Welding Inspection & Metallurgy API ICP Self Study Notes

More documents

Recommendations

Info

Content: 1 SCOPE
This recommended practice provides guidance to the API authorized inspector on welding inspection as encountered with fabrication and repair of refinery and chemical plant equipment and piping. Common welding processes, welding procedures, welder qualifications, metallurgical effects from welding, and inspection techniques are described to aid the inspector in fulfilling their role implementing API 510, API 570, API Std 653 and API RP 582. The level of learning and training obtained from this document is not a replacement for the training and experience required to be an American Welding Society (AWS) Certified Welding Inspector (CWI).
Page 1: Welding Inspection & Metallurgy API
Page 5 and 6: API 577 - Advanced Welding Inspecti
Page 7: This recommended practice provides
Page 10 and 11: Speaker: Fion Zhang 2014/5/4
Page 12 and 13: 5 WELDING PROCESSES 5.1 General 5.2
Page 14 and 15: 9 NON-DESTRUCTIVE EXAMINATION 9.1 D
Page 16 and 17: 11 REFINERY AND PETROCHEMICAL PLANT
Page 20 and 21: This recommended practice provides
Page 28 and 29: API 577 is to aid the inspector in
Page 30 and 31: API Std 653 Tank Inspection, Repair
Page 32 and 33: How this API Standard relates with
Page 34: Typical E&P services are vessels as
Page 49 and 50: Keywords: The level of learning and
Page 52 and 53: This recommended practice does not
Page 54 and 55: This recommended practice does not
Page 58 and 59: The importance, difficulty, and pro
Page 60: A welding engineer should be consul
Page 64 and 65: Content: 2 REFERENCES 2.1 Codes and
Page 66 and 67: API • API 510 Pressure Vessel Ins
Page 68 and 69:
AWS • A2.4 Standard Symbols for W
Page 70 and 71:
API • RP 572 Inspection of Pressu
Page 72 and 73:
3 Definitions
Page 76 and 77:
The following definitions apply for
Page 78 and 79:
3.2 air carbon arc cutting (CAC-A):
Page 80 and 81:
Arc blow
Page 82 and 83:
3.6 arc welding (AW): A group of we
Page 84 and 85:
Crack
Page 86 and 87:
3.20 distortion: The change in shap
Page 88 and 89:
HAZ
Page 90 and 91:
HAZ
Page 92 and 93:
HAZ http://www.twi-global.com/techn
Page 94 and 95:
Hot Cracking
Page 96 and 97:
Hot cracking These cracks are known
Page 98 and 99:
Both solidification cracking and ho
Page 100 and 101:
Inspector: An individual who is qua
Page 102 and 103:
Qualified & Certified Inspectors
Page 104:
Qualified & Certified Inspectors
Page 107 and 108:
Figure A-1—Joint Types and Applic
Page 109 and 110:
3.36 lack of fusion (LOF): A non-st
Page 111:
Lamellar tear
Page 115 and 116:
3.41 nondestructive examination (ND
Page 117 and 118:
PMI
Page 119 and 120:
PMI
Page 121 and 122:
PMI
Page 123 and 124:
This is API 577 special way of defi
Page 125 and 126:
3.51 root face: The portion of the
Page 127 and 128:
Slag Inclusion
Page 129 and 130:
Slag Inclusions
Page 131 and 132:
3.58 throat theoretical: The distan
Page 133 and 134:
3.22 fillet weld size: For equal le
Page 135 and 136:
Transverse Cracks
Page 137 and 138:
Tungsten Inclusions - TIG Welding
Page 139 and 140:
TIG Welding - Tungsten Inclusions
Page 141 and 142:
3.64 welder certification: Written
Page 143 and 144:
3.69 weld reinforcement: Weld metal
Page 145 and 146:
weld toe weld reinforcement
Page 147 and 148:
weld toe weld reinforcement
Page 149 and 150:
Content: 4 WELDING INSPECTION 4.1 G
Page 151 and 152:
4.2 TASKS PRIOR TO WELDING The impo
Page 153:
4.2.1 Drawings, Codes, and Standard
Page 158 and 159:
i. Preheat requirements and accepta
Page 160 and 161:
Review requirements for the weldmen
Page 162 and 163:
4.2.2.1 Quality control items to as
Page 164 and 165:
Page 167:
4.2.4 NDE Information Confirm the N
Page 171 and 172:
Welding Equipment and Instruments
Page 173 and 174:
4.2.6 Heat Treatment and Pressure T
Page 175 and 176:
4.2.7 Materials Ensure all filler m
Page 177 and 178:
Materials
Page 179 and 180:
Page 181 and 182:
Weld Preparation- Fit-up & Dimensio
Page 183 and 184:
4.2.10 Welding Consumables Confirm
Page 186 and 187:
4.3.1 Quality Assurance Establish a
Page 188 and 189:
. Mock-up weldment, if required, me
Page 190 and 191:
In-process ferrite measurement
Page 192 and 193:
In-process ferrite measurement Why
Page 194 and 195:
Schaeffer diagram
Page 196 and 197:
4.4.1 Appearance and Finish Verify
Page 198 and 199:
Field hardness check
Page 200 and 201:
4.4.2 NDE Review Verify NDE is perf
Page 202 and 203:
4.4.3 Post-weld Heat Treatment Veri
Page 204 and 205:
PWHT Procedure
Page 206 and 207:
Metal temperature of component meet
Page 208 and 209:
4.5 NON-CONFORMANCES AND DEFECTS At
Page 210 and 211:
4.7 SAFETY PRECAUTIONS Inspectors s
Page 212 and 213:
Sevan Driller I
Page 214 and 215:
5 Welding Processes
Page 216 and 217:
Equipments & Piping
Page 218 and 219:
Equipments & Piping
Page 220 and 221:
Equipments & Piping
Page 222 and 223:
Equipments & Piping
Page 224 and 225:
5.2 SHIELDED METAL ARC WELDING (SMA
Page 226 and 227:
5.2.2 Advantages of SMAW Some commo
Page 228 and 229:
Shielded metal arc welding
Page 230 and 231:
SMAW
Page 232 and 233:
SMAW- Underwater Welding
Page 234 and 235:
SMAW- Qualification of Underwater W
Page 236 and 237:
SMAW- Structural Welding
Page 238 and 239:
SMAW- Transmission Pipeline Welding
Page 240 and 241:
SMAW- Weld Profile
Page 242 and 243:
SMAW- Weld Profile
Page 244 and 245:
SMAW- Weld Profile
Page 246 and 247:
SMAW- Weld Profile
Page 248 and 249:
SMAW- Grinding at Start-Stop
Page 250 and 251:
SMAW- Root Pass + Hot Pass
Page 252 and 253:
SMAW- Pipeline Tie-in Joint
Page 254 and 255:
SMAW- WPQ Test Coupon
Page 256 and 257:
SMAW- WPQ Test Coupon
Page 258 and 259:
SMAW- Smiling Experts at Work
Page 260 and 261:
Gas tungsten arc welding
Page 262 and 263:
Gas tungsten arc welding
Page 264 and 265:
GTAW
Page 266 and 267:
5.3.1 Advantages of GTAW Some commo
Page 268 and 269:
GTAW / TIG Weld a. Produces high pu
Page 270 and 271:
GTAW / TIG Weld
Page 272 and 273:
Tungsten Electrodes
Page 274 and 275:
Tungsten Electrodes
Page 276 and 277:
Tungsten- Automation
Page 278 and 279:
Gas metal arc welding GMAW / MIG (m
Page 280 and 281:
GMAW http://www.docslide.com/gmaw-f
Page 282 and 283:
GMAW CV
Page 284 and 285:
5.4.1 Short Circuiting Transfer (GM
Page 286:
Short Circuit mode http://www.ualbe
Page 289 and 290:
5.4.2 Globular Transfer This proces
Page 291 and 292:
Globular transfer mode http://www.u
Page 293 and 294:
Globular transfer mode http://www.w
Page 295 and 296:
5.4.3 Spray Transfer The spray tran
Page 297 and 298:
5.4.4 Advantages of GMAW Some commo
Page 299 and 300:
Pulsed GMAW - Modified Spray Mode h
Page 301 and 302:
GMAW-MIG CV
Page 303 and 304:
GMAW-MIG CV
Page 305 and 306:
GMAW-MIG CV
Page 307 and 308:
GMAW- Automation
Page 309 and 310:
GMAW- Automation
Page 311 and 312:
GMAW- Stainless Steel Piping
Page 313 and 314:
5.5 FLUX CORED ARC WELDING (FCAW) F
Page 315 and 316:
FCAW CV
Page 317 and 318:
FCAW-Self shield CV
Page 319 and 320:
FCAW
Page 321 and 322:
FCAW
Page 323 and 324:
3G FCAW WPQT
Page 325 and 326:
FCAW http://www.brewerweldingandfab
Page 327 and 328:
5.6 SUBMERGED ARC WELDING (SAW) Sub
Page 329 and 330:
SAW CV
Page 331 and 332:
Submerged arc welding (SAW)
Page 333 and 334:
Page 335 and 336:
Page 337 and 338:
Page 339 and 340:
SAW- Triple Electrodes Set-up (tilt
Page 341 and 342:
SAW - Experts at Work
Page 343 and 344:
Spiral Welded SAW Pipes
Page 345 and 346:
SAW- Vessel Internal Welding
Page 347 and 348:
SAW- Spiral Welded Pipes
Page 349 and 350:
SAW- Serious Experts at Work
Page 351 and 352:
SAW- Vessel Ellipsoidal Disk Head
Page 353 and 354:
SAW- Pipe Can Welding
Page 355 and 356:
SAW- Structural Welding
Page 357 and 358:
5.7.1 Advantages of SW Some commonl
Page 359 and 360:
Stud arc welding (SW)
Page 361 and 362:
Stud arc welding (SW)
Page 363 and 364:
Welding Transfer Modes: SMAW - CC T
Page 365 and 366:
1.0 Considering the benefits of pul
Page 367 and 368:
1.3 The short-circuit process In th
Page 369 and 370:
The short-circuit process is not a
Page 371 and 372:
By using 0.035- and 0.045-in.-dia.
Page 373 and 374:
1.6 Summary Equipment for short-cir
Page 375 and 376:
2.0 Understanding transfer modes fo
Page 377 and 378:
2.1 Short-circuit Transfer In short
Page 379 and 380:
Maintaining a constant contact tip-
Page 381 and 382:
Stainless steel GMAW electrodes nor
Page 383 and 384:
Spray Transfer Mode Shield Gas & Tr
Page 385 and 386:
This transfer mode is used mostly i
Page 387 and 388:
2.4 Pulse-Spray Transfer Mode In th
Page 389:
3.0 Pulsed GMAW Pulsed GMAW is tech
Page 394 and 395:
CV/CC Current Transfer Modes: Volta
Page 396 and 397:
5. Other Interesting Reading: 5.1 C
Page 398 and 399:
6: Welding Procedure
Page 400 and 401:
WPS/PQR
Page 402 and 403:
6.1 GENERAL Qualified welding proce
Page 404 and 405:
construction codes and proprietary
Page 406 and 407:
WPS 6.2 WELDING PROCEDURE SPECIFICA
Page 408 and 409:
ASME B31.3, Chapter V Fabrication,
Page 410 and 411:
6.2.1 Types of Essential Variables
Page 412 and 413:
These requirements should be reflec
Page 414 and 415:
Section IX requires that the manufa
Page 416 and 417:
Mechanical Testing
Page 418 and 419:
Mechanical testing- Tensile Testing
Page 420:
Tensile testing: Stress Strain Diag
Page 423 and 424:
Calculation of Tensile Properties o
Page 425 and 426:
Weld Hardness Test
Page 427 and 428:
Charpy Impact Testing
Page 429 and 430:
Guided Bend Test
Page 431 and 432:
Guided Bend Test
Page 433 and 434:
6.4 REVIEWING A WPS AND PQR Inspect
Page 435 and 436:
For simplicity purposes, the follow
Page 437 and 438:
6.4.1 Items to be Included in the W
Page 439 and 440:
y. Tungsten electrode size and type
Page 441 and 442:
q. Electrical Characteristics. r. T
Page 443 and 444:
WPS for Offshore Spar
Page 445 and 446:
WPS for Offshore Spar
Page 447 and 448:
WPS for Process Piping
Page 449 and 450:
7: Welding Materials
Page 451 and 452:
SAW
Page 453 and 454:
7.2 P-NUMBER ASSIGNMENT TO BASE MET
Page 455 and 456:
7.3 F-NUMBER ASSIGNMENT TO FILLER M
Page 457 and 458:
Keywords: 1. Consideration should b
Page 459 and 460:
F-Numbers
Page 461 and 462:
7.5 A-NUMBER (filler metal) To mini
Page 463 and 464:
7.6 FILLER METAL SELECTION Inspecto
Page 465 and 466:
To reduce exposure to moisture, wel
Page 467 and 468:
Content: 8 WELDER QUALIFICATION 8.1
Page 469 and 470:
8.2 WELDER PERFORMANCE QUALIFICATIO
Page 471 and 472:
Welder performance qualification ex
Page 473 and 474:
j. Backing gas used. k. Metal trans
Page 475 and 476:
9: Non-destructive Examination
Page 477 and 478:
ASME V Article Numbers: Gen Article
Page 479 and 480:
Discontinuities
Page 482 and 483:
NDT Capability: Table 4
Page 484 and 485:
NDT Capability: Table 5
Page 486 and 487:
Table 6- Discontinuities Commonly E
Page 488 and 489:
9.2 MATERIALS IDENTIFICATION During
Page 490 and 491:
PMI
Page 492 and 493:
9.3 VISUAL EXAMINATION (VT) 9.3.1 G
Page 495:
ASME Section V, Article 9, (Paragra
Page 499 and 500:
Vision Test
Page 501 and 502:
Robotic Visual Inspection Crawler
Page 503 and 504:
Remote Control Visual Inspection Cr
Page 505 and 506:
3. Magnifiers- helpful in bringing
Page 507 and 508:
Mirrors
Page 509 and 510:
9.3.2.2 Mechanical Aids a. Steel ru
Page 511 and 512:
Angle Ruler
Page 513 and 514:
Feeler Gauge
Page 515 and 516:
Vernier scale- a precision instrume
Page 517 and 518:
Gap Gauge and Thickness Gauge
Page 519 and 520:
Depth Gauge
Page 521 and 522:
Bridge Cam Gage
Page 523 and 524:
Adjustable fillet weld gauge
Page 525 and 526:
Measures the angle of the vertical
Page 527 and 528:
Weld fillet gauge being used to det
Page 529 and 530:
d. Weld size gauge (see Figure 19)
Page 531 and 532:
Hi-lo welding gauge
Page 533 and 534:
Digital pyrometer
Page 535 and 536:
What The Expert Say: http://youtu.b
Page 537 and 538:
MPI
Page 539 and 540:
The pattern formed by the particles
Page 541 and 542:
MPI
Page 543:
MPI
Page 546 and 547:
Some of the requirements listed in
Page 548 and 549:
Pie gauge
Page 550 and 551:
Pie Gauge
Page 552 and 553:
MT Calibration Shims
Page 554 and 555:
MT-Calibration Shims
Page 556 and 557:
MT- Wet fluorescent magnetic partic
Page 558 and 559:
Page 560 and 561:
Page 562 and 563:
MT Magnetic Particle Testing
Page 564 and 565:
Jack-up drilling rig
Page 566 and 567:
Drilling Rig in Operations
Page 568 and 569:
MT-Underwater
Page 570 and 571:
Magnetic Particle Testing
Page 572 and 573:
Page 574 and 575:
Page 576 and 577:
Page 578 and 579:
9.4.3 Demagnetization When the resi
Page 580 and 581:
Demagnetization
Page 582 and 583:
Gauss Meter
Page 584 and 585:
9.5 ALTERNATING CURRENT FIELD MEASU
Page 586 and 587:
ACFM uses a probe similar to an edd
Page 588 and 589:
Two components of the magnetic fiel
Page 591 and 592:
ACFM- Paint Removal is Not Necessar
Page 593 and 594:
Further Reading on ACFM
Page 595 and 596:
The ACFM Technique The ACFM method
Page 597 and 598:
Figure 1 B z B Z
Page 599 and 600:
Specialist Windows software is used
Page 601 and 602:
Once a defect is identified the dep
Page 603 and 604:
ACFM: This benefit is used to good
Page 605 and 606:
ACFM http://www.tscinspectionsyste
Page 607 and 608:
http://www.ndt.net/article/v08n09/w
Page 609 and 610:
9.6 LIQUID PENETRANT EXAMINATION (P
Page 611 and 612:
A limitation of PT is that standard
Page 613 and 614:
Figure 28—Florescent Penetrant Te
Page 615 and 616:
Some requirements listed in this ar
Page 617 and 618:
PT- Color Contrast Method
Page 619 and 620:
Page 621 and 622:
Page 623 and 624:
Page 625 and 626:
PT- Fluorescent Method
Page 627:
Eddy current uses a magnetic field
Page 639 and 640:
RT principles
Page 641 and 642:
RT profile radiography
Page 643 and 644:
RT- X Ray
Page 645 and 646:
RT-Source http://tv.sohu.com/upload
Page 647 and 648:
RT- Gamma Ray
Page 649 and 650:
RT- Gamma Ray
Page 651 and 652:
X-Ray Machine
Page 653 and 654:
RT- Gamma Ray
Page 655 and 656:
X-Ray Crawler
Page 657 and 658:
Golden Joint
Page 659 and 660:
RT- Techniques
Page 661:
RT- Techniques
Page 664:
RT- Interpretations
Page 667 and 668:
Digital RT
Page 669 and 670:
An NDT examiner interprets and eval
Page 671 and 672:
Break Time mms://a588.l3944020587.c
Page 673 and 674:
IQI- Image Quality Indicators
Page 675 and 676:
IQI- Image Quality Indicators ASTM
Page 678 and 679:
Page 680:
IQI Placement
Page 684 and 685:
IQIs (penetrameters) are tools used
Page 686 and 687:
Hole type IQI
Page 688:
Page 691 and 692:
Hole type IQI
Page 693 and 694:
RT Film coverage & overlaps Locatio
Page 695 and 696:
Keywords: (exam questions) Ir 192 C
Page 697 and 698:
Gamma Ray Radiography: Source
Page 699 and 700:
Gamma Ray Radiography: Source
Page 701 and 702:
Ir191- Ir 192 is typically supplied
Page 703 and 704:
Ir192
Page 705 and 706:
The gamma spectrum is shown in Fig.
Page 707 and 708:
Co 60
Page 709 and 710:
Search dosimeter-radiometer MKS-11
Page 711 and 712:
Film processing
Page 713 and 714:
9.8.6 Surface Preparation Where a s
Page 715:
RT Films
Page 718 and 719:
9.8.8 Radiographic Techniques The m
Page 720 and 721:
Planar defects
Page 722 and 723:
Planar & Volumetric defects
Page 724 and 725:
9.8.8.1 Single-wall Technique A sin
Page 726:
9.8.8.3 Double-wall Technique When
Page 729 and 730:
For double-wall viewing of welds, t
Page 731 and 732:
DWDI-DWV Double wall, double images
Page 733 and 734:
DWDI- Superimposed
Page 735 and 736:
9.8.9.1 Facilities for Viewing Radi
Page 737 and 738:
9.8.9.2 Quality of Radiographs Radi
Page 740 and 741:
Radiographic Density Radiographic d
Page 742 and 743:
Radiographic Density I o I t https:
Page 744 and 745:
Densitometer
Page 746 and 747:
9.8.9.4 Excessive Backscatter A lea
Page 748 and 749:
Because radiographic interpreters h
Page 750 and 751:
i. Film manufacturer and type/desig
Page 752 and 753:
X-Ray
Page 754 and 755:
X-ray
Page 756 and 757:
Figure 34—Interpass Slag Inclusio
Page 758 and 759:
Figure 36—Lack of Side Wall Fusio
Page 760 and 761:
LOF- Lack of Side wall Fusion
Page 762 and 763:
Wagon Track
Page 764 and 765:
Figure 38—Burn-through 1. A sever
Page 766 and 767:
Burn Through
Page 768 and 769:
Burn Through
Page 770 and 771:
Figure 40—Excessive Penetration (
Page 772 and 773:
Weld Joint
Page 774 and 775:
Figure 42—Transverse Crack 1. A f
Page 776 and 777:
Figure 44—Root Pass Aligned Poros
Page 778 and 779:
Gen Article 1 RT Article 2 Nil Arti
Page 780 and 781:
9.9 ULTRASONIC INSPECTION (UT) UT i
Page 783 and 784:
Straight beam techniques are used f
Page 785:
Straight beam UT
Page 788 and 789:
B-Scan
Page 790 and 791:
Figure 47—C-scan
Page 792 and 793:
The A-scan, as shown in Figure 45,
Page 794 and 795:
UT Testing- A-Scan
Page 796 and 797:
Article 4 requires a written proced
Page 798 and 799:
The reference standard (calibration
Page 800 and 801:
Calibration Blocks
Page 802 and 803:
Calibration Blocks
Page 804 and 805:
Calibration Blocks
Page 806 and 807:
Calibration Blocks
Page 808 and 809:
Calibration Blocks
Page 810 and 811:
Calibration Blocks
Page 812 and 813:
Calibration Blocks
Page 814 and 815:
Calibration Blocks
Page 816 and 817:
Calibration system checks should be
Page 818 and 819:
System checks are typically perform
Page 820 and 821:
9.9.1.1 Echo Evaluation with DAC Th
Page 822 and 823:
Figure 48—DAC Curve for a Specifi
Page 824:
DAC Plots
Page 827 and 828:
DAC / TCG
Page 831:
DAC Curve with a specific reflector
Page 834 and 835:
Unknown reflectors (flaws) are eval
Page 836 and 837:
UT testing
Page 838 and 839:
Reading Ultrasonic testing and imag
Page 840:
Numbers to remember • Each pass o
Page 843 and 844:
UT Transducers
Page 845 and 846:
UT Transducers
Page 847 and 848:
• 10% scanning overlapped Min of
Page 849:
9.9.4 Straight Beam Examination A s
Page 852 and 853:
Plate lamination checks
Page 854 and 855:
Lamination Checks
Page 856 and 857:
Lamination Checks
Page 858 and 859:
Lamination Checks
Page 860 and 861:
Lamination Checks
Page 862 and 863:
Angle Beam UT http://www.ndt-ed.org
Page 864 and 865:
9.9.5 Angle Beam Examination Typica
Page 866 and 867:
UT Scanning Patterns
Page 868 and 869:
Fillet weld defects
Page 870 and 871:
9.9.7 Discontinuity Evaluation and
Page 872 and 873:
The 6 dB drop technique is commonly
Page 874 and 875:
Other through-thickness sizing tech
Page 876 and 877:
The 6 dB drop technique Material Pr
Page 878 and 879:
Other through-thickness sizing tech
Page 880 and 881:
The ID Creeping wave method
Page 882 and 883:
9.9.7.3 The High Angle Longitudinal
Page 884 and 885:
AUT Vs RT http://www.olympus-ims.co
Page 886 and 887:
AUT Vs RT
Page 888 and 889:
TOFD
Page 890 and 891:
The Tip Diffraction Method http://w
Page 892 and 893:
Angle Beam Transducer http://www.ol
Page 894 and 895:
9.10 HARDNESS TESTING Hardness test
Page 896 and 897:
API 582- Vickers Hardness Test Prof
Page 898 and 899:
Hardness Testing
Page 900 and 901:
Hardness Testing
Page 902 and 903:
Hardness Testing
Page 904 and 905:
Weld Macro
Page 907 and 908:
Hardness Testing
Page 909 and 910:
Hardness Testing
Page 911 and 912:
Portable Hardness Testing
Page 913 and 914:
Page 915 and 916:
Page 917 and 918:
Page 919 and 920:
Page 921 and 922:
Page 923 and 924:
Page 925 and 926:
9.11 PRESSURE AND LEAK TESTING (LT)
Page 927 and 928:
Pressure Testing
Page 929 and 930:
Pressure Testing
Page 931 and 932:
Pressure Testing
Page 933 and 934:
Pressure Testing
Page 935 and 936:
Pressure Testing
Page 937 and 938:
Pressure Testing
Page 939 and 940:
Pressure Testing
Page 941 and 942:
Pressure Testing
Page 943 and 944:
Pressure Testing- Incidence
Page 945 and 946:
Page 947 and 948:
Page 949 and 950:
Page 951 and 952:
Page 953 and 954:
Pressure Testing- Risk
Page 955 and 956:
Page 957 and 958:
Page 959 and 960:
Page 961 and 962:
Page 963 and 964:
Page 965 and 966:
Leak testing Leak testing may be re
Page 967 and 968:
A wide variety of fluids and method
Page 969 and 970:
Bubble Leak Test- Vacuum Box
Page 971 and 972:
Leak Testing- Sensitive Leak Test
Page 973 and 974:
9.12.1.2 Inspection Information a.
Page 977 and 978:
10 Metallurgy
Page 979 and 980:
10 Metallurgy 10.1 GENERAL Metallur
Page 981:
Knowledge of cast structures is imp
Page 984 and 985:
Fe-4Mo Phase Diagram
Page 986 and 987:
Phase Diagram http://www.slideshare
Page 988 and 989:
Weld Grains
Page 990 and 991:
HAZ Weld region Fusion Boundary Coa
Page 992 and 993:
http://encyclopedia2.thefreediction
Page 994 and 995:
The properties of the cast structur
Page 996 and 997:
Steel & Alloy- Grains
Page 998 and 999:
http://www.power-eng.com/articles/p
Page 1000 and 1001:
Gases, such as hydrogen, which beco
Page 1002 and 1003:
10.2.2 The Structure of Wrought Mat
Page 1004 and 1005:
Cast VS. Wrought 1. Cast ingot has
Page 1006 and 1007:
Alloys may also consist of more tha
Page 1010 and 1011:
Steel & Alloy- Annealed Pearlite
Page 1012 and 1013:
Hypoeutectic Steel
Page 1014 and 1015:
1055 Steel Q&T 1055, used in swords
Page 1016 and 1017:
4140 Steel Annealed Ferrite Pearlit
Page 1018 and 1019:
10.2.3 Welding Metallurgy Welding m
Page 1020 and 1021:
SAW Welding
Page 1022 and 1023:
Dendritic- usually solidify in the
Page 1024 and 1025:
INCONEL alloy 690 is a high-chromiu
Page 1026 and 1027:
Overlay Welding
Page 1028 and 1029:
Each weld pass applied will have it
Page 1030 and 1031:
Overlay Welding
Page 1032 and 1033:
Weld Macro- Fillet Welds
Page 1034 and 1035:
An important aspect of welding meta
Page 1036 and 1037:
10.3 PHYSICAL PROPERTIES The physic
Page 1038 and 1039:
Alloyed metals start to melt at a t
Page 1040 and 1041:
Solidus/Liquidus
Page 1042:
10.3.2 Thermal Conductivity The the
Page 1045 and 1046:
The thermal conductivity of a mater
Page 1047 and 1048:
10.3.4 Coefficient of Thermal Expan
Page 1050 and 1051:
10.3.5 Density The density of a mat
Page 1052 and 1053:
Casting Defects
Page 1054 and 1055:
10.4 MECHANICAL PROPERTIES The mech
Page 1056 and 1057:
Tensile testing - Tensile /Yield St
Page 1058 and 1059:
Tensile testing - Tensile /Yield St
Page 1060 and 1061:
Charpy impact testing
Page 1062 and 1063:
Page 1064 and 1065:
Hardness testing- Sample polishing
Page 1066 and 1067:
Hardness testing
Page 1068 and 1069:
Hardness testing
Page 1070 and 1071:
Ductility
Page 1072 and 1073:
Ductility- Bend Tests
Page 1074 and 1075:
When the specimen is subjected to s
Page 1076 and 1077:
Tensile Testing
Page 1078 and 1079:
Tensile Testing Yield point Sample
Page 1081 and 1082:
http://practicalmaintenance.net/?p=
Page 1083 and 1084:
10.4.2 Ductility In tensile testing
Page 1085 and 1086:
The tensile specimen is punch marke
Page 1087 and 1088:
One of the most common tests used i
Page 1090:
Bend Test Jig
Page 1093 and 1094:
ASTM E290- Guided bend testing
Page 1095 and 1096:
Bend Testing
Page 1097 and 1098:
10.4.3 Hardness The hardness of a m
Page 1099 and 1100:
Knoop and Vickers Hardness Tester .
Page 1101:
One Brinell test consists of applyi
Page 1106 and 1107:
The Rockwell test is simple and rap
Page 1108:
The Vickers hardness value is prece
Page 1111 and 1112:
10.4.4 Toughness The toughness is t
Page 1115 and 1116:
Further Reading
Page 1117 and 1118:
Online Metallurgy Course http://hyp
Page 1119 and 1120:
Online Metallurgy Information http:
Page 1121 and 1122:
Online Metallurgy Course http://fre
Page 1123 and 1124:
Further Reading: http://practicalma
Page 1125 and 1126:
Introduction The component elements
Page 1127:
Phase Diagram
Page 1130 and 1131:
Austenite Austenite (γ), is a soli
Page 1132 and 1133:
Shows the grain structure of an aus
Page 1134:
This secondary electron SEM image s
Page 1137 and 1138:
Low carbon steel with a microstruct
Page 1139 and 1140:
Figure 1. Part of the equilibrium d
Page 1141 and 1142:
Martensite Martensite is commonly f
Page 1143 and 1144:
Martensite https://www.flickr.com/s
Page 1145 and 1146:
The strain energy involved in the m
Page 1147 and 1148:
Figure 1. Part of the equilibrium d
Page 1149 and 1150:
Bainite https://www.flickr.com/phot
Page 1151 and 1152:
Proof Stress Re0.2% Since it is dif
Page 1153 and 1154:
STEEL Steel is an alloy of iron, wi
Page 1155 and 1156:
Aluminum Cables
Page 1157 and 1158:
10.5 PREHEATING
Page 1159 and 1160:
Preheating
Page 1161 and 1162:
Preheating
Page 1163 and 1164:
• Bring temperature up to preheat
Page 1165 and 1166:
Preheat can be applied using severa
Page 1167 and 1168:
The temperature of PWHT is selected
Page 1169 and 1170:
Discussion: However there may also
Page 1171 and 1172:
Typical PWHT Chart Insertion temper
Page 1173 and 1174:
PWHT Chart
Page 1175 and 1176:
PWHT
Page 1177 and 1178:
PWHT
Page 1179 and 1180:
PWHT
Page 1181 and 1182:
PWHT
Page 1183 and 1184:
PWHT
Page 1185 and 1186:
PWHT
Page 1187 and 1188:
PWHT- Local
Page 1189 and 1190:
PWHT- Local
Page 1191 and 1192:
PWHT- Local
Page 1193 and 1194:
PWHT- Local
Page 1195 and 1196:
PWHT- Equipments
Page 1197 and 1198:
PWHT- Equipments
Page 1199 and 1200:
PWHT- Equipments
Page 1201 and 1202:
PWHT- Equipments
Page 1203 and 1204:
Fun-Photo: Induction Bending Pipe b
Page 1205 and 1206:
Fun-Photo: Induction Bending Pipe b
Page 1207 and 1208:
Other factors can also affect harde
Page 1209 and 1210:
http://www.azom.com/article.aspx?Ar
Page 1212 and 1213:
Welding variables, such as heat inp
Page 1214 and 1215:
Welding- Plate thickness & Weld Geo
Page 1216 and 1217:
Weld Macro- Geometry
Page 1218 and 1219:
Page 1220 and 1221:
Page 1222 and 1223:
The simplest means to determine har
Page 1224 and 1225:
Jominy Bar
Page 1226 and 1227:
Jominy Bar
Page 1228 and 1229:
It may be important for the welding
Page 1230 and 1231:
Typical Hardness Values Table 11—
Page 1232 and 1233:
HIC
Page 1234 and 1235:
HIC- Hydrogen Induced Cracking
Page 1236 and 1237:
TTT Curve
Page 1238 and 1239:
Martensite
Page 1240 and 1241:
10.8 MATERIAL TEST REPORTS Material
Page 1242 and 1243:
Billets/Ingots
Page 1244 and 1245:
Billets/Ingots
Page 1246 and 1247:
Billets/Ingots
Page 1248 and 1249:
Billets/Ingots
Page 1250 and 1251:
Billets/Ingots
Page 1252 and 1253:
Billets/Ingots
Page 1254 and 1255:
Product analysis- Pipe
Page 1256 and 1257:
For the purposes of this publicatio
Page 1258 and 1259:
Ductile to brittle transition tempe
Page 1260 and 1261:
Fracture toughness
Page 1262 and 1263:
Page 1264 and 1265:
Elevated mechanical property testin
Page 1266 and 1267:
Further Reading
Page 1268 and 1269:
Quiz 1) See the figure below for po
Page 1270 and 1271:
c) 50% coarse pearlite + 25% bainit
Page 1272 and 1273:
10.9 WELDABILITY OF STEELS
Page 1274 and 1275:
Weldability is related to many fact
Page 1276 and 1277:
The addition of carbon generally ma
Page 1278 and 1279:
Typically, ■ ■ ■ Steels with
Page 1280 and 1281:
The simplest weldability tests are
Page 1282 and 1283:
Weldability Test- Cruciform testing
Page 1284 and 1285:
Another approach to measuring susce
Page 1286 and 1287:
10.10 WELDABILITY OF HIGH-ALLOYS Th
Page 1288 and 1289:
Hot Shortness: • solidification c
Page 1290 and 1291:
Ferrite Meter
Page 1293 and 1294:
Coefficients of Linear Thermal Expa
Page 1295 and 1296:
Sensitized Austenitic SS Common to
Page 1297 and 1298:
Weld Decay http://www.corrosionclin
Page 1299 and 1300:
Inert Backing Gas
Page 1301 and 1302:
Inert Backing Gas
Page 1303 and 1304:
Inert Backing Gas
Page 1305:
Inert Backing Gas http://www.foodpr
Page 1308 and 1309:
Inert Backing Gas
Page 1310 and 1311:
Inert Backing Gas http://www.juncti
Page 1312 and 1313:
Inert Backing Gas
Page 1314 and 1315:
Inert Backing Gas
Page 1316 and 1317:
One of the main differences between
Page 1318 and 1319:
Sluggish tendency- LOF
Page 1320 and 1321:
Wider Bevel Angle & Thinner Root Fa
Page 1322 and 1323:
Nickel Welding: The faster a nickel
Page 1324 and 1325:
Content: 11 REFINERY AND PETROCHEMI
Page 1326 and 1327:
11.2 HOT TAPPING AND IN-SERVICE WEL
Page 1328 and 1329:
Hot Tapping
Page 1330 and 1331:
Hot Tapping
Page 1332 and 1333:
Hot Tapping
Page 1334 and 1335:
Hot Tapping
Page 1336 and 1337:
Hot Tapping
Page 1338 and 1339:
Burn Through
Page 1340 and 1341:
11.2.1 Electrode Considerations Hot
Page 1342 and 1343:
Cellulosic type electrodes (e.g., E
Page 1344 and 1345:
If the normal flow of liquids excee
Page 1346 and 1347:
Points to consider: Is it 36” or
Page 1348 and 1349:
Case Study: 1. Is it 36” or great
Page 1350 and 1351:
Case Study: Is it 36” or greater
Page 1352 and 1353:
Page 1354 and 1355:
Page 1356 and 1357:
Page 1358 and 1359:
11.2.3 Other Considerations To avoi
Page 1361 and 1362:
11.2.4 Inspection Inspection tasks
Page 1363 and 1364:
GMAW-S LOF
Page 1365 and 1366:
Due to this inherent nature of the
Page 1367 and 1368:
The quick freeze characteristic, wh
Page 1369 and 1370:
Hazards
Page 1371 and 1372:
Mechanical Integrity
Page 1373 and 1374:
Happy Inspectors
Page 1375:
ICP Status http://myicp.api.org/Dir
show all

Welding Inspection & Metallurgy API ICP Self Study Notes

Create successful ePaper yourself

Delete template?

Save as template?