Tubular & Non Tubular AWS D1.1

Presented By : Farid Moch. Zamil

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TUBULAR & NON TUBULAR Oleh : Farid Moch. Zamil PENDIDIKAN DAN PELATIHAN INSPEKTUR LAS (WELDING INSPECTOR) MARET - MEI 2015

Kerjasama POLITEKNIK PERKAPALAN NEGERI SURABAYA dengan BADAN NASIONAL SERTIFIKASI PROFESI (BNSP) dan LEMBAGA SERTIFIKASI PROFESI LAS (LSPL)

SECTION – 1 GENERAL REQUIREMENET Oleh : Farid Moch. Zamil

LATAR BELAKANG FAKTA LAPANGAN 1.

Pekerjaan Plate Form & Steel Structure yang semakin berkembang.

2.

Potensi bahayanya yang cukup tinggi.

3.

Konstruksi pada umumnya dilas.

4.

Keterbatasan tenaga pemeriksa yang memahami AWS D1.1 Std.

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WELDING INSPECTOR COURSE Farid Moch. Zamil

Welding Inspector PPNS

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PENGERTIAN  PIPE  Bentuk Tubular dengan penampang melingkar.

 TUBULAR  Bagian yang berongga dari berbagai bentuk konfigurasi

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Sect.1 – Ketentuan umum SCOPE AWS D1.1 Std. 1.

General Requirement. 

2.



3.

Requirements for exempting (Not Qualifications) WPS.

Qualification. 

5.

Requirements for design welded connections between

Prequalification of WPSs. 

4.

Basic on the scope & limitations of the Code.

Design of Welding Connections.

Requirements for qualification of WPS & personnel to perform work to Code requirements.

Fabrication. 

Requirements for the preparation, workmanship of welded steel structure.

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assembly


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Sect.1 – Ketentuan umum 6. Inspection.  Criteria for qualification and responsibility of welding inspectors, acceptance criteria of welds, procedure for visual inspection & NDE.

7.

Stud Welding. 

8.



•

Requirements for the welding of studs to structural steel.

Strengthening & Repair Existing Structure. Provisions for design/welding modification or repair of existing steel structures.

Annex 

Normative  Informasi & Requirement bahwa menjadi pertimbangan



Informative 

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Tidak dijadikan pertimbangan WELDING INSPECTOR COURSE Farid Moch. Zamil


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Sect.1 – Ketentuan umum TASK (TUGAS) INSPECTOR AWS D1.1 1. Review of drawings, specification & manufacturing instructions. 2. Review of the manufacturer’s approved QA/QC. 3. Verification of welding procedure & personnel qualification. 4. Verification of approved procedure for qualifying welding & inspection personnel. 5. Selection & examination of production test sample. 6. Evaluation of test results. 7. Preparation of test reports & maintenance of records. 8. Observance & monitoring of recommended safety guidelines. 3/29/2015


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Sect.1 – Ketentuan umum PLATFORM ACCORDANCE AWS D1.1 Std.

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Sect.1 – Ketentuan umum BOILER STRUCTURE ACCORDANCE AWS D1.1 Std.

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Sect.1 – Ketentuan umum LIMITATIONS AWS D1.1 Std. Pekerjaan WELDED STEEL STRUCTURE dengan material Carbon Steel atau Low Alloy Steel dibatasi tebal 1/8” (3 mm) atau lebih tebal yang mempunyai nilai Yield Strength 100 ksi (690 MPa).

Other AWS D1…… Std. a.

AWS D1.2

Aluminium.

b.

AWS D1.3

Sheet Steel equal or less than 3/16” (5 mm) Thick.

c.

AWS D1.4

Reinforcing Steel.

d.

AWS D1.5 Bridge Welding Code.

e.

AWS D1.6 3/29/2015

Stainless Steel. WELDING INSPECTOR COURSE Farid Moch. Zamil

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Sect.1 – Ketentuan umum Code application of D1.1 and D1.3 Based on material thickness being joined

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SECTION – 2 DESIG (PERENCANAAN) Oleh : Farid Moch. Zamil


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Sect.2 – Perencanaan (Design) BATASAN MATERIAL AWS D1.1 Std. 

The Material grouped into STRENGTH GROUP & TOUGHNESS CLASS :

•

STRENGTH 1.

Group I Mild Structural Carbon Steel specified Minimum Yield Strength 40 Ksi or less, CE 0.4% or less. Can be welded by Code

2.

Group II Intermediate strength low alloy steel specified minimum Yield Strength 40 Ksi – 52 Ksi, CE up to 0.45% and Higher. Required the use of low hydrogen welding process.

3.

Group III High Strength low alloy steel specified excess Yield Strength 52Ksi – 75 Ksi.

4.

Group IV dan V material Higher Strength over 75 Ksi – 100 Ksi.

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Sect.2 – Perencanaan (Design) •

TOUGHNESS CLASS 1.

Class C Diapplikasikan di welded structure yang mempunyai temperature service diatas 100C.

2.

Class B material yang mempunyai nilai CVN pada temperatur pengujian 100C – 00C

3.

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a.

Group I  Nilai CVN = 20 Joule.

b.

Group II  Nilai CVN = 34 Joule.

c.

Group III  Nilai CVN = 48 Joule.

Class A a.

Temperature 200C s/d – 300C  Subfreezing.

b.

Temperature -300C s/d – 400C  Brittle Fracture. WELDING INSPECTOR COURSE Farid Moch. Zamil

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Sect.2 – Perencanaan (Design)

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Sect.2 – Perencanaan (Design) BATASAN MATERIAL AWS D1.1 Std.

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Sect.2 – Perencanaan (Design) Lanjutan material structural steel tabel C-2.27.2

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Sect.2 – Perencanaan (Design) BATASAN WELDING MATERIAL AWS D1.1 Std. Ref Annex V

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Sect.2 – Perencanaan (Design) BATASAN WELDING MATERIAL AWS D1.1 Std. Ref Annex V

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Sect.2 – Perencanaan (Design) DESIGN WELDING JOINT AWS D1.1 Std.

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Sect.2 – Perencanaan (Design) 

Ukuran effektive pada Complete Joint Pentration (CJP) :

•

Ukuran pengelasan sesuai dengan tebal pada material yang paling tipis di sambungan tersebut.

•

Penambahan Effektive area pengelasan yang tidak sesuai design calcultaion Tidak diperbolehkan. Contoh : Weld Reinforcement.

•

Groove weld size T, Y dan K yang disambungkan pada bagian konstruksi Tubular tercantum pada Tabel 3-1 AWS D1.1

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Sect.2 – Perencanaan (Design) DESIGN WELDING JOINT AWS D1.1 Std.

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Ukuran effektive Pentration (PJP) :

pada

Partial

Joint

•

Ukuran pengelasan > dari “required weld size (E)”atau sekurang-kurangnya = ukuran yang tercantum di WPS.

•

Kombinasi PJP Groove dan Fillet weld harus lebih pendek dari bagian root ke permukaan Minus 3 mm (1/8 in)

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Fillet Weld :

•

Minimum Fillet Weld seperti tercantum pada tabel 5.8.

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Fillet Weld :

•

Maksimum Weld Size in Lap Joint : a) Tebal < 6 mm (1/4 in).

b) Tebal > 6 mm (1/4 in)

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Sect.2 – Perencanaan (Design) Fillet Weld :



•

Minimum Overlap antara tebal material yang berbeda HARUS 5 X TEBAL PELAT PALING TIPIS TETAPI TIDAK BOLEH KURANG DARI 25 mm (1 in)

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INTERMITTEN FILLET WELD :

• •

Minimum panjang segment Filled Weld 38 mm (1-1/2 in).

•

Maksimum spacing intermitten weld dua atau lebih rolled shape (profil material) NOT EXCEED 600 mm (24 in). Lihat gambar dibawah.

Maksimum intermitten weld antara plate dengan componen lainnya NOT EXCEED 24 THICK, THINNER PLATE or NOT EXCEED 300 mm (12 in).

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PLUG & SLOT WELDS :

•

Min. dia. Lubang atau lebar deposite tidak boleh kurang dari tebal material, untuk material up to 8 mm (5/8 in).

•

Maks. dia lubang atau lebar tidak lebih dari Min diameter + 3 mm atau 2-1/4 x tebal, pilih mana yang lebih besar.

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Sect.2 – Perencanaan (Design) TRANSITION WELDING JOINT AWS D1.1 Std.

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Sect.2 – Perencanaan (Design) TRANSITION WELDING JOINT AWS D1.1 Std.

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Sect.2 – Perencanaan (Design) PROHIBITED JOINT & WELDS AWS D1.1 Std. 

FLAT POSITION GROOVE WELDS :

• 

FILLET WELD KURANG DARI 5 mm (3/16 in).

• 

Bevel-groove dan J groove weld dilarang karena tidak dapat dipraktekkan. Jika ada sambungan Fillet welds kurang dari 5 mm (3/16 in).

T & CORNER CJP Weld With Backing

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SECTION – 3 PREQUALIFIED WPS (WPSs) Oleh : Farid Moch. Zamil

Sect.3 – Prequalified WPSs RUANG LINGKUP AWS D1.1 Std. 

WPSs : WPS yang tidak dipersyaratkan untuk dilakukan testing seperti yang tercantum pada Clause 4 AWS D1.1.

•

Persyaratan. 1.

Operator & Tack Welder Harus dikualifikasi sesuai ketentuan Clause 4.

2.

Semua prequalified WPS harus tertulis Sesuai sesuai ketetuan di Clause 3

3.

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Welding Proses •

Welding proses yang direkomendasikan SMAW, SAW, GMAW (kecuali type Short circuit) dan FCAW.

•

Welding proses ESW, GTAW dan GMAW type Short circuit boleh digunakan : WPS harus dikulaifikasi sesuai ketentuan Clause 4. WELDING INSPECTOR COURSE Farid Moch. Zamil

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Sect.3 – Prequalified WPSs

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Sect.3 – Prequalified WPSs BATASAN MATERIAL & FILLER METAL 

Batasan material & Filler metal yang digunakan untuk WPSs seperti yang terdaftar pada tabel 3-1 AWS D1.1 Std.



Jika Material/Filler yang tidak tercantum pada list Tabel 3-1, boleh digunakan dengan syarat chemical komposisi sesuai list material di Tabel 3-1, harus mendapat persetujuan dari Engineer.

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PREQUALIFIED WPS (WPSs) TABEL 3-1

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PREQUALIFIED WPS (WPSs) TABEL 3-2

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Sect.3 – Prequalified WPSs PREHEAT & INTERPASS TEMPERATUR AWS D1.1 Std. Preheat temperature • Adalah : Temperatur pada benda kerja didaerah dekat daerah pengelasan (weld zone) sebelum welding operation (termasuk tack welding)

• Biasanya dinyatakan sebagai minimum Interpass temperature • Luasan daerah preheat sama dengan tebal dari lasan (tetapi tidak boleh kurang dari 75 mm.

• Tujuan preheat adalah untuk mencegah terjadi Cracking seperti yang diisyaratkan AWS D1.1 Clause 3, part 3.5

• Ketentuan preheat untuk WPSs seperti yang tercantum pada tabel 3-2 AWS D1.1.

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Sect.3 – Prequalified WPSs PREHEAT & INTERPASS TEMPERATUR AWS D1.1 Std.

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Sect.3 – Prequalified WPSs BATASAN PREQUALIFIED WPSs AWS D1.1 Std. 

BATASAN WPSs :

•

Persyaratan. 1.

Dibuat dan disiapkan oleh Manufacturer, Fabricator dan Contractor.

2.

Parameter WPSs harus harus tercantum seperti yang disyaratkan pada Tabel 3-8 Essential Variable.

3.

Jika terjadi perubahan parameter yang masuk kategori Essential Variable seperti yang disyaratkan pada Tabel 3-8 maka WPSs harus direvisi atau dikualifikasi seperti yang disyaratkan pada Clause 4 AWS D1.1.

4.

Kombinasi Qualified WPS dan WPSs dapat digunakan tanpa dilakukan kualifikasi dengan batasan Essential Variable sesuai yang disyaratkan oleh masing-masing proses.

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•

Note.

•

Essential Variable berubah sifat mekanik akan berubah WELDING INSPECTOR COURSE Farid Moch. Zamil

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Sect.3 – Prequalified WPSs PERSYARATAN UMUM WPSs AWS D1.1 Std. 

Semua persyaratan tercatum pada tabel 3.7



Vertical Up Welding semua layer atau pass harus dilakukan pada posisi up hill (upward) kecuali :



1.

Undercut boleh dilakukan pengelasan down hill (downward) atau up hill (upward) jika disyaratkan Preheat sesuai tabel 3.2 tetapi tidak boleh kurang dari 200C (700F).

2.

Semua pengerjaan tubular dapat dilakukan pengelasan dengan down hill (downward) atau up hill (upward).

Witdh/Depth Pass gambar 3.1

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Sect.3 – Prequalified WPSs PERSYARATAN UMUM WPSs AWS D1.1 Std. Single-Pass Fillet Weld Maksimal



yang dibuat menngunakan filler metal pada group II dan base metal pada list Tabel 3.1 yaitu :

• 1.

SMAW

6 mm (1/4 in).

2.

SAW

8 mm (5/16 in).

3.

GMAW/FCAW

8 mm (5/16 in).

Shielding Gas

 • 

untuk GMAW dan FCAW-G harus sesuai dengan AWS A5.32/A5.32M.

Weathering Steel (material yang terkena korosi). •

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Material yang dalam kondisi tidak dicat atau tidak dilapisi bahan anti korosi weld metal mudah terserang korosi maka electrode atau electrode fluxnya harus menggunakan electrode seperti yang disyaratkan pada Tabel 3-3. WELDING INSPECTOR COURSE Farid Moch. Zamil

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Sect.3 – Prequalified WPSs PERSYARATAN UMUM WPSs AWS D1.1 Std. Limitation Nontubular Fillet Weld Requirement



Figure 2.1 & 2.4

•

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Sect.3 – Prequalified WPSs PERSYARATAN FILLET WELD AWS D1.1 Std. Limitation tubular Fillet Weld Requirement



Figure 2.15 Fillet weld details in lap joint

•

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Sect.3 – Prequalified WPSs PERSYARATAN FILLET WELD AWS D1.1 Std. Limitation tubular Fillet Weld Requirement

 •

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Figure 3.2 Fillet Welded tubular by SMAW, GMAW or FCAW



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Sect.3 – Prequalified WPSs PERSYARATAN FILLET WELD AWS D1.1 Std. Limitation Skewed T-Joint Requirement

 •

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Figure 3.11


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Sect.3 – Prequalified WPSs PERSYARATAN PJP GROOVE WELD AWS D1.1 Std. Disyaratkan pada gambar 3.3 :



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Sect.3 – Prequalified WPSs PERSYARATAN CJP GROOVE WELD AWS D1.1 Std. 

Disyaratkan pada gambar 3.4:

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Sect.3 – Prequalified WPSs PERSYARATAN PWHT AWS D1.1 Std. PERSYARATAN PWHT :



1. Nilai Yield Strength Base Metal tidak lebih dari 50 Ksi. 2. Tidak syaratkan pengujian impact pada base metal, HAZ dan weld metal. 3. Base metal pada saat pembuatannya tidak mengalami proses Treatment (Quenching dan Tempering). 4. Kondisi saat didemonstrasikan PWHT weld metal tidak mengalami pengurangan nilai Strength dan ductility. 5. Pelaksanaan PWHT diatur pada Section 5 (Fabrication) AWS D1.1. 3/29/2015


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SECTION – 4 QUALIFIED WPS Oleh : Farid Moch. Zamil

Sect.4 – Qualified WPS Quick Review on Essential Variables 1.

Guide (Position) : •

CJP Groove Weld (Plate or Tubular) or Fillet Weld (Plate or Tubular) QUALIFICATION TEST POSITION TEST

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POSITION QUALIFIED*

1G, 1G (Rotated)

F

2G

F, H

3G

V

4G

OH

5G

F, V, OH

(2G+5G), 6G, 6GR

ALL

1F, 1F (Rotated)

F



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Sect.4 – Qualified WPS 1.

Guide (Position) – Continued : POSITION TEST

POSITION QUALIFIED*

2F, 2F (Rotated)

F, H

3F

V

4F (Plate)

OH

4F (Tubular)

F, H, OH

5F

ALL

* Note : * CJP Groove qualify CJP, PJP & Fillet Welds. * Fillet qualify Fillet only. * Groove weld on plate qualifies pipes ≥ 24 in (600) nominal outer dia. * Vertical uphill to downhill essential variable and vise versa * Plug/Slot Welding qualifies for only the tested position 3/29/2015


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(a) Guide (Thickness of Base Metal) : •

Test on Plate, CJP Groove Welds :

•

T = Thickness of Test Coupon Welded THICK. TEST COUPON

THICKNESS QUALIFIED

1/8 in. (3 mm) < 1 in. (25 mm)

Min. 1/8 in. (3 mm) ~ Max. 2T

1 in. (25 mm) and over

Min. 1/8 in. (3 mm) ~ Unlimited

T test on ESW & EGW

0.5 T min ~ 1.1 T Max.

Note Any PJP qualification shall also qualify any fillet weld size on any thickness. 3.

FILLET WELD WPS QUALIFICATION (qualify all plate/thickness) •

Test shall be based on Max. Single pass and min. multiple pass fillet weld size to be used in construction – Table 4.4

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Sect.4 – Qualified WPS d)

Guide (Diameter of Base Metal) : •

Test on Pipe (Tube), CJP Groove Welds :

 JOB SIZE TEST PIPE  DIA. OVER or LESS THAN 24 in. (600mm OD) THICKNESS TEST COUPON

THICKNESS QUALIFIED

1/8 in. (3 mm)  3/8 in. (10 mm), incl

Min. 1/8 in. (3 mm) ~ Max. 2T

Over 3/8 in. (10 mm)  ¾ in. (20 mm)

Min. 0.5T ~ Max. 2T

Over ¾ in. (20 mm)


 JOB SIZE STANDARD TEST PIPE • 2 in. Sch.80 (50 mm OD x 6 mm WT or 3 in. sch.40 (75 mm OD x 6 mm WT). THICKNESS TEST COUPON

THICKNESS QUALIFIED

Above write red

Min. 1/8 in. (3 mm) ~ Max. ¾ in. (20 mm)

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Guide (Diameter of Base Metal) cont’d

 JOB SIZE STANDARD TEST PIPE • 2 in. Sch.80 (50 mm OD x 6 mm WT or 3 in. sch.40 (75 mm OD x 6 mm WT). DIA. (PIPE or TUBE) TEST COUPON

DIA. (PIPE or TUBE) QUALIFIED

Above write red

Min. ¾ in. (20mm) ~ 4 in. (100 mm)

 JOB SIZE STANDARD TEST PIPE • 6 in. Sch.120 (150 mm OD x 14 mm WT or 8 in. sch.80 (200 mm OD x 12 mm WT). THICKNESS TEST COUPON

THICKNESS QUALIFIED

Above write red


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Guide (Diameter of Base Metal) cont’d

 JOB SIZE STANDARD TEST PIPE • 6 in. Sch.120 (150 mm OD x 14 mm WT or 8 in. sch.80 (200 mm OD x 12 mm WT). DIA. (PIPE or TUBE) TEST COUPON

DIA. (PIPE or TUBE) QUALIFIED

Above write red

Min. 4 in. (200mm) and Over

Note CJP groove weld qualification on any thickness or diameter shall qualify any size of fillet or PJP groove weld for any thickness or diameter (see Clause 4.11.3 for macro etch test requirement.

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Guide (Base Material) – See Table 3.1, 4.8 & 4.9 QUALIFY TEST COUPON

TEST QUALIFIED

Any Group I to Group I

Any Group I to Group I

Any Group II to Group II

Any Group I to Group I Any Group II to Group I Any Group II to Group II

Any Group III to Group I

Specific Group III Tested to Any Group I

Any Group III to Group II

Specific Group III Tested to Any Group I or II

Any specific Table 4.9 To Group I

Specific Table 4.9 Tested To Any Group I

Any specific Table 4.9 To Group II

Specific Table 4.9 Tested To Any Group I or II

Any Group III To Group III Any Group IV To Group IV Any Table 4.9 to Table 4.9

Steel shall be of the same material specification grade/type and minimum yield strength as steel listed in the PQR

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Guide (Base Material) – See Table 3.1, 4.8 & 4.9 – Cont’d QUALIFY TEST COUPON

TEST QUALIFIED

Any combination of Group III, IV and Table 4.9

Only the specific combination of steel listed in the PQR

Any Unlisted Steel To Any Unlisted or Any Listed in Table 3.1 or Table 4.9

Only the specific combination of steel listed PQR.

Note Group I through IV are found in Table 3.1 5.

Guide (Preheat) The need for & temperature of preheat dependent upon number of factors such as Chemical analysis, degree of restraint of the parts being joined, elevated temperature, mechanical properties and material thickness.

•

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Guide (Preheat) – Cont’d •

When welding two different material groups, the minimum preheat temperature required shall be the higher temperature for the material to be welded. For prequalified procedures, preheat applicable to the higher strength group, as per note 1 of table 3.1-AWS D1.1. Also, thickness referred to for the minimum preheat is the greater of the nominal thickness at the weld of parts to be joined.

•

AWS D1.1, Table 4.5 : Decrease from preheat and interpass temperature 25 F (15 C) and 100 F (55 C) for GTAW is essential variable.

•

AWS D1.1, Table 4.5 : PQR Essential Variable (except ESW and EGW process), for Non-CVN Testing applications.

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Guide (Joint) AWS D1.1. TABLE 4.5 : ESSENTIAL VARIABLE FOR JOINTS

• •

A change in groove type (e.g, Single-V → double V) except qualification of any CJP groove weld qualifies for any groove detail conforming to the requirements of 3.12 (PJP-Figure 3.3) or 3.13 (CJP- Figure 3.4)

•

A decrease in the groove angle and root opening, an increase in the root face exceeding the tolerance (increase in the groove angle above 10 degree) for any groove detail conforming to the requirement of 3.12 (PJP-Figure 3.3) or 3.13 (CJP-Figures 3.4), 3.13 and 5.22.4.1 or 5.22.4.2 (Tubular and Non Tubular).

•

The omission, but not inclusion of backing or backgouging.

•

A change in the type of groove to square groove and vice versa.

•

AWS D1.1, Table 4.5 PQR Essential Variables (except ESW and EGW process), for Non-CVN testing application.

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Guide (Heat Input) •

See AWS D.1.1, Table 4.5 : PQR essential variables (except ESW and EGW process), for Non-CVN testing application.

•

See AWS D1.1, Table 4.5 : PQR Supplementary essential variables (except ESW and EGW process), for Non-CVN testing applications.

•

AWS D1.1, Table 4.5 : PQR Essential Variable (except ESW and EGW process), for Non-CVN Testing applications.

•

AWS D1.1, 5.7 HEAT INPUT CONTROL for QUENCHED and TEMPERED STEELS : When quenched and tempered steels are welded, the heat input shall be restricted in conjunction with the maximum preheat and interpass temperatures required. Such consideration shall include the additional heat input produced in simultaneous welding on the two sides of a common member. The preceding limitations shall be in conformance with the procedure’s recommendations.

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Sect.4 – Qualified WPS

8.

Guide (Welding Process) •

Essential Variables for SMAW, SAW, GMAW, FCAW & GTAW.

•

AWS D1.1, Table 4.5 PQR Essential Variables, for Non CVN Testing Applications.

•

AWS D1.1, Table 4.5 PQR Supplementary Essential Variables, for CVN Testing Applications.

•

AWS D1.1, Table 4.7 PQR Essential Variable changes requiring WPS requalification.

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Sect.4 – Qualified Welder Quick Review on Performance Qualification 1.

Guide (Position) : •

AWS D1.1, Table 4.10, Groove Test (Plate, Pipe or Box Tube) POSITION QUALIFIED*

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POSITION TEST

GROOVE

FILLET

1G, 1G (Rotated)

F

F, H

2G

F, H

F, H

3G

F, H, V

F, H, V

4G

F, OH

F, H, OH

5G

F, V, OH

F, V, OH

6G, 6GR

ALL

ALL



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Sect.4 – Qualified Welder Quick Review on Performance Qualification 1.

Guide (Position) – Cont’d •

AWS D1.1, Table 4.10, Fillet Test (Plate, Pipe or Box Tube) POSITION TEST

POSITION QUALIFIED*

1F, 1F (Rotated)

F

2F, 2F (Rotated)

F, H

3F

F, H, V

4F

F, H, OH

5F

F, V, OH

* Note : * Vertical uphill to downhill or vice versa is Essential Variable. * Groove test on pipe or box tube also qualifies plate for the same positions. * Groove test using box tubing also qualifies pipes ≥ 24 in (600) nominal outer dia. 3/29/2015


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Sect.4 – Qualified Welder 1.

Guide (Position) – Cont’d

* Note : * Groove test on plate qualifies pipes ≥ 24 in (600 mm) in diameter with backing, backgouging or both. * Groove test on plate qualifies plug or slot welds for the test position indicated. * Plug test qualifies plug and slot welding for only the position test. * ESW or EGW process test qualifies welding for only the position tested.

2.

Guide (Thick Base Metal) – AWS D1.1, Table 4.11, (Pipe or Box Tube) WELD TYPE Pipe or Box Tube

T – TESTED (in)

T – QUALIFIED (in)

Pipe or Box Tube

Plate, Pipe or Box Tube

Groove (CJP)

T : Unlimited ( 4 Max)

1/8 Min. – ¾ Max.

Groove (CJP)

T : 3/8 or less (Over  4)

1/8 Min. – ¾ Max.

Groove (CJP)

T : Over 3/8 (Over  4)

3/16 Min. – Unlimited.

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SECTION – 5 FABRICATION Oleh : Farid Moch. Zamil


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Sect.5 – Fabrication Preparation (Persiapan). •

SHOP DRAWING SHALL SHOW 1.

Size and location of all structural members & connection material.

2.

Complete information necessary for the fabrication of member including : cuts, holes, stiffeners and weld.

3.

Type, size & location of bolts and welds.

4.

Surface preparation and finishes.

5.

Details of assembly.

6.

Identification of WPS.

7.

Furnish setting drawing, tempaltes and directions for installation of anchor bolts and other anchorages to be installed as work of other sections.

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Sect.5 – Fabrication Preparation (Persiapan). • ERECTION DRAWING SHALL SHOW 1. Location of all structural material. 2. Identification mark of members. 3. Setting elevations for column basses. 4. Orinetation and relation members to appropriates grid lines (Sesuai lines). 5. Details of assembly. 6. Identification of WPS.

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Sect.5 – Fabrication BASE METAL AWS D1.1 Std. •

BASE MATERIAL 1.

Seperti yang tercantum pada Tabel 3-1 & 4-9. Selain Material ASTM direkomendasikan material API & ABS (American Bureau of Shipping).

2.

Toleransi Dimension. Terdapat pada ASTM Std  A. 6 & A. 20

•

Weld Tab, Backing dan Spacer. a.

Direkomendasikan berasal dari base materialnya

b.

Backing material selain yang disyaratkan pada point (a) diatas dapat diganti material A109 T3 & T4 kecuali yang mempunyai nilai minimum Yield Strength 100 Ksi harus menggunakan material yang mempunyai minimum nilai Yield Strength 100 ksi.

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Sect.5 – Fabrication

Materials arriving at the site/work shop need to be inspected for the following:

1) Size 2) Condition 3) Specification*

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Sect.5 – Fabrication Rolling Imperfections Direction of rolling Cold Laps*

Laminations Segregation

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Lamination

Lapping

Lamination

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Sect.5 – Fabrication WELDING CONSUMABLE AWS D1.1 Std. Welding Consumables: •filler material must be stored in an area with controlled temperature and humidity •poor handling and incorrect stacking may damage coatings, rendering the electrodes unusable •there should be an issue and return policy for welding consumables (system procedure) •control systems for electrode treatment must be checked and calibrated; those operations must be recorded •filler material suppliers must be approved before purchasing any material 3/29/2015


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Sect.5 – Fabrication General Requirement Welding Consumables & Electrode: •Certification electrode or electrode flux combination jika diminta oleh Engineer maka contractor/fabricator harus menyiapkannya. •Parameter las harus dalam range yang direkomendasikan oleh electrode manufacturer. •Gas or gas mixture yang dipakai untuk shielding gas harus conform AWS 5.32 Specification for Welding Shielding Gasses. Prosentase gas atau mix gas yang digunakan harus sesuai yang disyaratkan WPS. •Welding Consumable yang sudah dibuka dari sealed boxnya harus diproteksi dan disimpan akan berpengaruh pada welding properties. •Electrode harus kering dan dalam kondisi baik jika digunakan. 3/29/2015


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Sect.5 – Fabrication Covers welding materials. A-5.1, as well as all other specifications, states the marking requirements. It requires marking as follows: • Packages • The AWS specification and class • The supplier's name and designation • Standard size and net weight Lot, control or heat number • Electrodes • The electrode shall be marked with the AWS classification stamped no more than 2-1/2" from the grip end.

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Sect.5 – Fabrication BAKING PROCEDURE for BASIC ELECTRODES Unopened packet

Re-dry to ensure Low hydrogen condition

AWS A5.1 Low Hydrogen

Time period Tabel 5.1 Column A Bake 260-430oC 2 Hrs

Quiver 70oC min 4 hrs max

Hold 150oC

Time period Tabel 5.1 Column B AWS A5.5 Low Hydrogen

Bake 370-430oC 1 Hrs

Hold 150oC

Quiver 70oC min Over 4-10 hrs

Note : 1. Baking yang melebihi satu kali & electrode basah tidak boleh digunakan. 2. Electrode untuk ASTM A514 atau A517 dengan electrode classification E100XX-X kecuali E70XXH4R di baking sekurang-kurangnya 1 Jam pada temperatur 370-4300C 3/29/2015


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Sect.5 – Fabrication General Requirement Welding Consumables & Electrode: •SAW Electrode dan Fluxes : AWS A5.17 dimana kondisi Fluxe harus kering dan bebas dari kontaminasi. Fluxes yang tersimpan di storage sekurang-kurangnya 6 bulan. Fluxes yang rusak harus di baking pada temperatur 2600C selama 1 Hour atau dibuang. Fluxes yang basah tidak boleh dipakai. •GMAW/FCAW Electrodes yang menghasilkan Weld Metal dengan nilai YS < 60 Ksi harus sesuai dengan AWS A5.18 dan YS > 60 Ksi ke AWS A5.28. •GTAW Tungsten harus conform dengan AWS A.512 dan Filler Metal ke AWS A5.18, A5.28 dan A5.30.

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Sect.5 – Fabrication PREHEAT & INTERPASS TEMP AWS D1.1 Std. • Adalah : Temperatur pada benda kerja didaerah dekat daerah

pengelasan (weld zone) sebelum welding operation (termasuk tack welding)

• Biasanya dinyatakan sebagai minimum Interpass temperature • Luasan daerah preheat sama dengan tebal dari lasan (tetapi tidak boleh kurang dari 75 mm.

• Preheat & Interpass temp mengacu pada tabel 3.5 dan tabel 4.5

Minimum interpass temperature = Preheat temperature Pre heat maintenance temperature = Minimum temperature pada weld zone yang harus dimaintain (dipelihara) jika welding akan mengalami gangguan dan harus dimonitor selama pengelasan. 3/29/2015


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Sect.5 – Fabrication PREHEAT & INTERPASS TEMP AWS D1.1 Std. Quenched & Tempered Steel Heat Input harus ditentukan, terutama untuk pengelasan dua sisi. Gouging tidak boleh digunakan.

Electrical Heated Elements 3/29/2015

Manual Gas Operation


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Sect.5 – Fabrication STRESS RELIEF HEAT TREATMENT AWS D1.1 Std. The inspector, in general, should ensure that:

• Equipment is as specified • Temperature control equipment is in good condition • Procedures as specified, is being used e.g. o Method of application o Rate of heating and cooling o Maximum temperature o Soak time o Temperature measurement (and calibration)

• DOCUMENTATION AND RECORDS 3/29/2015



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Sect.5 – Fabrication PWHT Procedures - Basic Requirement

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Sect.5 – Fabrication PWHT Procedures - Basic Requirements 1.

Furnace Temperatur Kondisi temperatur furnace tidak boleh lebih dari 3150C.

2.

Maximum Heating Rate Diatas Temperatur 3150C Max. heating rate tidak boleh dari 2040C/jam dibagi Max. thick pada material yang paling tebal dalam satuan inchi. Selama periode Heating variasi temperatur pada benda kerja tidak boleh melebihi 1400C sepanjang 5 meter. Heating rate dan cooling tidak boleh kurang dari 550C/jam.

3.

Minimum Soak/Holding Time Setelah max. temperatur 6000C dilakukan “ HOLD “ dengan waktu penahanan (Holding Time) seperti pada tabel 5.2.

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Sect.5 – Fabrication PWHT Procedures - Basic Requirements 4. Maximum Cooling Rate Diatas temperatur 3150C Max. cooling rate tidak boleh melebihi 2600C/jam dibagi Max. thick pada material yang tebal dalam satuan inchi. 5. Alternatif PWHT Diatur dalam tabel 5.3. 6. Material Not Recommended PWHT Material Tempered & Quenched (A.514, A.517, A.709 Grades 100 dan 100 w, A.710) sambungan wedingnya tidak direkomendasikan PWHT. 3/29/2015


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Sect.5 – Fabrication Local Post Weld Heat Treatment

Furnace Post Weld Heat Treatment

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Sect.5 – Fabrication Backing Thickness Requirements

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Sect.5 – Fabrication BACKING & MISALLIGMENT AWS D1.1 Std. Fillet & PJP Groove Weld : •Root opening tidak boleh lebih dari 5mm kecuali untuk material yang mempunyai ketebalan diatas 75mm. •Jika root opening yang melebihi batas toleransi misal 8mm boleh digunakan dengan syarat harus menggunakan backing. Butt Joint misaligment : •Misaligment tidak boleh melebihi 10% dari tebal yang paling tipis pada sambungan atau 3 mm diambil mana yang lebih kecil.

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Sect.5 – Fabrication TOLERANSI DIMENSI SAMBUNGAN

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Sect.5 – Fabrication THERMAL CUTTING & ACCESS HOLE AWS D1.1 Std. Roughness Requirement base on ANSI/ASME B46.1 : Thickness

Roughness

Inchi

mm

in.

Up to 4

Up to 100

1000

mm. 25

4–8

100 - 200

2000

50

Roughness Requirement base on AWS C4.1-77 : Thickness

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Roughness

Inchi

mm

Sample

Up to 4 (include)

Up to 100 (include)

No.3

Over 4 – 8

Over 100 - 200

No.4


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Oxyfuel gas cutting quality • Good cut - sharp top edge, fine and even drag lines, little oxide and a sharp bottom edge

• Cut too slow - top edge is melted, deep groves in the lower portion, heavy scaling, rough bottom edge 3/29/2015

•

Cut too fast pronounced break in the drag line, irregular cut edge


110

Sect.5 – Fabrication Gouging or Notch Limitations •Hole gouges tidak lebih dari 3/16 in (5 mm) kedalamannya, roughness permukaan dapat di machining atau di grinding. •Hole gouges melebihi 3/16 in (5 mm) kedalamannya roughness permukaan boleh direpair grinding .

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Sect.5 – Fabrication STRAIGHTNESS of COLUMNS & TRUSSES AWS D1.1 Std.

Gou

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Sect.5 – Fabrication Dimensional Tolerances of Welded Structural Members

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Sect.5 – Fabrication Backing Thickness Requirements

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Sect.5 – Fabrication TOLERANSI DIMENSI SAMBUNGAN Fillet & PJP Groove Weld : •Root opening tidak boleh lebih dari 5mm kecuali untuk material yang mempunyai ketebalan diatas 75mm. •Jika root opening yang melebihi batas toleransi misal 8mm boleh digunakan dengan syarat harus menggunakan backing. Butt Joint misaligment : •Misaligment tidak boleh melebihi 10% dari tebal yang paling tipis pada sambungan atau 3 mm diambil mana yang lebih kecil.

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Sect.5 – Fabrication TRANSITION of BUTT JOINT PARTS of UNEQUAL THICKNESS (NON TUBULAR)

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Sect.5 – Fabrication TRANSITION of BUTT JOINT PARTS of UNEQUAL THICKNESS (TUBULAR)

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FABRICATION TOLERANSI DIMENSI SAMBUNGAN TRANSITION of BUTT JOINT PARTS of UNEQUAL THICKNESS (TUBULAR)

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Sect.5 – Fabrication GROOVE DIMENSION – NON TUBULAR

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Sect.5 – Fabrication GROOVE DIMENSION – NON TUBULAR

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FABRICATION TOLERANSI DIMENSI SAMBUNGAN GROOVE DIMENSION – TUBULAR

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SECTION – 6 INSPECTION Oleh : Farid Moch. Zamil


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Sect.6 – Inspection PENDAHULUAN Tingkat pemeriksaan dan persyaratannya harus didefinisikan dalam applikasi standard atau kesepakatan dengan pihak Client dengan Manufacturer Welding inspection selama proses fabrikasi meliputi :

Before welding (Before assemble & After assembly) During welding After welding 3/29/2015


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Sect.6 – Inspection Measuring devices: • flexible tape, steel rule • Temperature indicating crayons • Welding gauges • Voltmeter • Ammeter • Magnifying glass • Torch / flash light • Gas flow-meter 3/29/2015


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Sect.6 – Inspection 10mm

10mm

G.A.L.

G.A.L.

1 2

L

S.T.D. 16mm

3 4

S.T.D. 16mm

5 6

0

HI-LO Single Purpose Welding Gauge

Fillet Weld Gauges IN 1/4 1/2 3/4

Multi-purpose Welding Gauge 3/29/2015

Misalignment Gauges Hi-Lo Gauge



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Sect.6 – Inspection

Voltmeter

Ammeter

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Sect.6 – Inspection BEFORE WELDING Preparation: Familiarisation with relevant ‘documents’… • Application Standard/Code requirements

-

for

visual

acceptance

• Drawings - item details and positions/tolerances etc • Quality Control Procedures - for activities such as material handling, documentation control, storage & issue of welding consumables • Quality Plan/Inspection & Test Plan/Inspection Checklist details of inspection requirements, inspection procedures & records required 3/29/2015


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Sect.6 – Inspection Welding Procedures: • are applicable to joints to be welded & approved • are available to welders & inspectors Welder Qualifications: • list of available qualified welders related to WPS’s • certificates are valid and ‘in-date’ Equipment: • all inspection equipment is in good condition & calibrated as necessary • all safety requirements are understood & necessary equipment available 3/29/2015



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Sect.6 – Inspection Materials: • can be identified & related to test certificates, traceability ! • are of correct dimensions • are in suitable condition (no damage/contamination) Consumables: • in accordance with WPS’s • are being controlled in accordance with Procedure Weld Preparations: • comply with WPS/drawing • free from defects & contamination Welding Equipment: • in good order & calibrated as required by Procedure 3/29/2015


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Sect.6 – Inspection Weather conditions • suitable if site / field welding Welding Process(es) • in accordance with WPS Welder • is approved to weld the joint Pre-heat (if required) • minimum temperature as specified by WPS • maximum interpass temperature as WPS 3/29/2015


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Sect.6 – Inspection DURING WELDING Welding consumables • in accordance with WPS • in suitable condition • controlled issue and handling Welding Parameters • current, voltage & travel speed – as WPS Root runs • if possible, visually inspect root before single-sided welds are filled up

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Sect.6 – Inspection Inter-run cleaning • in accordance with an approved method (back gouging) to good workmanship standard Distortion control • welding is balanced & over-welding is avoided

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Sect.6 – Inspection AFTER WELDING Weld Identification • identified/numbered as required • is marked with welder’s identity Visual Inspection • ensure weld is suitable for all NDT • visually inspect & ‘sentence’ to Code requirements Dimensional Survey • ensure dimensions comply with Code/drawing Other NDT • ensure all NDT is completed & reports available 3/29/2015


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Sect.6 – Inspection VISUAL - WELDING •

Semua lasan (Weld) harus bebas dari Crack, Overlap dan Unacceptable discountunuities seperti yang tersaji pada gambar 5.4, Tabel 5.9 dan Tabel 5.10 . Adapun Acceptance criteria Visual tercantum pada tabel 6.1

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Sect.6 – Inspection VISUAL – WELD PROFILE

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Sect.6 – Inspection NON DESTRUCTIVE TEST (NDT) A welding inspector should have a working knowledge of NDT methods and their applications, advantages and disadvantages. Four basic NDT methods • Radiographic inspection (RT) • Ultrasonic inspection (UT) • Magnetic particle inspection (MT) • Dye penetrant inspection (PT) 3/29/2015


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Sect.6 – Inspection Surface Crack Detection •

Liquid Penetrant (PT or Dye-Penetrant)

•

Magnetic Particle Inspection (MT or MPI)

Volumetric & Planar Inspection •

Ultrasonics (UT)

•

Radiography (RT)

Each technique has advantages & disadvantages with respect to: •

Technical Capability and Cost

Note: The choice of NDT techniques is based on consideration of these advantages and disadvantages 3/29/2015



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Sect.6 – Inspection 

Acceptance criterias Radiographic Testing refer to section 6.12

X – Rays Electrically generated

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Gamma Rays Generated by the decay of unstable atoms


160

Sect.6 – Inspection Source Image quality indicator

Radiation beam

Radiographic film with latent image after exposure 3/29/2015

Test specimen


161

Sect.6 – Inspection 

Acceptance criterias Radiographic Testing refer to section 6.31

Pulse echo signals A scan Display

Digital UT Set,

Compression probe 3/29/2015

checking the material Thickness WELDING INSPECTOR COURSE Farid Moch. Zamil


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Sect.6 – Inspection NDT – ULTRASONIC TESTING Back wall echo

defect echo

initial pulse

Material Thk defect

0

Compression Probe 3/29/2015

10

20

30

40

50

CRT Display


163


Collection of ink particles due to leakage field

Electro-magnet (yoke) DC or AC

Prods DC or AC 3/29/2015


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Sect.6 – Inspection  Acceptance criterias Radiographic Testing refer to section 6.10

A crack like indication

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INSPECTION NDT – PENETRANT TESTING

 Acceptance criterias Radiographic Testing refer to section 6.10

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Sect.6 – Inspection Fluorescent Penetrant

Bleed out viewed under a UV-A light source

Bleed out viewed under white light Colour contrast Penetrant 3/29/2015


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Tubular & Non Tubular AWS D1.1

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