WELDING CODES

WELDING CODES, STANDARDS & SPECIFICATIONS

WELDING CODES, STANDARDS & SPECIFICATIONS INCLUDE A PLAN TO ASSURE THAT PRODUCTION WELDS PROVIDE THE QUALITY REQUIRED FOR THE PRODUCT.

WELDING CODES

WELDING CODES INCLUDE METHODS FOR

WELDING PROCEDURE

WELDER QUALIFICATION TESTS

CERTIFICATION

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WHY ARE WELDING CODES USED ?

WELDING CODES HAVE EVOLVED OVER MANY YEARS.

IT CONTAIN A BODY OF COLLECTIVE EXPERIENCE ON HOW TO MAKE SOUND WELD

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WHY ARE WELDING CODES USED ?
BY FOLLOWING ESTABLISHED CODES, WELD RELIABILITY IS GREATLY INCREASED

CODES

ARE

UPDATED

CONTINUALLY

AS

PROCESSES
CHANGE.

&

PRODUCT

REQUIREMENTS

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WHERE DO WELDING CODES COME FROM ?
WELDING CODES ARE ISSUED BY PROFESSIONAL BODIES SUCH

AS

AMERICAN WELDING SOCIETY (AWS)

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

AMERICAN PETROLEUM INSTITUTE (API)

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AWS, ASME, API

KNOWN AS CONSENSUS STANDARDS.

COMMITTEE

OF

HIGHLY

EXPERIENCED

ENGINEERS & SCIENTISTS MEET TO ESTABLISH & UPDATE THE CODE

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WHO DETERMINE WHICH CODE TO USE FOR AN APPLICATION?

FEDERAL, STATE, CITY, AND PROVINCIAL LAWS MANDATE CODES FOR MANY APPLICATIONS

WHEN THE CODE IS NOT DETERMINED BY LAW, THE CONTRACT BETWEEN THE MANUFACTURER AND BUYER MAY SPECIFY THE CODE THAT APPLIES.

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TYPICAL EXAMPLES OF WELDED PRODUCTS WHERE
WELDING CODES ARE A MATTER OF LAW AIRCRAFT NUCLEAR REACTOR PRESSURE VESSELS CONSTRUCTION EQUIPMENT INDUSTRIAL MACHINERY ORDINANCE RAILROAD ROLLING STOCK

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TYPICAL EXAMPLES OF WELDED PRODUCTS WHERE
WELDING CODES ARE A MATTER OF LAW

SHIPS, DRILLING RIGS

STORAGE TANKS

STRUCTURAL STEEL FOE BUILDINGS & BRIDGES

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TYPICAL EXAMPLES OF WELDED PRODUCTS WHERE WELDING CODES ARE A MATTER OF LAW

AIRCRAFT

APPLICABLE STANDARDS & SPECIFICATIONS ARE FOR MATERIAL SAE & AIAA CODES FOR WELDING NASA SPECIFICATION MIL STANDARD

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TYPICAL EXAMPLES OF WELDED PRODUCTS WHERE WELDING CODES ARE A MATTER OF LAW NUCLEAR REACTOR

APPLICABLE STANDARDS & SPECIFICATIONS ARE FOR MATERIAL ASME SECTION III FOR WELDING ASME SECTION IX

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TYPICAL EXAMPLES OF WELDED PRODUCTS WHERE WELDING CODES ARE A MATTER OF LAW

PRESSURE VESSEL
APPLICABLE STANDARDS & SPECIFICATIONS ARE FOR MATERIAL ASME SECTION II FOR WELDING ASME SECTION IX

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TYPICAL EXAMPLES OF WELDED PRODUCTS WHERE WELDING CODES ARE A MATTER OF LAW

CONSTRUCTION EQUIPMENT APPLICABLE STANDARDS & SPECIFICATIONS ARE FOR MATERIAL ASTM, DIN STANDARDS FOR WELDING AWS

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TYPICAL EXAMPLES OF WELDED PRODUCTS WHERE WELDING CODES ARE A MATTER OF LAW

INDUSTRIAL MACHNERY APPLICABLE STANDARDS & SPECIFICATIONS ARE FOR MATERIAL ASTM, DIN STANDARDS FOR WELDING AWS

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TYPICAL EXAMPLES OF WELDED PRODUCTS WHERE
WELDING CODES ARE A MATTER OF LAW

ORDINANCE

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TYPICAL EXAMPLES OF WELDED PRODUCTS WHERE WELDING CODES ARE A MATTER OF LAW

RAILROAD ROLLING STOCK APPLICABLE STANDARDS & SPECIFICATIONS ARE

FOR MATERIAL FOR WELDING ASTM, DIN STANDARDS ASSOCIATION OF AMERICAN RAILROADS

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TYPICAL EXAMPLES OF WELDED PRODUCTS WHERE
WELDING CODES ARE A MATTER OF LAW

SHIPS

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TYPICAL EXAMPLES OF WELDED PRODUCTS WHERE
WELDING CODES ARE A MATTER OF LAW

DRILLING RIGS

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TYPICAL EXAMPLES OF WELDED PRODUCTS WHERE
WELDING CODES ARE A MATTER OF LAW

STRUCTURAL STEEL FOR BUILDING STRUCTURES, BRIDGES & BUILDINGS

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TYPICAL EXAMPLES OF WELDED PRODUCTS WHERE
WELDING CODES ARE A MATTER OF LAW

STORAGE TANK

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WHAT ARE SOME OF THE MOST COMMON WELDING CODES ?
WELDING CODE
AWS D1.1 AWS D1.2 ASME SECTION - IX ASME B 31 API STD 1104

TITLE
STRUCTURAL WELDING CODE STEEL STRUCTURAL WELDING CODE ALUMINIUM BOILER & PRESSURE VESSEL CODE (WELDING QUALIFICATIONS) CODE FOR PRESSURE PIPING STANDARD FOR WELDING PIPELINES & RELATED FACILITIES.

LIKE MOST CODES THESE REQUIRE QUALIFICATION AND CERTIFICATION OF WELDERS

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ASME Code for Pressure Vessels & Boilers

Section I Section II

Section III Section IV Section V Section VI

Power Boilers Material Specifications - ferrous Material Specifications - non-ferrous Material Specifications - welding rods, electrodes, and filler metals Nuclear Power Plant Components Heating Boilers Non Destructive Examination Recommended rules for the care and operation of heating boilers

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ASME Code for Pressure Vessels & Boilers

Section VII

Recommended rules for the care of power boilers Section VIII Pressure Vessels, Division I & II Section IX Section X Section XI Welding Qualifications Fiber glass - reinforced plastic pressure vessels Rules for in-service inspection of nuclear reactor coolant system

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ASME CODE SYMBOL STAMPS
MANUFACTURERS OR CONTRACTORS WHO

REGULARLY BUILD OR INSTALL PRESSURE VESSELS OR PRESSURE PIPING WILL USUALLY ASME SYMBOL STAMP. HAVE AN

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ASME CODE SYMBOL STAMPS
THIS MEANS THEY HAVE BEEN APPROVED BY AMERICAN SOCIETY OF MECHANICAL THE

ENGINEERS

(ASME) AS AN AUTHORIZED
INSTALLER OF THE TYPE SPECIFIED.

MANUFACTURER
OF

OR

EQUIPMENT

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PROCESS TO GET ASME CODE SYMBOL STAMPS
MANUFACTURER OR CONTRACTOR TO APPLY AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) BOILER & PRESSURE CODE COMMITTEE FOR ASME CODE SYMBOL

REQUIRED.

PREPARE A WRITTEN QUALITY CONTROL MANUAL DESCRIBING CONTROLLED MANUFACTURING SYSTEM.

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PROCESS TO GET ASME CODE SYMBOL STAMPS
ASME SURVEY TEAM WILL INSPECT THE FACILITIES

REVIEW THE QUALITY CONTROL

MANUAL &
THE

WITNESS A DEMONSTRATION OF ALL

ITEMS AFECTING QUALITY SCOPE OF CERTIFICATE

WITH

IN

THE

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PROCESS TO GET ASME CODE SYMBOL STAMPS

ASME SURVEY TEAM WILL

ISSUE A CERTIFICATE OF AUTHORIZATION & APPLICABLE CODE SYMBOL

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ASME Code Symbol Stamps

N
PP U S H

Nuclear Vessel
Pressure Piping Pressure Vessel Power Boilers Heating Boilers

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WHERE DOES THE QUALIFICATION AND CERTIFICATION CYCLE BEGIN & HOW IT IS DONE?

DESIGN OF THE JOINT, PROCESS DEVELOP WELDING PROCEDURE SPECIFICATION (WPS) QUALIFICATION OF WPS RECORDED AS PROCEDURE QUALIFICATION RECORD (PQR) WELDER PERFORMANCE QUALIFICATION

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WHAT WELDING VARIABLES ARE DESCRIBED IN WPS?

WELDING PROCESS BASE MATERIAL BASE MATERIAL THICKNESS/ PIPE DIAMETER

FILLER METAL
WELD TYPE WELDING POSITION (S) SHIELDING GAS PREHEAT CONDITIONS

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WHAT WELDING VARIABLES ARE DESCRIBED IN WPS?

POST WELD HEAT-TREATMENT ELECTRICAL CHARACTERISTICS

POLARITY CURRENT, VOLTAGE

TRAVEL SPEED WIRE FEED SPEED WELD TYPE ELECTRODE SIZE SHIELDING GAS BACKING

WELDING PROCEDURE SPECIFICATION

(QW 201.1 SECTION IX, ASME PRESSURE VESSEL CODE)

COMPANY NAME WPS NO. 1

ABC PRESSURE VESSEL COMPANY DATE AUGUST 11, 1991 GMAW REVISION NO. TYPE

PREPARED BY DATE

FRANK JONES, WELDING ENGR. SUPPORTING PQR NO.

WELDING PROCESS(ES)

SEMI AUTOMATIC DETAILS

75O

JOINT (QW 402)

JOINT DESIGN BACKING (YES) SINGLE VEE (NO)

BACKING MATERIAL (TYPE)

METAL NONMETALLIC NONFUSING METAL OTHER
2 MM 2 MM

V - GROOVE JOINT

BASE METALS (QW 403)

P. NO.
OR OR

GROUP NO.

TO

P. NO.
TO TO 4 MM TO 25 MM UNLIMITED

GROUP NO.
SPECIFICATION, TYPE AND GRADE

SPECIFICATION, TYPE AND GRADE CHEM. ANALYSIS & MECH. PROPERTIES BASE METAL GROOVE GROOVE

CHEM. ANALYSIS & MECH. PROPERTIES

THICKNESS RANGE PIPE DIA. RANGE

FILLET FILLET OTHER

FILLER METALS (QW 404)

SPECIFICATION NO. (SFA) AWS NO. (CLASS) F. NO. A. NO. SIZE OF FILLER METAL THICKNESS RANGE ELECTRODE FLUX (CLASS) FLUX TRADE NAME CONSUMABLE INSERTS, OTHER NONE ~ NONE 5.18 ER 70S 3 6 1 2 MM

WELDING PROCEDURE SPECIFICATION

(QW 201.1 SECTION IX, ASME PRESSURE VESSEL CODE)

POSITIONS (QW 405)

POSITION(S) OF GROOVE WELDING PROGRESSION UP 2G DOWN

POST WELD HEAT TREATMENT (QW 407)

TEMPERATURE RANGE TIME RANGE GAS (QW 408) PERCENT COMPOSITION 45O C GAS(ES) (MIXTURE) FLOW RATE NONE ~

POSITION(S) OF FILLET PREHEAT (QW 406)

PREHEAT TEMPERATURE (MINIMUM)

INTERPASS TEMPERATURE (MAXIMUM)

PREHEAT MAINTENANCE
(CONTINUOUS OR SPECIAL HEATING WHERE APPLICABLE SHOULD BE RECORDED

100O C
45O C

SHIELDING
TRAILING BACKING

CO2
NONE NONE

WELDING GRADE

20 CFH

ELECTRICAL CHARACTERISTICS (QW 409)

CURRENT AC or DC DC POLARITY DCEP AMPS (RANGE) 150 170 VOLTS (RANGE)

21 - 23

(AMPS AND VOLTS RANGE SHOULD BE RECORDED FOR EACH ELECTRODE SIZE, POSITION, AND THICKNESS, ETC. THIS INFORMATION MAY BE LISTED IN A TABULAR FORM SIMILAR TO THAT SHOWN BELOW)

TUNGSTEN ELECTRODE SIZE AND TYPE ELECTRODE WIRE FEED SPEED RANGE

NONE 750 CM / MINUTE

MODE OF METAL TRANSFER FOR GMAW

SHORT CIRCUIT MODE

TECHNIQUE (QW 410)

STRING OR WEAVE BEAD WEAVE BRUSH TO CLEAN ORIFICE OR GAS CUP SIZE METHOD OF BACK GAUGING 12.5 MM ID NONE 12.5 MM TO 18 MM SINGLE INITIAL AND INTERPASS CLEANING (BRUSHING, GRINDING ETC) OSCILLATION AS REQUIRED MULTIPLE PEENING

CONTACT TUBE TO WORK DISTANCE MULTIPLE OR SINGLE ELECTRODES NONE

MULTIPLE OR SINGLE PASS (PER SIDE) TRAVEL SPEED (RANGE) OTHER

WELD LAYER (S) PROCESS

600 MM/MIN

ALL TACK WELDS TO GROUND TO FEATHER EDGE. ALL STARTS AND STOPS TO BE GROUND TO SOUND METAL. ALL SURFACE CRACKS OR HOLES TO BE REMOVED BEFORE CONTINUING.

FILLER METAL CLASS DIA

CURRENT TYPE POLARITY AMP RANGE

VOLT RANGE

TRAVEL SPEED RANGE

REMARKS

1
SUBSEQUENT LAYERS

GMAW
GMAW

ER70S-6
ER70S-6

2 MM
2 MM

DC
DC

DCEP
DCEP

150-170
150-170

21-23
21-23

600 MM/MIN
600 MM/MIN

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HOW THE TEST SPECIMEN IS PREPARED?
STEP 1

PREPARE A SINGLE V - GROOVE BUTT JOINT TEST PIECE

TEST PIECE DIMENSIONS

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HOW THE TEST SPECIMEN IS PREPARED?
STEP 2 A WELDER TO DO WELDING AS PER APPLICABLE WPS

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TESTS ON QUALIFICATION WELD TEST SPECIMEN
IN MOST CASES, TESTING INCLUDES ONE OR MORE OF THE FOLLOWING: VISUAL INSPECTION GUIDED BEND TEST TENSILE TESTS FRACTURE TEST MACRO - ETCH TEST

RADIOGRAPHIC TESTS

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WHAT ARE THE VISUAL EXAMINATION CRITERIA ?
REFERENCE STANDARD AWS D1.1, SECTION 4.8.1

ACCEPTANCE CRITERIA

WELD SHALL BE FREE OF CRACKS

HAVE ALL CRATERS FILLED TO FULL C.S. OF WELD

UNDERCUT SHALL NOT EXCEED 1 MM

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WHAT ARE THE VISUAL EXAMINATION CRITERIA ?
REFERENCE STANDARD ACCEPTANCE CRITERIA WELD REINFORCEMENT NOT TO EXCEED 3 MM AWS D1.1, SECTION 4.8.1

ROOT NO EVIDENCE OF CRACK, INCOMPLETE FUSION

MAXIMUM ROOT CONCAVITY = 1.6 MM

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IF THE VISUAL EXAMINATION IS GOOD, WHAT OTHER TESTINGS ARE NEEDED ?

TEST THE INTEGRITY OF THE WELD BY 1. NDT METHODS

RADIOGRAPHIC TEST

ULTRASONIC TEST

GOVERNING CODE IS AWS D1.1, SECTION 6 PART C

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IF THE VISUAL EXAMINATION IS GOOD, WHAT OTHER TESTINGS ARE NEEDED ?

TEST THE INTEGRITY OF THE WELD BY 2. MECHANICAL TESTS

ROOT AND FACE BEND TESTS

SIDE BEND TEST

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HOW THE MECHANICAL TEST SPECIMENS ARE PREPARED? CUT THE BEND TEST SPECIMEN FROM THE LOCATION SHOWN

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TEST PIECE DIMENSIONS

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BEND TEST PREPARATION
150 MM 3 MM 9.5 MM

IF THERMAL CUT, ALLOW NOT LESS THAN 3 MM TO BE MACHINED FROM EDGE.

T WHEN t EXCEEDS 38.1 MM CUT ALONG THIS LINE. EDGE MAY BE THERMAL CUT

1.

FOR PLATE OVER 38.1 MM THICK, CUT THE SPECIMEN INTO APPROXIMATELY EQUAL STRIPS WITH T BETWEEN 19 MM AND 38 MM & TEST EACH STRIP
t = PLATE OR PIPE THICKNESS

2.

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A

PLUNGER

DIE

HARDENED ROLLERS, MAY BE SUBSTITUTED FOR JIG SHOULDERS

C D

BEND TEST PLUNGER AND GUIDE

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BEND TEST PLUNGER & GUIDE - DIMENSIONS

SPECIFIED OR ACTUAL BASE METAL YIELD STRENGTH

KG / MM2

A
MM

B
MM

C
MM

D
MM

35.34 & BELOW OVER 35.4 TO 63.6 63.6 & OVER

38.1 50.8 63.5

19.05 25.4 31.75

60.3 73 85.7

30.15 36.5 42.85

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AFTER THE DESTRUCTIVE TESTS COMPLETION WHAT DETERMINES ACCEPTABILITY ? EXAMINE THE CONVEX SURFACE OF SPECIMEN FOR DISCONTINUITIES
FOR ACCEPTANCE, NO DISCONTINUITIES EXCEEDING FOLLOWING DIMENSIONS

3 MM MEASURED IN ANY DIRECTION ON SURFACE 10MM - THE SUM OF THE GREATEST DIMENSION OF ALL DISCONTINUITIES EXCEEDING 1 MM BUT LESS THAN EQUAL TO 3 MM

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AFTER THE DESTRUCTIVE TESTS COMPLETION WHAT DETERMINES ACCEPTABILITY ?

6 mm - The maximum corner crack, except when that corner crack resulted from visible slag inclusion or other fusion type discontinuities, then 3 mm maximum applies.

Specimens with corner cracks exceeding 6mm with no evidence of slag inclusion or other fusion type discontinuities are disregarded.

WELDING POSITIONS
FLAT POSITION 1G HORIZONTAL POSITION 2G

PLATE - VERTICAL AXIS OF WELD - HORIZONTAL

PLATE & AXIS OF WELD - HORIZONTAL

FLAT POSITION 3G

OVERHEAD POSITION 4G

PLATE - VERTICAL AXIS OF WELD - VERTICAL

PLATE & AXIS OF WELD - HORIZONTAL

WELDING POSITIONS FOR GROOVE WELD :- PLATE

WELDING POSITIONS
FLAT POSITION 1F HORIZONTAL POSITION 2F

AXIS OF WELD HORIZONTAL AXIS OF WELD HORIZONTAL

VERTICAL POSITION 3F

OVERHEAD POSITION 4F

AXIS OF WELD VERTICAL

AXIS OF WELD HORIZONTAL

WELDING POSITIONS FOR FILLET WELD :- PLATE

WELDING POSITIONS
PIPE POSITION FLAT 1G PIPE POSITION HORIZONTAL 2G

AXIS OF CYLINDER VERTICAL AXIS OF CYLINDER HORIZONTAL PIPE SHALL BE TURNED WHILE WELDING

PIPE POSITION HORIZONTAL FIXED 5G V

PIPE POSITION 6G

450 50

AXIS OF PIPE AT 450 AXIS OF CYLINDER HORIZONTAL PIPE SHALL NOT BE TURNED OR ROLLED WHILE WELDING

WELDING POSITIONS FOR GROOVE WELD :- PIPE

WELDING CODES
What positions can this weld be made in?
Welding can be performed in any of the four positions. Welding Position Flat Horizontal Vertical Overhead Overhead & Vertical Qualification Range Flat, Groove & Fillet Flat & Horizontal Flat, Horizontal & Vertical Flat & Overhead All Positions

TESTING QUALIFICATION WELDS

What type of weld testing is required for qualification?
Groove Weld Cut Guided bend test specimens from specified location of test piece Bend in Specified Jigs Fillet Weld Weld Break Test Macro - Etch Test

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FILLET WELD TEST PIECE

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HOW IS THE FILLET WELD BREAK TEST PERFORMED ?

THE LOAD SHALL BE INCREASED OR REPEATED UNTIL IT FRACTURES OR BEND FLAT UPON ITSELF.

TESTING QUALIFICATION WELDS What are the acceptable criteria for a fillet weld break test ?

Visual Examination before break test

Weld must be uniform in appearance Free of Cracks, Undercut

The Broken specimen passes if, The specimen bend flat upon itself Fracture surface showing complete fusion to the root of the joint No inclusion or porosity larger than 2 mm in greatest dimension The sum of greatest dimensions of all inclusion or porosity do not exceed 10 mm

TESTING QUALIFICATION WELDS

What testing is required for pipe qualification ?

SPECIMENS FOR 1G & 2G POSITIONS

TESTING QUALIFICATION WELDS

What testing is required for pipe qualification ?

SPECIMENS FOR 6G POSITION

POST WELD HEAT TREATMENT

ANNEALING

SOAKING TEMPEMPERATURE IS ABOVE CRITICAL TEMPERATURE ( + 38O C)

COOLING IS DONE IN THE FURNACE

POST WELD HEAT TREATMENT

NORMALIZING

SOAKING TEMPEMPERATURE IS ABOVE CRITICAL TEMPERATURE ( + 38O C)

COOLING IS DONE IN THE STILL AIR STRUCTURE OBTAINED IS OF GREAT STRENGTH BUT LESS DUCTILITY

POST WELD HEAT TREATMENT

TEMPERING

SOAKING TEMPEMPERATURE IS BELOW CRITICAL TEMPERATURE ( + 38O C)

IT IS 566O C TO 649O C

COOLING IS DONE BY QUENCHING

POST WELD HEAT TREATMENT

STRESS - RELIEVING
SOAKING TEMPEMPERATURE IS BELOW CRITICAL TEMPERATURE ( + 38O C)

IT IS 566O C TO 649O C

SOAKING TIME IS 1 HOUR / 25 MM THICKNESS

COOLING & HEATING RATE 144OC / Hr. 179OC / Hr.