ASME SECTION IXASME SECTION IX

S.SINGARAVELU

SM/ WTC

QUALIFICATION STANDARD FOR

WELDING AND BRAZING PROCEDURES,WELDERS,BRAZERS,

AND WELDERS AND BRAZING OPERATORS.

CONTENTSCONTENTSPART QW : WELDINGPART QB : BRAZING APPENDICES:

- A : Mandatory – Submittal of Tech enquiry - B : Non Mandatory- Welding & Brazing Forms

- D : Non Mandatory – P number Listing - E : Mandatory- Permitted SWPSs -F : Mandatory -Standard units used in equations - G : Non Mandatory- Guidance for use of US

Customary & SI units in ASME code.

TITLE QW WELDING QB BRAZING

General Requirements

ARTICLE I and Appendix I ( Rounded Indication Charts) QW- 100

ARTICLE XI QB- 100

Procedure Requirements

ARTICLE II QW- 200

ARTICLE XIIQB- 200

Performance Requirements

ARTICLE IIIQW- 300

ARTICLE XIIIQB-300

DATA ARTICLE IV QW -400

ARTICLE XIVQB-400

Standard Welding Procedure Specifications

ARTICLE VQW -500

QW-100QW-100 QW-110 Weld orientation QW-120 Test positions for Groove welds QW-130 Test positions for Fillet welds QW-140 Types and Purpose of test and Examinations QW-150 Tension Tests QW-160 Guided Bend Tests QW-170 Notch- Toughness Tests QW-180 Fillet- Weld Tests QW-190 Other Tests and Examinations

QW-200QW-200

QW-210 Preparation of Test CouponQW-250 Welding VariablesQW-290 Temper Bead Welding

QW-300QW-300

QW-310 Qualification Test CouponsQW-320 Retests and Renewal of QualificationQW-350 Welding Variables for WeldersQW-360 Welding Variables for Welding

operatorsQW-380 Special processes

QW-400QW-400

QW-410 Technique QW-420 Material Groupings QW-430 F-Numbers QW-440 Weld Metal Chemical Composition QW-450 Specimens QW-460 Graphics QW-470 Etching- Processes and Reagents QW-490 Definitions

QW-500QW-500

QW-510 Adoption of SWPSsQW-520 Use of SWPSs Without Discrete

Demonstration QW-530 FormsQW-540 Production Use of SWPSs

RESPONSIBILITYRESPONSIBILITY

MANUFACTURER- Operational ControlPREPARTION OF WELDING &

SPECIMENS , TESTING-Sub contracted.Welder/operator-Full Supervision &

Control of the manufacturer.

QUALITY ASSURANCEQUALITY ASSURANCE

Degree of quality required is ascertained based on

1. Application needs

2. Standard to be established based on service needs

3. Consideration of the engineering performance and

safety factors.

Five Ps Assure QualityFive Ps Assure Quality

1. Process selection.The process selected must be the most appropriate one for the job under the given conditions on all considerations.

2. Preparation.The joint configuration must be right and compatible with the welding process.

Five Ps Assure QualityFive Ps Assure Quality

3.Procedure.To assure uniform results, the process must be clearly spelled out in detail and followed religiously during welding.

4.Pretesting. By a full- scale mock-up test, the process,preparation,and procedures are proved to have the desired standard of quality.

Five Ps Assure QualityFive Ps Assure Quality

5.Personnel. Personnel assigned for the job

shall be qualified to perform the assigned

tasks.

WPS – Welding Procedure SpecificationWPS – Welding Procedure Specification

PQR – Procedure Qualification RecordPQR – Procedure Qualification Record

WELDING PROCEDURE WELDING PROCEDURE SPECIFICATIONSPECIFICATION

The welding procedure specification(WPS) is a proposal for welding a joint between two specified base metals. The purpose of a WPS is to define and document the details that are to be carried out in specific materials or parts. To fulfill the purpose efficiently, the WPS should be as concise and clear as possible with out extraneous details.

From a designer’s point of view,the properties of the weld joint are designated as follows:

1.Yield stress

2.Ultimate tensile strength

3.Percentage elongation

4.Impact strength and so on

The welding procedure specifications are written exactly to these property requirements on to relevant welding parameters comprising of mainly two factors;

1.Physical soundness (free from discontinuities)

2.Metallurgical compatibility

Physical soundness is related to the mode of deposition. In other words ,the process techniques are influenced by the skill of the welder or welding machine operator. Metallurgical compatibility is by itself dependent upon the chemical composition of the weld metal, filler metal,flux or gas,and the heat cycles the weldment undergoes during welding and post weld heat treatment.

Radiography can give conclusive account of physical soundness of the weld,where as the metallurgical compatibility is revealed only by conducting a mechanical test.

Purpose of WPS & PQRPurpose of WPS & PQR

To determine that the Weldment proposed for construction is capable of having the required properties for its intended application

BASIC INFORMATION FOR BASIC INFORMATION FOR THE WPSTHE WPS

The information needed for the WPS includes

1.Base metals to be joined

2.Typical weld joint configuration

3.Dimensions of parts to be joined

4.Welding process to be employed

Of these,the first three details could be gathered from either the purchase order or the technical specification or from the applicable standards,whereas the fourth could be decided based on the manufacture experience.

WPSWPS

A written document that provides direction to the welder or welding operator for making production welds in accordance with the CODE requirements. It establishes the properties of the weldment, not the skill of the welder.

PQRPQRShall document what occurred during welding the test coupon and results of testing of the coupon.

As a minimum, the PQR shall document all the essential variables and other specific information for each process used during welding the test coupon and the results of the required testing.

PROCEDURE PROCEDURE QUALIFICATION RECORDQUALIFICATION RECORD

The five basic steps involved in the qualification of a welding procedure are

1.Preparation and welding of suitable samples

2.Testing of representative specimens

3.Evaluation of overall preparation, welding,testing,and end results

4.Possible changes in procedure

5.Approval

As per ASME Section IX, Test requirements for a procedure qualification

record(PQR) are spelled out in QW 451, Test specimens in QW 462,Preparation of samples in QW 463.Acceptance criteria for welding are specified in

QW 150,QW 160,QW 170,QW 180,and QW 190. The suggested format for the preparation of PQR

is given QW 483)

WELDING VARIABLES WELDING VARIABLES Depending on their influence on obtaining the desired

quality weldments, the welding parameters are listed and classifieds as essential,supplementary essential,and non essential variables.

These welding variables are described in article IV: Welding Data under clauses QW 400 to Qw410.

For a process under consideration,only a few among them may be applicable,and these are given in sections QW252 to QW 265 for welding procedure and QW352 to QW 357 for performance qualification,and QW 361 to QW384 for welding machine operators, special processes,etc., against each welding process.

VariablesVariables

Essential

Non-essential

Supplementary essential

Essential variables Essential variables are those in which a change,as

described in specific variables,is considered to affect mechanical properties of the weldment and shall require requalification of the WPS.

Supplementary Essential variables Supplementary Essential variables are those variables

which are also to be considered essential variables when other sections of the code call for notch toughness testing.

Non Essential variables Non Essential variables are those in which a change,as

described in specific variables, may be made in the WPS with out requalification.

Essential VariablesEssential Variables

A change in welding condition which will affect the mechanical properties of the weldment.

e.g.: A) Change in P Number

B) Filler metal

C) Electrode

D) PWHT, etc.

Non Essential VariablesNon Essential Variables

A change in welding condition which will NOT affect the mechanical properties of the weldment.

e.g. : A) Change in Joint Design

B) Methods of Back gouging

C) Cleaning. etc.

Supplementary Essential Supplementary Essential VariablesVariables

A change in welding condition which will affect the Notch-Toughness (Impact) properties of the weldment.

e.g. : A) Change in Heat input

B) Uphill or Down Vertical welding

C) Diameter of Electrode

D) Position, etc.

Points to be considered for Points to be considered for establishing WPSestablishing WPS

Code of constructionDetailed drawing of

weldmentMaterialThicknessConfigurationProcess

Contract/Customer/ Code/TPI

Preheat/Postheat/ PWHT requirements

Skilled welder Good welding m/c with

accessories Application

Release of WPS with out PQR for Procedure Qualification Test (QW 482)

WPS FLOW DIAGRAM

Procedure Qualification Test

(Welding and Testing)

Release PQR(QW483)

Revise the WPS with

PQR (QW482)

Issue the WPS for production

Welds (QW 482)

PRODUCTION WELDS

Issue the WPS for performance Qualification Test

performance Qualification Test

Issue the manufacturers record of welder/operator Qualification

Add on to welders list Add on to renewal Log sheet

Selection of welder or operator

Renewal of performance Qualification

Client spec+code+Drawing

Decision on welding process

Selection of PQR from past records

Preparation of draft WPS (QW482)

Procedure Qualification Test

DT and NDT

Preparation of PQR (QW 483)

Release of WPS Rev 1 for work

Certification of WPS by third party Inspection Agency

Applicable ASME Code+Client Specification+drawing

Welding process for all joints+essential/supplementary essential variables to be specified

Select a PQR from the past data matching essential / supplementary essential variables of the job

Release of WPS for job

Release of draft WPS-R0 with out PQR

Release of WPS R1 with all essential, supplementary essential and non essential variables

Welding procedure Qualification test as per QW 483

DT & NDT to yield acceptable results as per QW 150,160,170,180 or 302 as acceptable

Preparation of PQR based on test results + consequential qualification of the welder

Documentation for future use

WPS for specific job (QW 482) NO

CONTENTS CONTENTS

OF OF

WPS / PQRWPS / PQR

IX recommends formats for WPS in QW 482 wherein the following details shall be filled in:

1.Joints QW 402 2.Base metals QW 403 3.Filler metals QW 404 4.Positions QW 405 5.Preheat QW 406 6.Post weld heat treatment QW 407 7.Gas QW 408 8.Electrical characteristics QW 409 9.Techniques QW 410The details are to be filled in depending on applicability to

the particular welding process selected in the WPS.

Joints (QW-402)Joints (QW-402)

Joint Design (V-groove, U-groove, Single-bevel etc.)

Backing (YES/NO)

Backing Material Type(Metal/Non-fusing Metal/Non-metallic/Others)

Base Metals (QW-403)Base Metals (QW-403)

P. Number & Group Number Specification Type & Grade ORChemical Analysis & Mechanical Properties

Thickness Range Groove : ______ Fillet:______

Pipe Diameter Range Groove : ______ Fillet :_______

Thickness RangeThickness Range

Min. Max.

Less than 1.5 T 2T 2t

1.5 to 10, incl. 1.5 2T 2t

Over 10, but less than 19 5 2T 2t

19 to less than 38 5 2T 2t when t < 19

2T when t > 19

38 and over 5 200 2t when t < 19

200 when t > 19

Range of Thickness T of Base Metal, Qualified (mm)Thickness T of Test Coupon,

Welded, (mm)Maximum Thickness t of Deposited Weld Metal, Qualified, (mm)

Filler Metals (QW-404)Filler Metals (QW-404)

AWS ClassificationSFA NumberF. NumberA. Number

Size of Filler metalFlux trade nameConsumable insertElectrode flux class

• Deposited Weld Metal Thickness range Groove: ______ Fillet:______

F-Number grouping of electrodes & welding rods is based essentially on their

usability characteristics to reduce the number of tests required to qualify

procedures and welders.

F - NUMBERS

A - NUMBERS

Used to describe the weld deposit chemistry and is applicable only to the ferrous metals for the qualification of a welding procedure.

Position (QW-405)Position (QW-405)

Position Of Groove

Position Of Fillet

Weld Progression (UP/DOWN)

Others

Preheat (QW-406)Preheat (QW-406)

Preheat Temperature (min.)

Interpass Temperature (max.)

Preheat Maintenance

Others

PWHT (QW-407)PWHT (QW-407)

Temperature Range

Time Range

Others

• Preheat & PWHT requirement Preheat & PWHT requirement based on based on DiameterDiameter, , ThicknessThickness

and and Composition Composition ofofBase MaterialBase Material

GAS (QW-408)GAS (QW-408)

Gas Mix % Flow Rate

Shielding

Trailing

Backing

Electrical Characteristics (QW-409)Electrical Characteristics (QW-409)

Current (AC/DC)Polarity (EP/EN)Amps & VoltsW-Electrode type & sizeMode of Metal Transfer (GMAW)Electrode Wire Feed Speed range

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

BHARAT HEAVY ELECTRICALS LIMITED Form No. TIRUCHIRAPALLI-620014 101-403 WELDING TECHNOLOGY CENTRE PROCEDURE QUALIFICATION RECORD

Page 1 of 2

Procedure Qualification Record No : Date : WPS No : Type : Welding Process : (Auto,Semi-Auto,Manual,Machine)

JOINTS (QW-402) BASE METALS (QW-403) Matl. Specn. : Type or Grade : P. No. : Thickness : Size : Groove Design used Others :

FILLER METALS (QW-404) POSITION (QW-405) AWS No. (Class) : Welding Position : SFA : Weld Progression : Filler Metal F No. : (Uphill/Downhill) (Weld Metal Analysis) A No : Others: : Filler metal size : PREHEAT (QW-406) Preheat temp. : Deposited weld Metal thickness : Interpass temp. : Postheat : Brand : Others :

PWHT (QW-407) GAS (QW-408) Gas Mixture(%) Flow rate Temperature : Shielding : ----- ------ ----- Time : Trailing : ----- ------ ----- Others : Backing : ----- ------ -----

ELECTRICAL CHARACTERISTICS (QW-409) TECHNIQUE (QW-410) Current : Polarity: String/Weave Bead : Amps : Oscillation : Volt : Multipass or single pass : ROL (mm/Electrode) : Multiple or single electrode: Tungsten Electrode type and size: Travel speed : Mode of metal Transfer: Others : Others :

BHEL Page 2 of 2 Tiruchirappalli-14 PQR No. :

TENSILE TEST (QW-150)

Specimen No.

Width mm

Thickness mm

Area mm²

Ultimate Total Load

kN

Ultimate Unit Stress

N/mm²

Failure Location

GUIDED BEND TESTS (QW-160)

Type & Fig No. QW-462.2

Result Type & Fog No. QW-462.2

Result

TOUGHNESS TEST (QW-170)

Lateral Exp. Drop Weight Specimen No

Notch Location

Notch Type

CVN’2’mm

Test Temp.

ºC

Impact Values Kg.m

%Shear Mills Break No Break

FILLET WELD TEST (QW-180) Result-Satisfactory (Yes/No) : Macro Results (Yes/No) : Penetration into Parent metal (Yes/No) :

OTHER TESTS

Type of Test : Result : Report No. : Deposit analysis : Others :

Welder’s Name: Stamp No.: Test conducted by: BHEL Plant 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 Sec IX of the ASME code Edition 2004 and addenda July 2005. Approved by : Prepared by : (XXXXXXXX) (XXXXXXXX) XXXXXXX XXXXXXXXX

BHARAT HEAVY ELECTRICALS LIMITED Form No. TIRUCHIRAPPALLI-620014 101 - 401

WELDING TECHNOLOGY CENTRE WELDING PROCEDURE SPECIFICATION

Page 1 of 2

WPS No. : Date : Supporting Rev No. : Date : ---- PQR No: Welding Process : Type :

(Auto/Semi-Auto/Manual/Machine) Application :

JOINTS (QW-402) Joint Design :. Backing (Yes/No) : Backing Material (Type) : Metal/Non fusing metal Non metallic/Others

BASE METAL (QW-403) P.No.: Group No.: TO P.No.: Group No.: Spec. Type & Grade : . Chem. Analysis & Mech. Prop. : . Thickness Range :- Groove : Fillet : Pipe Diameter Range :- Groove : Fillet : Others :

FILLER METALS (QW-404) AWS No.(Class) : Size of filler metal : Specn. No.(SFA) : Flux trade Name : F.No. : Consumable insert : A.No. : Electrode flux class : Deposited weld metal thickness range :- Groove : Fillet :

POSITION (QW-405) PREHEAT (QW-406) Position of Groove : Preheat Temp. (min) : Position of Fillet : Inter pass Temp. (max) : Weld Progression : Post heat : (Up/Down) Others :

BHEL Page 2 of 2 Tiruchirappalli – 14 WPS No : Rev :

PWHT(QW-407) GAS ( QW - 408) Gases Mix % flow Rt Temp. Range : Shielding : --- --- Time Range : Trailing : --- --- Others : Backing : --- ---

ELECTRICAL CHARACTERISTICS ( QW – 409 ) Current (AC/DC) : See table Polarity : See table Amps (Range) : See table Volts : See table Tungsten Electrode type and size : . Mode of Metal transfer for (GMAW) : . Electrode wire feed speed range : . Pulsing current (GTAW) : .

TECHNIQUES (QW-410) String or Weave Bead Orifice or Gas cup size : Initial and Interpass Cleaning : Brushing / Chipping / Grinding. Method of Back Gouging : . Oscillation : Contact tube to work distance : Multiple or single pass (per side) : Multiple or single Electrode : Electrode spacing : . Peening : Others : Nil

Filler Current Weld Layer

Process Class Dia.

mm. Type Amps.

Voltage Range

Travel speed

Range

Others (Hot wire,Torch

angle,ROL.)

Root & Capping

Others

-- do --

Approved by : Prepared by : (xxxxxxxxx) (xxxxxxxxxxxx) xxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxx

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

Fillet welding of plate

Vertical

Horizontal

Flat

overhead

1F

2F

3F

4F

GMAW in different positions

Base Metal ClassificationBase Metal Classification

P nos depend on composition, weldability & mechanical properties. Group nos classify metals within P nos for procedure qualification where notch toughness requirements are specified. But base metals can not be indiscriminately substituted.

Base Metal P NumbersBase Metal P Numbers

P1 - P11 SteelP21 - P25 Al alloysP31 - P35 Cu alloysP41 - P47 Ni alloysP51 - P53 Ti alloysP61 - P62 Zr alloys

Base Metal P NumbersBase Metal P Numbers

Examples of P nosP1 C Steel

P3 1/2 Mo steels

P4 1 Cr 1/2 Mo steels

P5A 2 1/4 Cr 1 Mo steels

P6 13 Cr steel

P7 17 Cr steel

P8 ASS

P9A 2 1/2 Ni steels

P10A Mn - 1/2 Ni - V steels

P11 9 Ni steels

Base Metal P NumbersBase Metal P Numbers

Examples of P nosP1 C Steel

P3 1/2 Mo steels

P4 1 Cr 1/2 Mo steels

P5A 2 1/4 Cr 1 Mo steels

P6 13 Cr steel

P7 17 Cr steel

P8 ASS

P9A 2 1/2 Ni steels

P10A Mn - 1/2 Ni - V steels

P11 9 Ni steels

Base Metal for WPSBase Metal for WPS

Test Coupon Base Metal qualified

Px - Px Px

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

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

BM used for procedure qualification coupon Base Metals Qualified

One metal from a P-No. to any metal from the same P-No.

Any metal assigned that P or S No.

One metal from a P-No. to any metal from the any other P-No.

Any metal assigned the 1st P or S No. to any metal assigned the 2nd P or S No.

One metal from P-No. 3 to any metal from P-No. 3

Any P or S No. 3 metal to any metal assigned P or S No. 3 or 1

One metal from P-No. 4 to any metal from P-No. 4

Any P or S No. 4 metal to any metal assigned P or S No. 4, 3 or 1

One metal from P-No. 5A to any metal from P-No. 5A

Any P or S No. 5A metal to any metal assigned P or S No. 5A, 4, 3 or 1

One metal from P-No. 5A to any metal from P-No. 4, 3 or 1

Any P or S No. 5A metal to any metal assigned P or S No. 4, 3 or 1

One metal from P-No. 4 to any metal from P-No. 3 or 1

Any P or S No. 4 metal to any metal assigned P or S No. 3 or 1

Any unassigned metal to the same unassigned metal

The unassigned metal to itself

Any unassigned metal to any P-No. metal The unassigned metal to any metal assigned to the same P or S No. as the qualified metal

Any unassigned metal to any other unassigned metal

The first unassigned metal to the second unassigned metal

S - NumberS - Number

They are mostly ASTM specification materials that have not been adopted within Section II, Part D but that are referred within Code Cases and the ASME B31 Code.

e.g. A 588 Gr A S-No. 3

Group No. 1A 576 G10100 S-No. 1

Group No. 1

SFA NO. DESCRIPTION5.01 Filler Metal Procurement Guidelines5.1 Carbon Steel Electrodes for Shielded Metal Arc Welding5.2 Carbon and Low Alloy Steel Rods for Oxy Fuel Gas Welding5.3 Aluminum and Aluminum Alloy Electrodes for Shielded Metal Arc Welding5.4 Stainless Steel Electrodes for Shielded Metal Arc Welding5.5 Low Alloy Steel Electrodes for Shielded Metal Arc Welding5.6 Covered Copper and Copper Alloy Arc Welding Electrodes5.7 Copper and Copper Alloy Bare Welding Rods and Electrodes5.8 Filler Metal for Brazing and Braze Welding5.9 Bare Stainless Steel Welding Electrodes and Rods5.10 Bare Aluminum and Aluminum Alloy Welding Electrodes and Rods5.11 Nickel and Nickel Alloy Welding Electrodes for Shielded Metal Arc Welding5.12 Tungsten and Tungsten Alloy Electrodes for Arc Welding and Cutting5.13 Solid Surfacing Welding Rods and Electrodes5.14 Nickel and Nickel Alloy Bare Welding Electrodes and Rods5.15 Welding Electrodes and Rods for Cast Iron5.16 Titanium and Titanium Alloy Welding Rods and Electrodes5.17 Carbon Steel Electrodes and Fluxes for Submerged Arc Welding5.18 Carbon Steel Filler Metals for Gas Shielded Arc Welding5.19  5.20 Carbon steel Electrodes for Flux Cored Arc Welding5.21 Composite Surfacing Welding Rods and Electrodes5.22 SS Electrodes for FCAW and SS Flux Cored Rods for Gas Tungsten Arc Welding

5.23 Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding5.24 Zirconium and Zirconium Alloy Welding Electrodes and Rods5.25 Carbon and Low Alloy Steel Electrodes and Fluxes for Electro-slag Welding5.26 Carbon and Low Alloy Steel Electrodes for Electro-gas Welding5.27  5.28 Low Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding5.29 Low Alloy Steel Electrodes for Flux Cored Arc Welding5.30 Consumable Inserts5.31 Fluxes and Brazing and Braze Welding5.32 Welding Shielding Gases

F-Number Description

1 CS, LAS and certain SS (EXX2X) electrodes

2 CS titania-coated (EXX12, EXX13, EXX14 & EXX19) electrodes

3 CS cellulose-coated (EXX10 & EXX11) electrodes

4 CS & LAS all position, low hydrogen (EXX15, EXX16, EXX18 & EXX48) electrodes & martensitic, ferritic & ppt. hardening SS all position (EXX15, EXX16 & EXX17) electrodes

5 Austenitic and duplex SS all-position (EXX15, EXX16 & EXX17) electrodes

6 Solid, Flux-cored & composite ferrous electrodes & rods

--- ---

Filler Metal F NumbersFiller Metal F Numbers

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

F1 E XX20F2 E XX12, E XX13F3 E XX10, E XX11F4 E XX18F5 ASS, Duplex SSF6 Bare rods

F-No. ASME Classification AWS Classification

4 SFA-5.4 other than austenitic and duplex EXXX(X)-154 SFA-5.4 other than austenitic and duplex EXXX(X)-164 SFA-5.4 other than austenitic and duplex EXXX(X)-174 SFA-5.5 E(X)XX15-X4 SFA-5.5 E(X)XX16-X4 SFA-5.5 E(X)XX18-X4 SFA-5.5 E(X)XX18M4 SFA-5.5 E(X)XX18M1

5 SFA-5.4 austenitic and duplex EXXX(X)-155 SFA-5.4 austenitic and duplex EXXX(X)-165 SFA-5.4 austenitic and duplex EXXX(X)-17

6 SFA-5.2 All classifications6 SFA-5.9 All classifications6 SFA-5.17 All classifications6 SFA-5.18 All classifications6 SFA-5.20 All classifications6 SFA-5.22 All classifications6 SFA-5.23 All classifications6 SFA-5.25 All classifications6 SFA-5.26 All classifications6 SFA-5.28 All classifications6 SFA-5.29 All classifications6 SFA-5.30 INMs-X6 SFA-5.30 IN5XX6 SFA-5.30 IN3XX(X)

F - NUMBERS (QW - 432)

F-No. ASME Classification AWS Classification

1 SFA-5.1 EXX201 SFA-5.1 EXX221 SFA-5.1 EXX241 SFA-5.1 EXX271 SFA-5.1 EXX281 SFA-5.4 EXXX(X)-251 SFA-5.4 EXXX(X)-261 SFA-5.5 EXX20-X1 SFA-5.5 EXX27-X

2 SFA-5.1 EXX122 SFA-5.1 EXX132 SFA-5.1 EXX142 SFA-5.1 EXX192 SFA-5.5 E(X)XX13-X

3 SFA-5.1 EXX103 SFA-5.1 EXX113 SFA-5.5 E(X)XX10-X3 SFA-5.5 E(X)XX11-X

4 SFA-5.1 EXX154 SFA-5.1 EXX164 SFA-5.1 EXX184 SFA-5.1 EXX18M4 SFA-5.1 EXX48

Steel and Steel Alloys

A-No.

Types of Weld DepositWeld Metal Analysis, % [Single values shown are maximum ]

C Cr Mo Ni Mn Si

1 Mild Steel 0.20 … … … 1.60 1.00

2 Carbon-Molybdenum 0.15 0.50 0.40-0.65 … 1.60 1.00

3Chrome (0.4% to 2%)-Molybdenum

0.15 0.40-2.00 0.40-0.65 … 1.60 1.00

4Chrome (2% to 6%)-Molybdenum

0.15 2.00-6.00 0.40-1.50 … 1.60 2.00

5Chrome (6% to 10.5%)-Molybdenum

0.15 6.00-10.50 0.40-1.50 … 1.20 2.00

6 Chrome-Martensitic 0.15 11.00-15.00 0.70 … 2.00 1.00

7 Chrome-Ferritic 0.15 11.00-30.00 1.00 … 1.00 3.00

8 Chromium-Nickel 0.15 14.50-30.00 4.00 7.50-15.00 2.50 1.00

9 Chromium-Nickel 0.30 19.00-30.00 6.00 15.00-37.00 2.50 1.00

10 Nickel to 4% 0.15 … 0.55 0.80-4.00 1.70 1.00

11 Manganese-Molybdenum 0.17 … 0.25-0.75 0.85 1.25-2.25 1.00

12Nickel-Chrome-Molybdenum

0.15 1.50 0.25-0.80 1.25-2.80 0.75-2.25 1.00

Selection of Filler MetalSelection of Filler Metal

Tube Material

P1/Gr1,2 P3/Gr1 P4/Gr1 P5A/Gr1 P5B/Gr2 P8/Gr1,2

P1/Gr1,2

ER80S-G

(RT ½ Mo)

E7018-1

ER80S-G

(RT ½ Mo)

E7018-1

ER80S-G

(RT ½ Mo)

E7018-1

ER80S-G

(RT ½ Mo)

E7018-1

ERNiCr-3

ENiCrFe-3

P3/Gr1

ER80S-G

(RT ½ Mo)

E7018-A1

ER80S-G

(RT ½ Mo)

E7018-A1

ER80S-G

(RT ½ Mo)

E7018-A1

P4/Gr1

ER80S-G

(1Cr ½ Mo)

E8018-B2

ER80S-G

(1Cr ½ Mo)

E8018-B2

ER80S-G

(1Cr ½ Mo)

E8018-B2

ERNiCr-3

ENiCrFe-3

P5A/Gr1

ER90S-G

(2¼Cr1Mo)

E9018-B3

ER90S-G

(2¼Cr1Mo)

E9018-B3

ERNiCr-3

ENiCrFe-3

P5B/Gr2ER90S-B9

E9018-B9

ERNiCr-3

ENiCrFe-3

Base Metal 304L 308 309 309S 310 310S 316,316H 316L 317 321,321H 347,347H,348,348H

304,304H,305 308L 308L 308,309 308,309 308,309, 310 308,309, 310 308,316 308,316 308,316, 317 308 308

304L 308L 308,309 308,309 308,309, 310 308,309, 310 308,316 308L,316L 308,316, 317 308L,347 308L,347

308 308,309 308,309 308,309, 310 308,309, 310 308,316 308,316 308,316, 317 308 308,347

309 309 309,310 309,310 308,316 309,316 309,316 309,347 309,347

309S 309,310 309S,310S 308,316 309S,316L 310,317 309,347 309,347

310 316 310,316 317 308,310 308,310

310S 316 316,317 308,310 308,310

316,316H 316 317 308,316 308,316, 347

316L 316L 316L,347

317 308,317 308,317, 347

321,321H 308L,347

Filler metals suitable for welding joints between Filler metals suitable for welding joints between dissimilar austenitic stainless steelsdissimilar austenitic stainless steels

Procedure QualificationProcedure Qualification

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

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

Thickness RangeThickness Range

Min. Max.

Less than 1.5 T 2T 2t

1.5 to 10, incl. 1.5 2T 2t

Over 10, but less than 19 5 2T 2t

19 to less than 38 5 2T 2t when t < 19

2T when t > 19

38 and over 5 200 2t when t < 19

200 when t > 19

Range of Thickness T of Base Metal, Qualified (mm)Thickness T of Test Coupon,

Welded, (mm)Maximum Thickness t of Deposited Weld Metal, Qualified, (mm)

WPS for SMAWWPS for SMAW

Essential variables

Change in qualified Thickness

Change in P no

Change in F no of filler metal

Change in A no of filler metal

Change in deposited metal thickness

Decrease of more than 100 F in preheat

Change in PWHT

WPS for SMAWWPS for SMAW

Supplementary Essential variables

Change in Group no of base metal

Change in T limits for impact test

Change in dia of filler metal > 1/4”

Change in AWS class of filler metal

Change in welding position

Increase of more than 100 F in preheat

Change in PWHT Time and temp range

Change in current or polarity

WPS for SMAWWPS for SMAW

Non Essential variables

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

Change in dia of filler metal

Change in AWS class of filler metal

Change in welding position

Change in preheat maintenance

Change in current or polarity

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

WPS for GTAWWPS for GTAW

Essential variables

Change in qualified Thickness

Change in P no

Change in F no & A no of filler metal

Addition/deletion of filler metal

Change in size of filler metal, product form

Decrease of more than 100 F in preheat

Change in PWHT

WPS for GTAWWPS for GTAW

Essential variables (cond)

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

gasChange in Closed to out

chamber technique

WPS for GTAWWPS for GTAWSupplementary Essential variables

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

preheatChange in PWHT Time and temp

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

electrodes

WELDING PERFORMANCEWELDING PERFORMANCE QUALIFICATION1. Welder,welding operator,and tack welder qualification

tests determine the ability of those tested to produce acceptably sounds welds with processes, materials,and procedures called for in the test.

2. The qualification tests are not intended to be used as a guide for welding during actual construction,but rather to assess whether an individual normally will or can do in production.

QUALIFICATIONQUALIFICATIONWelding variables applicable for

performance in QW 350 and QW 360.Allowable visual,mechanical,and

radiographic examination requirements are described in QW 304 and QW 305.

Retests and renewal of qualifications are given in QW 320.

Suggested format for performance qualification tests is given in QW 484

Welders Performance QualificationWelders Performance Qualification

The performance qualification tests are intended to determine the ability of welders to make sound weldsA welder is qualified by radiography of a test coupon or by radiography of initial production welding or by bend tests taken from a test coupon

Performance QualificationPerformance Qualification

The basic criterion for welder’s qualification is to determine the welder’s ability to deposit sound weld metal. The purpose of performance qualification test is to determine the welding operator’s mechanical ability to operate the welding equipment.

Release of WPS Latest Revision

Preparation Welder / Operator Qualification Tests

Welder / Operator Qualification test

NDT or DT as per ASME Section IX

Release of WPQ record

Add to list of welder / operators

Add to Renewal test Register

Applicable WPS with PQR to be released for the conduct of welders list

Preparation of specimen for the test using materials of compatible quality

Preparation of WPQ Records as per QW 484

NDT & DT as per QW 160, 302 to yield satisfactory results

Renewal test as required in QW 322

Welders Performance QualificationWelders Performance Qualification

Weld Plate & pipe Pipe of ODFillet

>24”OD 2 7/8 - 24”

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

Welders Performance QualificationWelders Performance Qualification Weld Plate & pipe Pipe of ODFillet

>24”OD 2 7/8 - 24”

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

Welders Performance QualificationWelders Performance Qualification

Weld Plate & pipe Pipe of ODFillet

>24”OD 2 7/8 - 24”

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

Welders Performance QualificationWelders Performance Qualification

Weld Plate & pipe Pipe of OD Fillet

>24”OD 2 7/8 - 24”

Pipe 1F F

Pipe 2F F, H

Pipe 2FR F, H

Pipe 4F F, H, O

Pipe 5F All

Welders Performance QualificationWelders Performance Qualification Thk Max tk of dep. Metal Test3/8” 2t 1FB, 1RB>3/8” 2t 1FB, 1RB>1/2” Max to be welded2SB

OD of test coupon Range of OD qualified

<1” Size welded - unlimitd

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

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

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

Welders Performance QualificationWelders Performance Qualification

Variables for SMAW

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

depositChange in welding position

Welders Performance QualificationWelders Performance Qualification Variables for GTAW

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

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

Welders Performance QualificationWelders Performance Qualification

Welded QualifiedWithout Backing

Fx FxWith Backing

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

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

Tests for QualificationTests for Qualification Tension test Minimum values for specified tensile strength

For dissimilar joint, lesser of the two values

If break outside weld, if tensile st. value not < 5% of the base metal

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

Impact test In accordance with the section

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

1/3 t for t 3/8 - 2 1/4”

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

aggregate length t in 12 t unless separated by 6L

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

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

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

Tests for Initial QualificationTests for Initial Qualification

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

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

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

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

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

may be accepted as alternative to the above tests

Examination of the weld for Examination of the weld for initial Qualificationinitial Qualification

PLATE QUALIFICATION (Fillet weld)

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

QUESTIONS PLEASEQUESTIONS PLEASE