An introduction to ASME & ASME SEC IX QA/QC DEP DEPARTMENT ARTMENT
Contents The
ASME System Introduction to Section IX Organization and Use Section IX Section IX Responsibilities Responsibilities
of the Authorized Inspector or Ow ner User Inspector
Responsibilities
of the Manufacturer Welding Processes and weld types Section II, Part C Welding Materials Welding Procedure Specification QW-200 Procedure Qualification Record (PQR) Qualifying a WPS Miscellaneous Application Welding Variables Welder performance Qualification QW-300 Welder Essential Variables SMAW
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The ASME System
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Outline The ASME System ASME Boiler & Pressure Vessel Codes Section IX Subcommittee Organization
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The ASME The American American Society of Mechanical Engineers Provides minimum safety rules for Construction
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The Members
The American American Society of Mechanical Engineers (ASME) Manufacturer/Certificates Holders Manufacturer/Certificates Owners/Users Authorized Inspection Agencies Agencies Jurisdiction/Regulatory Jurisdiction/Regulatory Agencies Members voluntarily supported by their organizations
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Manufacturers
AIAs
Owner/Users
ASME Voluntary Members
Jurisdictions
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Boiler & Pressure Vessel Committee 1911: ASME establishes a committee for the purpose of formulating standard rules for the construction of power boilers and other pressure vessels.
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Construction Codes Section I – I – Power Boilers III – Divs. 1 & 2 – 2 – Nuclear Components Section III – Section IV – IV – Heating Boilers Section VIII, Divs. 1, 2 & 3 Pressure Vessels Section X – X – Fiberglass Reinforced Plastic Pressure Vessels
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History of Construction Codes 1914: Section I – I – Power Boilers IV – Heating Boilers 1923: Section IV – 1928: Section VIII – VIII – Unrefined Pressure Vessels 1965: Section III- Nuclear Power Plant Components.
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History of Construction Codes 1968: Renamed Section VIII, Div. 1 Pressure Vessel Code 1968: Section VIII, Div. Div. 2 Alternate Alternat e Rules for Pressure Vessels 1969: Section X – X – Fiberglass Reinforced Plastic Pressure Vessels
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Reference Codes Section II – II – Materials Nondestructive Examination Section V - Nondestructive Section IX - Welding & Brazing Qualification
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History of Reference Codes 1924: Section II - Material IX – Welding Welding Qualification 1937: Section IX –
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Subgroup Organization Section IX Committee
Subgroup Performance
Subgroup Procedures
Subgroup General Requirements
Subgroup Brazing
Subgroup Materials
Subgroup Strength of Weldment
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Introduction to Section IX
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Outline Foreword WPS/PQR Qualifications Addenda Organization and Use of Section IX
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Foreword Foreword covers topics such as: History of ASME Committee Submitting interpretations to ASME ASME as referenced in Appendix A Effect date of Addenda Addenda may be used upon issuance although it is not mandatory six month after issue Material requiremen
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ASME Code Section IX
Qualification Standard for Welding and Brazing Procedures Welders, Braziers, Welding and Brazing Operators. Welders,
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WPS/PQR Qualification Article I Paragraph QW-100.2 QW-100.2 discusses “OLD” procedures and Welders Qualifications Qualification prior to 1962: Requires updating to a later edition or discard as valid After 1962, the Procedures and Welders are good forever
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Addenda Changes to the Code Issued annually Mandatory use six months after issue May be used upon issue
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Reference Code Section IX is a reference Code and may be used only when referenced and as it is referenced by the Construction or Governing Code
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Organization and Use Section IX
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Organization
Part QW Article 1 – 1 – General Requirements Article 11 – 11 – Welding Procedure Qualification Article 111 – 111 – Welding Welding Performance Qualification IV – Welding Variables Article IV – Article V – V – Standard Welding Procedure (AWS)
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Article I
General Requirements QW-100 General QW-110 Weld Ordination Ordinati on QW-110 QW-120 Test Position for Groove welds QW-130 Test Position for Fillet Welds QW-140 Types and purpose of test and examinations
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Article I
General Requirements QW-150 Tension Test QW-160 Guided bend test QW-170 Notch Toughness Test QW-180 Fillet Weld Test QW-190 Other test & examinations
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Article II
Welding Welding Procedure Qualification QW-200 General QW-210 Preparation of test coupon QW-250 Welding Variables ariable s
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Article III
Welding Welding Performance Qualification QW-300 General QW-310 Qualification test coupon QW-320 Reset and renewal of qualification QW-350 Welding variables for welders QW-360 Welding variable for welding Operators QW-380 Special processes
Article IV
Welding Data QW-400 Variables QW-410 Techniques QW-320 P-Number QW-430 F- Numbers QW-440 Weld metal chemical composition QW-450 Specimens QW-460 Graphics QW-470 Etching process and reagents QW-490 Definitions
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Section IX Responsibilities
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Outline
Responsibilities Authorized Inspector Manufacturer
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Responsibilities of the Authorized Inspector or Owner User Inspector
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Before Construction
Verify that Procedure comply with procedure Procedure have been properly qualified Welding and Operators are properly qualified QC Manual has been followed
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During Construction
Make sure welding is preformed within the parameters of the welding procedure Verify welder qualification limits are neither exceeded nor expired
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Responsibilities of the Manufacturer
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Qualification of Procedure Establish a QC program to control qualification List parameters for construction Prepare a written WPS Assure metallurgical compatibility between filler and base metal Prepare and certify PQR based upon recorded data
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Notes Recommended Recommended that each Manufacturer has, or has access to, a welding metallurgist QW-200.3 Hold the manufacturer responsible for QW-200.3 assuring that material are compatible when welded
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Qualification of Welders
Establish QC program to control welder qualification Qualify each welder to the process being used Weld the test coupon in accordance with a written WPS
Cont’d…
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Qualification of Welder Control and supervise during the welding of coupon Maintain welder identification Document welder qualification
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Subcontracted Welding Procedures Applicable to Section I only when using “PP” “PP” stamp to ASME/ ANSI B31.1 Code Code The National Certified Pipe Welder Welder ’s Bureau (NCPWB), a national organization made up of member companies, provides welding procedures to its members.
Cont’d…
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Subcontracted Welding Procedures
The member company must Sign each WPS and PQR Accept responsibility for its use and Code compliance
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Subcontracted Welding
Allowed by the construction Code, provided; Use is described in the QC Manual Work performed within the scope of the Certificate of Authorization Certificate holder has contractual control over the Welders.
Cont’d…
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Subcontracted Welding Certificate Holder has final responsibility for the welding Welder is under subcontract to the Certificate holder Welder Welder Welder are qualified by the Certificate Holder
– Company Procedures Inter – QW-201
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Welding procedure may be used among different companies, provided they are within the same corporate structure Each company must state how they control such procedure in their QC Manual and satisfy the ASME ASME during joint review
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Example Company “A” qualifies and files several PQRs Company “B” files their own PQR and combines with the PQRs from company “A” to develop a WPS The PQR from company “A” was not qualified. Is this permissible?
– Company Procedures Inter – QW-300.2
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Allows to use the Welders amongst different companies without prequalification, provided both companies are within the same corporate structure Each company must satisfy the ASME requirements during the joint review and incorporate the necessary control in the QC Manual
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Welding Processes and Weld Types
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Outline Welding Processes Weld Types
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Welding Processes OFW
Oxyfuel Welding
SMAW
Shield Metal Arc Welding
SAW
Submerge Arc Welding
GMAW
Gas Metal Arc Welding
FCAW
Flux-Core Arc Welding
GTAW GTAW
Gas Tungsten Arc Welding
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Welding Processes PAW
Plasma Plasma Arc Welding Welding
ESW
Electro Slag Welding
EGW
Electro Gas Welding
EBW
Electro Beam Welding
LBW
Laser Beam Welding
Stud Welding Inertia and Continuous Friction
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Special Processes Corrosion resistance overlay and hard surface overlay welding Qualification requirement: QW-453 Essential variables: QW-250
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Weld Types Three types of welds covered in Section IX Groove Weld U Groove J Groove V Groove Partial Penetration Fillet Welds Stud Welds
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‘J’ and ‘U’ Preparations
“U” preparation Root radius
Land
Double “U” butt
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Groove Weld ?
1
Cont’d……
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Groove Weld
1
Groove Angle
Cont’d……
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Groove Weld
1
?
2
Cont’d……
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Groove Weld
1 2
Bevel Angle
Cont’d……
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Groove Weld ?
3 1 2
Cont’d……
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Groove Weld 3 1 2
Groove Face
Cont’d……
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Groove Weld 3 1 2
? 4
Cont’d……
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Groove Weld 3 1 2
Root Face
4
Cont’d……
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Groove Weld 3 1 2
4
5 ?
Cont’d……
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Groove Weld 3 1 2
Root Gap
4
5
Cont’d……
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Groove Weld Groove Face Groove Angle Bevel Angle
Root Face Root Gap
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Fillet Weld
1
?
Cont’d……
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Fillet Weld
1
?
Toe of Weld
Cont’d……
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Fillet Weld
1 2
?
Cont’d……
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Fillet Weld
1 2 Weld Face
Cont’d……
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Fillet Weld
?
1 2
3
Cont’d……
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Fillet Weld
1 2
3
Weld Size
Cont’d……
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Fillet Weld
1 2 4
3
?
Cont’d……
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Fillet Weld
1 2 4
3
Weld Leg
Cont’d……
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Fillet Weld
1 2
3
4
5 ?
Cont’d……
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Fillet Weld
1 2
3
4
5 Weld Root
Cont’d……
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Fillet Weld
1 2
3
4
5
6 ?
Cont’d……
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Fillet Weld
1 2
3
4
5
6 Weld Throat
Cont’d……
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Fillet Weld
Toe Face Leg
Root
Weld Size
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Stud Welding
1
?
Cont’d……
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Stud Welding
Work Piece
1
Cont’d……
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Stud Welding
? Work Piece
2
1
Cont’d……
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Stud Welding
Stud Work Piece
2
1
Cont’d……
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Stud Welding
Stud Work Piece
2
1 3 ?
Cont’d……
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Stud Welding
Stud Work Piece
2
1 3
Weld
Cont’d……
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Section II, Part C Welding Material
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Outline
Scope of Section II, Part C
Electrode Identification
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ASME Section II, Part C
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Scope Section II- material specifications referenced in the fabrication Code. Part C – C – Material Specification for welding materials
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Section II, Part C
Information includes: Processes that may be used with various electrodes Recommended Recommended storage requirements AWS marking Recommended Recommended electrode positions Recommended Recommended polarity Information on “how” to meet SFA specification
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Table of Contents SFA-5.1 Carbon Steel covered arc welding electrodes. SFA-5.4 Corrosion resistance Cr and Cr-Ni steel covered electrodes SFA- 5.5 Low alloy steel-covered arc welding electrodes SFA-2.18 Carbon steel filler metals for Gas Shielded Arc Welding
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Specification SFA-5.1 Requirements for classifying carbon steel electrodes used for Shielded Metal Arc Welding (SMAW) Example: E6010, E6011, E7018 and E7028
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Specification SFA-5.4 Requirement for classifying stainless steel-covered electrodes used for SMAW Example: E308H, E309L, E317L and E317L
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Specification SFA-5.5 Requirements for classifying low alloy steel-covered electrodes used for SMAW Example: E7018-A1, E8016-B2, E9015-B3 and E9018-B3L
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Specification SFA-5.18 Requirements for classifying carbon steel electrodes and rods used for Gas Shielded Arc Welding (GSAW) Examples: ER70S2, ER70S3, ER70SG and ER70CGM.
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Electrode Identification
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Marking Requirements SFA-5.1 requires marking on both the package and electrode Package • AWS classification and class • Supplier’s name and trade designation • Size and net weight • Lot, control or heat number Electrode • Classification must be within 2.5” of grip end • Prefix “E” may be omitted
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Classification Classificatio n SFA-5.1
Position Electrode
EXXXX- 1
For 018 Electrodes, “1” indicates that charpy values of 20 ft-lbs at -50 F have been met
Minimum tensile strength (ksi) Type of coating and recommended current
Cont’d……
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Classification Classificatio n SFA-5.1
Position Electrode
EXXYY- 1
For 016 E7016 & E7018 Electrodes, “1” indicates that charpy values of 20 ft-lbs at -50 F have been met
Minimum tensile strength 70 ksi Type of coating and recommended current
Cont’d……
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Classification Classificatio n SFA-5.1
Position Electrode
EXXYY-1
For E7016 & E7018 Electrodes, “1” indicates that charpy values of 20 ft-lbs at -50 F have been met
Minimum tensile strength 70 ksi Type of coating and recommended current
Cont’d……
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Classification SFA-5.1
All Position Electrode
EXX18- 1
For E7016 & E7018 Electrodes, “1” indicates that charpy values of 20 ft-lbs at -50 F have been met
Minimum tensile strength 70 ksi Low Hydrogen, Potassium, Iron powder and use for AC or DCEP Cont’d……
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Classification Classificati on SFA-5.1
Position Electrode
EXXYY-1
For E7016 & E7018 Electrodes, “1” indicates that charpy values of 20 ft-lbs at -50 F have been met
Minimum tensile strength 70 ksi Type of coating and recommended current
Cont’d……
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Example of SFA-5.1 Electrode E6010, E7018, E7024 Note: Only 60 ksi and 70 ksi tensile electrode are covered by this specification
Cont’d……
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Specification SFA-5.4 Requirements for classifying corrosion-resistant and chromium nickel steel-covered arc welding electrodes used for SMAW
Cont’d……
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Classification Classificatio n SFA-5.4
Electrode
Usability (Position & Current type
E-XXX-XXX-XX Chemical Composition (first three digits)
One or more letters indicating modification of basic composition
Cont’d……
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Classification Classificatio n SFA-5.4
Usability (Position & Current type Electrode
E-XXX-YYY-XX Chemical Composition (first three digits)
One or more letters indicating modification of basic composition
Cont’d……
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Classification Classificatio n SFA-5.4 Usability (Position & Current type
Electrode
E-308-YYY-XX 19 Cr, 10 Ni One or more letters indicating modification of basic composition
Cont’d……
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Classification Classificatio n SFA-5.4 Usability (Position & Current type
Electrode
E-XXX-L-XX Chemical Composition (first three digits) Low carbon contents 0.04% max
Cont’d……
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Classification Classificatio n SFA-5.4
Electrode
DCEP or AC/ all position
E-XXX-YYY-16 Chemical Composition (first three digits)
One or more letters indicating modification of basic composition
Cont’d……
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Example of SFA-5.4 E308L, E308L-16, E309Cb Legend
L
Low Carbon
Cb
Addition of columbium, Reduction of Carbon
Mo
Addition of molybdenum, reduction of carbon
15
Lime covering, use DCEP
16
Lime or titania, use with DCEN or DCEP
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Specification SFA-5.5 Requirements for classifying low-alloy steel electrode used for SMAW
Cont’d……
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Classification Classificatio n SFA-5.5
Position Electrode
One or more letters & number indicating chemical composition of deposited metal
EXX (X) XX-XXX Minimum tensile strength (ksi) Type of coating & recommended current Cont’d……
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Classification SFA-5.5
Position Electrode
One or more letters & number indicating chemical composition of deposited metal
EXX (X) YY-XXX Minimum tensile strength (ksi) Type of coating & recommended current Cont’d……
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Classification Classificatio n SFA-5.5
Position Electrode
One or more letters & number indicating chemical composition of deposited metal
E 100 XX-XXX Minimum tensile strength 100 ksi Type of coating & recommended current Cont’d……
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Specification SFA-5.5
All Position Electrode
One or more letters & number indicating chemical composition of deposited metal
EXX (X) 16-XXX Minimum tensile strength (ksi) Low hydrogen Potassium AC/DCEP Cont’d……
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Classification Classificatio n SFA-5.5
All Position Electrode
One or more letters & number indicating chemical composition of deposited metal
EXX (X) 16-B2L Minimum tensile strength (ksi) Low hydrogen Potassium AC/DCEP Cont’d……
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Classification Classificatio n SFA-5.5 Position Electrode
Chromium- molybdenum steel electrode
EXX (X) YY-B2L YY-B2L Minimum tensile strength (ksi) Type of coating & recommended current
Cont’d……
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Example of SFA-5.5 E7012, E7013-B3“A” E7013-B3“A” Chemical Composition Number A1- C Mo (1/2 % Mo) B1- Cr Mo (1/2%Cr,1/2%Mo) B2- Cr Mo (1-1/4%Cr, 1/2%Mo) B3- Cr Mo (2-1/4%Cr, 1/2%Mo)
“A” 2 3 3 4
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Specification SFA-5.18
Requirements for classifying carbon steel electrodes and rods used with the following welding methods: Gas Metal Meta l Arc GMAW) Gas Tungsten Arc (GTAW) Plasma Arc (PAW)
Cont’d……
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Classification Classificatio n SFA-5.18 Rod Suffix relating to manufacture chemical composition
Electrode
ERXXS-X(XX) Minimum tensile strength (ksi) Bare, Solid wire or rod
Cont’d……
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Classification Classificatio n SFA-5.18 Rod Suffix relating to manufacture chemical composition
Electrode
ERXXC-X(XX) Minimum tensile strength (ksi) Composite wire
Cont’d……
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Classification Classificatio n SFA-5.18 Rod
Electrode
Suffix relating to manufacture chemical composition
ER70S-X Minimum tensile strength 70ksi Bare, Solid wire or rod
Cont’d……
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Classification Classificatio n SFA-5.18 Rod Suffix relating to manufacture chemical composition
Electrode
ERXXS-X(XX) Minimum tensile strength (ksi) Solid Wire
Cont’d……
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Classification Classificatio n SFA-5.18 Rod Low carbon with trace of Ti, Zr and Al content Electrode
ERXXS-2(XX) Minimum tensile strength (ksi) Bare, Solid Wire or rod
Cont’d……
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Classification Classificati on SFA-5.18
ER70S-2, ER70S-3
Suffix
"A"
Shielding Gas
2
1
Ar/O2, Ar, Ar, Ar/CO2
3
1
Ar/CO2, CO2
4
1
CO2
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Welding Procedure Specification QW-200
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Outline Weld Procedure Specification (WPS) qualification Procedure Qualification Record (PQR) Writing a WPS Qualifying a WPS Testing weld specimens Groove weld Qualifications Miscellaneous applications Miscellaneous Welding variables
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WPS Qualification
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What is a WPS?
A document that has been prepared by qualification and is used to provide necessary direction and control for making a weld joint
Contents of a WPS
A WPS must address: Essential and Non-essential variables in QW-250 Supplemental variables, when impact testing required Acceptance Acceptance qualification ranges Other information
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Category of Variables Essential Must be qualified when a change occur Non- Essential Must be addressed in the WPS Supplementary Essential Must be requalified when notch toughness is involved
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Considerations Joint designs Weld and base metal compatibility Heat treatment Metallurgical properties Desired mechanical properties Service requirements Welders’ ability Equipment availability Weld location Economy
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Procedure Qualification Record (PQR)
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PQR Record of welding data used to weld a test coupon Modifies or justifies the WPS Supporting document that includes the results of welding and testing a coupon
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Contents of PQR Essential variables (as a minimum) Supplemental Essential Variables (When impact testing required) Other information, if desired
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WPS/PQR Forms
Recommended, Recommended, non-mandatory sample forms in QW-482 and QW-483
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Multiple PQRs Supporting One WPS
Example PQR No. 1 with PWHT and PQR No. 2 without PWHT supports a WPS with and without PWHT
It is possible to have one WPS that covers all possible welding circumstances circumstances
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Single PQR Supporting Multiple WPS
Example A PQR is qualified for F4 and F6 electrodes. This PQR can be used to support a WPS using F4 electrodes and the second WPS using the F6 electrodes
QW-200.2 allows the use of one PQR to support several WPS
Permitted Change without Requalification
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Changes in non-essential variable Corrections or update, supported by an exciting PQR
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Permitted Changes to a PQR
Obvious errors or changes supported by data recorded during test coupon welding
Example: Code- driven material specification change in a later edition
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Example of a Revised RQR A section IX revision assigns a P-number to a material previously qualified by material specifications The PQR may now be revised to identify a P-number rather than just a specific material
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PQR Review
PQRs may be written but Always maintain the original Never White-out or pencil-in an original PQR Always rectify a PQR if revised and note reason for revision
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Combining Welding Procedures Several welding processes may be included in one WPS (qualified separated or combined) Section IX treats the following combination procedures: More than one welding process used More than one F-No. filler metal More than one A-No. A-No. electrode, except A-1 and A-2
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Examples of Combination Procedures WPS with ¼” GTAW and ¾” SMAW (F -1) and ½” SMAW (F-4) (F-4) WPS with ½” SMAW (F GTAW WPS and SMAW WPS used to make the same weld WPS with E7018-A1 and E8018-B2 (A-No. difference)
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Qualifying a WPS
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Six steps to Qualify a WPS Review Essential Variables Write Draft WPS Weld the test coupon using the WPS Prepare test specimens Evaluate test results Document results on a PQR and certify
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Writing a WPS
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Writing a WPS What base material will be welded? What filler material will be used? What welding processes will be used? What service or production restriction (s) will be required?
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Base Material P-Number: QW-422 Substitute most economical material for testing: QW-424
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Filler Material F-Number: QW-432 A-Number: QW-442 Shielding (Gas, Flux) Position restriction
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Processes to be used Required variables: QW-250 Production joint types Welder technique Equipment available
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Service Requirements Code/Customer Preheat/PWHT Corrosion Notch toughness (supplemental variable)
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Qualifying a WPS
Write an unqualified WPS around job parameters.
Watch variables QW-250 and QW-260
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Qualifying a WPS Weld the test coupon using unqualified parameters QW250, QW-260 Monitor all essential variables and record the actual values on the PQR Recommended Recommended also recording non-essential variables Record supplementary variables if required
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Qualifying a WPS Prepare the test coupon into specimens per QW-462, QW-463 Cut test coupon to size per QW-451, QW-462, QW463 Make the required test per QW-451
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Qualifying a WPS Evaluate results against Article Article 1 standards, QW-150 to QW-260 Compare unqualified WPS (essential and supplementary if required) Variable with results of the PQR Assure compliance to section IX
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Qualifying a WPS
When acceptable, certify the PQR The Certificate Holder • Approves WPS • Develops WPS and file • Uses the WPS for production welding
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Additional Qualification
An Additional PQR is required when: An essential variable changes The validity of the procedure is in doubt
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Notes A manufacturer must have a WPS that describes the welding parameters The WPS may reference production drawings to covers some variables The WPS may be pieces of paper or documents The WPS documentation must be controlled
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How to Change WPS Amendment (i. e additional additional PQR’s) PQR’s) New (Including Revision)
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Groove Weld Qualification Thickness Limits and Test Specimens
See reference table QW-451
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QW- 451.1: Example 1 T= .062” to 0.20” t= 0.20” max
T= 0.10”
GTAW
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QW- 451.1: Example 2 T= 1/16” to 1/2” t= 1/2” max
T= 1/4”
SMAW
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QW- 451.1: Example 3 T= 3/16” to 1” t= 1” max
T= 1/2”
SMAW
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QW- 451.1: Example 4
T= 3/16” to 1” GTAW t= 1/4” max SMAW t=3/4” max
SMAW = 3/8” T= 1/2”
GTAW = 1/8”
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QW- 451.1: Example 5
T= 3/16” to 2” GTAW t= 1/2” max SMAW t=2” max
SMAW = 3/8” T= 1”
GTAW = 1/4”
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QW- 451.1: Example 6
T= 3/16” to 2” F-4 F-4 SMAW = 2” max F-3 F-3 SMAW t=1/2” max
3/4“ SMAW F-4 F-4 T= 1”
1/4” SMAW F-3 F-3
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QW- 451.1: Example 7
T= 3/16” to 8” GTAW t= 8” max SMAW t=8” max
SMAW = 3/4” 1-1/2”
GTAW = 3/4”
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QW- 451.1: Example 8
T= 3/16” to 8” F-4 F-4 SMAW t= 8” max F-1 F-1 SMAW t=1/2” max
1-1/4“ 1-1/4“ SMAW F-4 F-4 1-1/2”
1/4” SMAW F-1 F-1
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Observation If the welding material is less than 8” thick, a test coupon greater than 1-1/2” 1-1/2” is not required. weld-deposited metal of 3/4” thick qualifies the weld to A weld-deposited be deposited on maximum thickness. Filler metal is still limited to 8” maximum.
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Miscellaneous Application
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WPS for Root Pass or Tack Welding QW-200.4(b) QW-200.4(b) allows special qualification for root deposit or tack welds only. Deposit filler metal on a 1/2” minimum base metal; the base metal qualification thickness range is unlimited. “t” deposit is limited to 2t
General Variables QW-202.2
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Variables that may be applicable or may reduce the number of procedures qualified. Partial penetration welds Groove and filler weld relationship P-11 requirement Weld metal repair and build-up Dissimilar base material thickness
Full Penetration Groove Welds QW-202.2(a)
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Full Penetration Groove Welds shall qualify for both base metal and deposited metal used in production
Qualification for Filler Welds QW-202.2(c)
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Groove weld test coupon qualifies for all fillet welds: Thickness Sizes Pipe Diameter Within essential variables
Note: exemption is P-11A groups 3,4,5 and P-11B which requires special qualification
Fillet Weld Qualification QW-202.2(c)
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Table QW-451.3: information for types of tests that must be performed Fillet weld qualification may not be used for pressureretaining welds
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Welding Variables
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QW-253: All Welding Variables (SMAW) QW-402: Joints QW-403: Base Metal QW-404: QW-404: Filler Metals QW-405: Positions QW-406: Preheat QW-407: PWHT Qw-409: Electrical QW-410: Technique
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Essential Variables: SMAW QW-403.7: T/t limits>8" limits> 8"
QW-404.5 Ø A No.
QW-403.8:Ø T qualified qualifi ed
QW-404.30: Ø t
QW-403.9: t pass > 1/2"
QW-406.1 Decrease > 100 ºF
QW-403.11: QW-403.11: Ø P-No. qualified qualifi ed
QW-407.1 Ø PWHT
QW-403.13: Ø P-No. 9/10
QW-407.4: T limits
QW-404.4: Ø F-No.
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QW-403.7: T/t Limits > 8” For thickness > 8”, the procedure test coupon thickness shall not be less than the thickness of the joint to be welded in production weld divided by 1.33, and the maximum thickness thickness of deposited weld metal qualified is 1.33 or 1.33t as applicable.
PWHT QW-407.1
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A separate PQR is required for each of the following conditions: For P-No. 1,3,4,5,6,9,10 and 11 materials, the following PWHT conditions apply: • No PWHT • PWHT below the lower transformation temperature
Cont’d……
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PWHT • PWHT above the upper transformation temperature (e.g. Normalizing) • PWHT above the upper transformation temperature followed by heat treatment below the lower transformation temperature (e.g. Normalizing or quenching, followed by Tempering) • PWHT between the upper and lower transformation temperatures
Cont’d……
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PWHT
For all other materials, the following condition apply: No PWHT PWHT within a specified temperature range
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Alternative Preheat
For thickness over 1-1/4 to 1-1/2” 1-1/2” thick, you may preheat at 200 ºF
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Non-Essential Variable QW-402.1 QW-402.4 QW-402.10 QW-402.11 QW-402.11 QW-404.6 QW-404.33 QW-405.1 QW-405.3
Ø Groove design – Backing Ø Root Spacing ± Retainers Retainer s Ø Diameter Ø AWS Class + Position Ø Vertical up or down
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Non-Essential Variable QW-406.2 QW-409.8 QW-410.1 QW-410.5 QW-410.5 QW-410.25 QW-410.26
Ø Preheat maintenance Ø Type I or I & E range Ø String/Weave Ø Method Cleaning Ø Method back gouging Ø Manual or Automatic ± Peening
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QW-402.1
Change in type of groove Vee-groove U-groove Single bevel Double bevel
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QW- 402.4
Deletion of backing in single welded grove welds Double welded groove welds are considered welding with backing
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QW-402.10
A change in specified root spacing.
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QW-402.11 The addition or deletion of nonmetallic retainers or nonfusing metal retainers
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QW-404.6 A change in the nominal size of the electrode or e electrodes specified in WPS
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QW-404.33 A change in the SFA specification filler metal classification; or, if not conforming to an AWS filler metal classification, a change in the manufacturer’s trade name for the electrode or filler metal
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QW-405.1 The addition of the welding position than those already qualified (See QW-120, QW-130 and QW- 303)
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Limits of Position
Electrode must be suitable for the position to be used. Example: E7024 May not be used for vertical welding without special qualification Section II only recognize E7024 for flat groove and horizontal fillet welds
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QW-405.3 A change from upward to downward, or from downward to upward in the progression specified for any pass of a vertical weld (the cover or wash pass may be up or down) A change in the range of electrode wire feed speed may be used as an alternative to amperage
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QW-406.2 A change in the maintenance or reduction of preheat upon completion or welding prior to any required postweld heat treatment
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QW-409.8 A change in the type of current or polarity, a change in the range of amperage, except for SMAW and GTAW welding, a change in the range of voltage A change in the range of electrode wire feed speed may be used as an alternative to amperage
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QW-410.1 A change from the stringer bead technique to the weave bead technique, or vice versa
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QW-410.5 A change in the method of initial and inter-pass cleaning, (brushing, grinding, etc.)
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QW-410.6
A change in the method of back gouging
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QW-410.25 A change from the manual or semi-automatic to machine or automatic welding and vice versa
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QW-410.26
Addition or deletion of peening
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Non-Essential Variables Must be addressed on the WPS but do not require qualification
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Welder performance Qualification QW-300
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Outline Rules & Definitions Welders’ Performance Qualification Record Welder/Operator Record Welder/Operator Test Coupons: Mechanical Testing Radiography Essential Variables (SMAW)
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Rules and Definitions
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Rule
Use QW-300, Article III to qualify welder plus: Applicable QW-100 paragraphs Applicable QW-100 paragraphs
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Define a Welder
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A Welder is… One who performs a manual or semi-automatic welding operations
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A Welder Operator… … is one who operates machine or automatic welding equipment
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Purpose of Qualifying a Welder Operator To determine the operator’s ability to operate the welding equipment
Welders’ Performance Qualification Qualificatio n Record
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A document used to record the Welder and Welding operator qualification
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Contents of the WPQ All applicable variables used by the Welder to make a test coupon Results of test Ranges of qualification (same variables only have minimum or maximum values)
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Essential Variables For Welders see QW-350 For Welding Operators see QW-360 Performance Qualification Record only has essential variables
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Welder/Operator Welder/Opera tor Records QW-103.2 QW-103.2 requires the Manufacturer to maintain a record for the results obtained in i n performance qualification Records must be certified by the Manufacturer
See non-mandatory Appendix A for Sample from QW-484
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Welder/Operator Welder/Opera tor Records Welder’s Welder’s Continuity Log: used by Manufactures to comply with QW-322.1
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Test Coupons
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Welding of Test Coupon Must use a WPS (qualified or not) Each coupon must be stamped with the number, symbol or letter assigned to identify the welder Preheat nor PWHT is not required WPS qualification may be used for the welder who made the weld
Visual Examination QW-302.4
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Plate coupon: Shall be performed on all surfaces (not marked “discard”) Pipe: Shall be performed over the entire circumference, inside and out. Visual examination shall be per QW-194
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Qualification by Radiography
Visual Examination QW-302.4
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Plate coupon: Shall be performed on all surfaces (not marked “discard”) Pipe: Shall be performed over the entire circumference inside and out. Visual examination shall be per QW-194
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Qualification by Radiography Radiography may be used in-lieu of mechanical testing as permitted in QW-304 and QW-305 Only limited to the following processes SMAW, SAW, PAW, GTAW (except for P-6X materials) GMAW (except short circuit)
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Welder Qualification by Radiography QW-304, QW-302
Test coupon: 6” min. weld length Production weld: 6” min. weld length Qualification on pipe shall include the entire weld circumference Small dia. pipe may require multiple coupons – coupons – the quantity need not exceed four
Welder Operator Qualification by Radiography QW-304, QW-302
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Test coupon: 6” min. weld length Production weld: 6” min. weld length Qualification on pipe shall include the entire weld circumference Small dia. pipe may require multiple coupons – coupons – the quantity need not exceed four coupons
Requirements of Radiography QW-191
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Technique must meet mee t ASME Code Section Secti on V, V, Article 2 Acceptance Criteria per QW-191.2
Welding Operator Radiographic Acceptance Criteria
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Same as welder as using test coupons Same as Construction Code acceptance criteria on production test coupon (QW-191.2.3)
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Failure of Test Coupon Immediate retest using same method Mechanical: Two consecutive test coupons Radiography: Two consecutive test coupons (NOT 12” in one coupon) With additional training, just start over No specific requirements for training in Section IX
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WPS Exceptions Examples of welding variables with no impact for performance qualification Preheat and PWHT Substitution of base material per QW-423 Possible substitution of filler metal Impact testing
Requirements of Radiography QW-191
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Not welding with a process during a six month period Specific reason to question ability
Renewal of Qualification QW-322.2 For each process One test Any material, thickness, plate or pipe Any position Requalifies all previous qualifications
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Welder Essential Variables SMAW
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QW-353: SMAW Paragraph
QW-402 Joints
Brief of Variables
.4
Deletion of Backing
QW-403 Base Material
.16
Ø Pipe Diameter
.18
Ø P-No.
QW-404 Filler metals
.15
Ø F-No.
.30
Ø t weld deposit
QW-405 Position
.1
Ø position
.3
Ø ↑↓ Vertical Welding
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QW-402.4 The deletion of the backing in single welded groove joints Double- welded groove welds are considered welding with backing
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QW-353: SMAW Paragraph
QW-402 Joints
Brief of Variables
.4
Deletion of Backing
QW-403 Base Material
.16
Ø Pipe Diameter
.18
Ø P-No.
QW-404 Filler metals
.15
Ø F-No.
.30
Ø t weld deposit
QW-405 Position
.1
Ø position
.3
Ø ↑↓ Vertical Welding
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QW-403.16 A change in pipe diameter beyond the range qualified in QW-452, except as otherwise permitted in QW-303.1 and QW-303.2
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QW-353: SMAW Paragraph
QW-402 Joints
Brief of Variables
.4
Deletion of Backing
QW-403 Base Material
.16
Ø Pipe Diameter
.18
Ø P-No.
QW-404 Filler metals
.15
Ø F-No.
.30
Ø t weld deposit
QW-405 Position
.1
Ø position
.3
Ø ↑↓ Vertical Welding
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QW-403.18 A change from one P-Number to another P-Number or to a base metal not listed in QW-422, except as permitted in QW-423 and QW- 420.2 (S-Number)
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QW-353: SMAW Paragraph
QW-402 Joints
Brief of Variables
.4
Deletion of Backing
QW-403 Base Material
.16
Ø Pipe Diameter
.18
Ø P-No.
QW-404 Filler metals
.15
Ø F-No.
.30
Ø t weld deposit
QW-405 Position
.1
Ø position
.3
Ø ↑↓ Vertical Welding
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QW-404.15 A change from one F-Number in QW-432 to any FNumber or to any other filler metal, except as permitted in QW-433
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QW-353: SMAW Paragraph
QW-402 Joints
Brief of Variables
.4
Deletion of Backing
QW-403 Base Material
.16
Ø Pipe Diameter
.18
Ø P-No.
QW-404 Filler metals
.15
Ø F-No.
.30
Ø t weld deposit
QW-405 Position
.1
Ø position
.3
Ø ↑↓ Vertical Welding
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QW-404.30 A change in deposited weld metal thickness beyond the range qualified in QW-452, QW-452, except as otherwise permitted in QW-303.31 and QW-303.2 When a welder is qualified using Radiography, the thickness range of QW-452.1 apply
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Deposited Metal Thickness QW-452.1 Type of Joint
Thickness of test Coupon Welded
Thickness "t" of deposited weld metal qualified
Max Groove Groove Groove
Up to 3/8"
2t
Over 3/8"
2t
1/2" and Over
Max. to be Welded
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Test Positions Four positions for welding with plate IG, 2G, 3G, 4G Four positions for welding with pipe IG, 2G, 5G, 6G
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Groove Weld in Plate Test Position
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Groove Weld in Plate Test Position
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Groove Weld in Plate Test Position
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Groove Weld in Plate Test Position
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Groove Welds Pipe Test Position
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Groove Welds Pipe Test Position
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Groove Welds Pipe Test Position
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Groove Welds Pipe Test Position
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Fillet Weld Plate Test Position
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Limits of Qualified Position and Diameter Welders Welders qualified in the grooves position in QW-461.9 shall be qualified to weld for that position in both groove and fillet welds Welders shall also be qualified to make fillet welds in all Welders thickness and pipe diameter
Qualification Test
Position and type Weld Qualified [Note [Nback ote 1]
Groove
Fillet
Plate and Pipe Plate – Plate – Groove
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Pipes ≤ 24" OD
Plate and Pipe
1G
F
F [Note 2]
F
2G
F,H
F,H [Note 2]
F,H
3G
F,V
F [Note 2]
F,H,V
4G
F,O
F [Note 2]
F,H,O
3G and 4G
F,V,O
F [Note 2]
All
2G, 3G and 4G
All
F,H [Note 2]
All
Special Positions
SP
SP [Note 2]
SP,F
1F
...
...
F [Note 2]
2F
...
...
F,H [Note 2]
3F
...
...
F,H,V [Note 2]
4F
...
...
F,H,O [Note 2]
3F and 4F
...
...
All [Note 2]
Special Positions
...
...
SP,F [Note 2]
1G
F
F
F
2G
F,H
F,H
F,H
5G
F,V,O
F,V,O
All
6G
All
All
All
2G and 5G
All
All
All
Special Positions
SP
SP
SP,F
Plate - Fillet
1F
...
...
F
[Note 3]
2F
...
...
F,H
2FR
...
...
F,H
4F
...
...
F,H,O
5F
...
...
All
Pipe – Pipe – Filter
Pipe – Pipe – Groove
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Position Qualificatio Qualification n The Welder is qualified to weld Vertical Overhead Flat Positions For both Pipe Plate
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Position Qualificatio Qualification n
The Welder Welded in Position 5G Pipe.
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Position Qualificatio Qualification n
The Welder Welded in Position: 2G Pipe.
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Position Qualificatio Qualification n
The Welder Welded 2G, 3G & 4G Plate
2G
3G
4G
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Position Qualificatio Qualification n The Welder is qualified to weld in both horizontal and flat positions
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Position Qualificatio Qualification n The Welder is qualified to all positions in both plate and pipe, NPS 24 and over Is the Welder qualified to weld all positions on an NPS 10 pipe
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QW-353: SMAW Paragraph
QW-402 Joints
Brief of Variables
.4
Deletion of Backing
QW-403 Base Material
.16
Ø Pipe Diameter
.18
Ø P-No.
QW-404 Filler metals
.15
Ø F-No.
.30
Ø t weld deposit
QW-405 Position
.1
Ø position
.3
Ø ↑↓ Vertical Welding
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QW-405.3 A change from upward to downward, or from downward to upward, in the progression specified for any pass of a vertical weld, except that the cover or wash pass may be up or down The root pass may be run either up or down when the root pass is removed to sound weld metal in preparation for welding the second side
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