Presentation Asme Sec-Ix Wps PQR Wpq..

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The key takeaways are that welding procedure and welder qualifications are required by codes like ASME to ensure weld strength and integrity for pressure applications. Procedure qualification verifies that welds meet design criteria.

Some of the main requirements for welding procedure qualification include conducting tests to verify weld strength meets design requirements, documenting test results and qualification records, and conforming to applicable codes and standards.

Some limitations of ASME Section IX code include that it does not guide electrode selection or joint design, specify non-destructive testing types/acceptance, or define impact test energy values. The applicable design code must be referenced for these details.

Training Program

ASME Sec IX

WELDING PROCEDURES

and

WELDERS QUALIFICATION
WELDING QUALIFICATIONS
Why Procedure Qualification required?

• Design engineer: Selects material for a specific


application

• Welding Engineer: Verify that weldment also meet the


design criteria

• Welding : Important and critical operation in


fabrication of pressure vessels, piping, boiler.

• ASME SEC- IX : Establishes the basic criteria for welding


which are observed while preparation of requirements
which affect procedure and performance.
WELDING QUALIFICATIONS

 A Mandatory Requirement from Codes


/Standards / Regulations

 In accordance with the Applicable Code /


Standard / Regulation.

 Acceptance Criteria of Test Results as per the


Code of Construction

 Qualification Records and Test Results to be


Documented
WHY PROCEDURE QUALIFICATION REQUIRED ?

DESIGN REQUIREMENT :
• Mechanical strength and Chemical composition of Material at
intended Pressure and temperature.

WELD JOINT REQUIREMENT


• Part of the component
• Shall be as strong as the parent material
• Shall have the strength same as that of base material at intended
pressure & Temperature

PROOF FOR CONFIRMATION


• NDT (Only Indicates weld Soundness)
• Destructive Testing (determines Strength of Welds)
• Sample of the weld and test for the required properties.
• Call for a testing, for every new job and every new joint.
• Concept of welding procedures helps to reduce the number of tests
and hence the cost.
QUALIFICATION REQUIREMENTS
Welding Qualifications
APPLICATION
•Equipments, Vessels & Piping to be fabricated as per
ASME Boiler & Pressure Vessel Code, Process & Power
piping, American Petroleum Institute etc

APPLICABLE CODES / STANDARDS


• ASME Sec IX + Applicable Design Code
( ASME Sec. VIII Div I or II, Sec. I, Sec. III, API 650, ASME ANSI B 31.3
/ 31.1, API 1104, API 650 etc)

ASME Sec IX is applicable for

• Welding Procedure Qualification

•Welders’ or Welding Operators’ Performance Qualification


ASME SEC IX CODE INTRODUCTION

ASME Sec IX deals with


 Part QW (Welding)

 Part QB (Brazing)

 Each part is divided into further 4 articles


 1. General requirements
 2. Procedure Qualification
 3. Performance Qualification
 4. Data

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

2. Does not guide in the selection of electrode

3. Does not guide in the design of joints

4. Does not specify the type and extent of radiography/ NDT to be


used

5. Does not specify the acceptance criteria (i.e. types and extent of
discontinuities acceptable).

6. Does not specify Energy value for impact testing

Refer the Design code For points specified in 3,4,5 and 6 7


ASME SEC IX CODE INTRODUCTION

WELDING PROCEDURE QUALIFICATION


When A WPS / PQR is Qualified:
Proves the Quality / Properties of Weld Joint Prepared by a
set of welding variables
- Welding Process
- Base Material
- Welding consumable
- Welding Parameters & Techniques ( Position, Polarity,
Preheat, Inter Pass Temp. Back Gouging etc)
- PWHT
Qualification is limited to the essential variables of the
Specific Process
WELDING PROCEDURE SPECIFICATION [QW-482]

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

Variables are listed for each welding process in QW-252 to QW-265

WPS should be available for reference and review by the inspector.


It should also be made available with welding supervisors, welders
WELDING PROCEDURE QUALIFICATION
PROCEDURE QUALIFICATION RECORDS
• A mock up : Represent welding done in a shop under similar
conditions.
• Some codes call for a production weld coupons as an additional
measure.
• Production coupons also act as qualification tests for the PQR
• Prepare A Weld Coupon Using an Preliminary WPS.
• Weld Coupon Undergoes Destructive Test
• Testing Requirements are specified in Sec IX
• Acceptance norms shall be as per Construction Code.
• PQR is limited to the essential variables of the Specific Process
WELDER PERFORMANCE QUALIFICATION

• Process of testing capability of the welder is known as


"Welder Performance Qualification test
• Ascertain the skill of a welder or a welding operator to
Produce defect free/Sound weld
• Makes A Weld Coupon Using an Approved WPS
• Weld Coupon Undergoes Soundness Test (NDT or DT)
• Each Qualified Welder Shall be Assigned by A Unique
Welder Number
• Welders’ Qualifications Records Are Documented
• Performance Qualification is limited to the essential
variables of the Specific Welding Process
UNDERSTAND ASME SEC. IX REQUIREMENTS

• 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.

Article II - Welding Procedure Qualifications.


• WPS, PQR
• Their contents, Format
• List of variables
• Qualification ranges
• Type and number of examinations required
UNDERSTAND ASME SEC. IX REQUIREMENTS

Article III - Welding Performance Qualifications

• 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

- Welding Data - Essential, Non Essential & Supplementary


Essential Variables.
- Parent Metal Grouping - “P” No
- Filler Metal Grouping – “ F” No
- Weld Metal Composition Grouping – “A” No
- Welding Positions, Groove & Fillet
- Types of Tests – Tension, Guided Bend, Notch Toughness
- Test Requirements & Acceptance Limits
- Test Specimen – Location, Dimension & Testing Procedure
- Qualifications – Range in Thickness & Diameter
- Record & Documentation of WPS , PQR & WP
UNDERSTAND ASME SEC. IX REQUIREMENTS

Understand ASME Sec.II Part C.

- Specification for Filler Analysis – SFA No

- AWS Classification of Welding Consumable

-Limits for Chemical Composition & Mechanical


Properties (including capability after PWHT) of
Consumables
UNDERSTAND ASME SEC. IX REQUIREMENTS

Selection of Filler metal:

•“Match" the base metal properties; ( Ys & UTS are expected to meet or
exceed the minimum specified properties)

• Matching filler metal is required for complete joint penetration groove


welds in tension or fillet welds loaded in shear .

• Depending on the type of weld joint and loading, lower filler metal
strengths may be acceptable or desirable for specific designs.

•Codes, specifications, or contract documents may require specific


mechanical properties that these recommendations do not meet.

• In those cases, electrode selection should be limited to those products


that meet the specific application requirements.
UNDERSTAND ASME SEC. IX REQUIREMENTS

• Check required levels of diffusible hydrogen in deposited weld


metal

• The permissible H2 level dependent on many factors, including


preheat and inter pass temperatures intended to be used.

• The selected filler metals shall have proper preheat and inter
pass temperatures

• Consider notch toughness (example Charpy V-Notch properties),

• PWHT (SR / Normalizing) requirements.


UNDERSTAND ASME SEC. IX REQUIREMENTS
Welding Filler Metal Designators:
1. Carbon Steel Electrodes:
UNDERSTAND ASME SEC. IX REQUIREMENTS
UNDERSTAND ASME SEC. IX REQUIREMENTS

Alloy Steel Electrodes:


UNDERSTAND ASME SEC. IX REQUIREMENTS

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

• Describes all essential and non-essential variables for


each welding process used in WPS.

• Also mention the supporting procedure qualification


records.

FORMAT OF WPS :
• May be written in any format suitable to the
manufacturer.

• Ensure that all essential and supplementary essential


variables are listed
.
STEP BY STEP PROCEDURE OF PREPARING A WPS

• Selection of a suitable welding process


• Fill in the suggested format of PQR
• Ensure that all the welding variables are covered
• Make a preliminary WPS based on the above PQR
• Weld a coupon as per the above WPS
• Carry out the examinations
• Make final WPS & PQR if the results are satisfactory
• It Provides Direction for A Specific Welding
• WPS Format is Available in ASME Sec. IX
• Each WPS Shall be Assigned with A Unique Number
STEP BY STEP PROCEDURE OF PREPARING A WPS
PREPARE A TEST COUPON AS PER WPS

- Coupon Size: Pair of 300 mm X 150 mm Plates or


Or Pipes 150 mm long as Specified in WPS
(Length of plate or diameter of pipes shall be capable of include all
Mechanical tests)
- Keep every items ready required as per Written WPS
- Complete the Welding by Reasonably Skilled Welder
- All Welding Variables Shall be Used Within the Limit Specified in WPS.
- All Variables Actually Used Shall be Documented as Annexure to PQR
NDT Of Weld Coupon – Optional

- X-Ray/ Radiograph the Weld Joint ( Not a Code


Requirement)

- Mark Transverse Tensile & Guided Bends As Per


QW463

- Eliminate Defective Weld Portion If Any, While


Marking the Test Specimens

- Preserve RT Report & X-Ray Film as Annexure to


PQR
TYPE OF TEST REQUIRED

• Weld metal should also have the essential properties of the


base metal.
• Qualification on grooves weld also qualifies for fillet welds.
• Procedure Qualification in any position qualify for all
position, provided welding, process and electrodes are
suitable for use in a specific position.
• Where notch-toughness is a requirement of construction
code the PROCEDURE QUALIFICATION should be carried
out in 3G or 6G only.
• Welder who makes successful procedure qualification test
is qualified to weld in applicable position
TYPE OF TEST REQUIRED

6) Mechanical Tests – QW 451, Groove Weld.

Up to 9 mm Thickness
- Transverse Tensile :– 2 No
- Root Bend :- 2 No
- Face Bend :- 2 No

From 10 mm to less than 19 mm Thickness


- Transverse Tensile :– 2 No
- Root Bend :- 2 No
- Face Bend :- 2 No
OR Side Bend :- 4 No (in place of Face & root Bend)

From 19 mm and above Thickness


- Transverse Tensile :– 2 No
- Side Bend :- 4 No
Location of Test Specimens From Test coupon
QW 463.1
Plates Less Than 19 mm

Discard Balance Plate Discard

Root Bend 2No


*
*

Face Bend 2No *


*

Reduced Section Tensile 2No


*
*
T < 19 mm

When Plate Thickness is 19 mm or more, In place of Root & Face, 4 Side


Bends shall be Taken
Location of Test Specimens From Test coupon
QW 463.1 Pipe

. @ = Reduced section Tensile 2No £ = Bends - Root & Face or Side

@
Root Bend £ £ Face Bend

45˚- 60˚ 45˚ - 60˚


Horizontal Plane
Pipe is welded in Horizontal fixed position

Face Bend £ £ Root 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

Weld Width M/c ed minimum

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)

- Minimum Tensile Strength of Material Used


- Minimum Tensile Strength of weaker Material when two different
minimum tensile strength materials are used
- If the specimen breaks in the BM or HAZ, TS shall not be less than 95%
below the minimum specified T.S of the BM
Bend Test (QW - 163)
- Opening Not More Than 3 mm in Any Direction on Convex Surface Within
the Weld & HAZ

GENERAL NOTE: For Tensile tests, failure in HAZ is


considered as ‘base metal failure’ whereas for bend
tests, the failure in HAZ is considered as a ‘weld metal
failure’.
ACCEPTANCE CRITERIA FOR PROCEDURE

Fillet welds Macro examination (QW-183)

• Cross sections of the weld metal and HAZ


shall show complete fusion and freedom
form cracks
• There shall not be more than 1/8 in (3mm)
difference in the legs of the fillet weld.
PQR – PROCEDURE QUALIFICATION RECORD

- PQR Format Available in Sec. IX (FORMAT QW- 483)


- Record All Relevant Data in the Format.

- Record Actual values/range of all essential, Non essential


and supplementary essential(whenever required) variables

- Record All Mechanical Test Results

- Attach All Test Reports & Welding Parameters Used as


Annexure to PQR

- Assign Unique Number to Each PQR

- WPS No Shall be Referred in PQR


PROCEDURE QUALIFICA TION RECORD (PQR)

• Types of test conducted.


• Number of test conducted. Results of tests.
• A PQR should be certified by the Manufacturer.
• Changes to PQR are not permitted. However,
correction can be made for example, if P No. or F
No. or any other information is wrong then the
same can be corrected.
• Additional information can be incorporated at a
later date provided it can be substantiated as
having been part of original qualification
condition by some lab Record or similar
document.
• PQR used for supporting WPS should be
PROCEDURE QUALIFICA TION RECORD (PQR)

Qualification of Groove Butt Weld


Procedure
THICKNESS LIMIT FOR GROOVE BUTT WELD
PROCEDURE
QW451
Thickness “t” of
Thickness “T” Of Range Of Thickness “T” Deposited Weld
Test Coupon of BM Qualified in mm metal Qualified
Welded in mm in mm
Minimum Maximum Maximum

Less Than 1.6 (1/16”) T 2T 2t

1.6 to 10 (1/16” to” ⅜”) 1.5 (1/16”) 2T 2t


10 to 19 ( ⅜” to ¾ ”) 5 (3/16”) 2T 2t
19 to 38 ( ¾ ” to 1 ½”) 5 (3/16”) 2T 2t When t < 19
19 to 38 ( ¾ ” to 1 ½”) 5 (3/16”) 2T 2T When t ≥19
38 (1 ½”) and over 5 (3/16”) 200 ( 8” ) 2t When t < 19

38 (1 ½”) and over 5 (3/16”) 200 ( 8” ) 200 When t ≥19


Over 200 (8”) – QW
5 (3/16”) 1.33 T 1.33 t
403.7
THICKNESS LIMIT FOR GROOVE BUTT WELD
Qualification of Groove Butt Weld Procedure
PROCEDURE
QW451
Thickness selection is the important and mostly confused parameter

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

Appendix-I describes thickness selection in more detail.

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

Determination of test coupon thickness for welding procedure qualification

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.

Let us take an example to illustrate the above point

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

Step 2: choose 16mm (arbitrary), This will qualify us for,


Reference Thickness
T of base metal t of weldmetal, max

From To GTAW SMAW


As per QW-450 (Based on Thickness of the 5 32 10 22
coupon)
As per QW-407.4 (due to normalizing) 5 @18 5.5 12
As per QW-403.6 (due to impact test 16 32 10 22
requirement)
Result 16 @18 5.5 12
THICKNESS LIMIT FOR GROOVE BUTT WELD PROCEDURE

QW451

Step 3: choose 32 mm (arbitrary), This will qualify us for,

Reference Thickness
T of base metal t of weld metal, max

From To GTAW SMAW


As per QW-450 (Based on Thickness of the coupon) 5 64 10 64
As per QW-407.4 (due to normalizing) 5 35 5.5 @ 30
As per QW-403.6 (due to impact test requirement) 16 64 10 64

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

QW-253 SMAW Variable


Group of Supplementary Nonessentia
Brief Of Variables Essential
Variables Essential l
Change in Groove Design --- ---
QW 402 *
Joints Addition / Deletion of Backing --- --- *
Change in group Of P No --- * ---
T Limits Impact --- * ---
T/t Limits  203 mm --- ---
QW 403
*
Change in T Qualified --- ---
Base Metals *
“t” pas  13 mm --- ---
*
Change of P Number Qualified --- ---
*
Change in F No --- ---
*
Change in A No --- ---
*
Change in Dia --- ---
QW 404 *
Filler Metals
Change in Dia  6 mm --- * ---
Change in AWS classification --- * ---
Change in t qualified --- ---
*
PROCEDURE QUALIFICATION

QW-253 SMAW Variable


Group of Supplementary Nonessentia
Brief Of Variables Essential
Variables Essential l
Addition of Position --- ---
QW 405 *
Positions Change in Position --- ---
*
QW 406 Decrease  56°C --- ---
*
Preheat
Increase  56°C IP --- * ---

Addition / Deletion of PWHT --- ---


QW 407 *
PWHT Change in Time & Temp. Qualified --- ---
*
Increase in Heat Input --- * ---
QW 409
Electrical Change in Current / Polarity --- * ---
Characteristics Change in Current / Voltage --- ---
*
Change from String / Weave --- ---
*
Method of Cleaning --- ---
QW 410 *
Technique Method of Back Gouging --- ---
*
Change From Multiple to Single Pass --- * ---
PROCEDURE QUALIFICATION
PROCEDURE QUALIFICATION
PROCEDURE QUALIFICATION CLAUSES
QW-402.11 The addition or deletion of nonmetallic retainers or
nonfusing metal retainers.
QW-403.5 Welding procedure specifications shall be qualified using one of
the following:
(a) the same base metal (including type or grade) to be used in production
welding
(b) for ferrous materials, a base metal listed in the same P-Number Group
Number in table QW/QB-422 as the base metal to be used in production
welding
(c) for nonferrous materials, a base metal listed with the same P-Number UNS
Number in table QW/QB-422 as the base metal to be used in production
welding
For ferrous materials in table QW/QB-422, a procedure qualification shall be
made for each P-Number Group Number combination of base metals, even
though procedure qualification tests have been made for each of the two
base metals welded to itself. If, however, two or more qualification records
have the same essential and supplementary essential variables, except that
the base metals are assigned to different Group Numbers within the same P-
Number, then the combination of base metals is also qualified.
PROCEDURE QUALIFICATION CLAUSES
QW-404.4 A change from one F-Number in table QW-432 to any other
F-Number or to any other filler metal not listed in table QW-432.

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
table QW-442. Qualification with A-No. 1 shall qualify for A-No. 2 and vice
versa.
QW-407.1 A separate procedure qualification is required for each of the
following:
(a) For P-Numbers 1 through 6 and 9 through 15F materials, the following
post weld heat treatment conditions apply:
(1) no PWHT
(2) PWHT below the lower transformation temperature
(3) PWHT above the upper transformation temperature (e.g., normalizing)
(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 PWHT or (2) PWHT within a specified temperature range
PROCEDURE QUALIFICATION
QW-256 GTAW Variable

Group of Supplementary
Brief Of Variables Essential Nonessential
Variables Essential

Change in Groove Design --- --- *


QW 402
Joints Addition / Deletion of Backing --- --- *
Change in group Of P No --- * ---
T Limits Impact --- * ---
T / t Limits  203 mm * --- ---
QW 403
Base Metals Change in T Qualified * --- ---
Change From T Qualified * --- ---
Change From P Number Qualified * --- ---
Change in F No * --- ---
Change in A No * --- ---
Change in AWS Classification --- * ---
QW 404
Filler Metals Addition / Deletion of Filler * --- ---
Addition / Deletion of Consumable Insert --- -- *
Change From Solid – Flux / Powder Cored * --- ---
PROCEDURE QUALIFICATION
QW-256 GTAW Variable

Group of Essentia Supplementar Nonessentia


Brief Of Variables
Variables l y Essential l
QW 405 Addition of Position --- --- *
Positions Change in Position --- * ---

QW 406 Decrease  56°C * --- ---


Preheat
Increase  56°C IP --- * ---

Addition / Deletion of PWHT * --- ---


QW 407
Change in Time & Temp. Qualified --- * ---
PWHT
Change in T thickness Qualified * --- ---

Addition / Deletion / Change in Trailing Gas --- --- *


Addition / Deletion / Change in Shielding Gas * --- --
QW 408 Gas Change in Flow Rate of Shielding / Backing Gas --- --- *
Deletion of Backing Gas * --- ---
PROCEDURE QUALIFICATION
QW-256 GTAW Variable

Group of Essentia Supplementary


Brief Of Variables Nonessential
Variables l Essential
Increase in Heat Input --- * ---
QW 409 Change in Tungsten Electrode Size --- --- *
Electrical
Addition / Deletion of Pulsing --- --- *
Characteristics
Change in Current or Polarity --- * ---

Change in Nozzle / Gas Cup Size --- --- *


Method of Cleaning --- --- *
Change in Oscillation --- --- *
QW 410 Method of Back Gouging --- --- *
Technique Change From Single to Multi Electrode --- * ---

Change From Closed Chamber to Out Side * --- ---

Change From Manual to Auto / Auto to Manual --- --- *


Addition or Deletion of Preening --- --- *
P – NUMBER GROUPING
Base Metal For Qualification

P number is the grouping : Based on BM chemical composition, weldability


and mechanical properties etc.

P stands for Parent metal.

Table QW422 lists the P numbers of various materials.

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.

Group number is a sub-grouping of ferrous Base Materials having


specified impact test requirements, within a P number. Table QW422 lists
the Group numbers of various materials. Group number depends on
strength of material. This will be an additional restriction on P number
when impact testing is required for the base / weld metal in the job
specification.
P – NUMBER GROUPING
Base Metal For Qualification
Example:

A procedure qualified using a plates confirming to SA516 Gr.60 can be used to


weld a joint between the pipes confirming to SA106 Gr. B assuming that all
other parameters remain unaffected.

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 Met. Quality &


P- No Met. Spec. Grade
No Form

1 SA 515 / SA 516 60 CS – Plate


P1 SA 515 / SA 516
2 70 CS – Plate
1 SA 106 A/B CS – Pipe
P1
2 SA 106 C CS - Pipe
1 SA333 6 CS – Pipe
P1
3 SA 333 10 CS - Pipe
1 SA 234 WPB CS Pipe Fitting
P1
2 SA 234 WPC CS Pipe Fitting
P1 1 SA 285 C/B CS Plate
P1 1 SA 179 --- CS Tube
2 SA 105 --- CS Forging
P1
2 SA 181 Cl 70 CS Forging
P – NUMBER GROUPING (SAMPLE : C + Mo /Mn))
(Base Metal For Qualification)

Group Met. Quality &


P- No Met. Spec. Grade
No Form

P3 2 SA 302 A Mn – 0.5 Mo – Plate


3 SA 302 B,C,D Mn – 0.5 Mo – Plate
P3 1 SA 335 P1 / P2 C – 0.5 Mo – Pipe

P3 3 SA 533 TP- B, Cl- 1 or 2 C – 0.5 Mo – Plate

P3 1 SA 209 T1, T1a, T1b C – 0.5 Mo – Tube

P3 2 SA 282 F1 C – 0.5 Mo – Forging


P – NUMBER GROUPING (SAMPLE : LAS)
Base Metal For Qualification

Group
P- No Met. Spec. Grade Met. Quality & Form
No

P4 1 SA 387 12, Cl –1 / 2 1Cr. 0.5 Mo – Plate


3 SA 387 11, Cl –1 / 2 1.25 Cr. 0.5 Mo – Plate

P4 1 SA 335 P12 / P11 1Cr (1.25 Cr) – 0.5 Mo – Pipe

P4 2 SA 423 TP - 1 / 2 1.25 Cr. 0.5 Mo – Tube

P4 1 SA 282 F12, Cl- 1 / 2 1. Cr – 0.5 Mo – Forging


SA 336 F11, Cl –1 / 2 / 3 1.25 Cr – 0.5 Mo – Forging
P – NUMBER GROUPING (SAMPLE : LAS)
Base Metal For Qualification

Group Met.
P- No Grade Met. Quality & Form
No Spec.

P5A 1 SA 387 22, Cl –1 / 2 2. 25 Cr. 1 Mo – Plate


P5B 1 SA 387 5, Cl - 2 5 Cr. 0.5 Mo - Plates

P5A 1 SA 335 P22 2. 25 Cr. 1 Mo – Pipe

P5A 1 SA 213 TP - 22 2. .25 Cr. 1 Mo – Tube

P5B 1 SA 182 F5 5 Cr – 0.5 Mo – Forging


P5C 1 SA 182 F22V 2. 25 Cr – 1 Mo,V – Forging
P5A 1 SA 336 F22, Cl –1 / 3 2. 25 Cr – 1 Mo – Forging
P – NUMBER GROUPING (SAMPLE : High Alloy)
Base Metal For Qualification

Group Met. Quality &


P- No Met. Spec. Grade
No Form
P6 2 SA 240 TP 429 15Cr. – Plate

P6 4 SA 731 S41500 13Cr., 4.5 Ni, Mo - Pipe

P6 1 SA 268 TP410 13Cr. – Tube

P6 3 SA 336 F6 13Gr.– Forging


P7 2 SA182 F430 17Cr. - Forging
P7 2 SA 240 TP 430 17Cr. - Plate
P7 2 SA 268 TP430 17Cr. Tube
P7 2 SA 731 TP439 18Cr., Ti – Pipe
P – NUMBER GROUPING (SAMPLE : SS)
Base Metal For Qualification

Group
P- No Met. Spec. Grade Met. Quality & Form
No

1 SA 312 TP321 18Cr., 10Ni, Ti - Pipe


P8 1 SA 312 TP347 18Cr., 10Ni, Cb - Pipe

1 SA336 TP316 18Cr., 8 Ni, 2Mo -Forging


P8 1 SA 336 TP310 25Cr., 20 Ni, Forging

1 SA 240 TP304 18Cr, 8Ni - Plates


P8 2 SA 204 TP309S 23Cr. 12Cr. - Plates

1 SA 249 TP317 18Cr, 13Ni, 3Mo –Tube


P8 1 SA 249 TP316L 16Cr, 12Ni, 2Mo - Tube

3/19/2018
P – NUMBER GROUPING (SAMPLE : Ni based LTCS )
Base Metal For Qualification

Group
P- No Met. Spec. Grade Met. Quality & Form
No

1 SA 333 3 3.5Ni - Pipe


P9B

P9A 1 SA334 7 2.5Ni - Tube

1 SA 350 LF5, Cl. 2 1.5Ni - Forging


P9A
1 SA 350 LF3 3.5Ni. - Forging
P9B

1 SA 203 A 2.5Ni. - Plate


P9A
1 SA 203 E 3.3Ni. - Plate
P9B
P – NUMBER GROUPING (SAMPLE : Ni
+ Alloy based )
Base Metal For Qualification

Group Met.
P- No Grade Met. Quality & Form
No Spec.

P11A 1 SA 333 8 9Ni - Pipe

P11A 1 SA334 8 9Ni - Tube


P11A 5 SA 508 4N, Cl. 2 3.5Ni –1.75 Cr.-0.5Mo.- V, Forging
P11A 5 SA 508 5, Cl. 2 3.5Ni –1.75 Cr.-0.5Mo.- V, Forging
P11A 4 SA 533 TP B, Cl. 3 Mn, 0.5 Mo, 0.5Ni – Plate
P11A 4 SA 533 TP C, Cl. 3 Mn, 0.5 Mo, 0.75Ni - Plate
P – NUMBER GROUPING
P Numbers SS
materials
F – NUMBER GROUPING
Filler Metal For Qualification

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

F Carbon Steel Low Alloy Steel Stainless Product form


No steel &
Duplex steel
F5 E-308 L 16 Electrodes
E 316 L 15
E-309 -16
F4 E-7018 , E-7016 E-8018 B2, E-9018 C3 Electrodes
E-8018-G (SFA 5.5)
(SFA 5.1)
F-3 E-6010, E-7010 E-6010, E-7010 Electrodes
E-6011 E-6011
(SFA-5.1) (SFA-5.1)
F-2 E-6013 E(X)XX13-X Electrodes
F-1 EXX20 EXX20-X Electrodes
F-6 ER 70 S2 ER 80S B2 ER 308 L, ER Bare filler wire
ER 70 S6 (SFA- ER 90 S C3 309 L, ER 316
5.18) (SFA-5.28) (SFA- 5.9)
F – NUMBER GROUPING
A -NUMBER GROUPING
Filler Metal For Qualification
A number
• Grouping of electrodes and filler material
• Based on the weld metal chemical composition.
• 'A' stands for weld metal Analysis.
• Described in QW440 / QW 442
A -NUMBER GROUPING
TESTING REQUIREMENTS FOR WPS/PQR
TESTING REQUIREMENTS FOR WPS/PQR
WELDING PERFORMANCE QUALIFICATIONS

ASME Sec IX:

-Variables For Different Processes – QW 350

-Limits Of Positions Qualified & Diameter – QW 461

-Testing Requirements – QW 304-1


WELDER QUALIFICATION

Train The Welder For The Process To Be Qualified

- Shall Posses Adequate Skill In Performing the Process.

- Shall have Necessary Knowledge In


 Operation Of Machine
 Precautions In Storage & Usage Of Consumable,
 Defects In Welding, Their Causes And Remedy.

- Shall Practice Welding In The Particular Position In Which


He Is To Be Tested / Qualified
WELDER QUALIFICATION
Preparation Of Test Coupon

- Prepare A Test Coupon Out of 300 х 150 х 13 mm


Plates Or Pipe Of 150mm long As Per Applicable WPS.

- WEP ( Angle, Root Face & Root Opening ) Shall Be As


Per The WPS

- Provide Run in & Run Out Coupons on plate & Fix the
Test Coupon In In Any One Of The Positions To Be
Qualified.

- Weld The Groove Fully In The Position

- All Welding Variables Shall be Strictly Within The


Qualified WPS
WELDER QUALIFICATION
Type Of Test Required On Welded Coupon (QW-302)

• Visual Examination – QW 302.4


Completed Coupon Shall be Subjected To Visual Inspection

• Mechanical Test - QW 452


Root Bend :-1 No, Face Bend :-1 No (<19 mm Thick)
Or
Side Bend :- 2 No (≥19 mm Thick)
(For 5G / 6G – 2 Face & 2 Root Or 4 Side Bends)

• Alternate to Mechanical Tests, Radiograph the Coupon


– 6 ” Minimum Length
WELDER QUALIFICATION
Location of Test Specimens From Test coupon – QW463.2
Plates Less Than 19 mm

Discard Discard

Root Bend 1No *


Face Bend 1No *

<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

Side Bend 2No *


*

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

£ = Bends - Root & Face or Side

Root Bend £ Face Bend


£
45˚- 60˚ 45˚ - 60˚

Pipe is welded in Horizontal


Horizontal Plane fixed position

£ £ Root Bend
Face Bend

When Pipe Thickness is 19 mm or more, In place of Root & Face,


4 Side Bends shall be Taken
WELDER QUALIFICATION
Location of Test Specimens From Test Pipe 6 NPS
Welded in Combination of 5G & 2G – QW 463.2

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˚

Face Bend When Pipe Thickness is 19 mm


202.5˚ or more, In place of Root & Face,
180˚ Side Bends shall be Taken
WELDER QUALIFICATION
Acceptability Criteria For Tests
• Visual Examination – Qw 302.4
Free From Incomplete Fusion / Penetration and Surface
Defect
• Bend Test - QW 163
Opening not more than 3 mm in any direction on Convex
Surface Within the Weld & HAZ
• Radiographic Testing – QW 191.2
No Crack, L/F & Incomplete Penetration
No Slag, Cluster Of Porosity & Other Inclusions Beyond
Specified Limit
GENERAL NOTE: For Tensile tests, failure in HAZ is
considered as ‘base metal failure’ whereas for bend
tests, the failure in HAZ is considered as a ‘weld metal
failure’.
WELDER QUALIFICATION
Acceptability Criteria For Fracture test
(Fillet weld test) QW 182

• The stem of 4 in. fracture test specimen centre shall be


loaded laterally in such a way that the root of the weld is
in tension. The load shall be steadily increased until the
specimen fractures or bends flat upon itself. The stem
shall not peel off from the base surface, which happens
when the fusion is only skin deep

• If the specimen fractures, the fractured surface shall


show no evidence of cracks or incomplete root fusion,
and the sum of the lengths of the inclusions and porosity
visible on the fractured surface shall not exceed 3/8 in.
(10 mm)
Welder Qualification
Acceptance Criteria For Performance Macro
Examination (Fillet Weld) QW 184
The smoothened and etched surface of the specimen
should give a clear definition of the weld metal and
HAZ. In order to pass the test:
• Visual examination of the cross section of the weld
metal and HAZ shall show complete fusion and
freedom from cracks, except that linear indications at
the root not exceeding 1/32 in. shall be acceptable
• The weld shall not have a concavity or convexity
greater than 1/16 in.
• There shall not be more than 1/8 in. difference in the
lengths of the legs of the fillet.
WELDER QUALIFICATION
Performance Qualification
Thickness Limits – QW 452.1(b)

Thickness “t” of Weld Thickness of Weld


Metal in the Coupon metal Qualified

Less than 13 mm (1/2”) 2t

13 mm (1/2”) and Over With Maximum To Be


Minimum Three Layers Welded

Note: There is no minimum limit for thickness for WPQ


WELDER QUALIFICATION
Groove Weld Positions – QW461

Groove Base Metal Position Inclination


Sr No.
Position Plate Pipe of Axis in °
1G Pipe Axis Horizontal –
1 Horizontal 0 -15
Flat in Rotation
2G
2 Vertical Pipe Axis Vertical 0 - 15
Horizontal
3G 80 – 90
3 Vertical NA
Vertical 15 - 80
4G NA
4 Horizontal 0 - 80
Over Head
Pipe Axis Fixed
5 5G NA 0 -15
Horizontally
Pipe Axis Fixed 45°
6 6G NA + or - 5
inclined
Welder Performance Qualification
Plate Groove Weld Positions – QW461
WELDER PERFORMANCE QUALIFICATION
Pipe Groove Weld Positions – QW461
WELDER PERFORMANCE QUALIFICATION
Position & Diameter Limits- QW461.9
Qualification Test Position & Type of Weld Qualified
Plate & Pipe Fillet Plate &
Weld Position Pipe ≤ 24”
Over 24” Pipe
1G F F* F
2G F, H F*&H* F,H
Plate 3G F,V F* F,H,V
Groove 4G F,O F* F,H,O
2G, 3G &4G ALL F*&H* ALL
Special. Position SP & F SP & F SP & F
1G F F F
2G F,H F,H F,H
Pipe 5G F,V,O F,V,O ALL
Groove 6G ALL ALL ALL
2G &5G ALL ALL ALL
Special. Position SP & F SP & F SP& F
•* Pipe 2 ⅞” OD and Over
$ Pipe OD Restrictions As Per QW 452.3, 452.4 and 452.6
Welder Performance Qualification
Performance Qualification
Groove-Weld, Pipe Dia. Limits QW 452.3

Out Side Dia. Of Test Out Side Dia. Qualified


Coupon in mm ( in) Min. Max.
Less Than 25 (1”) Size Welded Unlimited
25 (1”) to 73 (2⅞”) 25 (1”) Unlimited
Over 73 (2⅞”) 73 (2⅞”) Unlimited
Notes:-
1) Type & Number of Tests as per QW-452.1
2) 73 mm OD is equivalent to 2½” NB Pipe
3) Welders Qualified on Groove, Are Also Qualified for making Fillets of all Sizes
on Any Thickness & Any Pipe Dia.
WELDER PERFORMANCE QUALIFICATION
Welding Variables- Qw 416
Group of Essential Variables
Variable Brief Of Variables SMAW SAW. GMAW GTAW
s QW -353 QW-354 QW-355 QW-356

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

Addition of New Position + + + +


QW 405
Position Change from up hill to Down hill –
+ --- + +
3G
QW 408
Deletion of Inert Gas Backing --- --- + +
Gas
QW 409 Change in Mode of Metal Transfer --- --- + ---
Electric
Charact. Change in Type of Current / Polarity --- --- --- +
WELDER PERFORMANCE QUALIFICATION
FORMAT QW 484
• WPQ test: To determine the ability of the welder to
deposit sound welds using qualified WPS.

• 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......)

iii) Alternatively, at the manufacturer's option a welder


may be qualified on the job by Radiography examination
of his first 6" of production weld (for SAW 3 feet).

REQUALIFICATION AFTER FIRST FAILURE:


•A welding supervisor/engineer may terminate the
performance test at any stage if it becomes apparent that
the welder/welding operator does not have the requisite
skill.

•If a welding operator /welder fails in performance test


immediate re-test can be taken.
WELDER PERFORMANCE QUALIFICATION
REQUALIFICATION AFTER FIRST FAILURE (Cont......)
• If the mechanical test have failed then the welder will
make two consecutive sample and all mechanical tests
from both samples shall meet test requirements.

• If the qualification test have failed radiography


examination then 2 additional 6" long plate coupon or 2
pipe coupons total circumstance of weld of which will 12"
long shall be made and all shall meet the requirements of
radiography.

• In case of radiography of first 6" failure of production


weld then at the manufactures option further 12" of weld
shall be radiographed and shall meet the radiography
requirement.
Welder Performance Qualification
REQUALIFICATION AFTER FIRST FAILURE (Cont......)

• If on radiography re-test a welder meets the


requirement then the area on which the welder failed
to meet the requirement shall be repaired by him or
other qualified welder.

• In case the welder fails in re-test or the manufacturer


does not wish to offer for re-test then the entire weld
made by this welder shall be radiographed and all
defective areas shall be repaired by other qualified
welder.
WELDER PERFORMANCE QUALIFICATION
FORMAT QW 484
RENEWAL OF QUALIFICATION
• The performance qualification of welder/welding
operator
RENEWAL OFshall expire when he has not welded with a
QUALIFICATION:
process for a period of 3 months or more. However when
he has welded with another process, the period may be
extended to six months.

• Renewal of qualification can be made for any process by


welding a single coupon of either plate or pipe, of any
material and by testing of that coupon.

• When there is a specific reason to doubt the ability of the


welder to make welds that meet specification,
requirements, his qualification which support the
welding which he is doing shall be revoked.
RENEWAL OF QUALIFICATION

• In such case the welder or welding operator will have


to weld OF
RENEWAL a test coupon for re-qualification which will
QUALIFICATION:
be tested as required by the code before he is put on
the job.

• Performance qualification-position and diameter


limitations are mentioned in QW- 461-9 and QW-454
(see Annexures).

• Performance Qualification, tests can be carried out


by using a combination of welding process on single
test coupon limits of thickness for which he will be
qualified will depend upon the amount of weldment
thickness deposited by each process.
RENEWAL OF QUALIFICATION:
RENEWAL OF QUALIFICATION (cont....)

• Two or more welders can be qualified on a single test


RENEWAL OF QUALIFICATION:
coupon using same or different welding processes
limits of qualification for each welder will be related to
weld metal deposited by him with his specific welding
process.

• The requirements for welding Procedure Specification


(WPS), Procedure Qualification Record (PQR) and
welders performance Qualification (WPQ) are given in
ASME Sec. IX Article I, II and III respectively.
IMPORTANT POINTS FOR WPS/ PQR &
WPQ
• A double welded (welded from both the sides after B/G) joint is considered
RENEWAL
as a joint with OF QUALIFICATION:
backing. Weld metal becomes the Backing material.

• Size of base metal, normally designated as T and size of weld deposit


normally designated as t must be considered separately.

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

• A test coupon of thickness 40mm used for procedure qualification test


covers largest range from 5 mm to 200mm (without heat treatment or
impact requirements).

• 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 change of filler metal (F number) needs a re-qualification of welder. A


welder qualified with F4 is allowed to weld F1, F2 & F3 with backing.

• Presence or absence of impact test or PWHT / normalizing does not affect


the welder's skill and hence the qualification.

• 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

A - Excessively thick root face


A

B B - Too small a root gap

C - Misplaced welds
C

D D - Power input too low

E E - Arc (heat) input too low


BURN THROUGH (NON STANDARD)
Definition: When an undesirable open hole has been completely
melted through the base metal. The hole may or may not be open

Cause: Excessive Heat Input


BURN THROUGH
Slag inclusion
Slag or other non-metallic foreign materials
entrapped in a weld.
ARC STRIKE
GOOD ROOT RUN BY TIG

Proper TIG Root weld

Proper TIG Root weld


ROOT WELD BY SMAW

SMAW Root with slag


SMAW Root with E 6010
Comparison of weld beads

The Good, the Bad and the


Ugly
VISUAL INSPECTION (NON-DESTRUCTIVE TEST)
REQUIREMENTS

Degree of undercut.

Smoothness of joint where


welding is recommended.

Freedom from surface


cavities, spatters, under cuts
and trapped slag.

Deposition of runs, single or


multiple.

Penetration bead in butt


weld.

Quality of the weld metal.


MEASUREMENT OF CURRENT &
VOLTAGE
MEASUREMENT OF CURRENT &
VOLTAGE
MEASUREMENT OF TEMPERATURE
HOW TO WRITE A WPS FORMAT
Company Name 1 CO INC. by 2 (not required by rules of IX)
Welding Procedure Specification 3 #134 (no rules for numbering) Date 4 01 August 87
Revision No. 5 1 Date 6 06 October 1998 Peat McSquinty, Welding Engineer by 7
Supporting PQR No.(s) 8 # Q134
Process 9 SMAW (Stick welding) Type 10 Manual
11 For welding carbon steels with E6010 & E7018, without PWHT, (not qualified for notch
toughness or impact tested applications)

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)

Paragraph Brief of Essential Non Essential


Variables
QW-402 . .1 φ Groove NE
Joints design
.4 - Backing NE

.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 bevel No backing 3/16" max 45 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

Square groove T-joint 1/32" max

Square groove No backing 3/32" 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

provided the joint design is available for reference by the:

•• 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

QW-253 WELDING VARIABLES PROCEDURE SPECIFICATIONS (WPS)


SHIELDED METAL-ARC WELDING (SMAW)

Paragraph Brief of Variables Essential Non


Essential

QW-403 . .7 T/t limits > 8 inch (203 mm) E


Joints
.8 φ T Qualified E

.9 t Pass > ½ inch (13 mm) E

.11 φ P-No. qualified E

.13 φ P-No. 5/9/10 E


HOW TO WRITE A WPS FORMAT
The first rule for determining how each essential variable is to be
applied, is to review the specific essential variable of QW-253, such
as QW-403.8, φ T qualified. It is very difficult to understand and use
the variable from the description noted in the “Brief of Variables”
column. Read the actual variable, such as 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).”
Base Metals (QW-403)
P-No. 1 Gr No: 1 & /or 2 Thickness Range: 0.1875 in. to 1.8120 in.

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

Weld Deposit Limits: 0.2500 in. maximum


AWS Classification: ER70S-2 SFA Specification: 5.18
F-No.: 6
A-No. or Chemical Composition:
1
Filler Metal Product Form: Bare (Solid)
Consumable Insert: None GTAW Flux: None
HOW TO WRITE A WPS FORMAT

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 & SMAW

Postweld Heat Treatment (QW-407)


PWHT Type: PWHT below lower transformation temperature
PWHT Temperature : 11000 °F
PWHT Holding Time: 1.0 hr./in., 0.25 hr. min.
HOW TO WRITE A WPS FORMAT
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

Tungsten Type: EWTh-2 Size: 3/32"

Max. Heat Input (J/in): None


First Process Welding Parameters

Layer(s) Filler Metal Current Travel Speed


and/or AWS Size Type and Amperage Voltage Range (in/min)
Pass(es) Classification (in.) Polarity Range Range
Any ER70S-2 1/16 DCEN 70-150 n/r Var.
(straight)
Any ER70S-2 3/32 DCEN 80-180 n/r Var.
(straight)
Any ER70S-2 1/8 DCEN 130-275 n/r Var.
(straight)
Any ER70S-2 3/16 DCEN 200-375 n/r Var.
(straight)
HOW TO WRITE A WPS FORMAT

Electrical Characteristics (QW-409)


Current Type and Polarity: DCEP (reverse)

Max. Heat Input (J/in): None


Second Process Welding
Parameters

Layer(s) and/or Filler Metal Current Travel


Pass(es) AWS Size Type and Amperage Voltage Speed
Classification (in.) Polarity Range Range Range
(in/min)
Any E7018 3/32 DCEP (reverse) 70-110 n/r Var.
Any E7018 1/8 DCEP (reverse) 90-160 n/r Var.
Any E7018 5/32 DCEP (reverse) 130-220 n/r Var.
Any E7018 3/16 DCEP (reverse) 200-300 n/r Var.
Any E7018 7/32 DCEP (reverse) 250-350 n/r Var.
HOW TO WRITE A WPS FORMAT
HOW TO WRITE A WPS FORMAT
HOW TO WRITE A WPS FORMAT
HOW TO WRITE A WPS FORMAT

GTAW

SMAW
HOW TO WRITE A WPS FORMAT

Technique (QW-410) (For First Process GTAW)


Stringer or Weave Bead: Weave bead
Nozzle / Gas Cup Size: #5 to #10

Peening: None
Multiple / Single Pass (per side): Multipass

Technique (QW-410) (For Second Process SMAW)


Stringer or Weave Bead: Stringer and weave bead
Peening: None
Multiple / Single Pass (per side): Multipass
HOW TO WRITE A WPS FORMAT

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