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WELDING, SPEC. NO. A06-000009 REV 7

FABRICATION, PAGE: 1 of 18
AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
1.0 SCOPE
This specification defines welding, fabrication, and inspection requirements for grinding
mills.
2.0 PURPOSE
The purpose of this document is to provide a detailed specification for suppliers,
contractors, designers, buyers, etc., and to outline specific requirements and code
references applicable to grinding mills.
3.0 STANDARDS AND CODES
3.1 This specification contains proprietary techniques that have been developed by
Engineering.* This specification shall govern in case of conflict with any code or
standard.
3.2 This specification has been prepared using AWS D1.1 - Structural Welding Code -
Steel, as a reference. In the case of workmanship or procedures not covered by this
specification, AWS D1.1 shall be used. This specification is compatible with AWS D1.1
1996 and later editions.
3.3 All prequalified joint welding procedures to be used shall be prepared by the
manufacturer, contractor, or fabricator as written weld procedure specifications (WPS),
and shall be available to those authorized to examine them.
3.4 Changes to welding methods or standards referenced herein, as well as welding
procedures not conforming to the requirements of this specification, shall be submitted
to Division Engineering/Quality Assurance for approval before being used in production,
and are subject to qualification. (Paragraph 8.3.2.1)
3.5 Compliance with all requirements of this specification shall be demonstrated to the
satisfaction of Division Engineering/Quality Assurance.
3.6 Non-compliance with any requirement of this specification shall be documented and
approved by Division Engineering/Quality Assurance.
4.0 UNITS OF MEASUREMENT
Within this specification, values are stated as US Customary units and SI units. SI units
are shown in parentheses. The values stated in each system are not exact equivalents.
Combining values from the two systems may result in nonconformance with this
specification.
_____________________________________________________________________________
*Where the terms Engineering, Quality Assurance or Division Engineering/Quality
Assurance are used within this specification, it shall be understood to mean Metso
Minerals Grinding Division Engineering, Metso Minerals Grinding Division Quality
Assurance or Metso Minerals Grinding Division Engineering/Quality Assurance,
respectively.
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WELDING, SPEC. NO. A06-000009 REV 7
FABRICATION, PAGE: 2 of 18
AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
5.0 WELDER AND INSPECTOR QUALIFICATION
5.1 All welders, welding operators, and tackers (even tack welds, which are completely
removed) to be employed under this specification shall be qualified in accordance with
AWS D1.1, Section 5 or ASME Section IX or foreign equivalent.
5.2 Personnel performing nondestructive testing (NDT) shall be qualified in accordance with
the American Society for Nondestructive Testing (ASNT) Recommended Practice
SNT-TC-1A, December 1988 edition. Foreign equivalents will be considered by Division
Engineering/Quality Assurance.
6.0 BASE METALS
6.1 All base metals shall be ASTM A36, ASTM A516 Grade 60, or foreign equivalents*.
*The foreign equivalents are to be fully compatible with ASTM A36 or A516 Grade 60,
including silicon (Si) chemistry.
6.2 The following materials shall meet the requirements of Spec. No. A06-000012 -
Specification for Lamellar Tear-Resistant Steel. `
a. All flange material.
b. All cone plates. Cone plate for bolt-on mill heads may be released from this
requirement by Division Engineering.
c. Trunnion or filler ring mounting rings.
6.3 For all base metals under this specification, certified chemical and mechanical test
reports are required from the supplier. Maximum carbon (C) content is not to exceed
0.30 percent (0.30%).
6.4 TRACEABILITY
6.4.1 The mill shell shall have a unique identification number, so that all operations, such as
heat treatment, inspections, repairs, etc., can be traced and identified to the individual
component.
6.4.2 The identification number shall always be on the component and all corresponding
records. If steel stamping is used for identification LOW STRESS stamps must be
used.
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WELDING, SPEC. NO. A06-000009 REV 7
FABRICATION, PAGE: 3 of 18
AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
7.0 WORKMANSHIP
7.1 PREPARATION OF BASE METALS
Surfaces and edges to be welded shall be smooth, uniform, and free from fins, tears,
cracks, and other defects which could adversely affect the quality or strength of the
weld. Surfaces to be welded shall be free from loose scale, rust, slag, grease, moisture,
or other material that will prevent proper welding. All mill scale shall be removed from all
surfaces on which tee or corner welds are to be made. Surfaces within 6 inches (152
mm) of any weld location shall be free of any paint or other material that would prevent
proper welding or produce objectionable fumes.
7.1.1 Thermal cutting processes are limited to arc-cutting and oxyfuel gas processes.
7.1.1.1 The roughness of thermal cut surfaces shall be per code.
7.2 FIT-UP
7.2.1 If root openings do not permit fit-up within limitations of approved weld procedures, set
forth in paragraph 8.3 of this specification, the procedure necessary to bring the material
within the limit, shall be approved by Division Engineering. The use of permanent filler
bars to compensate for poor fit-up is prohibited.
7.2.2 ALIGNMENT
7.2.2.1 Abutting parts shall be carefully aligned.
7.2.2.2 Where parts are effectively restrained against bending due to eccentricity in alignment,
an offset not exceeding 1/8 inch (3 mm) is permitted as a departure from the theoretical
alignment. In correcting misalignment in such cases, the parts shall not be drawn into a
greater slope than 1/2 inch in 12 inches (4.25 mm in 100 mm). Measurement of the
offset shall be based on the centerline of the parts, unless otherwise specified on
drawings or approved by Division Engineering.
7.2.2.3 Temporary attachments welded to sections, members, or components to facilitate
assembly, alignment, etc., shall be removed after the operation is complete, and the
surface shall be restored to the required contour and thickness. Areas from which
attachments have been removed shall be inspected by methods covered under this
specification, and are subject to the same requirements as permanent welds.
7.2.2.4 If local heating of the plate is required in order to obtain proper alignment at any stage of
fabrication, a detailed procedure must be submitted to and accepted by Division
Engineering prior to use.
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WELDING, SPEC. NO. A06-000009 REV 7
FABRICATION, PAGE: 4 of 18
AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
7.2.2.5 Radial offset of abutting edges shall not exceed 1/8 inch (3 mm). (See Sketch 7.2.2.5)
Circumferential and Longitudinal Flange to Shell
1/8 Inch (3 mm) Maximum
Inside Surface
Butt Joint
1/8 Inch (3 mm) Maximum
Inside Surface
Contour Flange
Inside Surface

1/8 Inch (3 mm) Maximum

SKETCH 7.2.2.5
7.2.2.6 Cone Plates and Trunnion Rings (See Sketch 7.2.2.6)
Cone Plate and Trunnion Ring
Inside Surface
0 30' Maximum
0 30' Maximum
Inside surfaces of cone plate and trunnion ring must be parallel after welding. Machine
inside surface of trunnion ring during final machining, if necessary, to obtain parallelism.
(Notify Division Engineering/QA before machining to obtain parallelism.)
SKETCH 7.2.2.6
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WELDING, SPEC. NO. A06-000009 REV 7
FABRICATION, PAGE: 5 of 18
AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
7.2.3 SHELL BRACING
Bracing shall be per drawing. Any variations must be submitted to Division Engineering/
Quality Assurance for approval before use.
7.3 ASSEMBLY OF MATING PARTS
7.3.1 The maximum allowable step across the longitudinal flanges of the shell segments is 1/8 inch
(3.2 mm), and may be achieved by flange grinding in the step. (See Sketch 7.3.1)
Longitudinal Flange to Longitudinal Flange Joint
1/8 Inch (3.2 mm) Maximum
1. Inside of flange may be ground to achieve the 1/8 inch (3.2 mm) maximum step.*
2. Division Engineering/QA must be notified before grinding.
* When grinding to correct misalignment or provide smooth transitions, plate
thickness shall not be reduced by more than 1/32 inch (1 mm).
SKETCH 7.3.1
7.3.2 When the liners cross the flange joint, the maximum allowable across-the-cans step is
1/8 inch (3.2 mm). When the liners do not cross the flange joint, the maximum
allowable across-the-cans step is 7/32 inch (5.5 mm). This will be a maximum for all
tolerance accumulation. This must be considered for each can before the fabrication
process starts. (See Sketch 7.3.2)
Circumferential Flange to Circumferential Flange Joint
7/32 Inch (5.5 mm) Maximum
1. Inside of flange may be ground to achieve the 7/32 inch (5.5 mm) maximum step.*
2. Division Engineering/QA must be notified before grinding.
*When grinding to correct misalignment or provide smooth transitions, plate
thickness shall not be reduced by more than 1/32 inch (1 mm).
SKETCH 7.3.2
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WELDING, SPEC. NO. A06-000009 REV 7
FABRICATION, PAGE: 6 of 18
AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
7.4 WELD PROFILES
7.4.1 Weld profiles shall be in accordance with AWS D1.1, Section 5.24.
7.4.2 Groove welds shall be made with slight or minimum reinforcement, unless otherwise
specified. The reinforcement shall not exceed 1/8 inch (3 mm) in height on the inside
and outside surfaces, and shall have gradual transition to the plane of the base metal
surface. Grinding of weld reinforcement shall be per drawing.
7.4.3 Welds to be ground per drawing shall have a maximum surface finish of 125 inches
(3.2 m). The final grinding passes will be done with equipment to minimize the heating
of the weld and base metal.
7.4.4 Surfaces required to be flush shall be finished so as not to reduce the thickness of the
thinner base metal or weld metal by more than 1/32 inch (1 mm), and must blend
smoothly into the plate surfaces, with transition areas free from edge weld undercut.
7.4.5 Undercut shall be no more than 0.01 inch (0.25 mm) deep if the weld is transverse to
the primary stress direction in the part that is undercut. Undercut shall be no more than
1/32 inch (1 mm) deep if the weld is parallel to the primary stress direction in the part
that is undercut.
7.5 REPAIRS
7.5.1 REPAIRS OF WELDS
7.5.1.1 Welds that are found unacceptable in accordance with this specification or by contract
requirements, shall be repaired within the limitations of this specification.
7.5.1.2 A repair procedure shall be developed and utilized by the manufacturer.
7.5.1.3 A repaired or replaced weld shall be retested by the nondestructive test method (NDT)
originally used, and the same technique and acceptance criteria shall be applied.
7.5.1.4 A report shall be submitted for each NDT inspection performed, including repairs.
7.5.1.5 For repairs after stress relief, see paragraph 10.4.1 of this specification.
7.5.2 REPAIRS OF BASE METAL
7.5.2.1 After stress relief, any repair of base metal requires Division Engineering/Quality Assurance
approval.
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WELDING, SPEC. NO. A06-000009 REV 7
FABRICATION, PAGE: 7 of 18
AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
7.6 PEENING
The use of manual slag hammers, chisels and lightweight vibrating tools for the removal
of slag and spatter is permitted and is not considered peening.
7.6.1 MANUAL PEENING
7.6.1.1 Controlled peening may be performed to minimize distortion only when authorized by
Division Engineering.
7.6.1.2 All Controlled peening shall be performed per code and a procedure written.
7.7 CLEANING
7.7.1 Before welding over previously deposited metal, all slag shall be removed, and the weld
and adjacent base metal shall be brushed clean. This requirement shall apply to
successive layers, as well as to successive beads and the crater area when welding is
resumed after any interruption.
7.7.2 On completed welds not requiring grinding or finishing, all spatter shall be removed and
the finished welds wire brushed, if necessary, to provide a clean surface which is free of
scale, slag, etc.
8.0 WELDING
8.1 WELDING PROCESSES
The following welding processes are permitted, as defined by this specification.
Shielded Metal Arc Welding (SMAW)
Flux Cored Arc Welding (FCAW)
Submerged Arc Welding (SAW)
8.1.1 ELECTRODES FOR SHIELDED METAL ARC WELDING (SMAW)
a. Electrodes for shielded metal arc welding (SMAW) shall conform to the
requirements of AWS A5.1 - Specification for Carbon Steel Electrodes for Shielded
Metal Arc Welding.
b. When requested by Division Engineering, the contractor or fabricator shall furnish
the electrode manufacturer's certification stating that the electrode will meet the
requirements of classification or grade, as set forth in this specification.
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WELDING, SPEC. NO. A06-000009 REV 7
FABRICATION, PAGE: 8 of 18
AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
8.1.2 LOW HYDROGEN ELECTRODE STORAGE CONDITIONS
a. All electrodes having low hydrogen coverings conforming to AWS A5.1 shall be
purchased in hermetically sealed containers or shall be dried for at least two (2)
hours between 500 F (260 C) and 800 F (430 C) before they are used.
Immediately, after opening hermetically sealed containers or removal of the
electrodes from the drying ovens, electrodes shall be stored in an oven and held at
a minimum of 250 F (120 C). Electrodes that have been exposed for extended
periods shall be redried in accordance with AWS D1.1, Section 5.3.2.4, or the
electrode manufacturers recommendations.
b. Electrodes that have been wet shall not be used.
8.1.3 ELECTRODES AND SHIELDING GAS FOR FLUX CORED ARC WELDING (FCAW)
a. The electrodes and shielding gas accepted by this specification are:
i. E70T-1, E71T-1, E70T-5 for flux cored electrodes per AWS A5.20 -
Specification for Carbon Steel Electrodes for Flux Cored Arc Welding.
ii. Welding grade carbon dioxide (CO
2
) or C-25 having a dew point of -40 F
(-40 C) or lower.
b. When requested by Division Engineering, the contractor or fabricator shall furnish
the electrode manufacturer's certification stating that the electrode will meet the
requirements of classification or grade, as set forth in this specification.
8.1.4 SUBMERGED ARC WELDING (SAW)
a. Submerged arc welding may be performed with a single electrode. The approval
of Division Engineering/Quality Assurance is necessary before more than one
single electrode, one or more parallel electrodes, or combinations of single and
parallel electrodes may be used. Division Engineering/Quality Assurance approval
is also necessary for the welding of more than one joint simultaneously.
8.1.5 ELECTRODES AND FLUXES FOR SUBMERGED ARC WELDING (SAW)
a. The bare electrodes and flux used in combination for submerged arc welding of
steels shall conform to the requirements in AWS A5.17 - Specification for Carbon
Steel Electrodes and Fluxes for Submerged Arc Welding.
b. When requested by Division Engineering, the contractor or fabricator shall furnish
an electrode and flux manufacturer's certification stating that the electrode and flux
combination will meet the requirements of the classification or grade, as set forth
in this specification.
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WELDING, SPEC. NO. A06-000009 REV 7
FABRICATION, PAGE: 9 of 18
AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
8.1.6 CONDITION OF FLUX
a. The requirements of this section are necessary to assure that the flux is not a
medium for introduction of hydrogen into the weld due to absorbed moisture in the
flux. Whenever there is a question about the suitability of the flux due to improper
storage or package damage, the flux should be discarded or dried in accordance
with the manufacturers recommendations.
b. Flux used for submerged arc welding shall be dry and free of contamination from
dirt, mill scale, or other foreign material.
c. Flux that has been wet shall not be used.
8.1.7 ALTERNATIVE WELDING PROCESSES
Any welding process not specifically covered by this specification requires Division
Engineering/Quality Assurance approval.
8.2 PREHEAT AND INTERPASS TEMPERATURES
8.2.1 Preheat shall be in accordance with the applicable welding procedure specification, but
in no case less than that specified in Table 8.2.1.
THICKNESS - inches PREHEAT - F
t 3/4 inch None*
1 inches t > 3/4 inch 70F
2 inches t > 1 inches 150F
5 inches t > 2 inches 225F
8 inches t > 5 inches 300F
t > 8 inches 350F
THICKNESS - mm PREHEAT - C
t (19.0 mm) (None*)
(38.1 mm) t > (19.0 mm) (21C)
(63.5 mm) t > (38.1 mm) (66C)
(127.0 mm) t > (63.5 mm) (107C)
(203.2 mm) t > (127.0 mm) (149C)
t > (203.2 mm) (177C)
*When the base metal temperature is below 32 F (0 C), the base metal shall be
preheated to at least 70 F (21 C), and this minimum temperature maintained during
welding.
TABLE 8.2.1
8.2.2 Preheat shall be checked using temperature indicating crayons, pyrometers, or other
suitable devices.
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WELDING, SPEC. NO. A06-000009 REV 7
FABRICATION, PAGE: 10 of 18
AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
8.3 WELDING PROCEDURES
All welding procedures to be used shall be prepared by the manufacturer, contractor, or
fabricator as written weld procedure specifications (WPS) and procedure qualification
records (PQR), and shall be available to those authorized to review them. Submittal of
procedures may be required.
8.3.1 PREQUALIFIED WELDING PROCEDURES
All prequalified joint welding procedures to be used shall be prepared by the
manufacturer, contractor, or fabricator as written weld procedure specifications (WPS),
and shall be available to those authorized to examine them. Submittal of procedures
may be required.
8.3.2 WELDING PROCEDURES REQUIRING QUALIFICATION
8.3.2.1 Welding procedures not conforming to the requirements of prequalified procedures,
shall comply with the following:
a. Welding procedures shall be qualified prior to use by tests as prescribed in AWS
D1.1, Section 5, Part B.
b. Welding procedures shall be submitted as written procedure qualification records
(PQR) and weld procedure specifications (WPS).
c. Welding procedures require the approval of Division Engineering/Quality
Assurance before being used in fabrication.
8.3.2.2 At the discretion of Division Engineering/Quality Assurance, evidence of previous
qualification of the joint welding procedures to be used, or qualifications of welders,
welding operators, and tackers may be accepted.
8.4 GROOVE WELD BACKING and RUN-OFF TABS
8.4.1 Extension bars, starting and run-off tabs, backing bars, etc. used during welding of the
base metals, as defined by paragraph 6.1 of this specification, shall be of equivalent
material.
8.4.2 Backing bars, spacers, tabs, etc. shall be completely removed.
9.0 STRESS RELIEF (HEAT TREATMENT)
9.1 Stress relief shall be performed after all welding has been completed, but before final
machining.
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WELDING, SPEC. NO. A06-000009 REV 7
FABRICATION, PAGE: 11 of 18
AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
EXAMPLE POSITIONS FOR MILL SHELLS DURING STRESS RELIEF
* PREFERRED POSITION:
B R A C I N G
L O C A T I O N
F L O O R
S I D E V I E W *
BRACING LOCATION
FLOOR FLOOR
SUPPORT UNDER
BRACING
BRACING LEG MUST BE PERPENDICULAR
TO SUPPORTS UNDER SHELL
END VIEW SIDE VIEW
FIGURE 9.2
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WELDING, SPEC. NO. A06-000009 REV 7
FABRICATION, PAGE: 12 of 18
AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
9.2 It shall be the responsibility of the manufacturer to ensure dimensional stability during
stress relief by use of additional temporary bracing, stiffeners, or other adequate means.
All bracing or temporary attachments shall be properly vented. Drawings and
procedures shall be submitted to Division Engineering/Quality Assurance for review.
(See Figure 9.2)
9.3 Stress relief shall conform to the following requirements.
9.3.1 The temperature of the furnace shall not exceed 600 F (315 C) at the time the weld
assembly is to be placed inside.
9.3.2 Above 600 F (315 C), the rate of heating shall be no more than 400 F (220 C) per
hour divided by the maximum metal thickness of the thickest part in inches*, but in no
case more than 400 F (220 C) per hour. During the heating period, variation in
temperature throughout the part being heated shall be no greater than 250 F (140 C)
within any 15 feet (4.6 m) interval of length.
*The rates of heating and cooling need not be less than 100 F (55 C) per hour.
However, in all cases, consideration of closed chambers and complex structures may
indicate reduced rates of heating and cooling to avoid structural damage due to
excessive thermal gradients.
9.3.3 After a mean temperature range between 1100-1200 F (590-650 C) is reached, the
temperature of the part shall be held within this range for a time not less than that
specified in Table 9.3.3, based on the thickness of the thickest weld. During the holding
period, there shall not be a difference greater than 150 F (84 C) between the highest
and lowest temperature throughout the part being heated. Hold time shall start when
the lowest thermocouple reading reaches 1100 F (590 C).
t 1/4 inch
t (6.4 mm)
2 inches t > >> > 1/4 inch
(50.8 mm) t > >> > (6.4 mm)
t > >> > 2 inches
t > >> > (50.8 mm)
2 hours + 15 minutes
15 minutes 1 hour/inch (25.4 mm) for each additional inch (25.4 mm)
over 2 inches (50.8 mm)
NOTE: t = thickness of weld
TABLE 9.3.3
9.3.4 Above 600 F (315 C), cooling shall be done in a closed furnace or cooling chamber at
a rate no greater than 500 F (278 C) per hour divided by the maximum metal thickness
of the thickest part in inches*, but in no case more than 500 F (278 C) per hour. From
600 F (315 C) the assembly may be cooled in still air.
*The rates of heating and cooling need not be less than 100 F (55 C) per hour.
However, in all cases, consideration of closed chambers and complex structures may
indicate reduced rates of heating and cooling to avoid structural damage due to
excessive thermal gradients.
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AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
9.3.5 A minimum of four (4) thermocouples shall be attached to each piece being stress
relieved, and temperature charts shall be maintained and submitted to Division
Engineering/Quality Assurance. One thermocouple shall be attached to the thinnest
section and one to the thickest section of the piece. The number of thermocouples may
be reduced with the approval of Division Engineering/Quality Assurance.
10.0 INSPECTION
a. A report shall be submitted for each nondestructive testing (NDT) inspection
performed, including repairs.
b. Additional testing may be required by Quality Assurance, if weld repairs are
excessive.
10.1 MATERIALS INSPECTION
10.1.1 Prior to acceptance for use in fabrication, all plate shall be visually (VT) inspected in the
following manner:
a. No laminar discontinuities shall be permitted. Repair or rejection of plate shall be
decided by Division Engineering/Quality Assurance prior to any weld repair.
b. If approved for repair by Division Engineering/Quality Assurance, laminar
discontinuities shall be gouged out and the affected area shall be weld repaired.
Laminar discontinuities too large to be economically weld repaired shall be
repaired by cutting out the affected area and welding a section of sound plate in its
place.
c. Weld repair procedures shall be in accordance with the requirements of this
specification.
d. Repair welds shall have the same quality requirements as finished welds. Testing
shall be performed immediately following repairs.
10.1.2 Prior to acceptance for use in fabrication, all plate shall be ultrasonically (UT) inspected
in the following manner:
a. Inspection shall be in accordance with ASTM A578 - Standard Specification for
Straight-Beam Ultrasonic Examination of Plain and Clad Steel Plates for Special
Applications.
b. 9-inch grid of plate surface shall be tested.
c. Acceptance criteria shall be ASTM A578 Level B, as follows:
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AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
Any area where one or more discontinuities produce a continuous total loss of
back reflection accompanied by continuous indications on the same plane that
cannot be encompassed within a circle whose diameter is 3 inches (75 mm), or 1/2
of the plate thickness, whichever is greater, is unacceptable.
In addition, two or more discontinuities smaller than described above shall be
unacceptable unless separated by a minimum distance equal to the greatest
diameter of the larger discontinuity or unless they may be collectively
encompassed by the circle described above.
10.2 INSPECTION OF FLAME CUT OR MACHINED EDGES PREPARED FOR WELDING
10.2.1 Visual (VT) inspection shall be performed on all edges prepared for welding as follows:
a. Visual (VT) inspection for linear indications shall be in accordance with paragraph
10.1.1 of this specification.
b. In addition notches shall be repaired in accordance with AWS D1.1 paragraph
5.15.
10.2.2 Ultrasonic (UT) inspection shall be performed on all steel plate in accordance with
ASTM A578 and in the following manner:
a. 100% of plate within 2 lineal inches (50 mm) of prepared edges or within twice the
thickness of the plate, whichever is greater.
b. 100% of all flange material.
c. Acceptance criteria shall be as follows:
i. Cylinder Plates
A. ASTM A578 Level B, as follows:
Any area where one or more discontinuities produce a continuous total loss
of back reflection accompanied by continuous indications on the same
plane that cannot be encompassed within a circle whose diameter is 3
inches (75 mm), or 1/2 of the plate thickness, whichever is greater, is
unacceptable.
In addition, two or more discontinuities smaller than described above shall
be unacceptable unless separated by a minimum distance equal to the
greatest diameter of the larger discontinuity or unless they may be
collectively encompassed by the circle described above.
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AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
ii. Flange Material, Cone Plates and Trunnion Ring Bolting Material
A. All discontinuities causing complete loss of back reflection are unacceptable.
B. For material 1 inches and thicker, all indications with amplitudes equal to
or greater than 50% of the initial back reflection and accompanied by a
50% loss of back reflection that cannot be encompassed within a 3 inch
(75 mm) diameter circle are unacceptable.
d. If approved by Division Engineering, plate may be repaired in accordance with this
specification.
10.3 ADDITIONAL INSPECTION OF CONTOURED FLANGES
10.3.1.1 Magnetic particle (MT) inspection, using dry method, after rough machining shall be
performed as follows:
a. All weld prep areas.
b. Contour radius side of flange that does not receive additional machining.
10.3.2 Magnetic particle (MT) inspection, using dry or wet method, after final machining shall
be performed on all machined surfaces.
10.3.3 Acceptance criteria for magnetic particle (MT) inspection of contoured flanges shall be
as follows:
a. No linear indications larger than 1/8 inch (3.2 mm).
b. No rounded indications larger than 1/8 inch (3.2 mm).
10.4 WELD INSPECTION
10.4.1 WELD INSPECTION CRITERIA FOR VT, MT, AND UT
Any rejectable areas after stress relief must be reviewed by Division Engineering/Quality
Assurance on an individual case basis to determine approved procedures for repair and
repeat of stress relief. No procedure using air arc or welding will be permitted after
stress relief without a repeat of stress relief.
10.4.1.1 VISUAL (VT) INSPECTION CRITERIA - ALL WELDS
Acceptance criteria shall be as follows:
a. The weld has no cracks.
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AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
b. Thorough fusion exists between adjacent layers of weld metal and between weld
metal and base metal.
c. All craters are filled to the full cross-section of the weld.
d. Weld profiles shall be in accordance with AWS D1.1, Section 5.24 and paragraph
7.4 of this specification.
e. The frequency of piping porosity in fillet welds shall not exceed one (1) instance in
each 4 inches (100 mm) of length, and the maximum diameter shall not exceed
3/32 inch (2 mm).
f. A fillet weld in any single continuous weld shall be permitted to underrun the
nominal fillet weld size required by 1/16 inch (1.6 mm) without correction, provided
that the undersize portion of the weld does not exceed 10 percent (10%) of the
length of the weld.
g. Complete joint penetration groove welds in butt joints transverse to the direction of
computed tensile stress shall have no piping porosity. For all other groove welds,
the frequency of piping porosity shall not exceed one (1) instance in each 4 inches
(100 mm) of length, and the maximum diameter shall not exceed 3/32 inch (2 mm).
h. Undercut shall be no more than 0.01 inch (0.25 mm) deep if the weld is transverse
to the primary stress direction in the part that is undercut. Undercut shall be no
more than 1/32 inch (1 mm) deep if the weld is parallel to the primary stress
direction in the part that is undercut.
i. All welds designated per the drawing shall be contoured by grinding to provide a
gradual and smooth transition between base metal and weld metal. Grinding shall
be performed in accordance with paragraph 7.4 of this specification.
10.4.1.2 MAGNETIC PARTICLE (MT) INSPECTION CRITERIA - ALL WELDS
a. Magnetic particle inspection shall be performed in accordance with ASTM E709 -
Standard Guide for Magnetic Particle Examination.
b. Acceptance criteria shall be to AWS D1.1 statically loaded in table 6.1 for all
welds.
10.4.1.3 ULTRASONIC (UT) INSPECTION CRITERIA - FULL PENETRATION WELDS
a. Ultrasonic inspection shall be performed in accordance with AWS D1.1, Section 6,
Part F.
b. Acceptance criteria shall be to AWS D1.1, table 6.2, for all welds.
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AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
c. All weld reinforcements shall be ground smooth, so that proper coupling is
achieved between the ground surface and the transducer.
d. All full penetration welds shall be scanned with 45, 60, and 70 angles at 20 dB
over reference level when single leg (Leg 1) is used, otherwise AWS D1.1 must be
followed.
e. Additional inspection for full penetration tee and corner welds shall be as follows:
i. Ultrasonic inspection shall be performed from the surface opposite the weld for
a distance equal to twice the weld thickness. (See Sketch 10.4.1.3)
2 t
t
T r a n s d u c e r
SKETCH 10.4.1.3
ii. The method used shall be as described by ASTM A435 - Standard
Specification for Straight-Beam Ultrasonic Examination of Steel Plates.
iii. Material separation or lamellar tears shall be rejected.
f. All full penetration welds shall be tested for transverse cracks.
g. Additional procedures may be required by Division Engineering/Quality Assurance
due to joint configuration.
10.4.2 EXTENT OF WELD INSPECTION
10.4.2.1 UPON COMPLETION OF ALL WELDS OR PRIOR TO STRESS RELIEF
a. Visual (VT) Inspection: All welds shall be visually inspected 100% over their entire
length.
b. Magnetic Particle (MT) Inspection: All welds shall be magnetic particle inspected
100% over their entire length.
c. Ultrasonic (UT) Inspection: All full penetration welds shall be ultrasonically
inspected 100% over their entire length.
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WELDING, SPEC. NO. A06-000009 REV 7
FABRICATION, PAGE: 18 of 18
AND INSPECTION APPROVED BY: VS
REQUIREMENTS - ISSUE DATE: 10 March 2004
MILL SHELLS SUPERSEDE DATE: 11 Oct 2000
10.4.2.2 AFTER STRESS RELIEF
a. Magnetic Particle (MT) Inspection: All welds shall be magnetic particle inspected
100% over their entire length.
b. Ultrasonic (UT) Inspection: Full penetration welds shall be ultrasonically inspected
10%. When testing reveals rejectable indications, 100% of the entire weld joint
shall be tested.
10.4.2.3 After stress relief, any rejectable areas must be reviewed by Division Engineering/
Quality Assurance on an individual case basis to determine approved procedures for
repair and repeat of stress relief. No procedure using air arc or welding will be permitted
after stress relief without a repeat of stress relief.
10.5 OTHER REQUIREMENTS FOR INSPECTION
10.5.1 Any additional inspection to be performed shall be described on detail drawings or in
special addendums to this specification.
10.5.2 Additional testing, as mentioned in paragraph 10.0 of this specification, shall be
addressed in writing.
11.0 QA DOCUMENTATION TO BE SUBMITTED
The following documents are to be submitted when the following inspections or
processes are to be performed (per this specification).
11.1 MATERIAL CERTIFICATIONS: [including ultrasonic (UT) inspection reports of raw
materials, if performed at the mill.]
11.2 NONDESTRUCTIVE TEST (NDT) REPORTS
11.2.1 MAGNETIC PARTICLE (MT) INSPECTION
a. Reports for plate prepared for welding
b. Reports for welds before and after stress relief
11.2.2 ULTRASONIC (UT) INSPECTION
a. Reports for plate prepared for welding
b. Reports for welds before and after stress relief
11.3 HEAT TREATMENT RECORDS
11.4 RECORD OF DIMENSIONAL INSPECTION