1. What is WPS?

Answer: WPS stands for Welding Procedure Specification. A WPS is a written document that
provides direction to the welder or welding operator for making production welds in accordance with
code requirement.
(Refer: ASME Sec IX; QW:100.1)

2. What is PQR?

Answer: PQR stands for procedure qualification record. The PQR documents what occurred during
welding the test coupon and the results of testing of the coupon.

3. Why a WPS needs qualification?

Answer: The purpose for qualification of a WPS is to determine that the weldment proposed for
construction is capable of providing the required properties for its intended application.

Welding Procedure Qualification establishes the properties of the weldment not the skill of the
welder or welding operator.

4. Why a performance qualification is done for welder?

Answer: In performance qualification, the basic criteria established for welder qualification is to
determine the welders ability to deposit sound weld metal. The purpose of the performance
qualification test for the welding operator is to determine the welding operators mechanical ability to
operate the welding equipment.

5. Is there any expiry date for WPS/PQR/WPQ/WOPQ?

Answer: NO.

WPS, PQR, WPQ/WOPQ made in accordance with the requirements of the 1962 edition or any later
edition of section IX may be used in any construction built to the ASME Boiler and Pressure Vessel
Code or the ASME B 31 Code for pressure piping.

1. Is WPS, PQR or WPQ/WOPQ need to be amended for using it according to a later edition of ASME
BPV Section IX?
Answer: No. Except as specified in QW:420 (Last Paragraph)

2. What are the different types of mechanical tests used in procedure or performance qualification as
per ASME Section IX?

Answer: 1. Tension test. 2. Guided bend test. 3. Fillet weld test 4. Notch toughness test

3. Why the different mechanical tests are conducted for procedure or performance qualification as per
ASME Section IX?

Answer:
1. Tension test: Used to determine the ultimate strength of groove-weld joints

2. Guided bend test: Used to determine the degree of soundness and ductility of groove-weld joints.

3. Fillet weld test: Used to determine the size, contour and degree of soundness of fillet welds.

4. Notch toughness test: Used to determine the notch toughness of the weldment

4. What are the tests done for stud welding procedure and performance qualification?

Answer: Deflection bend, hammering, torque or tension tests and macro examination.

5. What is the first test that to be done on a procedure or performance qualification test coupon ?

Answer: Visual Testing.

1. Can NDT be used to replace mechanical testing for the performance qualification of welders?

Answer: Yes

AS per QW-142, Radiographic or ultrasonic examination may be substituted for mechanical testing for groove-
weld performance qualification as permitted in QW-304 to prove the ability of welders to make sound welds.
As per QW-304. Welders may be qualified by volumetric NDE when making a groove weld using SMAW,
SAW, GTAW, PAW and GMAW (except short circuiting mode for radiographic examination) or a
combination of these process, except for P.No.21 through P No.26, P.No.51 through P No.53, and P.No.61
through P No.62 metals.

Welders making groove welds in P.No.21 through P No.26 and P.No.51 through P No.53 metals with
the GTAW process may also be qualified by volumetric NDE

2. Can NDT be used to replace mechanical testing for the perfomance qualification of welding operator?

Answer: Yes

AS per QW-142, Radiographic or ultrasonic examination may be substituted for mechanical testing for groove-
weld performance qualification as permitted in QW-305 to prove the ability of welding operators to make
sound welds.

As per QW-305. Welding operators may be qualified by volumetric NDE when making a groove weld using
SMAW, SAW, GTAW, PAW, EGW and GMAW (except short circuiting mode for radiographic examination)
or a combination of these process, except for P.No.21 through P No.26, P.No.51 through P No.53,
and P.No.61 through P No.62 metals.

Welding operators making groove welds in P.No.21 through P No.26 and P.No.51 through P No.53
metals with the GTAW process may also be qualified by volumetric NDE

3. Is a written radiographic examination procedure is needed for welders/welding operator

qualification using radiographic examination?

Answer: No

As per QW-191.1.1 (a), A written radiographic examination procedure is not required. Demonstration of
density and image quality requirements on production or technique radiographs shall be considered satisfactory
evidence of compliance with article 2 of sectionV.
4. Is a written ultrasonic examination procedure is needed for welders/welding operator
qualification using ultrasonic examination?

Answer: Yes

As per QW-191.2.1 (b), Ultrasonic examination shall be performed using a written procedure verified by the
manufacturer to be in compliance with paragraph T-150, Article1, Section V and the requirements of Article 4,
Section V for methods, procedure and qualification.

5. Is there any base material thickness restriction for ultrasonic examination of test coupons of welders
and welding operators?

Answer: Yes

As per QW-191.2.1 (a), The ultrasonic examination for welder and welding operators may be conducted on
test welds in material 1/2in. (13mm) thick or greater.

1. How many studs are to be welded for procedure qualification of stud weld test?

Answer: Ten Studs; as per QW 192.1.1

2. Any requirement for stud welding equipment for procedure qualification as per ASME Sec IX?

Answer: The equipment used for stud welding shall be completely automatic except for manual starting.

3. What are the test to be done for the procedure qualification of stud welding?

Answer:

1. Every other welding stud (five joints) shall be tested either by hammering over until one fourth of its length
is flat on the test piece, or by bending the stud to an angle of atleast 15 degree and returning it to its original
position using a test jig and an adapter location dimension that are in accordance with figure QW-466.4

2. The remaining five welded stud joints shall be tested in torque using a torque testing arrangement that is
substantially in accordance with figure QW-466.5. Alternatively where torquing is not feasible, tensile strength
test may be used.

4. What is the acceptance criteria for bend and hammer tests?

Answer: In order to pass the test(s), each of the five stud welds and heat affected zones shall be free of visible
separation or fracture after bending and return bending or after hammering.

5. What is the acceptance criteria for torque tests?

Answer: In order to pass the test(s), each of the five stud welds shall be subjected to the required
torque shown in the table, which is given with QW 192.1.3

1. Is it required to certify the PQR?

Answer: Yes.

The PQR shall be certified accurate by the manufacturer or contractor.

Refer ASME Section IX QW 200.2 (b)

2. What is the expiry date of welder qualification if a welder has not worked with that qualification?

Answer: 6 Months.

3. A welder is qualified with backing. Is he qualified to weld without backing in the case of SMAW
welding?

Answer: No. As per QW 353, deletion of backing is a re-qualification criteria for the welder in the
case of SMAW.
4. A welder is qualified with inert gas backing. Is he qualified to weld without
inert gas backing in the case of GTAW welding?

Answer: No. As per QW 356, deletion of inert gas backing is a re-qualification

criteria for the welder in the case of GTAW.

5. A welder is qualified with DCEN. Is he qualified to weld DCEP in the case of

GTAW welding?

Answer: No. As per QW 356, Change in polarity is a re-qualification criteria

for the welder in the case of GTAW.
Familiarize with inspection instruments,

Site engineers should be able to identify the make/name of the radiography source projectors (Radiography
Camera) used in their site.

9. RADIOGRAPHY CAMERA - ROLI

(MANUFACTURER:BOARD OF RADIATION AND ISOTOP TECHNOLOGY - INDIA)
 10. RADIOGRAPHY CAMERA - SENTINAL MAKE

11. RADIOGRAPHY CAMERA - SPEC 2T

12. RADIOGRAPHY CAMERA - GAMMAMAT

 ASME BPVC SECTION IX WELDING_TRAINING - PART 6
8/17/2015 07:00:00 AM
How to decide the PQR requirements in a project?

One of the toughest tasks of a project manger is making the decision upon the PQR requirements for the entire
project. He should be able to select the minimum number of test coupons to be qualified to cover the entire
range of material and thickness.

The decision is done considering the thickness, process, electrode/filler wire and the material used in the
project.

Material
The first step for the decision of PQR starts with the listing of materials in that project. This can be obtained
from drawings, Line index chart (In case of piping), project documents etc.

Thickness
The second step for the decision of PQR requires the highest and lowest thickness of each material in that
project. This can be decided by the review of drawings, Line schedule chart/line index chart (In case of
piping), project documents etc.

Based on the lowest and highest thickness, by referring QW 451.1. The thickness range qualified by PQR
decides what are the thickness of test coupon are to be made for a particular metal for qualifying the entire
thickness range.

Please refer http://hareeshkv.blogspot.com/2015/06/asme-section-ix.html for details on how this is done.

Process
The third step for the decision of PQR requires the decision of which welding process is to be adopted.

For a small thickness joint normally GTAW welding is preferred. (Not necessary but this gives a good defect
free joint in most cases.) This decision is also done based on the material being welded. Suppose the material
is Stainless Steel (SS) or Alloy Steel (AS) GTAW is done and if it is Carbon Steel (CS) SMAW welding is
done. (These are normal cases and does not contain any rules)

For thicker joints SMAW welding will be done. In this case also if, more productivity is needed
FCAW/GMAW etc will be used

For very higher thickness joints SAW/FCAW/GMAW welding will be preferred as those process are highly
productive.

Electrode/Filler Wire
The fourth and final step for the decision of PQR requires the decision of which welding electrode/filler wire
to be used.

There are many cases where there are options in choosing a electrode/filler wire for a particular process.
Example: For the welding of a CS material we can use E6013 or E7018 in SMAW welding.

If these all are decided we can start the process of making a weld coupon for PQR.

Examples of this will be given in the next post.

Continuation of the blog ASME BPVC SECTION IX WELDING_TRAINING - PART 6

How to decide the PQR requirements in a project?

Please see example in the below tables in which how can we come to a conclusion of the number of PQR tests
required.

In a project we collected the details (for deciding the PQR requirements) as below.
From the above data the PQR requirements are derived as in the below table.

Now may be there is a question in your mind why for the material carbon steel - water line and carbon steel -
Process Liquid Line different process are used. It is as per the project requirements only.

Below is another project. Column 1 to 5 contains the collected data and column 6 & 7 are the requirements of
PQR (we derived from the data) for that project.
 LINE HISTORY SHEET (LHS) - PIPING - [1]
8/24/2015 07:00:00 AM

LINE HISTORY SHEET (LHS)

Line History Sheet or LHS is the recording sheet made for keeping the records of
the joints in a pipeline in a systematic manner. LHS gives tractability of joints in a
pipeline. In LHS each process done on a joint is recorded with its process report
number and date.

Creating and maintaining a LHS is one of the hectic task in a piping project. Proper
and timely maintenance of LHS is necessary for the successful completion of a
piping project. Another most important thing is that, in most of the projects
billing/payments are obtained/done based on the stage of completion of different
process in a joint. For each process to be done on a pipe joint the record of
previous process is needed, which can be easily done with the help of a LHS.
What are the records to be maintained in a LHS, how it is to be
maintained, the importance and requirement of maintaining each record and how
these records can be used to manage a piping project is explained in this series of
blog.

There are many ways to record the LHS. The most popularly used method is
maintaining the records in a Microsoft Excel Format. There are other softwares
available like Parascadd ( www.parascadd.com). Some organisations will use in-
house developed software's.

Here things are explained with the assumption that the LHS is maintained in MS
Excel.
BW [1] - AN INTRODUCTION TO MECHANICAL CONSTRUCTION
INDUSTRY
8/29/2015 07:00:00 AM

AN INTRODUCTION TO MECHANICAL CONSTRUCTION INDUSTRY

Construction, the word is familiar to everyone mainly with the picture of civil
construction in mind. How a factory is made? How a refinery is made? How a ship
is made? These all to be constructed by mechanical process and that is mechanical
construction to my definition.

Mechanical construction history dates back to metal age where man became
familiar to use metal as the medium in various activities. In the development of
new metal processing methods and inventions of new metal formulations made the
metal applicable to almost all activities.

In the development of metal and its uses necessitated the requirement of

specialized persons for performing activities in metal. The engineering branch
based on mechanical was developed and mechanical engineers came in to scene.
When come to the mechanical engineering branch, the most known area where a
mechanical engineer can work is the automobile industry. The requirement of
mechanical engineer for refineries, cement plants, petrochemicals, fertilizer plants,
pharmaceuticals and other types of plant construction and maintenance
necessitated specialized mechanical engineer in these areas and mechanical
construction engineer came in to picture.

What are the roles of a mechanical engineer in the field of construction? He acts as
planning engineer, quality control engineer, quality assurance engineer, erection
engineer, piping engineer, structural engineer, static equipment engineer, rotating
equipment engineer, billing engineer, estimation engineer, pressure testing
engineer, commissioning engineer, box-up engineer, welding engineer, NDT
engineer etc.

The implementation of more and more refineries, petrochemicals, cross country

piping’s, pharmaceutical plants etc increased the requirement of mechanical
construction engineer. The increase in requirement demanded more and more
experts/specialists in the field.

The knowledge for working in the mechanical construction cannot be limited to

mechanical engineering related fields also. Familiarity with Civil, electrical and
instrumentation field also needed to some extend to become successful as a
mechanical construction engineer in his career.

Each and every item for this mechanical construction industry is supplied by other
mechanical/ electrical/ instrumentation industries and those industries also require
mechanical engineers for their day to day activities. There is an interlinked system
of requirements of mechanical engineers everywhere in world where the
mechanical works are happening.
A mechanical engineer working in mechanical construction industry can be called
“mechanical construction engineer”. This is to differentiate the mechanical
engineer working in other fields such as automobile industry, production related
functions, logistics related functions etc.
BW [2] - ORGANISATION STRUCTURE OF MECHANICAL
CONSTRUCTION INDUSTRY - 1
8/30/2015 07:00:00 AM

ORGANISATION STRUCTURE OF
MECHANICAL CONSTRUCTION INDUSTRY

The common organisation structure in a medium sized mechanical construction

industry in India is as follows.

Under each manager the organizational structure will be as follows.

 LINE HISTORY SHEET (LHS) - PIPING - [2]
9/05/2015 07:00:00 AM

LINE HISTORY SHEET (LHS)

Why MS Excel became a popular platform for maintaining LHS?

1. A software programming crew is not required.

2. The process of entering and managing rows and columns is a simple process.
3. People can be trained easily on the software.
4. With a single license for a system, it can be used by any number of persons.
5. Filtering option makes it easy for searching conditions of the entered data.

Now we will discuss about starting the data entry.

There are rows and columns in a excel sheet. Each row and column intersects in a
cell. Each data is entered in a cell.

For each column, column heading is given in the top most row (Row 1)

For each row, row numbering is given in the first column. (There is a numbering
system available in excel in the left most side. That can be used or else a column
with Serial number for each row can be maintained.)

We will enter each data of a line history sheet separately in a column in the excel
sheet. This is for the easiness of filtering the data depending on different
conditions.

For starting the LHS the person should be familiarize with,

1. A line numbering system - for starting the column heading in LHS.

2. The data's in the isometric drawings.
3. The joint numbering system
4. The reports generated for a joint.

In the next blog we will discuss about familiarizing the line number system in a
project.
INSPECTION INSTRUMENTS [PART 7] - PAINTING INSPECTION
9/08/2015 07:00:00 AM

Familiarize with inspection instruments,

13. HOLIDAY TESTER - WET SPONGE TYPE

Used for detecting the holiday in painting.

13. SURFACE PROFILE COMPARATOR
 Photography support given by Mr.Ajeesh

BW [3] - ORGANISATION STRUCTURE OF MECHANICAL

CONSTRUCTION INDUSTRY - 2
9/13/2015 07:00:00 AM

ORGANISATION STRUCTURE OF
MECHANICAL CONSTRUCTION INDUSTRY
The common organisation structure followed in the construction sites are as
follows.

Under each department there will be a Lead engineer. Engineers, trainee engineers
and supervisors will report to the lead engineer of their corresponding department.

All the Lead engineers will report to Resident construction Manager (RCM). In big
projects, it will be divided in to small projects and each small project will have one
RCM. All the RCM will report to the Project Manager.

There will be difference in site and office organogram but we can see that all these
functions are executed in one department or the other for example in some
organizations, Quality, Health and Safety will be under one department (QHSE).
The decision of the organization structure will be done by the top level
management of an organization in such a way that managing the entire system is
easy for the top level management.

In the next blog of this series we will discuss about the functions executed by each
department.
 INSPECTION INSTRUMENTS [PART 8] - RADIOGRAPHY
INSPECTION
9/20/2015 07:00:00 AM

Familiarize with inspection instruments,

15. RADIATION SURVEY METER

(Used to detect the intensity of radiography at different locations)

11. VEHICLE EQUIPPED WITH RADIOGRAPHY SOURCE STORAGE

(Used for the transportation of radiography source)
 PWHT - [Part 6] PWHT OF BRANCH CONNECTIONS
5/20/2016 07:00:00 AM

PWHT OF BRANCH CONNECTIONS

There is a lot of confusion regarding the PWHT of branch connections.

For the PWHT of branch connections the entire header/mother pipe is to be wrapped. This is to be done
whether the branch connection is of 1/2" size or of same size as header pipe.

The recommendations regarding the same are given in the code, AWS D 10.10M.
 There is a general concept in
the piping industry that the support welding of piping is a simple one and any
welder can do it. Also it is a common thought that there is no need to take care of
welding of the pipe support, because it’s just a support.

The above picture shows the water coming out of the trunion support due to hole in
the elbow which was the result of improper welding practices of welding the pipe
support.

This picture was taken at the time of hydro test.

Please ensure welding of pipe support with due care and these issues can be
avoided.
Here the hydro test is offered for inspection after one coat of painting!!!!!!!

1. What is "sensitivity"?

Ans: Sensitivity in a radiograph is a function of 'contrast' and 'definition'.

2. What is "Contrast"?

Ans: Contrast is the comparison between film densities for different areas.

3. What is "Definition"?

Ans: Definition is the demarcation between areas of different densities.

4. What is "Penubra"?

Ans: The fuzzy edges of the image are called Penubra. This is related to geometrical unsharpness.

5. What is the relation between radiography film grain size and exposure time?

Ans: Large grain size needs less exposure time compared to small grain size films.

1. What is the half life of Iridium-192 Isotope?

Ans: 73.83 days.

2. What is meant by half value layer?

Ans: The thickness of a material at which the intensity of radiation becomes one half that of radiation falling at
its surface is called half value layer.

3. What is the difference between primary and secondary radiation?

Ans: Radiation that is part of the original beam is called primary radiation. When this radiation hits the atoms
of a material radiation is produced that is called secondary radiation or scattered radiation.

4. Iridium-192, natural or artificial isotope?

Ans: Artificial isotope.

5. What is the difference between atomic number and mass number?

Ans: Atomic number is the number of protons in an atom where as mass number is number of protons and
neutrons in an atom.
1. What is the minimum length of volumetric NDE required for welder qualification?

Ans: 6 in (150mm) [QW 302.2]

2. Please tell about one etching reagent used for ferrous materials.

Ans: One part of nitric acid and 3 parts of water by volume is one of the etching agent used for ferrous
materials.

3. What is the P number of IS 2062 grade material.

Ans: P number is 1

4. What is a linear indication?

Ans: An indication in which the length of indication is more than 3 times the width.

5. What is a rounded indication?

Ans: An indication in which the length of the indication is 3 times the width or less.

SCAR: Small Controlled Area Radiography

EPC: Engineering, Procurement and Construction
EPCM: Engineering, Procurement, Construction and Management
RFQ: Request For Quote
MSD: Material Selection Diagram
SFD: Source to Focal Distance
AISC: American Institute of Steel Construction
WPS: Welding Procedure Specification
PQR: Procedure Qualification Standard
DIN: Deutsches Institute fur Norming
CS: Carbon Steel
MS: Mild Steel
SS: Stainless Steel
MOC: Material Of Construction

1. For a protective oxide layer to form, the ratio of the volume of oxide formed to that of metal
consumed should be
Answer: >1

2. The key properties required for good oxidation resistance of an oxide film are

Ans: Low electrical conductivity and continuous oxide film

3. What are the elements that are added to iron to improve its oxidation resistance?

Ans: Chromium , Aluminum and Nickel

4. The peak in corrosion rate of martensite occurs when

Ans: Tempered at about 400deg C

5. What is the 18-8 stainless steel?

Ans: Stainless steel that contains 18% Cr and 8% Ni

1. In piping when design consideration is needed as a miter?

Ans: An angular offset of 3 deg or less does not require design consideration as a miter bend.
[Clause 304.2.3; ASME B 31.3 Ed: 2004]

2. Can we use more than one gasket in a flange?

Ans: No more than one gasket shall be used between contact faces in assembling a flange joint
[Clause 335.2.4; ASME B 31.3 Ed:2004]

3. If a threaded joint is leaked during hydrostatic leak test can it be welded?

Ans: A joint containing thread compound which leaks during leak testing may be seal welded provided,
a) All compound uses in the threaded joint is removed from exposed threads
[Clause 335.3.2; ASME B 31.3 Ed:2004]
b) Seal welds shall cover all exposed threads
[Clause 328.5.3; ASME B 31.3 Ed:2004]
c) Seal welding shall be done by a qualified welder
[Clause 328.5.3; ASME B 31.3 Ed:2004]
4. Is welder qualification required for welding Thermocouple (TC) using capacitor discharge method?

Ans: No. WPS and PQR also not required. After removing the TC the areas shall be visually examined for
evidence of defects to be repaired. [Clause 330.1.3(b); ASME B 31.3 Ed:2004]

5. What are the methods that can be used for temperature verification of preheat in welding?

Ans: a) Temperature indicating crayons

b) Thermocouple pyrometers
c) Thermocouple
[Clause 330.1.3(a) & (b) ; ASME B 31.3 Ed:2004]

1. What is IQI?

Ans: IQI stands for image quality indicator. Penetrameter is the another word used for IQI.

2. What is the difference in placing DIN and ASTM penetrameter in a radiography film?

Ans: ASTM standard penetrameter is placed on the left side of the radiography film as the smallest thickness
wire is on the left side of the penetrameter.
DIN type penetrametr is placed on the right side of the radiography film as the thinnest wire is on the right
most side of penetrameter.

3. How many wires are there in a ASTM and DIN penetrameter?

Ans: ASTM penetrameter is having 6 wire's where as DIN penetramaeter is having 7 wire's.

4. What are the main classification of penetrameter?

Ans: Hole type and wire type are the two types of penetrameter.

5. Which is the material of construction of penetrameter?

Ans: Same material or a material similar to the specimen being radiographed.

1. What is Galvanic series?

Answer: To describe the tendency to corrode in a given environment common metals and alloys are arranged
on a qualitative scale called the galvanic series.
Eg: 18-8 stainless steel is passive in a a water and it is on the top on the top of the table of the galvanic series
in sea water environment.

2. What is a sacrificial anode?

Answer: Sacrificial anode is related to corrosion protection. Protection by galvanic action is provided by
connecting the structure to be protected to a sacrificial anode. The sacrificial anode to be replaced periodically.

3. What is passivation?

Answer: Passivation refers to the formation of a thin, high resistance oxide layer which reduces the corrosion
current by two or three orders of magnitude.

4. What are the common methods that are adopted in piping to avoid corrosion?

Answer: Wrapping and Coating, Painting and Cathodic Protection.

5. For the grid blasting (For the surface preparation for painting)of stainless steel material which grid
material is most preferred?

Answer: Aluminum Oxide

What is baking of an electrode?

The coating of the electrode is having the tendency to absorb moisture. Baking is the process of removing
moisture from the electrodes, with the help of heat, thereby reducing the level of dissolved H2 in the weld
metal which is prone to make delayed cracking in the weld metal.

How baking is done?

Baking is done with the help of ovens. These ovens are fitted with electrical resistant heating coils which will
generate heat upon giving electrical current. The heat in the coils are controlled by temperature controllers.
The temperature required is set in the temperature controllers. It automatically controls the temperature in the
oven.

What is the difference between mother oven, holding oven and portable oven (Heated Electrode
Quiver)?
Mother oven is the oven in which fresh electrodes are put which are taken from the original electrode packets.

Holding oven is the oven in which the electrodes are put to maintain the holding temperature.

Portable oven is the oven which are used to carry the electrodes, transferred from the holding oven, to the job
location, where it is electrically connected and holding temperature is maintained.

Electrode Issue Process:

Electrode as per requirement at site/job location are assessed by welding engineer. Welding engineer will raise
the requisition to issue the electrodes through electrode issue slip.

The welding assistant (Helper to the welder) will take the electrode issue slip to the electrode store and
handover the slip to the electrode issuer (electrode store keeper). The welding assistant will take the electrode
bits of the previously issued electrodes along with the electrode issue slip and that also will be handed over to
the electrode issuer.

The electrode issuer cross check the signature of the welding engineer with the specimen signature list of
welding engineers available with him. He will also cross check the welder details (qualification to use the
requested electrode) with the qualified welder list available with him. He will issue the electrodes as per
requirement in the electrode issue slip.

If the electrode is of low hydrogen type, electrodes are taken in a portable oven by the welding assistant, if else
the welding assistant will take it as a loosely tied bundle.

Storage and Handling of Electrodes [Part 2]

5/27/2015 08:42:00 AM

What is the procedure for baking of electrodes?

The electrodes are removed from their original packets(hermetically sealed containers will discussed later) and
are put in the trays in the mother oven at a temperature not exceeding one half the final baking temperature for
a minimum of one half hour prior to increasing the oven temperature to the final baking temperature. The
temperature is set in the automatic temperature controller. When the set temperature is reached it will be
allowed to remain at that temperature(baking temperature) as per manufacturer recommendation/as per
standard/code/procedure requirement. When the time is completed it will be transferred to the holding/storage
oven, where a constant temperature is maintained. Electrodes as required for the job will e transferred to the
portable oven from the holding oven.
The baking temperature will be as per manufacturer recommendation. As per AWS D1.1, Clause 5.3.2.4,
1. All electrodes having low-hydrogen coverings conforming to AWS A5.1 shall be baked for at least two
hours between 260 Deg C and 430 Deg C

2. All electrodes having low-hydrogen coverings conforming to AWS A5.5 shall be baked for at least one hour
at temperature between 370 Deg C and 430 Deg C

As per AWS D1.1, Clause 5.3.2.1, the holding oven temperature shall be maintained at a minimum
temperature of 120Deg C.

PORTABLE OVEN

How the electrodes are arranged in an mother/portable oven?

The most common design of mother/portable oven consists of heating coil at the bottom and 3 or 4 grilled
racks at the top of it. The electrodes are to be placed in each rack such that the hot air will move to the next
rack above it. Normally 2 to 3 layer of electrode is placed in a rack which will give a uniformity in heating.
The entire oven can be placed with same electrode of different sizes or each rack can be used for different
electrodes.
Though filling different racks with different type of electrodes is the most preferable method, there is risk of
mixing of electrodes.

It can happen in the following ways.

1. There are chances that the electrode may accidentally fall from one rack to the another while filling/issuing
the electrodes. This will cause mixing of electrodes.

2. While filling the electrodes there are chances that the electrodes are wrongly filled in a rack.

Who should issue the electrodes?

Electrodes are to be issued by a experienced store keeper/person (Electrode Issuer). No body is allowed to
enter to the electrode issuing area for taking the electrodes by their own other than the electrode issuer.

There should be an engineer/supervisor responsible for electrode handling process and he should monitor the
process of electrode issuer and corrections/directions to be issued by time to time

What is the experience required for an electrode issuer?

He should have the basic knowledge of English for reading and writing. He should know the electrode names,
brand, baking procedure and electrode issue procedure.

What are the Duties of an electrode issuer/electrode store keeper?

1. Maintain and update the stock records of electrode.

2. Maintain the correct backing procedure.
3. Maintain the baking register.
4. Issue of electrodes based on the electrode slip approved by welding engineer.
5. Liaison with the engineer/supervisor in-charge of the electrode handling process for stocks, discrepancy
happened if any, damages in electrode if any etc.
6. Maintain the mother oven and portable oven in good condition
7. Calibration of ovens before due dates and maintain a valid calibration certificate.
8. Replenish the electrodes in the ovens as per work load and in communication with welding engineer.
9. Electrode mix if happened to be brought to the knowledge of welding engineer.
10. If power has gone during baking re-baking to be done in consultation with the engineer/supervisor in
charge for electrode handling process.

BE: Bevelled End

BW: Butt Welding
ERW: Electric Resistance Welding
HAZ: Heat Affected Zone
LR Elbow: Long Radius Elbow
SR Elbow: Short Radius Elbow
MAWP: Maximum Allowable Working Pressure
MPI: Magnetic Particle Inspection
NDE: Non Destructive Examination
NDT: Non Destructive Testing
NPT: National Pipe Thread
PBE: Plain Both Ends
PED: Pressure Equipment Directive
PFD: Process Flow Diagram
P&ID: Process and Instrumentation Diagram
RFC: Released For Construction
Smls: Seamless
SW: Socket Welding
TBE: Threaded Both Ends
TIG Welding: Tungsten Inert Gas Welding
WPS: Welding Procedure Specification
PQR: Procedure Qualification Record
ASNT: American Society for Non destructive Testing
ASTM: American Society for Testing of Materials
Ecc Reducer: Eccentric Reducer
Conc. Reducer: Concentric Reducer
CV: Control Valve
CPLG: Coupling
RTJ: Ring Type Joint
Spec: Specification
STD: Standard
GI: Galvanized Iron
AARH: Arithmetic Average Roughness Height

Storage and Handling of Electrodes [Part 3]

5/30/2015 08:21:00 AM

Baking register:

The baking process of electrodes are recorded in the baking register. The responsibility of filling the baking
records is with the electrode issuer. These records are to be reviewed by the welding engineer/supervisor.

One of the formats of baking register is as below.

BAKING REGISTER

Col 1: Serial number

Col 2: Date in which the row entry is made
Col 3: AWS class of electrode. eg:- E 7018, E8018-B2 etc.
Col 4: Size of electrode. eg:- 1.6mm, 2.5mm, 3.15mm, 4.0mm etc.
Col 5: Manufacturer of the electrode. eg:-D&H, ADOR, ESAB etc.
Col 6: Quantity put in the baking oven.
Col 7: Batch number of the electrode placed in the oven for baking.
Col 8: Opening balance in the baking oven. This is significant if two or more batch electrodes are placed in the
oven.
Col 9: Time when the electrodes are placed in the oven are to be entered in this column.
Col 10: Time at which the baking temperature is reached is to be recorded in this column.
Col 11: Entry time in holding oven. If the baking time is one hour, the electrodes are to be removed from the
mother oven one hour after the time recorded in Col 10 and are to be kept in Holding Oven.
Col 12: The total qty of electrodes in the holding oven are to be recorded here.
Col 13: The qty of electrodes issued to the job site ( as per the electrode issue slip) is to be recorded in this
column..
Col 14: Balance quantity of electrodes are to be recorded in this column.
Col 15: Welder to whom the electrodes are to be issued are to be recorded in this column.
Col 16: Area of the job to which the electrodes are to be issued.
Col 17: Signature of the electrode issuing person.
Col 18: Verification signature to be done on random basis by welding engineer/supervisor
additional one more column can be given as 'REMARKS' if required.

Electrode Issue Slip

Electrodes are issued based on the written requisition by a welding engineer. The written requisition is called
electrode issue slip.
One of the format for the electrode issue slip is as below.

ELECTRODE ISSUE SLIP

(1): Organisation name and logo to be given.
(2): Welder name to be given.
(3): Welder identification number to be given.
(4): Date at which the requisition is raised to be entered in this area.
(5): Serial number
(6): AWS class of the required welding electrode to be specified.
(7): Brand name of the electrode to be entered here. This is having significance only if there is any specific
brand of electrode are to be used in the job.
(8): Size of the electrode in millimeter.
(9): Quantity (in numbers) of electrode required for the job are to be mentioned by the welding engineer.
(10): Signature of welding engineer who raises the electrode issue requisition to be signed in this column.
(11): Quantity of electrodes issued to be recorded in this column and this is done by the electrode issuer.
(12): Signature of the electrode issuer to be done
(13): Remarks if any are to be recorded.

Storage and Handling of Electrodes [Part 4]

5/31/2015 08:58:00 AM

Duties of the welding engineer/supervisor

[who is responsible for monitoring the baking and electrode issue process.]

There shall be a designated welding engineer/supervisor for monitoring the electrode managing process as a
whole.

His duties are,

1. Physical cross checking of qty of electrodes in the oven with that written in the baking register.
2. Physical cross checking of type of electrodes in the oven (both mother oven and portable oven) with that
written in the baking register.
3. Checking of the electrode issue slip against baking register for,
3.a. Welder number
3.b. Qualification of welder and electrodes issued
3.c. Quantity of electrode issued and that recorded in the baking register.
4. Communication with all site engineers for the electrode requirement according to their job planning.
5. Necessary instructions to the electrode issuer for maintaining the required quantity of electrode for the next
day.
6. Random physical check of baked electrodes for
9.a. Cracks in electrode flux if any
9.b. Over heating or under heating of electrodes
9.c. Communication with welders for the quality of baked electrodes.
7. Stock verification of electrodes against issued electrodes.
8. Order for electrodes if reorder level is reached.
9. Followup for the timely supply of electrodes.
10. Receipt of fresh electrodes
10.a. Verification of quantity, size and AWS class of electrodes against delivery challan.
10.b. Verification of the material test certificate (MTC) of the electrodes for confirmation that the same are
meeting the project specification requirements.
10.c. Preparation of the incoming material inspection report and get it signed by Client/TPI if required.
10.d. On receipt of electrodes if damaged electrodes or broken hermetically sealed packets are found it
should be brought to the notice of the purchasing officer and necessary corrective actions are to be
suggested/taken.

Electrode bit returning process.

ELECTRODE BIT

The electrode bit is the 1" long electrode end (the holder end) that becomes balance after welding.

The electrode bits are to be returned by the welder assistant (helper to welder) to the electrode issue store and
to be handover to the electrode issuer.
This is done for 3 reasons.

1. The electrode bit will not be spreaded all over the welding area as it usually occurs.
2. It is having a resale value.
3. This makes a control for the electrode issue process

The welder assistant will return the electrode bits to the electrode issuer. The electrode issuer after verifying
the quantity will issue the next lot of electrodes (For the next lot of electrodes electrode bits along with
electrode issue slip is needed). Based on the minimum quantity of the two conditions (electrode bit returned
and the quantity in the electrode issue slip) electrodes are given to the welding assistant by the electrode issuer.

RADIOGRAPHY - EXPIRY OF VALIDITY CERTIFICATION OF

RADIOGRAPHY CAMERAS
6/02/2015 12:54:00 PM

Industrial Gamma Radiography Exposure Devices(s) (IGREDs) or radiography camera can be used only with a
valid type B(U) certificate from AERB in india. There are similar certification methods for radiography
cameras in different countries.

600 Series of Techops/Amertest

It is to be noted that the 600 series of Techops/Amertest cannot be used in India after 31-12-2015 as per the
notification from AERB.

[Source: http://www.aerb.gov.in/AERBPortal/get/cnNkb3JkZXIucGRm]

NOTIFICATION FROM AERB

SPEC-2T

Another important news related to radiography camera is that M/s.Source Production & Equipment
Company Inc. (SPEC) the manufacturer of SPEC-2T camera is stopping the production of SPEC-2T as per
the information given in their website www.spec150.com. From April 30, 2015 onwards they stopped the
supply of the spare parts for that camera also.
 Storage and Handling of Electrodes [Part 5]
6/05/2015 08:58:00 AM

What is the time period that an electrode can be kept at atmospheric temperature after electrodes are
taking out from hermetically sealed containers or from baking or storage ovens?

As per AWS D1.1, Clause 5.3.2.2 and Table 5.1, approved atmospheric time periods are as per the below table.
After hermetically sealed containers are opened or after electrodes are removed from baking or storage ovens,
the electrode exposure to the atmosphere shall not exceed the values shown below in column A.
Electrodes exposed to the atmosphere for periods less than those allowed by column A, in the above table may
be returned to a holding oven maintained at 120 Deg C (min); after a minimum hold period of four hours at
129 deg C (min) the welding electrodes may be reissued.
The alternative exposure time values given in Column B in the above table may be used provided testing
establishes the maximum allowable time.

Procedure for handling of electrodes having hermetically sealed containers.

Now a days electrodes are available in hermetically sealed containers. The main advantage of these electrode is
that there is no need for baking of electrodes. It can be directly transferred to the portable oven at site.

Immediately after opening hermetically sealed container, electrodes shall be stored in ovens held at a
temperature of at least 120 deg c.

If it is found that the hermetically sealed packet is teared, then the entire baking procedure is to be followed.

Storage and Handling of Electrodes [Part 6]

6/06/2015 09:17:00 PM

Wrong storage practices in mother/holding/storage ovens.

1. Maximum of 4 layers of electrode should only be placed in each rack. (This is not a mandatory rule, but
practically , then only proper heating will be obtained.)

2. Electrodes shall not be kept in bundle. Proper baking of the electrodes will not be obtained if kept in bundle.
3. Electrodes shall not be placed other than the area for it. Placing the electrodes over the heating coil area will
obstruct the heating of the electrodes on the racks above it. It will also cause the over heating of the electrodes
placed over the heating coil area.
4. Care shall be taken to avoid falling of electrodes from one rack to the bottom of it. Particularly when the
racks contain different electrodes.

5. Separating a rack for storage of different electrodes by temporary means is not a healthy practice. This may
cause mixing of electrodes.
 Storage and Handling of Electrodes [Part 7]
6/09/2015 05:59:00 AM

What is the expiry date of an electrode?

There is no expiry date for an electrode. Before using the electrodes/before placing the electrodes in an oven
ensure that the electrodes are in good condition.

If you have doubt about the quality of electrodes, take some electrodes and do a test weld. If the electrode is
giving a good weld then the electrode can be used.

Oven validation Process

Periodic validation of mother oven, holding oven and portable oven is required. This is to ensure that the oven
is working properly.

Validation process involves checking the temperature of the oven with a thermometer against the set
temperature of the oven. If any abnormalities are found it should be repaired. During the validation process the
physical condition of the oven, loose electrical connections etc. if any also to be checked.

A sticker will be pasted on the oven with the signature of the validating person. A register will be maintained
with the details of validation.
 VALIDATION STICKER

Duration of oven validation: Duration will be fixed based on the usability, chances of abnormalities of
machines etc. Normally mother oven and holding oven are validated once in 6 months. Portable ovens are
validated once in 3 months. But it is advisable to validate the mother oven and holding oven once in 3 months
and portable oven in every month.

WELDING ACTIVITY AUDIT

6/10/2015 06:13:00 AM

WELDING ACTIVITY AUDIT

Welding activity audit is done to ensure that all welding related activities are taking place in the required
manner. Audit is done for ensuring qualified welders, qualified welding procedures , compliance of proper
electrode handling and related methods and good engineering practices are adhered in the welding production
process.

The audit is to be done by a team of welding engineers, site engineers and welding supervisors.

Necessary remedial action to be taken, if any failures are there in those activities and proper system to be
implemented to avoid the repetition of the same.

The points that are inspected in the welding audit process are,

1. Identity card availability with welders.

2. Certificate of welders.
3. Whether the welder doing the job is having the Qualifications ,Based on thickness, based on the position of
the job, based on material to be welded, based on electrode/filler to be used.
4.Proper weaving is done.
5. Cleaning after welding is done.
6. Small pits if any due to the removal if tacks are properly filled and grinded.
7. Whether all the portable ovens are having proper valid calibration certificate.
8. Whether all the mother ovens and holding ovens are having valid calibration certificate.
9. Whether all the potable ovens are properly electrically connected.
10. Check the temperature inside the portable oven. If not proper send for repair.
11. Check for electrode mix in the portable oven.
12. Check whether all the electrodes/ filler wires are returning to the electrode storage area after a days work.
13. Check whether the baking register records are properly maintained.
14. Check whether re-baking is done, if so check the condition of the electrode .
15. Check whether all the filler wires are properly stored in the electrode storage area.
16. Check whether the electrode storage area is properly protected from weather conditions.
17. Knowledge of welders and welding helpers regarding welding, cleaning of the job, baking of electrodes
etc. If not tool box talk is to be conducted.
18. Check whether the welder is having the knowledge of different materials and welding electrodes.
19. Check whether the welder and welding helper is familiar with the electrode issue process.
20. Check whether the welder is aware about the safety aspects.

TOOLBOX TALK - TOPICS - WELDERS

6/12/2015 08:39:00 AM

Toolbox talk is done to make aware about a particular topic, mostly informal in nature and done in short
duration of time.

In construction sites toolbox talks are given to all people related to their field by persons who are experienced
(need not be engineers or managers, senior experienced people from work group can also do the tool box talk)
in their field. These are done before starting of specialized jobs to make people aware about what to do, how to
do, safety aspects, tools to be used etc.

Toolbox talk can be done once in two days, involvement of workmen also to be ensured on discssions so that
issues if any at site can be sorted out.

Below are the different topics normally discussed in the toolbox talks.

Tool Box Talk with welders

1. Weld area cleaning: Need of chipping in each pass, need of filling the pits due to removal of tacks, cleaning
using wire brush after the weld, visual inspection of weld by welder after completion of welding.

2. Electrode handling: Need for proper baking, basics of baking, requirement of baking, returning of balance
electrodes to the electrode storage area, use of portable oven

3. Documents needed with a welder: need of keeping welder identity card, welder certificate

4. Welding positions qualified by welders: different positions of welding, qualified positions by each welder

5. Material and electrodes that can be welded: based on qualifications materials that can be welded by each
welder, based on qualifications electrodes that can be used by each welder

6. Safety in welding: earthing, proper clamping of holders, arc strike, proper use of safety glasses, problems
due to welding with naked eye, use of hand gloves, use of welding helmet, electric shock, first aid during
electric shock, dehydration, heat generation during welding, hot surfaces, ultra violet rays, dress code for
welders

7. Welding defects, causes and solutions: porosity, arcstike, spatter, lack of penetration, incomplete fusion,
undercut, excessive reinforcement, crack, slag inclusion,

PWHT - [Part 2] Thermocouples

6/14/2015 07:13:00 AM
Thermocouples are used t o detect the temperatures in the process of PWHT. If the ends of the dissimilar wires
are in contact with each other and also with a hot and a cold surface, a voltage difference between the two
junctions is created. These voltage differences are proportional to the differences in temperature. Therefore a
properly calibrated instrument to measure the voltage difference can translate voltages in to temperature
readings at the hot junction.

Each combination of wires required a separate calibration and an instrument designated for that combination.

The three commonly used thermocouple combinations are (Data from AWS D10.10)

The letter designation applies only to the temperature voltage relationship and not to the material. For ease of
understanding it is to be noted that the negative side in all cases is of red colour.

Thermocouples are available in various sizes. Faster response is obtained from thinner wires but there are
chances that the thinner wires are easily get damaged.

The commonly used thermocouple is having a diameter of 0.81mm (#20AWG).

The thermocouple wires are to be in touch at the point where the heat is to be detected. Balance all portions of
the thermocouples shall be protected from radiant heat and also from touching each other. Touching each other
can be prevented by the sheath provided, usually by the manufacturer. Radiant energy can be prevented by
proper protection by ceramic wool.

Thermocouple extension wires: Usually the job will be farther from the instrument for recording and
controlling the temperature. Thermocouple extension wires are used to connect the thermocouple at the job and
the instrument. The thermocouple extension wires will be of same composition of thermocouples or designated
to match the thermocouple system. For a J type thermocouple the thermocouple extension wire is designated as
JX, for E it will be EX and for K it will be KX.

The positive side of the thermocouple to be connected to the positive side of thermocouple extension wire and
positive side of thermocouple extension wire to be connected to the positive lead of the temperature controlling
instrument.Change in leads will cause error in the detected voltage and there by the recorded temperature.

The thermocouples are usually connected to the job/material for PWHT by capacitor discharge method.

Storage and Handling of Electrodes [Part 8]

6/16/2015 07:49:00 AM

Specification for Mother/holding Oven.

This is a reference specification of mother oven/Holding oven. This is extracted from a tender raised by
M/s.Bharat Heavy Plate and Vessels Limited (A subsidiary BHEL).
 Storage and Handling of Electrodes [Part 9]
6/20/2015 07:28:00 PM

HANDLING OF GTAW FILLER WIRES

For GTAW welding, filler wires are used. Colour coding of filler wires are done for easily identifying them.

How colour coding is done:

Both the ends of the filler wire are dipped in paint and will be kept at sunlight for drying. Approximate one
inch length of both sides to be dipped in paint. Each AWS code of filler wire will have different colour. This
will make identification easier.

Colour shall be applied at both ends: The GTAW welders will cut the filler wires in the middle for easily
handling them while welding. So for identifying both the cut pieces colour coding is done on both ends.

Same filler wire but with some special properties can be easily identified by this method only. Example: ER 70
S2 for normal CS welding and NACE qualified material welding are different. For NACE qualified material
the ER 70 S2 will be of NACE qualified. So differentiate between these two can be done only with the colour
coding.

Cut pieces of filler wires returned to the store, after welding with out colour coding or identification marks
shall be stored in consultation with welding engineer only. The safest way is to discard those pieces or else
PMI methods shall be used to identify them. After identifying the filler wire colour coding to be done.

Colour coding chart are to be made available to all welders, welding engineers, site supervisor s and electorde
issuer.

A sample colour coding chart is given below

Refer the above chart, if you see the filler wire with yellow colour on on one end, you can easily identify from
the chart that it is ER70 S2.
 INSPECTION INSTRUMENTS [PART 1] - WELDING INSPECTION
6/21/2015 08:42:00 PM

Familiarize with the inspection equipment's

1. WELD GAUGE (ALL PURPOSE WELD GAUGE)

 Photography Support given by Mr.Gokul Gopi

Photography Support given by Mr.Jidhin Sudhakaran

 Photography Support given by Mr.Jidhin Sudhakaran

The weld gauge can be used for measuring,

1. Weld thickness of fillet.
2. Reinforcement thickness of a butt weld.
3. Depth of undercut.
4. Depth of pit due to corrosion/indentations on material
.
2. HI-LO GAUGE
 Photography Support given by Mr.Gokul Gopi

Photo from Internet

Photography Support given by Mr. Jidhin Sudhakaran

HI-LO Welding gauge is used for measuring the,
1. Offset in fitup.
2. Ovality of a joint at a location.
3. Internal misalignment.
4. Height of reinforcement in the weld.
5. Fillet weld leg length.

ASME BPVC SECTION IX WELDING_TRAINING - PART 4

6/24/2015 10:30:00 AM

For reducing the number of procedure qualifications, another group qualification is also provided by ASME
Section IX.

Refer QW 424, Base metals used for procedure qualification (ASME Section IX Ed:2010)
Based on this if we qualify a procedure a procedure same group or some other groups can also be qualified.

example:
Please refer row 6 on the above table.

P No 4 to P No 4 will qualify P No 4 To P No 4, P No 4 to 3 and P No 4 to P No 1

Please refer row 7 on the above table.

P No 5A to P No 5A will qualify P No 5A To P No 5A, P No 5A to 4, P No 5A to P No 3 and P No 5A to P

No 1

That means if we have a procedure qualification of P No 5A to P No 5A, we can make a WPS for P No 5A To
P No 5A, P No 5A to 4, P No 5A to P No 3 and P No 5A to P No 1 with out further qualifications.

ASME BPVC SECTION IX WELDING_TRAINING - PART 5

6/26/2015 07:00:00 AM

In the process of PQR preparation we should know about,

1. Material to be welded with its P number (http://hareeshkv.blogspot.com/2013/05/asme-bpvc-section-ix-

welding-training.html)

2. Filler wire or electrode to be used and its F number (Thttp://hareeshkv.blogspot.com/2015/04/asme-bpvc-

section-ix-welding-part-2.html)

3. The thickness of base material that is to be used for the PQR process.

The third one will be discussed here.

The table (QW 451.1, ASME SEC IX, ED:2010, Page:144) below shows that the thickness of test coupon used
for the procedure qualification and the range qualified by it.

Please note that there is a maximum and minimum range of thickness of weld metal and base metal that will be
qualified as per the table.
Please see that up to 38mm of base material thickness of test coupon, the range of base material qualified is
double the thickness of base material thickness used for test coupon for PQR.

Example: 1
If our job (in the project) ranges in between 5 to 20mm thickness, we will go for a test coupon of 10mm
thickness for the base material.

By qualifying a test coupon of 10mm base material thickness, we can weld job ranging from 1.5 to 20mm
thickness as per second row in the table QW-451.1.

Example: 2
If our job ranges in between 3 to 40mm thickness, we will go for a test coupon of 20mm thickness for the base
material.

By qualifying a test coupon of 20mm base material thickness, we can weld job ranging from 5 to 20mm
thickness as per fourth row in the table QW-451.1.

So in this case to qualify the range from 3mm to 5mm we need to do another test coupon having thickness less
than or equal to 10mm as per second row in the table QW-451.1.
We have discussed about the thickness of base material qualified, now we will see the case of qualified weld
metal thickness.

Please see that up to 38mm of base material thickness of test coupon, the range of weld material qualified is
double the thickness of the deposited weld material thickness used in the test coupon for PQR.

Suppose in a 10mm test coupon, if we weld 5mm with GTAW welding process and the next 5mm with
SMAW welding process, as per the code, the qualified range of 20mm of the base material coupon can be
welded with 10mm of GTAW welding process and the other 10mm with SMAW welding process.

This way we can select the test coupon thickness for PQR based on the range of base material thickness (and
based on the weld metal thickness) that will be qualified by the qualification of the test coupon and the range
of base material thickness is assessed by the thickness of the work pieces/job that are to be welded in the
project.