Module 5 - 1

Module 5

Documents Governing
Welding Inspection and
Qualification

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Document Types
 Purchase orders
 Contract documents
 Codes
 Standards
 Specifications
 Recommended Practices
 Drawings

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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

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Example of Fabrication Drawing

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Dimensions

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Tolerances

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Notes

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Welding Details
 Location
 Size
 Length
 Joint configurations
 Material call-outs
 NDE requirements
 Processing requirements

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Hold Points
 Specific prearranged steps
 Inspection required
 Acceptance required
 Fabrication continued

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Inspection Information
 Visual or other NDE
 Test method
 Test procedure
 Location for testing
 Extent of testing
 Acceptance/rejection criteria
 Personnel qualifications

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Code

“A body of laws, as of a nation, city, etc.,

arranged systematically for easy reference”

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Types of Codes
 Building codes
 Electrical codes
 Plumbing codes
 Fabrication codes

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Codes:
 Have legal status
 Use “Shall” and “should”
 Mandatory
 Methods to determine compliance

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Code Producers
 AWS
 ASME
 API
 ABS
 DOT
 Others

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Standard

“Something established for use as a rule or

basis of comparison in measuring or judging
capacity, quantity, content, extent, value,
quality, etc.”

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Welding Codes and Standards

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ASME Code by Sections

 I - Const - Power Boilers  V - NDE
 II - Materials  VI - Operations of Power B.
– Part A - Ferrous  VII - Care of Power Boilers
– Part B - Nonferrous  VIII - Unfired Pres. Vessels
– Part C - Filler Metals – Divisions 1, 2, and 3
– Part D - Properties  IX - Welding Qualifications
 III - General Requirements  X - FRP Pressure Vessels
 IV - Const - Heating Boilers  XI - Nuclear Inspections

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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.”

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AWS Filler Metal

Specifications

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AWS Welding Specifications

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Recommended
Practice

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Other Standards Organizations

 ANSI
 ASTM
 ISO
 IIW
 NACE

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Control of Materials

“The identification and traceability of materials”

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Material Test Report (MTR)

The starting point for material control

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MTR

 Review:
 Product Form
 Heat Number
 Chemistry
 Mech. Properties

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Material Control Systems

 Should be simple
 Contain checks and balances
 Specify marking methods

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Material Control Methods

 Segregation
 Color coding
 Alphanumeric
 Bar coding
 Tagging
 Stamping

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Alloy Identification Systems

 Industry associations
– SAE
– AISI
– CDA
– Castings
– Tool steels
 UNS
 ASTM

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ASTM
STANDARDS

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ASTM A514

“Standard specification for high yield

strength, quenched and tempered alloy steel
plate, suitable for welding”

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Typical ASTM Specification

 Scope  Mechanical
 Applicable Documents Requirements
 General Delivery  Hardness Requirements
Requirements  Test Specimens
 Process  Number of tests
 Heat Treatment  Retest
 Chemical  Marking
Requirements  Supplemental
Requirements

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AWS A5.1

“Specification for covered carbon steel arc

welding electrodes”

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Typical AWS Filler Specification

 Scope  Required Tests,
 General Requirements Methods
– Classification  Manufacturing,
– Acceptance Packaging,
– Certification Identification
– Retests  Details of Tests
– Method of manufacture
 Appendix
– Marking
– Packaging, Rounding-off

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Qualification
Fabricators’ responsibility
 Procedures
 Welders
 Welding operators
 Tack welders

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Procedure Qualification
Determines compatibility of:

 Base metal(s)
 Filler metal(s)
 Process(es)
 Techniques

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Procedure Qualification
Three methods:

 Prequalified procedures
 Procedure qualification testing
 Mock-ups

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Prequalified Procedures
 Used by AWS D1.1 & D1.5
 No need for testing
 Saves time and money

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Procedure Qualification Testing

 ASME, API, AWS, & most Codes &
Standards
 Welding and brazing
 Defines essential welding variables
 Testing required

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Essential Welding Variables

“Those variables, that if changed beyond

certain limits, require a new procedure
qualification”

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ASME Qualification
 Section IX
 Welding procedure specification (WPS)
– Lists essential welding variables
 Procedure qualification record (PQR)
– Notes actual test conditions

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Mock-ups

“Used for special joint configurations”

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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
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Procedure Qualification Steps - 1 of 2

 Select welding variables
 Check equipment and materials
 Monitor fitup & welding - document!
 Identify test specimens
 Test and evaluate specimens

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Procedure Qualification Steps - 2 of 2

 Review results for compliance
 Release approved procedure
 Qualify other welders
 Monitor production welding

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Welder Qualification

“Determines if individual welders have

sufficient skill to produce satisfactory welds
using a qualified procedure”

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Welding Variables
Examples of essential variables in some codes:
 Welding position
 Joint configuration
 Electrode type and size
 Base metal type, thickness
 Welding techniques
 Use of backing

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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

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Thickness Range Qualified

 Depends on Code used
 Depends on test specimen thickness
 See Figure 5.24 for D1.1 requirements

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Backed and
Non-backed
Joint

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Fillet Weld Test Specimen

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6GR Test Weldment

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Electrode Classification Groupings

Group AWS
Designation 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

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Qualify vs Certify

Qualify - Welder has skill to weld

Certify - Documents support above

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Welding Inspection Requires:

 Availability of documents
 Knowledge of documents
 Use of documents
 Materials control
 Qualifications

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Quality is:

...conformance to specifications.
so…..
Know Your Specifications!

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