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A
Accu-Pulse (MTE) - MIG process that delivers precise control of the arc even over tack welds and in tight corners.
Provides optimum and precise molten puddle control.
Accu-Rated Power (MTE) - The standard for measuring engine-driven generator power. Guarantees delivery of all power
promised.
Active Arc Stabilizer (MTE) - Enhances arc starts and provides a softer arc throughout all ranges, with less puddle
turbulence and less spatter.
Adaptive Hot Start (MTE) - Automatically increases the output amperage at the start of a Stick weld, should the start
require it. Helps eliminate sticking of the electrode at arc start.
Advanced Active Field Control Technology (MTE) - A simple and reliable patented way of accurately controlling an
engine drive's generator weld output.
Air Carbon Arc Cutting (CAC-A) - A cutting process by which metals are melted by the heat of an arc using a carbon
electrode. Molten metal is forced away from the cut by a blast of forced air.
Alternating Current (AC) - An electrical current that reverses its direction at regular intervals, such as 60 cycles alternating
current (AC), or 60 hertz.
Aluminum Pulse Hot Start (MTE) - Automatically provides more arc power to the Millermatic 350P to eliminate a "cold
start" that is inherent with aluminum starts.
Amperage - The measurement of the amount of electricity flowing past a given point in a conductor per second. Current is
another name for amperage.
Arc - The physical gap between the end of the electrode and the base metal. The physical gap causes heat due to
resistance of current flow and arc rays.
Arc-Drive (MTE) - Automatically enhances Stick welding, especially on pipe, by focusing the arc and preventing the
electrode from going out.
Auto-Crater (MTE) - Allows a TIG arc on the Trailblazer Series to crater-out, allowing time for the addition of filler,
without the loss of shielding gas. Eliminates the need for a remote control at arc end.
Auto-Line (MTE) - Allows for any primary input voltage within a range, single- or three-phase, 50 or 60 Hz. Also adjusts
for voltage spikes within the entire range.
Auto-Link (MTE) - Internal inverter power source circuit that automatically links the power source to the primary voltage
being applied (230 V or 460 V), without the need for manually linking primary voltage terminals.
Automatic Start at Idle (MTE) - Idles engine immediately when started, extending engine life and reducing fuel
consumption and noise.
Automatic Welding - Uses equipment which welds without the constant adjusting of controls by the welder or operator.
Equipment controls joint alignment by using an automatic sensing device.
Auto-Refire (MTE) - Automatically controls the pilot arc when cutting expanded metal or multiple pieces of metal, without
manual re-triggering.
Auto Remote Sense (MTE) - Automatically switches machine from panel to remote control with remote connected.
Available on Dimension NT 450, XMT 350, Trailblazer Series, and PRO 300. Eliminates confusion and need for
panel/remote switch.
Auto-Stop (MTE) - Allows a TIG arc to be stopped without the loss of shielding gas on the Trailblazer Series.
Axcess File Management (MTE) - Software that turns a standard Palm handheld into a data card and a remote pendant
for all Axcess systems. Allows e-mailing, storage, and transfer of welding programs.
C
Constant Current (CC) Welding Machine - These welding machines have limited maximum short circuit current. They
have a negative volt-amp curve and are often referred to as "droopers".
Constant-Speed Wire Feeder - Feeder operates from 24 or 115 VAC supplied by the welding power source.
Constant Voltage (CV), Constant Potential (CP) Welding Machine - This type of welding machine output maintains a
relatively stable, consistent voltage regardless of the amperage output. It results in a relatively flat volt-amp curve.
Cool-On-Demand (MTE) - Integrated cooler runs only when needed on Syncrowave 250 DX & 350 LX.
Current - Another name for amperage. The amount of electricity flowing past a point in a conductor every second.
D
Defect - One or more discontinuities that cause a testing failure in a weld.
Dig - Also called Arc Control. Gives a power source variable additional amperage during low voltage (short arc length)
conditions while welding. Helps avoid sticking Stick electrodes when a short arc length is used.
Direct Current (DC) - Flows in one direction and does not reverse its direction of flow as does alternating current.
Direct Current Electrode Negative (DCEN) - The direction of current flow through a welding circuit when the electrode lead
is connected to the negative terminal and the work lead is connected to the positive terminal of a DC welding machine. Also
called direct current, straight polarity (DCSP).
Direct Current Electrode Positive (DCEP) - The direction of current flow through a welding circuit when the electrode lead
is connected to a positive terminal and the work lead is connected to a negative terminal to a DC welding machine. Also
called direct current, reverse polarity (DCRP).
Dual Power Option (MTE) - Gives the option on the PipePro 304 engine drive to use 230 volt single- or three-phase
electric input power, eliminating engine wear, noise and emissions, as well as fuel costs.
Duty Cycle - The number of minutes out of a 10-minute time period an arc welding machine can be operated at maximum
rated output. An example would be 60% duty cycle at 300 amps. This would mean that at 300 amps the welding machine
can be used for 6 minutes and then must be allowed to cool with the fan motor running for 4 minutes.
E
Engine Save Start (MTE) - Idles engine 3 - 4 seconds after starting on Trailblazer 275 DC and 302. Extends engine life
and reduces fuel consumption.
F
Fan-On-Demand (MTE) - Internal power source cooling system that only works when needed, keeping internal
components cleaner.
FasTip Contact Tip (MTE) - Patented, single-turn for quick change - no tools needed!.
Fixed Automation - Automated, electronically controlled welding system for simple, straight or circular welds.
Flexible Automation - Automated, robotically controlled welding system for complex shapes and applications where
welding paths require torch-angle manipulation.
Flux Cored Arc Welding (FCAW) - An arc welding process which melts and joins metals by heating them with an arc
between a continuous, consumable electrode wire and the work. Shielding is obtained from a flux contained within the
electrode core. Added shielding may or may not be provided from externally supplied gas or gas mixture.
G
Gas Metal Arc Welding (GMAW) - See MIG Welding.
Ground Lead - When referring to the connection from the welding machine to the work, see preferred term Workpiece Lead.
Gun-On-Demand (MTE) - Allows you to use either a standard gun or a Spoolmatic gun on Millermatic 210, 251, and
350 without flipping a switch. The machine senses which gun you are using when you pull the trigger.
H
Hertz - Hertz is often referred to as "cycles per second". In the United States, the frequency or directional change of
alternating current is usually 60 hertz.
High Frequency - Covers the entire frequency spectrum above 50,000 Hz. Used in TIG welding for arc ignition and
stabilization.
Hot Start (MTE) - Used on some Stick (SMAW) machines to make it easier to start difficult-to-start electrodes. Used for
arc starting only.
I
Inverter - Power source which increases the frequency of the incoming primary power, thus providing for a smaller size
machine and improved electrical characteristics for welding, such as faster response time and more control for pulse
welding.
K
KVA (Kilovolt-amperes) - Kilovolt-amperes. The total volts times amps divided by 1,000, demanded by a welding power
source from the primary power furnished by the utility company.
KW (Kilowatts) - Primary KW is the actual power used by the power source when it is producing its rated output. Secondary
KW is the actual power output of the welding power source. Kilowatts are found by taking volts times amps divided by 1,000
and taking into account any power factor.
L
Lift-Arc (MTE) - This feature allows TIG arc starting without high frequency. Starts the arc at any amperage without
contaminating the weld with tungsten.
Low OCV Stick (MTE) - Reduces OCV on several Maxstar and Dynasty models when power source is not in use
eliminating need for add-on voltage reducers.
LVC (Line Voltage Compensation) (MTE) - Keeps the output of a power source constant, regardless of minor
fluctuations in input power.
M
Microprocessor - One or more integrated circuits that can be programmed with stored instructions to perform a variety of
functions.
MIG Welding (GMAW or Gas Metal Arc Welding) - Also referred to as solid wire welding. An arc welding process which
joins metals by heating them with an arc. The arc is between a continuously fed filler metal (consumable) electrode and the
workpiece. Externally supplied gas or gas mixtures provide shielding.
Short Circuit Transfer Gets its name from the welding wire actually short circuiting (touching)
the base metal many times per second. Some spatter is produced, but the transfer can be used in
all welding positions and on all thicknesses of metal.
Globular Transfer Named for globs of weld metal transferring across the arc in a gravity feed.
Droplets across the arc are usually larger than the electrode diameter. It does not produce a very
smooth weld bead appearance, and some spatter can occur. Usually limited to the flat and
horizontal welding positions, and not used on thin metals.
Spray Transfer - Named for a spray of tiny molten droplets across the arc, usually smaller than
the wire diameter. Uses relatively high voltage and amperage values, and the arc is on at all times
after the arc is established. Very little if any spatter is produced. Usually used on thicker metals in
the flat or horizontal welding positions.
Pulsed-Spray Transfer For this variation of spray transfer, the welding machine pulses the
output between high peak currents and low background currents. The weld pool gets to cool slightly
during the background cycle, making it slightly different than Spray Transfer. This can allow for
welding in all positions on either thin or thick metals.
For more information on MIG Welding, please see MIG Tech Tips.
MVP (Multi-Voltage Plug) (MTE) - Allows connection of Millermatic DVI or Passport to 115- or 230-volt receptacles
without tools - just choose the plug that fits the receptacles without tools - just choose the plug that fits the receptacle.
O
Open-Circuit Voltage (OCV) - As the name implies, no current is flowing in the circuit because the circuit is open. The
voltage is impressed upon the circuit, however, so that when the circuit is completed, the current will flow immediately.
P
Palm OS Compatibility - Replaces the need for data cards and remote control pendants on Axcess models.
Plasma Arc Cutting - An arc cutting process which severs metal by using a constricted arc to melt a small area of the work.
This process can cut all metals that conduct electricity. For more information on Plasma Cutting, please see Plasma Tech
Tips.
Pounds Per Square Inch (psi) - A measurement equal to a mass or weight applied to one square inch of surface area.
Power Efficiency - How well an electrical machine uses the incoming electrical power.
Power Factor Correction - Normally used on single-phase, constant current power sources, to reduce the amount of
primary amperage demanded from the power company while welding.
Primary Power - Often referred to as the input line voltage and amperage available to the welding machine from the shop's
main power line. Often expressed in watts or kilowatts (KW), primary input power is AC and may be single-phase or three-
phase.
Pulsed MIG (MIG-P) - A modified spray transfer process that produces no spatter because the wire does not touch the weld
puddle. Applications best suited for pulsed MIG are those currently using the short circuit transfer method for welding steel,
14 gauge (1.8 mm) and up.
Pulsed TIG (TIG-P) - A modified TIG process appropriate for welding thinner materials.
Pulsing - Sequencing and controlling the amount of current, the frequency, and the duration of the welding arc.
R
Rated Load - The amperage and voltage the power source is designed to produce for a given specific duty cycle period. For
example, 300 amps, 32 load volts, at 60% duty cycle.
Regulated Metal Deposition (RMD) (MTE) - Precisely controlled short-circuit transfer technology, available as an option on
Axcess models. For spatter reduction, up to 20% reduced heat input, or filling gaps.
Resistance Spot Welding (RSW) - A process in which two pieces of metal are joined by passing current between
electrodes positioned on opposite sides of the pieces to be welded. There is no arc with this process. For more information
on Resistance Spot Welding, please see Resistance Spot Welding Tech Tips.
RMS (Root Mean Square) - The "effective" values of measured AC voltage or amperage. RMS equals 0.707 times the
maximum, or peak value.
S
Semiautomatic Welding - The equipment controls only the electrode wire feeding. The welding gun movement is controlled
by hand.
SharpArc (MTE) - Optimizes the size and shape of the arc cone, bead width and appearance, and puddle fluidity.
Available on the Millermatic 350/350P.
Shielding Gas - Protective gas used to prevent atmospheric contamination of the weld pool.
Single-Phase Circuit - An electrical circuit producing only one alternating cycle within a 360 degree time span.
Smart Fuel Tank (MTE) - Tank's design minimizes chance of fuel backflow.
Spatter - The metal particles blown away from the welding arc. These particles do not become part of the completed weld.
Spot Welding - Usually made on materials having some type of overlapping joint design. Can refer to resistance, MIG or
TIG spot welding. Resistance spot welds are made from electrodes on both sides of the joint, while TIG and MIG spots are
made from one side only.
Squarewave - The AC output of a power source that has the ability to rapidly switch between the positive and negative
half cycles of alternating current.
Stick Welding (SMAW or Shielded Metal Arc) - An arc welding process which melts and joins metals by heating them with
an arc, between a covered metal electrode and the work. Shielding gas is obtained from the electrode outer coating, often
called flux. Filler metal is primarily obtained from the electrode core. For more information on Stick Welding, please see Stick
Tech Tips.
Submerged Arc Welding (SAW) [PDF] - A process by which metals are joined by an arc or arcs between a bare metal
electrode or electrodes and the work. Shielding is supplied by a granular, fusible material usually brought to the work from a
flux hopper.
Sun Vision (MTE) - Allows easy reading of digital meters in direct sunlight or shade on Trailblazer 275 DC and 302.
SureStart (MTE) - Provides consistent Axcess arc starts by precisely controlling power levels for specific wire and gas
combinations.
Syncro Start (MTE) - Allows selectable customized arc starts on Syncrowave 200, Syncrowave 250 DX and 350 LX
T
Three-Phase Circuit - An electrical circuit delivering three cycles within a 360 degree time span, and the cycles are 120
electrical degrees apart.
TIG Welding (GTAW or Gas Tungsten Arc) - Often called TIG welding (Tungsten Inert Gas), this welding process joins
metals by heating them with a tungsten electrode which should not become part of the completed weld. Filler metal is
sometimes used and argon inert gas or inert gas mixtures are used for shielding. For more information on TIG Welding,
please see TIG Tech Tips.
Tip Saver Short Circuit Protection (MTE) - Shuts down output when the MIG contact tip is shorted to the work, on the
Millermatic 135 and 175. Extends contact tip life and protects machine.
Torch - A device used in the TIG (GTAW) process to control the position of the electrode, to transfer current to the arc, and
to direct the flow of the shielding gas.
Torch Detection (MTE) - Syncrowave 250 DX and 350 LX detect if TIG torch is water- or air-cooled.
Touch Start - A low-voltage, low-amperage arc starting procedure for TIG (GTAW). The tungsten is touched to the
workpiece; when the tungsten is lifted from the workpiece an arc is established.
Tri-Cor Technology (MTE) - Stabilizer design on the Bobcat 250 that delivers smoother welds and decreased spatter with
E7018 electrodes, without sacrificing performance with E6010 electrodes.
Tungsten - Rare metallic element with extremely high melting point (3410o Celsius). Used in manufacturing TIG electrodes.
V
Voltage - The pressure or force that pushes the electrons through a conductor. Voltage does not flow, but causes amperage
or current to flow. Voltage is sometimes termed electromotive force (EMF) or difference in potential.
Voltage-Sensing Wire Feeder - Feeder operates from arc voltage generated by welding power source.
Volt-Amp Curve - Graph that shows the output characteristics of a welding power source. Shows voltage and amperage
capabilities of a specific machine.
W
WaveWriter File Management (MTE) - Includes all Axcess File Management functions, plus a simple, graphical wave-
shaping program for the most demanding pulsed MIG applications.
Weld at Idle (MTE) - Allows PipePro 304 to automatically weld at a quieter, lower RPM, using less fuel. When more
output is required, he machine goes to high speed without a change in arc.
Weld Metal - The electrode and base metal that was melted while welding was taking place. This forms the welding bead.
Weld Transfer - Method by which metal is transferred from the wire to the molten puddle.
Wet-Stacking - Unburned fuel and engine oil collecting in the exhaust stack of a diesel engine, characterized by the exhaust
stack being coated with a black, sticky, oily substance. The condition is caused by the engine being run at too light of a load
for extended periods of time. Caught early, this does not cause permanent damage and can be alleviated if additional load is
applied. If ignored, permanent damage can occur to the cylinder walls and piston rings. Improved emission standards and
higher quality fuel make engines less prone to wet-stacking in recent years.
Wind Tunnel Technology (MTE) - Internal air flow on many Miller inverters, that protects electrical components and PC
boards from contamination, significantly improving reliability.
Wire Feed Speed - Expressed in in/min or mm/s, and refers to the speed and amount of filler metal fed into a weld.
Generally speaking the higher the wire feed speed, the higher the amperage.
Workpiece Connection - A means to fasten the work lead (work cable) to the work (metal to be welded on). Also, the point
at which this connection is made. One type of work connection is made with an adjustable clamp.
Workpiece Lead - The conductor cable or electrical conductor between the arc welding machine and the work.
The requirement for weld procedures and the coding of welders is specified in
application standards such as:
BS 2971 Class 2 Arc Welding of Carbon Steel Pipework {Gas Pressures less
than 17 barg}
Application Standards
All the above application standards require welding procedures to EN ISO
15614 Part 1 (Formerly BSEN 288-3) and welders coded to BSEN 287 Part 1.
Some applications of BS 2971 and BS 5169 permit welders to be qualified
without procedures to BS 4872, a less stringent standard.
Welding Procedures
Welding procedures are required when it is necessary to demonstrate that your
company has the ability to produce welds possessing the correct mechanical
and metallurgical properties.
4. If the test is successful you or the test body complete the appropriate
documents which the test bodies surveyor signs and endorses. The
necessary documents are as follows:-
Note The E1, E2, E3, E4 designations are used by some Inspection Authorities
to refer to the individual forms. Examples of these forms are given in annexes
of EN ISO 15614 and EN287.
In general a new welding procedure must be qualified for each of the following
changes subject to the individual requirements of the appropriate standard
used:-
The diameter range for pipe given by the welding standard is exceeded.
Typically 0.5xD to 2xD.
Welder Approval
Once the procedure is approved it is necessary to demonstrate that all your
welders working to it have the required knowledge and skill to put down a
clean sound weld. If the welder has satisfactorily completed the procedure test
then he is automatically approved but each additional welder must be approved
by completing an approval test to an appropriate standard such as EN 287 part
1 as follows:-
Note The above changes that require a new welding procedure may also
apply to the welders approval, refer to the standard for precise details.
ASME 9
ASME 9 as far as the pressurised systems regulations are concerned can be
considered as equivalent to EN ISO 15614-1 /EN 287. However it may not be
contractually acceptable. The advantage in using ASME is that generally fewer
procedure tests are required particularly when welding pipework.
Acceptance Standards
In general welds must show a neat workman like appearance. The root must be
fully fused along the entire length of the weld, the profile of the cap should
blend in smoothly with the parent material and the weld should be significantly
free from imperfections. Reference should be made to the acceptance standard
for precise details.
Its a good idear to ensure that you can achieve the appropriate standard before
you call in an Inspection Body. Penetration defects and lack of fusion can often
be easily detected by sectioning welds and bending them
Procedure number
Process type
Thickness range.
Welding Position
MIG
SUB
Specific To Welding Processes MMA TIG MAG
ARC
FCAW
Sketches
A sketch of the joint configuration is required which should include the
basic dimensions of the weld preparation. Some indication of the run
sequence is also beneficial, particularly if the correct sequence is
essential to ensure the properties of the weld are maintained.
Production Sequence
Whilst this is good practice it is not a requirement of either ASME 9 or
EN288 Part 2; it could be issued as a separate QA procedure if preferred.
Job knowledge 51: Cutting processes - plasma arc cutting - process and equipment
considerations
The plasma cutting process is described covering process characteristics, power source, cut
edge quality and process variants (dual gas, water injection, water shroud, air plasma, high
tolerance plasma)
Job knowledge 27: Health, safety and accident prevention - oxyacetylene welding,
cutting and heating
Guidelines are given on the principal health and safety considerations for oxyacetylene
welding to ensure safe welding practices.
Job knowledge 28: Health, safety and accident prevention: electrical hazards -
power source and installation
Article gives the principal health and safety considerations to ensure safe welding practices
and prevent accidents, particularly on power source installation and electrical hazards
Job knowledge 29: Health, safety and accident prevention - arc welding
This article gives guidelines on health and safety considerations when arc welding to ensure
safe practice and prevent accidents. The principal hazards are associated with electric shock
and arc radiation.
Job knowledge 30: Health, safety and accident prevention - health risks of welding
fume/gases
The principal health and safety considerations are looked at to ensure safe welding
practices. A general overview of the hazards associated with fume and gases generated
during welding.
Job knowledge 31: Health, safety and accident prevention - health risks from fume
and gases during welding
Factors affecting welding fume composition for gas, MMA, FCA, MIG/MAG, TIG, plasma and
submerged arc processes.
Job knowledge 32: Health, safety and accident prevention - control of welding
fume
Factors that affect welder's exposure to fume are summarised. The measures and
equipment used to control welding fume and gases are described.
Joint design
Mechanical testing
Job knowledge 38: Standards - application standards, codes of practice and quality
levels
The requirements for standards on welding procedure and welder approval are explained
together with the quality levels for imperfections.
Job knowledge 64: A review of the application of weld symbols on drawings - Part
1
Introduces weld symbols according to BS EN 22553
Job knowledge 65: A review of the application of weld symbols on drawings - Part
2
Presents example of symbols used on weld drawings to indicate the location, type, size etc
of welds required, welding process to use, and so on.
Job knowledge 19: Weldability of materials - carbon manganese and low alloy
steels.
Guidance is given on ferritic steel weldability and the causes of weld imperfections: porosity,
solidification cracking, hydrogen cracking and reheat cracking. Procedure and welder
techniques for reducing the risk of these in arc welding are recommended.
Welding consumables
Job knowledge 86: Welding consumables Part 5 - MIG/MAG and cored carbon steel
wires
The characteristics of solid and cored wires are briefly described.
Job knowledge 46: Defects - hydrogen cracks in steels - prevention and best
practice.
Methods of reducing the risk of hydrogen cracking when arc welding steels are described.
Job knowledge 67: A general review of geometric shape imperfections - types and
causes - part 1.
Looks at those imperfections related to poor geometric shape, particularly excess weld
metal (reinforcement), undercut, overlap (cold lapping), linear misalignment, and
incompletely filled groove. Causes, acceptability and avoidance are covered.
Job knowledge 68: A general review of the causes and acceptance of shape
imperfections - Part 2
Covers causes, avoidance and acceptance criteria for imperfections in butt and fillet weld
bead shape: excess penetration, root concavity, excess convexity, oversize and undersize
fillets (large or small throat), asymmetric fillet, and poor fit-up
Welding equipment
Job knowledge 13: Equipment for oxyacetylene welding
Gas welding torch, hoses, gas regulators and flame traps are described. Differences
between oxygen and acetylene cylinders are listed. Typical gas pressures and flow rates for
work on C-Mn steels are given. Safety checks are indicated.
Job knowledge 14: Equipment for manual metal arc (MMA or SMA) welding
The power source, electrode holder, cables, protective clothing and fume extraction
equipment required for safe MMA welding are described. Care of covered electrodes is
described, including storage and drying.
Job knowledge 17: Equipment for tungsten inert gas (TIG, GTA) welding
Power sources, torches, backing systems and protective clothing for TIG welding are
described.
Job knowledge 56: Hot gas welding of plastics: Part 1 - the basics
Describes the hot gas welding process, welding equipment and welding parameters,
materials that can be hot gas welded and welder certification.
Job knowledge 56b: Hot gas welding of plastics: Part 2 - welding techniques
The hot gas welding process is described covering material preparation, joint preparations,
procedures for round nozzle welding and speed welding, weld shape and finishing.
Calculating the volume of a weld is one of the first steps to be taken when estimating the
cost of making a weld.
With this information, and knowing the deposition rate of the process, it is possible to
determine the arc time (the length of time that an arc is burning and depositing weld metal)
and the amount of welding consumables required to fill the joint. Both of these are required
in order to calculate the cost of making the weld. Costing will be dealt with in future Job
Knowledge articles.
With a fillet weld or a 45 single bevel joint this is relatively simple but the calculations
become lengthier as the weld preparation becomes more complex. Fig.1 illustrates how
simple this calculation is for an equal leg length fillet weld; the area of such a weld is half
the square of the leg length, Z. When using this formula do not forget that welders seldom
deposit precisely the size of weld called up on the drawing or in the welding procedure and
that there may be some excess weld metal on the face of the weld.
An asymmetrical fillet weld is a little more difficult; the area of a triangle is given by the
base Z times the height Z divided by 2 so when a fillet weld is deposited with unequal leg
2 1
lengths the area can be calculated from multiplying the throat, a, by the length of the face I
and divided by 2 as illustrated in Fig.2.
Fig.2. Area of an unequal leg length fillet
Turning now to butt welds, the calculations become a little more complex.
There are three factors that determine the volume of the weld in a single V butt weld. These
are the angle of the bevel, b, the excess weld metal and the root gap, g, as illustrated in Fig
3. To calculate the area of this weld we need to be able to add together the areas of the four
components illustrated in Fig.3.
The dimension 'c' is given by (tan b x t); the area of a single red triangle is therefore t(tan b
x t)/2. The total area of the two red regions added together can be calculated using the
formula 2t(tan b x t)/2 or t(tanb x t).
The area of the excess weld metal is approximated by the formula (W x h)/2.
The bevel angles, b, most often used are 10 = (tan 0.176), 15 = (tan 0.268), 22.5 =
(tan 0.414) 32.5 = (tan 0.637) and 45 = (tan 1.00). As will become obvious when the
weight is calculated, it is easier to ensure that the decimal point is in the right place if
centimetres are used in the calculations rather than millimetres.
As a worked example, if the weld is in a plate 2.5cm thickness, 0.3cm root gap, 65
included angle ( b = 32.50; tan 32.5 = 0.637) and with a cap height of 0.2cm we have:-
This gives a total area of 5.07sq cm. The volume can then be calculated by multiplying the
length of the weld by the area - ensuring that this length is also given in centimetres!
Conventionally, the volume is often expressed in cubic centimetres (cu.cm). per metre so in
this example the volume is 507 cu. cm/metre.
To obtain the weight of weld metal this figure is then multiplied by the density of the alloy.
Table 1 gives the density of some of the more common alloys in gm/cu.cm. Note that with
some alloys the alloying elements can change the density quite significantly.
iron 7.87
nickel 8.90
copper 8.94
7% Al bronze 7.89
aluminium 2.70
Al 5052 2.65
Al 7075 2.8
The weight of weld metal to fill one metre length of the joint described above would
therefore be; in carbon steel (507 x 7.86) = 3985gms or 3.98kgs/metre; in a 5XXX series
aluminium alloy (507 x 2.65) = 1343gms, 1.34kgs/metre.
Calculating the weight of weld metal in double sided V-joints uses the same approach by
dividing the weld into its individual 'V's and adding the products.
A J-preparation, however, adds another area into the equation; that of the half circle at the
root of the weld, see Fig.4. The formulae given above to calculate 'c', the area of the two
red components and the excess weld metal remain unchanged but the width of the cap
must be increased by 2r. There are also the two areas, 'A' and 'B', to calculate and the two
white root radius areas to be added to the total.
a. the dimension 'c' is given by (tan b x (t-r)); the total area of the two red regions is
therefore given by the formula 2((t-r)(tan b x (t-r))/2 or ((t.-r)(tan b x (t-r)).
c. the area of the excess weld metal is given by the formula (w x h)/2.
For a double-U preparation it is necessary to calculate the areas of both sides and add these
together.
Having calculated the weight of weld metal required to fill a weld preparation it is then
possible to calculate the weight of filler metal required (these two figures are not necessarily
the same) and to estimate the time required to deposit this weld metal; both essential in
order to arrive at a cost of fabricating the weld. This will be covered in future Job Knowledge
articles.
The previous Connect article, number 95, dealt with the methods of determining the weight
of deposited weld metal in a joint, enabling the cost of welding consumables to be
calculated.
These costs are dependent on the accounting practices of the organisation. They comprise
factors such as rent, rates, bank interest, cost of indirect workers, ie those not directly
involved in fabricating, depreciation of plant etc. In addition, other accounting decisions (for
example, where the costs of machining and assembly are absorbed) may affect the
decisions on which is the most cost-effective joining method.
One of the most significant costs is that of labour and this inevitably varies with industry,
time and country. The costs mentioned above cannot generally be influenced by the
decisions made by a welding engineer. These articles will therefore concentrate on those
aspects of welding activities that are not subject to accounting practices, overhead or labour
costs.
There are many costs, other than the cost of depositing weld metal that will affect the price
of a welded fabrication.
The work done by the designer in designing the most cost-effective joint in an item that can
be placed in the most advantageous position for welding will have major effect on costs. For
example, the type of joint preparation the designer selects; a single or double-V preparation
can be flame cut, a J-preparation must be machined and is generally far more expensive. A
machined J-preparation, however, may have less volume than a single-V, depending on
thickness; will be more accurate and therefore quicker to assemble within tolerance and
may result in a lower repair rate leading to a lower cost than the V preparation.
Costs that are directly affected by welding engineering decisions, in addition to the cost of
actually depositing weld metal, are therefore; joint preparation, assembly time (which
includes positioning in any jig or fixture and tacking), cleaning and dressing the weld,
removal from jigs or fixture, post weld heat treatment, costs of non-destructive testing and
cost of repairs.
The amount of weld metal deposited is rarely the same as the amount of filler metal
purchased. This is the result of losses when, for example, GMAW or submerged arc welding
wire is trimmed back to the contact tip, when the wire reel runs out and the length of wire
between the drive roll and the contact tip is scrapped or the wire or reel is damaged.
Such losses tend to be quite small but this is not the case with coated electrodes. Damaged
flux coatings, incorrectly stored electrodes and the stub ends discarded by the welder all
contribute to as much as a third of the purchased weight of manual metallic arc electrodes
being scrapped. Some electrode manufacturers' catalogues give figures for these losses
which can vary depending on electrode type and diameter.
Table 1 Multiplication factor. Weight of weld metal to give the weight of filler
metal required.
FCAW 1.2
MCAW 1.1
The other consumables in this cost equation are shielding gases or flux.
The conventional shoulder height welding gas cylinder contains approximately 10,000 litres
of shielding gas at a pressure of 200bar. As the gas flow rates normally used in production
are around 12 to 15 litres per minute, this typical cylinder should provide in the region of 10
to 12 hours of welding time, allowing for losses at the beginning and end of the arcing
period.
The rate of flux consumption in submerged arc welding is approximately 1kg of flux for
every 1kg of deposited weld metal. This assumes good housekeeping and an efficient flux
recirculation system. Calculation of the amount required (and hence the cost) of these
consumables is therefore relatively straightforward.
The cost of the welder's time to weld a joint does not depend solely on the deposition rate
of the process. A most important factor in determining the time required by the welder is
what is known as the 'duty cycle' or 'operating factor'. This is a percentage figure giving the
amount of time that the arc is burning and weld metal is being deposited versus the total
time that the welder is working.
Table 2 gives some figures for the more common arc welding processes. Note that these do
NOT include set-up or assembly time and individual circumstances can increase or decrease
these figures.
MMA (SMAW) 15 - 30
TIG (GTAW) 25 - 40
Mechanised TIG 80 - 90
MIG/MAG (GMAW) 30 - 45
Mechanised MIG/MAG 80 - 90
FCAW 25 - 45
Mechanised FCAW 70 - 85
MCAW 30 - 45
The lost time in this figure can be accounted for by considering all of the other activities that
the welder performs. In MMA welding, for example, time is required for tacking, de-slagging
and cleaning a weld pass, for changing electrodes, for changing position, for rest breaks and
for removal of the item from a fixture. Similar activities need to be performed using the
other welding processes.
Increasing the duty cycle is therefore one method of increasing productivity, either by
organising the shop floor such that lost time is reduced or by the use of a higher duty cycle
process. However, remember that the arcing time may well be only a very small proportion
of the total time to manufacture and attention to other aspects of the manufacturing cycle
may give better returns than simply increasing the welding duty cycle.
Reference to Table 1 also suggests that mechanisation is one method to increase the duty
cycle. Caution needs to be exercised, however, if the total (floor to floor) time is to be
reduced. For one-off or small batch items the time taken to prepare and set up a
mechanised system to weld the item may be longer than that taken to weld using a manual
process. Note also that if a mechanised system is used, the duty cycle may in fact decrease,
as the welding speed is increased and the weld is completed in a shorter time although the
number of items welded per day will increase. It is therefore essential to consider the
complete manufacturing cycle to achieve the most cost effective solution.
Part 2
Part 1
The final step in costing a weld is to determine the length of time to deposit this weight of
weld metal. This is obviously a function of the deposition rate of the process. The deposition
rate is generally expressed as kgs/hr or lbs/hr deposited at a given welding current, welding
continuously and without any breaks for electrode changing or deslagging.
The deposition rate will be affected by many factors and it will not be possible within the
limitations of these articles to list the precise deposition rates for any specific process or
welding current. Such data can be found in publications referenced below or by a web
search. The ranges of approximate deposition rates for the commoner arc welding processes
are listed in Table 1.
MAG 0.6 12
FCAW 1.0 15
To obtain an accurate figure for the specific parameters to be used is a relatively simple
exercise. Weighing a plate, depositing weld metal using the required parameters on this
plate for a fixed time and then re-weighing the plate will give an accurate figure that may be
used for estimating purposes.
There is one golden rule for minimising the cost of making a weld and, whilst this may seem
to be self-evident, it is worth repeating: deposit the minimum amount of the highest quality
weld metal with the largest gauge electrode or wire at the highest current in the shortest
possible time. This is obviously the ideal and can seldom be achieved in practice because of
limitations on heat input, access etc.
a. To deposit the minimum amount of weld metal the designer, aided by the welding
engineer, must select the smallest weld preparation that is capable of providing the
required weld quality. If the included angle is too narrow then lack of side wall fusion
is a possibility with the consequent costs of repair; too wide an angle is wasteful in
terms of deposited weld metal. Remember, though, that the cost of providing a weld
preparation (by flame-cutting, edge planning, milling etc) must also be included in
any costing exercise as must the cost of assembly. Machined weld preparations are
more accurate than flame cut edges and this may result in faster set-up times and a
reduced weld repair rate.
It may be possible to use a square edge preparation by using the deep penetration
characteristics of some of the welding processes; electron beam and laser welding
are the best examples of this technique. Plasma-TIG and activated flux TIG can
penetrate up to 10mm in a single pass; the 'finger' penetration of spray transfer MAG
welding can penetrate up to 6mm and a submerged arc weld can penetrate up to
15mm. There is also the benefit when using a square edge preparation in that the
consumption of filler metal is substantially reduced, the bulk of the weld metal being
provided by the parent material.
The final option on reducing costs when butt welding is for the designer to specify a
partial penetration joint. The most expensive weld pass in any full penetration butt
weld is the root pass and if this can be eliminated by using partial penetration joints
then substantial savings can be made. However, the decision to use partial
penetration welds should not be taken lightly but only if service conditions permit the
presence of a large crevice at the weld root. The designer will therefore need to
consider whether fatigue, creep, corrosion etc are likely to occur and must clearly
specify where the joints are permitted and the minimum acceptable weld throat.
b. Depositing the highest quality weld metal infers that the weld repair rate will be
reduced. Repair weld metal is very costly, particularly if the unacceptable defects are
detected late in the fabrication programme; perhaps after final assembly where
access is difficult or after post weld heat treatment. Accurate weld preparations and
fit-up, easy access for the welder, welds made in the flat position and well trained
welders will all help to minimise the weld repair rate.
c. Depositing weld metal with the largest electrode or wire at the highest current will
obviously give the highest weld deposition rate and shortest joint completion time.
The deposition rate figures in Table 1 give the minimum and maximum deposition
rates at minimum and maximum welding currents. As an example, a 1.2mm
diameter MAG wire at 120amps will deposit around 1.2 kgs/hr, at 380amps around 8
kgs/hr. To enable high welding currents to be used the item must be placed in the
flat position and there must be easy access for the welder. One benefit of using the
high welding currents is that the number of weld runs to fill the joint will be reduced
and this, in most circumstances, will result in less distortion than a large number of
low current weld passes. Remedial work to correct distortion can therefore be
reduced. A further benefit when welding the ferritic steels is that high current and
therefore high heat input may allow any preheat to be reduced or eliminated entirely.
However, there are limitations to this approach to improving productivity. If achieving high
toughness is a factor then it is likely that heat input will need to be controlled when welding
the ferritic steels, placing a limit on the welding current and travel speed. High welding
currents also imply a large, fluid weld pool and it may not be possible to control this pool
when welding in any other than the flat position - for example, MAG welding cannot be
performed using spray transfer (high welding current) in the vertical position due to the
absence of a flux to hold the pool in place. Using a manual process at such high currents
also results in increased welder fatigue resulting in a reduced duty cycle. A solution to this
problem is to mechanise or automate the process.
To achieve the most cost effective solution to producing a welded structure is therefore not
simply to increase duty cycle or deposition rate but to consider all aspects of fabrication
from the design stage to final inspection, involving all members of the team from designer
to welder.
References:
The magnitude of thermal stresses induced into the material can be seen by the volume
change in the weld area on solidification and subsequent cooling to room temperature. For
example, when welding CMn steel, the molten weld metal volume will be reduced by
approximately 3% on solidification and the volume of the solidified weld metal/heat affected
zone (HAZ) will be reduced by a further 7% as its temperature falls from the melting point
of steel to room temperature.
If the stresses generated from thermal expansion/contraction exceed the yield strength of
the parent metal, localised plastic deformation of the metal occurs. Plastic deformation
causes a permanent reduction in the component dimensions and distorts the structure.
What are the main types of distortion?
Longitudinal shrinkage
Transverse shrinkage
Angular distortion
Buckling
Twisting
The principal features of the more common forms of distortion for butt and fillet welds are
shown.
Contraction of the weld area on cooling results in both transverse and longitudinal
shrinkage.
For example, in a single V butt weld, the first weld run produces longitudinal and transverse
shrinkage and rotation. The second run causes the plates to rotate using the first weld
deposit as a fulcrum. Hence, balanced welding in a double side V butt joint can be used to
produce uniform contraction and prevent angular distortion.
Similarly, in a single side fillet weld, non-uniform contraction produces angular distortion of
the upstanding leg. Double side fillet welds can therefore be used to control distortion in the
upstanding fillet but because the weld is only deposited on one side of the base plate,
angular distortion will now be produced in the plate.
Longitudinal bowing in welded plates happens when the weld centre is not coincident with
the neutral axis of the section so that longitudinal shrinkage in the welds bends the section
into a curved shape. Clad plate tends to bow in two directions due to longitudinal and
transverse shrinkage of the cladding; this produces a dished shape. Dishing is also produced
in stiffened plating. Plates usually dish inwards between the stiffeners, because of angular
distortion at the stiffener attachment welds (see main photograph).
In plating, long range compressive stresses can cause elastic buckling in thin plates,
resulting in dishing, bowing or rippling.
Distortion due to elastic buckling is unstable: if you attempt to flatten a buckled plate, it will
probably 'snap' through and dish out in the opposite direction.
Twisting in a box section is caused by shear deformation at the corner joints This is caused
by unequal longitudinal thermal expansion of the abutting edges. Increasing the number of
tack welds to prevent shear deformation often reduces the amount of twisting.
Transverse Shrinkage
Fillet Welds 0.8mm per weld where the leg length does not exceed 3/4 plate thickness
Butt weld 1.5 to 3mm per weld for 60 V joint, depending on number of runs
Longitudinal Shrinkage
If a metal is uniformly heated and cooled there would be almost no distortion. However,
because the material is locally heated and restrained by the surrounding cold metal,
stresses are generated higher than the material yield stress causing permanent distortion.
The principal factors affecting the type and degree of distortion, are:
Amount of restraint
Joint design
Part fit-up
Welding procedure
Parent material properties which influence distortion are coefficient of thermal expansion
and specific heat per unit volume. As distortion is determined by expansion and contraction
of the material, the coefficient of thermal expansion of the material plays a significant role
in determining the stresses generated during welding and, hence, the degree of distortion.
For example, as stainless steel has a higher coefficient of expansion than plain carbon steel,
it is more likely to suffer from distortion.
Restraint
If a component is welded without any external restraint, it distorts to relieve the welding
stresses. So, methods of restraint, such as 'strong-backs' in butt welds, can prevent
movement and reduce distortion. As restraint produces higher levels of residual stress in the
material, there is a greater risk of cracking in weld metal and HAZ especially in crack-
sensitive materials.
Joint design
Both butt and fillet joints are prone to distortion. It can be minimised in butt joints by
adopting a joint type which balances the thermal stresses through the plate thickness. For
example, a double-sided in preference to a single-sided weld. Double-sided fillet welds
should eliminate angular distortion of the upstanding member, especially if the two welds
are deposited at the same time.
Part fit-up
Fit-up should be uniform to produce predictable and consistent shrinkage. Excessive joint
gap can also increase the degree of distortion by increasing the amount of weld metal
needed to fill the joint. The joints should be adequately tacked to prevent relative
movement between the parts during welding.
Welding procedure
This influences the degree of distortion mainly through its effect on the heat input. As
welding procedure is usually selected for reasons of quality and productivity, the welder has
limited scope for reducing distortion. As a general rule, weld volume should be kept to a
minimum. Also, the welding sequence and technique should aim to balance the thermally
induced stresses around the neutral axis of the component.
The article was prepared by Bill Lucas in collaboration with Geert Verhaeghe and Rick
Leggatt. E-mail: nmo@twi.co.uk
Design principles
At the design stage, welding distortion can often be prevented, or at least restricted, by
considering:
elimination of welding
weld placement
Elimination of welding
As distortion and shrinkage are an inevitable result of welding, good design requires that
not only the amount of welding is kept to a minimum, but also the smallest amount of weld
metal is deposited. Welding can often be eliminated at the design stage by forming the plate
or using a standard rolled section, as shown in Fig 1.
Weld placement
Placing and balancing of welds are important in designing for minimum distortion. The closer
a weld is positioned to the neutral axis of a fabrication, the lower the leverage effect of the
shrinkage forces and the final distortion. Examples of poor and good designs are shown in
Fig 2.
In thick section material, as the cross sectional area of a double-V joint preparation is often
only half that of a single-V preparation, the volume of weld metal to be deposited can be
substantially reduced. The double-V joint preparation also permits balanced welding about
the middle of the joint to eliminate angular distortion.
As weld shrinkage is proportional to the amount of weld metal, both poor joint fit-up and
over-welding will increase the amount of distortion. Angular distortion in fillet welds is
particularly affected by over-welding. As design strength is based on throat thickness, over-
welding to produce a convex weld bead does not increase the allowable design strength but
it will increase the shrinkage and distortion.
Completing the joint with a small number of large weld deposits results in more longitudinal
and transverse shrinkage than a weld completed in a larger number of small passes. In a
multi-pass weld, previously deposited weld metal provides restraint, so the angular
distortion per pass decreases as the weld is built up. Large deposits also increase the risk of
elastic buckling particularly in thin section plate.
Best practice
The following design principles can control distortion:
eliminate welding by forming the plate and using rolled or extruded sections
balance the welding about the middle of the joint by using a double-V joint in
preference to a single-V joint
Adopting best practice principles can have surprising cost benefits. For example, for a
design fillet leg length of 6mm, depositing an 8mm leg length will result in the deposition of
57% additional weld metal. Besides the extra cost of depositing weld metal and the increase
risk of distortion, it is costly to remove this extra weld metal later. However, designing for
distortion control may incur additional fabrication costs. For example, the use of a double-V
joint preparation is an excellent way to reduce weld volume and control distortion, but extra
costs may be incurred in production through manipulation of the workpiece for the welder to
access the reverse side.
This article was prepared by Bill Lucas with help from Rick Leggatt and Gene Mathers.
Last Reviewed 2010 / Copyright 2004 TWI Ltd
(1) Codes, standards and specifications: Interpretation of the intent and ensuring the requirements of codes, standards
and specifications are met.
(2) Welding procedures: Ensuring that a procedure is available, has been approved and is being employed in production.
(3) Witnessing of welder and procedure approval tests: Witnessing the preparation of test plates and destructive tests
and verifying compliance with appropriate standards and specifications.
(4) Welder approvals: Verifying that adequate and valid welder approvals are available, and that only approved welders are
used in production.
(5) Parent material: Verifying parent material against documentation and markings.
(6) Welding consumables identity: Verification of correctness of welding consumables (electrodes, filler wires,
consumable inserts, gases, fluxes etc.)
(7) Pre-weld inspection: Verification that dimensions, fit-up and weld preparations are in accordance with specifications.
(8) Preheating: Verification that any required preheat is in accordance with the specified procedure.
(9) In-process welding inspection and surveillance: Surveillance during welding to verify compliance with specified
procedures including any preheat, interpass temperature control and post heat requirements.
(10) Inspection and Test Plans: Assistance and agreement with the preparation of Inspection and Test Plans (ITPs)
(11) Post-weld heat treatment: Verification, when required that post weld heat treatment has been conducted in
accordance with specification requirements.
(12) Post-weld visual inspection: Visual inspection and dimensional check of completed weldment against specification
requirements and drawings.
(13) NDT reports: The study and cognisance of NDT results on any welding work for which the welding inspector is
responsible. Where the duties of the welding inspector include using NDT methods such as liquid penetrant, magnetic
particle, radiography or ultrasonic inspection then it is suggested that he/she obtains certification in accordance with the
related approval schemes.
(14) Reports: Evaluation of and preparation of inspection reports for the employer or the client.
- Always ensure the welding is being carried out within the limits of the approved procedure.
- Never approve anything that does not meet the requirements unless it has been accepted by the client.
- Be in a good physical condition and be able to go where the welder has been.
Interested in improving your welding inspection knowledge, then contact HERA on 09 262 4847 or email your interest to
iqc@hera.org.nz
Permanent/Home Location/Address
Country INDIA
Current Location/Address
Country QATAR
Languages
Primary Fluency
Language
Nationalities
Experience Classification
QA/QC Engineer 10
Welding Inspector 5
Qualifications
Highest Degree
Qualifications
Work Locations
Availability
looking for work in a QA/QC Engineer / welding inspector role in the middle east and its open to all
offers.
USD2000- 2500 per month( basic for 8 hours) plus paid housing and fooding plus atleast 15 days paid
leave after 180 days of work.
Employment History
Summary
More than 10 years of experience in Oil & Gas Projects including 5 years experience in Middle East in
the field of QA/QC. Working in Qatar Kentz as a QA/QC Engineer / Welding Inspector for the past 5
years for its ongoing various onshore and offshore project. Through knowledge of welding processes.
Through knowledge of stage wise and final inspection. Fully conversant with various codes like
ASME, AWS and API etc. Familiar with various engineering materials. Familiar with destructive and
non destructive tests. Fully conversant with engineering drawings, codes, standards and specification
Work Experience
RESPONSIBILITIES:
Supervising and managing all Quality Control functions in the work place.
Leading a team of QC inspectors for day to day QC functions.
Preparing and submitting the Project Quality Plan and Inspection Test Plan to client for approval.
Inspection and verification of various raw material like pipes, fittings, valves, structural material and
welding consumables with certificates as per codes and project specification.
Reviewing of documents like project quality plan, inspection test plan, design, drawings, codes,
project specification etc.
Identifying, preparing and witnessing WPS and PQR as per codes and project specification.
Witnessing Welder Qualification Test as per code and project specification.
Preparing, implementing and monitoring the procedure for low hydrogen electrodes.
Performing stage wise and final inspection for the production weld joint in coordination with client.
Checking Preheat and PWHT requirement for Piping and Equipments.
Identifying the joints for NDE and making request for NDE.
Witnessing PT, MT & UT and Reviewing the Radiographic film.
Performing review and recording of the test results.
Preparing the Test Pack for Hydro Test and Pneumatic Test.
Preparing Final QC Dossier for handing over to client and maintaining proper filing system with full
traceability to retrieve the documents.
Acting as focal point in implementing the Project Quality Plan to clients satisfaction.
Establishing and maintaining excellent relationship with clients.
Coordinating with third party inspection agencies for all related inspection activities.
Acting as coordination point for internal and external audits.
Petron Engineering Construction Ltd. has seen steady growth over two and a half decades from
1976.The Group consists of five operating divisions employing more than 5,000 people. The company
provides services in Mechanical, Erection, Piping, Electrical, Instrumentation, Painting, Refractory &
Insulation work for Refineries, Chemicals, Petrochemicals, Cement, Fertilizers, Metallurgical, Power
plants and other Industrial Plants.
RESPONSIBILITY:
Reviewed clients specifications , work scope and prepared detailed quality execution plan for project
Reviewed Sub contractors WPS/PQR, Inspection/Test Plan and Procedures
Identified and prepared Welding Procedure Specification (WPS) & PQR for jobs as per project
specifications and verified Welders meet PQR requirements.
Coordinated with clients to undertake Procedure Qualification Tests (PQT), done inspection of
prepared test specimens and witnessed destructive tests.
Ensured product / work are in line with applicable quality and technical standards, contractual
agreements and company approved quality control procedures.
Done Verification of welding machines to ensure equipment meets the job requirements.
Conducted fitt-up and dimension inspections as per Inspection and Test Plan (ITP) and provided
technical guidance for welding sequence and distortion control.
Monitored Welder performance and conducted visual inspections of welds and repairs of welds in
accordance with Company procedures and international codes of practice.
Made sure welding consumables are as per WPS and Code.
Prepared the NDT request as per Clients requirement and co-ordinated with NDT sub contractors.
RESPONSIBILITIES:
Performed Inspection of Raw Materials, stage wise fabrication and Final Inspection of fabricated items.
Conducted Fit up, Visual, Dimensional inspection & Monitoring of Welding parameters during welding.
Prepared and Witnessed procedure tests and welder/welding operator qualification tests.
Maintained Welders continuity record and prepared Welders Performance/ Qualification Records.
Monitored the construction process from all aspects to ensure activities meet job quality and design
requirements in accordance with Company procedures and international standards
Prepared the NDT request and co-ordinated with NDT sub contractors.
Witnessed the hardness test, reviewed PHWT charts, NDT activities.
Reviewed hydrostatic/pneumatic test packages for piping systems and monitored test and also
ensuring procedures are adhered to & witnessed Hydrostatic and Pneumatic Test for Vessels and Piping.
Prepared all equipment punch lists and verify all items are in place and act as an agent for the
Company during punch list activity.
-20670 8 Add Message
seetharaman
Personnel profile:
Technical Qualification:
DIPLOMA IN TOTAL QUALITY MANAGEMENT and ISO-9000.
Review of project Quality plans, Inspection Test plans and construction Method
Statements to cover all project activities.
Witnessing for the welder qualification test (WQT) and procedure qualification
test with various materials P1-P1, P1-P3, P1-P4
Daily visit to consumable store, check for consumable storage and handling,
baking and holding oven temperature as per specification.
Raise RFI for joint fit-up and welded joints of tubes, tube attachments, skin
bars welding and structural welding.
Monitoring welding inspection with various materials P1-P1, P1-P3, P1-P4.
Periodically inspect the electrode issuance and issuance log, electrode backing
and maintaining oven temperature log.
Preparing weld map, joint number and enter the joint detail, RT reports in the
AUTOCAD.
Request for NDT and co-ordinate with NDT crew, review and control the NDT
documents.
Prepare welding inspection summary report.
Controlling the issue of NCRs to record any non- conforming items and
ensuring that appropriate corrective actions are taken.
Ensuring the accurate calibration records is maintained for welding
equipments, ovens and measuring instruments.
Maintain all the records of welder qualifications, performance etc.
Resolve clients non-conformities
Carry out 100% weld visual inspection
Maintaining the welders performance record.
PROJECTS
SADAF (SABIC)-Expansion project, jubail.
SAUDI ARAMCO JUAYMA GAS PLANT, RASTANURA.
SADAF (SABIC) TANK Repair and maintenance project
HADEED STEEL PLANT BACKHOUSE project.
ZAMIL STEEL SUPER STRUCTURAL PLANT (SSP), DAMMAM
Responsibilities
Fit-up inspection of pipe spools at fabrication shop and site, check for root
gap, root face bevel angle, alignment, mismatch as per WPS, levelness, line
number, drawing number, joint number etc as per ISO drawing.
Fit-up inspection of pipe support, platform, column and all type of structural
works.
Review project specification, approved drawings quality control plan,
procedures, method of statements and other relevant documents.
Review material traceability reports against the actual heat number of
materials.
Carry out line check inspection, check for orifice flange, valve type and
direction, gasket, bolt and nut as per specification on ISO drawing, any missing
items, check levelness, straightness, plumbness.
Monitor NDT requirements as per applicable codes or standards.
Site investigation and preparation of technical clarification/ queries for design
changed. I.e. changed for piping and piping components, pipe sizing, material
specifications and re-route of pipelines.
Responsible for test package preparation consisting of piping and instruments
diagram (P&ID), line list and isometric drawing of the above ground piping.
Reflect the as-built drawing to the isometric drawings master file.
Checked piping lines to ensure all the associated appurtenances for the piping
system was properly installed i.e. bolts/nuts, gaskets, pressure taps, plugs,
vents and drains including the pipe supports.
Make punch list and witness the punch items. Offer line for hydrotest to client.
Prepare line history sheet for the test packages prior to hydrostatic testing.
Reinstatement and installation of control valves including permanent bolts /
nuts and gaskets