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CS: ANSI/ASME B36.10; Sch./ wall Thk.in mm; density = 7.85 kg/dm3SS: ANSI/ASME ch./Wall Thk. In mm; d =B36.19; Aus. Steel 7.93 kg/dm3Wt / m = π x (OD-t) x t x density
INCH OD (mm) STD
LENGTH VOLUME
1 33 3
1 Pound = 0.454 Kg. 1 Inch = 25.4 mm 1 UK gal = 4.5461 L
2 60 4
1 Metric Ton = 1000 Kg. 1 mil = 0.0254 mm 5 mL = 5 cc = 1 tsp.
3 89 5
1 Ton = 1016.05 Kg. 1 mm = 1000 micron PRESSURE
FORCE WORK / ENERGY 1 Pa = 1N/m2 4 114 6
1 Kgf = 9.81 N 1 ft-lb = 1.3558 J 1 Mpa = 1 N/mm2 6 168 7
1 lb (Pound) = 4.45 N POWER 1 Mpa = 10 bar
1 N = 105 Dyne 1 Watt = 1 J/s 1 bar = 14.5 PSI 8 219 8
1 Watt= 1 Amp x 1 volt 1 bar = 0.9869 atm 10 273 9
DENSITY 1 ppm =1 mg/l = 1 mg/kg 1KSI = 6.90 Mpa
Density of steel = 484 to 503 Pcf, or 7.75 to 8.05 g/cm3 1 Kgf /cm2 = 14.22 PSI
o 3
Density of Water at 4 C = 1 gm / cm 1 bar = 750.06 mm Hg at 0oC
O 3
Density of Hg at 0 C = 13.5951 g/cm 1 bar = 10197.44 mm H2O at 4oC
12 324 10
CODES
PRESSURE PIPING CODE Flanges :- ASME section I : - ROC of power boiler.
ASME B 31.1 – Power ASME B16.1 : - CI PF & FF. ASME Section II : - Materials.
ASME B 31.2 – Fuel ASME B16.5 : -CS PF & FF Part A – Ferrous.
ASME B16.47 : - steel flanges. (Above Part B – Non-Ferrous materials.
ASME B 31.3 – Process
24”) Part C – Spec.- Electrodes & filler wire.
ASME B 31.4 – Transportation of HC /LPG Part D – Properties.
Butt welded fittings :-
ASME B 31.5 – Refrigeration ASME B16.9 : - Steel BW F ASME Section IV : - ROC of Heating Boiler.
ASME B 31.8 – Gas transportation & distribution ASME B16.28 : - BW SR elbows & ASME Section V : - NDE.
ASME B 31.9 – Building service returns bends. ASME Section VI : - RRCO of heating boiler.
ASME B 31.11 – Slurry transportation Gasket :- ASME Section VII : - RGC of power boiler.
ASME B16.20 / API -601: - Metal ASME Section VIII : - ROC of pressure vessels. (Division I & II)
Socket & Threaded fittings : ASME Section IX : - Welding & Brazing qualification.
ASME B16.21 : - Non metallic.
I. ASME B16.11:
Valves :- Pipes :-
ASME B16.10: - F to F & E to E dim. ASME B36.10 : - Welded & Seamless
II. ASME B16.34 : - Flanged & butt-welded ends wrought iron pipes.
steel valves (Pressure &Temperature ratings) ASME B36.19 : - SS pipes.
Materials
P No. / Steel designation Forgings Wrought Fitting Pipe Plate Stud & Nut Remark
Group No.
SA-516, Gr.70
SA-193, B7 SA-193, B7M (NACE)
Carbon Steel SA-105 SA-234, WPB SA-106 GR.B SA-36,(Non pr.
SA-194, 2H SA-194, 2HM (NACE)
1/1 Prat)
SA-320-7
SA-350, LF2 SA-420, WPL6 SA-333 GR.6 Low. Temp.
SA-194, 4
1Cr-0.5Mo SA-182, F12 SA-234, WP12 SA335, P12 SA-387-12 A/Steel
4/1
1.25Cr-0.5Mo SA-182, F11 SA-234, WP11 SA335, P11 SA-387-11
5A / 1 2.25Cr-0.5Mo SA-182, F22 SA-234, WP22 SA335, P22 SA-387-22 A/Steel
5Cr-0.5Mo SA-182, F5 SA-234, WP5 SA335, P5 SA-387-5 A/Steel
5B / 1
9Cr-1Mo SA-182, F9 SA-234, WP9 SA335, P9 SA-387-9
18Cr-8Ni SA-182, F304 SA-403, WP304 SA-312, TP304 SA-240, 304 SS
SA-193, B8
18Cr-8Ni SA-182, F304H SA-403, WP304H SA-312, TP304H SA-240, 304H SS
SA-194, 8
8/1 18Cr-8Ni SA-182, F304L SA-403, WP304L SA-312, TP304L SA-240, 304L Low C SS
16Cr-12Ni-2Mo SA-182, F316 SA-403, WP316 SA-312, TP316 SA-240, 316 SA-193, B8M SS
16Cr-12Ni-2Mo SA-182, F316H SA-403, WP316H SA-312, TP316H SA-240, 316H SA-194, 8M SS
16Cr-12Ni-2Mo SA-182, F316L SA-403, WP316L SA-312, TP316L SA-240, 316L Low C SS
43 67Ni-30Cu SB-164 SB-165 SB-127 Monel
45 35Ni-35Fe-20Cr-Cb SB-462 SB-366 SB-729 SB-463 Alloy 20
Materials
Product CS: 235 TP, MDT ≥ CS: 235LT TP CS: 360LT TP SS: 316 TP SS: 316 TP SS: 316 TP
15⁰C & Thk. < 16 mm Imp. Test Imp. Test 22 Cr Duplex 25 Cr Duplex
Pipes SMLS A106 Gr.B A333 Gr. 6 API 5L Gr. X52 A312 Gr. TP316 A790 UNS S31803 A790, UNS S32550
ASTM A672 CC60/70, A671 Gr. CC60/70, Cl. A671 Gr.CC70, Cl.
Pipes Welded A358 Gr. 316 A928 A928
Cl. 12,22; API 5L Gr.B 12,22 12,22
Fittings A234 Gr. WPB A420, Gr. WPL 6 A860 Gr.WPHY52 A403 Gr.WP316 A815 UNS S31803 A815,UNS S32550
A182
Forgings A105 A350 Gr. LF2 A694 Gr.F52 A182 Gr. F316 A182 Gr. F51 / F60
F53/F55/F61
Plate A 516 Gr. 60/70 A 516 Gr. 60/70 A 516 Gr. 70 A240 Gr.316 A240 A240
A351 Gr.CF8M or A995 UNS Gr. A995,A5 (UNS
Castings A216 Gr. WCB A352 Gr. LCC A352 Gr. LCC
CF3M 4(J92205) J93404)
Bar A276 UNSS31600 A276 UNS S31803 A276, UNS S32550
Tube A269 Gr.316 A789 UNS S31803 A789, UNS S32550
Product SS: Cu/Ni 90/10 Ni-alloy Ti-alloy, Gr.2 High Strength Low
06 Mo TP & Cu-alloys Alloy Steel
Pipes SMLS A312,UNS S31354 B466,UNS C70600 B705,UNS N06625 B861,Gr.2 A519 AISI 4130
Fittings A403,WP S31254 UNS C70600 B366 B363,Gr.WPT2 A234 AISI 4130
ASTM A788,AISI
A182,Gr.F44,UNS
Forgings UNS C70600 B564,UNS N06625 B381,Gr.F2 4140,API 6A
N08367
60K,A182 F22
Plate A 240 B171 B443 B265,Gr.2
ASTM A 487,Gr.
Castings B148,UNS C95800 A494,Gr.CW-6MC B367,Gr.C2
A 351,CK-3MCuN 2B/2C
Bar A276,UNS S31254 B446 B348,Gr.2
Tube A269,UNS S31254 B444 B338,Gr.2
Difference between API 5L PSL 1 & PSL2
. 1. EN10025-2 S275JR steel has better comprehensive performance than ASTM A36 steel.
17-4HP SS / ASTM A693 Typ.630/UNS S17400 =>Precipitation Hardening Stainless Parts Material
Steel (UNS S17400)(Page 497 / 2013) Body ASTM-A105N; A350, Gr. LF2; A216, WCB
ASTM A564 Gr. 630: Hot Rolled, Cold Finished Age-Hardening SS Bar/Shape (Page 296 Bonnet ASTM-A105N; A350, Gr. LF2; A216, WCB
/ 2013) Ball ASTM-A182,Gr. F44 (UNS S31254), B564 (UNS N06625)
ASTM A216, WCB: Steel Casting and carbon suitable for fusion welding for ↑ Temp. Seat ASTM-A182,Gr. F44 (UNS S31254),
Service (UNS J03002) (Page 388 / 2013). Stem ASTM-A182,Gr. F44 (UNS S31254); 17-4HP SS; A564 Gr.630;
ASTM A193, Gr.B7M:AS and SS Bolting Materials for ↑ Tempr or ↑ Pr. Service and other
ASTM B637 (Inconel 718)
special applications. Cr-Mo (Page 314 / 2013).
Stem Key AISI 4140 / ASTM A29 Gr. 4140
ASTM A194, Gr.2HM: CS & AS Nut for bolt for ↑Pr. or ↑Temp. service or both (Page 332
/ 2013). Wedge ASTM-A182,Gr. F44 (UNS S31254), A351Gr.CF8M
ASTM B637: Precipitation-Hardening Ni-Alloy bar, forging and forging stock for ↑Temp. Bolt /Stud ASTM A193, Gr.B7M; A320 Gr. L7M
Service Inconel 718 (UNS N07718) (Page 979 / 2013). Nut ASTM A194, Gr.2HM;
ASTM B564: Precipitation-Hardening Ni-Alloy bar, forging and forging stock for ↑Temp. ASTM-A105N: CS forging for piping application, N= Normalised, A= Annealed, NT=
Service Inconel 625 (UNS N06625) (Page 862 / 2013). Normalised + Tempered, QT= Quench + Tempered (Page 240-2013)
A320 Gr. L7M:AS and SS Bolting materials for ↓Temp. services (Page 562 / 2013). ASTM-A350, Gr. LF2: Specialized CS /Low AS Forging ,Notch Toughness Reqd. Pipe
AISI 4140 / ASTM A29 Gr. 4140 : Carbon and Alloy steel Bar, Hot Wrought (Page 170 / Component (Page 636 / 2013)
2013) ASTM-A182, Gr. F44:Forged/Rolled Alloy and SS pipe flanges, Forged fittings, Valves &
valves parts for ↑Tempr UNS S31254 (Page 291-2013)
A351Gr.CF8M:Casting Austenitic. Duplex for pressure
containing Parts. (Page 648 / 2013).
GRE Items Inspection RAW material test GRE Items Inspection Production test
WA Test of resin-ASTM D 570: 1Hr@105ºC cured sample=> in water Specific Tangential Initial Stiffness (STIS) & Structural Hoop Flexural
@ 24 hrs.=> Accp. ≤ 0.03% Modulus of pipe: TM-002 & ASTM D 2412. Stiffness ≥ 5000 Pa and
RI of epoxy resin hardener mix - RMT-011 & ASTM D 1045=> ABBE Structural hoop flexural modulus ≥ 20500 MPa. 5% Deflection in Dia.
Axial Tensile Strength of Pipe TM-003 & ASTM D 638 ≥ 55 Mpa.
Refractometer => Accp. 1.5530 to 1.5865
Hoop Tensile Strength of Pipe TM-004 & ASTM D 2290 ≥ 210 Mpa.
Viscosity of Epoxy Resin- RMT-001A & ISO 2555 => conditioning @ Degree of Curing (Tg Value) of Pipes and Fittings – (DSC / (Differential
25ºC=>Brookfield Viscometer => Accp. 10000 - 12000 Cps Scanning Calorimeter)Method-Glass transition temperature) Tg ≥ 95%
Resin Gel Time, Cure Time and Peak Temperature- RMT-002 & ASTM of minimum Tg value measured for qualifying component in 1000 hours
D 2471 => conditioning @ 25ºC + mix hardener => Gel-Time : 90 ± 30 survival test.
Min. Gel-to-peak : 10 ± 5 Min. Peak Temp. : 200 ± 40 °C . Tg ≥ 135% for Pipes, Fittings, Flanges & Lamination Joints
Glass Fibers: - M/C, Size/ Binder content & Tex properties - RMT-003, Tg ≥ 110% for Cement Joints
RMT-004 & RMT-005. WA Test, Boil Resistance of Pipes, Fittings & Flanges-ASTM D 570:
Moisture Content : < 0.15 % [105ºC@3hrs] 1Hr@105ºC cured sample=> in water @ 3 hrs.=> Accp. ≤ 1% and no
Binder content: Nom. ± 30 % [LOI 600ºC@30 min.] detoriation or delamination after boiling.
Tex Number : Nom. ± 15 % [weight in grams of 1000 m] LOI Test TM-005 & ASTM D 2584– Structural Glass content of Pipes
C-Glass Veil & W/R Mat: - Moisture content, Size/Binder content & and Fittings
Density- RMT-003, RMT-004 & RMT-005. The glass content in the structural wall shall be,
Moisture Content : < 0.15 % [105ºC@3hrs] For pipes, 70-82%,
Binder content : Nom. ± 30 % [LOI 600ºC@30 min.] For Molded fittings, 65-75%
Tex Number : Nom. ± 15 % [1m2 of the W/R mat / glass veil.] For Hand Lay-up fittings, 50-65%.
Conductivity Test (Determination of Electrical Resistance) ONTW-42
The electrical resistance value shall be less than 10 X 106 Ohm.
Barcol Hardness Test of Pipes and Fittings ≥40.
ELEMENT
C (Carbon): Strength & hardening in steel
Mn( Manganese ): Toughness & Hardening second to carbon
Si (Silicon): Deoxidizer, moderate strengthener <0.3%
Al (Aluminium) : <0.008%Deoxidizer ↑mech. prop.+ toughness, Grain Refiner
Cr (Chromium): Hardness (low) - corrosion resistance (high)
Mo (Molybdenum): Hardenability - high temp tensile - creep Ω
V (Vanadium): Strength - Improves mechanical properties
Ni(Nickel): Hardening - cold toughness-low Temp. Application
Cu (Copper): Corr. Ω(low) - cracking (high), weathering (Corten)
P (Phosphorus): Causes cracking if too high
S (Sulfur): Aids in machining - Cracking problems like P
B (Boron): Very small amounts increase hardness
Ti (Titanium): Removes: Oxygen, S, N, and C, Grain Refiner
N (Nitrogen): Improves strength - lowers toughness
Nb (Columbium): Grain Refiner - ↑ mech.Prop. Strength+toughness
Ferrite number FN) is a measure of = Chromium & Nickel equivalent in
an Austenitic stainless steel material. It should be between 3-7% max.
ASME Sec IX: Table QW 422 (page 93) P No. EN288 Base Metal
P-no. Reducing WPS 41 Pure Ni 8 9
ASS, 4-SG
Steel => 1 to 15F 42 Ni-Cu:- Monel 500 G-1, Gr.304, 316, 347
Al => 21 to 26 43 Ni-Cr Ferrite:- Inconel
G-2,Gr.309, 310
G-3, Gr.↑Mn
G-4, Gr.254 SMO
10 H 10 D&SD, Gr. 31803, S32750
MONEL: nickel-copper alloy R-405 (UNS N04405)
Nickel (plus Cobalt) 63.0 min, Copper .28.0 - 34.0
Inconel 625: Nickel-Chromium-Molybdenum Alloy (UNS N06625)
Material Root run / Filler Wire / Filling Electrode Base Metal / AWS Electrode Specification / Electrodes
SA106, Gr. B (CS, Pipe Smls, ↑Temp.) E 6010 / ER 70-S2 / E 7018 Carbon Steel (AISI 1018,ASTM A36, A516)
Welder Performance Qualification Test 1. Base Material: ASME Sec II A (Ferrous Materials) / IIB (Non Ferrous Materials)
Table QW 353: SMAW Essential Variable 2. Filler Materials (SFA No.) ASME Sec IIC
3. Welding Variable Process wise: QW-350 (Table QW-351 to 357)
OFW, SMAW, SAW, (GMAW / FCAW), GTAW, PAW
Table QW 452.3 : diameter limit Groove weld - Backing – All (QW-433)
Slab welded O / Dia. Qualified Dia. - BM thickness – only OFW
< 25 mm Min. Size welded, Max. Unlimited - Pipe Dia. – Except OFW (Table QW-452.3)
25 to 73 mm Min. 25 mm, Max. Unlimited - P Number – All (Table of QW-423.1)
>73 Min. 73 mm, Max. Unlimited - Filer – OFW, PAW
73 mm O/D ≡ NPS 2½ “ - F Number – All (Table of QW-433)
- F 1 = Iron powder
F No. qualification
- F 2 = Rutile
W/B F – F same and higher not F5 - F 3 = Cellulose
WO/B – Only same F - F 4 = Low Hydrogen
Table QW 433 - F 5 = Stainless Steel
- Weld Deposit – All (Table QW-452.1 (b))
F 31 to 33, 35 to 37, 71 to 72 – only same electrode
- Weld Deposit (S. Cir. Arc) – GMAW/FCAW
- Filler Metal Product Form – GTAW, PAW
Steel & Alloy Steel F 1 to 6 - Position – All (Table QW-461.9)
Al & Al Alloy F 21 to 26 - Uphill / Downhill - Except OFW & SAW
- GAS Backing - Except OFW, SMAW, SAW
Cu & Cu Alloy F 31 to 36
- Type of Fuel Gas – Only OFW
Ni & Ni Alloy F 41 to 46 - Transferred mode – GMAW/FCAW,
Ti & Ti Alloy F 51 to 56 - Current / Polarity - GTAW
Zr & Zr Alloy F 61 4. Backing
Hard Facing F 71, 72
Welding Position NACE MR – 0175 : Sulphide Stress Cracking Resistant Metallic
ASME Sec IX BS EN Materials for Oilfield Equipment. Max. hardness of CS and low AS
Groove Fillet exposed to sour service - 250 BHN. Main requirement in NACE
Not mentioned about 3F/5F
Pi Plt Pi Plt Sd MR0175 -PWHT
1GR 1G 1FR 1F 1S PA F and down head = 1G/1F NACE MR – 0284 : Evaluation of Pipeline and Pressure Vessel
2F PB H-V = 2F Steel for Resistance to Hydrogen Induced Cracking.
2G 2G 2F 2S NACE TM – 0177 : Laboratory Testing of Metals for Resistance to
2FR PC H = 2G
PF V-up = 3G/5G Sulfide Stress Cracking in H2S Environment
x 3G x 3F x
PG V-down = 3G/5G Raised face finish –AARH (Arithmetic Average Roughness Height)
PD H-V (OH) = 4F Low Temp. Service additional Mechanical Test – Impact
x 4G 4F 4F 4S
PE O = 4G Attribute of Tensile Test – YS, UTS, % Elongation
5G x 5F x
PF V-up = 3G/5G SS 316L contain less carbon than standard grade SS
PG V-down = 3G/5G To have a better corrosion resistant property ( Less carbon means less
Inclined pipe (upwards) = Chromium carbide formation and hence less depletion of Chromium,
H-LO45
6G
6G x x x which enhance the Corrosion Resistance.)
Inclined pipe (downwards)=
J-LO45
6G
Long Radius Elbow Short Radius Elbow NPSH: Net Positive Suction Head = is the pressure available at the
C enter-to-Face dimension pump suction after vapour pressure is subtracted.
1.5 D D It is calculated as : Static head + surface pressure head - the vapour
used typically where space is a constraint pressure of your product - the friction losses in the piping, valves and
fluid flow is also restricted fittings. It thus reflects the amount of head loss that the pump can
Eccentric Reducer: sustain internally before vapour pressure is reached.
Horizontal liquid reducers are always eccentric, top flat which prevents Base Metal / AWS Electrode Specification / Electrodes
the build up of air bubbles in the system. Cast iron to mild Steel => Lincoln. NI 55 or NI 99
Horizontal gas reducers are always eccentric, bottom flat, which allows Mild steel to Stainless steel =>
condensed water or oil to drain at low points. Electrode selection is determined from the base metal chemistries and
To maintain elevation (BOP) in rack. the percent weld admixture. The electrode should produce a weld
At the suction side of pumps to ensure air does not accumulate deposit with a small amount of ferrite (3-5 FN) needed to prevent
Source of supply below pump => Top Flat cracking. When the chemistries are not known, our Blue Max® 2100
Source of supply above pump => Bottom Flat electrode, which produces a high ferrite number, is commonly used.
Concentric reducers: Dissimilar Metals: Welding Stainless Steel to Mild Steel
Used at Pump discharge, vertical pipeline etc.
Interpass Temp.: The yield and ultimate tensile strengths of the weld Care of Base Materials before cladding
Care and preservation of solid CRA, CRA-clad or -lined materials is very
metal are both a function of the interpass temp. High values of important during fabrication and welding and should begin as materials are
interpass temp. tend to reduce the weld metal strength. received. CRAs should not be stored outside without adequate protection.
Temperature Indicating Sticks Plate clamps and other hard metallic devices should not be used in handling,
unless the CRA surfaces are protected from marring. When stacking these
PWHT: To relieve the stress developed during welding. materials, new, clean wood blocks should be used to separate each piece.
Chemical elements such as sulphur, phosphorous, lead, zinc and copper can
“lethal substances” are meant poisonous gases or liquids of contaminate CRA and cause embrittlement if not completely removed before
such a nature that a very small amount of the gas or of the welding and heat treating. These contaminants may be present in cutting
vapour of the liquid mixed or unmixed with air is dangerous to-life fluids, grease, oil, waxes, household detergents and soaps, primers, marking
crayons and temperature-indicating crayons. They must be removed by
when inhaled. It is up to the user to determine if a service is swabbing the affected area with a nonchlorinated solvent such as toluene,
lethal. methyl-ethyl-ketone (MEK), acetone or isopropyl alcohol. In addition, the
chemical content of the hydrotest water, cleaners, paints and inks must be
ASME VIII-1 Lethal Service Code References carefully selected to avoid the contaminants
UW-2 Service Restrictions
CE = C + + +
ADMA: STD-128 (Standard for pipe fittings) ADMA: STD-121 (Relief Valve)
CSWIP: Type of Joint: Autogeous Weld: Fusion Weld without Filler metal –Plasma, OFW
BS EN 970 (Visual Inspection): Butt => 135 -180⁰, Homogeneous: no significant diff. Mech. Prop & Chem. Comp.
=> Every 1 yr. vision Check T => 5 upto and 90⁰ Betw Weld Metal & Parent Metal
=> Illumination 350 Lux / Corner => 30 - 135⁰
Recommended 500 Lux
CS plates welding with matching CS electrode.
=> 600 mm Distance
Edge => 0 - 30⁰ Heterogeneous: Have significant diff. Mech. Prop & Chem. Comp.
=> not < 30⁰ Cruciform => + Betw Weld Metal & Parent Metal.
=> x2 to X5 Lap => 0 - 5⁰
Repair of cast Iron with Ni-based alloy electrode.
Welding Position: ISO 6947 Type of Weld: Butt & Fillet
Root Face: 1-2mm (CS Com. WP) Dissimilar: Have significant diff. Mech. Prop & Chem. Comp.
PA(1G/2FR), PB(2F/2FR),
PC(2G), PD(4F), PE(4G), Root Gap: 1- 3mm Betw both Parent Metals to be weld
PF(3G/3F↑) & PG (3G/3F↓), Land: Straight Portion of fusion face CS Lug weld to Aus. Steel Pr. Vessels.
PH (5F/5G↑), PJ(5F/5G↓) btw. Root face and curved part of J or Heat Effected Zone: Part of Parent metal Metallurgically effected by
H-LO45(6G↑), J-LO45 (6G↓) U weld heat by Thermal Cutting / welding but not melted.
Toe: Boundary btw. Weld face & Parent metal / Btw. Runs.
PE PD a (Throat)= 0.707 x z (leg length)
High tress concentration,=> Fatigue crack, cold crack.
PF PG PC
PA PB
Dim Tolerance AWS D 1.1 : 5.23.4 Beam and Girder Camber (without Designed
5.23.2 Straightness of Columns and Trusses: Concrete Haunch):
at mid span => ± 40 mm ≥ 30 m
1mm/m [10m] 10mm [15m] 10mm+ 3mmx => ± 20 mm < 30 m
at supports => 0 for end supports
5.23.3 Beam and Girder Camber (Typical Girder): => ± 3 mm for interior supports
at mid span => -0, +40 mm ≥ 30 m
=> -0, + 20 mm < 30 m
at intermediate points=> ±
at supports => 0 for end supports
=> ± 3 mm for interior supports
5.23.5 Beam and Girder Sweep: ±1 mm x No. of meters of total length
at intermediate points=> – 0, + AWS D1.1 gives requirements for stud welding. FALSE
Does AWS D1.1 require a welder to be qualified when pre-qualified
weld procedures are used? YES
AS => Australian; DIN => Germany; BS => Great Britain; ISO =>
(a) for moderate Temp. service; (b) for High-Temp service or where Tress
The tell-tale hole can be used for two purposes:
1. During the welding the trapped gases can escape easily without
causing a problem to the welds.
2. Testing the weld for leak as indicated above.
Ref: UAE Collection => metal and non-metal => Engineering materials
Engineering Materials Metallurgy:
↓ a) Physical Metallurgy b) Extraction Metallurgy a) Process Metallurgy
For selecting the materials:
↓ ↓ ↓ a) Commercial factors such as: Cost, availability, ease of manufacture.
Metals Non-metals Metalloid b) Engineering properties of materials such as:
↓ ↓ ↓ Electrical conductivity, strength, toughness, ease of forming by
↓ ↓ Synthetics Naturals extrusion, forging and casting, machinability and corrosion Ω.
Ferrous Non-Ferrous Ferrous Metals:
↓ S = Steel, CI = Cast Iron, WI = Wrought Iron,
LCS = Low Carbon Steel, MCS = Medium Carbon Steel, HCS = High
Metal------ Alloy
Carbon Steel, AS = Alloy Steel.
S---CI---WI ↓
GCI = Gray Cast Iron, WCI = White Cast Iron, MCI = Malleable Cast Iron,
Al-Cd-Cr-Co-Cu-Au-Pb-Mg-Mn-Mo-Ni-Pl-Ag-Sn-Ti-W-V-Zn
HDCI = High-dity Cast Iron, ACI = Alloy Cast Iron
GCI---WCI---MCI---HDCI---ACI
Alloy => Brass(Cu+Zn)-Tin Bronze(Cu+Sn)-Al Bronze(Cu+Al)-Cu Ni
LCS---MCS---HCS---AS see next page
Alloy-Al Alloy-Mg Alloy-Zn Based Die-casting Alloy-Sn Pb alloy
2. Toughness => Toughness can be expressed as a material's ability 6. Stiffness => A stiff material requires high loads to elastically deform. A
to withstand shock loads without fracture. stiff material has a high Young's modulus.
Most tools need toughness especially hammers, spanners, chisels, 7. Brittleness => A material is brittle if it fractures without appreciable
punches and Links of chains. Impact Test deformation under an applied load, particularly a suddenly applied load.
3. Malleability => ability to be shaped by hammering, rolling or Brittleness = opposite of ductility, ↑ hardness = ↑ brittleness
pressing, without fracture occurring. The glass covers on fire alarm systems. Weak in tension strong in compression. Grey cast
All ductile materials => malleable but not all malleable materials => ductile iron is a good example of this
Malleability ↑=> Temp.↑; Malleable materials =>Au, Ag, Pb, Al & Cu 8. Elasticity => the ability of a material to return to its original shape and size
Heating a material in a forge before hammering or pressing into shape. after a load causing it to deform has been removed
4. Hardness => ability of a material to resist indentation or wear. 9. Plasticity => the ability of a material to remain deformed after the load which is
causing the deformation has been removed. Plasticity needs to be shaped by bending,
Ex. cutting tools drawing or pressing.
5. Ductility => ability of a material to be drawn out in tension without
fracture. Ex. Copper Wire. Bend Test CREEP TEST => Even at constant stress, materials continue to deform
for an indefinite period of time. This time – dependent deformation is
called creep. creep test is commonly thought of as a high-temperature
test.
https://www.youtube.com/watch?v=9hG38JnM4nA
Ferrous materials: => 1) Steel, 2) Cast Iron, 3) Wrought Iron
Steel : =>
1) Plain Carbon Steel => C% = < 0.3 to 1.5
a) Low < 0.3 C%, Commonly used
Low Carbon steel = often called Mild Steel
b) 0.3 < Medium < 0.6 , ↑hardness & TS, ↓Ductility & Machinability
c) 0.6 < High < 1.0, challenging to weld
d) 1.25 < Very High ≤ 2, metal cutting tools and truck springs
2) Low Allow Steel => C% < 0.25 (Often < 0.15)
Add Alloying Element – Ni, Cr, Mn, Si etc.
+ve influence of Alloying element ↑Low Temp. Notch
Toughness, Strength at room temp. and Corr. Ω
-Ve influence of Alloying element crack susceptibility
Low Hydrogen welding Process
3) High allow Steel => Stainless Steel => Cr% ≥ 12 and Ni
crystalline structure a) Austenitic, b) Ferritic and c) Martensitic
Duplex and super duplex stainless steel maretial AD197-473-G-00503 ADMA Spec
7.4 ACCEPTANCE CRITERIA PMI
Material - tolerance of +/- 10%.
Welds - tolerance of +/-12.5%.
Set of IQI: ASME Sec V-2015, T-276, Page No. 30
NDT RADIOGRAPHY
Selection of IQI: ASME Sec V-2015, T-276, Page No. 32
Pressure Vessel
Hydrotest Pressure = DP x 130%, or DP x 150%,
Max. Allowable Working Pressure
= DP x 100 / 110 /116/ 121% (Non fire w.o
valve / non fire, 1 Valve/ non fire, > 1 valve / fire)
Design Pressure = DP
Operating Pressure = DP x 90%
https://www.youtube.com/watch?v=1UQ40agA8Aw
Metallurgy of Iron
https://www.youtube.com/watch?v=Bmd7T6SLKSE
https://www.youtube.com/watch?v=uh4obOPltpw
Iron crystal structures
Magnetic Particle Testing 9) Lifting Capacity: 10 lbs (4.5 Kgs)- AC Yoke
1) Applicable only for FERROMAGNETIC materials. Iron, nickel and 40 lbs (18 kgs)- Permanent magnet
cobalt alloys 10) Magnetic Field Strength: Shims Gages (Indicators)
2) Heated e Material to temp. Curie Point => Demagnetise Pie Gages
Iron => 770⁰C, Steel => 880⁰C, Nickel => 380⁰C, Cobalt => 1121⁰C Gauss/Tesla Meter (Field Strength Meter)
3) Good Lighting > 500 Lux. A light intensity of at least 1000 lux (100 Slotted strips, also known as Burmah-Castrol Strips
fc) is recommended /( 1076 lux (100 fc) is recommended
ASTM E709 MPI or E165 LPT)
4) Surface Temp: Dry powder for hot surface 316˚C
Wet Particle 50˚C
5) Dark area UV lamp
6) White background lacquer in order to contrast with magnetic particle.
7) A.C. Yoke 1-2 mm depth from surface
8) D.C. / Permanent magnate 4-7 mm depth from surface.
Magnetic Field = describes a volume of space where there is a Ferromagnetic = a large, positive (attracted) susceptibility to magnetic
change in energy within that volume = a magnetic field is a change fields = able to retain the magnetic properties = Iron, nickel, and cobalt
in energy within a volume of space.
Magnetic poles = never been detected in isolation = a dipole is an Magnetic properties (Ferromagnetic) = atoms carry a magnetic moment +
object that has a magnetic pole on one end and a second, equal but
the material is made up of small regions known as magnetic domains.
opposite, magnetic pole on the other.
A magnetic field is produced whenever an electrical charge is in Magnetic domains can be detected using Magnetic Force Microscopy (MFM)
motion. The strength of this field is called the magnetic moment. Magnetized = the magnetic domains within the material are aligned.
Magnetically saturated = all of the domains are aligned.
All materials are affected in some way by a magnetic field.
Magnetic Lines of Force :
Diamagnetic = a weak, negative (repelled) susceptibility to magnetic fields
=> the exit poles = North, the entrance poles = South
= does not retain the magnetic properties = copper, silver, and gold
Paramagnetic = a small, positive (attracted) susceptibility to magnetic => seek the path of least resistance
fields = does not retain the magnetic properties = magnesium, molybdenum,
lithium, and tantalum.
PEC
Zinc As per MNL 01 ADMA Spec. Clause No. 10.2
Holiday volt => 100 Volts per 25.4 µm (1 mil), Thumb rule (4 Volt /
Iron / Steel Micron)
= (
= Sin-1 - - - -11
= - - - -12
S = Skip distance
B = Beam Path - - - - - - 13
d1 = Depth of defect
Ѳ
S1 = Surface Distance
- - - - - - 14
b1 = Beam Path < S
S/2 d1 = b1 cos Ѳ - - -15
d2 = Depth of defect
Ѳ B/2 B/2S1 = b1 sin Ѳ - - t- 16
S2 = Surface Distance d2 = 2t – b2 cos Ѳ--17
b2 = Beam Path > S2 = b2 sin Ѳ -- - - 18
b2 = + x
S1
S2
t Ѳ B/2 xѲ b1 d2 td1
VL VT Z (g.cm-2.S-1 ) x VL VT Z (g.cm-2.S-1 ) x
Material (m/s) (m/s) 105 ρ(g/cm3) x103 Material (m/s) (m/s) 105 ρ(g/cm3) x103
Aluminium 6320 3080 17.00 2.69 Tungstan 5180 2870 99.80 19.27
steel (Iron) 5900 3230 46.50 7.88 Glass 5770 3430 14.40 2.50
S. Steel(302) 5660 3120 45.50 8.04 Lucite 2670 1120 3.20 1.20
S. Steel(410) 7390 2990 56.70 7.67 Teflon 1350 - 3.00 2.22
Cast Iron: from 3500 2200 25.00 7.14 Nylon 1800 - 2200 1.80 - 2.20 1.00 - 1.00
Cast Iron: to 5600 3200 40.00 7.14
Quartz 5730 - 15.20 2.65
Copper 4700 2260 42.00 8.94
Perspex 2730 1430 3.20 1.17
Brass 3830 2050 33.00 8.62
Glycerin 1920 - 2.40 1.25
Nickel 5630 2960 42.00 7.46
Water 1483 - 1.48 1.00
Lead (Pure) 2160 700 24.50 11.34 Oil 1410 - 1.12 0.79
Titanium 6100 3120 27.50 4.51 Rubber 2300 - 2.50 – 3.70 1.09 - 1.61
Attenuation:
Intensity diminishes with distance travels through a medium. 1.22 → null →% peak
scattering + absorption => attenuation 1.08 → 20 dB →10% peak
Attenuation α f 2
Scattering => Reflection other than original direction.
Absorption => Conversion of sound energy to other energy.
A = A0 e-αz - - - - - - 19
A = Amplitude changed, A0 = Initial Amplitude, α = 0.88 → 10 dB →32% peak
Attenuation Co-eff.[Np/m], Z = Travel Distance [m] 0.70→ 6 dB →50% peak
Np = Neper; Np / 0.1151= dB Gain dB Echo Height %
dB = Decibel = Log of ratio of two measurement. 42 80 %
36 -6 dB 40%
ΔI(dB) = 10 log = 10 log 30 - 6 dB 20%
CALIBRATION CHECKING:
Longitudinal Wave Probe:
A time base in terms of steel thickness:
A. Calibration of the
a) 25 thk. of IIW Block V1,
25 b)
mm If the echoes will not
coincide with appropriate
25mm / scale divisions, the time base A&B
is not linear and a graphical calibration required., c)
B
C 4-5MHz probe
<10mm, gives better accuracy. d) Higher
f => Lower Dead Zone, 10mm&5mm Perspex side
B. Check on linearity of amplifier: C
The amplification is linear when the ratio of
the height of any two consecutive echoes remains
constant
D when the degree of sensitivity is altered.
C. Assessment of (a) Relative sensitivity:
Echo from the 1.5 mm diameter hole D
http://www.inspection-for-industry.com/ultrasonic-
F= Frequency testing.html3.
P = Penetration ↑ ↓ ↑ ↓ ↑ ↓ ↑ ↓ ↑ ↓ General:
A = Attenuation F P A D S C R Y N Sd 3.1-Basic Requirements and Terms
D = Divergence ↓ ↑ ↓ ↑ ↓ ↑ ↓ ↑ ↓ ↑ ASME V-article 1 (General Requirement), 4 (Weld) & 5
S = Sensitivity (Material) ASME SEC.VIII, DIV.1.
C = Crystal Thickness 3.2-Examination coverage: Scan Overlap ≤ 10% of the
R = Resolution transducer (piezo-electric element) dimension ┴ to the
Y – λ = Wave Length direction of the scan.
N = Near Field 3.3- Rate of search unit movements < 150 mm/s.
Sd = Size of discontinuity detected 4. Personnel Qualification: Level II, ASNT-SNT-TC-1A.
AWS D1.1
Step 1: Selection of probe:
Table 6.2
Difference between an electrolytic cell and a galvanic cell
A Galvanic cell converts chemical energy into electrical An electrolytic cell converts electrical energy into chemical
energy. energy.
Here, the redox reaction is spontaneous and is The redox reaction is not spontaneous and electrical energy
responsible for the production of electrical energy. has to be supplied to initiate the reaction.
Here the anode is negative and cathode is the positive Here, the anode is positive and cathode is the negative
electrode. The reaction at the anode is oxidation and electrode. The reaction at the anode is oxidation and that at
that at the cathode is reduction. the cathode is reduction.