4. SECTION 05 WELDING.pdf

USIBWC Amistad Reservoir and Dam Turbine Pit Pipeline and Supports Corrosion Mitigation

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July 2020 USIBWC Solicitation

Welding 05.05.23-Page 11

SECTION 05.05.23

WELDING

PART 1 - GENERAL

1.1 SECTION INCLUDES

Part 1 - General

1.1 Section Includes

1.2 Related Requirements

1.3 Reference Standards

1.4 Submittals

1.5 Measurement and Payment

1.6 General

1.7 Welding Procedure Sections (WPS)

1.8 Welder Qualification

1.9 Nondestructive Tester Qualifications

Part 2 - Products

2.1 Welding Equipment and Materials

Part 3 - Execution

3.1 Procedure Qualification

3.2 Workmanship

3.3 Stud Welding

3.4 Weld Quality

3.5 Nondestructive Examination

3.6 Acceptability of Welds

3.7 Corrections

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1.2 RELATED REQUIREMENTS

(Not Used).

1.3 REFERENCE STANDARDS

A. American Society of Nondestructive Testing (ASNT)

1. ASNT/ANSI CP-189-2011 Standard for Qualification and Certification of

Nondestructive Testing Personnel

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B. American Welding Society (AWS)

1. AWS A5.4 2012 Specification for Stainless Steel Electrodes for Shielded Metal Arc

Welding

2. AWS A5.9 2012 Specification for Bare Stainless Steel Welding Electrodes and Rods

3. AWS A5.10 2012 Welding Consumables–Wire Electrodes, Wires and Rods for

Welding of Aluminum and Aluminum-Alloys–Classification

4. AWS D1.1 2015 Structural Welding Code Steel, 2nd printing

5. AWS D1.2 2014 Structural Welding Code Aluminum

6. AWS D1.3 2008 Structural Welding Code Sheet Steel

7. AWS D1.4 2011 Structural Welding Code Reinforced Steel

8. AWS D1.5 2015 Bridge Welding Code

9. AWS D1.6 2007 Structural Welding Code Stainless Steel

1.4 SUBMITTALS

A. Submittals shall be transmitted by the Contractor in accordance with the requirements of the PWS. The Contractor shall be responsible for certifying that all submittals are in compliance with the Contract requirements.

B. Required submittals in this Section include:

1. Welding Procedure Sections (WPS)

2. Welder Certifications

a. A copy of an AWS welder certification card.

b. Miscellaneous Weld Qualification Test witnessed by the COR.

3. Weld Inspection Tests Provide all nondestructive, visual, and coupon test results to the COR.

1.5 MEASUREMENT AND PAYMENT

Include cost of welding, welds, inspections, and tests in applicable prices offered in Contract for items for which welding is required.

1.6 GENERAL

A. The Contractor shall shop or field weld metal members as required to complete project.

B. Welding to or on structural steel shall be in accordance with AWS D1.1. Welding of reinforcing steel shall conform to AWS D1.4. Welding of stainless steel shall conform to AWS D1.6. Welding of aluminum shall conform to AWS D1.2. Most references in this

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Section only call out items in AWS D1.1. When materials other than steel are being welded, the Contractor shall assume that the reference is to the applicable AWS standards in this paragraph instead.

1.7 WELDING PROCEDURE SECTIONS (WPS).

A. When welding on any load bearing structure or water control gate, a WPS shall be provided with sufficient details that any competent person will be able to apply the information and produce a weld of acceptable quality. The WPS shall include:

1. Procedure number.

2. Process type.

3. Consumable Size, Type and full Codification.

4. Consumable Baking Requirement if applicable

5. Parent material grade and spec.

6. Thickness range.

7. Plate or Pipe, Diameter range.

8. Welding Position.

9. Joint Fit Up, Preparation, Cleaning, Dimensions etc.

10. Backing Strip, Back Gouging information.

11. Pre-Heat (minimum temp and method).

12. Interpass, if required (maximum temperature recorded).

13. Post Weld Heat Treatment, if required (time and temp).

14. Welding Technique (weaving, maximum run width etc.).

15. Arc Energy Limits shall be stated if impact tests are required or if the material being welded is sensitive to heat input.

16. Additionally, provide these details dependent upon the type of weld:

a. MMA

(1) Welding Current

(2) Type of Welding Current

b. TIG

(1) Welding Current

(2) Type of Welding Current

(3) Arc Voltage

(4) Pulse Parameters (pulse time, peak and background current)

(5) Shielding Gas (composition and flow rate)

(6) Purge Gas (composition and flow rate)

(7) Tungsten Electrode (diameter and type)

(8) Nozzle Diameter

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c. MIG, MAG, or FCAW

(1) Welding Current

(2) Type of Welding Current

(3) Arc Voltage

(4) Pulse Parameters (pulse time, peak and background current)

(5) Shielding Gas (composition and flow rate)

(6) Purge Gas (composition and flow rate)

(7) Nozzle Diameter

(8) Wind Shelter Description, if required

d. SAW

(1) Welding Current

(2) Type of Welding Current

(3) Arc Voltage

(4) Wire Configuration

(5) Type of Flux (codification and brand name)

(6) Nozzle Standoff Distance

1.8 WELDER QUALIFICATION

A. Provide certification papers for each welder for each welding process to be used before welding, except for miscellaneous welds described in Miscellaneous Welding Applications.

1. Welding operators, welders, and tack welders shall be qualified and requalified if necessary for the particular type of work to be done. Qualification shall be in accordance with AWS D1.1, Section 4, Part C or ASME BPVC Section IX.

B. The Contractor shall certify by name to the COR the welders and welding operators so qualified, including the date of qualification, certificates, and code and procedures under which qualified. All expenses in connection with qualification and requalification shall be borne by the Contractor.

C. Welder, Welding Operator, and Tacker Qualification

Each welder, welding operator, and tacker assigned to work on this Contract shall be qualified in accordance with the applicable requirements of AWS D1.1 and as specified in this Section. Welders, welding operators, and tackers who make acceptable procedure qualification test welds will be considered qualified for the welding procedure used.

1. Previous Personnel Qualifications

At the discretion of the COR, welders, welding operators, and tackers qualified by test within the previous six (6) months may be accepted for this Contract without re-qualification if all the following conditions are met:

a. Copies of the welding procedure specifications, the procedure qualification test records, and the welder, welding operator, and tacker qualification test records are submitted and compliance confirmed in accordance with the specified requirements for detail Contract Drawings.

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b. Testing was performed by a compliance confirmed testing laboratory or technical consultant.

c. The previously qualified welding procedure conforms to the requirements of this specification and is applicable to welding conditions encountered under this Contract.

d. The welder, welding operator, and tacker qualification tests conform to the requirements of this specification and are applicable to welding conditions encountered under this Contract.

2. Certificates Before assigning any welder, welding operator, or tacker to work under this Contract, submit the names of the welders, welding operators, and tackers to be employed, and certification that each individual is qualified as specified. State in the certification the type of welding and positions for which the welder, welding operator, or tacker is qualified, the code and procedure under which the individual is qualified, the date qualified, and the name of the firm and person certifying the qualification tests. Keep the certification current.

3. Renewal of Qualification Re-qualification of a welder or welding operator is required under any of the following conditions:

a. It has been more than six (6) months since the welder or welding operator has used the specific welding process for which he is qualified.

b. There is specific reason to question the welder or welding operator's ability to make welds that meet the requirements of these specifications.

c. The welder or welding operator was qualified by an employer other than those firms performing work under this Contract, and a qualification test has not been taken within the past twelve (12) months. Submit as evidence of conformance all records showing periods of employment, name of employer where welder, or welding operator, was last employed, and the process for which qualified.

d. A tacker who passes the qualification test is considered eligible to perform tack welding indefinitely in the positions and with the processes for which he/she is qualified, unless there is some specific reason to question the tacker's ability. In such a case, the tacker is required to pass the prescribed tack welding test.

D. Miscellaneous Welding

1. A qualified welder is an experienced welder who is capable of making welds of sound quality but does not have American Welding Society certification papers. Before welding begins, the COR will compliance confirm the welder’s ability by conducting a jobsite test in accordance with Miscellaneous Weld Qualification Test. The Contractor shall furnish all materials and equipment necessary for this test.

2. Miscellaneous Welding Applications A welder certified for structural or reinforcing steel or a qualified welder may make miscellaneous welds of the following types:

a. Vehicular gate fabrication or repair.

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b. Fencing

c. Other similar miscellaneous members that have no load-carrying capacity in the completed structure.

3. Miscellaneous Weld Qualification Test

A qualified welder must pass a jobsite Miscellaneous Weld Qualification Test before welding:

a. Make a single-pass fillet weld of one quarter (¼) inch maximum size in the vertical position approximately two (2) inches long on one half (½) inch plate in the location shown in Figure 1. Use the same electrode proposed for the work.

b. The COR will visually inspect the fillet weld for a reasonably uniform appearance and then rupture the weld as shown in Figure 2 with a force or by striking it with a hammer.

c. The fractured surface of the weld will be inspected to ensure complete penetration into the root of the joint, complete fusion to the base metal and no inclusion or porosity larger than 3/32 inch in its greatest dimension.

4. A welder who fails the Miscellaneous Weld Qualification Test may take a retest under the following conditions:

a. The retest occurs immediately and consists of two (2) test welds as described above with both test specimens meeting all of the requirements.

b. The retest occurs after thirty (30) days if the welder provides evidence of further training or practice.

c. In this case the test consists of a single test weld.

5. Qualification by the Miscellaneous Weld Qualification Test is effective immediately upon satisfactory completion of the test and remains in effect for the duration of a project.

E. Certified Steel Structures Welder

1. Welders shall hold a current American Welding Society certification prior to welding on any load bearing structure or water control gate. Ensure that the certifications match the material and conditions to be welded on the project.

2. Code

a. API 1104 Welding of Pipelines and Related Facilities

b. AWS D1.1 Structural Welding Code Steel

c. AWS D1.2 Structural Welding Code-Aluminum

d. AWS D1.4 Structural Welding Code Reinforcing Steel

e. AWS D1.5 Bridge Welding Code

f. AWS D1.6 Structural Welding Code-Stainless Steel

g. AWS D14.3 Specification for Welding Earthmoving, Construction and

Agricultural Equipment

3. Filler Material

a. ER309 Stainless Steel TIG Welding Rod

b. E7018 Low-Hydrogen Iron Powder Arc Welding Electrodes

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c. ER70S Mild Steel TIG Welding Rod

d. E71T Carbon-Steel Flux-Cored Welding Wire

4. Process

a. SMAW Shielded Metal Arc Welding

b. GMAW Gas Metal Arc Welding

c. GMAW-S Gas Metal Arc Welding-Short Circuit

d. FCAW Flux Cored Arc Welding

e. GTAW Gas Tungsten Arc Welding

f. SAW Submerged Arc Welding

g. BZ Brazing

5. Base Metal The nomenclature listed here shall be the ASTM Designation of the metal to be welded.

6. Position Qualified

a. 1G Groove Weld, Flat

b. 2G Groove Weld, Horizontal

c. 3G Groove Weld, Vertical

d. 4G Groove Weld, Overhead

e. 5G Groove Weld, Pipe Vertical

f. 6G Groove Weld, Pipe 45° Vertical

g. 1F Fillet Weld, Flat

h. 2F Fillet Weld, Horizontal

i. 3F Fillet Weld, Vertical

j. 4F Fillet Weld, Overhead

k. V Vertical Progression Up

l. D Vertical Progression Down

m. A All

7. Thickness

a. U Unlimited (⅛" to unlimited)

b. L Limited

c. xx-xx Range in sheet gauges

d. x/x Thickness in fractions of an inch

e. SCH Schedule listing for pipe thickness

f. WB With Backing

g. WOB Without Backing

8. Before making non-miscellaneous welds on structural steel, a welder must hold certifications for plates of unlimited thickness in the vertical (3G) and overhead (4G) positions.

9. For SMAW, a welder certified using EXX18 electrodes is qualified to weld with all compliance confirmed SMAW electrodes up to E90XX to join metals with a maximum specified yield strength of sixty five (65) kips per second.

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Figure 1-Miscellaneous Qualification: Fillet Weld Break Specimen

Figure 2-Miscellaneous Qualification: Method of Rupturing Specimen

1.9 NONDESTRUCTIVE TESTER QUALIFICATIONS

A. Nondestructive (NDT) testers shall be fully qualified and possess the skills to set up equipment, conduct tests, and to interpret, evaluate, and document the results.

B. Testers shall be certified in accordance with ASNT CP-189 as Level II or Level III in the given NDT test method. Test methods include:

1. Magnetic Particle Testing (MT)

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2. Liquid Penetrant Testing (PT)

3. Radiographic Testing (RT)

4. Ultrasonic Testing (UT)

5. Visual and Optical Testing (VT)

6. Electromagnetic Testing (ET)

C. Upon COR approval, Level I technicians may be used onsite if they are qualified and are working under the direct supervision of a Level II individual.

D. Organizational Changes.

1. The Contractor shall obtain the COR’s acceptance before replacing any NDT technicians. Requests shall include the names, qualifications, duties and responsibilities of each proposed replacement.

2. The Government reserves the right to require the Contractor to make changes in the NDT staff, including removal of personnel, as necessary, to obtain the quality specified.

PART 2 - PRODUCTS

2.1 WELDING EQUIPMENT AND MATERIALS

A. Provide all welding equipment, electrodes, welding wire, and fluxes capable of producing satisfactory welds when used by a qualified welder or welding operator performing qualified welding procedures.

B. Provide welding equipment meeting the requirements of the compliance confirmed welding procedure Section (WPS), if required, and capable of making consistent high-quality welds.

C. All items of welding equipment shall conform to the requirements of AWS D1.1.

PART 3 - EXECUTION

3.1 PROCEDURE QUALIFICATION

A. The Contractor shall use the proper classification and size of electrode, arc length, voltage, and amperage for the thickness of the material, type of groove, welding positions and other circumstances of the work.

B. Submit WPS’s for compliance confirmation before welding any load bearing structure or water control gate.

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3.2 WORKMANSHIP.

A. Preparation of Base Metal Prior to welding, the Contractor shall inspect surfaces to be welded to assure compliance with AWS D1.1, Sections 5.15 through 5.17, and 5.19.

B. Temporary Welds

Temporary welds required for fabrication and erection shall be made under the controlled conditions prescribed herein for permanent work. All temporary welds shall be made using low-hydrogen welding electrodes and by welders qualified for permanent work as specified elsewhere in these Sections. The preheating furnished for temporary welds shall be as required by AWS D1.1 for permanent welds, except that the minimum temperature shall be one hundred twenty degrees Fahrenheit (120°F) in any case. In making temporary welds, arcs shall not be struck in other than weld locations. Each temporary weld shall be removed after serving its purpose and ground flush with adjacent surfaces.

C. Tack Welds

Tacks welds that are to be incorporated into the permanent work shall be subject to the same quality requirements as the permanent welds. Preheating shall be performed as specified above for temporary welds. Such tack welds shall be cleaned and fused thoroughly with the permanent welds. Multiple-pass tack welds shall have cascaded ends.

Defective tack welds shall be removed before permanent welding.

3.3 STUD WELDING

A. Stud welding, unless otherwise specified shall conform to the applicable provisions of

Section 7 of AWS D1.1.

B. Stud Materials The type, size and length of studs shall be as indicated on the Contract Drawings. The Contractor shall furnish for compliance confirmation the manufacturer's certified test reports and certification that the studs conform to the applicable requirements of AWS D1.1, Subsections 7.2 and 7.3.

C. Stud Base Application Qualification

As a condition of compliance confirmation, the Contractor shall furnish, a certified report giving data, procedures and results of tests performed in accordance with the provisions of Article 7.4 of AWS D1.1. The test specimens shall be prepared using suitable specimen plates of the same base metal to which the studs are to be welded.

D. Workmanship

The studs shall be welded in accordance with the provisions of Article 7.4 of AWS D1.1.

Studs on which a full three hundred sixty degree (360°) weld fillet is not obtained may, at the option of the Contractor, be repaired by adding a 3/16 inch fillet, using shielded metal arc process with low-hydrogen welding electrodes. If the reduction of the length of studs

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05.05.23-Page 11 becomes less than normal as they are welded, welding shall be stopped immediately and not resumed until the cause has been corrected.

E. Inspection

1. The welding of stud connectors will be subject to visual inspection by the Government's Inspector.

2. Each stud connector that does not show a full three hundred sixty degree (360°) weld fillet, that has been repaired by welding, or the reduction in length due to welding is less than normal shall be tested in accordance with the requirements for testing.

F. Testing

1. Prior to starting welding operation and at the beginning of each day's operation, two stud connectors shall be welded in the same general position (flat, vertical, overhead, sloping) to a separate piece of material of similar thickness and composition as the member to which the studs are to be welded. After being allowed to cool, these studs shall be tested by bending to an angle of thirty degrees (30°) by striking the stud with a hammer. If failure occurs in the weld zone of either stud, the procedure shall be corrected and two successive studs successfully welded and tested before any studs are welded to the member.

2. The foregoing testing shall be performed after any change in the welding procedure.

If failure occurs in the stud shank, an investigation shall be made to ascertain and correct the cause before further welds are made.

3. In addition to the foregoing tests, at least one stud in every one hundred (100) shall be struck with a hammer and bent to an angle of fifteen degrees (15°), or if threaded, shall be torque tested with a calibrated torque wrench as indicated in Figure 7.3 of AWS D1.1. If the stud fails, two more of the existing studs shall be bent or torque tested. If either of these two studs fails, all of the studs represented by the tests shall be rejected.

4. Studs under testing that crack either in the weld, the base metal, or the shank shall be rejected and replaced by the Contractor at no additional cost to the Government.

3.4 WELD QUALITY

A. Provide welds that are sound throughout with no cracks in the weld metal or weld pass.

B. Completely fuse the weld metal and the base metal and each subsequent pass.

C. Keep welds free from overlap and keep the base metal free from undercut more than

1/100 inch deep when the direction of undercut is transverse to the primary stress in the part that is undercut.

D. Fill all craters to the full typical section of the welds.

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3.5 NONDESTRUCTIVE EXAMINATION

A. The nondestructive (NDT) examination of welds shall be performed as designated and/or described in the sections of these Specifications covering the particular items of work.

B. Testing Agency

Certified Welding Inspectors (CWI) shall be qualified and certified in accordance with the provisions of AWS QC1. The laboratory and all personal performing nondestructive testing shall be qualified in accordance with ASNT CP-189. Only individuals qualified for NDT Level II or individuals qualified for Level I and working under the direct supervision of a Level II shall perform nondestructive testing. Level III NDT Inspectors shall possess a currently valid ASNT Level III certificate in each of the processes they are qualifying inspectors to. Copies of the certifications, including the Level III NDT Technician that certified the Level I and Level II Technicians shall be included in the submittals.

C. Examination Procedures

1. Ultrasonic Testing Making, evaluating and reporting ultrasonic testing of welds shall conform to the requirements of AWS D1.1, Section 6, Part F. A record shall be made of each weld tested.

2. Radiographic Testing Making, evaluating and reporting radiographic testing of welds shall conform to the requirements of AWS D1.1, Section 6, Part E. Only film types designated as "fine grain" or "extra fine" shall be employed.

3. Magnetic Particle Inspection Magnetic particle inspection of welds shall conform to the applicable provisions of ASTM E709 and in addition all magnetic particle inspections of welds shall be made using the Wet Contrasting Black on White Method.

4. Dye Penetrant Inspection Dye penetrant inspection of welds shall conform to the applicable provisions of

ASTM E165.

3.6 ACCEPTABILITY OF WELDS

A. Welds shall be unacceptable if shown to have defects prohibited by AWS D1.1, Section

6, Part C.

1. Visual and magnetic particle testing acceptance criteria shall be for the applicable criteria for either "Cyclically Loaded Nontubular Connections" or "Tubular Connections" per AWS D1.1, Table 6.1.

2. Ultrasonic acceptance criteria shall be the applicable criteria for either "Cyclically Loaded Nontubular Connections" or "Tubular Connections, Class R."

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3. The RT will have to meet the applicable criteria for either "Cyclically Loaded Nontubular Connections (Tensile Stress)" or "Tubular Connections."

B. Visual Examination

Prior to any welding, the Contractor shall visually inspect the preparation of material for welding to assure compliance with AWS D1.1 Section 5 and Section 6, Part C. All completed welds shall be cleaned and carefully examined for insufficient throat or leg sizes, cracks, undercutting, overlap, excessive convexity or reinforcement, and other surface defects.

C. Welds to be Subject to Nondestructive Examination

1. Full Penetration Welds Full penetration welds, where indicated, shall be examined by the Contractor using ultrasonic testing (UT) and/or radiographic testing (RT) procedures described above. In additional to the full penetration welds specified for testing, a randomly chosen twenty-five percent (25%) of the remaining full penetration welds shall be ultrasonically tested to ensure the quality of the procedure and process. The random testing shall include a representative sample of welds from all welders and each of the processes each welder used.

The random testing shall be spread throughout the project. A schedule for implementing the random testing shall be developed by the Contractor and submitted for compliance confirmation prior to fabrication.

2. Fillet Welds and Partial Penetration Groove Welds The Contractor shall test all fillet welds and partial penetration welds as indicated on the drawing. Additionally, there will be twenty-five percent (25%) random testing of the remaining fillet and partial penetration groove welds. This testing shall be done by the magnetic particle testing procedures described above. This additional twenty-five percent (25%) shall include a representative sample of welds from all welders and each of the processes each welder used. The random testing shall be spread throughout the project. A schedule for implementing the random testing shall be developed by the Contractor and submitted for compliance confirmation prior to fabrication.

3.7 CORRECTIONS

A. When welding is unsatisfactory or indicates inferior workmanship, the COR will require corrective measures and approve the subsequent corrections.

B. Conduct corrections in accordance with the requirements of AWS D1.1, AWS D1.2, AWS D1.4, or D1.6 as appropriate.

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