4 Asme Sec Ix Wps Pqr Slide 1 to 35

WPS/PQR 153 Slides

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ASME Section IX, WPS/PQR Prepared by SCB

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A Welding Procedure is a recipe of variable welding parameters, which will produce the same results of certain quality & properties of weld if carried out in the same way eachh time ti Or a procedure which has been welded and tested to a specification such as ASME IX. Welding procedure qualification established the properties of weldment NOT the skill of the welder.

It is a document of a qualified welding procedure used to give a welder the information which he needs in order to carry out the work. It has been issued iss ed as a res result lt of a ssuccessful ccessf l Welding Procedure test (WP test). Additional ddi i l WPS’s can be b issued i d on a successful f l WP test as long as they remain within the Extent off Approval. l 30 เมษายน 53


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Drawing Construction Code Materials Design Impact testing PWHT etc ABC WPS W ldi Welding variables 9 Essential; 9 Nonessential; 9 Supplementary (if applicable).


ABC

Draft WPS From all range of welding variables 9Essential; 9 Nonessential; 9 Supplementary (if applicable). applicable) ABC PQR Record of actual variable and test results certification Date sign

Welding of a test coupon f from th the Range of variables

Record of welding variables


9Specimen preparation 9Mechanical test 9Documentation

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Once the welding of test coupon has been completed under some welding variables , No Radiography or any examination required The test coupons shall be Mechanically tested to ensure that the desired level of mechanical pproperties p have been met If all the desired properties have been met, then a procedure qualification record (PQR) is completed with all the test results reviewed, and the draft WPS then becomes qualified From thi F this data, d t a workable k bl document d t for f production d ti welding ldi is i prepared and called a Welding Procedure Specification. (WPS) and the welding work may proceed.

QW-200.1 Each manufacturer and contractor shall prepare written Welding Procedure Specifications which are defined as follows. (a) Welding Procedure Specification (WPS). A WPS i a written is i qualified lifi d welding ldi procedure d preparedd to provide direction for making production welds to Code requirements The WPS or other documents may be requirements. used to provide direction to the welder or welding operator p to assure compliance p with the,Code requireq ments. 30 เมษายน 53


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QW-200.2 Each manufacturer or contractor shall be required to prepare a procedure qualification record which is defined as follows. QW-200(a) Procedure Qualification Record (PQR). A PQR iis a recordd off the h welding ldi data d usedd to weld ld a test coupon. The PQR is a record of variables recorded during the welding of the test coupons. coupons It also contains the test results of the tested specimens. Recorded variables normallyy fall within a small range g of the actual variables that will be used in production welding. 30 เมษายน 53


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The terms “manufacturer” or “contractor” are: 9 Own the certificate of authorization,, can be a conventional or a nuclear stamp(s), where required 9 Responsible for the welding 9 Can be an installer, assembler or fabricator 9 Can be an organization effective operational control of welding qualification for TWO or more companies of different name, see QW 201.



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Question (1): If Company A reviews and approves Section IX qualified WPS’s submitted by Companies B and C for a given project, may Company A use Company B and C‘s WPS’s? Reply R l (1): (1) No. N Question (2): If Company A reviews and approves S ti IX qualified Section lifi d WPS’s WPS’ submitted b itt d Companies C i B andd C for a given project, may Company A authorize company B to use Company C C‘ss WPS’s WPS s on that project? Reply (2): No. 30 เมษายน 53


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Question: May a contractor provide his qualified welding we d g procedure p ocedu e spec specifications, ca o s, for o use by hiss subcontractors, to perform welding in accordance with the requirements q of ASME BPV Code Section IX? Reply: No.



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Question: In a contract involving piping construction work, our company subcontracted the piping prefabrication work to a subcontractor. This subcontractor is managed g by y our company p y but has a different name. The subcontractor proceeded to qualify welding procedures which were conducted in the presence and with the approval of our company’s welding engineer i who h monitored i d the h welding ldi off the h test coupons andd signed approval on the PQRs. The Quality Control System of the subcontractor and our company fully described the operational e ti l control t l off procedure ed e qualifications. lifi ti W our client Was lie t right in rejecting the use by our company of the subcontractor qualified welding procedures for the erection work of the prefabricated piping? Reply: This is a contractual issue, which ASME does not address. 30 เมษายน 53


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Three construction companies have participated in a nuclear power plant construction project as a consortium contractor. They have a unified Quality Assurance Program, but the consortium does not hold a Certificate of Authorization. Authorization Each of the construction companies holds its own Certificate of Authorization. Question: Does “two two or more companies of different names in an organization” in QW-201 apply to the consortium described in the Background? g Reply: No 30 เมษายน 53


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Background Two companies are contracted by a client company to undertake pipe work installation on its facility. All stages g of the Welding g Procedure Q Qualification Processes for the two contracted companies are witnessed by the client companies representative and the documentation duly stamped and signed as accepted by the client. Question (1): May these procedures be used by the client company? Reply p y ((1): ) No. Question (2): Does the client company have to re-qualify these procedures in order to perform in-house maintenance a t a later date using all the same essential and nonessential variables with its own qualified welders? Reply (2): Yes. 30 เมษายน 53


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WPSs may be used by the new owner(s) without requalification, provided all of the following are met: (a) the new owner(s) takes responsibility for the WPSs and PQRs (b) the WPSs reflect the name of the new owner(s) (c) the Quality Control System/Quality Assurance Program reflects the source of the PQRs as being from the former manufacturer or contractor



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Background: Company A and Company B merge divisions to form a new Company, C. Question (1):May the new Company C , use PQRs and WPSs developed previously by Company A and Company B? Reply (1): Yes, provided operational control is in accordance with QW-201. Question (2): May the new Company, C, use the central materials laboratory of Company A to develop WPSs and PQRs? Reply (2): Yes, provided operational control is in Q accordance with QW-201. 30 เมษายน 53


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Background: When one of a company' s plants is sold, it is not clear if the new owner can use the Welding Procedure Specifications (WPS) and Procedure Qualification Records (PQR) qualified by the original company when the original company wishes to continue company. using those WPS/PQR. Question: Company A sells one of its plants to Company B. May both Company A and Company B use the WPSs/PQRs Q ppreviously y qqualified by y Company p yA Reply: Yes. provided the requirements of QW-201.1 are addressed by Company B. 30 เมษายน 53


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(b)Contents (b)C t t off the th WPS. WPS The Th completed l t d WPS shall h ll describe all of the essential, nonessential, and, when required, supplementary essential variables for each welding process used in the WPS. These variables are listed in QW-250 through QW-280 and are defined in Article IV, Welding Data. The WPS shall reference the supporting Procedure Qualification lifi i Record(s) d( ) (PQR) ( ) described d ib d in i QW-200.2. The manufacturer or contractor may include any other information in the WPS that may be helpful in making a Code weldment. 30 เมษายน 53


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QW-401.1 Essential Variable (Procedure) A change in a welding (Procedure). condition which will affect the mechanical properties ti (other ( th than th notch t h toughness) t h ) off the weldment (for example, change in PNumber, welding process, filler metal, postweld beat electrode,, ppreheat or p treatment, etc.). 30 เมษายน 53


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QW-401.3 Supplemental Essential Variable (Procedure). A change in a welding condition which will affect the notch-toughness properties of a weldment (for example, change in welding process, uphill or down vertical welding heat input, welding, input preheat or PWHT, PWHT etc.). etc ) When a procedure has been previously qualified to satisfy all requirements other than notch toughness, it is then necessary only to prepare an additional test coupon using the same procedure with the same essential variables, i bl but b t additionally dditi ll with ith all ll off the th required i d supplementary l t essential ti l variables, with the coupon long enough to provide the necessary notchtoughness specimens. When a pprocedure has been ppreviously y qqualified to satisfy y all requirements including notch toughness, but one or more supplementary essential variable is changed, then it is only necessary to prepare an additional test coupon using the same welding procedure and the new supplementary essential variable(s), with the coupon long enough to provide the necessary notch-toughness specimens. If a previously qualified weld procedure has satisfactory notch-toughness values in the weld metal, then it is necessary only to test notch-toughness specimens from the heat affected zone when such are required. required 30 เมษายน 53


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QW-401.4 Nonessential Variable (Procedure). A change in a welding condition which will not affect the mechanical properties of a weldment (such as joint design, method of back gouging or cleaning, etc.)



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((c)) Ch Changes to t the th WPS. WPS Changes Ch may be b made d in i the th nonessential variables of a WPS to suit production requirements without requalification provided such changes are documented with respect to the essential, nonessential, and, when required, supplementary essential variables for each process. This may be by amendment to the WPS or by use of a new WPS. Changes h i essential in i l or supplementary l essential i l (when ( h required) variables require requalification of the WPS (new or additional PQRs to support the change in essential or supplementary essential variables). 30 เมษายน 53


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Question: Does QW-200.l(c) require that there be a history of changes such as margin notes or other record documenting what specific changes were made in the essential, nonessential, or supplemental variables each time a WPS is revised? Reply: No.



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(d) Format of the WPS. The information required to be in the WPS may be in any format, written or tabular, to fit the needs of each manufacturer or contractor, contractor as long as every essential essential, nonessential, nonessential and, when required, supplementary essential variables outlined in QW-250 through QW-280 is included or referenced. Form QW-482 (see Nonmandatory Appendix B) has been provided as a guide for the WPS. This Form includes the required data for the SMAW, SAW, GMAW, and GTAW p processesIt is only y a guide and does not list all required data for other processes. It also lists some variables that do not apply to all processes (e.g., listing shielding gas which is not required for SAW). The guide does not easily lend itself to multiple process procedure specification (e.g., GTAW root with SMAW fill). 30 เมษายน 53


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Each manufacturer or contractor shall maintain a record of the results obtained in welding procedure and welder and welding operator performance qualifications. These records shall be certified by a signature or other means as described in the manufacturer’s manufacturer s or contractor’s contractor s Quality Control System and shall be accessible to the Authorized Inspector. Refer to recommended Forms in Non mandatory Appendix B.



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Question: Is it acceptable to satisfy the requirements of QW103.2 for record maintenance, certification, and accessibility by means of an electronic storage medium, e .g., computer database? Reply: Section IX does not address the media in which records d are required i d to t be b maintained. i t i d



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OFW Oxyfuel Gas Welding SMAW Shield Metal-Arc Welding SAW Submerged-Arc Welding GMAW Gas Metal Metal-Arc Arc Welding &FCAW & Flux-Core-Arc Welding GTAW Gas Tungsten-Arc Welding PAW Plasma-Arc Plasma Arc Welding ESW Electroslag Welding EGW Electrogas Welding EBW Electron Beam Weldingg Stud & Inertia and Continuous Drive Friction Welding Resistance Welding LBW Laser Beam Weldingg Flash Welding Each welding process has its own welding variables (table QW-252 to 265)



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QW-250 WELDING VARIABLES QW-251 General QW-251.1 Types of Variables for Welding Procedure Specifications (WPS). These variables (listed for each welding elding process in tables QWQW 252 through QW-265) are subdivided into essential variables,, supplementary pp y essential variables, and nonessential variables (QW-401). The "Brief of Variables" listed in the Tables are for reference only. only See the complete variable in Welding Data of Article IV. 30 เมษายน 53


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Question (1): Is it required that all of the essential and nonessential variables listed in QW QW-250 250 through QW QW-280 280 for each welding process be addressed in the WPS, even though some of these variables are not applicable? li bl ? Reply (1): Yes. Yes



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QW-250 WELDING VARIABLES QW-251.4 Special Processes (a) The special process essential variables for corrosion corrosion- resistant and hard-surfacing weld metal overlays are as indicated in the following tables for the specified process. Only the variables specified, for special processes shall apply. A change in the corrosion-resistant i i t t or hardsurfacing h d f i welding ldi process shall h ll require i requalification. QW-218 Applied Linings QW 218 1 WPSs QW-218.1 WPS for f attaching tt hi applied li d linings li i shall h ll be b qualified lifi d in accordance with QW-202.2(a), (b), or (c). QW-219 Flash Welding Fl h welding Flash ldi shall h ll be b limited li it d to t automatic t ti electrical l t i l resistance it flash welding of tubular cross-sections. Procedure qualification tests shall be conducted in accordance with QW-199.1. 30 เมษายน 53


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QW-252 QW-252.1 QW-253 QW 253 1 QW-253.1 QW-254 QW-254.1 QW-255 QW-255.1 QW 256 QW-256 QW-255.1 QW-257 QW 257 1 QW-257.1


OFW OFW (special process) SMAW SMAW (special ( i l process) SAW SAW (special process) GMAW and FCAW GMAW and FCAW (special process) GTAW GTAW (special process) PAW PAW (special process)

QW-258 QW-258.1 QW-259 QW 259 1 QW-259.1 QW-260 QW-261 QW-262 Q QW-263 QW-264 QW-264 1 QW-264.1 QW-265 QW-290.4


ESW ESW (special process) EGW EGW (special ( i l process)) EBW Stud Welding Inertia and Continuous Drive Friction Welding Resistance Welding LBW LBW (special process) Flash Welding Temper Bead

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4 Asme Sec Ix Wps Pqr Slide 1 to 35

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