WELDER OPERATOR TRAINING

BOSCONGO YARD
 Objectives
Aim of this presentation is to provide to Welders and
Welding Operators basic instructions about :
How to read WPSs.
Preheat and Interpass Temperature: methods of
application, control etc.
Tack Welding Procedure.
Handling and Storage of Welding consumables.
 Summary
WPS
WPS details
Groove dimension
Welding parameters
Bevel cleaning
Tack Welding
Handling of welding consumables
 Reading WPS
What is WPS?
A Welding Procedure Specification (or WPS) is a
technical specification that defines/as a guidance
how to run a weld, according to different operating
conditions.

Why we need WPS?

To ensure the integrity of each welded joint is in
accordance with the Code & Standard, and specific
Project Specification.
WPS
Welding Procedure Specification
WPS
Details
WPS number

Process
SAW

Preheat
requirement
WPS
Groove details

Process
WPS
Welding parameters

Welding
parameters
WPS
Welding sequence

1st pass SAW s.w.

Hot pass SAW s.w.
Fill pass SAW
tandem
Cap SAW s.w.
SAW Tandem
Any Questi on

??
 Before welding, check:

Groove dimension
Groove cleanliness
Welding parameters
Preheat temperature
Groove dimension
 Bevel cleaning
Bevel Cleaning: to be performed before welding. Bevels shall be free from
Oxidations, slags, rust, oil etc. Cleaning to be performed by brushing/grinding
Interpass Cleaning: to be performed during welding
Check and ensure no slag trapped before depositing the next pass
Interpass cleaning can be minimized by make the good weld bead and preparation
before depositing the next pass.
 Preheat

Preheat is a minimum temperature to be achieved prior

to execution of welding for each passes.

Preheat is an ESSENTIAL VARIABLE of WPS.

Why Preheat?
To remove the moisture content in the material.
Slower cooling rate.
To prevent distortion
To prevent Hydrogen Induced Cracking (HIC)
Any Questi on

??
 Tack Welding Procedure
Tack Weld defined as a weld made to hold the parts of weldment
in proper alignment until the final weld are made.

The surfaces to be tack weld shall be free from :

Moisture,
Dirt,
Slag,
Rust,
Oxidation,
etc.
Tack Welding Procedure

Generally the procedure of Tack weld as follow:

Clean the surface of material to be tack welded.
Preheat as per applicable WPS shall be performed prior to
Tack Weld.
Perform the tack weld refer to applicable WPS and use
qualified welder and/or qualified tack welder.
Defective tack weld shall be removed, by grinding to sound
metal.
Performed VT and MT/PT on grinded area if required. The
report shall be kept by QC department
 Handling and Storage of welding consumables

Welding consumables should be stored in dry conditions and at a constant temperature

and low humidity rate, in order to minimize any effects of atmospheric moisture.
The characteristics SAW fluxes and flux-cored wires, in particular, are detrimentally
affected by moisture pick up.
 Flowchart for SAW wire

STORAGE
Temperature : 15C 25C
Humidity: < 55%

WELDING

YES
SURPLUS TO
BE LEFT FOR
MORE THAN 8
HOURS

NO
Flowchart for SAW flux STORAGE
Temperature : 15C
25C
Humidity: <55%

Opening of sealed
packages HOLDING OVEN
and marking on pack for new flux
Opening date
Opening time
Signature

75% New
Flux

N
Heated (110C
O
min)
25% Feeder
Recovered Hopper YE
Flux S

HOLDING OVEN SAW Hopper

(Table 2)

DRYING OVEN SAW Hopper

(Table 2)

N
RECOVERED WELDING O
Surplus
FLUX
after 4
YEhours
S
SAW
Flux handling
Holding
oven

Storage

Hopper Welding