Inspect Production WeldMetal shop QC

Presentation OUT LINE# SADAF WELDING SERIES# ASME/AWS STANDARDS# SADAF STANDARDS# RESPONSIBILITIES# JOB FILEDRAWING / SCOP OF WORK / REQUEST FOR WPS APPROVED / PQRCONTECT LEST / INSPECTION WELD FIT UP

Presentation OUT LINE CONTINUE .. # CONSTRUCTION MATERIAL / BASE MATEL# WELD JOINT PREPARATION / FIT UP / TACK WELD# WELDING ENVIRONMENT/ SAFTY PROCEDURE# WELDING ELECTRODE / PREHEAT TEMPRATURE# WELDING TECHNIQUE /WELD SEQUENCE/ SHIELDING# WELDING VARIABLES # VOTAGE / AMPERAGE / TRAVEL SPEED / CURRENT /NTERPASS CLEANING & BACK GOUGING

SADAF W - SERIESThis series provides background information on welding and outlines engineering considerations to aid the inspector in understanding the mandatory requirements of welding standards

ASME StandardsASME standards are published by The American Society of Mechanical Engineers

AWS StandardsThe American Welding Society (AWS) publishes standards containing information which the inspector may require during pre welding inspection

SADAF STANDARDSdescribes the procedure and general requirements for qualifying all welders and welding operators in SADAF

Metal Shop QC RESPONSIBILITIES

The QC Welding Inspector reviews WPS and Qualification of welders according to SADAF approved welding procedures.

His role is to inspect fit ups and make dimensional checks and visual inspection of completed welds.

Responsible for Quality control in the field and Shop. To monitor each job to ensure quality workmanship.

Responsible for periodic and annual evaluations of the Welders he supervises.

Checks storage and handling of welding consumables and electrodes/filler wires.

Prepares daily welding inspection reports and welds summary sheets.

Coordinates with SEI inspectors for witnessing Hydro test of spools .

Maintains and keeps record in all NDT results and coordinates with clients.

Works closely with the SADAF Metal Shop Supervisor.

Maintains a networking relationship with other Supervision.

Works closely with all technical and inspections groups (Stationary, Rotating )

Identifies any training needs of the craftsmen under his supervision and discuss appropriate training action with the SADAF supervisor Metal Shop QC RESPONSIBILITIES CONTINUE ..

Job FileJob File

Inspecting a Weld Set - UpThe 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 MaterialsThe inspector must verify that the materials to be used in a construction project are as specified

Base MetalMetal on site must be the same as the metal specified for the job

Welding ElectrodesThe inspector must check the electrodes

Weld Joint PreparationBevel Angle

Root FaceWall Thickness

Joint Fit UpIf 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

Lack of PenetrationEntrapped SlagExcess Penetration

Joint Fit UpThe inspector checks these during fit up

Root Opening

Joint Fit UpThe inspector checks these during fit upMismatch(high-low)

Joint Fit UpThe root face must be clean dry and smooth

Joint Fit UpThe inspector can use a welding gauge to measure the bevel angle

Joint Fit UpThe inspector can use a welding gauge to measure the bevel angle

Joint Fit UpThe bevel angle can also be measured with a ruler and a protractor

Bevel Angle

Joint Fit UpThe High low is the amount of misalignment when joining metals

Joint Fit UpHigh Low can be measured using a Hi lo Welding Gage

Tack WeldsTack welds must be performed by qualified welders

Welding EnvironmentThe inspector must assess the wind conditions at the welding site

Welding EnvironmentToo much wind will blow the gas shield away and welding discontinuities will result

Safety ProceduresWelding 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 TemperatureSome metals to be welded must be pre heated to a specified temperature prior to welding

TemplestiksThe inspector uses a Templstik to ensure the correct pre heat has been attained .

Pre Heat TemperatureThe pre heat must be extended over a distance of not less than 75mm

75 mm75 mmWeld

Welding TechniqueA good welding Bead depends on the followingCorrect ElectrodeCorrect CurrentCorrect Polarity

Welding TechniqueA good welding Bead depends on the following

Correct Movement of the WelderCorrect Arc DistanceSteady Travel Speed

Stringer BeadA stringer bead is a weld bead that is made without much side to side motion

Root Pass

Weave WeldingWeave welding is a running bead with side to side motion

Weave Welding

Weld SequenceThe inspector makes certain that the welder follows the required weld sequence

12354

ShieldingTo obtain a weld of high quality, the welder must maintain efficient shielding throughout the welding operation

Gas Shielding

Gas MixturesThe welder uses various gases to create the gas shield

Gas Flow RateThe gas flow rate is the amount of gas that flows from the gas cylinder during a given period of time

Welding VariablesWelding variables are conditions that affect the weld

Welding Variables ASME IXFiller Metal & Flux Drying Procedure

Filler Metal ClassificationElectrical ParametersTravel Speed & Wire Feed Speed

Inter pass Temperature Post Weld Heat Treatment Pre - Heat Temperature

Welding Variables ASME IX

VoltageVoltage is a variable that can affect the weld

AmperageThe inspector must check the WPS for the specified amperage level

Travel SpeedThe inspector must check the WPS for the designated travel speed

CurrentIt is possible to do arc welding with either alternating current (AC) or direct current (DC)

Interpass CleaningThe welder must remove all slag from the weld

Back GougingBack gouging occurs when weld metal and base metals are removed from the opposite side of a partially welded joint

Gouged Weld

Air Carbon Arc GougingThis process is used for cutting of steels and back gouging of welds

Thank You