Inspectipn Test Plan

8/13/2019 Inspectipn Test Plan

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Browse: Home Welding Inspection Inspection Test Plan on Welding Quality Control

Inspection Test Plan on Welding QualityControl

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Welding Inspection

Inspection Test Plan (ITP# is a &uality document t%at must 'eprepared 'yt%e a'ricator prior a'ari)asi process* constru)si* run+ Here are step,tep %owto create and prepare an ITP in t%e wor)consturction a'rication:

$tep -Read t%e contract documents (including t%e tec%nical speci ications# and prepare a list oany discrepancies* am'iguities* missing in ormation and standards o materials and.orwor)mans%ip t%at it is considered are inappropriate+

$tep Contact t%e customer and resol"e t%e issues listed as a result o $tep -+

$tep /01amine t%e scope o wor) and di"ide it into separate areas re&uiring an Inspection andTest Plan (w%ere not already prescri'ed in t%e contract documents#+ 2s a general guide itis normally most con"enient to document a separate Inspection and Test Plan or eac%trade or wor) area.section+

$tep 3 4ote t%e Hold and Witness Points re&uired 'y t%e customer (including as listed in t%econtract documents#+

$tep 5Re"iew t%e contract documents again and note t%e re&uirements t%at %a"e t%e mostimpact on t%e &uality o t%e inis%ed wor)+ or eac% as) t%e &uestion 6W%at will 'e t%econse&uences i it is not made sure t%is is rig%t78 Be certain to include any re erences totests* su'mitting in ormation to t%e customer* o'taining appro"als and Hold and WitnessPoints+
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$tep !9etermine rom $tep 5 w%ic% items or aspects o eac% inspection will need to 'e recordedon c%ec)lists and prepare t%ese+

$tep

9iscuss t%e c%ec)lists wit% t%ose directly in"ol"ed wit% t%e wor) and o'tain t%eir input+T%is input s%ould particularly 'e directed at identi ying t%ose issues t%at %a"e caused pro'lems (and in"ol"ed e1tra costs# in t%e past* and t%ere ore warrant c%ec)ing at t%eearliest opportunity to a"oid unnecessary and costly recti ication+

$tep ;Prepare eac% Inspection and Test Plan to re lect t%e re&uirements o t%e contractdocuments+ Re erence t%e ITP in t%e Quality ust t%em to suit any comment recei"ed (or act as ot%erwise re&uired in t%econtract documents#+

$tep -?9ecide %ow 'est to di"ide t%e w%ole o t%e wor) into wor) areas or control purposes andindicate t%ese locations eit%er on a sc%edule (wit% re erence to grids and le"els# or 'ymar)ing up drawings+

$tep --

Prepare and issue c%ec)lists or eac% wor) area and identi y t%em according to location+

$tep -Train t%ose directly in"ol"ed wit% eac% o t%e ITP in t%eir use+ ormalise a procedure ort%e noti ication o Witness and Hold Points to t%e appropriate person(s#+

$tep -/Carry out inspections and tests in accordance wit% t%e Inspection and Test Plans* pro"idenotices to t%e customer and.or regulatory aut%orities or Hold or Witness Points* asdesignated or applica'le* and record t%e results on c%ec)lists+

2n Inspection and Test Plan identi ies t%e items o materials and wor) to 'e inspected ortested* 'y w%om and at w%at stage or re&uency* as well as Hold and Witness Points*re erences to rele"ant standards* acceptance criteria and t%e records to 'e maintained+Inspection and Test Plans* w%en properly implemented* %elp ensure t%at* and "eri yw%et%er* wor) %as 'een underta)en to t%e re&uired standard and re&uirements* and t%atrecords are )ept+


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ITP is t%e minimum re&uirement o t%e acti"ities or &uality control and inspection o t%eield construction wor)+ T%is Inspection and Testing Plan outline t%e e1tent o witnessinspection and its reporting+

HomeFailure Analysis

TIG Welding

MIG Welding

Flux Cored Weldin

g

Stick Welding

SAW

Resistance Weldin

g

Electron Beam Wel

ding

Ro otic Welding

Bra!ing " Solderin

g

Ex#ert Witness

Ex#erience

Fees

$inks

ASME P-Numbers

To reduce t%e num'er o welding and 'ra@ing procedure &uali ications re&uired 'a

metals w%ic% %a"e speci ied impact test re&uirements %a"e 'een assigned roup 4

T%ese assignments %a"e 'een 'ased on compara'le 'ase metal c%aracteristics* suc%

Composition Welda'ility Bra@ea'ility


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9istortion 9iscontinuities

2lloy $election $teel $tainless $teel 2luminum

$ection IE o t%e 2$


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3 4ic)el* C%romium* Tungsten

3 to 5? 4ot sed

5-* 5 * 5/ Titanium 2lloys

!-* ! irconium 2lloys

Test


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We can provide:

Platecoupons

Pipecoupons

Commonor special alloys

$tandardcode si@es

Bac)ingrings or 'ars

Practicesi@es

$pecialsi@es (see p%oto#

ust one coupon si@e+

SIMPLIFIES WEL E! Q"ALIFICATI#$%

-+ Quali ies or all t%ic)nesses per QW,35 +-('#*

+ Replaces testing on 'ot% 8 and !8 coupons*

/+ Quali ies or all diameters down to -8 D9 per QW,35 +/* and

3+ Quali ies or P,4um'ers - --* /3* 3- 3 L as limited 'y ,4o+ perQW,3//+


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STA$ A! SI&ES ' ,/.38 D9 E 5.;8 wall 1 38 longL / MN 1 -.-!8 'e"el#

T()*+,-)L% $2,-?!* r+ B material (P,4o+ -#* 'e"eled on one end

se or &uali ication testing

T()*+,-+L% $2,-?!* r+ B material (P,4o+ -#* 'e"eled on 'ot% ends

se or training or &uali ication testing

S"PE! PLATE C#"P#$S

I you do not need to &uali y or pipe* our new $ P0R PO2T0 CD PD4$o er similar ad"antages+ 2ccording to 2$


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can determine at least a good starting point for a welding procedure that produces thedesired weld."

Ta7le ). Weight o8 Welding Wire

Ta7le 9. Cap Pass Weld Application

Ta7le /. 2ee 1roo4e 5utt Weld Application
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mat% wit% a ew simple ormulas* we can determine at least a good starting point or awelding procedure t%at produces t%e desired weld+

EP#SITI#$ !ATEIt is essential to recall t%at 9eposition Rate is directly proportional to t%e speed at w%ic% a

particular wire diameter emerges rom a welding gun during welding+ 9eposition rate %asnot%ing to do wit% %ow ast t%e gun is tra"eling* nor t%e "oltage setting on t%e mac%ine+9eposition rate is simply a measure o %ow many pounds o wire come rom t%e weldinggun in a certain amount o time* typically measured in l'.%r+

I wire, eed speed increases* deposition rate increases+ We also understand t%at i wemaintain t%e wire, eed speed and c%ange to a larger diameter wire* deposition rate willincrease as well+ 2rmed wit% t%is understanding* calculating deposition rate ends up

'eing a "ery power ul e1ercise t%at gi"es you a num'er t%at can 'e used to calculate )eywelding parameters+ Oet s loo) at t%e ormula and an e1ample:

eposition !ate Calculation9eposition rate (l'.%r# -/+- S (Wire diameter# S (Wire, eed speed# S (0 iciency# ; Wire diameter in inc%es (in# ; Wire, eed speed in inc%es per minute (ipm# ; 0 iciency (-+? or solid wire* ?+;5 or cored wire# ; T%is calculation is or steel only ; e.g. : Wire diameter ?+?35 in (-+ mm# solid wire* W $ /?? ipm

9eposition rate -/+- S (?+?35# S (/??# S (-+?# +=! l'.%r

Calculating Tra4el Speed With eposition !ate

Gnowing t%e deposition rate* we can calculate t%e tra"el speed in inc%es per minute (ipm#or a particular weld+ Oet s say we want to ma)e a /.; in steel illet weld (assume -? percent rein orcement or ?+3- 5 in leg# using ?+?35 in solid wire at /?? ipm* t%e weig%to weld metal per oot can 'e calculated 'y multiplying t%e density o steel (?+ ;/ l'.in / #

'y t%e "olume o weld metal per oot as ollows:

Weld Weight Per Foot CalculationAolume o weld metal. t -. S ' S % S - in -. S ?+3- 5 in S ?+3- 5 in S - in -+? in /

Weig%t o weld metal. t o /.; in illet weld (?+ ;/ l'.in / # S (-+? in / # ?+ ;; l'. t

rom t%e calculation 'elow* we see t%at t%e tra"el speed or a one,pass* /.; in illet weldwould 'e 5+5 ipm* --+?/ ipm or a two,pass illet weld* or -!+55 ipm or a t%ree,passweld+

Tra4el Speed CalculationTra"el speed (deposition rate# S ( o passes#.5 S (weig%t o weld metal per ootUl'. tV# ( +=!# S (-#.5 S (?+ ;; # 5+5 ipm


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CALC"LATI$1 WI!E*FEE SPEE WIT< EP#SITI#$ !ATEOet s assume a re&uirement to ma)e illet welds at a rate o - l'.%r using ?+?35 inwelding wire+ We can calculate t%e W $ using t%e ormulas 'elow and Weig%t o WeldWire per oot in Ta7le ) +

Wire*Feed Speed CalculationWire, eed $peed (deposition rate#.5 S (weig%t o wire per oot Ul'. tV# (- #.5 S(?+??53# 333+3 ipm

D course* t%e tra"el speed or a one,pass /.; in illet weld at a - l'.%r deposition ratewould 'e ;+/- ipm as calculated 'elow:Tra"el $peed (deposition rate# S ( o passes#.5 S (weig%t o weld metal Ul'+. tV# (- #S (-#.5 S (?+ ;; # ;+/- ipm

MA3I$1 IT EASIE! T%e Bartonian Con"ersion actor (see Ta7le + # ma)es t%ings a 'it easier or illet welds+

T%e e1ample 'elow uses t%e con"ersion actor to calculate tra"el speed at 5+5 ipm ort%at same /.; in illet weld using a ?+?35 in solid wire+

Tra"el $peed +=! S ?+ 5+5 ipm (+ ;; #

Weig%t o weld metal per oot can 'e calculated or any >oint type 'y calculating t%e"olume and multiplying 'y t%e density o t%e weld metal (eg+ ?+ ;/ l'.in / or steel#+Howe"er* t%e "alues s%own in Ta7le , through Ta7le 9 eliminate t%e need to do t%ecalculation+ T%ese "alues are ta)en rom Ta'le - ,- in The Procedure Handbook of ArcWelding 'y t%e Oincoln 0lectric Co+* and s%ow t%e Weig%t o Weld


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SAMPLE CALC"LATI#$ $#.,W%at s%ould my wire, eed speed 'e i I want to ma)e a at* -.3 in illet weld at ? ipmtra"el speed using ?+?35 in solid wire and =?J2r.-?JCD s%ielding gas7

Re,arranging t%e Tra"el $peed calculation a'o"e to sol"e or 9eposition Rate we get:

9eposition rate 5 S Tra"el speed S (Weig%t o weld metal Ul'. tV#.( o passes# 5 S? ipm S (?+-!5#.- -!+5 l'.%r

Re,arranging t%e 9eposition Rate calculation a'o"e to sol"e or Wire, eed $peed we get:Wire, eed speed 9eposition rate.-/+- S (Wire diameter# S (0 iciency# -!+5.-/+- S(+?35 in+# S (-# ! ipm

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Inspectipn Test Plan