7/26/2019 Notes 4 Insp.

1/21

Metal Joining and Cutting Process

Welding Process: 1. Arc Welding 2. Solid state welding

3. Resistance Welding

4. Ox !uelgas Welding

". Soldering

#.$ra%ing

&. Ot'er Welding 1.('er)al s*ra Welding

2. Ad'esi+e $onding

3. ('er)al Cutting, Ox-Arc- Ot'er Cutting

SMAW: Stic/ Welding

0lectrode se S'ielding

eoxidation

Alloing

oni%ing

nsulating

0lectrode Classi5cation AWS S*eci5cation A".1-A"."

1 2 3 4

0 &617

1 2 Means Min (ensile Strengt' in t'ousands o! *ounds *er s8.nc',&6666

3 *osition

7/26/2019 Notes 4 Insp.

2/21

1An Position

2. Onl 9lat and ori%ontal Positions. $ecause Molten )etal is not9luid.

4. own 'ill Progression.

4. Coating ;O*eration C'arecteristics,7 and reco)onded 0lectrical current.

7/26/2019 Notes 4 Insp.

3/21

ARC

7/26/2019 Notes 4 Insp.

4/21

Mec'anical *ro*erties o! Metals

1. Strengt'2. uctilit3. ardness4. (oug'ness". 9atigue strengt'

Strengt': ('e ailit o! a )aterial to wit'stand an a**lied load.

u)erous (*esN e*endent u*on 'ow t'e load is a**lied to t'e )aterial.

1. (ensile strengt'2. S'ear strengt'3. (osional strengt'4. )*act Strengt'". 9atigue Strengt'

(ensile Strengt': Ailit o! a )aterial to resist !ailure w'en suect to atensile - or *ulling load

(ensile strengt' is ex*ressed in two was.1.(S- 2.Hield

(S ('e )axi)u) load carring ca*acit o! t'e Material. Or t'e strengt' o!a)aterial at t'e t'e exact *oint w'en !ailure occurs.

A)ount o! stretc' A**lied load 0lastic e'a+ior is reLered to eing

7/26/2019 Notes 4 Insp.

5/21

SF F ! (e)*F S

uctilit('e ailit o! aMaterial to de!or) or stretc' under load wit'out!ailing.

?('e )ore ductile )aterial is )ore stretc' e!ore it rea/s.

?uctile )aterial will end e!ore rea/.

! (e)*F F

A )aterial 'a+ing 'ig' ductilit is reLered to as eing ductile.

W'ile a )aterial 'a+ing low ductilit re!erred to as eing rittle.

0x E

7/26/2019 Notes 4 Insp.

6/21

R( KW 16

P no. Sno. Kw 266263

Welder Kual Kw 366

7/26/2019 Notes 4 Insp.

7/21

KW176,9illet weld tests

Procedure

Cut (rans+ersel " test s*eci)ens eac' a**roxi)atel 2 inc' long !or

*late to *late9or *i*e to *i*e 4 s*eci)ens.

Macro exa)ineN

Procedure

Cut (rans+ersel 2 test s*eci)ens eac' a**roxi)atel 4 inc' long 9or*i*e to *i*e .

1 !or )acro- and one !or 9racture test.KW 1&6 otc' (oug'ness: C'ar* + notc' i)*acct test in accordancewit' SA 3&6.

KW 172 9racture (est:

Sno: Sno.s are assigned to )aterial t'at are acce*tale !or use t'eASM0 $ 31code !or *ressure *i*ing.-or selected $PGC cases- $ut w'ic'are not included in ASM0 $PGC )aterial s*ec Sec .

?Kuali5cation using a P.no )aterial 8uali5es corres*onding S.no )aterials.$ut not corres*onding *.no )aterials.

?Kuali5es o! welders using a *.no )aterials 8uali5es t'e) to weld oncorres*onding S.no )aterials and +ice +ersa.

.

7/26/2019 Notes 4 Insp.

8/21

1) Difference between S no. and P no.

S no. Materials mentioned in B31.3 and not mentioned in ASME sec II

S no: - S nos are assined to material t!at are acce"table for #se b$ t!e ASME B

31code for "ress#re "i"in.% or b$ selected BP&' cases% B#t w!ic! are not incl#ded inASME BP&' material s"ec Sec II.

(#alification #sin a P.no material *#alifies corres"ondin S.no materials. B#t not

corres"ondin ".no materials.

(#alifies of welders #sin a ".no materials *#alif$ t!em to weld on corres"ondin S.no

materials and +ice +ersa.

,) M-1/0 S#l"!ide stress cracin resistance material for #se of oil field

E*#i"ments 2SS')

3) SP-1/1 PD4 S"ecification for *#alit$ Ass#rance

5) IS4-61- Model for #alit$ Ass#rance in desin %de+elo"ment% "rod#ction%

installation and ser+ices.

0) IS4-6, Model for #alit$ ass#rance in Prod#ction and installation.

7) DSS filler wire E -,01,% Electrode E-,00%,06,%,065.

/) 8illet weld si9e ;e Si9e < .//

( S ( S sin 4"

4"T

7 eat in*ut UJ;in. ,J;))V Goltage A)*erage #6 (ra+el S*eed Uin.;)in ,));)inV

o

9) CE = C +Mn + Cr+Mo+V + Ni+Cu6 5 15

7/26/2019 Notes 4 Insp.

9/21

10) HI= V X A X 60 KJ/min or V X A/TS *1000 KJ/mm

Tra!" #$!!% X 1000

&'EN ( &iin '!#i#an Euia"!n No, ASTM A -.

In SA 105 SA m!an# SA or ASME 2S$!3i43aion an%A$$"i3aion)

In A 105 A or ASTM

E"!3ro%!# !n%in i 56. 7 8o H%ro!n E"!3ro%!#

Ma!mai3a"" S3!%u"! No, i# :!4n!% a#

Maxi)u) Per)issile nternal Pressure 1666

Maxi)u) Per)issile Material stress

Ca"3u"aion or &r!!a AS&E' E8ECT';:E:ATASHEET

C! = C3 + C

C = C3 X 0,005

X mm

C3 = C +Mn + Cr+Mo+V +Ni+Cu, 6 515

Preheat temperature= &>HT '!uir!%? &ro3!##? I# SS r!uir!% &>HT?ASME @

7/26/2019 Notes 4 Insp.

10/21

H!a r!am!n !m$!raur! #a"" ! #$!3i4!% in ! Enin!!rinan% %!#in an% %!mon#ra!% &ro3!%ur! ua"i43aion,

T! !ain #a"" ! urna3! In%u3ion 3oi"# or r!#i#an3!!a!r#, 8o3a" am! !ain #a"" no ! u#!%, D"am!# #a"" no

im$in! %ir!3" on ! !"%m!n or $ar!n ma!ria",>!n a urna3! i# u#in ! !m$!raur! #a"" no ! ao!-00C !n ! $i$! i# in#!r!%, T! !ain an% 3oo"in ra!#a"" no !F3!!% -00C, An%

&i$!# a"" G, $ o 5mm 0C $!r our,Dor o!r 5mm G, 5500/TC or 55 C $!r our !r! T i# in mm,An% o"%in im! ,-min $!r mm or mor! an 19mm G an%minimum 1our,

& &. 2Hi a""o#!!" !rri3 an% Au#!nii3 SS)a"" i3G an% &1

!"o 19mm9A9@ "!##an 19mm 5A5@ "!##an 1HT an% 10H ma ! r!uir!% or no r!uir!%,2 @!"%in i# 3a""!% ;Fi%aion,I 3an 3onro" i! &urin ;r a3Gin i In!r a#,!n!ra"" Aron,

1 Aron a# i# u#!% or &urin?

@!3au#! o 8!## $oi#on C!a$!r Non D"amma"!,

basemetal base metal group

p-no

1 Carbon steel

3 Alloy steel cr cr < or = 2 %

5 Alloy steel 2 1/4 % > or = cr < or = 10%

6 High alloy steels martensitic

7 High alloy steels ferrite

8 High alloy steels austenitic

9a,9b Nicel alloy steels

10 Cr!cu steel

10a "N!#!steel

10e 2$ cr steel

7/26/2019 Notes 4 Insp.

11/21

11a sg 1 Ni& ' Ni steel

11a sg 2 ( Ni steel

1-) >a i# Hi $r!##ur!?

Hi $r!##ur! i# 3on#i%!r!% o ! a# ASME @ 16,5 &N -0 23"a##500 'ain)

8o T!m$!raur! ( (-.C or (55D,

Com$on!n San%ar%# ASME @ S : 15,1 'ai" roa% !"%in S$!3,

7/26/2019 Notes 4 Insp.

12/21

:1-,1 #$!3i43aion or !"%in in%u#ria" an% mi"" 3ran!# :1-, #$!3i43aion or m!a" 3uin ma3in! oo" !"%m!n# :1-,< #$!3i43aion or !"%in Earmoin an% 3on#ru3ion!ui$m!n :1-,- #$!3i43aion or !"%!% Loin# or ma3in!r an%

!ui$m!n :1-,5 #$!3i43aion or $r!##!# an% $r!## 3om$on!n# :1-,6 #$!3i43aion or 'oain !"!m!n# o !ui$m!n

PO (0RG0W K0S(OS 9OR KC SP0C(OR

1,@i! our $a# !F$!ri!n3! in %!ai"# i,! rom $a## ou o a# ono%a a#i3a"" aou our !F$!rian3! ?

, >a i# our ro"! a ! mom!n in ! @EC?

7/26/2019 Notes 4 Insp.

13/21

An% Ho i"" ou im$ro! ! ua"i 3onro" ##!m a #i!?

&. >a %o ou m!an Ho"% >in!## '!i! an% Sur!i"an3!?

A) H(Ho"% an In#$!3ion #a! %urin

3on#ru3ion/ari3aion/$r!(3ommi##ionin a i3 !r!#$!3i! auorii!# #a"" ! $r!#!n an% in!## ! $ari3u"ara3ii, T! a3ii #a"" no $ro3!!% ur!r iou $riora$$roa" in riin,

>(>in!## an In#$!3ion #a! %urin3on#ru3ion/ari3aion/$r!(3ommi##ionin a i3 !r!#$!3i! auorii!# #a"" in!## ! $ari3u"ar a3ii,Ho!!r ! a3ii 3an $ro3!!% i ! auori#a33!$an3!,

'('!i! an In#$!3ion #a! %urin3on#ru3ion/ari3aion/$r!(3ommi##ionin a i3 ! r!"a!%%o3um!n# #a"" ! r!i!!%,

S(Sur!i""an3! an In#$!3ion #a! %urin3on#ru3ion/ari3aion/$r!(3ommi##ionin a i3 ! r!"a!%a3ii i# monior!% ! r!#$!3i! auorii!# a ran%om,

Ho"%(&rior noi3! a!n%an3! an% 3"!aran3! ! 3on3!rn!%$ar i# r!uir!% !or! ! n!F a3ii,

>in!##(&rior noi3! r!uir!% u orG ma $ro3!!% iouaiin or a/3 a33!$an3!,

Sur!i""an3!( In#$!3ion %urin 3on#ru3ion a3ii u !orG ma $ro3!!%,

Monior(Monior ! a3ii

9,>a %o ou m!an Caron !uia"!n an% H!a in$u?10, >a ar! ! ua"i oL!3i!# #! or N' $roL!3?

Ho i"" ou !n#ur! ! #u$!ri#or# an% ao! Gno ! ua"i$o"i3 an% oL!3i!#?

11, Ho i"" ou monior >!"%!r $!rorman3! A3iii!#?

7/26/2019 Notes 4 Insp.

14/21

1, Ar! ou ami"iar i CCMS or >in( &3# ##!m?

1a ar! ! mo# 3ommon ua"i r!3or%# ar! o ! mainain!%a #i!?

Wor/ *rocedures- Met'od state)ents- (Ps- WPS- Material ins*ectionrecords- Caliration list o! 08ui*)ents- ns*ection records

1-, Ho i"" ou !n#ur! ! Su 3onra3or ua"i r!3or%# orua"i 3onro" a3iii!#?

@ in!rna" au%i# Sur!i""an3! in#$!3ion rou IT&

15, Ho i"" ou mana! ! Con#ru3iona" $!r#onn!" in 3a#! o%i#3r!$an3i!#?

16, Ho i"" ou mana! ! >!"%in 3on#uma"! 3onro" a #i!?1, >a a3ion ou i"" aG! i !"% r!$air !F3!!% ! a33!$a"!$!r3!na!?

1., Ho i"" ou inima! ! ;n!r or ! in#$!3ion a3iii!#?

19, Ho ou i"" 3on4rm ! in#$!3ion an% m!a#urin %!i3!# ar!!rror r!! o u#!?

0, Ho ou i"" r!#o"! ! 'T a3G"o a #i!?

1, Ho ou i"" 3onro" ! &r!#!raion o $roL!3 ma!ria"#?

, A# a C In#$!3or >!"%in a i# our r!#$on#ii"i a #i!?

EFra u!#ionnair! or Enin!!r

1,>a i"" ! a#i# o $r!$ar! ! ariu# IT?

, >a %o ou m!an Corr!3ion, Corr!3i! a3ion &r!!ni!

a3on?

7/26/2019 Notes 4 Insp.

15/21

6, :o ou a! Au%iin !F$!ri!n3! in ! oi" a# 4!"%?

, >a ar! ! mo# im$oran in# o 3!3G!or! "aminaion orA%!#i! on%in in 'E?

., 'E on%in "aminaion 3!mi3a"# i# n!!% o o 3!3G or !F$ir"a!"?

9, ;!ra"" 3onro" #u$!ri#ion an% im$"!m!naion o 3onra3ua"i an% !3ni3a" r!uir!m!n#P r!#o"uion o ua"i $ro"!m#P$r!$!raion an% mainnan3! o 3onra3 u"i r!3or%#?

Sam$"! an% #im$"! u!#ionnair! o ua"i 'Ein#$!3or#O

'! O IS;1-69(- :E&a i# 'E? EF$"ain ri! aou ! 'E ma!ria"?

, >a ar! ! %i#a%ana!#/"imiaion# o 'E o!r m!a""i3

ma!ria"#?

a ar! ! !n!ra" %!!3# in 'E $i$in ma!ria"#?

6, >a 3au#!# i ! 'E $i$in ma!ria" i# #or!% un%!r %ir!3

#un"i or "on $!rio%#?

A) '!#in "oom V %!ra%aion

, :o ou a! an i%!a on ! manua3urin $ro3!## o 'E $i$in

ma!ria"#?

., >a i# ! $ro3!%ur! o""o!% or Loinin?

9, >a i# ! m!o% o m!a#urin ! oru!?

10, >a i# ! a""oa"! o"!ran3! on ! maG!u$ oru!/r!a%

#an% oB?

11, >a i# ! ma!ria" u#!% or Loinin a3or ma%! r!a%#

2oF an% $in)?

1, I# !r! an !a a##i#an 3urin r!uir!%? >a i# ! 3urin

im! an% !m$!raur!?

A) 50 %!r!!#

7/26/2019 Notes 4 Insp.

16/21

1a ar! ! !##!nia" aria"!# o ! 3onro""!% %urin

3on#ru3ion o Loin#?

A) A%!#i! T!m$!raur! Humi%i

1-, >a ar! ! 3onro""in %o3um!n# ar! !in a$$"i!% or !

3on#ru3ion o 'E o "in!#?15, >a ar! ! %iB!r!n $!# o r!3or%# !n!ra!% %urin

in#a""aion?

16, Can ou !F$"ain our %ui!# an% r!#$on#ii"ii!# a# 'E

In#$!3or?

A) Conro""in r!3or%#

1, >a ar! ! %iB!r!n $!# o oo"# an% !ui$m!n# u#!% or

! 3on#ru3ion o Loin#?

1., Ho i"" ou !n#ur! ! a"inm!n o ! Loin#?

19, Ho %o 3onro" ! #ora! o 3!mi3a"# #u3 a# i$ro r!a%

#!a"an Tr!a% $a#! !,,3?

0, Ho %o ou 3onro" ! miFin $ro3!## o r!a% $a#! an%

#!a"an ma!ria"#?

1, >a i# $o "i!?

A) T! !F$iraion $!rio% o ! a%!#i! ma!ria" a!r miFin on%!r

an% ar%!n!r,

, Ho %o ou 3!3G ! 3urin $ro$!ri!# o ! ma!ria"#? >a

i# r!3omm!n%!% in ! in#a""aion $ro3!%ur!?

A) >i T!rmo3ou$"!

a ar! ! a33!$an3! 3ri!ria or ! a33!$an3! or!a%#?

-, >a ar! ! $aram!!r# ou "ooG or %urin ! r!3!iin

in#$!3ion o 'E ma!ria"# o #i! #or!# an% in#a""aion "o3aion#?

5, >a ar! ! $r!3auion# aG!n or an%"in 'E $i$in

ma!ria"# %urin ran#$or #ora! #rinin "o!rin an% $o#

$a%%in #a!#?

6, >a ar! ! a%%iiona" r!uir!m!n# or in#a""aion o 'E

$i$in in roa% an% a%i 3ro##in#?

A) C!n!r "in!r# #ou"% no 3ona3 i m!!or, >a 3!3G# %o ou $!rorm $rior o H%ro !#in ! 'E

$i$!"in!?

., >a ar! ! o #a!# o %ro !#in i%!ni4!% in ! IT&?

>a ar! ! $r!##ur! an% im! r!uir!m!n# in !a3 #a!?

7/26/2019 Notes 4 Insp.

17/21

9, >a ar! ! aQar%#, 'i#G a##!##m!n an% miiaion or

3onro" m!a#ur!m!n# o minimiQ! ! ri#G in 'E $i$in in#a""aion

a3ii?

Dor Su$!ri#or#?

1, >a i# ! ro"!# an% r!#$on#ii"ii!# o Su$!ri#or?

, Ho %o ou $"an our orG?

a i# ! $"an an% arran!m!n or ! #ora! o 3!mi3a"# an%

$i$in ma!ria"#?

-, Ho ! ma!ria" i# ran#$or!% o ! $oin o orG?5, Ho %o ou 3onro" ! in#a""aion $ro3!##?

6, Ho %o ou oraniQ! ! H%ro !#in o $i$in?

, V!ri43aion o ! !n!ra" Gno"!%! on ! In#$!3ion an% !#in

o 'E $i$in ma!ria"#?

ua"i Conro"

ua"i Conro" i# a $ro3!%ur! or #! o $ro3!%ur!#

in!n%!% o !n#ur! a a manua3ur!% $ro%u3 or$!rorm!% #!ri3! a%!r!# o a %!4n!% #! oua"i 3ri!ria or m!!# r!uir!m!n# o !3u#om!r,

Inspection, analysis and action required to ensure quality of inputs and

outputs.

11) >a ar! T! E##!nia" $ro3!%ur!# or #i!?

1, Conro" o :o3um!n#, Conro" o r!3or%#

7/26/2019 Notes 4 Insp.

18/21

5, Corr!3i! a3ion6, &r!!ni! a3ion

15) :iB!r!n3! !!!n In!r$r!aion an% Ea"uaion?

nter*retation is 5nding discontinuities or anor)alities0+aluation is co)*aring discontinuities wit' /nowing standards.

16) @aGin r!uir!m!n#?

7/26/2019 Notes 4 Insp.

19/21

=PS- WPS is a written document that provides direction to welder or welding operator for

making production welds in accordnce with code requirements.

Essential variable! Change the "aterial )ro)ertiesSupplementary Essential ariable* Change the +m)act an, -oughness .ro)erties

Concrete strengt' $S 1771 *rt 11#

& das &6> )in.. cue si%e 1"61"61"6 grade c3" so acce*ted

is &6> 2";))2Re8uired

90 is t'e acce*tance.

S

7/26/2019 Notes 4 Insp.

20/21

Put t'e s)aller dia down side e!ore *ouring. A!ter 5ll )a/e it u*side down.

A!ter re)o+e t'e co)*lete water t'e )easuring o! t'e de*t' is t'e water

content in t'e concrete.

SO 164&4 3.1 n 'ouse certi5cate

3.1

SO 164&4 3.1c i)ensional- (P or (P certi5cate

SO 164&4 2.1 Mill certi5cate in 'ouse sa)*ling ase

SO 164&4 2.2 n 'ouse certi5cate gi+e co)*l or guarantee

0 16264 t*e 3.1

0 16264 3.2 SO 16264 3.1c atc' testing certi5cate (P

Persuade 'er nac'ac'e**ada)Stuorn MondiSus*ended @+eladata)0x*atriates li+ing aroad9igurati+el c'aracteri%ed 5gures o! s*eec'(ic/lingntricate *atterns +er co)*licated

S)udge @ lurred or s)eared line$etrot'ed 0ngaged to MarrSi)*ering s)ile in si)*le r aLected wawea/ling 9eedale *erson r ani)al ,ALecti+e ;acti+eindulge ta/e *leasure easilScri)*ing Origin un/nownMeager si*

7/26/2019 Notes 4 Insp.

21/21

Crouc'