Module 5

Documents Governing
Welding Inspection and
Qualification
 Introduction

Information from the documents review :

 Part size and geometry

 Base and filler metals to be used
 Requirements for hold points
 Processing details
 Processes to be used
 Specification for nondestructive inspection
 Extent of inspection
 Acceptance / rejection criteria
 Qualification requirements for personnel
 Procedure and welder qualification
 Materials control requirements
 Drawings

Drawings - describe the part or structure in graphic detail.

Should be reviewed by the inspector:

 Drawing dimensions
 Tolerances
 Notes
 Weld and Welding details
 Accompanying documents

Dimensions provided on a blueprint have two basic functions:

 To provide the sizes needed to fabricate the parts.

 To indicate locations where the individual components of each part
should be placed
Tolerances – are the total amount of variation permitted from the design
size of a part.

Tolerances may be expressed in three ways:

1. as a variation between limits,

2. as the design size followed by the tolerance,
3. when only one value is given, the other value is assumed to be
zero.

Generally, tolerances should always as large as practical , all other factors

considered to reduce the manufacturing cost.
Drawing notes – provide both instructions and information
which are additions to the illustrations, as well as the
information contained in the Title Block, or List of Materials.

- “Notes” = eliminates the need for repetition on the face of

the drawing., such as the size holes to be drilled ,machining
operations etc.

= when he notes become extensive in the case of structural

fabrication. It is often type or printed in a separate sheet
and included along with the drawing . Found in “specs
package”

Notes can be classified depending on their application on the

blueprint as:

1. General – apply to the entire drawing and are usually

placed above or to the left of the Title Block in a horizontal
positions.

2. Local or Specifications – specific notes apply only to

certain feature or areas and are located near and directed
to the feature. Denotes materials required, welding process,
type, size of welds etc.
Example of Fabrication Drawings
The welding inspector should be aware of the following factors :

- Specification requirements on the drawing such as locations, lengths,

joint configuration, material call-out,

- Processing Techniques

- Hold Points during fabrication process.

- The specification of the welding process

- Review of the welding procedure

- Requirement for NDT Nondestructive Examination

- Requirements for visual inspection

- Information related to the qualification of personnel.

Standards, Codes, and Specifications

Organizations responsible for the production

and revision of various documents. They
include, but, are not limited to:

 American Welding Society (AWS)

 American Society of Mechanical Engineers
(ASME)
 American National Standards Institute (ANSI)
 American Petroleum Institute (API)
 American Bureau of Shipping (ABS)
 Department of Transportation (DOT)
 Military Branches (Army, Navy, etc.)
 Other Government Agencies
 Codes

Code – is a body of laws, as of a nation, city, etc., arranged

systematically for easy reference.

The welding inspector will often inspect work according to several

codes for various areas of concern which covers different types of
industrial welding applications:

AWS CODES
 AWS D1.1 Structural Welding Code – Steel
 AWS D1.2 Structural Welding Code – Aluminum
 AWS D1.3 Structural Welding Code – Sheet Steel
 AWS D1.4 Structural Welding Code – Reinforcing
Steel
 AWS D1.5 Bridge Welding Code
 AWS D9.1 Sheet Metal Welding Code
 Codes applicable to the Design
and Construction of Pressure Vessels

ASME CODE SECTIONS

 Section I Rules for Construction of Power Boilers

 Section II Materials
 Section III Subsection NCA – General Requirements
for
Division I and Division II
 Section IV Rules for Construction of Heating Boilers
 Section V Nondestructive Examination
 Section VI Recommended Rules for the Care and
Operation
of Heating Boilers
 Section VII Recommended Guidelines for the Care of
Power
Boilers
 Section VIII Rules for Construction of Pressure Vessels,
Divisions 1, 2, and 3
 Section IX Welding and Brazing Qualifications
 Section X Fiber-Reinforced Plastic Pressure Vessels
 Section XI Rules for In-service Inspection of Nuclear
Power
Plant Components
 ASME Criteria

In fabrication sequence of a carbon steel, unfired pressure vessel,

the sections used might include:

 Section II Part A – Ferrous Material Specifications

 Section II Part B – Nonferrous Material Specifications
 Section II Part C – Specifications for Welding Rods,
Electrodes, and Filler Metals
 Section II Part D - Properties
 Section V Nondestructive Examination
 Section VIII Rules for Construction of Pressure Vessels,
Divisions 1, 2, or 3
 Section IX Welding and Brazing Qualifications

Note : Section II Part C – is identical to AWS Filler Metal

Specification
 Standards

Standards – something established for used as a rule or basis of

comparison in measuring or judging capacity, quantity,
content, extent, value, quality.

- is treated as separate document classification.

However , it
also applies to odes and specification. Other types of
documents considered standards are procedure,
recommended , practices, group of graphic symbols,
and
definition of terms.

2 Types of Standards

1. Mandatory – this means that the information is an absolute

requirements. The information contained are precise, clearly
defined and suitable for adoption as part of law or regulation.
Ex. Codes
2. NonMandatory – the information has been put forth to serve a
guidelines for a performance of a specific task. However it
doesn’t mean rejectable when it does not comply with the
guideline. Ex. Recommended Practice

- can provide a basis for mandatory document

development
 Standard

API 1104 – “Standard for Welding of Pipelines and Related Facilities”

- applies to the welding of cross-country pipelines and other
equipment.
- this standards covers the requirements for qualification of
welding procedures , welder and welding operator qualification .

ASTM – “American Society for Testing Materials”

- produces many volumes of specification covering numerous
materials and test methods.
 SPECIFICATION

Specification – a detailed description of the parts of a whole ; statement or

enumeration of particular , as to the actual required size, quality
performance, terms.

- a detailed description or listing of attributes of some item or

operations.

The federal government agencies develop or adopt specifications and

standards for items and services that are in public domain rather than
private.

Other Organizations:

API Specifications – govern the requirements for materials ad equipment in

the petroleum industry

AWS Specs :
A5.XX – series of specification for welding filler metal types from A5.1 to
A5.33

A5.01 – AWS Specification for “ Filler Metal procurement Guidelines”

 AWS Specifications
 D14.1 Specification for Welding Industrial and Mill Cranes
 D14.2 Specification for Metal Cutting Machine Tool Weldments
 D14.3 Specification for Welding Earthmoving and Construction Equipment
 D14.4 Specification for Welded Joints in Machinery and Equipment
 D14.5 Specification for Welding Presses and Press Components
 D14.6 Specification for Rotating Elements of Equipment

ANSI - American National Standard Institute

is private organization responsible for coordinating national standards
for use within the United States. ANSI does not actually prepare the
documents but its form national interest review to determine whether
the proposed standards are in the public interest.

AWS Publications cover the following subject areas:

 Definitions and Symbols

 Filler Metals

 Qualification and Testing

 Welding Processes

 Welding Applications

 Safety
 Control of Materials

 Mill Test Report (MTR) or Material Test Certificate (MTC)

- these documents are usually notarized statements from the
manufacturer tabulating the chemical and physical properties for
the material.

1. The welding inspector may be responsible for the reviewing the MTC
of the materials ordered.
2. The material will be physically identified to its type, grade and heat
number.
3. A system should be implemented whereby the received materials
can be traced back though various fabrication processes.
4. The inspector may be involved with the total material system or just
a particular aspect.

A successful system for material control has several important attributes:

1. It should be as simple as possible
2. Contain an adequate heck and balances to ensure that the system
will not break and result in the loss of traceability.
3. Method of Identification
- Color Coding
- Marking - high chlorine content will cause damage to austenitic SS
high sulphur will cause damage to high nickel alloys
- Alpha numeric
- bar code
 Alloy Identification

UNS – Unified Number System- was develop to help interconnect

many nationally used numbering systems that are currently
supported by societies.

- is a means to avoid confusion by the used of more than one

identification number for the same material.

- devised to assign alphanumeric designation for each family of

metals and alloys.

- UNS established 18 series of primary numbers of metals and

alloys.
 Typical Steel Specification

Important Sections and Features of Specification:

1. Scope – this statement explains exactly what is to be described by the

specification

2. Applicable Documents – listing of other documents which may be referred to

within the text of the specification.

3. General Requirements for Delivery – statement regarding the required

condition of the materials if ordered to comply with the specification.

4. Process – The approved method of producing the product listed

5. Heat Treatment – For alloys requirement heat treatment , the details of the
treatment will be stated.

6. Chemical Requirements – table which list the actual chemical composition

requirements.

7. Tensile Requirements – table which defines the required tensile values for the
alloy.

8. Brinell Hardness Requirements – for materials requiring brinell hardness

testing.

9. Test Specimens – relating to the location, preparation and treatment t of the

specimens
10. Number of Tests – the number of test specimens required to show
compliance.

11. Retest – describes what procedures will be followed if any of the specimens
failed.

12. Marking – a statement regarding how the materials will be identified.

13. Supplemental Requirements – any additional details

 Typical Filler Metal Specification

Important Sections and Features of Specification:

1. Scope – coverage of the specification

Section A – General Requirements

1. Classification – reference is made, base on type current, covering, welding positions,

chemical composition and mechanical properties.

2. Acceptance – states that the electrode will be accepted if they comply with the
requirements of AWS A5.01

3. Certification – States that the manufacturer must certify that his product meets all the
requirements of this specification

4. Retest– If any test fails , two retests must be conducted and each must pass.

5. Method of Manufacture – Any method which produces a product in accordance with

this specification satisfactory.

6. Marking –what minimum identification must be visible on the outside package.

7. Packaging – describe suitable packaging.

8. Rounding –Off Procedures – Explains how tensile data will be rounded to the nearest
1,000.00

Section B – Required Test and Test Methods

- Describes the various chemical and mechanical method which may be require
to judge the acceptability of a filer metal

Section C – Manufacture, Packaging and Identification

- Details the specification requirements for these details

Section D – Details of Tests

- Describes the actual details of performing test used to measure the suitability of the
filler metal to meet this specification

Appendix
- Contain additional information
 Qualification of Procedures and Welders

1. The welding inspector may become involved in the Qualification of

procedures and Welder , mainly to witness the actual welding and
testing.

2. The welding inspector may be involved in the review both welding

procedures and welder qualification forms.

Procedure Qualification
Welding procedure qualification is performed to show the
compatibility of:

1. Base Metal(s),
2. Weld or Braze filler metal(s),
3. Process(es), and
4. Techniques

Three General Approach to Procedure Qualification

1. Prequalified – there is no need to perform actual welding qualification

testing as long as the welding parameters are within the prescribed
limits.

- AWS D1.1 list the various welding processes , base metal ,

thicknesses, joint configurations and welding technique which
when used in specific combinations are considered qualified.

- SMAW, SAW, FCAW and GMAW except short circuiting transfer.

Prequalified Procedures
2. Qualification of Procedure by Testing – these details the essential
variables which dictate the extent of a given procedure qualification

List of essential variables:

1. Welding Processes
2. Welding Parameters
3. Base Metal Types
4. Base Metal Thicknesses
5. Filler Metal Types
6. Specific Welding technique

WPS – Welding Procedure Specification =

list the range of the essential variables.

PQR – Procedure Qualification Record

- record the actual test conditions

Test Coupon : = It can either be plate or pipe for ASME while always
tubular in API
= it shall be welded according to the conditions which will
be encountered during production welding.

= upon completion of welding, test coupon will be

subjected to the required destructive test based in
accordance to applicable codes.

= these test are designed to evaluate the effects of the

welding technique and the compatibility of the base and
filler metals
3. Special Test Weld Mock- Ups – these techniques is used for complex
elements where there is concern about how the overall shape or
condition of that component might be affected by the welding
operations.
- these is an exclusive type of test.

Welding Procedure Qualification Specification

1. Select welding variables.

2. Check equipment and materials for suitability.
3. Monitor weld joint fit up as well as actual welding, recording all
important variables and observations.
4. Select, identify and remove required test specimens.
5. Test and evaluate specimens.
6. Review test results for compliance with applicable code requirements.
7. Release approved procedure for production.
8. Qualify individual welders in accordance with this specification.
9. Monitor the use of that procedure during production to assure that it
continues to produce satisfactory results.
3. Special Test Weld Mock- Ups
These techniques is used for complex elements where there is
concern about how the overall shape or condition of that component
might be affected by the welding operations. These is an exclusive
type of test.

Welding Procedure Qualification Specification

1. Select welding variables.

2. Check equipment and materials for suitability.
3. Monitor weld joint fit up as well as actual welding, recording all
important variables and observations.
4. Select, identify and remove required test specimens.
5. Test and evaluate specimens.
6. Review test results for compliance with applicable code requirements.
7. Release approved procedure for production.
8. Qualify individual welders in accordance with this specification.
9. Monitor the use of that procedure during production to assure that it
continues to produce satisfactory results.

Purpose of Welding Procedures during production:

- Comparison of actual parameters being used by the welder in

production
- in-process monitoring of the welding.
 Welder Qualification

Welder Qualification- a welding test performed by welder using the

approved Welding Procedure to verify his ability to produce sound
welds.

Essential Variable for Welder Qualification Test:

1. Welding Position
2. Process
3. Base Metal Type
4. Base Metal Thickness
5. And Specific Welding Technique
General sequence for the qualification of welder:

1. Identify essential variables.

2. Check equipment and materials for suitability.

3. Check test coupon configuration and position.

4. Monitor actual welding to assure that it complies with the

applicable welding procedure.

5. Select, identify and remove required test samples.

6. Test and evaluate specimens.

7. Complete necessary paperwork.

8. Monitor production welding.