cswip intro
DESCRIPTION
TRANSCRIPT
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AN INTRODUCTION TO
CSWIP 3.1
By
MR ANSAR BALOCH
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Contents
Terms & DefinitionTypes of WeldsTypes of JointsWeld PreparationsTypes of Single Butt PreparationButt Welded JointFillet Weld ProfileEffect of a Poor Toe Blend AngleSummary of TermsDuties of Welding InspectorResponsibilities of Welding InspectorImperfections in Welded JointsMechanical TestingMacro Inspection
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A Joint:* A configuration of members
A Weld:* A union between materials caused by heat, and or pressure
Text Page Ref 1:1
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Butt welds:*
Fillet welds:*
Spot/Seam welds:*
Plug/Slot welds:*
Edge welds:*
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Closed corner
Open corner*
T joints: *
Lap joints: *
Corner joints:*
Butt joints: *
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Angle of bevel*
Included angle*
Root gap*
Root face*
Root radius*
Root landing*
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Single V
Single bevel
Single J
Single U*
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Double bevel
Double V
Double J
Double U*
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A butt welded butt joint*
A fillet welded butt joint*
A compound welded butt joint*
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A butt welded T joint*
A fillet welded T joint*
A compound welded T joint*
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A compound welded Lap joint*
A spot welded Lap joint*
A fillet welded Lap joint*
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A butt welded Closed Corner joint*
A fillet welded Closed Corner joint*
A compound welded Closed Corner joint*
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An outside fillet welded Open Corner joint*
An An inside filletinside fillet welded Open C welded Open Corner jointrner joint**
A double fillet welded Open Corner joint*
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1 2
43
A
B
A + B = Excess Weld Metal**
Weld Face*
Weld Width*
Design Throat Thickness*1.2.3.4. Weld Toes*
Weld Root*HAZ*
Actual Throat Thickness*
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Weld face*
Vertical Leg Length*
Horizontal Leg Length*
Design throat*Actual throat*
Excess weld metal **
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80°
20°
6 mm
3 mm*
Very Poor Weld Toe Blend Angle
Improved Weld Toe Blend Angle
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Extremely poor toe blend, but excess weld metal is within limits*
3 mm90°
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Weld Sizing (Fillets): DTT. ATT. Excess weld metal. Leg length *
Weld Sizing (Butts): DTT. ATT. Excess weld metal.
Weldment Terms: Weld face & root. HAZ. Weld toes.Weld width
Preparation Terms: Bevel/included angle. Root face/gap. Land/Radius
Types of Preparation: Bevel’s. V’s. J’s. U’s. Single & Double Sided.
Types of Joint: Butt. T. Lap. Corner (Open & Closed)
Types of Weld: Butt. Fillet. Spot. Seam Plug. Slot. Edge.
Weld Preparation: Preparing a joint to allow access and fusion.
Joint: A Configuration of members
Weld: A Union of materials
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It is the duty of all welding inspectors: To ensure that welding operations are carried out in accordance with written, or agreed practices or specifications
Before
During
After
*
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Discuss the following
1) Safety:
Rules.
2) Documentation: Spec. Drawings. Procedures. Welder approvals. Certificates. Mill sheets
3) Welding Process and accessories: Equipment,Cables, Regulators, Ovens etc
4) Incoming Consumables:
Materials/welding consumables (Size. Condition. Specification. Storage)
5) Marking out preparation & set up: Method. Angles/Root face/gap values. Distortion control. Pre-heat prior to tack welding if applicable*
Before Welding:
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During Welding:
1) Pre-Heating (Min 15 C as per UW-30 ASME Section VIII Div-I)
2) In process distortion control (Balance or sequence welding)
3) Consumable control. (Correct baking for E-7018 260-425 C and storage 30-140 C prior to use)
4) Welding process (Related parameters i.e. volts/amps. gas flow rate)
5) Welding run sequence and inter-pass cleaning
6) Minimum/maximum Inter-pass temperatures (150 C for SS, 250 C for CS.
7) Full compliance with all elements given on the WPS*
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After Welding:
1) Visual Inspection
2) Non Destructive testing
3) Repairs*
4) Repair procedures (NDT/Welding/Welder approval)
5) PWHT
6) Hydro-static testing
7) Submission of all inspection reports to QC departments*
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To Record
To Compare
To Observe Activities & Imperfections*
Activities & Imperfections*
Activities & Imperfections*
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A Welding Inspectors toolbox should contain*
A welding gauge (Cambridge style, or high low gauges etc)
A tape measure and scale
A wire brush
A magnifying glass
A torch and mirror
A specification, pen and report, or note paper
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Welding imperfections can be categorized into groups:
3) Solid Inclusions
4) Lack of fusion
1) Cracks
6) Mechanical or Surface damage
5) Profile & Lack of Filling
2) Gas Pores & Porosity
7) Misalignment*
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A HAZ hydrogen crack, initiated at the weld toe
Most cracks are initiated from stress concentrations *
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Surface breaking porosity
Fine cluster porosity Blow hole > 1.6 mm Ø
Hollow root bead
An isolated internal porosity
Coarse cluster porosityShrinkage cavity*
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Internal solid inclusion causing a lack of sidewall fusion
Surface breaking solid inclusionInternal solid inclusion causinga lack of inter-run fusion*
Solid inclusions caused by undercut in the previous weld run
Internal solid inclusion
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Lack of root fusion
Overlap (Causing cold laps)
Lack of inter-run fusion Lack of sidewall fusion
Lack of sidewall fusion & incompletely filled grove*
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An Incompletely filled groove
Lack of root fusion
Spatter
A
Poor toe blend
Bulbous, or irregular contourArc Strikes
Incomplete root penetration
B
*
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Root Run or “Hot pass” undercut
Parent metal, surface undercut
Weld metal, surface undercut*
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Weld metal, surface undercut Parent metal, “top toe” undercut*
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Any surface damage caused by:
Grinding
Hammering/chisel marks
Slag chipping hammer marks
Arc strikes
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Linear misalignment measured in mm (over 13mm to 19mm as per UW 33 of ASME Sec VIII Div-I)
3 mm
Angular misalignment measured in degrees*
15
Excess weld metal heightLowest plate to highest point
Linear
Angular
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Why ?* To establish the level of mechanicalTo establish the level of mechanical propertiesproperties*
Which properties ?*
4) Ductility*3) Tensile strength*
2) Toughness (Impact Test)*
1) Hardness*
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We test welds to establish minimum levels of mechanical properties, and soundness of the welded joint*
We divide tests into Quantitative & Qualitative methods:*
1) Quantitative tests: (Have units)*1) Quantitative tests: (Have units)*
2) Qualitative tests: (Have no units)*2) Qualitative tests: (Have no units)*
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Types of tests include:
1) Quantitative tests:
Hardness tests
Toughness tests
Tensile strength tests*
1) Quantitative tests:
Hardness tests
Toughness tests
Tensile strength tests*
2) Qualitative tests:
Macro tests
Bend tests
Fracture tests*
2) Qualitative tests:
Macro tests
Bend tests
Fracture tests*
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The specimen below has been polished and is ready to be hardness tested
= Hardness Survey
Thickness
Base metal HAZ Fusion boundary Weld metal
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Generally we use a diamond or steel ball to form an indentation
We measure the width of the indentation to gauge the hardness*
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1)1) Vickers Diamond Pyramid:Vickers Diamond Pyramid: Always uses a diamond*
2)2) Brinell hardness test:Brinell hardness test: Always uses a steel ball*
3)3) Rockwell hardness test:Rockwell hardness test: Uses a ball, or diamond depending on the scale*
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10 x 10 mmMachined notch
Pendulum Hammer
Location of specimen
The specimen may be tested from different areas of the weld.*
Graduated scale of absorbed energy in Joules*
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1)1) Charpy V test:Charpy V test: 10 x 10 (Specimen horizontal) Joules*
2)2) Izod test:Izod test: 10 x 10 (Specimen vertical) Ft.lbs*
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Weld
HAZ
Plate material
Test gripping area
Radius (For radius reduced test specimens only)
Reduced Section
Used to assess the tensile strength of the weld metal
Direction of test
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Tensile test piece cut along weld specimen.
Direction of the test *
All Weld Metal Tensile Testing
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Firstly, before the tensile test 2 marks are made 50mm
During the test, Yield point & Tensile strength are measured
The specimen is put together and the marks are re-measured
A new measurement of 75mm will indicate Elongation E50 %*
50 mm
75 mm
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3) Lack of Root Fusion
1) Excess Weld Metal Height 7) Poor Toe Blend*
4) Slag inclusion & Lack of inter-run fusion
2) Lack of Sidewall Fusion5) Root Penetration
6)Porosity
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Bend tests are used to establish fusion in the area under test
FormerTest Piece
Lack of root fusion shown here*
Further tests include face, side and longitudinal bend tests*
For material over 12 mm thickness, side bend test may be used*
Force
A Guided root bend test*Guide
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Specimen prior to test* Specimen after test*
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The main difference between Macro & Micro is that Micro is the study of the micro-structure at much higher magnification
The limit of Macro inspection is magnification < X 10
The specimen is usually cut from a stop/start in the test piece
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Remember! The process of inspection is to first:
Observe, then Report, then Compare!*