Standards that Impact Fabrication

Codes
&
Standards

Standards that Impact Fabrication

Codes
and Standards

Lesson Objectives
When you finish this lesson you will
understand:
Codes and Standards and Standards
Writing Bodies
Welding Procedure Development and
Qualifications

Learning Activities
1. Read Handbook
412-464
2. View Slides;
3. Read Notes,
4. Listen to lecture
5. Do on-line
workbook
6. Do homework

Keywords
Codes, Specifications, Recommended Practices, Guides,
Classifications, Methods, ANSI, ISO, Welding Procedure
Specification (WPS), Procedure Qualification Record (PQR),
Welder Performance Qualification

Standards that Impact Fabrication

Introduction

Types of Standards

Codes are generally applicable to processes

Shall/will
and indicate the mandatory use of materials or
actions
Specifications are generally associated with Shall/will
a product and indicate the mandatory use of
materials or actions
Should/may
Recommended practices and guides are
offered primarily as aids to the user
Classifications and methods provide lists of
established practices or categories for
processes or products
0.1.1.6.0.T1.95.12

Standards that Impact

Fabrication
Code
Writing Agencies

This Table
is in the
Welding
Handbook

Standards that Impact Fabrication

Introduction

What is Covered by Standards

Products
Piping - American Petroleum Institute
Filler metals - American Welding Society
Ships - American Bureau of Shipping
Pressure vessels and boilers - American Society of Mechanical
Engineers
Bridges - American Institute of Steel Construction

Health & Safety

Terminology
Testing Procedures

0.1.1.6.0.T2.95.12

Standards that Impact Fabrication

Standards that Impact Fabrication

Introduction

American National Standards Institute (ANSI)

Coordinating organization for the U.S. voluntary

standards system
There are approximately 10,000 American National
Standards, which encompass nearly every field and
discipline
ANSI standards are developed and used voluntarily; they
become mandatory when adopted or referenced by a
governmental body

International Organization for Standardization (ISO)

Establishment of Uniform Standards for International Trade

0.1.1.6.0.T3.95.12

Standards that Impact Fabrication

Professional Society Standards

International Organization for Standards (ISO)

80 countries, 4000+ standards, ANSI is the U.S.

representative
ISO 9000-9004 (ANSI/ASQC Q90) is a series of quality
management and assurance standards in manufacturing
Designed for manufacturing sector
EC has adopted ISO 9000 and prefers US suppliers
that are

ISO 9000 certified

DoD, DuPont, 3M, AT&T are asking suppliers to comply
with ISO 9000

ISO 3834 - Factors to be Considered When Assessing

Firms Using Welding as a Prime Means of Fabrication
0.1.1.6.2.T20.95.12

Standards that Impact Fabrication

Health and Safety

Health & Safety

ANSI/ASC Z49.1-1988 Safety in Welding and Cutting

Included in the General Industry Standards of OSHA
Specifically covers arc, oxyfuel gas, resistance welding
Health and Safety in Welding and Allied Processes 4th
edition, ed. N.C. Balchin and H. R. Castner,
McGraw-Hill Inc. 1993

0.1.1.6.1.T4.95.12

Standards that Impact Fabrication

Professional Society Standards

American Welding Society (AWS) Standards

Definitions and Symbols (A)

Filler Metals (A5)
Qualification and Testing (B, C, and D)
Welding Processes (C)
Welding Applications (D)

0.1.1.6.2.T12.95.12

Standards that Impact Fabrication

Professional Society Standards

Definitions and Symbols

ANSI/AWS A2.4 Symbols for Welding, Brazing, and

Nondestructive Examination
Communication between designers and fabricators
Joint geometry, weld contour, surface finish
ANSI/AWS A3.0 Standard Welding Terms and
Definitions
Standard terms for use in written and oral communication

conveying materials joining information

Non-standard terms

0.1.1.6.2.T13.95.12

Standards that Impact Fabrication

Professional Society Standards

ANSI/AWS D1.1 Structural Welding Code: Steel

Guidelines for design of welded joints as well as

prequalified joint geometries
Statically loaded structures
Dynamically loaded structures
Tubular sections
Details the processes used with particular joints
How to qualify welding procedures and personnel
Outlines quality and inspection in welded construction
Filler metal recommendations

0.1.1.6.2.T14.95.12

Standards that Impact Fabrication

Professional Society Standards

AWS D1.1 Prequalified Joint Design

0.1.1.6.2.T15.95.12

Standards that Impact Fabrication

Professional Society Standards

ASTM (American Society for Testing and Materials)

Specifications cover virtually all materials used in

industry and commerce, but not welding consumables
Annual Book of ASTM Standards, 15 sections (65
volumes)
1 - Iron and Steel
2 - Non-ferrous
3 - Metal test methods and analytical procedures
Specification of groups of similar steel (A)
A36 - general construction steels
A387 - chromium-molybdenum steel for elevated-temperature
service in piping and pressure vessel systems
0.1.1.6.2.T16.95.12

Standards that Impact Fabrication

Professional Society Standards

American Society of
Mechanical Engineers (ASME)

Boiler and Pressure Vessel Code has 11 sections and

is referenced by most states, major cities in the U.S.,
Canadian provinces, a number of federal agencies
Before fabricating a boiler or pressure vessel, a
company must have a quality control system and a
manual describing it
ASME issues a Certificate of Authorization and a code symbol
stamp

Unique in that it required 3rd party inspection

independent of fabricator and user
Uses same steel designations as ASTM
0.1.1.6.2.T17.95.12

Standards that Impact Fabrication

Professional Society Standards

Boiler and Pressure Vessel Code

Section II- Materials Specifications for base metals, filler

metals, fluxes
Section V - Nondestructive Examination
Section IX - Welding and Brazing Qualifications for
personnel and procedures
Delineates a P number grouping of steels for the purpose of

welding qualification
P1 - carbon-manganese steels with a minimum UTS of 45-90 ksi
P5 - alloy steels with 2.25-9% chromium, <10% total alloy
All steels within a P number can be welded with the same
procedure
0.1.1.6.2.T18.95.12

Standards that Impact Fabrication

Professional Society Standards

Other Standards

American Petroleum Institute (API) Standard 1104

Welding of Pipelines and Related Facilities
Qualifications of Welding Procedures and Welders
Inspection and nondestructive testing
Repair and removal of defects
Unified Numbering System (UNS)
Cross references the numbering systems from different

countries
Over 3500 metals, alloys, and filler metals
Designated SAE HSJ1086 / ASTM DS56

0.1.1.6.2.T19.95.12

Standards that Impact Fabrication

Questions?

Turn to the person sitting next to you and discuss (1 min.):

What does being a third party consensus standards
writing body mean?

Standards that Impact Fabrication

Qualification
&
Certification

Standards that Impact Fabrication

Welding Procedure Specification (WPS)

A document that provides in detail required welding
conditions for a specific application.

Procedure Qualification Record (PQR)

A record of actual welding conditions used to produce an
acceptable test joint and the results of the qualification tests.

Welder Performance Qualification-Certification

A record of a welders or welding operators ability to produce
welded joints that meet prescribed standards

Standards that Impact Fabrication

Pre-Qualified Procedures

Standards that Impact Fabrication

(Some Codes 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 Prequalified Status

Standards that Impact Fabrication

Basic Steps in Qualification of a Procedure

1. Prepare a preliminary WPS
2. Prepare and weld a suitable test weldment using WPS
3. Conduct required NDT and Destructive Tests
4. Evaluate Results of prep, welding, testing
5. Document results on PQR
6. Issue approved PQR
7. Issue approved WPS

PQR - WPS Variables Considered

Standards that Impact Fabrication

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
Passes
Weave
Position *
Preheat and Interpass
Peening
Second Side Prep
Post Weld Heat Treat
Records (If Required)

Check Specific Code for List of Essential Variables

(Essential Variable Must Be Included in the WPS)

Standards that Impact Fabrication

Standards that Impact Fabrication

Standards that Impact Fabrication

PQR
Page 1

Standards that Impact Fabrication

PQR
Page 2

Tests Commonly Used for PQRs

Standards that Impact Fabrication

Test
Fracture Tests
(Charpy, COD, Drop)
Nick-break
Free Bend
Shear Test
Hardness
All-Weld-Metal Tension
Elevated Temp
Restraint Test
Corrosion
NDE
Delayed Cracking

Evaluation
Risk of Brittle Fracture at Use
Temperature
Determine Weld Soundness
Ductility of Weld Metal
Shear Strength of Fillet Welds
Adequacy of Heat Treatment
Mechanical Prop of WM
Prop at Elev. Service Temp
Crack Susceptibility
Prop. In Aggressive Environ.
Soundness of Weld
Resistance to H Cracking

Standards that Impact Fabrication

WPS

Welder Performance Qualification

Standards that Impact Fabrication

Variables

Welding Process
Filler Metal
Position
Joint Details
Thickness
Technique
(Qualifying in a more difficult position
may qualify in an easier position)

Duration Of Qualification
Dependent upon Code
(Usually inactivity of 3 to 6 months required requalification)

Standards that Impact Fabrication

Performance
Qualification
Record

Standards
that Impact
Fabrication
Welding
Procedure
and Performance
Qualification Variable That May Require Requalification

Procedure Variable
Base Metal (Type,
Composition, Process)
Thickness of BM
Joint Design
Pipe Diameter
Type of Current, Polarity
Electrode Classification, Size
Welding Current
Position, Progression
Deposition of Filler Metal
Root Prep , Other Side
Preheat, Interpass Temp
Postheat Temp

Procedure Requalification
May Be Required
Change in BM, Some Codes
List Equivalencies
Change Outside Thickness
Range
Change in Root, Included
Angle, Dimensions
Usually Not Required
Usually Not Required
Change in Electrode
Classification or size
When Outside Range
Usually not Required, But
Desirable
For Marked Changes
When Method or Extent Has
Changed
When Outside Range
When Outside Range

Welder or Operator
Requalification
Usually Not Required
Change Outside Range
Change in Root, Included
Angle, Dimensions
When Reduced Below Some
Minimum
Usually Not Required
Change in Electrode
Classification or size
Usually Not Required
When Change Exceeds Limits
Usually Not Required
Usually Not Required
Usually Not Required
Usually Not Required

Standards that Impact Fabrication

Demonstration
Run the Welding Procedure Specification
from the Demonstration Page of the WE300
Web Page

Standards that Impact Fabrication

Homework
Please do Assignment 14