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Module 4

This document provides an overview of quality assurance and control topics related to welded fabrication including welding procedures, personnel qualifications, non-destructive testing, health and safety, economics, and case studies. Specific areas covered include welding sequence, residual stresses and distortion, plant facilities, measurement and recording, imperfections and acceptance criteria, repair welding, and reinforced steel welded joints.

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pratik charkhawala
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110 views4 pages

Module 4

This document provides an overview of quality assurance and control topics related to welded fabrication including welding procedures, personnel qualifications, non-destructive testing, health and safety, economics, and case studies. Specific areas covered include welding sequence, residual stresses and distortion, plant facilities, measurement and recording, imperfections and acceptance criteria, repair welding, and reinforced steel welded joints.

Uploaded by

pratik charkhawala
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Module 4: Fabrication, applications engineering

4.1 Introduction to quality assurance in welded fabrication

• Concept of quality assurance and quality control (including analysis, continuous Improvement)
• Weldability ISO/TR 581
• Testing and Inspection Plan (the goal, content and sources to develop it) Audit of plant.
• Personnel and Equipment
• Maintenance
• Inspection
• Activities of the welding engineer/technologist/specialist/practitioner in the different functions in
industry (ISO 14731) e.g. RWC
• Standards (ISO 9000, ISO 3834, national and international standards). Development of quality
plans - ISO 10005)
• Software (overview, availability, demonstration, use)

4.2 Quality control during manufacture


• Advantages to the quality of brazed and welded constructions
• Brazing and Welding sequence
• Welding coordination and inspection personnel; qualification tasks and responsibilities (ISO 14731,
ISO 9712, CEN and National standards)
• Brazer and Welder Approval /Qualification and Brazing and Welding Procedure Qualification -
Introduction/Overview
• Brazer and Welder Approval/Qualification (ISO 9606, CEN and National Standards)
• Brazing and Welding Procedure Specification – The goal, how to create and develop (ISO 15607
and 15609, CEN and National Standards)
• Brazing and Welding Procedure Qualification (ISO 15610, 156111, 15612, 15613 and 15614), CEN
and National standards)
• Brazing and Welding Operator Qualification (ISO 14732, CEN and National Standards)
• Traceability (materials identification, welder/operator, procedures, certificates)

4.3 Residual Stresses and Distortion


• Influencing factors
• Thermal data of the materials
• Origin of the residual stresses and deformation
• Relationship between the material at a certain temperature and its mechanical characteristics
• Magnitude of longitudinal and transverse shrinkage stresses
• Distribution of the residual stresses at weld (parallel to the weld axis, perpendicular, and through
thickness, influence of the material thickness)
• Relationship between heat input, shrinkage stresses and distortion
• Methods of residual stress measurement
• Welding sequence techniques
• Effects of residual stresses on the behaviour of the structure in service
• Methods of reducing residual stresses or distortion
• Examples to prevent and control of distortion
• Weld straightening, correction and removal of welding deformation (pressing, rolling, local heating,
etc.)
4.4 Plant facilities, welding jigs and fixtures
• Layout of production line
• Jigs, fixtures and positioners (types, applications, advantages, special precautions)
• Roller beads, manipulators
• Cables, electrical connections, and special precaution
• Operational environment
• Auxiliary equipment (for fit up, movement, backing gas devices, flow meters, etc)
• Joint fit up
• Tack welding (specific cares, distribution, length and their removal)
• Equipment for preheat, postheat, and other heat treatments, also temperature control including
furnace and local heat treatment

4.5 Health and Safety


• Introduction to health and safety requirements
• Survey of safety and environmental aspects, risk assessment
• Hazards of electric power
• Electro-magnetic fields
• Connecting of equipment
• Problems with shielding gases
• Radiation and eye protection
• Welding fume emission
• Exposure limits (Maximum Allowable Concentration) MAC and UEL (Upper Exposure Limit) values
• Ventilation filters (ISO 15012) and fume extraction (type of equipment and airflow)
• Ergonomics
• Determination of acceptable emissions
• Tests for measuring emissions
• Noise levels and ear protection
• Special risks for automated processes
• Standards and National regulations
• Protective clothing
• Health effects of grinding (vibration and dust)
• Hazards regarding the heat (spatter, flame, combustion, fire)
• Oxygen environment enrichment
4.6 Measurement, Control and Recording in Welding

• Methods of measurement (electrical parameters, gas flow rate, temperature, velocity)


• Instruments (types, measuring applications)
• Temperatures (ISO 13916), humidity, wind
• Cooling time e.g. t 8/5
• Welding parameters (voltage, current, speed, gas flow rate, etc.)
• Control in heat treatment (heating and cooling rate, ISO/TR 17663)
• Calibration and validation of equipment (ISO 17662)

4.7. Imperfections and Acceptance Criteria


• Types of weld imperfections according to ISO 6520 standards
• Acceptance criteria (e.g. ISO 5817, ISO 10042, ISO 13919, ISO 9013, ISO 17635)
• Significance of imperfections
• Introduction to ISO/TR 15235
• Engineering critical assessment techniques
4.7 Non-Destructive Testing

• Fundamentals of NDT methods (visual, dye penetrant, magnetic particle, eddy current, acoustic
emission, radiography, digital RT, ultrasonic, etc.)
• Field of application and limitations
• Design in respect of NDT
• Calibration
• Interpretation (IIW Radiographic reference)
• Recording of data
• Correct selection of the NDT methods versus application (e.g. CEN/TR 15135)
• Qualification and certification of NDT personnel (EN ISO 9712)
• NDT procedures
• Automation of NDT (computer aided evaluation, etc.)
• Use of standards and specifications
• Health and safety aspects
• Review of documents and protocols from NDT test sites

4.9 Economics and Productivity


• Analysis of welding costs
• Deposition rate
• Costs of labour
• Costs of welding consumables
• Costs of equipment
• Return on investment
• Costs of energy
• Welding processes operation factor
• Calculation of welding costs
• Cost awareness (of labour, consumables, equipment, gases, energy, etc.)
• The application of software, calculation programmes
• Measures for decreasing welding costs
• Mechanisation
• Automation
• Robotics

4.10 Repair Welding


• Welding repair procedure specification
• Welding repair plan
• Welding repair procedure qualification
• NDT of the weld repair
• Special precautions

4.11 Reinforcing-steel welded joints


• Reinforcing-steel types, properties
• Direct and indirect loading
• Types of joints used (lap, cruciform)
• Calculation
• Weldability with respect to weld joint strength
• Preheating in respect to bar diameter
• Application of welding processes
• Standards and specifications (ISO 17660 series and National Standards)
4.12 Case Studies
• Steel and lightweight structures, boilers and pressure vessels, chemical plants and pipelines,
shipbuilding and offshore applications, transportation (automobiles, railways), aerospace
applications.
• Common items to be covered:
o Standards and specifications, design,
o Choice of materials, welding processes,
o Site welding (transport and final assembly),
o Consumables, welding procedures,
o Tolerances on weld preparation and fit-up,
o Post weld heat treatment, NDT and quality control,
o Visual Inspection practice (interpretation and evaluation of fractures and welds including
interpretation of fracture tests of fillet welds)

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