TRAINING FOR CONTRACTORS WELDING SUPERVISOR

PREPARED BY : J. B. PATEL

INTRODUCTION AND OVERVIEW

(A) SHOP WELD PLAN (SWP)

SHOP WELD PLAN (SWP)SEAM NUMBERS:These are sequential numbers used for identification of weld seam for NDT purpose.BASE METAL: P-Numbers: These are materials having similar properties which are grouped in order to reduce number of PQR and WPS.JOINT DETAILS: This is shown at the bottom of SWP. It gives a brief idea about weld joints. WELD PROCESS: SAW: Submerged Arc WeldingSMAW: Shielded Metal Arc WeldingFCAW: Flux Cored Arc WeldingGMAW: Gas Metal Arc WeldingGTAW: Gas Tungsten Arc Welding

SHOP WELD PLAN (SWP)LAYERS: Overlay Barrier and Subsequent layers.Groove 2-Run and All.WPS NO.: e.g. 130-174 (45316)Welding must be done in accordance with the specified WPS no. along with the project no. unless otherwise specified by the welding engineer. WELDING MATERIAL: Flux, electrodes, strips, wire spools as specified.FILLER MATERIALS:F-Numbers: These are materials having similar properties which are grouped in order to reduce number of PQR and WPS.

SHOP WELD PLAN (SWP)PQR No.: e.g. 3398. These are specified numbers which support the WPS.PREHEAT TEMPRATURE AND ITS IMPORTANCE: It is the temperature prior to start welding.INTERPASS TEMPRATURE AND ITS IMPORTANCE: It is the temperature of the base metal prior to start consecutive bead. POSITION: Flat, Horizontal, Vertical and Overhead.NOTES: The Serial No. is to be referred thoroughly from the lower-right corner of SWP. REVISION IN SWP:Refer revision shown in category.

WELD PROCEDURE SPECIFICATION (WPS)

WELD PROCEDURE SPECIFICATION (WPS)This is a welding procedure specification containing all welding parameters that are to be maintained during welding. For e.g. flow rate of shielding and purging gas, current and voltage range, travel speed, bead length, type of polarity.

SIGNIFICANCE OF WPS WITH JOB NO.:WPS with job no. shown in SWP must be used on job unless otherwise instructed by the welding engineer.WELDING POSITIONS:Groove positions PlatePipe1G: Flat1GR: Flat with Job 2G: Horizontal2G: Horizontal3G: Vertical5G: Welder 4G: Overhead6G: 45 degree W

WELD PROCEDURE SPECIFICATION (WPS)

WELD PROCEDURE SPECIFICATION (WPS)

WELD PROCEDURE SPECIFICATION (WPS)Fillet positions: Plate

1F: 2F:

3F:4F:

45o

WELD PROCEDURE SPECIFICATION (WPS)

MEASUREMENT OF ODD PREHEAT AND INTERPASSIMPORTANCE OF TEMPERATURE STICKS &HOW TO MEASURE?

PREHEAT TEMPERATUREPreheating is decided on basis of thickness of material,type of material and process.Reason to preheat:To slow down cooling rate.To reduce Thermal indifference.To control moisture and Hydrogen which will may create problem of crack and porosity.It is measured on base material T thickness from seam.

MEASUREMENT OF ODD PREHEAT AND INTERPASSIMPORTANCEA)TEMPERATURE OF PREHEAT MUST BE ON HIGHER SIDE OF GIVEN PREHEAT.B)TEMPERATURE OF INTERPASS MUST BE ON LOWER SIDE OF GIVEN INTERPASS.e.g:If interpass temperature is 275c temp stick available with welder is 250c He can use or not? Answer :Yes

MEASUREMENT OF ODD PREHEAT AND INTERPASSe.g:If preheat temperature is 150c temp stick available with welder is 125c He can use or not? Answer :No.

Note:For preheat measure with higher temp stick.For interpass measure with lower temp stick.

MEASUREMENT OF ODD PREHEAT AND INTERPASSNote :check interpass before starting another consecutive bead.Apply Temperature chalk t:thickness apart from weld seam on Base metal.

PARAMETER SLIP IMPORTANCEParameter slip :It is a Slip given to welder containing welding parameters to be used during welding .Barcode (LEMF):Ensure Issue of barcode to each welder must be given of that particular seam only.For SMAW/GTAW:Bead LengthFor SAW/FCAW/GMAW:Travel Speed

IMPACT/NON IMPACT WPS.Weaving :Allowed 3times diameter of Electrode. e.g : 3.15mm diameter electrode used3.15x3=9.45mm allowed.

IMPACT/NON IMPACT WPS.Bead length:It is the length of weld metal deposited on base metal by one single electrode. Dia(length):3(75mm),4(125mm) e.g:

IMPACT/NON IMPACT WPS.Weaving and Bead length control must be there during welding joints having impact WPS.As more heat input will be there due to crossing above parameter which will leads to coarse grain structure, which is very hard and brittle in nature and at the end it fails in IMPACT TEST.

TEST PLANAll Joints of jobs have seam no: for NDT identification.From test plan we can able to see each and every stage for NDT of particular seam.Note :move to further stage after completing NDT of above stage.BaaN system is available through we can offer seam for NDT to Inspection.

TEST PLANPTC:Production Test Coupon.Mentioned in Drawing and TEST PLAN.It is to be weld along with seam .

TEST PLANPTC is only mean to know properties by doing Destructive Testing.Note:Ensure PTC to be welded along with JOB.Failure of PTC is Failure in Job which will leads to cutting of that seam by raising NCR.

WELDING QUALIFICATIONWelder QualificationQualification done as per ASME SEC IX.ASME SECTION IX:Welding and Brazing Qualification.WML:Welder Master ListIt is list of Qualified Welders working in organization through which we can get full information of welder.

WELDING QUALIFICATIONWML CONTAINS.a)STAMP NO:It is identification number given to welder.b)NAME:Name of the welder.c)TEST DATE:Date on which welder welded test coupon.d)SPOT CHECK DATE:Date on which spot check was done by L&T person.

WELDING QUALIFICATION WML conte) VALIDITY DATE:Date on which welders validity to weld on JOB vanish.Duration is of 6 months from the test date or Spot check date.f) WELDING PROCESS: e.g.SMAW/SAW/GMAW/FCAW etc.g) WPS NO:Welding Procedure Specification followed during welding test coupon.h) POSITION:Position of welding during welding test coupon (Specified above).

WELDING QUALIFICATION WML conti) THICKNESS OF TEST COUPON: Pipe or plate thickness to be mentioned that welded during welding test coupon.j) 1st P NO:Parent material no to be specified.k) 2nd P NO:Parent material no to be specified.l) DIAMETER(mm):Diameter of Pipe welded during welding Test coupon.m)1st F NO:Filler no used in welding qualification.n) 2nd F NO:Filler no Qualified with.

WELDING QUALIFICATION WML conto) P NO: P no qualified with.p) POSITION:Position qualified with.q)THICKNESS:Thickness of weld metal qualified with.(GROOVE)/Thickness of base metal qualified with.(OVERLAY).r) DIAMETER(mm):Diameter qualified with.s) INSPECTION AGENCY:Name of inspection agency.t) CONTRACTOR: Name of contractor.

WELDING QUALIFICATIONA Mandatory Requirement from Codes /Stds / RegulationsQualification Tests in accordance with the Applicable Code / Standard / Regulation.Acceptance Criteria of Test Results as per the Code of Construction Qualification Records and Test Results to be Documented

WELDING QUALIFICATIONQualification Requirements For Equipments to be Made as per ASME Boiler & Pressure Vessel Code

ASME Sec IX + Applicable Design Code (Sec.VIII Div I or II, Sec. I, Sec. III)

WELDING QUALIFICATION

Welders or Welding Operators Performance Qualification

WELDING QUALIFICATIONAscertain the skill of a welder or a welding operator to Produce defect free/Sound weld Makes A Weld Coupon Using an Approved WPS of a Qualified Procedure.Weld Coupon Undergoes Soundness TestEach Qualified Welder Shall be Assigned by A Unique Welder Number Welders Qualifications Records Are DocumentedPerformance Qualification limited to the essential variables of the Specific Process

WELDING QUALIFICATIONHow To Qualify Groove Butt Weld Procedure? 1) Read & Understand ASME Sec. IX - Welding Data - Essential, Non Essential & Supplementary Essential Variables. - Test Requirements - Testing ProceduresASME Sec.II Part C. Classification of Welding Consumable -Properties of Consumables

WELDING QUALIFICATION CONT.. 2) Write A Welding Procedure Specification - WPS Provides Direction for A Specific Welding - WPS Shall Include All Essential, Supplementary Essential & Non Essential Variables - WPS Format Available in ASME Sec. IX. - Each WPS Shall be Assigned with A Unique Number.

WELDING QUALIFICATIONCONT 3) Prepare A Test Coupon As Per WPS - Coupon Size: Pair of 300 mm X 150mm Plate Or as Specified in WPS - All Other Details as per Written WPS -Complete the Welding by Reasonably Skilled Welder - All Welding Variables Shall be Used Within the Limit Specified in WPS. - All Variables Actually Used Shall be Documented as Annexure to PQR ( Procedure Qualification Record)

WELDING QUALIFICATIONCONT 4) NDT Of Weld Coupon - Optional - X-Ray / Radiograph the Weld Joint ( Not a Code Requirement ) -Mark Transverse Tensile & Guided Bends As Per QW461 - Eliminate Defective Weld Portion If Any, while Marking the Test Specimens -Preserve RT Report & X-Ray Film as Annexure to PQR

WELDING QUALIFICATIONCONT5) Mechanical Tests Qw 451, Groove Weld. Up to 10 mm Thickness -Root Bend :- 1No - Face Bend :- 2No10-19 mm Thickness Side Bend :- 2No OR Root Bend :- 1No Face Bend :- 1NoOver 19mm Thickness - Side Bend :-2No

WELDING QUALIFICATIONCont 6) Acceptance Criteria for Test Results. Bend Test (Qw 163) Opening Not More Than 3.2 mm in Any Direction on Convex Surface Within the Weld & HAZRT(Qw 191.2.2) Read from code. ASME SEC IX

WELDING QUALIFICATIONPerformance limits.(QW452.1b)GROOVE

WELDING QUALIFICATIONGROOVE POSITIONS :QW461

WELDING QUALIFICATIONPosition & Dia Limits-: QW461.9

WELDING QUALIFICATION Groove-Weld, Pipe Dia. Limits :QW 452.3

WELDING QUALIFICATIONOVERLAY QUALIFICATIONTHICKNESS LIMITS

WELDING QUALIFICATIONINSTRUCTION DURING WELDING ON JOBWelder Stamp punch:Stamp to be punch at 3feet OR 900mm interval of welding seam.Where to use punch and where to Engrave.ASME SECTION VIII DIV A. QW:37. Ferrous Non ferrous P >6mm>13mm E

WELDING QUALIFICATIONINSTRUCTION DURING WELDING ON JOBSeam wise welders record to be kept by qualified contractor welding supervisor.Spot checks to be done at particular interval.Discrepancy must be reported to W.E. LEMF.

WELD CONSUMABLE RELATEDWelding Electrodes:Storage,Baking & Issue.Done as per procedure HED-HZW-WEL-P-007Baking of Electrodes and Flux done as per procedure for electrodes Example:LOW HYDROGEN ELECTRODES-E70XX E80XX Baking :250-300c for 2-2.5hrs Holding:100-120c till issue

WELD CONSUMABLE RELATEDWelding Flux: Normal e.g. UV420TTR FOR CS/LAS -Baking done at 300-325cfor 2 to 2.5hrs-Holding temp 130-170c till issue-Issue shall be held at 130-170c only after baking

WELD CONSUMABLE RELATED Issue:a) SMAW maximum 15nos electrodes at a time.b) SAW flux max 10kg at a time.c) ESSC/SASC flux maximum 25kg at a time.d) Filler wires and strips to be issued as required. Note: Electrodes to be issue in portable oven or vacuum packed condition only.

WELD CONSUMABLE RELATEDReturn:a) Return each and every weld consumable to issue stores.Dont keep it any where lying.b) Try to recover flux by flux recovery unit and return it to store.c) Stores:If flux particle size to be observed very small or lumps shall be discarded and the matter shall be informed to welding engineering. Note:If any consumable found in contractors stores than Discrepancy will be given to contractor with penalty.

GENERAL PARAMETERS FOR FOLLOWED PROCESSES

1.SMAW PROCESS

e.g.:E7018,E8018 B2 CS/LAS ELECTRODES

ELECTRODE DIA AMPERES VOLTS 2.5MM70-90 22-283.5MM 100-140 22-284.0MM 150-180 22-285.0MM 200-240 22-286.0MM 270-350 22-28

e.g.:E309,E347,E316L etc. SS ELECTRODES

ELECTRODE DIA AMPERES VOLTS 2.5MM 50-60 20-263.5MM 60-90 20-264.0MM 110-140 20-265.0MM 150-180 20-266.0MM 200-230 20-26

GENERAL PARAMETERS FOR FOLLOWED PROCESSES

e.g.:ENiCrFe3,ENiCrMo3 ELECTRODES` ELECTRODE DIA AMPERES VOLTS 2.5MM 50-70 20-263.5MM 70-100 20-264.0MM 100-120 20-265.0MM 120-140 20-266.0MM 150-180 20-26

GENERAL PARAMETERS FOR FOLLOWED PROCESSES

2.SAW PROCESS

e.g.: CS/LAS/SS/INCONNEL WIRE SPOOLS

ELECTRODE DIA AMPERES VOLTS T.Speed(mm/min) 1.6MM(F43) 200-250 32-36 300-350 2.5MM(F6) 350-450 28-30 350-4504.0MM 450-550 28-32 450-550 5.0MM 550-650 28-32 550-650 6.0MM 650-750 28-32 650-750

GENERAL PARAMETERS FOR FOLLOWED PROCESSES

3.FCAW PROCESS

e.g. E308L,E309,ENiCrMo3

ELECTRODE DIA AMPERES VOLTS T.Speed(mm/min) 1.2MM(F6/F43) 160-200 20-32 290-400

GENERAL PARAMETERS FOR FOLLOWED PROCESSES

4.GTAW PROCESS

e.g.ER70S2,ER80SB2.

ELECTRODE DIA AMPERES VOLTS T.Speed(mm/min)1.6MM 80-110 10-15 502.4MM110-140 10-15 50

e.g.ER 308L,ER NiCrMo3ELECTRODE DIA AMPERES VOLTS T.Speed(mm/min)1.2MM70-150 15-22 551.6MM 70-150 15-22 552.4MM70-150 15-22 50

GENERAL PARAMETERS FOR FOLLOWED PROCESSES

4.GMAW PROCESSe.g. ERNICRMO3 ,E309LELECTRODE DIA AMPERES VOLTS T.Speed(mm/min) 1.2MM (F6/F43) 230-270 30-36 400-500

GENERAL PARAMETERS FOR FOLLOWED PROCESSES

LARSEN & TOUBROLIMITEDWELDING ENGINEERINGHAZIRA WORKSACHIEVABLE WELD DEPOSITION RATE FOR VARIOUS WELDING PROCESSES(Kg PER Arc hour)PROCESS MATERIAL DIA CURRENT DEPOSITIONRATE NO. ELECTRODES (mm) (Amps) (Kg per Arc hour) PER ARC HOUR SMAW CS 2.5 80 0.7 56 3.2 130 1.1 44 4.0 180 1.5 38 5.0 240 2.4 34 FCAW CS 1.2 200 3.3 SS 1.2 200 3.4

PROCESS MATERIAL DIA CURRENT DEPOSITIONRATE NOELECTRODES (mm) (Amps) (Kg per Arc hour) SAW CS 4.0 550-580 6.5

TWIN WIRE CS 2.4X2 550-580 6.6

SAW 2.4X2 750 8.9

TANDEM CS 4.0 570-600 14

ESSC SS 60X.5 1200 22 90X.5 1800 33 120X0.5 2200 42 ACHIEVABLE WELD DEPOSITION RATE FOR VARIOUS WELDING PROCESSES(Kg PER Arc hour)

SMAW PROCESS WITH E7018 TRIAL RESULT

Sheet1

ELECTRODECURRENTCURRENTSR NOLENGTH OFTIME REQBEADTRAVELAvgHEAT INPUT

RANGE(Amps)(Amps)SR NOEECTRODEFOR CONSIMINGLENGTHSPEEDTravel speed(KJ/mm)

CONSUMED(mm)ELECTRODE(Sec)(mm)(mm/min)(mm/min)

70-9070129085180127117.50.894

2.5mm29075135108

ultimate-1880229075135108110.51.086

31077145112.98

9033007011094.3100.91.338

30067120107.5

3.15mm100-1401001385100175105110.91.352

390100185111.1

40090175116.6

12023758513595.389.32.016

3859012583.3

140339575806488.92.36

385739073.9

440075161128.8

4mm150-180150138510515085.790.852.476

39010016096

16524009514591.5788.422.799

3979513585.26

18033909014596.661002.7

39090155103.33

5mm200-2402001390150240961022.94

390150270108

220238512016582.598.753.34

385120230115

240339011517088.6990.593.973

39012018592.5

HEAT INPUT=VoltagexCurrentx60V=22-28 approx 25v

Travel Speedx1000

KJ/mm

&LPRACTICAL RESULTSAFTER WELDINGE7018 ELECTRODE.

Sheet2

Sheet3

GENERAL /GOOD ENGINEERING PRACTICESNCRs:NON CONFERMATIVE REPORT.It is defined as deviation from code standards,customer requirements for the job.NCRs can be given on:a)Base metal repair: for Welding please issue repair plan from welding engineering and repair.b)Arc-strike/NDT requirements after touch ups. NDT is must after touch ups(PT/MT)c)Un cleaned weld joints: Weld joints must be cleaned properly

GENERAL /GOOD ENGINEERING PRACTICESTemporary attachment joints must be welded as per WPS specified in SWP.Buttering:e.g: Buttering must be at least 5mm. LAS buttering on CS moon plates for spiders.NDT to be perform properly on Temp joints to avoid defect in Base metal.

GENERAL /GOOD ENGINEERING PRACTICES DEFECT MARKING a) Match the RT spot punch to tracing. b) Transfer Defect marking :Mark 100mm on both side of the defect.Start grinding as per marking.Ensure that Grinding must be in Proper direction with help of 100mmreference line marked on both side.

GENERAL /GOOD ENGINEERING PRACTICESAs per code, required reinforcement for different thickness required UW:35material nominal thk max reinforcementmmcategory B &C otherLess than 2.42.40.82.4-4.83.21.64.8-134.02.413-254.82.425-515.03.251-766.04.076-1026.06.0102-1276.06.0127 and above8.08.0

GENERAL /GOOD ENGINEERING PRACTICESImportance of removal of slag and interpass cleaning.Cleaning between two consecutive bead should be done properly otherwise Slag inclusion will be there in weld metal which will not be permitted.Run in Run out:It is required as in starting and ending of arc chances of defects like: Pore/Improper bead overlap/Slag is more as there is much more variation in current and arc gap during starting and ending which leads to defects.

GENERAL /GOOD ENGINEERING PRACTICESDHT :De-hydrogenation heat treatment.It is post heating of the LAS job where weld metal is >50mm to avoid hydrogen cracking in weld metal.It is generally done at 300-350c for 3.5 to 4 hrs.

GENERAL /GOOD ENGINEERING PRACTICES DCEP:DIRECT CURENT ELECTRODE POSTIVEElectrons flow ve terminal to +ve terminal.Electrodes : Metal burning ratio is 7:3.Used in all welding process.Except:GTAW process.DECN: DIRECT CURRENT ELECTRODE NEGATIVE.Electrode: Metal burning ratio is 0. 5 : 9. 5Used in GTAW process as tungsten is used as electrode.

GENERAL /GOOD ENGINEERING PRACTICESACAlternative currentUsed in SA387 GR22 CL2 which requires 1.6 kj heat input for 29c impactUsed in Al welding,Al film removed by AC welding.Due to alternative variation in current is more so chances of LF is more in AC welding .DCDirect currentUsed all overPenetration is goodLess chance of LF

GENERAL /GOOD ENGINEERING PRACTICES

Overlay to be properly overlap >=50% of beadfor proper dilution to achieve chemistry.

GENERAL /GOOD ENGINEERING PRACTICES

DWT :Double welder TechniqueDOT :Double welding operator technique.Both method to be used for TSR Tray support ring or fillet weld for minimization distortion.L&T qualification requires :fillet welded Fracture test to be done.

GENERAL /GOOD ENGINEERING PRACTICES

Categories of Weld Joints.A: All L/S in Nozzle,Dends,Shell,Cones (Hemispherical Dend # Shell)B: All C/S Nozzle# shell,Nozzle #Flange,Corner joints Dends(Ellipsoidal Dend # shell.C: Flange to ForgingsD: Nozzle # Shell Lip type(butt)