Asme Section IX Educational Series
Asme Section IX Educational Series
Asme Section IX Educational Series
The first thing to look at is whether your weld joint is large or small, whether the joint is out-of-position or not, and whether the base metal is thick or thin.
In welding, the needs of any joint are expressed in four terms: Fast-Fill (high deposition rate), Fast-Freeze (the joint is out-of-position - overhead or vertical), Fast-Follow (high arc speed and very small welds), and Penetration (the depth the weld penetrates the base metal)
Fast-Follow suggests that the molten metal follows the arc at rapid travel speed, giving continuous, well-shaped beads, without "skips" or islands. This trait is especially desirable on relatively small single-pass welds, such as those used in joining sheet metal. Penetration varies with the joint. With some joints, penetration must be deep to provide adequate mixing of the weld and base metal and with others it must be limited to prevent burnthrough or Cracking.
Information (on the deposition rate and arc-speed characteristics of each process from literature)on the ability of various processes to fulfill the needs of the joint
Volume of Production Weld Specifications Operator Skill Auxiliary Equipment Accessory Equipment Base-Metal Conditions Arc Visibility Fixturing Requirements Production Bottlenecks
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.
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.)
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.)
Joints(QW:402)
Why P numbers?
To reduce the number of welding procedure qualifications, base metals have been assigned P-nos and for ferrous base metals which have specified impact test requirements, group numbers within P-nos are again given P nos depend on composition, weldability & mechanical properties. Group nos classify metals within P nos for procedure qualification where notch toughness requirements are specified. The above assignments do not imply that base metals can be substituted without consideration of metallurgical properties,etc.,
P1 - P11 P21 - P25 P31 - P35 P41 - P47 P51 - P53 P61 - P62
Base Metal(QW-403)
P. Number Group Number Specification Chemical Analysis & Mechanical Properties Thickness Range Pipe Diameter Range
Forgings Castings
SA105 SA266CL2 SSA350LF 2 SA216WC B SA216WC C SA352LCC
Pipes
Plates
Forgings Castings
P3/Group 1
Mo (CMOLY 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
Pipes
SA335P22
Plates
Forgings
Castings
SA217WC9
SA387Gr22 SA182F22
P5B/Group 1
5Cr Mo
Tubes
SA213T5
Pipes
SA335P5
Plates
SA387Gr5
Forgings
Castings
9Cr 1Mo
Tubes
SA213T9
Pipes
SA335P9
Plates
Forgings
Castings
Pipes
SA335P91
Plates
Forgings
Castings
SA387Gr91 SA182F91
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
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
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%)
Preheat(QW:406)
Preheat temperature (Minimum) Interpass temp.(Maximum) Preheat maintenance
PWHT(QW:407)
Temperature range Time range Thickness range
Gas(QW:408)
Mixture %
Flow rate
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
Globular transfer
Medium voltage & current Applications
Spray transfer
High voltage & current
Techniques(QW-410)
Stringer or Weave Bead Orifice/Gas Cup Size Initial or Interpass Cleaning Method of Back Gauging Oscillation Contact Tip to Work Distance Multiple or Single Pass Multiple Or Single Electrode Electrode Spacing Peening Others
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
Procedure Qualification Thickness limits T Range of T max t Tests (longtl bend) 2T, 2 FB, 2 RB -do-do-
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:
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:
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
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
Acceptable
Date of Test:
12/25/01
Side (QW-462.2)
Result
Type
Type
Result
Acceptable Acceptable
Acceptable Acceptable
Alternative Radiographic Examination Results: Specimens Evaluated By: Company Ever Welding Supervised By: Welders Name: Dianna Ross James Brown
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 welders qualification is to determine the welders ability to deposit sound weld metal. The purpose of performance qualification test is to determine the welding operators mechanical ability to operate the welding equipment.
3F
Vertical
4F
overhead
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
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
F F, H F, H, V F, H, O All
Welders Performance Qualification Weld Plate & pipe >24OD F F, H F, V, O All All Pipe of OD 2 7/8 - 24 F F, H F, V, O All All Fillet
1G 2G 5G 6G 2G + 5G
Welders Performance Qualification Weld Plate & pipe >24OD Pipe of OD 2 7/8 - 24 Fillet
1F 2F 2FR 4F 5F
F F, H F, H F, H, O All
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
Welders Performance Qualification Test coupon More than 2 welders different procedure can do a single test coupon. Failure then both are failed. Retest - 2 consecutive test coupons to pass Renewal if no welding for 6 months. Single test coupon plate/pipe, any thickness, material, position. If passed then complete previous qualification is restored.
Welders Performance Qualification Variables for SMAW Removal of backing Change in Pipe diameter Change in P number Change in F Number Change in thickness of weld deposit Change in welding position
Bend test
Impact test
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 W ith 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
P 1 - P 11 W ith backing 6 Upto Max to be welded A ll Positions Down Hill NA DC Electrode Negative
Dt.23.2.04.
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
Case study
Objective : To develop a WPS for pipe to pipe butt joint( dia. 406 * 12mm) of SA 106 GrC SA106 GrC as per ASME sec IX Requirement of mechanical property: Impact toughness at room temperature Tensile strength
Joints(QW:402)
Base Metal(QW-403)
P. Number Group Number Specification Chemical Analysis & Mechanical Properties Thickness Range Pipe Diameter Range
Filler Metals(QW-404)
AWS Number SFA Number F. Number A. Number
Size of Filler metal Flux trade name Consumable insert Electrode flux class
Welding test positions are defined differently for plate and pipe
Welding position(QW-405)
Preheat(QW:406)
Preheat temperature Min Interpass temp.(Max.) Preheat maintenance
PWHT(QW:407)
Temperature range Time range Thickness range
Gas(QW:408)
Gases Mix % Shielding Trailing Backing Flow rate
Electrical Characteristics(QW-409)
Current (AC/DC) Polarity (EP/EN) Amps & Volts W-Electrode type & size Mode of Metal Transfer Electrode Wire Feed Speed range Pulsing Current
Techniques(QW-410)
Stringer or Weave Bead Orifice/Gas Cup Size Initial or Interpass Cleaning Method of Back Gauging Oscillation Contact Tip to Work Distance Multiple or Single Pass Multiple Or Single Electrode Electrode Spacing Peening Others
Filling up of WPS-Joints(QW:402)