Gulcle to weld symbols @® For Senior Welding Inspectors CSWIP 3.2 1) BS 409 BSEn 22888 8 AWS A2.4 By OB Whitaker 15-08-02 Snc Eng. Sac Me Weld Snot. LCS. SWS. Convention of 85 499 (UK): The arrow line: a) Shall touch the joint intersection. b) Shai not be parallel to the drawing. ©) Shall point towards a single plate preparation: Reference line: a) Shall join the arrow line. b) Shall be parallel to the bottom of the drawi ™ Symbols: @) Welds this side of joint, go underneath the reference line. b) Welds the other side of the joint, go on top of the reference line. ©) Symbols with a vertical line component must be drawn with the vertical line to the left side of the symbol. 4) Allcross sectional dimensions’are shown to the left of the symbol. ) Alllinear dimensions are shown on the right of the symbol i.e. Number of welds, length of welds, length of any spaces. Fillet welds Bevels a. Throat. b. Leg Ss Number. X Length. (Space). Example: a.7 b.10 10 X 50 (100) Examples of BS 499 double sided butt weld symbols Double bevel Double V DoubleJ ~~ Double Utetas 30 oS 2) Supplementary & further weld symbols to BS 499: ‘Square butt weld Weld on site a Profile of fillet weld ie) Weld all round 10 a ‘~, 444 (Welding process) Spot weid 10 |// rerre weld (Singie bevel and fillet) Intermittent plug and fillet welds are shown pitched to the start of each weld as, shown below: 3No's. 20mm endth Staggered ‘50 mm gap to each weld start. 3) Convention of 1S02553/ BS En 22553: (Has replaced BS 499 in UK & Europe) This standard uses a different method to represent arrow side and other side of the weld joint. A broken line shall be shown above or below the reference line, except in the case of welds that are totally symmetrical about the central axis of the plate Weld symbols are basically as per BS 499 however, fillet weld leg length must always be preceded by the letter Z and nominal throat thickness by the letter a. In deep penetration fillet welds and partial penetration butt welds, the effective throat thickness must always be indicated by the letter S Removable backing strip Welding process Reference information Broken line indicating other side. Weld toes to be ground smoothly4) Convention of AWS A2.4 (USA): This standard uses the same convention as BS499 to show this side and other side of the reference line. Some special symbols are used in this standard. A difference between the conventions is that in AWS A2.4 a change of direction in the arrow line is used to indicate single plate preparations. SMAW AWS A2.4 may also use a number of reference lines from the arrow line to indicate the sequence or procedure of welding. 1 operation __3/8, Staggered arrow shows a * Y GATW Single plate preparation 2° operation __1/4 GMAW 3 operation RT A further difference between BS 499 and AWS standards is that the AWS A2.4 standard, dimensions the pitch of intermittent fillet welds and plug welds to the centre of each weld. (BS dimensions these to the start of each weld) ‘Staggered intermittent fillet welds are indicated to AWS as below: Length of weld. 3-5 %\ Pitch to weld centres.8S 499 : Part 2 1980 Table 10.* Numerical indication of process No 1 " my nz 43 na 15 ue 2 121 12 aa 135 18 4 141 149 18 18 181 185 au 312 313 32 a 322 4 a a 3 aa 441 45 Process Sire welding Metal-are welding without ges protection Matal-are welding with covered electrode Gravity are welding with covered electrode Bare wire metal arc walding Flux cored metal-are welding Coated wire metal-are welding Firecracker welding Submerged are welding Submerged are welding with wire electrode Submerged are welding with strip electrode Gar shielded metal-are welding MIG welding MAG welding: metalare welding with nondnert gas shield Flux cored metal gas shiela Gas-shielded welding with non-consumable electrode TIG welding Atomie-hydrogen welding Plasma are welding (Other arc welding processes ‘Carbon are welding Fotating ore welding re welding with nen-inert Resistance welding Spot waiding Seam welding Lap seam welding ‘Seam welding with strip Projection welding Flash welding Resistance butt welding (Other resistance welding processes HE resistanes welding Gas waiding Oxy-fual gas welding Oxyacetylene welding ‘Oxy-propane welding Oxychydrogen welding Air fual gus welding Airacorylene wedi Alr-propane welding 2 Solid phase welding; Pressure wel Utwrasonic welding Friction welding Forge welding Welding by high mechanical energy Explosive welding Diffusion welding No a7 48 7 n 2 3 oy 75 751 752 753 6 n 8 781 782 9 a a oz on3 a4 8 16 917 28 a9 s2a 924 951 952 953, 954 97 971 972 Process Gas pressure welding Cold waleing Other welding processer ‘Thermit welging Etectrostag wetding Electragas welding Induction weiding Light radiation wel Later welding Are image welding Infrared welding Electron beam welding Percussion welding ‘Stud welding ‘Are stud welding Resistance stud welding Brazing, soldering and braze welding Brazing Infrared brazing Flame brazing Furnace brazing Dip brazing Salt bath brazing Induetion brazing \Uterasonie brazing Resistance brazing Diffusion brazing Friction beazing ‘Vacuum brazing Other brazing processes Soldering Infrared solering Flame soldering Furnace soldering Dip soldering Salt bath soldering Inctuetion soldering Ultrasonic soldering Resistance soldering Diffusion soldering Flow soldering Soldering with soldering iron Friction soldering Vacuum soldering Gas braze welding Are braze welding * This table complies with Intemational Standard ISO 4063TECHNICAL NOTES RAD,U/T,MPI,PENPENETRANT/MPI TEMP. PEN. 5-50C [ABOVE 50 USE DRY POWDER] VIEWING LIGHT PEN/MPI 500 LUX+ FLOURESCENT USE FLOURESCENT INK [NO BACKGROUND] LAMP POWER UVA 800 MICROWATT/SQ. CM VIEWING DARKNESS BELOW 10 LUXMPI THROUGH PAINT—UP TO 50 MICRON SUB SURFACE DEFECTS-YES -ON D.C ONLY—2MMDEEP MAX YOKE NO CURRENT RECORDED BUT MUST SHOW LIFT POWER 4.5KG NORMALLY A.C [ BUT CAN BE EITHER} PRODS 7.5 AMPS/M (OF SPACE} TYP. TE: 200MM SPACE = 1500 AMPS THEREFORE MUST RECORD SPACE + AMPS ALL MUST RECORD ‘2 DIRECTIONS AT 99 DEG BURMAH CASTROL STRIP INDICATIONS (3 LINES VISIBLE}ULTRASONICS PROBES 0 [COMPRESION PROBE ] FOR LAMINATIONS, LESS THAN 1OMMt ~70 10- 1SMMt MHz “NORMAL WELDS”—4—5 MHz [HIGHER /LESS PEN) RECORD CRYSTAL SIZE{ USUALL JOMMYSINGLE/TWIN ? SENSITIVITY WHAT CALIBRATION BLOCK? HOLE DIA.+DEPTH {SIDE DRILLED HOLE] COUPLANT RECORD TYPEVARIOUS TECH INFO U/T ASME V =NDT CODE eg ARTICLE 4= U/T F.S.H = FULL SCREEN HEIGHT B.W.E = BACK WALL ECHO SINGLE COMP. PROBES HAVE A “DEAD ZONE”; SO DEFECTS MAY BE MISSED. RECORD BATCH No’'s/ SERIAL No's RAD SENSITIVITY= IQ DIAMETER OF SMALLEST WIRE THICKNESS OF METAL UNDER WIRE $98%———RADIOGRAPHY XRAY KV AS LOW AS POSS. =BEST DEFINITION GEN, 80 KV LOWEST[PERHAPS OK ON ALUMINIUM] MINIMUM @ [40 K.V FOR STEEL FOCALSPOT THE LARGER ITIS / LONGER FFD { FILM FOCUS DISTANCE} GAMMA SED _typicat @ 500MM BUT VARIES GREATLY) SOURSE SIZE TYP. 1SX1.5 MM IRIUM 192. NORMAL. COBALT60_ OVER @ 25MM UTERBIUM ONLY USED ON THIN SECTION [ BELOW 10 MO] TIME /COST SCREENS 0.1 MMFRONTANDBACK = GAMMA MUST HAVE XRAY OVER 120KV DEVELOPMENT _TYP.; sMINS AT 20C DENSITY _TYP. [EXPECT READINGS ON WELD + PLATE] SENSITIVITY _TYP.2 OR LESS (LOWER IS BEST]° QUALITY CHECK LISTS RAD,MPI,PENETRANT,U/TQUALITY CHECK as as 8S Bs Bs LIST: Radiography » 3683 Pt 3: Terms used in NOT Radiological Flaw Detection 2600 : Methods for radiographic exam: putt joints in steel Pt 1: 2mm up to and includ: 50mm thick Pt 2 : Over SOnm up to and including 200mm thick. 2910 : Radiographic exam: putt joints in steel pipes fusion welded circumferential 3971 : Image quality indicators for radiography and recommendations for their use 2737 : Radiology of internal def: ts in castings as revealed by radiography. Radiography in Modern Industry - kodak 1) 2) 3) 4) 5) 6) 7) 8) a) 10) an Focal spot or source size and strength should be displayed on the apparatus. Evidence of this to be available. Calibration o: densitoneters using 2 traceable film sity st Regular checks to be carried out on safelights. Records to be kept of processing sol fans including replenisher. Lead and salt screens to be checked regularly Characteristic cur be available. es, exposure charts and I@I charts should Metal step wedges should be available. Radiation safety measures should be employed to the latest regulations. Evidence of radiation monitor calibration should be availab Film storage Certificates of competency. Film test strips should be used for both manual and automatic systems.ANDT SCHOOL CE APPLIED NON-DESTRUCTIVE TES: QUALITY CHECK LIST: Magnetic Particle BS 6072 : Magnetic particle flaw de ction BS 4069 : Magnetic flaw detection inks and powders BS 4489 : Measurement of UV.A radiation (black light) used in NDT BS 3683 Pt 2: Terms used in NDT : Magnetic particle flaw detection BS S044 : Contrast aid paints used in magnetic particle flaw detection BS 89 Spec for direct acting indicating electrical measuring instruments and their accessor: 1) Vapour degreaser for aci 2) Ammeter checks - difference between check ammeter shall not exceed 10% of scale rea ammeter shall be calibrated to a tracead nd a/c ng. tote check e standard. 3) Magnetic ink - composition. Non-fluorescent - not less than 1.28% and not more than 3.5% by volume. Fluorescent ~ not Less than 0.1% and not more than 0.3% by volur Other solids if present not more than 10% vy mass of ferro~ magnetic content. Particle size - inks - in at least 99% of a representative sample no particle shall exceed 10Qun. Powders — in at least 99% of a representative sample no particle shi 20pm. 4) Test for solid content and fon of inks - agitate ink, place sample of 100ml into a settlement flask, allow to settle for 60 minutes. Read off result to nearest O.Inl. Record as solid contents by volume. Special test for Fluorescent inks ~ check ink for evidence of yellow - green fluorescence in the supernatant liquid. observed, discard i S) Functioning test magnetic inks and powders - use ring ty piece, Fig 2 BS 4069, Usizg 7S0A (FMS) at least 2 holes should give an indication. Residual magnetism technique for powders - use test piece Fig 3 BS 4063. Mount test piece on insulated rod, apply SO0A DC through threading bar and apply dry powder to each hole in turn commencing with the hole nearest to the surface. Powder should be applied at a distance of 200-300mm. At least five holes should give an indication. Magnetic flow cechnique for inks and pouders ~ use test piece Fig 4 BS 4069, Magnetise test piece parallel to coil axis or use electro-magnets. The hole should give an indication. Aerosol containers should be date stamped.6) 7 a) 9) Corrosion test - use low carbon stee! bar 150mm long, 12.8em dia, surface texture 3.2un Ra Partially immerse bar in ink sample for minimum 12 hrs at 25°C There should be no evidence of corrosion. Black light - check minimum intensity depending upon type. 50 lux or 0.8q4/em? or B00uM/en™ Check level of anent magnetic & PC electro~ Shall have maximim pole spaci For pole spacing less than 7Smm the lifting capacity shall be not less than 0.2dkg per mm of pole spacing. If greater than 75mm the lifting power shall be at least 18kg. AG electro-magnets ~ for pole spacing of 300mm or less the Lifting capacity shall be 4.5kg.STANDARD No’s U/T__BS 3923 NOW PEN. BS 6443 “84 BS EN 571 MPI_ BS 6072 RAD. BS 2600 | GENERAL/PLT| RAD_ BS 2910 [| PIPE NOW IQi__ BS 3971 BS EN 462-1R. Sarl var, F* Terms Associated with QA/OC Duties of a Senior Inspector Aw Awigimpatetin fi ite pun aa emu cd Cee eres : poe eee Sonn) Stic orb ‘Minor: Unlikely to cause failure of the product meen “ 2) Sapenie Ton nd het ee Dome taper ie Pent tocae tei it yn ree Cis Bat et ene iti Tope ae Frans eer “Te realy nice thing about not planning ‘i te erg tg nt enh yee ‘The really nice thing about not planning is Coveted onthe cu, make a fevers ated panto Jour era that failure comes as a complete surprise and is ds tlsng your rable Bes encour pas ness ode not preceded by long periods of worry and ‘exible in cae ther ar any changes othe coum sete, depression” ‘Remember that Radiographic Interpretation (Theory, pesca, or We make plans every day for the most trivial of things ‘sensitometry) isnot covered on the course syllsbs, [Al Slegee tat eve pad tcone bre ey” Many tos wed fr potion planing inling Se chars Forward oa Revre Scedleg Cre Path Amis ec" «one a ingoson pet as ben made orguiston cee tab ge ml snt i =a Senet acer ma et ae 7 pes cuoiaysommgeatnen eh 7 requires certain specific management skills: 1) Anyi & een id chlo al en il et hey ik pices Sa 5 Sina fe cl nine ete 3 Tayatbiie tad eee Pers 3) seoecaon tae 9 Aevemelae etme Doerr deel nk bs ened = ieeeR- So eben © Weleg Pocdter Wetton Br Pal —Days____..., For WIS 10K CSWIPS2 Exam 9am—Spm For WIS 10 f# _TheCSWIP3.2Exam | Specie Ther rata: Wea Sata Tete Radi Hales af PN or CSIP Rad tien? op Roding leptin x6 Time Lhe Mes Mats Cece asta Time 0 msm“ Terms & Definitions ,.,| Bust welds: AWell:t — Aunion between material exused by heat, 4 and or pressure Fillet welds: ‘Spot/Seam welds: " Plug/Slot welds: Bage welds: are am ‘Lap jotats: = Sometime we ned ta prepare the joint to succesflly cary ‘ule proceeof welding. Fall sion trough the faces and acces forthe proces. The toms for Vand bevel ‘elds are given telow Angle of bevel a For U& 3 reparations thee ae other scasrenent that ned tebe now and given when machining the preparationDoble bevel Double V — Dowtie 5 eee TR Double U* aa Y | Remember, he pupotes of weld propsraton io allow accent {ar the welding proces penton ad ison through he sea ofthe joist and is aces ‘The base rae this The more ou take on, the more you must pat hack in. “This has major effects on economics and ditrton cota ete The root Bie, oot gap and angle of bevel ves the choice of Single, oc double sided pepation, se dicatad only by the ype sf selding proces the poston and scent ofthe jest [7 Welded Joints _,] Bam Joins: i comand veld ttt y A Dut welded bt joint A filler welded bot joint § Welded Joints _.] Thos ne f _h, Aut welded jlat A gonpound welded joint* fs Welded Joints _,] (ap domts A fillet welded Lap joint A spat welded Lap joint A compound welled Lap jint® _Welded Joints __] - ‘A compound welded Close Corner jot A lu welded Closed Corner Joint[Welded Joints _., Ope Coenen Metin, An inside fillet welded Open Corner joint ~ } \ j An eutide lt welded Open Corner joint A doable filet welded Open Corner joints se oe Weld neon Weld rot ‘Nominal throat Deep threat fillet welds from FCAW & SAW ets EST ete ofa Poor Toe Blend Anois... [2 sitctofa Poor Toe Blend Angie. igh stress conentration, x or = a5 eel eee “Lower stres concentation® ey‘pict ofa Poor Tee Blend Ansia,.,| [° Fillet Weld Profiles _, | ti io possible ta th bight of exca weld metal i itn oF a applied tara, bu the toe Bled imasesalable a show below ry =| 3am j im oe) a aa “Gaol bg- ‘barely por toe bod at excess wed etl within inst (Qualty Assurance: Alle plnned and systematic ations sd etvtegreqoied to provide adequate ‘onfdeace ina prodot What ie wanted Fearon Tem (Quality Control The operational ecaiques and ste ‘Welinet Tere sed to FAG ay. ‘What most be dae, in onder achieve Sina Bao OTT what i wanted* ‘Wei sg Fe F* Terms Associated with QA/OC... Tnapection Specification: A octment containing of feing ‘pall infomation requ inthe level of napestion for a prot® In process inspection: napecton & eurvillnee cased oat Non~ Compliance: writen report tht states that clause inctrucion nthe conrct document, code cr atandar cansot be, or wasnt mt Cortiete of Conformance: A signed cenit, decasng hata rode has been prodoced it Concession: An agreed Svistion ith the catomer) sccondance witha pcietiont Bom ps-agreed pth or pecieaion*AltibutlSkil ofa lective Senior Welling Inspectr® Honesty “Knowledgeable “Planning skills «Experienced ‘Organisational skills Leadership skills Responsible "Communication skills ‘Delegation skills Record keeping sills ‘Motivation skills Impartial & fair Decisivenese «Problem solving sills Analytical* Diplomatic ee, et" fa Aud Adit To cay outa periodic and netematc eee on 2 ‘sten/proces este that thas boon aed ob ak wpeiiod® + Staff + Equipment + QaiQCrInspection + Documentation (LeNDT reports) + Health & Safety For a supervisor the principles are: Heatly: ind eft! 2, Measure: Assess the fics ops Obeerve:—Inglement & moniter $ [The 4 of theconon tps OF NDT usd when apssing ents ae pal Penetrant Testing .,| “Procedure J ‘Ft the wok mst be emo thaoughy, hen a ‘ener is applied fora pied tine" ‘Once the contact ime har lapend the pena removed anda developers then api ‘ay genta that has buen den into acrakeby apy ion wil be dan ou into the developet “Two types of peotrants are: 1) Colour contrast 2) Florescent Penetrant* [oon Cont Pec Sethe 9 RAT Apt Pesca Clean ten ppy Dear(avaaages] (Besranaes | inthe wok mat elena white appid oe ‘oneast. A magic at then applied by permanent mage, [Ditewepersor sitio | [1) igh ean meal] tote gnc or sph caret (yA ma - face laws on ‘Armagnatic inks applied which wil concentrate in areas of {2yAmaeriats ] {2} Surfoce tawscoly—] ‘She eng, a thes conc by laws 5) Law cost method [DEnvenyneny “The wel lenght be rots 90" by the mapa elt [@Smpleeuipmest——] [No permanent rend] ‘The types of magnetic media ud are: Daa yay ponder 3) Force ike m ia Magnetic Particle Testing | a nt Ss ‘Advantages | [Diwopreramied) Die asi] [sbsarice tam] )Demagnetin a DM esta ap] [)Coneawe are sir a [Simple suipmont——] [Ne permanent reco] ai aa When ung the sts crea prod ecnique Contrast paint Magnet Jak Resalt® fed Es ee I) Apply Couplant Soundwave Rewult= int the wore mstbe ceed thoroughly then couple pei Cos pple o increase ound ansission™ cursinty | oe hepa eo _ en 25g ey forrest ae[DMoamaterts—] [2)Difict to interpret wproceiae Alm is place inside a cssete beeen ead secon [i then placed to the ero the bjt ob adiorahod exposed othe wok ad fn for ay inpecection i ine wih the beam of rian wl be shown onthe fim ar exposure and development” ‘The2 types ofraistion uted in industrial radiography: 1) Xraye (trom Cathode Ray Tube) 2) Gamma rays (froma Radioactive Isotope)* Leadim — Esposueto Radiation Intervet Geaph vcewen 2 ed f pe SS [aiannge} iT Apwrnaaeatecord? | [High oper ail —] {Des marine] [2)Ditiiterpretaion] {Spas rot pew inipe (3) Lackotsttewal sion ] [0 Game ray perabi] [1 Satay reir} Disadvantages act of your dation a Senior Welding nepoctr, and therefore leo prt of your 3.2 ial exam ito 20d (or stinize epore foemissng, or incre information, ‘Aknowodge of NDT is of couse eisai to cary atthe ask fe NDT reports. Make a it ofthe elements that you would consider wold need checking on a NDT report, pitt accepting i (10 Min')* Weice Rretig nt “Cru TH™Rsorbeoe.. ‘Steels are classified into groups as follows:* Plain Carbon Steels:* 1)Lav, Carbon Stee ODT 05% exrbont—) 3) High Carbon Stee Princaron tl ortain ny on &ctbon in eying laces, faces of Mn $i AUS BP ay alo be reset” F* Classification of Steels. An Alloy stat tone that consing more than Ino & Carbon as main alloying cements” “Tie lowing basic foutdation information on metllurs aint form any part of your CSWIP examination ‘Amt important finotion in the alley of tea is Ne ability fron to caove atton in oition= ‘Tae abo stom every much smaller than the ro tart and dows nt replace it inthe tom trstre, bu fi bates Tonia eloeat tan eit n29pes ofeabie nte, Aepeaing om the tenperture. Thi i anspor fete Alpha iron Fe 4 Tis ects corr bolo 723°C and is yea, or BCC in structure ican ony dissolve w to DOR Carbon ‘Aso kaown as Ferrite or BCC iron* 333: ae (emperor above the Ae, (OCT ene y Gamma iron ‘This trace osu sbove the UCT in Plain Caton Stel dis FCC in tts, Kean dsl wp 2.06% Carbon A called Austenite or FCC iron sentation vould appear ke his tel ia heat and then ood sloly in ql then exact revone sume changes fake place 1a steal tat container than 0.3% Carboni cone quickly, then the carbon door not hve tine io ise out of hon, hence tping the carbon i the BCC form of rn, ‘This now distr the cae tan inepula cubs of ekagoa™ ‘This soperstrated solton i caled Martensite saith Indes setae tht canbe produced in sect >Marini canbe defi Asupersatrated solution of carbon in [BCT iron ody Conted Tetagnsl) {Rie the hardest etrctre we cn reduce Solubity of Carbon in BCC & FCC phases of tec Ferrite: CL Lom cathon sluby. Maximum 0.02%" Austen High arbon solubility, Masium 2.06% “Martenste: The hardest phase in secs which is peoduced by rapid coking om the Aste pe Henle 300" ra eS “This ina term wed to acre the bility sea to hden Ahrougha cos section. Wonew indersad the mechanic of hateing and its reliance on the ate of cooling fom Shove the UCT ofthe tale “The Hardenabilty of 2 seis ected by the nonce of te alloying cement in delaying the tnafemation lepers ofa tel achalloying clement at deen severity on thi fet and fom ths was Dome the following faruslae eqn %C+Mn+ Crt Mo+Y ++ Cu 6 $s 13" ‘The Fel equilibria diagram i of ile we tothe engineer when itcomesto practi het ieaens, sal pes ae Shown in eum cooling” “To mdentand the relative phases of tel under diting cooling conn we aced to roduc a diagram tees this information” ‘A Time Temperstae Transformation diagram show this {information and a dierent digram is produced for ay ne ‘ype of sel, The following diagrams show how the eect of bon ad alloying element effet the hrderability and ence the dopth ef hardening of tes? T Sie 1) Austeit to Pesriteriteansformation begin® 1) Aaseit to PeatitlFeie transformation begin. {2 Asante to Peat asermation end t vcr oe ver “e" cape od cornmenmaraie __Thneinecond “ avoetonnBIA aT i000 ‘Tie in seconds fa Effect of Hardenabili ‘ardenbiy has a msjor effect on the welbilty of tenet Consider 2 ound bars ofthe same coe setonal ar Plain Carbon > Low Alloy Stet 04% Carton 7 01% Carbon v 16% Min ‘i 22shcr 05% Mo After heatiag above the UCT and queach coking thy are ‘eclioned ani hardnos tested ares the area soo vers ardness readings 'A) Unhardoned area 5S a ; ) Completely ardenel ‘through the CSA. (On analysing hs experince, ice be determined atthe only ference between has two specimens i their composites” By sustwing the ales inthe Ce fore wecansce hat he ardenbility of pocimens fll Am%C= coy 04 Bas C+ 026+ 045 +005 coq 0.764 ean be datrmined fm his experiment hat boty hema compriion and mata ichnes havea major efit onthe ardent of toe" ‘To summarize the fect of increasing the hades of tec by ‘ermal treatment tcon besa ht he formation of Mateo is caused by the entrapment of carbon insolation, produecd ‘by api ooing fom temperate Above the Upper Cotial™ 1a plain carbon tel thre must tlicint carbon to Wap. In ow alloy oes homever, the alloying elements ply 2 significant pat inthe thermal slening of sels in medio, high carom toes an alloy es, the formation of ‘Marteast is very dependant on cheial congestion and the ong tet lo very Sopendant on scion hckrss® ‘This foundation in metargy i for information only and vill not form any part of your CSWIP examination” compunsnrnan # Sie 3.1 eal .P ‘ydcosen Induced Cracking. Crack ype ‘WP HAZ,& weld metal cracking Location HAZ (Lonitadinl) 1. Weld meta (Transverse) ‘Stel pes: 2 All bardenable stds incating: 1HSLA secs © Quench & Tempered steaks Micrtrsnae: — Martensites (Oscar when Hydrogen fs above 15 ml 100 gm weld etl Hardness i above 350 VPN Sires fs greater than 05 ofthe yd stress Temperature below 300°C* Colle elactodespodoee SSiegmactasege, ff Hoar haetne ogee odd fo Somers -yrogen crck waste OF Zl [sit Macensie firms om? Sy stsesto yin HAZ FHSLA or Mcroloye Sls arc high sueagh steels that rv theirhigh stength en fie alloying™ ‘Typically the leva of alloying is inthe region of 005% and clement ach arvana melybdengm ad tiem, ae ‘eed. It would be inposstet mach his mir llyig ia the dectrode dt the effet oars arom an elec ar tis however imptnt to match te strength ofthe wold tothe strength of te pats, ond so single way of ratching weld Strength must be food and utc” ‘Tofind a simple method we would need to lok athe fet of Increasing caton content on he pope of en Increasing the carbon content wil increase the strength, bt wil lbs incre reat the formation of masts inthe mel “Thieme now produce, Crock acces eld™ [TTramtere Waa cracks im HSLA Stele ‘Longitudinal contractonal stain| | teels... (Quench a tempered sts ae highly alloyed tel to produce a ‘Martens ase on cooing 90%) * A tpieal chemical compotion ofthis pe of ta it Carbon 08% Manganese 10% Chromivm 08% + atuninium (38 gia refines) * Titania, Coq> 0.78 * Molybdenum 039% ‘The carbon equvaent will ned to increase she thickness of {he steel increavs tallow forthe slower coling, or mass effect. “This isto incrose the Hardonailty” or rling ston * in QT Steels, , Quench & Tempered, QT sel te ht pode etic ih igh kadensly pode fie warenic rin drctee dng mane These ec en fly {Sapa wrenve he atte an fie gin fe, wh sof ih sven and tuahnn Imrie al hee eclecon aden ugh he thick, thor ehemfaconpoin hangs the ple thelaes incense oman lng ese te eon eter wordt nase thereby ft et “he elt wea eel lo, ad get cae mt on od I? css i Weld & HAZ Caccomterten smut be given keoping any rns concentration a weld oct Sand the H, coment nese ow 8 posible connables ae aecly baked & sort ar required" 5) ering celldosc E 10 for the ot ran ier the “Hut pass" s00n a8 posible. (Before HAL=300°C)* E Eom apostle] ave any tl we hy wld ea [FeO Sea nie a Soe onto] case ype: Solidification cracking Location Weld centre (longi) Stel pes: igh sulphur phorphoras sce Mzrotnictre: Celemnar grane In dreion of soliifstiont Ocean wen igo ron sulphides are formed around slifying tains. High contractional strains are preve High dition processes are being used ‘Theresa high carbon content inthe weld metaltfat {phe Gntsep in eliminating this problem would beta] [aioe eel [3) Add Manganese to the electrode to form spherical Mal Recetas ase a exponentially and isa majorite. Carbon coment shoud | bra minimised by cael contin electrode and dion" 5) Lite et inp, bee lw contraction, & mnie) fa wit Fe Steels, Crack ype Shrinkage cavity Location Wel entre Sub Surface) Stel yp: Fenitie Sel Misronractue: —Cohamnar gis cure when: igh contactiona erie ar prec in wos having > 2:1 The soliying weld metal cannot support this igh level of rin anda partic tea rats jt blow Ue weld taco ‘on the ceneline. This ula er ha sharp edges od ay ‘hue ule of the weld during sevice atin a igh ses ‘concentration Itmay ako progres oe face dune the solidification proces to appear ke a saliifistion ack Controling occurrence of shrinkage caves: Keep dow <2:1* Liquation Cracking Fe Steels, Crack ype: Liguation cracking Location HAL dongiudiest) Stel pes: igh super & phosphorus tcl, Micrsrectur: Areas entaning hgh §content™ Occur when ‘When welding low quality, high sulphur content tos, itis postble that ares containing Fe nthe HAZ. wil ql ‘Twi low melting pont Hquid FelS wil orm around the rain boundaries nthe HAZ. Opposing strains inthe weld lind HAZ may real in acrck inthe HAZ, caused bythe igh contractional strain in thse areas * Oppeing comteation in HAZ & Weld metal[Diet glint aca] 2) Minis eat ipat™ (5) Tee pees to cond comtaction rc [> Minimize esti 7 cack ype Lamellar tearing Location alow weld HAZ Ste ype ‘Minroatuctte (ccs when igh contractlona stain are through fe short transverse direction, There a high sulfur content inthe bare metal. Thor sow through thickness ducityin the base metal, ‘Theres high restraint on the work igh contsctionl strains gy T Ful sion compound welded efor joint” Pte to be tetas Contention stain ‘The et piace i machined from th caf eit ae placed under enion. If Lael ering war present ‘would lat low ales F Control of Lamellar Tearing Redesign weld rind a a ith sale weld meta ‘Contd retin Forcritel work 3 forged = "Tce maybe wed" afed Assessment of susceptibility to Lamellar Tearing + Carry out through thickness teniletst + Cary out Ultra sonic testing + Cary oat ponetrant testing of pate edges + Carry out fll chemical analysis (S-< 0.05%)" Maths of siting Lamelr Tearing * {pave [B__Ue controled low sulfur plate = 1 (3 Gand oetsertace and batter" (0 Change joint design = 1) crack types Sidiication cracking Laton Weld centre lngiteinst Sea type: _Natenits Staines Stel, Micostrctae: Columnar graine In dirctin of sliification® Low melting pont impurities form around the large solving austen ram structure onthe weld centri “igh contratinal strains are preseot igh dilation processes are Being wed. ‘Theres alow, or no ferrite content Inthe weld metal® P ‘itein Casing hs Sle, ‘Low mstng pointes (DBs chain rose, al mal th jit ig] [By As dota fete bon mask maler grin rin iron weed to increase th pin boundary aca ding he welling of state aide tela in mount of beeen 5 = 1596" | Limit he Ret iput, Rees Tow conzacton, & minimise | ciproto erate * fad crake: Location: ‘Weld HAZ. Conga) Sto rp Stainis atels Micostucter: Senstsed grain boundarees Occ whe: ‘An areain the HAZ/bas been sensitised bythe formation ‘chromium carbides This area fin the form of line running parallel to and 7 bth rides ofthe wel ‘This depletion of chromium wil leave the effected grains low inchoalum oxide which's what produces he erosion reiting elect of stares steals. fle untreated corrosion and alae il be rapid?fal tergranular Corrosion... uae Dang the welding of stanie tec aaa gain aes in the HAZ, paral to the weld wil form chemi cshide ste ‘rin Wound, This dep hr gran ofthe cooion ‘esting bvome oxide ‘We say thatthe stot has become “Senstsed” or hat bacome mnirol wlar Comasion 1) se Stabe Statens Stor 2) Use Low Carbon Sti es Stele ( Below 04%)" 23) A sensitised Stank Steel may be desensitsed by ‘eating ita above 1100°C where the Chrome carbide lll be isolved. The sta normally quenched from this temperatare to stp re-asocaton” Crack ype Re eat cracking ‘scala (Coarse grained HAZ. & weld, Sta ype Low allay creep resistant tel Miso: “Embritled coare grain Osean me: ‘Daring tess elie As the allo has bon strengthened agit aut, te alp occur in concentied ars of lw act arng tren reicring t tempers between 450-359 ‘Az 2 rel lhe plato tains ocuring in concentra ‘re & the UTS ofthe steal inca eaced, fring» onc ‘Tis wll aces in teas of igh stress concentration such 28 the wed tee ray Re-Heat Cracking . Rete Coking Fatrcton gos presi ‘or PHT fs Ay §_ (exp Resisting Stee Control of Re-Heat Cracking 2) Using higher peel teperatre and Ue oe of PWHTT daring the stage of welding large fbreations,frolce the | Deening of fillet weld toes and morale attachments welds, on competion ofthe weld before it ool to edu sis. {0 Teetwe of wad eta wi igh daly wl abo lane | rikoftehot nekHeat Treatments .. ([Hiliertncnt applied to mets we ele of ces] [D__ Heats | Heat Treatments A [Rardoog [Weston sme’ \ =] eerie Sas rier] ? Heat Treatments rer | leseeeeeersl buen fat er wiinga Dee was | Somedays | ress eure fobs ea eyalapome Sa Plsbal veer fate ton staiehiowe on tioese sed mainly on daca ova te cooling ate of: hardnable scl ad reduce the Psrdening effet (Matenste formation) 1s alto used 1 Bep dtsion of yrogen from the HAZ of hardemable tds to avid nydogen caching. Typealy < 350°C ts to use a produce moc form te of cooling and cael Gatti, ese of high cenratonal ssn ‘The 3 mechnions, or odes tht cate in evs fres that wil be covered ons coure ate flows" Fatigue Fracture+ | Brittle Fracture- Ductile Fracture: {ts important to ote that al filres require a tation pain, Which are invariably stress concentrations®pal Fatigue Failures... Fig faces ae inte ke all ates, om aren where ‘the stresan ae higher than other areas. We call thse es Stress ‘Concentration nd they occur at pots whee thre ix an abrupt change in CSA sach asthe tac of welds of a are sike™ Fatigue irs occa to cystic lang and 3st levee ‘wall below the materials UTS Sothat weld designe can have cafe inst 0 werk within, pape have Been producod for welded joins to give ctor to ppl ith cera jin deg, Other gaps have been roduced fr most metals ving safe lini tres fr materials ner eylie loading ctor id i 1930] Digs ane led Scans ede ees, Se pnd sees mtb lu i a welded fabrications ictos ae farther pple for specifi joint dion When a welded members expsod to fatigue and ako 2 comotve condition ten cotain ftpue wil ost adhe fag limit. ‘il be he reed” "The graph shown onthe set ide i fo atypical Fete te {A graph for Non Peso alloys ix shown on te foiwing side A ‘S/N Curves for a Ferritic Steel Facts wil cutie sido ofthe pap ne® ‘S/N Curves for a Non Ferrous Alloy Faces will cer this Side the raph ie ‘Number of eels of rss sees ———— ples oft Limit of Endurance F Observations of Fatigue Faces atigue facture a inated Som set concotions and te progress eowiy trough he section in dct atu there ‘is infficient CSA to sport the applied oad™ ‘Areas of siden plastic lip are characternd by beach mats, ‘which en be observed on he fal ste srice “The epicentre of the radi sways points othe erckstart® sage {Gm Fractured rotating sha a far 1) Fatigue ite ae ays nits fom sess 2) Theil actured mfice is characterised by aes of ‘lai lip thse are known a each mat” 3) Theepcen ofthe rai ston post ofthe face” 4) Thefts genrlly contin to ove util inalicien (CSAs avalabeta cary he increased level of et * 5) Fatigue wil nthe the inal mode of ctr, bat tis very olen the st”Baile rctare are pid fies of metalic stracuesht occur ‘when a etal hs some ile and in th presence of cme Kind ‘fares and on most ocasons #103 teageatare® This stress can be satis o ynamic sts, or the nal mode of Sire ssocinted with another fara of acti ‘The acre maces chars by lt and features appearance that aay 3 9° t the plain of the tese® ‘Te mice it markt With chewrons ©>>¥ 350VPN_| Hydrogen >15ml | c > 0.5 Re (YS)_| Temp > 300 °C HSLA weld cracks High strength] High carbon weld | Low ductility metal [ Weld contraction. ‘Transverse crack | Micro alloy Nb T V| Longitudinal « [QM Steels “[ Thickness concentrations | High hardenability HAZ or Weld metal | Martensite Low ductility High risk cracking _| Prevention: (Q/T Steels in bold) [Pre-heat [ Control of He Bake consumable | Low H*Process Minimise restraint | Remove coatings _| Control o conent_| y S/S Weld metal Arcenergy [Use low Ceq plate | Hot pass ASAP__| Use low H” Cons? Solidification cracking in C/Mn steels. Keywords: Caus ‘Sulphur. Fe/Sulphides Weld centreline | Contraction Low_m.p. films Contraction forces| Loss of cohesion | Hot shortness Prevention: High manganese % _| Use low restraint | Control carbon % | Use low dilution _| Control heat input | Control sulphur % | Change Prep _| Seal laminations Lamellar tearing in C/Mn steels. Key words: Cause: Poor ductility Plastic strain Sulphur Laminations Contraction Short transverse _| Stepped crack | Segregation Prevention: NDT forlaminations | Through ttensile_| Buttering layers __| Contraction gap Re-design joint Forged T piece Chem analysis Control heat input Senior Welding Inspection ~ The Weldability of Steels ll Rey 09-09 Copyright © 2002 TWI Ltd,TWI TDi. Solidification cracks in y stainless steels. Key words: Cause: Austenite grains | Coarse structure [Boundary area | Low m.p Sulphur _| Contractional force | Co-ef conduction | Co-ef contraction | Last solidification Weld centreline [Plastic strain__| Hot shortness Prevention: [Ferrite content Inc boundary area | Minimise dilution | 10-15% Ferrite [Reduce restraint _| Duplex S/S Contraction rate Consumables Inter - crystalline corrosion in stainless steels. Key words: Cause: a [Chromium depletion [Temp gradient _[ Cr Carbide Sensitisation (Parallel to weld In HAZ Loss of resistance | Stress CC Prevention: Low Carbon .04%| Stabilising elements [ Niobium Molybdenum [Tantalum | Titaniumfor plate [Solution anneal | Rapid cooling Re-heat cracking in alloy steels. Key words: Cause: Precipitation Carbides Grain strengthen _| Stress relieve Loss of ductility Con’ plastic strain | PWHT450-600°C | Temper embritle Molybdenum Vanadium ‘Boron Creep resistance Prevention: Control PWHT. Minimal restraint [V below 0.1% __| Higher Pre heat High ductility weld | Stage PWHT Reduce o areas _| Use clean plate Tony Whitaker Manager TWI Middle East Training and Examination Services. Dated 25-10-02 Senior Welding Inspection — ‘The Weldability of Steels Copyright © 2002 TWI Ltd. 12. ‘THE WELDING INSTITUTE Rey 09-09-ete a ras Tey tee meme Tey ati ethan Thayne ter owes tine a a perenne ee nnn eee eR URES Testing the Weldment.,, vpn @ P.Sorhene. ‘The et wel sully oat into seston fellows: ‘The location of specimens wil depend wp the standard Fensietet fr Macro Imspection..,, 1) cost Weld Wat Helght £8) Poor Toe Bleni* 1) Sag incon & Lac of intern fon Hardness Testing. ..,, The specimen may then be hans tested (O-= Hardness Survey Furthehardneessrveysmay be taken asthe hsknes ofthe specimen acest" = Hardness Testing, | (Generally we wes damon ote for am inden det doy Bey We measiethe with ofthe indentation to gnuge the hardcs® a Hi Testi 1) Vickers Diamond Pyramid: always uss diamond [BS 27 Vickers Hardness Testing * 2) Brin wardness tests Alayna ste ll 3) Rockwell hardness test User bl sediamord Aepending on the tekpal Toughness Testing ,,,| TOs 10 mm specincn {BS 131 Charpy V Testing. BSEN I aod. 10% 10 mm sgecinen Same ‘= Charpy V, bat poimen inteld verily" eron: ‘Specinen sae adage] Cntieerintninns of sta component” “The specimen maybe tested How eet aeo ofthe weld —— ofabierbed | nergy in Jules Perdue Hares Location oF pecinen pa ¢ Testi ous Min < 1.6 % increases Joules absorbed (seg Pole Bractre “Tose sotcimer re noally {ested atech temperstce 28 aster easton Temperate Range “The fisted fae and ses comions are salyd sad very acerse ascent canbe piven of terial behaviorP Transverse Tensile Test. ‘A Sesion of welds et, machined oot acronthe tet pcos nd tee intension ofr, Theta aly in Nin? Direction of applied stress Dy 1L Weld Metal Tensile T [BS 709/18 En 10002 All Weld Metal Tene Testing ‘est pose testa in AN ree est Mongol cine —Duatility Elongation %_..| Fitly, befor theese test 2 mac are made Se apart. ===) ot apse ee Aneirmeasuetent of Sem wil indist Hongaion £50 %t 3B. St: ve ‘Bend tests are wet stich fasion inthe area under et otto. A Gulded rot bend tet” Further tes include fs, side and Tongitial bend tsot For material over 12mm thickness, sid bend tet may be weod* Any stain ines “Lacleo roo fason”= Fa fick B Te: sence Hanmer blow v .[Summary of Mechanical Testing “Were welds to etic minimum eel of mechanical operat, and soundrse othe welded it, ‘We divide tests into Qualitative & Quantitative methods (Quanttatve: Glave only {Qeatratve Gave nowt) | ends Bractures But & Filet) Macros ‘arness (VPN & BHN) Stength (mam & PSI) Toughness Joules & fib) i __Welding Procedures _. A definition of the term “Procedure™* Asystemati method of producing an aim" ‘Therefore, a “Welding procedure” is* A ystematc method of producing 3 sound welé* ns + Planning the tasks + Collecting the data + Writing procedure for use of for tral + Maing test welds + Evaluating the results of the tests + Approving the procedure of the relevant code + Preparing the documentation FS Welding Procedures 2) Matas pes and orm to be weed? Low Aly Ste Pipe 2) Woling Psion? Fd Vere Pipe horizon wed vereal_ BJ ©) Woling Proce Consumables +e ini? wouBNE ashes" C ese Bl ©) Sint design? Sor Single Butt welded butts © Hestrstmet Pree 297 C+ PVE Sr Reeve 506 Examples of “Estets of Approval” ncade:= 2) Diameter of pipe, or thickness of plate 1) Welding poston, amperage ngs or member fons ©) Process (On mult process procedures oly) Certain material erp 1) Change of consumable 10 oe ofthe same clasifcation Only the slaes ir given ia the oigizal procedere 1) Heating eange (n)* [A Welding Proce i arexge of variable parame, which ‘wil race these resulting & open f Cased outinthe ime way each ine To ovale a Welding Procol we nc to check il he psmeter set wil wrk together produce the dosied. reralier Welding Pocodures tts are fen cated out to tite easly of et of unasal parameters i The we oF ‘ross of consumable Tor pial appcation®—Welding Procedures _.,, ‘Onc the weld hasbeen completed itis uly vill ‘napcte, then Radlography or Ultraconicteting it ‘aly appiod= Fialy, an most importantly, Mechanically ested 12 cnr that th desired evel of mechanical propre fave been met all he dsc popetes hav been mt then 2 procedure ‘yalifeation rsord(WPQR) completed wit llth test rool, and the procedure thn becomes quliied® Welder Approval _, (one the procedure bat ben approved iis then important to test each olde, to cane tat he an thes to reach he ‘mlamum evel quality in the wel, aid down i the ‘pplication standard ‘Thee no need io cay ot the mechanical tl ofthe procedure, athough bed tea oflen wed ere good fide wal fica ‘Normally visu xy, bends, acters snd crs ae wed inwelderappreal testo" Aa rvton execs of the common wedng poses ‘here will a flo 3 uray Uist ofthe rouemente svanage nd dsntvanages of the common welding cesses i 3) Cont ver & fla al fey clang nel craton] Seiattnd —] 5) Blewode pe | [6) Daly Cycle ] 1) Slag inctasions 2) Arcstikee 3) Persity 2) Uaderat Mest welding imperfection in MMA ae cased by alk of welder kl he incor sotings ofthe euipment or ihe nome we, and wentnent of electrodes" pmo eit »Pal MMA Welk - Constituent arta Tinta f E =] tie Bais — | 10, a a 8 | Caco | oo ee Ee 5 Sipe ease ] (Braap comer ecrereemgmanua tn mama ap D/Stichnropecscotsonstnearatbemeane” : 7 [DA Tromerieniior Constant caest 9) (BA pve ad pover en ale } (Bassas | [asain] [Ae liner ahiekding aa. (Argon or Helin) [B__AcerDe +Potatiy | [Speed of Travel Gas be Twn, & pear 5 imenpao | [> DayGrie ——] 3)__THG torch Rea with wound tne, colle eres [&) Method ofa ignition (igh Requency ria) [_Tegeenveterange]| [)_ Camestins [Gap owint | [twain orton] : [)_ Comes seal sft clothing pd good eration Ti) Cosmic conden ) Gas oa ital 8) Optional file rod to comet peifietion™ | HO! 1) Tange incisions (Low skill or wong verte I) 2 Secace porosity (Los of shield mainly on ite) 3) Cenerppe ad wed fnih tetngu Slope ox) 4) Oxidation of 1 wed ead, o 10 poo as cover Most welling impecetons wth TI are came by lack of welder kl or incomes oting ofthe equipment. Carent torch manipulation, welding peed, sas low ate es [eal Disadvant f Dandvantge Dwar eeae [ovens aaer [9 Gone een 5__uprgreseGases for TIG Welding...) F” Requirements of MIGMAG cqammne | i | Argon or Heli os mint of thee guest | )__Aponendpone ran | etiam ga has phe cizatonpotatilthan argon and gives See deeper pentaton his argn sds thn iran gives god [5 Gain Sowa: & or ‘overage ofthe weld ares inthe down band postion, We wld ‘ood 2-3) times the flowrate ofa ogo the sume coverage {elim less dae tana nthe overhead postion the fever is tue, We olen mit thee gases to ge both benefis® "Goweiewvio ewe pont rer 5) Ni hws er ie cmp eae | ‘We sometimes use adton of ntuogen when welding some Sunless tel, come S_ Corer ner gan ty cing aad Typical Ing ions, Sica inlsins (Por intra lessing) | Wipe | [SET Veiage | > B_ Wisma] [Gace fiowme > Cains tpn ala & pew (Conta pian | [Rote ts peau] Moet welding pects in MIGIMAG ae coved byte [Diese] [atts ns Pele sas ence sting ef be oppo a Thee eli wie wll ne ie feat pb Geet ‘Wom cont tis il cae poor owe pice po tte [Dba] seep] Ba power cometins wileanse los of voltage inthe ae Lack of side wall fision Primarily wih ip want) Porosity (From les of gas shld east cts)* Gases ned for MIG: Argon or Bim, aes wed for MAG: CO, or mintxes £CO, 4nd Argon” (C04: Very good penetation, canal suport spy tater ‘produces an mntable t.ho fale Argon: Shallow sentation. Vary able ar, with Low sate | ‘We mix both ge in mice of between 520% CO, in augon to setibe benef of oth pases” | Rory sins steels we vs argon with 2% oxygen, this ven more ity tthe meld ad an improved toe ed®| Wis must be drawn as deposited and are deere of vey high | | galt: lecrode wires for MUG ae the sme sro for TIG* The qalty of temper and copper ong is alo very ior The copper costing on MIG wires maximise the cent pick op Speifction for wise are at per tc cernieal compositions” Grades: [Composition + Single, done, 25 wile de-oxitised wires Quality of winding: Random wovad. ayer wound, & Precision layer wound | Wires diameters: [05->2:4mm@ soplid on 1k fine wie) & 15 ka spool aa [Adiabene] 5) A ftuc delivery sytem (9) _Aflarreaneyeysem 3) Conectafay clothing and goed etmcton™ | ii fection 1) Lack offison (Caused by high levels of blow) 2) Soldiiaion craks (Fam S pickup fom high dition) 3) Shrinkage cavities (From high dep with ratio) 4) Ponty Using damp fuses, or umclenedplts)™ Most weling imperfsions in SAW are case by income ‘eting ofthe eqlpmeat, wing incoret or wrongly died ‘orsumabies, of welding pss hat Rave not been ropery leaned Minor change inthe welding parameter of SAW fan havea major ext on Weld composition and weld guy vine and ae cma treat vance] “The wits sila to tht of solid wire MIGIMAG and is ‘chosen rom a table of chemical compritons™ ‘roses ar varied and are classified by tr method of ‘manefactire snd composition |In BS 4165 Axes ay be cls intr Basicity Index* elie <09Binanber ‘Flates are grouped in BS 4165 by the amount of acid or basic Neutral 09-1.2BI mumber ‘Sen eon by meted ale he Satyr SeniBaic 12-18Binmber ‘ss coal by ding te Bae lanen ty th Aid baie 18-25tnmber ements fellows Highly Basic 25~3.5 Baumert aie eee ee ee “The hihe the bscicity index sumer, then the higher the “Rie mente 9 veld ally, Opie stem & gins nh wed ‘Ret though the moe dealt becomes oe Tee higher eines te mornin” (Ce tolemat of por epsation ee) Welding Symbols | 1) Convention of the arrow ine: tt atin nl 18. BSTa.& AWS | the workshop Phat ld hw * 1) Sha uch jin terecton 1 as 9 Sponsor ry “The shove information doc not tl x mach abut the wishes cf the designer We obvouty need some sor of code which ‘would be understood by everyone ‘Most couniries have tir ava standard fo symbols rc | Some of thm are BS 499 Part 2 AWS AZ.4 BS fn 22653 ] 3) Convendan of The ference ie a oes 18.409 19 & AWS A244 Spa sa 2 Slee bern ne 3 Saptari mie | 1 Shatiepantto te om f be davigt Rory attri neh | a okoy 5 Tate BS WI UR & AWS AICS) | > omlacaermicmaeeimnne | >) Wells the other se of he jis. gp om top ofthe cefirnce ne | ©) Symbols stain mpm matte sw | seal ln eee bat ©) ACSA dimen ae 00m Wie eye ©) Alina ise sown te Het of ot EE Nr of yeah fee eg ye 7 axe ‘Symbols: BSEn 22553, (SO 2553) Welt tee ofa 0 obounbakan rece ‘Wel hearse a, 9 oh olan eee ‘Sym a ea congener he ‘aloe tot tse sym NCSA desi sown eM ey [Al Bsns re shone of sot e Sie af esng of wlhi fwy opee Alege hal npr a hy ae * TGF |” Weld Symbols on Drawings | ssuvaansara Weld Symbols on Drawings [BS En 72853 1302553) | Supplementary Weld Symbols | Toes tobe grousd L,snenthly. BSEn oly) Ce ‘Ground tush ry Site Weld Weldiog proces [Numerica BS Ea & |" Further supplementary iafrmaton such 2s WPS. |__ numer, or NDT may be placed ine sh ale Reprerentation of welds done fiom bath ies ot the jit interection touched bythe arom hed Filet weld Double bevel Double J* Double ¥ Double U 10@ “SENIOR WELDING INSPECTOR _ A Rosusiedes QUESTION: ‘You are required to visit a ‘site on which your inspectors have been involved. ‘The work involves the inspection of 2 welded structure to an application standard and is now ready for final approval. 1. What questions do you ask? 2. What documents do you review or require before submitting an inspection report to the authorities concerned? TYPICAL ANSWER: Prior to the site visit it is important to spend some time planning the visit, in order that 2 logical approach be made and that vital details are not oF A knowledge of the standard that wes used for fabrication, and the servi he Binal product will t beneficial in assessing the fitness of the product for service. A list of the inspection team and the team leadey will ensure that those involved with the fabrication and inspection of the product are on hand to ansiver pertinent questions. These questions could include the completeness of the job, repair rate during production and safety standards on site, housekeeping, etc. The standard of access and scaffolding can have a direct bearing on the quality levels attained as safe confident workers are much more likely to produce quality fit ups and welds. Certain documents can greatly assist the overall audit plan such as quality plans and inspection check lists, if used on the job. Some standards (¢.g: BS:5500) will tabulate a list of the required documentation which may be required to be included in the final data book package. If not specified by code or client Specifications, then the following documents should be reviewed as a minimum signing off and issu all stage$ are 1. A review of the qu completed and signed off. 2, Material certificates, mill test reports and material traceability records are documented and accepted. This may include consumable certification. rocess control 5 es should be reviewed for adequacy, accuracy and approval. These procedures should inciude approved cutting and welding procedures, weld repair and NDT procedures, heat treatment if required, testing, ead finally, coating procedures . w qualification review should include welder qualifications, NDT and should be up to date and current in the Personnel Inspection personnel approvals and al particular discipline of expertise.P Terms Associated with QA/OC.... Defect A.elding iperfostion ht fills ouside of eve of acepanceinan applied tandard™ Gases of defects: Minor: Unlikely cau Gil of the roduc Major: Likelyto cause ure, bu mal ik of los of i Criteasstemely Lely to cae fire, with high rik of lows of hie* ») Pan An sso, pro-dteinod and strstr {thoay, tht mest» spose sim 2) Organise ——-Tomakeall nexouryaangements required to cary oo ful plan 13 Superve To inert, od contol the wrk of salt in areas for which you ae rapenible 4) Aust To cany ot prod and systematic “check on syaten/proces fo rma that ‘thas oon camod out specfed® “The really nice thing about not planning is ‘that failure comes as a complete surprise and is ‘not preceded by long periods of worry and depression”» ‘We make plans every day forthe most trivial of things All delegates must have planned to come here today Many tools are used for production planning including: GGont Charts, Forward and Reverse Seheduling. Critical Path Analysis. tc ‘Using the flowing headings andthe day on which they wi be ‘covered onthe couse, make a reverse schedule plan 0 your exh ‘ite ttbing your available sme: You plan neds o be Aesibie neat there ace any changes tothe cone sac. Remomber hat Radiographic intrpectation (Theery,paticl or sensilorety) isnot covered on the couse slab Specific tery Rad tt ~~. 270% Foctues. —> ‘Weld symbole ray 7 Suse rcpt fa Organisation ‘Once an inspection plan hat been made the organisation rust then begiot ‘This may ivove the follwing leet 1) Any eaning & eviction required 2) Staling the plan 3) Procurement of eqvpments 4) Transport tofim sit, and at ste 5) Accommodation nd mesiog ©) Aay special needs Religions ee) 7) Leave eyelet ‘Once plan as heen organise it ictal that ont is ceverinad hat the pln is voces inplemented A supervise caenialy 2 manager of men wish requires cartsin specific management sl Each student should ive a titel at they think important fo “efective supervision of welding npectors” Stuleat anes to be placed net othr choice onthe ite tard Do not open net se util this task has ben carried outFOLDER 1 1 Re DUC DOCUMENTATION USER GUIDE 1.0 [Cerificate of Completion 2.1 {Inspection & Release Nate RS) 1.2 [inspection and Test Plan 2.0 [Procedures eed 28 [P.W.H.T procedure _ EE 3.0 {NOT Procedures _ } 3 v [Radiography Test Procedure [Ultrasonic Test Procedure [MPI Procedure [Liquid Penctrant Inspection Procedure | [Equipment Calibration Certificate (Cise oF NDT, Operators & Centif 40 [Welding Procedures (WPS + FOR) (as per index) 4.1 [List of Welders & Certificates (Certificates as per list) i ser guide st0AR Pagel of3DOCUMENTATION USER GUIDE 5.4[NDERepons_ RT Repos }—> ut Repors > MTRepons 5.5[Visual Inspection Reports 5.6 [Dimensional Control Reports 7 (As per DCR Register) _ Calibration Certificates i 3.8[P.WHLT. Report : 5.9(Haxcness Test Report =a 5.10fSite Query Repos? 1 [Non-conformance Reports 5.11[Painting Control Repors 5.12[Paint Warrany (Concrete Tex Centifieates — FOLDER 4 60 [Rebuilt Drawings (as per as-built drawing resisen) 6.1 [Asbuilt Weld Maps ° ste pide eW/AR Paget of