63325700-asme-sec-9-A

ASME SEC IX - Welding Procedure and

performance qualification

What is the need for WPS & performance qualification?

• To ensure the safety of the welded constructions

• Bhopal tragedy,three mile island accident, Chernbyl accident,Breakage of ship in the midsea

Why ASME qualification & certification?

• To ensure that design practices,

manufacturing practices,

fabrication techniques, &

inspection techniques are

performed by personnel who are

qualified in accordance with good

engg. practices and standards

Selecting Your Welding Process1. The joint to be welded is analyzed in terms

of its requirements.

2. The joint requirements are matched with the capabilities of available processes. One or more of the processes are selected for further examination.

3. A checklist of variables is used to determine the ability of the selected processes(s) to meet the particular application

4. Finally, the proposed process or processes deemed most efficient are reviewed

Step 1 - Analysis of Joint Requirements

The first thing to look at is whether your weld joint is large or small, whether the joint is out-of-position or not, and whether the base metal is thick or thin.

In welding, the needs of any joint are expressed in four terms: Fast-Fill (high deposition rate), Fast-Freeze (the joint is out-of-position - overhead or vertical), Fast-Follow (high arc speed and very small welds), and Penetration (the depth the weld penetrates the base metal)

Fast-Fill is required when a large amount of weld metal is needed to fill the joint. A heavy weld bead can only be laid down in minimum arc time with a high deposition rate. However, Fast-Fill becomes a minor consideration when the weld is small.

Fast-Freeze implies that a joint is out-of-position, and therefore requires quick solidification of the molten crater. Not all semiautomatic processes can be used on fast-freeze joints.

Step 1 - Analysis of Joint Requirements

Fast-Follow suggests that the molten metal follows the arc at rapid travel speed, giving continuous, well-shaped beads, without "skips" or islands. This trait is especially desirable on relatively small single-pass welds, such as those used in joining sheet metal.

Penetration varies with the joint. With some joints, penetration must be deep to provide adequate mixing of the weld and base metal and with others it must be limited to prevent burnthrough or Cracking.

Analysis of Joint Requirements

Step 2 - Matching Joint Requirements With Processes

Information (on the deposition rate and arc-speed characteristics of each process from literature)on the ability of various processes to fulfill the needs of the joint

Step 3 - The Checklist

• Volume of Production• Weld Specifications• Operator Skill• Auxiliary Equipment• Accessory Equipment• Base-Metal Conditions• Arc Visibility• Fixturing Requirements• Production Bottlenecks

Step 4 - Review of the Application by Manufacturer's Representative

WPS – Welding Procedure Specification

PQR – Procedure Qualification Record

What is a WPS?

A WPS is a "Welding Procedure Specification" or "Welding Procedure" as it is commonly called. It contains the combination of variables used to make a certain weld. This includes the process (SMAW, FCAW etc.), the electrode type, electrical characteristics, base metal used, preheat and interpass temperatures, travel speed and position, post weld heat treatment, shielding gas and flow rate, and the type of joint being welded.

What is WPS in a layman view

point• WPS lists all the parameters required to

produce a sound weld to the specific code

• Specific parameters such as process,

technique,filler,current,voltage,etc., to be

included

• It should list a range on each parameter such

as amps = 110-150, voltage =17-22 with the

more essential or critical parameters more

closely defined or limited

• It should give enough details so that any

qualified welder could follow and produce the

desired weld.

Purpose of WPS Qualification

To determine that the weldment is capable of providing the required properties for the intended application.

WPS establishes the properties of the weldment and not the skill of the welder.

Welding Procedure Specification

It is a written document that provides direction to the welder for making production welds in accordance with code requirements. Any WPS must be qualified by the manufacturer. WPS specifies the condition (ranges) under which welding must be performed called variables. WPS addresses essential, supplementary essential and non essential variables

Procedure Qualification Record

It documents what occurred during welding the test coupon and the results of the test coupon.PQR documents the essential variables and other specific information and the results of the required testing. In addition, when notch toughness is required for procedure qualification, the applicable supplementary essential variables shall be recorded.

Points to be considered for establishing WPS

• Code of construction

• Detailed drawing of weldment

• Material• Thickness• Configuration• Process

• Contract/Customer/ Code/TPI

• Preheat/Postheat/ PWHT requirements

• Skilled welder• Good welding

m/c with accessories

• Application

Variables• Preheat• PWHT• Joint design• Backing material• P Number• Welding Process• Filler metal• Electrode• Method of back

gauging

• Essential

• Non-essential

• Supplemental essential

Essential Variables

A change in welding condition which will affect the mechanical properties of the weldment.(Change in base metal, welding process, Filler metal, Electrode, Pre-heat, PWHT, etc.)

Non Essential Variables

A change in welding condition which will NOT affect the mechanical properties of the weldment.(Change in Joint Design, Methods of Back gauging, Cleaning, etc.)

Supplementary Essential Variables

A change in welding condition which will affect the Notch-Toughness (Impact) properties of the weldment.(Change in Heat input, Uphill or Down Vertical welding, Diameter of Electrode, Position, etc.)

Joints(QW:402)

• Joint Design• Backing• Baking

Material Type

Base Metal Classification Why P numbers?

To reduce the number of welding procedure qualifications, base metals have been assignedP-nos and for ferrous base metals which have specified impact test requirements, group numbers within P-nos are again givenP nos depend on composition, weldability & mechanical properties. •Group nos classify metals within P nos for procedure qualification where notch toughness requirements are specified. •The above assignments do not imply that base metals can be substituted without consideration of metallurgical properties,etc.,

P1 - P11 Steel

P21 - P25 Al alloys

P31 - P35 Cu alloys

P41 - P47 Ni alloys

P51 - P53 Ti alloys

P61 - P62 Zr alloys

Examples of P numbers

P1 C Steel

P3 1/2 Mo steels

P4 1 Cr 1/2 Mo steels

P5A 2 1/4 Cr 1 Mo steels

P6 13 Cr steel

P7 17 Cr steel

P8 Austenitic StainlessSteel

P9A 2 1/2 Ni steels

P10A Mn - 1/2 Ni - V steels

P11 9 Ni steels

Examples of P numbers

P1 C Steel

P3 1/2 Mo steels

P4 1 Cr 1/2 Mo steels

P5A 2 1/4 Cr 1 Mo steels

P6 13 Cr steel

P7 17 Cr steel

P8 Austenitic StainlessSteel

P9A 2 1/2 Ni steels

P10A Mn - 1/2 Ni - V steels

P11 9 Ni steels

Base Metal P NumbersBase Metal P Numbers

Base Metal for WPS Test Coupon Base Metal qualified

Px - Px PxPx - Py Px - PyP3 - P3 P3 – ( P3 / P1)P4 - P4 P4 – ( P4 / P3 / P1)P5A - P5A P5A – ( P5A / P4 / P3

/ P1) P5A – (P4 / P3 / P1) P5A – (P4 / P3 / P1) P4 – (P3 / P1) P4 – (P3 / P1)

Base Metal(QW-403)

• P. Number• Group Number• Specification• Chemical Analysis & Mechanical

Properties• Thickness Range• Pipe Diameter Range

P. No. & Gr. No COMMON NAME

TUBES PIPES PLATES FORGINGS CASTINGS

P1 Gr1 CARBON STEELS SA179 SA192 SA210GrA1 SA334Gr1 SA334Gr6

SA106GrB SA333Gr1 SA333Gr6

SA36 SA515Gr55 SA515Gr60 SA515Gr65 SA516Gr55 SA516Gr60 SA516Gr65

SA266CL1 SA350LF1

SA216WCA SA352LCA SA352LCB

P1 Gr2 -do-

SA210GrC

SA106GrC

SA515Gr70 SA516Gr70 SA299

SA105 SA266CL2SSA350LF2

SA216WCB SA216WCC SA352LCC

OTHER SPEC.

-do-

IS1239

API5LGrB

IS226 IS2062 BMC10 BMC16 BMC20

P3 Gr1 C – MOLY STEELS ½ Cr 1/2Mo

SA209T1 SA213T2

SA335P1 SA335Gr2

SA204GrA SAA387Gr2

SA217WC1

P4 Gr1 1Cr ½ MO 11/4Cr1/2Mo

SA213T12 SA213T11

SA335P12 SA335P11

SA387Gr12 SA387Gr11

SA182F12 SA182F11

SA217WC6

P5A Gr1 2, ¼Cr 1Mo SA213T22 SA335P22 SA387Gr22 SA182F22 SA217WC9

P5B Gr1

5Cr ½ Mo 9Cr1Mo

SA213T5 SA213T9

SA335P5 SA335P9

SA387Gr5

SA182F5 SA336Cl F5 SA182F9 SA336Cl F9

SA217C5 SA217C9

P5B Gr2

9Cr1Mo¼ V

SA213T91 SA199T91

SA335P91

SA387Gr91

SA182F91

P8 Gr1 P8 Gr2

18Cr 8Ni 25Cr-20Ni (Type 310)

SA213TP304 SA213TP304H SA213TP316 SA213TP321 SA213TP347 SA213TP347H SA213TP310H

SA376TP304 SA376TP304H SA376TP316 SA376TP321 SA376TP347 SA376TP347H

SA240TP304 SA240TP321 SA240TP347 SA240TP310

SA182F304 SA182F321 SA182F347 SA336F304 SA336F321 SA336F347 SA182F310

SA351CF3 SA351CF8 SA351CF3M SA351CF8M SA351CF10 SA351CF10M SA351CK20

P1/Group 1Carbon Steel

Tubes Pipes Plates Forgings Castings

SA179SA192 SA210GrA1SA334Gr1SA334Gr6

SA106GrBSA333Gr1SA333Gr6

SA36SA515Gr55SA515Gr60SA515Gr65SA516Gr55SA516Gr60SA516Gr65

SA266CL1SA350LF1

SA216WCASA352LCASA352LCB

P1/Group 2Carbon Steel

Tubes Pipes Plates Forgings

Castings

SA210GrC

SA106GC

SA515Gr70SA516Gr70

SA299

SA105SA266CL2SSA350LF2

SA216WCBSA216WCCSA352LCC

Other SpecificationCarbon Steel


Castings

IS1239 API5LGrB

IS226IS2062BMC10BMC16BMC20

P3/Group 1

Tubes Pipes Plates Forgings CastingsSA209T1 SA335P1

SA204GrASA217WC1

½ Cr ½ Mo - P3 Group 2Tubes Pipes Plates Forgings Castings

SA213T2 SA335Gr2 SAA387Gr2

½ Mo (C–MOLY STEELS)

P4/Group 1

Tubes Pipes Plates Forgings CastingsSA213T12 SA335P12 SA387Gr1

2 SA182F12 SA217WC

6

1¼ Cr ½ MoTubes Pipes Plates Forgings Castings

SA213T11 SA335P11 SA387Gr11

SA182F11

1Cr ½ Mo

P5A/Group 12¼Cr 1Mo


SA213T22 SA335P22 SA387Gr22

SA182F22 SA217WC9

P5B/Group 1

Tubes Pipes Plates Forgings CastingsSA213T5 SA335P5 SA387Gr5 SA182F5

SA336Cl F5

SA217C5

9Cr 1Mo Tubes Pipes Plates Forgings Castings

SA213T9 SA335P9 SA182F9SA336Cl F9

SA217C9

5Cr ½ Mo

P5B/Group 29Cr 1Mo ¼ V


SA213T91SA199T91

SA335P91 SA387Gr91

SA182F91

P8/Group 118Cr 8Ni


Castings

SA213TP304SA213TP304HSA213TP316SA213TP321SA213TP347SA213TP347H

SA376TP304SA376TP304HSA376TP316SA376TP321SA376TP347SA376TP347H

SA240TP304SA240TP321SA240TP347

SA182F304SA182F321SA182F347SA336F304SA336F321SA336F347

SA351CF3SA351CF8SA351CF3MSA351CF8MSA351CF10SA351CF10M

P8/Group 225Cr 20Ni (Type 310)

Tubes Plates Forgings CastingsSA213TP310H

SA240TP310

SA182F310

SA351CK20

Filler Metals(QW-404)

• AWS Number• SFA Number• F. Number• A. Number

• Size of Filler metal

• Flux trade name

• Consumable insert

• Electrode flux class

• Deposited Metal thickness range

Filler Metal F Numbers Based on usability characteristics i.e ability of welders to make satisfactory welds with given filler

F1 E XX20,XX24,XX27F2 E XX12, E

XX13,XX14F3 E XX10, E XX11F4 E XX15,XX16,XX18F5 ASS, Duplex SSF6 Bare rods ERXX

Filler Metal A Numbers Based on chemical composition

A1 Mild steelA2 C - Mo steelA3 Cr - Mo steel (Cr 0.4 - 2%)A4 Cr - Mo steel (Cr 2 - 6%)A5 Cr - Mo steel (Cr 6 - 10.5%)A6 Cr MartensiticA7 Cr FerriticA8 Cr Ni steels (Cr 14.5 - 30% Ni 7.5

- 15%)

A9 Cr Ni steels (Cr 19 - 30% Ni 15 - 37%)

A10 Ni steels (Ni 0.8 - 4%)A11 Mn Mo steels(Mn 1.25-2.25 Mo 0.25-

0.75%)

A12 Ni Cr Mo steels (Cr 1.5% Mo 0.25-0.8%

Ni 1.25 -2.8%)

Preheat(QW:406)

• Preheat temperature (Minimum)

• Interpass temp.(Maximum)• Preheat maintenance

PWHT(QW:407)

• Temperature range• Time range• Thickness range

Gas(QW:408)

• Gases Mixture % Flow rate

(e.g. 75% Ar 25%CO2)

• Shielding • Trailing• Backing

Trail shield

Electrical Characteristics(QW-409)

• Current (AC/DC)• Polarity (EP/EN)• Amps & Volts• W-Electrode type & size• Mode of Metal Transfer• Electrode Wire Feed Speed

range• Pulsing Current

METAL TRANSFER IN GMAW

Application

Thin sheet &

all position welding

capability

Globular transferGlobular transfer

Short circuit transferShort circuit transfer

Spray transferSpray transfer

Medium voltage & current

Low voltage & current

High voltage & current

Applications

Down hand position welding

Sheet thickness > 2 mm

Techniques(QW-410)• Stringer or Weave Bead• Orifice/Gas Cup Size• Initial or Interpass Cleaning• Method of Back Gauging• Oscillation• Contact Tip to Work Distance• Multiple or Single Pass• Multiple Or Single Electrode• Electrode Spacing• Peening• Others

Procedure Qualification PQR is a record of welding data to weld a test coupon. It also contains test results. Completed PQR shall document all essential variables including ranges. PQR to be certified accurate and shall not be subcontracted. If more than one process then weld deposit thickness for each process and filler metal to be recorded.

Procedure Qualification Several WPSs may be prepared from one PQR.eg. 1G plate PQR may support WPSs in 2G, 3G, 4G, pipe 5G, 6G etc provided other parameters are kept same.A single WPS may cover several PQRs eg. A single WPS may cover 1.6 mm to 32 mm thickness if PQRs for 1.6 to 4.8 mm and 4.8 mm to 32 mm thickness ranges.

Weld Orientation Plate groove positions 1G, 2G, 3G, 4GPipe groove positions 1G, 2G, 5G, 6GPlate fillet positions 1F, 2F, 3F, 4FPipe fillet positions 1F, 2F, 2FR, 4F, 5F1F - 0 to 302F - +15 -10 wrt 454F - 0 - 1253F - 125 - 235

Procedure Qualification When two or more procedures (diff processes or other essential variables) are used in one joint, use table for determining the applicable range of thickness qualified. Carry out tension test for each weld metal.

One or more processes from a combination may be deleted provided remaining metal meets the requirements.

Procedure Qualification Thickness limits

T Range of T max t Tests (transverse bend)

<1/16” T - 2T 2t 2T, 2 FB, 2 RB

1/16-3/8” 1/16 - 2T 2t -do-

3/8-3/4” 3/16 - 2T 2t -do-

3/4-1.5” 3/16 - 2T 2t if t<3/4 2T, 4 SB

2T if t>3/4

>1.5” 3/16 - 8” 2t if t<3/4” -do-

8 if t>3/4”

Procedure Qualification Thickness limits

T Range of T max t Tests (longtl bend)

<1/16” T - 2T 2t 2T, 2 FB, 2 RB

1/16-3/8” 1/16 - 2T 2t -do-

> 3/8” 3/16 - 2T 2t -do-

WPS for SMAW

Essential variables

Change in qualified Thickness

Change in P no

Change in F no of filler metal

Change in A no of filler metal

Change in deposited metal thickness

Decrease of more than 100 F in preheat

Change in PWHT

WPS for SMAW

Supplementary Essential variables

Change in Group no of base metal

Change in T limits for impact test

Change in dia of filler metal > 1/4”

Change in AWS class of filler metal

Change in welding position

Increase of more than 100 F in preheat

Change in PWHT Time and temp range

Change in current or polarity

WPS for SMAW

Non Essential variables

Change in Groove design, backing, root spacing, retainers etc

Change in dia of filler metal

Change in AWS class of filler metal

Change in welding position

Change in preheat maintenance

Change in current or polarity

Change in string/weave, cleaning, back gouging, peening, manual/automatic

WPS for GTAW

Essential variables

Change in qualified Thickness

Change in P no

Change in F no & A no of filler metal

Addition/deletion of filler metal

Change in size of filler metal, product form

Decrease of more than 100 F in preheat

Change in PWHT

WPS for GTAW

Essential variables (cond)

Change in single, mixture % gasDeletion of backing gasChange in shielding / trailing

gasChange in Closed to out

chamber technique

WPS for GTAWSupplementary Essential variables

Change in Group no of base metalChange in T limitsChange in AWS class of filler metalChange in welding positionIncrease of more than 100 F in

preheatChange in PWHT Time and temp

rangeChange in current/polarity, incr. in heat inputChange in multi to single pass,

electrodes

Welding Conditions

Specification, type and grade of Base Metal(s): SA106 Gr B

To Specification, type and grade of Base Metal(s): SA106 Gr B

Base Metal P or S-number 1 to Base Metal P or S-number 1Thickness: 0.218

Welding Process(es) used: GTAW followed by SMAW

Plate X Pipe (enter diameter if pipe or tube): NPS 2, Sch 80

Groove type (Single V, Double V, Single U, etc): Single Vee

Initial cleaning method: Solvent wipe and grinding

Backing (metal, weld metal, backwelded, etc): None / Weld metalFiller Metal (SFA) Specification: 5.18 / 5.1

Filler Metal or Electrode Classification: ER70S-2 / E7018

Filler Metal or Electrode Trade Name: Linde 65, Lincoln 7018+

Tungsten electrode type and size for GTAW: EWTh-2, 3/32"

Consumable Insert Class and size for GTAW or PAW: None

Backing Gas composition and Flow rate for GTAW, PAW, GMAW: Not Used Preheat Temperature (°F): 75

Position (F, V, OH, H or 5G, 3G, etc.) of weld: 5G

Progression (Uphill or Downhill): Uphill GTAW / downhill SMA

Interpass cleaning method: Wire brushing

Measured interpass temperature (°F): less than 400

Approximate Deposit Thickness for each filler metal or electrode type (in.): 0.093 (3/32) / 0.125

Current Type/Polarity (AC, DCEP, DCEN): DCEN/DCEP Postweld Heat Treatment Time and temperature: 1100-1200°F, 65 hr.

Visual Examination of Completed Weld: Acceptable Date of Test: 12/25/01

Bend Test X Transverse Root and Face (QW-462.3(a)) Side (QW-462.2)

Type Result Type Result Type Result

Face Acceptable Root Acceptable

Face Acceptable Root Acceptable

Alternative Radiographic Examination Results: N/A

Specimens Evaluated By: Dianna Ross Title: Leader Company: The Best Testing Company Ever

Welding Supervised By: James Brown Title Soloist Company: Joe-Bob's B&NPW Shop

Welder’s Name: Wolfgang Amadeus Mozart Stamp No: A1

We certify that the statements in this record are correct and that the weld described above was prepared, welded and tested in accordance with the requirements of Section IX of the ASME Code.

Performance Qualification

The basic criterion for welder’s qualification is to determine the welder’s ability to deposit sound weld metal.

The purpose of performance qualification test is to determine the welding operator’s mechanical ability to operate the welding equipment.

Fillet welding of plate

Vertical

Horizontal

Flat

overhead

1F

2F

3F

4F

GMAW in different positions

Welders Performance Qualification

The performance qualification tests are intended to determine the ability of welders to make sound welds

A welder is qualified by radiography of a test coupon or by radiography of initial production welding or by bend tests taken from a test coupon

Variables affecting the welders qualification

Welding conditions that affect the ability of welder to produce sound welds are qualification variables

• Welding process• Filler metal• Welding position• Joint backing• Thickness of test coupon

Welding process

• A change in welding process –

from SMAW to GTAW, for

eg.,requires the requalification

of the welder since skill required

to use one process is different

from another one.

Filler metals• Filler metals used in welding are

grouped based on their usability characteristics. These are assigned F-numbers

• Ordinarily welder is qualified for a F no and do the same in production

• SAW :F1-F4: Qualification in higher Fno entails qualfication for lower F nos of electrodes

Backing

• Joint backing includes any material placed at the root of the weld to support the liquid metal(e.g backing strip,non fusing bars, root weld with another process,etc)

• If a welder qualifies using a backing on the test coupon but the backing is removed for the production welding for a joint made from one side, then he must requalify

• If a welder qualifies using without a backing, for a joint with backing he is automatically qualified


Welded QualifiedWithout Backing

Fx FxWith Backing

F1 F1F2 F2, F1F3 F3, F2, F1F4 F4, F3, F2, F1F5 F5, F1


F No qualification with backingF1 with backing F1 with backingF1 without backing F1 with & without backingF2 with backing F1 & F2 with backingF2 without backing F2 with & without backing, F1 with backingF3 with backing F1, F2 & F3 with backingF3 without backing F3 with & without backing, F1, F2 with backingF4 with backing F1, F2, F3 & F4 with backingF4 without backing F4 with & without backing, F1, F2, F3 with backingF5 with backing F1 & F5 with backingF5 without backing F5 with & without backing, F1 with backing

Welding position(QW-405)• Welding test positions are defined differently

for plate and pipe• A change in welding position from that

qualified may require requalification• Certain test position qualify for more than one

production welding position

(E.g.qualification in 3G position qualifies the welder for vertical and flat positions)

• In vertical position welding, a change in welding progression from uphill to downhill would require requalification

• Qualification in difficult position qualifies for less difficult positions: E.g 6 G qualifies for all positions


Weld Plate & pipe Pipe of ODFillet

>24”OD 2 7/8 - 24”

Plate 1F FPlate 2F F, HPlate 3F F, H, VPlate 4F F, H, O3F &4 F All


Weld Plate & pipePipe of OD Fillet

>24”OD 2 7/8 - 24”

Plate 1G F F FPlate 2G F, H F, H F, HPlate 3G F, V F F, H, VPlate 4G F, O F F, H, O



>24”OD 2 7/8 - 24”

Pipe 1G F F FPipe 2G F, H F, H F, HPipe 5G F, V, O F, V, O AllPipe 6G All All AllPipe 2G + 5GAll All All



>24”OD 2 7/8 - 24”

Pipe 1F FPipe 2F F, HPipe 2FR F, HPipe 4F F, H, OPipe 5F All

Test coupon thickness

• The thickness of the production work determines the thickness of the plate or pipe test coupon to be welded

• Thumb rule is a welder is qualified to deposit in production welding two times the thickness of the weld deposited on the test coupon (e.g. test coupon of 9 mm qualifies a person to weld upto 19mm thick production weld)

• Some code makes once a weld of 1 inch is made, the welder is qualified to weld all thickness

Test coupon thickness(contd.)

• The weld deposit thickness(t) determines the thickness of the weld metal the welder is allowed to use in production not the thickness of the base metal in the test coupon.

• When welding a test coupon using more than one process or filler metal, the thickness of the weld in production depends on the deposit thickness for the process and the type of test of filler metal that was used on the test coupon.


Thk Max tk of dep. Metal Test<3/8” 2t 1FB, 1RB>3/8” 2t 1FB, 1RB>1/2” Max to be welded2SB

OD of test coupon Range of OD qualified

<1” Size welded - unlimitd

1 - 2 7/8” 1” - unlimited> 2 7/8” 2 7/8” - unlimited


Test coupon More than 2 welders different procedure can do a single test coupon. Failure then both are failed.

Retest - 2 consecutive test coupons to pass Renewal if no welding for 6 months. Single test coupon plate/pipe, any thickness, material, position. If passed then complete previous qualification is restored.


Variables for SMAW

Removal of backingChange in Pipe diameterChange in P numberChange in F NumberChange in thickness of weld

depositChange in welding position


Variables for GTAWRemoval of backingChange in Pipe diameterAddition / deletion of filler metalAddition / deletion of insertChange in P numberChange in F NumberChange in solid filler to flux cored filler

metalChange in thickness of weld depositChange in welding positionRemoval of inert gas backingChange in current or polarity

Tests for Qualification

Tension test Minimum values for specified tensile strength For dissimilar joint, lesser of

the two valuesIf break outside weld, if tensile

st. value not < 5% of the base metal

Bend test No open discontinuity > 1/8” in any direction

Impact test In accordance with the section

Tests for Qualification

Radiography No crack or LOP or LOFAny elongated slag >1/8” for t <3/8”

1/3 t for t 3/8 - 2 1/4”

3/4 “ for t>2 1/4”Any group of slag in a line with

aggregate length t in 12 t unless separated by 6L

Max permissible dimension for rounded indication smaller of 20% of t or 1/8”

For thickness<1/8”, max no of accepted rounded indication 12 in 6” length

For thickness>1/8”, charts for max acceptable types of rounded indication

A 106 Gr B, Sch 160

C. R. Ratheeskumar

FCAW(S)

8"

P No.:1 Gr.:1

Yes(Root)E71T8-K6

6 6

FCAW(S) -19 mm Upto Max to be welded

FCAW(S)

2 7/8" & Above

With backingP 1 - P 11

ACTUAL VALUE RANGE QUALIFIED

A 106 Gr B, Sch 1608"

P No.:1 Gr.:1

Yes(Root)

E71T8-K6

6 6

FCAW(S) -19 mm Upto Max to be welded

6G All Positions

Down Hill

NA

DCElectrode Negative

Accepted

NA

NA

NA

NA

2 7/8" & Above

With backing

Down Hill

NA

DC

NA

Welding Research Institute, BHEL, Trichy, India.

P 1 - P 11

NDT / 250A / 03 Dt.23.2.04.

ASME BPV Code Section IX. Welder Identity Card issued

Electrode Negative

Welder’s Performance Qualification as per

Indian Boiler Regulations

Welder’s Performance Qualification as per IBR

Initial qualification of welders - Certificate valid for 24 months provided welder has been employed with reasonable continuity

If preceding three months, no welding carried out or if there is any doubt on welder’s stability then requalification needed

Welder’s Performance Qualification as per IBR

Requalification of welders must for the following

Omission of backing strip Change in class of electrode

Change in base metal to be welded(CS or AS)

Change in welding processChange from dc to ac and vice

versa

Tests for Initial Qualification

• Theoretical examination• Groove welds in plate - single or double vee 299 x 381 x 16 mm min size in flat, horizontal or vertical. Vertical or horizontal position also qualifies for all •Fillet weld in plate - 16 x 381 mm min in flat, horizontal, vertical or overhead. Horizontal or vertical also qualifies for flat. Vertical position also qualifies for flat, horizontal or vertical.

Tests for Initial Qualification

Pipe welding in the following positions (i) Horizontally rolled (ii) Horizontal turned (iii) Vertical fixed (iv) Horizontal fixed. Qualification in (ii) or (iii) also qualifies (i). Qualification in (iv) also qualifies (i) or (ii).

Branch to pipe weldingPipe size 127 OD x 10 tk. Tube 89 OD x 6 tk.

Tube welding with axis vertical and tubes of same size fixed in adjoining positions.

Tests for Requalification • No theoretical examination• Plate welding 152 length x 229 x 16 tk in 45 deg position. Weld to be done from underside.• Pipe welding with axis of pipe horizontal. • Branch to pipe as earlier• Tube welding axis vertical and tubes of same size in adjoining position. • Regular production weld to the satisfaction of competent authority

may be accepted as alternative to the above tests

Examination of the weld for initial Qualification

PLATE QUALIFICATION (Groove weld)

• Visual examination• Radiography• 2 no of Tensile test• 2 no each of Bend test - face and root

bend ( 3t for both C steel and alloy steel 180 deg bend)• 1 no Micro examination• 1 no Macro examination


PLATE QUALIFICATION (Fillet weld)

• Specimen shall not fracture during load application• If fractures, no evidence of cracks / ICP / sum of inclusions and gas pockets < 51 mm• Macro examination shall show complete fusion• concavity / convexity < 1.6 mm• difference in leg length < 1.6 mm


PIPE QUALIFICATION

• Visual examination• Macro examination• 2 no each of Bend test - face and root

bend ( 3t for C steel and 4t for alloy `steel 90 deg bend)

Examination of the weld for Requalification

PLATE QUALIFICATION • Radiography• 1 no each of Bend test - face and root

bend• 2 no of macro examination

PIPE QUALIFICATION• 1 no each of bend test - face and root

bend• Macro examination

A 106 Gr B, Sch 160

FCAW(S)

8"

P No.:1 Gr.:1

Yes(Root)E71T8-K6

6

FCAW(S) -19 mm

6G

Down Hill

NA

DCElectrode Negative

ACTUAL VALUE

Steps involved in qualifying the welding process & welder/

operator• A tentative welding procedure is

prepared• Test samples welded with the above

and parameters recorded on PQR• Tested as per required codes• If test is passed, the procedure has

completed qualification.• If test is not passed, the tentative

WPS value of the parameters are changed as deemed feasible

Steps involved in qualifying the welding process & welder/

operator

• The welder making the test samples to be used in qualifying the procedure is normally considered qualified.

• Other welder to be qualified weld test samples as per WPS and the samples are tested as per applicable requirements.

• A qualified WPS is usable for an indefinite length of time

• The welder’s qualification is normally considered effective for an indefinite period of time, unless the welder is not engaged in the specific process of welding for which she is qualified for a period of exceeding 6 months

Case study

Objective : To develop a WPS for pipe to pipe butt joint( dia. 406 * 12mm) of SA 106 GrC – SA106 GrC as per ASME sec IX

• Requirement of mechanical property: Impact toughness at room temperature

Tensile strength

Filling up of WPS- Draft

• WPS: No: Date:• Supporting PQR• Welding process : • Type : Manual/ Machine/Auto/

Semi Auto• Application:

Joints(QW:402)

• Joint Design• Backing• Baking Material Type

Base Metal(QW-403)

• P. Number• Group Number• Specification• Chemical Analysis & Mechanical

Properties• Thickness Range• Pipe Diameter Range

Filler Metals(QW-404)

• AWS Number• SFA Number• F. Number• A. Number

• Size of Filler metal

• Flux trade name

• Consumable insert

• Electrode flux class

• Deposited Metal thickness range

Welding position(QW-405)• Welding test positions are defined

differently for plate and pipe

Preheat(QW:406)

• Preheat temperature Min• Interpass temp.(Max.)• Preheat maintenance

PWHT(QW:407)

• Temperature range• Time range• Thickness range

Gas(QW:408)

• Gases Mix % Flow rate• Shielding • Trailing• Backing

Electrical Characteristics(QW-409)

• Current (AC/DC)• Polarity (EP/EN)• Amps & Volts• W-Electrode type & size• Mode of Metal Transfer• Electrode Wire Feed Speed

range• Pulsing Current

Techniques(QW-410)• Stringer or Weave Bead• Orifice/Gas Cup Size• Initial or Interpass Cleaning• Method of Back Gauging• Oscillation• Contact Tip to Work Distance• Multiple or Single Pass• Multiple Or Single Electrode• Electrode Spacing• Peening• Others

Filling up of WPS-Joints(QW:402)

Date post:	28-Apr-2015
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