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Tubular Non Tubular AWS D1 1 PDF
Tubular Non Tubular AWS D1 1 PDF
Tubular Non Tubular AWS D1 1 PDF
Zamil 29/03/2015
SECTION – 1
GENERAL REQUIREMENET
Oleh :
Farid Moch. Zamil
LATAR BELAKANG
FAKTA LAPANGAN
PENGERTIAN
PIPE
Bentuk Tubular dengan penampang melingkar.
TUBULAR
Bagian yang berongga dari berbagai bentuk konfigurasi
6. Inspection.
Criteria for qualification and responsibility of welding
inspectors, acceptance criteria of welds, procedure for visual
inspection & NDE.
7. Stud Welding.
Requirements for the welding of studs to structural steel.
8. Strengthening & Repair Existing Structure.
Provisions for design/welding modification or repair of
existing steel structures.
• Annex
Normative Informasi & Requirement bahwa menjadi pertimbangan
Informative Tidak dijadikan pertimbangan
SECTION – 2
DESIG (PERENCANAAN)
Oleh :
Farid Moch. Zamil
• TOUGHNESS CLASS
1. Class C
Diapplikasikan di welded structure yang mempunyai
temperature service diatas 100C.
2. Class B
material yang mempunyai nilai CVN pada temperatur
pengujian 100C – 00C
Fillet Weld :
• Minimum Fillet Weld seperti tercantum pada tabel 5.8.
Fillet Weld :
• Maksimum Weld Size in Lap Joint :
a) Tebal < 6 mm (1/4 in).
Fillet Weld :
• Minimum Overlap antara tebal material yang berbeda HARUS 5 X
TEBAL PELAT PALING TIPIS TETAPI TIDAK BOLEH KURANG DARI 25 mm
(1 in)
SECTION – 3
Oleh :
Farid Moch. Zamil
• Persyaratan.
1. Operator & Tack Welder
Harus dikualifikasi sesuai ketentuan Clause 4.
2. Semua prequalified WPS harus tertulis
Sesuai sesuai ketetuan di Clause 3
3. Welding Proses
• Welding proses yang direkomendasikan SMAW, SAW,
GMAW (kecuali type Short circuit) dan FCAW.
• Welding proses ESW, GTAW dan GMAW type Short
circuit boleh digunakan : WPS harus dikulaifikasi sesuai
ketentuan Clause 4.
PERSYARATAN PWHT :
1. Nilai Yield Strength Base Metal tidak lebih dari 50 Ksi.
SECTION – 4
QUALIFIED WPS
Oleh :
Farid Moch. Zamil
* Note :
* CJP Groove qualify CJP, PJP & Fillet Welds.
* Fillet qualify Fillet only.
* Groove weld on plate qualifies pipes ≥ 24 in (600) nominal outer dia.
* Vertical uphill to downhill essential variable and vise versa
* Plug/Slot Welding qualifies for only the tested position
Note
CJP groove weld qualification on any thickness or diameter
shall qualify any size of fillet or PJP groove weld for any
thickness or diameter (see Clause 4.11.3 for macro etch test
requirement.
4. Guide (Base Material) – See Table 3.1, 4.8 & 4.9 – Cont’d
5. Guide (Preheat)
• The need for & temperature of preheat dependent upon number
of factors such as Chemical analysis, degree of restraint of the
parts being joined, elevated temperature, mechanical
properties and material thickness.
• AWS D1.1, Table 4.5 : PQR Essential Variable (except ESW and
EGW process), for Non-CVN Testing applications.
6. Guide (Joint)
• AWS D1.1. TABLE 4.5 : ESSENTIAL VARIABLE FOR JOINTS
• A change in groove type (e.g, Single-V → double V) except
qualification of any CJP groove weld qualifies for any groove
detail conforming to the requirements of 3.12 (PJP-Figure 3.3) or
3.13 (CJP- Figure 3.4)
• A decrease in the groove angle and root opening, an increase
in the root face exceeding the tolerance (increase in the groove
angle above 10 degree) for any groove detail conforming to the
requirement of 3.12 (PJP-Figure 3.3) or 3.13 (CJP-Figures 3.4), 3.13
and 5.22.4.1 or 5.22.4.2 (Tubular and Non Tubular).
• The omission, but not inclusion of backing or backgouging.
• A change in the type of groove to square groove and vice versa.
• AWS D1.1, Table 4.5 PQR Essential Variables (except ESW and
EGW process), for Non-CVN testing application.
POSITION QUALIFIED*
POSITION TEST GROOVE FILLET
1G, 1G (Rotated) F F, H
2G F, H F, H
3G F, H, V F, H, V
4G F, OH F, H, OH
5G F, V, OH F, V, OH
6G, 6GR ALL ALL
* Note :
* Vertical uphill to downhill or vice versa is Essential Variable.
* Groove test on pipe or box tube also qualifies plate for the same positions.
* Groove test using box tubing also qualifies pipes ≥ 24 in (600) nominal outer dia.
3/29/2015 WELDING INSPECTOR COURSE 79
Farid Moch. Zamil
SECTION – 5
FABRICATION
Oleh :
Farid Moch. Zamil
Sect.5 – Fabrication
Preparation (Persiapan).
• SHOP DRAWING SHALL SHOW
1. Size and location of all structural members & connection
material.
2. Complete information necessary for the fabrication of
member including : cuts, holes, stiffeners and weld.
3. Type, size & location of bolts and welds.
4. Surface preparation and finishes.
5. Details of assembly.
6. Identification of WPS.
7. Furnish setting drawing, tempaltes and directions for
installation of anchor bolts and other anchorages to be
installed as work of other sections.
Sect.5 – Fabrication
Preparation (Persiapan).
Sect.5 – Fabrication
Sect.5 – Fabrication
1) Size
2) Condition
3) Specification*
Sect.5 – Fabrication
Rolling Imperfections
Direction of rolling
Cold Laps*
Laminations
Segregation
Sect.5 – Fabrication
Lapping Lamination
Lamination
Sect.5 – Fabrication
Sect.5 – Fabrication
General Requirement Welding Consumables & Electrode:
•Certification electrode or electrode flux combination jika
diminta oleh Engineer maka contractor/fabricator harus
menyiapkannya.
•Parameter las harus dalam range yang direkomendasikan oleh
electrode manufacturer.
•Gas or gas mixture yang dipakai untuk shielding gas harus
conform AWS 5.32 Specification for Welding Shielding Gasses.
Prosentase gas atau mix gas yang digunakan harus sesuai yang
disyaratkan WPS.
•Welding Consumable yang sudah dibuka dari sealed boxnya
harus diproteksi dan disimpan akan berpengaruh pada welding
properties.
•Electrode harus kering dan dalam kondisi baik jika digunakan.
3/29/2015 WELDING INSPECTOR COURSE 89
Farid Moch. Zamil
Sect.5 – Fabrication
Sect.5 – Fabrication
Bake Quiver
AWS A5.1 Hold 70oC min
260-430oC
Low Hydrogen 150oC 4 hrs max
2 Hrs
Time period
Tabel 5.1
Column B
Bake Quiver
AWS A5.5 Hold 70oC min
370-430oC
Low Hydrogen 150oC Over 4-10 hrs
1 Hrs
Note :
1. Baking yang melebihi satu kali & electrode basah tidak boleh digunakan.
2. Electrode untuk ASTM A514 atau A517 dengan electrode classification
E100XX-X kecuali E70XXH4R di baking sekurang-kurangnya 1 Jam pada
temperatur 370-4300C
3/29/2015 WELDING INSPECTOR COURSE 91
Farid Moch. Zamil
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
PWHT Procedures - Basic Requirement
Sect.5 – Fabrication
1. Furnace Temperatur
Kondisi temperatur furnace tidak boleh lebih dari 3150C.
Sect.5 – Fabrication
Sect.5 – Fabrication
5. Alternatif PWHT
Diatur dalam tabel 5.3.
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
Backing Thickness Requirements
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
Thickness Roughness
Inchi mm in. mm.
Up to 4 Up to 100 1000 25
4–8 100 - 200 2000 50
Thickness Roughness
Inchi mm Sample
Up to 4 (include) Up to 100 (include) No.3
Over 4 – 8 Over 100 - 200 No.4
• Good cut - sharp top edge, fine and even drag lines, little oxide
and a sharp bottom edge
Sect.5 – Fabrication
Gouging or Notch Limitations
•Hole gouges tidak lebih dari 3/16 in (5 mm) kedalamannya,
roughness permukaan dapat di machining atau di grinding.
•Hole gouges melebihi 3/16 in (5 mm) kedalamannya roughness
permukaan boleh direpair grinding .
Sect.5 – Fabrication
STRAIGHTNESS of COLUMNS & TRUSSES
AWS D1.1 Std.
Gou
Sect.5 – Fabrication
Dimensional Tolerances of Welded Structural Members
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
Backing Thickness Requirements
Sect.5 – Fabrication
Sect.5 – Fabrication
TOLERANSI DIMENSI SAMBUNGAN
Fillet & PJP Groove Weld :
•Root opening tidak boleh lebih dari 5mm kecuali untuk material
yang mempunyai ketebalan diatas 75mm.
•Jika root opening yang melebihi batas toleransi misal 8mm
boleh digunakan dengan syarat harus menggunakan backing.
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
TRANSITION of BUTT JOINT PARTS of UNEQUAL THICKNESS
(TUBULAR)
Sect.5 – Fabrication
TRANSITION of BUTT JOINT PARTS of UNEQUAL THICKNESS
(TUBULAR)
FABRICATION
TOLERANSI DIMENSI SAMBUNGAN
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
Sect.5 – Fabrication
GROOVE DIMENSION – NON TUBULAR
FABRICATION
TOLERANSI DIMENSI SAMBUNGAN
SECTION – 6
INSPECTION
Oleh :
Farid Moch. Zamil
Sect.6 – Inspection
PENDAHULUAN
Tingkat pemeriksaan dan persyaratannya harus didefinisikan
dalam applikasi standard atau kesepakatan dengan pihak
Client dengan Manufacturer
Before welding
(Before assemble & After assembly)
During welding
After welding
Sect.6 – Inspection
Measuring devices:
• flexible tape, steel rule
• Temperature indicating crayons
• Welding gauges
• Voltmeter
• Ammeter
• Magnifying glass
• Torch / flash light
• Gas flow-meter
Sect.6 – Inspection
10mm 10mm 1
G.A.L. G.A.L. 3
4
S.T.D. L S.T.D.
16mm 5
16mm
6
IN
0 1/4 1/2 3/4
Sect.6 – Inspection
Voltmeter Ammeter
Sect.6 – Inspection
BEFORE WELDING
Preparation:
Familiarisation with relevant ‘documents’…
• Application Standard/Code - for visual acceptance
requirements
• Drawings - item details and positions/tolerances etc
• Quality Control Procedures - for activities such as material
handling, documentation control, storage & issue of
welding consumables
• Quality Plan/Inspection & Test Plan/Inspection Checklist -
details of inspection requirements, inspection procedures &
records required
3/29/2015 WELDING INSPECTOR COURSE 137
Farid Moch. Zamil
Sect.6 – Inspection
Welding Procedures:
• are applicable to joints to be welded & approved
• are available to welders & inspectors
Welder Qualifications:
• list of available qualified welders related to WPS’s
• certificates are valid and ‘in-date’
Equipment:
• all inspection equipment is in good condition & calibrated as
necessary
• all safety requirements are understood & necessary
equipment available
Sect.6 – Inspection
Materials:
• can be identified & related to test certificates, traceability !
• are of correct dimensions
• are in suitable condition (no damage/contamination)
Consumables:
• in accordance with WPS’s
• are being controlled in accordance with Procedure
Weld Preparations:
• comply with WPS/drawing
• free from defects & contamination
Welding Equipment:
• in good order & calibrated as required by Procedure
3/29/2015 WELDING INSPECTOR COURSE 139
Farid Moch. Zamil
Sect.6 – Inspection
Weather conditions
• suitable if site / field welding
Welding Process(es)
• in accordance with WPS
Welder
• is approved to weld the joint
Pre-heat (if required)
• minimum temperature as specified by WPS
• maximum interpass temperature as WPS
Sect.6 – Inspection
DURING WELDING
Welding consumables
• in accordance with WPS
• in suitable condition
• controlled issue and handling
Welding Parameters
• current, voltage & travel speed – as WPS
Root runs
• if possible, visually inspect root before single-sided welds are
filled up
Sect.6 – Inspection
Inter-run cleaning
• in accordance with an approved method (back
gouging) to good workmanship standard
Distortion control
• welding is balanced & over-welding is avoided
Sect.6 – Inspection
AFTER WELDING
Weld Identification
• identified/numbered as required
• is marked with welder’s identity
Visual Inspection
• ensure weld is suitable for all NDT
• visually inspect & ‘sentence’ to Code requirements
Dimensional Survey
• ensure dimensions comply with Code/drawing
Other NDT
• ensure all NDT is completed & reports available
3/29/2015 WELDING INSPECTOR COURSE 143
Farid Moch. Zamil
Sect.6 – Inspection
VISUAL - WELDING
• Semua lasan (Weld) harus bebas dari Crack, Overlap dan Unacceptable
discountunuities seperti yang tersaji pada gambar 5.4, Tabel 5.9 dan Tabel 5.10 .
Adapun Acceptance criteria Visual tercantum pada tabel 6.1
Sect.6 – Inspection
Sect.6 – Inspection
Sect.6 – Inspection
Sect.6 – Inspection
Sect.6 – Inspection
Sect.6 – Inspection
Sect.6 – Inspection
Sect.6 – Inspection
Sect.6 – Inspection
Sect.6 – Inspection
Sect.6 – Inspection
Sect.6 – Inspection
Sect.6 – Inspection
Sect.6 – Inspection
Sect.6 – Inspection
Surface Crack Detection
• Liquid Penetrant (PT or Dye-Penetrant)
• Magnetic Particle Inspection (MT or MPI)
Sect.6 – Inspection
Sect.6 – Inspection
Source
Sect.6 – Inspection
Sect.6 – Inspection
NDT – ULTRASONIC TESTING
Material Thk
defect
0 10 20 30 40 50
Sect.6 – Inspection
Collection of ink
particles due to
leakage field
Electro-magnet (yoke) DC or AC
Prods DC or AC
3/29/2015 WELDING INSPECTOR COURSE 164
Farid Moch. Zamil
Sect.6 – Inspection
A crack like
indication
INSPECTION
NDT – PENETRANT TESTING
Sect.6 – Inspection
Fluorescent Penetrant Bleed out viewed
under a UV-A
light source