Presentasi Design WPS- 1 Dec 10 BW_copy

transcript

WPS DESIGN using ASME SECTION IX CODE

REQUIREMENTS

Politeknik Perkapalan Negeri Surabaya

Surabaya, 1 December 2010

By Condro Widiyarto

1. Flow of Welding Procedure Qualification:

2. ASME SECTION IX CODE REQUIREMENTS:1). Article 12). Article 23). Article 34). Article 4

3. SPECIFIC MATERIAL Overview:

4. WPQT-WPS-PQR:1). CS – With impact requirements

1. FLOW CHART PEMBUATAN KUALIFIKASI PROSEDUR LAS

• DRAWING• STD• REFERENCE• CUSTOMER SPEC

PELAKSANAAN TEST PROSEDUR LAS

PEMBUATAN / MACHININGTEST PIECE

TEST LABORATORY

Result PQR WPSQualified for product

Welder Qualified( Certificate welder )

Not ok

1.1 Customer Overview:• Code Requirements:o International Code: ASME, API, AWS, EN, ETC

o Indonesia Code: SII, SNI, ETC

• Regulation:o MIGAS, DEPNAKER, BKI, ETC.

• Additional Requirements:o Customer Data Sheet

o Customer Specification

1.2 ASME Code Requirements:• ASME Section VIII Division 1 to VIII Division 3:o Section VIII Division 1: Rules for Construction of Pressure Vessels

o Section VIII Division 2: Alternative Rules - Rules for Construction of Pressure Vessels

o Section VIII Division3: Alternative rules for Construction of High Pressure Vessels

• ASME Section II Part A, B, C, D:

o Part A: Ferrous Material Specification

o Part B: Non Ferrous Material Specification

o Part C: Specification for Welding Rods, Electrodes and Filler Metals

o Part D: Properties (Customary)/(Metrics)

• ASME Section V: Non Destructive Examinations

• ASME Section IX: Qualification standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operator

o QW- Qualification Welding

o QB- Qualification Brazing

2. ASME Section IX Code Requirements:

• Part QW:o Article 1: Welding General Requirements

o Article 2: Welding Procedure Qualification

o Article 3: Welding Performance Qualification

o Article 4: Welding Data

• Part QB:o Article 1: Brazing General Requirements

o Article 2: Brazing Procedure Qualification

o Article 3: Brazing Performance Qualification

o Article 4: Brazing Data

• Appendices: A to G

• Index

Section IX Part QW Article-1

• It is mandatory to read every article of Section IX in order to apply the code rules

• QW-100.1 Purpose of WPS

• QW-100.3 Purpose of WPS and WPQ qualified accordance with rules of this section may be used in any construction built to the requirements of the ASME Boiler & PV or the ASME B31 code for pressure piping.

• QW-120, 130 & QW-132 Test position with written definition & reference to Article IV where of these position to be found

• QW-141. up to QW-141.5 Explanation of the various test and examination required

Test Position

• QW-142 & QW-143 Special examination for welder & welding operator and QW-144 Visual examination (See QW-194 Visual Inspection – Performance).

• QW-150 For Tension test, QW-160 for guided bend test.

• Acceptance criteria are listed for each type of test described with one exception being the Notch Toughness test of QW-170

• QW-190 Other type test & examination are listed. RT and PT examination referred to Section V article 2 and 6 respectively technique. Acceptance standard QW-191.2 & QW-195.2 respectively must be met the examination

Section IX Article 1: Test/Examination & Acceptance Criteria

Section IX Part QW Article-2• 3 Types of variable:

1. Essential Variable: Any time an essential variable is changed of the range given in the WPS, the procedure must be re qualified by welding a new coupon and mechanical testing. You must generate a new PQR.

2. Non Essential Variable: Changes in this can be made with out requalification of the WPS, however WPS must be revised to reflect these changes.

3. Supplement Essential variable: Need only be given if the weld must have specific impact properties for low temperature services. If impact test are required they become essential variable.

Section IX Part QW Article-2• Learning the review method for SMAW process will

serve to teach all process (May use SMAW, GTAW, GMAW/FCAW or SAW)

• Essential variable for SMAW as described on table QW-253 as follows:

• Joint:

�QW-402.1 Ø Groove Design, 402.4 - Backing, 402.10 Ø Root Spacing and 402.11 ± Retainers are Non essential variable, on the WPS do not leave blank – You should indicate this variable as being By Sketch at list groove design used, “With OR Without Backing”, “1/32 OR 1/16” Root spacing, “With OR Without Retainers” or simplify place X’s in both blocks.

Section IX Part QW Article-2 – Essential Variable

Section IX Part QW Article-2• Base Metals:

� QW-403.5 Ø Group no. and 403.6 T Limits Impact (Minimum thickness range qualified by impact testing) are Supplement Essential Variable, become essential variable when impact properties are required.

�QW-403.8 Ø T qualified (Table QW-451.1 for maximum thickness range by qualified test coupon used in PQR), 403.9 t pass > ½ “ (13 mm), 403.11 P no Qualified (See QW-424.1) and 403.13 P no. 5/9/10 are essential variable.

• Filler Metal:

2.2 Section IX - Article-2 QW-422

2.2 Section IX Part QW Article-2 – Ess. Var.: Welding Data

2.2 Section IX Article-2 Essential Variable: QW-424.1

2.2 Section IX Part QW Article-2 – Ess. Var.: Welding Data

Section IX Part QW Article-2� QW-404.5 Ø diameter and QW-404.33 Ø Classification are not

essential variable.

� QW-404.4 Ø F No. (See QW-432), 404.5 Ø A No. (See QW-442 except as given in QW-404.5), 404.30 Ø t (See QW-451.1) are essential variable.

� QW-404.7 Ø diameter > ¼” (6mm), QW-404.12 Ø Classification (SFA number given in Section II of the ASME Code) are supplement essential variable.

• Position:

� QW-405.1 + Position and QW-405.3 Ø Vertical Welding are not essential variable

� QW-405.2 Ø Position (Ø Any position to vertical up hill but not reverse. In up hill progression, a change from stringer bead to weave bead) is supplement essential variable.

Section IX Part QW Article-2• Preheat:� QW-406.1 Decrease > 100˚F (55˚C) is essential variable

� QW-406.2 Ø Pre heat maintenance (This is of continuance of pre heat after completion of weld) is not essential variable

� QW-406.3 Increase > 100˚F (55˚C) (IP) is supplement essential variable

• PWHT:� QW-407.1 Ø PWHT(If PWHT will not performed, this should

be indicated on the WPS by entering the words ‘Not PWHT” or simply “none” and 407.4 T limit (PWHT upper transformation temperature) are essential variable.

Section IX Part QW Article-2�QW-407.2 Ø PWHT (T x T range) is supplement

essential variable (again when impact properties are required of a weldment, a change of the time span of PWHT or the temperature range will require re-requalification of the procedure.

• Electric Characteristics:

�QW-409.1 > Heat Input (HI = Amp x Volt/Speed) and QW-409.4 Ø Current (AC or DC) or Polarity (EN or EP) are supplement essential variable.

�QW-409.8 Ø I & E range is not essential variable.

• Technique:

�QW-410.1 Ø String or weave, 410.5 Ø Method

cleaning. 410.6 Ø Method back gouge, 410.25

Manual or Automatic and 410.26 ± Peening

are not essential Variable.

�QW- 410.9 Ø Multiple to Single pass/side is

supplement essential variable.

3. Base material Overview:

SA516-70 NP1 Gr2

CS with Impact

Requirements

3.1 CS 3.1 CS overviewoverview

3.1 CS with Impact Requirements for Low Temperature

� Cold Crack (< 200º C):o Hydrogen (Crack and Blow Hole)o Stress Concentrationo Brittle in weld

� Hot Crack (Elevated Temperature):o Hydrogen (Crack and Blow Hole)o Stress Concentrationo Brittle in weldo Impurities P & S

� Effect Heat Input (HI):o HI Increase: Toughness decreaseo SAW: HI high due to high ampere can prevent cold crackingo HI have limited value due to cause hot cracking in weld metal

Effect of preheating on hardness of HAZ

Ensuring WeldEnsuring Weld--abilityability

• Cooling Rate •Restraint Intensity•Amount of Hydrogen pick up •Chemical composition of the steel plate (Pcm and Ceq taken into consideration)•Etc (Good resistance to Lamelartearing)

NOTE: Lower P content and add Ni for improving the toughness andNOTE: Lower P content and add Ni for improving the toughness andfor ensuring resistance to lamellar tearingfor ensuring resistance to lamellar tearing..

Prevent Weld Defect:

• Pre - Heating• PWHT• Low Hydrogen filler metal • Material Requisition Sheet with Normalized material & simulated PWHT • NDE (UT examination)• Hardness control

4. WPQT-WPS-PQR: Engineering Drawing

GA Drawing

DATA SHEETWELDING JOINT NUMBER

DETAIL JOINT

MATERIAL SPECIFICATION

POS or PART NUMBER

MATERIAL THICKNESS

4.1 WPQT-WPS-PQR: GA DRAWING

4.1 WPQT-WPS-PQR: DATA SHEET

4.1 WPQT-WPS-PQR: Typical Weld Map

To Prepare WPQT for GA drawing 37-S-101 A B

Summary Material Spec. (P No. Gr. No.) x Thickness as follows:Pipe 2“x Schedule 160 = 8.74 mm thick x SA333-6 (P No. 1 Gr. 1)

Pipe 8” x schedule 120 = 18.26 mm thick x SA333-6 (P No. 1 Gr.1)

Pipe Shell 16” x Schedule 60 = 16.6 mm thick x SA333-6 (P No. 1 Gr.1)

CAP (A) 16” schedule 60 = 16.6 mm thick x SA420 WPL 6 (P No.1 Gr.1)

CAP (B) 16” schedule 80 = 21.4 mm thick x SA420 WPL 6 (P No.1 Gr.1)

Flange x 8.74 to 21.4 mm thick x SA350 LF2 (P No. 1 Gr.2)

Reinforcing Pad 12 mm thick x SA516-70 (P No.1 Gr.2)

1CW - Joint Cap to Shell Pipe: P1 Gr1 to P1 Gr12CW – Joint Flange to Shell Pipe: P1 Gr2 to P1 Gr1Joint Reinforcing Pad to Shell Pipe/Nozzle: P1 Gr2 to P1 Gr1

Essential Variable WPS PQR Remarks

P no. Gr No. P1 Gr1 to P1 Gr1

P1 Gr1 to P1 Gr2

Thickness (mm) 8.74 - 12

16.6 – 21.4

PWHT Yes

Impact Yes (- 45˚C)

Welding Process GTAW (8.74-12)

GTAW+SMAW (≥ 16)

Others

Essential Variable WPS PQR Remarks

P no. Gr No. P1 Gr1 to P1 Gr1 P1 Gr1 to P1 Gr1

P1 Gr1 to P1 Gr2 P1 Gr1 to P1 Gr2

Thickness (mm) 8.74 - 12 8

16.6 – 21.4 16

PWHT Yes Yes

Impact Yes (- 45˚C) Yes (- 45˚C)

Welding Process GTAW (8.74-12) GTAW (8 mm)

GTAW+SMAW (≥ 16) GTAW+SMAW 16 mm)

Others

WPQT GTAW with Impact Requirements of CS

PQR GTAW with Impact Requirements of CS

PQR GTAW with Impact Requirements of CS PQR GTAW with Impact Requirements of CS

WPS GTAW with Impact Requirements of CS WPS GTAW with Impact Requirements of CS

WPQT GTAW+SMAW with Impact Requirements of CSWPQT GTAW+SMAW with Impact Requirements of CS

PQR GTAW + SMAW with Impact Requirements of CSPQR GTAW + SMAW with Impact Requirements of CS

PQR GTAW + SMAW with Impact Requirements of CS PQR GTAW + SMAW with Impact Requirements of CS

PQR GTAW+SMAW with Impact Requirements of CS PQR GTAW+SMAW with Impact Requirements of CS

WPS with Impact Requirements of CS WPS with Impact Requirements of CS

SUMMARIZED:• The accurate understanding which went into all aspect of the

design and qualification welding procedures for the

material/CS with impact requirements according to Section

IX ASME Code requirements was presented with sample of

WPQT, PQR and WPS under GTAW and SMAW process.

• The best way to understanding of CS Welding with impact

test requirements (Toughness) is to study with CS equilibrium

diagram/CCT diagram,

Condro Widiyartocondro06@yahoo.co.id

085652010809

Presentasi Design WPS- 1 Dec 10 BW_copy

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