Welding Inspection & Metallurgy API ICP Self Study Notes

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11.1 GENERAL This section provides details of specific welding issues encountered by the inspector in refineries and petrochemical plants. This section will be expanded as more issues reflecting industry experience are added.
11.2 HOT TAPPING AND IN-SERVICE WELDING <strong>API</strong> Publ 2201 provides an in depth review of the safety aspects to be considered when hot tapping or welding on inservice piping or equipment. Prior to performing this work, a detailed written plan should be developed and reviewed. The following is a brief summary of welding related issues. Two primary concerns when welding on in-service piping and equipment are: ■ ■ burn through and cracking. Burn through will occur if the un-melted area beneath the weld pool can no longer contain the pressure within the pipe or equipment. Weld cracking results when fast weld-cooling rates produce a hard, crack-susceptible weld microstructure. Fast cooling rates can be caused by flowing contents inside the piping and equipment, which remove heat quickly.
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Welding Inspection & Metallurgy API
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Content: 10 METALLURGY 10.1 General
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10.2 THE STRUCTURE OF METALS AND AL
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http://www.sv.vt.edu/classes/MSE209
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Phase Diagram http://www.azom.com/a
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10.2.1 The Structure of Castings Th
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HAZ- Heat Affected Zone
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HAZ http://www.oocities.org/ferrit
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1mm / 1mm 0.2mm 0.2+1+1= 2.2 mm API
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Steel & Alloy- Grains
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Steel & Alloy- Microvoid Coalescenc
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Minimizing trace elements or “inc
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Casting
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Discussion: Why Wrought products ar
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Wrought materials may consist of on
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Hypoeutectic Steel - Annealed
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Steel & Alloy- Annealed Pearlite
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1055 Steel Annealed 1055, used in s
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4140 Steel http://en.wikipedia.org/
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4140 Steel Q&T
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The metallurgy of each weld area is
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Dendritic - usually solidify in the
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Dendrite- usually solidify in the s
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Weld Macro- CS
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The heat-affected zone (HAZ) is adj
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http://www.twi-global.com/technical
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Overlay Welding
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The third component in a welded joi
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An important factor in selecting sh
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10.3.1 Melting Temperature The melt
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Phase Diagram
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Phase Diagram http://www.calphad.co
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10.3.3 Electrical Conductivity The
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Aluminum Welds
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Metals with a high coefficient of t
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Weld porosity
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A gas with a higher density is more
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Tensile testing - Tensile /Yield St
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Charpy Testing Samples
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Charpy impact testing
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Hardness testing- Hardness tester
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Hardness testing
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Hardness testing
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Ductility- Bend Tests
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10.4.1 Tensile and Yield Strength T
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For design purposes, the maximum us
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Note 1 A= proportional limit, B=ela
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Tensile Testing
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Actual tensile testing plot Elastic
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Elongation is the increase in gage
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The design of items should be based
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Bend Testing
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ASTM E290- Guided bend testing
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Bend Testing
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Bend Testing
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Knoop and Vickers Hardness Tester
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http://wes.ir/files/6936303material
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Rockwell hardness testing differs f
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Vickers hardness testing follows th
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http://www.twi-global.com/technical
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The type of notch and the impact te
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Online Metallurgy Course: http://ww
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Online Metallurgy Course http://210
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Online Metallurgy Course-Steel Maki
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Steels - The Structure of Engineeri
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Steels - The Structure of Engineeri
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Crystal Structures
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Phase Diagram
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Austenite
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This is a hypereutectoid alloy and
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Pearlite Pearlite is a phase mixtur
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This steel is of the eutectoid comp
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http://www.gowelding.com/met/carbon
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Martensite https://www.flickr.com/s
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Martensite https://www.flickr.com/s
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Bainite If the steel is cooled such
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FIGURE 2. The TTT diagram for aisi
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Bainite https://www.flickr.com/sear
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R e 0.2% Yield strength is the amou
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http://www.gowelding.com/weld/prehe
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End of reading! http://oregonstate.
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Preheating
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Preheating
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Preheating, for our purposes, is de
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If preheat is specified in the WPS
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10.6 POST-WELD HEAT TREATMENT Post-
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The primary reason for post-weld he
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PWHT (stress relief) can be applied
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Typical PWHT Chart
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PWHT- Typical PWHT Chart
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT- Local
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PWHT- Local
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PWHT- Local
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PWHT- Local
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PWHT- Equipments
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PWHT- Equipments
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PWHT- Equipments
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PWHT- Equipments
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Fun-Photo: Induction Bending Pipe b
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10.7 HARDENING Hardening or hardena
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AISI 1040 / 4340 http://www.azom.co
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AISI 4340 http://www.efunda.com/mat
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Welding- Thick plate welding
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Thick plate welding
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Weld Macro- Geometry
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Jominy Bar
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Jominy Bar
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Jominy Bar
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Hardening of the weld and base meta
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HIC- Hydrogen Induced Cracking
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TTT Curve
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Martensite
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A product analysis is a statement o
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Billets/Ingots
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Billets/Ingots
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Billets/Ingots
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Billets/Ingots
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Heat analysis- Billets/Ingots
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Billets/Ingots- Steel Mill Ladle An
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Product analysis- Pipe
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i. Any supplemental information or
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Grain size determination
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Fracture toughness
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Elevated mechanical property testin
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The inspector should review the mat
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http://www.slideshare.net/fullscree
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Quiz 1) See the figure below for po
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End of reading!
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10.9 WELDABILITY OF STEELS There ar
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Page 308 and 309: Weld restraint induces stresses tha
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Page 312 and 313: 10.10.1 Austenitic Stainless Steels
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Page 316: Weldability of austenitic stainless
Page 319 and 320: Welding can reduce the corrosion re
Page 321 and 322: Austenitic Stainless Steel Weld Cor
Page 323 and 324: Stainless Weld
Page 325 and 326: Inert Backing Gas
Page 340 and 341: 10.10.2 Nickel Alloys Nickel alloys
Page 342 and 343: Sluggish tendency- LOF
Page 344 and 345: Sluggish tendency- LOF
Page 346 and 347: Nickel alloys are also susceptible
Page 348 and 349: 11 Refinery and Petrochemical Plant
Page 352 and 353: Hot Tapping
Page 362 and 363: Burn Through
Page 364 and 365: Burn through: un-melted area beneat
Page 366 and 367: Electrode Considerations http://www
Page 368 and 369: 11.2.2 Flow Rates Under most condit
Page 370 and 371: For making attachment welds to equi
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Page 374 and 375: Case Study: Is it 36” or greater
Page 384: Adverse effects can also occur from
Page 387 and 388: 11.3 LACK OF FUSION WITH GMAW-S WEL
Page 389 and 390: The gas metal arc welding (GMAW) pr
Page 391 and 392: Since the transfer mode may be diff
Page 393 and 394: Hazards
Page 395 and 396: Hazards
Page 397 and 398: Mechanical Integrity
Page 399 and 400: Competent Inspectors http://amirazl
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