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Welding.pdf

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WELDING
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i n t e r n a t i o n a l ? WorldSkills International TD10 v2.0 - WSC2009 Technical Description Welding TD10_40CA_EN Date: 04.11.08 – v2.0 ? WorldSkills International – Technical Description Welding 1 of 20 WorldSkills International, by a resolution of the Technical Committee and in accordance with the Constitution, the Standing Orders and the Competition Rules, has adopted the following minimum requirements for this skill for the WorldSkills Competition. The Technical Description consists of the following: 1. INTRODUCTION ........................................................................................................2 2. COMPETENCY AND SCOPE OF WORK ..................................................................2 3. THE TEST PROJECT.................................................................................................3 4. SKILL MANAGEMENT AND COMMUNICATION......................................................9 5. ASSESSMENT .........................................................................................................10 6. SKILL-SPECIFIC SAFETY REQUIREMENTS.........................................................12 7. MATERIALS Manual Metal Arc Welding, MMAW ? 131 - Metal Inert Gas Welding, MIG. ? 135 - Gas Metal Arc Welding, GMAW (MAG) both solid and metal cored wire. ? 136 - Flux Cored Arc Welding, FCAW and Metal Cored Arc Welding, MCAW. ? 141 - Gas Tungsten Arc Welding, GTAW; Tungsten Inert Gas Welding, TIG. Materials to be welded are low carbon steel, austenitic stainless steels (300 series) and aluminium (5000, 6000 series) in the form of plates, pipes and rolled metal sections. TD10_40CA_EN Date: 04.11.08 – v2.0 ? WorldSkills International – Technical Description Welding 3 of 20 2.2 Theoretical knowledge 2.2.1 Theoretical knowledge is required but not tested explicitly. The theoretical knowledge is limited to that necessary to carry out the practical work, welding procedures and competency assessment. The Competitor shall have an appropriate level of knowledge and understanding of the Competition safety regulations. The Competitor shall have the knowledge to select the appropriate materials and consumables during the Competition. 2.2.2 Knowledge of rules and regulations is not examined. 2.3 Practical work The Competitor has to be able to carry out, unaided, the following tasks: Butt and fillet welding of plates, pipes and rolled metal sections, in all working positions and with seams of different angles of inclination and rotation. Welding positions terminology shall be to both ISO2553 and AWS A3.0/A2.4 Plate or pipe Welding position Test position AWS ISO and EN Plate Flat 1G, 1F PA Plate Horizontal 2G, 2F PC, PB Plate Vertical up 3G, 3F uphill PF Plate Overhead 4G, 4F PE, PD Pipe Axis vertical, fixed 2G PC Pipe Axis horizontal, fixed 5G uphill PF Pipe Axis @ 45o, fixed 6G uphill H-L045 The appropriate minimum technical skills are: ? Selecting the most suitable size and type of electrode or filler material. ? Selecting the appropriate current and polarity for the welding process. ? Selecting the appropriate gas pressure, type and rate of flow. ? Adjusting and welding with different modes of metal transfer i.e. short arc, globular, spray arc or pulsed arc. ? Adjusting all welding parameters to give the desired weld type i.e. voltage, wire speed feed, travel speed, welding angles, contact tip to work distance etc 3. THE TEST PROJECT 3.1 Format / structure of the Test Project The format of the Test Project is a series of standalone modules and must be validated as defined below. 3.2 Test Project design requirements General Requirements: Overall, the Test Project shall be modular. Materials and Equipment: Welding power sources: ? 111 SMAW, MMAW, 141 GTAW, TIG: AC/DC, 300 Amps Inverter-Type with Hi-Frequency, AC- Frequency (Hz) and Pulse controls ? 135 GMAW, MAG, 136 FCAW: DC, 300 Amps with Pulse control TD10_40CA_EN Date: 04.11.08 – v2.0 ? WorldSkills International – Technical Description Welding 4 of 20 Welding accessories: ? 111 SMAW, MMAW Welding cable and electrode holder ? 141 GTAW, TIG gun and accessories, contact tips, diffusers, shielding gas accessories, regulator, hoses, remote variable amperage controls, foot- and hand-operated, hose for purging ? 135 GMAW, MAG gun and accessories, contact tips, diffusers, shielding gas accessories, regulator, hoses, etc. ? 136 FCAW gun and accessories, contact tips, diffusers, shielding gas accessories, regulator, hoses, etc. During the Competition only materials provided by the host country may be used. Practice plates for the Competition: The host country shall provide 2 sets (4 pieces each) of material for each of the test coupons and 10 pieces each (100x50mm) of Aluminium and Stainless Steel material in the thickness of the tasks, to be used for practice plates. These plates shall be made available to the Competitor for practice on the day set aside for testing the installations before the Competition and for adjusting the welding parameters during the Competition. Dimensions of practice plates: The practice plates shall be the same width and thickness as the actual project pieces, but they shall each be shorter by 20mm in length. Basic materials: Steel groups according to CR ISO/TR 15608 (1999), Group 1, 2 or 3 for low carbon steel; Group 8 for stainless steel (300 series), and aluminium in the 5000 and 6000 series. Plates: ? High quality low carbon steel, 2mm to 20mm thick to ISO 10038. ? For pressure vessel, plates are to have through-thickness tested certification. ? Austenitic stainless steel, 1.5mm to 10mm thick e.g. 18/8 types X5CrNi 18 ? Aluminium, 1.5mm to 10mm thick e.g. 5000 or 6000 series. Pipes: ? High quality low carbon steel pipes to ISO 10038, dia. 25mm to 250mm, wall thickness 1.6mm to 10mm ? Stainless steel and aluminium, diameter 25mm to 250mm, wall thickness 1.6mm to 6mm. All material with bevelled weld surfaces shall be milled or turned, so that they are smooth and parallel and all other prepared edges are to be smooth and square. Module 1: Test coupons ? Time: 5 or 6 hours approximately. ? Quantity: 3 to 5 specimens, either Single V-groove butt joint welds or fillet welds. ? Processes: See Appendix 9.1. ? Positions: See Appendix 9.1. ? Drawings: See Appendix 9.2 The Competitor shall submit the test coupons fully assembled to the jury for stamping prior to welding. The two Fillet test Coupons shall each consist of two (2) pieces, each 12mm in thickness, one piece 125mm wide, 250mm in length and the other 100mm wide, 250mm in length. One test plate coupon shall consist of two (2) pieces, each 10mm in thickness, 100mm wide and 250mm in length. TD10_40CA_EN Date: 04.11.08 – v2.0 ? WorldSkills International – Technical Description Welding 5 of 20 The second test plate coupon shall consist of two (2) pieces, each 16mm x 150mm x 350mm. The 16mm test coupon welded shall contain a stop/restart in the centre 75mm of the cap pass. GMAW (MAG), FCAW or MCAW (136) only is to be used for the fill and cap passes and the stop and restart shall take place only at the cap pass. A weave or the last pass on a multi-pass weld is considered for the stop and restart. GMAW (MAG) is also qualified to be used for a root pass and a stop and restart as above shall be applied for the root pass. FCAW or MCAW (136) shall not be used for making root passes. The final test coupon shall be a pipe welding test, consisting of two (2) pieces of 114.3 dia x 8.56 wall (4” SCH 40) carbon steel pipe. HOLD POINT: All directed stops shall be inspected by a jury and stamped before restarting. For all test plates, 20mm at the start and finish shall be discarded for all aspects of inspection and marking. All butt weld test coupons shall be milled or turned at 30o to a featheredge. At least two test plates shall contain a set of bend test specimen. SEE APPENDIX 9.2 FOR TEST COUPON DRAWINGS. Module 2: Pressure vessel Description: A completely enclosed plate/pipe structure, which shall encompass all four of the process types and all weld positions as described in this Technical Description. ? Time: 10 hours approximately. ? Size: Overall dimensional space, approximately 350mm x 350mmx 400mm. ? Plate thickness: 6, 8 and 10mm ? Pipe wall thickness 3 to 10mm ? Pressure test minimum 1000psi The pressure vessel shall not weigh more than 35kg in the welded condition. The Experts reserve the right to amend the design test pressure of any pressure vessel prior to the contest. Module 3: Aluminium structure Description: A partially enclosed structure of aluminium, which shall be welded with TIG (141). ? Time: 2 or 3 hours approximately. ? Size: Overall dimensional space approximately 200mm x 200mm x 250mm ? Aluminium plate/pipe material thickness 1.5 to 3mm This project shall be sawed in half, if necessary, to enable weld penetration inspection and marking. Module 4: Stainless Steel structure Description: A partially enclosed structure of stainless, which shall be welded with TIG (141). ? Time: 2 or 3 hours approximately. ? Size: Overall dimensional space approximately 150mm x 150mm x 200mm ? Stainless Steel plate/pipe material thickness 1.5 to 3mm All root passes of butt joints and corner joints shall be purged with Argon. TD10_40CA_EN Date: 04.11.08 – v2.0 ? WorldSkills International – Technical Description Welding 6 of 20 This project shall be sawed in half, if necessary, to enable weld penetration inspection and marking. Competition Specific Instructions Welding machines, tools and equipment usage: ? It is a requirement that the host country supplies welding machines that can be used in basic modes of operation. ? Welding machines may be used to their full technical potential. ? It is a requirement that the host country provides detailed operation manuals to all attending countries at least six (6) months prior to the Competition. ? The welding machines provided shall have the capability to be operated using both standard amperage control and remote amperage control. Remote variable amperage devices shall be made available and include hand-held and foot controls. Grinding and the use of abrasive materials and equipment: ? Material removal is not permitted on any of the root penetration or cap weld surfaces. “Cap pass” shall be defined as the final layer of the weld that meets the weld size, grooves and fillets. Restarts may be prepared before welding over them. ? Grinding the surfaces of the fillet coupon material before welding is permitted but the preparation angles shall not be changed. Wire brushing: ? Wire brushing, manual or powered, may be used on all weld surfaces of the test plates/pipes (Module 1) and pressure vessel (Module 2). However, wire brushing is not permitted on any of the cap welds of aluminium project (Module 3) and the stainless steel project (Module 4). Backing bars / plates and restraining devices: ? No copper (Cu) chill plates or ceramic backing tapes/bars are to be used in the Competition. ? Purging equipment may only be used with the Gas Tungsten Arc Welding process on the stainless steel project. ? Restraining devices shall not be used during welding of the test plates. Such devices include: clamps, jigs, fixtures or steel plates, tack welded to the test plates. ? Welding of the test plates is to be carried out without the aid of restraining devices; this is so the Experts can assess the control of distortion. Weld cleaning of GTAW (TIG) projects: ? The weld faces on the aluminium and stainless steel GTAW (TIG) projects are to be presented in the “as welded” condition. Cleaning, grinding, steel wool, wire brushing or chemical cleaning is NOT permitted on any of the cap welds. Tack welds: ? Tack welds shall be maximum 15mm in length. Tacking of the fillet coupons is as follows: One 25mm tack weld placed within the centre 50mm of the coupon to the rear of the weld area and one tack at each end of the test coupon. ? When assembling the pressure vessel, the Competitor may use any of the welding processes listed on that drawing for tack welding, in any position. ? No tack welds shall be made on the inside of the pressure vessel project. ? All tasks are to be fully assembled prior to submission for stamping. ? HOLD POINT: A jury member shall inspect the inside of the vessel to ensure the lack of tacks before enclosing the vessel. This is to be confirmed by stamping. Welding of test plates/pipes: ? Once welding has commenced, the test plates may not be separated and then re-tacked. Re- tacking may only take place, if root welding has not commenced. HOLD POINT: A jury member shall inspect the positioning of the test pipe coupon in the coupon holder and mark the 12 O’clock position before welding commences. This is to be confirmed by stamping and will also act as a reference point if bend test coupons are to be taken.
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