Tubular & Non Tubular AWS D1.1

Presented By : Farid Moch.
Zamil
29/03/2015
TUBULAR & NON TUBULAR

Oleh :
Farid Moch. Zamil
PENDIDIKAN DAN PELATIHAN INSPEKTUR LAS (WELDING INSPECTOR)
MARET - MEI 2015
Kerjasama
POLITEKNIK PERKAPALAN NEGERI SURABAYA dengan BADAN
NASIONAL SERTIFIKASI PROFESI (BNSP) dan LEMBAGA SERTIFIKASI
PROFESI LAS (LSPL)
SECTION 1
GENERAL REQUIREMENET
Oleh :
Farid Moch. Zamil
LATAR BELAKANG
FAKTA LAPANGAN
1.
Pekerjaan Plate Form & Steel

Structure
yang
semakin
berkembang.
2.
Potensi bahayanya yang cukup

tinggi.
3.
Konstruksi pada umumnya dilas.
4.
Keterbatasan tenaga pemeriksa

yang memahami AWS D1.1 Std.
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WELDING INSPECTOR COURSE

Farid Moch. Zamil
Welding Inspector PPNS
Presented By : Farid Moch. Zamil
29/03/2015
PENGERTIAN
PIPE
Bentuk Tubular dengan penampang melingkar.
TUBULAR
Bagian yang berongga dari berbagai bentuk konfigurasi
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Sect.1 Ketentuan umum

SCOPE AWS D1.1 Std.
1.
General Requirement.
2.
3.
Requirements for exempting (Not Qualifications) WPS.
Qualification.
5.
Requirements for design welded connections between
Prequalification of WPSs.
4.
Basic on the scope & limitations of the Code.
Design of Welding Connections.
Requirements for qualification of WPS & personnel to perform

work to Code requirements.
Fabrication.
Requirements
for
the
preparation,
workmanship of welded steel structure.
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and
5

6. Inspection.
Criteria for qualification and responsibility of welding
inspectors, acceptance criteria of welds, procedure for visual
inspection & NDE.
7.
Stud Welding.
8.
Requirements for the welding of studs to structural steel.
Strengthening & Repair Existing Structure.

Provisions for design/welding modification or repair of
existing steel structures.
Annex
Normative Informasi & Requirement bahwa menjadi pertimbangan
Informative
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Tidak dijadikan pertimbangan

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TASK (TUGAS) INSPECTOR AWS D1.1
1. Review of drawings, specification & manufacturing instructions.
2. Review of the manufacturers approved QA/QC.
3. Verification of welding procedure & personnel qualification.
4. Verification of approved procedure for qualifying welding &
inspection personnel.
5. Selection & examination of production test sample.
6. Evaluation of test results.
7. Preparation of test reports & maintenance of records.
8. Observance & monitoring of recommended safety guidelines.
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PLATFORM ACCORDANCE AWS D1.1 Std.
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BOILER STRUCTURE ACCORDANCE AWS D1.1 Std.
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LIMITATIONS AWS D1.1 Std.
Pekerjaan WELDED STEEL STRUCTURE dengan material Carbon Steel
atau Low Alloy Steel dibatasi tebal 1/8 (3 mm) atau lebih tebal
yang mempunyai nilai Yield Strength 100 ksi (690 MPa).
Other AWS D1 Std.

a.
AWS D1.2
Aluminium.
b.
AWS D1.3
Sheet Steel equal or less than 3/16 (5 mm) Thick.
c.
AWS D1.4
Reinforcing Steel.
d.
AWS D1.5 Bridge Welding Code.
e.
AWS D1.6
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Stainless Steel.
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Code application of D1.1 and D1.3
Based on material thickness being joined
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SECTION 2
DESIG (PERENCANAAN)
Oleh :
Farid Moch. Zamil
29/03/2015
Sect.2 Perencanaan (Design)

BATASAN MATERIAL AWS D1.1 Std.
The Material grouped into STRENGTH GROUP & TOUGHNESS CLASS :
STRENGTH
1.
Group I
Mild Structural Carbon Steel specified Minimum Yield Strength
40 Ksi or less, CE 0.4% or less. Can be welded by Code
2.
Group II
Intermediate strength low alloy steel specified minimum Yield
Strength 40 Ksi 52 Ksi, CE up to 0.45% and Higher. Required the
use of low hydrogen welding process.
3.
Group III
High Strength low alloy steel specified excess Yield Strength
52Ksi 75 Ksi.
4.
Group IV dan V
material Higher Strength over 75 Ksi 100 Ksi.
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TOUGHNESS CLASS
1.
Class C
Diapplikasikan di welded structure yang mempunyai
temperature service diatas 100C.
2.
Class B
material yang mempunyai nilai CVN pada temperatur
pengujian 100C 00C
3.
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a.
Group I Nilai CVN = 20 Joule.
b.
Group II Nilai CVN = 34 Joule.
c.
Group III Nilai CVN = 48 Joule.
Class A
a.
Temperature 200C s/d 300C Subfreezing.
b.
Temperature -300C s/d 400C Brittle Fracture.

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BATASAN MATERIAL AWS D1.1 Std.
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Lanjutan material structural steel tabel C-2.27.2
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BATASAN WELDING MATERIAL AWS D1.1 Std. Ref Annex V
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BATASAN WELDING MATERIAL AWS D1.1 Std. Ref Annex V
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DESIGN WELDING JOINT AWS D1.1 Std.
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Ukuran effektive pada Complete Joint Pentration (CJP) :
Ukuran pengelasan sesuai dengan tebal pada material yang paling

tipis di sambungan tersebut.
Penambahan Effektive area pengelasan yang tidak sesuai design

calcultaion Tidak diperbolehkan. Contoh : Weld Reinforcement.
Groove weld size T, Y dan K yang disambungkan pada bagian

konstruksi Tubular tercantum pada Tabel 3-1 AWS D1.1
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DESIGN WELDING JOINT AWS D1.1 Std.
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Ukuran effektive
Pentration (PJP) :
pada
Partial
Joint
Ukuran pengelasan > dari required

weld size (E)atau sekurang-kurangnya
= ukuran yang tercantum di WPS.
Kombinasi PJP Groove dan Fillet weld

harus lebih pendek dari bagian root ke
permukaan Minus 3 mm (1/8 in)
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Fillet Weld :
Minimum Fillet Weld seperti tercantum pada tabel 5.8.
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Fillet Weld :
Maksimum Weld Size in Lap Joint :

a) Tebal < 6 mm (1/4 in).
b) Tebal > 6 mm (1/4 in)
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Fillet Weld :
Minimum Overlap antara tebal material yang berbeda HARUS 5 X

TEBAL PELAT PALING TIPIS TETAPI TIDAK BOLEH KURANG DARI 25 mm
(1 in)
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INTERMITTEN FILLET WELD :
Minimum panjang segment Filled Weld 38 mm (1-1/2 in).
Maksimum spacing intermitten weld dua atau lebih rolled shape

(profil material) NOT EXCEED 600 mm (24 in). Lihat gambar dibawah.
Maksimum intermitten weld antara plate dengan componen lainnya

NOT EXCEED 24 THICK, THINNER PLATE or NOT EXCEED 300 mm (12 in).
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PLUG & SLOT WELDS :
Min. dia. Lubang atau lebar deposite tidak boleh kurang dari tebal
material, untuk material up to 8 mm (5/8 in).
Maks. dia lubang atau lebar tidak lebih dari Min diameter + 3 mm
atau 2-1/4 x tebal, pilih mana yang lebih besar.
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TRANSITION WELDING JOINT AWS D1.1 Std.
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TRANSITION WELDING JOINT AWS D1.1 Std.
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PROHIBITED JOINT & WELDS AWS D1.1 Std.
FLAT POSITION GROOVE WELDS :
FILLET WELD KURANG DARI 5 mm (3/16 in).
Bevel-groove dan J groove weld dilarang karena tidak dapat

dipraktekkan.
Jika ada sambungan Fillet welds kurang dari 5 mm (3/16 in).
T & CORNER CJP Weld With Backing
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SECTION 3
PREQUALIFIED WPS (WPSs)
Oleh :
Farid Moch. Zamil
Sect.3 Prequalified WPSs

RUANG LINGKUP AWS D1.1 Std.
WPSs : WPS yang tidak dipersyaratkan untuk dilakukan testing

seperti yang tercantum pada Clause 4 AWS D1.1.
Persyaratan.
1.
Operator & Tack Welder

Harus dikualifikasi sesuai ketentuan Clause 4.
2.
Semua prequalified WPS harus tertulis

Sesuai sesuai ketetuan di Clause 3
3.
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Welding Proses
Welding proses yang direkomendasikan SMAW, SAW,

GMAW (kecuali type Short circuit) dan FCAW.
Welding proses ESW, GTAW dan GMAW type Short

circuit boleh digunakan : WPS harus dikulaifikasi sesuai
ketentuan Clause 4.
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BATASAN MATERIAL & FILLER METAL
Batasan material & Filler metal yang digunakan untuk WPSs seperti
yang terdaftar pada tabel 3-1 AWS D1.1 Std.
Jika Material/Filler yang tidak tercantum pada list Tabel 3-1, boleh
digunakan dengan syarat chemical komposisi sesuai list material
di Tabel 3-1, harus mendapat persetujuan dari Engineer.
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TABEL 3-1
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TABEL 3-2
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PREHEAT & INTERPASS TEMPERATUR AWS D1.1 Std.
Preheat temperature
Adalah : Temperatur pada benda kerja didaerah dekat daerah
pengelasan (weld zone) sebelum welding operation (termasuk tack
welding)
Biasanya dinyatakan sebagai minimum Interpass temperature

Luasan daerah preheat sama dengan tebal dari lasan (tetapi tidak
boleh kurang dari 75 mm.
Tujuan preheat adalah untuk mencegah terjadi Cracking seperti

yang diisyaratkan AWS D1.1 Clause 3, part 3.5
Ketentuan preheat untuk WPSs seperti yang tercantum pada tabel 3-2
AWS D1.1.
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BATASAN PREQUALIFIED WPSs AWS D1.1 Std.
BATASAN WPSs :
Persyaratan.
1.
Dibuat dan disiapkan oleh Manufacturer, Fabricator dan

Contractor.
2.
Parameter WPSs harus harus tercantum seperti yang

disyaratkan pada Tabel 3-8 Essential Variable.
3.
Jika terjadi perubahan parameter yang masuk kategori

Essential Variable seperti yang disyaratkan pada Tabel 3-8
maka WPSs harus direvisi atau dikualifikasi seperti yang
disyaratkan pada Clause 4 AWS D1.1.
4.
Kombinasi Qualified WPS dan WPSs dapat digunakan tanpa

dilakukan kualifikasi dengan batasan Essential Variable
sesuai yang disyaratkan oleh masing-masing proses.
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Note.
Essential Variable berubah sifat mekanik akan berubah

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PERSYARATAN UMUM WPSs AWS D1.1 Std.
Semua persyaratan tercatum pada tabel 3.7
Vertical Up Welding semua layer atau pass harus dilakukan pada

posisi up hill (upward) kecuali :
1.
Undercut boleh dilakukan pengelasan down hill

(downward) atau up hill (upward) jika disyaratkan Preheat
sesuai tabel 3.2 tetapi tidak boleh kurang dari 200C (700F).
2.
Semua pengerjaan tubular dapat dilakukan pengelasan

dengan down hill (downward) atau up hill (upward).
Witdh/Depth Pass gambar 3.1
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Single-Pass Fillet Weld Maksimal
yang dibuat menngunakan filler metal pada group II dan base

metal pada list Tabel 3.1 yaitu :
1.
SMAW
6 mm (1/4 in).
2.
SAW
8 mm (5/16 in).
3.
GMAW/FCAW
8 mm (5/16 in).
Shielding Gas
untuk GMAW dan FCAW-G harus sesuai dengan AWS

A5.32/A5.32M.
Weathering Steel (material yang terkena korosi).
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Material yang dalam kondisi tidak dicat atau tidak dilapisi

bahan anti korosi weld metal mudah terserang korosi maka
electrode atau electrode fluxnya harus menggunakan
electrode seperti yang disyaratkan pada Tabel 3-3.
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Limitation Nontubular Fillet Weld Requirement
Figure 2.1 & 2.4
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PERSYARATAN FILLET WELD AWS D1.1 Std.
Limitation tubular Fillet Weld Requirement
Figure 2.15 Fillet weld details in lap joint
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Limitation tubular Fillet Weld Requirement
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Figure 3.2 Fillet Welded tubular by SMAW, GMAW or FCAW

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Limitation Skewed T-Joint Requirement
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Figure 3.11

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PERSYARATAN PJP GROOVE WELD AWS D1.1 Std.
Disyaratkan pada gambar 3.3 :
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PERSYARATAN CJP GROOVE WELD AWS D1.1 Std.
Disyaratkan pada gambar 3.4:
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PERSYARATAN PWHT AWS D1.1 Std.
PERSYARATAN PWHT :
1. Nilai Yield Strength Base Metal tidak lebih dari 50 Ksi.

2. Tidak syaratkan pengujian impact pada base metal,
HAZ dan weld metal.
3. Base metal pada saat pembuatannya tidak
mengalami proses Treatment (Quenching dan
Tempering).
4. Kondisi saat didemonstrasikan PWHT weld metal tidak
mengalami pengurangan nilai Strength dan ductility.
5. Pelaksanaan PWHT diatur pada Section 5 (Fabrication)
AWS D1.1.
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SECTION 4
QUALIFIED WPS
Oleh :
Farid Moch. Zamil
Sect.4 Qualified WPS

Quick Review on Essential Variables
1.
Guide (Position) :
CJP Groove Weld (Plate or Tubular) or Fillet Weld (Plate or

Tubular) QUALIFICATION TEST
POSITION TEST
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POSITION QUALIFIED*
1G, 1G (Rotated)
2G
F, H
3G
4G
OH
5G
F, V, OH
(2G+5G), 6G, 6GR
ALL
1F, 1F (Rotated)

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1.
Guide (Position) Continued :

POSITION TEST
POSITION QUALIFIED*
2F, 2F (Rotated)
F, H
3F
4F (Plate)
OH
4F (Tubular)
F, H, OH
5F
ALL
* Note :
* CJP Groove qualify CJP, PJP & Fillet Welds.
* Fillet qualify Fillet only.
* Groove weld on plate qualifies pipes 24 in (600) nominal outer dia.
* Vertical uphill to downhill essential variable and vise versa
* Plug/Slot Welding qualifies for only the tested position
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2.
(a) Guide (Thickness of Base Metal) :
Test on Plate, CJP Groove Welds :
T = Thickness of Test Coupon Welded

THICK. TEST COUPON
THICKNESS QUALIFIED
1/8 in. (3 mm) < 1 in. (25 mm)
Min. 1/8 in. (3 mm) ~ Max. 2T
1 in. (25 mm) and over
Min. 1/8 in. (3 mm) ~ Unlimited
T test on ESW & EGW
0.5 T min ~ 1.1 T Max.
Note
Any PJP qualification shall also qualify any fillet weld size on
any thickness.
3.
FILLET WELD WPS QUALIFICATION (qualify all plate/thickness)
Test shall be based on Max. Single pass and min. multiple

pass fillet weld size to be used in construction Table 4.4
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d)
Guide (Diameter of Base Metal) :
Test on Pipe (Tube), CJP Groove Welds :
JOB SIZE TEST PIPE DIA. OVER or LESS THAN 24 in. (600mm OD)
THICKNESS TEST COUPON
THICKNESS QUALIFIED
1/8 in. (3 mm) 3/8 in. (10 mm), incl
Min. 1/8 in. (3 mm) ~ Max. 2T
Over 3/8 in. (10 mm) in. (20 mm)
Min. 0.5T ~ Max. 2T
Over in. (20 mm)
JOB SIZE STANDARD TEST PIPE

2 in. Sch.80 (50 mm OD x 6 mm WT or 3 in. sch.40 (75 mm
OD x 6 mm WT).
THICKNESS QUALIFIED
Above write red
Min. 1/8 in. (3 mm) ~ Max. in. (20 mm)
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d)
Guide (Diameter of Base Metal) contd

2 in. Sch.80 (50 mm OD x 6 mm WT or 3 in. sch.40 (75 mm
OD x 6 mm WT).
DIA. (PIPE or TUBE) TEST COUPON
DIA. (PIPE or TUBE) QUALIFIED
Above write red
Min. in. (20mm) ~ 4 in. (100 mm)

6 in. Sch.120 (150 mm OD x 14 mm WT or 8 in. sch.80 (200
mm OD x 12 mm WT).
THICKNESS QUALIFIED
Above write red
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d)
Guide (Diameter of Base Metal) contd

6 in. Sch.120 (150 mm OD x 14 mm WT or 8 in. sch.80 (200
mm OD x 12 mm WT).
DIA. (PIPE or TUBE) TEST COUPON
DIA. (PIPE or TUBE) QUALIFIED
Above write red
Min. 4 in. (200mm) and Over
Note
CJP groove weld qualification on any thickness or diameter
shall qualify any size of fillet or PJP groove weld for any
thickness or diameter (see Clause 4.11.3 for macro etch test
requirement.
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4.
Guide (Base Material) See Table 3.1, 4.8 & 4.9

QUALIFY TEST COUPON
TEST QUALIFIED
Any Group I to Group I
Any Group II to Group II

Any Group II to Group I
Any Group II to Group II
Any Group III to Group I
Specific Group III Tested to Any Group I
Any Group III to Group II
Specific Group III Tested to Any Group I or II
Any specific Table 4.9 To Group I
Specific Table 4.9 Tested To Any Group I
Any specific Table 4.9 To Group II
Specific Table 4.9 Tested To Any Group I or II
Any Group III To Group III

Any Group IV To Group IV
Any Table 4.9 to Table 4.9
Steel shall be of the same material

specification grade/type and minimum
yield strength as steel listed in the PQR
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4.
Guide (Base Material) See Table 3.1, 4.8 & 4.9 Contd
QUALIFY TEST COUPON
TEST QUALIFIED
Any combination of Group III, IV and

Table 4.9
Only the specific combination of steel

listed in the PQR
Any Unlisted Steel To Any Unlisted or

Any Listed in Table 3.1 or Table 4.9
Only the specific combination of steel

listed PQR.
Note
Group I through IV are found in Table 3.1
5.
Guide (Preheat)
The need for & temperature of preheat dependent upon number
of factors such as Chemical analysis, degree of restraint of the
parts being joined, elevated temperature, mechanical
properties and material thickness.
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5.
Guide (Preheat) Contd
When welding two different material groups, the minimum

preheat temperature required shall be the higher temperature for
the material to be welded. For prequalified procedures, preheat
applicable to the higher strength group, as per note 1 of table
3.1-AWS D1.1. Also, thickness referred to for the minimum
preheat is the greater of the nominal thickness at the weld of
parts to be joined.
AWS D1.1, Table 4.5 : Decrease from preheat and interpass

temperature 25 F (15 C) and 100 F (55 C) for GTAW is essential
variable.
AWS D1.1, Table 4.5 : PQR Essential Variable (except ESW and
EGW process), for Non-CVN Testing applications.
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6.
Guide (Joint)
AWS D1.1. TABLE 4.5 : ESSENTIAL VARIABLE FOR JOINTS
A change in groove type (e.g, Single-V double V) except

qualification of any CJP groove weld qualifies for any groove
detail conforming to the requirements of 3.12 (PJP-Figure 3.3) or
3.13 (CJP- Figure 3.4)
A decrease in the groove angle and root opening, an increase

in the root face exceeding the tolerance (increase in the groove
angle above 10 degree) for any groove detail conforming to the
requirement of 3.12 (PJP-Figure 3.3) or 3.13 (CJP-Figures 3.4), 3.13
and 5.22.4.1 or 5.22.4.2 (Tubular and Non Tubular).
The omission, but not inclusion of backing or backgouging.
A change in the type of groove to square groove and vice versa.
AWS D1.1, Table 4.5 PQR Essential Variables (except ESW and
EGW process), for Non-CVN testing application.
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7.
Guide (Heat Input)
See AWS D.1.1, Table 4.5 : PQR essential variables (except ESW
and EGW process), for Non-CVN testing application.
See AWS D1.1, Table 4.5 : PQR Supplementary essential variables

(except ESW and EGW process), for Non-CVN testing
applications.
AWS D1.1, Table 4.5 : PQR Essential Variable (except ESW and
EGW process), for Non-CVN Testing applications.
AWS D1.1, 5.7 HEAT INPUT CONTROL for QUENCHED and TEMPERED
STEELS : When quenched and tempered steels are welded, the
heat input shall be restricted in conjunction with the maximum
preheat
and
interpass
temperatures
required.
Such
consideration shall include the additional heat input produced in
simultaneous welding on the two sides of a common member.
The preceding limitations shall be in conformance with the
procedures recommendations.
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8.
Guide (Welding Process)
Essential Variables for SMAW, SAW, GMAW, FCAW & GTAW.
AWS D1.1, Table 4.5 PQR Essential Variables, for Non CVN Testing
Applications.
AWS D1.1, Table 4.5 PQR Supplementary Essential Variables, for

CVN Testing Applications.
AWS D1.1, Table 4.7 PQR Essential Variable changes requiring

WPS requalification.
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Sect.4 Qualified Welder

Quick Review on Performance Qualification
1.
Guide (Position) :
AWS D1.1, Table 4.10, Groove Test (Plate, Pipe or Box Tube)
POSITION QUALIFIED*
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POSITION TEST
GROOVE
FILLET
1G, 1G (Rotated)
F, H
2G
F, H
F, H
3G
F, H, V
F, H, V
4G
F, OH
F, H, OH
5G
F, V, OH
F, V, OH
6G, 6GR
ALL
ALL

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Quick Review on Performance Qualification
1.
Guide (Position) Contd
AWS D1.1, Table 4.10, Fillet Test (Plate, Pipe or Box Tube)
POSITION TEST
POSITION QUALIFIED*
1F, 1F (Rotated)
2F, 2F (Rotated)
F, H
3F
F, H, V
4F
F, H, OH
5F
F, V, OH
* Note :
* Vertical uphill to downhill or vice versa is Essential Variable.
* Groove test on pipe or box tube also qualifies plate for the same positions.
* Groove test using box tubing also qualifies pipes 24 in (600) nominal outer dia.
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1.
Guide (Position) Contd
* Note :
* Groove test on plate qualifies pipes 24 in (600 mm) in diameter with backing,
backgouging or both.
* Groove test on plate qualifies plug or slot welds for the test position indicated.
* Plug test qualifies plug and slot welding for only the position test.
* ESW or EGW process test qualifies welding for only the position tested.
2.
Guide (Thick Base Metal) AWS D1.1, Table 4.11, (Pipe or Box
Tube)
WELD TYPE
Pipe or Box Tube
T TESTED (in)
T QUALIFIED (in)
Pipe or Box Tube
Plate, Pipe or Box Tube
Groove (CJP)
T : Unlimited ( 4 Max)
1/8 Min. Max.
Groove (CJP)
T : 3/8 or less (Over 4)
1/8 Min. Max.
Groove (CJP)
T : Over 3/8 (Over 4)
3/16 Min. Unlimited.
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SECTION 5
FABRICATION
Oleh :
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Sect.5 Fabrication
Preparation (Persiapan).
SHOP DRAWING SHALL SHOW

1.
Size and location of all structural members & connection

material.
2.
Complete information necessary for the fabrication of

member including : cuts, holes, stiffeners and weld.
3.
Type, size & location of bolts and welds.
4.
Surface preparation and finishes.
5.
Details of assembly.
6.
Identification of WPS.
7.
Furnish setting drawing, tempaltes and directions for

installation of anchor bolts and other anchorages to be
installed as work of other sections.
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Sect.5 Fabrication
Preparation (Persiapan).
ERECTION DRAWING SHALL SHOW
1. Location of all structural material.
2. Identification mark of members.
3. Setting elevations for column basses.
4. Orinetation and relation members to appropriates
grid lines (Sesuai lines).
5. Details of assembly.
6. Identification of WPS.
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Sect.5 Fabrication
BASE METAL AWS D1.1 Std.
BASE MATERIAL
1.
Seperti yang tercantum pada Tabel 3-1 & 4-9.

Selain Material ASTM direkomendasikan material API & ABS
(American Bureau of Shipping).
2.
Toleransi Dimension.
Terdapat pada ASTM Std A. 6 & A. 20
Weld Tab, Backing dan Spacer.

a.
Direkomendasikan berasal dari base materialnya
b.
Backing material selain yang disyaratkan pada point (a)

diatas dapat diganti material A109 T3 & T4 kecuali yang
mempunyai nilai minimum Yield Strength 100 Ksi harus
menggunakan material yang mempunyai minimum nilai
Yield Strength 100 ksi.
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Sect.5 Fabrication
Materials arriving at the site/work shop need to be

inspected for the following:
1) Size
2) Condition
3) Specification*
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Sect.5 Fabrication
Rolling Imperfections
Direction of rolling
Cold Laps*
Laminations
Segregation
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Sect.5 Fabrication
Lamination
Lapping
Lamination
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Sect.5 Fabrication
WELDING CONSUMABLE AWS D1.1 Std.
Welding Consumables:
filler material must be stored in an area with controlled
temperature and humidity
poor handling and incorrect stacking may damage
coatings, rendering the electrodes unusable
there should be an issue and return policy for welding
consumables (system procedure)
control systems for electrode treatment must be checked
and calibrated; those operations must be recorded
filler material suppliers must be approved before purchasing
any material
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Sect.5 Fabrication
General Requirement Welding Consumables & Electrode:
Certification electrode or electrode flux combination jika
diminta oleh Engineer maka contractor/fabricator harus
menyiapkannya.
Parameter las harus dalam range yang direkomendasikan oleh
electrode manufacturer.
Gas or gas mixture yang dipakai untuk shielding gas harus
conform AWS 5.32 Specification for Welding Shielding Gasses.
Prosentase gas atau mix gas yang digunakan harus sesuai yang
disyaratkan WPS.
Welding Consumable yang sudah dibuka dari sealed boxnya
harus diproteksi dan disimpan akan berpengaruh pada welding
properties.
Electrode harus kering dan dalam kondisi baik jika digunakan.
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Sect.5 Fabrication
Covers welding materials. A-5.1, as well as all other
specifications, states the marking requirements. It requires
marking as follows:
Packages
The AWS specification and class
The supplier's name and designation
Standard size and net weight Lot, control or heat
number
Electrodes
The electrode shall be marked with the AWS
classification stamped no more than 2-1/2" from the
grip end.
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Sect.5 Fabrication
BAKING PROCEDURE for BASIC ELECTRODES
Unopened
packet
Re-dry to ensure
Low hydrogen
condition
AWS A5.1
Low Hydrogen
Time period
Tabel 5.1
Column A
Bake
260-430oC
2 Hrs
Quiver
70oC min
4 hrs max
Hold
150oC
Time period
Tabel 5.1
Column B
AWS A5.5
Low Hydrogen
Bake
370-430oC
1 Hrs
Hold
150oC
Quiver
70oC min
Over 4-10 hrs
Note :
1. Baking yang melebihi satu kali & electrode basah tidak boleh digunakan.
2. Electrode untuk ASTM A514 atau A517 dengan electrode classification
E100XX-X kecuali E70XXH4R di baking sekurang-kurangnya 1 Jam pada
temperatur 370-4300C
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Sect.5 Fabrication
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Sect.5 Fabrication
General Requirement Welding Consumables & Electrode:
SAW Electrode dan Fluxes : AWS A5.17 dimana kondisi Fluxe
harus kering dan bebas dari kontaminasi. Fluxes yang
tersimpan di storage sekurang-kurangnya 6 bulan. Fluxes yang
rusak harus di baking pada temperatur 2600C selama 1 Hour
atau dibuang. Fluxes yang basah tidak boleh dipakai.
GMAW/FCAW Electrodes yang menghasilkan Weld Metal
dengan nilai YS < 60 Ksi harus sesuai dengan AWS A5.18 dan YS
> 60 Ksi ke AWS A5.28.
GTAW Tungsten harus conform dengan AWS A.512 dan Filler
Metal ke AWS A5.18, A5.28 dan A5.30.
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Sect.5 Fabrication
PREHEAT & INTERPASS TEMP AWS D1.1 Std.
Adalah : Temperatur pada benda kerja didaerah dekat daerah
pengelasan (weld zone) sebelum welding operation (termasuk tack

welding)
Biasanya dinyatakan sebagai minimum Interpass temperature

Luasan daerah preheat sama dengan tebal dari lasan (tetapi tidak
boleh kurang dari 75 mm.
Preheat & Interpass temp mengacu pada tabel 3.5 dan tabel 4.5
Minimum interpass temperature = Preheat temperature

Pre heat maintenance temperature = Minimum temperature pada
weld zone yang harus dimaintain (dipelihara) jika welding akan
mengalami gangguan dan harus dimonitor selama pengelasan.
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Sect.5 Fabrication
PREHEAT & INTERPASS TEMP AWS D1.1 Std.
Quenched & Tempered Steel
Heat Input harus ditentukan, terutama untuk pengelasan dua sisi.
Gouging tidak boleh digunakan.
Electrical Heated Elements

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Manual Gas Operation

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Sect.5 Fabrication
STRESS RELIEF HEAT TREATMENT AWS D1.1 Std.
The inspector, in general, should ensure that:
Equipment is as specified
Temperature control equipment is in good condition
Procedures as specified, is being used e.g.
o Method of application
o Rate of heating and cooling
o Maximum temperature
o Soak time
o Temperature measurement (and calibration)
DOCUMENTATION AND RECORDS

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Sect.5 Fabrication
PWHT Procedures - Basic Requirement
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Sect.5 Fabrication
PWHT Procedures - Basic Requirements
1.
Furnace Temperatur
Kondisi temperatur furnace tidak boleh lebih dari 3150C.
2.
Maximum Heating Rate

Diatas Temperatur 3150C Max. heating rate tidak boleh dari
2040C/jam dibagi Max. thick pada material yang paling tebal
dalam satuan inchi.
Selama periode Heating variasi temperatur pada benda kerja
tidak boleh melebihi 1400C sepanjang 5 meter.
Heating rate dan cooling tidak boleh kurang dari 550C/jam.
3.
Minimum Soak/Holding Time

Setelah max. temperatur 6000C dilakukan HOLD dengan
waktu penahanan (Holding Time) seperti pada tabel 5.2.
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Sect.5 Fabrication
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Sect.5 Fabrication
PWHT Procedures - Basic Requirements
4. Maximum Cooling Rate
Diatas temperatur 3150C Max. cooling rate tidak boleh
melebihi 2600C/jam dibagi Max. thick pada material yang
tebal dalam satuan inchi.
5. Alternatif PWHT
Diatur dalam tabel 5.3.
6. Material Not Recommended PWHT
Material Tempered & Quenched (A.514, A.517, A.709
Grades 100 dan 100 w, A.710) sambungan wedingnya tidak
direkomendasikan PWHT.
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Sect.5 Fabrication
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Sect.5 Fabrication
Local Post Weld Heat Treatment
Furnace Post Weld Heat Treatment
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Sect.5 Fabrication
Backing Thickness Requirements
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Sect.5 Fabrication
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Sect.5 Fabrication
BACKING & MISALLIGMENT AWS D1.1 Std.
Fillet & PJP Groove Weld :
Root opening tidak boleh lebih dari 5mm kecuali untuk material
yang mempunyai ketebalan diatas 75mm.
Jika root opening yang melebihi batas toleransi misal 8mm
boleh digunakan dengan syarat harus menggunakan backing.
Butt Joint misaligment :
Misaligment tidak boleh melebihi 10% dari tebal yang paling
tipis pada sambungan atau 3 mm diambil mana yang lebih
kecil.
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Sect.5 Fabrication
TOLERANSI DIMENSI SAMBUNGAN
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Sect.5 Fabrication
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Sect.5 Fabrication
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Sect.5 Fabrication
THERMAL CUTTING & ACCESS HOLE AWS D1.1 Std.
Roughness Requirement base on ANSI/ASME B46.1 :
Thickness
Roughness
Inchi
mm
in.
Up to 4
Up to 100
1000
mm.
25
48
100 - 200
2000
50
Roughness Requirement base on AWS C4.1-77 :

Thickness
3/29/2015
Roughness
Inchi
mm
Sample
Up to 4 (include)
Up to 100 (include)
No.3
Over 4 8
Over 100 - 200
No.4

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Oxyfuel gas cutting quality

Good cut - sharp top edge, fine and even drag lines, little oxide
and a sharp bottom edge
Cut too slow - top edge is melted,

deep groves in the lower portion,
heavy scaling, rough bottom edge
3/29/2015
Cut
too
fast
pronounced break in
the drag line, irregular
cut edge

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Sect.5 Fabrication
Gouging or Notch Limitations
Hole gouges tidak lebih dari 3/16 in (5 mm) kedalamannya,
roughness permukaan dapat di machining atau di grinding.
Hole gouges melebihi 3/16 in (5 mm) kedalamannya roughness
permukaan boleh direpair grinding .
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Sect.5 Fabrication
STRAIGHTNESS of COLUMNS & TRUSSES
AWS D1.1 Std.
Gou
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Sect.5 Fabrication
Dimensional Tolerances of Welded Structural Members
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Sect.5 Fabrication
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Sect.5 Fabrication
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Sect.5 Fabrication
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Sect.5 Fabrication
Backing Thickness Requirements
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Sect.5 Fabrication
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Sect.5 Fabrication
Fillet & PJP Groove Weld :
Root opening tidak boleh lebih dari 5mm kecuali untuk material
yang mempunyai ketebalan diatas 75mm.
Jika root opening yang melebihi batas toleransi misal 8mm
boleh digunakan dengan syarat harus menggunakan backing.
Butt Joint misaligment :
Misaligment tidak boleh melebihi 10% dari tebal yang paling
tipis pada sambungan atau 3 mm diambil mana yang lebih
kecil.
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Sect.5 Fabrication
TRANSITION of BUTT JOINT PARTS of UNEQUAL THICKNESS
(NON TUBULAR)
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Sect.5 Fabrication
(NON TUBULAR)
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Sect.5 Fabrication
(NON TUBULAR)
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Sect.5 Fabrication
(TUBULAR)
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Sect.5 Fabrication
(TUBULAR)
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FABRICATION
(TUBULAR)
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Sect.5 Fabrication
(TUBULAR)
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Sect.5 Fabrication
(TUBULAR)
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Sect.5 Fabrication
(TUBULAR)
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Sect.5 Fabrication
GROOVE DIMENSION NON TUBULAR
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Sect.5 Fabrication
GROOVE DIMENSION NON TUBULAR
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FABRICATION
GROOVE DIMENSION TUBULAR
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SECTION 6
INSPECTION
Oleh :
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Sect.6 Inspection
PENDAHULUAN
Tingkat pemeriksaan dan persyaratannya harus didefinisikan
dalam applikasi standard atau kesepakatan dengan pihak
Client dengan Manufacturer
Welding inspection selama proses fabrikasi meliputi :
Before welding
(Before assemble & After assembly)
During welding
After welding
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Sect.6 Inspection
Measuring devices:
flexible tape, steel rule
Temperature indicating crayons
Welding gauges
Voltmeter
Ammeter
Magnifying glass
Torch / flash light
Gas flow-meter
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Sect.6 Inspection
10mm
10mm
G.A.L.
G.A.L.
1
2
S.T.D.
16mm
3
4
S.T.D.
16mm
5
6
HI-LO Single Purpose Welding Gauge
Fillet Weld Gauges

IN
1/4 1/2 3/4
Multi-purpose Welding Gauge

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Misalignment Gauges
Hi-Lo Gauge

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Sect.6 Inspection
Voltmeter
Ammeter
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Sect.6 Inspection
BEFORE WELDING
Preparation:
Familiarisation with relevant documents
Application Standard/Code
requirements
for
visual
acceptance
Drawings - item details and positions/tolerances etc

Quality Control Procedures - for activities such as material
handling, documentation control, storage & issue of
welding consumables
Quality Plan/Inspection & Test Plan/Inspection Checklist details of inspection requirements, inspection procedures &
records required
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Sect.6 Inspection
Welding Procedures:
are applicable to joints to be welded & approved
are available to welders & inspectors
Welder Qualifications:
list of available qualified welders related to WPSs
certificates are valid and in-date
Equipment:
all inspection equipment is in good condition & calibrated as
necessary
all safety requirements are understood & necessary
equipment available
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Sect.6 Inspection
Materials:
can be identified & related to test certificates, traceability !
are of correct dimensions
are in suitable condition (no damage/contamination)
Consumables:
in accordance with WPSs
are being controlled in accordance with Procedure
Weld Preparations:
comply with WPS/drawing
free from defects & contamination
Welding Equipment:
in good order & calibrated as required by Procedure
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Sect.6 Inspection
Weather conditions
suitable if site / field welding
Welding Process(es)
in accordance with WPS
Welder
is approved to weld the joint
Pre-heat (if required)
minimum temperature as specified by WPS
maximum interpass temperature as WPS
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Sect.6 Inspection
DURING WELDING
Welding consumables
in accordance with WPS
in suitable condition
controlled issue and handling
Welding Parameters
current, voltage & travel speed as WPS
Root runs
if possible, visually inspect root before single-sided welds are
filled up
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Sect.6 Inspection
Inter-run cleaning
in accordance with an approved method (back
gouging) to good workmanship standard
Distortion control
welding is balanced & over-welding is avoided
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Sect.6 Inspection
AFTER WELDING
Weld Identification
identified/numbered as required
is marked with welders identity
Visual Inspection
ensure weld is suitable for all NDT
visually inspect & sentence to Code requirements
Dimensional Survey
ensure dimensions comply with Code/drawing
Other NDT
ensure all NDT is completed & reports available
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Sect.6 Inspection
VISUAL - WELDING
Semua lasan (Weld) harus bebas dari Crack, Overlap dan Unacceptable
discountunuities seperti yang tersaji pada gambar 5.4, Tabel 5.9 dan Tabel 5.10 .
Adapun Acceptance criteria Visual tercantum pada tabel 6.1
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Sect.6 Inspection
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Sect.6 Inspection
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Sect.6 Inspection
VISUAL WELD PROFILE
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49
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Sect.6 Inspection
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Sect.6 Inspection
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Sect.6 Inspection
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50
29/03/2015
Sect.6 Inspection
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Sect.6 Inspection
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Sect.6 Inspection
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Sect.6 Inspection
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Sect.6 Inspection
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Sect.6 Inspection
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Sect.6 Inspection
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Sect.6 Inspection
NON DESTRUCTIVE TEST (NDT)
A welding inspector should have a working
knowledge of NDT methods and their applications,
advantages and disadvantages.
Four basic NDT methods
Radiographic inspection (RT)
Ultrasonic inspection (UT)
Magnetic particle inspection (MT)
Dye penetrant inspection (PT)
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Sect.6 Inspection
Surface Crack Detection
Liquid Penetrant (PT or Dye-Penetrant)
Magnetic Particle Inspection (MT or MPI)
Volumetric & Planar Inspection
Ultrasonics (UT)
Radiography (RT)
Each technique has advantages & disadvantages with respect to:
Technical Capability and Cost
Note:
The choice of NDT techniques is based on consideration of these advantages and
disadvantages
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Sect.6 Inspection
Acceptance criterias Radiographic Testing refer to section 6.12
X Rays
Electrically generated
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Gamma Rays
Generated by the decay of
unstable atoms

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Sect.6 Inspection
Source
Image quality indicator
Radiation beam
Radiographic
film
with latent image
after exposure
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Test specimen

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Sect.6 Inspection
Pulse echo
signals
A scan
Display
Digital
UT Set,
Compression probe
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checking the material Thickness

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Sect.6 Inspection
NDT ULTRASONIC TESTING
Back wall
echo
defect
echo
initial pulse
Material Thk
defect
Compression Probe
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10
20
30
40
50
CRT Display

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Sect.6 Inspection
Collection of ink
particles due to
leakage field
Electro-magnet (yoke) DC or AC
Prods DC or AC
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Sect.6 Inspection
A crack like
indication
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INSPECTION
NDT PENETRANT TESTING
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Sect.6 Inspection
Fluorescent Penetrant
Bleed out viewed

under a UV-A
light source
Bleed out viewed

under white light
Colour contrast Penetrant
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56

Tubular &amp; Non Tubular AWS D1.1

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Tubular &amp; Non Tubular AWS D1.1

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Presented By : Farid Moch.

TUBULAR & NON TUBULAR

Pekerjaan Plate Form & Steel

Potensi bahayanya yang cukup

Konstruksi pada umumnya dilas.

Keterbatasan tenaga pemeriksa

WELDING INSPECTOR COURSE

Welding Inspector PPNS

Presented By : Farid Moch. Zamil

WELDING INSPECTOR COURSE

Sect.1 Ketentuan umum

Requirements for exempting (Not Qualifications) WPS.

Requirements for design welded connections between

Basic on the scope & limitations of the Code.

Design of Welding Connections.

Requirements for qualification of WPS & personnel to perform

WELDING INSPECTOR COURSE

Sect.1 Ketentuan umum

Requirements for the welding of studs to structural steel.

Strengthening & Repair Existing Structure.

Normative Informasi & Requirement bahwa menjadi pertimbangan

Tidak dijadikan pertimbangan

Welding Inspector PPNS

Presented By : Farid Moch. Zamil

Sect.1 Ketentuan umum

WELDING INSPECTOR COURSE

Sect.1 Ketentuan umum

WELDING INSPECTOR COURSE

Sect.1 Ketentuan umum

WELDING INSPECTOR COURSE

Welding Inspector PPNS

Presented By : Farid Moch. Zamil

Sect.1 Ketentuan umum

Other AWS D1 Std.

Sheet Steel equal or less than 3/16 (5 mm) Thick.

AWS D1.5 Bridge Welding Code.

Sect.1 Ketentuan umum

WELDING INSPECTOR COURSE

Welding Inspector PPNS

Presented By : Farid Moch. Zamil

Sect.2 Perencanaan (Design)

The Material grouped into STRENGTH GROUP & TOUGHNESS CLASS :

WELDING INSPECTOR COURSE

Sect.2 Perencanaan (Design)

Group I Nilai CVN = 20 Joule.

Group II Nilai CVN = 34 Joule.

Group III Nilai CVN = 48 Joule.

Temperature 200C s/d 300C Subfreezing.

Temperature -300C s/d 400C Brittle Fracture.

Sect.2 Perencanaan (Design)

WELDING INSPECTOR COURSE

Welding Inspector PPNS

Presented By : Farid Moch. Zamil

Sect.2 Perencanaan (Design)

WELDING INSPECTOR COURSE

Sect.2 Perencanaan (Design)

WELDING INSPECTOR COURSE

Sect.2 Perencanaan (Design)

WELDING INSPECTOR COURSE

Welding Inspector PPNS

Presented By : Farid Moch. Zamil

Sect.2 Perencanaan (Design)

WELDING INSPECTOR COURSE

Sect.2 Perencanaan (Design)

Tubular & Non Tubular AWS D1.1

Tubular & Non Tubular AWS D1.1