SECTION 6.

II

FABRICATION

ANb

WELDING

MANUFACTUREAND 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12

WORKMANSHIP

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. .. .. ... ... ...

65 65 65 65 67 71 71 72 74 74 75 75 75 79 79 85

Approval of Design Welded Joints, General Considerations

Design of Welded Joints Preparation of Parent Metal

Assembly of Plates ntid Fit-Up Alignment and Tolerances

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... .. ... ... *.. ... ... ... .*.

Welding Procedure Welding of Non-ferrous Rectification of Welds Metals

Repair of Drilled Holes Repair of Cracks Post Weld Heat Treatment

7.

WELDINO QUALIFICATIONS 7.1 7.2 Welding Procedure Qualifications Qualifications

Welders Performance

IS : 2825 - 1969 6. MANUFACTURE AND WORKMANSHIP The manufacturer shall conduct the tests required in this code ( see 7.1 anJ 7.2 ) to qualify the welding procedure employed and to judge performance of the welders who apply this procedure. 6.2.4 The manufacturer shall maintain a record of the results obtained in welding procedure qualilocation tests ( see Appendix H ). These records giving an acctuate description of all the particulars of the materials and procedure concerned shall be certified by him and shall be accessible to the inspecting authority who should be permitted to witness the tests if he so desires. 6.2.5 Any person who wishes to qualify for a welders performance test under this code shall not be below the age of 18 years and shall have been employed as a welder in a workshop or firm for a period of not less than two years. A record shall be kept to show that the welder has been employed on work of the kind covered by his performance tests, during the previous six months. These records shall contain the results of the welders performance tests and the identification mark assigned to each welder. T!rey shall be certified by the manufacturer and be accessible to the inspecting authority ( see Appendix H ). The welds made by each welder shall he marked with a stamp showing the welders identity at intervals of one metre or less, Care shall be taken to avoid notching or stress concentration due to Deep stampdeep stamping of welders identity. ing as a means of identifying welded seam is not recommended on carbon steel plates less than 7 mm thick or vessels subject to low temperatures or on austenitic and alloy steels. When deep stamping is not permitted, a record shall be kept by the manufacturers of welders and welding operators employed on each joint which shall be available to the inspecting authority; suitable stencil or other surface markings may be used additionally. 6.2.6 The inspecting authority shall have the right to disqualify a welder any time during the fabrication of a vessel, when there is a specific reason to question his ahility to make welds that meet this code requirements. Such a disqualified welder at the option of the manufacturer may be put up for retests, under the conditions specified in 7.2.8.1. 6.3 Design of Welded Joints 6.3.1 Single fillet welded lap joints should not be used without previous consent of the inspecting authority. 6.3.2 In the design of all details the aim shall to avoid disturbances in the flow of the lines force, in particular in constructions subjected fatigue stresses. Holes and openings shall not positioned on or. in the heat affected zones be of to be of 65

6.1 Approval of Design - Refore commencing the manufacturer, if so required, manufacture, shall submit for approval by the purchaser a fully dimensioned drawing showing the pressure portions of the vessel and carrying the following information:

4 b)

A statement that the vessel is to he constructed to this standard. Specification(s) conform. to which materials shall for all the and the and the and and

C! Welding 4

process(es) parts of the vessel.

to be adopted

Large-scale dimensional details of weld preparation for the longitudinal circumferential seams and details of joints for branch pipes, seatings, etc, the position of these joints relative to longitudinal and circumferential seams other openings. Design pressure(s) and temperature(s) major structural loadings. Test ,pressure(s) .

4 f) g)

Amount and location of corrosion allowance. No modification shall be made to the approved design except with prior agreement between the purchaser and the manufacturer. Additional requirements, by the purchaser. Joints, General if any, specified

h)

i.2 Welded

Considerations of pressure vessels general conditions.

6.2.1 Welded construction 1s subjected to the following

6.2.1.1 All details of design and construction shall generally conform to the provisions of this code. ( Examples of typical designs of welded connections are given in Appendix G. ) 6.2.1.2 The materials shall conform to the requirements of the appropriate Indian Standards or shall be any other approved material. 6.2.1.3 The welders shall be qualified for the type of welding concerned in conformity with the welders performance qualification ( see 7.2 ). 6.2.2 Nozzles, pads; branches, pipes, tubes, etc, and non-pressure parts may be welded to pressure parts provided that the strength and the characteristics of the material of the pressure parts are not affected adversely. If heat treatment is mandatory under the requirements of this code, the attachment of parts mentioned above by welding shall take place before the final heat treatment. 6.2.3 The manufacturer of a pressure vessel built according to this code, shall be responsible for all the welding work done under this code.

IS:2825-1969
Where such openings are unwelded joints. avoidable? such holes can be located on circumferential Joints provided the weld is radiographitally solmd for a length of three times the diameter of the hole on either side. 6.3.2.1 Further, welded joints should be positioned in such a manner that they are subjected to lowest possible bending stresses. *Joints between cylindrical shells and domed end plates shall not be located in the curved part of the domed end ( gee Table 6.2 ). When dished end plates are assembled from a number of plates, the welded joints bettveen these plates shall preferahly cross the corner curvature for the shortest possible length. 6.3.2.2 Attachment of parts by welding which cross or which are in the immediate vicinity of existing main welds in pressure parts should, as far as possible, be avoided. If such welds cannot he avoided, they should cross the main weld completely rather than stop abruptly near the main weld so that stress concentrations in these areas are avoided. Further, such a part should be subjected to local radiographic examination or other approved non-destructive tests and stress relief, where necessary. 6.3.3 The entire assembly as well as the individual welded joints shall be designed after giving not possible to comply with this requirement, the intersection of the welds should be radiographed, 100 mm on each side of intersection ( SM8.7.1 and 8.7.2 ). This involves among other things that the longitudinal joints should be, wherever possible, staggered when assembling a cylindrical shell from two parts by means of a circumferential joint. The distance shall he at least five times the thickness of thicker plate. 6.3.5 Where a butt joint is required between plates which differ in thickness by more than onefourth the thickness of thinner plate or more than 3 mm, the thicker plate shall have a tapered transition section as shown in Fig. 6.1 ( see also Table 6.2 ). The transition section shall have a minimum length of four times the offset between the abutting plate edges, The transition section may be fnrmcd by any process that will provide a uniform taper. The weld may be partly or entirely in the tapered section or adjacent to it. It is recommended that width of the parallel portion may not be less than 32 mm when the butt weld is to be radiographically examined. 6.3.6 The types of butt joints recommended for fusion welding processes ( arc and gas welding 1, their shapes and dimensions are given in Table 6.1. The dimensions and shape of the edges shall 4C

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BE INSlOE OR OUTSILX

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PREFERRED

PERMISSIBLE

Fro. 6.1

BUTT WELDING PLATES OF UNEQUAL THICKNESS

due consideration to the method of welding and the specific character of the joints. The aim shall be to avoid welding in dificult positions. Further, welded joints shall be so positioned that they permit visual and other methods of inspection and re-welding of the root side of the welds wherever posslblb. Welded joints should be free from undue restraint. 6.3.4 Concentration of welded joints should be avoided and the design should he made in such a way that no two main seams come together under an acute angle or cross each other. Where it ir

Qualifipermit complete fusion and penetration. cation of welding procedure as required under 7.1 is acceptable aq proof that the welding groove is satisfactory. 6.3.6.1 Where butt joints welded from one side only are credited with a joint factor equal to that permitted for butt joints with backing strips, the procedure of welding should be such as to obtain the same quality of deposited weld metal The joint shall have on the inside and outside. complete joint penetration and complete fusion for the full length of the weld and shall be free