TWI Um ‘THE WELDING INSTITUTE, CODES AND STANDARDS CLASS OF WORK There are many types of work which require engineering materials to be joined by welding, for example: pressure vessels bridges oil rigs earth moving equipment aero—engines ventilation systems storage tanks heavy vehicle chassis car bodies food processing plant The quality requirements of the joints in these fabrications depend on their fitness-for-purpose and differ significantly from one application to the next. Pressure vessels require welds which can withstand the stresses and high temperatures experienced in operation. Bridges must take into account the effect of differing vehicle loads and wind loading. Oil rigs are designed to withstand the effect of wave formation and wind loads. Earth moving equipment has to accommodate differences in terrain and earth conditions and is subject to fatigue loading. Welds in food processing plants must withstand corrosion by hot acidic liquors. On the next page some typical Codes of practice and Standards which cover various types of constructions being fabricated by welding are listed. Note: Throughout this text, the term Code is used to cover Code of Practice, Standard and Specification. WELDING TECHNOLOGY Issue 0191 3.4TWI a 3.2 ‘THE WELDING INSTITUTE Code Class of Work BS 5500 Unfired fusion welded pressure vessels ASME Vill American boiler and pressure vessel code BS 2633 Class 1 Arc welding of ferritic steel pipework for carrying fluids BS 4515 Process of welding steel pipelines on land and offshore BS 5950 Structural use in steelwork in building AWS 01.1 Structural welding code (American) BS 5400 Steel concrete and composite bridges BS 6235 Code of Practice for fixed offshore structure API 1104 ‘Standard for welding pipelines and related facilities These documents can also provide a useful source of data for applications where Codes do not exist. It should be remembered, however, that the principal criterion in the Codes listed is the quality of the joint in relation to the service conditions, There are other applications where success is judged by different criteria, such as dimensional accuracy. Another important consideration is controlling the cost of welding. Variations in weld times and quantities of consumables can readily result if the method of making a weld is left to the welder to decide. ‘The continuous and satisfactory performance of weldments made to various Codes requires that specific guidelines are laid down to cover materials, design of joints, welding processes, welding consumables, acceptance criteria and inspection techniques. ‘These guidelines are usually grouped under the general heading of a Weld Procedure, WELDING TECHNOLOGY Issue 0191TWI iM ‘THE WELDING INSTITUTE SENIOR WELDING INSPECTOR "SIGNING OFF A PRODUCT" In many fields of fabrication it is a requirement that on completion of a product a review is made of all documentation to ensure conformity to the specification, code and drawing requirements. Usually until this review is completed and perhaps a Release Note or Shipping Note is signed, the product is not complete with possible late payments and penalties on delivery being incurred. It could be part of the Senior Welding Inspector's duties to carry out this task, The requirements for such a check would normally be stated in the client's specification although some standards, e.g. BS5500, lay down what documents must be available and checked. Some, if not all, of these documents may have to be incorporated into a Data Book on completion of the contract. In order to perform this task, a check list of all documents used on the product must be prepared. The task is made easier if Quality Plans or at least Inspection Check lists are in use on the job. The numbers and types of documents will obviously depend upon the complexity and quality standard of the product, but among the documents to be reviewed could be: Quality Plan All stages complete and signed off Inspection Check List All stages complete and signed off Materials All certificates checked. In some cases this may include tests carried out by the consumable(s) supplier. Procedures for: Cutting Welding Repair NOT All have to be approved PWHT Testing Coating Qualification of: Welders NDT Personnel _Alll have to be approved and Inspectors are up to date WELDING TECHNOLOGY Issue 0191 3.3TWI im 3.4 Inspection Reports for: Calibration Certificates: PWHT Charts: Hydro Test: As Built Drawings: Materials & Weld Map: Nameplate Rubbings: ‘THE WELDING INSTITUTE Visual Ensure they cover all NOT appropriate joints and Dimensional structures: for those items of equipment deemed necessary, e.g. pressure gauges for Hydro Test Ensure all necessary information is on records, e.g, job descriptions, chartspeeds Reports are complete All are completed All are completed When applicable Concessions/Deviations/Site Query sheets Permits to work/Degas certificates applicable Coating Reports WELDING TECHNOLOGY Issue 0191QUESTIONS Qi. a2 a3. aa. Qs. CODES AND STANDARDS List the typical items to be found in a Code of Practice Explain the meanings of the terms: a) ‘Shall b) ‘Should’ What is meant by the term ‘concession’? Does a Code of Practice contain all relevant information? State the three (8) parties generally mentioned in Codes or Standards aQs3QUESTIONS Qi Q2. Q3. a4. Qs. SENIOR WELDING INSPECTOR CODES AND STANDARDS List the contents of a typical Code of Practice. Are the requirements legally binding ‘At what point of production should the inspector ensure the correct use of consumables. Can a non-approved welder be employed on production work. Long question (300 words) Write in an essay format a "signing off of product" to your respective code. Qs3A