Welding Inspection & Metallurgy API ICP Self Study Notes

More documents

Recommendations

Info

This recommended practice provides guidance to the <strong>API</strong> authorized inspector on welding inspection as encountered with fabrication and repair of (a) refinery and (b) chemical plant equipment and piping.
This recommended practice provides guidance to the <strong>API</strong> authorized inspector on welding inspection as encountered with fabrication and repair of (a) refinery and (b) chemical plant equipment and piping.
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 18 and 19: Content: 1 SCOPE
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?