Attachment_3_Training_Standard.pdf

NAVAL SHIPS’ TECHNICAL MANUAL

CHAPTER 074 - VOLUME 1

WELDING AND ALLIED

PROCESSES

THIS CHAPTER SUPERSEDES CHAPTER 074 VOLUME 1, DATED 23 AUGUST 1999

DISTRIBUTION STATEMENT C: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT

AGENCIES AND THEIR CONTRACTORS; ADMINISTRATIVE AND OPERATIONAL USE

(31 JANUARY 1992). OTHER REQUESTS FOR THIS DOCUMENT WILL BE REFERRED

TO THE NAVAL SEA SYSTEMS COMMAND (SEA-03M2).

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS

RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C., SEC. 2751, ET

SEQ.) OR EXECUTIVE ORDER 12470. VIOLATIONS OF THESE EXPORT LAWS ARE

SUBJECT TO SEVERE CRIMINAL PENALTIES. DISSEMINATE IN ACCORDANCE WITH

PROVISIONS OF OPNAVINST 5510.161, REFERENCE (JJ).

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLO-

SURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENT.

S9086-CH-STM-010/CH-074V1R5

REVISION 5

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PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND.

31 JAN 2003

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REVISION RECORD

REVISION

NO. DATE TITLE AND/OR BRIEF DESCRIPTION/PREPARING ACTIVITY

5 31 JAN 2003 PARAGRAPH(S)074-10.8.1.1, 074-10.8.2.2, 074-10.8.3.1AND 074-10.8.4.1

TMDERS/ACNS INCORPORATED:

CWP8 - FIREWATCH - CWP8 AI2129

S9086-CH-STM-010/CH-074V1R5

REVISION RECORD-1 / (REVISION RECORD-2 Blank)

REVISION RECORD-2

TABLE OF CONTENTS

Chapter/Paragraph Page

074 VOLUME 1

WELDING AND ALLIED PROCESSES . . . . . . . . . . . . . . . . . . . . . . 74-1

SECTION 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-1

074-1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-1 074-1.1.1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-1 074-1.1.2 MANDATORY REFERENCING. . . . . . . . . . . . . . . . . . . . . . . . . 74-1

074-1.1.3 NUCLEAR AND COMBAT WEAPONS SYSTEMS.. . . . . . . . . . . . . 74-1

074-1.1.4 SHIP STRUCTURE AND SYSTEMS.. . . . . . . . . . . . . . . . . . . . . 74-1 074-1.1.5 RESPONSIBILITY FOR COMPLIANCE.. . . . . . . . . . . . . . . . . . . 74-1 074-1.1.6 REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-1

074-1.2 WELD CATEGORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-2

074-1.3 REFERENCE DOCUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-2 074-1.3.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-2

074-1.3.2 MANDATORY REFERENCE DOCUMENTS.. . . . . . . . . . . . . . . . . 74-5

074-1.3.3 GUIDANCE DOCUMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . 74-5

074-1.4 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-5

SECTION 2 QUALIFICATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . 74-7

074-2.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-7

074-2.2 WELDING, BRAZING, AND THERMAL SPRAYING PROCEDURE AND

PERFORMANCE QUALIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 74-7

074-2.2.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-7

074-2.2.2 MILITARY ACTIVITIES OTHER THAN SHIPYARDS. . . . . . . . . . . . 74-7

074-2.2.3 APPROVAL AGENCIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-7

074-2.2.4 CIVILIAN PERFORMANCE QUALIFICATIONS. . . . . . . . . . . . . . . 74-7

074-2.2.5 NONDESTRUCTIVE TESTING QUALIFICATIONS. . . . . . . . . . . . . 74-7

074-2.2.6 MILITARY PERFORMANCE (WELDER) QUALIFICATION. . . . . . . . 74-8

074-2.2.6.1 Initial Qualification.. . . . . . . . . . . . . . . . . . . . . . . . . 74-8 074-2.2.6.2 Specific Qualification.. . . . . . . . . . . . . . . . . . . . . . . . 74-8 074-2.2.6.3 Validation of Qualification.. . . . . . . . . . . . . . . . . . . . . 74-8 074-2.2.6.4 Welding Navy Enlisted Classification Code Achievement.. . . . 74-8

074-2.2.7 NAVY ENLISTED CLASSIFICATION TEST REQUIREMENTS.. . . . . . 74-8

074-2.2.7.1 Completion of Tests.. . . . . . . . . . . . . . . . . . . . . . . . . 74-9 074-2.2.7.2 Welding Limitations. . . . . . . . . . . . . . . . . . . . . . . . . 74-9

074-2.2.8 COURSE A-701-0025, BASIC WELDING.. . . . . . . . . . . . . . . . . . 74-9

074-2.2.9 COURSE A-701-0026, NEC 4954, GENERAL MAINTENANCE WELDER.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-9 074-2.2.9.1 Minimum Requirements.. . . . . . . . . . . . . . . . . . . . . . 74-9 074-2.2.9.2 Weld Categories.. . . . . . . . . . . . . . . . . . . . . . . . . . . 74-10 i

TABLE OF CONTENTS - Continued

074-2.2.10 COURSE A-701-0027, NEC 4955, NON-NUCLEAR WELDER.. . . . . . 74-10

074-2.2.11 EXTENT OF QUALIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . 74-11

074-2.3 UNDERWATER WELDING AND NDT QUALIFICATION . . . . . . . . . . . . . . 74-12

074-2.4 MILITARY RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-12 074-2.4.1 QUALIFICATION TEST RECORDS.. . . . . . . . . . . . . . . . . . . . . . 74-12 074-2.4.2 VISION TEST RECORDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-12 074-2.4.3 PERSONNEL SERVICE RECORD ENTRIES.. . . . . . . . . . . . . . . . . 74-12 074-2.4.4 QUALIFICATION MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 74-12 074-2.4.5 RENEWAL OF QUALIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . 74-12 074-2.4.6 EQUIPMENT QUALIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . 74-13

SECTION 3 QUALITY ASSURANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-14

074-3.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-14

074-3.2 MATERIALS REQUIREMENTS AND CERTIFICATION. . . . . . . . . . . . . . . 74-14

074-3.3 WELDING MATERIAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-14

074-3.4 INSPECTION AND RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-14 074-3.4.1 CATEGORY A AND C WELDS. . . . . . . . . . . . . . . . . . . . . . . . . 74-14 074-3.4.2 CATEGORY B WELDS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-15 074-3.4.3 EMERGENCY WELDS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-15 074-3.4.4 CATEGORY D WELDS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-15 074-3.4.5 Category E and F welds.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-15

SECTION 4 WELDING AND BRAZING REQUIREMENTS . . . . . . . . . . . . . . . . . . . 74-16

074-4.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-16

074-4.2 GENERAL REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-16

074-4.3 WELDING IN WAY OF WETTED SURFACES . . . . . . . . . . . . . . . . . . . . 74-16

074-4.4 TEMPERATURE-INDICATING CRAYONS . . . . . . . . . . . . . . . . . . . . . . 74-17

074-4.5 BIMETALLIC BOND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-17

074-4.6 WELD DEPOSITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-17

074-4.7 OXYFUEL GAS CUTTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-17

074-4.8 HOT OR COLD FORMING OF CASTINGS. . . . . . . . . . . . . . . . . . . . . . 74-17

074-4.9 PREPARATION OF FULL PENETRATION DOUBLE BEVEL WELD JOINT

DESIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-18 ii

074-4.10 REDUCED SOCKET DEPTH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-18

074-4.11 REDUCED COUNTERBORE DEPTH. . . . . . . . . . . . . . . . . . . . . . . . . 74-18

074-4.12 BRAZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-18

074-4.13 ALLIED PROCESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-18 074-4.13.1 RESISTANCE WELDING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-18 074-4.13.2 METALLIZING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-19 074-4.13.3 ELECTROPLATING.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-19

074-4.13.3.1 Selective Electroplating.. . . . . . . . . . . . . . . . . . . . . . . 74-19 074-4.13.3.2 Shaft Electroplating.. . . . . . . . . . . . . . . . . . . . . . . . . 74-19

SECTION 5 STRAY CURRENT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 74-20

074-5.1 UNDERWATER CORROSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-20

074-5.2 CURRENT FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-20

074-5.3 WELDING EQUIPMENT REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . 74-20

074-5.4 GROUNDING CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-20 074-5.4.1 CABLE LUGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-20 074-5.4.2 CABLE SIZE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-21 074-5.4.3 RESISTANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-23

074-5.5 WELDING UNIT ARRANGEMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . 74-23

074-5.6 SPECIAL PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-35 074-5.6.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-35 074-5.6.2 WELDING CURRENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-35 074-5.6.3 SPLITTING GROUND RETURN CABLES.. . . . . . . . . . . . . . . . . . 74-35 074-5.6.4 RESISTANCE CHECKS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-35

074-5.6.5 LOCATION OF GROUND RETURN CABLES.. . . . . . . . . . . . . . . . 74-35

SECTION 6 SURFACE SHIP HULL STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . 74-36

074-6.1 HULL MATERIAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 74-36 074-6.1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-36 074-6.1.2 HY-80 AND HY-100 STEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . 74-36 074-6.1.3 ALUMINUM ALLOY 6061-T6. . . . . . . . . . . . . . . . . . . . . . . . . . 74-36

074-6.2 STEEL SONAR DOMES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-36

074-6.3 REPAIR OF MECHANICAL FASTENERS. . . . . . . . . . . . . . . . . . . . . . . 74-36

074-6.4 DUCTILE METAL OVERLAY TO ARREST CRACKS IN SHIP PLATES . . . . . 74-37

iii

074-6.5 WELDING CORRODED PLATE SURFACES AND WELDS. . . . . . . . . . . . . 74-38

074-6.5.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-38 074-6.5.2 ABRASIVE BLASTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-39 074-6.5.3 CORRODED PLATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-39 074-6.5.4 ISOLATED PITS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-39 074-6.5.5 CORRODED WELDS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-39

074-6.6 ALUMINUM DECKHOUSE REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . 74-39

074-6.7 CLOSURE PATCHES FOR TEMPORARY OPENINGS AND ACCESSES. . . . . 74-40

074-6.7.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-40 074-6.7.2 NEW ACCESS HOLES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-40

074-6.7.3 CLOSURE PATCHES ON PREVIOUSLY MADE JOINTS.. . . . . . . . . 74-43

074-6.7.4 WELDING REQUIREMENTS FOR PATCHES AND CLOSURE PLATES.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-44 074-6.7.5 PROXIMITY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . 74-44

074-6.7.6 CLOSURE PATCHES ON MECHANICALLY FASTENED JOINTS.. . . . 74-45

074-6.8 MECHANICAL FASTENER REQUIREMENTS. . . . . . . . . . . . . . . . . . . . 74-45

074-6.9 UNDERWATER WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-46 074-6.9.1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-46 074-6.9.2 DEFINITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-46

074-6.9.2.1 Customer.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-46 074-6.9.2.2 Dry Chamber Welding.. . . . . . . . . . . . . . . . . . . . . . . 74-46 074-6.9.2.3 Underwater Welding.. . . . . . . . . . . . . . . . . . . . . . . . 74-46

074-6.9.3 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-46 074-6.9.4 SAFETY REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . 74-48

074-6.9.4.1 General.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-48 074-6.9.4.2 Dry Chamber Support Requirements.. . . . . . . . . . . . . . . 74-48 074-6.9.4.3 Explosive and Hazardous Materials.. . . . . . . . . . . . . . . . 74-48 074-6.9.4.4 Power Cables and Connectors.. . . . . . . . . . . . . . . . . . . 74-49 074-6.9.4.5 Electrode Holders.. . . . . . . . . . . . . . . . . . . . . . . . . . 74-49 074-6.9.4.6 Diving Helmets.. . . . . . . . . . . . . . . . . . . . . . . . . . . 74-49 074-6.9.4.7 Diver Dress.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-49 074-6.9.4.8 Safety Switches.. . . . . . . . . . . . . . . . . . . . . . . . . . . 74-49

074-6.9.5 UNDERWATER WELDING PROCEDURE AND PERFORMANCE

QUALIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-49

074-6.9.5.1 Dry Chamber Welding Procedure Qualification.. . . . . . . . . . 74-49 074-6.9.5.2 Dry Chamber Welding Performance Qualification.. . . . . . . . 74-50 074-6.9.5.3 Wet Welding Procedure Qualification.. . . . . . . . . . . . . . . 74-51 074-6.9.5.4 Wet Welding Performance Qualification.. . . . . . . . . . . . . . 74-53 074-6.9.5.5 Maintenance of Dry Chamber and Wet Welding Performance

Qualification. . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-55

074-6.9.6 UNDERWATER WET NDT PROCEDURE AND PERSONNEL

QUALIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-55 iv

074-6.9.7 UNDERWATER DRY CHAMBER NDT PROCEDURE AND PERSONNEL

QUALIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-55

074-6.9.8 RECORDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-56 074-6.9.8.1 Welding Qualification.. . . . . . . . . . . . . . . . . . . . . . . . 74-56 074-6.9.8.2 Maintenance of Records.. . . . . . . . . . . . . . . . . . . . . . 74-57

074-6.9.9 INSPECTION REQUIREMENTS.. . . . . . . . . . . . . . . . . . . . . . . . 74-57 074-6.9.10 MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-57

074-6.9.10.1 Wet Welding Filler Materials.. . . . . . . . . . . . . . . . . . . . 74-57

074-6.9.11 WELDING AND WORKMANSHIP REQUIREMENTS.. . . . . . . . . . . 74-58

074-6.9.12 CONFIRMATION WELD TEST. . . . . . . . . . . . . . . . . . . . . . . . . 74-58

074-6.9.12.1 General.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-58 074-6.9.12.2 Examination Requirements.. . . . . . . . . . . . . . . . . . . . . 74-58

074-6.9.13 ELECTRODE TRANSPORT.. . . . . . . . . . . . . . . . . . . . . . . . . . 74-58 074-6.9.14 VIDEO EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-59 074-6.9.15 QUALITY ASSURANCE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 74-59 074-6.9.16 NAVSEA CERTIFICATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . 74-59 074-6.9.17 DRY CHAMBER WELDING. . . . . . . . . . . . . . . . . . . . . . . . . . . 74-59

074-6.9.18 THIRD PARTY MONITORING AND CERTIFICATION. . . . . . . . . . . 74-60

074-6.9.18.1 Third Party Qualifications.. . . . . . . . . . . . . . . . . . . . . 74-60 074-6.9.18.2 Third Party Surveillance Requirements.. . . . . . . . . . . . . . 74-61 074-6.9.18.3 Third Party Reporting.. . . . . . . . . . . . . . . . . . . . . . . . 74-61

074-6.10 RANDOM OR PARTIAL INSPECTIONS. . . . . . . . . . . . . . . . . . . . . . . . 74-62

SECTION 7 SUBMARINE HULL STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . 74-63

074-7.1 PATCHES, ACCESS HOLE CLOSURES AND PENETRATIONS. . . . . . . . . . 74-63

074-7.2 PROCEDURE FOR MAKING PARTIAL CIRCULARITY CHECK . . . . . . . . . 74-63

074-7.3 HULL PATCH DIMENSIONAL AND ALIGNMENT REQUIREMENTS . . . . . . 74-68

074-7.4 CUTTING REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-68

074-7.5 PATCH FORMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-70

074-7.6 HOLE REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-70

074-7.7 PRESSURE HULL PENETRATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . 74-70

074-7.7.1 STEEL ALLOYS REQUIRING SPECIAL WELDING TECHNIQUES. . . . 74-70

074-7.7.2 PENETRATION SURFACING.. . . . . . . . . . . . . . . . . . . . . . . . . 74-70 074-7.7.3 EXCESSIVE CARBON CONTENT.. . . . . . . . . . . . . . . . . . . . . . 74-72 074-7.7.4 LOCATION OF PENETRATIONS.. . . . . . . . . . . . . . . . . . . . . . . 74-72

074-7.7.5 PENETRATION BLANKING AND REMOVAL. . . . . . . . . . . . . . . . 74-72

074-7.7.5.1 Pressure Hull Envelope.. . . . . . . . . . . . . . . . . . . . . . . 74-72 074-7.7.5.2 Other Structure.. . . . . . . . . . . . . . . . . . . . . . . . . . . 74-77

074-7.7.6 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-78 v

074-7.7.7 REPAIR OF PRESSURE HULL PENETRATORS.. . . . . . . . . . . . . . 74-82

074-7.8 WELD REPAIR OF CORRODED STRUCTURE, CORRODED WELDS, AND

FABRICATiON SCARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-82

074-7.8.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-82 074-7.8.2 CORRODED STRUCTURE.. . . . . . . . . . . . . . . . . . . . . . . . . . . 74-82 074-7.8.3 CORRODED WELDS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-83 074-7.8.4 FABRICATION SCARS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-83

SECTION 8 PIPING, PRESSURE VESSELS, AND MACHINERY . . . . . . . . . . . . . . . 74-84

074-8.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-84

074-8.2 REPAIRS TO BOILERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-84

074-8.3 RESTRICTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-84

074-8.4 REQUESTING APPROVAL FOR WELDING . . . . . . . . . . . . . . . . . . . . . 74-85

074-8.5 WELDING REPAIR OF MAIN PROPULSION SHAFT. . . . . . . . . . . . . . . . 74-85

074-8.6 STRAIGHTENING AND REPAIR WELDING OF BRONZE SHIP PROPELLERS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-85

074-8.7 REPAIR OF DIESEL ENGINE CRANKCASE FOUNDATIONS AND FRAMES. . 74-85

SECTION 9 INSPECTION REQUIREMENTS AND ACCEPTANCE STANDARDS . . . . . 74-86

074-9.1 SURFACE SHIPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-86 074-9.1.1 INSPECTION REQUIREMENTS.. . . . . . . . . . . . . . . . . . . . . . . . 74-86

074-9.1.1.1 Welds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-86 074-9.1.1.2 Base Material Inspection.. . . . . . . . . . . . . . . . . . . . . . 74-86

074-9.1.2 INSPECTION OF WELD REPAIRS TO CORRODED STRUCTURES AND

WELDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-86

074-9.1.3 ACCEPTANCE STANDARDS.. . . . . . . . . . . . . . . . . . . . . . . . . 74-86

074-9.1.4 INSPECTION OF MECHANICAL FASTENERS.. . . . . . . . . . . . . . . 74-86

074-9.2 SUBMARINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-87 074-9.2.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-87 074-9.2.2 HARD TANKS (HY-80/100 ONLY). . . . . . . . . . . . . . . . . . . . . . . 74-87

074-9.2.3 INSPECTION EXPANSION REQUIREMENTS.. . . . . . . . . . . . . . . 74-87

074-9.2.3.1 Radiographic or Ultrasonic Inspection.. . . . . . . . . . . . . . 74-88 074-9.2.3.2 Magnetic Particle or Liquid Penetrant Inspection of HY-80/100

Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-88 074-9.2.3.3 Magnetic Particle or Liquid Penetrant Inspection of Higher

Strength Steel Pressure Hull Envelope.. . . . . . . . . . . . . 74-89 074-9.2.4 BASE MATERIAL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 74-90 vi

074-9.2.5 WELD REPAIR OF CORRODED STRUCTURE AND WELDS.. . . . . . 74-90

074-9.2.5.1 Weld Repairs to Ordinary Strength and Higher Strength Steels and Associated Welds.. . . . . . . . . . . . . . . . . . . . . . 74-90 074-9.2.6 HOLE REPAIRS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-90

074-9.3 PIPING, MACHINERY, AND PRESSURE VESSELS. . . . . . . . . . . . . . . . . 74-91 074-9.3.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-91

074-9.3.2 PIPING, AND PRESSURE VESSEL INSPECTION EXPANSION

REQUIREMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-91

SECTION 10 SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-92

074-10.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-92

074-10.2 PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-92

074-10.3 GAS CYLINDERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-92

074-10.4 GAS HOSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-92

074-10.5 TORCH HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-93

074-10.6 PLACEMENT OF CYLINDERS, OUTLET HEADERS, AND SIMILAR

EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-93

074-10.6.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-93 074-10.6.2 HAZARDS INSIDE THE SHIP.. . . . . . . . . . . . . . . . . . . . . . . . . 74-93 074-10.6.3 HAZARDS OUTSIDE THE SHIP. . . . . . . . . . . . . . . . . . . . . . . . 74-93

074-10.7 INSTALLATION AND OPERATION OF ARC WELDING AND CUTTING

EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-94

074-10.7.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-94 074-10.7.2 ELECTRODE HOLDERS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-95

074-10.7.3 WELDING SERVICE CABLE AND COUPLINGS.. . . . . . . . . . . . . . 74-95

074-10.7.4 GROUNDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-95 074-10.7.5 PROTECTION FROM SHOCK.. . . . . . . . . . . . . . . . . . . . . . . . . 74-96

074-10.7.6 GAS METAL ARC AND GAS TUNGSTEN ARC WELDING. . . . . . . . 74-96

074-10.7.7 OPERATIONS INVOLVING THE WELDING OR MELTING OF LEAD. . 74-96

074-10.7.8 THORIATED ELECTRODES.. . . . . . . . . . . . . . . . . . . . . . . . . . 74-97

074-10.8 FIRE PREVENTION AND CONTROL OF DAMAGE FROM HOT WORK

PROCESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-97

074-10.8.1 SCOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-97 074-10.8.1.1 Hot Work by Private Shipyards.. . . . . . . . . . . . . . . . . . 74-97

074-10.8.2 HOT WORK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-98 074-10.8.2.1 Hot Work Definition. . . . . . . . . . . . . . . . . . . . . . . . . 74-98 074-10.8.2.2 Hot Work Classes.. . . . . . . . . . . . . . . . . . . . . . . . . . 74-98

074-10.8.3 FIRE PREVENTION PRECAUTIONS DURING HOT WORK.. . . . . . . 74-99

vii

074-10.8.3.1 Flammable Liquids and Atmospheres.. . . . . . . . . . . . . . . 74-99 074-10.8.3.2 Inspect Far Side.. . . . . . . . . . . . . . . . . . . . . . . . . . . 74-99 074-10.8.3.3 Deenergize Equipment.. . . . . . . . . . . . . . . . . . . . . . . 74-99 074-10.8.3.4 Remove Hazardous Material.. . . . . . . . . . . . . . . . . . . . 74-99 074-10.8.3.5 Relocate or Protect Combustibles.. . . . . . . . . . . . . . . . . 74-99 074-10.8.3.6 Protect Equipment.. . . . . . . . . . . . . . . . . . . . . . . . . 74-99 074-10.8.3.7 Protect Openings.. . . . . . . . . . . . . . . . . . . . . . . . . . 74-99 074-10.8.3.8 Protect Ducts.. . . . . . . . . . . . . . . . . . . . . . . . . . . .74-100 074-10.8.3.9 Protect Combustible Construction.. . . . . . . . . . . . . . . . .74-100

074-10.8.3.10 Protect Pipes.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-100 074-10.8.3.11 Notify Ship. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-100

074-10.8.4 FIRE WATCHES.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-100 074-10.8.4.1 Fire Watch Requirements.. . . . . . . . . . . . . . . . . . . . . .74-100 074-10.8.4.2 Fire Watch Training.. . . . . . . . . . . . . . . . . . . . . . . . .74-101

074-10.8.5 FIRE EXTINGUISHING EQUIPMENT FOR FIRE WATCHES.. . . . . . . 74-102

074-10.8.5.1 Fire Extinguishers Suited for Submarine Hull Insulation.. . . . 74-102 074-10.8.5.2 Fire Extinguisher Maintenance.. . . . . . . . . . . . . . . . . . .74-102

074-10.8.6 ADDITIONAL REQUIREMENTS FOR HOT WORK ON SUBMARINES.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-102

074-10.8.7 ADDITIONAL REQUIREMENTS FOR HOTWORK IN WAY OF

ACOUSTIC INSULATION WITH SEPTUM MATERIAL. . . . . . . . . 74-104

074-10.9 PROTECTION OF PERSONNEL. . . . . . . . . . . . . . . . . . . . . . . . . . . .74-105 074-10.9.1 FALL PREVENTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-105 074-10.9.2 PROTECTIVE GEAR.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-105

074-10.9.2.1 Hearing Protection.. . . . . . . . . . . . . . . . . . . . . . . . .74-105 074-10.9.2.2 Helmets and Goggles.. . . . . . . . . . . . . . . . . . . . . . . .74-105 074-10.9.2.3 Protective Clothing.. . . . . . . . . . . . . . . . . . . . . . . . .74-106

074-10.9.3 WORKING IN RESTRICTED ACCESS SPACES.. . . . . . . . . . . . . . 74-106

074-10.9.4 WORKING WITH ARC WELDING EQUIPMENT.. . . . . . . . . . . . . . 74-107

074-10.9.5 WORKING WITH OXYFUEL OR INERT GAS WELDING, CUTTING,

AND BRAZING EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . .74-107

074-10.10 VENTILATION AND HEALTH PROTECTION . . . . . . . . . . . . . . . . . . . .74-107 074-10.10.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-107 074-10.10.2 RESPIRATORS.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-108 074-10.10.3 VENTILATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-108 074-10.10.4 LOCAL EXHAUST HOODS AND BOOTHS.. . . . . . . . . . . . . . . . .74-108 074-10.10.5 INERT GAS SHIELDED ARC WELDING. . . . . . . . . . . . . . . . . . .74-109

A Technical Manual Deficiency/Evaluation Report (TMDER) . . . . . . . . . . . . A-1 viii

LIST OF TABLES

Table Title Page

074-1-1. MANDATORY REFERENCE DOCUMENTS. . . . . . . . . . . . . . . . . . . . . . 74-2

074-1-2. GUIDANCE DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-6

074-2-1. WELDING COURSE NUMBER, TITLE, AND NAVY ENLISTED

CLASSIFICATION CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-8

074-4-1. ELECTROPLATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 74-19

074-7-1. MEASUREMENTS REQUIRED FOR REMOVAL AND REPLACEMENT OF

SUBMARINE HULL PLATING AND FRAMING . . . . . . . . . . . . . . . . . 74-64

074-7-2. HULL PATCH DIMENSIONS WITHOUT SHAPING . . . . . . . . . . . . . . . . . 74-72

074-9-1. MAGNETIC PARTICLE OR LIQUID PENETRANT INSPECTION EXPANSION

OF SERVICE-PROVEN FULL PENETRATION WELDS IN OR TO HY-80/100

PRESSURE HULL ENVELOPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-88

074-9-2. MAGNETIC PARTICLE AND LIQUID PENETRANT INSPECTION EXPANSION

OF SERVICE-PROVEN FULL PENETRATION WELDS IN OR TO HIGHER

STRENGTH STEEL PRESSURE HULL ENVELOPE. . . . . . . . . . . . . . . 74-90

074-10-1. EYE PROTECTION LENS SHADE GUIDELINES. . . . . . . . . . . . . . . . . .74-107

074-10-2. VENTILATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .74-109 ix

LIST OF ILLUSTRATIONS

Figure Title Page

074-5-1. Nomograph for Copper Ground Wire Size. . . . . . . . . . . . . . . . . . . . . . . . 74-22

074-5-2. Nomograph for Copper Electrode Lead Cable Size. . . . . . . . . . . . . . . . . . . 74-23

074-5-3. Hookup for Single Ship at Pier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-27

074-5-4. Hookup for Two Ships at Pier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-28

074-5-5. Hookup for Ships Afloat (Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . 74-29

074-5-5. Hookup for Ships Afloat (Sheet 2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . 74-30

074-5-6. Hookup for Ship in Floating Docks or HRD or LSD. . . . . . . . . . . . . . . . . . 74-31

074-5-7. Hookup for Ships in Dry or Graving Dock. . . . . . . . . . . . . . . . . . . . . . . 74-32

074-5-8. Grounding Corrections on Steel Surface Ships. . . . . . . . . . . . . . . . . . . . . 74-33

074-5-9. Grounding Connections on Submarines. . . . . . . . . . . . . . . . . . . . . . . . . 74-34

074-6-1. Ductile Metal Overlay To Arrest Cracks in Surface Ship Hull Structure. . . . . . . 74-38

074-6-2. New Inserts on Patches Crossing Existing Butt Welds. . . . . . . . . . . . . . . . . 74-41

074-6-3. Example of Access Hole Intersecting Existing Welds. . . . . . . . . . . . . . . . . . 74-42

074-6-4. Example of Boundary Location for Welded Patch Installation. . . . . . . . . . . . . 74-43

074-6-5. Example of Patch Removal Where More Than Two Existing Multiple Cuts Are Involved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-44

074-6-6. Patch Plate Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-45

074-6-7. Dry Chamber Ventilation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-48

074-7-1 Standard Partial Circularity Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-64

074-7-2 Partial Circularity Check Where Tank Top Intersects Hull. . . . . . . . . . . . . . . 74-64

074-7-3 Use of Range Wire To Establish Elevation. . . . . . . . . . . . . . . . . . . . . . . . 74-65

074-7-4 Example of Template Used To Establish Radial Geometry. . . . . . . . . . . . . . . 74-66

074-7-5 Method of Recording All End Point Elevation and Contour Measurements Before Cutting and After Rewelding Hull. . . . . . . . . . . . . . . . . . . . . . . . . . . 74-67

074-7-6 Existing Access or Closure Plates Intersecting Hull Butt Welds. . . . . . . . . . . . 74-69

074-7-7 Submarine Penetration Surfacing Requirements. . . . . . . . . . . . . . . . . . . . . 74-71

074-7-8 Closure of Two-Sided Stuffing Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-73

074-7-9 Standard Compensating Hull Penetration Closure. . . . . . . . . . . . . . . . . . . . 74-74 x

LIST OF ILLUSTRATIONS - Continued

Figure Title Page

074-7-10 Closure of Welding of Nonthreaded Stuffing Box or Sleeve Fitting. . . . . . . . . . 74-75

074-7-11 Closure and Welding of One Side of Stuffing Box. . . . . . . . . . . . . . . . . . . 74-76

074-7-12 Closure and Seal Welding of Threaded Stuffing Box. . . . . . . . . . . . . . . . . . 74-77

074-7-13 Patch or Cover for Pipe or Valve Connection Through Bulkheads Only, Where Liner Is Already Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-78

074-7-14 Shoulder Type Fitting or Shoulder Type Sleeve. . . . . . . . . . . . . . . . . . . . . 74-79

074-7-15 Shoulder Type Fitting and Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-80

074-7-16 Pressure Hull Full Penetration Weld Joint Design. . . . . . . . . . . . . . . . . . . . 74-81

074-10-1. Site Preparation for Welding on Bulkhead Insulated With Acoustic Insuation and Septum Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74-104 xi / (xii Blank) xii

CHAPTER 074

VOLUME 1

WELDING AND ALLIED PROCESSES

SECTION 1

INTRODUCTION

074-1.1 GENERAL

074-1.1.1 SCOPE. This chapter furnishes both the minimum mandatory requirements (indicated by the word shall) and guidance information (indicated by the words should or may) necessary for welding, brazing, inspec-tion, and safety when used for ship maintenance, repair, and alteration.

074-1.1.2 MANDATORY REFERENCING. Table 074-1-1lists mandatory reference documents that form a part of this volume. Fabrication documents are used as basic mandatory references for all welding, fabrication, and inspection requirements and related material, and quality assurance requirements, unless specifically modi-fied by the requirements of this volume.

074-1.1.3 NUCLEAR AND COMBAT WEAPONS SYSTEMS. This volume does not cover welding, brazing, or other work on nuclear or combat weapons systems. Unless otherwise specified, all the requirements contained in this volume apply to all activities performing repair or alterations on Navy ships and small boats. Other infor-mation, appropriate to nuclear systems, is contained in applicable technical manuals and shall be obtained from the cognizant authority before working on a nuclear system. Welding information for combat weapons and weap-ons systems is contained in individual technical manuals for components or systems. Application of these manu-als shall be determined from the cognizant authority before working on weapon systems.

074-1.1.4 SHIP STRUCTURE AND SYSTEMS. To maintain the integrity of ship structure and systems when welding or brazing is performed, it is essential and mandatory to ensure complete compliance with the require-ments specified in this volume, including those of the mandatory reference documents that form a part of this volume.

074-1.1.5 RESPONSIBILITY FOR COMPLIANCE. The Commanding Officer is responsible for ensuring compliance with requirements of this volume. Particular attention shall be given to using only trained and quali-fied personnel for welding, brazing, and inspection as defined inSection 2and to personnel and equipment safety precautions given in Section 10 of this volume and inNSTM Chapter 074, Volume 3, Gas Free Engineering

074-1.1.6 REQUIREMENTS. The requirements of some paragraphs in reference documents such as MIL- STD-248,Welding and Brazing Procedure and Performance Qualification and MIL-STD-278, Fabrication, Welding, and Inspection, and Casting Inspection and Repair for Machinery, Piping, and Pressure Vessels in Ships of the U.S. Navyare preceded by the words,When specified in the contract or orderor similar words to this effect. These requirements are mandatory and shall be invoked and fully met without exception. Such requirements are not meant to be subject to discretion (including that of the Naval Sea Systems Command (NAVSEA)) as to applicability. Activities, including all levels of subcontractors, shall be specifically made aware of the mandatory nature of the aforementioned requirements.

74-1

074-1.2 WELD CATEGORIES

074-1.2.1 Welding on ships by crew members or activities other than shipyards shall be categorized as described in the following:

a. Category A. Category A welds are permanent repairs and alterations to submarine safety boundaries on sub-marine safety (SUBSAFE) certified submarines.

b. Category B. Category B welds are emergency temporary repairs to SUBSAFE certified submarines (see Section 3concerning reporting of emergency temporary repairs).

c. Category C. Category C welds are:

1 Permanent repairs and alterations on the pressure hull envelope of submarines that are not certified as

SUBSAFE

2 Permanent repairs and alterations on any submarine pressure hull supporting structure

3 Permanent repairs and alterations of the primary structures of surface ships, including ballistic plating and superstructure designed for blast loading

4. Permanent repairs and alterations of all P-1, P-LT, and P-3a piping systems; A-1, A-2, A-F, A-LT pressure vessels; and T-1 steam turbines

5 Permanent repairs and alterations of those portions of machinery or components essential to the mission of the ship.

d. Category D. Category D welds are temporary repairs and alterations on items listed under category C.

e. Category F. Category F welds are repairs performed on assemblies where the possibility of failure is remote, and failure would not result in danger to ship personnel or the ship.

f. Category E. Category E welds are permanent repairs and alterations on items not listed under category A or C, unless repairs and alterations are exempted by category F.

074-1.3 REFERENCE DOCUMENTS

074-1.3.1 GENERAL. Both mandatory reference and guidance documents are included in reference documents pertaining to welding and allied processes.

Table 074-1-1. MANDATORY REFERENCE DOCUMENTS

Identification Title General Applicability

MIL-STD-22 Welded Joint Designs All weld joints MIL-STD-101 Color Code for Pipelines and for Compressed Gas

Cylinders MIL-STD-248 Welding and Brazing Procedure and Performance

Qualifications Procedure and personnel qualifica-tion requirements for welding and brazing

MIL-STD-271 Nondestructive Testing Requirements for Metals Performance on all nondestructive testing when specified

MIL-STD-278 Welding and Casting Standard All classes of piping and machinery in submarines and surface ships

MIL-STD-1687 (SH) Thermal Spray Processes for Naval Ship Machin-ery Applications

Thermal spraying for machinery applications

74-2

Table 074-1-1. MANDATORY REFERENCE DOCUMENTS - Continued

Identification Title General Applicability

MIL-STD-1688 (SH) Fabrication, Welding, and Inspection of HY-80/ 100 Submarine Applications

HY-80/100 Submarine Applications

MIL-STD-1689 (SH)

SeeNote 1 andNote 2 )

Fabrication, Welding, and Inspection of Ships Structure

For all materials used in combatant surface ships and submarines except HY-80/100 used in submarines in hull construction

MIL-STD-2191 (SH) Repair Welding, Weld Cladding, Straightening and Cold Rolling of Main Propulsion Shafting

DOD-STD-480 Configuration Control - Engineering Changes, Deviations and Waivers

DOD-STD-2138 Metal Sprayed Coating Systems for Corrosion Protection Aboard Naval Ships

Thermal sprayed aluminum for cor-rosion control use

DOD-STD-2182 Engineering Chromium Plating (Electrodeposited) for Repair of Shafting (Metric)

DOD-STD-2185 Requirements for Repair and Straightening of Bronze Naval Ship Propellers

MIL-C-14550 Copper Plating (Electrodeposited) MIL-C-24576 Cloth, Silica Glass, Cloth, Glass, Silicone Rubber

Coated MIL-G-45204 Gold Plating, Electrodeposited MIL-E-22200/1 Electrode, Welding, Mineral Covered, Iron Pow-der, Low Hydrogen Medium and High Tensile Steel As Welded or Stress Relieved Weld Applica-tion

MIL-E-22200/2 Electrode, Welding Covered Austenitic Chromium-Nickel Steel

MIL-E-22200/7 Electrode, Welding, Covered, Molybdenum Alloy Steel Application

MIL-E-22200/8 Electrodes, Welding, Covered, Low-Hydrogen and Iron - Powder Low-Hydrogen Chromium Molyb-denum Alloy Steel and Corrosion Resisting Steel

MIL-P-15280 Plastic Material, Unicellular Sheets and Lub MIL-P-81728 Plating, Tin-Lead, Electrodeposited MIL-S-22698 Steel Plate, Shapes and Bars, Weldable Ordinary

Strength and Higher Strength: Hull Structural MIL-T-10727 Tin Plating: Electrodeposited or Hot Dipped, for

Ferrous and Nonferrous Metals FED Spec GGG-H-211 Helmet, Welders, Handshield, Welding, and

Plates, Welding QQ-N-290 Nickel Plating (Electro-deposited) QQ-C-320 Chromium Plating (Electro-deposited) QQ-S-365 Silver Plating:

Electrodeposited: General Requirements for

NAVSEA SO300-BB-

MAN-010

U.S. Navy Underwater Cutting and Welding Manual

NAVSEA 0900-LP-

001-7000

Fabrication and Inspection of Brazed Piping Sys-tems

All piping systems brazed joints

74-3

NAVSEA 0900-LP-

003-8000

Surface Inspection Acceptance Standards for Met-als Includes MT, PT, and Visual Inspection

When specifically referenced

NAVSEA 0900-LP-

003-9000

Radiography Standard for Production and Repair Welds

When specifically referenced

NAVSEA 0900-LP-

006-3010

Ultrasonic Inspection Procedure and Acceptance Standard for Hull Structure Production and Repair Welds

NAVSEA 0900-LP-

006-3020

Supplement to NAVSEA 0900-LP-006-3010

NAVSEA 0900-LP-

038-6010

Deposition of Metals by Contact (Brush-on Method) Electroplating

NAVSEA 0900-LP-

060-4010 Note 3.

Fabrication, Welding, and Inspection of Metal Boat and Craft Hulls

When specifically referenced

NAVSEA 0900-LP-

082-3010

Ship Hull Structure Maintenance and Repair

NAVSEA 0905-LP-

501-7010

Trident Submarine Logistic Support Master Plan Introduction 1 July 74

NAVSEA 0924-LP-

062-0010 Rev A (or latest revision in effect)

Submarine Material Certification Requirements Manual for the Submarine Safety (SUBSAFE) Program

NAVSEA 0929-LP-

000-8010

Underwater Cutting and Welding Manual

NAVSEA 0948-LP-

045-7010

Material Identification and Control (MIC) for Pip-ing Systems

When specifically referenced

NAVSEA 0951-LP-

031-8010

Repair and Overhaul Main Boilers, 1200 PSI, Steam Propulsion Plant

NAVSEA 0951-LP-

038-6030

Repair and Overhaul Instructions, 1,200 PSI Pres-sure Fired Boiler and Supercharger

NAVSEA 0994-LP-

001-9010

U.S. Navy Diving Manual Volume 1 (Air Diving)

NAVSEA S9086-BS-

STM-000/CH-050

NSTM Chapter 050, Readiness and Care of Inac-tive Ships

NAVSEA S9086-CH-

STM-020/CH-074

NSTM Chapter 074, Volume 2, Nondestructive Testing of Metals, Qualification and Certification Requirements for Naval Personnel (Non-Nuclear)

NAVSEA S9086-CH-

STM-030/CH-074

NSTM Chapter 074, Volume 3, Gas Free Engi-neering

NAVSEA S9086-C1-

STM-000/CH-091

NSTM Chapter 091, Submarine Hull Inspection

NAVSEA S9086-DA-

STM-000/CH-100

NSTM Chapter 100, Hull Structures

NAVSEA S9086-HB-

STM-000/CH-233

NSTM Chapter 233, Diesel Engines

NAVSEA S9086-S3-

STM-010/CH-555

NSTM Chapter 555, Surface Ship Firefighting

NAVSEA S9086-S3-

STM-020/CH-555

NSTM Chapter 555, Submarine Firefighting

74-4

NAVSEA 0901-LP-

884-0004/CH-9880

NSTM Chapter 9880, Damage Control, Compart-ment Testing and Inspection

American Bureau of Shipping

(ABS)

Note 1.

Rules for Building and Classing Steel Vessels For all materials used in noncomba-tant surface ships

ANSI B16.11 Forged Fittings, Socket-Welding and Threaded ASTM A106 Std Specification for Seamless Carbon Steel Pipe for High-Temperature Service ASTM A441 Std Specification for High Strength Low Alloy

Structural Manganese Vanadium Steel ASTM B633 Electrodeposited Coating of Zinc on Iron and

Steel AWS A3.0 American Welding Society Definitions; Terms and

Definitions All welding and cutting terminology

AWS A5.28 Specification for Low Alloy Steel Filler Metals AWS D3.6-93 American Welding Society Specification for

Underwater Welding Underwater welding

NAVEDTRA

43119-2C

Personnel Qualification Standard for Damage Control Qualifications, Section No. 2, General Damage Control

OP NAV 5100.19 Navy Safety Precautions for Forces Afloat SSPC-SP5 Volume 2, White Metal Blast Cleaning

1.Where reference is made in this volume to MIL-STD-1689,Fabrication, Welding, and Inspection of Ships Structure , for surface ships, American Bureau of Shipping (ABS) rules may be used for applications involving noncombatant surface ships and ships originally built to ABS standards.

2.Where reference is made in this volume to MIL-STD-1689 for small boats and craft, NAVSEA 0900-LP-060- 4010,Fabrication, Welding, and Inspection of Metal Boat and Craft Hulls , may be used.

3.Where NAVSEA 0900-LP-060-4010 is referenced in this volume, MIL-STD-1689 may be used.

074-1.3.2 MANDATORY REFERENCE DOCUMENTS. The latest editions of the mandatory reference docu-ments are listed inTable 074-1-1. Requirements specified in changes or revisions to these documents, or to NAVSEA instructions of a date later than the issue date of this volume, supersede the requirements herein.

074-1.3.3 GUIDANCE DOCUMENTS. Documents which provide guidance information are listed inTable 074-1-2.

074-1.4 DEFINITIONS

074-1.5

Terminology concerning work being performed is included in the applicable fabrication document. Defini-tions of terms commonly used are as follows:

74-5

a. Approval or Approved. The item under consideration requires formal acceptance by NAVSEA or its autho-rized representative. The words approval or approved shall be used by NAVSEA’s authorized representative to indicate acceptance, unless NAVSEA approval is specified. Authorized representatives of NAVSEA for approval purposes are:

1 Naval Shipyard Commanders

2 Supervisor of Shipbuilding (SUPSHIP)

3 Naval Ship Systems Engineering Station (NAVSSES)

4 Naval Ship Repair Facilities Commanders

5 Authorized agent as defined in the applicable fabrication document

6 Representatives specifically authorized by NAVSEA.

b. Certification. Certification indicates that the item under consideration has been tested by the manufacturer or that on receipt, inspection tests were conducted by an authorized government agency. Certification indicates that the item has been verified to be in conformance with the procurement specification requirements. Certi-fication of conformance will be received in writing, properly signed by the manufacturer or other authorized individual.

c. Fabrication Document. The fabrication document is the document invoked by this volume for the contracts, purchase orders, and other requirements which govern work being accomplished. Examples include MIL- STD-1688 (SH),Fabrication, Welding, and Inspection of HY-80/100 Submarine Applications, MIL-STD- 1689, Fabrication, Welding, and Inspection of Ships Structure , MIL-STD-278, Welding and Casting Standard , and so forth.

d. Higher Strength Steels. Higher strength steels are a class of steels in MIL-S-22698,Steel Plate, Shapes and Bars, Weldable Ordinary Strength and Higher Strength: Structure , which supersedes grade HT of MIL- S-16113C and MIL-S-20166B.

e. Ordinary Strength Steels. Ordinary strength steels are a class of steels in MIL-S-22698B, which supersedes grades A, B, and D of MIL-S-22698A and grade M of MIL-S-20166B.

f. Submarine Safety Boundaries. Submarine safety boundaries are defined in NAVSEA 0924-LP-062-0010, Rev A (or latest revision in effect),Submarine Safety (SUBSAFE) Requirementsmanual.

g. Welding Terminology. Terms related to welding shall be according to American Welding Society, Publication AWS A3.0, American Welding Society Definitions; Terms and Definitions.

Table 074-1-2. GUIDANCE DOCUMENTS

Identification Title

ANSI/ASC Z49.1* Safety in Welding and Cutting AISI 8620 Carbon and Alloy Steels AWS B4.0 Standard Methods for Mechanical Testing of Welds NAVSEA 0900-LP-038-8010 Ship Metallic Material Comparison and Use Guide NAVSEA 0389-LP-031-7000 Procedures for Maintenance and Repair of Naval Reactor Plants NFPA 51B** Standard for Fire Prevention in Use of Cutting and Welding Processes

*Available from American Welding Society (AWS), 550 LeJeune Road, Miami, FL 33126

** Available from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

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SECTION 2

QUALIFICATION REQUIREMENTS

074-2.1 INTRODUCTION

074-2.1.1 Shipyards (naval and privately owned) and commercial contractors performing work according to this volume shall meet the qualification requirements of the applicable fabrication document. Other military activities shall meet the requirements of this section. All activities shall meet the qualification requirements of 074-6.9for underwater welding and NDT.

074-2.2 WELDING, BRAZING, AND THERMAL SPRAYING PROCEDURE AND PERFORMANCE

QUALIFICATIONS

074-2.2.1 INTRODUCTION. All welding shall be performed according to written procedures that have been prepared and qualified according to MIL-STD-248,Welding and Brazing Procedure and Performance Quali-fication . All brazing shall be performed according to written procedures that have been prepared and qualified according to MIL-STD-248 or Naval Sea Systems Command (NAVSEA) 0900-LP-001-7000,Fabrication and Inspection of Brazed Piping Joints, as referenced therein. All thermal spraying shall be performed according to written procedures prepared and qualified according to the requirements of MIL-STD-1687 (SH)Thermal Spray Processes for Naval Ship Machinery Applicationsor DOD-STD-2138,Metal Sprayed Coating Sys-tems for Corrosion Protection Aboard Naval Ships, as applicable.

074-2.2.2 MILITARY ACTIVITIES OTHER THAN SHIPYARDS. Except for underwater welding, military activities other than shipyards may use welding or brazing procedures which have been qualified according to the requirements of the appropriate qualification document by a naval shipyard or ship repair facility. Procedures contained in NAVSEA 0389-LP-031-7000, General Procedures for Maintenance and Repair of Naval Reac-tor Plants may be used by forces afloat, Ship Repair Facilities (SRF’s), and Intermediate Maintenance Activities (IMA’s). Organizational and administrative changes may be made to adapt the welding or brazing procedure to the specific military activity. Changes to the technical content of any such procedure shall not be permitted unless approval is obtained from the activity that qualified the procedure.

074-2.2.3 APPROVAL AGENCIES. Agencies authorized to approve welding, brazing, or thermal spraying procedure qualifications are specified in MIL-STD-248, NAVSEA 0900-LP-001-7000, MIL-STD-1687, or DOD- STD-2138, as appropriate.

074-2.2.4 CIVILIAN PERFORMANCE QUALIFICATIONS. Civilian welder and brazer performance qualifi-cations shall be according to MIL-STD-248 and NAVSEA 0900-LP-001-7000, as applicable for non-nuclear applications. Thermal spray operator performance qualifications shall be according to the requirements of MIL- STD-1687 or DOD-STD-2138, as applicable.

074-2.2.5 NONDESTRUCTIVE TESTING QUALIFICATIONS. Nondestructive testing personnel and proce-dure qualification requirements for military personnel shall be according toNSTM Chapter 074, Volume 2, Nondestructive Testing of Metals, Qualification and Certification Requirements for Naval Personnel (Non- Nuclear) . Nondestructive testing personnel and procedure qualification requirements for civilian facilities shall be according to MIL-STD-271,Nondestructive Testing Requirements for Metals. Additional NDT qualifica-tion requirements for underwater welding are specified in074-6.9.

74-7

074-2.2.6 MILITARY PERFORMANCE (WELDER) QUALIFICATION. The qualification of naval welders shall be according to the performance qualification requirements of MIL-STD-248 and the following paragraphs.

074-2.2.6.1 Initial Qualification. Naval welders will normally receive their initial qualification at the welding school under MIL-STD-248.