Some Codes Permit - Example AWS D1.1 Code)( p )

Based on the reliability of certain proven procedures spelled out by the applicable code or specification

U W i P d F C d Use Written Procedures From Code All Essential Variable Specified Weld Qualification Tests Not Required Weld Qualification Tests Not Required Employer Accepts Responsibility for Use Deviations Negate Prequalified Statusg q


AWS D1.1 Prequalified Joint Design


Welding personnel


W ldi lWelding personnel

[Authorised Welding Coordinator[Welding Engineer[Welding Supervisorg p[Inspectors[Welders and operators[Welders and operators


Welding coordinator tasks

[Pre-production [Productionl Contract & design

reviewM t i l d

l Equipment, jigs fixturesA bl ldil Materials and

consumablesSubcontract work

l Assembly, welding sequencesInspection & testingl Subcontract work

l WPS, WPQR, work instructions

l Inspection & testingl Environment, health

& safetyinstructions & safety


Welding engineer/technologist

[Degree in engineering or science[Plus post graduate education in welding

l PhD, MSc, diploma [Or post graduate experience in welding and

joiningj g[Should be employed on complex projects


Welding supervisor

[Trade qualifications and experience[Steel structures AS1554

l AS 2214[Pressure equipment AS1200

l AS1796 Certificate 10S 96 Ce t cate 0[International welding specialist

l IIW recognisedl IIW recognised


Welding inspector

[Suitable training, trade experience and lifi tiqualifications

[International welding inspector[WTIA certificate in weld inspection[CBIP New Zealand[CBIP New Zealand[CSWIP Britain


Welders and operators

[Weldersl Trade experience, training and qualificationsl Manual/physical skill l Technical knowledgel Works with minimum supervision

[Welding operatorsl Semi-skilled (non-trade)( )l May require close supervisionl Processes such as spot welding only


p g y

W ld t i i & lifi tiWelder training & qualification

[Education and training[Welder certification to AS1796[Welder qualificationq[Performance monitoring

l Auditl Auditl Review of defective welding


Welder qualification

[Test whereby the welder produces a test weld which has to meet the visual & NDT standards requiredhas to meet the visual & NDT standards required

[Variablesl Welding processl Welding processl Material and consumablesl Joint detaill Joint thickness l Welding positionl Pipe diameter


Welder Performance Qualification

Variables Welding Process Filler Metal Position Joint Details

Thi k Thickness Technique

(Qualifying in a more difficult position(Qualifying in a more difficult positionmay qualify in an easier position)

Duration Of QualificationQ

Dependent upon Code (Usually inactivity of 3 to 6 months required requalification)


( y y q q )

PerformanceQualification

Record

P No. EN288 Base Metal

1 1

Carbon Manganese Steels, 4 Sub Groups Group 1 up to approx 65 ksi Group 2 Approx 70ksi Group 3 Approx 80ksiGroup 3 Approx 80ksi Group 4 ?

2 - Not Used

3 4 3 Sub Groups:- Typically half moly and half chrome half moly

4 5 2 Sub Groups: Typically one and a quarter chrome half moly4 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 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, 310Group 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 Steel10A,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 7 9 Nickel Steels

11 A Groups 2 to 5 ? Mixed bag of high strength low alloy steels.

11B ? 10 Sub Groups:- Mixed bag of high strength low alloy steels.

12 to 20 - Not Used

21 21 Pure Aluminium


21 21 Pure Aluminium

22 22a Aluminium Magnesium Grade 5000

23 23 Aluminium Magnesium Silicone Grade 6000

24 - Not Used

Inspection & test plan

[Lists production and inspection activities in a logical sequencesequence

[Describes who is responsible for the completion of each activity & if / how it is reportedeach activity, & if / how it is reported

[Can cover quality, safety & environment control[Hold and witness points[Hold and witness points

l Hold point - must be signed off as completed before undertaking the next activity

l Witness point - requires the clients authority to witness the activity as it is undertaken


Codes and QA & QC in Welding

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