John-Lucas.pdf
- 1. Welding Procedure Specification’s (WPS) Presented By John Lucas Welding Engineer UTI Corporation
- 2. What Is Welding? AWS defines welding as: “ The art and science of joining metals by using the intrinsic adhesive and cohesive forces of attraction that exist within metals”. Welding, Brazing, Soldering Does not include mechanical fastening such as bolts, rivets, screws, etc.
- 3. When Did Welding Begin? Pressure Welding of Noble Metals Over 2,000 years ago Forge Welding Blacksmiths Over 1,000 years ago Modern Welding 1880’s
- 4. Interesting Fact Temperature Of The Sun? 9,941°F Temperature Of The Arc? 12,632°F
- 5. WELDING PROCEDURES • What Is a Welding Procedure? • Why Have Welding Procedures? • Who Should Have Welding Procedures? • What Information Should Procedures Contain? • How do we know If Our Procedures Are Good?
- 6. What Is A Welding Procedure? • A document that contains important variables on how to make the weld in question.
- 8. Why Have Welding Procedures? • Required By Code • Proves To Engineers & Regulators You Know What You Are Doing • Helps To Produce Quality Welds
- 9. Who Should Have Welding Procedures? • Manufacturing • Automotive • Heavy Equipment • Pipeline Industry • Construction
- 10. What Information Should I Include?
- 11. Important Information • Governing Code • API, AWS, ASME, ISO • Foreign Codes
- 12. Important Information • Material Parameters • Spec & Grade • Wall Thickness • Size (Diameter) • Yield/Tensile Strength • Metallurgical Concerns
- 13. Important Information • Welding Process • GMAW (MIG), GTAW (TIG), SMAW (STICK) • Automated Or Not?
- 14. Important Information • Process Parameters • Volts, Amps, Travel Speed • Travel Direction • Polarity • Wire Welding Transfer Mode • Globular, Spray, Short Circuit, Plasma • Flux Core or Shielding Gas • Number of Passes • Number of Welders • Electrodes Size Group Number = 1, 2, 3, etc. AWS Specification = A5.1, A5.5, etc.
- 15. Important Information • Pre/Post Weld Heat Treatment • Temps • Time • Cooling Rates • Heat Input • Time Interval Between Passes
- 16. Important Information • Joint Design • Material Thickness • Joint Type • Bevel Angles • Root Opening Dimension • Backer Rods • Etc.
- 17. Important Information • Filler Metals E 6010 E = Electrode 60 = Tensile Strength (60,000psi) 1 = All Position 0 = Type Of Coating & Polarity Cellulose, Low Hydrogen, Potassium, etc.
- 18. Important Information • Cleanliness • Joint Cleaning • Coating Removal • How to Remove Coatings • Joint Fit Up • Line Up Clamps • Internal or External
- 19. Procedure Qualification Record • Lab Report • Parameters/Materials • Info Made for Each Pass • Ambient Conditions
- 20. Procedure Qualification Record Testing Reports
- 21. Welder Qualification • Three Welder Testing Procedures API 1104 Field Welding ASME Section 9 Fab Shop Welding Part 192-Appendix C Low Stress 12 Inch And Less Pipe
- 22. Welder Qualification • Initial Test • Initial Test = Destructive • 6 Month Retest • Non Destructive • Compressor Station & Components » Part 192.229 » Destructive Only • If a Welder Performs a Procedure Qualification, Is The Welder Also Qualilfied?
- 23. Weld Quality
- 24. Weld Quality • Lack of Fusion
- 25. Weld Quality • Lack of Penetration
- 27. Weld Quality • Under Cut
- 28. Welding Safety
- 29. • Eye Safety • Wear a Hood • Skin Safety • Burns » Wear Sun Screen - SPF 45 • White Wall Effect
- 30. Conclusion • Comments Or Questions?