TWI tm THE WELDING INSTITUTE SENIOR WELDING INSPECTION COURSE REF: WIS10 TWI Ltd Granta Park Great Abington Cambridge CBI 6AL UK Copyright © 2001, TWI LtdO Sennen off of A YeB. @ svovreenrsoer Qovesrion . @® Ferecroeee TESTS ® N.O.7T Reroars. © Oear.TWI NN THE WELDING INSTITUTE SENIOR WELDING INSPECTOR COURSE DETAIL ALL COURSE MEMBERS PLEASE READ CAREFULLY 1. The general working programme is attached. 2. Any alterations will be announced by the course tutor. 3, The lectures and tutorials etc are supported by the course text, please read as appropriate. 4. Question papers are included at both welding and senior inspector level and will be used to reinforce most sessions please attempt the questions. 5. The end of course assessments are marked and the results recorded. 6. CSWIP3.2 examination candidates are reminded that examination success is based not only on course attendance, but also previous experience, (i.e. CSWIP require a minimum of five years experience as a Senior Welding Inspector, or hold a CSWIP 3.1 qualification for two years). Candidates are therefore advised to attend other courses in welding inspection or NDT (if appropriate) in order to improve their knowledge and competence. Discussion with the course tutor is advised. Standards reproduced with the permission of British Standards Institute.KEY KNOWLEDGE FOR WELDING INSPECTION PERSONNEL, ELDING INSTITUTE The information contained in this course text supplements the lectures given in courses WIS 5 and WIS 10. Terminology given in the test is that recommended in BS 499 Pt.1:1983; Weld Symbols to BS 499 Pt indication of both International (ISO) and American standards is given. }980. To supplement this further, however, an The sections are written in general terms and do not include all of the conditions that may apply to a specific fabrication or product. The examining body, CSWIP, expect candidates, for the Senior Welding Inspectors' Examination, to have sufficient knowledge of both 3:1 and 3:2 levels. Because of this, the text is based on the established Welding Inspectors’ course and additional information required for the senior level has been included. It is assumed course members have previously attended course WIS 5.TWI ————L NNN THE WELDING INSTITUTE SENIOR WELDING INSPECTOR COURSE REF: WIS10 CONTENTS SECTION TERMINOLOGY 1 THE DUTIES OF A WELDING INSPECTOR & THE SENIOR WELDING INSPECTOR CODES AND STANDARDS: WELDING PROCEDURES, PROCEDURE WELDER APPROVAL & DOCUMENTATION 4 MECHANICAL TESTING 5 SYMBOLS 6 MATERIALS 7 CONSUMABLES 8 THE FOUR FACTORS FOR ESTABLISHING A WELD 9 MANUAL METAL ARC WELDING 10 TUNGSTEN INERT GAS WELDING W DEFECTS WHICH MAY BE DETECTED BY SURFACE INSPECTION 12 METAL INERT GAS WELDING 13 SUBMERGED ARC WELDING 14 15 16 7 18 19 20 on CALIBRATION OF EQUIPMENT RESIDUAL STRESS AND DISTORTION WELDABILITY HEAT TREATMENTS NON DESTRUCTIVE TESTING REPAIR BY WELDING GAS WELDING, CUTTING & GOUGING 21 ARC CUTTING 22 OTHER WELDING SYSTEMS 23 INTERNAL DEFECTS & THEIR INTERPRETATION 24 WELD FAILURES 25 SAFETY 26 APPENDIX.SECTION 1TWI LN THE WELDING INSTITUTE TERMINOLOGY Use of the correct terminology is important. This course uses BS 499. GENERAL TERMINOLOGY WELDS and JOINTS Frequently the terms ‘weld’ and ‘joint’ are used incorrectly. Exact definitions are given in BS 499 ‘Welding terms and symbols’. TYPES OF WELD BUTT WELD og = FILLET WELD ales EDGE WELD Saat hdentations af each vole SPOT WELD SRE Illustration depicts resistance weld. Spot welds can be made with MIG or TIG processes. WELDING TECHNOLOGY Issue 0191 11TWI NN THE WELDING INSTITUTE TYPES OF JOINT The four basic welds can be used to join various types of joints. The following are some typical joints TYPE OF JOINT EXAMPLES BUTT TEE CORNER Lap Sh WELDING TECHNOLOGY 12 Issue 0191TWI Oe 32D TCE PLATE EDGE PREPARATION FOR BUTT WELDS The illustrations show standard terminology for the various features of plate edge preparations. FEATURES OF COMPLETED WELD A butt weld in a plate, made by welding from both sides, has two weld faces, four toes. In a full penetration weld made from one side, the protruding weld ‘on the underside is the penetration bead. Tee pace Tee =_ Face Toe WELDING TECHNOLOGY Issue 0191 13TWI a ‘THE WELDING INSTITUTE If a weld is sectioned, polished and etched, the fusion boundary can be established. Metal lying between the two fusion boundaries is weld metal, a mixture of deposited metal and plate material that has been melted. Adjacent to the fusion boundary is the heat affected zone (HAZ), in which the plate material has a metallurgical structure modified by the heat of welding. Fillet welds also have Toes Aweld face A root A tusion boundary A heat affected zone fat attcreg The shape of a fillet weld in cross-section is described by three terms Mitre filet ——_ 1B» Convex fillet Concave fillet Excess weld metal, as illustrated, is often referred to as ‘weld reinforcement’. This does not necessarily mean it strengthens a joint. WELDING TECHNOLOGY 14 Issue 0191TWI NN THE WELDING NSTITUTE SIZE OF WELDS For full penetration butt welds, the general rule is: design throat thickness, t, = thickness of the thinner part joined. Partial penetration butt welds ‘The term partial penetration strictly implies butt welds that are designed to have less than full penetration. Failure to achieve full penetration when it is wanted should be listed as the defect INCOMPLETE PENETRATION. The throat thickness of a partial penetration weld made from both sides is t, + t,, and the design throat thickness t, + t,. Note that the degree of penetration must be known. Fillet weld sizes are calculated by reference to allowable shear stress on the throat area, i.e. throat area = design throat thickness x length of weld. The size required is specified on drawings in terms of leg length (1). For fillet welds with equal leg lengths: CoD) 131.44, A where t, is as defined for mitre and convex fillets. RO) x WELDING TECHNOLOGY Issue 0191 15TWI i ‘THE WELDING INSTITUTE if an asymmetrical fillet weld is required, both leg lengths are specified and t, is taken as the minimum throat dimension. TT Cer Deep penetration fillet weld w With high current density processes, e.g. submerged arc and MIG (spray). penetration along the joint line can be produced. This gives an increase in throat thickness with no change in leg length. WELDING TECHNOLOGY Issue 0191QUESTIONS Qi. Q2. Q3. 4. TERMINOLOGY Sketch a single vee butt joint and a single bevel butt joint ‘Sketch a tee joint and indicate for fillet welds: a) leg length b) throat thickness ©) root d) toes Complete the necessary features of the sketch: \— 7 CAS Describe the three (3) types of fillet weld shape. What is ‘excess weld metal’? QsiSECTION 2TWI MT | ‘THE WELDING INSTITUTE THE DUTIES OF THE WELDING INSPECTOR VISUAL INSPECTION At any point in the course of welding, i.e. tacking, root pass, filler pass or capping pass, but particularly for the root and cap, a detailed inspection may be required. British Standard 5289 : 1976 gives guidance on tools and responsibilities together with sketches of typical defects. The inspector at this point must - @) observe, identify and perhaps record the features of the weld. b) decide whether the weld is acceptable in terms of the particular levels which are permitted; defect levels may be ‘in-house’ or National Codes of Practice. When the defect size is in excess of the permitted level then either a concession must be applied for (from a competent person) or the weld rejected. CODE OF PRACTICE FOR VISUAL INSPECTION ‘A code of practice for an inspection department could take the form outlined below. It is appreciated that full implementation of the code would be extremely costly and therefore it may be necessary to reduce the amount of inspection to less than is theoretically required, AIDS OF VISUAL INSPECTION Mlumination: Good lighting is essential Inspection lenses: The magnification should not exceed 2-2% diameters. If higher magnification is required use a binocular microscope. Optical viewing devices area progressive development from the use of a hand torch and mirror, frequently with the addition of a magnifier and light source. In order to achieve accessibility probe units are available down to a diameter, properties for which are: Large field of vision. Freedom from distortion of image. Accurate preservations of colour values. ‘Adequacy of illumination. Popo WELDING TECHNOLOGY Issue 0191 24TWI 22 NN THE EL DING INSTITUTE VISUAL INSPECTION PRACTICE The inspector should be familiar with the following: All applicable documents. Workmanship standards. All phases of good workshop practice. Tools and measuring devices. PONS INSPECTION BEFORE WELDING Before assembly: Check: 1. Application standard 2. Welding procedure sheets 3. Drawings 4, Welder qualifications 5. Material composition 6. Condition of material 7. Type of edge preparation, method and finish 8. Consumables, ie. type of electrodes, filler wires, fluxes, shielding and backing gases (composition) and special drying requirements for electrodes 9. Welding process.processes After assembly: Check: 1. Clearance dimensions, tolerances, type of backing (if any) 2. Alignment, tack welds, bridging pieces, etc. 3. Cleanliness 4. — Preheat (if any) Note: Good inspection prior to welding could eliminate conditions that lead to the formation of defects. WELDING TECHNOLOGY Issue 0191TWI NN THE WELDING INSTT TY INSPECTION DURING WELDING Check: 1. Welding process 2. Preheat and interpass temperatures 3. Inter-run cleaning 4, — Joint preparation 5. Filler metals 6. Control of distortion 7. Root and subsequent runs Welding current and voltage Chipping, grinding, gouging . Fluxes and shielding gases . Compliance with weld procedure sheet and application standard 8. 9. a3! 1 1 AFTER WELDING Check: 1. Dimensional accuracy 2. Conformity of drawings and standard requirements 3. Acceptability of welds regarding appearance 4, Post-heat treatment (if any) 5. Repairs REPAIRS Mark out area positively and clearly. Use a method established and understood by all inspection and repair personnel. Check when partially removed (visual and NDT). Check when fully removed (visual and NDT). Check rewelding. Reinspect. no pane WELDING TECHNOLOGY Issue 0191 23QUESTIONS RESPONSIBILITIES AND DUTIES OF A WELDING INSPECTOR Qi. Q2. Q3. Qs. Give three (3) main responsibilities of a welding inspector ComPuasce WITH STALDAEDS, Romaine MeARLEACTLRE, PrreRsoeic | Give three (3) attributes which all welding inspectors must possess ENEsIaWT -— PANSICALLN ET, QAI RICA TIONS , Lsreneury, Liregacy Sie s, What documents or records should be referred to by the welding inspector? . Peoceduees, WerBee Qvars, Ere What are the duties of the welding inspector? ‘Should the most up to date code or specification be used? Wier \S SreeD I THE Conreactr. aQs2TWI Lm THE WELDING INSTITUTE THE DUTIES OF THE SENIOR WELDING INSPECTOR 24 The fabrication industry has come to accept the need for detailed inspection of welding for a combination of two reasons: 1. The quality of a manually made weld is critically dependent on the skill of the welder. 2. Much fabrication is made under sub-contracting conditions. There has developed, therefore, a system which is quite general, but is more obvious in the fabrication field, of client appointed inspectors who may work independently or alongside the fabricators own inspectors with or sometimes without the full co— operation of the welding supervisors and welders. Welding inspection in the general sense is the monitoring of the formation of the weld, i.e. materials, equipment, consumables, approvals of staff and procedures, examination of the completion, i.e. size, excess metal, undercut, surface defects, spatter etc., and the compilation of the documents into the fabrication file, Many quality welds are required to be examined by a non-destructive testing technique and operatives with the required skills are called in as required and the welding inspector obtains the NDT reports for the fabrication file. The senior welding inspector grade is able to assess and control welding inspection with a wide perspective because of his wider qualifications and experience. In addition he must have a knowledge of the practice of supervision and to have the necessary personal quality of leadership. It is not possible to be a senior welding inspector without technical knowledge BUT the quality of leadership is an essential addition. Itis sometimes said that leadership cannot be taught and there is a lot of truth in this. But the ability to lead can be improved by teaching,/ The technical skills required are: Knowledge of technology Knowledge of Codes of Practice Knowledge of Planning Knowledge of Organisation Knowledge of Auditing gaoNye Leadership requires : WELDING TECHNOLOGY Issue 0191TWI a ‘THE WELDING INSTITUTE Ability to do if so required Willingness to direct Acceptance of responsibility Understanding of problems Ability to delegate - willingness to trust staff 6. Commitment to ones staff gPone Knowledge of Technology: The scope and level of the technical aspects of welding with wnich the senior welding inspector needs to be familiar are similar to those of the welding inspector with slightly more depth but in addition a good appreciation of NDT is required together with (for CSWIP) a proven ability in radiographic interpretation. Knowledge of Codes of Practice: Neither welding inspectors or senior welding inspectors would be expected to have a detailed recall of the requirements of a code of practice. What is expected is at the senior level an appreciation of the commonly used codes and degree of stringency implied. That is what the product type is and what the general quality requirements are. As a first check list: 1. Standards for consumables BS 639 DIN 1913 AWS A‘5:81 2. Standards for welding procedure approval BS 4870 ASME IX 3, Standards for welder approval BS 4871 & 4872 ASME IX DIN 8560 4, Standards for quality of fabrication BS 5500 ASME Vill AWS Structural Code It is to be noted that standards are merely convenient collections of good practice data. As such a client who is commissioning the manufacture may incorporate this into the legal contract: but a client can (and often will) add requirements of his own devising. Most major fabrications and many smaller ones are in fact controlled by a code plus a special client requirement. WELDING TECHNOLOGY Issue 0191 25SENIOR WELDING INSPECTOR THE DUTIES OF A SENIOR WELDING INSPECTOR (SWI) QUESTIONS: 1. In general terms what are the duties of a Senior Welding Inspector. 2. State the five technical skills which are required by the Senior Welding Inspector. 3. State the six essential elements which comprise Leadership. QS2ATWI a 26 THE WELDING INSTITUTE NOTES ON INSPECTION, QUALITY CONTROL & QUALITY ASSURANCE It must be said that these terms, although they are all widely used and definitions of their meanings defined in many documents, are not sufficiently precise for really general application. It is not uncommon to find that these functions overlap or that in particular instances QA is planned and organised as a department which in practice covers inspection and quality control. Again many UK and USA manufacturing plants are organised with a Project Office dealing with the aims of quality and an Inspection Office dealing with the attainment of quality. Hence these notes are written in terms of functions rather than departments, that is they attempt to identify WHAT is done, not the title of the person performing the job ‘or function. DEFINITIONS: Extract BS 4778 Pt 1 1987 (Quality Vocabulary) Quality Assurance - “All those planned and systematic actions necessary to provide adequate confidence that a product or service will satisfy given requirements for quality.” Quality Control - "The operational techniques and activities that are used to fulfill requirements for quality.” Inspection - Activities such as measuring, examining, testing, gauging one or more characteristics of a product ‘or service and comparing these with specified requirements to determine conformity." In basic terms an alternative way of putting this is: Quality Assurance - States what is wanted in general terms Quality Control - States what to observe and measure in order to meet the QA requirements Inspection - Observes and measures specific details WELDING TECHNOLOGY Issue 0191SENIOR WELDING INSPECTOR INSPECTION, QUALITY CONTROL & QUALITY ASSURANCE QUESTIONS: 1 In an organisation which has departments of Production Engineering and Design Engineering, how may the functions of Inspection, Quality Control and Quality Assurance be organised. 2. _ Inanorganisation with departments of Inspection, Quality Control and Quality Assurance which departments would be responsible for the following functions: a) Measuring excess metal b) Deciding on the appearance requirements of a weld ©) Setting the level of toughness d) Setting the limits of amperage variation e) Collecting and analyzing inspection documents f) Granting concessions with respect to defects 9) Setting inspection requirements 3. Briefly describe two methods by which the Quality Control department can control the level of inspection (j.e. the details etc.) Qs2BTwi Za ‘THE WELDING INSTITUTE NOTES FOR PLANNING The planning function may be taken to mean the consideration of the necessary arrangements which must be made from the general notification of the job requirement through to the final advice of completion. It is usual to find that this falls into three (8) stages. 1. Preparation and dispatch of staff i.e. collection of codes, tickets, hotels, travel time. 2. The inspection and documentation: ie, Equipment Personnel approvals Procedure approvals Material Consumables Edge preparations Tacks Pre-heat Welding 3. Collection of test data and certificates and return to base. There are various methods of dealing with the planning function and the three (3) most common are: 1. Allocate staff on a block basis i.e, send an inspector on to the site and allow and expect him to make a useful return on his time 2. Use of charts in which each job function (or group of job functions) is estimated for time. In some instances this enables a considerable saving of staff time to be made, but by implication the inspector works "harder" and tens to travel more. WELDING TECHNOLOGY Issue 0191 27TWI (La 28 ‘THE WELDING INSTITUTE 3. Use of critical path analysis in which a detailed assessment is made or obtained of the overall production plan and the inspection function is meshed into this. Which of these approaches is used will depend on the nature of the work flow and the number of calibre of the available inspection and back-up staff. Also critical is the degree of competition, which may be the driving force for economic use of staff and hence low tendering. WELDING TECHNOLOGY Issue 0191SENIOR WELDING INSPECTOR QUESTIONS A fabricated product is required to be made with “increased” toughness. Outline the QA, QC and Inspection requirements which must be undertaken in order to attain this requirement. In an organisation which has departments of QA, QC and Inspection, which department(s) would be responsible for sanctioning "small" deviations in: a) size of weld b) welding parameters A, V, S c) material specifications d) mechanical properties A product being made to a pressure vessel code has a QC requirement that defects should be limited to 80% of the stated values, but that defects between 80% and 100% values should be referred to QC for approval. Give your appreciation of the reasons for this. as2cTWI MT ‘THE WELDING INSTITUTE PLANNING ASPECTS Planning can be taken to mean ‘to make the general arrangements’. There are many ways of increasing productivity. Amongst them, production or project planning is high on the list. Apart from improving the utilization of resources it also forms the basis for effective production or project control, and thereby reduces the risk of over spending budgets and for failing to achieve delivery targets. ‘Some advantages of planning (@) Jobs are planned and issued in correct sequence thereby reducing unnecessary work-in-progress and minimising the need for overtime or subcontractors. (>) Men and machines are supplied with the correct materials and tools at the right time. (©) The correct quality standards are achieved for minimum cost. (4) Completed goods are despatched to customers as promised. (e) Adequate stock levels of materials and components are maintained. () Greater job satisfaction for employees. (g) Greater job security. A sound system of planning should clearly show the stages of manufacture and inspection. It should draw attention to bottlenecks and areas of unused resources, and show what, and where, additional resources are needed. The system and methods of planning must be fully understood by the supervisor, and prove capable of coping with sudden changes to programme. Simplicity should be foremost in the mind of the planner when developing a system, or selecting a planning technique. Reverse Scheduling and Network Planning are two principal planning techniques. Reverse Scheduling Most jobs consist of a sequence of operations and in most cases it is essential that the correct sequence and a brief description of each operation is determined before work is issued. In addition a time estimate should be made for each operation. By fixing the very last operation at the required completion date, and working back in reverse sequence, the target dates for all operations can be determined. This is called "Reverse Scheduling" and is a well proven method of planning. Figure 1 shows part of a reverse scheduling plan. The target date for the last operation ‘Ship’ is week 26. Provided the operation sequence and time estimates are known itis then WELDING TECHNOLOGY Issue 0191 29TWI im 2.10 ‘THE WELDING INSTITUTE a simple task to determine target dates for all remaining operations as shown: Final Build | Test | insp_| Ship 14 15 16 17 18 19 20 21 22 23 Figure 1__Part of a reverse scheduling plan showing completion target dates Network Planning (Forward Scheduling) About twenty years ago a few British firms began to experiment with a planning technique developed by the U.S. Navy called ‘Programme Evaluation Review Technique’ (Pert), and a more simple but similar technique called Critical Path Analysis (C.P.A). Both techniques are based on a single idea of showing the correct sequence of jobs by means of links or arrows in a network. An example is shown in Figure 2. A project is broken down into major tasks or work packages called ‘activities’. The junction between the finish of one and the start of another activity is shown by circle. The planner defines the very first job (in this example Design) and would shown this as an arrow at the extreme lefthand side of a sheet of paper. The immediate succeeding jobs (their start being controlled by the finish of the preceding job) are drawn in a similar fashion as shown in Figure 2. Hence ‘Order Materials’, ‘Determine Methods’ and 'Order Components’ cannot start until the ‘Design’ is finished. ‘Inspection’ follows immediately after ‘Order Material’ and ‘Order Components’ and so on. The very last activity is Test and Final Inspection’. Many components involved with projects now use this method of planning, and the supervisor is often called upon to estimate the duration time for the job, or work package, for which he will be responsible. The estimate should be based on normal practice and methods i.e. the most efficient methods. If the supervisor finds he is unable to complete a job according to schedule he must report this immediately to the project manager or co-ordinator. Any delay may cause the project to run late which could cause unsatisfactory customer relations and the possible loss of future contracts. WELDING TECHNOLOGY Issue 0191SENIOR WELDING INSPECTOR PLANNING QUESTIONS: 1. Give a brief definition of the planning function. 2. Planning may be taken to mean the sequential combination of three sub- functions. What are these? 3. The planning function may be approached in three ways. Briefly describe these, Foesmem + Ceverse SereDoLne. 4. You are to prepare data for tendering on an unusual offshore inspection job at a distance of 2 days travel from your base office. Draw up a preliminary check list of items which myst be considered, ScoPe oF Woe , Vis, 2AD, MPI. Qe oF sone Cmanvooes) 5. Give two advantages of the use of "BAR" charts when planning. SimeurstTic | Nor Veesernice 6. Give two advantages of the use of “Critical Path Analysis" when planning. Veet Frexiere , @s2DTWI a THE WELDING INSTITUTE NOTES FOR ORGANISATION FITTING THe STAFF TO TE PLAN. The organisation function may be taken to mean the fitting of staff to the plan which must then be supervised to completion. In these terms the organisation function means the ability to assess the detailed requirements of the plan and to gauge the ability of individual staff to be technically competent, available and temperamentally able to perform the tasks involved. ‘As a preliminary check list organisation involves : Total man hours of inspection required Maximum time allowed Number of inspectors required Analysis of job functions (see planning) Estimation of job times Analysis of job sequences Preparation time Travel time Leave CONDOM AwYN> FUGUTS , TABS , VisaS, HeTeE:S, Sarery & WELDING TECHNOLOGY Issue 0191 anSENIOR WELDING INSPECTOR ORGANISATION QUESTIONS: Met+ MATERIALS TO 1. Give a brief description of the organisation function. €rr Tue PLAN. 2. What should be completed before attempting to organise. 3. What function is used to ensure that the plan and organisation is proceeding correctly AND that deviations are recognised and corrected. 4. What are the personal aspects of an Inspector which should be considered and perhaps assessed when attempting to organise him/her into the plan. WsTEQRrt™ » PeesSonar Ciaeomeraces , Sere- MOTIVATED 5. __ In the context of welding inspection of heavy fabrications what is the aspect which most commonly causes the "time" assessment made in the plan and organisation to be invalid. How can this problem be dealt with during tendering. Lorre. Morea iALs> (perven) RePmies, Weare. Sraexese + ARgcvtTEESm . QS2ETWI Zt ‘THE WELDING INSTITUTE NOTES FOR AUDITING The term audit has been taken from accounting practice and means: a) An overall check of inspection b) A detailed check of a very limited area of inspection a) _ Inthe overall check the general content of the fabrication file is examined for: () completeness (i) presentation and a general impression is formed as to the visual quality of the product. b) For the detailed check the requirements of a very limited zone is examined with great care and (as appropriate) the code requirements are checked against the documents in the fabrication file. WELDING TECHNOLOGY 212 Issue 0191TWI Ci ‘THE WELDING INSTITUTE Auditing There are three types of audits currently used in the fabrication industry. 1. Pre-production - this is usually undertaken to assess ability in terms of staff and facilities to perform a task. 2, In-production = this is to confirm that welding and the related activities are being conducted according to the requirements specified or to an acceptable workshop standard, 3. Post-production the objective in this instance is to ensure that the welding and the welding inspection are satisfactory. WELDING TECHNOLOGY Issue 0191 2.13TWI a 2.14 ‘THE WELDING INSTITUTE SUPERVISION What is a supervisor? A supervisor is any person who is given authority and responsibility for planning and controlling the work of others with whom they are in close touch. Supervisors and Operators The difference between a supervisor and an operator is that an operator performs his ‘own work but the supervisor gets work done through his operators. Supervisors and Managers ‘Supervisors are part of the management structure. The term "supervision", however, generally implies overseeing and controlling a working group on the spot dealing with situations and details as they arise. The term "management" implies planning ahead and controlling work more remotely using administrative procedures and reporting systems. “The man in the middle" The supervisor is in a key position between operators and management able to encourage smooth working or cause disruption (wilfully or unintentionally), He is also Subject to pressures from both sides who each expect him to support their views. He must seek to earn the respect and support of managers and operators, carrying out sometimes unpopular orders and duties at the same time as looking after the interests of the group he leads. Working with others The job of the supervisor is enhanced and becomes more satisfying if he makes use of the assistance of specialist advisers on personnel, work scheduling, work study, finance, etc. thereby allowing him to spend more time on organising and dealing with his staff. The supervisor should also recognise the role of the shop steward and endeavour to promote a good working relationship through a straightforward exchange of information and explanations on plans, problems, changes and complaints. Strict adherence to agreed procedures, faimess in dealings and a joint effort to settle problems at supervisor/shop steward level should produce mutual respect and improve the working "atmosphere". WELDING TECHNOLOGY Issue 01917TWI a THE WELDING INSTITUTE Responsibilities of a Supervisor A supervisor is responsible for his subordinates, the activities and the work place which he is given formal authority to control. This usually includes: 1. Staff - morale, consultation, discipline, welfare, safety, employment induction, training 2. Work- maximum economy 3. Cost - maximum economy 4. Machines and equipment - maintenance, loading, operation 5. Materials - supplies, suitability, economic use 6. Workplace - layout, tidiness, good housekeeping Qualities of a good supervisor Particular circumstances will give different emphasis to the following essential basic qualities required in the good supervisor. 1. Technical skill and knowledge — ability to explain why and how jobs are to be performed to eliminate faults, dangerous practices, wastage, to keep up to date. 2. Intelligence - judgement, sound common sense, ability to determine priorities. 3. Drive - vitality, energy, enthusiasm and general good health. Vigour is as infectious as fatigue is demoralising. 4. Leadership - maintenance of high personal standards, goal setting, trustworthiness, reliability, consistency, fairness, stability, persistence and a sense of humour. Motivation Some of the better-known theories on what induces people to work more purposefully have been put forward by Abraham Maslow, Frederick Hergberg and Douglas McGregor. The main features of their research findings are : Abraham Maslow People will strive to satisfy basic human needs. These needs have an ascending order of importance so that when one need is satisfied it no longer acts as an effective motivator. The need that is next in the order of importance becomes the motivator. Hence, the theory is sometimes referred to as “Maslow's Ladder of Needs’. Five levels of need (or rungs on the ladder) are identified. In ascending order of importance they are : WELDING TECHNOLOGY Issue 0191 215TWI im 2.16 ‘THE WELDING INSTITUTE 1. Survival - —_ e.g. hunger, thirst 2. Safety - @.g. security, protection 3. Social - eg. belonging, acceptance in a group 4. Esteem - e.g. success, respect 5. Self fulfilment - e.g. achievement, inner satisfaction Whilst striving to satisfy the next level of need, if a lower order of need is at risk, attention reverts to satisfying that level (e.g. illness, loss of job etc. will temporarily at least, affect ambition and alter a person's priorities). Maslow's theory helps our understanding of what people are seeking from their work. In today's welfare state, many of the lower order needs are satisfied by social legislation and attention is therefore concentrated on the higher levels (e.g. social, respect etc.) Frederick Herzberg Herzberg's contribution to understanding what induces people to work is the identification that what satisfies people at work is not the opposite of the same factors that cause dissatisfaction. Satisfaction, according to Herzberg, comes from the job itself through interest in the work, a feeling of achievement, of meeting a challenge, of effort recognised, or responsibility carried and of professional growth. Dissatisfaction arises more from the work environment and conditions, relationships with supervisors and others, policies and organisations pay, status and security. Attention paid to removing causes of dissatisfaction is important if the contribution of people at work is not to fall below a “fair days effort. However, in order to induce an increased effort, more attention needs to be paid to involving people in their work improving the interest and challenge of the job. Concern for the context in which the job is done may reduce the complaints but improving the content of the job is necessary if greater effort is to be induced. (Ref. The Motivation to Work by F. Herzberg). Douglas McGregor McGregor's work is based on his idea that effective leadership depends on a supervisor's assumptions about the nature of supervision and about people in general = summarised by theory "X" and theory "Y" in his book "The Human Side of Enterprise’. Theory "X" applies where a supervisor considers his operators inherently dislike work, will attempt to avoid assuming responsibility whenever possible and are generally not WELDING TECHNOLOGY Issue 0197TWI af ‘THE WELDING INSTITUTE ambitious. They therefore need to be coerced, controlled directed and if necessary punished. Theory "Y* assumes that work is a natural activity and that if encouraged through reward involvement and respect people will work well, exercise self discipline or have potential for development. Both theories recognise that much work as organised in the modern world is an unnatural form of behaviour and some kind of pressure is needed. Theory "X" leads to submission to orders, compulsion and threats whilst theory "Y" involves coaxing and the creation of opportunities for achievement and personal improvement. Motivation and the Supervisor These and other theories on behaviour of people at work emphasise the need for a supervisor to take an interest in his operators, to try to understand their attitudes and reactions, to treat them responsibly and with respect for their views, efforts and skills. Responsible treatment includes correcting or reprimanding those who fail to respond responsibly. Good operators expect the supervisor to act justly when dealing with those who do not conform to working requirements. Staff Assessment Linking motivation with the responsibility of a supervisor to achieve targets of performance is the assessment of staff and the development needs of the supervisor's section, Whatever policy an organisation applies to staff assessment, a supervisor inevitably forms judgements on the varying capabilities and attributes of his operatives. Assessment procedures only differ in the degree to which they are formalized. Ifno other agreed system applies, a supervisor should first decide the factors that are important in constituting a good worker. These usually include such factors as quantity of output, quality of output, versatility (range of capabilities) co-operation, timekeeping, conduct, relationships with others etc. On the basis of factual records where possible, each operative can be assessed against each factor using for instance a three or give grading scale. The five grades might show AVERAGE performance with two levels above average and two levels below: POOR BELOW AVERAGE ABOVE EXCELLENT AVERAGE AVERAGE A simpler three grade scale may be : BELOW AVERAGE ABOVE WELDING TECHNOLOGY Issue 0191 247TWI im 2.18 ‘THE WELDING INSTITUTE Operatives should be made aware of those factors which are satisfactory and by discussion methods should be agreed for improving those aspects which are not satisfactory. Assessing Section Development Needs Similar principles of assessment can be applied to the needs of the section over the whole range of the supervisor's responsibilities. For this purpose it is useful to construct a simple grid, listing a heading to the columns the tasks or jobs for which the supervisor is responsible. The rows of the grid carry the names of the operatives in the supervisor's section. The grid is then completed by indicating in the squares the tasks each operator is capable of performing and how well he performs that particular task. Different colour marks could be used to indicate ability to perform a task averagely well, above average, exceptionally well or poorly. Such a grid is a valuable document for a supervisor. In compiling it, the supervisor is compelled to consider the full range of present and known future commitments and the abilities of each member of his team. The completed grid exposes weaknesses in job coverage, limitations of staff versatility and highlights development and training needs, to make best use of labour resources. Discipline The aim in exercising industrial discipline is not to punish but to obtain co-operation in achieving the company's targets, but ensuring that personal behaviour confirms to the company's rules and standards, In dealing with offenders, a supervisor should consider the likely reaction not only on the offender but on others in the working group. By his influence and example, a supervisor should try to encourage self-discipline, a responsible attitude (making requirements known and why; giving responsibility; involving workers). To be accepted, discipline must be seen to be fair: a) Rules and standards expected should be known b) The consequences of failure should be known c) Consistent application of discipline - no favourites, no scapegoats; in accordance with custom and practice WELDING TECHNOLOGY Issue 0191TWI “i ‘THE WELDING INSTITUTE @) Impartial administration - a natural and expected consequence; in the company's interest - not a personal vendetta. ) In accordance with agreed procedure. To be effective discipline needs to be progressive - repetition being considered more serious. It is therefore necessary to consider the levels available e.g. Continuous checking and correcting of performance and behaviour (being ‘on the ball") 2. Reprimand (in private) 3. Reprimand with written warning 4, Suspension, transfer, demotion, with-holding privileges, etc. 5. Dismissal with notice (e.g. incompetence) 6. Dismissal without notice (e.g. serious misconduct) Some general tips for the supervisor: Know the extent of your authority (how far can you go) Know company practice in similar cases Find out all the facts of the case Act promptly — do not let things slide Avoid frequent reprimands (they lose effect and encourage suppression of faults) Mean what you say — no idle threats Elements of a Supervisor's Authority A supervisor responsible for achieving specific company objectives within the framework of company policy, can rely on : 1. "Formal authority"- delegated (stemming from ownership). the right to make decisions. the right to give orders and require compliance. power to reward or punish. (consumable? Submission?) 2. Authority of knowledge - ability to inform. ability to solve problems. ability to correct errors. (‘authority" on a subject) 3. Personal Influence - —_ acceptance by subordinates based on : Trust “means what he says". “a man of his word" - keeps promises. reliable - "you know where you stand with him". WELDING TECHNOLOGY Issue 0191 219TWI ‘THE WELDING INSTITUTE Confidence - _ inhis ability to cope with situations. facing up to problems ~ not passing the buck. making effective decisions. taking action, Fairness - Objective in dealing with people. consistent within department and company. consistent over time. no favourites: no scapegoats. Respect - involvement, participation, consultation (reciprocal) delegation of responsibility. setting of targets. accountability (‘on the ball") keeping people informed, explaining reasons, regular staff assessment. invites suggestions and comments. The measure of a supervisor's leadership is the response of the subordinates. Co- operation is an attitude formed from experience. In his dealings a supervisor should anticipate likely reactions, WELDING TECHNOLOGY 2.20 Issue 0197TWI im THE WELDING INSTITUTE The Supervisors Role in Project Planning To make an effective contribution to project planning the supervisor should be able to answer the following question : WHAT IS THE CURRENT FORWARD WORK LOAD IN YOUR DEPARTMENT? If the supervisor can answer this question he should be able to deal with the following: (i) Can additional work be confidently accepted and a reliable completion date be given. (i) If itis necessary to accept a ‘rush job’ what will be the effect on other orders. (ii) | How much additional work must be found to avoid resources from being under utilized. (v) _ Ifan order is cancelled how will it effect the department budget. If an answer is to be found to the former question some form of work load record is essential. This may be in the form of : (a) awritten record () visual display (©) a.computer file and print out Written Records Awitten record may take the form of a ‘Department Work Load Summary Sheet as. shown in Figure 3. The average man hours (capacity) available for a given period is first determined, and as orders for work are received this is taken away from the available capacity and the balance shown. Looking at the example Fig.3 the Inspection Department has a capacity of 200 man days per period (say a month). A number of jobs need inspecting in connection with contract ZU/76/107. The first requires 2 days therefore the balance is 198, the next job requires 7 days so the balance drops to 191 and so on. The method is very simple and takes very little time to maintain. The effect of order cancellation or rescheduling can be readily determined. A further innovation would be to provide an additional column showing actual time taken so the supervisor could, over a period, check the accuracy of the estimates. WELDING TECHNOLOGY Issue 0191 2.21TWI Oe ONG NSTC Fig. 3 Department Work Load Summary Sheet _ Inspection Department Capacity Period:7 Section & Control Systems 200 days/ period Contract Activity Estimated Available Number Number Days Capacity 3-7 2 198 Zu/76/107 3-9 7 191 12-13 10 181 Zuy76/201 4-10 12 169 5-7 20 149 ZXI76/159 8-10 16 133 8-14 4 129 8-17 5 124 zx76/187 5-11 34 90 WELDING TECHNOLOGY 2.22 Issue 0191SECTION 3TWI | SS CODES AND STANDARDS CLASS OF WORK There are many types of work which require engineering materials to be joined by welding, for example: pressure vessels bridges oll rigs earth moving equipment aero-engines ventilation systems storage tanks heavy vehicle chassis car bodies food processing plant The quality requirements of the joints in these fabrications depend on their fitness-for-purpose and differ significantly from one application to the next. Pressure vessels require welds which can withstand the stresses and high temperatures experienced in operation. Bridges must take into account the effect of differing vehicle loads and wind loading. Oil rigs are designed to withstand the effect of wave formation and wind loads. Earth moving equipment has to accommodate differences in terrain and earth conditions and is subject to fatigue loading. Welds in food processing plants must withstand corrosion by hot acidic liquors. On the next page some typical Codes of practice and Standards which cover various types of constructions being fabricated by welding are listed. Note: Throughout this text, the term Code is used to cover Code of Practice, Standard and Specification. WELDING TECHNOLOGY Issue 0191 3.1TWI 3.2 LN THE WELDING INSTITUTE Code Class of Work BS 5500 Unfired fusion welded pressure vessels ASME VIII American boiler and pressure vessel code BS 2633, Class 1 Arc welding of ferritic steel! pipework for carrying fluids BS 4515 Process of welding steel pipelines on land and offshore BS 5950 Structural use in steelwork in building AWS D1.1 Structural welding code (American) BS 5400 Steel concrete and composite bridges BS 6235 Code of Practice for fixed offshore structure API 1104 Standard for welding pipelines and related facilities These documents can also provide a useful source of data for applications where Codes do not exist. It should be remembered, however, that the principal criterion in the Codes listed is the quality of the joint in relation to the service conditions, There are other applications where success is judged by different criteria, such as dimensional accuracy. Another important consideration is controlling the cost of welding. Variations in Weld times and quantities of consumables can readily result if the method of making a weld is left to the welder to decide. The continuous and satisfactory performance of weldments made to various Codes requires that specific guidelines are laid down to cover materials, design of joints, welding processes, welding consumables, acceptance criteria and inspection techniques. ‘These guidelines are usually grouped under the general heading of a Weld Procedure. WELDING TECHNOLOGY Issue 0191Twi MT ‘THE WELDING INSTITUTE SENIOR WELDING INSPECTOR “SIGNING OFF A PRODUCT" In many fields of fabrication it is a requirement that on completion of a product a review is made of all documentation to ensure conformity to the specification, code and drawing requirements. Usually until this review is completed and perhaps a Release Note or Shipping Note is signed, the product is not complete with possible late payments and penalties on delivery being incurred. It could be part of the Senior Welding Inspector's duties to carry out this task. The requirements for such a check would normally be stated in the client's specification although some standards, e.g. BS5500, lay down what documents must be available and checked. Some, if not all, of these documents may have to be incorporated into a Data Book on completion of the contract. In order to perform this task, a check list of all documents used on the product must be prepared. The task is made easier if Quality Plans or at least Inspection Check lists are in use on the job. The numbers and types of documents will obviously depend upon the complexity and quality standard of the product, but among the documents to be reviewed could be: Quality Plan All stages complete and signed off Inspection Check List All stages complete and signed off Materials All certificates checked. In some cases this may include tests carried out by the consumable(s) supplier. Procedures for: Cutting Welding Repair NOT All have to be approved PWHT Testing Coating Qualification of: Welders NDT Personnel All have to be approved and Inspectors are up to date WELDING TECHNOLOGY Issue 0191 a3TWI “La 3.4 Inspection Reports for: Calibration Certificates: PWHT Charts: Hydro Test: As Built Drawings: Materials & Weld Map: Nameplate Rubbings: ‘THE WELDING INSTITUTE Visual Ensure they cover all NOT appropriate joints and Dimensional ‘structures for those items of equipment deemed necessary, e.g. pressure gauges for Hydro Test Ensure all necessary information is on records, e.g. job descriptions, chartspeeds Reports are complete All are completed All are completed When applicable Concessions/Deviations/Site Query sheets Permits to work/Degas certificates applicable Coating Reports WELDING TECHNOLOGY Issue 0191QUESTIONS Qi. Q2. Q3. a4, 5. CODES AND STANDARDS List the typical items to be found in a Code of Practice Explain the meanings of the terms: @) ‘Shall Mancreed wiTtout Qoestion) b) ‘Should ADVIGEARLE What is meant by the term ‘concession’? AneeeD + SiuneD BY ALL Rerevanss PART VES. Does a Code of Practice contain all relevant information? State the three (3) parties generally mentioned in Codes or Standards Qs3SENIOR WELDING INSPECTOR QUESTIONS CODES AND STANDARDS Q1. List the contents of a typical Code of Practice. Q2. Are the requirements legally binding Q3. At what point of production should the inspector ensure the correct use consumables, AT THE POWT OF commencrenT (ArmruicAT Q4. Can a non-approved welder be employed on production work, me Bere NO ry SOE — CeQrenerrs - QS. Long question (300 words) Write in an essay format a “signing off of product" to your respective code. essed Nor NecessaeyY AS Lonuw AS Bes @SPEeTH ACE Covered. QS3ASECTION 4TWI im ‘THE WELDING INSTITUTE THE WELDING PROCEDURE The task of collecting the data and drafting the documentation is often referred to as writing a weld procedure. In many ways this is an unfortunate term as the writing of documents is the last in a sequence of tasks. Producing a weld procedure involves: planning the tasks collecting the data writing a procedure for use or for trial making test welds evaluating the results of the tests approving the procedure of the relevant Code preparing the documentation In each Code reference is made to how the procedures are to be devised and whether approval of these procedures is required. In most Codes approval is mandatory and tests to confirm the skill of the welder are specified. Details are also given of acceptance criteria for the finished joint. The approach used depends on the Code, for example: BS 2633 : (Class 1 arc welding of ferritic steel pipework for carrying fluids) provides general comments on various aspects of a suitable weld procedure. AWS D.1.1 (Structural welding code - steel) favours more specific instructions for different joints and processes which are, in effect, pre— qualified procedures. Other Codes do not deal specifically with the details of the weld procedure but refer to published documentation, e.g. BS 5135 ‘process of arc welding carbon and carbon manganese steels’. WELDING TECHNOLOGY Issue 0191 44TWI a ‘THE WELDING INSTITUTE COMPONENTS OF A WELD PROCEDURE Items to be includes 1, Parent metal 1 1.2 13 4 3d in the procedure can be some of the following: Type Thickness (for pipe this includes outside diameter) Surface condition Identifying marks 2. Welding process 21 22 23 24 3, Joint design 4. Welding position 41 42 43 44 45 46 47 5. Thermal treatmer 51 5.2 42 Type of process (MMA, TIG, MAG etc) Equipment Make, brand, type of welding consumables When appropriate the temperature and time adopted for drying and baking of electrode/consumables Welding position Edge preparation Method of cleaning, degreasing etc Fit up of joint Jigging or tacking procedure Type of backing Whether shop or site welding Arrangement of runs and weld sequence Filler material, composition and size (diameter) Welding variables - voltage, current travel speed Weld size Back gouging Any specific features, e.g. heat input control, run-out length nt Preheat and interpass temperatures including method and control Post weld treatment including method and control WELDING TECHNOLOGY Issue 0191TWI “a ‘THE WELDING INSTITUTE APPROVING THE PROCEDURE When the data has been collected, the procedure must be validated by producing and testing a trial weld. If the procedure is to be used on a fabrication which has been designed to meet the requirements of a Code, the test weld is done under the supervision of an independent witness. The detailed arrangements for the test are subject to agreement between the contracting parties. A number of British Standards make cross reference to another Standard which covers approval testing. Other Codes of practice include their own weld procedure/welder approval information. In general they include a standard format which can be used to report the results of an approval test. WELDING TECHNOLOGY Issue 0191 43TWI mW ‘THE WELDING 1 MANUFACTURER'S WELDING PROCEDURE SPECIFICATION (WPS) (s00 EN 288-2) ‘STITUTE Location: ....7W1 TRAINING WORKSHOP... Examiner or test body:...-B.D LTD... Manufacturer's Welding Procadure: ....BWPS OO1/A... Floference No: «81820 ,nrnnnnnn WPAR No: 0228. . : Manutacturer ....FRED BLOGGS INDUSTRIES. DEGREASE & Method of Preparation and Cleaning... MACHINE... Parent Material Specification: .316L STAINLESS STEEL C.08% Cr 17% Mn 1.5% Mo 25% Welders Name: ....AN OTHER... : Ni11% SIOS% + Residuals Welding Process: ....141(T1G. OOTY A FILL & CaPi... Material Thickness (mm): ...15mm Joint Type: (GLE VEE BUTT... ‘Outside Diameter (mm): 155mm. Welding Position: HLO4S.. Weld Preparation Detalls/Joint Design (Skatch)* Welding Sequences Welding Details Run | Process Size of Current Voltage Type ot Travel Heat Filler Metal a v curren Speeds | Input" Polarity 1 ta1_| aurocencous | 60-70 so12 CEN 2 4ommimn | 1.0K as | om 3.2mm 110-120 20-22 DcEP. : 40mm ROL_|1.0Kymm so | im 3.2mm 5-110 20-22 cer - 130mm ROL 1.0KVimm tow | i 25mm 70-90) 20-22 CEP : 00mm ROL_| 1.0K/mm completion 25mm 70-80 2022 cep : t00mm ROL_ | 1.0K/mm Metal Ciassitication and trade name:.... SOUDOMETAL SUPERCROM 316L to ISO 9581-£19:123:LA23, ‘Any Special Baking or Drying”... RY AT 100°C FOR 2 HOURS QUIVER AT 75°C. (GasiFlux: shielding: ....ARGON ~ COMMERCIAL PURITY... Other Information’: : backing: .... ARGON - COMMERCIAL PURITY .ssvsennsnm @.G, weaving (maximum width of run) .2 * 6. Gas Flow Rate ~ Shielding: ...8 UTRESIMINUTE rns IZ Oselilation: amplitude, trequency, dwell time: as required Backing: ...4 UTRES/MINUTE. Conan Pulse welding [NOT REQUIRED .. ‘Tungsten Electrode Type/Size:...2% THORIUM 25 bon Stand off distance: .... NOT REQUIRED .... Details of Baek-Gouging/Backing: ....RETAIN UNTIL RUN § ONWARD. Plasma welding detalis:.... OT REQUIRED Preheat Temperature... NONE, ‘Torch angle: TILT 90° SLOPE 70*. . Interpass Temperature: 150°C MAXIMUM, Post-Weld Heat Treatment and/or Ageing... NONE.. ‘Time, Temperature, Method: ... OT REQUIRED. Heating and Cooling Ratest AS PROCEDURE. Manufacturer Examiner or test body Name Seep Name tc. Toaned Date. 0000-180 Date 00-0095, Signature ; Signature, 44 WELDING TECHNOLOGY Issue 0197TWI “iW STITUTE THE WELDING IN: WELDING PROCEDURE SPECIFICATION With the information provided below check W.P.S. for contents. 4. tems in a welding procedure test 4.1 General. The ems stein 42 and the items n.3 relevant tothe partcular welding process shall be recorded for exch welding procedure test NOTE Notat ot inese tame need be melded nthe approved SrengpocecreSocamanaton 42 items for all welding processes. Details eating to the folowing items shale recorded forall weling ma) welding processor processes when more han one ss used n mauinga comple ome (8) parent metal specication thickness and or inet the outside ameter or mension (6) whether shop orsite welding (8) edge preparation (sketch! (e) cleaning degreasing ete: 1 theup (sketch (9) aging or tacking. backing. ere. (h welding positon including direction for vera! postion! (make, brand and type of welding consumables {fer materai composition and sie (diameter (k)_re:heating and inerpass temperature. including method and conta (0 travel speed (mechanized welding: {rm approximate number and arrangement of runs and weld imension okt {nl welding sequence: (0) back ovens 1B) post-weld neat treatment. including method and conto (a) when appie, the temperature and ume adopted for drvng/bakng of welding consumables betore uae (fay speci features, including heat nput contol requrements. eg run-out engin (ROL) 4.3 Items for particular welding processes. Details ‘elating to the tems given in 4.3(a) to 4.31") shall be recorded {or these particular processes in addition to the ems in 42. For pipe welding, where back purging is used, ne purge gas. flow rate of purge gas, and period shall be recorded, Welding Technology Issue 0191 a) Manual metalare welding (a6 orde. ano polanty, (2) current, (31 for pulses welding, the pulse time, pulse current, background current ang Background voltage (b) MIG wetging. sod or cored wire, including cored wire £0, and gastess welding (1) shuetcing gas and flow rate; (2) nozale diameter, (3) arc voltage; (4) wire feed speed or current. Additional for dip transfer technique (5) electrode extension (mechanized welding); (8) cwcut inductance or setting: (7) for pulsed welcing, the pulse time, pulse current, Background current and background voltage. (0) 716 werding (tungsten electrode diameter and type: 12) shielding gas and flow rate (3) nozzle diameter (4) a¢.or dee. and polarity: (5) current, {6) arc tength or voltage for mechanized welding: (71 for pulses weiding, the pulse time, pulse current, Background current and background voltage. (0) Submerged are welding and continuous covered clectrode atc welding with or without CO; oF fax shielding (1) number and configuration of electrode wires and electncal connections, (21 shielding gas and flow rate, (3) electrode extension; {41 26.01 de. and polanty: (5) current (6) voltage, (7) power source characteristic. (0 Gas wetaing (1) oxygen pressure: (2) fuel gas and pressur (3) nozzle size; (4) lame characteristic (oxidizing. reducing or neutral: (5) rightward or letward technique. 44aTWI if ‘THE WELDING INSTITUTE WELDING PROCEDURE APPROVAL RECORD FORM (WPAR) TO EN 288 WELDING PROCEDURE APPROVAL - TEST CERTIFICATE Manufacturers Welding Procedure Examiner or test body 80% LTD. Reference No. 41920/001/A. Reference No. 80! 71000125 Manufacturer. ..FRED BLOGGS INDUSTRIES Address ...975 LONDON ROAD, CAMBRIDGE UK. Code/Testing Standard:...EN 288 .. Date of Welding:....00-00-199- .. EXTENT OF APPROVAL Welding Process: ...141 TIG ROOT 111 MMA FILL & CAP ‘Joint Type :..ANY BUTT JOINT IN PIPE OR PLATE/FILLET WELDS IN PIPEIPLATE & T BUTT WELDS Parent metal(s):... AUSTENITIC STAINLESS STEELS... CCondtions of tempered: NOT APPLICABLE. Motal thickness (mm): ...12mm ~ 16.5mm ‘Outside Diameter (mm): ..78mm - 310mm (eum) Filler Metal type : ....3161 SOUDOMETAL SUPERCROM TO ISO £19:12:3:L R23 ONLY ‘Shielding Gas/Flux.....ARGON IRECT CURRENT 141 OCEN 111 OCEP Type of Welding Current. Welding Positions... ALL POSITIONS EXCEPT P.G. (VERTICAL. DOWN) AmBiesr Ser... Ream Fred Preheat... OT REQUIRED. Post-Weld Heat Treatment andior ageing... NOT REQUIRED. ‘Other Information: ....TACK WELDING NOT PERMITTED LINE UP CLAMPS ONLY Erecreope SIZEe Certified that test welds prepared, welded and tested satistactorily in accordance with the requirements of the codestesting stand: Indicated above. 2 2 Location Date of 8800-00199 nn Examiner or test body Name... 6.0% LTD - LC. ITCANBE WELDING TECHNOLOGY Issue 0191 45TWI a ‘THE WELDING INSTITUTE DETAILS OF WELD TEST Location: ...SHOP - TWI TRAINING WORKSHOP. ones Examiner or test body: ..8.D.1. LTD... Manutacturer's Welding Procedure Reterence No::...41920 ... WPAR No: ... WPAR OO1/A.. ‘Method of Preparation and Cleaning: - M/C & DEGREASE rant Material Specitication: .916. STAINLESS STEEL [FRED BLOGGS INDUSTRIES ‘AN OTHER Welding Process: ....141 (TIG) "111 (MMA). olnt Type | SINGLE VEE BUTT nen ‘Weld Preparation Detalis (Sketch) Material Thickness (mm): Sem ‘Outside Diamatar (mm): 155mm Welding Position : ots. Joint Design Welding Sequence = Tom Welding Detaits Fun | Process ‘Size of Current | vottage | Type ot curren | wire Feed | Travel | Heat Input Filer Metal A v Polarity Speed Speed K/men 1 ta1__| auroceneous | es if DCEN 2 45mm 0.95 ne a mm 4s 2 Deer z 150mm 096 5-10 a 3.2mm 105, 2 CEP : 150mm os, tow | i 3.2mm 8 2 ber - 110mm 096 completion 3.2mm 2 2 DcEP - 110mm 0.96 Filler Metal Classification and trade name: ..SOUDOMETAL SUPERCROM 3161, ‘Any Special Baking or Drying:...RIED AT 100°C - 2 HAS, — GasiFlux: ‘hlelding:..BOC ARGON cron backing: ....BOC ARGON... Other information 2-9, weaving (Maximum width of run}: .NONE.. Gas Flow Rate - Shielding: 6 UTRESIMIN. vo Oscillation: amplitude, frequency, dwell time ‘Backing: 4 UTRESIMIN. a Pulse welding detals:.. NONE. ‘Tungsten Electrode Typa/Size:...2% THORIUM 2.5mm Stand off distance: .. NONE wo Details of Backing: .... RETAINED UNTIL FUN 6.. Plasma welding details: .. NONE... Preheat temperature... ONE APPLIED. Toreh angle... AS REQUIRED Interpass Temperature: .... MAXIMUM 130°C. _— — Post-Weld Heat Treatment and/or Ageing... NONE Time, Temperature, Method: .....NONE... Heating and Cooling Rates®:.... NONE. MANUFACTURER, Examiner or test body Name: Name: Date: . Date: ‘Signature: Signature: Page 2013 WELDING TECHNOLOGY 46 Issue 0191TWI My Manufacturers Welding Procedure Reterence No. ....41920001A.. TUTE ‘THE WELDING IN! TEST RESULTS Examiner or test body Fisterene® NO......BD! 7100025 Radiography*:.... ACCEPTABLE Visual Examination: Untragonie Examination®.....NOT REQUIRED PenetranvMagnetic Particie Test. Tensile Tests Temperature: ....+20°C [7 tren. Rm Amon | 2% Fracture Location Remarks, wmmé | _Wmmt ‘TRANSVERSE: 48 550 40% : PARENT ACCEPTABLE ‘TRANSVERSE, a7 550 38% = PARENT ACCEPTABLE Bend Tests Former Diameter. ......60mm Typeino. Bend Angle Elongation’ Result ROOT (UPPER) 10" NOT REQUIRED ACCEPTABLE: FACE (UPPER) 120" : : ROOT (LOWER) a0 : : Macro Examination: Rca Toner = 7 Micro Examination®: Impact Test" CHARPY ‘Type: VEE NOTCH Ske: 025mm femont: Noteh Location Direction Temp. Values ‘Average Remarks 123 WELD METAL, ~100°C. 7 40 39 ACCEPTABLE HAZ, 100°C 3998 37 ACCEPTABLE PARENT METAL, 100°C. 2 63S 3 ACCEPTABLE Hardness Tests? ‘Typaiload..... NOT REQUIRED. Location of Measurements(Sketeh") Parent Mota... NOT APPLICABLE. HAZE vse fs Weld Metal... f Other Tests: . Remarks... ACCEPTABLE TO EN 288. ‘Tests cartied out in accordance withthe requirements of Examiner or test body Laboratory Report Reference No.: 7654/0/2/1 ‘Test resuits were acceptableinot acceptable (Delete as appropri) ‘Test cartied out In the presence of: HUG! I required Welding Technology Issue 0191TWI Za ‘THE WELDING INSTITUTE SENIOR WELDING INSPECTOR PROCEDURE QUALIFICATION RECORD OR WELD PROCEDURE APPROVAL RECORD With the information provided below, check W.P.A.R. for “Range of Approval" Welding Technology eee) Issue 0191‘THE WELDING INSTITUTE DOCUMENTATION The objectives of a procedure or welder approval test are: a) to prove the procedure meets the necessary requirements with reference to feasibility, mechanical strength etc b) to prove the welders are competent to work in a particular job If a customer queries it, evidence can and would be supplied to prove validity, even though the approval tests might have been some considerable time ago. Approval Test Specifications call for a paper record which can be know as either: procedure/welder approval certificate procedure/welder approval record procedurefwelder approval report The following records should also be kept: a) NDT reports b) records of visual examination or mechanical testing ¢) test pieces from destructive testing Other records which are equally important are: a) PROOF of regular employment on a job b) for scheduling re-tests ¢) to avoid duplication on procedure approval TEST CERTIFICATE Should state clearly that it is a welder approval; and not a PROCEDURE approval, and, depending on the particular Standard, should contain the following: a) welder's name and identity number ~ could be his/her clock or payroll number, or possibly a photograph b) date of the test ©) Standard of Code in full, ie. BRITISH STANDARD 4872 PT 1 : 1982 d) testpiece details including material specification e) equipment and consumable details: welding equipment, type of filler etc ) extent of approval @) sketch of run sequence, preparation and dimensions WELDING TECHNOLOGY Issue 0191 azTWI 48 NS THE WELDING INSTITUT! h) other factors, operating parameters etc i) the test results (visual, NDT, DT etc) j) remarks k) witnessed by 1) test supervisor m) location Most Standards give an example of the test certificate. SIGNATURES ON CERTIFICATES MUST BE ENDORSED WITH COMPANY ‘STAMP. STORAGE AND RETRIEVAL Most companies prefer to store the records in a conventional filing system. With larger companies it may be useful to use a computer filing system or register which could automatically give an indication of re-approval. WELDING TECHNOLOGY Issue 0191WELDER APPROVAL TEST CERTIFICATE Dest: AN 27 an a Exar Ht 809 BD! ETD a8 SEA 229 a a eee nn BRN a at an pac fn 28 OCEMBER 882 nen Er. nn FRED BLOGES NOUSTRIES = Reweet ren mae tees fom a eran mee peers er maronnucrwen fer ms reourre wos ome 10 sPvA en EGP FLEA owe sue sean cn — macnn “| oe Thame oats mt = So recom aoe pt te cencnneweae = ra es roancre EET VerTO Dom coronas vermomes eGanED on sum ers SS IC Zante comune tame tn wospaan Seroa = fanny SAT Racoorey vw Magneve parce ~ Dave of ve 00-00-100- on pra Ma sro - ‘Locavon TW TRAINING WORKSHOP = = Bene — ‘Valkany of approWe Un 00-00-108~ Action Tests -— * eed oan ae en Sinteing stereo wae wear om some a | rangaton rary. terne olen 2 yas yer 102) owe Sau Poekan oe WELDING TECHNOLOGY Issue 0191 49SENIOR WELDING INSPECTOR WELDER APPROVAL CERTIFICATE With the information provided below check welder approval certificate for extent of approval. 6.3 Joint types Depenaing on the test piece, the range of welds for which the welder's approved is snown in table 3; the following eriteria are apoli- cable: a} approval for butt welds in pipes includes butt welds in plates: I approval for butt welds in plates in all relevant positions covers burt welds on pipes having an outside diameter > 500 mm, for rotating pipes item c) applies: Cc) approval on test butt joints in plates welded in the flat (PA) of honzontal vertical (PC) position shall ncluce approval for butt joints in pipes of outside diameter > 150 mm welded in similar positions according to table 7; 1 welding from one side without backing approves welds from one side with backing and welds from both sides with ang without gouging: €€)_welaing in plates or pipes with backing approves welds made from both sides, but not for welds without backing: 1) butt welds approve fillet welds for similar welaing conaitions: 9) ncases wnere ine procuction work is preaominantiy fillet welding, itis recommended that the welder should be approved also by an appropriate fillet welding test. Le. on plate. pioe or orancn connection (see EN 288-3); |h}_ welding from bath sides without gouging approves welas {rom one side with backing and welds from both sides with gouging: |) approval for butt welds in pipes without backing incluaes aoproval for branch connections within the same range of approval as in tables 3 to 7. For a branch weld the range of approval 's Dased on the diameter of the branch: il in cases where the production work is either oreaominantly branch welding or involves a complex branch connection, itis recommendea that the welder should receive special training. In some cases a welder approval test on a branch connection may be necessary. Table 3: Range of approval for tests on butt joints (Details of weld type! Range of approval Butt words pate Burt weigs Be Details of wels type ‘weed from one sae] welded from both sises | warded fom one nae fear easing] no oecxng [won goumne] no gouene [wom sacnng] To BeSOnp ae "2 3s 3 m0 2 ES 5 ih [eeee Lense eT oe. resousrs | vo | © aun wea] wosed vom | wansectng [me [+ ‘come | onset noc |e [es 1 See 6.38) ana 6.36) Key ‘+ ‘indicates ne weld for which the welder 1s approved in the approval test 2X inaicates those welds for which the welgera also approved ‘naicates thoxe welds for which the welder is not approved 410 Welding Technology Issue 0191SENIOR WELDING INSPECTOR 6.4 Material groups According to the matenal group of the test piece, the range of materials for which a welder is approved 1s shown in tables 4 and 5 (see 5.4). For any ste! not covered by any of the steel groups the welder shall carry out an approval test, which only approves tor that steel. Table 4: Range of approval for parent metal Table 5: Range of approval for dissimilar metal joints Matenai group of Range of aoproval approval test piece Maternal grouo of Range of aoproval sooroval test orece wor ere 0 WO2 weicteto wor” wo2 W02 weisea to wor ™ ae wo3 W003 weiges to WO! woe W03 weises to W02 "! wn W 02 weisee to wo1 woe W046 welces to WO!" ° wen using titer meta tm group W 11 Wa weaerse wor" key * eates ine matenal group for whch the weet Wii ween te wor2? . wit W11 wetgea to W022 W 11 waises to W032) = Maicates mse matanal groups for which the weiger snot WT welgee t9 W082 ora cram metal unt tne fil corressona to NOTE: This tani anoles only when parent metalincicated by # lee to and filer metal aren the name grou, 2) When using ene parent from mater group W 11 6.5 Covered electrodes aor rarer veeecree of electrode coating may requie a change in the welders techniaue. An approval est of electrode coating will confer approval of the weider for otner coatings as specified in table 6. Table 6: Range of approval for electrode coating Type of covers eectroges Range of approval 3 anoroval est niece of approval test ec Dae 5 = = jr E : p= fp st | > 5 L eI "'S oniy gves approval for he specific type of electroae coating usea in tne test 3s he covered electrode type for when the welaer x moteates tnose electroae groups for wnien tne welge’ 30 approved ~_mmoieates those electroge groups for wnich the welger is not aparoved 6.6 Shielding gas and flux A.change of shielding gas or flux is permitted (see §.5.1). However, a change from active to inert shielding gas or from inert to active shielding gas requires a new approval test for the welder, Welding Technology Issue 0191 4.100SENIOR WELDING INSPECTOR Page 13 EN 287-1: 1992 Table 7: Range of approval according to welding position Range of anerova Welding position of approval test o1ece Ban wees Gat wea Pa Burt 2 Plates ~ Filet ~ Filet welds Pose Welding Technology Issue 0191 4100QUESTIONS Qi. Q2. Q3. Q4. Qs. WELD PROCEDURE & WELDER APPROVAL State six (6) essential variables ‘State the meaning of ‘extent of approval’ and give five (5) examples Explain the difference between a welding procedure specification, a procedure qualification record and a welder approval certificate Why are procedures and welders approved? State two (2) reasons for re~approval of: a) — Aweld procedure b) — Awelder aQs4SENIOR WELDING INSPECTOR PROCEDURE AND WELDER APPROVAL Q1. Describe briefly 2 (two) methods of producing approved procedures. Q2, Can a welder be approved when welding without a procedure. Q3. If a welding procedure has been approved state six reasons for re-approval. Fone a4. Bee ‘a welder approval test should the welder be given time to practice before attempting a test’. Q5. Give a typical "Extent of Approval" for a) thickness b) diameter c) process Q6. Sketch the following weld positions for pipe ) 1G ii) 2G iil) 3G iv) 4G vy) 5G vi) 6G Q7. State 4 (four) reasons for re~approving a welder. Q8. If a welder is approved to weld plate would he be allowed to weld pipe? Q9. Ina welder approval test should the procedure be explained to the welder. Q10. Long question: State briefly the main details of conducting a procedure/welder approval. Welding Technology asa, Issue 0197SECTION 5‘Ww im ‘THE WELDING INSTITUTE DESTRUCTIVE TESTING Destructive tests on welded The test pieces are out from the joints are usually made as part test weld and their location is often of the approval of a welding specified in the standard. procedure or a welder. British Standards for Testing of Welds BS 709: 1983 Methods of testing fusion welded joints and weld metal in steel Commonly used destructive tests are: Fracture tests Macro section a Test weld along Discard. centre of plate Bend Tensile ip 1 \Tensie Removal of test-pieces con for destouctive Testing Discard WELDING TECHNOLOGY Issue 0191 51TWI My BEND TESTS (transverse and longitudinal) 52 Object To determine the soundness of weld metal, heat affected zone and weld zone. These tests may also be used to give some measure of the ductility of the weld zone. It is not usual to use longitudinal and transverse bend tests for the same application. Method The specimen is bent by the movement of a former of prescribed diameter, the relevant side of the specimen to be placed in tension. Angle of bend and diameter of former should be as specified in the appropriate application standard. Reporting Results 1. Thickness of specimen 2. Direction of bend (root or face) 3. Angle of bend 4. Diameter of former 5. Appearance of joint after bending, e.g. type and location of flaws. ‘THE WELDING INSTITUTE ‘This side in tension for face bend \ ‘ This side in tension for root bend Testpiece tor face or root bend Surface in contact with former is ground flat (a) Face bend F ® © {b) Root bend R= Roller support F + Former fof specified radius (atene WELDING TECHNOLOGY Issue 0191TWI Zh LN TE WELDING INSTITUTE SIDE BEND TEST 10, Object Fe Thickness To determine the soundness of a Jor welded joint in a cross section. selate This may be preferred to the transverse bend test on thick materials. or) tension for side bend “ Method Test piece for side bend The testing method is the same as that used for transverse bends. Force Reporting Results 1. Width and thickness of specimen — 2. Angle of bend @®@ © (e) Side bend 3. Diameter of former R= Roller sport, 4. Appearance of joint after bending 9. type and location of flaws WELDING TECHNOLOGY Issue 0191 53TWI NN THE WELDING INSTITUTE TRANSVERSE TENSILE TEST Object Used to measure the transverse tensile strength under static loading of a butt joint employing butt welds. The test is not designed to give the tensile strength of the weld metal. Method The testpiece is clamped at each end and a load is applied by a hydraulic or screw mechanism. The load is increased until fracture occurs. Reporting Results 1. 2. 5.4 Type of specimen (e.g. reduced section) Whether excess weld metal is removed or not Tensile strength in N/mm, is calculated from maximum load and original cross sectional areas. When excess weld metal is not removed the cross sectional area shall be the product of the parent metal thickness and the width of the specimen. Location of fracture, whether in parent metal, heat affected zone or weld metal. If the fracture is in the parent metal, the distance from the weld zone shall be stated. Location and type of any flaws present on the fracture surfaces. WELDING TECHNOLOGY Issue 0191TWI “a CHARPY V NOTCH IMPACT TEST Object To determine the amount of energy absorbed in fracturing a standardised testpiece at a specified temperature. Method A machined, notched specimen is broken by one blow from a pendulum. Because scatter occurs in the results, at least three specimens are used to assess the joint represented. Testing is carried out at a temperature specified in the appropriate application standard in accordance with BS 131: Pt 2: 1972. Reporting Results 1. Location and orientation of the notch 2. Testing temperature 3. Energy absorbed 4, Description of fracture appearance 5. Location of any defects WELDING TECHNOLOGY Issue 0191 ‘THE WELDING INSTITUTE Charpy testpiece B, Bn Root radius | 0.25 mm Hammer Dial calibrated in joules ‘Testpiece (Charpy impact machine Testpiece Hammer Anu blow Energy absorbed during lracture is proportional to (A~ Test piece in position (on anvil 55TWI THE ELD ING INSTITUTE FILLET WELD FRACTURE TEST Object To break the joint through the weld to permit examination of the fracture surfaces. Method The specimen is cut to length and a saw cut, normally 2mm deep, is made along the centre of the weld face. The specimen is fractured by bending or by hammer blows. Reporting Results 1 2. 5.6 Thickness of parent metal Throat thickness and leg length Location of fracture Appearance of joint after fracture Depth of penetration/lack of penetration or fusion Hammer or bend. Saw cut WELDING TECHNOLOGY Issue 0191TWI LN THLE WELDING INSTITUTE ‘NICK' BREAK TEST Object As for fillet weld fracture Method The specimen is cut transversely to the weld, and a saw cut is applied along the centre of the weld face. The specimen is fractured by bending or by hammer blows. Reporting Results 1. Thickness of material 2. Width of specimen 3. Location of fracture 4. Appearance of joint after fracture WELDING TECHNOLOGY Issue 0191 57QUESTIONS Qi Q2 Q3 Q4 Qs MECHANICAL TESTING OF WELDMENTS From a tensile test the following items were progressively recorded a) load b) extension If the original length is also known, state what can be assessed. Yeup Pour, Eroncnmrion | OTS, State the objectives of: a) a reduced transverse tensile test eTRe maT OF b) a radius reduced transverse tensile test. = “YeaysT * What is the purpose of a Charpy test? What is the purpose of : a) face bend test 6 er Face: b) root bend test BouRDNESS OF ROE ©) side bend test ? " a owt What is the purpose of the ‘nick’ in a nick bend test ? assQi. Q2. Q3. Qa. Qs. 6. Q7. Qs. Q10. SENIOR WELDING INSPECTOR MECHANICAL TESTING What is the purpose of a) An “all weld" tensile test MecvanicaL TEniene Properne b) —_ Arradius reduced tensile test PROPEATIES GF “SOIT” Calculate the following for a transverse tensile test a) Yield stress b) — % elongation If the maximum load applied at failure is 400kN while extension at the failure was 5mm on an original length of 20mm given the specimen size is 100mm x 10mm in cross section. Why should a macro be examined before etching, OBVievS DberectS State 10 (ten) surface defects/features. State 10 (ten) sub-surface defects/features. Describe briefly the method of producing a bend test. Gaw-coT —THerd Beorers ‘State the objective of . “4 a) a fillet fracture test \estec QT oF LED. b) — anick break test Boospness of Sow If a bend test failure has occurred what would be your course of action. R&-Test~ In which type of tests would an assessment of ductility be made. Tenove + Bend Tests Below the sketches show two typical results. Report. CS A Welding Technology oe Issue 0191SECTION 6TWI “I ‘THE WELDING INSTITUTE WELD SPECIFICATIONS Welds must be specified by clear instructions to ensure that the welder produces an acceptable result. It may only be necessary to specify the weld size and electrode to be used. Or, the full details of a weld procedure may be needed. Three methods are commonly used to specify a weld: Written statement ‘Weld AZ321 is to be a single V butt welded from the outside of the vessel. The surface of the weld is to be ground flush. The root is to be sealed with a weld run deposited from inside the vessel. The completed weld is to be radiographed.' Symbols on a drawing WELDING TECHNOLOGY Issue 0191 61‘THE WELDING INSTITUTE STANDARDS FOR WELD SYMBOLS. 62 Although the main features of weld symbols are international, variations in detail occur from country to country. Symbols are specified by National ‘Standards. . BS 499 Pt 2: 1980 . AWS2.4-79 . NFE 04-021- 1978 . DIN 1912 . NS1421 69-10 In this text, symbols are in accordance with BS 499. Indicating Joint Position The position of the joint is indicated by an arrow. Other side Arrow side The arrow points to one side of the joint. This is called the ARROW SIDE. The side remote from the arrow is the OTHER SIDE. WELDING TECHNOLOGY Issue 0191TWI im THE WELDING INSTITUTE WELD DETAILS Information about the weld is given ‘on a reference line attached to Kreterence line the arrow. The reference line is always horizontal. Details of the weld on the arrow side ofthe joint are given below Other side information the line. Arrow side information Other side information is above the line. A fillet weld is indicated by a triangle placed on the reference line. A triangle below the reference line ‘specifies a fillet weld on the arrow side of the joint. VT iH] 7 A triangle above the line calls for a fillet weld on the other side of the joint. —NhK— ll Fs WELDING TECHNOLOGY Issue 0191 63TWI 64 SS z ‘THE WELDING INSTITUTE TYPES OF BUTT WELD The common types of edge preparation associated with a butt weld are indicated as follows : Square edge preparation Single V preparation NDS [ Double V preparation Single U preparation Double U preparation ,thyby Hh Using symbols it is not necessary to draw the shape of the edge preparation. The joint is shown as a single line. H WELDING TECHNOLOGY Issue 0191TWI “i ‘THE WELDING INSTITUTE ASYMMETRICAL PREPARATIONS In some joints, only one component is prepared, e.g. single bevel butt or single J butt. i A= Arrow side 0 = Other side In these cases the arrow points at the edge which is to be prepared. SURFACE PROFILE ‘The surface profile can be indicated by an extra symbol placed on the top of the weld symbol. Single V butt weld with a fiat surface, (Flushed after welding. Usually by grinding). Convex fillet weld. ) Concave fillet weld. (May be achieved by C welding alone or by subsequent grinding). WELDING TECHNOLOGY Issue 0191 65TWI My ‘THE WELDING INSTITUTE ‘SEALING RUN If the root of a butt weld is to be sealed the symbol is placed on the reference line, opposite the weld symbol. - ct = C85 DIMENSIONING FILLET WELDS The leg length of a fillet weld is located in front of the weld symbol (triangle). The dimension is in millimetres. 10 me 0mm (eg Length = fet wea Throat thickness is indicated in the same way but is preceded by the letter ‘a’. a7. me fillet weld vith = 7mm design throat thickness When both leg length and throat thickness are given, the dimension for the leg length is preceded by the letter ‘b' oar ~ number of weld elements (n). nxlar = length of weld element (!). - distance between weld elements (e). WELDING TECHNOLOGY 66 Issue 0191 Intermittent fillet welds are dimensioned by giving:SUPPLEMENTARY SYMBOLS Three supplementary symbols are in general use: Weld all round the component Inspect by NDT Weld this joint on site pe WELDING TECHNOLOGY Issue 0191 67QUESTIONS Qi Q2 Q3 a4 a5 SYMBOLS FOR WELDING SPECIFICATION ‘Sketch/describe the weld shown below 6 ‘Sketch/describe the weld shown below ‘Specify the weld shown below by means of symbols Specify the weld shown below by means of symbols 14t1al Describe the following: 2 paSENIOR WELDING INSPECTOR SYMBOLS 1. Describe sketch the weld shown below. a7 bI0| 2. State the symbol for a spot weld. “Oo, 3. State the symbol for a seam weld. = 4. Describe/sketch the following symbol PLon Deu | pimession 1 5. Describe/sketch the following weld Z 6. ‘Sketch in the weld position U 7. Describe/sketch the following 10 [110 (75) Welding Technology QS6A Issue 01978. Comment on the following 9. Describe the following — 10. What information may be placed at the end of the reference line. Welding Technology Issue 0191SECTION 7TWI ‘THE WELDING INSTITUTE REVIEW OF STEELS AND MATERIAL DEFECTS The term ‘steel’ is used to describe many different metals, they are all alloys based on iron, but the alloying additions, such as carbon, manganese, silicon and chromium, ete., singly or in combination produce a range of metals with widely differing physical and mechanical properties as well as quite different weldability. IRON Fe + S°~@ = Stee CARBON C Peceerses wEADABUITY er MANGANESE Mn @r@encruene® = BuoT CAN ALSO D .WLABLT SILICON si SMALL QoATITIES De oxi DR SHTION ALUMINIUM A “ . ” oun CHROMIUM Cr WeDAguity Decasnees — Sma Amo MOLYBDENUM Mo muimises caeer : * TITANIUM Ti omiero- AUSY e.ement Deas eridemestS NIOBIUM Nb _ A i . VANADIUM vow . . SreENaTHeEndeR ‘SULPHUR S ResiboAL cremenr (Bad meds) CRAUS NICKEL Ni imPaaves “TEOQUNnESS.F STRENGTH. COPPER Cu ResibuAL = Coerens ProsPreRooS PP Poot Varmeuity , HoT SHORTNESS RIMMING STEEL Composition 0.09%C. 0.9%Mn + residuals Weldability The weld pool will require to have added deoxidant via a filler rod. LOW CARBON STEEL Composition 0.2%C 0.9%Mn. + residuals Weldabilty The general weldability is good but the level of residuals (S) may cause weld metal/heat affected zone cracking. MEDIUM CARBON STEEL Composition 0.45%C 0.90%Mn_ + residuals Weldability The high carbon content induces hydrogen cracking in the~ HAZ as the section size increases. WELDING TECHNOLOGY Issue 0191 7ATWI 7.2 NN THE WELDING NST HIGH CARBON STEEL Composition 0.8%C. 0.9%Mn + residuals Weldability ‘The weld pool is subject to solidification type cracking and the HAZ suffers hydrogen cracking. CARBON-MANGANESE STEEL Composition 0.2%C 1.5%Mn + residuals may also contain Ti, Nb and V. Weldability ‘These high Mn steels have good toughness, particularly the Ti, Nb and V grades, and the main weldability problem is to maintain these. QUENCHED AND TEMPERED STEEL Composition -4%6 02% 1.0%Mn 0.8%Cr 0.3%Mo +TiorAl + residuals Weldabilty These steels are difficult to weld, and defect free welds with good mechanical properties are only attained by using the greatest care. HIGH TEMP. STEEL Composition 0.25-9%Cr 0.25-3%Mo etc. Weldability The weldability of the low Cr is difficult. LOW TEMP. STEEL Composition 3.5-9%Ni etc, Weldability The higher Ni are subject to solidification cracking. WELDING TECHNOLOGY Issue 0191Za ‘THE WELDING INSTITUTE MICRO ALLOYED STEEL (HSLA) Composition Weldability 0.25%C. 1.5%Mn 0.002% ) 0.005%Nb ) min. 0.003%Ti ) These steels may suffer hydrogen cracking in the weld metal. STAINLESS STEELS 1. MARTENSITIC SS. Composition Weldability 2, FERRITIC SS Composition Weldability 11%Cr 0.08%C + residuals Poor due to hydrogen cracking. 12-27%Cr 0.08%C + residuals Poor due to cracking, brittleness and temper embrittlement. 3. AUSTENITIC SS (NB NON-MAGNETIC) Composition Weldability WELDING TECHNOLOGY Issue 0191 18-27%Cr 8-22%Ni 0.08%C + residuals Problems with solidification cracking and weld decay. 73TWI ay THE WELDING INSTITUTE A great variety of materials may require to be inspected with a view to satisfactory welding. Inspection points are: Specification/supplier - to mill sheet or reference number. Quantity: Size = length, breadth, thickness, diameter Distortion - — flatness/ovality Condition - — rust/paint, heat treatment Defects - laps, bands, laminations Storage SPECIFICATION It is not, in general, safe for the inspector to identify materials by composition from mill sheet, since very small variations or additions to the metal may give rise to significant changes in properties and weldability. However, limited selectivity is permissible, such as % carbon maximum, etc. The procedure is for the mill sheet to be submitted for approval and then the inspector records and transfers the reference number. SUPPLIER This can be found on the Goods Inwards documents or the receipt documents, or occasionally on packaging or even marked on the metal. QUANTITY The quantity being inspected should always be noted as well as the sample size, if 100% inspection is not being employed. SIZE ‘Sizes must be checked for secondary identification as well as conformance. The inspector will, as appropriate, be given tolerances on size which are permissible. WELDING TECHNOLOGY 4 Issue 0191TWI Me ‘THE WELDING INSTITUTE DISTORTION A check is often required on the degree of distortion, i.e. Flatness squareness straightness ovality consistent wall thickness CONDITION Rust, paint and grease on the surface of the metal are all harmful to welding and must usually be removed at least near to the actual weld. Guidance is normally given to the inspector regarding acceptable levels or the treatment which is required. An inspector should be alert to gradual changes, such as increased corrosion. Carefully maintained specimens showing acceptable conditions are often the best method. Heat treatment condition, annealed, normalised etc, DEFECTS In wrought products the most common defects are laps and laminations. Both these will normally be subsurface so unless NDE is being employed only, the edges of plate, and particularly cut edges, can be inspected. The lapflamination will appear as a narrow black line parallel to the surface. STORAGE After inspection and approval for use it is essential that the metal is stored in such a way as to maintain its good condition. Protect from corrosion and mechanical damage. Questions to be asked: Do the markings on the material match those on the procedure sheet or drawing? Are the dimensions correct? Is the surface condition satisfactory for welding? WELDING TECHNOLOGY Issue 0191 75QUESTIONS: Qi Q2 Q3 Qs REVIEW OF STEELS AND MATERIAL DEFECTS Name two (2) wrought plate defects. Give examples of composition a) — Arimming steel b) A low carbon steel ©) A tool steel Give an example by composition of a stainless steel What is the purpose of the increased Mn content of a carbon-manganese ste! State the features/defects which should be noted when inspecting wrought plate as7SENIOR WELDING INSPECTOR MATERIALS Q1. What is the metallurgical/production cause of lamellar tearing? Q2, _Whyisit desirable to ‘seal’ in a lamination which is found to break into an edge preparation? Q3. Does wrought plate contain residual stresses due to manufacture? Q4, What is a LAP in a steel? Q5. State three (8) factors which contribute to or control the mechanical properties of wrought steel. Q6. What feature(s) of a steel determine its weldablity? Q7. List six (6) different types of steel by type name and approximate composition. @8. For each of the steels given in state the main weldability problem. @9. During an inspection audit, no material mill sheet can be found. How would you proceed? Q10. Long question: During preweld inspection you require an inspector to check ‘the actual material. Draw up a check list/schedule. Welding Technology @s7A Issue 0191SECTION 8TWI VT ‘THE WELDING INSTITUTE CONSUMABLES Welding consumables are the: Electrodes Wire (lengths or rolls) Fluxes Gases. Each consumable is critical in respect to - Specification/supplier Condition Treatment (if any) Take as an example a common MMA covered electrode. This will be to a specified type but an additional requirement may be that only one or two suppliers/manufacturers are acceptable. The electrode must be in good condition with regard to corrosion and mechanical damage and so storage and mechanical handling are important. If the electrode requires heat treatment for low hydrogen potential then the temperature, time and oven condition require attention. The issue of electrodes to the welder for use and the procedures for recycling and scrap must often be dealt with care. There are many codes in existence which cover the various consumables. The only reasonable rule is to keep to what is specified unless (and only unless) a written order for variation is received, Covered Electrodes BS 639 AWS AS 1 ISO 2560 BS 2493, BS 2926 Gas-shielded wires BS 2901, Part 1-5 Gases BS 4365 BS 4105 WELDING TECHNOLOGY Issue 0191 atTWI Identification of covered electrodes ‘THE WELDING INSTITUTE In the BS system for carbon and carbon manganese steels the electrode may be partially or completely specified by a letter/number. ‘The summary sheet gives details. British Standards System BS specification: BS 639: 1986 rinst Gnour covenng erncency ecvows [Tau [Mnmonvag] [8 ] bee recovery] | nienes Essien | esegtn | stesn wim? | | 66 | han effciecy Renertto% | | to Nim & | chun iste oneateg Ee 8 | ee a (ibm Est S100. 380 RR | rutile (heavy coated) 5" | soermpee ' 8 7 6 wm Secon Grour rosmon o1a ELECTRICAL OTT Fr 1 | a pono case Brac corant| Atwnning carat oot 2 | thpousonsexcet vera! down +3 | flat and, for filet welds, horizontal vertical Recommended | Minimum open. alles reat votage,¥ $ 8 | Rit versa down ado et welts, } ora wore Patri | Rakai for 2 «| toy outer or comtinaion of poston ot S| |r 3 Snag above yma ; a | Ror |Second| Temperat } tern s digit | impact value of 2 z so 473,°C 3 > LJ apecified 4 term 70 | “Se f] 5 x 2 oO £ x | -» 7] ees ‘ i] 2B 3 : 2 s| 3 A é so 5 | oe i | on WELDING TECHNOLOGY 8.2 Issue 0191TWI it THE WELDING INSTITUTE BRITISH STANDARD 639 1986 MANUAL METAL ARC WELDING CONSUMABLES FOR C.C/Mn STEELS E 51 33 B 160 2 0 COVERED ELECTRODE STRENGTH TOUGHNESS COVERING EFFICIENCY (%) POSITIONAL CAPABILITY ELECTRICAL CAPABILITY LOW HYDROGEN POTENTIAL (H) WELDING TECHNOLOGY Issue 0191 83TWI AMERICAN WELDING SOCIETY AS. 1-81 MANUAL METAL ARC WELDING CONSUMABLES FOR C. C/Mn STEELS E 70 1 8 G ARC WELDING ELECTRODE TENSILE STRENGTH Ib/"? (PSI) WELDING POSITION = ALL POSITIONAL 2 = FLAT & HV FILLETS \ FLUX COVERING CURRENT TYPE AND POLARITY A5.5-81 LOW ALLOY STEEL (ALLOY CONTENT) ————-_ — WELDING TECHNOLOGY 84 Issue 0191QUESTIONS: THE BRITISH STANDARD CLASSIFICATION OF MMA ELECTRODES Qi. Q2. Q3. Qs. Explain the following factors: 51 33 B 160 2 OO (H) covering What is the compulsory part? State the meaning of the following: a B= __ basic b) RO = o) AR = d oO = 2 Cc = ) RR = When an electrode specification terminates with an (H), what is usually required in order to give the specified results? What is the meaning of: assSENIOR WELDING INSPECTOR CONSUMABLES Q1. What would be the manganese content of an S2 wire-specified to BS 4165? Q2. _Whatis the significance of the prefix letter 'S' in the following wire specification: Q3. If your wire/fiux specification indicates a basicity number of 2.8, would you expect it to be an acid or basic type of flux? Q4, How are the wires classified in respect to composition using AWS A5.17.80? Q5. Basic electrodes are to be used for a fabrication and hydrogen control to 1.5mi/100g of weld metal as-deposited is called for a) Generally comment b) Draw up an inspection schedule c) Draw up a quality control schedule @) Draw up a workshop method of ensuring that the electrodes are fully hydrogen controlled. Q6. An electrode is specified as E51 32B 160 20H Write out a description of the requirements of this electrode. Q7. What is the effect of increasing the percentage of ‘ines’ in a submerged arc flux? Q8. After hydrogen control treatment some MMA electrodes are suffering flux flaking. Review your course of action. Q9. Some rolls of MIG/MAG wire consumable shows incomplete copper cover. Comment. Q10. A very high quality TIG weld is to be made. Draw up a check list. Welding Technology QS8A Issue 0191SECTION 9TWI THE FOUR ESSENTIAL FACTORS FOR ESTABLISHING A WELD Welding is usually regarded as a joining process in which the work pieces are in atomic contact often with a filler metal of broadly similar properties. Hence soldering and brazing are excluded but both solid-state and fusion welding are included. Solid state processes include: Forge welding Friction welding Fusion welding processes include: Oxy-acetylene Manual metal arc (MMA) Metal inervfactive gas (MIG/MAG) Submerged arc welding (SAW) Electro-slag welding (ESW) Fusion welding factors 1. Fusion (melting) The metal must be melted which requires a high intensity heat source. 2. The process must remove any oxide and other contamination from the joint faces. 2 . Contamination by the atmosphere must be avoided. s . The welded joint must possess adequate properties. WELDING TECHNOLOGY Issue 0191 91