61769477 welding-inspection-cswip-gud

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CSWIP PPT FOR EASY STUDIES

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  • Welding Inspector 4/23/2007 1 of 691 Duties and Responsibilities Section 1

Main Responsibilities 1.1 4/23/2007 2 of 691 Code compliance Workmanship control Documentation control Personal Attributes 1.1 Important qualities that good Inspectors are expected to have are: Honesty Integrity Knowledge Good communicator Physical fitness Good eyesight 4/23/2007 3 of 691 Standard for Visual Inspection 1.1 Basic Requirements 4/23/2007 4 of 691 BS EN 970 - Non-destructive examination of fusion welds - Visual examination Welding Inspection Personnel should: be familiar with relevant standards, rules and specifications applicable to the fabrication work to be undertaken be informed about the welding procedures to be used have good vision (which should be checked every 12 months) Welding Inspection 1.2 4/23/2007 5 of 691 Conditions for Visual Inspection (to BS EN 970) Illumination: 350 lux minimum required (recommends 500 lux - normal shop or office lighting) Vision Access: eye should be within 600mm of the surface viewing angle (line from eye to surface) to be not less than 30 30 600mm Welding Inspection 1.3 Aids to Visual Inspection (to BS EN 970) When access is restricted may use: a mirrored boroscope a fibre optic viewing system Other aids: welding gauges (for checking bevel angles, weld profile, fillet sizing, undercut depth) dedicated weld-gap gauges and linear misalignment (high-low) gauges straight edges and measuring tapes magnifying lens (if magnification lens used it should have magnification between X2 to X5) 4/23/2007 6 of 691 usually by agreement } Welding Inspectors Equipment 1.3 Measuring devices: flexible tape, steel rule Temperature indicating crayons Welding gauges Voltmeter Ammeter Magnifying glass Torch / flash light Gas flow-meter 4/23/2007 7 of 691 Welding Inspectors Gauges 1.3 4/23/2007 8 of 691 TWI Multi-purpose Welding Gauge Misalignment Gauges Hi-Lo Gauge Fillet Weld Gauges G.A.L. S.T.D. 10mm 16mm L G.A.L. S.T.D. 10mm 16mm 0 1/4 1/2 3/4 IN HI-LOSinglePurposeWeldingGauge 1 2 3 4 5 6 Welding Inspectors Equipment 1.3 4/23/2007 9 of 691 Tong Tester AmmeterVoltmeter Welding Inspection 1.3 4/23/2007 10 of 691 Stages of Visual Inspection (to BS EN 970) Extent of examination and when required should be defined in the application standard or by agreement between the contracting parties For high integrity fabrications inspection required throughout the fabrication process: Before welding (Before assemble & After assembly) During welding After welding Typical Duties of a Welding Inspector 1.5 4/23/2007 11 of 691 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 Typical Duties of a Welding Inspector 1.5 4/23/2007 12 of 691 Before Welding Welding Procedures: are applicable to joints to be welded & approved are available to welders & inspectors Welder Qualifications: list of available qualified welders related to WPSs certificates are valid and in-date Typical Duties of a Welding Inspector 1.5 Before Welding Equipment: all inspection equipment is in good condition & calibrated as necessary all safety requirements are understood & necessary equipment available Materials: can be identified & related to test certificates, traceability ! are of correct dimensions are in suitable condition (no damage/contamination) 4/23/2007 13 of 691 Typical Duties of a Welding Inspector 1.5 Before Welding Consumables: in accordance with WPSs 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 4/23/2007 14 of 691 Typical Duties of a Welding Inspector 1.5 Before Welding Fit-up complies with WPS Number / size of tack welds to Code / good workmanship Pre-heat if specified minimum temperature complies with WPS 4/23/2007 15 of 691 Typical Duties of a Welding Inspector 1.5 4/23/2007 16 of 691 During Welding 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 Typical Duties of a Welding Inspector 1.6 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 4/23/2007 17 of 691 Typical Duties of a Welding Inspector 1.6 During Welding Inter-run cleaning in accordance with an approved method (& back gouging) to good workmanship standard Distortion control welding is balanced & over-welding is avoided 4/23/2007 18 of 691 Typical Duties of a Welding Inspector 1.6 4/23/2007 19 of 691 After Welding Weld Identification identified/numbered as required is marked with welders 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 Typical Duties of a Welding Inspector 1.6 After Welding Repairs monitor repairs to ensure compliance with Procedure, ensure NDT after repairs is completed PWHT monitor for compliance with Procedure check chart records confirm Procedure compliance Pressure / Load Test ensure test equipment is suitably calibrated monitor to ensure compliance with Procedure ensure all records are available 4/23/2007 20 of 691 Typical Duties of a Welding Inspector 1.6 After Welding Documentation ensure any modifications are on as-built drawings ensure all required documents are available Collate / file documents for manufacturing records Sign all documentation and forward it to QC department. 4/23/2007 21 of 691 Summary of Duties A Welding Inspector must: Observe To observe all relevant actions related to weld quality throughout production. Record To record, or log all production inspection points relevant to quality, including a final report showing all identified imperfections Compare To compare all recorded information with the acceptance criteria and any other relevant clauses in the applied application standard 4/23/2007 22 of 691 It is the duty of a Welding Inspector to ensure all the welding and associated actions are carried out in accordance with the specification and any applicable procedures. Welding Inspector Terms & Definitions Section 2 4/23/2007 23 of 691 Welding Terminology & Definitions 2.1 4/23/2007 24 of 691 What is a Weld? A localised coalescence of metals or non-metals produced either by heating the materials to the welding temperature, with or without the application of pressure, or by the application of pressure alone (AWS) A permanent union between materials caused by heat, and or pressure (BS499) An Autogenous weld: A weld made with out the use of a filler material and can only be made by TIG or Oxy-Gas Welding Welding Terminology & Definitions 2.1 What is a Joint? The junction of members or the edges of members that are to be joined or have been joined (AWS) A configuration of members (BS499) 4/23/2007 25 of 691 Joint Terminology 2.2 4/23/2007 26 of 691 Edge Open & Closed Corner Lap Tee Butt Cruciform Welded Butt Joints 2.2 4/23/2007 27 of 691 A_________Welded butt jointButt A_________Welded butt jointFillet A____________Welded butt jointCompound 4/23/2007 28 of 691 Welded Tee Joints 2.2 A_________Welded T jointFillet A_________Welded T jointButt A____________Welded T jointCompound Weld Terminology 2.3 4/23/2007 29 of 691 Compound weld Fillet weld Butt weld Edge weld Spot weld Plug weld Butt Preparations Sizes 2.4 4/23/2007 30 of 691 Full Penetration Butt Weld Partial Penetration Butt Weld Design Throat Thickness Design Throat Thickness Actual Throat Thickness Actual Throat Thickness 4/23/2007 31 of 691 Weld Zone Terminology 2.5 Weld Boundary C A B D Heat Affected Zone Root Weld metal A, B, C & D = Weld Toes Face Weld Zone Terminology 2.5 4/23/2007 32 of 691 Excess Root Penetration Excess Cap height or Weld Reinforcement Weld cap width Design Throat Thickness Actual Throat Thickness Heat Affected Zone (HAZ) 2.5 4/23/2007 33 of 691 tempered zone grain growth zone recrystallised zone partially transformed zone Maximum Temperature solid-liquid Boundarysolid weld metal unaffected base material Joint Preparation Terminology 2.7 4/23/2007 34 of 691 Included angle Root Gap Root Face Angle of bevel Root Face Root Gap Included angle Root Radius Single-V Butt Single-U Butt Joint Preparation Terminology 2.8 & 2.9 4/23/2007 35 of 691 Root Gap Root Face Root FaceRoot Gap Root Radius Single Bevel Butt Single-J Butt Angle of bevel Angle of bevel Land Single Sided Butt Preparations 2.10 4/23/2007 36 of 691 Single Bevel Single Vee Single-J Single-U Single sided preparations are normally made on thinner materials, or when access form both sides is restricted Double Sided Butt Preparations2.11 4/23/2007 37 of 691 Double sided preparations are normally made on thicker materials, or when access form both sides is unrestricted -VeeDouble-BevelDouble - JDouble - UDouble Weld Preparation 4/23/2007 38 of 691 Terminology & Typical Dimensions: V-Joints bevel angle root face root gap included angle Typical Dimensions bevel angle 30 to 35 root face ~1.5 to ~2.5mm root gap ~2 to ~4mm Butt Weld - To

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