welding subparte

8/6/2019 Welding SubpartE

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Welding Terms Welding Terms

------ and other strangeand other strangenomenclaturenomenclature


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WeldingWeldingA joining process that produces aA joining process that produces acoalescence of metals (or noncoalescence of metals (or non --metals) by heating them to themetals) by heating them to thewelding temperature,welding temperature,

with or without the application ofwith or without the application of

pressure, or by pressure alone, andpressure, or by pressure alone, and

with or without the use of fillerwith or without the use of filler

metalsmetals


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ProcessProcess

A method of performing welding,A method of performing welding,such as:such as:

shielded metal arc weldingshielded metal arc welding submerged arc weldingsubmerged arc welding gas metal arc weldinggas metal arc welding gas tungsten arc weldinggas tungsten arc welding oxyacetylene weldingoxyacetylene welding


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ProcedureProcedure

A way of performing or effectingA way of performing or effectingsomething; a course of action.something; a course of action.

WPSWPS --Welding Procedure SpecificationWelding Procedure SpecificationA document providing in detail theA document providing in detail therequired variables for specificrequired variables for specificapplication to assure repeatability byapplication to assure repeatability byproperly trained weldersproperly trained welders


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Shielded Metal Arc WeldingShielded Metal Arc Welding(SMAW)(SMAW)

An arc welding process that produces aAn arc welding process that produces acoalescence of metals by heating withcoalescence of metals by heating withan arc between a covered metalan arc between a covered metalelectrode and the work pieces.electrode and the work pieces.

-continued-

Stick Welding


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Shielded Metal Arc WeldingShielded Metal Arc Welding(SMAW)(SMAW)

Shielding is obtained fromShielding is obtained fromdecomposition of the electrodedecomposition of the electrodecovering.covering.

Filler metal is obtained from theFiller metal is obtained from the

electrode.electrode.

3


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Submerged Arc WeldingSubmerged Arc Welding(SAW)(SAW)

An arc welding process that usesAn arc welding process that usesan arc between a bare metalan arc between a bare metalelectrode and the weld pool. Theelectrode and the weld pool. Thearc and molten metal are shieldedarc and molten metal are shieldedby a blanket of granular flux.by a blanket of granular flux.

5


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Gas Metal Arc WeldingGas Metal Arc Welding

(GMAW)(GMAW)

An arc welding process that producesAn arc welding process that producescoalescence of metals by heatingcoalescence of metals by heatingthem with an arc between athem with an arc between acontinuous filler metal (consumable)continuous filler metal (consumable)electrode and the workelectrode and the work ..

MIG welding


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Gas Metal Arc WeldingGas Metal Arc Welding(GMAW)(GMAW)

Shielding is obtained entirely fromShielding is obtained entirely froman externally supplied gas or gasan externally supplied gas or gasmixturemixture ..

2


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Gas Tungsten Arc WeldingGas Tungsten Arc Welding(GTAW)(GTAW)

An arc welding process that producesAn arc welding process that producescoalescence of metals by heatingcoalescence of metals by heatingthem with an arc between a tungstenthem with an arc between a tungsten(non(non --consumable) electrode and theconsumable) electrode and thework piecework piece ..

-continued-

TIG welding


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Gas Tungsten Arc WeldingGas Tungsten Arc Welding(GTAW)(GTAW)

Shielding is obtained from anShielding is obtained from anexternally supplied gas or gasexternally supplied gas or gasmixture.mixture.


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Oxyacetylene WeldingOxyacetylene Welding(OAW)(OAW)

An oxyAn oxy --fuel gas welding processfuel gas welding processthat uses acetylene as the fuelthat uses acetylene as the fuelgas.gas.

4


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Base metalBase metal

The metal to be welded or cut. MayThe metal to be welded or cut. Maybe referred to as the work piece.be referred to as the work piece.


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Weld metalWeld metal

The portion of the base metal thatThe portion of the base metal thathas been melted during welding.has been melted during welding.


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HeatHeat --affected zone (HAZ)affected zone (HAZ)

That portion of the base metal that hasThat portion of the base metal that hasnot not been melted during welding, butbeen melted during welding, butwhose mechanical properties and/orwhose mechanical properties and/ormicrostructure have been altered by themicrostructure have been altered by theheat of welding or cutting.heat of welding or cutting.

2


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JointJoint

The junction of members or the edgeThe junction of members or the edgeof members that are to beof members that are to be

joined.Usually beveled or otherwise joined.Usually beveled or otherwisedesigned for welding.designed for welding.

V Groove or U Groove


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Butt weld (joint)Butt weld (joint)

A joint between two members alignedA joint between two members alignedapproximately in the same planeapproximately in the same plane ..


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Fillet weldFillet weld

A weld of approximately triangular crossA weld of approximately triangular crosssection joining two surfaces atsection joining two surfaces atapproximately right angles to eachapproximately right angles to eachother.other.

1


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Welding electrodeWelding electrode

A component of the welding circuitA component of the welding circuitthat terminates at the arc. Maythat terminates at the arc. Mayalso be the source of filler metal.also be the source of filler metal.

2


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PolarityPolarity

Manner in which the electrodeManner in which the electrodeholder and work piece connectionholder and work piece connectionare connected to the electricalare connected to the electricalsupply.supply.

-continued-


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PolarityPolarity

DCEN direct current electrodeDCEN direct current electrodenegative. (straight polarity)negative. (straight polarity)

DCEP direct current electrodeDCEP direct current electrodepositive. (reverse polarity)positive. (reverse polarity)


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Welding positionWelding position

flatflat horizontalhorizontal verticalvertical overheadoverhead

fixedfixed rolledrolled

3


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Weld passWeld pass

A single progression of weldingA single progression of weldingalong the joint. The result of a passalong the joint. The result of a passis a weld bead.is a weld bead.


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Stringer (root) beadStringer (root) bead

The first pass in the weld, usuallyThe first pass in the weld, usuallymade without any appreciablemade without any appreciableweaving motion.weaving motion.


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Hot passHot pass

The weld pass that immediatelyThe weld pass that immediatelyfollows the stringer (root) pass.follows the stringer (root) pass.


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Filler passesFiller passes

The weld passes that follow the hotThe weld passes that follow the hotpass and fill the weld groove flushpass and fill the weld groove flushor almost flush with the surface ofor almost flush with the surface ofthe work pieces.the work pieces.


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Cover passCover pass

The weld pass that finishes theThe weld pass that finishes thewelded joint. The cover bead iswelded joint. The cover bead ishigher than the adjacent surfacehigher than the adjacent surfaceand overlaps the grooveand overlaps the groove ..

1


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Arc burnArc burnA metallurgical notch, caused byA metallurgical notch, caused byground clamps or from striking anground clamps or from striking anarc on the base metal at any pointarc on the base metal at any pointother than:other than:

in the weld groove, orin the weld groove, orthe immediate surface next to thethe immediate surface next to thegroove that will be covered by thegroove that will be covered by theweld capweld cap

3


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WeldingWeldingWeldingSubpar t " E"ubpa r t " E"ubpa r t " E"

Not applicable to weldingduring manufacture

of pipe and components

Not applicable to weldingduring manufacture

of pipe and components


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192.225 WELDING192.225 WELDING - GENERALENERAL

Performed by aPerformed by a QualifiedQualifiedWelderWelder

UsingUsing QualifiedQualified WeldingWeldingProceduresProcedures

ProceduresProcedures QualifiedQualified bybyDestructive TestingDestructive Testing


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192.225 WELDING192.225 WELDING - GENERALENERAL

Qualified Procedure Qualified Procedure vs vs Qualified Welder Qualified Welder

qualified procedure test qualified procedure test verifies integrity/verifies integrity/metallurgy of that weldmetallurgy of that weld

qualified welder test qualified welder test verifies ability of thatverifies ability of thatwelderwelder


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192 .225 Weld ing proc edures192 .225 Weld ing proc edures

Welding Performed byWelding Performed byQualified WelderQualified WelderWelding ProceduresWelding ProceduresQualified Using APIQualified Using API1104 Section 5 or1104 Section 5 or

ASME B&PV Section IX ASME B&PV Section IXRecorded in Detail andRecorded in Detail andDestructively TestedDestructively TestedFollowed Whenever theFollowed Whenever theProcedure is UsedProcedure is Used


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COUPON TEST REPORT

DateLocationState

WelderWelding timeWelding temperatureWeather conditionsVoltageWelding machine typeFiller metalReinforcement sizePipe type and gradeWall thickness

Test No.

Weld Positions

Mark Time of dayWind break used

AmperageWelding machine size

Outside diameter

Roll Fixed

Coupon stenciled

Original specimen dimensions

Original specimen area

Maximum load

Tensile strength per square inch of plate areaFracture location

1 2 3 4 5 6 7

ProcedureWelder

Qualifying testLine test

QualifiedDisqualified

Maximum tensile

Remarks on tensile-strength tests1.2.3.4.

Remarks on bend tests1..2.3.4.Remarks on nick-break tests1.2.3.4.Test made at

Tested byNote: Use back for addition remarks. This form can be used to report either a procedurequalification test or a welder test.

Minimum tensile Average tensile

Date

Supervised by

Greater than or equal to 2 3/8 " (60.3 mm)but less than or equal to 4 1/2" (114.3 mm);also, less than or equal to 4 1/2" (114.3 mm)when all thickness is greater than1/2 " (12.7 mm)

Top of pipe Root orside bend

Nick-break

Root orside bend

Nick-break

Top of pipeNick-break

Rootbend

Under2 3/8"

(60.3 mm)

See Note 2

Top of pipe

TensileNick-break

Nick-break

Tensile

Root orside bend

Face orside bend

Face orside bend

Root orside bend

Top of pipe

Tensile

Nick-break

Nick-break

Tensile

Face or side bend

Face or side bend

Root or side bend

Greater than 12 3/4" (323.8 mm)

Nick-break

Tensile

TensileNick-break

Face or side bend

Root or side bend

Root or side bend

Root or side bend

Face or side bend

Notes:1. At the company's option, the locations may be rotated, provided they are equally spaced around the pipe; how-ever, specimens shall not include the longitudInal weld.2. One full-section tensile-strength test specimen may be used for pipe with a diameter less than or equal to 1 5/16inch (33.4 millimeters).

Greater than 4 1/2" (114.3 mm)

but less than or equal to12 3/4" (323.8 mm)


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Essen t ia l Var iab less sen t i a l Var i ab les -API 11 04 Proc .PI 110 4 Proc . Qualua l .

Joint Design (U or V groove)Joint Design (U or V groove)Position ( fixed or rolled,Position ( fixed or rolled,

horizontal or tilted)horizontal or tilted)

Wall Thickness GroupWall Thickness Group< 3/16 (.1875)< 3/16 (.1875)

3/16 3/16 -- 3/4 (.18753/4 (.1875 -- .750).750)> 3/4 (.750)> 3/4 (.750)


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Time Between PassesTime Between PassesMax time betweenMax time between

root and secondroot and second

Direction of weldingDirection of weldingUphill or downhillUphill or downhill


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Shielding Gas and Flow RateShielding Gas and Flow Rate

Shielding FluxShielding Flux

Speed of TravelSpeed of Travel

Filler MetalFiller MetalGroupGroup

AWSSpecification

Electrode

1 A5.1A5.5

E6010 E6011E7010 E7011

2 A5.5 E8010 E8011

3 A5.1 or A5.5

A5.5

E7015 E7016E7018E8015 E8016

E8018

Group


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192 .227 Qua l i f i ca t ion92 .227 Qua l i f i ca t ionof Weld ersf Welde rs

Section 6 of API Standard 1104Section 6 of API Standard 1104

Section IX of ASME Boiler and PressureSection IX of ASME Boiler and Pressure Vessel Code Vessel Code

Less than 20% SMYSLess than 20% SMYS -- Appendix C Appendix C


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192 .227 Qua l i f i ca t ion92 .227 Qua l i f i ca t ionof Weld ersf Welde rs

Welder Qualified under Earlier Edition of Welder Qualified under Earlier Edition of API 1104 or ASME Section IX API 1104 or ASME Section IX ------

May Continue to WeldMay Continue to Weld

May Not Requalify underMay Not Requalify underthat Editionthat Edition


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Qual i f i ed Weld ersua l i f i ed Welder s

Must Must have funny looking hatshave funny looking hatsMust Must havehavehelpershelpersMust Must havehave

BBQ grillsBBQ grills


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API 11 04PI 1 10 4 - We l de r Si ng l ee lder Sing leQua l i f i c a t ion (Bu t t o r Fi l l e t )ua l i f i c a t i on (Bu t t o r Fi l l e t )

If Qualified on ButtIf Qualified on ButtWelds in Fixed PositionWelds in Fixed Position@ 45 Angle, Qualified@ 45 Angle, Qualified

for Butt Welds and Lapfor Butt Welds and LapFillet Welds in allFillet Welds in allPositionsPositions


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Essen t i a l Var iab less sen t i a l Var i ab le s -Welder Sing le Qual i f i c a t ione lde r Sing le Qua l i f i c a t ion

Change inChange in any oneany one of:of:ProcessProcessDirection of WeldingDirection of Welding

FillerFiller--metal Classificationmetal ClassificationOutside Diameter GroupOutside Diameter GroupWall Thickness GroupWall Thickness Group

PositionPositionJoint DesignJoint Design


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API 11 04PI 11 04 - Weldere lde rMult ip le Qua l i f i c a t i onu l t i p le Qua l i f ic a t i on

Butt Weld Must Be MadeButt Weld Must Be Madeon Pipe at Least 6.625 on Pipe at Least 6.625 (12.75" qualifies for(12.75" qualifies for allall diasdias .).)

Branch Must Be of PipeBranch Must Be of Pipeat Least 6.625 at Least 6.625

Butt Weld Made in FixedButt Weld Made in FixedHorizontal or 45 AngleHorizontal or 45 AnglePositionPosition

ld


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API 11 04PI 11 04 - Weldere lde rMult ip le Qua l i f i c a t i onu l t i p le Qua l i f ic a t i on

Cut FullCut Full --Size HoleSize Holein Run Pipein Run Pipe

Run Pipe Shall BeRun Pipe Shall BeHorizontalHorizontal

Branch Shall ExtendBranch Shall Extend Vertically Downward Vertically Downward

From Run PipeFrom Run Pipe


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Essen t i a l Var iab less sen t i a l Va r i abl e s -Welde r Mul t ip le Qua l i f i c a t ione lde r Mul t ip l e Qua l i f i c a t ion

Change in weldingChange in weldingprocessesprocesses

Change in directionChange in directionof weldingof welding

Change in filler metalChange in filler metalclassificationsclassifications

192 229 Li i i92 229 Li i i


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192 .229 Lim i t a t i ons on92 .229 L im i t a t i ons onWelderse lde rs

Welder whose qualification is based onWelder whose qualification is based onnondestructive testing may not weld onnondestructive testing may not weld oncompressor station pipe and componentscompressor station pipe and components

Must weld in particular process within everyMust weld in particular process within every6 calendar months6 calendar months

192 229 Addi i l92 229 Addi t i l


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192 .229 ~ Addi t iona l92 .229 ~ Addi t iona lL i m i t a t i o n si m i t a t i o n s

Welder qualified under Section 6 of APIWelder qualified under Section 6 of API1104 or Section IX of ASME1104 or Section IX of ASME

To weld on pipe operating atTo weld on pipe operating at 20%20%SMYS or moreSMYS or more , must have weld tested:, must have weld tested:

Every 6 months per API 1104Every 6 months per API 1104Section 6 or 9, orSection 6 or 9, or

Twice each CY at intervalsTwice each CY at intervalsNot exceeding 7Not exceeding 7 --1/2 months1/2 months

192 229 Addi i l92 229 Addi t i l


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Welder qualified under Section 3 of APIWelder qualified under Section 3 of API1104 or Section IX of ASME1104 or Section IX of ASME

To weld on pipe operatingTo weld on pipe operating < 20 % SMYS< 20 % SMYS , must:, must: Have weld tested every 6 monthsHave weld tested every 6 months

per API 1104 Section 6 or 9, orper API 1104 Section 6 or 9, or Requalify under Appendix C everyRequalify under Appendix C every

calendarcalendar year n.t.e. 15 months, oryear n.t.e. 15 months, or Cut out and test a production weldCut out and test a production weld

twice each calendar yeartwice each calendar year

192 229 Addi t i l92 229 Addi t i l


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Welder qualified under Appendix CWelder qualified under Appendix C MustMust requalifyrequalify under Appendix C everyunder Appendix C every

calendarcalendar year n.t.e. 15 months, oryear n.t.e. 15 months, or Must cut out and test a production weldMust cut out and test a production weld

twice each calendar yeartwice each calendar year (interval(interval

cannot exceed 7 1/2 months), orcannot exceed 7 1/2 months), or For service lines 2 inches and smallerFor service lines 2 inches and smaller

only, 2 welds tested per App. C, Sec. IIIonly, 2 welds tested per App. C, Sec. III


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192 .233 Mi t e r J o in t s192 .233 Mi t e r J o in t s

30% or more SMYS,30% or more SMYS,Maximum of 3Maximum of 3

10%


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192 .235 Prepara t ion fo r Weld ing192 .235 Prepara t ion fo r Weld ing

Before beginning any welding, theBefore beginning any welding, thewelding surfaces must be clean andwelding surfaces must be clean andfree of any material that may befree of any material that may be

detrimental to the weld, anddetrimental to the weld, and

Must be aligned to provide the mostMust be aligned to provide the mostfavorable condition for depositing thefavorable condition for depositing theroot bead. This alignment must beroot bead. This alignment must bepreserved while root is deposited.preserved while root is deposited.


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192.241192.241 I n sp e c t i o n a n d Te st o fn s pe c t i o n a n d Te st o fWeldse lds

Visual inspection (by individual qualified Visual inspection (by individual qualifiedby training & experience) of theby training & experience) of theWELDINGWELDING must be donemust be doneto insureto insure ----

Welding is done accordingWelding is done accordingto procedure, andto procedure, and

Weld is acceptableWeld is acceptableper API 1104 Section 9.per API 1104 Section 9.


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192 .243 Nondes t ruc t ive Tes t ing192 .243 Nondes t ruc t ive Tes t ing

NDTNDT must be performed:must be performed:In accordance withIn accordance withwritten procedures;written procedures;andand

By persons trainedBy persons trainedand qualified in theand qualified in theprocedures andprocedures andwith the equipmentwith the equipmentbeing utilizedbeing utilized


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192 .243 Nondes t ruc t i ve Tes t i ng192 .243 Nondest ruc t i ve Tes t i ng

Procedures must be established forProcedures must be established forinterpretation of each test tointerpretation of each test toensure acceptabilityensure acceptability

of the weld perof the weld per API 1104 Section 6 API 1104 Section 6 ..


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192 .243 Nondes t ruc t i ve Tes t i ng192 .243 Nondest ruc t i ve Tes t i ng

Must test some of each welders work Must test some of each welders work each dayeach dayMust retain for life;Must retain for life;

Record by milepost, engineering station,Record by milepost, engineering station,etc.;etc.;

II Num ber of weldsNum ber of w eldsII Num ber testedNum ber testedII Num ber rejectedNum ber rejectedII Disposition of rejectsDisposition of rejects


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l f f192 245 R i R l f D f


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192 .245 Repa i r o r Rem oval o f Defec t s192 .245 Repa i r o r Rem oval o f Defec t s

Repair of a crack or defectRepair of a crack or defectin a previously repaired areain a previously repaired areamust be done in accordancemust be done in accordance

with written repair procedureswith written repair proceduresthat have been qualifiedthat have been qualifiedunderunder 192.225192.225

Arc Burn

19 2 309 R i f St l Pi192 309 R i f St l Pi


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19 2.309 Repa i r o f St ee l Pipe192 .309 Repa i r o f St ee l Pipe

(c) Each arc burn on steel pipe(c) Each arc burn on steel pipeto be operatedto be operated 40% SMYS 40% SMYSmust be repaired or removed.must be repaired or removed.

If repaired by grinding, mustIf repaired by grinding, mustcheck remainingcheck remaining w.tw.t . .. .Use dilute solution of Use dilute solution of ammoniumammonium persulfatepersulfate to check to check

Arc Burn


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Appe ndix C Bas i c Tes tppen d ix C B a si c Test

Test on pipe 12 orTest on pipe 12 orsmallersmallerWeld in horizontal,Weld in horizontal,

fixed positionfixed positionWeld according to aWeld according to aqualified, writtenqualified, writtenprocedureprocedure


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What shou ld s t a t e /federa lha t shou ld s t a t e /f ede ra li n sp e c t o r s o r o p er a t o r s c h e c k f orn s pe c t o r s o r o p er a t o r s c h e c k f o r


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i n sp e c t o r s o r o p er a t o r s c h e c k f orn s pe c t o r s o r o p er a t o r s c h e c k f o rc om pl i anc e r ega rd ing Subpar t E?om pl ianc e r ega rd ing Subpar t E?

Adherence to welding procedures/ Adherence to welding procedures/code requirements/housekeeping duringcode requirements/housekeeping duringfield weldingfield welding

Use of N.D.T. / qualifications of N.D.T.Use of N.D.T. / qualifications of N.D.T.technicianstechniciansSpecial procedures for hot or repairSpecial procedures for hot or repair

weldingweldingRepair criteria for defective weldsRepair criteria for defective weldsMaintenance of required recordsMaintenance of required records

welding subparte

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