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2.
3.
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Oral (~ 10 to 15 min) 1 Question: - subject will be related to supervision of welding inspectors or to safety matters
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EXAMINATION
Examination in 5 (or 8) Parts
(Each part has a 70% pass mark)
If a candidate for the Senior Welding Inspector Examination does not hold a recognised qualification in Radiographic Interpretation (a CSWIP or PCN Certificate) he is required to sit 3 additional examination parts, namely: 6. Radiographic Interpretation (1h 30min)
6 dense metal welds - steel
7.
8.
(ability to interpret)
Planning Systems
(ability to plan & carry out some auditing) World Centre for Materials Joining Technology
PRODUCTION PLANNING
T = Tier
H = Head
N = Nozzle
T1 N1 H1 W1
T2
T3 W2 H2
S1
W = Wrapper plate S = Saddle
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N2
S2
PRODUCTION PLANNING
PRESSURE VESSEL: Typical Production Sequence
1. Prepare drawings & material list 2. Order materials - plate 3. 4. 5. - fittings - heads - welding consumables 11. Fit & weld - N1 + H1
12. Mark out, cut & roll wrapper plates 13. Weld W1 & W2 to shell plates 14. Fit & weld nozzles N2 & N3 15. Cut, assemble & weld saddles S1 & S2 16. Fit & weld S1 & S2 to W1 & W2 17. Carry out all final inspection 18. Pressure test 19. Blast & paint 20. Deliver
6. Mark out, cut & roll shell plates 7. Weld longitudinal seams
8. Fit & weld 9. - T3 to H2 - T2 to (T3 H2)
10.
- N1 + H1
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PRODUCTION PLANNING
PRESSURE VESSEL: Typical Production Sequence Bar Chart or Gantt Chart
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Drawings Material procurement - plate - fittings - heads - welding consumables Mark, cut & roll shell plates Weld longitudinal seams Fit & weld T3 to H Fit & weld T2 to T3H2 Fit & weld N1 to H1 Fit & weld N1H1 to T2T3H2 Cut & roll W1 & W2 Weld W1 & W2 to shell Fit & weld N2 & N3 Cut, assemble & weld S1 & S2 Fit & weld S1 & S2 to W1 & W2 Complete final Inspection Pressure test Shot blast & paint Deliver
- - - - - - - - - - - - - - - - - - - - - - - - - -
OPERATION
Welder makes a test weld in accordance with the pWPS Welding Inspector records all welding details used for making the test weld (as-run details)
(EN standard states that an Independent Examiner or Examining Body or a Third Party Inspector may be required to monitor the qualification process)
Finished test weld is subjected to NDT by the specified methods
Test weld subjected to destructive testing according to specified methods Application Standard or Client may require additional tests such as impact tests, hardness tests (for some materials - corrosion tests) Welding Procedure Qualification Record (WPQR) prepared giving range of qualification allowed by the Welding Standard (EN or ASME IX) WPQR package submitted to Independent Examiner for endorsement (& usually to Client)
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Welder Qualification
A WPS is written for a each test weld required
Welder makes a test weld in accordance with the WPS Welding Inspector checks that weld is made according to the WPS requirements
(EN standard states that an Independent Examiner or Examining Body or a Third Party Inspector may be required to monitor the qualification process)
Finished test weld is subjected to NDT by the specified methods
Test weld may need to be destructive tested for certain materials or welding processes
A Welder Qualification Certificate is prepared giving range of qualification allowed by the Welding Standard (EN or ASME IX) The Welder Qualification certificate is submitted to Independent Examiner for endorsement
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Destructive Testing
WELD PROCEDURE QUALIFICATION TESTING (example)
1 2 3 4 5 SPECIMEN TYPE 6 7 8 macro + hardness transverse tensile Charpy weld metal Charpy fusion line POSITIONS 1, 9, 11 2, 8, 10, 12 3, 5, 6 4, 7
12 11
10 9
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Destructive Testing
QUANTITATIVE TESTS & QUALITATIVE TESTS
QUANTITATIVE TESTS
- macro examination
(micro examination for some metals)
Destructive Testing
Tensile Testing - Transverse Tensile Test
gauge length
weld
Position of failure not usually in weld metal but in base material or HAZ
(Some standards accept 95% of base material Tensile Strength) World Centre for Materials Joining Technology
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Destructive Testing
Tensile Testing: All-Weld Tensile Test
TEST OBJECTIVE To measure Yield Strength & Tensile Strength of weld metal
(% Elongation also measured & usually also % Reduction of Area)
RESULTS Satisfactory if all values are not less than minimum specified for base metal (or required by desig) at ambient or at elevated temperature
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Destructive Testing
MECHANICAL TESTING: Charpy V-notch Test Positions
For each notch position 3 specimens are tested . May need to take test pieces from weld metal, fusion line, fusion line + 2, fusion line + 5 from both weld faces and from root - total of 36 tests weld metal (surface)
fusion line
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Destructive Testing
MECHANICAL TESTING: Charpy V-notch Impact Testing TEST OBJECTIVE
To measure the impact toughness of each region of the weld joint (weld metal, HAZ & base metal) at a specified temperature that is related to the service conditions RESULTS Satisfactory if all values are not less the minimum specified by the Application Standard
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Welding Technology
HAZ TOUGHNESS
Toughness
Charpy V-notch energy (Joules)
degraded HAZ
good toughness in steel at design temp. low toughness in HAZ at design temp. design temperature
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Welding Technology
THE HEAT AFFECTED ZONE (HAZ)
Maximum Temperature
solid weld metal solid-liquid transition zone
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Destructive Testing
MECHANICAL TESTING: Hardness Testing
usually the hardest region ~1.5 to 3mm fusion line (fusion boundary) HAZ
HAZ
TEST OBJECTIVE
RESULTS
Satisfactory if no values are above the max. specified by the Application Standard
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Welding Technology
HAZ Hardness of Carbon-Manganese Steels
HAZ Hardness
low heat-input welding tends to give a high HAZ hardness
fast
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slow
Welding Technology
HAZ Hardness of Low-Alloy Steels
(such as the higher Cr-Mo grades)
HAZ Hardness
fast cooling
Time to Cool
slow cooling
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Destructive Testing
QUALITATIVE TESTS: Bend Tests for joint thicknesses < ~ 12mm
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Destructive Testing
QUALITATIVE TESTS: Fillet Fracture & Nick Break Tests Tests are used instead of radiography or ultrasonic examination to show
force
machined slot
PWHT
Steels are given a PWHT to reduce residual stresses caused by welding [and also to temper (soften) the hardest regions of the HAZ] The main benefit of reducing residual stresses is to improve resistance to brittle fracture - explained as follows: Residual stresses can be higher than the max. allowed design stress and are powerful driving forces for propagating flaws (usually cracks) In the as-welded condition, the steel joint has a lower tolerance to flaws that may become initiation points for brittle cracks A crack that could cause brittle fracture is called a critical crack The size of a critical crack depends on the material toughness and total stress that the crack experiences in the joint (design + residual)
An as-welded joint may only be able to tolerate a small critical crack - possibly so small that it could be missed by RT or UT
When residual stresses are removed, a critical crack should be so big that it could not be missed during NDT and so would be repaired
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PWHT
Removal of Residual Stress
At PWHT temp. the yield strength of steel reduced so that it it is not strong enough to give restraint. Residual stress reduced to very low level by straining
100
200
300
400
500
600
700
Temperature (C)
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PWHT
Other Benefits of PWHT The toughness of the HAZ may be improved - particularly for the more hardenable low alloy steels & improves brittle fracture resistance Removal of residual stress will give steels resistance to stress corrosion cracking in certain media - for example in sour oil/gas, in ammonia or in contact with nitrates and chlorides It enables a welded component to be machined to accurate tolerances that may otherwise be impossible due constant re-balancing of tensile and residual stresses when metal is removed during machining. This may be referred to as a stabilising* PWHT
(* not to be confused with stabilised when referring to stabilising stainless steels by alloying additions of Nb or Ti)
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PWHT
PWHT Procedures - Basic Requirements
A PWHT should specify the following: The max. heating rate
usually from 300 or 400C depending on Code or item to ensure temp.
gradients are not excessive (up to ~ 200C/h max. may be allowed) distortion
large temp. gradients cause high stresses which may give cracking or
PWHT
PWHT Procedures -Additional Considerations
Before a PWHT commences it is necessary to: Decide the number of thermocouple attachments and their positions
so that the temperature of the whole component is monitored
The width of the temp. decay bands beyond the heated zone
to ensure high stresses are not produced by large temperature gradients
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The width of the temp. decay bands beyond the heated zone
to ensure high stresses are not produced by large temperature gradients should be specified by Code - usually same width as heated band
The position of the thermocouples to monitor the width of heated bands and the temp. gradient in the decay bands
temp. decay heated band temp. decay
pipeline weld
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Cracking Mechanisms
RE-HEAT CRACKING
Re-heat cracking occurs because: some strengthening of the steel occurs during heating to the PWHT temp. (or if in as-welded condition while in service at an elevated temp.) strengthening occurs by carbide formation
- steels with Vanadium, Chromium and Molybdenum are most susceptible because these elements are strong carbide formers
the carbides & nitrides strengthen the grains so that relief of residual stresses takes place by all the strain concentrating at the weaker grain boundaries
if the steel contains certain levels of impurities (such as Tin, Arsenic & Phosphorus) they concentrate at the grain boundaries and reduce their rupture strength the presence of large grains in the HAZ means that the impurities are more concentrated and such regions become the most sensitive to cracking
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Cracking Mechanisms
AVOIDING RE-HEAT CRACKING
The risk of re-heat cracking can be minimised by: using steel that has very low impurity levels various formulas have been developed to relate sensitivity to cracking to levels of impurities for particularly sensitive steels (usually those with higher Vanadium) ensure that: weld bead positions and heat input are controlled to give a fine grained HAZ (temper-beading) avoid stress concentrations - poor fit-up and sharp weld toes heat through the sensitive temperature range quickly during PWHT
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0.40 0.60
water quenched & tempered at 595 to 480C (100mm round section) 540 to 655 703 to 800 20 to 25 water quenched & tempered at 595 to 480C (100mm round section)
0.15 0.30
0.70 0.90
0.40 0.60
0.40 0.70
495 to 595
660 to 780
21 to 26
0.80 1.10
0.15 0.25
oil quenched & tempered at 650 to 540C (100mm round section) 580 to 685 772 to 883 19 to 23 oil quenched & tempered at 650 to 540C (100mm round section) 786 to 1000 924 to 1138 16 to 20
0.60 0.80
0.70 0.90
0.20 0.30
1.65 2.00
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Mechanical Properties
Yield / 0.2%PS (N/mm2) Tensile Strength (N/mm2) Elongation (% on 50mm)
0.50
= 415
585
= 22
= 500
700 -850
= 16
= 440
= 620
= 22
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Si
0.60 0.50 0.50 0.50
Mn
1.60 1.60 1.60 1.40
Cr
0.70 0.70 0.70 0.80
Mo
0.70 0.70 0.70 0.70
Ni
2.0 2.0 2.0 3.0
Nb
0.04 0.04 0.04 0.04
V
0.09 0.06 0.06 0.08
Ti
0.04 0.04 0.04 0.02
Other
N (min) 0.0015 B (max) 0.005 N (min) 0.0015 B (max) 0.005 N (min) 0.0015 B (max) 0.005 N (min) 0.0015 B (max) 0.005
Yield/0.2%PS (N/mm2)
Elongation (% on 50mm)
= 18 = 16 = 16 = 12
Chemical compositions and tensile properties of some HSLA steels used for structural applications
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Alloying additions used to achieve strengthening also will give hardening of the HAZ Higher HAZ hardness give higher risk of cracking and the need to always use low Hydrogen welding processes and also the need to use pre-heat for most grades Higher HAZ hardness usually mean that many of these steels require PWHT to improve resistance to brittle fracture Careful control of heat input - not too high - may be needed for some steel types to avoid softening of the HAZ and loss of strength For the highest strength grades there may be difficulty in achieving matching strength weld metal that has good toughness and ductility
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Pre-heat should be checked on the other side from the pre-heated side - if access allows
If hand held gas pre-heating is used, temp. should be checked a short time after the heating torch has been removed
Interpass Temperature
This is the temp. at the position that the welder will re-start welding in a muti-run weld Temperature should be measured on the steel as close as practical to the re-start position (it can be taken on the weldat that point)
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