A quick guide to welding and weld inspection

153 Pages·2009·4.988 MB·English

by  Hughes, Steven E

A Quick Guide to Welding and
Weld Inspection
WoodheadPublishingLtd–AQuickGuidetoWeldingandWeldInspection
DataStandardsLtd,Frome,Somerset–17/9/200900QGWeldingPrelims.3d Page1of14
QGPublishingisaMatthewsEngineeringTrainingLtdcompany
MATTHEWS
ENGINEERING TRAINING LTD
www.matthews-training.co.uk
Training courses forindustry
. Plantin-serviceinspectiontraining
. Pressuresystems/PSSR/PED/PRVs
. NotifiedBodytraining
. PressureequipmentcodedesignASME/BS/EN
. APIinspectortraining(UK):API510/570/653
. On-linetrainingcoursesavailable
Matthews Engineering Training Ltd provides training in pressure
equipment and inspection-related subjects, and the implementation
ofpublishedcodesandstandards.
Morethan500classroomandhands-oncourseshavebeenpresented
tomajorclientsfromthepower,process,petrochemicalandoil/gas
industries.
We specialise in in-company courses, tailored to the needs of
individualclients.
[email protected]
Tel:[phone]
MatthewsEngineeringTrainingLtdisanAuthorizedGlobalTraining
providertoTheAmericanSocietyofMechanicalEngineers(ASME)
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A Quick Guide to
Welding and Weld Inspection
Steven E. Hughes
Series editor: Clifford Matthews
MatthewsEngineeringTrainingLimited
www.matthews-training.co.uk
Oxford Cambridge NewDelhi
WoodheadPublishingLtd–AQuickGuidetoWeldingandWeldInspection
DataStandardsLtd,Frome,Somerset–17/9/200900QGWeldingPrelims.3d Page3of14
Published by Woodhead Publishing Limited, Abington Hall, Granta Park,
GreatAbington,CambridgeCB216AH,UK
www.woodheadpublishing.com
and
MatthewsEngineeringTrainingLimited
www.matthews-training.co.uk
Woodhead Publishing India Private Limited, G-2, Vardaan House, 7/28
AnsariRoad,Daryaganj,NewDelhi-110002,India
www.woodheadpublishingindia.com
PublishedinNorthAmericabytheAmericanSocietyofMechanicalEngineers
(ASME),ThreeParkAvenue,NewYork,NY10016-5990,USA
www.asme.org
First published 2009, Woodhead Publishing Limited and Matthews
EngineeringTrainingLimited
#2009,S.E.Hughes
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WoodheadPublishingISBN978-1-84569-641-2 (book)
WoodheadPublishingISBN978-1-84569-767-9 (e-book)
ASMEISBN978-0-7918-5950-6
ASMEOrderNo.859506
ASMEOrderNo.85950Q (e-book)
TypesetbyDataStandardsLtd,Frome,Somerset,UK
PrintedbyCromwellPressLimited,Trowbridge,Wiltshire,UK
WoodheadPublishingLtd–AQuickGuidetoWeldingandWeldInspection
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Contents
ForewordbySeriesEditor viii
Introduction x
A10MinuteGuide xii
Chapter1:Abbreviations,TerminologyandWelding
Symbols
Abbreviations 1
Commonterms 2
Jointterminology 2
Weldterminology 2
Drawingrulesandweldsymbols 8
Chapter2:DutiesofaWeldingInspector
Beforewelding 17
Duringwelding 19
Afterwelding 19
Repairs 20
Chapter3:AnalysisofaFusionWeld
Componentsofaweldedjoint 22
Whatmakesagoodfusionweld? 24
Weldjoint:preparationmethods 26
Weldjoint:shape 27
Residualstressanddistortion 27
Minimisingstressesanddistortion 32
Chapter4:MaterialsandTheirWeldability
Carbonequivalency 36
Classificationofsteels 37
Alloyingelements 38
Materialproperties 43
Heattreatmentofsteels 44
Chapter5:WeldingProcesses
Manualmetalarc(MMA)/shieldedmetalarc
welding(SMAW) 49
Metalinertgas(MIG)/metalactivegas(MAG)/
gasmetalarcwelding(GMAW) 53
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AQuickGuidetoWeldingandWeldInspection
Flux-coredarcwelding(FCAM) 59
Tungsteninertgas(TIG)/gastungstenarc
welding(GTAW) 61
Submergedarcwelding(SAW) 63
Chapter6:Non-destructiveandDestructiveTesting
Liquidpenetranttesting(PT) 67
Magneticparticletesting(MT) 69
Ultrasonictesting(UT) 71
Radiographictesting(RT) 73
Tensiontests 77
Bendtests 77
Charpytests 78
Hardnesstesting 81
Macrosamples 83
Microsamples 85
Filletfracturetest 85
Buttweldfracturetest(nickbreak) 85
Chapter7:FractureModesandWeldingDefects
Imperfectioncategories 88
Hydrogen-inducedcoldcracking(HICC) 88
Solidificationcracking 90
Reheatcracking 93
Lamellartearing 93
Welddecay 97
Porosity 98
Solidinclusions 101
Lackoffusion 101
Incompleterootpenetration 102
Rootconcavity 102
Excessiverootpenetration 103
Overlap 103
Underfill 104
Undercut 104
Craterpipe 105
Burn-through 106
Rootoxidation 106
Arcstrike 106
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Contents
Spatter 107
Magneticarcblow 107
Chapter8:Codes,StandardsandDocumentation
Codesandstandards 108
ThePEDandUKPER 111
Weldingprocedurequalifications 113
Procedurequalificationrecord(PQR) 114
Weldingprocedurespecification(WPS) 114
Welderqualifications 117
Chapter9:HealthandSafety
HealthandSafetyatWorkAct 125
Electricalsafety 126
Welding/cuttingprocesssafety 127
Personalprotectiveequipment(PPE) 128
Gasesandfumes 129
COSHHandworkplaceexposurelimits(WEL) 130
Liftingequipment/pressuresystem
requirements 132
Handtoolsandgrindingmachines 133
Otherprecautionsbeforeweldingstarts 133
Causesofaccidents 133
Permit-to-work 134
Tanksanddrums 134
Index 135
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Foreword by Series Editor
WearepleasedtointroducethisnewbookbySteveHughes
in our ongoing Quick Guide series. Intended for inspection
engineers and technicians the Quick Guide to Welding and
Weld Inspection will provide a useful reference for those
involved inthe plant inspection discipline.
Steve Hughes provides valuable lecturing input to our
ASME Plant Inspector and API 510/570/653 Certified
inspection training courses run by Matthews Engineering
TrainingLtd,bringinghistechnicalknowledgeunderpinned
by sound engineering practical experience. As a discipline,
Plant Inspection incorporates many subjects, but welding
and weld inspection forms a common thread running
through the majority of them. For pressure systems in
particular, weld joining design, welding techniques, NDE
anddefectacceptanceareprimeconsiderationsinequipment
repair andassessing the risk of existingequipment.
The documentation aspects of weld inspection often
remain a bit of a mystery to plant inspectors (even
experienced ones). In assessing the quality of weld repairs it
becomesalltooeasytoassumethatthenecessaryWPS/PQR
weld documentation and welder qualifications are in place,
without properly checking. Equally it is easy to be
intimidated bythe technicaldetailandterminology symbols
and acronyms. You should find this book useful in helping
youthrough suchsituations.
Despite the predominance given in technical publications
to advanced technology-intensive NDE and inspection
activities, it remains a fact that 90% of all pressure
equipment inspections include only well-proven established
inspection activities. In writing this book, Steve Hughes has
addressedtheserealissuesofmostpracticalweldinspections,
distilling a wide subject into a simplified and digestible
format.Youdon’thavetobeaqualifiedweldingengineeror
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ForewordbySeriesEditor
metallurgisttoreadthisbook,andyoumaystillbenefitfrom
itifyou are.
Finally, we are always interested in hearing from people
who are interested in writing a Quick Guide book (like this
one)inaninspection-relatedsubject.Youdon’thavetobean
experiencedauthororanacknowledgedexpertonthesubject
(all experts are self-appointed anyway – we know that),
justhavesufficientexperiencetoknowwhatyouaretalking
about and be able to write it down in a way that other
people will understand. We’ll do the rest. Contact me on
[email protected] or through our website
www.matthews-training.co.uk.
CliffMatthews
Series Editor
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