CODE, STANDARD,
WELDING PROCEDURE &
WELDER QUALIFICATION
Dr. Ir. Winarto, M.S c.
DEFINISI
DEFINISI
Contoh Specification :
Filler Metal Specification (AWS A5.X)
Material & Consumable of Welding (ASME sec. IIC)
CONTOH APLIKASI
ASME Sec VIII
ASME
B31.3
AWS D1.1
CONTOH APLIKASI
API 6A Crismas Tree
/ Well Head
Refinery / Kilang/
Processing Plant
AWS
AWS
AWS
AWS
AWS
AWS
D l.1,
D l.2,
D l.3,
D l.4,
D l.5,
D l.6,
ASME STANDARD
API - STANDARD
Examination and
Testing
ASM E V
Quality of
Welds
Welding Personnel
And Welding
Procedure
ASM E IX
Welding Material
ASM E II C
10
11
Table 1 Examples of application codes and standards and related welding procedure and welder approval standards
Welding S tandard
Procedure
Welder
approval
approval
Application
Application
code/standard
Pressure
Vessels
B S 5500
ASME VIII
B S EN 288
ASME IX
B S EN 287
ASME IX
Process
Pipe-work
B S 2633
B S 4677
ANSI/ASME B 311
ANSI/ASME
B 31.3
B S 2971
B S EN 288 (Part 3)
B S EN 288 (Part 4)
ASME IX
ASME IX
B S EN 288 (Part 3)
(if required)
B S EN 287 (Part 1)
B S EN 287 (Part 2)
ASME IX
ASME IX
B S 4872/BS EN 287
S tructural
Fabrication
AWS D1.1
AWS D1.2
B S 5135
B S 8118
AWS D1.1
AWS D1.2
B S EN 288 (Part 3)
B S EN 288 (Part 4)
AWS D1.1
AWS D1.2
B S EN 287
B S EN 287
B S 4872
S torage
Tanks
B S 2654
B S 2594
API 620/650
B S EN 287
B S EN 287
ASME IX
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pWPS
pWPS
Preliminary
Preliminary
W
ication
Welding
eldingProcedure
ProcedureSpecif
Specification
Welders
Welders approval
approval
WAR
WAR
Approval
Approvalof
ofwelding
weldingprocedure
procedure
Testwelding
Testwelding
Testing
Testing
Reporting
Repor ting
WPAR
WPAR
WPS
WPS
Approved
Approvedconsumables
consumables
Ex
Experience
perience
Required
Required
Approvals
Approvals
Available?
Available?
Standard
Standardprocedure
procedure
Pre-production
Pre-productiontests
tests
Yes
Yes
Welding
WeldingProcedure
ProcedureSpecification
Specification
PRODUCTION
PRODUCTION
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Why a WPS
A weld cannot be checked to the full extent!
strength, ductility and corrosion resistance can
only be checked by destructive techniques.
properties can only be guaranteed for the
actual product when manufactured to
exactly the same written procedure,
and carefully controlled.
Why a WPS
The main objective of a
WPS is to make a
welding operation
reproducable
14
Methods of approval
welding procedure tests -
EN 288 part 3 or 4
EN 288 part 6
EN 288 part 7
EN 288 part 8
Acceptance criteria
Strength
according to parent metal
Impact requirements
(temperature, energy)
according to the design requirements
(and application standard)
15
Additional tests
Such tests may include:
16
Material groups
The use of particular method of approval
of a WPS is often a mandatory requirement of an application standard.
In the absence of such a requirement the
method of approval shall be agreed between the contracting parties at the
enquiry or at the order stage.
Approval of WPS
Preliminary welding procedure
specification
( pWPS )
Approval on the pWPS by a method
acc. to EN 288 part 3/4, 5, 6, 7 or 8
Approved welding procedure
specification
( WPS )
17
18
Welders approval
The welder who undertakes the
welding procedure test satisfactory,
is approved for the appropriate
range of approval given in the
relevant part of EN 287
Re - testing
If the test piece fails to comply with any of the
requirements for visual examinaton or NDE,
one further test piece shall be welded
and subjected to the same examination.
If this additional test piece does not comply with
the relevant requirements, the pWPS shall be
regarded as not capable of complying with the
requirements of this standard without
modification.
19
Re - testing
If any test specimen fails to comply with the
relevant requirements only due to geometric
weld imperfections, two further test specimens shall be obtained for each one that failed.
These can be taken from the same test piece
if there is sufficient material available or from
a news test piece, and shall be subjected to the
same test.
Re - testing
If either of these additional test specimens
does not comply with the relevant requirements, the pWPS shall be regarded as
not capable of complying with the requirements of this standard without modification.
20
Range of approval
An approval of a WPS obtained by a
manufacturer is valid for welding in
workshops or sites under the same
technical and quality control of
that manufacturer.
Essential variables
Process: 111; 114; 131; 135; 136; 137; 141
Material: group 1, 9
(EN 288-3)
group 21, 22a, 22b (EN 288-4)
Parent metal thickness:
Size of fillet weld:
Pipe diameter:
3 - 40 mm
3 mm
> 25 mm
21
Previous experience
A manufacturer may have a pWPS approved by referring to previous experience on
condition that he can prove by appropiate documentation of an independant
nature that he has previously satisfactorily
welded the type of joint and materials in
question
22
Previous experience
Previous experience shall involve:
Satisfactory documentation of tests (e.g. nondestructive, destructive, leak or pressure
tests) in all cases.
AND
A summary of welding manufacturing of at
least one year during an appropriate period
(5 years)
OR
Suitability of welds in service for an appropriate period (5 years)
23
Essential variables
Process: 111; 114; 131; 135; 136; 137; 141
Material: group 1, 9
(EN 288-3)
group 21, 22a, 22b (EN 288-4)
Parent metal thickness:
Size of fillet weld:
Pipe diameter:
3 - 40 mm
3 mm
> 25 mm
24
25
Content of a WPs
preparation of the components to be welded
assembling of components for welding
welding process
post work of the welded connections
(e.g.grinding)
heat treatment (during fabrication/finalizing)
Material groups
a procedure test with one steel of a group covers the lower alloyed steels of the same
group or the steels with equal or lower specified yield strength of this group
as long as the welding consumables used for
the test can also be used for the steels of this
group
group 2 covers group 1
26
WPAR
Welding Procedure Approval Record
(WPAR)
The welding procedure approval record WPAR)
is a statement of results of assessing each test
piece including re-tests.
It shall be signed by the examiner or test body
Pressure vessel
The welding procedure tests for pressure vessels
are detailed in the AD-Merkblatt HP 2/1.
Welding and testing must be witnessed by the
authorised Inspector.
The results of the procedure qualification testing
shall be available prior to the production.
The qualification is based on
EN 288-3
EN 288-4
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Pressure vessel
Additional requirements are given for:
material groups
welding positions
amount of testing
approval requirements for testing
Production tests
The number of the test pieces and the type of destructive and non-destructive testing depends on:
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Summary
Which possibilities of approval of welding
procedures are available ?
What are the limits of these possibilities ?
Which important essential variables are
included in the WPS ?
What type of test pieces are standard types
according to EN 288-3 ?
Which tests (non destructive or destructive)
are necessary for EN 288-3 ?
Summary
W h at a r e th e a cc e p t a n c e c rit er ia fo r the
w el de d jo in t o f th e p r o du c tio n te s t ?
W h at e a s e g iv e s th e g r ou p in g s ys tem fo r
st e e l a c c o r di ng to E N 2 8 8- 3 ?
W h at a r e th e ra n g e s o f ap p r o v a l for th ic k ne s s a n d d ia m ete r ?
W hic h c h a n ge s to E N 2 88 - 3 ar e m a d e in th e
G er m a n s t a n d ar d s a n d r e g ula tio n s ?
W ha t is th e s e n s e o f a p r o d u c t io n te s t ?
29
Production tests
The requirements of
production tests in the field of
steel structures
are given in guideline
DV S 170 2.
For aluminium and aluminium
alloys the DIBt guid eline is
app lica ble
Steel structures
B a se d o n th e re q u ir e m e n ts o f D I N 1 8 8 0 0 T e i l 7 ,
w e ld in g p ro c e d u r e t e st s fo r s te e l st ru c tu r e s a re
re q u ir e d if :
a)
f u lly m e c h a n iz e d p ro c e ss e s a re u s e d
b)
f in e g ra in s te e ls w ith a yie ld s tr e n g h t
2
( R e ) > 36 0 N/m m ar e u se d
W e ld in g a n d te s tin g h a s to b e p e rf o rm e d u n d e r t h e
w it n e ss o f a re p r e se n ta t ive o f t h e a c cre d e te d in sp e c t io n a u t h o ra t y f o r t h e c o m p re h e n sive f o rm o f v e rific a t io n .
30
Steel structures
F or the fully m ec hanized processes and for
fine grain steels with (Re) > 360 N/m m 2 ,the
requirements of E N 288-3 are applicabl e.
Exception s:
F illet w eld s are not covered by butt welds.
W elding and testing of fill et welds has to be d one in accordance w ith G uideline DV S 1702
(cruziform test).
Aluminium structures
Welding procedure tests for aluminium
structures must be performed in accordance with the guideline of the German
Institute of Structural Engineering (DIBt)
For butt welds the guideline is based on
EN 288-4
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Fabrication
of Pipes
Welding
Eng
WPS
Technology
turer
WPQR
Manufac
Material
Selection
Science
der
Operation
Requiremen
t
Wel
Standard
Welding Application
Inspection
Welding
Inspect
Project Eng
PENGELASAN PIPA
WELDING PROCEDURES
Dokumentasi ( Record)
Detail mengenai p rosedur haru s d idokumentasi (record) yang berisi
hasil lengkap tentang procedure qualification test.
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Shielding Flux
Speed of T ravel in in ch per
minute
Range of Pipe
Wall Thickness
Number
of Layers
Remark
3/8 to 5/8 in
5/8 to 7/8 in
3
2
1
7/8 to 1 1/8
in
4
3
2
1
1 = Rott pass
2 = Cover pass
1 = Root pass
2 = Hott pass
3 = Cover pass
1
2
3
4
=
=
=
=
Root pass
Hott pass
Filler pass
Cover pass
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.
Filler Pass
3/16 Electrode
180 - 190 A DC +
Cover Pass
3/16 Electrode
160 - 190 A DC +
Base Metal
Hot Pass
5/32 Electrode
170 - 200 A DC +
Root/Stringer Bead
5/32 Electrode
135 - 175 A DC +
SPEED OF TRAVEL
Layer
Trav el Speed,
Cm/Minute
Root Pass
7.5 - 20
Hot Pass
7.5 - 20
Filler Pass
12.5 - 25
Cov er Pass
12.5 - 25
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FILLER METAL
.
Filler Metal Group
Group
1
2
3
AWS
Specificatio
n
A5.1
E6010, E6011
A5.5
E7010, E7011
A5.5
Current
A
Votage,
Arc Volt
3/32
40 - 80
23 - 25
1/8
75 - 125
24 -
E8010, E8011
5/32
110 - 170
26
A5.1 or 5.5
3/16
140 - 215
24 - 26
A5.5
7/32
170 - 250
26 - 30
1/4
210 - 320
26 - 30
5/16
275 - 425
28 - 34
A5.17
4
Electrode
28 - 34
Preheating Method
Furnace Heat Treatment
Preheating Reaquired
Up to 0.45
Preheat optional
0.45 to 0.60
Over 0.60
Preheating Temperatur, oC
Induction Heating
Below 0.2
Torch Heating
0.20 - 0.30
93 - 150
Resistance Heating
0.30 - 0.45
150 - 260
Exothermal Heating
0.45 - 0.80
260 - 425
Up to 93
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Equipment
Electric induction
Required when
Electric resistance
Fuel-fired torch
Temperature Controller
work-piece
Thermocouple pyrometer
Stress-Relief Time & Temperature for Carbon
Steel
Metal Temp.
oC
593
565
538
510
482
10
METHODS OF INSPECTION
NDT
Visual
Radiographic Testing
Magnetic Particle Testing
Liquid Penetrant Testing
Ultrasonic Testing
The method use d shall pr oduce
indications of defects that ca n be
accurately interpreted and evaluated.
Qualification of Inspection Personnel
Weldi ng i nspection personnel shall
be qualified by ex perie nce a nd
training
for
the
specified
inspection task they performed.
Radiographic testing
least by Level I
pe rformed at
or
navigable
river,
36
BASIC CONCEPT
Preparation
Radiographic
Test
Interpretation
and Evaluation
Acceptanc
e
Yes
Welding is Perfect
No
Repair
Terima Kasih
37