WELDING CODE, STANDARD

& WELDING PROCEDURE

Dr. Ir. Winarto, M.Sc.

DEPARTEMEN METALURGI & MATERIAL

FAKULTAS TEKNIK UNIVERISTAS INDONESIA

DEFINISI
n “Standard
Standard”” adalah kumpulan dokumen
dokumen-- dokumen berisikan
kode (codes), spesifikasi (specification), Saran aplikasi
(recommended practice), klasifikasi
klasifikasi,, dan petunjuk (guide)
yang telah dipersiapkan oleh suatu institusi organisasi dan di
sahkan (approved) sesuai dengan prosedur yang ada
(berlaku
berlaku).
).

n “Codes
Codes”” adalah suatu standard yang berisikan kondisi dan
persyaratan yang berhubungan dengan bidang khusus (a
particularly subject) dan mengindikasikan bahwa prosedur
yg digunakan telah sesuai dengan persyaratannya
persyaratannya.. Codes ini
HARUS diikuti (mandatory) karena menyangkut
kepentingan umum yang merefer kepada kebijakan otoritas
pemerintahan.. (Codes
pemerintahan (Codes is a body of laws arranged
systimatically for easy reference)

1
 DEFINISI
n “Specification
Specification”” (spesifikasi
spesifikasi)) adalah suatu
standard yang berisikan penjelasan yang rinci
dan akurat tentang persyaratan teknis dari
material, produk
produk,, sistim atau jasa
jasa..
n Contoh Kode :
– Structural Welding Code-
Code-Steel (AWS D1.1)
– Boiler & Pressure Vessel Code (ASME)
– Welded Pipeline & Vessel (API)
n Contoh Specification :
– Filler Metal Specification (AWS A5.X)
– Material & Consumable of Welding (ASME sec. IIC)

AWS – Structural Welding Code

n AWS D l.1, Structural Welding Code—

Code—Steel
n AWS D l.2, Structural Welding Code—
Code—Aluminum
n AWS D l.3, Structural Welding Code—
Code—Sheet Steel
n AWS D l.4, Structural Welding Code—
Code—Reinforcing Steel
n AWS D l.5, Bridge Welding Code
n AWS D l.6, Structural Welding Code—
Code—Stainless Steel

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Welding Code – Steel (AWS D.1.1)

3
4
 ASME STANDARD

API - STANDARD
n API 1104, Standard for Welding Pipeline
and Related Facilities
n API 620, Recommended Rules for Design
and Construction of Large Welded Low-
Low-
Pressure Storage Tanks
n API 650, Standard for Welded Steel Tank
for Oil Storage

5
Persyaratan Dasar dalam Menentukan
Kualitas dalam Pengelasan

Standar Eropa dan Amerika

dalam mendukung Kualitas Lasan

n ASME (American Society of Mechanical

Engineers)
n EN (European Norm) / European Standard
n AWS (American Welding Society )

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 ASME Standard untuk Welding

n ASME Sec IX (Qualification Standard for

Welding and Brazing Procedure, Welder,
and Welding & Braze Operator.
n ASME Sec II C Standard for Material and
Consumable of Welding.

STANDARD KUALITAS LAS dari ASME

Basic
BasicConstruction
ConstructionCode
Code//Standard
Standard::
•ASME
•ASMESec
SecI,I,ASME
ASMEB31.1
B31.1,,ASME
ASMEB31.3
B31.3
•ASME
•ASMESec
SecVIII
VIIIDiv
DivII&&22

Examination
Examinationand
and Welding
WeldingPersonnel
Personnel
Testing
Testing And Welding
Quality of And Welding
••ASME Procedure
ASME VV Welds Procedure
••ASME
ASMEIX
IX

Welding
WeldingMaterial
Material
••ASME
ASMEIIIICC

7
European Standard For Welding

n EN 288 (Standard & Qualification Welding

Procedure)
n EN 287 ( Standard & Qualification of
Welder)
n EN 1418 ( Standard & Qualification of
Welding Operator )

STANDARD KUALITAS LAS dari EN

8
 PROSEDUR LAS - EN 288
n EN 288 - 1 . General rules fusion welding.
n EN 288 - 2. WPS for Arc Welding
n EN 288 - 3. Welding procedure test for Arc welding of
steel.
n EN 288 - 4. Welding Procedure Test for Arc welding
of Aluminum and It’
It’ s alloys
n EN 288 - 5. Approval by using approved welding
consumables for arc welding
n EN 288 - 6. Approval related to previous experience
n EN 288 - 7. Approval by a standard welding procedure
for arc welding
n EN 288 - 8. Approval by a pre-
pre-production welding test.

KUALIFIKASI WELDER - EN 287

n EN 287 - 1 . Approval testing of welders – Fusion welding
part 1 : Steels.
n EN 287 - 2. Approval testing of welders – Fusion welding
part 2 : Aluminum and aluminum Alloys.
n EN 287 - 3. Approval testing of welders – Fusion welding
part 3 : Copper and Copper Alloys.
n EN 287 - 4. Approval testing of welders – Fusion welding
part 4 : Nickel and Nickels alloys
n EN 287 - 5. Approval testing of welders – Fusion welding
part 5 : Titanium and Titanium, Zirconium and Zirconium
alloys
n EN 288 - 6. Approval related to previous experience
n EN 288 - 7. Approval by a standard welding procedure for arc
welding
n EN 288 - 8. Approval by a pre-
pre-production welding test.

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Table 1 Examples of application codes and standards and related welding procedure and welder approval standards

Welding Standard
Application
Application Procedure Welder
code/standard
approval approval
Pressure BS 5500 BS EN 288 BS EN 287
ASME VIII ASME IX ASME IX
Vessels
Process BS 2633 BS EN 288 (Part 3) BS EN 287 (Part 1)
BS 4677 BS EN 288 (Part 4) BS EN 287 (Part 2)
Pipe-work ANSI/ASME B311 ASME IX ASME IX
ANSI/ASME ASME IX ASME IX
B31.3 BS EN 288 (Part 3) BS 4872/BS EN 287
BS 2971 (if required)
Structural AWS D1.1 AWS D1.1 AWS D1.1
AWS D1.2 AWS D1.2 AWS D1.2
Fabrication BS 5135 BS EN 288 (Part 3) BS EN 287
BS 8118 BS EN 288 (Part 4) BS EN 287
BS 4872
Storage BS 2654 BS EN 288 (Parts 3 & 4) BS EN 287
BS 2594 BS EN 288 (Parts 3 & 4) BS EN 287
Tanks API 620/650 ASME IX ASME IX

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.

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 Why a WPS

The main objective of a

WPS is to make a
welding operation

reproducable

What is a WPS ?
The welding procedure is somewhat
analogous to a cook's recipe.

It outlines the steps required to make a quality

weld under specific conditions.

The WPS is a communication tool, and it is the

primary means of communication to all the
parties involved regarding how the welding is
to be performed.
It must therefore be readily available to
foremen, inspectors and the welders.

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 What is a WPS ?
According to QW-100.1 ASME Sec IX.
Welding Procedure Specification (WPS).
WPS is a written document that provides direction to the
welder or welding operator for making production welds
in accordance with Code requirements.

According to QW-200.2 ASME Sec IX.

Procedure Qualification Record (PQR).
A PQR is a record of the welding data used to weld a test
coupon. The PQR is a record of variables recorded
during the welding of the test coupons. It also contains
the test results of the tested specimens. Recorded
variables normally fall within a small range of the actual
variables that will be used in production welding.

What is WPS Variables ?

Process (SMAW, FCAW, etc.)
Electrode specification (AWS A5.1, A5.20, etc.)
Electrode classification (E7018, E71T-1, etc.)
Electrode diameter (1/8 in., 5/32 in., etc.)
Electrical characteristics (AC, DC+, DC-)
Base metal specification (A36, A572 Gr50, etc.)
Minimum preheat and interpass
temperature
Welding current (amperage)/wire feed speed
Arc voltage
Travel speed
Position of welding
Post weld heat treatment
Shielding gas type and flow rate
Joint design details

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 What is Variales in WPS ?
1. Essential Variable :
QW-401.1 Essential Variable (Procedure).
A change in a welding condition which will affect the
mechanical properties (other than notch toughness) of the
weldment (for example, change in P-Number, welding
process, filler metal, electrode, preheat or postweld heat
treatment, etc.).
QW-401.2 Essential Variable (Performance).
A change in a welding condition which will affect the
ability of a welder to deposit sound weld metal (such as a
change in welding process, deletion of backing, electrode,
F-Number, technique, etc.).

What is Variales in WPS ?

2. Supplemental Essential Variable :
QW-401.3 Supplemental Essential Variable (Procedure).
A change in a welding condition which will affect the notch-
toughness properties of a weldment (for example, change in
welding process, uphill or down vertical welding, heat input,
preheat or PWHT, etc.).
When a procedure has been previously qualified to satisfy all
requirements other than notch toughness, it is then necessary
only to prepare an additional test coupon using the same
procedure with the same essential variables, but additionally
with all of the required
supplementary essential variables, with the coupon long
enough to provide the necessary notch-toughness specimens.

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 What is Variales in WPS ?
3. Nonessential Variable :

QW-401.4 Nonessential Variable (Procedure).

A change in a welding condition which will not affect the

mechanical properties of a weldment (such as joint design,
method of back gouging or cleaning, etc.)

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 ASME SECTION IX MATERIAL GROUPING P-NUMBERS

The material group are based on comparable base material

characteristics, such as composition, weldability, braze-ability,
and mechanical properties.

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 P No. EN-288 Base Metal
Carbon Manganese Steels, 4 Sub Groups
Group 1 up to approx 65 ksi
1 1 Group 2 Approx 70ksi
Group 3 Approx 80ksi
Group 4 Special (e.g. SA-724 gr. A, B, C)
2 - Not Used
ASME & EN 3 4 3 Sub Groups:- Typically half moly and half chrome half moly
4 5 2 Sub Groups:- Typically one and a quarter chrome half moly

MATERIAL 5A 5 Typically two and a quarter chrome one moly

2 Sub Groups:- Typically five chrome half moly and nine chrome
5B 5
one moly
P NUMBER 5C 6 5 Sub Groups:-Chrome moly vanadium
6 8 6 Sub Groups:-Martensitic Stainless Steels Typically Grade 410
7 8 Ferritic Stainless Steels Typically Grade 409
Austenitic Stainless Steels, 4 Sub groups
Group1 Typically Grades 304, 316, 347
8 9 Group 2 Typically Grades 309, 310
Group 3 High manganese grades
Group 4 Typically 254 SMO type steels
9A, B, C 7 Typically two to four percent Nickel Steels
10A,B,C,F,G ? Mixed bag of low alloy steels, 10G 36 Nickel Steel
10 H 10 Duplex and Super Duplex Grades 31803, 32750
10J ? Typically 26 Chrome one moly
11A Group 1 7 9 Nickel Steels
11 A Groups 2 to
? Mixed bag of high strength low alloy steels.
5
11B ? 10 Sub Groups:- Mixed bag of high strength low alloy steels.

ASME F Numbers
F No. General Description
1 Heavy rutile coated iron powder electrodes :- A5.1 : E7024
2 Most Rutile consumables such as :- A5.1 : E6013
3 Cellulosic electrodes such as :- A5.1 : E6011
4 Basic coated electrodes such as : A5.1 : E7016 and E7018
5 High alloy austenitic stainless steel and duplex :- A5.4 : E316L-16
6 Any steel solid or cored wire (with flux or metal)
2X Aluminium and its alloys
3X Copper and its alloys
4X Nickel alloys
5X Titanium
6X Zirconium
7X Hard Facing Overlay

Note:- X represents any number 0 to 9

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ASME Welding Positions
Note the welding progression, (vertically upwards or downwards), must always be stated and it is an essential variable for
both procedures and performance qualifications.
Welding Positions For Groove welds:-
Welding Position Test Position ISO and EN
Flat 1G PA
Horizontal 2G PC
Vertical Upwards Progression 3G PF
Vertical Downwards Progression 3G PG
Overhead 4G PE
Pipe Fixed Horizontal 5G PF
Pipe Fixed @ 45 degrees Upwards 6G HL045
Pipe Fixed @ 45 degrees Downwards 6G JL045
Welding Positions For Fillet welds:-
Welding Position Test Position ISO and EN
Flat (Weld flat joint at 45 degrees) 1F PA
Horizontal 2F PB
Horizontal Rotated 2FR PB
Vertical Upwards Progression 3F PF
Vertical Downwards Progression 3F PG
Overhead 4F PD
Pipe Fixed Horizontal 5F PF

POSISI LAS - ASME IX

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ASME
WELDING
POSITION

POSISI LAS - EN 288

18
WELD
POSITION
EN-287

POSISI LAS - AWS

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 CONTOH TAHAPAN PROSES
PENGELASAN PIPA
.

. Operation
WELDING AND JOINING
Operation

Project Eng
Requirement
Requirement

Material
Material
Science Selection
Selection

WPQR
WPQR

Welding
Eng
Technology WPS
WPS

Manufac
Fabrication

turer
Fabrication
of
of Pipes
Pipes
Standard

Wel
der
Welding
Welding Application
Application

Welding
Inspect
Inspection
Inspection

WELDING PROCEDURES
WPQR AND WPS
WELDING AND JOINING

n Kualifikasi Prosedur (Procedure Qualification)

Ä Sebelum mengelas komponen (pipa atau lainnya) umumnya
prosedur pengelasan (welding procedure) harus dibuat dan
dikualifikasi.

n Dokumentasi (Record)
Ä Detail mengenai prosedur harus didokumentasi (record) yang berisi
hasil lengkap tentang “procedure qualification test”.

n Kualifikasi Operator Las (Qualification of Welders)

Ä Setiap welder atau operator las harus dikualifikasi menurut
prosedur baku sebelum melakukan pengelasan komponen (pipa
atau lainnya). Tujuannya adalah untuk menentukan kemampuan
operator las (welder) dalam menghasilkan lasan yang baik tanpa
cacat dengan menggunakan prosedur sebelumnya yang telah lulus
qualifikasi.

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 ISI WELDING PROSEDUR
WPQR AND WPS

¥ Process è Manual, Semi-or ¥ Time Between Passes è Max

WELDING AND JOINING
automatic welding process
¥ Pipe and Fitting Material è API
5L or ASTM
¥ Diameter and Wall Thickness
¥ Joint Design
¥ Filler Metal and Number of Bed
è The size and classification
number of the filler metal and
minimum number and sequence
of bead
¥ Electrical Characteristics è The
range of voltage and amperage
¥ Position è Roll or fix
¥ Direction of Welding è Uphill or
downhill
time between completion of the
root bed and start of the second
and other bed
¥ Type and Remove of Lineup
Clamp
¥ Cleaning and or Grinding
¥ Pre and Post-Heat Treatment è
Methods, Temp. temp-control
methods
¥ Shielding Gas and Flow Rate è
Composition and range of flow
rate
¥ Shielding Flux
¥ Speed of Travel è in inch per
minute

CONTOH PENGELASAN PIPA

NUMBER OF WELD METAL-LAYER

n The number of weld metal-layer (pass) in welding of pipe depend on

WELDING AND JOINING

pipe wall thickness. Recommended number of layer as shown below.

Range of Pipe Number

Cross Section of Weld Remark
Wall Thickness of Layers

1 = Rott pass
3/8 to 5/8 in 2
2

1
2 = Cover pass

3 1 = Root pass
5/8 to 7/8 in 3
2

1 2 = Hott pass
3 = Cover pass

4 1 = Root pass
2 = Hott pass
3

7/8 to 1 1/8 4 2

1
3 = Filler pass
in
4 = Cover pass

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 PIPE WELDING PROCEDURES
TYPE OF PASS
WELDING AND JOINING
.
Filler Pass Cover Pass
3/16 Electrode 3/16 Electrode
180 - 190 A DC + 160 - 190 A DC +

Base Metal

Root/Stringer Bead Hot Pass

5/32 Electrode 5/32 Electrode
135 - 175 A DC + 170 - 200 A DC +

PIPE WELDING PROCEDURES

SPEED OF TRAVEL

.
WELDING AND JOINING

Travel Speed,
Layer Cm/Minute

Root Pass 7.5 - 20

Hot Pass 7.5 - 20

Filler Pass 12.5 - 25

Cover Pass 12.5 - 25

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 PIPE WELDING PROCEDURES
FILLER METAL

.
WELDING AND JOINING

Filler Metal Group AWS E6010 AND E6011

AWS Electrode Current Votage,

Group Electrode
Specificatio Dia, In A Arc Volt
n
A5.1 E6010, E6011
3/32 40 - 80 23 - 25
1
A5.5 E7010, E7011 1/8 75 - 125 24 -
2 A5.5 E8010, E8011 5/32 110 - 170 26
A5.1 or 5.5 E7015, E7016, E7018 3/16 140 - 215 24 - 26
3
A5.5 E8015, E8016, E8018 7/32 170 - 250 26 - 30

A5.17 EL8, EL8K, EL12, EM5K 1/4 210 - 320 26 - 30

4 5/16 275 - 425 28 - 34
EM12K, EM13K, EM15K
28 - 34

PIPE WELDING PROCEDURES

PRE HEATING AND STRESS RELIEF

n Preheating shall be performing when:

.
WELDING AND JOINING

Ä Carbon steel having a carbon content in Preheating Requirement Based on CE

excess of 0.32 % (ladle analysis) or a
CE
carbon equivalent (C + 1/4 ( Mn + Si ) ) % Preheating Reaquired
in excess of 0.65 % (ladle analysis).
Ä Steel having lower carbon content or CE Up to 0.45 Preheat optional
when the welding procedure indicates 0.45 to 0.60 Preheat to 93 - 205 deg C
that chemical composition, ambient/or
Over 0.60 Preheat to 205 to 370 deg C
metal temperature, material thickness
or weld geometry require such
treatment to produce satisfactory welds
(Source ASME B31.8) Preheating Requirement Based on C Content
n Preheating Method
C Content, % Preheating Temperatur, oC
Ä Furnace Heat Treatment
Ä Induction Heating Below 0.2 Up to 93
Ä Torch Heating 0.20 - 0.30 93 - 150
Ä Resistance Heating 0.30 - 0.45 150 - 260
Ä Exothermal Heating 0.45 - 0.80 260 - 425

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 PIPE WELDING PROCEDURES
PRE HEATING AND STRESS RELIEFING

Stress - Reliefing Ä Equipment

WELDING AND JOINING
Ä To eliminate or greatly reduce built § Electric induction
up stress caused by welding. § Electric resistance
Ä Required when § Fuel-fired ring burner
§ Following a welding operation on a big § Fuel-fired torch
work piece (wall thickness >)
Ä Temperature Controller
§ On that is likely to have large built up
stress in it, § Thermocouple pyrometer
§ Having trouble with work -piece Stress-Relief Time & Temperature for Carbon
warping out of shape. Steel
Ä Methods of Stress Relieving Metal Temp. Time per Inch of Section
o
§ Heat the complete structure as a unit C Thickness, h
§ Heat a complete section containing the 593 1
weld to be stress relief
565 2
§ Heat a part of work by slowly heating a
circumferential band containing the 538 3
weld at the center.
510 5
§ Branch or other welded attachment
482 10

PIPE WELDING INSPECTION

METHODS OF INSPECTION

þ NDT þ Percentages of each day’s field butt

WELDING AND JOINING

n Visual weld, at randomly by operators

n Radiographic Testing
n Magnetic Particle Testing
n Liquid Penetrant Testing
n Ultrasonic Testing
þ The method used shall produce
indications of defects that can be
accurately interpreted and evaluated.
þ Qualification of Inspection Personnel
n Welding inspection personnel shall
be qualified by experience and
training for the specified
inspection task they performed.
þ Radiographic testing performed
least by Level I
þ Only Level II or III personnel shall
interprete test results.
n Class 1 location, except offshore,
at least 10 %
n Class 2 location, at least 15 %
n Class 3, and class 4 location, at
crossing or navigable river,
offshore and rail road or public
highway right of way, including
tunnels, bridges and over head
road crossing, 100 %, unless
impracticable, at least 90 %.
n Pipelines tie-in, 100 %
at

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 PIPE WELDING INSPECTION
BASIC CONCEPT
WELDING AND JOINING
Preparation
Preparation

Radiographic
Radiographic
Test
Test

Interpretation
Interpretation
and
andEvaluation
Evaluation

Acceptance
Acceptance

Yes No

Welding
Weldingis
isPerfect
Perfect Repair
Repair

Terima Kasih
.
WELDING AND JOINING

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