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WELDING CODE, STANDARDWELDING CODE, STANDARD& WELDING PROCEDURE& WELDING PROCEDURE

Dr. Ir. Winarto, M.Sc.

DEPARTEMEN METALURGI & MATERIAL

FAKULTAS TEKNIK UNIVERISTAS INDONESIA

DEFINISIDEFINISInn ““StandardStandard”” adalahadalah kumpulankumpulan dokumendokumen--dokumendokumen berisikanberisikan

kodekode (codes), (codes), spesifikasispesifikasi (specification), Saran (specification), Saran aplikasiaplikasi(recommended practice), (recommended practice), klasifikasiklasifikasi, , dandan petunjukpetunjuk (guide) (guide) yang yang telahtelah dipersiapkandipersiapkan oleholeh suatusuatu institusiinstitusi organisasiorganisasi dandan didisahkansahkan (approved) (approved) sesuaisesuai dengandengan prosedurprosedur yang yang adaada((berlakuberlaku).).

nn ““CodesCodes”” adalahadalah suatusuatu standard yang standard yang berisikanberisikan kondisikondisi dandanpersyaratanpersyaratan yang yang berhubunganberhubungan dengandengan bidangbidang khususkhusus (a (a particularly subject) particularly subject) dandan mengindikasikanmengindikasikan bahwabahwa prosedurprosedurygyg digunakandigunakan telahtelah sesuaisesuai dengandengan persyaratannyapersyaratannya. Codes . Codes iniiniHARUS HARUS diikutidiikuti (mandatory) (mandatory) karenakarena menyangkutmenyangkutkepentingankepentingan umumumum yang yang merefermerefer kepadakepada kebijakankebijakan otoritasotoritaspemerintahanpemerintahan. (. (Codes is a body of laws arranged Codes is a body of laws arranged systimaticallysystimatically for easy reference)for easy reference)

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DEFINISIDEFINISInn ““SpecificationSpecification”” ((spesifikasispesifikasi) ) adalahadalah suatusuatu

standard yang standard yang berisikanberisikan penjelasanpenjelasan yang yang rincirincidandan akuratakurat tentangtentang persyaratanpersyaratan teknisteknis daridarimaterial, material, produkproduk, , sistimsistim atauatau jasajasa..

nn ContohContoh KodeKode ::–– Structural Welding CodeStructural Welding Code--Steel (AWS D1.1)Steel (AWS D1.1)–– Boiler & Pressure Vessel Code (ASME)Boiler & Pressure Vessel Code (ASME)–– Welded Pipeline & Vessel (API)Welded Pipeline & Vessel (API)

nn ContohContoh Specification :Specification :–– Filler Metal Specification (AWS A5.X)Filler Metal Specification (AWS A5.X)–– Material & Consumable of Welding (ASME sec. IIC)Material & Consumable of Welding (ASME sec. IIC)

AWS AWS –– Structural Welding CodeStructural Welding Code

nn AWS D l.1, Structural Welding CodeAWS D l.1, Structural Welding Code——SteelSteelnn AWS D l.2, Structural Welding CodeAWS D l.2, Structural Welding Code——AluminumAluminumnn AWS D l.3, Structural Welding CodeAWS D l.3, Structural Welding Code——Sheet SteelSheet Steelnn AWS D l.4, Structural Welding CodeAWS D l.4, Structural Welding Code——Reinforcing SteelReinforcing Steelnn AWS D l.5, Bridge Welding CodeAWS D l.5, Bridge Welding Codenn AWS D l.6, Structural Welding CodeAWS D l.6, Structural Welding Code——Stainless SteelStainless Steel

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Welding Code – Steel (AWS D.1.1)

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ASME STANDARD

API - STANDARD

nn API 1104, Standard for Welding Pipeline API 1104, Standard for Welding Pipeline and Related Facilitiesand Related Facilities

nn API 620, Recommended Rules for Design API 620, Recommended Rules for Design and Construction of Large Welded Lowand Construction of Large Welded Low--Pressure Storage TanksPressure Storage Tanks

nn API 650, Standard for Welded Steel Tank API 650, Standard for Welded Steel Tank for Oil Storagefor Oil Storage

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PersyaratanPersyaratan DasarDasar dalamdalam MenentukanMenentukanKualitasKualitas dalamdalam PengelasanPengelasan

StandarStandar EropaEropa dandan AmerikaAmerikadalamdalam mendukungmendukung KualitasKualitas LasanLasan

nn ASME (American Society of Mechanical ASME (American Society of Mechanical Engineers) Engineers)

nn EN (European Norm) / European StandardEN (European Norm) / European Standardnn AWS (American Welding Society )AWS (American Welding Society )

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ASME Standard ASME Standard untukuntuk WeldingWelding

nn ASME Sec IX (Qualification Standard for ASME Sec IX (Qualification Standard for Welding and Brazing Procedure, Welder, Welding and Brazing Procedure, Welder, and Welding & Braze Operator.and Welding & Braze Operator.

nn ASME Sec II C Standard for Material and ASME Sec II C Standard for Material and Consumable of Welding.Consumable of Welding.

STANDARD KUALITAS LAS STANDARD KUALITAS LAS daridari ASMEASME

Quality of Welds

Basic Construction Code / Standard :

•ASME Sec I, ASME B31.1 , ASME B31.3

•ASME Sec VIII Div I & 2

Basic Construction Code / Standard :

•ASME Sec I, ASME B31.1 , ASME B31.3

•ASME Sec VIII Div I & 2

Welding Personnel And Welding

Procedure

• ASME IX

Welding Personnel And Welding

Procedure

• ASME IX

Welding Material

• ASME II C

Welding Material

• ASME II C

Examination and Testing

• ASME V

Examination and Testing

• ASME V

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European Standard For WeldingEuropean Standard For Welding

nn EN 288 (Standard & Qualification Welding EN 288 (Standard & Qualification Welding Procedure)Procedure)

nn EN 287 ( Standard & Qualification of EN 287 ( Standard & Qualification of Welder)Welder)

nn EN 1418 ( Standard & Qualification of EN 1418 ( Standard & Qualification of Welding Operator )Welding Operator )

STANDARD KUALITAS LAS STANDARD KUALITAS LAS daridari ENEN

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PROSEDUR LAS PROSEDUR LAS -- EN 288EN 288nn EN 288 EN 288 -- 1 . General rules fusion welding.1 . General rules fusion welding.nn EN 288 EN 288 -- 2. WPS for Arc Welding2. WPS for Arc Weldingnn EN 288 EN 288 -- 3. Welding procedure test for Arc welding of 3. Welding procedure test for Arc welding of

steel.steel.nn EN 288 EN 288 -- 4. Welding Procedure Test for Arc welding 4. Welding Procedure Test for Arc welding

of Aluminum and Itof Aluminum and It’’s alloyss alloysnn EN 288 EN 288 -- 5. Approval by using approved welding 5. Approval by using approved welding

consumables for arc weldingconsumables for arc weldingnn EN 288 EN 288 -- 6. Approval related to previous experience6. Approval related to previous experiencenn EN 288 EN 288 -- 7. Approval by a standard welding procedure 7. Approval by a standard welding procedure

for arc weldingfor arc weldingnn EN 288 EN 288 -- 8. Approval by a pre8. Approval by a pre--production welding test.production welding test.

KUALIFIKASI WELDER KUALIFIKASI WELDER -- EN 287EN 287

nn EN 287 EN 287 -- 1 . Approval testing of welders 1 . Approval testing of welders –– Fusion welding Fusion welding part 1 : Steels.part 1 : Steels.

nn EN 287 EN 287 -- 2. Approval testing of welders 2. Approval testing of welders –– Fusion welding Fusion welding part 2 : Aluminum and aluminum Alloys.part 2 : Aluminum and aluminum Alloys.

nn EN 287 EN 287 -- 3. Approval testing of welders 3. Approval testing of welders –– Fusion welding Fusion welding part 3 : Copper and Copper Alloys.part 3 : Copper and Copper Alloys.

nn EN 287 EN 287 -- 4. Approval testing of welders 4. Approval testing of welders –– Fusion welding Fusion welding part 4 : Nickel and Nickels alloyspart 4 : Nickel and Nickels alloys

nn EN 287 EN 287 -- 5. Approval testing of welders 5. Approval testing of welders –– Fusion welding Fusion welding part 5 : Titanium and Titanium, Zirconium and Zirconium part 5 : Titanium and Titanium, Zirconium and Zirconium alloysalloys

nn EN 288 EN 288 -- 6. Approval related to previous experience6. Approval related to previous experiencenn EN 288 EN 288 -- 7. Approval by a standard welding procedure for arc 7. Approval by a standard welding procedure for arc

weldingweldingnn EN 288 EN 288 -- 8. Approval by a pre8. Approval by a pre--production welding test.production welding test.

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

BS EN 287BS EN 287ASME IX

BS EN 288 (Parts 3 & 4)BS EN 288 (Parts 3 & 4)

ASME IX

BS 2654BS 2594

API 620/650

Storage Tanks

AWS D1.1AWS D1.2BS EN 287BS EN 287BS 4872

AWS D1.1AWS D1.2

BS EN 288 (Part 3)BS EN 288 (Part 4)

AWS D1.1AWS D1.2BS 5135BS 8118

Structural Fabrication

BS EN 287 (Part 1)BS EN 287 (Part 2)

ASME IXASME IX

BS 4872/BS EN 287

BS EN 288 (Part 3)BS EN 288 (Part 4)

ASME IXASME IX

BS EN 288 (Part 3)(if required)

BS 2633BS 4677

ANSI/ASME B311ANSI/ASME

B31.3BS 2971

Process Pipe-work

BS EN 287ASME IX

BS EN 288ASME IX

BS 5500ASME VIII

Pressure Vessels

Welder approval

Procedure approval

Application code/standard

ApplicationWelding Standard

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 Why a WPSa WPS

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WhyWhy a WPSa WPS

The main objective of a WPS is to make awelding operation

reproducable

What isWhat is a a WPS ?WPS ?The welding procedure is somewhat

analogous to a cook's recipe.

It outlines the steps required to make a qualityweld 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 isWhat is a a WPS ?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 testcoupon. The PQR is a record of variables recordedduring the welding of the test coupons. It also containsthe test results of the tested specimens. Recorded variables normally fall within a small range of the actualvariables that will be used in production welding.

What isWhat is WPS Variables ?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 interpasstemperatureWelding current (amperage)/wire feed speedArc voltageTravel speedPosition of weldingPost weld heat treatmentShielding gas type and flow rateJoint design details

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What isWhat is Variales in WPS ?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 isWhat is Variales in WPS ?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 requiredsupplementary essential variables, with the coupon long enough to provide the necessary notch-toughness specimens.

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What isWhat is Variales in WPS ?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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10 Sub Groups:- Mixed bag of high strength low alloy steels.?11B

Mixed bag of high strength low alloy steels.?11 A Groups 2 to 5

9 Nickel Steels711A Group 1

Typically 26 Chrome one moly?10J

Duplex and Super Duplex Grades 31803, 327501010 H

Mixed bag of low alloy steels, 10G 36 Nickel Steel?10A,B,C,F,G

Typically two to four percent Nickel Steels79A, B, C

Group 4 Typically 254 SMO type steels

Group 3 High manganese grades

Group 2 Typically Grades 309, 310

Group1 Typically Grades 304, 316, 347

Austenitic Stainless Steels, 4 Sub groups

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Ferritic Stainless Steels Typically Grade 40987

6 Sub Groups:-Martensitic Stainless Steels Typically Grade 41086

5 Sub Groups:-Chrome moly vanadium65C

2 Sub Groups:- Typically five chrome half molyand nine chrome one moly55B

Typically two and a quarter chrome one moly55A

2 Sub Groups:- Typically one and a quarter chrome half moly54

3 Sub Groups:- Typically half molyand half chrome half moly43

Not Used-2

Group 4 Special (e.g. SA-724 gr. A, B, C)

Group 3 Approx 80ksi

Group 2 Approx 70ksi

Group 1 up to approx 65 ksi

Carbon Manganese Steels, 4 Sub Groups

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Base MetalEN-288P No.

ASME & EN

MATERIAL

P NUMBER

ASME F Numbers

Hard Facing Overlay7X

Zirconium6X

Titanium5X

Nickel alloys4X

Copper and its alloys3X

Aluminium and its alloys2X

Any steel solid or cored wire (with flux or metal)6

High alloy austenitic stainless steel and duplex :- A5.4 : E316L-165

Basic coated electrodes such as : A5.1 : E7016 and E70184

Cellulosic electrodes such as :- A5.1 : E60113

Most Rutile consumables such as :- A5.1 : E60132

Heavy rutile coated iron powder electrodes :- A5.1 : E70241

General DescriptionF No.

Note:- X represents any number 0 to 9

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ASME Welding PositionsNote 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:-

JL0456GPipe Fixed @ 45 degrees Downwards

HL0456GPipe Fixed @ 45 degrees Upwards

PF5GPipe Fixed Horizontal

PE4GOverhead

PG3GVertical Downwards Progression

PF3GVertical Upwards Progression

PC2GHorizontal

PA1GFlat

ISO and ENTest PositionWelding Position

Welding Positions For Fillet welds:-

PF5FPipe Fixed Horizontal

PD4FOverhead

PG3FVertical Downwards Progression

PF3FVertical Upwards Progression

PB2FRHorizontal Rotated

PB2FHorizontal

PA1FFlat (Weld flat joint at 45 degrees)

ISO and ENTest PositionWelding Position

POSISI LAS POSISI LAS -- ASME IXASME IX

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ASME WELDING POSITION

POSISI LAS POSISI LAS -- EN 288EN 288

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WELD POSITION EN-287

POSISI LAS POSISI LAS -- AWSAWS

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CONTOH TAHAPAN PROSES CONTOH TAHAPAN PROSES

PENGELASAN PIPAPENGELASAN PIPA

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Welding ApplicationWelding Application

WPSWPS

WPQRWPQR

InspectionInspection

OperationRequirementOperation

Requirement

MaterialSelectionMaterial

Selection

Fabrication of Pipes

Fabrication of Pipes

Science

Standard

Technology

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WELDING PROCEDURESWELDING PROCEDURESWPQR AND WPSWPQR AND WPS

nn KualifikasiKualifikasi ProsedurProsedur (Procedure Qualification)(Procedure Qualification)

Ä Sebelum mengelas komponen (pipa atau lainnya) umumnyaprosedur pengelasan (welding procedure) harus dibuat dandikualifikasi.

nn DokumentasiDokumentasi (Record)(Record)

Ä Detail mengenai prosedur harus didokumentasi (record) yang berisihasil lengkap tentang “procedure qualification test”.

nn KualifikasiKualifikasi Operator Las (Qualification of Welders)Operator Las (Qualification of Welders)

Ä Setiap welder atau operator las harus dikualifikasi menurutprosedur baku sebelum melakukan pengelasan komponen (pipaatau lainnya). Tujuannya adalah untuk menentukan kemampuanoperator las (welder) dalam menghasilkan lasan yang baik tanpacacat dengan menggunakan prosedur sebelumnya yang telah lulus qualifikasi.

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ISI WELDING PROSEDURISI WELDING PROSEDURWPQR AND WPSWPQR AND WPS

¥ Process è Manual, Semi-or automatic welding process

¥ Pipe and Fitting Materialè API 5L or ASTM

¥ Diameter and Wall Thickness

¥ Joint Design

¥ Filler Metal and Number of Bedè 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

¥ Positionè Roll or fix

¥ Direction of Welding è Uphill or downhill

¥ Time Between Passes è Max 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 TreatmentèMethods, Temp. temp-control methods

¥ Shielding Gas and Flow Rate èComposition and range of flow rate

¥ Shielding Flux¥ Speed of Travel è in inch per

minute

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CONTOH PENGELASAN PIPACONTOH PENGELASAN PIPANUMBER OF WELD METAL-LAYER

n The number of weld metal-layer (pass) in welding of pipe depend on pipe wall thickness. Recommended number of layer as shown below.

5/8 to 7/8 in 3 1

2

3 1 = Root pass2 = Hott pass3 = Cover pass

3/8 to 5/8 in 2 1

2 1 = Rott pass2 = Cover pass

Range of PipeWall Thickness Cross Section of Weld

Number of Layers

Remark

7/8 to 1 1/8 in

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2

3

4 1 = Root pass2 = Hott pass3 = Filler pass4 = Cover pass

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PIPE WELDING PROCEDURESPIPE WELDING PROCEDURESTYPE OF PASS

..

Root/Stringer Bead5/32 Electrode135 -175 A DC +

Hot Pass5/32 Electrode170 -200 A DC +

Filler Pass3/16 Electrode180 -190 A DC +

Cover Pass3/16 Electrode160 -190 A DC +

Base Metal

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PIPE WELDING PROCEDURESPIPE WELDING PROCEDURESSPEED OF TRAVEL

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LayerTravel Speed,

Cm/Minute

Root Pass

Hot Pass

Filler Pass

Cover Pass

7.5 - 20

7.5 - 20

12.5 - 25

12.5 - 25

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PIPE WELDING PROCEDURESPIPE WELDING PROCEDURESFILLER METAL

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Group ElectrodeAWS Specificatio

n

1A5.1 E6010, E6011

A5.5 E7010, E7011

2 A5.5 E8010, E8011

3A5.1 or 5.5 E7015, E7016, E7018

A5.5 E8015, E8016, E8018

4EL8, EL8K, EL12, EM5KA5.17

EM12K, EM13K, EM15K

ElectrodeDia, In

Votage,Arc Volt

CurrentA

40 -80

75 - 125

110 -170

140 -215

170 -250

210 -320

275 -425

3/32

1/8

5/32

3/16

7/32

1/4

5/16

23 -25

24 -

26

24 -26

26 -30

26 -30

28 -34

28 -34

Filler Metal Group AWS E6010 AND E6011

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PIPE WELDING PROCEDURESPIPE WELDING PROCEDURESPRE HEATING AND STRESS RELIEF

n Preheating shall be performing when:

Ä Carbon steel having a carbon content in excess of 0.32 % (ladle analysis) or a

carbon equivalent (C + 1/4 ( Mn + Si )) in excess of 0.65 % (ladle analysis).

Ä Steel having lower carbon content or CE when the welding procedure indicates

that chemical composition, ambient/or metal temperature, material thickness

or weld geometry require such treatment to produce satisfactory welds

(Source ASME B31.8)

n Preheating Method

Ä Furnace Heat Treatment

Ä Induction Heating

Ä Torch Heating

Ä Resistance Heating

Ä Exothermal Heating

..CE% Preheating Reaquired

Up to 0.45

0.45 to 0.60

Over 0.60

Preheat optional

Preheat to 93 - 205 deg C

Preheat to 205 to 370 deg C

Preheating Requirement Based on CE

C Content, % Preheating Temperatur, oC

Below 0.2

0.20 - 0.30

0.30 - 0.45

0.45 - 0.80

Up to 93

93 - 150

150 - 260

260 - 425

Preheating Requirement Based on C Content

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PIPE WELDING PROCEDURESPIPE WELDING PROCEDURESPRE HEATING AND STRESS RELIEFING

Stress - Reliefing

Ä To eliminate or greatly reduce built up stress caused by welding.

Ä Required when§ Following a welding operation on a big

work piece (wall thickness >)

§ On that is likely to have large built up stress in it,

§ Having trouble with work -piece warping out of shape.

Ä Methods of Stress Relieving

§ Heat the complete structure as a unit

§ Heat a complete section containing the weld to be stress relief

§ Heat a part of work by slowly heating a circumferential band containing the weld at the center.

§ Branch or other welded attachment

Ä Equipment

§ Electric induction

§ Electric resistance

§ Fuel-fired ring burner

§ Fuel-fired torch

Ä Temperature Controller

§ Thermocouple pyrometer

Metal Temp.oC

Time per Inch of Section Thickness, h

593

565

538

510

482

1

2

3

5

10

Stress-Relief Time & Temperature for Carbon Steel

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PIPE WELDING INSPECTIONMETHODS OF INSPECTION

þ NDT

n Visual

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 at least by Level I

þ Only Level II or III personnel shall interprete test results.

þ Percentages of each day’s field butt

weld, at randomly by operators

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 %

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PIPE WELDING INSPECTION

BASIC CONCEPT

PreparationPreparation

AcceptanceAcceptance

Interpretation and Evaluation

Interpretation and Evaluation

Radiographic Test

Radiographic Test

Welding is PerfectWelding is Perfect RepairRepair

Yes No

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Terima Kasih

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