ASME IX

1. What is WPS? Answer: WPS stands for Welding Procedure Specification. A WPS is a written document that provides direction to the welder or welding operator for making production welds in accordance with code requirement. (Refer: ASME Sec IX; QW:100.1) 2. What is PQR? Answer: PQR stands for procedure qualification record. The PQR documents what occurred during welding the test coupon and the results of testing of the coupon.

3. Why a WPS needs qualification? Answer: The purpose for qualification of a WPS is to determine that the weldment proposed for construction is capable of providing the required properties for its intended application. Welding Procedure Qualification establishes the properties of the weldment not the skill of the welder or welding operator. 4. Why a performance qualification is done for welder? Answer: In performance qualification, the basic criteria established for welder qualification is to determine the welders ability to deposit sound weld metal. The purpose of the performance qualification test for the welding operator is to determine the welding operators mechanical ability to operate the welding equipment. 5. Is there any expiry date for WPS/PQR/WPQ/WOPQ? Answer: NO. WPS, PQR, WPQ/WOPQ made in accordance with the requirements of the 1962 edition or any later edition of section IX may be used in any construction built to the ASME Boiler and Pressure Vessel Code or the ASME B 31 Code for pressure piping.

1. Is WPS, PQR or WPQ/WOPQ need to be amended for using it according to a later edition of ASME BPV Section IX? Answer: No. Except as specified in QW:420 (Last Paragraph)

2. What are the different type of mechanical tests used in procedure or performance qualification as per ASME Section IX? Answer: 1. Tension test. 2. Guided bend test. 3. Fillet weld test 4. Notch toughness test

3. Why the different mechanical tests are conducted for procedure or performance qualification as oer ASME Section IX? Answer: 1. Tension test: Used to determine the ultimate strength of grrove-weld joints 2. Guided bend test: Used to determine the degree of soundness and ductility of groove-weld joints. 3. Fillet weld test: Used to determine the size , contour and degre of soundness of fillet welds. 4. Notch toughness test: Used to determine the notch toughness of the weldment

4. What are the tests done for stud welding procedure and performance qualification ? Answer: Deflection bend, hammering, torque or tension tests and macro examination.

5. What is the first test that to be done on a procedure or performance qualification test coupon ?

Answer: Visual Testing.

. Can NDT be used to replace mechanical testing for the perfomance qualification of welders? Answer: Yes AS per QW-142, Radiographic or ultrasonic examination may be substituted for mechanical testing for groove-weld performance qualification as permitted in QW-304 to prove the ability of welders to make sound welds. As per QW-304. Welders may be qualified by volumetric NDE when making a groove weld using SMAW, SAW, GTAW, PAW and GMAW (except short circuiting mode for radiographic examination) or a combination of these process, except for P.No.21 through P No.26, P.No.51 through P No.53, and P.No.61 through P No.62 metals. Welders making groove welds in P.No.21 through P No.26 and P.No.51 through P No.53 metals with the GTAW process may also be qualified by volumetric NDE

3. Is a written radiographic examination procedure is needed for welders/welding operator qualification using radiographic examination? Answer: No As per QW-191.1.1 (a), A written radiographic examination procedure is not required. Demonstration of density and image quality requirements on production or technique radiographs shall be considered satisfactory evidence of compliance with article 2 of sectionV.

4. Is a written ultrasonic examination procedure is needed for welders/welding operator qualification using ultrasonic examination?

Answer: Yes

As per QW-191.2.1 (b), Ultrasonic examination shall be performed using a written procedure verified by the manufacturer to be in compliance with paragraph T150, Article1, Section V and the requirements of Article 4, Section V for methods, procedure and qualification.

5. Is there any base material thickness restriction for ultrasonic examination of test coupons of welders and welding operators? Answer: Yes As per QW-191.2.1 (a), The ultrasonic examination for welder and welding operators may be conducted on test welds in material 1/2in. (13mm) thick or greater 1. How many studs are to be welded for procedure qualification of stud weld test? Answer: Ten Studs; as per QW 192.1.1

2. Any requirement for stud welding equipment for procedure qualification as per ASME Sec IX? Answer: The equipment used for stud welding shall be completely automatic except for manual starting.

3. What are the test to be done for the procedure qualification of stud welding? Answer: 1. Every other welding stud (five joints) shall be tested either by hammering over until one fourth of its length is flat on the test piece, or by bending the stud to an angle of atleast 15 degree and returning it to its original position using a test jig

and an adapter location dimension that are in accordance with figure QW-466.4 2. The remaining five welded stud joints shall be tested in torque using a torque testing arrangement that is substantially in accordance with figure QW466.5. Alternatively where torquing is not feasible, tensile strength test may be used. 4. What is the acceptance criteria for bend and hammer tests? Answer: In order to pass the test(s), each of the five stud welds and heat affected zones shall be free of visible separation or fracture after bending and return bending or after hammering.

5. What is the acceptance criteria for torque tests? Answer: In order to pass the test(s), each of the five stud welds shall be subjected to the required torque shown in the table, which is given with QW 192.1.3

1. Is it required to certify the PQR? Answer: Yes. The PQR shall be certified accurate by the manufacturer or contractor. Refer ASME Section IX QW 200.2 (b) 2. What is the expiry date of welder qualification if a welder has not worked with that qualification? Answer: 6 Months. 3. A welder is qualified with backing. Is he qualified to weld without backing in the case of SMAW welding? Answer: No. As per QW 353, deletion of backing is a re-qualification criteria for the welder in the case of SMAW.

4. A welder is qualified with inert gas backing. Is he qualified to weld without inert gas backing in the case of GTAW welding? Answer: No. As per QW 356, deletion of inert gas backing is a requalification criteria for the welder in the case of GTAW. 5. A welder is qualified with DCEN. Is he qualified to weld DCEP in the case of GTAW welding? Answer: No. As per QW 356, Change in polarity is a re-qualification criteria for the welder in the case of GTAW.

We will discuss to prepare the pWPS (Proposed Welding Procedure Specification) based on the following situation: We have to weld a pipe to pipe joint using GTAW welding. The material of the pipe is SA106 Gr B, 2" X Sch 40. Prepare the pWPS (Proposed Welding Procedure Specification) for the same. As we discussed we will find out the P number of SA106 Gr B. P number is 1 (http://hareeshkv.blogspot.com/2013/05/asme-bpvc-section-ix-weldingtraining.html) We will find out the suitable filler wire for Welding the said material. From electrode manufacturers data sheet we found it as ER70S-2 and from ASME Sec IX we found that the F number is 6 (http://hareeshkv.blogspot.com/2015/04/asme-bpvc-section-ix-welding-part2.html) As the thickness is 3.9mm (Thickness of Sch 40 pipe), it is decided to use 2.4mm of filler wise.

Now from the filler wire manufacturers data sheet, find the current and voltage for using the same.

From the manufacturers data sheet the voltage required is 16-18V and the current required is 100-160A Now we have obtained the basic data of, the material to be welded, the filler wire to be used and the current and voltage required.

As we discussed the pWPS will be made and based on the test piece that is welded. The actuals that are happened at the time of welding and testing are recorded and PQR will be prepared. Based on the PQR, WPS will be made. There will be similarity, in most of the cases, between a pWPS and the WPS. But the WPS may also contain some other requirements(which will be in line with essential parameters, but changes such as different joint preparation requirements, some special instructions etc will be added as per job requirements.) In the next blog we will start filling the pWPS format for the above case.

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