WELDING PROCEDURE

&
WELDER QUALIFICATION

UMAIR ASLAM

Maintenance (E-III)

PAK-ARAB REFINERY LIMITED

AGENDA
Welding Terminologies
Arc Welding Processes
Welding Defects
Welding Symbols
ASME Section IX
Welding Procedure and Welder
Qualification
WELDING TERMINOLOGIES
Section-I

PAK-ARAB REFINERY LIMITED

 Welding Terminologies

Welding:
•A metal working process
•Joined by heating to the melting point and
•Allowing the molten portions to fuse
Weldability:
The capacity of a metal to be welded easily
ARC
A comparatively low voltage electrical discharge through a gas, between spaced electrodes.
1) Arc due to direct current
2) Arc due to alternating current
3) Arc due to pulse current
DCRP:
In this case electrode is negative and base metal is positive.
2/3 heat is produced at the base metal and 1/3 at the electrode.
 Welding Terminologies
DCSP:
In this case electrode is positive and work piece is negative.
2/3 heat is produced at the electrode and 1/3 at the base metal
ARC Welding:
Produce coalescence of metals by heating with Arc or Arcs
Gouging & Air Carbon Arc Cutting
An arc cutting process that melts base metal by the heat of a carbon arc and removes the
molten metal by a blast of air.
Arc Force:
The axial force developed by an Arc plasma.
Electrode Force:
The force between the electrodes in making spot, seams, or projection welds by resistance
welds:.
 Welding Terminologies
Deposition Rate:
Weight of metal deposited in a given period of time, usually expressed in kg/hr.
Deposition Efficiency:
The ratio between deposited and melted weight of the electrode.
Shielding Gas:
Protective gas used to prevent atmospheric contamination.
Argon, Helium & Carbon dioxide
Operation Factor:
Proportion of the total welding time an operator is actually fusing electrodes.
Dilution:
A change in composition of a welding filler metal caused by the admixture of the base
metal or previously deposited weld metal in the deposited weld bead.
 Welding Terminologies
Residual Stress:
Stress remaining in a structure or member as a result of thermal or mechanical treatment.
Peening.
The mechanical working of metals by means of impact blows.
Pre-heating.
The application of heat to the base metal prior to a welding or cutting operation.
Post-heating:
The application of heat to a weldment after welding
Inter-pass Temperature:
In a multiple-pass weld, the temperature minimum or maximum, (as specified) of the
deposited weld metal before the next pass is started.
.
 Welding Terminologies
KERF.
The width of a cut produced during a cutting process.
Puddling:
•If welding is done without filler rod,
•Used for plates of less than 3 mm thickness
Forehand Welding
•When welding torch or gun is directed towards the progress of welding.
•The forehand welding technique adopted for thin sheets.
Backhand Welding
•When welding torch or gun is directed opposite to the progress of welding.
• A backhand welding is used for the thickness greater than 3 mm.
Weaving.
A type of weld bead made with transverse oscillation, and consequently wider than the
stringer bead
 Welding Terminologies
Stringer.
A type of weld bead made without appreciable transverse oscillation.
Duty Cycle.
The percentage of a 10 minute period that an equipment can be operated at a rated
amperage without over heating or suffering other damage.
Flat position
The position of welding used to weld from the upper side of the joint with the face of
the weld approximately horizontal
Horizontal position
•In fillet weld The position of welding used to weld from the upper side of the joint of
an approximately horizontal surface and against an vertical surface
•In groove wed the position of weld wherein the axis of the weld lies in an
approximately horizontal plane and the face of the weld lies in an vertical plane
 Welding Terminologies
Vertical Position
The position of welding wherein the axis of weld is approximately vertical
Overhead Position
The position of welding in which welding is performed from the underside of the joint
Open Circuit Voltage
It is the voltage at the output terminals of a welding power source, when it is energized but
has no current out put
Welding variables(procedure/performance)
Essential Variable:
•A parameter that when changed outside its permitted range requires requalification
•Affect mechanical properties
Non Essential Variable
•A parameter that when changed does not require requalification
•Doesn’t affect mechanical properties
 Welding Terminologies
Supplementary Essential Variable
 Is an essential variable only when impact testing is required
 Affect impact properties

WPS -Weld Procedure Specification:

 Qualified instructions on how to complete the weld

PQR -Procedure Qualification Record (ASME)

 Record of the welding parameters and test results

Welders Performance Qualification (ASME)

 Record of Welder test results and ranges of approval

Welder Qualifications
 Range of approval is not as restrictive as Procedure testing with fewer essential
variables.
 One welder performance qualification can cover many WPS’s.
 IMPORTANT ARC WELDING
PROCESSES
Section-II

PAK-ARAB REFINERY LIMITED

SHIELDED METAL ARC WELDING

 Widely used of the various arc welding processes.

 SMAW uses an arc between a covered electrode and the weld pool.
 It employs the heat of the arc, coming from the tip of a consumable covered
electrode, to melt the base metal.

 Shielding is provided from the decomposition of the electrode covering.

 Either alternating current (ac) or direct current (dc) may be employed, depending
on the welding power supply.

 A constant-current (CC) power supply is preferred.

 SMAW deposition rate is 60-70% and operation factor is 20-30 %

 SMAW is a manual welding process.

 SHIELDED METAL ARC WELDING
Advantages of SMAW:

a. Equipment is relatively simple, inexpensive, and portable.

b. Process can be used in areas of limited access.
c. Process is less sensitive to wind and draft than other welding processes.
d. Process is suitable for most of the commonly used metals and alloys.

Limitations of SMAW:

The process is less sensitive to wind and draft than gas shielded are welding
process
a. Deposition rates are lower than for other processes such as GMAW.

b. Slag usually must be removed at stops and starts, and before depositing a
weld bead adjacent to or onto a previously deposited weld bead.
 SHIELDED METAL ARC WELDING

Application

Material
SMAW can be used to join most of the common metals and alloys, the list include carbon
steel, the low alloy steel, the stainless steel and cost iron as well as copper, nickel,
aluminum and their alloys
Thickness
SMAW can be applied to material having thickness greater than 1.6mm
Position of welding
One of the major advantage of SMAW is that welding can be done in any position on most
of the material for which process is suitable
Location of welding
The simplicity of process make SMAW extremely versatile process with respect to location
and environment of operation
GAS TUNGSTEN ARC WELDING
(GTAW)
•GTAW is an arc welding process that uses an arc between a non-
consumable tungsten electrode and the weld pool.

•The process is used with shielding gas and without the application of
pressure.

•GTAW can be used with or without the addition of filler metal.

•The CC type power supply can be used with either dc or ac, the choice
depends largely on the metal to be welded.

•Direct current welding is typically performed with the electrode negative

(DCEN) polarity.
•GTAW deposition rate is 90-100 % and operation factor is 20-30%
•Alternating current is mainly used for welding of Aluminium and
Magnesium
GAS TUNGSTEN ARC WELDING
(GTAW)

Advantages of GTAW:
 Some commonly accepted advantages of the GTAW process include:
 Produces high purity welds, generally free from defects.
 Little post-weld cleaning is required.
 Allows for excellent control of root pass weld penetration.
 Can be used with or without filler metal, dependent on the
application.

Limitations of GTAW:
 Deposition rates are lower than the rates possible with consumable
electrode arc welding processes.
 Has a low tolerance for contaminants on filler or base metals.
 Difficult to shield the weld zone properly in drafty environments
GAS METAL ARC WELDING
(GMAW)
 GMAW is an arc welding process that uses an arc between
continuous filler metal electrode and the weld pool.

 The process is used with shielding from an externally

supplied gas and without the application of pressure.

 GMAW may be operated in semiautomatic, machine, or

automatic modes.

 It uses either the short circuiting, globular, or spray

methods to transfer metal from the electrode to the work.
 GAS METAL ARC WELDING
(GMAW)
Types of Metal Transfer

The basic GMAW process includes three distinctive process techniques:

 Short Circuit (Short Arc)
 Globular Transfer
 Spray Arc Transfer

Short Circuit (Short Arc)

 Operates at low voltages and welding current and small fast-freezing weld puddle
obtained
 Useful in joining thin materials in any position, as well as thick materials in vertical
and overhead positions
GAS METAL ARC WELDING
(GMAW)
Globular Transfer

 Welding current and wire speed are high and droplets of metal have a greater
diameter

 Most effectively done in the flat position

Spray Arc Transfer

 Occurs when the current and voltage settings are increased higher than that used
for Globular Transfer

 Used on thick base material, for flat position

GAS METAL ARC WELDING
(GMAW)

Advantages of GMAW:
The only consumable electrode process that can be used to weld most
commercial metals and alloys.
Deposition rates are significantly higher than those obtained with SMAW.
Minimal post-weld cleaning is required due to the absence of a slag.
Limitations of GMAW:
Limitations associated with GMAW process are:
The welding equipment is more complex, more costly, and less portable than
that for SMAW.
The welding arc should be protected from air drafts that will disperse the
shielding gas.
When using the GMAW-S process, the weld is more susceptible to lack of
adequate fusion.
When using the GMAW-S process, the weld is more susceptible to lack of

SUBMERGED ARC WELDING (SAW)

• Submerged arc welding is an arc welding process that uses an arc or

arcs between a flux covered bare metal electrode and the weld pool.
•The arc and molten metal are shielded by a blanket of granular flux,
supplied through the welding nozzle from a hopper.
•The process is used without pressure and filler metal from the
electrode.
•The process can be applied in semiautomatic, automatic and machine
modes.
 SUBMERGED ARC WELDING (SAW)

Advantages of SAW:

 Some commonly accepted advantages of the SAW process include:

 Provides very high metal deposition rates.
 Produces repeatable high quality welds for large weldments and repetitive short
welds.

Limitations of SAW:

 Limitations associated with SAW process are:

 A power supply capable of providing high amperage at 100% duty cycle is
recommended.
 Weld is not visible during the welding process.
 Equipment required is more costly and extensive, and less portable.
 Process is limited to shop applications and flat position.
 Welding Consumables
Introduction:
Welding consumables are materials used up during welding such as electrodes, filler
rods, fluxes and externally applied shielding gases.
•Coated electrode
•Fluxes
•Filler wires/ filler rods
•Shielding gases
Selection of Electrodes:
•Base Metal Strength Properties
•Base Metal Composition
•Welding Position
•Joint Design and Fit-up
•Thickness and Shape of Base Metal
•Production Efficiency and Job Conditions
WELDING CONSUMABLES
Fluxes:
Flux is a material used during welding, brazing or braze welding to clean the surfaces,
the joint chemically, to prevent atmospheric oxidation and reduce impurities or float
them to the surface.
Fluxes are used in
 SMAW
 SAW
 FCAW
Welding Consumables
Welding Consumables

AWS Designation
A 5.1 EXXXX
Flux
coating
Position
Electrode 1 for all position
2X flat and horizontal
First two digit of four, and three of five digit
number indicates tensile strength
E60XX means 60kpsi
WELDING IMPERFECTIONS
Section III

PAK-ARAB REFINERY LIMITED

WELDING IMPERFECTIONS

Discontinuity:
 An interruption of the typical structure of a weldment, i:e
 lack of homogeneity, metallurgical, or physical characteristic

A discontinuity is not necessarily a defect.

Defect:
A discontinuity whose size, shape or location makes detrimental to the useful service of
the part in which it occurs.
Discontinuities may be found in the
 weld metal,
 heat affected zone, or
 base metal of many elements
WELDING IMPERFECTIONS

 Cracks
 Gas Pores
 Solid Inclusions Porosity
 Lack of fusion
 Incomplete Joint Penetration
 Dimensional Discontinuities
 Mechanical or Surface damage
 Misalignment
 WELDING IMPERFECTIONS
Cracks
Form when localized stresses exceed the ultimate strength of the material.
Occur at elevated temperatures during weld metal solidification

Classified as either
hot cracks
cold cracks.

Hot cracks develop at elevated temperatures. Cold cracks develop after solidification
is complete.

Hot cracks propagate along grain boundaries. Cold cracks propagate both along grain
boundaries and through grains.
WELDING IMPERFECTIONS
Causes of Cracks;

1. Highly rigid joint

2. Excessive dilution

3. Defective electrodes

4. Poor fit-up

5. High sulfur base metal

6. Crater cracking
 WELDING IMPERFECTIONS
Porosity:

Porosity is characterized by cavity type discontinuities formed by gas entrapment

during solidification.

Causes of Porosity:

1.Excessive hydrogen, nitrogen, or oxygen in welding atmosphere

2.High solidification rate

3.Dirty base metal

4.Dirty filler wire

5.Volatilization of zinc from brass

WELDING IMPERFECTIONS
Solid Inclusion:

Entrapment of solid particles results into solid inclusion

Causes of Solid Inclusion:

1. Failure to remove slag

2. Improper joint design

3. Slag flooding ahead of the welding

4. Poor electrode manipulative technique

5. Entrapped pieces of electrode covering

 WELDING IMPERFECTIONS
Incomplete Fusion:

Fusion which does not occur over the entire intended for welding and

between all adjoining weld beads.

Causes of Incomplete Fusion

1. Insufficient heat input

2. Wrong type or size of electrode

3. Improper joint design

4. Inadequate gas shielding.

5. Incorrect electrode position

 WELDING IMPERFECTIONS
Incomplete Joint Penetration

Penetration by weld metal that does not extend for the full thickness of the base

metal in a joint with a groove weld.

Causes of Incomplete joint penetration:

1. In correct electrode position
2. Weld metal running ahead of the arc
3. Trapped oxides or slag on weld groove or weld face
 WELDING IMPERFECTIONS
Misalignment:
Linear

Excess weld metal height

Lowest plate to highest point

3 mm
Linear misalignment measured in mm

Angular

15
WELDING IMPERFECTIONS
WELDING IMPERFECTIONS

 Surface breaking
porosity

 Fine cluster
porosity  Blow
hole > 1.6 mm Ø

 Hollow
root
bead
  
 Welding Joints
Symbols
Section IV

PAK-ARAB REFINERY LIMITED

 Welding Joints & Symbols
Weld Joints

There are five basic types of joints for bringing two member for weld

A)But joint:
 Laying approximately in same plane
 Angular limit of angle= 135 to 180 deg.

B)Corner joint
 Laying approx. at right angles to each other in the form of angle
 Angular limit of angle= 5 to 90 deg

C)T- joint
 Laying approx. at right angles to each other in the form of angle
 Angular limit of angle= 0 to 5 deg
 Welding Joints & Symbols
D)Lap joint:

Joint between two overlapping member

Angular limit of angle= 30 to 135 deg.

E) Edge joint

Joint between edges of two or more parallel member

Angular limit of angles= 0 to 30 deg.

Welding Joints & Symbols
Welding Joints & Symbols
 Welding Joints & Symbols
Types of Welds:

1)Fillet weld,

2)Groove weld

3)Back or backing weld

4)Flange weld,

5)Plug or slot weld,

6)Spot or projection weld

7)Seam weld,

8)Surfacing weld.
 Welding Joints & Symbols
Welding Symbols:
A weld symbol indicates the required type of weld while the welding
symbol includes the weld symbol and supplementary information.
 Welding Joints & Symbols
Combination of elementary symbols
Welding Joints & Symbols
Combination of elementary symbols
Welding Joints & Symbols
 Counter
Finish symbol
symbol
Length of
weld Pitch
Groove weld
size
Groove Field
angle weld
Depth of
bevel

Weld all
around

By process

Weld symbol
Arrow to
joint
Tail(omit when No. of Reference line
reference is not passes
used
 ASME Section IX
Section V

PAK-ARAB REFINERY LIMITED

ASME SECTION IX

It relates to
 Qualification of welder/operator
 Brazer and brazing/operator
 Welding procedure
 WPS/PQR

Section ix divided into two parts

 Welding
 Brazing
ASME SECTION IX
Each parts is divided into four articles

General procedure
 Article I(welding),article XI (brazing)

Procedure qualification
 Article II(welding),article XII (brazing)

Performance qualification
 Article III(welding),article XIII (brazing)

Data
 Article IV(welding),article XIV (brazing)

Standard welding procedure

 Article V(welding)
ASME SECTION IX
Articl
ASM
parts e II &
E
XII
Preparation of
210
test coupon
QW
Welding
250
variables
Section
IX
Preparation of
210
test coupon
QB
Welding
250
variables
ASME SECTION IX
Articl
ASM
parts e III &
E
XIII
Qualification of
310
test coupin

Welding
QW 350 variables for
welder

Retest and
Section 320 renewal of
qualification
IX
Qualification of
310
test coupin
QB
Retest and
320 renewal of
qualification
 ASME SECTION IX
P Numbers:

To reduce the number of welding and brazing procedure qualifications required base metals

have been assigned P-Numbers by the ASME BPVC. Ferrous metals which have specified

impact test requirements have been assigned Group Numbers

These assignments have been based on comparable base metal characteristics, such as:
      Composition
      Weldability
      Brazeability
      Mechanical Properties

within P-Numbers.
 ASME SECTION IX
P-Numbers Base Metal (Typical or Example)

1 Carbon  Manganese  Steels (four Group Numbers

3 Half Molybdenum or half Chromium, half Molybdenum

4 One and a quarter Chromium, half Molybdenum

5A Two and a quarter Chromium, one Molybdenum

5B Five Chromium, half Molybdenum or nine

Chromium, one Molybdenum

5C Chromium, Molybdenum, Vanadium (five Group

Numbers)

6 Martensitic Stainless Steels (Grade 410, 415,

429) (six Group Numbers)

7 Ferritic Stainless Steels (Grade 409, 430)

 ASME SECTION IX
F- Number:
F-No. is a filler metal (electrodes & welding rods) grouping for qualification, and is

based

essentially on their usability characteristics which determine the ability of welders to

make

satisfactory welds with a given filler metals.

F Number General Description

 1 Heavy rutile coated iron powder electrodes :A5.1 : E7024

 2 Most rutile consumables such as :A5.1 : E6013

 3 Cellulosic electrodes such as :A5.1 : E6011

 4 Basic coated electrodes such as : A5.1 : E7016 and E7018

 WELDING PROCEDURE
&
WELDER QUALIFICATION
Section VI

PAK-ARAB REFINERY LIMITED

 WELDING PROCEDURE AND WELDER
QUALIFICATION

Qualification of welding Procedure

Weldement capable having required properties

Codes and standard

AWS
API
ASME
ASTM
JIS
BS

WPS
Document
Detail of required welding condition for specific application
To assess repeatability
WPS intended to provide direction for the welder
 WELDING PROCEDURE AND
WELDER QUALIFICATION
Procedure include
Parent material
 Type (Grouping)
 Thickness
 Diameter (Pipes)
 Surface condition)
Welding process
 type of process (MMA, MAG, TIG, SAW etc)
 Equipment parameters
 Amps, Volts, Travel speed
Welding Consumables
 Type of consumable/diameter of consumable
 brand/classification
 Heat treatments/ storage
 Welding procedure and Welder
qualification
Joint design
 Edge preparation
 Root gap, root face
 Jigging and tacking
 type of baking
Welding Position
 Location, shop or site
 Welding position e.g. 1G,2G, 3G etc
 Any weather precaution
Thermal heat treatments
 Preheat, temps
 Post weld heat treatments e.g. stress relieving
 WELDING PROCEDURE AND
WELDER QUALIFICATION
Procedure qualification record(PQR)
 A document
 Detail of actual welding condition
 Used to produced an acceptable test joint
 Result of qualification are recorded

PQR lists what was used in qualifying the WPS and the test results

Types Of Tests

Tension tests

To determine ultimate strength of groove weld joint

Acceptance criteria

Minimum tensile strength of weld equal to base metal

 WELDING PROCEDURE AND
WELDER QUALIFICATION
Guided Bend Test

To determine degree of soundness and ductility of groove weld

Acceptance
 HAZ should be completely within bent portion
 No defect in HAZ and weld exceeding 1/8 inch after bending

Notch Toughness Test

 To determine notch toughness of weld

Acceptance

In accordance with that section specifying

impact requirement
 WELDING PROCEDURE AND
WELDER QUALIFICATION
Welder qualification

To determine the welder’s ability to deposit sound weld metal

WPQ (welder performance qualification)

A document for welder performance include

 Essential variables
 Types of tests/results
 Ranges qualifies for each welder
 Welding procedure and Welder
qualification
In how many ways a welder can be qualified?

1) By preparing a WPS qualification test coupon

2) On production weld

For welder
 R.T of 6” length of first production weld

For operator
 R.T of 3” length of first production weld

3) By preparing a WPQ test coupon

 WELDING PROCEDURE AND
WELDER QUALIFICATION
Types of test required
Visual examination
Performance test coupons shall show complete joint penetration with complete
fusion of
weld metal and base metal
Mechanical test
A) Thickness <3/4”
Face bend
Root bend
B) Thickness >3/4”
Side bend
Radiographic examination
A) For pipes
Full circumference for big dia pipes
B) For small dia pipes
Multiple coupons
Max 4 coupons
Consecutively weld
WELDING PROCEDURE AND
WELDER QUALIFICATION
Retest and renewal of qualification

Retest

Immediate retest using visual examination

 Two consecutive test coupons if fail in visual
 Any one can be used for mechanical

Immediate retest using mechanical testing

 If test coupons fail in mechanical test two consecutive test coupons should given and
required to pass

Immediate retest using radiographic

 Additional 12” and 3” length of same production weld should given to welder
WELDING PROCEDURE AND
WELDER QUALIFICATION
Expiration of qualification
 After six month

Renewal of qualification
 Renewal is of certification is given on only one test coupon of either plate or pipe
index.jpg
welding procedure specification.jpg
image049.jpg