Consultant expert, Dr. Mohamed Taha Mechanical engineering codes and specifications
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Consultant expert, Dr. Mohamed Taha
Mechanical engineering codes and specifications
CONTENTS
foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Conlmittee Roster ................................................ ..................... vii
Introduction ................................................. .......................... x
SUlnn1ary of Changes ............................................... ................... xii
Chapter I
Contents
Qualifi cation titles covered by this specifi cation 1
What are BTEC Firsts? 2
Edexcel BTEC Level 2 Certifi cate – 15 credits 3
Edexcel BTEC Level 2 Extended Certifi cate – 30 credits 3
Edexcel BTEC Level 2 Diploma – 60 credits 4
Key features of the BTEC Firsts in Engineering 4
Rationale for the BTEC Firsts in Engineering 4
National Occupational Standards (NOS) 5
Rules of combination for Edexcel BTEC Level 2 First qualifi cations 6
Edexcel BTEC Level 2 Certifi cate in Engineering 7
Edexcel BTEC Level 2 Extended Certifi cate in Engineering 8
Edexcel BTEC Level 2 Diploma in Engineering 9
Edexcel BTEC Level 2 Diploma in Engineering (Maintenance) 10
Edexcel BTEC Level 2 Diploma in Engineering (Manufacturing) 11
Edexcel BTEC Level 2 Diploma in Engineering (Electronics) 12
Assessment and grading 13
Grading domains 13
Calculation of the qualifi cation grade 14
Quality assurance of centres 15
Approval 15
Programme design and delivery 16
Mode of delivery 16
Resources 17
Delivery approach 17
Meeting local needs 17
Limitations on variations from standard specifi cations 18
Additional and specialist learning 18
Functional Skills 18
Personal, learning and thinking skills 18
Access and recruitment 19
Restrictions on learner entry 19
Access arrangements and special considerations 19
Recognition of Prior Learning 20
Unit format 20
Unit title 20
QCF level 20
Credit value 20
Guided learning hours 21
Aim and purpose 21
Unit introduction 21
Learning outcomes 21
Unit content 21
Assessment and grading grid 22
Essential guidance for tutors 22
Units 23
Unit 1: Working Safely and Effectively in Engineering 25
Unit 2: Interpreting and Using Engineering Information 37
Unit 3: Mathematics for Engineering Technicians 49
Unit 4: Applied Electrical and Mechanical Science for Engineering 61
Unit 5: Engineering Maintenance Procedures 73
Unit 6: Preparing and Controlling Engineering Manufacturing Operations 83
Unit 7: Electronic Devices and Communication Applications 93
Unit 8: Selecting Engineering Materials 105
Unit 9: Engineering Assembly Methods and Techniques 115
Unit 10: Using Computer Aided Drawing Techniques in Engineering 127
Unit 11: Operation and Maintenance of Mechanical Systems and
Components 139
Unit 12: Operation and Maintenance of Electrical Systems and
Components 153
Unit 13: Operation and Maintenance of Electronic Systems and
Components 167
Unit 14: Selecting and Using Secondary Machining Techniques to
Remove Material 183
Unit 15: Part Programming CNC Machines 195
Unit 16: Application of Welding Processes 207
Unit 17: Fabrication Techniques and Sheet Metal Work 219
Unit 18: Engineering Marking Out 233
Unit 19: Electronic Circuit Construction 243
Unit 20: Using Specialist Secondary Machining Techniques 253
Unit 21: Production Planning for Engineering 265
Unit 22: Application of Quality Control and Measurement in Engineering 275
Unit 23: Casting and Moulding Engineering Components 285
Unit 24: Operation and Maintenance of Fluid Power Systems and
Components 297
Unit 25: Applying Continuous Improvement and Problem-solving
Techniques 311
Unit 26: Workplace Organisation and Standard Operating Procedures 321
Unit 27: PC Hardware and Software Installation and Confi guration 333
Unit 28: Mobile Communications Technology 345
Unit 29: Mathematics for Engineering Technicians 35
100
Chapter II
Part 1
101
102
Part 2
103
104
Part 3
105
106
107
108
Part 4
110
111
112
113
114
115
116
117
118
Part 5
119
120
121
Part 6
122
Chapter III
123
124
125
Chapter IV
126
ChapterV
127
128
129
130
131
Scope and definitions ............................................... ... .
General ................................................. ............. .
Design................................................... ......... ...... 10
Conditions and Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Design Conditions ………………. ... 10
Design Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Design of Piping Components ............................... 16
Criteria for Pressure Design of Piping Components. . . . . . . . . . . . . . . . . . . . . 16
Pressure Design of Components ...................................... 16
Selection and Limitations of Piping Components ..................... 29
Pipe................................................ ................. 29
Fittings, Bends, and Intersections ...................................... 30
Valves ................................................. ............... 31
Pipe Flanges, Blanks, Flange Facings, Gaskets, and Bolts ............. 32
Selection and Limitations of Piping Joints ............................ 33
Piping Joints ................................................ .......... 33
Welded Joints ................................................ .......... 33
Flanged joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Expanded or Rolled Joints ............................................ 33
Threaded Joints ................................................ ....... 33
Flared, Flareless, and Compression Joints, and Unions........." . . . . 38
Bell End Joints ............................................... .......... 39
Brazed and Soldered Joints ............................................ 39
Sleeve Coupled and Other Proprietary Joints ................... . . . . . . . . 39
Expansion, Flexibility, and Pipe Supporting Element .................. 39
Expansion and Flexibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Loads on Pipe Supporting Elements ................................... 42
Design of Pipe Supporting Elements ................................... 43
Systems................................................... .............. 46
Design Requirements Pertaining to Specific Piping Systems.. .. . .. . . . .. . 46
Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
General Requirements ................................................ 61
Limitations on Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Materials Applied to 1viiscellaneous Parts .............................. 63
Dimensional Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Iv1 material specifications and standards for Standard and Nonstandard
Piping Components....................................................... . 64
fabrication AssembLYt and Erection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Welding................................................... .............. 72
Brazing and Soldering ............................................... .. 81
Bending and Forming ............................................... .. 82
Requirements for Fabricating and Attaching Pipe Supports............. 82
\tVelding Preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
iii
Copyright © 2007 by the American Society of Mechanical Engineers. ~
No reproduction may be made of this material "without V\Titten consent of ASME. ~
132
133
135
Chapter VI
136
137
Chapter VII
138
139
140
141
Figures
100.1.2(A)
100.1.2(B)
100.1.2(C)
102.4.5
104.3.1(D)
104.3.1 (G)
104.5.3
104.8.4
122.1.7(C)
122.4
127.3
127.4.2
127.4.4(A)
127.4.4(B)
127.4.4(C)
127.4.8(A)
127.4.8(B)
127.4.8(C)
127.4.8(D)
127.4.8(E)
127.
List of Sections ......................................................................... v
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Statements of Policy .................................................................... ix
Personnel .............................................................................. x
Introduction ............................................................................ xxii
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxv
List of Changes in Record Number Order ................................................. xxix
PART QW WELDING ................................................................. .
Article I Welding General Requirements ............................ '" .............. .
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Appendix I
Article H
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Article HI
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Article IV
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General .................................................................... .
Weld Orientation ............................................................ .
Test Positions for Groove Welds .............................................. .
Test Positions for Fillet Welds ................................................ .
Types and Purposes of Tests and Examinations ................................ .
Tension Tests ............................................................... .
Guided-Bend Tests .......................................................... .
Notch-Toughness Tests ...................................................... .
Fillet-Weld Tests ............................................................ .
Other Tests and Examinations ................................................ .
Rounded Indication Charts ................................................. .
Welding Procedure Qualifications ........................................... .
General .................................................................... .
Preparation of Test Coupon .................................................. .
Welding Variables ........................................................... .
Temper Bead Welding ....................................................... .
Welding Performance Qualifications ........................................ .
General .................................................................... .
Qualification Test Coupons ................................................... .
Retests and Renewal of Qualification .......................................... .
Welding Variables for Welders ............................................... .
Welding Variables for Welding Operators ..................................... .
Special Processes ............................................................ .
2
2
3
3
4
5
6
6
7
13
14
14
17
19
49
52
52
55
56
57
58
59
Welding Data.... .... . ... .... . .... .... .... ........ . ... .... .... .... .... ... . .. 61
Variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Technique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Base Metal Groupings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
F-Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 133
Weld Metal Chemical Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 143
Specimens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 144
Graphics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 151
Etching - Processes and Reagents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 192
Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 193
iii
Article V
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PART QB
Article XI
QB-I00
QB-I1O
QB-120
QB-140
QB-150
QB-160
QB-170
QB-180
Article XII
QB-200
QB-210
QB-250
Article XIII
QB-300
QB-310
QB-320
QB-350
Article XIV
QB-400
QB-41O
QB-420
QB-430
QB-450
QB-460
Standard Welding Procedure Specifications (SWPSs) .. . ...... . .... ... .... . ... 202
General ..................................................................... 202
Adoption of SWPSs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 202
Use of SWPSs Without Discrete Demonstration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 202
Forms....................................................................... 203
Production Use of SWPSs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 203
BRAZING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 204
Brazing General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 204
General ..................................................................... 204
Braze Orientation ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 205
Test Positions for Lap, Butt, Scarf, or Rabbet Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 205
Types and Purposes of Tests and Examinations .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 205
Tension Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 206
Guided-Bend Tests. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 207
Peel Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 207
Sectioning Tests and Workmanship Coupons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 208
Brazing Procedure Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 209
General ..................................................................... 209
Preparation of Test Coupon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 211
Brazing Variables. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 211
Brazing Performance Qualifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 215
General ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 215
Qualification Test Coupons ......................................... , . ... . ..... 217
Retests and Renewal of Qualification ........................................... 217
Brazing Variables for Brazers and Brazing Operators. . . . . . . . . . . . . . . . . . . . . . . . . . .. 217
Brazing Data................................................................ 218
Variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 218
Technique ................................................................... 219
P-Numbers .................................................................. 219
F-Numbers .................................................................. 219
Specimens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 222
Graphics .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 225
APPENDICES
A
B
D
E
F
G
H
Index
Mandatory - Submittal of Technical Inquiries to the Boiler and Pressure
Vessel Committee... .... ........ .... . .... .... .... . .... ............ .... ... .. 245
Nonmandatory - Welding and Brazing Forms.. . ........ .... .... .... .... .... . .. 247
Nonmandatory - P-Number Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 258
Mandatory - Permitted SWPSs.... ..... .... .... .... . ... . ............ .... ..... 276
Mandatory - Standard Units for Use in Equations. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 279
Nonmandatory - Guidance for the Use of U.S. Customary and SI Units in the
ASME Boiler and Pressure Vessel Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 280
Nonmandatory - Waveform Controlled Welding... ......... .... .... .... .... ... 283
285
ORDERING STEEL CASTINGS .............................................................................................................................................3
Overview ............................................................................................................................................................................................... 3
Design.................................................................................................................................................................................................... 3
Background ....................................................................................................................................................................................... 3
Minimum Section Thickness............................................................................................................................................................. 3
Draft .................................................................................................................................................................................................. 3
Parting Line....................................................................................................................................................................................... 4
Cores ................................................................................................................................................................................................. 4
Internal Soundness/Directional Solidification .................................................................................................................................. 4
Machining ......................................................................................................................................................................................... 4
Layout ............................................................................................................................................................................................... 5
Material.................................................................................................................................................................................................. 5
Tests....................................................................................................................................................................................................... 6
SUMMARY OF MATERIAL SPECIFICATIONS FOR CARBON AND ALLOY CAST STEELS ......................................7
AISI Classification System ...................................................................................................................................................... 7
Type................................................................................................................................................................................................... 7
TENSILE REQUIREMENTS ........................................................................................................................................... 21
Class................................................................................................................................................................................... 21
SUMMARY OF MATERIAL SPECIFICATIONS FOR HIGH ALLOY CAST STEELS ....................................................32
SUMMARY OF MATERIAL SPECIFICATIONS FOR CENTRIFUGALLY CAST STEELS............................................51
SUMMARY OF STANDARD TEST METHODS FOR STEEL CASTINGS........................................................................57
Overview ............................................................................................................................................................................................. 57
Mechanical Testing.............................................................................................................................................................................. 57
Background ..................................................................................................................................................................................... 57
Tension Testing............................................................................................................................................................................... 57
Hardness Testing............................................................................................................................................................................. 57
Impact Testing................................................................................................................................................................................. 57
Nondestructive Examination ............................................................................................................................................................... 58
Background ..................................................................................................................................................................................... 58
Visual Examination......................................................................................................................................................................... 58
Liquid Penetrant Examination (PT) ................................................................................................................................................ 58
Magnetic Particle Examination (MT) ............................................................................................................................................. 59
Radiographic Examination (RT)..................................................................................................................................................... 61
Ultrasonic Testing (UT).................................................................................................................................................................. 61
SPECIAL STANDARD PRACTICES....................................................................................................................................62
Ferrite Content..................................................................................................................................................................................... 62
Welding ............................................................................................................................................................................................... 63
CODE AND SPECIFICATION AGENCIES..........................................................................................................................64
Lloyd’s Register of Shipping............................................................................................................................................. 64
(LR).................................................................................................................................................................................... 64
Mechanical engineering codes and specifications
CONTENTS
foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Conlmittee Roster ................................................ ..................... vii
Introduction ................................................. .......................... x
SUlnn1ary of Changes ............................................... ................... xii
Chapter I
Contents
Qualifi cation titles covered by this specifi cation 1
What are BTEC Firsts? 2
Edexcel BTEC Level 2 Certifi cate – 15 credits 3
Edexcel BTEC Level 2 Extended Certifi cate – 30 credits 3
Edexcel BTEC Level 2 Diploma – 60 credits 4
Key features of the BTEC Firsts in Engineering 4
Rationale for the BTEC Firsts in Engineering 4
National Occupational Standards (NOS) 5
Rules of combination for Edexcel BTEC Level 2 First qualifi cations 6
Edexcel BTEC Level 2 Certifi cate in Engineering 7
Edexcel BTEC Level 2 Extended Certifi cate in Engineering 8
Edexcel BTEC Level 2 Diploma in Engineering 9
Edexcel BTEC Level 2 Diploma in Engineering (Maintenance) 10
Edexcel BTEC Level 2 Diploma in Engineering (Manufacturing) 11
Edexcel BTEC Level 2 Diploma in Engineering (Electronics) 12
Assessment and grading 13
Grading domains 13
Calculation of the qualifi cation grade 14
Quality assurance of centres 15
Approval 15
Programme design and delivery 16
Mode of delivery 16
Resources 17
Delivery approach 17
Meeting local needs 17
Limitations on variations from standard specifi cations 18
Additional and specialist learning 18
Functional Skills 18
Personal, learning and thinking skills 18
Access and recruitment 19
Restrictions on learner entry 19
Access arrangements and special considerations 19
Recognition of Prior Learning 20
Unit format 20
Unit title 20
QCF level 20
Credit value 20
Guided learning hours 21
Aim and purpose 21
Unit introduction 21
Learning outcomes 21
Unit content 21
Assessment and grading grid 22
Essential guidance for tutors 22
Units 23
Unit 1: Working Safely and Effectively in Engineering 25
Unit 2: Interpreting and Using Engineering Information 37
Unit 3: Mathematics for Engineering Technicians 49
Unit 4: Applied Electrical and Mechanical Science for Engineering 61
Unit 5: Engineering Maintenance Procedures 73
Unit 6: Preparing and Controlling Engineering Manufacturing Operations 83
Unit 7: Electronic Devices and Communication Applications 93
Unit 8: Selecting Engineering Materials 105
Unit 9: Engineering Assembly Methods and Techniques 115
Unit 10: Using Computer Aided Drawing Techniques in Engineering 127
Unit 11: Operation and Maintenance of Mechanical Systems and
Components 139
Unit 12: Operation and Maintenance of Electrical Systems and
Components 153
Unit 13: Operation and Maintenance of Electronic Systems and
Components 167
Unit 14: Selecting and Using Secondary Machining Techniques to
Remove Material 183
Unit 15: Part Programming CNC Machines 195
Unit 16: Application of Welding Processes 207
Unit 17: Fabrication Techniques and Sheet Metal Work 219
Unit 18: Engineering Marking Out 233
Unit 19: Electronic Circuit Construction 243
Unit 20: Using Specialist Secondary Machining Techniques 253
Unit 21: Production Planning for Engineering 265
Unit 22: Application of Quality Control and Measurement in Engineering 275
Unit 23: Casting and Moulding Engineering Components 285
Unit 24: Operation and Maintenance of Fluid Power Systems and
Components 297
Unit 25: Applying Continuous Improvement and Problem-solving
Techniques 311
Unit 26: Workplace Organisation and Standard Operating Procedures 321
Unit 27: PC Hardware and Software Installation and Confi guration 333
Unit 28: Mobile Communications Technology 345
Unit 29: Mathematics for Engineering Technicians 35
100
Chapter II
Part 1
101
102
Part 2
103
104
Part 3
105
106
107
108
Part 4
110
111
112
113
114
115
116
117
118
Part 5
119
120
121
Part 6
122
Chapter III
123
124
125
Chapter IV
126
ChapterV
127
128
129
130
131
Scope and definitions ............................................... ... .
General ................................................. ............. .
Design................................................... ......... ...... 10
Conditions and Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Design Conditions ………………. ... 10
Design Criteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pressure Design of Piping Components ............................... 16
Criteria for Pressure Design of Piping Components. . . . . . . . . . . . . . . . . . . . . 16
Pressure Design of Components ...................................... 16
Selection and Limitations of Piping Components ..................... 29
Pipe................................................ ................. 29
Fittings, Bends, and Intersections ...................................... 30
Valves ................................................. ............... 31
Pipe Flanges, Blanks, Flange Facings, Gaskets, and Bolts ............. 32
Selection and Limitations of Piping Joints ............................ 33
Piping Joints ................................................ .......... 33
Welded Joints ................................................ .......... 33
Flanged joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Expanded or Rolled Joints ............................................ 33
Threaded Joints ................................................ ....... 33
Flared, Flareless, and Compression Joints, and Unions........." . . . . 38
Bell End Joints ............................................... .......... 39
Brazed and Soldered Joints ............................................ 39
Sleeve Coupled and Other Proprietary Joints ................... . . . . . . . . 39
Expansion, Flexibility, and Pipe Supporting Element .................. 39
Expansion and Flexibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Loads on Pipe Supporting Elements ................................... 42
Design of Pipe Supporting Elements ................................... 43
Systems................................................... .............. 46
Design Requirements Pertaining to Specific Piping Systems.. .. . .. . . . .. . 46
Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
General Requirements ................................................ 61
Limitations on Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Materials Applied to 1viiscellaneous Parts .............................. 63
Dimensional Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Iv1 material specifications and standards for Standard and Nonstandard
Piping Components....................................................... . 64
fabrication AssembLYt and Erection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Welding................................................... .............. 72
Brazing and Soldering ............................................... .. 81
Bending and Forming ............................................... .. 82
Requirements for Fabricating and Attaching Pipe Supports............. 82
\tVelding Preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
iii
Copyright © 2007 by the American Society of Mechanical Engineers. ~
No reproduction may be made of this material "without V\Titten consent of ASME. ~
132
133
135
Chapter VI
136
137
Chapter VII
138
139
140
141
Figures
100.1.2(A)
100.1.2(B)
100.1.2(C)
102.4.5
104.3.1(D)
104.3.1 (G)
104.5.3
104.8.4
122.1.7(C)
122.4
127.3
127.4.2
127.4.4(A)
127.4.4(B)
127.4.4(C)
127.4.8(A)
127.4.8(B)
127.4.8(C)
127.4.8(D)
127.4.8(E)
127.
List of Sections ......................................................................... v
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Statements of Policy .................................................................... ix
Personnel .............................................................................. x
Introduction ............................................................................ xxii
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxv
List of Changes in Record Number Order ................................................. xxix
PART QW WELDING ................................................................. .
Article I Welding General Requirements ............................ '" .............. .
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Appendix I
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General .................................................................... .
Weld Orientation ............................................................ .
Test Positions for Groove Welds .............................................. .
Test Positions for Fillet Welds ................................................ .
Types and Purposes of Tests and Examinations ................................ .
Tension Tests ............................................................... .
Guided-Bend Tests .......................................................... .
Notch-Toughness Tests ...................................................... .
Fillet-Weld Tests ............................................................ .
Other Tests and Examinations ................................................ .
Rounded Indication Charts ................................................. .
Welding Procedure Qualifications ........................................... .
General .................................................................... .
Preparation of Test Coupon .................................................. .
Welding Variables ........................................................... .
Temper Bead Welding ....................................................... .
Welding Performance Qualifications ........................................ .
General .................................................................... .
Qualification Test Coupons ................................................... .
Retests and Renewal of Qualification .......................................... .
Welding Variables for Welders ............................................... .
Welding Variables for Welding Operators ..................................... .
Special Processes ............................................................ .
2
2
3
3
4
5
6
6
7
13
14
14
17
19
49
52
52
55
56
57
58
59
Welding Data.... .... . ... .... . .... .... .... ........ . ... .... .... .... .... ... . .. 61
Variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Technique. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Base Metal Groupings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
F-Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 133
Weld Metal Chemical Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 143
Specimens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 144
Graphics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 151
Etching - Processes and Reagents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 192
Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 193
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Article V
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PART QB
Article XI
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Article XII
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Standard Welding Procedure Specifications (SWPSs) .. . ...... . .... ... .... . ... 202
General ..................................................................... 202
Adoption of SWPSs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 202
Use of SWPSs Without Discrete Demonstration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 202
Forms....................................................................... 203
Production Use of SWPSs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 203
BRAZING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 204
Brazing General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 204
General ..................................................................... 204
Braze Orientation ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 205
Test Positions for Lap, Butt, Scarf, or Rabbet Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 205
Types and Purposes of Tests and Examinations .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 205
Tension Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 206
Guided-Bend Tests. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 207
Peel Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 207
Sectioning Tests and Workmanship Coupons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 208
Brazing Procedure Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 209
General ..................................................................... 209
Preparation of Test Coupon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 211
Brazing Variables. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 211
Brazing Performance Qualifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 215
General ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 215
Qualification Test Coupons ......................................... , . ... . ..... 217
Retests and Renewal of Qualification ........................................... 217
Brazing Variables for Brazers and Brazing Operators. . . . . . . . . . . . . . . . . . . . . . . . . . .. 217
Brazing Data................................................................ 218
Variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 218
Technique ................................................................... 219
P-Numbers .................................................................. 219
F-Numbers .................................................................. 219
Specimens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 222
Graphics .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 225
APPENDICES
A
B
D
E
F
G
H
Index
Mandatory - Submittal of Technical Inquiries to the Boiler and Pressure
Vessel Committee... .... ........ .... . .... .... .... . .... ............ .... ... .. 245
Nonmandatory - Welding and Brazing Forms.. . ........ .... .... .... .... .... . .. 247
Nonmandatory - P-Number Listing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 258
Mandatory - Permitted SWPSs.... ..... .... .... .... . ... . ............ .... ..... 276
Mandatory - Standard Units for Use in Equations. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 279
Nonmandatory - Guidance for the Use of U.S. Customary and SI Units in the
ASME Boiler and Pressure Vessel Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 280
Nonmandatory - Waveform Controlled Welding... ......... .... .... .... .... ... 283
285
ORDERING STEEL CASTINGS .............................................................................................................................................3
Overview ............................................................................................................................................................................................... 3
Design.................................................................................................................................................................................................... 3
Background ....................................................................................................................................................................................... 3
Minimum Section Thickness............................................................................................................................................................. 3
Draft .................................................................................................................................................................................................. 3
Parting Line....................................................................................................................................................................................... 4
Cores ................................................................................................................................................................................................. 4
Internal Soundness/Directional Solidification .................................................................................................................................. 4
Machining ......................................................................................................................................................................................... 4
Layout ............................................................................................................................................................................................... 5
Material.................................................................................................................................................................................................. 5
Tests....................................................................................................................................................................................................... 6
SUMMARY OF MATERIAL SPECIFICATIONS FOR CARBON AND ALLOY CAST STEELS ......................................7
AISI Classification System ...................................................................................................................................................... 7
Type................................................................................................................................................................................................... 7
TENSILE REQUIREMENTS ........................................................................................................................................... 21
Class................................................................................................................................................................................... 21
SUMMARY OF MATERIAL SPECIFICATIONS FOR HIGH ALLOY CAST STEELS ....................................................32
SUMMARY OF MATERIAL SPECIFICATIONS FOR CENTRIFUGALLY CAST STEELS............................................51
SUMMARY OF STANDARD TEST METHODS FOR STEEL CASTINGS........................................................................57
Overview ............................................................................................................................................................................................. 57
Mechanical Testing.............................................................................................................................................................................. 57
Background ..................................................................................................................................................................................... 57
Tension Testing............................................................................................................................................................................... 57
Hardness Testing............................................................................................................................................................................. 57
Impact Testing................................................................................................................................................................................. 57
Nondestructive Examination ............................................................................................................................................................... 58
Background ..................................................................................................................................................................................... 58
Visual Examination......................................................................................................................................................................... 58
Liquid Penetrant Examination (PT) ................................................................................................................................................ 58
Magnetic Particle Examination (MT) ............................................................................................................................................. 59
Radiographic Examination (RT)..................................................................................................................................................... 61
Ultrasonic Testing (UT).................................................................................................................................................................. 61
SPECIAL STANDARD PRACTICES....................................................................................................................................62
Ferrite Content..................................................................................................................................................................................... 62
Welding ............................................................................................................................................................................................... 63
CODE AND SPECIFICATION AGENCIES..........................................................................................................................64
Lloyd’s Register of Shipping............................................................................................................................................. 64
(LR).................................................................................................................................................................................... 64