Coded Welding to BSEN and ASME Standards in the Energy-from-Waste Industry

The energy-from-waste (EfW) industry plays a pivotal role in addressing the world’s growing waste problem while contributing to sustainable energy production. To ensure these facilities operate safely, efficiently, and reliably, precision and expertise in engineering and fabrication are non-negotiable. Among the critical elements of this industry is coded welding — a highly specialised process that adheres to strict standards, such as BSEN and ASME, to ensure the structural integrity of components.

In this blog, we explore what coded welding entails, its importance in the EfW sector, and how compliance with these rigorous standards ensures safety and performance in high-pressure environments.

What is Coded Welding?

Coded welding refers to welding work performed by highly trained welders who hold certifications for specific welding techniques, materials, and positions. The term “coded” comes from the welder’s qualification to a specific “code” or standard, such as:

• BS EN ISO Standards: Widely used across the UK and Europe, covering various welding procedures and welder qualifications.

• ASME Standards: Originating in the United States, these are commonly applied in industries dealing with boilers, pressure vessels, and piping systems.

A welder certified to these standards undergoes rigorous testing to demonstrate their competence, ensuring their work meets the required quality and safety benchmarks.

The Role of Coded Welding in the EfW Industry

EfW facilities are designed to process large volumes of waste and convert it into energy through methods like incineration, anaerobic digestion, and gasification. These processes operate under extreme conditions, such as high temperatures, intense pressure, and exposure to corrosive substances. Coded welding is critical in manufacturing and maintaining key components, including:

1. Boilers and Heat Exchangers:

   • Welded joints must withstand extreme temperatures and thermal cycling without failure.

2. Pressure Vessels:

   • These must be constructed to handle high pressures safely, requiring welds with exceptional strength and durability.

3. Flue Gas Ducting:

   • Welds in these systems need to resist corrosion and wear from abrasive and chemical-laden gases.

4. Conveyors and Ash Handling Systems:

   • Structural welds ensure the reliability of these critical systems that handle abrasive materials.

BSEN and ASME Standards: A Closer Look

BS EN ISO Standards

The BS EN ISO standards provide comprehensive guidelines for welding processes, testing, and welder certification. Key aspects include:

• BS EN ISO 9606: Qualification of welders for fusion welding.

• BS EN ISO 15614: Specification and qualification of welding procedures.

• BS EN ISO 3834: Quality requirements for welding, ensuring consistency and compliance with best practices.

ASME Standards

The American Society of Mechanical Engineers (ASME) standards are particularly important in industries dealing with pressure-retaining components. Key codes include:

• ASME Section IX: Welding and brazing qualifications.

• ASME Section VIII: Pressure vessel construction.

• ASME B31.1 and B31.3: Codes for power piping and process piping, respectively.

Compliance with these standards ensures that welds meet stringent safety and performance requirements, minimising the risk of failure in critical systems.

Why Coded Welding is Essential in EfW

The unique challenges of the EfW industry make coded welding indispensable. Here are some key reasons why:

1. Safety:

   • Poorly executed welds can lead to catastrophic failures, endangering personnel and the environment. Coded welding ensures the highest safety standards are met.

2. Durability:

   • EfW components are subjected to wear, corrosion, and thermal stresses. Coded welds offer the strength and resilience needed to withstand these conditions.

3. Regulatory Compliance:

   • EfW facilities must adhere to strict regulations governing environmental and operational safety. Coded welding ensures compliance with these requirements.

4. Efficiency:

   • High-quality welds minimise downtime and maintenance, ensuring uninterrupted operation and cost savings.

The Process of Coded Welding

Coded welding involves several key steps to ensure quality and compliance:

1. Welding Procedure Qualification (WPQ):

   • A detailed specification is developed for the welding process, including parameters like material type, joint design, and welding technique.

2. Welder Qualification Testing (WQT):

   • Welders perform test welds under strict supervision, which are then inspected and tested for strength, quality, and adherence to standards.

3. Inspection and Testing:

   • Non-destructive testing (NDT), such as radiographic or ultrasonic inspection, verifies the integrity of welded joints without damaging them.

4. Certification and Traceability:

   • Each weld is documented and certified, ensuring traceability and accountability.

Real-World Applications in the EfW Industry

One UK-based EfW facility recently underwent a boiler retrofit to improve efficiency and reduce emissions. The project involved extensive coded welding to replace pressure vessels, piping, and structural components. By adhering to BSEN and ASME standards, the team ensured the plant’s long-term reliability, reducing downtime and maintenance costs while meeting environmental targets.

Partnering with Certified Welding Experts

For EfW operators, partnering with experienced and certified welding experts is essential. These professionals bring:

• Technical Expertise: Deep knowledge of materials, welding processes, and industry standards.

• Precision and Quality Assurance: Ensuring every weld meets the highest quality benchmarks.

• Ongoing Support: Providing maintenance and repair services to keep facilities running smoothly.

Conclusion

Coded welding to BSEN and ASME standards is the backbone of reliability and safety in the energy-from-waste industry. As EfW facilities continue to grow in importance, the demand for skilled welders and high-quality welding practices will only increase. By prioritising coded welding, the EfW sector can ensure efficient, sustainable, and safe operations for years to come.

If your facility requires expert coded welding services, make sure to partner with certified professionals who understand the unique challenges of the EfW industry. Together, we can build a cleaner, greener future — one weld at a time. For specialist advice and a no-obligation quotation, call IME on 02085996570 or email sales@imegroup.co.uk.