CG-47 CLASS ALUM SUPERSTRUCTURE - PSSRApssra.org/wp-content/uploads/2015/05/PCP_CG-47CLASs... · Web viewMIL-STD-2035A (SH) Nondestructive Testing Acceptance Criteria S9074-AQ-GIB-010/248

THIS SHEET IS ONLY A PLACE HOLDER.PLEASE REPLACE IT WITH

THE SWRMC COVER SHEET.

1[Revised November 26, 2012]

PROCESS CONTROL PROCEDURE FORCG-47 CLASS SUPERSTRUCTURE CRACK REPAIR

(INCLUDING SHIPALTS)

TABLE OF CONTENTS

SECTION PAGE

1.1 SCOPE.…………………………………………………………………........ 4 1.2 PURPOSE…………………………………………………………..…......... 4 1.3 REFERENCES……………………………………………………..….……. 4 1.4 ENCLOSURES………………………………………………………........... 5 2.1 QUALIFICATION REQUIREMENTS…………………………………....... 5 2.2 DIRECT KNOWLEDGE….…………………………………………..…….. 5 3.1 MATERIAL/EQUIPMENT………………………………….………..……... 6 3.2 SAFETY EQUIPMENT……………..………………………………..……... 6 3.3 SAFETY PRECAUTIONS…………..……………………………………… 6 3.4 PREPARATION…….…..………………...…………………….…………... 7 3.5 START OF PROCEDURE…………………………………………………. 7 3.6 ENVIRONMENTAL CONTROL…….…………………..………................ 8 3.7 JOINT PREPARATION………..…..………………………………...……… 8 3.8 JOINT DESIGN AND FITUP REQUIREMENTS…………..………..……. 9 3.9 CRACK REPAIR METHODS…………………………………………........ 10 3.10 WELDING EQUIPMENT AND SUPPLIES ……….………………...……. 10 3.11 WELDING REQUIREMENTS……………….….……….……….…………. 11 3.12 PREHEATING AND INTERPASS TEMPERATURE…………………...... 12 3.13 DISTORTION CONTROL/WELD BALANCING………………………...... 12 3.14 TACK WELDS………………………………………………………………... 13 3.15 BUTT WELDS AND JOINTS……………………………………………….. 13 3.16 BUTT JOINTS WELDED FROM ONE SIDE……………………………… 13 3.17 BUTT JOINTS WELDED FROM BOTH SIDES………………………….. 14 3.18 BIMETALLIC STRIP………………………………………………………… 14 3.19 CRITICAL ATTACHMENT (FILLET) WELDS……………………………. 14 3.20 SURFACE FINISHING OF WELDS………………………………………. 15 3.21 WELD NDT INSPECTION REQUIREMENTS…………………………… 16 3.22 IN-PROCESS NDT INSPECTION………………………………………… 16 3.23 FINAL ACCEPTANCE NDT INSPECTION………………………………. 17 3.24 INSPECTION ACCEPTANCE CRITERIA………………………………... 18 3.25 REPAIR OF WELD DEFECTS…………………………………………….. 18 3.26 IDENTIFICATION OF DEFECT AREAS………………………………….. 18 3.27 INSPECTION/DOCUMENTATION FORMS……………………………… 19 3.28 OBJECTIVE QUALITY EVIDENCE……………………………………….. 19 3.29 CONTROL OF THE PROCEDURE……………………………………….. 19 4.1 HAZARDOUS MATERIAL…………………………………………………… 19 5.1 LOCAL REGIONAL AND STATE REQUIREMENTS…………………….. 20


TABLE OF CONTENTS (CONTINUED)

APPENDICES PAGE 1) PCP Direct Knowledge Attendance Form………………………………. 212) Weld Technique Sheet……………………………...……………….……. 223) Weld In-Process Control/NDT Record ………………………………….. 234) Weld Defect Repair Record ……………………………………………… 245) Acceptable Groove/Fillet Weld Profiles………………………………..... 256) Definition of Critical/Non-Critical Fillet Welds…………………………… 267) Cleanliness Record……………………….……………………………….. 278) Shielding Gas Dew Point Record………………………………………… 289) Preheat/Interpass Temperature Record…………………………………. 2910) ShipAlt Accountability Record…………………………………………….. 30


1 SECTION 1 IDENTIFICATION1.1 SCOPE

1.1.1 This procedure applies to critical welds as defined by References (h) for the repair of Aluminum Superstructure Cracking. This procedure meets the specific requirements of paragraphs 5-9.6 thru 5-9.6.2 of Reference (g) Technical Manual for CG-47 Class Superstructure Cracking Repair S9CGO-BP-SRM-010/CG-47 CL. This procedure furthermore meets the requirements of References (a) through (h) and Enclosure (1).

1.1.2 While the scope of Reference (g) is for the repair of CG-47 class superstructure cracking it may also be invoked for Ship Alterations installed to reinforce CG-47 class superstructure and preclude further cracking. When this PCP is used in way of accomplishing Ship Alterations (S/A), the requirements of the S/A apply and not the Crack Repair Methods identified in Section 3.9.

NOTE:Process Control Procedures (PCPs) are SWRMC Code 200 approved documents for contractor execution of a specific repair item. PCPs are to be followed as written. However there may be circumstances where the PCP needs to be revised to meet field conditions. Revisions that in the opinion of the SWRMC Onsite Rep and the SWRMC Code 200 signatory are minor and do not degrade the overall performance of the process, require contract modifications, or significantly alter the scope of the work may be made onsite by the SWRMC Onsite Rep with concurrence of the SWRMC Code 200 PCP signatory. Changes will be noted with name, time, date and signature of SWRMC Code 200/Onsite Rep making the change on the KTR's copy of the PCP as pen-and-ink changes. The KTR will submit a formal revision to [email protected] (SWRMC PCP Inbox) within 3 working days of the pen-and-ink change. The PCP revision policy is stated in SWRMC SOP-225-002

1.2 PURPOSE1.2.1 The purpose of this procedure is to correct and/or minimize fatigue cracking that

has occurred in the aluminum superstructure of the CG 47 Class ships. In order to achieve satisfactory performance, high quality welding is imperative. The goal is to obtain welds which contain no rejectable defects while minimizing weld repair cycles.

1.2.2 NOTE: Aluminum Plate and sheet material shall be procured to ASTM B928/B 928 M Standard Specification for High Magnesium Aluminum-Alloy Sheet and Plate for Marine Service and Similar Environments and shall be procured, inspected, handled and stored per paragraph 3.1, 3.2 and 3.3 respectively of Reference (h).

1.3 REFERENCESa) NAVSEA Standard Items

b) MIL-STD-1689A (SH) Fabrication, Welding, and Inspection of Ships structure

c) MIL-STD-22D Welded Joint Design

d) T9074-AS-GIB-010/271 Requirements for Nondestructive (NDT) Testing Methods

e) MIL-STD-2035A (SH) Nondestructive Testing Acceptance Criteria


mailto:[email protected]

f) S9074-AQ-GIB-010/248 Requirements for Welding and Brazing Procedure and Performance Qualification

g) S9CGO-BP-SRM-010/CG-47 Class Superstructure Cracking Repair

h) SERMC DM 10-623 Rev B

1.4 ENCLOSURES1 Work Item/ MOD

2 Welder Qualifications

3 NDT Inspector Qualifications

4 Joint Design

5 Location of Work (Sketches)

6 Weld sequencing and Fixturing Plan

7 Material Certification Index

8 Nondestructive Inspection Report

2 SECTION 2 PERSONNEL QUALIFICATION2.1 QUALIFICATION REQUIREMENTS

2.1.1 Welders will be currently qualified in accordance with Reference (f). Welder qualifications shall be identified in Enclosure (2). Additions to Enclosure 2 shall be made by “Pen and Ink” and shall be initialed by the Welding Supervisor.

2.1.2 NDT Inspectors will be qualified in accordance with Reference (d). NDT Inspector qualifications shall be identified in Enclosure (3). Additions to Enclosure 3 shall be made by “Pen and Ink” and shall be initialed by the appropriate NDT Level III Inspector (i.e. Inspec Testing will change Inspec Testing; BAE will change BAE, etc.).

2.2 DIRECT KNOWLEDGE2.2.1 A briefing will be conducted prior to beginning work to ensure personnel

accomplishing this procedure have direct knowledge of the requirements of this procedure and the safety requirements of the job. Accomplishment of the briefing will be documented on Appendix 1.

2.2.2 Method utilized to ensure complete knowledge of the job:2.2.2.1 All personnel shall have a thorough knowledge of this procedure and

complete understanding of the system being worked, prior to starting work.

2.2.2.2 All personnel shall have the ability to foresee and resolve potential problem areas, and to complete the job in a timely yet efficient manner.

3 SECTION 3 PROCESS DESCRIPTION3.1 MATERIAL/EQUIPMENT


3.1.1 Fabrication Equipment: Welding Machine properly grounded per 009-12 (Welding, Fabrication, and Inspection Requirements; accomplish) of Reference (a), Welding Leads, Torch, Stinger, Portable Rod Oven/Rod Pouch, Pre/Post heat devices.

3.1.2 Welding equipment shall be of the specified type, in good repair, and properly adjusted. The equipment shall correspond to the type used for qualification of the weld procedure. For conventional GMAW, a constant voltage power source with constant wire feed speed is recommended. A constant voltage power source compensates for changes in arc length by varying the current, which affects the heat input and varies weld penetration.

3.1.3 Consumables: Weld Rod/filler material, Shielding Gasses, Torch Gas

3.1.4 Temperature Measuring Devices suitable for aluminum (Preheat and Interpass), digital thermometer, dewpoint indicator, all with current calibration

3.1.5 Cleaning Tools: White cleaning cloth, Carbide burr, Stainless steel wire brush, Aluminum oxide coated fiber wheels, and abrasive disks

3.1.6 Cleaning solvent: Denatured alcohol, Acetone, isopropyl alcohol or Met-L-Chek E-59A

3.1.7 Only manually operated, electric drive, or rear exhausted pneumatic tools shall be used for cleaning

3.1.8 Temporary enclosure materials

3.1.9 General Hand Tools as Required

3.2 SAFETY EQUIPMENT3.2.1 Ventilation (as required by Marine Chemist Certification)

3.2.2 Respiratory Protection: (When required)

3.2.3 Safety Clothing (PPE)

3.2.4 Welding Hood with Flash Burn Protection

3.2.5 Eye Protection

3.2.6 Gloves/long sleeve shirt (recommended)

3.2.7 Proper fire extinguishing agent

3.2.8 Fire Protection Covering

3.3 SAFETY PRECAUTIONS3.3.1 Accomplish the requirements of NSSI 009-07, (Confined Space Entry,

Certification, Fire Prevention and Housekeeping; accomplish) Reference (a).

WARNING: To prevent build up of fumes, sufficient time shall be given for evaporation and ventilation of any solvent used for cleaning prior to hot work.


3.3.2 When required, accomplish the requirements of NSSI 009-24 (Tag out, Isolation, Blanking, and Tagging Requirements; accomplish) Reference (a). Work authorization (WAF) shall be obtained.

3.3.3 When required, accomplish the requirements of 009-112 of Reference (a). for Radiographic Testing (RT), this shall include the submission of Attachment “A” no later than 5 working days prior to the scheduled test date.

3.4 PREPARATION3.4.1 Stage all required Materials for verification at the Start of Procedure Checkpoint.

3.5 START OF PROCEDURECHECKPOINT (I) (G) "START OF PROCEDURE"3.5.1 Start of this procedure is a CHECKPOINT IAW Paragraph 3.4 of NAVSEA

Standard Item 009-09 Process Control Procedure (PCP) Reference (a). Notify the QA office 4 hours prior to starting this procedure.

3.5.2 [email protected] shall be Included when notifying the government of required NDT “G” Check Points.

3.5.3 Identification of material shall be visually verified at the point of initial fabrication as being the same material identification or an approved alternate material identification as required by the installation plan or work item in accordance with paragraph 6.2.1 of Reference (b).

3.5.3.1 Aluminum plate, sheet metal and filler material shall be listed in Enclosure (7). All aluminum plate and sheet metal shall conform to ASTM-B928/B928M in accordance with paragraph 3.1 of Reference (h), unless otherwise directed by NAVSEA or Code 200.

3.5.3.2 All filler material shall conform to AWS A5.10 with Schedule J lot conformance testing in accordance with paragraph 3.1 of Reference (h).

3.5.3.3 Additions to Enclosure (7) will be made by “Pen and Ink” and signed by the Welding Supervisor or Quality Assurance Inspector.

3.5.4 Paragraph 5-9.6.1 of Reference (h) requires written sign-off of Key Fabrication Steps. Key Fabrication Step sign-offs will be accomplished as (I) or (I)(G) checkpoints in accordance with NAVSEA Standard Item 009-04 of Reference (a). The minimum Key Fabrication Steps required by Reference (h) are as follows:

3.5.4.1 (I)(G) Section 3.6 Protective Enclosure Installation3.5.4.2 (I)(G) Section 3.7 Joint Prep3.5.4.3 (I)(G) Section 3.8 Fit-Up3.5.4.4 (I) Section 3.22 5X Visual Inspection of Root Welds3.5.4.5 (I) Section 3.22 5X Visual Inspection of Back Gouge (When Required)3.5.4.6 (I) Section 3.22 5X Visual Inspection of the Final Weld Surface3.5.4.7 (I)(G) Section 3.23 PT and UT of Final Weld Surface

3.5.4.8 (I)(G) Sections 3.25 and 3.26 Any re-work/repair resulting from final NDT or after two weld repair cycles of a completed weld as defined in MIL-STD-1689 are accomplished and



involves repair welding1

Note 1: The contractor will be allowed two repair cycles to accomplish the weld prior to mandatory government oversight. If the weld does not pass final NDT after two repair cycles, the remaining work shall be accomplished at the discretion of NSA Code 200. If additional weld repair cycles are determined to be necessary, checkpoints 3.5.4.5 – 3.5.4.6 (and 3.5.4.7 as required) will become (I)(G) checkpoints through the completion of that specific weld sequence.

3.6 ENVIRONMENTAL CONTROL - Section 4.0 of Reference (h)(I)(G) “Protective Enclosure Installation” (Key Fabrication Step Sign-Off IAW Para. 3.5.4)

3.6.1 For welding in outside or exposed locations a taut or rigid, draft free protective enclosure shall be erected around area to be welded in such a manner as to ensure that shield gas will not be disturbed.

3.6.2 Enclosures shall provide adequate protection from the elements to prevent rain or other precipitation from contaminating the weld with moisture and to provide a still atmosphere (draft free) to ensure stability of the shield gas.

NOTE: High levels of moisture in the weld atmosphere are a major contributor to porosity in the weld. Even momentary interruption of the shield gas will adversely affect weld quality.


3.6.3 Protection provided by the enclosure shall be such that a common paper match will burn without interference. The match test shall be accomplished when containment is erected and whenever the containment has been repaired due to damage.

3.7 JOINT PREPARATION - Section 6 of Reference (h)Note: It is noted that PT inspection requirements cited in Reference (h) shall not be substituted with 5X VT inspections(I)(G) “PT INSPECTION OF BASE METAL”

3.7.1 The surfaces to be welded and adjacent surfaces shall be inspected 100 percent a minimum of 1/2 inch on both sides from the expected weld area using penetrant inspection (PT) prior to fit-up and repair welding.

3.7.2 For pre-existing material in the exterior of the deckhouse and sensitized material in the interior of the deckhouse, the 100 percent surface PT inspection shall be expanded to the 4 inches from the weld joint.

3.7.3 For pre-existing non-sensitized material in the interior of the deckhouse, a minimum of 1/2 inch on both sides from the expected weld area shall be PT inspected. The PT inspected surfaces shall be free of discontinuities such as

1


linear indications or defects that may affect weld quality or the condition of the base material.

3.7.4 The purpose of the PT inspection is to ensure that weld repair is made to sound base material. If discontinuities exist, a Condition Found Report (CFR) or similar reporting document shall be submitted, which document recommendations discussed between the contractor and the NSA. NSA Code 200 shall judge severity of discontinuities and determine which defects shall be repaired prior to fit-up and welding.

3.7.5 Once the above PT inspection is satisfactory, it shall be documented on Enclosure (8).

3.7.6 The surfaces to be welded and adjacent surfaces, including faying surfaces of attachment (fillet) welds, shall be thoroughly cleaned no less than a minimum of 4 inches on both sides from the expected weld area prior to fit-up and welding.

3.7.7 Surfaces shall be cleaned and solvent wiped with an approved ship board solvent and shall have the oxide film removed to bright metal by an approved mechanical or chemical means.


NOTE: Welding shall take place within six (6) hours after oxide film removal or the joint surface is to be re-cleaned. Date and Time of Inspection shall be documented on Appendix 7.

3.7.8 Solvent wipe to remove oil coating prior to use. Any items used for joint preparation which become contaminated shall be discarded and removed from the site.

3.7.9 Only manually operated, electric drive or rear exhaust pneumatic tools shall be used for cleaning. Tools being used shall be of low R.P.M.’s. All Starts and stops in the welding process shall be cleaned by approved mechanical means immediately prior to welding.

NOTE: Experience has shown that contamination of the surface to be welded is a major contributor to porosity and other critical weld defects. Care in selection of materials, good work habits, and attention to detail are essential to obtaining high quality welds and avoiding unnecessary and detrimental re-work.

3.7.10 Interpass Cleaning. After each weld pass, the weld shall be manually brushed with a clean stainless steel wire brush. Wire brushing after each pass removes

any residual soot that may have deposited on the weld bead and adjacent base metal. Removing the soot will help prevent the formation of porosity and lack of fusion in the subsequent weld passes.

3.8 JOINT DESIGN AND FIT-UP REQUIREMENTS - Section 6.3 of Reference (h)(I)(G) “Fit Up Inspection” (Key Fabrication Step Sign-Off IAW Para. 3.5.4)


3.8.1 Welded joint design and fit-up shall be in accordance with Reference (c) and the following additional requirements:3.8.1.1 When new plating is used to facilitate crack repairs, the new plate shall be

1/8” inch thicker than the existing plate per Section 4 of Reference (g).3.8.1.2 Appendix 2 shall be documented to reflect the existing (A) and new (B)

plating thicknesses.3.8.1.3 The edges of the thicker plate will be tapered to a four to one (4:1) slope

to conform to the thickness of the thinner plate.

Note: New plate 1/8 in. requirement is not applicable to SHIPALT’s. Work accomplished by ShipALT’s shall be in accordance with NAVSEA design drawings.

3.8.2 Weld joints and faying surfaces shall be prepared by sawing or routing using no lubricants.

3.8.3 Alignment tolerances and maximum allowable deviation shall be in accordance with the requirements of Reference (b) paragraph 12.3.1 and TABLE XIX.

3.8.4 Fairness shall be in accordance with the requirements of Reference (b).

3.8.5 Existing welds which are intersected by welds accomplished for this repair shall be cutback and re-welded for a distance of six (6) inches from the weld intersection.

3.9 CRACK REPAIR METHODS - Section 4-8 of Reference (g)

3.9.1 Temporary ceramic backing strips shall be used for crack and insert repairs if feasible. Use of ceramic backing strips has historically resulted in improved weld quality and cost savings through reduced NDT.

3.9.2 Table 1 below identifies typical crack repair methods which are found in Reference (g). Check the box of the applicable method(s) and add a copy of the applicable repair process paragraph(s) (including figure(s)) to this Process Control Procedure as part of Enclosure (4). The Paragraphs and Figures identifying repairs not part of the scope of work this PCP shall be left out when submitting for approval. NDT shall be accomplished in accordance with Paragraphs 3.21 thru 3.24 of this PCP.

TABLE 1Para. Typical Crack Repair Methods Applicable


No. to this PCPBase Metal Repair

4-8.1 Repair of Cracks in a Flat Plate

4-8.2 Repair of Crack in a Flat Plate That Extends Across a Structural Member

4-8.3 Repair of a Crack by a Plate Insert That Does Not Cross a Structural Member

4-8.4 Repair of a Crack by a Plate Insert Which Crosses a Structural Member

4-8.5 Repair of a Cracked Tee Beam to Plate Weld4-8.6 Repair of a Cracked and Tripped Tee Beam Frame

4-8.7 Repair of Cracked Welds Intersection of Bulkhead with Deck/Bulkhead

4-8.8 Repair of Cracks Around Structural Openings (Hatchways, Doors, Arches, Ventilation Cuts, Etc.)

4-8.9 Repair of Mast Leg Bracing Member 4-8.10 Repair of Damaged Mast Foundation Structure 4-8.11 Repair of Structural Damaged Fashion Plates

3.10

WELDING EQUIPMENT AND SUPPLIES - Section 5-8 of Reference (g), Section 7 of Reference (h)

3.10.1 Gas tungsten arc welding (GTAW) may be used for installation of pipe that is less than or equal to 2 inches in diameter and to repair isolated defects no more than 6 inches in length when there is no other rejectable area in the weld for a distance of not less than 24 inches in either direction measured along the weld axis in accordance with Reference (g).

NOTE: An isolated defect is a single rejectable area less than six inches in length such that there is no other rejectable area in the weld for a distance of not less than 24 inches in either direction when measured along the weld axis.

3.10.2 Shielding gases shall be checked and verified for acceptable dew point prior to welding. Any traces of air or moisture in the shielding gas will affect weld quality.

3.10.3 The gas delivery system and/or welding equipment shall be checked for leaks to avoid contaminating the shielding gas. Non-rubber hoses shall be used.

3.10.4 Hoses shall be a maximum of 100 feet in length and shall be limited to one mid-length connection to minimize the distance between the gas bottle and work area. Deviation from the maximum 100 foot inert gas hose requirement is allowed with local NSA, C200 approval.

3.10.5 The shielding gas dew point shall be checked as follows in accordance with Reference (h):3.10.5.1 Shielding gas dew point shall be -40º F or less when measured at the

welding torch head.3.10.5.2 Shielding gas dew point shall be verified to be -40º F or less at the torch

head prior to commencing welding on any shift.3.10.5.3 The welding apparatus shall be pre-purged with shielding gas for a


minimum of 10 seconds prior to welding. The rationale for this requirement is that there has been a downward trend in porosity levels since this requirement was employed.

3.10.5.4 The welding apparatus shall be purged and the shielding gas dew point shall be verified to be -40º F or less at the torch head each time there is a change in gas source or supply connection (e.g. gas bottle change or hose connection to manifold change).

3.10.5.5 Inert gas shall be water pumped or liquid pumped, not oil pumped.3.10.5.6 Quality Conformance Certification documentation shall be maintained for

procured shielding gas.3.10.5.7 Shielding gas dew point readings shall be documented on Appendix 8.

3.11 WELDING REQUIREMENTS - Section 5-4 of Reference (g), Section 7.0 of Reference (h)3.11.1 Aluminum Structural components shall be fabricated in accordance with the

workmanship requirements References (b), (g) and (h).

3.11.2 Appendix 2 shall be used to document weld procedure parameters and base / filler material information.

3.11.3 Ship alterations (SHIPALT’s) shall be indentified on Appendix 10 and weld joints documented on Appendix 3.

3.11.4 Cracks repaired by welding or by insert shall be identified on Enclosure (5) and documented on Appendix 3.

3.11.5 All weld/NDT inspections shall be documented on Appendix 3 except that UT inspection reports shall be provided by NDT Inspector on Enclosure (8).

3.11.6 All defect repairs shall be documented on Appendix 4.

3.11.7 Weld rework is time consuming, expensive and rapidly becomes counterproductive to the basic intent of the repair. Repeated welding in a single area enlarges the heat affected zone and adversely affects the base metal. Satisfactory weld quality can be achieved with a minimum of rework if there is a consistent high level emphasis on preparation, maintenance of cleanliness, exclusion of moisture, enforcement of process control, and correct welding techniques.

3.11.8 A primary requirement for quality aluminum welding is that the welding torch be angled in the direction of the welding. Use of either a vertical or drag torch angle inhibits the cleaning action of the welding arc. This in turn results in entrapment of oxide and welding smut, leading to lack of fusion and porosity defects. A welder can observe if proper cleaning is taking place by watching the edges of the weld puddle.

3.12 PRE-HEATING and INTERPASS TEMPERATURE


3.12.1 The welding surface shall be moisture free.

3.12.2 If required, preheating temperature shall be to a minimum of 60º F and maximum of 150º F and shall not be applied for longer than 30 minutes.

3.12.3 In accordance with MIL-STD-1689, preheating of 5XXX series aluminum alloys between 150º F to 450º F shall be avoided. Heating 5XXX series aluminum alloys between 150º F and 450º F for a prolonged period of time can result in the metal becoming sensitized and susceptible to stress corrosion cracking.

3.12.4 The maximum interpass temperature shall be 150º F. It is noted that 110º F interpass temperature is considered optimal. A high interpass temperature can result in slower cooling rates in the weld metal and heat affected zone (HAZ).

3.12.5 Temperature shall be checked by surface contact pyrometers or other temperature measuring devices suitable for aluminum. Temperature indicating crayons shall not be used. Document pre-heat and interpass temperature readings on Appendix 9.

3.13 DISTORTION CONTROL / WELD BALANCING AND SEQUENCING3.13.1 Structural fit-up methods and alignment procedures shall conform to 1689A for

guidance, and Chapter 4 through 5 of Reference (g); (Superstructure Cracking Repair Manual) Joint designs requirements to Mil-STD-22D.

3.13.2 Temporary Fitting aids fixtures utilized to maintain proper fit-up shall consist of strong backs, along with a series of dog and wedges to maintain proper fit-up alignment and tolerances during welding and/or control contraction during cooling.

3.13.3 After the fixtures are removed, the surface shall be flush with the adjacent metal and shall be inspected with 100 % PT. The PT inspected surfaces shall be free of discontinuities such as cracks and other rejectable defects as specified in Section 3.23 and shall be documented on Enclosure (8).

3.13.4 The order of fit-up and adjustment will be determined as a condition of ship fitting the adjacent surface.

3.13.5 Weld-out Balancing and Sequencing shall be accomplished in segments to minimize distortion and residual stress through utilizing such methods as balance welding around, (i.e., weld 2 or 3 inches, skip 3 or 4 inches and weld another 2 to 3 inches).

3.13.6 In addition, positioning welds near to the neutral axis of the weld structure, along with utilizing weld sequencing or back step welding to minimize distortion. When accomplishing the sequencing plan, weld sequence direction shall be maintained as indicated on the enclosures.

NOTE: Surfaces shall be wiped down with clean solvent soaked rags immediately prior to welding. All Starts and stops in the welding process shall be cleaned by approved mechanical means immediately prior to welding.



3.14 TACK WELDS3.14.1 Tack welds shall be made using qualified procedures and by qualified personnel

in accordance with Reference (f).

3.14.2 Tack welds may be incorporated into the final weld provided the tack welds are visually inspected by 5X VT and defects such as cracks, excessive undercut, entrapped slag, and excessive surface roughness shall be corrected to the extent necessary to assure that the final weld quality requirements will be met.

3.14.3 For tack welds that are not incorporated into the final weld, the tack welds shall be cleaned after tacking.

3.14.4 Prior to welding the final weld, tack welds shall be removed by grinding and the surface area to be welded shall be cleaned as described in Section 3.7.

3.14.5 After removal of tack weld, the surface of the plating in way of the tack weld shall be ground flush. The ground surface shall be inspected by 5X VT and shall be free of surface discontinuities that may affect weld quality.

3.15 BUTT WELDS AND JOINTS3.15.1 For butt welds, only full penetration, 100 percent efficient welds in accordance

with Reference (b) Table XVII and Reference (h) are acceptable.

3.16 BUTT JOINTS WELDED FROM ONE SIDE3.16.1 Welding from one side is preferred.

3.16.2 New temporary ceramic backing strips should be used instead of temporary or permanent aluminum backing strips.

3.16.3 Non-ceramic backing strips may be used only when the far (back) side of the weld is inaccessible or with minor DFS approval.

3.16.4 Butt joints welded from one side shall comply with the following:3.16.4.1 Surfaces shall be cleaned in accordance with Section 3.7.3.16.4.2 Backing strips shall be installed just prior to welding. If six or more hours elapse between

installation of backing strips and start of welding, the backing strip shall be removed and the surface cleaned again.

3.16.4.3 Weld the Root Pass.3.16.4.4 Accomplish the NDT inspection of the Root Pass in accordance with Section 3.22, when

required repair defects and re-inspect until satisfactory.3.16.4.5 Complete the welding of the Final Pass.3.16.4.6 Remove temporary backing, clean, grind, and perform visual inspection of the back side.

When required Remove defects, repair, re-inspect until satisfactory.3.16.4.7 Finish surface by contour grinding all welds in accordance with Section 3.20.3.16.4.8 Perform visual inspection of surface, when required repair defects and re-inspect.3.16.4.9 Perform final PT and RT/UT in accordance with Section 3.23. When required correct defects


and re-inspect until satisfactory.

3.17 BUTT JOINTS WELDED FROM BOTH SIDES3.17.1 Butt joints welded from two sides shall comply with the following:

3.17.1.1 Surfaces shall be cleaned in accordance with Section 3.7.3.17.1.2 Weld the Root Pass.3.17.1.3 Accomplish the Root Pass NDT in accordance with Section 3.22, repair defects and re-

inspect until satisfactory.3.17.1.4 Complete the welding of the Final Pass.3.17.1.5 Back gouge the Root Pass.3.17.1.6 Accomplish the Back Gouge NDT in accordance with Section 3.22.3.17.1.7 Remove all defects by back gouging prior to welding from the second side. Re-inspect to

verify defect removal with the inspection method that was utilized to identify the defect.3.17.1.8 Weld the second side.3.17.1.9 Finish surface by contour grinding all welds in accordance with Section 3.20.

3.17.1.10 Perform visual inspection of finished surfaces, repair defects and re-inspect.

3.17.1.11 Perform final PT and RT/UT in accordance with Section 3.23. Correct defects and re-inspect until satisfactory.

3.18 BIMETALLIC STRIP3.18.1 Welds made to a bimetallic strip shall be done at an interpass temperature of

400°F degrees Fahrenheit or below.

3.18.2 Bimetallic butt welds above and below shall be staggered to minimize distortion.

3.19 CRITICAL ATTACHMENT (FILLET) WELDS3.19.1 The following attachment (fillet) welds are designated as CRITICAL because the

deck house side toes of these welds which connect backup structure and attachments to the house side are susceptible to fatigue cracking. The geometry and the weld quality of these CRITICAL fillet welds must be controlled to minimize the potential for fatigue cracking:

3.19.1.1 Welds joining the 02 or 03 levels with the deckhouse side or the fashion plates in way of the deckhouse side transition.

3.19.1.2 Welds joining the deckhouse side stiffeners and secondary structural members (i.e., foundations, framing for false deck, etc.) to the deckhouse side in way of the deckhouse side transition.

3.19.1.3 Welds joining transverse frames or transverse bulkheads to the deckhouse side only in the transition area (necking down).

NOTE: These attachment welds shall receive the additional surface finishing (contour grinding) in accordance with Section 3.20 and NDT inspection in accordance with Section 3.22. Acceptance standards shall meet the requirements of Reference (g) paragraphs 5-9.5.3 through 5-9.5.4.


3.20 SURFACE FINISHING OF WELDS - Section 7.11 of Reference (h)NOTE: Aluminum welds are prone to fatigue cracking at the weld toes due to geometric discontinuities such as undercut and weld crown re-entry angle. Proper welding techniques can produce the required weld toe contour. In most cases, however, manual welding leads to some undercut and/or non-smooth weld re-entry angle. In such cases contour grinding is required to achieve the required weld toe contour.

3.20.1 Butt Welds3.20.1.1 After welding and prior to performing final NDT, all butt welds which do not meet the weld toe

contour requirements identified on Appendix 6 (Acceptable Groove Weld Profiles In Butt Joints sketch) shall be ground smooth and tapered gradually into the weld base metal.

3.20.1.2 The toes of welds shall have a smooth re-entry angle into the base plate of 180° degrees.3.20.1.3 The contoured surface shall not reduce the thickness of the thinner base metal by more than

10% or 1/64” inch, whichever is less.

NOTE: When contour grinding is used the final grinding marks should be perpendicular to the weld axis to maximize fatigue improvement. Grinding is not required if an acceptable weld profile exists at the completion of welding.

3.20.2 Critical Attachment (Fillet) Welds3.20.2.1 After welding and prior to performing final NDT, the attached (fillet) welds identified as critical

(see paragraph 3.19 above) which do not meet the weld toe requirements of Appendix 6 shall have their toes contour ground to provide an acceptable contour for their full length and to within 3 inches of any interfering attachment welds.

3.20.2.2 The contoured surface shall not reduce the thickness of the thinner base metal by more than 10% or 1/64” inch, whichever is less.

3.20.2.3 In no case shall the shorter leg of an attachment (fillet) weld be less than the minimum thickness of the member being joined. The throat of the fillet welds shall not be reduced to a size less than that required for the fillet leg size specified.

NOTE: Grinding of attachment (fillet) welds is not required if an acceptable weld profile exists at the completion of welding.

3.20.2.4 In order to minimize the amount of grinding required and eliminate over-grinding of weld throats, fillet welds may be initially welded so as to be non-symmetric about the weld root, with the longer legs being on the continuous member as identified on Appendix 6 resulting in only the critical weld and toe region requiring grinding.

3.21 WELD NDT INSPECTION REQUIREMENTS - Section 5-9 of Reference (g) and Section 8 Reference (h)

Note: It shall be noted that PT inspection requirements cited in this document shall not be substituted with 5X VT inspections.

3.21.1 [email protected] shall be Included when notifying the government of required NDT “G” Check Points.



3.21.2 Visual inspection and nondestructive inspection of critical welds associated with SHIPALT’s or repairs shall be performed in accordance with the requirements of MIL-STD-1689, NAVSEA Technical Publication T9074-AS-GIB-010/271, and the additional requirements below.

3.21.2.1 All acceptance criteria for nondestructive inspection shall be in accordance with MIL-STD-2035A except for instances in which MIL-STD-1689 explicitly specifies acceptance criteria.

3.21.2.2 NDT shall be accomplished in accordance with this section, the requirements of Reference (g), (d) and (h) and as indicated. All NDT inspections shall be documented on Appendix 3 and when applicable Enclosure (8).

3.21.2.3 All RT/UT inspection reports shall be included with the completed documentation of this PCP. Acceptance standards shall be in accordance with the requirements of Reference (e).

3.21.2.4 Repair of defects found shall be documented on Appendix 4.

3.22 IN-PROCESS NDT INSPECTION: In-process inspection of welds shall be made using 5X VT. The following in-process inspections shall be required in accordance with NAVSEA Technical Manual S9CG0-BP-SRM-010/CG-47 CL. The inspection of non-critical attachment (fillet) welds shall be in accordance with MIL-STD-1689.

3.22.1 Critical Butt Welds (Including Seam Welds)

(I) VISUAL INSPECTION OF ROOT WELDS (Key Fabrication Step Sign-Off IAW Para. 3.5.4)

3.22.1.1 Inspect 100% of the weld side of the root pass & 100% of subsequent weld passes by 5X VT. Document the inspection results on Appendix 3 and when applicable Enclosure (8).

3.22.1.2 If a temporary backing strip is utilized, after completion of welding and removal of the temporary backing strips, grind the surface flush, and inspect 100 percent of the backside of the weld by 5X VT.

3.22.1.3 When back-gouging is performed, 100 percent of the back-gouge side shall be inspected by 5X VT.

3.22.1.4 After completion of welding and prior to surface finishing (contour grinding), inspect 100 percent of the weld side by 5X VT.

3.22.2 Critical Attachment (Fillet) Welds

(I) VISUAL INSPECTION OF ROOT WELDS (Key Fabrication Step Sign-Off IAW Para. 3.5.4)

3.22.2.1 Inspect 100 percent of the root pass by 5X VT shall be documented on Appendix 3 and when applicable Enclosure (8).

3.22.2.2 Inspect 100 percent of the weld surface using 5X VT. The inspection shall be used to both identify defects, if present, and to establish the necessity for surface finishing by contour grinding in accordance with Section 7.11 of Reference (h).

3.22.2.3 Upon completion of contour grinding, where required, and prior to the final acceptance PT inspection as described in Section 8.3 of Reference (h) conduct a 100 percent 5X VT inspection of the ground surface. Where weld contours are satisfactory without surface finishing, only one satisfactory 5X VT inspection shall be required.

NOTE: Wherever Radiography Inspection (RT) is required for Final NDT Inspection, Ultrasonic Inspection (UT) may be substituted in accordance with the requirements of Reference (g) paragraph 5-9.1.4.


3.23 FINAL ACCEPTANCE NDT INSPECTION 3.23.1 The final acceptance inspection of welds shall be made in the final surface

condition after any surface modifications, grinding, or brushing is required to meet final acceptance criteria. For butt welds and seams, both PT and UT shall be required in accordance with Reference (g) and this document. Where PT inspection is utilized, the weld shall be thoroughly cleaned with a solvent after inspection in accordance with Reference (d). NDT Inspections shall be documented on Appendix 3 and Enclosure (8).

3.23.2 Critical Butt Welds (Including Seam Welds)

(I) (G) NDT INSPECTION OF FINAL SURFACE (Key Fabrication Step Sign-Off IAW Para. 3.5.4)

3.23.2.1 Final PT inspection shall be perform on 100% of critical butt welds (including seam welds) including a minimum of 4 inches on either side of the weld bead adjacent to pre-existing material and ½ inch on either side of the weld bead adjacent to new material to ensure that the entire HAZ is inspected. This inspection shall be identified and documented on Appendix 3 and Enclosure (8).

3.23.2.2 Final UT shall be performed on 100% of the length of butt weld and seams. This inspection shall be identified and documented on Appendix 3 and Enclosure (8).

3.23.3 Critical attachment (FILLET) Welds

(I) (G) NDT INSPECTION OF FINAL SURFACE (Key Fabrication Step Sign-Off IAW Para. 3.5.4)

3.23.3.1 For critical attachment (fillet) welds, both 5X VT and PT shall be required.3.23.3.2 Final 5X VT shall be performed on 100 percent of the weld and toe region. 5X VT shall be

performed prior to final PT. All rejectable defects identified by 5X VT shall be corrected prior to final PT.

3.23.3.3 Final PT shall be performed on 100 percent of the length of the fillet weld. This inspection shall be identified and documented on Appendix 3 and Enclosure (8).

3.24 INSPECTION ACCEPTANCE CRITERIA3.24.1 Acceptance criteria for 5X VT and PT shall be in accordance with MIL-STD-

2035A Reference (e), Class 3 and acceptance criteria for UT inspection shall be in accordance with MIL-STD-2035A, Class 1 except as described below:

3.24.1.1 Butt welds (including seam welds) shall not be below the adjacent base material surface, except for localized weld surface areas.

3.24.1.2 Welds and adjacent base material shall be free of arc strikes. Where arc strikes are removed, the resulting cavities shall not exceed 1/64 inch in depth or 10% percent of the adjacent base metal thickness, whichever is less, and shall be blended smoothly into the base metal (VT, Class 1 requirement).

3.24.1.3 Butt welds (including seam welds) and critical attachment (fillet) welds and toe regions shall have no allowable undercut, linear indications, or aligned porosity. Any porosity greater than 1/16 inch in diameter shall be rejectable.

3.24.1.4 Toes for all butt welds (including seam welds) shall have a smooth 180° degree re-entry angle (VT, Class 1 requirement).

3.24.1.5 Toes for critical fillet (attachment) welds shall have a re-entry angle not less than 90° degrees to the plating, which is continuous under the attachment.


3.24.1.6 All welds and at a minimum of 4 inches of the adjacent pre-existing base material and ½ inch of the new material shall be free of linear indications greater than 1/16 inch in length. Indications 1/16 inch and less shall be considered non-linear.

3.24.1.7 Expansion UT of existing welds shall be evaluated in accordance with the original fabrication acceptance criteria.

3.25 REPAIR OF WELD DEFECTS - Section 8 of Reference (h)

Note: The weld is considered completed when all weld material is deposited, the weld has cooled to ambient temperature and is visually accepted and is ready for other NDT inspection, this starts the repair cycle.

3.25.1 Repair of weld defects shall be documented on Appendix 4.

3.25.2 When Visual and NDT inspections accomplished require repair of weld defects, no more than two (2) weld repair cycles shall be permitted. If satisfactory inspections cannot be accomplished with two or fewer repair attempts, then the requirements of Reference (h), paragraph 8.4.1 shall be accomplished.

NOTE: Where in-process or final Visual and NDT Inspections reveal rejectable defects, the defect shall be completely removed by exploring to ensure that the full extent of the defective weld is identified and removed while, at the same time, removing only the minimum material necessary to ensure satisfactory repair.

3.26 IDENTIFICATION OF DEFECT AREAS3.26.1 Where in-process or final NDT inspection reveal rejectable defects, the defect

shall be completely removed by exploring to ensure that the full extent of the defective weld is identified and removed while, at the same time, removing only the minimum material satisfactory repair.

3.26.2 After repair of a defect identified by final PT or UT, the entire weld repair length plus 6 inches on both sides along the length of the weld repair shall be re-inspected by either PT or UT, which ever inspection method was utilized to identify the defect.

3.26.3 Re-welding shall be limited to two times. If rejectable defects remain after two repair cycles, report the conditions to the NSA via CFR for evaluation and determination of further repair procedures.

(I)(G) NDT RE-INSPECTION OF REPAIRS (As Required) (Key Fabrication Step Sign-Off IAW Para. 3.5.4)

3.26.4 Repairs shall be re-inspected in accordance with the requirements of Section 3.24. Repair of weld defects shall be documented on Appendix 4.

3.27 INSPECTION/DOCUMENTATION FORMS3.27.1 This Process Control Procedure and Completed Appendices and Enclosures

3.27.2 NDT Reports

3.27.3 Checkpoint/Inspection Notification Forms (Contractor Provided)

3.27.4 Associated CFR’s, DFS and Waivers


3.28 OBJECTIVE QUALITY EVIDENCE3.28.1 This procedure along with the material certifications (new aluminum plate,

sheet metal and filler material only) and all completed documentation (installations and inspections) forms comprise Objective Quality Evidence and traceability of materials and components. This OQE is a formal contract deliverable and shall be delivered to Quality Assurance for review and further disposition, per paragraph 3.5 of 009-09 of Reference (a).

3.29 CONTROL OF PROCEDURE3.29.1 A copy of the approved procedure shall be at the work site in the possession of

the project manager, foreman and/or lead man, during the performance of the work.

4 SECTION 4 HAZARDOUS MATERIAL4.1 HAZARDOUS MATERIALS

4.1.1 Hazardous material (HAZMAT):4.1.1.1 Cleaning Solvent (Isopropyl Alcohol, Acetone)

4.1.2 Hazardous waste:4.1.2.1 Solvent soaked rags

4.1.3 Hazardous waste disposal4.1.3.1 All waste generated will be disposed in accordance with local, state and federal regulations.4.1.3.2 Every effort will be made to limit the quantity of hazardous waste generated, i.e. the re-use of

wiping rags, etc.

5 SECTION 5 LOCAL, REGIONAL, AND STATE REQUIREMENTS5.1 No local, regional or state regulations require controls to achieve the required technical results

of the work item.


PCP DIRECT KNOWLEDGE ATTENDANCE FORMDescription of Briefing:

Date: PCP No:

Ship / Hull: Job #: Item No: Instructors; Please retain with completed PCP

No.

Attendee Name(Print or type) Dept

#Badge #

Attendee Signature/Excused Absence(Ink only)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Print Instructors Name (Company Name): Instructor Signature:

APPENDIX 1


WELD TECHNIQUE SHEETSHIP: HULL# ITEM# JOB# PCP# SYSTEM/DESCRIPTION

Weld Procedure(s) Procedure #

ProcessThickness Range

AmpsVolts

PolarityShielding gas / flow rate

Purge gas / flow ratePreheat / interpass tempJoint #’s welded with this

procedure.Joint designs applicable

to this procedureBase Material Component Letter # / size Class or type Applicable Document

Component A: (Existing Structure)

Component B: ( New material )

Component C:

Component D:

Component E:

Filler Material & Weld Procedure

Filler A:

Filler B:

COMMENTS: *Use Torch to Pre-heat base metal plate until warm to the touch.

APPENDIX 2


WELDING IN-PROCESS CONTROL/NONDESTRUCTIVE TEST RECORD (STRUCTURAL)(TO DOCUMENT WELDING IN-PROCESS AND NDT INSPECTION RESULT)

1. Ship/Hull: 2. Item/MOD #: 3. PCP #: 4. Brief Description (PCP Title): 5. Job #: 6. Contract #:

REFERENCES: MIL-STD-1689A(SH), MIL-STD-22D, MIL-STD 2035 [Acceptance Class: 1 2 3 ]

7. JOINT INFORMATION 8. ROOT PASS 9. BACK GOUGE 10. FINAL PASSWeld Identification (i.e. Joint I Number.)

Component (A)Size or Thick-ness Joint

Design

Fit-Up [SAT] [Un-Sat]4/

Welder NameRoot Insp

Acc / Rej

NDT Inspector Back Gouge Insp

ACCREJ1/

NDT Inspector Welder NameFinal Insp 3/

ACC REJ1/ 2/

NDT Inspector

Component (B)Size or Thick-ness

Date Welded Inspect Date Inspect Date Date Welded Inspect Date

WELD IDENTIFICATION:

SAT U/Sat

Init____

VT VT5X PT

ACC REJ

VT VT5X PT

ACC REJ

VT PT UT

ACC REJ


SAT U/Sat

Init____

VT VT5X PT

ACC REJ

VT VT5X PT

ACC REJ

VT PT UT

ACC REJ


SAT U/Sat

Init____

VT VT5X PT

ACC REJ

VT VT5X PT

ACC REJ

VT PT UT

ACC REJ


SAT U/Sat

Init____

VT VT5X PT

ACC REJ

VT VT5X PT

ACC REJ

VT PT UT

ACC REJ

11. VT INSPECTION 12. PT TECHNIQUE VT5X PENETRANT TYPE II DIMENSIONAL MANUFACTURER

MAGNAFLUX OTHER:VT INSPECTION PROCEDURE: PT INSPECTION PROCEDURE:

13. SIGNATURE VALIDATION PRINTED NAME SIGNATURE PRINTED NAME SIGNATUREWELDER NO. 1 NDT INSPECTOR NO. 1WELDER NO. 2 NDT INSPECTOR NO. 2WELDER NO. 3 NDT INSPECTOR NO. 3

NOTES: 1. REJECTED WELD JOINTS SHALL BE REPAIRED AND DOCUMENTED ON WELD DEFECT REPAIR FORM (APPENDIX 4).2. THE INSPECTOR ACCEPTING WELDS CERTIFIES BY PERSONAL OBSERVATION THAT THE WELD FILLET SIZE IS SATISFACTORY AS APPLICABLE.3. SEE RADIOGRAPHIC TEST (RT) OR ULTRASONIC TEST (UT) REPORT FOR INSPECTION RESULTS AS APPLICABLE.4. THE PERSON INITIALING FOR THIS BLOCK IS ALSO SIGNING IN ACKNOWLEDGEMENT THAT THE MATERIAL HAS BEEN VERIFIED PER PARAGRAPH 3.6.3

OF THIS PCP.

APPENDIX 3


WELD DEFECT REPAIR RECORD1

(TO DOCUMENT WELD JOINT REPAIR AS APPLICABLE)1. SHIP: 3. ITEM# 5. PCP# 6. CONTRACT#: 2. HULL: 4. MOD# 7. JOINT WELDED:

9. DEFECT DESCRIPTION (CHECK ALL THAT APPLY) CRACK INCOMP INSERT FUSION INCOMPLETE FUSION ARC STRIKE ROUNDED SLAG CRATER PIT BURN THRU WELD SPLATTER SHORT LEG SIZE POROSITY INTERNAL CONCAVITY MELT THRU ROOT EDGE FUSION COND OTHER: (ENTER BELOW UNDERCUT INTERNAL CONVEXITY TUNGSTEN LINEAR

OXIDATION CENTERLINE CREASE INCOMPLETE PENETRATION LINEAR DISPOSED

10. DEFECT LOCATION(S) AND EXTENT SEE SKETCH IN REMARKS

11. INSPECTOR (SIGNATURE/DATE)

12. DEFECT REPAIR. REPAIR CYCLES 1 2 13. TYPE OF REPAIR

GRIND ONLY GRIND AND WELD WELD ONLY OTHER (SEE

REMARKS)

14. REPAIR LOCATION(S) AND EXTENT

SEE SKETCH IN REMARKS

15. WELD PROC AND REV/CH

NA SAME AS

ORIGINAL

16. EXCAV NDT REQUIRED

Y (MARK REQD INSP BLK 23/24)

N

17. ROOT PASS INSP REQUIREDY (MARK REQD INSP

BLK 23/24)N

18. LAYERT/R/I/F

19. FILLERTYPE

20. PREHEAT/INTERPASS TEMP 21 WELDER (SIGNATURE/DATE)2

SAT

SAT

SAT

22. REPAIR NDT INSPECTIONSREPAIR WELD REQUIRES THE SAME INSPECTIONS AS THE ORIGINAL WELD. (R) ROOT (I) INTERMEDIATE (F) FINAL (T) TACKS23. INSPECTION 24 INSPECTION TYPE 25. PROCEDURE

USED26. INSPECTOR (SIGNATURE/DATE)

EXCAVNA

5X PT TYPE IIC SATREJ

ROOTNA

VT 5X SATREJ

BACKGOUGENA

5X SATREJ

VT ( I )NA 5X SAT

REJVT (F)NA VT 5X SAT

REJPT(F)NA

PT TYPE IIC SATREJ

RT(F)NA 60O 360O 100% SAT

REJFILLET SIZE (F)

N/ASATREJ

27. REMARKS (SKETCHES)

NOTE: 1. USE ONE SHEET PER WELD JOINT. 2. WELDER’S SIGNATURE INDICATES THAT ALL WELD PARAMETERS OF APPENDIX 2 HAVE BEEN VERIFIED.

APPENDIX 4


Acceptable Groove/Fillet Weld Profiles

Figure 1. Example of Unacceptable and Acceptable Butt Weld Profiles

APPENDIX 5


Definition of Critical/Non-Critical Portions of Fillet Welds

Figure 2. Critical and Non-critical Weld and Toe Regions for Symmetric andNon-symmetric Attachment (fillet) welds

APPENDIX 6


Ship Hull: PCP #: Joint ID:

Item/Mod: Job#: Contract#:

CLEANLINESS RECORD (OXIDE REMOVAL)

DATE TIME LOCATION SAT/UNSAT INSPECTED BY:

APPENDIX 7

APPENDIX 7


NOTE:1. Welding must commence within 6 hours of completion of cleanliness requirements. If welding has not commenced, joints must be re-cleaned and inspected.2. Shielding gas dew point shall be minus forty degrees Fahrenheit (-400F) or less when measured at the welding torch head and shall be verified prior to commencing welding on any shift.3. The welding apparatus shall be purged and the shielding gas dew point shall be verified to be minus forty degrees Fahrenheit (-400F) or less at the torch head each time gas supply bottles re-connected.4. A copy of this record shall be maintained at each worksite at all times.

Ship Hull: PCP #: Joint ID:Item/Mod: Job#: Contract#:

SHIELDING GAS DEW POINT RECORDCalibrated Equipment: ID#. Cal Due DateDATE TIME LOCATION DEW POINT

TEMP (oF)SAT/UNSAT Verified By:

APPENDIX 8

APPENDIX 8


NOTE:1. Welding must commence within 6 hours of completion of cleanliness requirements. If welding has not commenced, joints must be re-cleaned and inspected.2. Shielding gas dew point shall be minus forty degrees Fahrenheit (-400F) or less when measured at the welding torch head and shall be verified prior to commencing welding on any shift and after a bottle change.3. The welding apparatus shall be pre-purged with shielding gas for a minimum of 10 seconds prior to welding.4. The welding apparatus shall be purged and the shielding gas dew point shall be verified to be minus forty degrees Fahrenheit (-400F) or less at the torch head each time gas supply bottles re-connected.5. A copy of this record shall be maintained at each worksite at all times.

PRE-HEAT / INTERPASS TEMPERATURE RECORD1

Ship Hull: PCP #: Joint ID:

Job#: Work Item/Mod: Contract#:

Calibrated Equipment: ID#: Cal Due Date:

P=Preheat I= Interpass(Circle one)

DATE TIME TEMP(600F MIN – 150 0F

MAX)

SAT/UNSAT Verified By:

P IP IP IP IP IP IP IP IP IP IP IP IP IP IP IP IP IP IP IP IP IP I

NOTE: 1. USE ONE SHEET PER WELD JOINT.

APPENDIX 9


COMMENTS:

ShipAlt Accountability RecordShip: Hull: PCP #:

Item/Mod: Job #: Contract #:

DWG #: Rev #:

Prot

ectiv

e En

clos

ure

Inst

alla

tion

Join

t Pre

para

tion

Fit-U

p In

spec

tion

5X V

isua

l Ins

pect

ion

of R

oot P

ass

ND

T of

Roo

t Pas

s5X

Vis

ual

Insp

ectio

n of

Bac

k-G

ouge

ND

T of

Bac

k-5X

Vis

ual

Insp

ectio

n of

Fin

alN

DT

of F

inal

ND

T R

e-In

spec

tion

of R

epai

rsShipALT #:

Sheet / Elevation / Detail / Section

Initial Upon Completion or Mark “N/A”

Page ofAPPENDIX 10


Material Certification Index

Invoice No. Lot No. & Description Signature And Badge Number of Receipt Inspector 1/ 2/ 3/

123456789

10 NOTE 1: To be signed by the Welding Supervisor. Additions may be signed by the Welding Supervisor or Quality Assurance Inspector

NOTE 2: Signature indicates verification of procurement to ASTM-B928/B928M Standard Specification IAW Para 3.1 of Ref (h).

NOTE 3: Signature indicates verification of procurement of Filler Material to AWS A5.10 with Schedule J lot conformance testing IAW Para 3.1 of Ref (h).

ENCLOSURE 7


Ship /Hull Number: PCP Number: Date:

Contract Number: Job Number: Work Item:

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CG-47 CLASS ALUM SUPERSTRUCTURE - PSSRApssra.org/wp-content/uploads/2015/05/PCP_CG-47CLASs... · Web viewMIL-STD-2035A (SH) Nondestructive Testing Acceptance Criteria S9074-AQ-GIB-010/248