: /

:

.




.


.


:
- .

. . - .

:
SMAW GMAW GTAWFCAW -

:
- .

API 1104. - .

:
:
NDT

: .
: .

 :
.

.
.
.

:


.
A weld is, a localized coalescence of metals or nonmetals
produced either by heating the materials to the welding temperature, with
or without the application of pressure, or by the application of pressure
alone and with or without the use of filler metal .
Process features include a source of energy to provide heating, a
means of shielding the molten metal from the atmosphere, and a filler
metal (optional with some processes and joint configurations.)The
Welding Processes can be divided into following groups, Arc Welding,
Solid State Welding, Oxyfuel Gas Welding, Soldering, Brazing, and
Other Welding Processes (.

-:
. - 1
. - 2
.) ( - 3
:

.
.)DC ( ) AC

." " DCEN DCEP

 AC
AC

DC

:


.
1802.

.

 :
-:
- 1 Transformer

- 2 / Transformer/rectifier
- 3 Generator

.

.

/
.
: Duty Cycle

. Overheating
. nameplate 10
Duty Cycle 60% 6 10
.
:

.

1-2 .

Fillet

. Grove butt

:
Welding Face Throat leg Toe - Root

Root Face Root opening - Bevel angle

4 1 F Fillet G

(. Groove ).

6 .

. Overhead

. WPS

SMAW GMAW GTAW-

FCAW

( )1 Shielded Metal Arc Welding

)(SMAW

.

.

( )

Flux

-:
Shielding- 1
.

Deoxidation- 2 .
Alloying- 3
.
Ionizing- 4 .
- Insulating - 5
.

AWS

A5.5 &A 5.1

:

Electrode

X X

 E Electrode . 60 60.000

-:- 1 .
- 2 F, H,

-4
.

H, F, OH V

 3 .

AC

DC.

. Cracks

.
8 6 5
.

175 65 .
:SMAW
SMAW
.
( ).


.

-:
- 1 .
- 2 .

- 3 .
:
- 1 .
- 2 .
- 3 .
- 4 (
).
- 5 ( Arc Blow )
.

 SMAW

( )2 :
)Gas Metal Arc Welding (GMAW
:

( ) .
DCEP .

.

Ar He

Co2 .


.

Electrode Designation
ERXXSX

-Electrode Rod
-Strength in Ksi
-Solid
-Chemical Composition

- 1 .
- 2 .
- 3 .
:

- 1 .
- 2 ( ).

( )3
)GAS Tungsten Arc Welding (GTAW
-:

( ) .
.
.

AC

DC

-:

- 1 .

- 2 .
- 3 .
-:

- 1 ( ).
- 2 .
- 3 .
- 4 .
- 5

TORCH

).

Tungsten Electrode Classifications

Class
Alloy
Color
EWPPure tungsten..
Green
EWCe-2 1.8-2.2% ceria.
Orange
EWLa-11%lanthanum oxide..
Black
EWTh-10.8-1.2% thoria..
Yellow
EWTh-21.7-2.2% thoria..
Red
EWZr0.15-0.40%zirconia...
Brown

( )4
Flux Cored Arc Welding FCAW
-:



. .

.
-:

- 1 .
- 2 .
- 3 .

-:

- 1 .
- 2 .
- 3 .

Electrode Designation

EXXT-Electrode

-Strength in 10Ksi
-Position
-Tubular
-Chemical Composition


-:

- 1 .
Procedure
- 2 Certified Welder .

Qualified Welding

- 3 Certified Inspector .
- 4 .

-1 Qualified Welding Procedure .

.
1- 1 : Essential Variables
.

API-1104-1999

().

-:
- 1

Welding Procedure

- 2

Base Material

.
- 3
- 4

Joint design

Position

.
- 5

Wall thickness

: .

 - 6 (

Electrode

).

- 7 : .
- 8

Time between passes

.
- 9

Direction of Welding

.
- 10

Shielding gas flow rate

- 11 .
- 12

Speed of Travel

- 13
- 14

.
Preheat

Post Heat

2- 1 :

-:
- 1

.
- 2

Nick-break test

.
- 3

Root and Face Bend Test

.Cracks
- 4

Side bend test

.) (

WELDING PROCEDURE SPECIFICATION

WPS No.
Project
EPC Contractor
Description
Specifications
Process

WPS-P-01-00
PQR No.
Project
Company
Barchia Engineering
CLIENT
WPS for Carbon Steel, Pipe Welding
API 1104
SMAW
Type

JOINT DESIGN

BE-PQR-P-01-00

Manual

PASS SEQUENCE

SINGLE v Groove Design

1.

String Bead Technique for root and hot passes. Weaving up to 3 times Electrode
Diameter.

2.

Pass
Root
Hot pass
Fill
Cap

Number of Passes will vary according to joint thickness.

Electrode
AWS Class, Size
E6010,3.2mm
E-6013,3.25mm
E6013, 4.0mm
E6013, 3.25mmmm

VARIABLES
Base Metals
P. No To P. No
Type and material grade

Amperage

PARAMETERS
Voltage

60-90
110-150
120-170
105-160

25-34
20-28
20-30
20-30

ALLOWABLE RANGE
P1 G1 To P1 G1
GR.B or Equivalent

Travel Speed
(mm/min)
85-130
110-150
160-220
160-220

VARIABLES
PWHT
Not Applicable

Heat Input
(kJ/mm)
0.9-1.5
1.10-1.50
1.00-1.30
0.80-1.20

ALLOWABLE RANGE

Thickness
Diameter

Filler Metals
F No.
A No.
Spec No.
AWS Class
Electrode Size
Trade Name

Butt welds-up to 20mm

Fillet welds-All sizes
Not Applicable

2&3
1
SFA 5.1
E 6010 & E6013
3.2 & 3.25/4.0 mm
Bohler Foxcel &
Ador Super bond (OVERCORD-S

Position
Position of Groove
Weld Progression

1G & 2G
Flat & Horizontal

Pre heat
Preheat Temperature
Interpass temperature
Preheat Maintenance

Not Applicable
Max 150o C
N/A

Electrical Characteristics
Current and
Polarity

DC,-ve/+ve,

Gas
Not Applicable
Technique
Method of Clamping
String or Weave Bead
Inter pass cleaning

Notes

Tack welds
String and weave
Grinding/wire brush

-2 Certified Welder .

.
: Single qualification

.

-:
-

-:

- .

- 1
- 2

2.375

2.375

- 3
-

12.75

12.75

. -:
- 1 4.8.
- 2 4.8 19.1.
- 3 19.1.

Multiple Qualification

.
- 1

6.4

6G

6.65

. (

).
- 2

6.65

6.4

.
( ).

1
12.75
.

12.75

12.75

:
.

- .

- () 3
.

 :

.
-:

VISUAL TEST REPORT FOR WELDER QUALIFICATION

Company:
Materials: ASTM A53

Thickness:8.56mm

Project: pipeline Project

Diameters:4

Welder Name:
Welder ID:
Date:
Page:
WPS No:
Supporting
Process:SMAW
Joint Design:
Position:5G
Filler metals:
Current Type:
Polarity:
Welding progression:Uphill
Traveling Speed:
Type of Clamp:
Removal of Line up Clamp:
Interpass Temperature:
Preheat Temperature:

AFTER WELDING VISUAL TEST RESULTS

Face & root Condition: as Welded (Wire Brush Cleaning)
Max. Allowed
Type
Position ** Dimensions
remarks
Dim.

** Position from zero reference mark in cm.

FINAL RESULT: Pass

Fail

We the undersigned, certify that the statements in this record are

correct and the welds are tested according to the API
1104(1999.
Welding Engineer

Director

 - 3 .

Certified Welding Inspector

.

. -:
.1 .
.2 .
.3
.
.4.
.5 .
.6 .
.7 .
.8.
.4 :
.

Discontinuity

.

:
-1

Cracks

.


.


.
:

Hot or Cold

Hot Cracks

Cold Cracks

..
.Cold Cracks

Direction

Longitudinal Cracks

Transverse Cracks

.

.

Location

toe

throat

root

.HAZ
Cracks

Throat

root cracks

root gap

Toe Crack

.
Crater crack

Star Crack

E316-16, E309-16, E308-16

Under bead Crack

HAZ

48 72

( )

H+

HAZ

( )H2

..

..

HAZ

-2

Incomplete Fusion

.

inclusions

Slag

.


..

.

.

-3

Incomplete Joint Penetration

Penetration

Partial Joint

-4

Inclusions

.
I

Slag Inclusions

.
II

Tungsten Inclusion

GTAW

-:

spatter

. .
. - .

-5

Porosity

()

.

.

Scattered Porosity

Cluster Porosity

linear porosity

Elongated or Wormhole Porosity

SAW

Piping Porosity

Flux

SMAW

.
-6

Undercut

.


.
.

-7

Under fill

Suck Back

-8

Overlap

Roll Over

-9

Convexity

Fillet Weld

- 10

Weld Reinforcement

Convexity

Groove Weld

- 11

Arc Strike

HAZ

..

Prod

Atoms are so small that they cannot be seen, even with the most powerful
microscopes .
At certain temperature ranges, they tend to form substances having
specific shapes .
This is because there are definite forces acting between these individual
atoms These forces are in equilibrium.

I'Home' positions.
Interatomic Spacing.
Below a metal's yield point, Elastic, WHY?
Al It was noted before that the metal atoms exhibit a
very specific spacing at a given temperature, or
internal energy.
Expansion?

Liquid metal has a higher internal energy with greater

interatomic spacing, and is considered to be amorphous.
There are several ways of reducing or eliminating residual
stresses.
Stress relief.
Vibration.
Nteratomi

Crystal structure:
In a solid metal, the atoms tend to align themselves
into orderly lines, rows, and layers to form three
dimensional crystalline structures.

 "Unit cell".
Body-centered cubic (BCC),

Face-centered cubic (FCC),

 Body centered tetragonal (BCT), and

Hexagonal close-packed, (HCP).

Solidification:

Carbon Steel Microstructure:

The overall arrangement of grains, grain

boundaries, and phases present in a metallic
alloy is called its microstructure.
This microstructure is affected by the
composition or alloy content, and by other
factors such as forming and heat treating
operations

Iron and steels undergo changes in their

crystallographic arrangement as a result of
temperature changes.

 This allows us to change the mechanical properties of a

specific alloy through he application of various heat
treatments.
"Iron-Carbon Phase Diagram"
Ferrite,
Austenite,
Cementite
Hypoeutectoid, eutectoid and hypereutectoid types
At 723 C, the horizontal line representing transformation
temperature is referred to as the AC1.
Transformation will occur over a range of temperatures with
complete transformation occurring only when the temperature is
raised above the sloping line designated as the A3.
Pearlite can only occur when sufficient time is allowed for
the atoms to diffuse into that arrangement.
Diffusion is simply the migration of the atoms within the
solid metal structure.
When the cooling from the austenitic range occurs more
rapidly, there are significant changes in this
transformation for a given steel alloy.
Upon rapid cooling, principal microstructures produced include fine
pearlite, bainite and martensite.
However, martensite has characteristically the low ductility and
toughness.
To improve the ductility and toughness without significantly decreasing
the hardness and tensile strength of the martensite, a process referred to as
tempering is employed .

TTT diagram, or Time-Temperature-Transformation diagram.

These are also called isothermal transformation diagrams (ITT).
A similar diagram, the CCT, or Continuous Cooling
Transformation.
Critical cooling Rate.

Welding Metallurgy:

Preheat
Heat Input
Carbon Equivelant
Material Thickness

1538

L+

1400
120
0
1000o

912

4.3

1148
o

2.1
1

800

727
0.022

600

L+Fe3

+ Fe3C

0.77

+ Fe3C

400
200
0

%C

He at Treatment:
The basic heat treatments include annealing, normalizing,

quenching, tempering, preheat, post heat and thermal

stress relief.
Annealing is a softening treatment used to increase the
metal's ductility at the expense of its strength.
Metal is raised just into the austenitic range, held for one
our per inch of thickness or a minimum of one hour,
and then cooled very slowly.
Normalizing also softens the metal, but not as significantly
as annealing.
The only difference is cooling in still air.

NDT

Nondestructive Testing

-:

- 1 Radiographic Testing

- 2 Ultrasonic Testing

- 3
Testing
- 4 Dye Penetrant Testing

Magnetic Particles

.
-1 :

.
:
- 1 .
- 2 .
- 3 .
:
- 1 .

- 2 .

-2 :

Transducer

.
:
- 1 .
- 2
.
- 3 .
:

- 1 ( ) .
- 2 .

-3 :



( )
() .

 :
- 1 .
- 2 .
:

- 1
....
- 2 .

-4 :

( )

()
.
:
- 1 .
- 2 .
:
- 1 .
- 2 .
- 3 .

 :


.

.

.

.

Standard Symbols for Welding, brazing and nondestructive Examination

.
.

.

.

.


.
:

.

.
:

0.5

.


.
.

 :

.

( ).
:

(
)
.

280

 :

.
.
.
:

12
.

.
:

85

.
.

.
:
- 1 .
- 2 .
- 3 ( ).
- 4 .
- 5 .

Recommended Filter Shade Numbers for Different

Welding Processes
(Source: American Welding Society, Welding Handbook, 8th
edition)
Process
- Shielded Metal Arc Welding

- Gas Metal and Flux Cored Arc Welding

Gas Tungsten Arc Welding

Gas Tungsten Arc Welding

Oxyfuel cutting

Welding Current

Lowest Shade
Number

Comfort
Shade
Number

Under 60

60 160

10

160 250

10

12

250 550

11

14

Under 60

60 160

10

11

160 250

10

12

250 550

10

12

Under 50

10

50 150

12

150 500

10

14

Under 50

10

50 150

12

150 500

10

14

Under 1 thick

3.5

1-6" thick

4.5

Over 6 thick

5.6

References:
1. American Welding Society, welding handbook, 8th edition.
2. Welding principles and applications JEFFUS, JOHNSON, 1984.
3. Welding Fundamentals Roger W. Jellison.
4. CWI Course
Welding Inspection and Certification Dr. Hamed A. Nagy 2004

5.2001 .

.) (