PEW 209 .

02
Inspect Production
Weld
SAES – W - SERIES
This series provides background
information on welding and
outlines engineering considerations to
aid the inspector in understanding the
mandatory requirements of welding
standards…
ASME Standards
ASME standards are published by The
American Society of Mechanical
Engineers…
AWS Standards
The American Welding Society (AWS)
publishes standards containing
information which the inspector may
require during pre – welding
inspection…
 SAEP - 321
SAEP – 321 describes the procedure and
general requirements for qualifying all
welders and welding operators in
Saudi Aramco…
Job File
The job file contains documents
necessary to the project and welding
personnel who are doing the job…
Blueprints / Drawings
The job file contains blueprints or
drawings of the entire fabrication…
Scope of Work
The scope of work explains the main
activities of a project…
Procedure Qualification
Record (PQR)

All welding procedures must be pre –

qualified…
Contact List
The job file should include a contact
list…
Inspecting a Weld Set - Up
The inspector starts a weld set up
inspection after thoroughly inspecting
the job file and studying the standards
referenced there.The basic purpose of
the weld set up inspection is to verify
the following…
Construction Materials…
Weld Joint Preparation
Joint Fit Up
Tack Welds
Welding Environment
Safety Procedures
Construction Materials
The inspector must verify that the
materials to be used in a construction
project are as specified…
 Base Metal
Metal on site must be the same as the
metal specified for the job…
Welding Electrodes
The inspector must check the
electrodes…
 Weld Joint Preparation
Bevel Angle

Wall Thickness
Root Face
 Joint Fit Up
If the bevel is too narrow or wide,fusion
may not be complete, slag may be
trapped in the weld and there can be
lack of penetration or Excess
Penetration…
Excess Penetration

Entrapped Slag Lack of

Penetration
Joint Fit Up
The inspector checks these during fit
up…

Root Opening
Joint Fit Up
The inspector checks these during fit
up…

Mismatch
(high-low)
Joint Fit Up
The root face must be clean dry and
smooth…
 Joint Fit Up
The inspector can use a welding gauge
to measure the bevel angle…
Joint Fit Up
The bevel angle can also be measured
with a ruler and a protractor…

Bevel Angle
Joint Fit Up
The High low is the amount of
misalignment when joining metals…
 Joint Fit Up
High Low can be measured using a Hi lo
Welding Gage…
Tack Welds
Tack welds must be performed by
qualified welders…
Welding Environment
The inspector must assess the wind
conditions at the welding site…
 Welding Environment
Too much wind will blow the gas shield
away and welding discontinuities will
result…
 Safety Procedures
Welding is a safe operation if everyone
obeys the safety rules…
Safety (Bad Practice)
Safety (Good Practice)
Safety (Eye Protection)
You only have one pair of eyes…
Protect them !!!
 Pre Heat Temperature
Some metals to be welded must be pre
heated to a specified temperature
prior to welding…
Templestiks
The inspector uses a Templstik to
ensure the correct pre heat has been
attained ….
 Pre Heat Temperature
The pre heat must be extended over a
distance of not less than 75mm…
Weld

75 mm 75 mm
PEW 209.02 Continued

Inspect Production
Weld
Welding Technique
A good welding Bead depends on the
following…

Correct Electrode…
Correct Current…
Correct Polarity…
 Welding Technique
A good welding Bead depends on the following…
Correct Movement of the Welder…
Correct Arc Distance…

Steady Travel Speed…

Stringer Bead
A stringer bead is a weld bead that is
made without much side to side
motion…

Root Pass
 Weave Welding
Weave welding is a running bead with
side to side motion…

Weave
Welding
Weld Sequence
The inspector makes certain that the
welder follows the required weld
sequence…

5 3
4
2
1
Shielding
To obtain a weld of high quality, the
welder must maintain efficient
shielding throughout the welding
operation…

Gas Shielding
 Gas Mixtures
The welder uses various gases to create
the gas shield…
 Gas Flow Rate
The gas flow rate is the amount of gas
that flows from the gas cylinder during
a given period of time…
Welding Variables
Welding variables are conditions that
affect the weld…
Welding Variables ASME IX

• Filler Metal & Flux Drying Procedure

• Filler Metal Classification

• Electrical Parameters

• Travel Speed & Wire Feed Speed

Welding Variables ASME IX

• Interpass Temperature

• Post Weld Heat Treatment

• Pre - Heat Temperature

 Voltage
Voltage is a variable that can affect the
weld…
 Amperage
The inspector must check the WPS for
the specified amperage level…
 Travel Speed
The inspector must check the WPS for
the designated travel speed…
Current
It is possible to do arc welding with
either alternating current (AC) or
direct current (DC)
Interpass Cleaning
The welder must remove all slag from
the weld…
 Back Gouging
Back gouging occurs when weld metal
and base metals are removed from the
opposite side of a partially welded
joint…

Gouged Weld
Air Carbon Arc Gouging
This process is used for cutting of
steels and back gouging of welds…