Professional Documents
Culture Documents
Quality Assuarance in Welding
Quality Assuarance in Welding
Quality Assuarance in Welding
Quality Assurance of
Welded Structures
Content
Anything that
dissatisfies the
Customer (internal
or external)
Quality - Customer focus
v Customer requirements are dynamic
Dimensional Check
Conducting LPI, MPI, RT / UT as
applicable.
Confirming 1. LPI, MPI, RT / UT results.
2. Heat Treatment details
3. Verification of Heat
Treatment Charts and job correlation.
Quality - Sequence of approach
Inspection of prepared
material – Edge
Preparation, surface
condition etc.
Assemblies – Fit up, Root
gap, position, orientation
etc.
Welding Consumables –
E 7018, E 7018-A1 etc.
Operators – Qualification,
Position, sequence etc.
WPS Conformance
Quality - After Fabrication
Visual Inspection
a) Surface Defects: Blow
Holes, Porosity, Unfilled
Crater, Un-fused welds
b) Surface Cracks
c) Damaged to parent
metal:
Undercut, Burning,
Overheating
d) Profile Defects:- Overlap,
Excess penetration,
Incomplete penetration
Quality - After Fabrication
e) Incorrect Finish:-
Ripple Mark
Weaving Faults
Chipping & Peening marks
Spatter
Inspection of Weld
Dimensions – Fillet, Throat
size.
Mech.Testing:- Test Coupons,
Results.
NDE
Quality - Records
Register
Purchase Order
Material Receipt / Account
Raw material Test Certificates
Welder’s Log Book
NDE, Heat Treatment
Inspection ( Internal / TPI / IBR )
Audit Reports ( Internal / External )
Quality
“Quality is better defined
as…
Error free or Defect
free performance.
A. External defects
B. Internal defects
C. Both internal&external defects
External defects
1. Undercut
2. Cracks
3. Blowhole and porosity
4. Slag inclusions
5. Edge of the plate melted off
6. Excessive convexity/oversized
weld/ Excessive Reinforcement
7. Excessive Concavity/Insufficient
Throat thickness/ Insufficient fill
Contd
Hot crack
Cold crack
Crater crack
Crater cracks
Excessive current
2. proper parameters
a.current
b.voltage
c.flow rate
3.proper edge preparation
a.Angle
b.Root gap
Contd
6.Baking of electrode
Documentation
Agency
S
l Item Type Extend Format
Characteristic Catego Reference Acceptanc
. Description. Method of of Remarks
N s Checked ry Document e Norms
/ Operation of Check Check report P W V
o
Order / MTC
Chemical & 1
RAW Verificatio Specificati Lab
Physical 3
MATERIAL MA n 1 / Heat on Drg.Spec. Report 2
1 Properties 1
. S MA U. T. 100% Order / Drg. Spec. Lab 2 UT for Plates >12 mm thick
Internal Flaws 3
Plate MA Verificatio 100% Specificati Drg. Spec. Report 2
Chemical 1
Rounds n on Lab
Properties only 3
Drawing Report
1 Heat
Verificatio Size 1
Chemical Lab
2 MI n Order / Drawing Drg.Spec. 2 3
. FORGINGS Properties Report
MA Measure Spe Drawing Detail Drg. 2 1
Dimensions I. R.
ment cificati 3
on
Visual
1
Visual 100%
3
Fit up Dimensio 100% I. R.
MA Drg. Spec. Drg.Spec. 2 1
FABRI Welding n Order / I. R.
3 MI Drg. Spec. Drg.Spec. 2 3
. CATED Quality UT, RT, Spe UT
CR Drg. Spec. Drg.Spec. 2 1
ITEMS NDT MPT LDP cificati Report
MA Drg. Spec. Detail Drg. 2 3
Dimensions Visual on I.R.
1
Measure 100%
3
ment
Painting
Drg. Spec. Certifica
Visual 1
4 MA 100% Drg. / Drg.Spec. te 2
. PAINTING Paint Thickness Film 1
MI Sample Specificati Drg.Spec. Painting 2
Thickness 3
on. Certifica
te
Quality Standards
Basic Standards
Specifying general requirements with basic significance eg.Quality
Management Systems, drawings & tolerances
ISO 9000 ff, EN 4500 ff, ISO 17000 series
Special Basic Standards
Specifying matters for several applications eg. Test procedures,
welding requirements, materials
ISO 3834
Special Standards
Product or application standards eg. Pressure vessels, piping,
railway cars
ISO 16528, EN 1090, ISO/DIS 10721, EN 15085,
Quality Management in Welding
Fabrication companies
• Construction companies - on-site work
• Repair and maintenance contractors
• Manufacturers of products
• Welding workshops on sites under the same
technical and quality management
• Owners of plant with their own workshop(s)
9. What are the types of other organisation that
ISO 3834 can be applied to?
• Review of requirements
• Technical review
• Subcontracting
• Welding personnel
– Welders and welding operators, Welding coordination
personnel
• Inspection & testing personnel
– Welding Inspection personnel; Non-destructive
testing personnel
• Equipment
– Production and testing equipment; Description of
equipment; Suitability of equipment; New
equipment; Equipment maintenance
Welding and related activities
– Production planning; Welding procedure
specifications (WPS); Qualification of the welding
procedures; Work instructions; Procedures for
preparation and control of documents
• Welding Consumables
– Batch testing; Storage and handling
• Storage of parent materials
• Post-weld heat treatment
Inspection and testing
– Inspection & testing before welding; Inspection &
testing during welding; Inspection & testing after
welding; Inspection & test status
• Non-conformance and corrective actions
• Calibration and validation of measuring,
inspection and testing equipment
• Identification & traceability
• Quality records
Quality requirements as per
ISO 3834
Selection of Welding Quality
Requirement as per ISO:3834
Contract Welding Requirement Quality Requirement
1) Joints
2) Base metal
3) Filler metal
4) Position
5) Pre-heat
6) PWHT
7) Shielding Gas
8) Electrical Characteristics
9) Technique
Inspection Before Welding
1) Application Standard
2) WPS,PQR,WPQ
3) Drawings
4) Material Composition
5) Condition of Material
6) Type of edge preparation,method & finish
7) Consumables
8) Welding process
9) Clearance dimensions,Type of backing(if
any)
10) Alignment, Tack welds,Presets etc.
11) Pre-heat (if any)
WPS,PQR and WPQ
1) Dimensional accuracy
2) Appearance of the weld
3) Post Weld Heat Treatment (if any)
4) Evaluation of internal and surface defects
with or without the aid of Destructive/Non-
destructive testing.
Comparison Between ASME Sec. IX
and ISO 9606- Scope
As per ASME Sec. IX As per ISO 9606-1:1994
As per
ASME
Sec IX
As per
ISO
9606
Comparison Between ASME Sec. IX
and ISO 9606- Position-Plate-Fillet
As per
ASME
Sec IX
As per
ISO
9606
Comparison Between ASME Sec. IX
and ISO 9606- Position-Pipe-Fillet
As per
ASME
Sec IX
As per
ISO
9606
Comparison Between ASME Sec. IX
and ISO 9606- Position-Pipe-Butt
As per
ASME
Sec IX
As per
ISO
9606
Comparison Between ASME Sec. IX
and ISO 9606- Type of Test
Discontinuity
An interruption of the typical structure of a material, such as a
lack of homogeneity in its mechanical, metallurgical, or physical
characteristics.
A discontinuity is not necessarily a defect but all defects are
discontinuities.
Defect
A defect is a rejectable discontinuity, which occurs in an amount
great enough to render a particular object or structure unsuitable
for its intended service based on criteria in the applicable code.
Classification of Defects
• Repair: Grind off or weld on. Must blend smoothly into the base
metal.
Concavity
Convexity
Reinforcement
Excessive
Insufficient
Improper contour
Root Reinforcement
Excessive Reinforcement
Longitudinal
Transverse
Crater
Throat
Toe
Root
Under bead and Heat-affected zone
Hot
Cold or delayed
Cracks
Cracks
Laminations
• Base Metal Discontinuity
• May require repair prior to welding
• Formed during the milling process
Porosity - Types
Destructive Non-destructive
Crater- All crater shall be filled up to the full Applicable Applicable Applicable
cross section except for the ends of the
intermittent fillet welds outside the effective
length
As per BS 5289
Acknowledgements
We gratefully acknowledge the contributions of
the following faculty members for developing
this module
Mr.A.K.Bose
Mr.N.Sadasivan
R.Banerjee
Thank You