Weld Quality

Welding
Qualification
&
Certification

._._---~-----------~-------

------- --------- -- -------- ------- - ------_.~-------

.ecture 14 p1
Lecture ~3cope (

• Need for welding qualification

• Codes & standards requirements
- Welding procedure specifications
- Welding procedure qualification
- Welding operator qualification

• Company certification

_ _ _.• _ _. . _ _. -.l

----_ -
.. .. _--- -_. - - - - - - - _ .

- -_ -_. - - - - - -
.. -_. ----_.

p2
 Need IFor Weld Qualification

• Many variables influence weld quality, related to

the parts to be joined, the welding process and
welding operator skill
• The purpose of qualification is to demonstrate
that welding procedures and personnel are
adequately controlled and are capable of
acceptable results
• Such tests cannot foretell performance in
produc::tion. Quality of the production welds
should be determined by inspection during and
after the actual welding.

Lecture 14
 Codes & Standards (

• Application codes & standards that specify

qualification requirements for welding
include:
- ASME Boiler and Pressure Vessel Code

=~~~ ~~11 ~:~:~~i:e~~~~ Code ill~.~lft

- API 1104 Standard for Welding Pipelines and Related
Facilities
- eSA W59 Standard for Welded Steel Construction

• Standards for weld qualification

- AWS B2.1 Wt~lding Procedure and Performance
Qualification

--------------

14 p4
 Codes & Standards Requirements
• A common approach to qualify welding
procedures is by preparation and testing of
standard test pieces. The qualification tests
need not be repeated unless the welding
procedure specification is changed.
• Some' pressure vessel standards require test
plates to be welded at the same time as the
vessel seams and subsequently tested.
• Other standards accept certain welding
procedures as "prequalified"

lecture 14 pSi
 Welding I)rocedure Specification (
• Standards normally require the contractor to
prepare and qualify Welding Procedure
Specifications (WPS)
• A WPS should define the welding variables in
sufficient detail to ensure that the required
quality is met
• Standards differ with respect to the generality
or specificity of WPS
- Some standards are very specific in defining the content
of a WPS e.g. ASME Section IX. Other standards are
more general

--~---~- ------------------

---~----- ---------

e14 p6
 r------~----

Welding Procedure Specifications

-
Typical VVPS Contents

• scope • Joint preparation _

• Base metal • Welding details
• to simplify qualifications, • Welding positions
standards often group base
metals by similar composition or • Preheat & interpass
streng1h levels temperatures
• Welding process • Post weld heat treatment
• Filler metal and finishing
• Type of current and range
• Arc voltage
• Travel speed
• Heat input

--_._-------------

--~~-----------_._------------------------~

lecture 14 p7
 ASME Salmple WPS ( )

,14 p8
QW-482 1992 SECI10N IX

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174'
 NONMANQA~AI'Pl!NDIX A QW-482

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POSITIONS I _ I 5 ,. POSTWELD HEAT TREATME~ ~071
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Shtefding
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ELECTRICAL CHARACTERISTICS fO~t

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175
 WPS Clualification

• The pu rpose of qualification is to show that

weldin!~ in accordance with the WPS will-
produce sound welds with adequate
proper1~ies.

• The WPS qualification requirements are

specifil:!d by the applicable standard.
• Qualification may be achieved by:
1. Use of prequalified welding procedures
2. Qualification tests
3. Mock-up tests

L _

Lecture 14 p9
 -------------

WPS Qualification (

• Prequalified welding procedures

- The concept of prequalification is based on the reliability
of certain provl~n procedures as defined by the code or
standard (e.g. GSA W59, AWS 01.1)
- The contractor is nevertheless required to prepare WPS
documents and to accept responsibility for their use.
- Any deviation from the standard negates the prequalified
status

~~------------------ ------------------------

~~~ -------- ---

e 14 P 10
 WPS Clualification
-
• Prequalified weldinq procedures
~

• Qualification tests
- Qualifk~ation tests are intended to demonstrate that the
weldin!~ procedure results in sound welds with acceptable
mechanical properties
- Tests need not simulate the actual conditions for a given
job. They usually consist of conventional butt joints on
plates or pipes
- Base 2lnd filler materials, welding variables and heat
treatml~nts must follow production plans within specified
ranges.
- However, other variables such as joint geometry or
weldin!~ position might not be considered as qualification
variabl·es

lecture 14 P 11
1----- -------- -------------------,

WPS QUcllification (

• Prequalified welding procedures

• Qualification tests
• Mock-up te:sts
- Mock-up tests are intended to simulate actual production
or field conditions.
- Codes and standards do not require preparation of
welded mock-ups
- However, mc,ck-ups can help to anticipate or avoid
problems in production. They are also useful when difficult
access or other practical considerations may influence
results in-situ, such as repair welding of nuclear plants.

--------- ----- -----------------

--------- - - ---

P 12
 I Tests elf Qualification Welds
• Specimens are removed from the sample
welds for examination and testing
• The type and number of tests depend on the
require!ments of the particular standard
• Commonly specified tests include:
- tensile tests
- guided bend tests
- Charpy notch toughness tests, or other fracture
toughness tests such as drop weight tests
- macro-etch tests
- non-de,structive examination

L -------l

Lec:ture 14 p13
 Mechanic:al Test Specimens (
LONGITUDINAL WELD
SPECIMEN
IDENTICAL
DIMENSIONS

CHARPY. TRANSVERSE
~~ SPECIMEN

MINATURE ROUND
SPECIMENS DEPENDING ON T

------------ ------------- -----------

---~--- ------

!14 P 14
 1--- -----~--.--- . .- ------------------,

Face 8~ Root Bend Tests

FACE BEND

~~~~ROOT BEND
~ SIDE BEND

WELD JOINT

Lecture 14 P 15
 Guided Bend Test Jigs (
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e 14 P 16
 I
Charp:v Impact Specimen

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Lecture 14 p17
 ,------
Recordin!~ Test Results (

• The we1dinn conditions and the test results are

entered on a Procedure Qualification Record
(PQR)
• If the test re~sults meet the requirements of the
standard, the PQR is certified by the contractor
and the third-party inspector
• The WPS may then be issued for production

--------

314 P 18
 ,-----
I

ASME Sample PQR

Lecture 14 P 19
QW-483 1992 SEC110N IX

QW-483 SUGGESTED F(IRMAT FOR PROCEQU"E Ql.IAUFlc;ATlON RECORD WQR)

(SH QW-200.2. flection IX. ASME BciIIer end P _ , . V..... COde)
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176
Ii
 NONMANDATORY APPENDIX A QW-483

QW-483 (Back)

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Splc'men
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COeIaiI of reccHd of ........ illustrMive only and fNy be modified to conform to the iype and number of tescs required by the Code.'

177
 Changes in a qualified WPS (

• If a WPS is to be revised or modified beyond

the qualified ranges of the "essential variables"
it is necessary to do additional qualification
tests
• If the changE~s are within the qualified ranges of
essential variables, then a revised WPS can be
issued without requalification
• A PQR may support several WPS
• Since the PQR is a certified record of a
qualification test, it should not be revised.

~14 p20
 Welder Performance Qualification

• WeJder or welding operator qualification tests

are per1formed to determine the ability of the
persons tested to produce acceptable welds

. __ ._--_._-~------~----------

---_._-_._._---_._.- ---~. . __ . .

Lecture 14 p21
 Performance Qualification Req'ts (

• Most standards require each welder or welding

operator to make one or more test welds in
plate or pipe
• Variables that affect the ability of welders to
make sound welds are considered qualification
variables. These include:
- welding proc:ess
- filler metal
- welding position
- joint detail
- plate thicknElss
- welding tech nique

-- ------------'---
~------------------_._--

e14 P 22
 ,-------------------------------~

Standard Welding Positions - Plates

Te,st Position 1G Test Position 2G

Te!;t Position 3G Test Position 4G

~---

----------------

- - - - - - - - - - -------- - - - - - - - - - - - - - - - - - - - - - - -

-----------------------

Lecture 14 p23
,--------------

Welding Positions-Pipes (

~~.
-t;2J.J-.l16.
Tellt Position 1G

Test Position 2G

Test Position 6G

'--------~-~._---_. -_._~

-----_._-------------~_._----------------

p24

- - - - - -
 Perforrnance Qualification Tests
-
• Test spl 3cimens may be groove welds or fillet
welds
- groove weld qualification usually qualifies the operator to
weld bClth groove and fillet welds
- fillet weld qualification limits the welder to fillet welds in
only thEI position qualified or less difficult positions

• Tests consist of either bend tests, macro-etch

tests or radiography
• The we Ider who prepares a test plate for a
procedure qualification is usually qualified
within the variables in the WPS.

--------

lecture 14 p25
 Performan~::e Qualification Records (

• Responsibility for performance qualification

records lies with the employer
• After succe8sful qualification of a welder the
employer and third party inspector certify the
performancE~ qualification record.

• Most codes limit the duration of qualification to

three to six months inactivity
• For most codes qualification may be extended
indefinitely provided the welder performs
satisfactory work within the stated period

'----------- - - - ~ - - --~-------'
(

-~--------_._---- ----------

114 p26
 ---------- -----------------------,

CompClny Certification
• Some standards extend qualification to the
company's organisational practices
- ASME Boiler and Pressure Vessel Code
• requirE~ audit by ASME of a company's quality control program
before issuing a code symbol stamp for construction of
compcnents
• Sectiol1 III for nuclear components requires a quality assurance
program
-CSA WS9/W47.1
• requims employment of designated welding engineers and
welding supervisors, and preparation of welding standards and
WPS uudited by Canadian Welding Bureau
-ISO 9000
• generalized quality assurance program

Lecture 14 p27