PEW 209 .

02
Inspect Production Weld

SAES W - SERIES
This series provides background information on welding and outlines engineering considerations to aid the inspector in understanding the mandatory requirements of welding standards

ASME Standards
ASME standards are published by The American Society of Mechanical Engineers

AWS Standards
The American Welding Society (AWS) publishes standards containing information which the inspector may require during pre welding inspection

SAEP - 321
SAEP 321 describes the procedure and general requirements for qualifying all welders and welding operators in Saudi Aramco

Job File
The job file contains documents necessary to the project and welding personnel who are doing the job

Blueprints / Drawings
The job file contains blueprints or drawings of the entire fabrication

Scope of Work
The scope of work explains the main activities of a project

Request for Welding Procedure Approval

All welding procedures must approved by Saudi Aramco

Procedure Qualification Record (PQR)

All welding procedures must be pre qualified

Contact List
The job file should include a contact list

Inspecting a Weld Set - Up

The inspector starts a weld set up inspection after thoroughly inspecting the job file and studying the standards referenced there.The basic purpose of the weld set up inspection is to verify the following

Construction Materials

Weld Joint Preparation

Joint Fit Up

Tack Welds

Welding Environment

Safety Procedures

Construction Materials
The inspector must verify that the materials to be used in a construction project are as specified

Base Metal
Metal on site must be the same as the metal specified for the job

Welding Electrodes
The inspector must check the electrodes

Weld Joint Preparation

Bevel Angle

Wall Thickness

Root Face

Joint Fit Up
If the bevel is too narrow or wide,fusion may not be complete, slag may be trapped in the weld and there can be lack of penetration or Excess Penetration

Excess Penetration

Entrapped Slag

Lack of Penetration

Joint Fit Up
The inspector checks these during fit up

Root Opening

Joint Fit Up
The inspector checks these during fit up

Mismatch (high-low)

Joint Fit Up
The root face must be clean dry and smooth

Joint Fit Up
The inspector can use a welding gauge to measure the bevel angle

Joint Fit Up
The inspector can use a welding gauge to measure the bevel angle

Joint Fit Up
The bevel angle can also be measured with a ruler and a protractor

Bevel Angle

Joint Fit Up
The High low is the amount of misalignment when joining metals

Joint Fit Up
High Low can be measured using a Hi lo Welding Gage

Tack Welds
Tack welds must be performed by qualified welders

Welding Environment
The inspector must assess the wind conditions at the welding site

Welding Environment
Too much wind will blow the gas shield away and welding discontinuities will result

Safety Procedures
Welding is a safe operation if everyone obeys the safety rules

Safety (Bad Practice)

Safety (Good Practice)

Safety (Eye Protection)

You only have one pair of eyes Protect them !!!

Pre Heat Temperature

Some metals to be welded must be pre heated to a specified temperature prior to welding

Templestiks
The inspector uses a Templstik to ensure the correct pre heat has been attained .

Pre Heat Temperature

The pre heat must be extended over a distance of not less than 75mm Weld

75 mm

75 mm

Welding Technique
A good welding Bead depends on the following

Correct Electrode
Correct Current Correct Polarity

Welding Technique
A good welding Bead depends on the following

Correct Movement of the Welder Correct Arc Distance Steady Travel Speed

Stringer Bead
A stringer bead is a weld bead that is made without much side to side motion

Root Pass

Weave Welding
Weave welding is a running bead with side to side motion

Weave Welding

Weld Sequence
The inspector makes certain that the welder follows the required weld sequence

3
2

Shielding
To obtain a weld of high quality, the welder must maintain efficient shielding throughout the welding operation

Gas Shielding

Gas Mixtures
The welder uses various gases to create the gas shield

Gas Flow Rate

The gas flow rate is the amount of gas that flows from the gas cylinder during a given period of time

Welding Variables
Welding variables are conditions that affect the weld

Welding Variables ASME IX

Filler Metal & Flux Drying Procedure Filler Metal Classification Electrical Parameters

Travel Speed & Wire Feed Speed

Welding Variables ASME IX

Interpass Temperature Post Weld Heat Treatment

Pre - Heat Temperature

Voltage
Voltage is a variable that can affect the weld

Amperage
The inspector must check the WPS for the specified amperage level

Travel Speed
The inspector must check the WPS for the designated travel speed

Current
It is possible to do arc welding with either alternating current (AC) or direct current (DC)

Interpass Cleaning
The welder must remove all slag from the weld

Back Gouging
Back gouging occurs when weld metal and base metals are removed from the opposite side of a partially welded joint

Gouged Weld

Air Carbon Arc Gouging

This process is used for cutting of steels and back gouging of welds