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General Welding Fabrication and Testing PDF
General Welding Fabrication and Testing PDF
General Welding Fabrication and Testing PDF
10
Polaris
Rev.: 0
Engineering
Page: 1 of 24
Standard
Date: 07/06/09
I. SCOPE 2
II. REFERENCES 2
XI. REPAIRS 20
I. SCOPE
A. This Standard covers the minimum welding requirements, for welding of shop
and field fabrications and the weld inspection of the following:
3. Structural Steel
B. This Standard modifies the requirements of applicable ASME, AWS, API and
ANSI codes and standards in effect at the revision date.
D. Where conflicts exist between this Engineering Standard and other POLARIS
Engineering Standards and/or applicable codes or regulations, the more stringent
requirement shall govern. All conflicts shall be brought to the Clients attention
for resolution. The Client shall be the sole arbiter of any conflicts.
II. REFERENCES
This POLARIS Standard is to be used in conjunction with the latest revision of the
standards and codes listed below, unless specifically noted. The terminology "latest
revision" shall be interpreted as the revision in effect at the time of contract award. This
POLARIS Standard may reference specific sections of some of these codes and
standards. The revision of the codes and standards being referenced is noted below in
parenthesis. This information is provided to identify the subject matter being referenced.
Changes or exceptions made to the referenced code or standard shall apply to later
revisions as applicable.
D. This Standard includes additional requirements and restrictions, which may not be
listed in the Vendor's submitted welding procedures. They shall be listed, when
required by this Standard, either in the welding procedure or on the weld map.
The main additional requirements are summarized in Section XII below.
I. When impact testing is required by the code or POLARIS Standards, impact test
results for weld and heat affected zone shall be reported with the welding
procedure qualifications.
A. The following welding processes are permitted, subject to the limitations set forth
in Section V below, providing that satisfactory evidence is submitted showing that
the procedures qualified are in accordance with applicable codes, standards, and
this Standard.
B. Welding processes other than those listed above require specific approval by the
Client or Client's Engineer and shall not be assumed as acceptable by the Vendor
during bid preparation.
D. Client and Client's Engineer reserve the right to disallow the use of any welding
process or welder based on excessive rates of repair.
A. GMAW and FCAW processes shall have stated in the WPS, and on the required
weld map (see Appendix I), whether the current is in the short circuiting arc or
spray transfer range. The shop and the welding personnel shall have
demonstrated production welding experience with each process to the satisfaction
of the Client and Client's Engineer.
B. GMAW is acceptable for root passes and completion of welds up to 3/8 inch
deposited weld metal thickness for groove welds and 3/8 fillet weld size. When
specific Client permission is obtained to exceed this maximum deposited
thickness; all such welds shall be 100% ultrasonically shear-wave examined
throughout their entire length.
D. FCAW, spray transfer, without shielding gas, is acceptable with specific Client
approval for structural steel welding fabrication only.
E. FCAW, spray transfer, with shielding gas is acceptable for welding shop
fabricated pipe and for welding pressure retaining parts of pressure vessels
provided the following conditions are met:
F. GMAW and FCAW for field fabrication must have the Client's specific approval.
G. Automatic or machine type SAW is preferred. The SAW process shall have
stated on the WPS that the procedure is automatic or machine type welding in
order to be acceptable. Manual or semi-automatic SAW is prohibited.
H. Automatic or machine type SAW of P-1 materials shall be limited to 1/2 inch
maximum thickness per layer of deposit for material of 1-1/4 inch thickness or
greater and 3/8 inch maximum thickness per layer of deposit for material less than
1-1/4 inch thick. The maximum deposit for alloy and stainless steel shall be
limited to 0.4 inches per pass.
I. GTAW shall be utilized for pipe fabrication on first two layers for ferrous alloy,
and non-ferrous alloys on single welded groove joints accessible for one side only
and on other equipment as defined in the POLARIS Engineering Standards.
GTAW shall be used on all piping buttwelds on P-1 materials 2 NPS and
smaller.
A. Filler materials and fluxes shall be as specified in ASME, Section II, Part C.,
Filler Materials and Fluxes, other than those specified in the above code and
which meet other requirements of this Standard, shall not be assumed as
acceptable by the Vendor during bid preparation.
B. All welding shall employ a filler metal unless approved by the Client in writing.
Welding employing no filler metal shall not be assumed as acceptable by the
Vendor during bid preparation. Friction welding is prohibited.
C. The specific AWS grade, ASME specifications, Manufacturer and trade name for
filler metals and fluxes to be used on the project shall be indicated on the welding
procedure specification and weld map (Appendix I).
D. Use of filler metals and fluxes for other than the Manufacturer's primary
recommended application is prohibited. For example: Filler wire intended for
OFW shall not be used for GTAW. Filler wire intended for certain welding
positions specified by the Manufacturer shall not be utilized in other welding
positions. Fluxes recommended for single pass shall not be utilized on multi-pass
welds.
E. Automatic or machine submerged arc welding fluxes are subject to the following
limitations:
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1. Fluxes used for welding carbon or low alloy steels shall not contribute
alloying elements to the weld.
5. Alloy steel shall be welded using an alloy wire and a "neutral" flux. Fluxes
shall not contribute alloying elements to the weld deposit.
G. Carbon steels of group P-1 shall be welded with A-1 analysis weld metal only.
Use of other weld metal analysis numbers requires the Client's approval.
H. For welding 70 KSI tensile strength P-1 material subject to a PWHT, filler metals
containing 1/2% Mo are permitted in order to meet the minimum tensile strength
requirement.
I. Similar base materials shall be joined with a weld metal deposit that matches the
base metal in both chemistry and mechanical properties. In cases where this
cannot be accomplished, the Vendor shall propose a choice of filler together with
the reasons for the choice for the Client's review and approval.
J. Welds joining pressure containing parts of two different ferric steels shall have a
weld metal deposit conforming to the nominal composition of the higher alloy
base materials unless otherwise approved by the Client.
K. Welds joining two different ferric steels, only one of which is a pressure retaining
part, shall have a weld metal deposit conforming to the nominal composition of
the pressure retaining part unless the engineering design specifies otherwise and
written approval is given by the Client.
L. When joining two different austenitic stainless steels, the (A-8) filler metal may
match either and must result in a ferrite number range of 3-12. Delta ferrite shall
be determined from the certified chemical analysis and the "WRC Delta Ferrite
Diagram."
M. Welds joining austenitic stainless steels to ferritic steels shall be made with filler
metal as follows:
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3. TP 310 fillers are acceptable only for welding of Type 310 base materials
to themselves.
N. For GMAW and GTAW welding of P-1 materials exceeding 65 KSI minimum
tensile strength, only AWS classification ER70-S2 or ER70-S3, filler metals of
SFA 5.18 shall be used. The use of ER70-SG & GS, ER-70C-G & GS of SFA
5.18 is prohibited without prior submittal and approval of the filler metal material
test reports (MTRs) for each lot. Their utilization shall not be assumed as
acceptable by the Vendor during bid preparation. When use of this material is
approved by Client the material shall be marked and segregated for the job.
O. For FCAW of carbon steels exceeding 65 KSI minimum tensile strength, only
AWS Classification E7X-T1 or E7X-T5 filler metals of SFA 5.20 shall be used.
P. Use of SMAW electrode groups F-1, F-2, and F-3 as specified in ASME Section
IX, Table QW-432, are limited as follows:
2. F-1, F-2, and F-3 electrodes are not permitted on materials requiring
impact tests.
3. F-1 or F-2 electrodes shall not be used for pressure retaining parts or non-
pressure attachments to pressure retaining parts.
4. F-3 electrodes may be used for root passes of butt welds regardless of base
metal thickness.
Q. The receipt, use, dispersal and retrieval of welding filler materials shall be
maintained under strict control, with storage, baking and drying as recommended
by the Manufacturer to assure that completed welds conform to the approved
welding procedure specification requirements for welding materials.
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C. For austenitic material 2 inches and thicker, plate edges, including weld bevels
shall be liquid penetrated tested.
D. Welded butt joints shall meet the minimum requirements for penetration or fusion
in accordance with the applicable code or POLARIS Engineering Standard
requirements.
E. The addition of permanent backing such as rings, bars, or strips are unacceptable
and shall not be used without the Client's written approval. Their utilization shall
not be assumed as acceptable by the Vendor during bid preparation. The
additional backing referenced in this Standard is not defined by this Standard as
the weld installed on the first side of a butt weld welded from both sides.
F. Temporary (removable) backing rings, bars, or strips shall not be used without the
Client's written approval. Their utilization shall not be assumed as acceptable by
the Vendor during bid preparation.
G. If approved by the Client, the weld area exposed when backing is removed shall
be dressed and examined for cracks or defects by visual and liquid penetrated or
magnetic particle examination methods, whichever is applicable. All backing
material and unacceptable indications shall be removed completely and repaired
utilizing a weld procedure which has been accepted by the Client.
I. When Client's approval is given for use of backing rings, the Vendor welding
procedure and the weld map (Appendix I) submitted for review shall either
indicate that welding was qualified with backing ring (state on PQR) or that
backing ring will be added (stated on WPS and the weld map, Appendix I).
J. Consumable inserts require written approval by the Client. Their utilization shall
not be assumed as acceptable by the Vendor during bid preparation. If approved
by Client, they shall in all cases conform to the nominal chemistry of the weld
filler metal as defined in Section VI of this Standard. In all cases, they shall
require root shielding with inert gas.
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Standard
K. The materials used for pipe purging dams and methods employed in their
placement, use, and subsequent removal shall be as required to ensure that no
damage results to the piping or related components.
L. The method that is proposed by the Vendor to obtain and maintain adequate root
shielding shall be included either as part of the submitted welding procedure or as
a separate standard for review. The procedure for root shielding by inert gas shall
contain the following:
N. Weld joint tolerances for root opening and alignment shall meet the requirements
of applicable codes and POLARIS Engineering Standards, and also the weld joint
sketches contained in the submitted welding procedures to ensure against lack of
penetration and lack of fusion.
O. For shop and field fabrication, when poorly fitted joints occur with excessive joint
gap or excessive offset, the Vendor shall submit a separate weld repair procedure
indicating with a sketch the method proposed to bring the joint back to original
design requirements in conformance as close as possible to the original Client
accepted welding procedure. The Vendor cannot assume that backing rings or
strips, permanent or temporary, are acceptable without the Client's review. Any
weld joints of this nature found to be slugged with supplementary filler metal are
unacceptable. The weld build up of beveled ends to close excessive gap is
unacceptable unless a Vendor welding procedure is submitted for doing so and is
accepted by the Client.
P. Grinding and cleaning of stainless steels and nonferrous material shall be done
only with tools that will not leave detrimental deposits on the base metal;
aluminum oxide or silicone carbide grinding wheels and austenitic stainless steel
wire brushes shall be used. These tools shall not have been previously used on
other than the material to be cleaned.
Q. Surfaces to be welded shall be clean and free of paint, oil, dirt, scale and other
foreign materials, which may contain lead, sulfur, and other low melting point
elements detrimental to welding. Beveled edges are to be cleaned and coated with
deoxaluminate paint prior to shipment. Preparation of the bevel just prior to
welding shall be as specified on the applicable welding procedure specification.
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S. Tack welds which are to be incorporated into the final weld shall be subject to all
the same requirements as the applicable welding procedure, including preheat,
and are to be performed by welders qualified to perform the welding procedure
accepted for that joint. If separate tackers are used other than the welder
performing the joint weld, they shall be qualified for performance on all the same
welding variables for the portion of the weld they perform as stated in the
applicable accepted welding procedure or else the tack welds shall be completely
removed.
T. Tack welds shall be made with filler metal of the same composition as will be
used for the first pass of the weld as stated in the applicable accepted welding
procedure for the joint.
U. All slag shall be thoroughly removed from tack welds and the leading and trailing
edges shall be blend ground to a feather edge prior to welding the root pass or
covering pass.
V. Tack welds that violate any of the above requirements shall be completely
removed. Completed welds having tack welds found to violate any of the above
shall be subject to complete removal.
W. Removable start-up and run-off tabs shall be used for longitudinal welds.
Materials used for these tabs shall be of the same composition as the base weld.
X. For alloy clad plate and material, the following limitations shall apply for
preparation at the joint prior to back-cladding:
1. Cladding shall be stripped back to a minimum of 1/4 inch from the edge of
base material bevels by machining, grinding or arc gouging.
2. Removal of the cladding shall not reduce the base material thickness
below the design thickness.
4. Preparation of local repair cavities in overlay welds that penetrate into the
base material more than 10% of its thickness, or 3/16 inch, whichever is
less, shall have the base material rewelded with the appropriate Client
accepted welding procedure consistent with the base material prior to
completing the overlay repair.
Y. Strip type lining shall be attached to the shell circumferentially and shall be
designed so that the distance between attachment welds does not exceed that
shown below. The weld between the strips shall be at least 1/4 inch and not more
than 1/2 inch in width. Strip lining shall be a multi-pass fillet-butt weld of three
(3) weld minimum design with 100% dye penetrant testing of final weld. See
Figure A below.
Figure A
Z. Vessels with integrally clad type linings shall be made of explosion bonded plate
or plate clad with the required lining material in the steel mill in accordance with
the mills standards. These standards are to be approved by Client.
AA. Weld overlays shall consist of at least two layers so that the required depth of the
top layer will have the alloy composition required for the service. The first layer
may be made with electrodes of higher alloy content to compensate for dilution
effects. The finished surface shall be 100% examined by the liquid penetrant
method of examination.
BB. All stubs, rods, flux, slag or foreign material shall be removed from the equipment
or piping after completion of welding and prior to postweld heat treatment or
hydrostatic test.
CC. The use of temporary welded attachments shall be avoided where possible. All
locations of removed temporary attachments shall be examined visually after
removal of the attachment.
shall be removed and repaired and the area re-examined using the same
method of NDT that revealed the original defect.
DD. Vertical welding shall be performed vertical up. Downhill welding is not
permitted except for the GMAW root pass only.
EE. For field erection of API storage tanks, the weld seams of sketch plates for tank
bottoms and floating roofs shall contain a minimum of two weld passes. Single
pass seams are not acceptable.
A. Preheat shall be at least sufficient to dry surfaces to be welded but not less than
50oF. Higher temperatures may be required for highly restrained joints such as
closely spaced nozzles. Carbon steel plates 1.25 inch thick or more, shall be
preheated to 200oF minimum and ferritic alloy plates to 300oF minimum prior to
flame cutting and ground smooth prior to welding. All such prepared edges
including holes cut for nozzles or manways, shall be liquid penetrant examined or
magnetic particle inspected for cracks or laminations.
B. Minimum preheat temperatures shall not be less than that stated in ASME,
Section VIII, Division 1, Appendix R and Paragraph UCS 56; ASME B31.1,
Paragraph 131; or ASME B31.3, Table 330.1.1, as applicable. Minimum preheat
temperatures are required to be stated on the welding procedure specification.
C. Preheat maintenance shall be applied when required by the Client for the
conditions stated below. Preheat maintenance is the maintenance of the stated
minimum preheat temperature, without interruption, from start to completion of
welding. Vendor must either state on the WPS or weld map that preheat is to be
maintained when so required by Section VIII of this Standard. Loss of preheat
maintenance will require complete liquid penetrant or magnetic particle
inspection of the uncompleted seam prior to any further welding. Any defects
found must be reported to the Client's Inspector for his review.
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Standard
3. Pressure vessel and exchanger seams, nozzle and attachment welds of P-1,
P-3, P-4 and P-5 group materials, regardless of service, if shell or head
thickness is equal to or greater than 1-1/2 inch.
E. The same preheat requirements shall be met as are required on the Client accepted
welding procedures for thermal cutting, gouging, tack welding and welding
repairs.
F. The maximum preheat and interpass temperature for P-8 materials shall be 350 oF.
The maximum preheat and interpass temperature shall be specified on the WPS
for all materials of material group P-7 and higher.
1. For all equipment, except field fabricated tanks and piping, the post weld
heat treatment procedure outlined in the ASME Code, Section VIII,
Paragraphs UW-40, UW-49, and UCS-56, shall be followed. The
exemptions provided for in the notes to Table UCS-56 are permitted with
Client approval.
d. All carbon steel and low chrome piping shall be postweld heat
treated in accordance with POLARIS Engineering Standard 840.4.
B. Postweld heat treatment may be required for carbon steel equipment and piping
for certain service conditions even when not mandatory per the applicable code or
standard. Postweld heat treatment for these services will be indicated by the
POLARIS Engineering Standards.
5. All carbon steel equipment and piping in sour service with a fluid pressure
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7. All equipment in these services above shall have welds ground, smooth,
and wet fluorescent magnetic particle tested.
1. Furnace method
Other methods for postweld heat treatment require Client's written approval.
F. Postweld heat treatment for stainless steels of Material Group P-8, nonferrous
materials or dissimilar materials requires approval by the Client.
H. Equipment and piping postweld heat treated for any reason, code or process, shall
not be subjected to any further welding, hammering, pressing or forming after
postweld heat treatment without Client approval.
J. For local postweld heat treatment of thicknesses greater than 2 inches, the Vendor
shall verify that the minimum code required PWHT temperature is attained on the
unheated side of the joint. Verification may be established either by the
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K. PWHT is always required for all piping in which the wall thickness is 3/4 or
greater.
C. Plate 2 inches and thicker and clad material shall be 100% ultrasonically tested at
the mill with acceptance to SA-578, Level B.
a. One test for one longitudinal seam per course section, on the inside
surface where practical.
b. One test for each circumferential seam per 50 linear feet of weld,
on the inside surface where practicable.
c. One test for each major joint weld for box-type headers on air
coolers.
d. One test for each size nozzle 4 inches and over in size, if
accessible.
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5. Where NACE MR-0175 and/or RP-0472 are specified the hardness testing
requirements of those standards shall apply where more stringent than this
Standard.
d. Hardness for carbon steel shall not exceed 200 BHN; hardness for
low alloy shall be in accordance with applicable codes or
standards. For other materials requiring hardness testing,
acceptance values shall be as stated in the applicable codes and
standards.
1. One chemical analysis of overlay from each girth section and component
(such as head, tubesheet, etc.) and from each back-cladded longitudinal
and circumferential seam. Also, back-cladded manway attachment and a
representative number of nozzles, at least one of each size. Production
tests shall include a minimum of one test per welding process utilized and
one test per welder or welding operator employed.
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2. For austenitic stainless steel, the overlay or back-clad for TP 347 stainless,
when specified, shall have elements Cr, Ni, Mn, Si, C and Cb reported.
3. For others, the overlay or back-clad shall meet the minimum requirements
of the specified alloy.
F. Weld overlays and back-cladding for vessels and towers shall be examined by a
standard copper sulfate test prior to hydrostatic test and by liquid penetrant
examination following hydrostatic test. Overlay clad tubesheets shall be liquid
penetrant examined prior to hydro static test.
G. The Client's Inspector shall be authorized to reject work or materials and require
repair or corrections where the applicable specifications or acceptance levels have
not been met.
H. The Client's Inspector may require additional examination over and above the
minimum specified. If the weld proves to be acceptable, the cost of examination
shall be borne by the Client. If the weld proves to be unacceptable, the cost of the
examination, and all required repairs and re-examination shall be borne by the
Vendor.
I. Root and final welds in vessels, air cooler box headers, exchangers and piping
larger than 24 inches shall be magnetic particle examined when the material
thickness is equal to or greater than the following:
P-1 1-1/4
P-3 3/4
P-4 5/8
P-5 All
P-6 All
P-7 All
J. Welds in all non-magnetic materials, either of solid alloy or alloy clad plate shall
be examined by liquid penetrant methods.
K. Where strength welds for tube to tubesheet joints are required, Vendor shall
submit a cut-off sample before fabrication.
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L. Pressure retaining butt welds in shell or heads over 1.80 inches thick may be
manual arc process welded and shall be radiographed 100%.
M. Heads fabricated from more than one piece shall have welds radiographed 100%
prior to forming.
N. For equipment and piping requiring PWHT all required NDE of completed welds
shall be performed after the postweld heat treatment.
XI. REPAIRS
B. The repair procedures, using welding, shall be submitted for review and shall
include the following:
1. The method of defining the type and the extent of the defect.
2. Methods used for removing the defect, and testing conducted to ensure
that the defect has been removed.
D. Excavation for repairs by flame or arc gouging shall have the same preheat
requirements imposed as the welding procedures used to perform the weld.
F. Undercutting shall be repaired by blend grinding provided the required base metal
thickness by design is not reduced. Otherwise, weld metal buildup will be
required.
G. Defective work or materials that have been weld repaired shall, as a minimum, be
re-examined by the same non-destructive test method by which the defect was
originally located.
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H. Only two repair attempts shall be allowed on any one defective area. No further
attempts to repair shall be carried out without authorization of the Client.
C. Mode of transfer for GMAW and FCAW to be stated on WPS and weld map of
Appendix I.
G. Filler metals and fluxes. To have stated in the WPS and/or weld map (Appendix
I) the AWS grades ASME specifications, Manufacturers, and trade names of filler
metals and fluxes.
H. When backing is approved for use, it is required to be stated on PQR, WPS and
weld map (Appendix I).
L. Maximum preheat and interpass temperature to be stated on WPS for P-7 group
materials and higher.
1. Electrical characteristics: current and voltage ranges, and polarity, for all
welding processes.
3. Travel speed and whether single or multiple arc for automatic processes of
GTAW, GMAW, SAW, FCAW/CO2 and for overlay and back-clad
welding.
4. Amount of bead overlap, extent of oscillation and wire size for overlay
and back-clad welding.
O. Block welding is prohibited. However, The Temper Bead Welding Technique per
NBIC is allowable with Clients written approval.
P. When welding titanium, each bead and adjacent base metal shall be cleaned to
remove all surface discoloration prior to deposition of the next bead. The final
weld surface may have intermittent, iridescent straw-colored oxides.
Q. The root pass of butt welds in lube oil piping, accessible from one side only, shall
be welded with the GTAW process.
A. The Client requires Vendors and their Subvendors, if applicable, to submit a copy
of each welding procedure appropriate for fabrication. A copy of the weld map
(Appendix I) shall also be filled out and attached to the submittal. Procedures
cannot be reviewed unless accompanied by the weld map.
B. Submittals of welding procedures for review shall be directly to the Client and/or
Client's Engineer. No portion of this Standard shall be waived without written
approval.
C. Vendors shall review the welding procedures of their own Subvendors for
compliance to this Standard prior to submitting for review and acceptance.
D. The Client and/or Client's Engineer will review the submitted welding procedures
and weld map and make comments back to the Vendor in writing. Comments are
either (1) Acceptable without comment, (2) Acceptable with comments, (3)
Revise and resubmit per comments or (4) Unacceptable with comments. All
comments, if possible, will make reference the paragraph number of this Standard
with which the procedure must comply.
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E. Upon receiving the marked up welding procedure from the Client and/or Client's
Engineer, the Vendor must comply with the comments. The Vendor shall submit
corrected documents. The Surveillance Inspector assigned by the Client is to
verify that welding will be performed to the accepted and corrected welding
procedures, which incorporate the comments. Items in dispute shall be resolved
prior to fabrication being stated on the affected parts.
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APPENDIX I
WELD MAP
Supplier Name
Supplier Shop Order #
POLARIS PO # Pressure Vessel
Item/Tag # Heat Exchanger
Storage Tank
Design Temperature Fabricated Pipe Spools
Design Pressure Other
Min. Design Metal Temp.
Postweld Heat Treatment Yes No Required by Code Service
Time and Temperature
Impact Testing Yes No Required by Code Service
Temperature
Applicable Code or Standard
Draw a single-line sketch of the apparatus. For pipe spools, only show typical weld joints, i.e., butt, branch, and attachments, by
P-No.
Locate an example of all types of typical weld joints, dissimilar welds & attachments
Identify each different welding procedure by separate letter or number.
Email Address
Telephone
Revision
Date
This space for POLARIS Identification