Module 5

Module 5 - 1
Module 5
Documents Governing
Welding Inspection and
Qualification
Am e r i c a n We l d i n g So c i e t y
Module 5 - 2
Document Types
 Purchase orders
 Contract documents
 Codes
 Standards
 Specifications
 Recommended Practices
 Drawings
Module 5 - 3
Drawings
 Dimensions in U.S. Customary or S.I.
 When both are used, second system is
usually shown after the first in ( )
 Tolerances must be stated as a :
+ or -, maximum, minimum, or a range
 All drawing notes must be reviewed
 List of materials usually given
Module 5 - 4
Example of Fabrication Drawing
Module 5 - 5
Dimensions
Module 5 - 6
Tolerances
Module 5 - 7
Notes
Module 5 - 8
Welding Details
 Location
 Size
 Length
 Joint configurations
 Material call-outs
 NDE requirements
 Processing requirements
Module 5 - 9
Hold Points
 Specific prearranged steps
 Inspection required
 Acceptance required
 Fabrication continued
Module 5 - 10
Inspection Information
 Visual or other NDE
 Test method
 Test procedure
 Location for testing
 Extent of testing
 Acceptance/rejection criteria
 Personnel qualifications
Module 5 - 11
Code
“A body of laws, as of a nation, city, etc.,

arranged systematically for easy reference”
Module 5 - 12
Types of Codes
 Building codes
 Electrical codes
 Plumbing codes
 Fabrication codes
Module 5 - 13
Codes:
 Have legal status
 Use “Shall” and “Will”
 Mandatory
 Methods to determine compliance
Module 5 - 14
Code Producers
 AWS
 ASME
 API
 ABS
 DOT
 Others
Module 5 - 15
Standard
“Something established for use as a rule or

basis of comparison in measuring or judging
capacity, quantity, content, extent, value,
quality, etc.”
Module 5 - 16
Welding Codes and Standards
Module 5 - 17
ASME Code by Sections

 I - Const - Power Boilers  V - NDE
 II - Materials  VI - Operations of Power B.
– Part A - Ferrous  VII - Care of Power Boilers
– Part B - Nonferrous  VIII - Unfired Pres. Vessels
– Part C - Filler Metals – Divisions 1, 2, and 3
– Part D - Properties  IX - Welding Qualifications
 III - General Requirements  X - FRP Pressure Vessels
 IV - Const - Heating Boilers  XI - Nuclear Inspections
Module 5 - 18
Specification
“A detailed description of the parts of a

whole: statement or enumeration of
particulars as to actual or required size,
quality, performance, terms, etc.”
Module 5 - 19
AWS Filler Metal

Specifications
Module 5 - 20
AWS Welding Specifications
Module 5 - 21
Recommended
Practice
Module 5 - 22
Other Standards Organizations

 ANSI
 ASTM
 ISO
 IIW
 NACE
Module 5 - 23
Control of Materials
“The identification and traceability of materials”
Module 5 - 24
Material Test Report (MTR)
The starting point for material control
Module 5 - 25
MTR
 Review:
 Product Form
 Heat Number
 Chemistry
 Mech. Properties
Module 5 - 26
Material Control Systems

 Should be simple
 Contain checks and balances
 Specify marking methods
Module 5 - 27
Material Control Methods

 Segregation
 Color coding
 Alphanumeric
 Bar coding
 Tagging
 Stamping
Module 5 - 28
Alloy Identification Systems

 Industry associations
– SAE
– AISI
– CDA
– Castings
– Tool steels
 UNS
 ASTM
Module 5 - 29
ASTM
STANDARDS
Module 5 - 30
ASTM A514
“Standard specification for high yield

strength, quenched and tempered alloy steel
plate, suitable for welding”
Module 5 - 31
Typical ASTM Specification

 Scope  Mechanical
 Applicable Documents Requirements
 General Delivery  Hardness Requirements
Requirements  Test Specimens
 Process  Number of tests
 Heat Treatment  Retest
 Chemical  Marking
Requirements  Supplemental
Requirements
Module 5 - 32
AWS A5.1
“Specification for covered carbon steel arc

welding electrodes”
Module 5 - 33
Typical AWS Filler Specification

 Scope  Required Tests,
 General Requirements Methods
– Classification  Manufacturing,
– Acceptance Packaging,
– Certification Identification
– Retests  Details of Tests
– Method of manufacture
 Appendix
– Marking
– Packaging, Rounding-off
Module 5 - 34
Qualification
Fabricators’ responsibility
 Procedures
 Welders
 Welding operators
 Tack welders
Module 5 - 35
Procedure Qualification
Determines compatibility of:
 Base metal(s)
 Filler metal(s)
 Process(es)
 Techniques
Module 5 - 36
Procedure Qualification
Three methods:
 Prequalified procedures
 Procedure qualification testing
 Mock-ups
Module 5 - 37
Prequalified Procedures
 Used by AWS D1.1 & D1.5
 No need for testing
 Saves time and money
Module 5 - 38
Procedure Qualification Testing

 ASME, API, AWS, & most Codes &
Standards
 Welding and brazing
 Defines essential welding variables
 Testing required
Module 5 - 39
Essential Welding Variables
“Those variables, that if changed beyond

certain limits, require a new procedure
qualification”
Module 5 - 40
ASME Qualification
 Section IX
 Welding procedure specification (WPS)
– Lists essential welding variables
 Procedure qualification record (PQR)
– Notes actual test conditions
Module 5 - 41
Mock-ups
“Used for special joint configurations”
Module 5 - 42
Required Specimens
Prior to qualifying a procedure:
 Determine test specimen requirements for
selected Code
 Make test weldment large enough to obtain
proper number and type of samples
 Consider making it large enough for an extra
test specimen or two
 Maintain test weldment and specimen
orientation per Code
Module 5 - 43
Procedure Qualification Steps - 1 of 2

 Select welding variables
 Check equipment and materials
 Monitor fitup & welding - document!
 Identify test specimens
 Test and evaluate specimens
Module 5 - 44
Procedure Qualification Steps - 2 of 2

 Review results for compliance
 Release approved procedure
 Qualify other welders
 Monitor production welding
Module 5 - 45
Welder Qualification
“Determines if individual welders have

sufficient skill to produce satisfactory welds
using a qualified procedure”
Module 5 - 46
Welding Variables
Examples of essential variables in some codes:
 Welding position
 Joint configuration
 Electrode type and size
 Base metal type, thickness
 Welding techniques
 Use of backing
Module 5 - 47
Type & Position Limitations

 Depends on Code used
 Refer to Code for test weldment thickness
requirements and limitations on welder
qualification
 Use Module 5, Figure 5.19, as example for
review
Module 5 - 48
Weld Position Designation

Position Designations:
 Different for Plate and Pipe
 Different for Groove and Fillet welds
 Must know positions and designations
 See Module 5, Figures 5.20 - 5.23
Module 5 - 49
Thickness Range Qualified

 Depends on Code used
 Depends on test specimen thickness
 See Figure 5.24 for D1.1 requirements
Module 5 - 50
Backed and
Non-backed
Joint
Module 5 - 51
Fillet Weld Test Specimen
Module 5 - 52
6GR Test Weldment
Module 5 - 53
Electrode Classification Groupings

Group AWS
Designation Electrode Classification
F4 EXX15, EXX16, EXX18, EXX15-X,
EXX16-X EXX18-X
F3 EXX10, EXX11, EXX10-X, EXX11-X
F2 EXX12, EXX13, EXX14, EXX13-X
F1 EXX20, EXX24, EXX27, EXX28,
EXX20-X, EXX27-X
Module 5 - 54
Qualify vs Certify
Qualify - Welder has skill to weld

Certify - Documents support above
Module 5 - 55
Welding Inspection Requires:

 Availability of documents
 Knowledge of documents
 Use of documents
 Materials control
 Qualifications
Module 5 - 56
Quality is:
...conformance to specifications.
so…..
Know Your Specifications!

Module 5

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Module 5 - 1

Example of Fabrication Drawing

“A body of laws, as of a nation, city, etc.,

“Something established for use as a rule or

Welding Codes and Standards

ASME Code by Sections

“A detailed description of the parts of a

AWS Filler Metal

AWS Welding Specifications

Other Standards Organizations

“The identification and traceability of materials”

Material Test Report (MTR)

The starting point for material control

Material Control Systems

Material Control Methods

Alloy Identification Systems

“Standard specification for high yield

Typical ASTM Specification

“Specification for covered carbon steel arc

Typical AWS Filler Specification

Procedure Qualification Testing

Essential Welding Variables

“Those variables, that if changed beyond

“Used for special joint configurations”

Procedure Qualification Steps - 1 of 2

Procedure Qualification Steps - 2 of 2

“Determines if individual welders have

Type & Position Limitations

Weld Position Designation

Thickness Range Qualified

Fillet Weld Test Specimen

6GR Test Weldment

Electrode Classification Groupings

Qualify - Welder has skill to weld

Welding Inspection Requires:

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