CWB Welding Procedure Guide
Transcript of CWB Welding Procedure Guide
Welding
ProcedureGuide
© Copyright 2008 CWB Group - Industry Services
®
An easy to follow guide covering the preparation of welding procedure data sheets
© Copyright CWB Group - Industry ServicesRevised September 2008
All rights reserved.
CWB Group1-800-844-6790
www.cwbgroup.org
®
ii© Copyright CWB Group - Industry Services
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TABLE OF CONTENTS
1.0 Introduction 2
2.0 Welding Engineering Standards 3
3.0WeldingProcedureSpecification(WPS) 3
4.0WeldingProcedureDataSheet(WPDS) 4
4.1 BLOCK1(GeneralInformation) 6
4.2 BLOCK2(Processinformation) 7
4.3 BLOCK3(Jointinformation) 8
4.4 BLOCK4(Technicaldata) 11
4.5 BLOCK5(Jointpreparation) 13
4.6 BLOCK6(BaseandFillermaterial) 14
4.7 BLOCK7(Weldingdetails) 16
4.8 BLOCK8(Finalremarks) 20
5.0 Submission Of Welding Procedures 23
6.0 Review And Approval Of Welding Procedures 24
7.0 Sample Welding Procedure Data Sheets 26
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1.0 Introduction
ThisguidehasbeenpreparedtoassistweldingpersonnelwiththepreparationofweldingproceduresrequiredaspartoftheircompanycertificationtoCSAStandardsW47.1,W47.2andW186.
Thefollowingthreedocumentswillbedescribed:
(a)WeldingEngineeringStandards(Note:OnlyrequiredforW47.2)
(b)WeldingProcedureSpecifications
c)WeldingProcedureDataSheets
Therewillbeabriefdescriptionofthefirsttwodocuments;however,thisguidewillfocusonthepreparationof welding procedure data sheets. Each item on the welding procedure data sheet will be described and guidance will be provided to complete each section.
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2.0 Welding Engineering Standards
Welding engineering standards cover the design of welded joints encountered by the fabricator and
prepared primarily for the fabricator’s engineering and drafting personnel.
Theweldingengineeringstandardstypicallyinclude:
(a)Illustratedprofilesofeachtypicaljointintendedforuse,showing:
(i)Thetypeofjoint(eg,butt,lap,tee,corner,edge);
(ii)Thetypeofweld;
(iii)Thegeometryofthepreparationandfit-up;
(iv)Thestandardweldingsymbol;
(v)Therangeofthickness;and
(b)Minimumpermissiblesizesoffilletandpartialpenetrationgroovewelds.
Welding symbols shall be as shown in AWS Standard A2.4.
Sample welding engineering standards are available on our website www.cwbgroup.org
3.0 WeldingProcedureSpecification(WPS)
AllcompaniesapplyingorcertifiedtoCSAStandardsW47.1,W47.2orW186arerequiredtoprepareand
submitweldingprocedurespecificationstotheCWBforacceptance.
Aweldingprocedurespecification(WPS)setsbroadguidelinesfortheshopandfieldweldingpracticeofthe fabricator for each anticipated combination of essential variables. Welding parameters and ranges are specifiedandusedtopreparetheassociatedweldingproceduredatasheets.
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Thecompanyshallhaveweldingprocedurespecificationsforeachweldingprocessinuse,outliningthegeneral welding procedure to be followed in the construction of weldments built in accordance with the governingdesignormanufacturingstandard,orboth.WeldingprocedurespecificationssubmittedforacceptanceshouldcoverasaminimumtheitemsspecifiedinAppendixDofCSAStandardW47.1orAppendixAofCSAStandardW47.2,asapplicable.Eachweldingprocedurespecificationshallincludeapplicableessentialvariables.AllweldingprocedurespecificationsshallbesubmittedtotheBureauforacceptance and when stamped as accepted shall be considered as registered with the Bureau.
Sampleweldingprocedurespecificationsareavailableonourwebsitewww.cwbgroup.org
4.0 WeldingProcedureDataSheet(WPDS)
Aweldingproceduredatasheet(WPDS)isadocument,usedinconjunctionwithaWPS,detailingtheweldingparametersandrangesforweldingaspecificjoint,overarangeofthicknessesandweldsizes,asillustratedonthedatasheet.ThefollowingisthestandardweldingproceduredatasheetformsuggestedbytheCWB,however,otherweldingproceduredatasheetformatsmaybeused.Eachitemonthedatasheetwill be described and guidance on the completion of the form will be given. Common errors in completing theformwillbeidentified.
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4.1 BLOCK1(GeneralInformation)
Companynameandaddress
Enter the complete company name and address in this section. If the data sheets are to be used by twoormorecertifiedplantswithinthesamecompanytheapplicableplantsneedtobeidentifiedinthedocumentation submitted.
WPDS No.
Eachcompanyshouldhaveitsownmethodofnumberingweldingproceduredatasheets.Thiscanrangefromarelativelysimpleconsecutivenumbersystemtoonethatidentifiestheprocess,position,groovetypeand electrode. Each welding procedure data sheet number should be unique so that the WPDS can be easilyreferencedonproductionschedules,workorders,shopdrawingsetc.
Date and Revision
Enter the date the welding procedure data sheet was prepared and the revision number.
ReferenceStandards
Someweldingstandardsthatmaybereferencedare:
W47.1–CertificationofCompaniesforFusionWeldingofSteel
W59–WeldedSteelConstruction(MetalArcWelding)
W186 – Welding of Reinforcing Bars in Reinforced Concrete Construction
W47.2–CertificationofCompaniesforFusionWeldingofAluminum
W59.2 – Welded Aluminum Construction
AWSD1.1 – Structural Welding Code - Steel
AWSD1.3 – Structural Welding Code – Sheet Steel
AWSD1.6 – Structural Welding Code – Stainless Steel
AcommoncombinationisW47.1andW59.Forcertifiedcompanies,theremustalwaysbeacertificationstandardstated(eg.W47.1,W47.2,W186)plusa“Construction”standard(eg.W59,W59.2,D1.3,D1.6).
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ReferenceWPS
Recordtheweldingprocedurespecificationnumberthatappliestothisdatasheet.
SomecommonmistakeswithBlock1:
Thecompanynameandaddressarenotcompleted.•
Morethanonedatasheethasthesameidentificationnumber.•
Noreferencecodeisspecified.•
Referencecodesarespecifiedthathavedifferentqualificationrulesandessentialvariables.For•exampleW59andD1.3.
4.2 BLOCK2(Processinformation)
Welding Processes
Theweldingprocesstobeusedshouldbespecifiedinthissection.Iftwoweldingprocessesareusedtoweldthejointtheycanbeeachbeenteredintheareasidentified“1”and“2”.Someofthecommonprocessesusedarelistedbelowwiththeircorrespondingletterdesignations:
Process Letter Designation
ShieldedMetalArcWelding SMAW
GasMetalArcWelding GMAW
FluxCoredArcWelding FCAW
MetalCoredArcWelding MCAW
GasTungstenArcWelding GTAW
Submerged Arc Welding SAW
Plasma Arc Welding PAW
Electroslag Welding ESW
Electrogas Welding EGW
Stud Welding SW
Theletterdesignationmaybeusedtoidentifytheprocess.
FulldetailsaboutthevariousweldingprocessescanbefoundintheCWBmodules.
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Pulsed
Ifpulsedcurrentisusedcheckthisbox.Entertherootmeansquare(RMS)currentinblock7andthepeakandbackgroundcurrentintheremarkssectionofblock8.Thepulsedpowersourcebrand,modelnameandtheapplicableprogramnumbershouldalsobenotedintheremarkssection(Block8).
Shielding Gas type
Record the complete generic composition or gas trade name as shown on the label on the gas cylinder.
Use of the generic composition is advantageous as it allows the user to change brands of shielding gas with the same composition with no required changes to the WPDS.
Note:Ifthetradenameisused,achangetoanotherbrandname,evenifitisofidenticalcomposition,willrequire revised data sheets.
Thegasmanufacturer/suppliermaybeabletoprovideyouwiththegenericcomposition.Forgasmetalarcwelding,thewireisclassifiedusing100%CO2;however,argon-oxygen-carbondioxidecombinationsmaybeusedbasedontheoxygenequivalent.
ForfulldetailsofgascombinationsrefertoCSAStandardW48.
SomecommonmistakeswithBlock2:
Noweldingprocessspecified•
Nogascompositionspecified•
Gasnotcertifiedwiththefillermaterial•
4.3 BLOCK3(Jointinformation)
Positions
PositionsshownonthedatasheetshouldbetheproductionpositionclassifiedasFlat(F),Horizontal(H),Vertical-Up(V-U),VerticalDown(V-D)orOverhead.
Numberandlettercombinationsarealsousedtodesignateeachweldingpositionforquickreference.TheletterGstandsforgrooveweld,letterFforfilletweld.Thenumbers1,2,3and4correspondtoflat,horizontal,verticalandoverheadpositionsrespectively.Fortheverticalpositionindicateiftheprogressionis vertical up or vertical down.
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Inactualshopfabricationweldingcanbeinanyintermediateposition.FordetailedinformationonthedefinitionofthevariousweldingpositionspleaseconsultAppendixEofCSAStandardW59,WeldedSteelConstruction(MetalArcWelding)orAWSA3.0,StandardWeldingTermsandDefinitions.
Processmode(manual,semi-automatic,machineandauto)
Oneofthefourprocessmodesshouldbecheckedinthissectionbasedonthefollowingdefinitions.Donotenter more than one process mode unless multiple processes are used.
Manualwelding.Weldingwiththetorch,gunorelectrodeholderheldandmanipulatedbyhand.Accessoryequipment,suchaspartmotiondevicesandmanuallycontrolledfillermaterialfeedersmaybeused.AnexampleisSMAWorGTAW.
Semi-automaticwelding.Manualweldingwithequipmentthatautomaticallycontrolsoneormoreoftheweldingconditions.ExamplesareFCAW,GMAW
Machinewelding(mechanizedwelding).Weldingwithequipmentthatrequiresmanualadjustmentoftheequipmentcontrolsinresponsetovisualobservationofthewelding,withthetorch,gunorelectrodeholderheldbyamechanizeddevice.SAWisanexample.
Automatic welding. Welding with equipment that requires only occasional or no observation of the welding andwithnomanualadjustmentoftheequipmentcontrols.Anexampleisaroboticapplication.
Jointtype
Checkthebox(s)toindicatethejointtype.Thefivebasictypesarebutt,tee,corner,lapandedge.
Fordefinitionsanddetailsofjointtype,pleaseconsultCWBModule2,EngineeringDrawings,BasicJointsand Preparation for Welding.
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Penetration(complete,partial,ETT)
Thedepthofpenetrationofagrooveweldneedstobeidentified.
Acompletejointpenetrationgrooveweldisdefinedasoneinwhichtheweldmetalextendsthroughthejointthickness.Thiscanbeachievedwithorwithoutbacking.Ifcompletejointpenetrationisachievedtheboxmarked“Complete”shouldbechecked.
Apartialjointpenetrationgrooveweldisoneinwhichincompletejointpenetrationexists.Ifthisisthecasetheboxmarked“Partial”shouldbecheckedandtheeffectivethroatthickness(ETT)shouldbedimensionedinthespaceprovided.TheETTmaybespecifiedasapercentageofT,eg.ETT=0.75T.Table4-3ofCSAStandardW59showsminimumgroovedepthsforpartialjointpenetrationgrooveweldsbasedonthethicknessofthepartsandthegrooveangleattheroot.Verifythattheserequirementsaremet.
Fillet
Theboxmarked“fillet”shouldbecheckediftheweldisaweldofapproximatelytriangularcrosssectionjoiningtwosurfacesapproximatelyatrightanglestoeachotherinalap-joint,T-jointorcornerjoint.Jointswithagrooveanglegreaterthan135degreesorlessthan30degreesrequiregreaterdetailinthesketch(definedasskewedjoints).RefertoW59Clause4.5formoredetail.
Backing(materialandthickness)
Backingisamaterialordeviceplacedagainstthebacksideofthejointadjacenttothejointroottosupportand shield molten weld metal.
Permanentbackingisdesignedtoremaininplaceaspartofthefinishedweld.
Backingsusedfortheweldingofsteelsuptoandincluding480MPa(70ksi)minimumspecifiedtensilestrength may be any of the steels listed in clauses 11.2.1 and 12.2.1 of CSA Standard W59.
W59requiresthatbackingsusedfortheweldingofsteelsofover480MPa(70ksi)minimumspecifiedtensile strength and shall be of the same material as the base material.
Ifsteelbackingisusedenterthematerialandthicknessofbackinginthespaceprovided
Non-permanentbackingscanbemadefrommaterialssuchasceramic,copperorflux.Iftheyareusedenterthematerial,typeandformofthebackinginthespaceprovided.
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Backgouging(Yes/No,Method,Depth)
Backgougingistheremovalofweldmetalandbasemetalfromtheweldrootsideofaweldedjointtofacilitatecompletefusionandcompletejointpenetrationuponsubsequentweldingfromthatside.Methodsincludegrindingtosoundmetal(GTSM),aircarbonarcandplasma.
BackgougingshouldproduceagroovecontoursubstantiallyconformingtotheappropriateprequalifiedsingleU-jointinClause10ofCSAStandardW59,anditsdepthshouldbeadequatetoensurecompletepenetration into the previously deposited weld metal for the welding process to be used.
Ifbackgougingisused,thebackgougingboxshouldbechecked.Themethodusedandthedepthidentified.
SomecommonmistakeswithBlock3:
Noweldingpositionspecified.•
Incorrectweldingpositionspecified.Forexample,thedrawingshowshorizontal(2For2G)butposition•says“Flat”.
Progression of welding not shown for Vertical. •
PartialjointpenetrationspecifiedwithETT=T•
NoETTspecifiedforpartialjointpenetration•
Bothfilletandpartialboxesarechecked(Completeorpartialjointpenetrationonlyapplytogroove•welds)
4.4 BLOCK4(Technicaldata)
Electrode extension
Theelectrodeextensionforthegasmetalarcwelding,fluxcoredarcwelding,submergedarcweldingprocessesisthelengthofelectrodeextendingbeyondtheendofthecontacttip.
Theelectrodeextensionforthegastungstenarcweldingandplasmaarcweldingprocessesisthelengthofelectrodeextendingbeyondtheendofthecollett.
Entertheelectrodeextensioninthissection.Donotleaveitblank.IftheinformationrequesteddoesnotpertaintotheweldingprocessusedinsertN/A(NotApplicable)e.g.SMAW.
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Nozzlediameter
Thegasnozzleisthedeviceattheexitendofthetorchorgunthatdirectsshieldinggasingasshieldedprocesses.Enterthediameterofthisnozzleinthespaceprovided.Ifitdoesnotapply(eg.non-gasshieldedprocesses),enterN/A.
Fluxclassification
Forthesubmergedarcwelding(SAW)processthefluxclassificationorfluxtradenameshouldbeenterede.g.EM12Korthefluxtradename.Thisinformationcanbeobtainedfromthelabelonthebagofflux.Ifyouenterthefluxtradenameanddecidelatertochangethefluxthedatasheetwillneedtoberevised.Thegenericclassificationispreferred.
Tungstenelectrodes(type,dia.)
ThetungstentypeanddiameterusedshouldbespecifiedfortheGTAWprocess.ForotherprocessesenterN/A.Thechoiceofthetypeandsizeoftungstenelectrodeforaparticularapplicationdependsontheoperating current and current type.
Common tungsten types are listed below.
AWSCLASSIFICATION COMMONNAME COLOUR CODEEWCe-2 2%CeriatedTungsten OrangeEWLa-1 1%LanthanatedTungsten BlackEWTh-1 1%ThoriatedTungsten YellowEWTh-2 2%ThoriatedTungsten RedEWZr-1 1%ZirconiatedTungsten BrownEWG Other-NeedstobeSpecified Gray
Cleaning procedures
Enterthecleaningproceduresused.Thisisparticularlyimportantfortheweldingofaluminumalloysbecauseachangeincleaningmethodisconsideredanessentialvariable.Fulldetailsofthecleaningprocedureusedshouldbeincludedinthecorrespondingweldingprocedurespecification.
CSA W186 Rebar splice type.
ThissectionisonlyusedforweldingproceduredatasheetsforCSAStandardW186-ReinforcingBars.
ThetypesidentifiedinCSAStandardW186are:
direct splice•
indirect splice•
lap splice•
rebar to structural member•
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SomecommonmistakeswithBlock4:
Electrodestickoutnotspecified•
Incompleteornocleaningproceduresspecified•
4.5 BLOCK5(Jointpreparation)
JointConfigurationandPass/Layersequence
Asketchofthejointconfigurationwiththeweldingsymbolandatypicalsequenceofthelayersandpassesshouldbeincludedinthissectionoftheform.Itisrecommendedthatthesketchbedrawninthecorrectwelding postion.
Thejointconfigurationshouldincludethefollowinginformation:
thicknessofparts•
root opening•
root face•
bevel angle•
groove angle•
depth of preparation•
radius(forHSS)•
diameter(forsolidbars/tubing/pipe)•
effectivethroatthickness(ETT)•
SomecommonmistakeswithBlock5:
Missingdetailssuchasrootfaceorland(Rf),Rootgaporopening(G),grooveangle(Θ),radius•
Nonpre-qualifiedmaterialthickness.Ex:0.9mmGMAWwireisnotpre-qualifiedforgrooveweldswith•amaterialthicknessgreaterthan12mm.
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4.6 BLOCK6(BaseandFillermaterial)
Identificationofbasematerial(specificationandgrade,thicknessordiameter,specialrequirements)
Obtainacopyofthemilltestcertificateoranyotherdocumentfromthematerialsupplierthatshowsthespecificationandgradeofthebasematerials.Recordthecompletematerialspecificationsandgradesontheweldingproceduredatasheets.Checkwithyourpurchasingagent.
Thefollowingaresomeexamplesofcorrectandincorrectmaterialdesignations:
Incorrect Correct
44W CSA Standard G40.21 Grade 300W
A572 ASTMA572Grade50
Gr. 400 Rebar CSA Standard G30.18 Grade 400W
Notethatmanymaterials,especiallyASTMmaterials,haveagradedesignationwhichmustbeincluded.
Anothercommonmethodtodesignatematerialsondatasheetsistousesteelgroupssuchas“Steelsingroups1,2and3ofTable11-1/12-1ofCSAStandardW59.Thisisadvantageousasitensuresawiderange of materials are covered.
Identificationoffillermaterial(process,tradename,classification,group,fillertreatment)
FillermaterialclassificationscanbefoundinCSAStandardW48“FillermetalsandAlliedMaterialsforMetalArcWelding”orAWSSpecifications:
Checkthelabelonthefillermaterialboxorspooltoobtainthefullfillermaterialclassification.Thisinformationcanalsobeverifiedonourwebsitewww.cwbgroup.org.
PleasenotethereisanewdesignationsystemforwireelectrodesanddepositsforGMAWofnonalloyandfinegrainedsteelsasspecifiedinISOCAN/CSA-ISO14341.
FulldetailscanbefoundinCSAStandardW48.
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ThecommonlyusedclassificationsareB-G49A2CG3(formerlyER49S-3)andB-G49A3CG6(formerlyER49S-G).
Theelectrodeorelectrode-fluxcombinationforbuttjointsusingcompletejointpenetrationgrooveweldsshallbeinaccordancewithTable11.1or12.1ofCSAStandard.
Theelectrodeorelectrode-fluxcombinationfor:
completejointpenetrationgrooveweldsinjointsotherthanbuttjoints;•
partialjointpenetrationgroovewelds;or•
filletweldsmaybeoflowerorhigherstrengththanrequiredbyTable11.1or12.1,providedthatthe•conditionsofTable11.2(a),11.2(b),12.2(a),or12.2(b),asapplicable,arefullysatisfied.
RememberthatonlysteelsinColumn2ofTable5-3ofCSAStandardmaybeweldedwithSMAWwithotherthanlowhydrogenelectrodesandFCAWandMCAWwithoutdiffusiblehydrogendesignators.
Thefollowingfillermaterialgroupsmaybeusedforshieldedmetalarcwelding(SMAW):
Group ElectrodeClassifications
F1 EXX22,EXX24,EXX27,EXX28
F2 EXX12,EXX13,EXX14
F3 EXX10,EXX11
F4 EXX15,EXX16,EXX18,EXX48
Fillermaterialtreatmentshallbeinaccordancewithmanufacturer’srecommendationsandtherequirementsof the applicable standard.
SomecommonmistakeswithBlock6:
Thebasematerialisnotfullydescribed.Forexample:3XXStainlessSteel.Aprecisedescriptionmust•begivenfromthereferencecodesuchasGroupAorB,Table3.1,AWSD1.6.Aprecisematerialspecificationsuchas“ASTMA240,Grade304L”canalsobegiven.
Thefillermaterialclassificationisincorrect.•
Nothicknessisspecified.•
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4.7 BLOCK7(Weldingdetails)
Thickness
Recordthethicknessofmaterialtobeweldedinthespaceprovided.
Weldsize/ETT
Theweldsizeforafilletweldoreffectivethroatforagrooveweldshouldbeenteredinthissection.
Layerandpassnumber
Enterthenumberofpassesandsequenceofwelding.ThereareseveralwaysavailabletodeterminethenumberoflayersandpassesforaWPDSincluding:
• TheNomographMethod
• TheMathematicalEquationMethod
• TheWeldCalculatorProgramMethod
Thesemethodsrequireyoutocalculatetheareaofweldandtoselectadepositionrate.Depositionratescanbefoundinsomeweldingtextbooks,onlineorfromyourelectrodesupplier.
Steelandaluminumcalculators,Weld_ITsoftware,datasheetpreparationcoursesetc.areavailablefromthe CWB to help you calculate the number of layers and passes. Details can be obtained from our website www.cwbgroup.org.
Welding Processes
Enterthenumber“1”or“2”identifiedinBlock2ortheletterdesignationbelow.
Welding Process Letter Designation
ShieldedMetalArcWelding SMAW GasMetalArcWelding GMAW FluxCoredArcWelding FCAW MetalCoredArcWelding MCAW GasTungstenArcWelding GTAW Submerged Arc Welding SAW Plasma Arc Welding PAW Electroslag Welding ESW Electrogas Welding EGW Stud Welding SW
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Diameter
ThestandardunitsofmeasurementforelectrodediameteraremminSI(metric)andinch(imperial).ThefollowingshowscommonelectrodesizesinSI(metric)andImperialunits.
INCH MM 0.030 0.8
0.035 0.9
0.040 1.0
0.045 1.2
1/16 1.6
5/64 2.0
3/32 2.4
1/8 3.2
5/32 4.0
3/16 5.0
1/4 6.0
Be consistent with the selection of the choice of units.
Wirefeedspeed
Thestandardunitsofmeasurementforwirefeedspeedarem/mininS.I.(metric)andinches/min(imperial).
A calibrated wire feed meter is preferred for measuring wire feed speed when the actual welding is in progress.Ifaverificationoftherecordednumberisnecessaryorawirefeedmeterisnotavailable,measurethelengthofwiredischargedfromthegunforaperiodof20seconds.Multiplythelengthofdischargedwireby3togivethewirefeedspeedininches/minuteormeters/minute.Takecaretoensurethat these are the real wire feed speeds and not the run in values
Current
Currentvaluescanbefoundinweldingtextbooks,onlineorbycontactingyourelectrodesupplierforoneoftheirproductcatalogs.Thecurrenttobeuseddependsonmanyfactorsincludingelectrodetype,size,weldingposition,jointdesign.
Measuretheamperageusingacalibratedclamptypeampmeter.Followthemetermanufacturer’sdirectionsandmeasuretheamperageasclosetothegun/holderaspossiblewithoutinterferingwiththeoperator.Thisusuallyisabout3or4feetfromthegun/holder.Whenmeasuringvoltagedifferenttechniquescan be used depending on the welding process being used.
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Voltage
Whenmeasuringvoltage,differenttechniquescanbeuseddependingontheweldingprocessbeingused.FortheSMAWandGMAWprocessesthevoltagecanbetakenbetweenthecableterminalsontheweldingmachine.
FortheGMAWandFCAWprocesses,thevoltagecanbetakenbetweentheworkleadattheworkconnectionclampandtheelectrodeleadatthethecontractorinthewirefeedunit.Ifnotpractical,thevoltagecanalsobetakenbetweenterminalorbetweenthecableterminalsontheweldingmachine.
FortheSAWprocess,thevoltagecanbetakenbetweentheelectrodeleadconnectionatthetorchandtheworkleadclamp.
Warning-Weldingparametersshouldonlybemeasuredbyproperlytrainedpersonnelfollowingsafeworkpractices.Followmanufacturersrecommendations.
Current Polarity
Enterthecurrentandpolarityfortheelectrode,electrode-gasorelectrode-fluxcombinationbeingused.Thisinformationcanbefoundinweldingtextbooks(CWBLearningCentreModule4),electrodestandards,online or from electrode catalogues or from your supplier.
Directcurrentelectrodepositive(DCEP)isthearrangementofdirectcurrentweldingleadsinwhichtheelectrodeisthepositivepoleandtheworkpieceisthenegativepoleoftheweldingarc.Anonstandardterm for this is direct current reverse polarity.
Directcurrentelectrodenegative(DCEN)isthearrangementofdirectcurrentweldingleadsinwhichtheelectrodeisthenegativepoleandtheworkpieceisthepositivepoleoftheweldingarc.Anonstandardterm for this is direct current straight polarity.
Alternatingcurrentisthecurrentflowinanelectricalcircuit,usuallyatapre-determinedfrequency.
ArcTravelSpeed/WeldingSpeed
Thearctravelspeedcanbemeasuredbyrecordingthetimetakentoweldaspecificlengthofweld,thenconvertthemeasuredtimeandlengthtoinches/minuteormillimeters/minute.Recordthecalculatedarctravelspeed(ATS)valueandnotjustthemeasuredlengthandtime.Thiscanbedoneusingoneofthefollowingformulas:
ATS(ins/min)= MeasuredWeldLengthininchesx60 MeasuredTimeinSeconds
orATS(mm/min)= MeasuredWeldLengthinmillimetersx60 MeasuredTimeinSeconds
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Burn-offrate
Theburnofformeltingrateistheweightorlengthofelectrode,wire,rod,powdermeltedinaunitoftime.Record this information for arc spot welds.
Gasflowrate
Theshieldinggasflowrateshouldbehighenoughtomaintainadequateshieldingforthearcbutnotsohighthatitcausesturbulenceintheweldpool.Thegasflowratetobeuseddependsonanumberoffactorssuchastheprocess,weldingposition,shieldinggas,electrodeextensionandoperatingparameters.WithGTAW,flowratesaretypicallyintherangeof15to20cubicfeetperhour(CFH).WithGMAWandFCAWflowratestypicallyvarybetween25and45CFHdependingonthefactorsnotedabove.Manufacturer’sliteratureshouldbeconsultedformoredetails.
Thestandardunitsofmeasurementforgasflowratearel/mininS.I.(metric)andcubicfeet/hrCFH(imperial).ToconvertfromCFHtoL/minmultiplyby0.472.ToconvertfromL/minmultiplyby2.119.
CFH 15 20 25 30 35 40 45
L/min. 7 9.5 12 14 16.5 19 21
Checkthegasflowratewithameterandrecordtherateandtheunitofmeasurement(inbrackets).
Heat input
Entertheheatinputandtheunitofmeasurementwhentheheatinputneedstobecontrolled.Examplesarewhenweldingquenchedandtemperedsteelsandwhenspecificimpactpropertiesneedtobeachieved.
Heatinputistheenergysuppliedbytheweldingarctotheworkpiece.Theheatinputiscalculatedusingthefollowingformula:
H= VxAx60
1000xT
where:
H=heatinput(kJ/inorkJ/mm)
V=arcvoltage(volts)
A=current(amps)
T=travelspeed(in/minormm/min)
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SomecommonmistakeswithBlock7:
Nowirefeedspeedwithasemi-automaticprocess.(Thisisoneadjustmentthewelderneedstomake)•
IncorrectvoltageorwirefeedspeedparametersforGMAWsprayarctransfer.Chartsshowing•parameters for spray transfer are available from the CWB
Incompleterangeoffilletweldsizes•
Incorrectnumberofweldingpassesinflare-bevelorflare-Vjoints.Ex:8weldingpassestogetan•8mm effective throat
Noflowrateentered•
Flowrateunitwritten“CFM”insteadof“CFH”•
4.8 BLOCK8(Finalremarks)
Heattreatment(preheat,interpasstemperatures,postweldheattreatment)
ForpreheatorinterpasstemperaturesrefertotheapplicabletableinthestandardsuchasTable5-3,CSAStandardW59.AlternativelyenterthevaluesinCentigradeorFahrenheit.Thisboxcannotbeleftemptyormarkedasambientornotapplicable(N/A).
If a post weld heat treatment is used the temperature and time should be recorded.
Additionalremarks
Anyadditionalremarksorrequirementsshouldbeaddedinthissection.Itcanalsobeusedfornotesifthereisinsufficientspaceinothersectionsoftheweldingproceduredatasheetform.Examplesaredetailsof pulsed welding or welding techniques such as stringer or weave beads.
Companyauthorization
Thedevelopedweldingproceduresneedtobeacceptedbytheresponsiblepersonnelatthecompanybefore submission to the CWB.
ForcompaniesinvolvedincertificationtoCSAStandardW47.1-Division1or2,theirweldingproceduresmust indicate the acceptance by the designated welding engineer. Engineers submitting welding procedurestotheCWBmust,attheiroption,sealand/orsigneachdocument.
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ForcompaniesinvolvedincertificationtoCSAStandardW47.2-Division1,2.1or2.2,CSAStandardW186,theirweldingproceduresmustindicatetheacceptancebythedesignatedprofessionalengineerresponsible for welding procedures and practice. Engineers submitting welding procedures to the CWB must,attheiroption,sealand/orsigneachdocument.
ForcompaniesinvolvedincertificationtoCSAStandardW47.1-Division3orCSAStandardW47.2-Division3theirweldingproceduresmustindicatetheacceptancebyaqualifiedweldingsupervisor.Weldingsupervisors submitting welding procedures to the CWB must sign each document.
ForDivision3companies,whentheweldingsupervisorchangesthecompany’sapprovedweldingproceduresarestillconsideredvalid.Thecompanyisnotrequiredtosubmittheexistingweldingproceduresforre-approvalorprovideanacceptanceletter.Thenewweldingsupervisoristestedontheknowledgeandapplicationofthecompany’sweldingprocedures.
WhenacompanychangesitsstatusfromDivision3toDivision1,2(W47.1)or2.1or2.2(W47.2),orwhenanengineertakesovertheresponsibilitiesforpreviouslyapprovedweldingprocedures,theengineermay,athisorherdiscretion,useoneormoreofthefollowingoptions:
prepareandsubmitforapprovalnewweldingproceduresbearinghisorhersealand/orsignature;•
issue a dated and signed letter to the CWB listing all welding procedures previously approved by the •CWB that have been reviewed and found to be acceptable for the company’s operations.
review,signand/orsealtheexistingdocumentsandresubmittheappropriatenumberofcopiesforre-•approval. If the welding supervisor’s or engineer’s signature or the engineer’s seal has been removed from the document then the previous approval must also be removed. If the previous approval stamp has not been removed the documents are returned to the engineer without being reviewed.
iftheengineerdoesnotsubmitanydocumentationtotheBureauregardingtheexistingprocedures,•it is presumed that the engineer has reviewed the procedures and found them to be suitable for the company’sweldingoperations.TheengineerisnotrequiredtoadvisetheBureauoftheactionheorshehastaken.
WhenacompanychangesitsstatusfromDivision1or2toDivision3,thecompany’sexistingapprovedweldingproceduresarestillconsideredvalid.Thecompanymaysubmittheexistingweldingproceduresforre-approvalorprovideanacceptanceletter,althoughthisisnotarequirement.
Date
Thedatasheetshouldhaveanaccepteddate.
SomecommonmistakeswithBlock8:
Weldingproceduredatasheetsarenotacceptedbytheauthorizedpersonnel.•
Preheatisenteredas“none”orambient.•
IncorrectPreheatisspecified.•
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WELDINGPROCEDUREPREPARATION®
4.8 CHECKLIST:Thefollowingchecklistcanbeusedforcompletingweldingproceduredatasheets.
+ If heat input control is required
WELDINGPROCEDUREDATASHEETITEM SMAW GMAW FCAW MCAW GTAW SAW
GeneralInformation
Company name and address X X X X X X
WPDS No. X X X X X X
Date and Rev X X X X X X
ProcessInformation
Reference Standards X X X X X X
Welding Process X X X X X X
Pulsed current X X X X
Shielding gas type X X X X
JointInformation
Positions X X X X X X
Process mode X X X X X X
Jointtype X X X X X X
Penetration X X X X X X
Fillet X X X X X X
Backingmaterialandthickness X X X X X X
Backgouging X X X X X X
Technicalinformation
Electrodeextension X X X X
Fluxclassification X
Tungstenelectrode X
Cleaning X X X X X X
Jointpreparation
Jointconfiguration/jointtype X X X X X X
Baseandfillermaterial
Identificationtostandardorgroup X X X X X X
Identificationoffillermaterial X X X X X X
Welding details
Thickness X X X X X X
Weldsize X X X X X X
Layers X X X X X X
Pass No. X X X X X X
Welding Process X X X X X X
Diameter X X X X X X
Wire feed speed X X X X
Voltage + X X X + X
Current,CurrentType/polarity X X X X X X
Arc travel speed + X X X + X
Gasflowrate X X X X X
Additionalitems
Heattreatment/preheat/interpass X X X X X X
Additionalremarks
Companyauthorization X X X X X X
Charpy V-notch
Reference standard X X X X X X
Heatinput X X X X X X
Stringer or weave bead X X X X X X
ArcSpotwelds
Visible diameter X X
Coatingthickness X X
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© Copyright CWB Group - Industry Services
5.0 SubmissionOfWeldingProcedures
AcertifiedcompanyisrequiredbytheStandardtosubmitweldingproceduredatasheets,totheCWB,forthe types of welded joints used by the company.
Electronic submissions of welding procedures should be sent to [email protected].
HardcopysubmissionsshouldbesenttotheProceduresDepartment,7250WestCreditAve.,Mississauga,ON L5N 5N1.
AWPDScanbeacceptedbasedonthefollowing:
• Thejointgeometryandparametersarespecifiedbythegoverningstandardtobeprequalified
• ThecompanyhaspreviousprocedurequalificationtestdatarecordedonaPQR(procedurequalificationrecord)
• TherearesuccessfulproceduredatasheettestsintheCWBdatabasethatmatchtheinformationonyour WPDS
• Bysuccessfullypassingprocedurequalificationtestsconductedinaccordancewiththerequirementsof the applicable standard
• Bysuccessfullypassingprocedurequalificationtestsconductedinaccordancewithotherrecognizedspecificationsorstandards
• BysuccessfullypassingaspecialprocedurequalificationtestrecordedonaPQR(analternativetypetest)
TherequirementsforprocedurequalificationtestingwillbeidentifiedbytheProcedureEngineerinalettersent to the client.
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WELDINGPROCEDUREPREPARATION®
6.0 ReviewAndApprovalOfWeldingProcedures
General
Each submission is reviewed by a Procedure Engineer based on the requirements of the applicable standardsand/orcodes.Theapplicablestandardand/orcodemustbereferredonthedocumentsubmitted.
TheProcedureEngineersusetheirprofessionaldiscretionwhenreviewingalldocumentstoensurethattheyarefeasibleandmeettherequirementsassetoutinthecertificationstandards.
WhenaWeldingProcedureDataSheetmeetsallprequalifiedrequirementsbutdoesnotseemfeasiblesoundness tests are required.
Incasesnotdirectlycoveredbythecertificationstandards,theProcedureEngineersapplythegeneralconcepts of the standard combined with the requirements of other relevant standards and codes to complete the review and approval process.
Welding Engineering Standards
Welding Engineering Standards when required are stamped received.
WeldingProcedureSpecifications
Weldingprocedurespecificationsthatsatisfytherequirementsspecifiedintheapplicablestandardarestamped accepted.
Weldingprocedurespecificationssubmittedforapprovalshallinclude,asaminimum,theapplicableessential variables of the governing design or manufacturing standard.
Welding Procedure Data Sheets
PrequalifiedJoints:Weldingproceduredatasheets,usingjointsdesignatedasprequalifiedinthegoverningstandard,canbeacceptedbytheCWBasprequalifiedwithoutfurthertestingbythecompany,providedallotherrequirementsofthegoverningstandardhavebeenmet.ExamplesofgoverningstandardsthatdesignatejointsasprequalifiedareCSAStandardW59andAWSCodeD1.1.
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ApprovalusingtheCWBdatabase:WeldingproceduredatasheetsthatarenotprequalifiedinthegoverningstandardcanbeacceptedbytheCWBifsufficientrelevanttestinginformationhasbeenaccumulatedbytheCWB.TheCWBreviewsallsubmittedWeldingProcedureDataSheetsthatarenotprequalifiedagainsttheinformationinourdatabase.Thisdatabasecontainsprocedurequalificationtestscompletedbycompanies,andifsufficientinformationisfound,acceptancecanbegrantedwithoutprocedure testing. Welding Procedure Data Sheets that satisfy these requirements are stamped accepted on the basis of previous tests accumulated by the CWB.
NonPrequalifiedJoints-ProcedureTesting:WeldingproceduredatasheetsthatarenotprequalifiedinthegoverningstandardcanbeacceptedbytheBureauifrelevantprocedurequalificationtestingiscompletedbythecompanyandwitnessedbytheCWB.TherequirementsforprocedurequalificationtestingareidentifiedbytheProcedureEngineerinalettersenttotheclient.Weldingproceduredatasheetsthat are successfully tested are stamped accepted to the applicable standard on the basis of procedure qualification.
Morethanonequalificationstandard/codespecifiedontheWeldingProcedureDataSheet: If thereismorethanonestandard/code,therequirementsofallspecifiedstandards/codesmustbemet.Forexample:AfilletweldWeldingProcedureDataSheetwithbothCSAW47.1andAWSD1.6,willrequired3macro-etch tests.
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WELDINGPROCEDUREPREPARATION®
7.0 SampleWeldingProcedureDataSheetsCWB Form 160E/99-1
WELDING PROCEDURE WPDS NO.:DATA SHEET DATE: Rev.: 0
Company Name: Ref. Standards:
Address: Ref. WPS:
Welding Processes: Pulsed: Pulsed:Shielding Gas Type:
ETT=Material: Thickness:
Method:Depth:
Type: Dia.:
Part
III
Group
F4
Thick-ness (
)
WeldSize/ETT
PassNumber
WeldingProcess
Dia.( mm )
CurrentA
VoltV
CurrentPolarity
WeldingSpeed( )
Burn-OffRate
( )
Gas Flow Rate
( )
5.0 1 SMAW 3.2 120-140 AC/DC+ N/A6.0 1 SMAW 3.2 120-140 AC/DC+ N/A8.0 1-3 SMAW 3.2 120-140 AC/DC+ N/A10.0 1-4 SMAW 4.0 160-180 AC/DC+ N/A12.0 1-6 SMAW 4.0 160-180 AC/DC+ N/A16.0 1-7 SMAW 4.0 160-180 AC/DC+ N/A
Date:
To be signed by the engineer or supervisor before
submission to the CWB
Remarks: Preheat in accordance with Table 5-3 of CSA W59
5/27/2008
Interpasstemp.max.:Preheat min: 10° CInterpasstemp.min.: 10° C
Heat treatment : CWB Acceptance Company Authorization
1-3 N/A1-3 N/A
1-2 N/A1-2 N/A
1 N/A1 N/A
Heat Input( )
Joint Configuration & Pass/Layer Sequence
Special RequirementsIdentification of Base Material (for CSA W186 indicate carbon equivalent, max. phosphorus & sulphur content)
Tungsten Electrode:
LayerWire Feed Speed
( )
Nozzle Diameter(s):
SMAW-2F-85/27/2008
CSA W47.1/ W59Canadian Welding Bureau
N/A
7250 West Credit Avenue, Mississauga, ON L5N 5N1 SMAW-1
1 2N/ASMAW
Positions:Process Mode:Joint Type:
Horizontal
Use a chipping hammer and wire brush. Slag shall be removed from all finished welds and before welding over previously deposited metal.
CSA W186 Rebar Splice Type:
N/A
Penetration:
Flux Classification: N/A
Backing:
N/A
N/A
Electrode Extension:
Backgouging:
N/ACleaning Procedures
Identification of Filler MaterialSteels in Groups 1, 2 and 3 of Table 11-1/ 12-1
Thickness or Dia.
5.0 mm - 16.0 mm5.0 mm - 16.0 mm
Specification & Grade
Steels in Groups 1, 2 and 3 of Table 11-1/ 12-1
Process Trade Name Classification Filler Treatment
Welding Parameters
SMAW E4918 Cl. 5.2.2.4, W59
Yes No Yes No
Manual Semi-Auto Machine Auto
Butt Tee Corner Lap Edge
Complete Partial Fillet
Yes
No
Direct Splice Indirect SpliceRebar to Structural Member Only
Lap Splice
GAP 0-1 mm
231 4
567
SAMPLE
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WELDINGPROCEDUREPREPARATION®
© Copyright CWB Group - Industry Services
CWB Form 160E/99-1
WELDING PROCEDURE WPDS NO.:DATA SHEET DATE: Rev.: 0
Company Name: Ref. Standards:
Address: Ref. WPS:
Welding Processes: Pulsed: Pulsed:Shielding Gas Type:
ETT=Material: Thickness:
Method:Depth:
Type: Dia.:
Part
III
Group
N/A
Thick-ness (
)
Weld Size/ ETT
PassNumber
Welding Process
Dia. ( mm )
Current A
Volt V
Current Polarity
Welding Speed
( mm/min )
Burn-Off Rate
( )
Gas Flow Rate
( l/min )6 1 GMAW 1.2 260 28 DC+ 400-500 20
8 1 GMAW 1.2 260 28 DC+ 300-400 20
10 1 GMAW 1.2 260 28 DC+ 400-500 202-3 GMAW 1.2 260 28 DC+ 400-500 20
Date:
To be signed by the engineer or supervisor before
submission to the CWB
In accordance with Table 5-3, CSA Standard W59
5/27/2008
Interpasstemp.max.: 250° CPreheat min: 10° CInterpasstemp.min.: 10° C
Heat treatment : CWB Acceptance Company Authorization
1 10.02 10.0
1 10.0
1 10.0
Heat Input( )
Joint Configuration & Pass/Layer Sequence
Special Requirements
N/A
Identification of Base Material (for CSA W186 indicate carbon equivalent, max. phosphorus & sulphur content)
Tungsten Electrode:
LayerWire Feed Speed
( m/min )
Nozzle Diameter(s):
GMAW-2F5/27/2008
CSA W47.1/ W59Canadian Welding Bureau
N/A
7250 West Credit Avenue, Mississauga, ON L5N 5N1 GMAW-1
1 290%Ar/ 10% CO2GMAW
Positions:Process Mode:Joint Type:
Horizontal
Wire brush, clean between passes
CSA W186 Rebar Splice Type:
16 mm
Penetration:
Flux Classification: N/A
Backing:
20 mmElectrode Extension:
Backgouging:
N/A
N/ACleaning Procedures
Identification of Filler MaterialASTM A36, A516 Gr. 70 G40.21Gr. 300W, 350 W
Thickness or Dia.
6-10 mm6-10 mm
Specification & Grade
ASTM A36, A516 Gr. 70 G40.21Gr. 300W, 350 W
Process Trade Name Classification Filler Treatment
Welding Parameters
GMAW N/A B-G 49A 3 C G6 (ER49S-6) Cl. 5.2.4.5, CSA W59
Yes No Yes No
Manual Semi-Auto Machine Auto
Butt Tee Corner Lap Edge
Complete Partial Fillet
Yes
No
Direct Splice Indirect SpliceRebar to Structural Member Only
Lap Splice
231
GAP 0-1 mm
SAMPLE
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NOTES