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Training Manual-Fabricator

This training manual provides guidance on joint preparation, buttering or weld build-up, flame cutting, arc air gouging, tack welds, and weld identification for fabricators. Key points include: removing contamination from weld surfaces; drying wet joints prior to welding; limitations on buttering thickness; requirements for buttering over 1/3 base metal thickness; grinding cut surfaces; tack weld sizing, placement, and inspection criteria; avoiding overhead tack welding; protecting coated surfaces; and establishing a weld identification system.

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Sudeesh n
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© © All Rights Reserved
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Download as PPTX, PDF, TXT or read online on Scribd
46 views

Training Manual-Fabricator

This training manual provides guidance on joint preparation, buttering or weld build-up, flame cutting, arc air gouging, tack welds, and weld identification for fabricators. Key points include: removing contamination from weld surfaces; drying wet joints prior to welding; limitations on buttering thickness; requirements for buttering over 1/3 base metal thickness; grinding cut surfaces; tack weld sizing, placement, and inspection criteria; avoiding overhead tack welding; protecting coated surfaces; and establishing a weld identification system.

Uploaded by

Sudeesh n
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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TRAINING MANUAL FOR FABRICATORS

JOINT PREPARATION
 Remove Contamination from the weld surface and at least 25 mm of
adjacent base metal prior to welding

 If a weld joint is wet or has surface moisture or condensation, it shall


be dried by pre- heating for a distance of 100 mm from the weld joint,
until the weld area is completely dry.
BUTTERING OR WELD BUILD-UP ON JOINTS:

 Buttering shall be performed using a approved procedure


 Buttering or weld build-up on the prepared surfaces shall not exceed
the lesser of 19 mm or two times the base metal thickness,
whichever is less.
 If the buttering or build-up exceeds ⅓ of the base metal thickness or
10 mm, then the following requirements shall apply:
a) The buttering operation shall be witnessed by QC Engineer
b) The buttering shall be inspected by PT or MT after completion of
the build-up but before final welding of the joint.
FLAME CUTTING AND ARC AIR GOUGING
 Ragged and irregular edges shall be ground or machined to bright metal
 Thermally cut or gouged surfaces for all materials, including carbon
steels, shall be power brushed or ground prior to welding.
 Thermal cut surfaces of stainless steel and non-ferrous materials shall
be ground to bright (un-oxidized) material prior to welding.
TACK WELDS
 All tack welds shall be made by qualified welders.
 Welder ID card shall be available with qualified welders.
 All tacks or temporary welds shall be performed with the same care,
materials, electrodes, minimum preheat, and procedures that are used
for permanent welds.
 The recommended tack size is 3.2-4.8 mm (multi-pass) and min length is
25.4mm(1 ″ )
 The minimum number of tack welds are:
Pipe diameter of 4″ or less, three equally spaced tacks.
Pipe diameter above 4″, minimum of four equally spaced tacks.
 Tack welds that are to be incorporated into the final weld shall be thoroughly
cleaned, prepared at each end, and inspected for cracks. Any cracked tacks
shall be removed before welding the joint.
If the tack welds are to be incorporated into the final weld and are made
with a different process or electrode than the root pass, then the tack
weld process or electrode shall have been used as the root pass for an
appropriate procedure qualification.
Avoid overhead Bullet tacking, welder cannot start welding from that
position and tack piece traceability shall be maintained
Bridge tacks (located above the root area) are acceptable but such
tacks must be made completely within the weld groove and shall be
completely removed prior to completion of the weld.
 Arc strikes, gouges, and other indications of careless workmanship (such as
surface porosity, uneven weld profiles, and undercut) shall be removed by
grinding.
 Any temporary welded attachments or temporary tack welds shall be
ground off. Attachments may be thermally cut off no closer than 3
mm to the base metal surface, prior to the required grinding.
 If any grinding reduces the base metal wall thickness to less than the
design minimum, the ground area shall be re-welded and ground
flush with the original base metal surface or the component shall be
replaced. Re-welding shall be done only with the prior approval of QC
engineer
 Temporary attachments, grounding lugs, or supports welded to any
component shall be made with a compatible material. Under no
circumstances shall Scaffolding pipes, rebar, or galvanized steel be
used.
 Coated and clad or overlaid surfaces shall be protected from the
welding arc, associated weld spatter, and damage from ground clamps
or other associated equipment.
Weld Identification
 The fabricator shall establish and submit for approval an identification
system that shall uniquely identify each member and weld joint.
 The identification system shall be used to identify all examinations, surveys,
inspections, etc.

DRAWING NO
HEAT NUMBER
JOINT NO
THANK YOU

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