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Rigfab Welder's Handbook Flipbook PDF
Rigfab Welder's Handbook
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BOOK I SSU ED
CREATED BY
Spring 2020
Aubrey Greene
welder’s
Visual inspection
HANDBOOK This handbook is NOT intended to serve as a work procedure or to replace any existing p r o c e d u r e s . I t i s s o l e ly i n t e n d e d t o p r o v i d e b a s i c i n f o r m a t i o n a b o u t w e l d c o n d i t i o n s , weld gauges, symbols and weld terms. Refer to local procedures for technical or o t h e r s p e c i f i c d ata .
AWS C E RT I F I E D WELDER Powered by Rig Fab Energy Services
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SUCCESS THROUGH Training. “I hated every minute of training, but I said, ‘ ’ D o n ’ t q u i t. S u f f e r n o w and live the rest of your life as a champion.’’ Muhammad ALi
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CONTENTS THE PAGE OF CONTENTS. Visual Inspection Responsibilities and Technique..................... 4 H o w t o M e a s u r e F i l l e t W e l d S i z e .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 VT Attributes Cracks........................................................................... 6-7 Underfill....................................................................... 8-9 B u r n T h r o u g h.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 - 1 1 Incomplete Fusion...................................................... 12-13 R o u g h n e s s .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 - 1 5 Overlap...................................................................... 16-17 Undersized Fillet Weld............................................. 18-19 I n c o m p l e t e P e n e t r at i o n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 - 2 1 U n d e r c u t .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 - 2 3 C o r n e r - M e lt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4 - 2 5 E n d - M e lt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 6 - 2 7 C o n c a v e F i l l e t W e l d .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 8 - 2 9 C o n v e x F i l l e t W e l d .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 - 3 1 Arc Strikes................................................................32-33 O t h e r Fa b r i c at i o n S c a r s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 - 3 5 Porosity.....................................................................36-37 S p a t t e r .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 8 - 3 9 Slag............................................................................ 40-41 Weld Reinforcement................................................. 42-43 M e lt T h r o u g h .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 - 4 5 Offset........................................................................ 46-47 Ox i d at i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 8 - 4 9 C r a t e r P i t .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 - 5 1 p r e h e at / i n t e r pa s s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2 - 5 3 T y p e s o f W e l d J o i n t s.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4 - 5 6 Parts of a Weld......................................................................... 58 Structural Joint Numbering System......................................... 59 S ta n d a r d W e l d i n g S y m b o l L ay o u t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2 S t a n d a r d W e l d i n g S y m b o l s .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3 - 6 8 Using Finger Gauge................................................................ 69-71 Using Bridgecam Gauge......................................................... 72-74 Definitions.................................................................................. 75
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VISUAL INSPECTION responsibilities & techniques visual inspection responsibilities 1. WHEN – Final visual inspections must be performed:
a. When the weld is complete, and in the final surface and heat treated conditions
b. Before other NDT (when required)
c. Before being made inaccessible for inspection
2. WHERE - the weld inspection zone:
a. All work – Completed weld faces plus ½ inch on both sides of weld shall be visually inspected for the entire length
of the weld.
b. To gauge weld size:
i. Gauge where the weld size visually appears to be the smallest
ii. If the weld length is five feet or less, gauge a minimum of once per weld
iii. If the weld length is greater than five feet, gauge a minimum of once every five feet.
visual inspection technique 1. What – In order to perform final visual inspection you need:
a. Adequate lighting (use flashlight as needed)
b. Weld gauges (bridge cam and finger gauges recommended)
c. Prescription glasses (as required)
2. How – Distance and angle:
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a. The inspector’s eyes should be within 24 inches of the surface to be inspected and
b. At an angle of at least 30 degrees to the surface being inspected.
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how to measure fillet weld size The leg lengths and throat of the largest triangle that can be drawn within the fillet weld cross section.
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cracks
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cracks definition A tear, fracture or fissure in the weld or base metal appearing as a broken, jagged or straight line. NOTE:
Cracks are the most serious defect!
preventative action 1. Remove contaminents from the joint (rust, grease, moisture, etc.) prior to welding. 2. Apply and maintain required preheat. 3. Do not allow the base material to cool too quickly. 4. Maintain filler metal control requirements. 5. Use correct filler metal type for the joint. 6. Apply proper bead size and sequencing to eliminate excessive distortion and/or stress in the base material.
corrective action Repair in accordance with local procedures.
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underfill
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underfill definition A tear, fracture or fissure in the weld or base metal appearing as a broken, jagged or straight line. NOTE:
Cracks are the most serious defect!
preventative action 1. During welding of the reinforcement, gauge bead heights in any location that appears to be lower than the rest of the bead. 2. Adjust amps/volts. 3. Slow travel speed to allow increased weld puddle volume. 4. Sequence weld passes so that the toes of the beads sufficiently cover one another, minimizing valleys.
corrective action Apply additional weld beads until the joint is adequately filled (flush or above).
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burnthrough
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burnthrough definition Excessive heat and/or penetration that results in a hole completely through the backing ring or strip, fused root, or adjacent base material.
preventative action 1. Reduce amps/volts. 2. Increase travel speed. 3. Maintain appropriate arc length/wire stickout. 4. Use ceramic tape or approved metal backing strap on areas with root gap.
corrective action 1. Place ceramic tape or approved metal backing strap on the bottom side of the hole. 2. Weld repair the first side of the hole from the easiest side to weld. 3. Once sufficient weld metal has been deposited on the easiest top side, grind or carbon arc the other side of the hole to sound metal. 4. Weld the other side of the hole to the appropriate size or height
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incomplete FUSION
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incomplete FUSION definition A situation where the weld metal does not fuse or completely bond with the base metal or previously deposited weld metal.
preventative action 1.
Increase amps/volts.
2.
Decrease travel speed.
3.
Maintain appropriate arc length/wire stickout.
4.
Adjust torch/rod angle.
5.
Ensure previous beads are free of overlap (bead roll-over) and slag prior to welding additional passes.
corrective action 1. Place ceramic tape or approved metal backing strap on the bottom side of the hole. 2. Weld repair the first side of the hole from the easiest side to weld. 3. Once sufficient weld metal has been deposited on the easiest top side, grind or carbon arc the other side of the hole to sound metal. 4. Weld the other side of the hole to the appropriate size or height
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roughness
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roughness definition Sharp ridges (irregularities) or deep valleys between weld beads. The angle formed between the adjacent beads of the weld must be 90° or greater.
preventative action 1 .Adjust amps/volts. 2. Maintain a consistent travel speed. 3. Maintain appropriate arc length/wire stickout. 4. Adjust torch/rod angle. 5. Sequence weld passes so that the toes of the beads sufficiently cover one another, minimizing valleys. 6. Consult local Welding Engineering in cases where the bse material is magnetized.
corrective action 1. Grind or carbon arc the weld to sond metal. 2. Weld repair the affected area, if needed.
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overlap
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overlap DEFINITION A condition where the weld metal rolls over forming an angle less than 90°. Sometimes referred to as “weld bead rollover”.
PREVENTIVE ACTION 1.
Adjust amps/volts.
2.
Increase travel speed.
3.
Maintain appropriate arc length/wire stickout.
4.
Adjust torch/rod angle.
CORRECTIVE ACTION 1.
Grind or carbon arc the weld to souond metal.
2.
Weld repair the affected area, if needed.
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UNDERSIZED FILLET WELD
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UNDERSIZED FILLET WELD definition Any fillet or fillet reinforced weld that does not meet the minimum size requirements specified on applicable fabricatin documents. NOTE: Skewed fillets are exceptionally prone to having underzied weld on sides that have greater than 90° joint fit-up.
preventative action 1. Apply weld layers until weld size is met on all sides of joint. 2. Adjust amps/volts. 3. Decrease travel speed. 4. Maintain proper wire stickout. 5. Adjust torch/rod angle. 6. Avoid over grinding. 7. Sequence weld passes so that the toes of the beads sufficiently overlap one another.
corrective ACTION Apply additional weld passes until the affected areas are the proper size.
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INCOMPLETE PENETRATION
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INCOMPLETE PENETRATION definition A situation where the weld metal does not penetrate as deeply as required.
preventative action 1. Increase the bevel angle and/or root opening of the fit-up. Do not exceed the requirements of the joint design. 2. Ensure bevel edges of both members are lined up properly. 3. Increase amps/volts. 4. Decrease travel speed. 5. Maintain appropriate arc length/wire stickout. 6. Adjust torch/rod angle.
corrective ACTION 1. Grind or carbon arc the weld to sound metal. NOTE: Backgouge 2nd side to full penetration (remove fusion lines). Often, more than one fusion line will be present during back gouging. 2. Weld repair the affected area.
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UNDERCUT
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UNDERCUT definition A groove melted into the base metal and left unfilled by weld metal.
preventative action 1. Decreased amps/volts. 2. Decrease travel speed. 3. Maintain appropriate arc length/wire stickout. 4. Adjust torch/rod angle. 5. Feed more wire into the puddle when manual TIG welding. 6. Increase stop time (dwell time) on weaved beads. 7. Use undercut gauge to verify acceptability.
corrective ACTION 1. Grind the toe of the weld until the unacceptable undercut blends smoothly into the base material. 2. Weld repair the affected area, if needed.
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CORNER-MELT
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CORNER-MELT definition A groove melted in a corner of a welded member that is left unfilled.
preventative action 1. Start welds at end of joint and work inward. 2. Decrease amps/volts. 3. Decrease travel speed. 4. Maintain appropriate arc length/wire stickout. 5. Adjust torch/rod angle. 6. Feed more wire into the puddle when manual TIG welding. 7. Increase stop time (dwell time) on weaved beads.
corrective ACTION 1. Grind the toe of the weld until the unacceptable corner-melt blends smoothly into the base material. 2. Weld repair the affected area, if needed.
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end-MELT
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end-MELT definition A groove melted into the end of a ¼ inch or less welded member that is left unfilled by weld metal.
preventative action 1.
Start the weld passes at the ends, where possible.
2.
Decrease amps/volts.
3.
Decrease travel speed.
4.
Maintain appropriate arc length/wire stickout.
5.
Adjust torch/rod angle.
6.
Feed more wire into the puddle when manual TIG welding.
7.
Increase stop time (dwell time) on weaved beads.
8.
Use undercut or bridgecam gauge to verify acceptability.
corrective ACTION 1.
Grind the toe of the weld until the unacceptable end-melt blends smoothly into the base material.
2.
Weld repair the affected area, if needed.
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CONCAVE FILLET WELD
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CONCAVE FILLET WELD definition A groove melted into the end of a ¼ inch or less welded member that is left unfilled by weld metal.
preventative action 1.
Adjust amps/volts.
2.
Decrease travel speed.
3.
Maintain appropriate arc length/wire stickout.
4.
Adjust torch/rod angle.
5.
Feed more wire into the puddle when manual TIG welding.
6.
Increase stop time (dewll time) on weaved beads.
7.
Sequicence weld passes so that the toes of the beads sufficiently cover one another.
corrective ACTION Apply additional weld passes until the concavity requirements have been met.
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CONVEX FILLET WELD
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CONVEX FILLET WELD DEFINITION A fillet weld that bulges out in the center.
PREVENTIVE ACTION 1.
Adjust amps/volts.
2.
Increase travel speed.
3.
Maintain proper wire stickout.
4.
Adjust torch/rod angle.
5.
Feed less wire into the puddle when manual TIG welding.
6.
On multiple pass welds, avoid placing beads too close together.
CORRECTIVE ACTION Grind, carbon arc or weld the affected area until the convexity requirements have been met.
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arc strikes
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arc strikes DEFINITION A discontinuity consisting of any localized remelted metal, heat effected metal, or change in surface profile of a finished weld or base material surface resulting from an electrical arc. NOTE: Arch strikes may develop stress risers, which could lead to cracking.
PREVENTIVE ACTION 1.
Prior to energizing welding equipment, replace damaged welding lines and ground cables.
2.
Ensure grounds are properly installed.
3.
Hang lines on trees or J-hooks.
4.
Keep cas cups free of weld spatter on flux core processes.
5.
Do not allow sub-arc tips to contact the base material.
6.
Be careful when striking an arc.
CORRECTIVE ACTION 1.
Grind the affected area until the unacceptable arc strike blends smoothly into the base material or weld face.
2.
Weld repair the affected area, if needed.
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OTHER FABRICATION SCARS
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OTHER FABRICATION SCARS DEFINITION Any accidental groove or cut that penetrates the surface of the metal. Sometimes called nicks, gouges or handling marks.
PREVENTIVE ACTION 1.
Avoid dropping heavy or sharp objects on welds and surrounding base material.
2.
Be careful when grinding, carbon arcing or using scaling hammer.
3.
Use undercut gague to verify scar acceptability.
CORRECTIVE ACTION 1.
Grind the affected area until the unacceptable fabrication scar blends smoothly into the base material or weld face.
2.
Weld repair the affected area, if needed.
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POROSITY
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POROSITY DEFINITION Open holes formed by gas that was trapped when the weld cooled. Sometimes called “pinholes”.
PREVENTIVE ACTION 1.
Remove contaminants from the joint (rust, grease, moisture, etc.) prior to welding.
2.
Maintain filler metal control requirements.
3.
Maintain appropriate arc length/wire stickout.
4.
Adjust torch/rod angle.
5.
Use the largest size gas cup possible and keep it free of spatter.
6.
Position wind screens between the welding operation and any heavy flow of air.
CORRECTIVE ACTION 1.
Completely remove porosity from all intermediate weld areas.
2.
Grind or carbon arc the affected area until the unacceptable porosity is removed from the weld.
3.
Weld repair the affected area, if needed.
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SPATTER
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SPATTER DEFINITION The metal particles expelled during welding that do not form a part of the weld.
PREVENTIVE ACTION 1.
Remove contaminants from the joint (rust, grease, moisture, etc.) prior to welding.
2.
Maintain filler metal control requirements.
3.
Use Refrasil to protect surrounding surfaces from secondary weld spatter.
4.
Adjust amps/volts.
5.
Adjust torch/rod angle.
6.
Maintain appropriate arc length/wire stickout.
7.
Use ceramic tape or approved metal backing strap on areas with root gap.
8.
Consult local Welding Engineering in cases where the base material is magnetized.
CORRECTIVE ACTION 1.
Completely remove spatter from all intermediate weld areas.
2.
Remove all loose spatter with a needle gun.
3.
Grind all tightly adhering, unacceptable spatter until it blends smoothly into the base material or weld.
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slag
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slag DEFINITION The nonmetallic layer that forms on top of the molten metal.
PREVENTIVE ACTION NOTE: Slag is a byproduct of the welding process that cannot be prevented. Below are some actions that make slag removal easier. 1.
Adjust amps/volts.
2.
Maintain a consistent travel speed.
3.
Maintain an appropriate arc length/wire stickout.
4.
Adjust torch/rod angle.
5.
Sequence weld passes so that the toes of the beads sufficiently overlap one another, minimizing valleys.
CORRECTIVE ACTION 1.
Completely remove slag from all intermediate weld areas.
2.
Remove all loose slag with a needle gun.
3.
Grind all tightly adhering, unacceptable slag from the surface of the base material or weld.
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WELD REINFORCEMENT
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WELD REINFORCEMENT DEFINITION The amount of weld that is above a straight line drawn from the edges of the joint preparation of a groove weld.
PREVENTIVE ACTION 1.
Adjust amps/volts.
2.
Increase travel speed.
3.
Maintain appropriate wire stickout.
4.
Adjust torch/rod angle.
5.
Sequence beads so that the toes do not excessively overlap one another, creating high spots in the reinforcement.
CORRECTIVE ACTION Grind or carbon arc areas of weld reinforcement that exceed the maximum allowable height (if applicable).
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MELT THROUGH
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MELT THROUGH DEFINITION Excessive heat and/or penetration that results in irregularity on the surface of the backing ring or strip, fused root or adjacent base material.
PREVENTIVE ACTION 1.
Reduce amps/volts.
2.
Increase travel speed.
3.
Maintain appropriate arc length/wire stickout.
4.
Use ceramic tape or approved metal backing strap on areas with root gap.
CORRECTIVE ACTION 1.
Grind or carbon arc the weld to sound metal.
2.
Weld repair the affected area, if needed.
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offset
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offset DEFINITION A situation where base materials creating a butt or corner joint have moved out of alignment or position. Sometimes called “misalignment”. NOTE: Offset is one of the major causes of inservice failures!
PREVENTIVE ACTION 1.
Ensure installing trade provides proper fit-up prior to welding.
2.
Use approved temporary attachments (strongbacks, flatbar, etc.), as needed to reduce distortion.
3.
Gauge for offset acceptability prior to tack welding with bridgecam or finger gauges.
4.
Apply sufficient block tacks prior to welding.
NOTE: Stop welding and immediately notify your foreman anytime unacceptable offset occurs.
CORRECTIVE ACTION 1.
Installing trade may have to cut apart and re-fit the joint within tolerance.
2.
Offset may be repaired by applying weld build-up to the appropriate taper.
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OXIDATION
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OXIDATION DEFINITION A condition resulting from partial or complete lack of purge of a surface which is heated during welding resulting in formation of oxide on the surface. This condition may range from slight oxidation evidenced by a multicolored or tightly adhering black film to the extreme of a very rough surface having crystalline appaerance (referred to as “sugaring”).
PREVENTIVE ACTION 1.
Ensure adequate pipe purge is maintained prior to and throughout the welding process.
2.
Remove contaminants from the joint (rust, grease, moisture, etc.) prior to welding.
CORRECTIVE ACTION 1.
Grind the weld to sound metal.
2.
Weld repair the affected area, if needed.
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crater pit
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crater pit DEFINITION A hole extending into the weld resulting from shrinkage during cooling.
PREVENTIVE ACTION 1.
Remove contaminants from the joint (rust, grease, moisture, etc.) prior to welding.
2.
When breaking the arc for TIG welding, rapidly pop the trigger several times to avoid sudden pull-offs. This will provide sufficient
post purge of the weld puddle.
CORRECTIVE ACTION 1.
Grind the weld to sound metal.
2.
Weld repair the affected area, if needed.
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Preheat/Interpass
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Preheat/Interpass DEFINITION Preheat - The minimum temperature required prior to welding Inter pass - The Maximum temperature prior to welding The pre-heat and interpass are the “sweetspot” that the welder must stay within throughout the WHOLE welding process
PREVENTIVE ACTION Review the weld procedure specification (WPS) and/or the applicable code based on the parameters for the specific procedure.
CORRECTIVE ACTION Continuous monitoring of the temperature of the base metal via qualified/calibrated testing equipment. The heat affected zone (HAZ) shall be a minimum of three inches in all directions.
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TYPES OF WELD JOINTS
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TYPES OF WELD JOINTS
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TYPES OF WELD JOINTS
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PARTS OF A WELD
* This represents the theoretical throat (the minimum specified leg size multiplied by 0.7) which is the shorteste distance from the joint root to the hypotenuse (straight line drawn toe to toe) of the largest right triangel that can be drawn within the fillet weld cross section.
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STRUCTURAL JOINT NUMBERING SYSTEM
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STRUCTURAL JOINT NUMBERING SYSTEMs examples
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STRUCTURAL JOINT NUMBERING SYSTEMs examples
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STRUCTURAL JOINT NUMBERING SYSTEMs examples
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STANDARD WELDING SYMBOL LAYOUT
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STANDARD WELDING SYMBOLS
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STANDARD WELDING SYMBOLS
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STANDARD WELDING SYMBOLS
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STANDARD WELDING SYMBOLS
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STANDARD WELDING SYMBOLS
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STANDARD WELDING SYMBOLS
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USING FINGER GAUGE TO MEASURE:
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USE FINGER GAUGE TO MEASURE SKEWED FILLET AND FILLET REINFORCED WELDS
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FINGER GAUGE TO MEASURE SPATTER/SLAG
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USING BRIDGECAM GAUGE TO MEASURE:
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USING BRIDGECAM GAUGE TO MEASURE:
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Rig Fab Energy Services
Welder’s Visual Inspection Handbook
USING BRIDGECAM GAUGE TO MEASURE:
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Rig Fab Energy Services
Welder’s Visual Inspection Handbook
industry DEFINITIONS 1. Completed weld – A weld that is completed and is ready for final visual inspection. 2. Defect – Any harmful discontinuity that must be repaired to be acceptable. 3. Discontinuity – Any inperfection in the normal structure or configuration of a weld or the base material that may or may not need to be repaired. 4. Final visual inspection of welds – Visual inspection performed on a completed weld in the final surface condition and heat-treated condition. 5. Finished weld – A weld that has received final inspection and ahs been accepted. 6. In-process visual inspection of welds – Visual inspection performed on intermediate passes of multipass welds. 7. Sound metal – Metal that contains no defects. 8. Skewed fillet welds – Fillet or fillet reinforced weld that is less than 85° or greater than 95°.
industry abbreviations NDT = Nondestructive Testing VT = Visual Inspection MT = Magnetic Particle Inspection PT = Liquid Penetrant Inspection UT = Ultrasonic Inspection RT = Radiographic Inspection ET = Eddy Current Inspection
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Rig Fab Energy Services
Welder’s Visual Inspection Handbook
scale divisions reference
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