Presentation Asme Sec-Ix Wps PQR Wpq..
Presentation Asme Sec-Ix Wps PQR Wpq..
Presentation Asme Sec-Ix Wps PQR Wpq..
ASME Sec IX
WELDING PROCEDURES
and
WELDERS QUALIFICATION
WELDING QUALIFICATIONS
Why Procedure Qualification required?
DESIGN REQUIREMENT :
• Mechanical strength and Chemical composition of Material at
intended Pressure and temperature.
Part QB (Brazing)
6
ASME SEC IX CODE INTRODUCTION
LIMITATIONS:
1.To be referred only when the design code (such as SEC VIII div.1),
cross-refers to this section
5. Does not specify the acceptance criteria (i.e. types and extent of
discontinuities acceptable).
WPS
• Written document showing all the applicable welding variables
• Provide direction for making production welds which will meet
code requirements.
WELDING VARIABLES
• ESSENTIAL VARIABLE: significant effect on the weld properties if
changed
• NON-ESSENTIAL VARIABLE: N0 significant effect on weld
properties if changed.
• SUPPLEMENTARY ESSENTIAL VARIABLE: When other Sections
specify notch-toughness tests and are in addition to the essential
variables
• Section has two parts : welding and brazing. [UW & UB]
• Under Welding there are 4 chapters (Article I to V), in addition to
initial introduction.
Article I: General.
• Positions of welding
• Examinations (Various Types of Tests, Testing Procedures,
Specimen Details, Acceptance Criteria) etc.
• WPQ
• List of Variables
• Qualification ranges
• Type and number of examinations required
Article IV –
• Compiled welding data meant for using with articles I, II,
III
Hence, for example, one who wants to qualify a welder can directly
refer article III.
UNDERSTAND ASME SEC. IX REQUIREMENTS
Article V – Standard Welding Procedure Specifications (SWPs)
• Useful for small manufacturers, whose knowledge of welding is miniscule
• SWPSs will have to purchase them from AWS
• Instead of performing more PQR tests, manufacturer to perform and document a
demonstration weld following a typical SWPS.
• Manufacturer to demonstrate and document that he knows enough about welding to
follow the SWPS.
• After welding and testing one demonstration coupon, many other SWPSs may
typically be used without further demonstrations.
• Not permitted for construction where impact testing of the WPS is required
• The specific requirements of SWPSs are covered in Article V (i.e., QW-500)
• Sample form (QW 485) is demonstrated in non mandatory Appendix B.
• The permitted SWPSs are listed in Appendix E
• These SWPSs cover welding of P-1 and P-8 metals using SMAW, GTAW and GMAW-
FC.
• Typical thickness ranges permitted are 1/8” to 1-1/2” and both as-welded and post
weld heat treated procedures (for P-1 metals) are available
UNDERSTAND ASME SEC. IX REQUIREMENTS
Important points for reading the welding data:
• Never read the welding data given in article IV unless called
upon to do so by articles I, II or III
• Normally adding "a new qualification shall be done when
…" before reading data against essential variable given in the
tables of Article II and III (such as QW 253), makes the reading
easy
• Normally adding "a new qualification is not required when
…" before reading the data against non-essential variable
given in the tables of article II (such as QW 253), makes the
reading easy
UNDERSTAND ASME SEC. IX REQUIREMENTS
•“Match" the base metal properties; ( Ys & UTS are expected to meet or
exceed the minimum specified properties)
• Depending on the type of weld joint and loading, lower filler metal
strengths may be acceptable or desirable for specific designs.
• The selected filler metals shall have proper preheat and inter
pass temperatures
Table 1: Carbon and Low-Alloy Steel Welding Consumables for SMAW Process
UNDERSTAND ASME SEC. IX REQUIREMENTS
Legend:
A AWS A 5.1 Classification E 70XX low hydrogen (E7018 preferred)
B AWS A 5.1 Classification E6010
C AWS A 5.5 Classification E70XX - A1, low hydrogen
D AWS A 5.5 Classification E70XX-B2L or E80XX-B2, low hydrogen
E AWS A 5.5 Classification E80XX-B3L or E90XX-B3, low hydrogen
F AWS A 5.5 Classification E80XX-B6 or E80XX-B6L, low hydrogen
G AWS A 5.5 Classification E80XX-B7 or E80XX-B7L, low hydrogen
H AWS A 5.5 Classification E80XX-B8 or E80XX-B8L, low hydrogen
WRITE A WELDING PROCEDURE SPECIFICATION
CONTENTS OF WPS
FORMAT OF WPS :
• May be written in any format suitable to the
manufacturer.
Up to 9 mm Thickness
- Transverse Tensile :– 2 No
- Root Bend :- 2 No
- Face Bend :- 2 No
@
Root Bend £ £ Face Bend
When Pipe Thickness is 19 mm or more, In place of Root & Face, 4 Side Bends
shall be Taken
“Reduced Section” Tensile Specimen
From Pipe QW 462.1
19 mm
6 mm
25 mm R
Original Thickness
M/c ed from all 4 sides
Acceptance Criteria for Test Results
Tensile Strength (QW - 422) (QW 153)
Welding procedure
Following parameters governs in the selection of thickness
•Test coupon thickness - governs the range
• Impact requirement - governs the lower limit
• Normalizing requirement - governs the upper limit
Welders qualification
One must preferably qualify a welder with a coupon of 13 mm
thickness or more which will qualify him to weld deposit of any
thickness.
THICKNESS LIMIT FOR GROOVE BUTT WELD
PROCEDURE
QW451
Appendix I
Ideally one must start with tables such as QW-253/256, proceed to welding
data such as QW-403.8 (as specified in the tables) and then proceed to QW-
451(as specified in the data) and select the thickness in such a way as to
cover the largest range.
Process (assumption)
-2 layers (root and hot pass t=5 mm) of
GTAW and rest by SMAW (fill-up and
final).
-Thickness 16 mm (Case I) & 32 mm (Case II)
THICKNESS LIMIT FOR GROOVE BUTT WELD
PROCEDURE
QW451
Step 1: Start with thickness same as the job.
Heat treatment - Normalizing
But, code does not permit dissimilar thickness for the Min. design
temperature. - 48ºC test coupon
QW451
Reference Thickness
T of base metal t of weld metal, max
Result 16 35 5.5 @ 30
THICKNESS LIMIT FOR GROOVE BUTT WELD
PROCEDURE
QW451
One must note that the step 3 gives us the largest range. One may, however, choose any
thickness higher than 32 mm, but this would not yield any additional benefit due to the
presence of normalizing in the job requirement in this example.
Additionally QW407.2 indirectly restrains us from choosing a thickness varying too much
from that of job.
What happens when a production weld has two dissimilar metal thicknesses?
This shall be arrived at in two steps
1. Thickness of the thinner member shall be as permitted by QW-451
2. Thickness of the thicker member shall be
i. Unlimited for specified material provided
a) material are of same P number.
b) qualification is made on >¼”
ii. limited within the range of QW-451
PROCEDURE QUALIFICATION
Group of Supplementary
Brief Of Variables Essential Nonessential
Variables Essential
QW423 and QW424 describe the rules for using the P numbers for
qualifications. With the help of P numbers the number of qualification tests
required are greatly reduced. For example all plain carbon steels (SA105,
SA106, SA515, SA516 etc.) are assigned a P number of 1.
In the WPS it is enough if only P number and group number are specified.
When they are not known, material specification shall be written (ex.. if base
material IS2062). When specification also is not known, chemical composition
shall be written. The latter options actually reduce the range qualified
S – NUMBER GROUPING
Base Metal For Qualification
S Numbers
S-Numbers: Assigned to materials that were
acceptable for use by the ASME B31 Code for
Pressure Piping, or by selected Boiler and
Pressure Vessel Code Cases, but which were
not included within ASME Boiler and Pressure
Vessel Code Material Specifications (Section II).
P – NUMBER GROUPING (SAMPLE : CS)
Base Metal For Qualification
Group
P- No Met. Spec. Grade Met. Quality & Form
No
Group Met.
P- No Grade Met. Quality & Form
No Spec.
Group
P- No Met. Spec. Grade Met. Quality & Form
No
3/19/2018
P – NUMBER GROUPING (SAMPLE : Ni based LTCS )
Base Metal For Qualification
Group
P- No Met. Spec. Grade Met. Quality & Form
No
Group Met.
P- No Grade Met. Quality & Form
No Spec.
F number
• Grouping of electrodes and filler materials
• Based on their usability characteristics
• Governed by flux or shielding medium used (which also govern
their electrical characteristics).
• F stands for Filler metal.
•These are described in QW430 / QW 432
F – NUMBER GROUPING
Filler Metal For Qualification
- Provide Run in & Run Out Coupons on plate & Fix the
Test Coupon In In Any One Of The Positions To Be
Qualified.
Discard Discard
<19 mm
300 mm
( 150 mm Minimum)
Welder Qualification
Location of Test Specimens From Test coupon – QW463.2
Plates thickness 19 mm or more.
Discard Discard
Balance Material *
300 mm ≥19
mm
( 150 mm Minimum)
WELDER QUALIFICATION
Location of Test Specimens From Test coupon – QW463.2
Pipe in 5G or 6G position
£ £ Root Bend
Face Bend
337.5˚ 0˚
Root Bend = 5G Weld
50˚ = 2G Weld
Face Bend
292.5˚
Face Bend Pipe is welded in Horizontal
270˚Welded in 5G
fixed position
Welded in 2G 90˚
270˚ 90˚
Root Bend
247.5˚
Root Bend
130˚
QW 402
Deletion of Backing + + + +
Joints
QW 403 Change in Pipe Dia. + + + +
Base Metal Change in P Number + + + +
Deletion /Addition of FM --- --- --- +
Change in F Number + + + +
Dele. /Addi. of Consumable --- --- --- +
QW 404 Insert
Filler Metal
Solid – Metal/Flux Cored --- --- --- +
Change in t deposit Qualified + + + +
“t” deposit for Short Cir.Transfer --- --- + ---
WELDER PERFORMANCE QUALIFICATION
Welding Variables- Qw 416
Essential Variables
Group of
Brief Of Variables SMAW SAW. GMAW GTAW
Variables
QW -353 QW-354 QW-355 QW-356
• RECORD OF TESTS :
The record of WPQ contain
• Reference WPS
• Personal details of the welders,
• Essential variable
• Type of tests, and test results
•Range qualified
WELDER PERFORMANCE QUALIFICATION
FORMAT QW 484 (Cont......)
• A welder may be qualified as under.
i) A welder may weld a test coupon using
previously qualified WPS.
• Pre-heating or post-heating , PWHT required by
WPS may be omitted
• Specimens required for mechanical test shall be
removed from test coupon and will be tested.
• All the results should meet the requirements as
mentioned earlier.
ii) A test coupon, minimum length of which should
be 6" in case of plate and entire circumference of
pipe (min 6”) shall be radiographed.
WELDER PERFORMANCE QUALIFICATION
FORMAT QW 484 (Cont......)
WPS/PQR
• A procedure qualified using plates can be used for welding the pipes,
provided the P number - Group number criteria is met.
• A procedure qualified in any one position can be used to weld in any other
position provided job specifications do not specify impact test.
• A procedure qualified using grove welds can be used for fillet welds of any
size.
• One must always carry out impact testing at the lowest possible temperature,
in the procedure qualification test. This can be used for the jobs having impact
requirement or not
IMPORTANT POINTS FOR WPS/ PQR &
WPQ
• Technically, a procedure qualification test, which has failed to meet the
RENEWAL OFstrength
required tensile QUALIFICATION:
can be used for jobs with materials of lower
strength. For example, if the tensile test results showed a value of 65 ksi
when tested with a coupon material of SA516 Gr.70, E7018 electrode, on
normalizing can be used for welds made on equipment of SA516 Gr.60,
provided, all other parameters remain same
• The format recommended by Sec IX, commonly used for WPS/ PQR, is
common for processes SMAW, GTAW, SAW and GMAW. Hence, one must be
careful when using them, since, some of the points are not applicable for
some processes.
IMPORTANT POINTS FOR WPQ
• Normally a welder can be qualified using only a radiographic test. In
RENEWAL
GMAW, welderOF whoQUALIFICATION:
welds with short circuiting method shall be qualified with
bend tests only.
• A small diameter pipe requires more skill for welding. Hence, a welder
qualified on lower diameters can always weld higher diameters (plate is a
pipe with infinite diameter).
ASME Sec IX WELDING VARIABLES
Variables for WPQ
F Number Qualification For Welders
F NUMBER QUALIFICATION FOR WELDERS
PERFORMANCE TEST QUALIFICATION
RANGE
PERFORMANCE TEST QUALIFICATION
RANGE
PERFORMANCE TEST QUALIFICATION RANGE
PERFORMANCE TEST QUALIFICATION
RANGE
PERFORMANCE TEST QUALIFICATION RANG (P numbers)
Distortion & Residual Stress – The Problems
External Defects --- UNDERCUT
Undercut
A groove or channel formed in the parent metal at
the toe of the weld. (Fig 1, 2 & 3)
Under cut
UNDERCUT
OVERLAP
An overlap occurs when the molten metal from the
electrode flows over the parent metal surface
without fusing into it.
Overlap
OVERLAP
SPATTER
Small metal particles which are thrown out of
the arc during welding along the weld.
• ••
SPATTERS
EDGE OF PLATE MELTING OFF
Edge of plate melted off in lap and corner
joints only.
INCOMPLETE FUSION
UNDERFILL
EXCESSIVE CONVEXITY
EXCESSIVE CONCAVITY
EXCESSIVE WELD REINFORCEMENT
UNDERFILL
UNACCEPTABLE WELD PROFILE WELD PROFILES
POROSITY (PIN HOLES)
Blow hole or gas pocket Or group of pin holes on
the surface or inside of the weld caused by gas
entrapment.
POROSITY
Craters
Porosity
CRACK
A hairline separation exhibits in the root or
middle or surface of the weld metal or parent
metal.
CRACK
Crack which is visible on the surface is called a surface crack
and a crack which can only be detected by radiography or
fracturing, say by nick break test, is called Internal crack.
SURFACE
CRACK
INTERNAL DEFECTS
Incomplete
penetration
Failure of weld metal to reach the root of the
joint .
INCOMPLETE / EXCESS PENETRATION
Incomplete penetration
Excess penetration
INCOMPLETE ROOT FUSION
REASONS
C - Misplaced welds
C
Degree of undercut.
1 The Code user should use the same name that the Code user has in the quality
control manual
2 after the company name entitled “By:”. This was intended to be for the Code user's
authorization or certification to use the WPS
3 There are no rules in Section IX for a WPS numbering system. A good quality
program, however, should require a unique identification be assigned for each WPS.
4 The date that the WPS was certified or authorized in 2 is normally used in this space.
5 QW-200.1(c) allows changes to be made to a WPS provided such changes are
documented by revision or amendment. When a WPS is amended it should be
documented including a revision level.
6 The revision or amendment should be dated on the WPS per QW-200.1(.c)
7 The revision or amendment should be certified or authorized as detailed in 2. (Table
5.1, WPS # 134, listed the revision level at the top in the company identification block).
HOW TO WRITE A WPS FORMAT
8 QW-200.1(b) requires the WPS to reference its supporting PQRs. The supporting PQRs are normally noted in this
identification block. (Note: It may take more than one PQR to support all the essential variable ranges specified in a
WPS.)
9 The welding process is not listed as an essential variable in QW-253 , but is noted as an essential
variable in QW-401.
10 QW-410.25 is a nonessential variable “type of process”, that must be described on the WPS.
The type of welding is normally noted with the welding process,
Welder or Operator Process Type
Comments
Welder SMAW, GTAW Manual Hand held torch / Electrode holder
Welder GMAW, FCAW, Semi-automatic wire fed hand held torches
Welding Operator GMAW, FCAW,GTAW, SAW Machine
adjustments can be made by welding operator
Welding Operator GMAW, FCAW, GTAW,SAW Automatic
No adjustment by operator
11 There is no specified requirement for a description of what the WPS covers, but these
descriptions are very helpful after the Code user has established a procedure qualification
program with multiple WPSs. When a Code user has prepared dozens of WPSs, they all begin to
look alike. A brief description may prove to be very beneficial when retrieving or assigning WPSs.
(Table 5.1, WPS # 134 noted “For welding carbon steels with E6010 & E7018 without PWHT, (not
qualified for notch-toughness or impact tested applications.”)
HOW TO WRITE A WPS FORMAT
HOW TO WRITE A WPS FORMAT
QW-253 WELDING VARIABLES PROCEDURE SPECIFICATIONS
(WPS)
SHIELDED METAL-ARC WELDING (SMAW)
.10 φ Root NE
spacing
.11 ± Retainers NE
When preparing the WPS, it does not matter if the variable is essential
or nonessential. The WPS must address each variable listed for the
process. QW-402.1 may be addressed by stating on the WPS which
types of grooves may be used with the WPS.
HOW TO WRITE A WPS FORMAT
Joint Design (QW-402)
Weld Type: Groove and fillet welds
Joint Type Backing Root Opening Groove Angle Root Face Groove Radius
Single-V groove No backing 3/16" max 50 deg min 1/8" max
Single-V groove Gouged & back welded 1/4" max 50 deg min 3/16" max
Double bevel Gouged & back welded 1/4" max 45 deg min 3/16" max
Double-V groove Gouged & back welded 1/4" max 45 deg min 3/16" max
Fillet Welds: All fillet sizes on all base metal thicknesses and all diameters. Retainers: None
WELD JOINT DESCRIPTIONS SHOWN ARE NOT INCLUSIVE OF ALL THOSE FOUND ON A JOB. WELD JOINT DESIGN
REFERENCE IN AN ENGINEERING SPECIFICATION OR A DESIGN DRAWING SHALL TAKE PRECEDENCE OVER WELD
JOINTS SHOWN IN THIS WPS.
HOW TO WRITE A WPS FORMAT
Example: Groove details may also be specified by reference on the
WPS to:
• production drawings
• fabrication plans
• shop sketches
•• welder
•• inspector (Code user’s)
•• supervisor
• Authorized Inspector (AI, NBCI, or API 510 Inspectors)
HOW TO WRITE A WPS FORMAT
HOW TO WRITE A WPS FORMAT
to P-No. 1 Gr No: 1 & /or 2 Thickness Range: 0.0625 in. to 0.1660 in.
BASE METAL (QW-403)
MATERIAL SPECIFICATION : -IS-2062 E250 (Fe 410W) to IS-2062 E250 (Fe 410W)
TYPE AND GRADE : Gr B to Gr. B
P NO. : P1 Gr 1 to P-1 Gr.1
THICKNESS OF TEST COUPON.: 8 MM to 8 mm
DIAMETER OF TEST COUPON .: - Not applicable
MAXIMUM PASS THICKNESS : Less than 13 mm Yes
HOW TO WRITE A WPS FORMAT
HOW TO WRITE A WPS FORMAT
GTAW
SMAW
HOW TO WRITE A WPS FORMAT
First Process:
Filler Metal (QW-404)
GTAW Type: Manual
GTAW / SMAW
Position (QW-405)
Position of Joint: All Positions Weld Progression: Vertical up
HOW TO WRITE A WPS FORMAT
SMAW
GTAW
HOW TO WRITE A WPS FORMAT
Preheat (QW-406)
Minimum Preheat Temperature:
55 °F Maximum Inter pass
Temperature: 550 °F
Preheat Maintenance: None
Preheat to 175 F if "T" > 1 and C > 0.30%
HOW TO WRITE A WPS FORMAT
GTAW
HOW TO WRITE A WPS FORMAT
Gas (QW-408)
Shielding: 100% Argon / 14-21
CFH
Backing: None /
- CFH
Trailing: None /
- CFH
HOW TO WRITE A WPS FORMAT
HOW TO WRITE A WPS FORMAT
SMAW
GTAW
HOW TO WRITE A WPS FORMAT
Electrical Characteristics (QW-409)
Current Type and Polarity: DCEN (straight)
Pulsed Current: None
GTAW
SMAW
HOW TO WRITE A WPS FORMAT
Peening: None
Multiple / Single Pass (per side): Multipass
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