Asme Ix Binder

1Bureau Veritas Presentation _ Date© - Copyright Bureau Veritas

An Introduction to ASME Section IX

For the benefit of business and people

ASME IX


Welding Technology: Welding, Fabrication and Inspection (AWS, ASME and API Codes)


Applied Welding Technology


Why Weld?

Metal Structures can be made in several ways

Cast Fabricate

Castings can weigh 3 to 4 times as much as a fabrication - economics and limited by scale


Why Weld?

► Forgings - can also be large and heavy but size is limited by the capacity of the forging press.

► Extrusions – tend to be of a specific shape. Tool wear limits the materials that can be extruded.

► Sintered Components – tend to be small and of high value.► Prototyping – uses Lasers and metal powders to build a component.

Limited to high value items.

Metal Structures can be made in several ways


Fabrication

We can fabricate using rivetting, bolting or welding

Compare:

Rivetting Bolting


Or We Can WELD


What is a WELD?

A localised coalescence of metals or non-metals produced either by heating the material to the welding temperature with or without the application of pressure or by the application of pressure alone and with or without the use of a filler metal.

Definition:


Welding

§ It is therefore a special process

§ It brings together the disciplines of design, metallurgy, process and inspection

§ It is probably one of the most governed activities in the world

§ Governed by National and International Codes and Client/Customer Specifications


Metal Joining and Cutting Processes

Three Basic Groups:

§ Welding

§ Cutting

§ Brazing

Well over 100 different processes with new process being developed - especially hybrids.


Coverage of Processes

For the more common processes we will discuss:

► Advantages

► Limitations

Techniques and filler metals will be discussed later


Welding Processes to be Discussed

► Shielded Metal Arc Welding - SMAW (or MMAW)► Gas Tungsten Arc Welding - GTAW (or TIG)► Gas Metal Arc Welding - GMAW (or MIG/MAG)► Flux Cored Arc Welding - FCAW► Submerged Arc Welding – SAW► Special Welding Processes


Shielded Metal Arc Welding


SMAW Equipment

Simple Circuit Diagram for SMAW


SMAW Equipment


SMAW Advantages

► Simple equipment – smaller diameter electrodes can use single phase 240 V AC power.

► Inexpensive and long lasting equipment► Very portable – Modern Inverters weigh only a few kilograms► A large range of alloys is available, including alloy steels, stainless

steels, cast irons, hard-facing alloys, etc.► High quality welds


SMAW Limitations

► Requires a degree of welder skill, especially for positional work

► Relatively slow i.e. low deposit rate due to low duty cycle (Arc running time as a % age of total time)

► Can require strict control on electrode storage and preparation for welding

► A degree of fume is produced

► The slag must be removed


SMAW - Effect of Current

Can use: ► AC current, DC electrode +ve and DC electrode -ve► DC Straight or DC Reversed Polarity are not recommended - can mean

different things and very confusing.Welding with AC transformers :► Cheapest for equipment and is very robust► Suffers less from arc blow► Good heat balance between electrode and workpiece► Generally operates on higher open circuit voltage



Welding with DC transformer-rectifier or converters (engine driven):

► Unbalanced heat between electrode and workpiece

► Suffers more from arc blow

► Generally operates on lower open circuit voltage

For DC Electrode -ve :

► More heat developed at electrode, increases melt-off rate

► Less arc penetration into workpiece

► Less dilution of base metal

► Good for surfacing



For DC Electrode +ve:

► More heat developed at workpiece, decreased melt-off rate► More arc penetration into workpiece► More dilution of base metal

DC Electrode +ve is probably the most common method of welding with covered electrodes.


Gas Tungsten Arc Welding


GTAW Equipment


GTAW Equipment

Equipment can be simple and cost effective or expensive, it depends upon theapplication!


GTAW - DC Heat Balance

DC electrode -ve is common method for ferrous alloys


GTAW Electrodes


GTAW Electrodes

► Pure Tungsten - General Purpose AC electrode primarily used for Al, Mg, Ni and their alloys.

► Thoriated - Standard DC electrode for TIG and plasma welding. Thorium is a radioactive element.

► Ceriated - Similar to thoriated in performance but thoria-free. For DC TIG or plasma welding Ni, Mo, Ti, Cu, Ta and their alloys. A good replacement for Thoriated.

► Lanthanated - An AC/DC electrode for plasma cutting, welding and spray applications.

► Zirconiated - Very similar to the pure tungsten but with better overall performance.


GTAW Electrodes

Point shape - Usually ground to a point but in AC and DC + ve the electrode will ball up.Point shape - For thoriated, use a purpose - built grinder to collect dust particles.


GTAW Advantages

► High quality welds in almost all metals and alloys► Good control of current - good for thin materials► Very little, if any, post weld cleaning is required► Arc and weld pool clearly visible to the welder► No filler metal carried across the arc therefore little or no spatter► No slag produced that might be trapped in the weld.► All positional► Mechanisation – Can be used with automatic hot or cold wire feed or

fusion only


GTAW Limitations

► Very low deposition rate - slow process► Two handed operation► Skill level is high, especially root runs and in position.► Needs protection from the environment► Low tolerance for contamination► Equipment is similar but more expensive than SMAW


GTAW

► Be careful to avoid tungsten inclusions in weld► Avoid using scratch start power sources, especially for aluminium► Consider using lift start or HF start


Gas Metal Arc Welding


GMAW Equipment

Equipment becomes more complex


GMAW Transfer Modes

Factors affecting transfer mode includes shielding gas, current, voltage and power supply


GMAW - Spray Transfer

High current - good penetration and high deposition.

Droplet size << than wire diameter.

Droplets “pinched” and forced through arc.

Positional for aluminium (with pulse.)

Flat of H/V for other metals.


GMAW - Spray Transfer


GMAW - Globular Transfer

Droplet size ≤ than wire diameter

High current with CO2


GMAW - Globular Transfer


GMAW - Dip Transfer

Droplet size > than wire diameter

Low current, dilution and penetration

Wire contacts workpiece and resistance heating at A to DM

Droplet transferred across arc at D to F

Arc extinguished at H and wire moves to re-contact workpiece at I.All positional but metal must have high electrical resistance.


GMAW - Dip Transfer


GMAW - Pulsed Transfer

1 droplet transferred at each pulse

Spray transfer achieved at low currents - thin materials

Low heat input

Suitable for most metals


GMAW Transfer Modes

Typical operating ranges for Spray, Dip and Pulse transfer with 1.2 mm diameter wire


GMAW Advantages

§ High productivity

§ No slag to remove

§ Clean process

§ Welds most alloys

§ Lowest hydrogen potential of all processes

§ Continuous wire feed - semi automatic


GMAW Limitations

§ Unsuitable for windy conditions

§ Little tolerance for contamination

§ Usually limited to shop welding

§ Equipment more complex

§ Suffers from inherent weld defects(Welder training issue - discussed later)


GMAW Wire Feed Units

Many types of feed systems, chose one that is appropriate to the work intended.

2 or 4 roll drivesSpool mounted on gun or “push-pull’ system


Flux Cored Arc Welding

2 main types of FCAW

Self shielded or gas shielded

Equipment similar/same as GMAW


FCAW Advantages

► High Productivity► Tolerates contamination► High current density, deep penetration especially with DC electrode

+ve.► Suitable for field work, especially self shielded.► Sometimes the only method of obtaining semi-automatic welding with

high alloys, especially surfacing materials.► Combines advantages of GMAW and SMAW without inherent defects.


FCAW Limitations

§ Slag to be removed

§ Fumes are produced

§ Higher cost of consumables

§ Equipment can be more complex


Metal Cored Arc Welding

§ A derivative of Flux Cored Arc welding

§ No flux used - core filled with metal powders

§ Does not suffer from GMAW inherent defects with same penetration properties asFCAW.


Submerged Arc Welding


Sub-arc Equipment


Sub-arc Advantages

§ High deposition rate

§ Deep penetration

§ Automatic process

§ Good for surfacing

§ Can use alloy fluxes - but critical voltage dependency


Sub-arc Deposition Rates

Welding deposition rates for SAW


Sub-arc Limitations

► Mainly Flat but horizontal has been used► High set-up time► Needs positioning/rotating equipment► Arc is not visible► High heat input - not suitable for thin materials, aluminium, single phase

and quenched and tempered steels.► Needs slag removal► Needs flux drying, delivery and recovery systems► Defects can be large i.e. lack of fusion or slag lines


Special Welding Process

§ There are variations of the processes discussed

§ Many hybrid process being developed

§ Many other special welding process

§ There are too many to cover in this course but some can be mentioned


Plasma Arc Welding

Equipment can be complex but low cost units are now available which run on compressedair.


Electroslag Welding


Electrogas Welding


High Energy Processes

Electron Beam

High Vacuum Electron Beam



A LASER is a device that amplifies light

LightAmplification byStimulatedEmission ofRadiation

Lasers come in a great variety of forms, using many different materials, many different systems and many different excitation mechanisms.

Laser Processing



Laser Processing


Power Sources for Arc Welding

Will limit discussion to three most common types:

§ Transformer

§ Transformer /rectifier

§ Inverter - solid state


Main Components of a Power Source

§ Transformer§ Rectifier§ Inductor§ High Frequency unit or Capacitor Discharge (GTAW)§ Protection System for overheating and over current§ Burn-back§ Cooling fan or oil§ Enclosure


Transformer

§ Simple operation –V1/V2 = A2/A1

§ Many types including movable shunt, centre tap, single phase and 3 phase etc.

§ Cost increases with complexity§ AC current only


Transformer Rectifier


Arc Characteristics

§ Constant current

§ Constant voltage

§ CC/CV inverters


Constant Current


§ Manual welding has poor control of arc length§ When arc length is increased or decreased, the arc energy remains fairly constant and

therefore electrode melt-off rate remains constant as does the heat of the arc § Especially true when using equipment with high open circuit voltage§ SMAW and GTAW typically use constant current arc control

Constant Current


Constant Voltage


Constant Voltage

§ Typical arc control for semi automatic and automatic processes.§ These process could use CC but would need voltage sensing device to control wire

feed rate to keep arc length constant.§ Prior to electronic control, sensing was limited to supply frequency and feed motor

could not react fast enough.§ Controls arc length by adjusting melt-off rate§ Current and heat are not constant


Inverters


Inverters

§ Solid state units

§ Compact, portable and large weight saving

§ High frequency of operation

§ Combines best features of CC and CV units


Duty Cycle

§ The permissible temperature rises in a transformerwithout harming the insulation.


Arc Blow

The result of magnetic disturbances (including residual) which forcibly directs the arc away from the point of welding

Location of lead

Ends of ferromagnetic workpiece

Edge of steel plate


Arc Blow

§ Cannot always be elimimated, but may be controlled or reduced§ Change from DC to AC§ Use short arc technique§ Reduce welding current or voltage§ Use heavy tack welds at either end and intermittent tacks along length§ Angle electrode in the direction opposite to the arc blow§ Weld towards heavy tack or completed weld


Arc Blow

§ Use backstep technique§ Attach work cable to both ends of the joint to be welded§ Extend end of joint by attaching run-off plates§ Bridge joint in piping§ Wrap cable round workpiece and pass current through it - try winding both ways - aim

to neutralise the residual magnetism§ Can try magnetic particle yoke


Cutting Processes

§ Oxy-Fuel Gas Cutting

§ Plasma Cutting

§ Carbon Arc Cutting

§ (more often for gouging)

§ Mechanical

§ Laser Beam Cutting

§ Water Jet Cutting


Oxy-Fuel Gas Cutting

§ Uses same basic set-up as Oxyfuel welding§ Can be used for gouging§ Generally limited to carbon steels in a wide range of

thicknesses§ Can be mechanised§ Needs fluxing or abrasive powder additions to cut other

metals

DO NOT USE CUTTING HEAD TO PREHEAT WELD JOINTS


Plasma Arc Cutting

§ More expensive than Oxy-Fuel§ Small systems using compressed air as plasma

gas are available§ Cuts most metals§ Can inject water to supplement superheat or

shroud to minimise noise, fume etc.

Can submerge workpiece in water to minimise width of the HAZ and distortion.


Carbon Arc Cutting

§ Uses same equipment as SMAW but needs higher power i.e. 600 - 800A power sources are better

§ Can cut most metals § Can be automated§ High fume and noise§ Carburises cut surfaces

*Fire Hazard*


Laser Cutting

High speed cutting

Can cut most materials

Equipment is expensive


X* = Process applicable with special techniques

This table should be used only as a very general guide


Water Jet Cutting

§ High velocity water jet - large expensive installations.

§ Can cut range of non metallics up to about 9 mm.

§ Can cut metals but limited. Better with Garnet feed.

§ No thermal distortion of cut material

§ Relatively slow§ Noise problem


Mechanical Cutting

§ Grinding

§ Sawing

§ As with Water Jet cutting there is no heat from an arc

§ Ideal when there is a need to preserve the metallurgical structure or for cutting non-metals.

84

THANK YOU




ASME IXWelding and Brazing Qualifications


Qualification standard for Welding and Brazing

Produced by ASME subcommittee on welding

Applicable to any section of the ASME Boiler and Pressure Vessel code

Also applicable to ASME B31: code for Pressure Piping

ASME IX


There are 3 principal documents in the ASME System:-

1. WPS Welding Procedure Specification

2. PQR Procedure Qualification Record

3. Welder Qualification Record

ASME IX


Welding Procedure Specification

§ The Code user must describe on a WPS the details to guide the welder on how each weld is to be made.

§ The WPS shall specify an allowable range for each variable.

§ The WPS shall be used to provide direction for the welder and to control each of the variables for each welding process used.

ASME IX


Procedure Qualification Record

§ The PQR documents the actual parameters used during the test.

§ The Code user may perform the required mechanical tests, or testing may be subcontracted to a testing lab. The PQR is intended to prove weld ability of the base metal, filler metal, and welding process combinations.

§ The Code user in each case must certify the PQR thereby accepting responsibility for the results.

ASME IX



A WPS must address all VARIABLES

What is a Variable? It is any change that may affect the properties of the welded joint. The ASME System identifies 3 types of variable:

§ Essential§ Non-Essential§ Supplementary

ASME IX



Essential Variables are those that if changed outside specific limits, affect the mechanical properties of a joint to such an extent that re-qualification of the procedure becomes necessary.

Non-essential Variables are those that can be changed without affecting the mechanical properties. A new or revised WPS needs to be established but not a new PQR.

ASME IX



Supplementary essential variables are invoked when notch toughness is specified and impact tests are required as part of the procedure qualification test.

ASME IX



QW - 200.1 Each Manufacturer (Code user) shall prepare written WPS

QW - 200.1(a) A WPS is a written, qualified, document prepared to provide direction for making production welds to code requirements

QW - 200.1(b) The completed WPS shall describe all of the essential, nonessential and supplementary essential variables for each process used in the WPS. The WPS shall reference the supporting Procedure Qualification Record(s) PQR.

ASME IX



How do you know what are Essential, Non-essential and Supplementary variables?

If you start with QW 400, Variables, and start reading, it will not make much sense. You need to start with QW 250 through to QW 290. these detail the variables per process, and you only need to read those sections in QW 400 that are applicable.

ASME IX


QW – 402 Joints

QW – 402.1 A change in the type of groove (vee-

Groove, U-groove, single-bevel, double-bevel, etc.).

QW – 402.2 The addition or deletion of a backing.

QW – 402.3 a change in the nominal composition of the backing

QW - 402.4 The deletion of the backing in single-welded groove welds Double-welded groove welds are considered welding with backing.

QW – 402.5 The addition of a backing or a change in its nominal composition.

ASME IX


ASME IX


QW – 403.6 The minimum base metal thickness qualifiedis the thickness of the test coupon T or 5/8 in (16 mm),whichever is less. However, where T is less than ¼ in (6mm), the minimum thickness qualified is ½T. Thislimitation dose not apply when a WPS is qualified with aPWHT above the upper transformation temperature orwhen an austenitic material is solution annealed afterwelding.

ASME IX


QW – 403.8 A change in base metal thickness beyond therange qualified in QW-451, except as otherwise permittedby QW-202.4(b)

QW-403.9 For single-pass or multipass welding in whichany pass is greater than ½ in. (13 mm) thick, an increasein base metal thickness beyond 1.1 times that of thequalification test coupon.

ASME IX


Qw-403.10 For the short-circuiting transfer mode of thegas metal-arc process, when the qualification test couponthickness is less than ½ in. (13 mm), an increase inthickness beyond 1.1 times that of the qualification testcoupon. For thicknesses of ½ in. (13mm) and greater, usetable QW-451.1 or table QW-451.2, as applicable.

QW-403.11 Base metal specified in the WPS shall bequalified by a procedure qualification test that was madeusing base metals in accordance with QW-424.

ASME IX



QW - 200.2(c) Changes to the PQR are not permitted, except editorial corrections or an addendum to reflect Code changes. If substantiated as having been part of the original qualification by laboratory record or similar data, additional information may be addedto the PQR.

ASME IX



QW - 200.2(d) The information required to be in a PQR may be in any format, provided every essential and, when required supplementary essential variable, specified by QW- 250 through QW 280 (Table 3.3, QW - 253 for SMAW) is included. The type, number, and results of the tests shall also be recorded in the PQR

ASME IX



It is presupposed that the welder or welding operator performing the welding procedure qualification test is a skilled workman.

That is, the welding procedure qualification test establishes the properties of the weld and HAZ, not the skill of the welder or welding operator.

ASME IX


Welder Performance Qualification

§ The basic criterion established for welder qualification is to determine the welder’s ability to deposit sound weld metal.

§ The purpose of the performance qualification test for the welding operator is to determine the welding operator’s ability to operate mechanical welding equipment.

ASME IX


Revisions

Qualification of new Welding Procedure Specifications or Welders/Welding Operators and re-qualification of existing Welding Procedure Specifications or Welders/Welding Operators shall be in accordance with the current Edition (see Foreword) and Addenda of Section IX.

WPSs and PQRs to older editions are still valid!

ASME IX


Revisions

It is recommended that the Code user review each Edition and Addenda of the Code as they are issued.

Code users should address all technically sound new requirements.

Code users should consider re-qualification of PQRs and WQRs as variables are revised or added, although Section IX does not require this.

ASME IX


Materials

In order to prevent duplication of essentially similar tests, Base metals are grouped according to P numbers for the purposes of qualification.

These P numbers are listed in QW/QB 422Materials are listed under ASTM numbers

ASTM A 516 Gr 70

ASME adopts ASTM numbers and adds an S

SA 516 Gr 70

ASME IX


P Numbers

§ If base metals have specific impact properties, a Group number is assigned within the P number SA 182 Gr F12 = P no. 4 Group no. 1

§ QW/QB 422 also lists material UNS Numbers

§ All materials with same UNS Number are considered to be same P No. even if not listed in QW/QB 422

§ Procedures qualified to 1971 edition are valid to 1974 and later editions where P and Group no’s may have changed

ASME IX


S Numbers

§ S- Numbers are non mandatory

§ S numbers are listed for materials acceptable to ASME B31 Pressure Piping or selected Boiler and pressure Vessel Code Cases.

§ S numbers are also combined with Group numbers

A211 Gr A570-30 = S no. 1, Group no. 1

ASME IX


P Numbers

§ Material grouped under one P number or P number plus Group no qualifies all other materials under same P number (and Group number) or S no. and Group no.

§ Material grouped under one S number or S no plus Group no qualifies all other materials under same S no (and Group no.)

§ Material qualified under S numbers do not qualify P number materials.

ASME IX


ASME IX


F Numbers

§ F - Numbers group electrodes and welding rods according to usability characteristics.

§ Determines the welders ability to make satisfactory welds with a given filler metal.

§ Used to reduce the number of welding procedure and qualification tests.

§ Does not imply indiscriminate substitution. Metallurgical properties, design, post weld heat treatment and mechanical properties must be considered.

ASME IX


ASME IX


A Numbers

§ QW 440 Weld metal chemical composition

§ Applies only to ferrous metals

§ Needs to be designated on WPS and PQR (as per QW -404.5)

ASME IX


ASME IX


Post Weld Heat Treatment

QW-407.1 A separate procedure qualification is required for each of the following conditions.

a. For P-No. 1, P-No. 3, P-No. 4, P-No. 5, P-No. 6, P- No.9, P-No. 10, and P-No. 11 materials, the following postweld heat treatment conditions apply:

1. No PWHT2. PWHT below the lower transformation temperature3. PWHT above the upper transformation temperature

(e.g., normalizing)

ASME IX



4. PWHT above the upper transformation temperature followed by heat treatment below the lower transformation temperature (e.g., normalizing or quenching followed by tempering);

5. PWHT between the upper and lower transformation temperatures.

b. For all other materials, the following post weld heat treatment conditions apply:

1. No PWHT2. PWHT within a specified temperature range

ASME IX



ASME IX specifies minimum holding temperature and minimum holding time.

When using application Codes such as ASME VIII Division 1, also need to consider:

§ Heating rate§ Cooling rate§ Method (local or furnace, resistance or induction if

local)§ Control§ Insulation§ Thermocouple number and position

ASME IX


Preheat

Preheat temperature depends on:

§ Welding process and heat input

§ Chemical composition

§ Degree of restraint

§ Material thickness

§ Elevated temperature properties

§ Low temperature properties

ASME IX


Preheat Variables - QW 406

QW-406.1 A decrease of more than 56°C in the preheat temperature qualified. The minimum temperature for welding shall be specified in the WPS.

QW-406.2 A change in the maintenance or reduction of preheat upon completion of welding prior to any required post weld heat treatment.

QW-406.3 An increase of more than 56°C in the maximum interpass temperature recorded on the PQR.

ASME IX

38

THANK YOU

SECTION IX

Welder’s Qualifications / Essential Variables

We will discuss all of the welder’s essential variables listed in QW-353 for the SMAW process. So here goes, turn to page 52 of Section IX.

QW-353 Shielded Metal-Arc Welding (SMAW)

Essential Variables

Paragraph

QW 402Joints .4QW 403Base Metals .16

.18 QW 404Filler Metals .15

.30QW 405Positions .1

.3

Brief of Variables

Deletion of Backing

Change Pipe DiameterChange in P Number

Change in F NumberChange in weld t deposited

Addition of a positionChange from vertical Up to Down or Down to UP progression


Welder Essential VariablesThe first essential variable listed is – Backing (Removal of).

If a welder is qualified using any type of backing, and asked to perform an open root weld he must retest without backing to be qualified to perform the welding.The Code definition of backing is welding with a backing bar or retainer, welding double sided welds where the weld metal of the first pass is used after gouging/grinding as weld metal backing for the balance of the weld.Fillet and partial penetration welds are also considered welding with backing.


Welder Essential Variables

The next inline is change in Pipe Diameter qualified. As pipe diameters become smaller the difficulty for a welder is increased resulting in a higher skill level requirement.So this translates to a change in diameter to one smaller than qualified by the welder’s pipe coupon on a previous test with this process.The ranges of pipe diameters qualified are given in Section IX, turn to page 143 in Section IX.

QW-452.3 GROOVE-WELD DIAMETER LIMITS


As we can see:1. Under 1 inch (25mm) qualifies the diameter

down to the size welded to unlimited diameter, because it is only easier for the welder as the diameter of the Pipe welded increases.

2. From 1 inch (25mm) to 2-7/8 inch (73mm) qualifies 1 inch to unlimited.

3. Over 2-7/8 inch (73mm) qualifies 2-7/8 inch to unlimited.


Quiz1. If a welder qualified on a NPS 6 inch pipe coupon the range of diameter qualifications in production with the WPS he tested to will be _________.2. If tested with a NPS 2 inch coupon what is his minimum and maximum diameter range is ________


Quiz1. If a welder qualified on a NPS 6 inch pipe coupon the range of diameter qualifications in production with the WPS he tested to will be 2-7/8” to unlimited.2. If tested with a NPS 2 inch coupon what is his minimum and maximum diameter range is 1” to unlimited.

QW-353 Welder Essential Variables

P-Numbers. P-Numbers serve to group metals by mechanical and chemical properties. So it is reasonable to think that not all metals can be welded using the same technique, or have the same level of difficulty for welders. There are three basic P-No. groupings for welder qualifications. If a welder changes to a P-No. group that he/she has not qualified for then a retest is required. We will have a more thorough lesson on Alternate Base Metals later in this course.

QW-432 F Numbers

We have now arrived at the Filler Metal Number or F Number. F Numbers are a grouping of electrodes and filler metals that weld in a similar way and in general present more or less difficulty for a welder. In other words some F-Number filler metals require different skills than others.

Turn now to Page 132 of Section IX

QW-433 Alternate F-Numbers for Welder Performance Qualifications

Changing the F Number for a welder may affect his ability to weld and require re-qualification. There are some provisions for using lower F-Numbers when qualifying with numbers 2 to 4 but, there are restrictions on those qualifications.

Turn now to Page 137 of Section IX


Examples1. Using the table QW-433, if a welder qualifies with or without backing with a filler metal or electrode assigned to F-Number 4. What F-Numbers can he use with backing in a production weld?

2. What F Numbers can he weld without backing?


Solution 1. He can weld F-Numbers 1 through 4 with backing. Going right across the row titled “Qualified With” to F-Number 4 without backing then down to each x in the boxes, then left to read the “Qualified For” Column we find F Numbers 1, 2, 3 and 4 with backing.

2. Also the “Qualified For” F Number 4 without backing is included which makes sense as he performed that weld for his test.


Notice that the large table only addresses F-Numbers 1 through 5. The rest of the F-Numbers are in a small table along with notes beneath the large table. Let’s have a look at those.

QW-433 Alternate F-Numbers for Welders

QW-452.1 (b) Thickness Of Weld Metal Deposit

The fifth essential variable listed is change inthickness of Weld deposit.

A welder is restricted by the amount of weld metal he deposits during his performance qualification test with a particular, weldingprocess, electrode/filler metal F-number in a P-Number base metal combination. We will now have a look at those rules.

Turn to Page 142 of Section IX


The column ‘Thickness t, of weld metal in the coupon’ refers to the amount of weld metal from a process or a filler metal. Perhaps a bit of E-6010 and the rest E-7018 or GTAW root and SMAW fill and cap.


ExampleAssume one welding process, SMAW and one electrode E-7018 using a P-No.1 pipe. A coupon thickness of 3/8 inch was welded using E-7018. In the column on the right titled ‘Thickness of weld metal qualified’ we see 2t, so 2 x 3/8” = 3/4” this is the maximum amount of E-7018 (F-No. 4) , that the welder can deposit in production.


Suppose now the coupon is 1/2” thick and a welder welds it with 100% E-7018 using 3 weld layers, we see that welder’s limit of deposited weld metal with an F-No.4 is the maximum to be welded.


Another combination in the 1/2” coupon.

1/8” of E-6010 (F-No.3) and 3/8” of E-7018. By the first column 2 x 1/8” = 1/4” of E-6010 (F-No.3) and 2 x 3/8” = 3/4” of 7018 (F-No.4). The welder can deposit up to 1/4” of any F-No.3 and 3/4” of any F-No.4 with any production WPS he is otherwise fully qualified for, meaning position, diameter, P-No., backing, progression etc.


QuizHow can we qualify a welder for unlimited thickness with both F-No.3 and 4 in a single coupon? If he or she welds a coupon that is at least ___ thick and deposits at least___” of E-6010 and at least ___” of E-7018 using a minimum of ____ layers of each filler metal.

* Hint See Note 1 of table QW-452.1(b)


SolutionIf he or she welds a coupon that is at least 1”thick and deposits at least 1/2” of E-6010 and at least 1/2” of E-7018 using a minimum of three weld layers for each filler metal. The welder can deposit unlimited t with any F-No.3 and/or F-No.4 with any production WPS he is otherwise fully qualified for such as, position, P-No., backing, diameter, progression etc.

QW-353 Welder Essential Variables

The next essential variable listed is Position.Consider the welding positions versus the welder test positions for a moment. We will use pipe test coupons. Positions for pipe tests are designated such as 1G, 1 designates the coupon orientation, in this example the pipe is on the horizontal and is rotated/rolled beneath the welder and is considered to be flat welding. The G means a groove butt weld. The others are 2G, 5G and, 6G.

Turn to Page 148 QW-461.4 in Section IX.

QW-461.4Groove Welds in Pipe – Test Positions

The more difficult the test position, the more positions a welder can apply. The four positions for welding are Flat, Horizontal, Vertical and Overhead.

These are referred to as:F,H,V,O

QW-461.4Groove Welds in Pipe – Test Positions

There are corresponding pipe and plate test positions that qualify a welder for F,V,H, and O. We will use pipe in the examples.1G qualifies F (Rotated)2G qualifies H5G qualifies F, V, and O6G qualifies F, V, H and, O (this yields all positions)

QW-461.4 Groove Welds in Pipe – Test Positions

Section IX allows combing test positions to produce an all position welder. Therefore if a welder tests in 2G and 5G he/she was tested for all positions.

2G covers H and 5G covers F, V, and O Which is equal to 6G that qualifies F, V, H and, O. Either of these two yields an all positions welder.

QW-469.1Performance Qualifications - Position and

Diameter Limitations

All of this information is compiled into one table.

In this way you can go straight to a one page table and review a Welder Performance Qualification (WPQ) for position and diameter qualifications. Turn to Page 151 Section IX

Notice the entry on the top row rightPosition and Type Weld Qualified. [Note (1) ]Below that GrooveBelow Groove exists two sub-headingsPlate and Pipe Over 24 inches and Pipe less than or equal to 24 inches. Ignoring Fillets because any welder qualified for groove 1G is qualified for the same fillet 1F.

To the left we have Qualification Test

Which has the sub-headings Weld and Position

We will use the Pipe-Groove [ Note (3)] row. Starting at the top of the table in the Qualification Test column move down and stop at the 1G entry below. To the right we see the entries F F F ß ignore fillets.Move up at the first F and find Plate and Pipe Over 24 in. O.D. is qualifiedMove up from the second F and find Pipe less than or equal to 24 in. O.D. is qualified. See [ Note (3)]

Pipe less than or equal to 24 in. O.D. is qualified. See [ Note (3)]

Note (3) See diameter restrictions in QW-452.3, QW-452.4, and QW-452.6

Notice that while the welder can weld on pipe in the FLAT position he or she is still restricted by the diameters given in the table below on,Pipe less than or equal to 24 in. O.D..


The last essential variable listed is Progression.This as simple as it gets.

If a welder welds Vertically Up (Uphill) during a particular test he is only qualified for Vertically Up. Should the welder be required to weld Vertically Down(Downhill) it is required to test a coupon (keeping other variables the same) welding Vertically Down.The reverse is also true, qualify Downhill and you must weld another coupon to qualify Uphill.

QW-353 (SMAW) Welder Essential Variables

QuizA welder performs a test on a NPS 4” (4.5”) pipe coupon in the 6G position. The coupon is Schedule 160 and has a wall T of 0.531”. The welder will use SMAW with E-6010 for the root pass for a total weld deposit t of .125” (1/8”). The balance of the weld deposit t (.401”) will be performed using 3 weld layers of E-7018 filler metal. No backing will be used. All welding will be uphill during the test. What are his qualifications as listed in table QW-353?

(SMAW) Welder Essential Variables

Continued The test qualifies ___ positions with a minimum diameter of ______ and a maximum of _______. The test also qualifies the welder to deposit ___ inches of F- No. 3 and ____inches of F-No.4.

The welder will also be qualified to weld _____or _______backing. The thickest weld he can make using this combination in production is__________. The welder’s production welds must made using _______ progression.

(SMAW) Welder Essential Variables

Solutions The test qualifies all positions with a minimum diameter of 2-7/8” and a maximum of unlimited. The test also qualifies the welder to deposit .250”inches of F- No. 3 and .812” inches of F-No.4. The welder will also be qualified to weld with orwithout backing. The thickest weld he can make using this combination in production is .250 +.812 or 1.062”. The welder’s production welds must be made using uphill progression.


Welder Essential Variables

The next series of slides address the alternate base materials for welder qualifications. As you will see a welder can test for example on a P-No. 1 base material with a selected F-No. filler metal and, under the rules of Section IX he can weld many other P-Numbers using the F-No. selected for the test, maintaining all the other essential variables for the welder, position, diameter, etc.




ASME IX


SECTION IXQW 423 Alternate Base Materials for Welder Qualification VersusBase Metal Qualified


►Base metals used for welder qualification may be substituted for the metal specified in the WPS in accordance with the following in-text table.

►When a base metal in the left column is used for welder qualification, the welder is qualified to weld all combinations of base metals in the right column. Including unassigned metals of similar composition to these metals.

QW-423 Alternate Base Metals for Welder Qualification


Base Metal (s) Used forWelder Qualification

P-No. 1 through P-No. 11, P-No. 34, or P-No. 41 throughP-No. 47

P-No. 21 through P-No. 25

P-No. 51 through P-No. 53 or P-No. 61 through P-No. 62

Base Metal (s) forwhich the Welder is Qualified

P-No. 1 through P-No. 11, P-No. 34, or P-No. 41 throughP-No. 47

P-No. 21 through P-No. 25

P-No. 51 through P-No. 53 or P-No. 61 through P-No. 62



►So, all we need to do is qualify a welder to weld any P-No. from the list and he can weld all of the others. This would be great!

► There is however a problem with this theory. Welders are also limited by the Filler Metal Number (F-No.) used during a test.



If a welder qualifies on any P number from P 1 through P 11, P 34 or P 41 through P47 he/she is qualified to weld any of those metals together. Be warned this is further limited by the F-number (s)!



If a welder qualifies on P 21 to P 25 he/she is qualified to weld any of these metals together or any combination of these aluminum alloys together!



If a welder qualifies on P 51 to P 53 or P 61 to 62 he/she is qualified to weld any of these metals together or in any combination of Titanium or Zirconium alloy!



In theory a welder could be qualified for all the listed base materials by welding just three (3) coupons. Remember our lesson on Filler Metal Numbers (F-Numbers). This is where the welders limitations become very important.

One of the essential variables for a welder is the F- Number of the electrode he qualifies with during a given test.


Suppose a welder qualifies with SMAW using an F-No.4 electrode the test coupon is a P-No.1 base material.

The welder has qualified to weld P No. 1 to 11, 34 or 41 through 47. So let’s have him weld one of the nickels, a P-No.41. Assume it will be required to make the weld with a filler metal that is designated as a F-No.41 in Section IX. There is a problem , he has not qualified any of those metals with a F-No.41 filler metal. He would have to prove his skill with the F-No.41 filler metal.


He is qualified for SMAW using a F-No.4 electrode not F-No.41. The welder will have to test again on any of those metals using a SMAW electrode designated as a F-No.41, why because the F-Numbers 4 and 41 are considered to require different skill levels to weld. The F-Number is a welders essential variable as well as a procedures.

Welders are limited by all of the following essential variables (skill issues), which are in Section IX for the welding processes listed QW 350.


QW-353 Shielded Metal-Arc Welding (SMAW)Essential Variables

ParagraphQW 402 .4 JointsQW 403 .16 Base Metals .18 QW 404Filler Metals .15

.30QW 405 .1Positions .3

Brief of VariablesDeletion of Backing

Change Pipe DiameterChange in P Number

Change in F NumberChange in weld metal t depositedAddition of a positionChange from vertical Up to Down or Down to UP progression


Simply put the welder must qualify all of his/her essential variables, not just be qualified to weld a particular P Number. In our example he/she is disqualified for the nickel alloy weld because of the required F -Number qualification being F-No.41 as listed on the WPS/PQR.


A welder is limited by, process, pipe diameter, P- Number, F- Number, weld metal thickness, position, backing and progression.

All of these Essential Variables must meet the requirements of the WPS to be used in the production weld.

15

THANK YOU

Destructive Testing of Welder’s Qualification Coupons

There are three items that must be addressed when performing destructive testing of a welder’s test coupon.

1. The type of the specimens required.

2. Where in the test coupon specimens shall be taken from.

3. How many specimens are required.

These values are listed in Article IV Welding Data of Section IX in a tabular form, 452.1(a) and are accompanied by notes referencing paragraphs found in Article III, of Section IX .The type and number a listed in that paragraph.Turn now to Page 147 of Section IX.

We will now examine the figures referenced in QW-452.1(a) for removal of Welder’s Performance Coupons.

Turn to Page 179

Example - Billy Bob Welder’s performance test was made under the following conditions using Big Welding Company’s WPS CW-1010 :

1. P-Number 1 pipe coupon2. Pipe diameter NPS 8” (8.625”)3.Thickness 0.500” 4. 6G test position5. Uphill progression6. F-No.4 (SFA 5.1) 7. 3 layers/passes of weld metal8. Process SMAW only

Next we fill out the of Welder’s Performance Qualification (WPQ) Form QW-484 for Billy Bob Welder.

Finally an example of the coupons required for a 2G and 5G test in a single couponwhich will qualify a welder for all four of the positions, Flat, Horizontal, Vertical and ,Overhead just the same as the single 6G test.This coupon requires 6 bend specimens instead of the usual 4, taken from the locations indicated in the graphic.

THANK YOU

SECTION IX

Qualifying A Welding Procedure’s Essential Variables

All Referenced Section IX Pages are from the 2001 Edition with Addenda through 03

SECTION IX

When qualifying a welding procedure you must first determine the important properties of the planned weldment which then become the essential variables. The basic ones are;

• Base metal to be welded and thickness (T) required.

• Process (es) to be used including filler metal (s).• Preheat.• Postweld heat treatment or the lack of.• Various others based on welding process used.

For this instruction we will use the SMAW Process. The a brief of Essential, Supplementary Essential and Non-Essential Variables for the SMAW process are listed in table QW-253. However this part of the course will only cover Essential Variables not the supplementary or non-essentials. Those will be covered latter. A definition of these variables follows.

Essential Variable – A variable that if changed requires requalification of the procedure by the welding and testing of a new coupon or support from a previously qualified Procedure Qualification Record (PQR), i.e. a change in the base metal thickness (T) qualified.Supplementary Essential – An essential variable that is used only when impact testing of a base metal is required by a construction code, i.e. a change from one P-No. Group to another such as P1 Gr.1 to Gr.2.Non-Essential – A variable that can be changed as needed to suit production requirements without requalification.

QW-253 SMAW Brief of Variables Page 22We will start our discussion with the top half of the SMAW brief of variables, beginning with the first two Essential Variables, Base Metal and Filler Metal.

Defining Each Essential Variable

Base Metals QW-403.7• T/t Limits > 8 inches - this rule only applies at

thickness greater than 8 inches (203 mm) .• Unless you will be welding something over 8

inches this is of little concern. The rule for most welding procedures is the maximum that can be welded is 2 times T (the coupon). If you are welding a coupon over 8 inches you are restricted to 1.33T or 1.33t, as applicable. 1.33t is the weld metal thickness, it matters when mixing welding processes and/or filler metal F-Numbers.


Quiz1. An 8-1/2” T coupon was welded to produce a

PQR to support welding of a reactor shell course. The maximum T qualified with this coupon is ___”.


Quiz1. An 8.5” T coupon was welded to produce a PQR

to support welding of a reactor shell course. The maximum T qualified with this coupon is 11.305”.

8.5 X 1.33 = 11.305


Base Metals Pgs. 21, 58,159, &16• Change in Thickness (T) qualified.• QW-403.8 A change in base metal thickness beyond

the range qualified in QW-451, except as otherwise permitted by QW-202.4(b) (different thickness at joint)

• Of concern is the thickness range qualified by the supporting PQR (s) for the WPS, from less than a 1/16” to less than 1-1/2” it is 2 x T. To weld a thickness outside the range supported by the PQR the WPS production welding changes must be supported by providing an additional PQR from file or by welding a new PQR test coupon.


Base MetalsQuiz

1. A 1” to 1” P-No.1 coupon was welded entirely by the SMAW process. The minimum thickness qualified is ___ and the maximum is ___”


Base MetalsQuiz

1. A 1” to 1” P-No.1 coupon was welded entirely by the SMAW process. The minimum thickness qualified is 3/16 ” and the maximum is 2”.


Base Metalst (weld metal) pass greater than 1/2• QW-403.9 For single-pass or multi-pass welding in

which any pass (means layer of weld metal) is greater than 1/2 in. (13 mm) thick, an increase in base metal thickness beyond 1.1 times that of the qualification test coupon.

• The thickness range is affected. It will be restricted to 1.1 T as given above if you deposit more than 1/2” of weld metal in a single pass (layer). This has to do with heat input.

Defining Each Essential VariableA single pass refers to the number of weld beads required to fill up a layer of weld metal in the joint. If the single layer/pass, t (deposited weld metal), exceeds 1/2” in thickness the WPS will be restricted to 1.1 x T in production welding.

Defining Each Essential VariableQuiz

A PQR coupon is 1-1/4”(1.250) thick (T). The weld will be made in two passes, the root pass/layer will be 1/4” (.250) thick and second and third layers/passes will be each be 1/2”(.500) thick. The maximum range of thickness for this qualification will be ________”.

Defining Each Essential VariableQuiz

A PQR coupon is 1-1/4”(1.250) thick (T). The weld will be made in three passes, the root pass/layer will be 1/4” (.250) thick and second and third layers/passes will be each be 1/2”(.500) thick. The maximum range of thickness for this qualification will be 2-1/2 (2.500)”.Read closely, the rule states it must exceed 1/2” to be limited to 1.1 x T.


Alternate Base Metals for Procedures

• QW-403.11• Base metals specified in the WPS shall be

qualified by a procedure qualification test which was made using base metals in accordance with QW-424.

QW 424 –Base Metal (s) Used for Procedure Qualification Test Coupon VersusBase Metal Qualified for production

Let’s examine some of the items on the table.

One Metal From A P-No. To AnyMetal From The Same P-No.

Such as P1 to P1

One metal from a P-No. To anymetal from any Other P-No. We will Use P No.1 to P No.8 as an example. Other combinations are possible, P Nos. 1 to 3, P Nos.3 to 4 etc.

One metal from P-No. 3 To anyother metal from P-No. 3

One metal from P No. 3 to anyother metal from P No. 3

Also qualifies P No. 3 to P No. 1

However one metal from P No. 3 to anymetal from P No. 3 does not qualify P No. 1 to P No. 1

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

One metal from P No.4 to any other metal from P No.4 also qualifies P No.4 to 4, 3 and, 1

It qualifies one metal from P No. 4 to anymetal from P No. 4, 3 or 1. but does not qualify P No. 3 to P No. 3 or P No. 1 to P No.1

Quiz

Using the table list the base metals qualified if we successfully weld a procedure coupon joining P No. 5A to No. P 5A

Quiz # 1 - P No. 5A to P No. 5A Qualifies?

P No. 5A to __, __,__, or __. It does not qualify __, __, or __ to each other or to their selves.

P- No. 5A to P- No. 5A Qualifies?

P- No. 5A to 5A, 4, 3, or 1. It does not qualify 4 , 3, or 1 to each other or to their selves.

Quiz # 2 - P No. 5A to P No. 4, 3, or 1 Qualifies?

P No. 5A to any metal assigned __,__, or __. It does not qualify __, __, or __ to each other or to their selves.

Quiz # 2 - P No. 5A to P No. 4, 3, or 1 Qualifies?

P No. 5A to any metal assigned 4,3, or 1. It does not qualify 4, 3, or 1 to each other or to their selves.

Defining Each Essential VariableBase Metals Pages 21 & 58

• Change of P-No. 5/9/10• QW-403.13 A change from one P No. 5 to any

other P-No. 5 (P No. 5A to P No. 5B or P No. 5C or vice versa). A change from P No. 9A to P No. 9B but, not vice versa. A change from one P No.10 to any other P No.10 (P No.10A to P No.10B or P No.10C, etc., or vice versa).

• Simple, P-No. 5/9/10 - A,B,C.., are different P-Numbers and require individual qualifications, (with the exception of 9B to 9A)


Filler Metals• Change of F-Number Pages 21 & 59• QW-404.4 A change from one F-Number in QW-

432 to any other F-Number or to any other filler metal not listed in QW-432.

• Changing the F-Number to one other than that used for the procedure test coupon, during the creation the of the Procedure Qualification Record (PQR). Such as changing from F-No. 1 to F-No. 3.

• This rule also applies to a welder’s qualification test by the way.

Defining Each Essential VariableFiller Metals

• QW- 404.5 Change of A-Number Pages 21,59 & 138

• A-Nos. are the chemical analysis’ of the ferrous weld metal deposits produced by a given filler metal. Changing A numbers can change the chemistry and possibly the mechanical properties of the weld metal. This occurs by changing filler metals. It also changes the weld add mixture, that part that contains both base metal and weld metal. Changing the A No. to one other than that used to qualify requires a new test or additional PQR (s) from a file (with one exception).

The… below indicates trace amounts ,single values are maximums. i.e. C = 0.20 % max.

Filler MetalsConsider the following filler metals for the SMAW process.

1. E-7018 which has an A-Number of 1.2. E-7018 A1 which has an A-Number of 2

Let’s compare the chemistry tables from Section II Part C Filler Metals for these two AWS Classification SMAW Electrodes/Filler Metals to the A – Numbers of Section IX.

From Section IX QW-442 A No. 1 contains by %C 0.20/ Cr --/ Mo --/ Ni --/ Mn 1.60/ Si 1.00

From Section II Part C / E-7018 SFA 5.1

From the Section IX QW-442 A No. 2 contains by %C 0.15 / Cr 0.50/ Mo 0.40 – 0.65/ Ni --/ Mn 1.60/ Si 1.00

From Section II Part C / E-7018-A1 SFA 5.5

A note on the API Exams

• If you are taking any of the three API Exams you will be required to review a WPS and PQR. Part of that review might be a question about the A-Number listed for the filler metal on the documents. This is a protest question. You would need ASME Section II Part C to answer that question. Sect. II Part C is listed as required for the exam. You have no way of answering!

For our example we find the following rule, proving you must read Section IX carefully!

• QW-404.5 (Applicable only to ferrous metals.) A change in the chemical composition of the weld deposit from one A-Number to any other A-Number in QW- 442.Qualification with A-No. 1 shall qualify for A-No. 2 and vice versa. (Note: all other A-No. changes will force re-qualification).

Defining Each Essential VariableFiller Metals

• Change t deposited Pages 21 & 61• QW-404.30 A change in deposited weld metal

thickness beyond the range qualified in QW-451 for procedure qualification.

• Example: In a SMAW procedure 1/4” of E-6010 was qualified on the PQR by depositing 1/8” in the coupon (2t), the balance of the coupon was filled with E 7018. The need arises to increase the E-6010 t to 3/8” in production. This would require a new coupon or an existing PQR.


Preheat - Turn to Page 21

Defining Each Essential VariablePreheat - Pages 21 & 62

• A decrease in preheat greater than 100 o F• QW-406.1 A decrease of more than 100°F (56°C)

in the preheat temperature qualified. The minimum temperature for welding shall be as specified in the WPS.

• Example: A PQR coupon was welded using a preheat of 250 °F but the WPS requires a preheat of only 100 °F. This is a 150 °F decrease below that qualified and will require a new PQR or one from your files to support the lower temperature.

Defining Each Essential VariablePWHT

• Change in PWHT Pages 21 & 62• QW-407.1 This long paragraph specifies what is

considered a change in post weld heat treatments.The changes are P-Number specific with 5 different conditions of PWHT for P Nos. 1,3, 4, 5, 6, 9,10 and, 11.For all other materials there are two conditions

1. NO PHWT2. The specified PWHT for the P No. used

Defining Each Essential VariablePWHT

• T Limits (Thickness Limits) Pages 21 & 63• QW-407.4 For a procedure qualification test

coupon receiving a post weld heat treatment in which the upper transformation temperature is exceeded, the maximum qualified thickness for production welds is 1.1 times the thickness of the test coupon.

• This rule only applies when a production weld will undergo heat treatment at temperature that will alter the base metal’s physical properties, such as tempering, etc.

Producing The PQR

We have looked at all of the essential variables for the SMAW process. Let’s put it all together by filling out a SMAW PQR to support a Welding Procedure Specification (WPS). To do this it will be necessary to specify a list of the essential variables for the welding we have planned.

Producing The PQR

From QW-253 we need to address the basic essential variables and they will be:

1. Base Metal (s) – 2” SA-516 Gr. 70 Norm. P-No. 12. Filler Metal (s) – E-7018 Only3. Preheat – 175 o F for P-No.1 (from Sect. VIII Div. 1

non-mandatory Appendix R)4. PWHT – 1100 o F Minimum per inch of thickness

for P-No. 1 (from Sect. VIII Div. 1 UCS-56)

Producing The PQRNext we define the ranges of the variables:

Base Metal – SA-516 Gr.70 Normalized (2”max.)Preheat – 175 o FThen PWHT based on 2” per UCS-56 shall be 1 hour per inch, which in this example = 2 hours.The next step is to start filling out a Procedure Qualification Record as if we had actually welded the coupon. Here is the front of a blank PQR form.

First we will fill out the top half of the PQR from the company name to the base metal information on the left side and include a graphic of the joint design used to weld the coupon.

Next we will fill out the bottom half of the PQR with the filler metal and preheat on the left side. While not required on the PQR by Section IX the Non-Essential variables will be entered as well.

Now we will fill out the upper half of the PQR with the PWHT metal on the right side. Making the comment Not Applicable in the box for Gas, since the SMAW process does not use shielding gasses.

Finally the bottom right which consists of all non-essential variables. Once again these are not required by Section IX, but may be helpful for meeting a construction code requirement, i.e. Section VIII Div. 1 or B31.3.

Now we start completing the back of the PQR. To do so we need some test results for our required tension and bend tests. The tension test specimens are fabricated as given in Section IX QW-462.1(a). Page 152 .

The required number of tension test specimens are 2 as shown in Section IX QW-451.1 Page 139. The required number of tension specimens are always two, unless your coupon exceeds 1”, then you are allowed divide the two specimens into multiple pieces. (see QW-151.1 (c) and (d) )

The ultimate strength of the tension specimens must be computed as described in below in QW-152.

• QW-152 Tension Test ProcedureThe tension test specimen shall be ruptured under tensile load. The tensile strength shall be computed by dividing the ultimate total load by the least cross sectional area of the specimen as calculated from actual measurements made before the load is applied.

We must measure each specimen’s width and thickness after machining as shown in QW-462.1(a). Section IX requires two specimens be tested.The data for our specimens was;

TS1 - width = .750” thickness = .453”TS2 - width = .753” thickness = .456”Area for each specimen.TS1= .750 x.453 = .340 in.2

TS2= .753 x.456 = .343 in.2

We put the specimens in a tensile tester like this and pull each one apart;

The specimens were broke in the tensile tester and the breaking forces as read from the gage on the machine were recorded as follows ;

TS1 = 25,010 Lbs.TS2 = 24,050 Lbs.

Computing the ultimate strength for 1 square inch for each specimen;

‘Load divided by Area’25,010/.340 = 73,558 PSI24,050/.343 = 70,116 PSI

We now evaluate the specimens;

‘Load divided by Area’25,010/.340 = 73,558 PSI24,050/.343 = 70,116 PSI

Observing the character and location of the specimen failures, it was noted that both failed in the base metal outside of the weld heat affected zones and in a ductile manner.We can now record this information on the back side of the our Procedure Qualification Record.

‘But First’We must determine the required minimum specified strength from Section IX in the P-Number listings.


We find that SA-516 Grade 70 has a Minimum Specified Tensile Strength of:

70 KSI = 70,000 Pounds Per Square Inch.

Our tensile specimens exceeded the minimum. Now we have one more task to complete. We must do 4 side bend tests. This requirement is found in Section IX along with the accept/reject values for all bend tests. Turn now to Page 139 again.

The required type and number of bend tests based on a 1” thick coupon are 4 Side Bend tests. Remember side bends are mandatory after the coupon thickness reaches 3/4” or larger.

We must evaluate the bend specimens to section IX QW-163. Turn now to Page 6.

QW-163 - The guided-bend specimens shall have no open discontinuity in the weld or heat-affected zone exceeding 1/8 in. (3.2 mm), measured in any direction on the convex surface of the specimen after bending. Open discontinuities….etc. To see the details for making the bend specimens look at QW-462.2 Page 161.

We evaluated the bend specimens to section IX and had the following comments.

Side Bend S1. No open defects acceptableSide Bend S2. 1/32” acceptableSide Bend S3. No open defects acceptableSide Bend S4. No open defects acceptable

We have the correct type based on the coupon thickness and the correct number of acceptable side bend tests.

We can now fill out the top back of the PQR.

All that is left is to fill out the bottom of the back of the PQR. This will be easy, just a few housekeeping items to complete.

Here is the front side of the complete Procedure Qualification Record

Here is the back side of the complete Procedure Qualification Record

The WPS

• We have completed the Procedure Qualification Record, which is a laboratory report of the welding and testing of a coupon.

• From this we will write a Welding Procedure Specification. It must be in complete agreement concerning Essential Variables with the PQR.

The WPS

• The Welding Procedure Specification, must be complete. You must address all of the essential, supplementary essential (if Notch toughness testing is required), and non-essential variables. The best approach is through the use of the Brief of Variables found in QW-253 on Page 22as an item check list.

• We will go line by line and address all of the Essential and Non-Essential variables since our WPS will not require Notch toughness testing.

The WPS

Starting in box QW-402 we will address each of the non-essential variables.

• Groove Design• Backing• Root Spacing• Retainers The following is how it was completed.

The WPS

In box QW-402 we have addressed each of the non-essential variables as follows;

• Groove Design – Single Vee, Double Vee, J-Groove and, U-Groove

• Backing – The X in both the Yes and No boxes denotes that this WPS may be used with or without backing.

• Root Spacing –This is given below Details.• Retainers – Same as Root Spacing

The WPS

Since we have addressed each of the non-essential variables and thereby giving all the needed Joint information for making a weldment.It is complete for joint design and no one should have to ask what is allowed when using this WPS.

The WPS

Next QW-403 Base Metals

The WPS

We have addressed each of the essential variables under Base Metal QW-403.

It is complete for P-No., Thickness range and the restriction of No t Pass > 1/2” has been addressed. Supplementary Essentials need not be addressed, no impact testing is required of this weldment.

The WPS

Next QW-403 Filler Metals

The WPS

We have addressed each of the essential variables under Filler Metal QW-404.It is complete for AWS Classification, F-No., A-No., Size of Filler Metals, and Weld Metal Thickness Range. Again no impact testing is required so the Supplementary Essentials do not apply.

The WPS

Next the back and top of the WPS

We will now complete the Positions, Preheat, Electrical, and Postweld Heat Treatment on the WPS.

The WPS

1. The Positions for use with this WPS are, Flat, Horizontal, Vertical and, Overhead. This instructs that this WPS can be used with all positions.

2. The Preheat minimum is set at 100 o Fwhich is within 100 o F of the PQR actual value of 175 o F.

3. The Preheat Maintenance specified as none required.

The WPS

The Electrical Characteristics are;1. Direct Current Electrode Positive.2. Amps are set to a range of 90-190 and

the Volts are set to a range of 15-25, these values are normally obtained from the filler metal manufacturer’s literature or from actual experience.

3. The rest are not required for SMAW.

The WPS

The Postweld Heat Treatment values are;

1. 1150 +/- 50 o F Which is in agreement with the PQR minimum value of 1100 o F

2. Time at temperature is 1 hour, also in agreement with the PQR.

3. Gas variables are not required for SMAW.

The WPS

We will now complete the bottom half of the back of the WPS. Which consists of the Technique box QW-410 only.

The WPS1. String or Weave, restricted from 2 to 3 core

diameters (core wire exclusive of any coating).2. Cleaning is limited to Brushing or Grinding.

Back Gouging will be by Air Carbon Arc.3. Multiple Pass, Manual is entered in the

heading and Peening is not allowed.4. All others are not SMAW variables.

The Complete WPS Front

The Complete WPS Back

THANK YOU



Review of WPS’s and PQR’s

The API candidate will be given a WPS and a PQR and will be asked to identify errors or unsupported requirements.

Questions will be asked about individual blocks on the WPS/PQR. You will not be required to review the entire document. The exam is in multiple choice format, normally 3 to 6 questions come from the WPS/PQR review.When answering the questions about the WPS and/or the PQR, look for omitted information. Every Essential and Nonessential variable should be addressed. Common errors, such as filler metal F-Numbers and base metal thickness ranges are typically found. The PQR test coupon thickness T can and often does support only part of the thickness range stated on the WPS etc.

Review of the WPS’ and PQR’s

The API Body of Knowledge has limited the content of the WPS and PQR in the following key ways.

1. There will be only one welding process, and they have been limited to SMAW, GTAW, GMAW or SAW.

2. Just one filler metal i.e. all E-7018 with no mixing of F- Numbers.

3. There will not be different thickness’ or different base metals welded to each other.

4. The P-Numbers are limited to P1, P3, P4, P5 and, P8

5. For P1, P3, P4, and, P5 the lower transition temperature is 1,333 o F and the upper is transformation is 1600 o F

Limitations on the WPS/PQR Review

Limits Continued:

6. Supplemental powdered fillers or consumable inserts will not be on the WPS/PQR.

7. Special welding processes such as corrosion resistant weld metal overlay and hard surfacing will not be present.

8. Welds with buttering of the ferritic member or excluded.

In short the WPS/PQR review will be of the most basic type, and will not require a great deal of expertise in Section IX.

Limitations on the WPS/PQR Review

1. Missing variables, both Essentials and Non-Essentials on the WPS.

2. Missing Essential variables on the PQR, Non-Essentials are not required for the PQR.

3. Incorrect Essential Variables, such as the wrong F-Number for a filler metal or electrode. For example:“The electrode E-6010 has an F-Number of 3 and often the wrong F-Number is assigned to it such as F-Number 4”4. An Essential Variable listed on the WPS that is not supported by the PQR.

Note: Editorial mistakes such as misspellings of company names or typing errors are excluded from the exam. i.e.

WPS/PQR Mistakes are of Four Types

We will use the SMAW QW-253 Brief of Variables as a check list as we go through the reviews of two WPS’ and PQR’s.

Confusion Welding and Wee Welders

Turn now to Page 21 of Section IX and remove it for convenience during the review.

Brief of Variables

Now also turn to the WPS/PQR titled Confusion Welding in the class textbook. It starts on Page161 and is four pages total. Remove it from the textbook for convenience during the review.

We will review it step by step for errors.

Confusion Welding

The first checks are in the title of the WPS.

1. Does our WPS reference our PQR?2. Has our welding process been listed?3. Is the Type of welding listed, manual, automatic etc.?

* Note: The Type of Welding in box QW-410 at the bottom of QW-253 is out of order in reference to the box on the WPS, as it appears in the title instead of box QW-410 on the WPS.

Confusion Welding WPS

Conclusion:

1. WPS references our PQR.2. Our welding process is listed.3. Type of welding is listed as manual.

No mistakes in the title page.


Next we compare the variables in the row QW-402 Joints on QW-253 to the box QW-402 Joints on the WPS.

1. Groove design, is it addressed?2. Backing has it been listed?3. Has root spacing been detailed?4. Finally have retainers been mentioned?


For definitions see Page 56 of Section IX.

402.1 - A Change in Groove Design402.4 - Deletion/Removal of Backing402.10 - A Change in Root Spacing402.11 – Addition or Removal Retainers

We go line by line checking the WPS < ;

Conclusions: Nothing is missing, there are no mistakes in box QW-402 on the WPS. Note that Non-Essentials are only wrong if they are missing i.e. the Code user can choose any groove design, root spacing etc.

1. Groove Design is addressed as Single Vee.2. Backing as Flat Bar P-No.1 steel material.3. Retainers under Details are Not Allowed.4. Root Spacing is present under Details.


The next listings are in box QW-403 Base Metals.

1. Is the P-Number entered?2. Is Base Metal Thickness present?3. Has t pass > 1/2” been addressed?

* Note: During the review of the PQR we will confirm that all Essential Variables are in agreement between the WPS and the PQR regarding the specifications and ranges supported.


Conclusions:1. The P-Number is present.2. Base metal thickness range is present.3. t pass > 1/2” is missing, not addressed!This is a mistake, as all essentials variables must be addressed.* Remember, all variables that apply to the process must be addressed on the WPS, both essential and non-essential.

Confusion Welding

Check the box QW-404 on the WPS for omissions.

1. Is the F-Number present and is it correct?2. Is the A-Number present?3. Diameter of electrodes allowed?4. The range of weld metal t ?5. AWS Classification how about it?

You may remember from our previous lesson that A-Numbers cannot be correctly identified without Section II Part C of the ASME Code. So we can only check for its presence on the form.

Confusion Welding

Everything on the list is present, but is the Essential Variable F-Number correct? We can’t check the A-Number without Section II Part C.

Turn to Page 132 and look at the F-Numbers. Check the F-Number for E-7018 which appears under the title E-XX18.

Confusion Welding

Conclusions:

1. The F-Number is present but wrong!2. The A-Number is present.3. Diameter/Size of electrodes are missing!4. The range of weld metal t is present.5. AWS Classification is listed.

Confusion Welding

Now to the back of the WPS to the box QW-405 Positions.

1. Are the positions allowed for welding present?2. Has progression permitted been entered?

Since fillets are not on the list of QW-253 you may ignore this entry for the purposes of the test.

Confusion Welding

Conclusion:

1. The positions allowed for welding are present?2. Progression permitted has been entered?

There are no mistakes. However the positions allowed would have been better stated in actual practice by using Flat, Horizontal, Vertical and Overhead (F,H,V,O). 6G is a welder’s all positions qualification test.

Confusion Welding

Now Preheat in box QW-406.

1. Has Preheat Temp. been entered?2. Preheat Maintenance is it there?

Since Interpass Temp. is a Supplementary Essential you may ignore this entry for the purposes of the test.

Confusion Welding

Conclusion:

1. Preheat Temp. has been entered.2. Interpass Temp is present but was not required.3. Preheat Maintenance Temp. is missing!

There is one mistake. Preheat Maintenance Temp. is not present, this is an error by omission of a Non-Essential Variable.

Confusion Welding

Now Post Weld Heat Treatment in box QW-407.

1. Simple it is addressed as NONE.

We will check it against the PQR during the PQR review portion of this instruction.

Confusion Welding

Conclusion:

All we need do is to make sure it is in agreement with what occurred during the making of the supporting PQR test coupon. We will compare those during the PQR portion of this review.

Confusion Welding

Next up is the box QW-408 Gases.

This is not applicable to the SMAW Process. We will ignore it completely on this review.

Confusion Welding

Now for box QW-409 Electrical Characteristics.

1. Has the Current been entered?2. How about the Polarity?3. What about the Amps (I) ?4. Volts (E)?

Confusion Welding

Conclusion:

1. The Current has been entered.2. Polarity is there.3. Amps (I) are present.4. Volts (E) it is there.

No mistakes in block QW-409

Confusion Welding

Finally block QW-410 Technique

1. String or Weave allowed or both?2. Initial or interpass cleaning, how?3. Method of Back Gouging?4. Multiple to Single pass/side permitted?5. Peening, is it there?6. Manual or Automatic welding?

Confusion Welding

Conclusion:1. String or Weave both are allowed.2. Initial or interpass cleaning, addressed.3. Method of Back Gouging present.4. Multiple to Single pass/side, not addressed!5. Peening addressed as None Allowed.6. Manual/Automatic appears in the title.One mistake. Multiple or Single Pass an error by omission.

Confusion Welding

Now to the Front of the PQR and its title section.There isn’t much to see here. The correct company name etc., but the API Body of Knowledge specifies that the WPS will be supported by only one PQR and it will be the correct one. This leaves the welding Process which is addressed as SMAW. All others are non-essential variables and those are not required to be on the PQR, in fact they could be missing. Anything else in the title will fall under Editorial and is not considered on the exam WPS/PQR review questions.

Confusion Welding

Conclusion:

1. SMAW has been addressed, no mistakes in the PQR title.

Note: The PQR does not have to reference the WPS. A single PQR may support multiple WPS’ since WPS’ are often written years after the PQR was made. How could you know the WPS number years before it will be written?

Confusion Welding

We start all over using QW-253 and the box QW-402 Joints on the PQR, all of those are Non-Essential Variables and are not required on the PQR. Nothing to do here. The box is blank and that is not a mistake. Note: In a real world PQR, you would never leave the joint design information blank, in fact you would detail it, but Section IX clearly states that Non-Essentials are optional. However the Construction Code will usually force this information be present. For the PQR on this examination it is not required.

Confusion Welding

Using QW-253 in the box QW- 403 Base Metals, we check the following items:

1. Has the P-Number been addressed and does it agree with the WPS?

2. Has the thickness of test coupon been entered and does it support the full range stated on the WPS for production welding?

Confusion Welding

Conclusion:1. No P-Numbers listed!2. The thickness of the test Coupon is stated to be 0.500 but it does not support the full range stated on the WPS of 1/16” to 1”. There are two mistakes, No P-Numbers and the thickness range qualified by the coupon is not adequate for the WPS’ proposed thickness’.Turn now to QW-451.1 on Page 139.

Confusion Welding

Conclusion continued:We can see that the range supported by the coupon is from 3/16” to 2T. Our T is 0.500 so the range supported is from 3/16” to 1”. Look back to the front of the WPS, it states a range of 1/16” to 1”.

The entire range of thickness on the WPS is not supported by the PQR’s test coupon thickness, since it does not support a thickness below 3/16”.

Confusion Welding

One last thing to consider. What is the P-Number of SA-53 Grade B? What should have been entered in the P-Number boxes? Turn now to Page 69.

Confusion Welding

Turn your attention to box QW-404 Filler Metals.1.Has the F-Number been addressed and correctly?2. Has the A -Number been entered?3. AWS Classification, is it present?Note: Since Supplementary Essentials will not be on the exam, the AWS Class in this case is a Non-Essential Variable. By Section IX, it is not required on the PQR! Strange but true, it could be omitted and only the F-Number listed. Real world it would be there.

Confusion Welding

Conclusions:1. The F-No. for E-7018 is correct and is present.2. The A-No. is present.3. AWS Class is shown as E-7018.

No Mistakes!

Confusion Welding

Skipping the Non-Essentials of QW-405 Positions and turning to QW-406 Preheat we ask the following:

1. Preheat Temp, is it there and if so does it support the WPS values?2. Interpass Temp do we need it?

Confusion Welding

Conclusions:

1. Preheat Temp is there but does not support the WPS, the PQR must be within 100 o F of the WPS’ listed preheat for production which is only 60 o F. The PQR was qualified with a preheat of 175 o F ! To fix this you could revise the WPS to a minimum preheat of 75 o F (175 – 100 = 75 o F).Take a look at the paragraph QW-406.1 on Page 62 of Section IX.

Confusion Welding

Confusion Welding

Conclusions cont’d:

2. Interpass Temp is not there, but we do not need it since it is a Supplementary Essential.

One Mistake Preheat does not support the WPS.

Confusion Welding

Now the Postweld Heat Treatment.

1. Is it present and does it agree with the WPS’ Type, Temp and Time?

Confusion Welding

Conclusions:1. Well since the block is empty, there is only one conclusion. The Essential Variable PWHT has not been addressed. The block being empty does not mean it was not done, it may or may not have been postweld heat treated. How can anyone know for sure.One mistake, PWHT not addressed.

Confusion Welding

All the remaining blocks contain Non-Essential Variables and are blank.

They are not needed on a PQR so we will just pass those blocks and turn to the back of the PQR.

Confusion Welding

Next the Tensile Tests listed in the block QW-150.

1. Are the correct number of tension tests present?2. Is the math correct?3. Did the specimens fail at or above the Minimum stated in the rules of QW-153.1 for SA-53 Grade B?

Confusion Welding

Conclusions:

1. The correct number of tension tests are present, two.

2. The math is correct (using normal rounding).

3. The specimens did meet the Minimum stated by the rules of QW-153.1 for the SA-53 Grade B pipe.

Now confirm the above statements.

Confusion Welding

You can see on right that we need two tension tests.

By QW-152 area into load = Tensile Strength

Specimen No. 1

.750” x .453: = .340 sq.” 25010 lbs/.340 sq.” = 73,559 PSI

Specimen No. 2

.753” x .456” = .343 sq.”24,050 lbs/.343 sq.” = 70,116 PSI

Confusion Welding

Turn to page 69 of Section IX. The Minimum Specified Tensile Strength is 60,000 PSI.

Conclusions Continued:

3. The specimens did meet the Minimum stated in the rules of QW-151.3 for SA-53 Grade B. It has a minimum specified tensile strength of 60,000 PSI. According to the requirements of Section IX the specimens could have failed 5% below that and still been acceptable. They failed in the base metal which is also a requirement of QW-153.1

Confusion Welding

Now the Bend Specimens

1. Are the correct number present?2. Are they the correct types?3. Where the results reported and acceptable?

Confusion Welding

Conclusions:

1. The correct number is 4 and only three are fully present.

2. They are not the correct types, it should be all face and root bends (4 total), or since the coupon is at least 3/8” (.500) 4 side bends are permitted.

3. The results were reported and are not acceptable.

There are three mistakes, incorrect number and types of bend specimens, max size of defect

d 1/8”

Confusion Welding

Last, the bottom of the PQR.

1. Has the PQR been signed?

Conclusion: No.

This is a mistake a PQR is not certified without a signature.

Confusion Welding

Now we will do the second WPS/PQR review. We will go through this box by box and find the mistakes and do a recap at the end of this lesson.

Wee Welders

Mistakes on the WPS:

Joints (QW-402)

1. Root gap not addressed2. Retainers not addressed

Technique (QW-410)

3. Multi or single pass not addressed.

Mistakes on the PQR:

Filler Metals (QW-404)

4. E-8018 is not F-No. 3.

5. Weld metal thickness not addressed.

Mistakes on the PQR Cont’d:

Tensile Tests (QW-150)

6. First tensile specimen was not within the tolerance. The specimen failed at less than 95 % of the specified ultimate tensile strength for the material.

Guided Bend Tests (QW-160)

7. The test coupon is 0.365” and it must be 0.375 or greater to use side bends. The coupons should have been subjected to two face and two root bends.

Thank You

Asme Ix Binder

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