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WPS DESIGN using ASME SECTION IX CODE
REQUIREMENTS
Politeknik Perkapalan Negeri Surabaya
Surabaya, 1 December 2010
By Condro Widiyarto
1. Flow of Welding Procedure Qualification:
2. ASME SECTION IX CODE REQUIREMENTS:1). Article 12). Article 23). Article 34). Article 4
3. SPECIFIC MATERIAL Overview:
4. WPQT-WPS-PQR:1). CS – With impact requirements
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1. FLOW CHART PEMBUATAN KUALIFIKASI PROSEDUR LAS
• DRAWING• STD• REFERENCE• CUSTOMER SPEC
WPQT
PELAKSANAAN TEST PROSEDUR LAS
PEMBUATAN / MACHININGTEST PIECE
TEST LABORATORY
Result PQR WPSQualified for product
Welder Qualified( Certificate welder )
Not ok
1.1 Customer Overview:• Code Requirements:o International Code: ASME, API, AWS, EN, ETC
o Indonesia Code: SII, SNI, ETC
• Regulation:o MIGAS, DEPNAKER, BKI, ETC.
• Additional Requirements:o Customer Data Sheet
o Customer Specification
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1.2 ASME Code Requirements:• ASME Section VIII Division 1 to VIII Division 3:o Section VIII Division 1: Rules for Construction of Pressure Vessels
o Section VIII Division 2: Alternative Rules - Rules for Construction of Pressure Vessels
o Section VIII Division3: Alternative rules for Construction of High Pressure Vessels
• ASME Section II Part A, B, C, D:
o Part A: Ferrous Material Specification
o Part B: Non Ferrous Material Specification
o Part C: Specification for Welding Rods, Electrodes and Filler Metals
o Part D: Properties (Customary)/(Metrics)
• ASME Section V: Non Destructive Examinations
• ASME Section IX: Qualification standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operator
o QW- Qualification Welding
o QB- Qualification Brazing
2. ASME Section IX Code Requirements:
• Part QW:o Article 1: Welding General Requirements
o Article 2: Welding Procedure Qualification
o Article 3: Welding Performance Qualification
o Article 4: Welding Data
• Part QB:o Article 1: Brazing General Requirements
o Article 2: Brazing Procedure Qualification
o Article 3: Brazing Performance Qualification
o Article 4: Brazing Data
• Appendices: A to G
• Index
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Section IX Part QW Article-1
Section IX Part QW Article-2
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Section IX Part QW Article-1
• It is mandatory to read every article of Section IX in order to apply the code rules
• QW-100.1 Purpose of WPS
• QW-100.3 Purpose of WPS and WPQ qualified accordance with rules of this section may be used in any construction built to the requirements of the ASME Boiler & PV or the ASME B31 code for pressure piping.
• QW-120, 130 & QW-132 Test position with written definition & reference to Article IV where of these position to be found
• QW-141. up to QW-141.5 Explanation of the various test and examination required
Test Position
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Section IX Part QW Article-1
• QW-142 & QW-143 Special examination for welder & welding operator and QW-144 Visual examination (See QW-194 Visual Inspection – Performance).
• QW-150 For Tension test, QW-160 for guided bend test.
• Acceptance criteria are listed for each type of test described with one exception being the Notch Toughness test of QW-170
• QW-190 Other type test & examination are listed. RT and PT examination referred to Section V article 2 and 6 respectively technique. Acceptance standard QW-191.2 & QW-195.2 respectively must be met the examination
Section IX Article 1: Test/Examination & Acceptance Criteria
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Section IX Article 1: Test/Examination & Acceptance Criteria
Section IX Article 1: Test/Examination & Acceptance Criteria
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Section IX Article 1: Test/Examination & Acceptance Criteria
Section IX Article 1: Test/Examination & Acceptance Criteria
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Section IX Part QW Article-2• 3 Types of variable:
1. Essential Variable: Any time an essential variable is changed of the range given in the WPS, the procedure must be re qualified by welding a new coupon and mechanical testing. You must generate a new PQR.
2. Non Essential Variable: Changes in this can be made with out requalification of the WPS, however WPS must be revised to reflect these changes.
3. Supplement Essential variable: Need only be given if the weld must have specific impact properties for low temperature services. If impact test are required they become essential variable.
Section IX Part QW Article-2• Learning the review method for SMAW process will
serve to teach all process (May use SMAW, GTAW, GMAW/FCAW or SAW)
• Essential variable for SMAW as described on table QW-253 as follows:
• Joint:
�QW-402.1 Ø Groove Design, 402.4 - Backing, 402.10 Ø Root Spacing and 402.11 ± Retainers are Non essential variable, on the WPS do not leave blank – You should indicate this variable as being By Sketch at list groove design used, “With OR Without Backing”, “1/32 OR 1/16” Root spacing, “With OR Without Retainers” or simplify place X’s in both blocks.
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Section IX Part QW Article-2 – Essential Variable
Section IX Part QW Article-2 – Essential Variable
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Section IX Part QW Article-2 – Essential Variable
Section IX Part QW Article-2• Base Metals:
� QW-403.5 Ø Group no. and 403.6 T Limits Impact (Minimum thickness range qualified by impact testing) are Supplement Essential Variable, become essential variable when impact properties are required.
�QW-403.8 Ø T qualified (Table QW-451.1 for maximum thickness range by qualified test coupon used in PQR), 403.9 t pass > ½ “ (13 mm), 403.11 P no Qualified (See QW-424.1) and 403.13 P no. 5/9/10 are essential variable.
• Filler Metal:
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Section IX Part QW Article-2
2.2 Section IX - Article-2 QW-422
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2.2 Section IX Part QW Article-2 – Ess. Var.: Welding Data
Section IX Part QW Article-2 – Essential Variable
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Section IX Part QW Article-2 – Essential Variable
2.2 Section IX Article-2 Essential Variable: QW-424.1
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2.2 Section IX Part QW Article-2 – Ess. Var.: Welding Data
Section IX Part QW Article-2� QW-404.5 Ø diameter and QW-404.33 Ø Classification are not
essential variable.
� QW-404.4 Ø F No. (See QW-432), 404.5 Ø A No. (See QW-442 except as given in QW-404.5), 404.30 Ø t (See QW-451.1) are essential variable.
� QW-404.7 Ø diameter > ¼” (6mm), QW-404.12 Ø Classification (SFA number given in Section II of the ASME Code) are supplement essential variable.
• Position:
� QW-405.1 + Position and QW-405.3 Ø Vertical Welding are not essential variable
� QW-405.2 Ø Position (Ø Any position to vertical up hill but not reverse. In up hill progression, a change from stringer bead to weave bead) is supplement essential variable.
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Section IX Part QW Article-2 – Essential Variable
Section IX Part QW Article-2 – Essential Variable
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Section IX Part QW Article-2 – Essential Variable
Section IX Part QW Article-2 – Essential Variable
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Section IX Part QW Article-2• Preheat:� QW-406.1 Decrease > 100˚F (55˚C) is essential variable
� QW-406.2 Ø Pre heat maintenance (This is of continuance of pre heat after completion of weld) is not essential variable
� QW-406.3 Increase > 100˚F (55˚C) (IP) is supplement essential variable
• PWHT:� QW-407.1 Ø PWHT(If PWHT will not performed, this should
be indicated on the WPS by entering the words ‘Not PWHT” or simply “none” and 407.4 T limit (PWHT upper transformation temperature) are essential variable.
Section IX Part QW Article-2 – Essential Variable
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Section IX Part QW Article-2�QW-407.2 Ø PWHT (T x T range) is supplement
essential variable (again when impact properties are required of a weldment, a change of the time span of PWHT or the temperature range will require re-requalification of the procedure.
• Electric Characteristics:
�QW-409.1 > Heat Input (HI = Amp x Volt/Speed) and QW-409.4 Ø Current (AC or DC) or Polarity (EN or EP) are supplement essential variable.
�QW-409.8 Ø I & E range is not essential variable.
Section IX Part QW Article-2 – Essential Variable
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Section IX Part QW Article-2 – Essential Variable
Section IX Part QW Article-2 – Essential Variable
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Section IX Part QW Article-2 – Essential Variable
Section IX Part QW Article-2
• Technique:
�QW-410.1 Ø String or weave, 410.5 Ø Method
cleaning. 410.6 Ø Method back gouge, 410.25
Manual or Automatic and 410.26 ± Peening
are not essential Variable.
�QW- 410.9 Ø Multiple to Single pass/side is
supplement essential variable.
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Section IX Part QW Article-2 – Essential Variable
3. Base material Overview:
SA516-70 NP1 Gr2
CS with Impact
Requirements
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3.1 CS 3.1 CS overviewoverview
3.1 CS with Impact Requirements for Low Temperature
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3.1 CS with Impact Requirements for Low Temperature
3.1 CS with Impact Requirements for Low Temperature
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3.1 CS with Impact Requirements for Low Temperature
3.1 CS with Impact Requirements for Low Temperature
� Cold Crack (< 200º C):o Hydrogen (Crack and Blow Hole)o Stress Concentrationo Brittle in weld
� Hot Crack (Elevated Temperature):o Hydrogen (Crack and Blow Hole)o Stress Concentrationo Brittle in weldo Impurities P & S
� Effect Heat Input (HI):o HI Increase: Toughness decreaseo SAW: HI high due to high ampere can prevent cold crackingo HI have limited value due to cause hot cracking in weld metal
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3.1 CS with Impact Requirements for Low Temperature
3.1 CS with Impact Requirements for Low Temperature
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3.1 CS with Impact Requirements for Low Temperature
Effect of preheating on hardness of HAZ
3.1 CS with Impact Requirements for Low Temperature
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3.1 CS with Impact Requirements for Low Temperature
3.1 CS with Impact Requirements for Low Temperature
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3.1 CS with Impact Requirements for Low Temperature
3.1 CS with Impact Requirements for Low Temperature
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3.1 CS with Impact Requirements for Low Temperature
3.1 CS with Impact Requirements for Low Temperature
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Ensuring WeldEnsuring Weld--abilityability
• Cooling Rate •Restraint Intensity•Amount of Hydrogen pick up •Chemical composition of the steel plate (Pcm and Ceq taken into consideration)•Etc (Good resistance to Lamelartearing)
NOTE: Lower P content and add Ni for improving the toughness andNOTE: Lower P content and add Ni for improving the toughness andfor ensuring resistance to lamellar tearingfor ensuring resistance to lamellar tearing..
Prevent Weld Defect:
• Pre - Heating• PWHT• Low Hydrogen filler metal • Material Requisition Sheet with Normalized material & simulated PWHT • NDE (UT examination)• Hardness control
3.1 CS with Impact Requirements for Low Temperature
4. WPQT-WPS-PQR: Engineering Drawing
GA Drawing
DATA SHEETWELDING JOINT NUMBER
DETAIL JOINT
MATERIAL SPECIFICATION
POS or PART NUMBER
MATERIAL THICKNESS
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4.1 WPQT-WPS-PQR: GA DRAWING
4.1 WPQT-WPS-PQR: DATA SHEET
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4.1 WPQT-WPS-PQR: Typical Weld Map
To Prepare WPQT for GA drawing 37-S-101 A B
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To Prepare WPQT for GA drawing 37-S-101 A B
To Prepare WPQT for GA drawing 37-S-101 A B
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To Prepare WPQT for GA drawing 37-S-101 A B
To Prepare WPQT for GA drawing 37-S-101 A B
Summary Material Spec. (P No. Gr. No.) x Thickness as follows:Pipe 2“x Schedule 160 = 8.74 mm thick x SA333-6 (P No. 1 Gr. 1)
Pipe 8” x schedule 120 = 18.26 mm thick x SA333-6 (P No. 1 Gr.1)
Pipe Shell 16” x Schedule 60 = 16.6 mm thick x SA333-6 (P No. 1 Gr.1)
CAP (A) 16” schedule 60 = 16.6 mm thick x SA420 WPL 6 (P No.1 Gr.1)
CAP (B) 16” schedule 80 = 21.4 mm thick x SA420 WPL 6 (P No.1 Gr.1)
Flange x 8.74 to 21.4 mm thick x SA350 LF2 (P No. 1 Gr.2)
Reinforcing Pad 12 mm thick x SA516-70 (P No.1 Gr.2)
1CW - Joint Cap to Shell Pipe: P1 Gr1 to P1 Gr12CW – Joint Flange to Shell Pipe: P1 Gr2 to P1 Gr1Joint Reinforcing Pad to Shell Pipe/Nozzle: P1 Gr2 to P1 Gr1
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To Prepare WPQT for GA drawing 37-S-101 A B
Essential Variable WPS PQR Remarks
P no. Gr No. P1 Gr1 to P1 Gr1
P1 Gr1 to P1 Gr2
Thickness (mm) 8.74 - 12
16.6 – 21.4
PWHT Yes
Impact Yes (- 45˚C)
Welding Process GTAW (8.74-12)
GTAW+SMAW (≥ 16)
Others
To Prepare WPQT for GA drawing 37-S-101 A B
Essential Variable WPS PQR Remarks
P no. Gr No. P1 Gr1 to P1 Gr1 P1 Gr1 to P1 Gr1
P1 Gr1 to P1 Gr2 P1 Gr1 to P1 Gr2
Thickness (mm) 8.74 - 12 8
16.6 – 21.4 16
PWHT Yes Yes
Impact Yes (- 45˚C) Yes (- 45˚C)
Welding Process GTAW (8.74-12) GTAW (8 mm)
GTAW+SMAW (≥ 16) GTAW+SMAW 16 mm)
Others
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WPQT GTAW with Impact Requirements of CS
PQR GTAW with Impact Requirements of CS
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PQR GTAW with Impact Requirements of CS
PQR GTAW with Impact Requirements of CS PQR GTAW with Impact Requirements of CS
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PQR GTAW with Impact Requirements of CS PQR GTAW with Impact Requirements of CS
WPS GTAW with Impact Requirements of CS WPS GTAW with Impact Requirements of CS
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WPQT GTAW+SMAW with Impact Requirements of CSWPQT GTAW+SMAW with Impact Requirements of CS
PQR GTAW + SMAW with Impact Requirements of CSPQR GTAW + SMAW with Impact Requirements of CS
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PQR GTAW + SMAW with Impact Requirements of CS PQR GTAW + SMAW with Impact Requirements of CS
PQR GTAW+SMAW with Impact Requirements of CS PQR GTAW+SMAW with Impact Requirements of CS
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PQR GTAW+SMAW with Impact Requirements of CS PQR GTAW+SMAW with Impact Requirements of CS
WPS with Impact Requirements of CS WPS with Impact Requirements of CS
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SUMMARIZED:• The accurate understanding which went into all aspect of the
design and qualification welding procedures for the
material/CS with impact requirements according to Section
IX ASME Code requirements was presented with sample of
WPQT, PQR and WPS under GTAW and SMAW process.
• The best way to understanding of CS Welding with impact
test requirements (Toughness) is to study with CS equilibrium
diagram/CCT diagram,
Condro [email protected]
085652010809