ASME SEC IX Welding Procedure and performance qualification

Nitesh Garg

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 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.

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

Why P numbers?

Base Metal Classification

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,etc.,

Base Metal P Numbers

Examples of P numbers
P1 C Steel 1/2 Mo steels 1 Cr 1/2 Mo steels 2 1/4 Cr 1 Mo steels 13 Cr steel 17 Cr steel Austenitic StainlessSteel 2 1/2 Ni steels Mn - 1/2 Ni - V steels 9 Ni steels

P1 - P11 P21 - P25 P31 - P35 P41 - P47 P51 - P53 P61 - P62

Steel Al alloys Cu alloys Ni alloys Ti alloys Zr alloys

P3 P4 P5A P6 P7 P8 P9A P10A P11

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)
P. Number Group Number Specification Chemical Analysis & Mechanical Properties Thickness Range Pipe Diameter Range

P1/Group 1 Carbon Steel

Tubes Pipes Plates Forgings Castings
SA216WCA SA352LCA SA352LCB SA106GrB SA179 SA333Gr1 SA192 SA210GrA1 SA333Gr6 SA334Gr1 SA334Gr6 SA266CL1 SA36 SA515Gr55 SA350LF1 SA515Gr60 SA515Gr65 SA516Gr55 SA516Gr60 SA516Gr65

P1/Group 2 Carbon Steel

Tubes Pipes Plates
SA516Gr70 SA299

Forgings Castings
SA105 SA266CL2 SSA350LF 2 SA216WC B SA216WC C SA352LCC

SA210GrC SA106GC SA515Gr70

Other Specification Carbon Steel

Tubes
IS1239

Pipes

Plates

Forgings Castings

API5LGrB IS226 IS2062 BMC10 BMC16 BMC20

P3/Group 1

Mo (C MOLY STEELS)
Tubes
SA209T1

Pipes
SA335P1

Plates
SA204GrA

Forgings

Castings
SA217WC1

Cr Mo - P3 Group 2
Tubes
SA213T2

Pipes
SA335Gr2

Plates
SAA387Gr2

Forgings

Castings

P4/Group 1

1Cr Mo
Tubes
SA213T12

Pipes
SA335P12

Plates

Forgings

Castings
SA217WC6

SA387Gr12 SA182F12

1 Cr Mo
Tubes
SA213T11

Pipes
SA335P11

Plates

Forgings

Castings

SA387Gr11 SA182F11

P5A/Group 1 2Cr 1Mo

Tubes
SA213T22

Pipes
SA335P22

Plates

Forgings

Castings
SA217WC9

SA387Gr22 SA182F22

P5B/Group 1

5Cr Mo
Tubes
SA213T5

Pipes
SA335P5

Plates
SA387Gr5

Forgings

Castings

SA182F5 SA217C5 SA336Cl F5

9Cr 1Mo
Tubes
SA213T9

Pipes
SA335P9

Plates

Forgings

Castings

SA182F9 SA217C9 SA336Cl F9

P5B/Group 2 9Cr 1Mo V

Tubes
SA213T91 SA199T91

Pipes
SA335P91

Plates

Forgings

Castings

SA387Gr91 SA182F91

P8/Group 1 18Cr 8Ni

Tubes
SA213TP304 SA213TP304H SA213TP316 SA213TP321 SA213TP347 SA213TP347H

Pipes
SA376TP304 SA376TP304H SA376TP316 SA376TP321 SA376TP347 SA376TP347H

Plates
SA240TP304 SA240TP321 SA240TP347

Forgings
SA182F304 SA182F321 SA182F347 SA336F304 SA336F321 SA336F347

Castings
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 F2 E XX12, E XX13 F3 E XX10, E XX11 F4 E XX18 F5 ASS, Duplex SS F6 Bare rods

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

Filler Metal A Numbers

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

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

Gas(QW:408)

Gases Shielding Trailing Backing

Mixture %

Flow rate

(e.g. 75% Ar 25%CO2)

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 Applications

Spray transfer
High voltage & current

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 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 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 other parameters are kept same. A single WPS may 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 Tests (transverse bend) 2t 2T, 2 FB, 2 RB 2t -do2t -do2t if t<3/4 2T, 4 SB 2T if t>3/4 2t if t<3/4 -do8 if t>3/4 max t

<1/16 T - 2T 1/16-3/8 1/16 - 2T 3/8-3/4 3/16 - 2T 3/4-1.5 3/16 - 2T >1.5 3/16 - 8

Procedure Qualification Thickness limits T Range of T max t Tests (longtl bend) 2T, 2 FB, 2 RB -do-do-

<1/16 T - 2T 2t 1/16-3/8 1/16 - 2T 2t > 3/8 3/16 - 2T 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 maintenance Change in current or polarity Change in string/weave, cleaning, back gouging, peening, manual/automatic

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

WPS for 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 SA106 Gr B SA106 Gr B 1 Thickness:

to Base Metal P or S-number

Welding Process(es) used: Plate X

GTAW followed by SMAW

Pipe (enter diameter if pipe or tube): NPS 2, Sch 80 Single Vee None / Weld metal

Groove type (Single V, Double V, Single U, etc): Initial cleaning method: Solvent wipe and grinding Backing (metal, weld metal, backwelded, etc): Filler Metal (SFA) Specification: 5.18 / 5.1 Filler Metal or Electrode Classification: Filler Metal or Electrode Trade Name:

ER70S-2 / E7018 Linde 65, Lincoln 7018+

Tungsten electrode type and size for GTAW: EWTh-2, 3/32" Consumable Insert Class and size for GTAW or 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: Progression (Uphill or Downhill): 5G

Uphill GTAW / downhill SMA

Interpass cleaning method:

Wire brushing less than 400

Measured interpass temperature (F):

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

Visual Examination of Completed Weld: Bend Test X

Acceptable

Date of Test:

12/25/01

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

Side (QW-462.2)

Type Face Face

Result

Type

Result Root Root

Type

Result

Acceptable Acceptable

Acceptable Acceptable

Alternative Radiographic Examination Results: Specimens Evaluated By: Company Ever Welding Supervised By: Welders Name: Dianna Ross James Brown

N/A Company: Company: A1 The Best Testing Joe-Bob's B&NPW Shop

Title: Leader Title Soloist Stamp No:

Wolfgang Amadeus Mozart

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 requirements 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 Horizontal

Fillet welding of plate

3F Vertical 4F 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 & without backing, F1 with backing with backing F1, F2 & F3 with backing without backing F3 with & without backing, F1, F2 with backing with backing F1, F2, F3 & F4 with backing without backing F4 with & without backing, F1, F2, F3 with backing with backing F1 & F5 with backing without backing F5 with & without backing, F1 with backing

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

plate and pipe A change in welding position from that qualified 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 & pipe >24 OD Pipe of OD 2 7/8 - 24 Fillet

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

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

Welders Performance Qualification

Weld Plate & pipePipe of OD Fillet >24 OD 2 7/8 - 24 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 Plate & pipe >24 OD F F, H F, V, O All All Pipe of OD 2 7/8 - 24 F F, H F, V, O All All Fillet

Pipe Pipe Pipe Pipe Pipe

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

F F, H All All All

Welders Performance Qualification Weld Plate & pipe >24 OD Pipe of OD 2 7/8 - 24 Fillet

Pipe Pipe Pipe Pipe Pipe

1F 2F 2FR 4F 5F

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 >3/8 >1/2 Max tk of dep. Metal Test 2t 1FB, 1RB 2t 1FB, 1RB Max to be welded 2SB Range of OD qualified Size welded - unlimitd 1 - unlimited 2 7/8 - unlimited

OD of test coupon <1 1 - 2 7/8 > 2 7/8

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.

Welder Performance Qualification (WPQ)

Materials
The purpose of this test is to determine the welders ability to deposit a sound weld therefore the base material is not considered as critical as it is in the PQR. Hence a performance test on any material in P groups 1 to 11 approves all those groups and sub groups, also P34 and P4X (P40-P49). Providing a compatible consumable exists with the same F number used in the qualification test. Note a single sided weld is classed as a weld without backing and a double sided weld or weld with sealing run is classed as a weld with backing

Consumables
The F number cannot be changed without re qualification of the welder except that for performance qualification only using SMAW F numbers up to and including 4 approve all lesser F numbers for double sided or welds with backing only.

Variables
For each welding process there is a list of essential variables in QW352 to QW357 and QW360 for welding operators, these are not necessarily the same as the ones for the PQR. Essential variables cannot be changed. Explanations of all these variables is given in section IV of the code.

Diameter and Thickness Ranges

Diameter limits for all circular welds including groove welds, branch welds and fillet welds is given in QW452.3. there are no upper limits on diameters approved and pipe covers plate . Thickness limits, groove welds. The thickness limit only applies to the deposited weld metal thickness not the plate thickness and any groove weld approves all fillet weld sizes. For t greater than 12.5mm there is no restriction on the size that can be welded
Welder Performance Qualification (WPQ)

Thickness limits, fillet welds.

A test on plate greater than 3/16" approves all base metal thicknesses and fillet weld sizes ref. QW452.5. (Note the above diameter limits apply unless the fillet weld is qualified by a groove weld)

Joint Configuration
Joint geometry, a double V (or U) is considered the same as a joint with backing and does not qualify a single V (or U) without backing, but a single full penetration joint without backing qualifies all joint configurations.

Approval Range
Extent of approval is very well explained in QW461.9. Take particular note of welding positions which are also explained in QW461, for example to qualify a fillet weld in the normal horizontal-vertical position with a groove weld, the groove weld must be qualified in at least the 2G position. The welding positions defined in QW461.1.& QW461.2 should be referred to in the WPS. The position designations: 1G ,2G ,3G ,4G ,5G ,6G (Groove Welds) and 1F ,2F ,3F ,4F (Fillet Welds) are test positions
Welder Performance Qualification (WPQ)

Welder Performance Qualification (WPQ) Period of Validity/Renewal of Qualifications (QW 322.2)

Providing the welder uses the process for which he is qualified and there is no reason to question his ability then his qualification lasts indefinitely. If the welder does not use the welding process for which he is qualified for a period of 6 months or more then he must perform a new test in pipe or plate, any parent material, thickness and position, if successful all the welder approvals for that welding process are renewed in one test.

Testing Requirements
Test requirements for groove welds QW452 consists of either:One face bend and one root bend except for welding positions 5G & 6G which require 4 bends (Ref QW452.1 Note 4). If the plate exceeds 3/8" side bends may be used. See QW 466 for precise details and exceptions. Note:- Bend Tests can in most cases be replaced by Radiography Radiography is optional and must be supplemented by bend tests when using GMAW (MIG/MAG) with dip transfer (Short Circuiting Arc) or when welding some special materials. Ref. QW304. Note:- Ultrasonic Examination in lieu of Radiography is not permitted

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

Test requirements for fillet welds in plate ref.

QW452.5:One macro section (QW 184) and One fracture test (QW182). The location where each specimen has to be taken is defined in QW463

Radiography Ref QW 191

A length of at least 6" must be examined for plate or the entire circumference for pipe. If the pipe circumference is less than 6" then more samples must be welded up to a maximum of 4. Ref QW 302.2.

Visual Examination Ref QW 302.2 & QW 190

Performance test coupons must show complete joint penetration with full fusion of the weld metal and base metal. The welder performance test must follow a properly qualified W.P.S. Once qualified the welder must always work within the extent of approval of any properly qualified W.P.S. and his W.P.Q. The welder who qualifies the P.Q.R. is automatically approved within the limits specified in QW304, QW305 and QW303.

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 No open discontinuity > 1/8 in any direction In accordance with the section

Bend test

Impact test

Tests for Qualification

Radiography No crack or LOP or LOF Any elongated slag >1/8 for t <3/8 1/3 t for t 3/8 - 2 1/4 3/4 for t>2 1/4 Any group of slag in a line with aggregate length t in 12 t unless separated by 6L Max permissible dimension for rounded indication smaller of 20% of t or 1/8 For thickness<1/8 , max no of accepted rounded indication 12 in 6 length For thickness>1/8 , charts for max acceptable types of rounded indication

C. R. Ratheeskumar ACTUAL VALUE FCAW(S) 8" 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 6 Upto Max to be weld RANGE QUALIFIED FCAW(S) 2 7/8" & Above

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

2 7/8" & Above

P 1 - P 11 With backing 6 Upto Max to be welded All Positions Down Hill NA DC Electrode Negative

Accepted NDT / 250A / 03 NA NA NA NA Welding Research Institute, BHEL, Trichy, India. NA

ASME BPV Code Section IX. Welder Identity Card issued

Dt.23.2.04.

Steps involved in qualifying the welding process & welder/ operator

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

Steps involved in qualifying the 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 WPS is usable for an indefinite 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

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 (CS or AS) Change in base metal to be welded 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

QW

484 Welder Performance Qualification [WPQ]

Employer : TVS Motor Company, Mysore Welder s Name : Lakshmana Emp.No : M1829 Testing Conditions and Qualification Limits

Test Description
Specification of base metal Plate -----SA 414----------- Thickness ---------1.6mm --------Plate Plate

Pipe [enter dia if pipe]

Welding Variables (QW

350)

Actual Values GMAW Semi auto Nil SA 414 to SA 414 AWS A5.18 E70S 6 6 Solid wire 2F,3F Downhill Short Circuit Transfer 1.6mm

Range Qualified GMAW Semi auto Nil SA414 to SA 414 AWS A5.18 E70S - 6 6 Solid wire 1F,2F and 3F Downhill Short Circuit Transfer 0.8 to 3.2mm

Welding Process ( es ) Type [ie;manual, semi auto] Backing [metal, weld metal etc] Base metal P Number to P Number Filler metal specification (S) Filler metal classification (S) Filler metal F Numbers Filler type (Solid / flux cored) Position Qualification (2G, 2F etc ) Vertical Progression(Uphill or Downhill) Transfer Mode Thickness

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