Manual For Inspectors. Module 2: Welding

Manual for Inspectors.
Module 2: Welding
ALL PC 004/13 I Verison 1.0 I 12/12/2013 Page 1

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Manual for Inspectors. Module 2: Welding
Content
1 Copyright 7
2 General 7
3 Welding 7
4 Welding quality requirements 10
4.1 Quality requirements for fusion welding 10
4.2 Specification and qualification of welding procedures 12
4.3 Welding procedure qualification record (WPQR) 12
4.4 Welding procedure specification (WPS) 13
5 Terms and definitions 14
5.1 Review of requirements 14
5.2 Technical review 14
5.3 Subcontracting 15
5.4 Welding personnel 15
5.4.1 Welder 15
5.4.2 Welder operator 15
5.5 Equipment 16
5.6 Production planning 16
5.7 Qualification of the welding process 16
5.8 Welding procedure specification (WPS) 16
5.9 Work instructions 16
5.10 Welding consumables 16
5.11 Materials 17
5.12 Inspection and testing before welding 17
5.13 Inspection and testing during welding 17
5.14 Inspection and testing after welding 17
5.15 Post-weld heat treatment (PWHT) 17
5.16 Nonconformance and corrective actions 17
5.17 Calibration and validation of measuring, inspection, and testing equipment 18
5.18 Identification and traceability 18
5.19 Quality records 18
6 Welding joints, symbols, and dimensions 19
6.1 Descriptions of joint welds 19
6.2 Elementary symbols (DIN 1912) 24
6.3 Position of the symbols on drawings 25
6.4 Dimensions of drawings 27
6.5 General welding tolerances 29
7 Welding aspects for manufacturing 31
7.1 Traceability of material 31
7.2 Welding bevel preparation (per ISO 9013) 31
7.3 Important welding aspects 36
7.3.1 Tack welding 36
7.3.2 Welding of root 36
7.3.3 Interpass welding 36

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7.3.4 Execution of weld seams and welding supports 37

7.3.5 Full penetration welding 40
7.3.6 Welding of austenitic and irregular (carbon/austenitic) welding joints 40
7.3.7 After welding and repairing 41
7.3.8 Notchless ground welding seams 42
7.3.9 Tack welding and welding on fluid welding parts (piping) 42
7.4 Preheating & interpass temperature 44
7.5 Post-welding heat treatment (PWHT) 45
8 Excerpt of welding calculations 46
8.1 Examples of notch cases 48
8.2 Welded structural beams 52
9 Cladding of rollers for continuous casting 53
9.1 Preheating temperatures for single and dual-layer welding: 54
9.2 Diameter of single layer (only for in-house manufacturing) 54
9.3 Diameter of dual layer (used for suppliers) 55
9.4 Setting parameters 55
9.5 Torch alignment and movement 57
9.6 Causes of imperfections and corrective measures 59
10 Hand skill test 60
10.1 Introduction 60
10.2 Requirements for welder skill test 60
10.3 Hand skill test procedure 61
10.3.1 Preparation of test sample 62
10.3.2 Execution 63
10.3.3 Examination and testing of test pieces 65
10.4 Result of the welder test 68
10.5 Welder Pass 68
11 Appendixes 69
11.1 Appendix 1: Welding positions 69
11.2 Appendix 2: Important welding processes 73
11.3 Appendix 3: Scope of material application for WPQR 74
11.4 Appendix 4: Template for welding procedure qualification record form (WPQR) 75
11.5 Appendix 5: Extract of ISO 2553:1992-10 – Symbolic representation on drawings 78
11.6 Appendix 6: Extract of ISO 5817:2006-10 – Quality levels for imperfections 79
11.7 Appendix 7: Extract of ISO 9692-1 – Recommendations for joint preparation 86

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Figure 1: Overview of standards for welding 8

Figure 2: Types of butt weld preparation 20
Figure 3: Types of T-joint weld preparation 21
Figure 4: Typical example of fusion welds 22
Figure 5: Definition of weld layers and weld beads described with V-weld seam 22
Figure 6: Description of HAZ (heat affected zone) in detail 23
Figure 7: Elements of the reference symbol and indications at the symbol 25
Figure 8: Relation between arrow line and joint – fillet welds 26
Figure 9: Position of the symbols according to the reference line 26
Figure 10: Position of the symbols and welds according to the reference line 26
Figure 11: Methods of indicating dimensions of fillet welds 27
Figure 12: Partial-penetration welds 27
Figure 13: Designation of weld forms 27
Figure 14: Difference between theoretical welding thickness and effective welding thickness 28
Figure 15: Fillet weld versus partial-penetration welds 28
Figure 16: Methods of indicating dimensions for deep penetration of butt welds 28
Figure 17: Methods of indicating dimensions for intermittent fillet welds 29
Figure 18: Examples of angle leg and reference point 30
Figure 19: Marking – stamping 31
Figure 20: Chamfer with unacceptable gutters and impurities 32
Figure 21: Before and after grinding of gutter for welding 33
Figure 22: Unacceptable cutting procedure 33
Figure 23: Result of unacceptable cutting procedure 33
Figure 24: Unacceptable cutting procedure 33
Figure 25: Acceptable cutting procedure 33
Figure 26: Excellent sandblasted and ground chamfer 34
Figure 27: Ground chamfers 34
Figure 28: Ground chamfer with back strip 34
Figure 29: Hardness measurement 35
Figure 30: Imperfections – ignition spots 36
Figure 31: Open arc welding – disallowed beads (pendulum / oscillation torch movement) 37
Figure 32: Staggered and small string beads 37
Figure 33: Notch 38
Figure 34: Used run-out plates 38
Figure 35: Length of welding, usage of run-out plates 39
Figure 36: Non-tack-welded back strips and tack-welded strips 39
Figure 37: Through (full) penetration welds 40
Figure 38: Grinding of interpass layer (stainless steel) 41
Figure 39: Notchless ground radius of r30 42
Figure 40: Spray headers – oxidized weld seam 42
Figure 41: Annealing color depending on temperature (Source: Linde Group) 43
Figure 42: Electric preheating of converter-shell parts 44
Figure 43: Preheating by gas flames of upper lever for a ladle turret 44
Figure 44: Post-weld heat treatment of a converter shell (material 10CrMo9-10 equivalent to A-387 Gr.22) 45
Figure 45: Notch stress distribution of different kinds of filler weld 48
Figure 46: Example of drop in admissible stress level depending on notch factor 50
Figure 47: Example of drop in admissible stress level due to low-quality welding of temporary supports
on a highly loaded box girder. In this case the admissible stress level in the box girder will drop
to approx. 35% of the sound material. 50
Figure 48: Example of beam welding design for dynamically loaded steel structure (notchless) 52
Figure 49: Example of beam welding design for statically loaded steel structure 52
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Figure 50: Extract of Material Conversion Table Tool – Evaluation of Delta Ferrite 53
Figure 51: Torch alignment 57
Figure 52: Open arc welding – oscillation movement of the torch 57
Figure 53: Open arc welding – pendulum length and overlapping 58
Figure 54: Open arc welding – stick-out 58
Figure 55: Welding imperfections – pores 59
Figure 56: Open arc welding – hold time during oscillation movement 59
Figure 57: Dimensions of test of butt weld joint and T-joint [mm] 61
Figure 58: Test sample – preparation of butt weld joint 62
Figure 59: Test sample – dimensions of preparation of butt weld joint 62
Figure 60: Test sample – preparation of T-joint 63
Figure 61: Test sample – dimensions of preparation of T-joint 63
Figure 62: Test sample – V-seam weld 63
Figure 63: Test sample – cover layer and root of butt weld 64
Figure 64: Test sample – preparation of T-joint 64
Figure 65: Testing area, bending of T-joint, and cutting position of test piece for transverse side bending test 65
Figure 66: Specimens of transverse side bending test 66
Figure 67: Specimens of transverse bending test and microstructure section 67
Figure 68: Fracture test 67
Figure 69: UT and MT testing of test piece 67
Figure 70: Welding positions 69
Figure 71: Overhead position – PF vertical up position 69
Figure 72: Welding position – PG vertical down position 69
Figure 73: Welding position – H45 inclined position (pipe fixed) welding downward 69
Figure 74: Overview of welding positions in accordance to DIN ISO 6947 and AMSE IX Code 73
Figure 75: Extract of ISO 15608 – Scope of material application for the welding procedure 74
Figure 76: Extract of DIN EN 156014 – Contents of welding procedure quality record (WPQR) 75
Figure 77: Extract of DIN EN 15601 – Record of weld test belonging to WPQR 76
Figure 78: Extract of DIN EN 156014 – Test results of welding procedure 77
Figure 79: Extract of DIN EN 2553:1992-10 – Symbolic representation on drawings 78
Figure 80: Extract of DIN EN 5817:2006 – Quality levels for imperfections 78
Figure 81: Extract on DIN EN 9692-1:2006 – Recommendation for joint preparation 85

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Table 1: Quality requirements according to DIN EN ISO 3934 11

Table 2: Most important types of welding joints 19
Table 3: Designation of joint butt weld preparation in reference to the illustration above 20
Table 5: Designation of typical example of fusion welds in reference to the illustration above 22
Table 7: Welding symbols 24
Table 8: Complementary indications 24
Table 9: Examples of complementary indications 25
Table 10: Tolerances for linear dimensions 29
Table 11: Tolerances for angular dimensions 30
Table 12: Straightness, flatness, and parallelism tolerances 30
Table 13: Recommended filler material for fully stainless steel and irregular welding joints 40
Table 14: Minimum preheating temperature of several materials 44
Table 15: Maximum interpass temperature of several materials 44
Table 16: Stress-relieving temperature of several materials (Source: Metallurgy of Welding, VDI publisher) 45
Table 17: Basic values of the permissible stresses (St37…S235, St52…S355) 46
Table 18: Overview of welding symbols in DIN 15018 47
Table 19: Overview of welding symbols in DIN 15018 47
Table 20: Lifting classes and loading groups 51
Table 21: Examinations of test pieces 65
Table 22: Important welding processes 73

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1 Copyright
The content of this document is our copyrighted property. The unauthorized use of this documentation or use
contrary to its intended purpose is not permitted and will be prosecuted.
2 General
The technical metallurgical components of Siemens VAI are designed pursuant to DIN and EN Standards.
The technical calculation of most welded technological steel structures exposed to nonstatic loading is typically
based on DIN 15018 as well as ISO 13001. The execution of the manufacturing and particularly the welding is
based on DIN 18800 as well as DIN EN 1090.
In addition to these standards, national instructions for use and specification are also mandatory for this
manufacture. The quality assurance of welding work is to be carried out pursuant to
DIN EN ISO 14731 (DIN EN 719) and DIN EN ISO 3834 (DIN EN 729)
3 Welding
Welding is an individual process, and the welding quality depends on the successful performance of each
procedure step. Due to the fact that the welding quality cannot be checked on the final product, each step
must be controlled very carefully.
Welding has an essential influence on the quality and costs of the product. Consequently, it is important to
guarantee that the welding is applied effectively and that all procedure steps are supervised accordingly.
Standard e.g. DIN EN ISO 15607 – 156014 must be applied.
Target:
All factors of the welding procedure must be described and recorded to define the welding clearly and
traceably.
The method of qualification depends on standards, requirements, regulations, and legislation.
An overview of typical standards used for definition of the welding quality is shown in Figure 1.

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Figure 1: Overview of standards for welding
If a foreign manufacturer workshop does not posses the specified licenses, Siemens VAI will recognize
national licenses (e.g., AWS, TÜV, GL) if they are comparable and correspond with the construction standards.
The manufacturer must have at its disposal and must apply all required standards and processing guidelines.
The same requirements are mandatory for submanufacturers and SVAI contractual partners.

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Standards
DIN EN ISO 3834 Quality requirements for fusion welding of metallic

DIN 18800 Execution of steel structures (replaced by DIN EN 1090)
DIN EN 1090 Execution of steel structures and aluminum structures
DIN EN 15018, ISO 13001 Cranes
DIN EN 13445 Unfired pressure vessels
DIN EN ISO 15607, …, 15614 Specification and qualification of welding procedures for
ISO 15608 Guidelines for a metallic materials grouping system
DIN EN ISO 14731 Welding coordination – Tasks and responsibilities
DIN EN ISO 14732 Welding personnel – Approval testing of welding operators
(EN 1418) for fusion welding and resistance weld setters for fully
mechanized and automatic welding of metallic materials
DIN EN ISO 9606-1 Qualification testing of welders – Fusion welding (12/2013)
DIN EN 287-1 DIN EN 287-1 replaced by DIN EN ISO 9606-1
ISO 17659 Joint weld type description
ISO 2553 Welded, brazed, and soldered joints – Symbolic
DIN EN ISO 6947 Welding and allied processes – Welding process
EN ISO 13916 Guidance on the measurement of preheating maintenance
DIN EN ISO 13920 General tolerances for welded constructions
DIN EN ISO 9692-1 Recommendations for joint preparation
DIN EN ISO 5817 Quality levels for imperfections
DIN EN 25817 DIN EN 25817 replaced by ISO 5817
DIN EN 6947 Welding and allied processes – Welding positions
DIN EN ISO 17663 Welding – Quality requirements for heat treatment in
connection with welding and allied processes
EN 1011 Recommendation for fusion welding
DIN EN ISO 17663 Welding – Quality requirements for heat treatment in
connection with welding and allied processes
DIN EN 13480-4 Metallic industrial piping – Part 4: Fabrication and
installation
DIN EN 1320 Destructive tests on welds in metallic materials – Fracture
DIN EN ISO 5173 Destructive tests on welds in metallic materials – Bend tests
ISO/TR 25901 Welding and related processes - Vocabulary
Other Standards
ASME Code IX Welding and brazing qualification

D-STD-VT-01/03 VT – Examination procedure according to AMSE
D-STD-PT-01/03 PT – Examination procedure according to AMSE
D-STD-MT-01/03 MT – Examination procedure according to AMSE
D-STD-UT-01/03 UT – Examination procedure according to AMSE
SEW 88 Welding of fain grain steel

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4 Welding quality requirements
4.1 Quality requirements for fusion welding
Quality requirements for fusion welding are defined in DIN EN ISO 3834, which is divided into
3 quality levels:
Elementary welding requirements

Standard welding requirements
Comprehensive welding requirements
Additional quality requirements for welding are provided in the required product standards
(e.g.: DIN 18800 or EN 1090, ISO 13001), specifications, regulations, and drawings.
The following table shows the requirements of DIN EN ISO 3834:
No. Element 3834 - 2 3834 - 3 3834 - 4

1 Review of requirements Review required
Record is required Record may be Record is not required

required
2 Technical review Review required
Record is required Record may be Record is not required

required
3 Subcontractor Treat like a manufacturer for the specific subcontracted product,

services, and/or activities; however, final responsibility for quality
remains with the manufacturer
4 Welder and welder operator Qualification is required
5 Welding coordination Required No specific requirement

personnel
6 Inspection and testing Qualification is required

personnel
7 Production and testing Suitable and available as required for preparation, process
personnel execution, testing, transport, lifting, in combination with safety
equipment and protective clothes
8 Equipment maintenance Required to provide, maintain, and No specific requirement

achieve product conformity
Documented plans Records are

and records are recommended
required
9 Description of equipment List is required No specific requirement

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10 Production planning Required No specific requirement
Documented plans Documented

and records are plans and records
required are
recommended
11 Welding procedure Required No specific requirement

specification
12 Qualification of the welding Required No specific requirement

procedures
13 Batch testing of consumables If required No specific requirement
14 Storage and handling of A procedure is required in accordance In accordance with

welding consumables with supplier recommendations supplier
recommendations
15 Storage of parent material Protection from environmental influence
required; identification will be maintained
through storage
16 Post-weld heat treatment Confirmation that the requirements No specific requirement
according to product standards or
specifications are fulfilled
Procedure, record, Procedure and
and traceability of record are
the record to the required
product are required
17 Inspection and testing before, Required
during, and after welding
18 Nonconformance and Measures of control are implemented; Measures of control
corrective actions procedures for repair and/or rectification are implemented
are required
19 Calibration or validation of Required If required No specific requirement
measuring, inspection, and
testing equipment
20 Identification during process If required No specific requirement
21 Traceability If required No specific requirement
22 Quality records If required
Table 1: Quality requirements according to DIN EN ISO 3934

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4.2 Specification and qualification of welding procedures
Welding must be performed with a qualified procedure. For each application a welding procedure specification
(WPS) must be available in accordance with the relevant sections of EN ISO 15609 or AMSE Code IX.
The contractor must provide the WPQR to the appropriate standards. A WPS must be prepared from the
WPQR, which must be provided by the manufacturer (or contractor or subvendor).
The contractor is responsible for welding execution in compliance with the welding procedure specification
(WPS).
4.3 Welding procedure qualification record (WPQR)
A welding procedure qualification record (WPQR) is used to qualify a welding procedure.

The verification of t h e WPQR is given by qualifying a pre-WPS (welding procedure specification)
according to DIN EN ISO 15614 or AMSE Sec. IX, Welding Qualification.
The following steps must be followed to qualify the WPQR:
Preparation and creation of a pre-WPS (see 4.4 Welding procedure specification)

Cutting and preparing of a test sample
Surface irregularities, gutters, or impurities such as grease, oil, or slag must be removed completely
from the chamfer/groove before welding (cleaning and grinding).
Welding of a sample with a qualified welder per DIN 287-1 (DIN EN ISO 9606-1) or ASME Code – Section IX
Note that in several cases, according to AMSE Code, a welder can also be qualified through
the PQR qualification (QW 142).
During the welding an authorized welding coordinator must be present to examine the pre-WPS and the
welded test sample (visual testing and breaking test)
The test sample will be cut into examination samples according to the qualification standard for the required
tests (e.g., bending test, hardness test, tensile test, impact test)
Following positive test results from authorized third party (laboratory), the PQR is qualified.
If the results are negative the test sample must be welded and qualified again.
Further detailed information about qualification of the WPQR is given in ISO 15614-1 and
ASME Code Sec. IX for fusion welding.

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4.4 Welding procedure specification (WPS)
A welding procedure specification contains the welding instructions for the welders and is qualified by t h e
WPQR. Therefore, each WPS is to be related to its WPQR number.
A separate WPS must be created for e a c h welding procedure, welding procedure combination, joint type,
base material, filler material, heat treatment, or preheating.
If a different material thickness or diameter i s used, a separate preheating instruction plan must be created
or specified in a separate WPS.

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5 Terms and definitions
The terms and definitions for welding are based on ISO 14731.
Manufacturer: Person or organization responsible for the welding production
Welding coordination: Coordination of manufacturing operations for all welding and welding-related activities
Welding coordinator: Person responsible for and competent to perform welding coordination
Welding inspection: Conformance of welding-related matters by observation and judgment accompanied

by measurement or testing, as appropriate
Recommendations for technical knowledge in welding:
International welding engineer (IWE)

International welding technologist (IWT)
International welding specialist (IWS)
Essential welding-related tasks in accordance with ISO 3834 to be considered when appropriate.
5.1 Review of requirements
A product standard must be used together with any supplementary requirements. The capability of the
manufacturer to meet the prescribed requirements in accordance to ISO 3834.
5.2 Technical review
The technical review comprises the following:
Specification of parent materials

Location of the joint with relation to the design requirements
Quality and acceptance requirements for welds
Location, accessibility, and sequence of welds, including accessibility for inspection
and nondestructive testing
Other welding requirements, e.g. batch testing of consumables, aging, hydrogen content,
permanent backing, surface finish, weld profile
Dimensions and details of joint preparation and completed weld

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5.3 Subcontracting
The contractor is obligated to instruct subcontractors wi t h reference to requirements. With regard to

subcontracting, the sustainability of welding quality for any subcontractor for welding fabrication will be
considered.
5.4 Welding personnel
With regard to welding personnel, the qualification of welders and welding operators, brazers, and brazing
operators will be considered.
5.4.1 Welder
Welders must possess a valid certificate in accordance with DIN EN ISO 9606-1 (DIN EN 287-1) Certificates
in accordance wi t h other standards (e.g. ASME Section IX – QW304) will be accepted if they are
comparable. In several cases the welders must be qualified by SVAI.
In accordance with DIN EN ISO 9606-1, the welder qualification is valid for 2 years. After an interruption of
6 months, the qualification is no longer valid. A verifiable interruption of less than 6 months is permitted.
A welder qualification examination and certificate issued in accordance with DIN EN ISO 9606-1 can be
performed only through an authorized third party (e.g. SLV) or welder coordinator (DIN EN 14731)
nominated through a contractor’s qualification in accordance with EN1090 (DIN 18800 – part 7).
Note: A welder pass from the Republic of China is valid only for national use.
In accordance with AMSE Code Section IX (9), the welder qualification remains valid for an unlimited time, but
the manufacturer must provide welding practice evidence for each qualified welder. If for any reason
a welder cannot meet practice evidence for 6 months, the welder must be qualified again.
5.4.2 Welder operator
Welder operators perform fully mechanized or automatic welding and are approved by one of the
following methods:
Welding procedure test

Pre-production welding test and production test
Production sample testing
Function test
Welder operator setter’s approval remains valid for a period of 2 years. A verifiable interruption of less than
6 months is permitted; otherwise the operator must be qualified again.
The approval and qualification of welder operators is defined in DIN EN ISO 14732 and EN 1418.

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5.5 Equipment
Suitability of welding and associated equipment

Auxiliaries and equipment supply, identification, and handling
Personal protective equipment and other safety equipment directly associated with the applicable
manufacturing process
Equipment maintenance
Equipment verification and validation
5.6 Production planning
Reference to the appropriate procedure specification for welding and allied processes
Sequence in which the welds must be made
Environmental conditions (e.g. protection from wind, temperature, rain)
Allocation of qualified personnel
Equipment for preheating and post-heat treatment, including temperature indicators
Arrangements for any production test
5.7 Qualification of the welding process
With regard to the qualification of the welding procedures, the method and range of qualification
will be considered.
5.8 Welding procedure specification (WPS)
With regard to welding procedure specifications, the range of qualification will be considered.
5.9 Work instructions
With regard to work instructions, the issuing and use of work instruction will be considered.
5.10 Welding consumables
Compatibility
Delivery conditions
Any supplementary requirements in the welding consumable purchasing specifications,
including the type of welding consumable inspection document
Storage and handling of welding consumables

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5.11 Materials
Any supplementary requirements in the material purchasing specifications, including the type of
inspection document for the material
Storage and handling of parent material
5.12 Inspection and testing before welding
Qualification and certification of welders and welding operators

Suitability of the welding specification
Identity of the parent material
Joint preparation
Fitting, jigging, and tacking
Any special requirements in the welding procedure specification (e.g. prevention of distortion)
Suitability of working conditions for welding, including the environment
5.13 Inspection and testing during welding
Essential welding parameters (welding current, arc voltage, and travel speed)
Preheating/interpass temperature
Cleaning and shape of runs and layers of weld metal
Back-gouging
Welding sequence
Correct use and handling of welding consumables
Control of distortion
Any intermediate examination (e.g. checking dimensions)
5.14 Inspection and testing after welding
Use of visual inspection (for completeness of welding, weld dimensions, shape)

Use of nondestructive testing
Use of destructive testing
Form, shape, tolerance, and dimensions of the construction
Results and record of post-operators (e.g. post-weld heat treatment, aging)
5.15 Post-weld heat treatment (PWHT)
With regard to PWHT, performance in accordance with the specification will be considered.
5.16 Nonconformance and corrective actions
With regard to nonconformance and corrective actions, the necessary measures and actions
(e.g. weld repairs, reassessment) will be considered.

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5.17 Calibration and validation of measuring, inspection, and testing equipment
With regard to the calibration and validation of measuring, inspection, and testing equipment,
the necessary methods and actions will be considered.
5.18 Identification and traceability
Identification of production plans

Identification of routing cards
Identification of weld locations in construction
Identification of nondestructive testing procedure and personnel
Identification of weld consumables (e.g. designation, trade name, cast number)
Identification and/or traceability of parent material (e.g. type, cast number)
Identification of location of the repair
Identification of location of temporary attachments
Traceability of fully mechanized and automatic welding units to specific welds
Traceability of welder and welding operators to specific welds
Traceability of welding procedure specifications to specific welds
5.19 Quality records
With regard to quality records, the preparation and maintenance of the necessary records
(including subcontracted activities) will be considered.

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6 Welding joints, symbols, and dimensions
6.1 Descriptions of joint welds
The types of joints are determined by the number, dimensions, and relational orientation of the parts
to be joined, and are depicted as follows:
Designation Symbol Designation Symbol
Butt weld Lap joint
Parallel joint T-joint
Cruciform joint Corner joint
Angle joint Multiple joint
Table 2: Most important types of welding joints

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The following figures illustrate terms concerning types of joint preparation and joint geometry:
Figure 2: Types of butt weld preparation
Ref. no. Description Ref. no. Description

A Upper workpiece surface E Fusion face (prepared)
B Reserve side F Root face
C Plate edge X Weld pool backing
D Fusion face (unprepared) 1 Plate thickness
3 Side edge workpiece 4 Root gab
5 Side of gab face 6 Side of gab fusion face
7 Joint length 8 Longitudinal edge of preparation
9 Joint thickness 10 Root radius
11 Root gab 12 Depth of root face
14 Side edge of root face 15 Side edge of preparation
16 Width of preparation 17 Angle of bevel
18 Depth of preparation 19 Width of prepared face
20 Joint width 21 Included angles
Table 3: Designation of joint butt weld preparation in reference to the illustration above

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Figure 3: Types of T-joint weld preparation
Ref. no. Description Designation Symbol

E Fusion face (prepared) I Fusion face (fillet weld)
1 Plate thickness 4 Root gab
7 Joint length 8 Longitudinal edge of preparation
11 Root gab 12 Depth of root gab
13 Longitudinal edge of root face 14 Side edge of root face
15 Side edge of preparation 16 Width of preparation
17 Angle of bevel 18 Depth of preparation
20 Joint width 21 Included angle

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Figure 4: Typical example of fusion welds
Ref. no. Description Designation Symbol

1 Parent metal 2 Weld metal
3 Heat-affected zone 4 Weld zone
5 Fusion penetration 6 Fusion line
7 Root of weld 8 Weld width
9 Excess weld metal 10 Leg length
11 Penetration bead thickness 25 Root penetration
12 Fusion zone 1 Base material
Table 5: Designation of typical example of fusion welds in reference to the illustration above
Further joint weld terms are defined in ISO 17659.
The following figure describes the difference between weld layers and weld beads.
Definition of weld layers Definition of weld beads
6th cover layer

11&12 cover beads
5th layer
4th layer
3rd layer 4th bead

2nd layer 2nd bead 3rd bead
1 layer / root 1st bead / root 5th bead
Figure 5: Definition of weld layers and weld beads described with V-weld seam

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Figure 6: Description of HAZ (heat affected zone) in detail
Ref. no. Description

HAZ Heat-affected zone
1 Fusion line (transition area)
2 Coarse grain – brittle
3 Fine grain – tough
4-5 Transition from fine grain to base material
6 Base material

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6.2 Elementary symbols (DIN 1912)
The elementary symbols are to be combined for welding both sides in such a manner that the applicable
elementary symbols are arranged symmetrically to the reference line.

Single butt Single-V butt
weld weld with broad
root face
Single-V butt Single-bevel
weld butt weld with
broad root face
Single-bevel Single-U butt
butt weld weld
Single-J butt
Back run weld
weld
Steep-flanged Steep-flanged
single- bevel
single butt weld
butt weld
Double-V or Double-bevel
X-butt weld butt weld
Double-V butt Double-bevel

weld with broad butt weld with
root face broad face
Table 7: W elding symbols
Complementary indications may be necessary in order to specify some other characteristics of welds:
Shape
Execution Shape of
of weld Symbol Symbol Symbol
of weld weld surface
surface
Flat Toes blended Circumferential weld

smoothly
Use of permanent
Convex Side weld
backing strip
Sequence of
Use of removable
Concave information in the tail
backing strip
of the reference mark
Table 8: Complementary indications

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The information for joints and the dimensions can be supplemented by further information in
the tail in the following order:
Welding process in accordance with DIN 1910 or DIN EN 24063

Acceptance level in accordance with ISO 5817 or DIN EN 30042
Working position in accordance with DIN 1912 ISO 6947
Filler materials in accordance with DIN EN 499, DIN EN 440, ISO 544, ISO 2560 and ISO 3581

Flat (flush) Fillet weld
Concave (ground) with single-V
single-V butt weld butt weld
Flush finished
Concave (ground) (machined)
fillet weld single-V
butt weld
Table 9: Examples of complementary indications
6.3 Position of the symbols on drawings
Elements of reference symbol Indications at the reference symbol
1 = W eld joint 1 = Main dimension of weld thickness

2 = Arrow line 2 = Weld symbol
3a = Reference line (solid line)
3b = Reference line (dashed line) 3 = W eld length dimensions
4 = Forked line for supplementary 4 = Indication for welding process
indications
Figure 7: Elements of the reference symbol and indications at the symbol

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The side of the joint with the reference symbol is called the “arrow side.” The other side of the joint is called
the “opposite side.” The arrow line should point to the “upper workpiece face.” The following figure shows the
locations of the “arrow side” and “opposite side” of the joint:
Figure 8: Relation between arrow line and joint – fillet welds
The symbol is placed either above or below the reference line. If the symbol is shown on the solid reference
line, the weld is on the arrow side. If the symbol is shown on the dashed reference line, the weld is on the
opposite side. See the figure below.
Figure 9: Position of the symbols according to the reference line
Figure 10: Position of the symbols and welds according to the reference line
Further application examples are shown in ISO 2553 and descriptions of joint welds are shown
in ISO 17659.

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6.4 Dimensions of drawings
Each weld symbol may be accompanied by a number of dimensions. The main dimensions relative to the
cross section are written on the left-hand side of the symbol, and longitudinal dimensions are written on the
right-hand side.
For fillet welds there are two methods to indicate dimensions. Therefore, the indication “a” or “z”
should be placed in front of the corresponding dimension as follows:
z = a x ~1.41
a = z x ~0.7
Figure 11: Methods of indicating dimensions of fillet welds
Figure 12: Partial-penetration welds Figure 13: Designation of weld forms

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~ 3 mm root not clean S Theory
S Effective
Figure 14: Difference between theoretical welding thickness and effective welding thickness
A = a² A = 0.5 a²
Figure 15: Fillet weld versus partial-penetration welds
Partial penetration welds as shown in the figure above have the same stress level but are achieved with just
half of the welding volume.
The following symbol “s” shows the minimum distance from the surface of the part to the bottom of
the penetration, which cannot be greater than the thickness of the thinner part.
Figure 16: Methods of indicating dimensions for deep penetration of butt welds

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The symbol “l” indicates the length of the fillet weld. Fillet welds can be executed at different positions and
distances. The distance between the fillet welds is indicated with “(e)”.
Figure 17: Methods of indicating dimensions for intermittent fillet welds
6.5 General welding tolerances
General tolerances for welded constructions are defined by DIN EN ISO 13920. For welded structures
the following tolerances are applied:
“B” refers to linear measurements and angular dimensions

“F” refers to straightness, flatness, and parallelism
Table 10: Tolerances for linear dimensions
The length of the shorter angle leg will be used to determine, on the basis of the following table, which
tolerances are to apply. The length of the leg may also be assumed to extend to a specified reference point.
In this case, the pertinent reference point will be indicated on the drawing.

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Table 11: Tolerances for angular dimensions
Figure 18: Examples of angle leg and reference point
The straightness, flatness, and parallelism tolerances specified in the table below apply to both the overall
dimensions of a weld, welding assembly, or welded structure, and also to the section for which the dimensions
are indicated. Other tolerances for form and position are specified in EN ISO 1101.
Table 12: Straightness, flatness, and parallelism tolerances

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7 Welding aspects for manufacturing
7.1 Traceability of material
The requirements for material traceability and the type of marking are specified in SVAI technical
specifications or in product standards (e.g., DIN 18800, EN 1090).
For material traceability, all material certificates must be marked at a minimum with the drawing number or
with a number that relates to the bill of material (BOM) or to a cutting plan.
100% traceability all material is covered by the material certificate, bill of material (BOM),
cutting plan, and stamping of all parts or at least all main parts.
Figure 19: Marking – stamping
Note: During the welding work it is necessary to ensure that the marking remain on the plates.
7.2 Welding bevel preparation (per ISO 9013)
The joint preparation must be executed per ISO 9013.
Chamfers and grooves must be free of surface irregularities, gutters, or impurities such as grease, oil, and
slag before welding.
Gutters and surface irregularities must be repaired or ground to rounded form.

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There are 4 quality levels for bevel preparation. The engineer must choose the appropriate level.
Cutting and welding is one of most important steps.
Figure 20: Chamfer with unacceptable gutters and impurities

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Figure 21: Before and after grinding of gutter for welding
Figure 22: Unacceptable cutting procedure Figure 23: Result of unacceptable cutting procedure
Figure 24: Unacceptable cutting procedure Figure 25: Acceptable cutting procedure

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Figure 26: Excellent sandblasted and ground chamfer
Figure 27: Ground chamfers
Figure 28: Ground chamfer with back strip

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Preheating for cutting must be performed according to the carbon equivalence and thickness of plates.
All materials <0.45% carbon equivalent can be cut without preheating.
For the following materials preheating must be performed before and during the cutting:
S420N, S420NL, P420NH (min 120°C)

S460N, S460NL, P460NH (min. 150°C)
S690N, S690QL (min. 180°C)
10CrMo9-10 (min. 200°C)
Figure 29: Hardness measurement
In case of doubt, a hardness test can be applied as a prevention. The critical limits are defined in several
standards (350HV10 in accordance with SEW or 380HV10 in accordance with EN 1090).

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7.3 Important welding aspects
7.3.1 Tack welding
Tack welding must be executed with a minimum of 40 mm (>3mm plate thickness) and a distance of 300 mm
between tack welds. Before welding, all tack-welding cracks, binding defects, and accumulation of pores must
be removed completely by grinding.
Ignition spots and short tack-welded spots are deviations of material and should be avoided. Such spots lead
to quick heat dissipation, which creates a hard, brittle, crack-sensitive martensitic steel microstructure.
Inspection of such deviations must be performed by MT after grinding.
Figure 30: Imperfections – ignition spots
7.3.2 Welding of root
For high welding volumes, special materials such as S355NL, S420NL, 16Mo3, P420NH, S690QL,
10CrMo9-10, and stainless-steel string beads must be used in order to reduce the heat input (welding
deformation) and to meet their interpass temperature. Pendulum or oscillation movement should be avoided.
For critical and full-penetration weld seams, the use of SMAW instead of GMAW is recommended
for welding seam roots to avoid back-gouging and to guarantee welding quality.
7.3.3 Interpass welding
Slag and welding spatter must be removed by each interpass weld.

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7.3.4 Execution of weld seams and welding supports
All welds must meet visual execution standards according to ISO 5817. The group is defined in the drawing
or technical specifications; otherwise Group – C must be applied.
Additional information about the standards in ISO 5817 and evaluation of defects is described in the
appendixes.
String and pendulum beads for carbon steel welding have advantages and disadvantages, as follows:
String beads reduce the heat input and the deformations during welding (welding of root)
Too much pendulum increases the heat input, but causes and supports the quenching effect in
the multiple-layer procedure (cover layer)
Too much pendulum increases the danger of lack of fusion (casting effect)
~30 mm
Figure 31: Open arc welding – disallowed beads (pendulum / oscillation torch movement)
Figure 32: Staggered and small string beads
No more than 20 mm of oscillation (pendulum) is recommended.

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Notches as shown in following figures must be welded around or closed completely by welding. The notch
radius will be performed with 25-30 mm + t plate. Run-out (run-off) plates must be used and executed with
2 x plate thickness.
Figure 33: Notch
Figure 34: Used run-out plates

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Figure 35: Length of welding, usage of run-out plates
Back strips must be tacked or continuously welded on the back. It is recommended to use back strips greater
than 8 mm (minimum 6 mm).
Figure 36: Non-tack-welded back strips and tack-welded strips

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7.3.5 Full penetration welding
Welds with full penetration (100% UT) are indicated with a particular back-gouging or grinding symbol.
Removal of the root on the opposite side by grinding or gouging is recommended in order to perform
a subsequent MT or PT testing (free of cracks) to guarantee the welding quality.
Root must be cleaned /removed by grinding or gouging to guarantee welding quality
Figure 37: Through (full) penetration welds
7.3.6 Welding of austenitic and irregular (carbon/austenitic) welding joints
For fully stainless austenitic welding joints, the same types of welding consumables (electrode, wire, cored
wire) must be utilized. For irregular (carbon/stainless steel) welding joints, high alloyed welding consumables
are generally recommended, as shown in the table below.
Due to certain factors, the heat input and the dilution (intermixture) must be minimized. Following string
beads are applied to meet their interpass temperature of less then 150°C for fully austenitic stainless and
irregular joint welds (carbon/austenitic). Pendulum or oscillation movement of the torch should be minimized
or avoided.
In any case carbon steel has to be preheated in accordance to EN1011-1.
Base material Welding consumables

DIN EN ASTM / AISI EN AWS Boehler
X5CrNi18-10, X2CrNi18-9 304 19 9 L ER308L EAS 2
X6CrNiTi18-10 321 19 9 L; 19 9 Nb ER308L EAS 2
X2CrNiTi17-12-2 316 L 19 12 3 L ER316 L EAS 4
X5CrNi18-10 with unalloyed 304 with unalloyed 20 10 3 ER308Mo CN 19 9 M
steel (S355 e.g.) steel (S355e.g.)
X6CrNiTi18-10 with 321 with unalloyed 23 12 L ER309L CN 23/12
unalloyed steel (S355 e.g.) steel (S355 e.g.)
X2CrNiTi17-12-2 with 316 L with unalloyed 23 12 L ER309L CN 23/12
unalloyed steel (S355 e.g.) steel (S355 e.g.)
Table 13: Recommended filler material for fully stainless steel and irregular welding joints

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Be mindful of cleanliness during and after the welding – avoid dust, oil, and grease. Grinding, sandblasting,
and pickling must be applied. Grinding can be performed only with special tools for stainless steel.
Heat treatment must be avoided.
In any case, carbon and stainless steel must be stored separately to avoid airborne corrosion dust.
Figure 38: Grinding of interpass layer (stainless steel)
More details about welding of austenitc steels are provided in EN 1011-2.
7.3.7 Welding and repairing of structural steel (S355 e.g.)
Slag and welding spatter must be removed completely. All welded parts must be cleaned by sandblasting and
checked by visual testing according to DIN EN ISO 5817. Additional nondestructive testing (PT, MT, UT, or RT)
requirements are indicated in SVAI specifications or in drawings.
A hardness measurement should be performed between the melted zone and the base material –
the so-called heat-affected zone (HAZ) – after 3 repairs of a welding seam as a prevention. Hardness average
values over 350HV will be evaluated as critical. In this case the responsible engineering department must be
informed.
In certain cases parts can be rejected in coordination with Siemens VAI headquarters if the average hardness
values of at least 3 measurements in the HAZ are 350HV or higher.

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7.3.8 Notchless ground welding seams
Notchless ground welding seams are indicated in the drawing. The specified radius is ground and checked
against the template.
Figure 39: Notchless ground radius of r30
Attention: Notchless means not instantaneous notchless grinded!
7.3.9 Tack welding and welding on fluid welding parts (piping)
All welds must meet visual execution standards according ISO 5817. If no group is specified,
Group – C according ISO 5817 must be applied.
The welding surface must free of surface irregularities, gutters, or impurities such as grease, rust, coating, oil,
and slag before welding. Gutters and surface irregularities must be repaired or ground to rounded form
Figure 40: Spray headers – oxidized weld seam

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The root piping welding is to be performed by TIG (tungsten inert gas welding). Spatters in the inner surface
are not permitted.
Welding joints oxidize during welding due to heating of the area. The amount of oxidation depends on the
welding heat input, content, and access to oxygen from the surrounding air. Figure 41 shows oxidizing or
annealing color depending on the temperature.
High potential Potential High potential

for non-corrosion for corrosion for non-corrosion
resistance resistance resistance
Not permitted Permitted Not permitted
Figure 41: Annealing color depending on temperature (Source: Linde Group)
Oxidizing layers of stainless steel with a higher layer thickness (up to 300 nanometer), compared to normal
inactive layers (5 to 10 nanometer), are porous, which leads to non-corrosion resistance.
To avoid reaction of air with stainless steel, the piping must be flooded with inert gas (Ar with 2-10% H, N
with 2-5% H, or 100% Ar). The amount of gas must be adapted to the heat input and air access (by increasing
the proportion of inert gas). Each joint not to be welded must be covered during tack-welding and welding.
The outer surface of the piping should be cleaned by grinding, pickling, or blasting.
If annealing layers cannot be avoided, the inner and outer piping surface must be cleaned by pickling,
brushing, or grinding.
More details about welding of fluid parts are provided in EN 1011-1, EN1011-2 and in EN 13480-4.

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7.4 Preheating & interpass temperature
The preheating and interpass temperature must be selected on the basis of the type of material and the
thickness or diameter of the material. The following table shows the recommended preheating temperatures
depending on the plate thickness:
Material combinations Preheating temperature

<35 mm 35-55 mm 55-65 mm 65-85 mm >85 mm
< 355 N/mm² (e.g., S235, S275, P275) - 60°C 70°C 80°C 100°C
355 N/mm² (S355, P460) 60°C 80°C 100°C 120°C 150°C
10CrMo9-10, 13CrMo4-5 80°C 100°C 120°C 150°C 200°C
Stainless steels (austenitic Steels) No preheating
Table 14: Minimum preheating temperature of several materials
More details about preheating are provided in DIN EN 1011 and EN 13916.
Material Max. interpass

temperature
P250, S235, S275, S355, P235, P275, P355 >350°C

16Mo3, S355N, S355NL, S460N, S460NL, P420NH >300°C
10CrMo9-10, 13CrMo4-5 >250°C
Stainless steels (CrNi) >150°C
Table 15: Maximum interpass temperature of several materials
Figure 42: Electric preheating of converter-shell parts Figure 43: Preheating by gas flames of upper lever
for a ladle turret

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7.5 Post-welding heat treatment (PWHT)
Quality requirements for heat treatment in connection with welding and allied processes are defined in ISO
17663. PWHT is mainly used to reduce the stress and local stress peaks to avoid deformations during
machining.
The temperature selection depends on the material, as shown in the following table:
Base material PWHT temperature

P250GH 520 – 600°C
S235, S275, S355, P235, P275, P355 520 – 580°C
P420NH, 16Mo3 530 – 620°C
13CrMo4-5 600 - 700°C
10CrMo9-10 680 - 720°C
Table 16: Stress-relieving temperature of several materials (Source: Metallurgy of Welding, VDI publisher)
General heat treatment of austenitic steels should be avoided. If heat treatment of austenitic steel structure is
unavoidable, the release must be clarified and confirmed by a specialist or by the responsible person at SVAI.
Vibration stress relieving can be performed as an alternative.
Heating
The heating rate is defined as 50°C times the maximum thickness of the product for one minute.
Example: 30 mm maximum thickness of the product --> heat up to 50°C in 30 min.

100 mm maximum thickness of the product --> heat up to 50°C in 100 min.
Hold time
A minimum of 2 minutes of hold time is required for each millimeter of plate thickness.
The hold time is calculated by the maximum thickness of the product.
Example: For a plate thickness of 60 mm, the hold time is 120 min or 2 hours
Cooling
The cooling rate depends on the heating rate and should be 2 times higher than the heating rate.
Figure 44: Post-weld heat treatment of a converter shell (material 10CrMo9-10 equivalent to A-387 Gr.22)

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8 Excerpt of welding calculations
The welding of a typical dynamically loaded welded structure is based on DIN EN 15018.
For dynamically loaded welded structures (load cycles >2 104 = 20000) the service strength must be
calculated and compared with the actual stress level.
The allowable service strength depends on various factors:
Material under consideration

Type of welding
Lifting class
Loading groups
The lifting class and loading groups must be defined by the engineer. However, some guide values
are given in Table 20.
Table 17: Basic values of the permissible stresses (St37…S235, St52…S355)
A common loading group value for Siemens VAI products is B5.
Note: According to Table 17, for this loading group there is no difference between material S235 and S355.
Also, the application of post-weld heat treatment is not given any advantage in terms of permissible stresses.
An overview of the symbols used in this standard is shown in Tables 18 and 19.

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Table 18: Overview of welding symbols in DIN 15018
Table 19: Overview of welding symbols in DIN 15018

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8.1 Examples of notch cases
The figure below shows examples of different kinds of filler weld execution in accordance with the
notch stress distribution (sigma k).
Figure 45: Notch stress distribution of different kinds of filler weld
Different weld seam geometries and surface conditions lead to different notch cases.
Some types of weld joints with different notch cases will be described as follows:
NOTCH
CASE K0
NOTCH
CASE K1

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NOTCH
CASE K2
NOTCH
CASE K3
NOTCH
CASE K0
NOTCH
CASE K1
NOTCH
CASE K2
NOTCH
CASE K3
NOTCH
CASE K4
NOTCH
CASE K2
NOTCH
CASE K3
NOTCH
CASE K4

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Figure 46: Example of drop in admissible stress level depending on notch factor
NOTCH
CASE K4
OR WORSE
Figure 47: Example of drop in admissible stress level due to low-quality welding of temporary supports on a highly loaded box girder.
In this case the admissible stress level in the box girder will drop to approx. 35% of the sound material.

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Item Type of crane Lifting Loading

No. classes groups
1 Hand-operated cranes H1 81, 82
2 Erection cranes H1, H2 81, 82
3 Powerhouse cranes H1 82, 83
4 Storage cranes Intermittent operation H2 84
5 Storage cranes, spreader bar cranes, Continuous H3, H4 85,86
scrapyard cranes operation
6 Workshop cranes H2, H3 83, 84
7 Bridge cranes, ram cranes Grab or magnet H3, H4 85, 86
operation
8 Casting cranes H2, H3 85, 86
9 Soaking pit cranes H3, H4 86
10 Stripper cranes, charging cranes H4 86
11 Forging cranes H4 85, 86
12 Transporter bridges, semi-portal cranes, Hook operation H2 84, 85

portal cranes with trolley or slewing crane
13 Transporter bridges, semi-portal cranes, Grab or magnet H3, H4 85, 86

portal cranes with trolley or slewing crane operation
14 Traveling belt bridges with fixed or sliding belt(s) H1 83, 84
15 Dockyard cranes, slipway cranes, Hook operation H2 83, 84
fitting-out cranes
16 Wharf cranes, slewing cranes, floating cranes, Hook operation H2 84, 85

level -luffing slewing cranes
17 Wharf cranes, slewing cranes, floating cranes, Grab or magnet H3, H4 85, 86
level luffing slewing cranes operation
18 Heavy duty floating cranes, gantry cranes H1 82, 83
19 Shipboard cargo cranes Hook operation H2 83, 84
20 Shipboard cargo cranes Grab or magnet H3, H4 84, 85
operation
21 Tower slewing cranes for the construction H1 83

industry
22 Erection cranes, derrick cranes Hook operation H1, H2 82, 83
23 Rail-mounted slewing cranes Hook operation H2 83, 84
24 Rail-mounted slewing cranes Grab or magnet H3, H4 84, 85
operation
25 Railway cranes authorized on trains H2 84
26 Truck cranes, mobile cranes Hook operation H2 83, 84
27 Truck cranes, mobile cranes Grab or magnet H3, H4 84, 85
operation
28 Heavy-duty truck cranes, heavy-duty H1 81, 82

mobile cranes
Table 20: Lifting classes and loading groups

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8.2 Welded structural beams
The engineering of structural beams is generally based on DIN standards. However, DIN-compliant beams are
not available in countries such as India or China.
In principle there are 3 possible methods to overcome this issue:
Import DIN beams from overseas

Change engineering and use local-standard beams
Build beams by welding of plates
The third option is mostly used. Consequently, the welding of beams becomes an issue and the welding quality
is often a point of discussion.
For statically loaded beams, the welding of flange plate to web plate can be executed with filler weld seams on
both sides (filler weld dimension a = 2 x ts; quality according to ISO 5817 with quality level “C”).
For dynamically loaded beams, the welding of flange plate to web plate should be applied as a full- penetration
weld with back-gouged root and with additional concave ground fillet welds on both sides
(quality according to ISO 5817 with quality level “B”).
Figure 48: Example of beam welding design for dynamically loaded steel structure (notchless)
Figure 49: Example of beam welding design for statically loaded steel structure

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9 Cladding of rollers for continuous casting

Cladding for rollers is utilized to guarantee the wear resistance at specified temperatures during the continuous
casting process.
The wear resistance depends on the delta ferrite content, which must be less than approx. 9%.
The indication for correct delta ferrite content is described by hardness and the chemical analysis
(chrome and nickel equivalent at 0 to 2 mm depth) from the roller surface. Those requirements
are specified in the following SVAI standards:
Technical Specification – Plating for Rollers for continuous casters (Open Arc Welding)
Technical Specification – Weld cladding of rollers jackets (Submerged-Arc Welding)
In any case, the supplier must prepare and send a test sample (length of approx. 100 mm) to SVAI
for checking (see QCP step 14).
The Material Conversion Table MT Global Tool (Excel) includes a delta ferrite calculation tool,
which can be used to check the content in advance.
Figure 50: Extract of Material Conversion Table Tool – Evaluation of Delta Ferrite

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9.1 Preheating temperatures for single and dual-layer welding:
9.2 Diameter of single layer (only for in-house manufacturing)
All values are related to cold conditions. The heat expansion due to higher temperatures must be considered.
Nominal diameter = d (example: d = 230 mm)

Rough diameter (pre-turning dia.) = d – 3 (example: 230 – 3 = 227 mm)
Weld diameter = d + (3 to 4) (example: 230 + (3 to 4) = 233 mm to 234 mm)
Welding seam thickness = 3 to 3.5 mm

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9.3 Diameter of dual layer (used for suppliers)
All values are related to cold conditions. The heat expansion due to higher temperatures must be considered.
Nominal diameter = d (example: d = 230 mm)

Rough diameter (pre-turning dia.) = d – 8 (example: 230 – 8 = 222 mm)
Weld diameter first layer = d – (3 to 2) (example: 230 – (3 to 2) = 227 mm to 228 mm)
Welding seam thickness first layer = 2.5 to 3 mm
Note: If the weld diameter of the first layer is too high, the rollers must be machined to the diameter d – 3.
Weld diameter second layer = d + (3 to 4) (example: 230 + (3 to 4) = 233 mm to 234 mm)

Welding seam thickness second layer = 3 to 3.5 mm
9.4 Setting parameters
During training for single- and dual-pass layer buildup welding (open-arc welding process), the following
parameters were recommended:

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9.5 Torch alignment and movement
Alignment of torch is shown in the figure below:
Figure 51: Torch alignment
Z-axis position (10-20 mm):
a) If the distance is too small, the welding seam height will be nonuniform, and the discrepancy will be high.
b) If the distance is too large, the melting bath flows against the rotation direction of the roller, and the
discrepancy will be low
Torch oscillation Torch oscillation
Poor Quality Good quality

Figure 52: Open arc welding – oscillation movement of the torch

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Oscillation length 25 to 30 mm Overlapping

5 to 10 mm
Figure 53: Open arc welding – pendulum length and overlapping
Stick-out 20 to 25 mm
Figure 54: Open arc welding – hold time during oscillation movement

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9.6 Causes of imperfections and corrective measures
Imperfections in plating transition (overlapping) zone:
Lack of fusion
Figure 55: W elding imperfections – lack of fusion
The pores shown in the figure are caused by insufficient overlapping of beads.
The unregulated layer transition zone and imperfections such as undercuts can be caused by:
Improper oscillation of wire

Insufficiently broad bath > Increase the voltage [V]
The following corrective measures can be taken:
Decrease the step-over distance from 26 to 25 mm

Apply dwell time for the torch (short hold point); see figure below
Oscillation movement
Hold Hold
0.2 sec.
Figure 56: Open arc welding – hold time during oscillation movement
Increase voltage stepwise from 0.5 V to a maximum of 31 V

Increase z-axis to maximum possible position

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10 Hand skill test
10.1 Introduction
In certain cases a welding hand skill test may be given to evaluate the welding ability of welders and to
guarantee welding quality.
General requirements for welder qualifications are standardized and are given in product standards, technical
specifications, regulations, and legislation. Welders must be qualified in accordance with integrated standards
and regulations as a precondition for fulfilling the required demand for final quality of welding; welders must
provide a qualification document.
Note: If the end user (start-up engineer) is part of the European Economic Area (EEA), or if the end user
requirements are based on the European Standard (DIN EN), a welder qualification is absolutely essential.
The qualification can only be performed by an authorized third party such as SLV, TÜV, etc., or by a qualified
welding coordinator nominated by a manufacturing qualification in accordance with DIN 18800 or EN 1090.
10.2 Requirements for welder skill test
Material
The material must be chosen in accordance with primary use of the equipment. In any case, a certificate
of the material used must be submitted and accepted by SVAI.
Filler Material
Filler material for the tests must be provided by ERECTION COMPANY.
Personal
Each welder must provide the original welder certificate following the requirements of t he
European Standard DIN EN, ASME Standard, and local rules.
Testing Personal
Personnel must be qualified according to EN 473 – minimum Level 2 or equivalent.
Welding position
1x piece – butt weld joint in PA or 1G – flat position
1x piece – T-joint in PC or 2G – horizontal position
1x piece – T-joint in PF or 3F – uphill
Performance of examination
VT in accordance with D-STD-VT-01/03 (ASME CODE SECT. V ART 9 or ISO 5817)
MT in accordance with D-STD-MT-01/03 (ASME CODE SECT. V ART 7 and
SECT. VIII DIV, 1 APP 6)
UT in accordance with D-STD-MT-01/03 (ASME CODE SECT. V ART 4 and
SECT. VIII DIV, 1 APP 12)

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Types of welding joint and dimensions of test sample
For the test a butt weld and a T-joint weld must be prepared. The test sample must be cut to
specified dimensions shown in figure below in millimeters.
The minimum thickness of the test sample is 12 mm (16 to 20 mm recommended).
Figure 57: Dimensions of test of butt weld joint and T-joint [mm]
Dimensions of test pieces:
1x butt weld joint: 2 pieces 150 mm x 350 mm (300+25+25) x thickness

2x T-joint weld: 2 pieces 125 mm x 200 mm (150+25+25) x thickness
10.3 Hand skill test procedure
Before the hand skill test begins a WPS (welding plan specification) should be prepared and discussed with
the welders.
Each welder must be equipped with personal safety equipment such as glasses, gloves, shoes, etc.
The test sample must be cut to the proper dimensions. Welding machines and filler material must be prepared
by the welding company in adequate numbers. The number of welders must be appropriate to the site plus a
reserve for possible dropouts and some who do not pass the examination.

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The hand skill test is divided into the following steps (test situation):
Grinding and removing of slag, grease, and other contamination from the surface of the test sample
Preparation of plates and welding equipment to demonstrate preparation skills
Root welding and filler beads following the WPS to evaluate welding skills
Cleaning around the welding cover layers and removal of welding gutters to demonstrate care of welder
VT – examination of root, filler, and cover bead welding
Examination of welding
VT, MT (or PT), UT
Bending test
Brake test
10.3.1 Preparation of test sample
Welders must prepare the test sample without any instruction from Siemens VAI to demonstrate
fitting-up ability.
Figure 58: Test sample – preparation of butt weld joint
Recommended dimensions for butt weld welding chamfer:
Root gab b 2-3 mm

Included angles a 50-60°
Depth of root face c 0-1 mm
Figure 59: Test sample – dimensions of preparation of butt weld joint

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Figure 60: Test sample – preparation of T-joint
Recommended dimensions for T-joint welding chamfer:
Root gab b 0 mm
Included angles a 95–100° (90°after welding)
Root gab b 0–1 mm
Figure 61: Test sample – dimensions of preparation of T-joint
10.3.2 Execution
The welding qualification includes the welding of one butt weld in PA / 1G position and two T-joints
in PC and PF position.
PA / 1G position
3 layers (5-7 beads)
Figure 62: Test sample – V-seam weld

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The butt weld is to be executed with V-weld seams as full penetration in PA. On the cover beads the
welder should stop in the middle position of the test piece to demonstrate weld seam overlapping ability.
Cover layer with weld seams Root on the back side

overlapping on the front
Figure 63: Test sample – cover layer and root of butt weld
The T-joint weld must be performed with a10 in several layers. In addition, cover beads must be executed
with overlapping beads.
PC / 2G position
5 to 6 beads
10
Figure 64: Test sample – preparation of T-joint
The last sample T-joint must be welded with a10 and in 3G / PF position.

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10.3.3 Examination and testing of test pieces
Testing includes both nondestructive and destructive testing, to be executed according

to the following table:
Butt weld joint T- joint a10 T- joint a10
(PA / 1G position) (PC / 2G position) (PF / 3F position)
Visual testing in accordance X X X

with D-STD-VT-01/03
MT in accordance with X X X
D-STD-MT-01/03
UT in accordance with X
D-STD-UT-01/03
Transverse bending test in
accordance to X
DIN EN ISO 5173
Fracture test in accordance with

EN 1320 or microstructure section X X
DIN EN 1321
Table 21: Examinations of test pieces
Figure 65: Testing area, bending of T-joint, and cutting position of test piece for transverse side bending test

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Figure 66: Specimens of transverse side bending test

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Specimens and testing for bend testing of butt joints are to be in accordance with EN ISO 5173.
For longitudinal bend tests, the test specimen thickness (ts) should be equal to the thickness of the base
material but should not exceed 10 mm (ts :s 10 mm).
Figure 67: Specimens of transverse bending test and microstructure section
Figure 68: Fracture test
Figure 69: UT and MT testing of test piece

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10.4 Result of the welder test
10.5 Welder Pass
After a positive examination result the welder can be released for the welding work. Each of this welder will get
a welder pass, which has to be with the welder or wear during the welding work as long as they are working on
site or in the work shop. The welder pass for this group of welders should look like the following example:
A complete list of all welders with this pass should be handed over to SVAI before starting the welding on these
components.
Important note:
Only welders which have successfully passed the subjected skill test are authorized to weld on the current
equipment like converters and trunnion rings, ladle turrets and so on!

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11 Appendixes
11.1 Appendix 1: Welding positions
Welding positions are specified in standards DIN EN ISO 6947, AWS A3.Q, and ASME Section IX.
Figure 70: Welding positions
Figure 71: Overhead position - PF vertical up position
Figure 72: Welding position - PG vertical down position
Figure 73: Welding position – H45 inclined position (pipe fixed) welding downward

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Figure 74: Overview of welding positions in accordance to DIN ISO 6947 and AMSE IX Code
11.2 Appendix 2: Important welding processes
Code Description
111 SMAW – shield metal arc welding
121 SAW – submerged arc welding
125 SAW with cored wire electrode – submerged arc welding with cored wire electrode
131 IMAW – inert gas metal arc welding
135 GMAW – gas metal active welding
136 GMAW with cored wire electrode – gas metal active welding with cored wire electrode
141 GTAW – tungsten metal arc welding (TIG)
Table 22: Important welding processes

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11.3 Appendix 3: Scope of material application for WPQR
Figure 75: Extract of ISO 15608 – Scope of material application for the welding procedure

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11.4 Appendix 4: Template for welding procedure qualification record form (WPQR)
Figure 76: Extract of DIN EN 156014 – Contents of welding procedure quality record (WPQR)

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Figure 77: Extract of DIN EN 15601 – Record of weld test belonging to WPQR

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Figure 78: Extract of DIN EN 156014 – Test results of welding procedure

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11.5 Appendix 5: Extract of ISO 2553:1992-10 –

Symbolic representation on drawings
Figure 79: Extract of DIN EN 2553:1992-10 – Symbolic representation on drawings

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11.6 Appendix 6: Extract of ISO 5817:2006-10 – Quality levels for imperfections

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Figure 80: Extract of DIN EN 5817:2006 – Quality levels for imperfections

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11.7 Appendix 7: Extract of ISO 9692-1 – Recommendations for joint preparation

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Figure 81: Extract on DIN EN 9692-1:2006 – Recommendation for joint preparation

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Manual For Inspectors. Module 2: Welding

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Manual for Inspectors.

ALL PC 004/13 I Verison 1.0 I 12/12/2013 Page 1

ALL PC 004/13 I Verison 1.0 I 12/12/2013 Page 2

7.3.4 Execution of weld seams and welding supports 37

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Figure 1: Overview of standards for welding 8

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Table 1: Quality requirements according to DIN EN ISO 3934 11

ALL PC 004/13 I Verison 1.0 I 12/12/2013 Page 6

Standard e.g. DIN EN ISO 15607 – 156014 must be applied.

The method of qualification depends on standards, requirements, regulations, and legislation.

ALL PC 004/13 I Verison 1.0 I 12/12/2013 Page 7

Figure 1: Overview of standards for welding

ALL PC 004/13 I Verison 1.0 I 12/12/2013 Page 8

DIN EN ISO 3834 Quality requirements for fusion welding of metallic

ASME Code IX Welding and brazing qualification

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4 Welding quality requirements

4.1 Quality requirements for fusion welding

Elementary welding requirements

The following table shows the requirements of DIN EN ISO 3834:

No. Element 3834 - 2 3834 - 3 3834 - 4

Record is required Record may be Record is not required

2 Technical review Review required

Record is required Record may be Record is not required

3 Subcontractor Treat like a manufacturer for the specific subcontracted product,

4 Welder and welder operator Qualification is required

5 Welding coordination Required No specific requirement

6 Inspection and testing Qualification is required

8 Equipment maintenance Required to provide, maintain, and No specific requirement

Documented plans Records are

9 Description of equipment List is required No specific requirement

ALL PC 004/13 I Verison 1.0 I 12/12/2013 Page 10

10 Production planning Required No specific requirement

Documented plans Documented

11 Welding procedure Required No specific requirement

12 Qualification of the welding Required No specific requirement

13 Batch testing of consumables If required No specific requirement

14 Storage and handling of A procedure is required in accordance In accordance with

21 Traceability If required No specific requirement

22 Quality records If required

Table 1: Quality requirements according to DIN EN ISO 3934

ALL PC 004/13 I Verison 1.0 I 12/12/2013 Page 11

4.2 Specification and qualification of welding procedures

4.3 Welding procedure qualification record (WPQR)

A welding procedure qualification record (WPQR) is used to qualify a welding procedure.

The following steps must be followed to qualify the WPQR:

Preparation and creation of a pre-WPS (see 4.4 Welding procedure specification)

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4.4 Welding procedure specification (WPS)

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5 Terms and definitions

Manufacturer: Person or organization responsible for the welding production

Welding inspection: Conformance of welding-related matters by observation and judgment accompanied

Recommendations for technical knowledge in welding:

International welding engineer (IWE)

5.1 Review of requirements

5.2 Technical review

The technical review comprises the following:

Specification of parent materials

ALL PC 004/13 I Verison 1.0 I 12/12/2013 Page 14

The contractor is obligated to instruct subcontractors wi t h reference to requirements. With regard to

5.4 Welding personnel