Api 570 chapter 10-asme-ix-rev-005

Chapter Ten

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ASME Section IX – Procedures and Qualifications

Do Not Duplicate

ASME IX

These course notes have been prepared by TWI, strictly for the use of attendees to this TWI API-570 Examination Preparation Course. This manual is to be used as an aid to assist those persons wishing to take the API-570 Piping Inspector Certification Examination. This manual is not all-inclusive and may not be used in place of any recognized Code or Standard. This manual may not be reproduced by any

means without the express written consent of TWI.

THE WELDING INSTITUTE

REV.005 ASME IX (570 ED) 2 Copyright © TWI Ltd 2008

ASME SECTION IX Section IX covers welding and brazing. Section IX is divided into four Articles but has six distinct areas of information as follows:

• The Forward & Introduction

• Article I, Welding General Requirements

• Article II, Welding Procedure Qualification

• Article III, Welding Performance Qualification

• Article IV, Welding Data (Variables In written paragraph format)

• Article IV, Welding Data (Variables in chart and table format)

ASME SECTION IX - WELDING DOCUMENTS:

PQR: Procedure Qualification Record

• Used to document welding procedure qualification and test • Is a record of the actual measurements taken and conditions observed when producing

the qualification test coupon • Documents results of subsequent qualification tests such as tensile and bends. • Must address all essential variables listed for the processes used and supplementary

essential variables when notch toughness is a consideration required by the referencing code

• Deals with the soundness of the weldment to be made • Must be signed and dated

WPS: Welding Procedure Specification • Used to provide direction to the welder • Lists the ranges qualified as a result of welding the qualification coupon and

performing tests • Must address all essential and nonessential variables listed for the processes used and

supplemental essential variables when notch toughness is a consideration required by the referencing code.

• Deals with the soundness of the weldment to be made



WPQ: Welder Performance Qualification Record • Used to document welder qualification and tests • Must address all essential variables listed for the processes used • Is a record of the actual measurements taken and conditions observed and the ranges

qualified as a results of welding the qualification coupon • Documents the results of subsequent qualification tests such as bends and radiography • Must be signed and dated

Welding Variables:

There are three types of variables used in Section IX Essential Variable: Applicable to the PQR, WPS & WPQ

• Addresses information that must be included in the PQR, WPS or WPQ that is mandatory

to assure the soundness of the weldment (except for notch toughness properties) or skill of the welder

• Section IX gives specific ranges qualified for essential variables directly related to the actual measurements taken during production of the qualification coupon

• A change in the information requires re-qualification of the WPS or welder

Nonessential Variables: Applicable to the WPS

• Addresses information that is not mandatory to assure the soundness of the weldment • A change in the information does not require re-qualification of the WPS (all welder

variables are essential) but may require a new revision level of the WPS to be issued • No specific ranges are specified by Section IX for nonessential variables. (The

information given on a WPS to satisfy a nonessential variable requirement can be outside anything reasonable and satisfy “code requirements”. For example a root gap may be 3” or a welding rod diameter 1”. Although this will probably not be seen or work well in real life there are no restrictions on nonessential variables in the ASME Section IX.

• All non essential variables must be addressed on the WPS. (For example: peening is listed for most processes but seldom used. An appropriate statement is “None to be performed”. An inappropriate statement is “Not applicable”)

Supplemental Essential Variables: Applicable to the PQR AND WPS *

• Addresses information that must be included in the PQR and WPS that is mandatory to

assure the notch toughness qualities of the weldment • The construction codes which reference Section IX specify some ranges qualified for

supplemental essential variables directly related to the actual measurements taken and information recorded during production of the qualification coupon (For example: thickness qualified)

• A change in the information requires additional testing or requalification of the WPS



NOTE: Supplemental Essential Variables are excluded from the welding documents used on the actual 653 exam by the 653 Body of Knowledge.

ASME SECTION IX: QW-100 SERIES PARAGRAPHS: QW-100- GENERAL QW-100.1:

1) The WPS is a written document that provides directions to the welder/operator when making production welds.

2) WPS’s have to be qualified by each manufacturer, or it can be an AWS Standard WPS (SWPS) shown in Article V.

3) Both list conditions allowed to weld (variables). 4) Purpose of qualifying the WPS is to prove the weldment purpose for construction is

capable of the required properties. 5) Section IX does not contain specific requirements for notch toughness. These are

contained in the referencing Codes sections. 6) The PQR lists the information recorded during qualification of the procedure.

QW-100.2:

1) Welder Performance Qualification is used to determine the welders’ ability to deposit sound weld metal. Operator Performance Qualification is used to determine the operator’s ability to run the equipment.

QW-100.3

1) PQR’s & WPQ’s made in accordance with the 1962 or later Editions are still valid. 2) New WPS’s & PQR’s shall be in accordance with the current Edition and Addenda.

QW-103.1

1) Each organization is responsible for the welding they perform and must conduct the qualification tests required by Section IX.

2) However, the actual nondestructive & mechanical testing may be subcontracted (QW-201).

QW-103.2

1) Each organization must complete and certify records of all qualification tests and

the records must be kept on file. 2) These records must be available to the Authorised Inspector.

QW-142 & QW-143:

1) When permitted by QW-304 & QW-305 radiography may substitute for mechanical

testing.



QW-153.1: Tensile Test Criteria: 1) Specimens shall have a tensile strength not less than:

• Minimum tensile of the base metal. • Minimum tensile of the weaker base metal if different strengths are used. • Minimum tensile of the weld metal when allowed to have a lower room

temperature strength than the base metal by the referencing code section. • May be 5% below the minimum strength of the base metal if the break is

outside the weld or fusion line in the base metal.

QW-191

1) Special acceptance standards for testing welders using radiography are per QW-142

& 143. 2) The radiography must be performed in accordance with ASME Section V Article 2.

No written procedure is required, and geometric unsharpness is not required to be calculated. T-285 of ASME V (unsharpness) is only a guide.

QW-191.2

1) Lists the acceptance standards for welder qualification with radiography.

QW-191.2.3

1) RT qualification using production welds:

• For welding operators use acceptance standard from referencing code section. • For welders use acceptance standards in QW-191.2.2 (see QW-304 for processes and

modes of transfer permitted to be qualified by RT)

QW-194 Visual Examination – Performance Performance coupon visual exam – shall show complete penetration & fusion of weld & base metals

QW-200 SERIES PARAGRAPHS:



QW-200.1 Welding Procedure Specification:

Each organization shall prepare a written document defined as:

A) WPS – A written qualified welding procedure created to give guidance and direction when used to make production welds to code requirements.

B) The WPS shall contain: • Descriptions of all the essential, nonessential and, when required, supplementary

essential variables for each welding process used in the WPS. • Reference to the supporting PQR(S). • The WPS may include any other data considered helpful in completing the joint.

C) Changes made to WPS’s • Changes to nonessential variables may be made without re-qualification but must

be documented on the WPS by revision level or by use of a new WPS. • Changes to essential or supplementary essential variables to ranges outside those

allowed by Section IX requires re-qualification of the WPS. D) Format of the WPS:

• The WPS may be in any format. • Forms shown in Section IX are not required-only for reference & example.

E) Availability: • The WPS must be available for reference and available to the Authorised

Inspector. • The WPS must be available at the fabrication site.

QW-200.2- Procedure Qualification Records: Each organization shall prepare a written document defined as:

A) PQR – A written document used to record the welding information and data used

when welding a test coupon for qualification of a WPS and the results of the tests performed on specimens taken from the coupon.

B) The PQR shall contain: • Actual values observed for all the essential and, when required, supplementary

essential variables for each welding process used while welding the coupons for testing.

• Test results from tests performed on the speciemens removed from the coupon. • Other information may be included. • When values are included for other variables it must be the actual values observed

– not the full ranges to be used in production unless required by a specific variables or referencing code section.

• The organization qualifying the PQR shall certify the accuracy of the PQR. • Certification of the PQR may not be subcontracted. • The approximate deposited weld metal thicknesses for each filler metal or process

shall be recorded separately. C) Changes made to the PQR’S - Not permitted except as follows:



• Editorial changes may be made in a WPS or PQR; i.e: to correct errors or to reflect code changes.

• Additional information may be added later if it can be proven to be part of the original information recorded with reliable documentation such as lab test records.

D) Format of the PQR: • The PQR may be any format. • Forms shown in Section IX are not required – only for reference & example.

E) Availability • The PQR must be available to the Authorised Inspector upon request.

F) Multiple WPS’S & PQR’S. • Multiple PQR’S may be used to support a single WPS. • Multiple WPS’S may be supported by a single PQR • Multiple WPS’S may be used to complete a single joint.

QW-201: Responsibilities, Subcontracting Testing & Shared Qualifications

1) Nondestructive and mechanical testing may be subcontracted but the actual welding must be performed by the qualifying organization.

2) Two or more organizations may share qualification if effective operational control by both is demonstrated and described in the quality manuals of all the organizations involved.

QW-300 SERIES PARAGRAPHS: QW-300.2 – Responsibility

1) Each organization must tests all welders to assure they are qualified for the welding

activities they will be assigned to perform. 2) Welders must be tested under the supervision of the qualifying organization.

QW-300.3 Shared Qualifications

1) Qualifications may be shared among two or more companies as long as the system used is described in the companies’ quality systems and all other Section IX requirements are met.

QW-301.2 Tests

1) Coupons welded for welder qualification shall be welded in accordance with a

qualified WPS except that: • When preheat and PWHT are required in the WPS they may omitted during the

welding of the welders test coupon. • When a welder prepares a coupon for WPS qualification and the coupon passes

the tests for qualification the welder is also qualified within the limits specified for welders.



• Welder qualification tests may be stopped at any point at which it becomes apparent that the welder does not have the required skill.

QW-301.3

1) Each welder shall be assigned a unique identifying symbol, number or letter to use

when stamping or recording the work performed by the welder.

QW-302.2

1) Welders may be qualified using radiography as allowed by QW-304 & QW-305.

QW-304.2

1) When a welder fails qualification using radiography the entire section of the joint made by the welder be removed or completely radiographed and the defective areas repaired by a qualified welder.

QW-306

1) Welders may be qualified using separate coupons for each process or by welding with

multiple processes in a single coupon as long as all the requirements of Section IX are met.

2) Failure of any portion of a combination test in a single coupon constitutes failure of the entire coupon.

QW-321

1) When a welder fails a qualification test he may take an immediate retest.

QW-322

A welder’s qualification is affected when one of the following occurs: A) If he has not welded with a process in which he is qualified for a period of six

months or more his qualifications for that process expire unless within 6 months prior to the expiration: • a welder has welded using a manual or semiautomatic process which will

maintain his qualification for manual or semiautomatic welding with that process

• a welding operator has welded using a machine or automatic process which will maintain his qualification for machine or automatic welding with that process

B) Whenever there is a specific reason to question the welders’ ability to make welds that meet the specification the qualification required to make those weldments shall be revoked.



A welders qualifications may be renewed by:

A) When the welders qualifications have expired due to not having welded with the process they may be renewed for all positions, diameters, thicknesses and base metals by the welder welding a single test coupon of plate or pipe of any base metal using any thickness, diameter or position and performing the tests required by QW-301 & QW-302.

B) Revoked qualifications may be renewed by using a test coupon appropriate to the production work to be performed. The coupon shall be welded and tested as required by QW-301 & QW-302.

QW-350 These tables list the variables for welders. They are all essential variables, and as such, must be addressed on the WPQ in some manner. The variables for operators are given in QW-360. Article V – This article provides rules for using AWS Prequalified Welding Procedures. Reference is also made to Appendix E, which lists approximately 17 approved pre-qualified welding procedures which do not have to be qualified by the Manufacturer’s.

ASME Section IX - Procedure Qualification Testing Required Tests: 1. Tensile 2. Bends

• Face • Root • Side

3. Nondestructive Testing

General sequence for Procedure Qualification Testing



1. Select welding variables. 2. Check equipment and materials for suitability. 3. Monitor weld joint fit-up as well as actual welding, recording all-important variables and

observations. 4. Select, identify and remove required test specimens. 5. Test and evaluate specimens. 6. Review test results for compliance with applicable code requirements. 7. Release approved procedure for production. 8. Quality individual welders in accordance with this procedure. 9. Monitor production welding for procedure compliance.







ASME Section IX - Welder Qualification Establishes Skill Essential Variables

• Position • Joint Configuration • Electrode Type and Size • Process • Base Metal Thickness • Technique



General Sequence for Welder Qualification Testing 1. Identity essential variables. 2. Check equipment and materials for suitability 3. Check test coupon configuration and position. 4. Monitor actual welding, to ensure that is complies with applicable welding procedure. 5. Select, identify and remove required test specimens. 6. Test and evaluate specimens. 7. Complete necessary paperwork. 8. Monitor production welding.



ASME SECTION IX – WELDING – PRACTICE QUESTIONS:

1. The purpose of the WPS and PQR is to determined that:

1. the welder is qualified 2. the base metals are strong enough 3. the weldment has the desired properties 4. the skill of the welder

2. The WPS lists:

1. nonessential variables 2. essential variables 3. supplementary essential variables if required 4. all of the above

3. The PQR must list:

1. essential variables and supplementary essential variables when notch toughness is

required 2. nonessential variables 3. welder qualification variables 4. all of the above

4. What is the earliest Edition of Section IX recognized by the current edition?

1. 1958 2. 1992 3. 1987 4. 1962

5. New Welding Procedure Specifications must meet the ____________ Edition and addenda of Section IX.

1. 1962 2. current (latest mandatory) 3. Inspector 4. All of the above

6. Each ______________ shall conduct the tests required by Section IX to quality the

WPS’s used during the construction, alteration, or repair.

1. Welder or welding operator 2. Manufacturer or contractor 3. Inspector 4. All of the above



7. The records of procedure, welder and welding operator qualification must be available to the ________________.

1. Manufacturer or Contractor 2. Welder 3. Authorized Inspector 4. Foreman

8. A welder qualifying with a groove weld in plate in the 4G position is qualified to weld

groove welds in plate and pipe over 24” O.D. in the ______________ positions.

1. Overhead 2. Flat and horizontal 3. Flat and overhead 4. Horizontal

9. A welder qualifying with the plate fillet welds in the 3F and 4F positions is qualified to weld groove welds in plate in the ________________ positions.

1. Flat only 2. Flat and horizontal 3. Flat and vertical 4. None of the above

10. A welder qualifying by making a groove weld on pipe with an O.D. of 3/4" in the 5G

position is qualified to weld groove welds in:

1. 1/2" O.D. Pipe in the overhead position 2. 6” O.D. Pipe in the vertical position 3. 3/4" O.D. pipe in the horizontal position 4. None of the above

11. In general, qualification on groove welds also qualifies a welder to make:

1. Stud welds 2. Overhead welds 3. Fillet welds 4. All of the above

12. Charpy V-notch tests are performed to determine a weldment’s

1. Tensile strength 2. Ductility 3. Notch toughness 4. All of above



13. A welder making a groove weld using the SAW process on P1 materials may be qualified using radiography.

1. True 2. False

14. When a tensile specimen breaks in the metal outside of the weld or fusion line, the strength recorded may be _______________ below the specified tensile and be accepted.

1. 3.5% 2. .5% 3. 5% 4. All of the above

15. Guided-bend specimens shall have no open defects in the weld or heat effected zone exceeding ____________ measured in any direction on the convex surface of the specimen after bending.

1. 1/16” 2. 3/32” 3. 1/8” 4. None of the above

16. When using radiographs to qualify welders, the acceptance standards used are found in:

1. ASME Section V 2. ASME Section IX 3. ASME Section VIII 4. The referencing code

17. A WPS must describe:

1. Essential variables 2. Nonessential variables 3. Supplementary essential variables when required for notch toughness 4. All of the above

18. A PQR must describe:

1. Nonessential variables 2. Essential variables 3. Results of Welder Qualification tests 4. Project description & NDE methods



19. The ____________________ must certify the PQR as accurate.

1. Inspector 2. Manufacturer or contractor 3. Welder 4. All of the above

20. For the SMAW process ___________________ is an essential variable for the WPS.

1. Groove design 2. Post Weld heat treatment (PWHT) 3. Roof spacing 4. Method of cleaning

21. For the SAW process ________________ is an essential variable for the WPS.

1. Supplemental powdered filler metal (if used) 2. Filler metal diameter 3. Preheat maintenance 4. Addition or deletion of peening

22. The basic purpose of testing a welder is to establish the welder’s ______________.

1. Knowledge of welding requirements 2. Ability to deposit sound weld metal 3. mechanical ability to operate equipment 4. General attitude toward welding inspectors

23. The record of a welder’s performance tests is called a ________________.

1. PQR 2. WQR 3. WPS 4. WPQ

24. if a welder qualified with the manual SMAW process on Jan. 1, 1997 and last welded with manual SMAW on March 15, 1997, would he still be qualified on October 7, 1997?

1. Yes 2. No



25. A welder qualifying with the SMAW process with a double welded groove weld is qualified to weld.

1. Without backing 2. With all base metals 3. With backing only 4. With P1 backing only

26. Immediate retests of welders qualifications coupons __________________.

1. shall use the same method 2. May use any method 3. Are not allowed 4. Required Inspector approval

27. Welder performance qualification records must describe all the _____________ variables specified.

1. Essential & nonessential 2. Nonessential 3. Essential 4. Brazing

28. A welder depositing 1/2” of weld metal in three layers in a groove weld with the SMAW process is qualified to deposit up to __________________ of weld metal.

1. 8” 2. 1” 3. Max to be welded 4. 1/2"

29. “P” numbers are used to designate groups of

1. Electrodes 2. Flux 3. Base metals 4. Joints

30. A welder qualifying with P-No.21 is qualified to weld

1. P-1 – P-11 to P-1 – P-11 2. P-8 – P8 3. P-21 – P-25 to P-21 – P-25 4. P21 to P21 only



31. Section IX groups welding electrodes by

1. AWS class 2. ASME specification 3. SFA 4. “F” number

32. Ferrous weld metal chemical composition may be designated using

1. “P” number 2. Welder I.D. 3. “A” number 4. page number

33. For welder qualification with the SMAW process _________________ is an essential

variable.

1. Base metal thickness 2. Peening 3. P-number 4. Electrode diameter

34. Each welder must be assigned a(n)

1. P number 2. Unique identifier 3. Hood & gloves 4. Inspector

35. A welder qualification coupon welded in the 2G position of 5/16” thick plate material

must have how many root and face bends?

1. 2 – 1 each 2. 4 – 2 each 3. 6 – 2 face and 4 root 4. 8 – 4 each

36. A WPS shall have:

1. the welder referenced. 2. the PQR referenced. 3. the NACE referenced. 4. the PDQ referenced.



37. Welding in the 1G position qualifies a welder in what position?

1. horizontal 2. vertical 3. flat 4. overhead

38. Which of the following is an essential variable for qualification of an SMAW welding

procedure?

1. “F” number 2. joint design 3. diameter of the electrode 4. pipe diameter

39. A welder may be qualified by RT if:

1. The first 3’ of the first production weld is radiographed. 2. the first production weld passes mechanical tests. 3. If the first production weld passes mechanical tests. 4. If the first production weld is passes by MT examination.

40. A welder may be qualified using RT in these processes except for _______________.

1. GMAW (short-circuiting mode) 2. GMAW (pulsed-arc) 3. GMAW (spray-arch) 4. SMAW



ASME SECTION IX ANSWER KEY

1. 3,QW-100.1 2. 4,QW-100.1 3. 1,QW-100.1 4. 4,QW-100.3 5. 2,QW-100.3 6. 2,QW-103 7. 3,QW-103 8. 3,QW-461.9 9. 4,QW-461.9 10. 2,QW-461.9 & QW-452.3 11. 3,QW-303 12. 3,QW-171 13. 1,QW-304 14. 4,QW-153 15. 3,QW-163 16. 2,QW-191 17. 4,QW-200.1 18. 2,QW-200.2 19. 2,QW-200.2 20. 2,QW-253 21. 1,QW-254 22. 2,QW-100.2 & QW-301.1 23. 4,QW-300.3 & QW-301.4 24. 2,QW-322.1 25. 3,QW-402.4 & QW-310.2 26. 1,QW-321 27. 3,QW-301.4 28. 3,QW-452.1 29. 3,QW-420 30. 3,QW-423.1 31. 4,QW-431 32. 3,QW-441 33. 3,QW-353 34. 2,QW-301.3 35. 1,QW-452.1 36. 2,QW-200.1 (b) 37. 3,QW-303.1 & QW-461.9 38. 1,QW-253 39. 2,QW-304 40. 1,QW-304



ASME SECTION IX – WPS REVIEW AND PRACTICE QUESTIONS STEP 1: Variables table The welding process is SMAW therefore the brief of variables used will be those in Table QW-253. Look at table QW-253 and check the brief of variables for Base metals (QW-403). Note that QW-403.8 specifies that ‘change’ of thickness T qualified is an essential variable therefore the base material thickness must be addressed on the PQR. When we read QW-403.8 in section IX we see that it refers us to QW-451 for the thickness range qualified. Note:

• The PQR tells us under Base metals (QW-403) the coupon thickness T = 1 inch • QW-451.1 tells us that for a test coupon of thickness ¾ - 1 ½ inch the base material

range qualified on the WPS is 3/16 inch to 2T (therefore 2T = 2inches). The correct answers to the typical question below must therefore be (c) 1. (WPS) The base metal thickness range shown on the WPS

a) Is correct b) Is wrong – it should be 1/16” – 1 ½”

c) Is wrong – it should be 3/16” – 2” (QW 451.1)

d) Is wrong – it should be 3/8” – 1”

Look at Table QW-253 and note how QW-404.30 ‘change in deposited weld metal thickness ‘t’ is an essential variables (and refers to QW-451 for the maximum thickness qualified) therefore weld metal thickness must be addressed in the PQR. Note:

• PQR under QW-404 filler states weld metal thickness t = 1 inch • QW-451 states if t ≤ ¾ in the maximum qualified weld metal thickness = 2T where

T = base metal thickness. The correct answers to the typical question below must therefore be (d) 2. (WPS) The deposited weld metal thickness

a) Is correct b) Is wrong – it should be ‘unlimited’

c) Is wrong – it should be 8” maximum

d) Is wrong – it should be 2” maximum (QW-451.1)



NEXT STEP: Check of type of consumable used Note how QW-404.4 shows that a change in F-No from table QW-432 is an essential variable. This is addressed on the PQR which shows the E7018 electrode as an F-No 4. Table QW-432 and the WPS both show the E7016 electrode is also an F-No 4. The correct answers to the typical question below must therefore be (a) 3. (WPS) The electrode change from E7018 on the PQR to E7016 on the WPS

a) Is acceptable (QW-432) b) Is unacceptable – it can only be an E7018 on the WPS

c) Is acceptable – provided the electrode is an E7016 A1

d) Is unacceptable – the only alternate electrode is an E6010

NEXT STEP: Check of type of preheat QW-406.1 shows that a decrease of preheat > 100°F (55°C) is defined as an essential variable. The PQR shows a preheat of 200°F, which means the minimum shows on the WPS must be 100°F and not ‘none’ as shown.

The correct answers to the typical question below must therefore be (d) 4. (WPS) The preheat should read

a) 60º F minimum b) 100º F minimum

c) 250º F minimum

d) 300º F minimum

NEXT STEP: Check of tensile test results Note how the tensile test part of the PQR directs you to QW-150. On reading this section you will notice that it directs you to tensile test acceptance criteria in QW-153. This says minimum procedure qualification tensile test acceptance criteria in QW-153. This says minimum procedure qualification tensile values are found in Table QW/QB-422. Checking through the figures for material SA-672 Grade B70 shows a minimum specified tensile value of 70ksi (70000 psi) but the PQR specimen T-2 shows a UTS value of 63969 psi.



The correct answers to the typical question below must therefore be (c) 5. (PQR) The tension test results are

a) Acceptable b) Unacceptable – not enough specimens

c) Unacceptable – UTS does not meet ASME IX (QW-422-70ksi)

d) Unacceptable – Specimen width incorrect

NEXT STEP: Check of bend test results The PQR directs you to QW-160 for bend tests. For API exam purpose the bend tests will be transverse tests. Notes these important sections covering bend tests

• QW-163 gives acceptance criteria for bend tests • QW-451 contains PQR thickness limits and test specimens requirements, • QW-463.2 refers to performance qualifications

In relation to the question below: 6. (PQR) The bend test results are

a) Acceptable b) Unacceptable – defect size greater than permitted

c) Unacceptable – wrong type and incorrect number of specimens (QW-450)

d) Unacceptable – incorrect figure number – should be QW-463.2

NEXT STEP: Certification of PQRs The requirements for certifying of PQR is clearly shown in QW-201. Note how it says ‘the manufacturer or contractor shall certify that he has qualified’… The correct answers to the typical question below must therefore be (a) 7. (PQR) To be ‘code legal’ the PQR must be

a) Certified (QW-201) b) Notarized

c) Authorized

d) Witnessed



NEXT STEP: Check of variables shown on WPS/PQR Note how QW-253 defines QW-403.9 ‘t-pass’ as an essential variable. It must therefore be included on the PQR and WPS. Note how in the example it has been addressed on the WPS (under QW-410 technique) but has not been addressed on the PQR The correct answers to the typical question below must therefore be (b) 8. (WPS/PQR) Essential variable QW-403.9 has been

a) Correctly addressed on the WPS b) Incorrectly addressed on the WPS

c) Not addressed on the PQR

d) Both b) and c)

NEXT STEP: Variables shown on WPS/PQR Remember that weld positions are shown in QW-461. They are not an essential variables however so the weld position is not required to be addressed on the PQR. If it is (optionally) shown on he PQR it need to be checked to make sure it is correct. In this case the position shown refers to the test position of plate, rather than pipe. The correct answers to the typical question below must therefore be (c) 9. (PQR) The position of the groove weld is

a) Acceptable as shown b) Unacceptable – it is an essential variable not addressed

c) Unacceptable – position shown is not for pipe (QW-461.4)

d) Both b) and c)

NEXT STEP: Variables shown on WPS/PQR For SMAW, the type of weld bead used is not specified under QW-410 as an essential variable. This means it is a non essential variable and is not required in the PQR (but can be included by choice remember). QW-200. 1c permits changes to non essential variables of a WPS as long as it is recorded. It is therefore acceptable to specify string bead in the PQR but recorded it as ‘string and weave’ in the WPS.



The correct answers to the typical question below must therefore be (b) 10. (PQR/WPS) PQR shows ‘string beads but WPS shows ‘both’ string and weave beads. This is:

a) Unacceptable – does not meet code requirements b) Acceptable – meets code requirements (Non Ess variable – QW200.1c)

c) Acceptable – if string beads are only used on the root

d) Acceptable – if weave beads are only used on the cap



QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECTIONS (WPS) (See Qw-200.1, Section IX, ASME Boiler and Pressure Vessel Code)

Company Name__________TWI_________________________By________P.PAUL_________________________ Welding Procedure Specification No.___SMAW-01___Date__20/08/2007__Supporting PQR No. (s)___SMAW-01____ Revision no. ________0________Date_____20/08/2007______ Welding Process (es) _________SMAW_______________Type (s) __________Manual____________________ (automatic, Manual, Machine, or Semi-Auto)

JOINTS (QW-402) Details Joint Design________Single Vee Butt________________ Backing (Yes)__________________(No)______X______ Backing Material (Type) ___________________________ (Refer to both backing and retainers) □ Metal □ Nonfusing Metal □ Nonmetalinnic □ Other Sketches, Production Drawings, Weld Symbols or Written Description should show the general arrangement of he parts To be welded. Where applicable, the root spacing and the details of weld groove may be specified. (at the option of the Mfgr. Sketches may be attached to illustrate Joint design, weld layers and bead sequence, e.g., for notch Toughness procedures, for multiple process procedures, etc.) __________________________________________________________________________________________ *BASE METALS(QW-403) P-No.___1___Group No.___2___to P-No.______1_______Group No. __________2____________________ OR Specification type and grade ___________________________________________________________________ To Specification type and grade_________________________________________________________________ OR Chem. Analysis and Mech. Prop.________________________________________________________________ To chem. Analysis and Mech Prop.______________________________________________________________ Thickness range: Base Metal: Groove___________1/16” – 2”______________Fillet_________________________________ Pipe Diameter range: Groove ________All_________________ Fillet _________________All________________ Other_____________________________________________________________________________________

*FILLER METALS (QW-404) Spec. No. (SFA) SFA 5.1 AWS No. (Class) E7016 F-No. 6 A-No 4 Size of filler metals All Weld Metal Thickness Range Groove All Fillet All Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other

* Each base metal-filler metal combination should be recorded individually.



QW-482 (Back) WPS No.__SMAW-01 Rev___0___ POSITIONS (QW-405 Position(s)of Groove___________All______________ WeldingProgression: Up__Yes___Down_____Yes___ Position(s)of Fillet____________All_______________

POSTWELD HEAT TREATMENT (QW-407) Temperature Range___________None_______________ Time Range________________None___________________

PREHEAT (QW-406) Preheat Temp. Min_________None______________ Interpass Temp. Max_________None____________ Preheat Maintenance_________None____ (Continuous or special heating where applicable should be recorded)

GAS (QW-408) Percent Composition Gas (es) (Mixture) Flow Rate Shielding __None___ _________ ___________ Trailing __None___ _________ ___________ Backing __None___ _________ ___________

ELECTRICAL CHARACHTERISTICS (QW-409) Current AC or DC_____DC_______Polarity____Reverse______ Amps (Rang)______110-120_______Vots (Range)____12-20_____ (amps and volts range should be recorded for each electrode Size, position, and thickness, etc. This information may be Listed in a tabular form similar to that shown below) Tungsten Electrodes Size and Type________________________N/A_____________________________________________ (Pure Tungsten, 2% Thoriated, etc.) Mode of Metal Transfer for GMAW_________________________N/A_____________________________________________ (spray arc, short circuiting arc, etc.) Electrode Wire feed speed range__________________________N/A_____________________________________________ TECHNIQUE (QW-410) String or weave Bead_________________Both________________________________________________________________ Orifice or Gas Cup Size________________N/A________________________________________________________________ Initial and Interpass Cleaning (Brushing, Grinding, etc.)___________Brushing, grinding_________________________________ ______________________________________________________________________________________________________ Method of Back Gouging__________________None____________________________________________________________ Oscillation__________________________N/A_________________________________________________________________ Contact Tude to Work Distance______________N/A ________________________________ Multiple or Single Pass (per side)_____________ Multiple pass – no pass greater than ____________¾”___________________ Multiple or single Electrodes__________________Multiple________________________________________________________ Travel Speed (Range)_______________________10 IPM________________________________________________________ Peening_________________________________Allowed_________________________________________________________ Other__________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________

Filler Metal

Current

Weld Layer

(s)

Process

Class

Dia

Type Polar

Amp Range

Volt Range

Travel Speed Range

Other(e.g Remarks,

Comments, Hot wire Addition,

Technique, Torch

Angle, Etc)



QW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORDS (PQR) (See Qw-200.2, Section IX, ASME Boiler and Pressure Vessel Code)

Record Actual Conditions Used to Weld Test Coupon

Company Name______________TWI_______________________________________________________________ Procedure Qualification Record No.______________SMAW-01________________ Date_______20/07/07__________ WPS No._______________SMAW-01________________________________________________________________ Welding Process (es)___________SMAW____________________________________________________________ Types (automatic, Manual, Machine, or Semi-Auto)__________Manual_________________________________________

JOINTS (QW-402)

Single Vee Groove, 60 degree included angle. No backing

Groove Design of Test Coupon (For combination qualifications, the deposited weld metal thickness shall recorded for each filler metal or process used)

POSTWELD HEAT TREATMENT( QW-407) Temperature ______None____________________ Time _____________None____________________ Other_____________________________________ _________________________________________ _________________________________________ _________________________________________

BASE METALS (QW-403)

Material Spec._________SA672________________ Type of Grade_______B70____________________ P-No_____1________to P-No._______1_________ Thickness of test coupon ____________1”________ Diameter of Test Coupon__________36”_____ Other_____________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________

GAS (QW-408)

Percent Composition Gas(es) (Mixture) Flow Rate

Shielding __None___ ________ _________ Trailing __None___ ________ _________ Backing __None___ ________ _________

FILLER METALS (QW-404) SFA Specification____5.1______ AWS Classification___E7018___ Filler Metal F-No.______4______ Weld Metal Analysis A-No.__1___ Size of Filler Metal_____1/8”____ Other______________________ ___________________________ Weld Metal Thickness_____1”___

____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________

ELECTRICAL CHARACTERISTCS (QW-409)

Current _______Direct______________________ Polarity _______Reverse____________________ Amps______100________Volts_____10_______ Tungsten Electrode Size __________N/A______ Other____________________________________ ________________________________________ ________________________________________

POSITION (QW-405)

Position of Groove_______________3G_________ Weld Progression (Uphill, Downhill)_____________ Other_____________________________________ __________________________________________

PREHEAT (QW-406) Preheat Temp__________200ºF_______________ Interpass Temp_________650ºF_______________ Other_____________________________________

TECHNIQUE (QW-410)

Travel Speed_______________25 IPM__________ String or Weave Bead________ String___________ Oscillation__________N/A____________________ Multipass or Single Pass(per side)____multiple____ Single or Multiple Electrodes______Single________ Other_____________________________________ __________________________________________ __________________________________________



QW-483 (Back) PQR No.__SMAW 1

Tensile Test (QW-150)

Specimen No. Width Thickness Area Ultimate Total Load Ib

Ultimate Units Stress Psi

Type of Failure & Location

T - 1 0.750 0.985 0.7387 54100 73236 BF/WM T - 2 0.751 0.975 0.6253 40000 63969 BF/WM

Guided-Bead Tests (QW-160)

Type and Figure No. Result

QW-462.2 - FACE Opening 1/16” long - Acceptable QW-462.2 - ROOT Acceptable

Toughness Tests (QW-170)

Impact Values

Specimen No

Notch Location

Specimen Size

Test Temp.

Drop Weight Break (Y/N)

Comment: ____________________________________________________________________________________

Fillet-Weld Test (QW-180)

Result – Satisfactory: Yes___________No___________Penetration into Parent Metal: Yes_________No__________ Macro – Results_________________________________________________________________________________ Other Tests Type of Test____________________________________________________________________________________ Deposit Analysis________________________________________________________________________________ Other_________________________________________________________________________________________ …………………………………………………………………………………………………………………………………………. Weldder’s Name______Steve Francis_______Clock No.________________Stamp No._______SF3_____________ Tests conducted by______Testhouse_____________Laboratory Test No._________TH – 001__________________ We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code.

Manufacturer_______________TWI______________

Date__________20/07/07___________________ By___Mike Trinidad_______

(Detail of record of tests are illustrative only and may be modified to conform to the type and number of tests required by the Code)



Please Refer to SAW-02 WPS for questions 9 to 18.

9. (WPS/PQR) An essential variable not addressed on the PQR or WPS is

a) QW-403.9 b) QW-403.13 c) QW-404.36 d) All essential variables have been addressed

10. (WPS) The deposited weld metal thickness range shown

a) Is correct b) Is beyond the range permitted by the code c) Should be 4” max d) None of the above

11. (WPS) The SFA classification for the filler metal shown is

a) 5.7 b) 5.17 c) 5.20 d) 5.30

12. (WPS) The pipe diameter range listed on the WPS

a) Is incorrect

b) Is acceptable c) Should be 24” max d) None of the above

13. (PQR/WPS) PWHT shown on the PQR and WPS is

a) Incorrect, all codes require PWHT at this thickness b) Incorrect, as the PQR should have PWHT values filled in c) Incorrect, the WPS should specify a PWHT temp for production welds d) Acceptable – it is correctly addressed



14. (PQR) The tension test results are

a) Sufficiently strong for code compliance b) Not sufficiently strong for code compliance c) 10% over rated based metal UTS and therefore out of code compliance d) None of the above


a) Acceptable b) Unacceptable – insufficient specimen width c) Unacceptable – multiple specimens not allowed for 1” thickness welded d) Unacceptable – insufficient number of specimens

16. (PQR) the PQR

a) Need not be signed to be properly certified b) Must be signed by the Managing Director c) Must be signed to be properly certified d) None of the above

17. (PQR) Bend test results are

a) Acceptable as shown b) Unacceptable – incorrect type of specimens tested c) Unacceptable – incorrect figure number quoted d) Unacceptable – not enough specimens tested

18. (PQR) An essential variable(s) incorrectly omitted from the PQR is

a) QW-404.25 b) QW406.1 c) QW-407

d) QW-404.34




Company Name____________TWI_____________________By____________P.PAUL_______________________ Welding Procedure Specification No.___SAW-02_____Date___20/08/2007___Supporting PQR No. (s)____SAW-02___ Revision no. ____SAW_______Date______________________ Welding Process (es) __________________________________Type (s) _______Machine____________________

(automatic, Manual, Machine, or Semi-Auto)

JOINTS (QW-402) Details Joint Design________Double Vee Groove________________ Backing (Yes)_______X_________(No)__________________ Backing Material (Type) _________Weld metal____________ (Refer to both backing and retainers) □ Metal □ Nonfusing Metal □ Nonmetalinnic □ Other Sketches, Production Drawings, Weld Symbols or Written Description should show the general arrangement of he parts To be welded. Where applicable, the root spacing and the details of weld groove may be specified. (at the option of the Mfgr. Sketches may be attached to illustrate Joint design, weld layers and bead sequence, e.g., for notch Toughness procedures, for multiple process procedures, etc.) __________________________________________________________________________________________ *BASE METALS(QW-403) P-No.___1___Group No.___1____to P-No.______1________Group No. _____________1_____________

OR Specification type and grade __________________SA134 SA285 C__________________________________ To Specification type and grade________________SA134 SA285 C__________________________________ OR Chem. Analysis and Mech. Prop.________________________________________________________________ To chem. Analysis and Mech Prop.______________________________________________________________ Thickness range: Base Metal: Groove__________3/16” – 2”____________Fillet___________________________________ Pipe Diameter range: Groove ______________All__________________ Fillet ____________________________ Other_____________________________________________________________________________________

*FILLER METALS (QW-404) Spec. No. (SFA) SFA 5.17 AWS No. (Class) F7A-EM12 F-No. 6 A-No 1 Size of filler metals 1/8” – 1/4” Weld Metal Thickness Range Groove 2” max Fillet N/A Electrode-Flux (Class) F7A2 (neutral) Flux Trade Name Lincoln Consumable Insert N/A Other No supplemental powder




QW-482 (Back) WPS No.__SAW-02___Rev__0___ POSITIONS (QW-405 Position (s) of Groove___________1G________________ Welding Progression: Up_________Down_______________ Position (s) of Fillet_____________None_______________

POSTWELD HEAT TREATMENT (QW-407) Temperature Range_____________None__________________ Time Range_____________________________________

PREHEAT (QW-406) Preheat Temp. Min _____________60°F_________________ Interpass Temp. Max____________650° Max__________________ Preheat Maintenance____________None________________ (Continuous or special heating where applicable should be recorded)

GAS (QW-408) Percent Composition Gas (es) (Mixture) Flow Rate Shielding ___None___ _________ __________ Trailing ___None___ _________ __________ Backing ___None___ _________ __________

ELECTRICAL CHARACHTERISTICS (QW-409) Current AC or DC________DC________Polarity____Reverse______ Amps (Rang)______300 - 400__Vots (Range)_____34-40_______ (amps and volts range should be recorded for each electrode Size, position, and thickness, etc. This information may be Listed in a tabular form similar to that shown below) Tungsten Electrodes Size and Type________________N/A_____________________________________________________ (Pure Tungsten, 2% Thoriated, etc.) Mode of Metal Transfer for GMAW_________________N/A_____________________________________________________ (spray arc, short circuiting arc, etc.) Electrode Wire feed speed range___________________60 -100 IPM_____________________________________________ TECHNIQUE (QW-410) String or weave Bead__________________String_____________________________________________________________ Orifice or Gas Cup Size___________________________________________________________________________________ Initial and Interpass Cleaning (Brushing, Grinding, etc.)_______________Brushing, grinding____________________________ ______________________________________________________________________________________________________ Method of Back Gouging________________Air carbon arc_______________________________________________________ Oscillation____________________________None_____________________________________________________________ Contact Tude to Work Distance___________1/8” – ¼”___________________________________________________________ Multiple or Single Pass (per side)__________Multiple pass_______________________________________________________ Multiple or single Electrodes______________Single_____________________________________________________________ Travel Speed (Range)___________________27 – 40 IPM________________________________________________________ Peening______________________________Not Allowed________________________________________________________ Other__________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________

Filler Metal

Current

Weld Layer (s) Process

Class

Dia

Type Polar

Amp Range

Volt Range

Travel Speed Range

Other(e.g Remarks,

Comments, Hot wire Addition,

Technique, Torch Angle, Etc



QW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORDS (PQR) (See Qw-200.2, Section IX, ASME Boiler and Pressure Vessel Code)


Company Name______________TWI_______________________________________________________________ Procedure Qualification Record No.______________SAW-02________________ Date_______20/07/07__________ WPS No._______________SAW-02________________________________________________________________ Welding Process (es)___________SAW____________________________________________________________ Types (automatic, Manual, Machine, or Semi-Auto)__________Manual_________________________________________

JOINTS (QW-402)


POSTWELD HEAT TREATMENT( QW-407) Temperature ______None____________________ Time _____________None____________________ Other_____________________________________ _________________________________________ _________________________________________ _________________________________________


Material Spec._________SA-134________________ Type of Grade_______SA285 GrC______________ P-No_____1________to P-No._______1_________ Thickness of test coupon ____________1”________ Diameter of Test Coupon__________24”_____ Other_____________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________

GAS (QW-408)


Shielding __None___ ________ _________ Trailing __None___ ________ _________ Backing __None___ ________ _________

FILLER METALS (QW-404) SFA Specification____5.7______ AWS Classification__F7A-EM12___ Filler Metal F-No.______6______ Weld Metal Analysis A-No.__1___ Size of Filler Metal_____1/8”____ Other___No pass greater than ½”____ _____________________________ Weld Metal Thickness_____1”___

____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________


Current _______Direct______________________ Polarity _______Reverse____________________ Amps______100________Volts_______________ Tungsten Electrode Size ____________________ Other____________________________________ ________________________________________ ________________________________________

POSITION (QW-405)

Position of Groove_______________1G_________ Weld Progression (Uphill, Downhill)_____Flat____ Other_____________________________________ __________________________________________

PREHEAT (QW-406) Preheat Temp__________60ºF min_____________ Interpass Temp_________650ºF max___________ Other_____________________________________

TECHNIQUE (QW-410)

Travel Speed_______________30 IPM__________ String or Weave Bead________ String___________ Oscillation__________None____________________ Multipass or Single Pass(per side)____multiple____ Single or Multiple Electrodes______Single________ Other_____________________________________ __________________________________________ __________________________________________



QW-483 (Back)PQR No.______SAW-02__


Specimen

Width

Thickness Area Ultimate

Total Load Ib

Ultimate Unit Stress

Psi


T – 1 0.750 0.500” 0.375 37500 100000 DF/HAZ T – 2 0.750 0.500” 0.375 35000 93300 DF/HAZ T – 3 0.750 0.500” 0.375 37500 100000 DF/HAZ T – 4 0.750 0.500” 0. 375 35000 93300 DF/HAZ



QW-462.2 – SIDE 1 Pass QW-462.2 – SIDE 2 Pass QW-462.2 – SIDE 3 Pass QW-462.2 – SIDE 4 Pass


Impact Values Specim

en No.

Notch Location

Specimen Size

Test Temp. Ft. ibs % Shear Mils


Comment: ____________________________________________________________________________________


Result – Satisfactory: Yes___________No___________Penetration into Parent Metal: Yes_________No__________ Macro – Results_________________________________________________________________________________

Other Tests Type of Test____________________________________________________________________________________ Deposit Analysis________________________________________________________________________________ Other_________________________________________________________________________________________ …………………………………………………………………………………………………………………………………………. Weldder’s Name______STEVE FRANCIS________Clock No._____________Stamp No._______6969___________ Tests conducted by________Testhouse_____________Laboratory Test No._____________________________ We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code.

Manufacturer________________TWI________________

Date__________20/07/07_________________ By_________Mike Trinidad____



Please refer to GMAW-03 WPS for questions 19 - 28

19. (WPS) The base material thickness range shown;

a) Is correct b) Should be 3/16” – 4” c) Should be 3/16” – 8” max d) Should be 3/16” – 2”

20. (WPS) The deposited weld metal thickness range

a) Is correct b) Is beyond the range permitted by the code c) Is acceptable if impact testing is carried out d) None of the above

21. (WPS) The fillet metal shown is

a) Acceptable b) Unacceptable – ER70S-2 was qualified but ER 70S-7 is on the WPS c) Unacceptable – electrode should be 6010 on WPS d) Correct c and d answers

22. (WPS) The mode of metal transfer is

a) Unacceptable for that qualified on the PQR b) Is acceptable c) Unacceptable-Should be pulsed d) Unacceptable – Should be spray

23. (WPS) The gas shielding is

a) Acceptable b) Unacceptable – composition has changed c) Not required for GMAW d) None of the above



24. (PQR) The 3G position of the test pipe indicates it was

a) Welded in the horizontal position b) Welded in the overhead position c) Welded in the 45° fixed position d) None of the above –this is not a pipe test position


a) Acceptable b) Unacceptable-insufficient strength c) Unacceptable-not enough tests for thickness welded d) Unacceptable-calculations incorrect

26. (PQR) Bend test results are

a) Acceptable as shown b) Unacceptable-incorrect type of specimens tested c) Unacceptable – results do not meet code d) Unacceptable – not enough specimens tested

27. (PQR) A non-essential variable incorrectly omitted from the PQR is

a) Peening b) Electrode spacing c) Gas nozzle size d) None-non-essential variables do not have to be included in the PQR

28. (PQR) An essential variable(s) incorrectly omitted from the PQR is

a) QW-403.9 b) QW404.24 and QW-404.27 c) QW-402.1

d) Both a) and b)




Company Name__________TWI___________________By____________P.PAUL___________________________ Welding Procedure Specification No.____GMAW-03__Date_20/08/2007__Supporting PQR No. (s)____GMAW-03____ Revision no. _________________Date______________________ Welding Process (es) __________GMAW_________________Type (s) ______Semi-auto____________________ (automatic, Manual, Machine, or Semi-Auto) JOINTS (QW-402) Details Joint Design________Single Vee Groove______________ Backing (Yes)__________________(No)_____X________ Backing Material (Type) ___________none____________ (Refer to both backing and retainers) □ Metal □ Nonfusing Metal □ Nonmetalinnic □ Other Sketches, Production Drawings, Weld Symbols or Written Description should show the general arrangement of he parts To be welded. Where applicable, the root spacing and the details of weld groove may be specified. (at the option of the Mfgr. Sketches may be attached to illustrate Joint design, weld layers and bead sequence, e.g., for notch Toughness procedures, for multiple process procedures, etc.) __________________________________________________________________________________________ *BASE METALS(QW-403) P-No.__1___Group No.____1____to P-No._________1______Group No. __________1____________________ OR Specification type and grade ______________SA-333_______________________________________________ To Specification type and grade____________SA-333_______________________________________________ OR Chem. Analysis and Mech. Prop.________________________________________________________________ To chem. Analysis and Mech Prop.______________________________________________________________ Thickness range: Base Metal: Groove_______1/16” – 2”________________Fillet___________________________________ Other_____________________________________________________________________________________

*FILLER METALS (QW-404) Spec. No. (SFA) SFA 5.18 AWS No. (Class) E70S-7 F-No. 6 A-No 1 Size of filler metals 1/8” - 3/32” Weld Metal Thickness Range Groove Unlimited Fillet Unlimited Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert N/A Other




QW-482 (Back)

WPS No.__GMAW-03___Rev__0___

POSITIONS (QW-405 Position (s) of Groove___________All________________ Welding Progression: Up____X____Down _______________ Position (s) of Fillet_____________All_______________

POSTWELD HEAT TREATMENT (QW-407) Temperature Range_____________None__________________ Time Range_____________________________________

PREHEAT (QW-406) Preheat Temp. Min _____________60°F_________________ Interpass Temp. Max____________650° Max__________________ Preheat Maintenance____________None________________ (Continuous or special heating where applicable should be recorded)

GAS (QW-408) Percent Composition Gas (es) (Mixture) Flow Rate Shielding ___Ar/CO2___ __80/20__ _35CFH__ Trailing ___None___ _________ _______ Backing ___None___ _________ _______

ELECTRICAL CHARACHTERISTICS (QW-409) Current AC or DC________DC________Polarity____Reverse______ Amps (Rang)______120 - 200__Vots (Range)_____14-18_______ (amps and volts range should be recorded for each electrode Size, position, and thickness, etc. This information may be Listed in a tabular form similar to that shown below) Tungsten Electrodes Size and Type________________N/A_____________________________________________________ (Pure Tungsten, 2% Thoriated, etc.) Mode of Metal Transfer for GMAW_________________Short circuiting____________________________________________ (spray arc, short circuiting arc, etc.) Electrode Wire feed speed range__________________________________________________________________________ TECHNIQUE (QW-410) String or weave Bead__________________String_____________________________________________________________ Orifice or Gas Cup Size___________________________________________________________________________________ Initial and Interpass Cleaning (Brushing, Grinding, etc.)_______________Brushing, grinding____________________________ ______________________________________________________________________________________________________ Method of Back Gouging________________None_______________________________________________________ Oscillation____________________________Reverse____________________________________________________________ Contact Tude to Work Distance___________⅛” – ¼”___________________________________________________________ Multiple or Single Pass (per side)__________Multiple pass_______________________________________________________ Multiple or single Electrodes______________Single_____________________________________________________________ Travel Speed (Range)___________________10 – 15 IPM________________________________________________________ Peening ______________________________Not Allowed________________________________________________________ Other__________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________

Filler Metal

Current

Weld Layer (s)

Process

Class

Dia

Type Polar

Amp Range

Volt Range

Travel Speed Range

Other(e.g Remarks, Comments, Hot wire Addition, Technique, Torch Angle, Etc)



QW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORDS (PQR)(See Qw-200.2, Section IX, ASME Boiler and Pressure Vessel Code)


Company Name___________TWI__________________________________________________________________ Procedure Qualification Record No.__________GMAW-03_____________________ Date ________20/07/07_______ WPS No.___________GMAW-03____________________________________________________________________ Welding Process (es)______________GMAW_________________________________________________________ Types (automatic, Manual, Machine, or Semi-Auto)__________Semi-Auto______________________________________

JOINTS (QW-402)


POSTWELD HEAT TREATMENT( QW-407) Temperature _______None____________________ Time _____________None____________________ Other_____________________________________ _________________________________________ _________________________________________ _________________________________________


Material Spec._______SA333__________________ Type of Grade_________6___________________ P-No _____1__________to P-No._______1______ Thickness of test coupon _________2”__________ Diameter of Test Coupon___________48”________ Other_____________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________

GAS (QW-408)


Shielding __CO2___ __100%_ _20 CFH__ Trailing __None___ ________ _________ Backing __None___ ________ _________

FILLER METALS (QW-404) SFA Specification__5.18_______ AWS Classification___E70S-2___ Filler Metal F-No.______6______ Weld Metal Analysis A-No.___1__ Size of Filler Metal_____1/8”____ Other______________________ ___________________________ Weld Metal Thickness___2”____

____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________


Current_________Direct_____________________ Polarity_________Reverse____________________ Amps________130_________Volts_____17_____ Tungsten Electrode Size __________N/A________ Other____________________________________ ________________________________________ ________________________________________

POSITION (QW-405)

Position of Groove_________3G________________ Weld Progression (Uphill, Downhill)___Downhill____ Other_____________________________________ __________________________________________

PREHEAT (QW-406) Preheat Temp____________60________________ Interpass Temp___________650_______________ Other_____________________________________ __________________________________________

TECHNIQUE (QW-410)

Travel Speed_____________12 IPM____________ String or Weave Bead_______Weave___________ Oscillation________________None____________ Multipass or Single Pass(per side)___multiple____ Single or Multiple Electrodes________Single______ Other_____________________________________ __________________________________________ __________________________________________

__________________________________________



QW-483 (Back)PQR No.______GMAW-03__


Specimen No.

Width

Thickness

Area Ultimate

Total Load Ib


Psi


T – 1 0.750 1” 0.750 53200 70933 DF/HAZ T – 1 0.751 1” 0.751 52300 69640 DF/HAZ



QW-462.2 – FACE 1 Pass QW-462.2 – FACE 2 Pass QW-462.2 – ROOT 1 Pass QW-462.2 – ROOT 2 Pass


Impact Values Specimen

No. Notch

Location Specimen

Size Test

Temp. Ft. ibs % Shear Mils Drop Weight Break

(Y/N)

Comment: ____________________________________________________________________________________


Result – Satisfactory: Yes___________No___________Penetration into Parent Metal: Yes_________No__________ Macro – Results_________________________________________________________________________________

Other Tests Type of Test____________________________________________________________________________________ Deposit Analysis________________________________________________________________________________ Other_________________________________________________________________________________________ …………………………………………………………………………………………………………………………………………. Weldder’s Name______STEVE FRANCIS________Clock No._____________Stamp No._______SF3___________ Tests conducted by________Testhouse_____________Laboratory Test No._________TH-002________________ We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code.

Manufacturer________________TWI________________

Date__________20/07/07_____________________ By_________Mike Trinidad___ (Detail of record of tests are illustrative only and may be modified to conform to the type and number of tests required by the Code)



Please refer to GTAW-04 WPS for questions 29-40 29. (WPS) The base material thickness range shown;

a) Is correct b) Should be 1/16” – 1" c) Should be 3/16” – 1/2" d) Should be 3/16” – 1/4”

30. (WPS) The shielding gas on the WPS

a) Is correct b) Should be 95% argon 5% H2 c) Should be shown as 20-30 CFH d) Both b) and c)

31. (WPS) The correct preheat on the WPS is

a) Correct as shown b) 100° F minimum c) 250° F maximum d) 150° F minimum

32. (PQR/WPS) The supporting PQR

a) Is properly identified and traceable to the WPS b) Is not properly identified and not traceable to the WPS c) Is not traceable to the WPS d) Must be PWHT’d per ASME requirements

33. A drawing or sketch of the weld joint

a) Must be shown on the PQR b) Must be shown on the PQR and WPS c) Must be shown on the WPS but not the PQR d) None of the above



34. (PQR) The tension tests are

a) Full size pipe specimens b) Full size reduced section specimens c) Reduced section turned specimens d) Not required for this PQR


a) Acceptable b) Unacceptable-insufficient strength c) Unacceptable-due to size of the specimens (section ¼” t) d) Unacceptable-calculation incorrect

36. (PQR) Bend tests shown on the PQR

a) Are acceptable as shown b) Are insufficient in number c) Are the wrong type d) Both b) and c)

37. (PQR) Bend test shown on the PQR

a) Are acceptable as shown b) Do not meet ASME IX defect acceptance requirements c) Should be listed with each specimens length d) Need PWHT after bending

38. (PQR) The PQR is

a) Unacceptable – it was welded in 2G position but WPS states all positions b) Unacceptable – it is not certified c) Unacceptable – it has a backing gas not required on WPS d) All of the above



39. (PQR) The filler metal shown on the WPS

a) Is properly qualified by the PQR b) Is not properly qualified by the PQR c) Is not necessary because GTAW can be autogenous d) Will require peening

40. (PQR) The amps and volts shown on the WPS

a) Are acceptable as shown b) Are unacceptable as qualified on the PQR c) Must be higher to properly operate this electrode d) None of the above



QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECTIONS (WPS)(See Qw-200.1, Section IX, ASME Boiler and Pressure Vessel Code)

Company Name_______________TWI_____________________By_________P.PAUL_______________________ Welding Procedure Specification No.___GTAW-04___Date__20/08/2007__Supporting PQR No. (s)____GTAW-04____ Revision no. ________0________Date_____20/07/2007_______ Welding Process (es) __________GTAW__________________Type (s) _______Manual_____________________ (automatic, Manual, Machine, or Semi-Auto)

JOINTS (QW-402) Details Joint Design ______________All____________________ Backing (Yes)_________X________(No)_____X________ SEE PRODUCTION DRAWINGS Backing Material (Type) _______Carbon Steel____________ (Refer to both backing and retainers) □ Metal □ Nonfusing Metal □ Nonmetalinnic □ Other Sketches, Production Drawings, Weld Symbols or Written Description should show the general arrangement of he parts To be welded. Where applicable, the root spacing and the details of weld groove may be specified. (at the option of the Mfgr. Sketches may be attached to illustrate Joint design, weld layers and bead sequence, e.g., for notch Toughness procedures, for multiple process procedures, etc.) __________________________________________________________________________________________ *BASE METALS(QW-403) P-No.__4___Group No.____1____to P-No._______4________Group No. ____________1__________________ OR Specification type and grade ___________SA250 T11_______________________________________________ To Specification type and grade_________SA250 T11_______________________________________________ OR Chem. Analysis and Mech. Prop.________________________________________________________________ To chem. Analysis and Mech Prop.______________________________________________________________ Thickness range: Base Metal: Groove_________1/16” – 1/2"______________Fillet____________All___________________ Pipe diameter range: Groove __________1/16” – 1/2”___________Fillet ____________All_____________ Other_____________________________________________________________________________________

*FILLER METALS (QW-404) Spec. No. (SFA) SFA 5.29 AWS No. (Class) ER70S2 F-No. 6 A-No 3 Size of filler metals 1/16” – 1/8” Weld Metal Thickness Range Groove 1/2” max Fillet All Electrode-Flux (Class) N/A Flux Trade Name N/A Consumable Insert YES Other




QW-482 (Back) WPS No.__GTAW-04_Rev_0_

POSITIONS (QW-405 Position (s) of Groove___________All_________________ Welding Progression: Up____X____Down_______________ Position (s) of Fillet___________All____________________

POSTWELD HEAT TREATMENT (QW-407) Temperature Range_______1100°F_____________________ Time Range_________1 Hr per inch_____________________

PREHEAT (QW-406) Preheat Temp. Min ______________60ºF_______________ Interpass Temp. Max_____________650ºF max___________ Preheat Maintenance_____________none_______________ (Continuous or special heating where applicable should be recorded)

GAS (QW-408) Percent Composition Gas (es) (Mixture) Flow Rate Shielding __Argon___ __99.9%_ ____45_____ Trailing __None___ _________ ___________ Backing __None___ _________ ___________

ELECTRICAL CHARACHTERISTICS (QW-409) Current AC or DC______DC__________Polarity___Reverse_____ Amps (Rang)______110-160________Vots (Range)____12-17____ (amps and volts range should be recorded for each electrode Size, position, and thickness, etc. This information may be Listed in a tabular form similar to that shown below) Tungsten Electrodes Size and Type__________________________N/A_____________________________________________ (Pure Tungsten, 2% Thoriated, etc.) Mode of Metal Transfer for GMAW___________________________N/A____________________________________________ (spray arc, short circuiting arc, etc.) Electrode Wire feed speed range_____________________________N/A____________________________________________ TECHNIQUE (QW-410) String or weave Bead _______________________String or weave________________________________________________ Orifice or Gas Cup Size____________________________½”___________________________________________________ Initial and Interpass Cleaning (Brushing, Grinding, etc.)_____________Brushing, grinding______________________________ ______________________________________________________________________________________________________ Method of Back Gouging______________None_______________________________________________________________ Oscillation__________________________None________________________________________________________________ Contact Tude to Work Distance__________1/2”________________________________________________________________ Multiple or Single Pass (per side)________Multiple______________________________________________________________ Multiple or single Electrodes____________Single_______________________________________________________________ Travel Speed (Range)_________________20-30 IPM___________________________________________________________ Peening ____________________________Not Allowed_________________________________________________________ Other__________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________

Filler Metal

Current

Weld Layer (s)

Process

Class

Dia

Type Polar

Amp

Range

Volt Range

Travel Speed Range

Other(e.g Remarks, Comments, Hot wire Addition, Technique,

Torch Angle, Etc)



QW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORDS (PQR)(See Qw-200.2, Section IX, ASME Boiler and Pressure Vessel Code)


Company Name___________TWI__________________________________________________________________ Procedure Qualification Record No.__________GTAW-08________________________________________________ WPS No._________________GTAW-04______________________________________________________________ Welding Process (es) __________GTAW____________________________________________________________ Types (automatic, Manual, Machine, or Semi-Auto) ____________Manual______________________________________

JOINTS (QW-402)

SEE PRODUCTION DRAWINGS


POSTWELD HEAT TREATMENT( QW-407) Temperature_____1100°F___________________ Time________1 Hr_________________________ Other_____________________________________ _________________________________________ _________________________________________ _________________________________________


Material Spec._____SA-250__________________ Type of Grade_______T11____________________ P-No_______4________to P-No.________4______ Thickness of test coupon ____________1/4”______ Diameter of Test Coupon______2”______________ Other_____________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________ _________________________________________

GAS (QW-408)


Shielding __Ar/H2__ _95/5___ _20-30 CFH_ Trailing ___N/A__ ________ _________ Backing __Argon__ __99.9%_ _10-15 CFH_

FILLER METALS (QW-404) SFA Specification____5.9______ AWS Classification___ER70S-2_ Filler Metal F-No._______6_____ Weld Metal Analysis A-No.___1__ Size of Filler Metal_____1/6”___ Other______________________ ___________________________ Weld Metal Thickness___1/4”___

____________ ____________ ____________ ____________ ____________ ____________ ____________ ____________


Current _________Direct____________________ Polarity _________Straight____________________ Amps________110_________Volts______15____ Tungsten Electrode Size _______1/8”___________ Other____________________________________ ________________________________________ ________________________________________

POSITION (QW-405)

Position of Groove__________2G_______________ Weld Progression (Uphill, Downhill)______N/A_____ Other_____________________________________ __________________________________________

PREHEAT (QW-406) Preheat Temp________250°F___________________ Interpass Temp _______N/A_______________ Other_____________________________________ __________________________________________

TECHNIQUE (QW-410)

Travel Speed_____________10 IPM____________ String or Weave Bead _____string or weave_____ Oscillation_________________________________ Multipass or Single Pass(per side)_____multiple___ Single or Multiple Electrodes _______Multiple____ Other_____________________________________ __________________________________________ __________________________________________

__________________________________________



QW-483 (Back)PQR No.____GTAW___


Specimen No.

Width

Thickness

Area Ultimate

Total Load Ib


Psi


T-1 N/A 0.495” 0.190 14000 73684 DF/HAZ T-2 N/A 0.480” 0.180 13700 76111 DF/HAZ


Type and Figure No. Result QW-462.2- SIDE 1 Pass QW-462.2 - SIDE 2 ¼” Linear indication - Pass QW-462.2 – SIDE 3 Pass


Impact Values Specimen No.

Notch Location

Specimen Size

Test Temp. Ft. ibs % Shear Mils


Comment: ____________________________________________________________________________________


Result – Satisfactory: Yes ___________No__________ Penetration into Parent Metal: Yes _________No_________ Macro – Results_________________________________________________________________________________

Other Tests Type of Test____________________________________________________________________________________ Deposit Analysis________________________________________________________________________________ Other_________________________________________________________________________________________ …………………………………………………………………………………………………………………………………………. Weldder’s Name__________Steve Francis_______ Clock No. ________________Stamp No.__________________ Tests conducted by _________Testhouse_____________ Laboratory Test No .________TH - 004_____________ We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code.

Manufacturer _________ANZ.LTD______________________

Date____________20/07/07___________________ By______________________________________

(Detail of record of tests are illustrative only and may be modified to conform to the type and number of tests required by the Code)

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Api 570 chapter 10-asme-ix-rev-005

Engineering