231121_Eargle_ISO5817 VT-2 Training Material.pptx

Click to insert Picture VT Fundamentals per EN/ISO 17637     Sidney Eargle CWI KION NA - Summerville, SC November 28, 2023 Visual Welding Inspection (VWI) • VWI is our most powerful welding inspection method • "Welding" implies that it occurs throughout the fabrication process --­from desig...

Click to insert Picture VT Fundamentals per EN/ISO 17637     Sidney Eargle CWI KION NA - Summerville, SC November 28, 2023 Visual Welding Inspection (VWI) • VWI is our most powerful welding inspection method • "Welding" implies that it occurs throughout the fabrication process --­from design to final acceptance • "An effectively applied program of visual welding inspection will detect 80-90% of those weld discontinuities which may be detected later using some more expensive NDE method." − On-going inspection provides potential for prevention of defects − Verifies that work instructions and WPSs are being followed KION VT Fundamentals - 1 EN/ISO 17637 — basis for VWI • Non-destructive testing of welds - Visual testing of fusion-welded − Basic inspection guidelines and practices joints − Activities before, during and after welding − Also provides inspection requirements for repaired (reworked) welds KION VT Fundamentals - 1 Preliminary clauses • Scope - Specifies the visual testing of fusion welds in metallic materials • Normative references - none specified • Terms and definitions - none listed − References to other on-line sources KION VT Fundamentals - 1 4 Test conditions and equipment • Surface illumination − 350 lux [~35 lumen] minimum − 500 lux [~50 lumen] recommended − 45W bulb emits ~450 • Direct inspection − Eyes within 600 mm [24 in] of weld surface − At an angle no greater than 60° from normal (perpendicular) KION VT Fundamentals - 1 5 Personnel qualification B5.2 Individual (IWS) Welding Specialist • "Visual testing of welds and the evaluation of results for final acceptance shall be performed by qualified and capable personnel." • Qualification per ISO 9712 recommended for those performing indirect visual testing • ISO 9712 used by 3rd party labs to confirm qualification and personnel KION VT Fundamentals - 1 6.1 General • Extent of inspection is not defined, but shall be specified by reference to an application or product standard • Examiner shall have access to all necessary inspection and production documentation • Any visual testing performed before, during or after completion of welds should be performed using direct examination − May include visual testing of surface treatments KION VT Fundamentals - 1 6.2 VT of joint preparation a) Shape and dimensions of weld preparation shall meet WPS requirements b) Fusion faces and adjacent surfaces shall be clean and required surface treatment has been performed c) Parts to be welded shall be fixed in relation to each other according to drawings or instructions KION VT Fundamentals - 1 Joint fit up limitations per EN ISO 5817 • Fillet welds - maximum root opening • 5817 - QL B limit: For t > 3mm, h = 0.5 mm+ 0.1a − For a = 3 mm - h = 0.8 mm − For a = 4 mm - h = 0.9 mm − For a = 5 mm - h = 1.0 mm − For a = 6 mm - h = 1.1 mm − For a = 7 mm - h = 1.2 mm − For a = 8 mm - h = 1.3 mm KION VT Fundamentals - 1 Gap between the parts to be joined. Gaps exceed leg the appropriate limit may, in certain cased. Be compensated for by a corresponding increase on the throat thickness. Joint fit up limitations per EN ISO 5817 • Butt [Groove] welds - maximum joint misalignment [mismatch] • 5817 - QL B limit: For t > 3mm, h = 0.1t, 3 mm maximum − For t = 10 mm - h = 1.0 mm − For t= 15 mm - h = 1.5 mm − For t = 20 mm - h = 2.0 mm − For t = 25 mm - h = 2.5 mm − Fort t > 30 mm - h:::. 3.0 mm KION VT Fundamentals - 1 6.3 VT during welding a) Each bead/layer shall be cleaned prior to deposition of subsequent passes, with particular attention to weld and fusion faces b) Observed imperfections shall be corrected prior to subsequent welding c) lnterbead and weld/fusion face profiles shall be conducive to achieving adequate fusion of subsequent passes d) Depth and shape of gouging shall be controlled to assure complete removal of weld metal as specified e) Weld conforms to original requirements following and necessary rework/remedial action KION VT Fundamentals - 1 6.4 VT of finished weld • 6.4.1 General − Finished weld shall be examined to determine if it meets application or product standard, or other agreed acceptance criteria − For KION NA products ISO 5817 Class B 15 the applicable acceptance criteria for mast weldments • Finished welds shall be examined according to requirements found in 6.4.2 to 6.4.5 KION VT Fundamentals - 1 6.4.2 Cleaning and dressing a) All slag to be removed by manual or mechanical means so imperfections are not obscured b) No tool impressions or blow marks c) When weld finishing is required, overheating, grinding marks and uneven finish due to grinding shall be avoided d) Fillet and butt [groove] welds required to be finished flat/flush, shall be finished so weld blends smoothly with base metal KION VT Fundamentals - 1 6.4.3 Profile and dimensions a) Weld profile and height of weld reinforcement shall meet the requirements of ISO 5817 b) Weld surface shall be regular; pattern and pitch of weave marks show an even and satisfactory appearance; height and position of final layer weld beads shall be measured when required by WPS c) Weld width shall be consistent along the full length of the joint and meet applicable acceptance criteria; groove welds shall be filled to their required cross section KION VT Fundamentals - 1 6.4.4 Weld root and surfaces • Applies to single-sided groove welds, so not applicable for this product • Undercut shall be within acceptance criteria limits (causes stress concentrations). • Surface imperfections shall comply with applicable acceptance criteria, even when optical aids are required for detection • Applies to treatment of temporary attachments, so not applicable for this product • Arc strikes within acceptance criteria limits KION VT Fundamentals - 1 6.5 Post-weld heat treatment • Final VT shall be performed after PWHT • Not applicable for this product KION VT Fundamentals - 1 6.5 Visual testing of repaired welds • When defects are discovered, they shall be removed and rewelded • Reworked welds shall be re-examined using the same requirements as original welds • Whether excavated/removed for a portion or entire length of the joint, excavation shall be examined to assure complete defect removal and that the shape of the excavation is conducive to adequate fusion of repair welding • When completely removed, measures shall be taken to assure that final weldment dimensions are acceptable KION VT Fundamentals - 1