Welding_Norm_1-099-00-026-0

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Company Standard

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Guidelines for Design and Manufacturing Weld Seam Quality Assessment Groups: Imperfections – Tarnish – Surface Roughness (according to DIN EN ISO 5817)

1 General

1.1

1.2

1.3

Area of Application This standard applies to all steel, nickel, titanium, and alloys fusion welds (not beam welding).

Applied Standards

- DIN EN ISO 5817 (2003-12): Welding - steel, nickel, titanium, and alloys fusion welds (no to

beam welding) – imperfections assessment groups - AD 2000 Regelwerk: body of legislation concerning pressure vessels - ASME-BPVCode sec. VIII: Rules for Construction of Pressure Vessels - ASME-BPVCode sec. IX: Qualification Standard for Welding and Brazing Procedures, Welders,

Brazers and Welding and Brazing Operators - ASME-Code for pressure piping B 31.3 - ASME-BPE 2002 Bioprocessing Equipment - Technical Provision TP 60 (Anheuser Busch specification) - ANSI/AWS D 18.1 Specification for Welding of Austenitic Stainless Steel Tube and Pipe

Systems in Sanitary (Hygienic) Applications - Empfehlungen der EHEDG (European Hygienic Engineering and Design Group

recommendations)

First Issue First issue: unknown

Issue Date : 05.07.2004

Effecting Period : Immediately

Official Implementation Date : 05.07.2004

NOTE: This company standard describes and settles the basic principles of technical requirements concerning the subject in question. It does not include manufacturer-specific solutions for selection or adjustment. The concerned departments must have carried out the application of the technical or mechanical provisions of the KRONES Company Standard and its integration into the production process by the date of application of the Company Standard. The departments must try to work out uniform application concepts for Company Standard requirements concerning several divisions and thus support the standardisation process.

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2 Application

This standard applies to all steel, nickel, titanium, and alloys fusion welds (not to beam welding). The assessment groups concern the manufacturing quality of individual weld seams, not the entire component. Therefore, various assessment groups can be specified for the different welds of one component. The assessment groups are specified in such a way that they permit a broad application in welding production. They are designated by characters B+, B, C, and D. Assessment group B represents the highest demands placed on the weld. Additional requirement B+ is applied for welds in contact with product or gas. The assessment groups concern the manufacturing quality, not the usability of the product. (Please refer to 3.2) This standard applies to:

• unalloyed and alloyed steel • nickel and alloys • titanium and alloys

• manual, mechanised, and automatic welding

• all welding positions

• all weld types, e. g., butt welds, hollow welds, and pipe branches

• the following welding procedures and allocated individual procedures according to

ISO 4063: 11 Metal-arc welding without gas protection 12 Submerged arc welding 13 Gas-shielded metal-arc welding 14 Gas-shielded welding with non-consumable electrode 15 Plasma arc welding 31 Oxy-fuel gas welding (steel only)

Metallurgic aspects, e. g., grit size, hardness, are not considered.

Note on the use of assessment groups: The assessment groups are selected according to - design - subsequent processes and surface treatment procedures - types of strain (static, dynamic) - operating conditions (e. g., temperature) - cost

The highest demands placed on the weld quality (assessment group B or B+) normally require special treatment and frequently cause additional expenses. This may be the case for

• dynamically strained welds • weld surface with particular demands concerning process technology (e. g., with product

contact) With components subject to acceptance, e. g., pressure vessels, please consider, among other things, the project-oriented body of legislation.

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Page 3 of 27 3 Terms

The following terms are valid for the application of this standard: 3.1 Assessment Group Description of the quality of a weld based on type and size of selected Imperfections. 3.2 Usability The capacity of a product, a process, or a service to fulfill a specific purpose under specific conditions. 3.3 Short Imperfection One or more imperfections with a total length that does not exceed 25 mm in 100 mm weld length, or a maximum of 25 % of the total length of a weld that is shorter than 100 mm. The weld section comprising most imperfections must be used. 3.4 Systematic Imperfection Weld imperfections appearing repeatedly at regular intervals in the examined weld section. The dimensions of the individual imperfections are within the permitted imperfection limits according to table 1. 3.5 Projected Surface Surface on which the imperfections distributed over the weld volume are represented two-dimensionally. Contrary to the rupture surface, the appearance of imperfections in a radiographic representation depends on the weld seam thickness. (Please refer to figure 1.)

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3.6 Cross-sectional Area Rupture surface or polished surface to be examined

4 Symbols

The following symbols are used in table 1

a Nominal size of the hollow weld thickness (please refer to ISO 2553) b Weld seam width d Pore diameter h Height and width of the imperfection l Length of the imperfection in longitudinal weld direction lp Length of the projected area or cross-sectional area s Nominal size of the butt weld thickness (please refer to ISO 2553) t Pipe wall or steel sheet thickness (nominal size) wp Width of the weld seam or width/height at a rupture surface z Leg length of a hollow weld (please refer to ISO 2553) α Seam transition angle β Angle of angle offset

5 Imperfections Assessment Table 1 comprises the imperfections limits. These limits apply to the finished weld seam. The may also be used for an intermediate production stage. If a procedure other than macroscopic examination is used for detection of imperfections, only those imperfections may be considered which can be detected with tenfold magnification or less. External lacks of fusion (please refer to table 1, 1.5) and microcracks (please refer to table 1, 2.2.) are exempt from this. Systematic imperfections are permissible only under assessment group D, if other requirements according to table 1 are fulfilled. Please examine a weld only for one type of imperfection at a time. If a seam cross section shows several types of imperfections which weaken the cross section, particular assessments may be necessary (please refer to multiple imperfections).

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Page 5 of 27 Please apply the limits for multiple imperfections (refer to table 1) only if the requirements for a simple

imperfection are not exceeded. Two contiguous imperfections at a distance smaller then the main size of the smaller imperfection must be considered as one imperfection.

5.1

5.2

Multiple Imperfections

The combination of multiple imperfections shows a theoretical possibility of superposed individual imperfections. In this case, the total summation of all permissible deviations must be limited by specified values for the different imperfections. I. e., the limit value of an individual imperfection δ h, e. g., for a single pore, must not be exceeded. Fault Catalogue

This standard may be used in connection with a catalogue of realistic illustrations representing the size of the permissible imperfections for the different assessment groups on photographs. These photographs display the final run and the root of the seam/reproductions of radiographs and micrographs representing the weld seam cross section. One example for such a catalogue is indicated in .Reference radiographs for the assessment of weld imperfections according to ISO 5817. published by the International Institute of Welding (IIW) and Deutscher Verlag für Schweißen und verwandte Verfahren, Düsseldorf. This catalogue may be used with reference cards in order to assess the different imperfections. It may be used to settle discrepancies on the permissible size of imperfections.

6 Permissible Tarnish The permissible delivery status tarnish for weld surfaces and roots (for steels according to DIN EN 10088-3/ASME Code sec. IIA, etc.) is: For assessment group D: 1 – 7, according to the following example For assessment group C: 1 – 5, according to the following example For assessment group B and B+: 1 – 3, according to the following example Concerning the basic materials nickel and titanium, clarification between division and the production is required for each project.

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Reference colour chart only (Please use the original chart for colour comparison! Available from F&E-NORMEN)

7 Roughness of Weld Surfaces (final run and root) Assessment group B+ requires Ra ≤ 7 µm (untreated weld seam!). Higher-quality surfaces can be obtained only by further processing (e. g., grinding), or special welding procedures (e. g., mechanical welding, orbit welding, etc.). EHEDG recommends Ra ≤ 4 µm for hygienic design.

8 Quoted Bodies of Legislation This company standard comprises demands placed on weld seam quality from bodies of legislation and user specifications listed in section 1.2 which partly differ from DIN EN ISO 5817.

Resulting deviations from DIN EN ISO 5817 are marked. Supplement B shows a comparison of the requirements according to the different bodies of legislation.

9 Subdivision of Imperfections The imperfections are subdivided into the following groups, according to DIN EN ISO 5817:

1. Surface imperfections (no. 1.1 to 1.23) 2. Internal imperfections (no. 2.1 to 2.13) 3. Seam geometry imperfections (3.1 to 3.3) 4. Multiple imperfections (4.1 to 4.2)

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Page 25EN ISO 5817 : 2003


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Annex B

Table for comparison of the requirements from the different bodies of legislation on which this company standard is based, according to section 1.2 for

- too high seam (butt weld) - too high root - offset edges for girth welds - undercuts

Table 2 Imperfection according to ordinal no. ISO 6520

DIN EN ISO 5817 Assessment group B t = 0.5 – 3 mm

Anheuser-Busch specification TP 60

EHEDG recommendation

ANSI/AWS 18.1 ASME –Code sec. VIII section UW 33 / 35

ASME B 31.3 ASME BPE-2002

Ordinal no. 502 Too high seam (butt weld)

≤ 1mm + 0.1 b

max. 5mm

≤ 1.65 mm

≤ 0.4 mm

≤ 0.3 mm

0.8 mm

Reference to ASME sec. VIII +

sec. IV

Reference to ASME sec. VIII

+ sec. IV

Ordinal no. 504 Too high root

≤ 1mm + 0.1 b

≤ 0.1 t

≤ 0.1 t

≤ 0.3 mm

0.8 mm


sec. IV


+ sec. IV Ordinal no. 507 Offset edges with girth welds

≤ 0.5 t

max. 2mm

≤ 0.8 mm

≤ 0.2 t

≤ 0.1 t

0.25 t


sec. IV


+ sec. IV Ordinal no. 5011/5012 Undercuts Not permissible! No statement No statement No statement 0.1 t


sec. IV


+ sec. IV t= wall thickness; b = seam or root width

Welding_Norm_1-099-00-026-0

Documents

pressure vessels

alloys fusion

assessment

company standard

krones ag

bpvcode sec

weld surfaces

assessment