Asme Section Ix-com Rev 1-23-08-2013

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ASME Boiler and

Pressure Vessel CodeBasic Training Course

Section IX



Section IX – Welding & Brazing - Forewords

Addenda

• Addenda are changes to the Code and are issued annually. They may be used

upon issuance but are not mandatory for six months. It is strongly recommended

that you do not discard pages of the Code that are replaced by Addenda. For

example, if you have a procedure qualified to a previous Addenda, and it is being

reviewed, you must have access to the Code to which the procedure or welder was

qualified.

Reference Code• It is important to remember that Section IX is a reference Code. This means that it

is only used when it is referenced and as it is referenced.



Section IX – Welding & Brazing - Forewords

WPS/WPQ Qualifications

• Article 1, paragraph QW-100.2 discusses “old” procedures and welder’s

qualifications. It requires that for qualification prior t 1962, you must either

update to a later addenda or discard it as invalid. Procedures qualified after1962, however, are good forever. Welder’s qualifications are valid as long as

their continuity is maintained.

• Note: If you attempt to qualify procedures or welders to an earlier addenda,

they will most likely not meet the requirements of the latest addenda. They will

be valid only for fabrication being done to that earlier addenda.



Organisation, Content and Structure of Section IX

Structured in 2 Parts - Welding ( QW ) and Brazing ( QB )

Both identical subdivided in 4 articles• General requirements

• Procedure qualifications

• Performance qualifications

• Welding resp. brazing data

Additionally• Article V “ Standard Welding Procedure Specifications”

( SWPS’s )

and

• Appendices : Mandatory and nonmandatory requirements




Article I: Welding General Requirements

• QW-100: General

• QW-110: Weld Orientation

• QW-120: Test positions for groove welds

• QW-130: Test positions for groove welds

• QW-140: Types and purposes of tests and examinations

• QW-150: Tension tests

• QW-160: Guided-bend tests• QW-170: Notch-toughness tests

• QW-180: Fillet-Weld Tests

• QW-190: Other tests and examinations

• Appendix I: Rounded indication charts




Article II: Welding Procedure Qualifications

• QW-200: General

• QW-210: Preparation of test coupons• QW-250: Welding variables

Article III: Welding Performance Qualifications

• QW-300: General

• QW-310: Qualification test coupon• QW-320: Retests and renewal of qualification

• QW-350: Welding variables for welders

• QW-360: Welding variables for welding operations

• QW-380: Special processes




Article IV: Welding Data

• QW-400: Variables

• QW-410: Techniques

• QW-420: P-Numbers

• 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

• Appendix A (nonmandatory): Suggested welding forms

• Appendix B (mandatory): Preparation of technical inquires to the Boiler and

pressure Vessel Committee.



Welding



Definitions (QW/QB-492)

Definitions of common terms relating to welding/brazing

Backgouging – The removal of weld metal and base metal from the

weld root side of a welded joint to facilitate complete fusion andcomplete joint preparation upon subsequent welding from that side.

Backing – A material placed at the root of a weld joint for the purpose

of supporting molten weld metal so as to facilitate complete joint

preparation. The material may or may not fuse into the joint.

Retainer – Nonconsumable material, metallic or nonmetallic, which is

used to contain or shape molten weld metal.

Backing Gas – A gas, such as argon, helium, nitrogen, or reactive gas,

which is employed to exclude oxygen from the root side (opposite

from the welding side) of weld joints.

Base metal – The metal or alloy that is welded, brazed, or cut.





Build-up of base metal – This is the application of a weld material to a

base metal so as to restore the design thickness and/or structuralintegri ty. Also may be called base metal repair or buildup.

Butt joint – A joint between two member aligned approximately in the

same plane.

Buttering – The addition of material, by welding, on one or both faces

of a joint, prior to the preparation of the joint for final welding, for thepurpose of providing a suitable transition weld deposit for the

subsequent completion of the joint.

Consumable insert – Filler metal that is placed at the joint root before

welding, and is intended to be completely fused into the root to

become part of the weld.





Corner joint – A joint between two members located approximately at

right angles to each other in the form of an “ L” . Direct current electrode negative (DCEN) – The arrangement of direct

current arc welding leads in which the electrode is the negative pole

and the workpiece is the positive pole of the welding arc (straight

polarity).

Direct current electrode positive (DCEP) – The arrangement of directcurrent arc welding leads in which the electrode is the positive pole

and the workpiece is the negative pole of the welding arc (reverse

polarity).













(Tip : DCEN (DCSP) for E-7016 is wrong)





Double-welded joint – A joint that is welded from both sides.

Filler metal – The metal or alloy to be added in making a welded,

brazed, or soldered joint. Fillet weld – A weld of approximately triangular cross section joining

two surfaces approximately at right angles to each other in a lap joint,

tee joint, or corner joint.

Groove weld – A weld made in a groove formed within a single

member or in the groove between two members to be joined.

Heat affected zone – That portion of the base metal which has not

been melted, but whose mechanical properties or microstructures

have been altered by the heat of welding or cutting.





Interpass temperature – The highest temperature in the weld joint

immediately prior to welding, or in the case of multiple pass welds,

the highest temperature in the section of the previously depositedweld metal, immediately before the next pass is started.

Oscillation – For a machine or automatic process, an alternating

motion relative to the direction of travel of welding.

Overlay, corrosion resistance weld metal – Deposition of one or more

layers of weld metal to the surface of a base material in an effort toimprove the corrosion resistance properties of the surface. This

would be applied at a level above the minimum design thickness as a

nonstructural component of the overall wall thickness.





Overlay, hard facing weld metal – Deposition of one or more layers of

weld metal to the surface of a base material in an effort to improve

the wear resistance properties of the surface. This would be appliedat a level above the minimum design thickness as a nonstructural

component of the overall wall thickness.

Peening – The mechanical working of metals using impact blows.

Preheat Maintenance – Practice of maintaining the minimum specified

preheat temperature, or some specified higher temperature for somerequired time interval after welding or thermal spraying is f inished or

until post weld heat treatment is initiated.

Preheating – The application of heat to the base metal immediately

before a welding or cutting operation to achieve a specified minimum

preheat temperature.





Stringer bead – A weld bead formed without appreciable weaving.

Weave bead – For a manual or semiautomatic process, a weld bead

formed using weaving. Weaving – A welding technique in which the energy source is

osci llated transversely as it progresses along the weld path.

Welding, automatic – Welding with equipment which performs the

welding operation without adjustment of the controls by a welding

operator. The equipment may or may not perform the loading andunloading of the work.

Welding, machine – Welding with equipment that has controls that

are manually adjusted by the welding operator in response to visual

observation of the welding, with the torch, gun, or electrode holder

held by a mechanical device.





Welding, manual – Welding wherein the entire welding operation is

performed and controlled by hand.

Welding, semiautomatic arc – Arc welding with equipment whichcontrols only the filler metal feed. The advance of the welding is

manually controlled.















Weld types addressed by Section IX

Three Types of Welds Addressed by Section IX

• Groove Welds

• U Groove

• J Groove• V Groove

• Partial Penetration; Etc.

• Fillet Welds

• Stud Welds












Welding Processes addressed by Section IX

GTAW (Gas Tungsten Arc Welding)

GTAW is a welding process wherein coalescence is produced by

heating with an arc between a tungsten electrode and the work.

GTAW Advantages

• Works well with thin metals

• Welds have very few discontinuit ies

GTAW Disadvantages

• Poor Speed and high cost




GTAW (Gas Tungsten Arc Welding)




SMAW (Shielded Metal Arc Welding)

SMAW is a manual welding process in which the heat for welding is

generated by an arc established between a coated consumable

electrode and the work.

The shielding can be obtained from combustion and decomposition

of the flux covering.

Additional shielding is supplied for the molten metal in the weld

puddle by a covering of molten flux called slag.





SMAW Advantages

• Portable equipment (No facilit ies to supply shielding gas isrequired)

• Works well in difficult positions

• Usable on a wide variety of materials

SMAW Disadvantages

• Fixed lengths on electrode

• Additional cleaning for slag removal

• Slower than other processes








GMAW (Gas Metal Arc Welding, MIG Welding) / FCAW (Flux Cored

Arc Welding)

GMAW is a arc welding process which produces coalescence metalsby heating them with an arc between a continuous fil ler metal

(Consumable) electrode and the work. Shielding is obtained entirely

from an externally suppl ied gas or gas mixture.

FCAW is a arc welding process which produces coalescence metalsby heating them with an arc between a continuous fil ler metal

(Consumable) electrode and the work. Shielding is supplied by a flux

contained within a tubular electrode. Additional shielding may be

provided from an externally suppl ied gas or gas mixture.




GMAW/FCAW

Advantages

• Continuous feed of fi ller metal (high speed welding)

Disadvantages

• Welding equipment in so complex

• Electrode holder should be close to the work• More susceptible to cracking in hardenable steels

• Poor impact value




Typical Metal Transfer Mode

Spray Arc Mode

• The metal is t ransferred from the end of the electrode wire to the

puddle in an axial stream of f ine droplets.

• The sizes of droplets vary, but the maximum diameter is less

than the electrode diameter.

• Argon or Argon rich gas are generally used for shielding gas.

Globular Arc Mode

• Formation of a relatively large drop of molten metal at the end of

the tapered electrode wire.

• The drop forms at the end of the electrode wire until the force ofgravity overcomes the surface tension of the molten drop, at

which time the drop falls into the weld puddle.




Typical Metal Transfer Mode

Globular Arc Mode cont’d

• All types of shielding gases may be used.

• If overhead welding were attempted using globular transfer, themolten electrode metal would fall down into the electrode holder nozzle.

Short-circuiting Transfer • Metal transfer is which molten metal from a consumable

electrode is deposited during repeated short circuits.




GMAW (Gas Metal Arc Welding)




FCAW (Flux Cored Arc Welding)




Parts of A Weld






Weld Size




Weld Size




Penetration




Penetration




Fusion

Complete Fusion




Fusion

Incomplete Fusion




Weld Flaws




Weld Flaws




Weld Flaws



Article I – Welding General Requirements

QW-100.3

WPS, PQR, W(O)PQ made in accordance with the requirements of the

1962 Edit ion or any later Edition of Section IX may be used in any

construction buil t to the ASME Boiler and Pressure Vessel Code or

the ASME B31 Code for Pressure Piping.

QW-103.2

Each manufacturer or contractor shall maintain a record of the results

obtained in welding procedure and welder and welding operatorperformance qualif ications. These records shall be certified by the

manufacturer or contractor and shall be accessible to the AI.




QW-120 Test Posit ions for Groove Welds




QW-153 Acceptance Criteria – Tension Test

Minimum values for procedure qualification are provided under thecolumn heading “ Minimum Specified Tensile” of table QW/QB-422.

In order to pass the tension test, the specimen shall have a tensilestrength that is not less than :

(a) the minimum specif ied tensile strength of the base metal; or

(b) the minimum specified tensile strength of the weaker of the two;or

(c) if the specimen breaks in the base metal outside of the weld orweld interface, the test shall be accepted as meeting the

requirements, provided the strength is not more than 5% below theminimum specified tensile strength of the base metal

In case of material of SA-516 Gr.70 and if the specimen was brokenin the base metal, the ultimate unit stress calculated by area andultimate total load shall be over 70,000psi 0.95 = 66,500psi, if the

specimen was broken in the weld, the ultimate unit stress shall beover 70,000psi.




QW-163 Acceptance Criteria – Bend test

The guided-bend test specimens shall have no open discontinuity inthe weld or HAZ exceeding 1/8 inch, measured in any direction on the

convex surface of the specimen after bending.

For corrosion-resistant weld overlay cladding, no open discontinuityexceeding 1/16 inch, measured in any direction, shall be permitted inthe cladding, and no open discontinuity exceeding 1/8 inch shall bepermitted along the approximate weld interface.

Ti R ibil i i



Tip : Responsibil ities

Authorized Inspector

Before Fabrication

• WPS/PQR comply with ASME Sec. IX.• Welders and Welding Operators are properly qualified.

During Fabrication

• All welding is done within the parameters of the WPS.• Welder qualif ication limits are not exceeded or have not expired.

Ti R ibil iti




Manufacturer’s Responsibility for Records

The manufacturer has specific responsibilities regarding the preparation and qualification of

procedures. Among the manufacturer’s responsibilities are the following:

1. To prepare and qualify the WPS

2. To directly supervise and control the welder during the welding of the test coupons.

3. To maintain the WPS and then PQR while welding is being performed.

4. To certify the PQR.

5. To compile and certify a list of all qualified procedures for use on Code jobs.

Record Retention

• There are no requirements in the non-nuclear Codes to maintain welding procedures once

a job is finished – these requirements are normally found in a QC manual. But since

procedure qualifications do not expire, they are normally maintained as standard company

procedures. The nuclear codes, however, require retention for the life of the plant. In anycase, the procedures must be available during construction.

Ti R ibil iti




Manufacturer

Qualification of Procedures

• Establish a QC Program to control qualifications.• Prepare the written WPS addressing all required variables for

each process.

• Assure metallurgical compatibility of the filler metal and the base

metal.

• Prepare and certify a PQR based on data recorded during the

welding and testing of the coupon.





Manufacturer cont’d

Qualification of Welders

• Establish a QC Program to control welder’s qualification.• Qualify each welder with each process that welder is to use.

• Weld the test coupon in accordance with a WPS.

• Control and supervise welding of the coupon.

• Maintain identification of welders.• Document Welders qualifications such as WPQ, table of certi fied

welder l ist.

Article II - Welding Procedure Specifications - WPS



g p

A WPS is a written qualified welding procedure prepared to provide direction for makingproduction welds.

Completed WPS shall describe all of the essential, nonessential, and, when required,supplementary essential variables.

• Essential variables are those in which a change, as described in the specificvariables, is considered to affect the mechanical properties of weldment, and shallrequire requalification of the WPS.

• Supplemental essential variables for a process are those conditions which, whenchanged, will affect the impact properties of the weld.

(If impact test is not required, supplementary essential variables are not beconsidered as a nonessential variables. In this case this supplementary essentialvariables are not needed to be recorded in WPS)

• Acceptable (i.e. qualified) ranges

• Other information desired for additional control.




g p

Non-Essential Variables

• Non-essential variables for a process are those conditions which, when

changed, do not have a major impact on the weld. They must, however, be

considered and addressed on the WPS.

• A change of nonessential variables will requires a change in WPS but not

require a re-qualification.

The special process essential variables for corrosion-resistant and hard-

surfacing weld metal overlays are as indicated in the tables for the specified

process.(It means that separate PQR/WPS in accordance with QW-252.1/253.1……..

264.1 plus QW-453 for overlay shall be prepared. The PQR/WPS which

were prepared in accordance with QW-252/253…….264 shall not be used

for overlay process)



Welding Steps of Preparing PQR/WPS

S IX QW 201 S VIII 1 UW 28



<Sec.IX, QW-201, Sec VIII-1, UW-28>

Things to Consider When Preparing a WPS.

1. Compatibility of the weld metal and base metal

2. Metallurgical properties

3. Heat treatment requirements

4. Design of joints and loadings

5. Desired mechanical properties

6. Service requirements

7. Welder’s ability

8. Equipment available

9. Location of welds

10. Economy




<Sec IX QW 201 Sec VIII 1 UW 28>




Writing a WPS

Once you have identified the base metals you intend to weld and identified their P-Nos. per

QW-422, you should then select the most economical base metal from QW-424 to use

for the test coupon.

Next, the appropriate filler materials are selected and their A-Nos. determined from QW-

432 and QW-442. You may also need to consider shielding gas or flux and any

position restrictions that may apply.

Welding processes to be used should be determined and the required variables of QW-

250 addressed. It is also necessary to consider the types of production joints, weldertechniques, and available equipment.

Finally, you need to consider the service or production restrictions. These include such

things as Code / customer requirements, preheat / PWHT, corrosion, and notch

toughness.


<Sec IX QW 201 Sec VIII 1 UW 28>




Qualifying the WPS

The basic steps for qualifying a WPS are (using the parameters of the unqualified WPS):

Establish the test coupon size (QW-451, 462, 463).

Weld the test coupon following the parameters of the WPS (QW-210, 250, 260) :Monitor and document the specifics of the essential variables and, when

applicable, the supplemental essential variables (QW-200.2). It is recommended

that all other specifics be measured, documented, and maintained on file.

Cut the coupon into the required test specimens (QW-462, 463). This may be

performed by the testing laboratory.

Evaluate the test results per QW-150 to 180. This is the responsibility of the

manufacturer.

If the results are acceptable, document them on the PQR and certify.

Compare the PQR with the parameters listed the WPS (essential and supplementalvariables) to assure that the full range is supported by the PQR. If not, it may be

necessary to supplement the ranges with an additional PQR, or reuse the ranges

to within that which is supported.

The WPS may now be added to the certified list of qualified procedures required by

QW-201.


<Sec IX QW-201 Sec VIII-1 UW-28>




Permitted changes to a WPS

A WPS may be revised for several reasons. Among these reasons are:

• A change in a non-essential variable. This would require revision but no

requalification.• A change in an essential or supplementary essential and requalification.

• Corrections or updates due to inadvertent errors or to Code Addenda.

A WPS may be revised by:

• Writing a new WPS, including revision number.

• Adding an amendment. This would also require a revision number.




g p

If “ x” is located only in the supplementary essential variables, when impact testis not required, these variables are not considered as nonessential variables.




Manufacturer’s or Contractor’s Responsibility

• Each manufacturer and contractor shall qualify the WPS by the

welding of test coupons and the testing of specimens, and the

recording of the welding data and test results in PQR.

• The weldments to be tested for qualification of procedures shall be

welded either by direct employees or by individuals engaged by

contract for their services as welders under the full supervision and

control of the manufacturer or contractor.

• Supervision and control of welding of the test weldments performedby another organization is not permitted.

• If in an organization effective operational control of welding procedure

qualification for two or more companies of different names exists, the

companies involved shall describe in their Quality Control

System/Quality Assurance Program. In this case separate weldingprocedure qualifications are not required.






Variables are defined for each process in QW-250 through QW-280

• Each variable shall be addressed, do not state N/A but facts, yes, no,

none or any other meaningful definition.

Changes to WPS’s are allowed, however

• Changes in essential and supplementary essential variables require

requalification and a new WPS.

• Changes in nonessential variables can be made without

requalification, need to be documented and the WPS to be revised.

A WPS is a written qualified welding procedure prepared to provide

direction for making production welds.

A WPS used for Code production welding shall be available for referenceand review by the AI at the fabrication site.




Completion of a WPS

• All variables to be addressed.

• Do not state single figures but always ranges.

• Ranges should be as broad as possible but adequate for the process.

• Joint design (nonessential) : do not show only one joint design but

either make reference to joints as shown on workshop drawings or attach a separate sheet showing a variety of joints which can be usedfor the process.

• QW – 424 : Base metal used for procedure qualification test coupon

versus range of base metals qualified.





Cont’d completion of a WPS



Cont d completion of a WPS

No limitation in positions : qualification in one position qualifies theprocedure ( but not the welder !! ) for all (meaningful) positions,

QW-461 Positions of groove (G) and f illet (F) welds in plate and pipe

• 1G, 2G, 3G, 4G for plate groove weldsflat - horizontal - vertical - overhead

• 1G, 2G, 5G, 6G for pipe groove welds

f lat - horizontal - multiple

• 1F, 2F, 3F, 4F for plate fi llet welds

flat - horizontal - vertical - overhead

• 1F, 2F, 2FR, 4F, 5F for pipe f il let weldsflat -- horizontal - horizontal rotated - overhead - multiple




Cont’d completion of a WPS

Thickness ranges : “T“ for base metal, “ t“ for deposited weld metal

• Thickness ranges to be careful ly considered when GMAW shortcircuiting arc welding is employed (GMAW, short circuiting arc

welding, t<13mm => “ T” qualified shall be below 1.1 times of testcoupon thickness.

Preheat and postweld heat treatment temperatures to be considered.

Preheat decrease of 55 C become an essential variable.

The meaning of preheat maintenance is maintenance preheatupon completion of welding prior to any required postweld heattreatment.

Electrical characteristics and Technique

• Applicable variables for the process to be considered




Subcontracted Welding Procedures (Section I)

• Section I allows a unique method for “subcontracting” welding procedures for

use on PP stamped pipe. The National Certified Pipe Welders Bureau

(NCPWB), a national organization made up of member companies, provides

prequalified welding procedures to its members. These procedures can be

used for PP stamped pipe by member companies without requalification. The

member company must sign each WPS and PQR and accept responsibility for

its use and compliance to Code requirements. Remember, these are permitted

only for PP stamped boiler external piping




Combination of WPS’s More than one WPS having different variables may be used in a single

production joint.

• Each WPS may include one or a combination of processes, filler metals orother variables.

• Range of the deposited weld metal thickness qualified for each process tobe considered.

More than one process may be recorded in one WPS

• All variables associated with each process to be applied and addressed.

• Base metal and deposited weld metal thickness limits for each process tobe applied.

Format of the WPS : can be any format, as long as any variable for the processis included or referenced.

• Form QW-482 has been provided as a guide for the WPS .





Article II - Procedure Qualification Record - PQR



Example of a Revised PQR

• A valid reason to revise a PQR is a change in material classification by the Code. If,

at the time of the original qualification, the material had not been assigned a P-No., it

would have been qualified by specification and therefore good for use only when

welding that specification. But if at a later date Section IX assigned a P-No. to that

material, the PQR could be revised to indicate the P-No. making that procedureacceptable for use with any material in that P-No. grouping.

• Combination of Welding Procedures : It is considered a “combination of welding

procedures” whenever more than one WPS is used to complete a weld or when

using only one process from a WPS that was qualified with multi-processes.




Thickness ranges of test coupons and number of test specimen

QW-451.1 Number of tension and transverse bend tests

• Table generally to be used

QW-451.2 Number of tension and longitudinal bend tests

• Table may be used in lieu of transverse bend tests for testing weld

metal or base metal combinations, which dif fer markedly in bending

properties between either two base metals or the weld metal and thebase metal.

QW-451.3 Number of f il let weld tests

• macro test specimen required, however

• Groove tests qualify all f illet sizes on all base metal thicknesses andall diameter




QW-462 Dimensions of test specimen for tension, bend and impact test

specimen

QW-463 + QW-464 Location of test specimen in test plates

QW-466 to QW-469 Dimensions of test jigs

QW-470 Etching processes and reagents

• Specifies etching solutions for ferrous and nonferrous metals

Special testing requirements for P-No 11 base material, Corrosion –

Resistant Weld Metal, Electron and Laser Beam Welding, Hard-facing

Weld Metal Overlay, Joining of Composite (clad metals), Applied Liningsand Flash welding




Mechanical Tests for a WPS

• QW-202 covers the required tests for welding procedure qualifications. At minimum, themechanical tests are two tensile tests and four bend tests. The types of bend tests are:

• For test coupon thicknesses up to and including 3/8": Two face and two root bends.

• Over 3/8 but less than 3/4": May use two face and two root, or four side bend tests.

• 3/4" and over: Four side bend tests.

• Note: All filler metal and processes used must be included in the tensile and bend tests toqualify.

Types of Tests Based on Coupon Thickness• Tension tests are covered in QW-150. This paragraph is referenced from Table QW-451.

QW-151 states:

• If the coupon is greater than 1" thick, multiple specimens may be cut mechanically.

• Each set of multiple specimens shall represent one tensile specimen.

• There is a special exemption for pipe 3" or less. This pipe may be tested withoutcutting specimens.




One PQR may support a number of WPS’s

or

One WPS may require a number of PQR’s

Examples• 1 G plate PQR support WPS’s for the F, V, H, and O position on plate

or pipe within all other essential variables.

• One WPS with thickness range from 1.5 mm to 32.0 mm is supported

by two PQR’s with thickness ranges from 1.5 through 5.0 mm and

from 5.0mm through 32.0 mm.

• One WPS with a combination of processes ( 2 or more ) is supported

by 2 or more PQR’s with single process qualifications within all

other essential variables.

• One PQR with a combination of processes ( 2 or more ) support

WPS’s with single processes within all other essential variables.




Some notable requirements

• Qualification in one position qualifies the procedure for all positions.

• A welder making and passing the WPS qualification test is qualified withthe limits for posi tions specified in QW-303.

• Qualification in plate also qualifies for pipe welding and vice versa.

Diameter limits for welder performance qualification to be considered

• Dissimilar base metal thickness

• More than one procedure qualification may be required to qualify for

some dissimilar thickness combinations (QW-202.4).




The PQR shall be certi fied by the manufacturer.

• Is intended as the verif ication that the information on the PQR is a true

record of variables used during welding of the test coupon and that the

mechanical / chemical tests are in compliance with Code requirements.

Form QW-483 has been provided as a guide for the PQR, however, any other

format may be used as long as every essential and, when required,

supplementary essential variable for the process is included.

WORKSHOP – COMPLETION OF WPS’s + PQR’s




Weldability Performance

Not possible to be

found by NDE

Approval of weldability

Mechanical/Chemical)

Possible to be

found by NDE

Approval of welder

performance

Procedure Qualification Performance Qualification

Article III - Welding Performance Qualification



Welder’s Performance Qualif ication Record.

• The Welders Performance Qualification Record is a document used to record

welder’s and welding operator’s qualifications. The WPQ documents that welders

have been determined to have a necessary skill for depositing sound weld metal for

the processes within their qualified limits. The WPQ contains actual essentialvariables and test results, ranges to which the welder is qualified, and other

information as desired (for example, special positions).

Welder’s Essential Variables

• A welder’s essential variable is defined as a condition which, when changed, will Affect the welder’s ability to deposit sound weld metal. Welders do not have non-

essential or supplementary essential variables.




General Issues

• Article lists the welding processes with the essential variables that

apply to welder and welding operator performance qualifications.

• Welder qualification is limited by essential variables given for each

process.

• Variables are listed in QW-350 / QW-360 and defined in Article IV.

• Welder may be qualified by mechanical tests or by radiography of a

test coupon or radiography of his initial production welding (The

welder may be qualified by the production welding : minimum 6 inch

(150mm) length of the first production weld. This may be applied in

the field).

Welding Steps of Welder/welding Operator Qualification

(Sec IX, QW-300.2, Sec VIII-1, UW-29)Qualified WPS



Preparation of

Test Coupon

Preparation of

Test Specimen

Welding

Test

Record on WPQR

Certification of

Welder/welding

Operator

Full supervision

Mechanical Test

NDE

QW-463

Welding Data

Test Result

Acceptance Criteria (QW-

160,180 & 190)

Legends

: May use subcontractor

: Must be done by Manufacturer




General Issues

• Manufacturer is responsible for conducting tests to qualify the performance

of a welder in accordance with a qualified WPS.

Manufacturer’s Responsibil ities for Qualification of Welders

When qualifying welders, it is the manufacturer’s responsibility to:

• Establish a QC program to control welder’s qualification.• Qualify each welder with each process that welder is to use.

• Weld the test coupon in accordance with WPS (quality control)

• Control and supervise welding of the coupon.

• Maintain identification of welders.




General Issues

• If in an organization effective operational control of the welder

performance qualification for two or more companies of dif ferent

names exists, the companies involved shall describe in their QualityControl System.

In this case requalification of welders and welding operators within

the companies of such an organization will not be required.




General Issues

• When a manufacturer is acquired by a new owner, the WPQs may be used

by the new owner without requalification, provided all of the following are

met :

(1) the new owner takes responsibility for the WPQs

(2) the WPQs reflect the name of the new owner

(3) the Quality Control System/Quality Assurance Program reflects the

source of the WPQs as being from the former manufacturer or contractor


General Issues cont’d



General Issues cont d

• Responsibility cannot be delegated to another organisation, however

• Preparation of test coupon, test specimen, destructive and non-destructive tests can be subcontracted.

• The welder who has welded a WPS qualification test coupon is qualifiedwithin the limits of the performance qualifications for that process.

• Each welder shall be assigned an identifying number which shall be used toidentify the work of that welder.

• The record of the welder performance qualification (WPQ) tests shallinclude the essential variables, the type of test and test results and the

ranges qualified.


Welders who are not the employee of the manufacturer may be permitted



Welders who are not the employee of the manufacturer may be permittedprovided :

• All code construction is the responsibility of the manufacturer.

• All welding shall be performed in accordance with the manufacturer’s WPS

which have been qualified by the manufacturer in accordance with the

requirements of Section IX.

• The manufacturer has qualified all the welders.

• Complete and exclusive administrative and technical supervision for the

welders shall be performed by manufacturer.





Type of tests required



Type of tests required

Type and number of test specimen required for mechanical

testing shall be in accordance with QW-452

• Normally visual examination and 2 bend tests required

• When radiography: minimum length of test coupon shall be150 mm and if pipe: it shall include the entire weld

circumference

(If test coupon size for welder qualification is NPS 0.5inch (OD

21.34mm, 3 Coupons are required for satisfaction of min.length)

• Test coupon and specimen to be in accordance with QW-463




Special Processes QW-360 and QW-380

Requirements and tests on special processes

Electron beam, laser beam and friction welding

Corrosion resistant and hard-facing weld metal overlay

Joining of clad material

Resistance and flash welding operator qualification


Combination of welding processes



Combination of welding processes Welder may be qualified by either

• Making tests with each individual process

or

• With a combination of welding processes in a single test couponLimits of deposited weld metal careful ly to be considered

A welder qualified in combination on a single test coupon is

qualified to weld in production within his limits of qualificationwith each specific process.

Welding variables

• are summarized for each process in QW-416


Limits of qualified positions and diameters

• Table QW 461 9 defines the range of positions and diameters qualified



• Table QW-461.9 defines the range of positions and diameters qualifiedfor production groove and fillet welds based on their qualificationtests made in either plate, pipe, groove or f illet welds.

• Position of qualification test weld is decisive for position and typeof weld in production.

• Diameter limits for pipe production welds to be considered.

• Welders who pass the required tests for groove welds shall alsobe qualified to make fil let welds in all thicknesses and pipediameters of any size within the limits of variables given in QW-350 / QW-360.

• Fillet weld qualifications are restricted to thickness of material,size of f illet weld and diameter of pipe.

Article III – Welding Performance Qualification

Qualification thickness limits and test specimen

QW-452 1(a) Groove weld – thickness limits and test specimen



QW-452.1(a) Groove weld – thickness limits and test specimen

• 3 groups ( < 10mm, 10-19mm, >19mm )

• except for special positions 2 bend tests only required

QW-452.1(b) Groove weld - thickness of weld metal qualified• 2 groups only ( all, >13mm )

• either 2t or maximum to be welded

QW-452.3 Groove weld diameter limits

• based on outside diameter of test coupon

• 3 groups ( < 25mm, 25-73mm, >73mm )

QW-452.4 to QW-452.6 Fil let weld tests

• Limits on diameter and thicknesses, however, any groove weldqualifies all base material thicknesses, fillet sizes and diameter

Article III – Welding Performance Qualification

Important tables



p

QW - 423 : Alternate base metals for welder qualification




Expiration of qualification



• Performance qualification is affected when one of the fol lowing

conditions occur.

• When he has not welded with a process during a period of 6

month or more, his qualification for that process expire.• Whenever a change is made in one or more essential variables.

• When there is specific reason to question his ability to make

welds that meet the specification.

Renewal of qualification

Renewal of qualif ication expired may be made for any process by

welding a test coupon of

• Either plate or pipe, any material, thickness or diameter in any

position and by testing of the test coupon as required.



Article IV -- Welding Data

QW-400 to QW-416 Variables



Q Q

Section “ Variables” is covering all aspects of welding processes.

• Joints, base and f iller metal, positions, preheat, postweld heat

treatment, gas, electrical characteristics and technique.

However

Do NOT read individual paragraphs on their own but in conjunction with

procedure or personnel qualification requirements only.

Three Types of Variables

• Essential Variables - affect mechanical properties or ability of a

welder.

• Supplementary Essential Variable - affect notch toughness

properties.• Nonessential Variable - will not affect mechanical properties.


QW-420 to QW 424 Material groupings



g p g

Base metals are assigned P- or S- Numbers in table QW / QB – 422.

• P-Number : Ferrous / Nonferrous material according to base metal

spec.• S-Number : Ferrous / Nonferrous material acceptable for use ASME B

31

Each individual P- or S- Number cover a great variety of materials in order

to reduce the number of procedure qualif ications.

When a base metal with a UNS number designation is assigned a P- or S-

Number, then a base metal listed in a dif ferent ASME material

specification with the same UNS number shall be considered that P- or S-

Number whether or not these specifications are listed in table QW/QB422.













QW-451 and QW-451.X shall be used for procedure qualification by groove-

weld and fil let weld (PQR/WPS).



QW-452 and QW-452.X shall be used for performance qualif ication (WPQR).

QW-453 shall be used for procedure and performance qualification by hard-facing and corrosion resistant overlays (PQR/WPS/WPQR).

QW-461.9 shall be used for performance qualification (WPQR).

When applying the thickness range in the table from QW-451 to QW-453, “ T” is

the base metal thickness and “ t” is the weld metal thickness.


















If test welding for welder was performed by groove-welding, the welder is

qualified for all base metal thickness, all fillet sizes and diameters in fillet

welding.







Article V – Standard Welding Procedure Specifications

Standard Welding Procedure Specif ications (SWPS’s)



• Are standardized procedure specifications for the most common

processes and materials

• Are acceptable for Code construction• Are not permitted when impact testing is required

Prior to use

• Specified information must be entered in the SWPS

• One groove weld test coupon shall be welded

• Coupon shall be visually examined, mechanical tested (2 bend tests)

or radiographically examined

Article V – Standard Welding Procedure Specifications

Form QW-485

• is a suggested form for documenting the welding conditions and test



is a suggested form for documenting the welding conditions and test

results of the demonstration.

Production use• Welding shall be str ict in accordance with the SWPS.

• SWPS’s may not be supplemented with PQR’s or revised.

• SWPS’s shall not be used in the same product ion joint together with

WPS’s qualified by the manufacturer.• SWPS’s shall be certified by the manufacturer.

Advantage / Disadvantage

• Less qualification testing but limited use.

Appendices - Mandatory and Nonmandatory Requirements

Mandatory requirements

• Appendix A – Submittal of technical enquiries to the Boiler and Pressure



Appendix A Submittal of technical enquiries to the Boiler and Pressure

Vessel Committee

• Identical as for all other Code sections

• Appendix E – Permitted SWPS’s• Appendix F – Standard units for use in equations

Nonmandatory requirements

• Appendix B – Welding and brazing forms• Appendix D – P-Number listing

• Appendix G – Guidance for the use of U.S. customary and SI units

Tip : Welding monitoring

What should be monitored during production welding



• Use a qualified WPS

• Use a qualified Welder or Welding Operator

• Welding within the parameters of a qualified WPS

• Use only welding material described in the WPS

• Record the welder identification

• Inspect the weld for defects

• Assure required NDE is performed

Tip : Tube-to-Tubesheet Welds

Which methods are being used for preparing PQR/WPS and

WPQR?



• Dissimilar Base metal thickness in accordance with Sec. IX QW-202.4

• Use the rules in either section III, NX-4350 or Section VIII, Div. 2,

Article F-3

• Sec. IX QW-193 and QW-288



Tip : Tube-to-Tubesheet Welds

Interpretation : VIII-1-89-32

Date Issued : September 20, 1988



p ,

File Number : BC88-202

Question : Do the requirements of Section VIII, Div. 1 prohibit the

use of the rules in either Section III, Division 1, NX-4350 or Section

VIII, Division 2, Article F-3 to be used to qualify a tube-to-

tubesheet welding procedure?

Reply : No.

Tip : Preparation for Welder qualification

Type of welder qualif ications required in the shop



- Welders for groove and fillet welding in the plate

- Welders for groove welding for small diameter pipe

- Welding operators for automatic welding

- Welders for weld metal overlay

- Welders for tube-to-tubesheet welding

Section II, Part C

• Understand what is included in the SFA specifications of Section II, Part C and

how these specifications are used in the purchasing and use of welding filler

materials



materials.

• Part C of Section II covers welding materials. Information included in these

specifications are:• The process that may be used with various electrodes.

• Recommended storage requirements.

• An explanation of the AWS markings.

• Recommended positions for electrodes.

• Recommeded polarity and current.

• Information on how to meet an SFA Specification.

Section II, Part C



Section II, Part C

• Definitions for Section II C

• Some of the definitions in Part C are provided below. It is important, however, to

keep in mind that these definitions do not necessarily use the same terminology as



keep in mind that these definitions do not necessarily use the same terminology as

that used in the industry. For example, “rod” and “electrode”.

• A welding rod is defined as filler metal deposited separately from the electrode thatinitiates the arc. This would include brazing and OFW.

• An electrode is defined as the item that creates the arc in arc welding. It may or

may not be the filler metal.

• Filler metal is defined as the material, other than the base material being welded,that is deposited to from a weld.

• Flux is defined as a fusible material that serves to stabilize and shield the arc.

Section II, Part C

• Specifications of SFA-5.1

• Specification SFA-5.1 prescribes the requirements for the classification of carbon

steel electrodes for shielded metal arc welding Examples of the electrode



steel electrodes for shielded metal arc welding. Examples of the electrode

classifications in this specification include: E6010, E6011, E7018, and E7028 –

Only 60 and 70 ksi electrodes.

• Marking Requirements

• SFA-5.1 specifies marking requirements for both the package and the electrode.

• For packages: The AWS specification and class, supplier’s name and trade

designation, size and net weight, lot, control, or, or heat number. For electrodes: theelectrode classification must be within 2-1/2” of the grip end. The prefix letter “E”

may be omitted.

Section II, Part C

• Specif ications of SFA-5.1



Section II, Part C




Section II, Part C


• Example:

• An E7018 electrode has a minimum tensile strength of 70,000, uses low hydrogen



potassium/iron powder covering, and can use AC or DCEP.

• Example of SFA-5.1 Electrodes

• E-6010

• E-7018

• E-7024

• Only 60 and 70 thousand tensile electrodes are covered by this specification.

Section II, Part C


• Example:• An E7018 electrode has a minimum tensile strength of 70,000, uses low hydrogen

potassium/iron powder covering, and can use AC or DCEP.

E l f SFA 5 1 El t d



• Example of SFA-5.1 Electrodes

• E-6010

• E-7018

• E-7024

• Only 60 and 70 thousand tensile electrodes are covered by this specification.

Section II, Part C




Section II, Part C

• Specification SFA-5.4

• Specification SFA-5.4 prescribes the requirements for classification of Corrosion-Resisting Chromium and Chromium Nickel Steel Covered Welding Electrodes for

Shielded metal arc welding (SMAW Electrodes for Stainless Steel)





Section II, Part C

• Specification SFA-5.4

• Example:

• An E308L- 15 uses 308 austenetic stainless steel, with lower carbon than

straight E308, lime covering, and used with DCEP.



• Examples of SFA-5.4 Electrodes

• E-308L-15

• E-309Cb-15

Documents

Asme Section Ix-com Rev 1-23-08-2013