1、Welding Codes&StandardsLesson ObjectivesWhen you finish this lesson you will understand:Codes and Standards and Standards Writing Bodies Welding Procedure Development and QualificationsLearning Activities1.Read Handbook 412-4642.View Slides;3.Read Notes,4.Listen to lecture5.Do on-line workbook6.Do h
2、omeworkKeywordsCodes,Specifications,Recommended Practices,Guides,Classifications,Methods,ANSI,ISO,Welding Procedure Specification(WPS),Procedure Qualification Record(PQR),Welder Performance QualificationCodes and StandardsStandards that Impact FabricationTypes of StandardslCodes are generally applic
3、able to processes and indicate the mandatory use of materials or actionslSpecifications are generally associated with a product and indicate the mandatory use of materials or actionslRecommended practices and guides are offered primarily as aids to the userlClassifications and methods provide lists
4、of established practices or categories for processes or productsIntroduction0.1.1.6.0.T1.95.12Shall/willShall/willShould/mayThis Tableis in the Welding HandbookCode Writing AgenciesStandards that Impact FabricationWhat is Covered by StandardslProductsPiping-American Petroleum InstituteFiller metals-
5、American Welding SocietyShips-American Bureau of ShippingPressure vessels and boilers-American Society of Mechanical EngineersBridges-American Institute of Steel ConstructionlHealth&SafetylTerminologylTesting ProceduresIntroduction0.1.1.6.0.T2.95.12Standards that Impact FabricationAmerican National
6、Standards Institute(ANSI)lCoordinating organization for the U.S.voluntary standards systemlThere are approximately 10,000 American National Standards,which encompass nearly every field and disciplinelANSI standards are developed and used voluntarily;they become mandatory when adopted or referenced b
7、y a governmental bodyIntroduction0.1.1.6.0.T3.95.12International Organization for Standardization(ISO)Establishment of Uniform Standards for International Trade Standards that Impact FabricationInternational Organization for Standards(ISO)l80 countries,4000+standards,ANSI is the U.S.representativelI
8、SO 9000-9004(ANSI/ASQC Q90)is a series of quality management and assurance standards in manufacturingDesigned for manufacturing sectorEC has adopted ISO 9000 and prefers US suppliers that are ISO 9000 certifiedDoD,DuPont,3M,AT&T are asking suppliers to comply with ISO 9000lISO 3834-Factors to be Con
9、sidered When Assessing Firms Using Welding as a Prime Means of FabricationProfessional Society Standards0.1.1.6.2.T20.95.12Standards that Impact FabricationHealth&SafetylANSI/ASC Z49.1-1988 Safety in Welding and CuttingIncluded in the General Industry Standards of OSHASpecifically covers arc,oxyfuel
10、 gas,resistance weldinglHealth and Safety in Welding and Allied Processes 4th edition,ed.N.C.Balchin and H.R.Castner,McGraw-Hill Inc.1993Health and Safety0.1.1.6.1.T4.95.12Standards that Impact FabricationAmerican Welding Society(AWS)StandardslDefinitions and Symbols(A)lFiller Metals(A5)lQualificati
11、on and Testing(B,C,and D)lWelding Processes(C)lWelding Applications(D)Professional Society Standards0.1.1.6.2.T12.95.12Standards that Impact FabricationDefinitions and SymbolslANSI/AWS A2.4 Symbols for Welding,Brazing,and Nondestructive ExaminationCommunication between designers and fabricatorsJoint
12、 geometry,weld contour,surface finishlANSI/AWS A3.0 Standard Welding Terms and DefinitionsStandard terms for use in written and oral communication conveying materials joining informationNon-standard termsProfessional Society Standards0.1.1.6.2.T13.95.12Standards that Impact FabricationANSI/AWS D1.1
13、Structural Welding Code:SteellGuidelines for design of welded joints as well as prequalified joint geometriesStatically loaded structuresDynamically loaded structuresTubular sectionslDetails the processes used with particular jointslHow to qualify welding procedures and personnellOutlines quality an
14、d inspection in welded constructionlFiller metal recommendationsProfessional Society Standards0.1.1.6.2.T14.95.12Standards that Impact FabricationAWS D1.1 Prequalified Joint Design0.1.1.6.2.T15.95.12Professional Society StandardsStandards that Impact FabricationASTM(American Society for Testing and
15、Materials)lSpecifications cover virtually all materials used in industry and commerce,but not welding consumableslAnnual Book of ASTM Standards,15 sections(65 volumes)1-Iron and Steel2-Non-ferrous3-Metal test methods and analytical procedureslSpecification of groups of similar steel(A)A36-general co
16、nstruction steelsA387-chromium-molybdenum steel for elevated-temperature service in piping and pressure vessel systemsProfessional Society Standards0.1.1.6.2.T16.95.12Standards that Impact FabricationAmerican Society of Mechanical Engineers(ASME)lBoiler and Pressure Vessel Code has 11 sections and i
17、s referenced by most states,major cities in the U.S.,Canadian provinces,a number of federal agencieslBefore fabricating a boiler or pressure vessel,a company must have a quality control system and a manual describing itASME issues a Certificate of Authorization and a code symbol stamplUnique in that
18、 it required 3rd party inspection independent of fabricator and userlUses same steel designations as ASTMProfessional Society Standards0.1.1.6.2.T17.95.12Standards that Impact FabricationBoiler and Pressure Vessel CodelSection II-Materials Specifications for base metals,filler metals,fluxeslSection
19、V-Nondestructive ExaminationlSection IX-Welding and Brazing Qualifications for personnel and proceduresDelineates a P number grouping of steels for the purpose of welding qualificationP1-carbon-manganese steels with a minimum UTS of 45-90 ksiP5-alloy steels with 2.25-9%chromium,10%total alloyAll ste
20、els within a P number can be welded with the same procedureProfessional Society Standards0.1.1.6.2.T18.95.12Standards that Impact FabricationOther StandardslAmerican Petroleum Institute(API)Standard 1104 Welding of Pipelines and Related Facilities Qualifications of Welding Procedures and WeldersInsp
21、ection and nondestructive testingRepair and removal of defectslUnified Numbering System(UNS)Cross references the numbering systems from different countriesOver 3500 metals,alloys,and filler metalsDesignated SAE HSJ1086/ASTM DS56 Professional Society Standards0.1.1.6.2.T19.95.12Turn to the person sit
22、ting next to you and discuss(1 min.):What does being a“third party consensus standards writing body”mean?Qualification&CertificationWelding Procedure Specification(WPS)Procedure Qualification Record(PQR)Welder Performance Qualification-CertificationA document that provides in detail required welding
23、 conditions for a specific application.A record of actual welding conditions used to produce an acceptable test joint and the results of the qualification tests.A record of a welders or welding operators ability to produce welded joints that meet prescribed standards Pre-Qualified Procedures(Some Co
24、des Permit-Example AWS D1.1 Code)Based on the reliability of certain proven procedures spelled out by the applicable code or specification Use Written Procedures From Code All Essential Variable Specified Weld Qualification Tests Not Required Employer Accepts Responsibility for Use Deviations Negate
25、 Prequalified StatusBasic Steps in Qualification of a Procedure1.Prepare a preliminary WPS2.Prepare and weld a suitable test weldment using WPS3.Conduct required NDT and Destructive Tests4.Evaluate Results of prep,welding,testing5.Document results on PQR6.Issue approved PQR7.Issue approved WPSPQR-WP
26、S Variables Considered Base Metal Welding Process Filler Metal Type of Current/Range Voltage Heat Input Travel Speed Joint Design and Tolerances Joint and Surface Prep Tack Weld/Grind Off?Welding Details Electrode Size PassesWeave Position*Preheat and Interpass Peening Second Side Prep Post Weld Hea
27、t Treat Records(If Required)Check Specific Code for List of Essential Variables(Essential Variable Must Be Included in the WPS)PQRPage 1PQRPage 2Tests Commonly Used for PQRsTestEvaluationFracture Tests(Charpy,COD,Drop)Risk of Brittle Fracture at UseTemperatureNick-breakDetermine Weld SoundnessFree B
28、endDuctility of Weld MetalShear TestShear Strength of Fillet WeldsHardnessAdequacy of Heat TreatmentAll-Weld-Metal TensionMechanical Prop of WMElevated TempProp at Elev.Service TempRestraint TestCrack SusceptibilityCorrosionProp.In Aggressive Environ.NDESoundness of WeldDelayed CrackingResistance to
29、 H CrackingWPSWelder Performance QualificationVariables Welding Process Filler Metal Position Joint Details Thickness Technique(Qualifying in a more difficult positionmay qualify in an easier position)Duration Of QualificationDependent upon Code(Usually inactivity of 3 to 6 months required requalifi
30、cation)PerformanceQualification RecordWelding Procedure and Performance Qualification Variable That May Require RequalificationProcedure VariableProcedure RequalificationMay Be RequiredWelder or OperatorRequalificationBase Metal(Type,Composition,Process)Change in BM,Some CodesList EquivalenciesUsual
31、ly Not RequiredThickness of BMChange Outside ThicknessRangeChange Outside RangeJoint DesignChange in Root,IncludedAngle,DimensionsChange in Root,IncludedAngle,DimensionsPipe DiameterUsually Not RequiredWhen Reduced Below SomeMinimumType of Current,PolarityUsually Not RequiredUsually Not RequiredElec
32、trode Classification,SizeChange in ElectrodeClassification or sizeChange in ElectrodeClassification or sizeWelding CurrentWhen Outside RangeUsually Not RequiredPosition,ProgressionUsually not Required,ButDesirableWhen Change Exceeds LimitsDeposition of Filler MetalFor Marked ChangesUsually Not RequiredRoot Prep,Other SideWhen Method or Extent HasChangedUsually Not RequiredPreheat,Interpass TempWhen Outside RangeUsually Not RequiredPostheat TempWhen Outside RangeUsually Not RequiredRun the“Welding Procedure Specification”from the“Demonstration Page”of the WE300 Web PagePlease do Assignment 14
