ASME SEC 9

 ASME SEC IX Welding Procedure and performance qualification

What is the need for WPS & performance qualification? • To ensure the safety of the welded

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

Why ASME qualification & certification? • To ensure that design practices,

manufacturing practices, fabrication techniques, & inspection techniques are performed by personnel who are qualified in accordance with good engg. practices and standards

Selecting Your Welding Process 1. The joint joint to to be welded is analyzed analyzed in in terms terms of it requirements. 2. The joint requirements are matched with the capabilities of available processes. One or more of the processes are selected for further examination. 3. A checklist of variables is used to determine the ability of the selected processes(s) to meet the particular application 4. Finally, the proposed process or processes deemed most efficient are reviewed

Step 1 - Analysis of Joint Requirements The first thing to look at is whether your weld joint is large or small, whether the joint is out-of-position or not, and whether the base metal is thick or thin.

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

Step 1 1 - Analysis  Analysis of Joint Requirements Requirements Fast-Fill is required when a large amount of weld metal is needed to fill the joint. A heavy weld bead can only be laid down in minimum arc time with a high deposition rate. However, Fast-Fill becomes a minor consideration when the weld is small. Fast-Freeze implies that a joint is out-of-position, and therefore requires quick solidification of the molten crater. Not all semiautomatic processes can be used on fast-freeze joints.

 Analysis of Joint Requirements Requirements

Fast-Follow suggests that the molten metal follows the arc at rapid travel speed, giving continuous, well-shaped beads, without "skips" or islands. This trait is especially desirable on relatively small single-pass welds, such as those used in joining sheet metal. Penetration varies with the joint. With some joints, penetration must be deep to provide adequate mixing of the weld and base metal and with others it must be limited to prevent burnthrough or Cracking.

Step 2 - Matching Joint Requirements With Processes

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

Step 3 - The Checklist

• • • • • • • • •

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

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

WPS – Welding Procedure Specification PQR – Procedure Qualification Record

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

What is WPS in a layman view point • WPS lists all the parameters required to produce a

sound weld to the specific code • Specific parameters such as process,

technique,filler,current,voltage,etc., to be included • It should list a range on each parameter such as

amps = 110-150, voltage =17-22 with the more essential or critical parameters more closely defined or limited • It should give enough details so that any qualified

welder could follow and produce the desired weld.

Purpose of WPS Qualification To determine that the weldment is capable of providing the required properties for the intended application. WPS establishes the properties of the weldment and not the skill of the welder.

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

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

Points to be considered for establishing WPS • Code of • • • • •

construction Detailed drawing of weldment Material Thickness Configuration Process

• Contract/Customer/

Code/TPI • Preheat/Postheat/ PWHT requirements • Skilled welder • Good welding m/c with accessories •  Application

 Variables • • • • • • • • •

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

• Essential • Non-essential • Supplemental

essential

Essential Variables

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

Non Essential Variables

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

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

Joints(QW:402)

• Joint Design • Backing • Baking Material

Type

Base Metal Classification

Why P numbers?

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

Base Metal P Numbers Examples of P numbers P1

C Steel

P3

1/2 Mo steels

P4

1 Cr 1/2 Mo steels

P5A

2 1/4 Cr 1 Mo steels

P6

13 Cr steel

P7

17 Cr steel

P8

Austenitic StainlessSteel

P9A

2 1/2 Ni steels

P10A

Mn - 1/2 Ni - V steels

P11

9 Ni steels

Base Metal for WPS Test Coupon

Base Metal qualified

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

Base Metal(QW-403 Metal(QW-403)) P. Number Group Number Specification Chemical Analysis & Mechanical Properties • Thickness Range • Pipe Diameter Range • • • •

P1/Group 1 Carbon Steel Tubes

Pipes

SA179 SA106GrB SA192 SA333Gr1 SA210GrA1 SA333Gr6 SA334Gr1 SA334Gr6

Plates

Forgings

SA36 SA266CL1 SA515Gr55 SA350LF1 SA515Gr60 SA515Gr65 SA516Gr55 SA516Gr60 SA516Gr65

Castingss Casting SA216WCA SA352LCA SA352LCB

P1/Group 2 Carbon Steel Tubes

Pipes

Plates

SA210GrC SA106GC SA515Gr70 SA516Gr70 SA299

Forgings Castings SA105 SA266CL2 SSA350LF 2

SA216WC B SA216WC C SA352LCC

Other Specification Carbon Steel Tubes IS1239

Pipes

Plates

API5LGrB IS226 IS2062 BMC10 BMC16 BMC20

Forgings Castings

P3/Group 1

½ Mo (C –MOLY STEELS) STEELS) Tubes

Pipes

SA209T1

SA335P1

Plates

Forgings

SA204GrA

Castingss Casting SA217WC1

½ Cr ½ Mo - P3 Group 2 Tubes SA213T2

Pipes SA335Gr2

Plates SAA387Gr2

Forgings

Castingss Casting

P4/Group 1

1Cr ½ Mo Tubes SA213T12

Pipes SA335P12

Plates

Forgings

SA387Gr12 SA182F12

Castingss Casting SA217WC6

1¼ Cr ½ Mo Tubes SA213T11

Pipes SA335P11

Plates

Forgings

SA387Gr11 SA182F11

Castingss Casting

P5A/Group 1 2¼Cr 1Mo Tubes SA213T22

Pipes SA335P22

Plates

Forgings

SA387Gr22 SA182F22

Castingss Casting SA217WC9

P5B/Group 1

5Cr ½ Mo Tubes

Pipes

Plates

SA213T5

SA335P5

SA387Gr5

Forgings

Castingss Casting

SA182F5 SA217C5 SA336Cl F5

9Cr 1Mo Tubes

Pipes

SA213T9

SA335P9

Plates

Forgings

Castingss Casting

SA182F9 SA217C9 SA336Cl F9

P5B/Group 2

9Cr 1Mo ¼ V  Tubes SA213T91 SA199T91

Pipes SA335P91

Plates

Forgings

SA387Gr91 SA182F91

Castingss Casting

P8/Group 1 18Cr 8Ni Tubes

Pipes

SA213TP304 SA213TP304H SA213TP316 SA213TP321 SA213TP347 SA213TP347H

SA376TP304 SA376TP304H SA376TP316 SA376TP321 SA376TP347 SA376TP347H

Plates SA240TP304 SA240TP321 SA240TP347

Forgings

Castings

SA182F304 SA182F321 SA182F347 SA336F304 SA336F321 SA336F347

SA351CF3 SA351CF8 SA351CF3M SA351CF8M SA351CF10 SA351CF10M

P8/Group 2

25Cr 20Ni (Type 310) Tubes

Plates

Forgings

Castings

SA213TP310H SA240TP310 SA182F310 SA351CK20

Filler Metals(QW-404) •  AWS Number • SFA Number • F. Number •  A. Number •

• • • •

Size of Filler metal Flux trade name Consumable insert Electrode flux class

Deposited Metal thickness range

Filler Metal F Numbers Based on usability characteristics i.e ability of welders to make satisfactory welds with given filler F1 E XX20,XX24,XX27 F2 E XX12, E XX13,XX14 F3 E XX10, E XX11 F4 E XX15,XX16,XX18 F5 ASS, Duplex SS F6 Bare rods ERXX

Filler Metal A Numbers

Based on chemical composition  A1 Mild steel steel  A2 C - Mo steel  A3 Cr - Mo steel steel (Cr 0.4 - 2%)  A4 Cr - Mo steel steel (Cr 2 - 6%)  A5 Cr - Mo steel steel (Cr 6 - 10.5%) 10.5%)  A6 Cr Martensitic Martensitic  A7 Cr Ferritic Ferritic  A8 Cr Ni steels steels (Cr 14.5 - 30% Ni 7.5 - 15%)  A9 Cr Ni steels steels (Cr 19 - 30% Ni 15 - 37%)  A10 Ni steels (Ni 0.8 - 4%) Mn Mo steels(Mn 1.25-2.25 Mo 0.25-0.75%)  A11  A12 Ni Cr Mo steels steels (Cr 1.5% Mo 0.25-0.8% Ni 1.25 -2.8%)

Preheat(QW:406) • Preheat temperature (Minimum) • Interpass temp.(Maximum) • Preheat maintenance

PWHT(QW:407) • Temperature range • Time range • Thickness range

Gas(QW:408)

• Gases

Mixture %

Flow rate

(e.g. 75% Ar 25%CO2) • Shielding • Trailing • Backing Trail shield

Electrical Characteristics(QW-409) • Current (AC/DC) • Polarity (EP/EN) •  Amps & Volts • W-Electrode type & size • Mode of Metal Transfer • Electrode Wire Feed Speed range • Pulsing Current

METAL TRANSFER IN GMAW Short circuit transfer Low voltage & current

 Application Thin sheet & all position welding capability

Globular transfer Medium voltage & current

Spray transfer High voltage & current

 Applications Down hand position welding Sheet thickness > 2 mm

Techniques(QW-410) • • • • • • • • • • •

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

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

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

Weld Orientation Plate groove positions 1G, 2G, 3G, 4G Pipe groove positions 1G, 2G, 5G, 6G Plate fillet positions 1F, 2F, 3F, 4F Pipe fillet positions 1F, 2F, 2FR, 4F, 5F 1F - 0 to 30 2F - +15 -10 wrt 45 4F - 0 - 125 3F - 125 - 235

Procedure Qualification When two or more procedures (diff processes or other essential variables) are used in one joint, use table for determining the applicable range of thickness qualified. Carry out tension test for each weld metal. One or more processes from a combination may be deleted provided remaining metal meets the requirements.

Procedure Qualification Thickness limits T

Range of T

1.5”

3/16 - 8”

2t if t3/4”

-do-

Procedure Qualification Thickness limits T

Range of T

3/8”

2t

-do-

3/16 - 2T

WPS for SMAW Essential variables Change in qualified Thickness Change in P no Change in F no of filler metal Change in A no of filler metal Change in deposited metal thickness Decrease of more than 100 F in preheat Change in PWHT

WPS for SMAW Supplementary Essential variables Change in Group no of base metal Change in T limits for impact test Change in dia of filler metal > 1/4” Change in AWS class of filler metal Change in welding position Increase of more than 100 F in preheat Change in PWHT Time and temp range Change in current or polarity

WPS for SMAW Non Essential variables Change in Groove design, backing, root spacing, retainers etc Change in dia of filler metal Change in AWS class of filler metal Change in welding position Change in preheat maintenanc maintenance e Change in current or polarity Change in string/weave string/weave,, cleaning, back gouging, peening, manual/autom manual/automatic atic

WPS for GTAW Essential variables Change in qualified Thickness Change in P no Change in F no & A no of filler metal Addition/deletion Addition/dele tion of filler metal Change in size of filler metal, product form Decrease of more than 100 F in preheat Change in PWHT

WPS for GTAW Essential variables (cond) Change in single, mixture % gas Deletion of backing gas Change in shielding / trailing gas Change in Closed to out chamber technique

WPS for GTAW Supplementary Essential variables Change in Group no of base metal Change in T limits 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/polarity, incr. in heat input Change in multi to single pass, electrodes

Welding Conditions Specification, type and grade of Base Metal(s): To Specification, type and grade of Base Metal(s): Base Metal P or S-number 0.218

1

X

SA106 Gr B

to Base Metal P or S-number

Welding Process(es Process(es)) used: Plate

SA106 Gr B 1 Thickness:

GTAW followed by SMAW

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

Groove type (Single V, Double V, Single U, etc): Initial cleaning method:

Single Vee

Solvent wipe and grinding

Backing (metal, weld metal, backwelded, etc): Filler Metal (SFA) Specification: 5.18 / 5.1

None / Weld metal

Filler Metal or Electrode Classification:

ER70S-2 / E7018

Filler Metal or Electrode Trade Name:

Linde 65, Lincoln 7018+

Tungsten electrode type type and size for GTAW: GTAW: EWTh-2, 3/32" Consumable Insert Insert Class and size for GTAW or PAW: PAW: None Backing Gas composition and Flow rate for GTAW, PAW, GMAW: Not Used Preheat Temperature ( F): 75 °

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

5G

Interpass cleaning method:

Wire brushing

Measured interpass temperature ( F):

less than 400

°

Approximate Approxim ate Deposit Thickness Thickness for each filler metal or electrode type (in.): 0.093 (3/32) / 0.125 Current Type/Polarit ype/Polarity y (AC, DCEP DCEP,, DCEN): DCEN/DCEP Treatment Time and temper temperature: ature: 1100-1200 F, 65 hr.

Postweld Postwel d Heat

°

Visual Examination of Completed Weld: Bend Test X

Acceptable

Date of Test:

12/25/01

Transverse Tran sverse Root and Face (QW-462.3(a))

Side (QW-462.2)

Type

Result

Result

Face Face

Type

Result

Type

Acceptable

Root

Acceptable

Acceptable

Root

Acceptable

Alternative Radiographic Examination Results:

N/A

Specimens Evaluate Evaluated d By: Company Ever

Dianna Ross

Title: Leader

Company:

The Best Testing

Welding Supervise Supervised d By:

James Brown

Title

Company:

Joe-Bob's B&NPW Shop

Welder’s Name:

Wolfgang Amadeus Mozart

Soloist Stamp No:

A1

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

Performance Qualification The basic criterion for welder’s

qualification is to determine the welder’s ability to deposit sound weld

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

operate the welding equipment.

GMAW in different positions 1F 2F Flat

Fillet welding of plate

3F

 Vertical

4F

Horizontal

overhead

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

 Variables affecting the welders qualification Welding conditions that affect the ability of welder to produce sound welds are qualification variables • Welding process • Filler metal • Welding position • Joint backing • Thickness of test coupon

Welding process •  A change in welding process –from

SMAW to GTAW, for eg.,requires the requalification of the welder since skill required to use one process is different from another one.

Filler metals • Filler metals used in welding are

grouped based on their usability characteristics. These are assigned Fnumbers • Ordinarily welder is qualified for a F no and do the same in production • SAW :F1-F4: Qualification in higher Fno entails qualfication for lower F nos of electrodes

Backing • Joint backing includes any material placed at

the root of the weld to support the liquid metal(e.g backing strip,non fusing bars, root weld with another process,etc) • If a welder qualifies using a backing on the

test coupon but the backing is removed for the production welding for a joint made from one side, then he must requalify • If a welder qualifies using without a backing, for a joint with backing he is automatically qualified

Welders Performance Qualification Welded Without Backing Fx With Backing F1 F2 F3 F4 F5

Qualified Fx

F1 F2, F3, F4, F5,

F1 F2, F1 F3, F2, F1 F1

Welders Performance Qualification F1 F1 F2 F2 F3 F3 F4 F4 F5 F5

F No qualification with backing with backing F1 with backing without backing F1 with & without backing with backing F1 & F2 with backing without backing F2 with with & without backing, backing, F1 F1 with backing with backing F1, F2 & F3 with backing without backing F3 with with & without backing, backing, F1, F1, F2 with backing with backing F1, F2, F3 & F4 with backing without backing F4 with & without backing, F1, F1, F2, F3 with backing with backing F1 & F5 with backing without backing F5 with with & without backing, backing, F1 F1 with backing

•

Welding position(QW-405) position(QW-405 ) Welding test positions are defined differently for plate and pipe

in welding position position from that that qualified qualified •  A change in may require requalification • Certain test position qualify for more than one

production welding position (E.g.qualification in 3G position qualifies the welder for vertical and flat positions) • In vertical position welding, a change in welding

progression from uphill to downhill would require requalification • Qualification in difficult position qualifies for less

difficult positions: E.g 6 G qualifies for all positions

Welders Performance Qualification Weld

Plate 1F Plate 2F Plate 3F Plate 4F 3F &4 F

Plate & pipe >24”OD

Pipe of OD 2 7/8 - 24” 

Fillet

F F, H F, H, V F, H, O All

Welders Performance Qualification Weld Plate & pipePipe of OD Fillet 2 7/8 - 24”  >24”OD Plate 1G Plate 2G Plate 3G Plate 4G

F F, H F, V F, O

F F, H F F

F F, H F, H, V F, H, O

Welders Performance Qualification

Weld

Pipe Pipe Pipe Pipe Pipe

Plate & pipe >24”OD

1G 2G 5G 6G 2G + 5G

F F, H F, V, O All All

Pipe of OD 2 7/8 - 24” 

F F, H F, V, O All All

Fillet

F F, H All All All

Welders Performance Qualification

Weld

Pipe Pipe Pipe Pipe Pipe

1F 2F 2FR 4F 5F

Plate & pipe >24”OD

Pipe of OD 2 7/8 - 24” 

Fillet

F F, H F, H F, H, O All

Test coupon thickness • The thickness of the production work

determines the thickness of the plate or pipe test coupon to be welded • Thumb rule is a welder is qualified to deposit in production welding two times the thickness of the weld deposited on the test coupon (e.g. test coupon of 9 mm qualifies a person to weld upto 19mm thick production weld) • Some code makes once a weld of 1 inch is made, the welder is qualified to weld all thickness

Test coupon thickness(contd.) • The weld deposit thickness(t) determines the

thickness of the weld metal the welder is allowed to use in production not the thickness of the base metal in the test coupon. • When welding a test coupon using more than

one process or filler metal, the thickness of the weld in production depends on the deposit thickness for the process and the type of test of filler metal that was used on the test coupon.

Welders Performance Qualification Thk 3/8”  >1/2”

Max tk of dep. Metal Test 2t 1FB, 1RB 2t 1FB, 1RB Max to be welded 2SB

OD of test coupon 2 7/8” 

Range of OD qualified Size welded - unlimitd 1” - unlimited 2 7/8” - unlimited

Welders 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 Qualification  Variables for SMAW Removal of backing Change in Pipe diameter Change in P number Change in F Number Change in thickness of weld deposit Change in welding position

Welders Performance Qualification Variables for GTAW Removal of backing Change in Pipe diameter  Addition / deletion of filler metal  Addition / deletion of insert Change in P number Change in F Number Change in solid filler to flux cored filler metal Change in thickness of weld deposit Change in welding position Removal of inert gas backing Change in current or polarity

Tests 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 Qualification Radiography

No crack or LOP or LOF  Any elongated slag >1/8” for t 2 1/4”   Any group of slag in a line with 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” 1/8” For thickness1/8”, charts for max acceptable types of rounded indication

C. R. Ratheeskumar  ACTUAL VALUE

FCAW(S) 8"

RANGE QUALIFIE

FCAW(S) 2 7/8" & Above

 A 106 Gr B, Sch 160 P No.:1 Gr.:1 Yes(Root) E71T8-K6 6 FCAW (S) -19 mm

P 1 - P 11 With backing backing 6 Upto Max to be we

 A 106 Gr B, Sc h 160 P No.:1 Gr.:1

P 1 - P 11 With backing

Yes(Root) E71T8-K6 6

6

FCAW (S) -19 mm

Upto Max to be welded

6G

 All Positions P ositions

Down Hill

Down Hill NA

NA DC Electrode Negative

DC Electrode Negative

 Accepted  Acc epted NDT / 250A / 03

Dt.23.2.04. Dt.23.2. 04.

NA NA NA NA Welding Research Research Institute, BHEL, Trichy, India. India. NA

Welder’s Performance Qualification as per Indian Boiler Regulations

Welder’s Performance Qualification as per IBR Initial qualification of welders Certificate valid for 24 months provided welder has been employed with reasonable continuity If preceding three months, no welding carried out or if there is any doubt on welder’s stability then requalification

needed

Welder’s Performance Qualification as per IBR Requalification of welders must for the following Omission of backing strip Change in class of electrode Change in base metal to be welded(CS or AS) Change in welding process Change from dc to ac and vice versa

Tests for Initial Qualification • Theoretical examination • Groove welds in plate - single or double vee

299 x 381 x 16 mm min size in flat, horizontal or vertical. Vertical or horizontal position also qualifies for all •Fillet weld in plate - 16 x 381 mm min in flat, horizontal, vertical or overhead. Horizontal or vertical also qualifies for flat.  Vertical position also qualifies for flat, horizontal or vertical.

Tests for Initial Qualification Pipe welding in the following positions (i) Horizontally rolled (ii) Horizontal turned (iii)  Vertical fixed (iv) Horizontal fixed. Qualification in (ii) or (iii) also qualifies (i). Qualification in (iv) also qualifies (i) or (ii). Branch to pipe welding Pipe size 127 OD x 10 tk. Tube 89 OD x 6 tk. Tube welding with axis vertical and tubes of same size fixed in adjoining positions.

Tests for Requalification • •

• • • •

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

Examination of the weld for initial Qualification PLATE QUALIFICATION (Groove weld) • •  • •

• •

Visual examination Radiography 2 no of Tensile test 2 no each of Bend test - face and root bend ( 3t for both C steel and alloy steel 180 deg bend) 1 no Micro examination 1 no Macro examination

Examination of the weld for initial 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

Examination of the weld for initial Qualification PIPE QUALIFICATION • • •

Visual examination Macro examination 2 no each of Bend test - face and root bend ( 3t for C steel and 4t for alloy `steel 90 deg bend)

Examination of the weld for Requalification PLATE QUALIFICATION •  Radiography 1 no each of Bend test - face and root • bend 2 no of macro examination • PIPE QUALIFICATION 1 no each of bend test - face and root • bend Macro examination

ACTUAL VALUE

FCAW(S) 8"  A 106 Gr B, S ch 160 P No.:1 Gr.:1 Yes(Root) E71T8-K6 6 FCAW(S) -19 mm 6G Down Hill NA DC Electrode Negative

Steps involved in qualifying the welding process & welder/ operator p repared •  A tentative welding procedure is prepared • Test samples welded with the above and parameters recorded on PQR • Tested as per required codes • If test is passed, the procedure has completed qualification. • If test is not passed, the tentative WPS value of the parameters are changed as deemed feasible

welding process & welder/ operator • The welder making the test samples to be used in

qualifying the procedure is normally considered qualified. • Other welder to be qualified weld test samples as per WPS and the samples are tested as per applicable requirements. •  A qualified qualified WPS is usable usable for an indefinit indefinite e length of time • The welder’s qualification is normally considered

effective for an indefinite period of time, unless the welder is not engaged in the specific process of welding for which she is qualified for a period of exceeding 6 months

Case study Objective : To develop a WPS for pipe to pipe butt joint( dia. 406 * 12mm) of SA 106 GrC – SA106 GrC as per  ASME sec IX • Requirement of mechanical property: Impact toughness at room temperature Tensile strength

Filling up of WPS- Draft WPS: No: Date: Supporting PQR Welding process : Type : Manual/ Machine/Auto/ Semi Auto •  Application: • • • •

Joints(QW:402) • Joint Design • Backing • Baking Material Type

Base Metal(QW-403 Metal(QW-403)) P. Number Group Number Specification Chemical Analysis & Mechanical Properties • Thickness Range • Pipe Diameter Range • • • •

Filler Metals(QW-404) •  AWS Number • SFA Number • F. Number •  A. Number •

• • • •

Size of Filler metal Flux trade name Consumable insert Electrode flux class

Deposited Metal thickness range

Welding position(QW-405 position(QW-405))

• Welding test positions are defined

differently for plate and pipe

Preheat(QW:406) • Preheat temperature Min • Interpass temp.(Max.) • Preheat maintenance

PWHT(QW:407) • Temperature range • Time range • Thickness range

Gas(QW:408) Mix % • Gases • Shielding • Trailing • Backing

Flow rate

Electrical Characteristics(QW-409) • Current (AC/DC) • Polarity (EP/EN) •  Amps & Volts • W-Electrode type & size • Mode of Metal Transfer • Electrode Wire Feed Speed range • Pulsing Current

Techniques(QW-410) • • • • • • • • • • •

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

Filling up of WPS-Joints(QW:402)