- ASME SEC IX

Welding Procedure and

performance qualification

Dr G Ravichandran
Sr Manager, WRI,
BHEL, Trichy
 Welding Procedure Specification
It is a written document that provides direction to
the welder for making production welds in
.accordance with code requirements
Any WPS must be qualified by the
.manufacturer
WPS specifies the condition (ranges)
under which
.welding must be performed called variables
WPS addresses essential, supplementary essential
 Purpose of WPS Qualification
To determine that the weldment is capable of
providing the required properties for the
.intended application

WPS establishes the properties of the weldment

.and not the skill of the welder
 Procedure Qualification Record
It documents what occurred during welding the
.test coupon and the results of the test coupon
PQR documents the essential variables and other
specific information and the results of the required
testing. In addition, when notch toughness is
required for procedure qualification, the
applicable supplementary essential variables shall
be
.recorded
 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,
4G, pipe 5G, 6G etc provided other parameters are
,3G
.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
.mm thickness ranges 32
 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 - to 30 0
2F - wrt 10- 15+
4F - 45
3F - 125 - 0
 Base Metal Classification

& P nos depend on composition, weldability

.mechanical properites
Group nos classify metals within P nos for
procedure qualification where notch toughness
requirements are specified. But base metals
.can not be indiscriminately substituted
 Base Metal P Numbers

- P1 P11 Steel
P21 - P25 Al
P31 - P35 alloy
P41 - P47 s Cu
P51 - P53 alloy
P61 - P62 s Ni
alloy
s Ti
 Base Metal P Numbers
Examples of P nos
P1 C Steel
P3 Mo steels 1/2
P4 Cr 1/2 Mo steels 1
P5A Cr 1 Mo steels 1/4 2
P6 Cr steel 13
P7 Cr steel 17
P8 ASS
P9A Ni steels 1/2 2
P10A Mn - 1/2 Ni - V steels
P11 Ni steels 9
 Base Metal for WPS
Test Coupon Base Metal qualified
Px - Px Px
Px - Py Px to Py
P3 - P3 P3 P3, P3 - P1 -
P4 - P4 P4 P4, P4 - P3, P4 - P1 -
P5A - P5A - P5A - P5A, P4 ,P4 P4 - ,P3
P4 - P1
P4 - P3, P4 - P1 P4 - P3, P4 - P1
P5A - P4, P5A - }P3 P5A - P4, P5A - P3
P5A - P1 } P5A - P1
 Filler Metal F Numbers
Based on usability characteristics i.e ability
welders to make satisfactory welds with given of
filler
F1 E XX20
F2 E XX12 E XX13
F3 E , E XX11
F4 E XX10
F5 ASS, Duplex
, SS
F6 XX18Bare rods
 Filler Metal A Numbers
Based on chemical composition
A1 Mild steel
A2 C - Mo steel
A3 Cr - Mo steel Cr( )2% - 0.4
A4 Cr - Mo steel Cr( )6% - 2
A5 Cr - Mo steel Cr( )10.5% - 6
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%
 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 max t Tests (transverse
bend)
”1/16< T - 2T 2t ,2T ,FB 2 RB 2
”1/16-3/8 1/16 - 2T 2t -do-
”3/8-3/4 3/16 - 2T 2t -do-
”3/4-1.5 3/16 - 2T 2t if t<3/4 2T, 4 SB
2T if t>3/4
”1.5> ”8 - 3/16 ”2t if t<3/4 -do-
”if t>3/4 8
 Procedure Qualification Thickness limits

T Range of T max t Tests (longtdnl

)bend

”1/16< T - 2T 2t ,2T FB, 2 RB 2

”1/16-3/8 - 1/16 2t -do-
”3/8 > 2T 2t -do-
2T - 3/16
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
Decrease of more than 100 thickness
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
Change in metal 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, root
backing, 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
Decrease of more form than 100 F in
Change in PWHT preheat
WPS for GTAW
Essential variables (cond)

Change in single, mixture ge% 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
Change in metal welding position
Increase of more than 100 F in preheat
Change in PWHT Time and temp range
Change in current/polarity, incr. in heat
Change in input multi to single pass,
electrodes
 Performance Qualification
The basic criterion for welder’s qualification is to
determine the welder’s ability to deposit sound
weld metal. The purpose of performance
qualification test is to determine the welding
operator’s mechanical ability to operate the
.welding equipment
 Welding Performance Qualification
The performance qualification tests are to
intended determine the ability of welders to
make sound welds
A welder is qualified by radiography of a test
coupon or by radiography of initial production
welding or by bend tests taken from a test coupon
 Welding Performance Qualification

Weld Plate & pipe Pipe of OD Fillet

OD”24> 7/8 2 - ”24

Plate 1G F F F
Plate 2G FH FH F H
Plate 3G ,V , , H, V
Plate 4G FO F F H, O
, F ,
F F
 Welding Performance Qualification

Weld Plate & pipe Pipe of OD Fillet

OD”24> 2 7/8 - ”24

Plate 1F F
Plate 2F F H
Plate 3F , H, V
Plate 4F F H, O
,
F
 Welding Performance Qualification

Weld Plate & pipe Pipe of OD Fillet

OD”24> 7/8 2 - ”24

Pipe 1G F F F
Pipe 2G F, H F, H F, H
Pipe 5G ,F ,V O ,F ,V O All
Pipe 6G All All All
Pipe 2G 5G + All All All
 Welding Performance Qualification

Weld Plate & pipe Pipe of OD Fillet

OD”24> 2 7/8 - ”24

Pipe 1F F
Pipe 2F F H
Pipe 2FR , H
Pipe 4F F H, O
Pipe 5F All
,
F
 Welding Performance Qualification
Thk Max tk of .dep Metal Test
”3/8 2t ,1FB 1RB
”3/8> 2t ,1FB 1RB
”1/2> Max to be welded 2SB

OD of test coupon Range of OD qualified

”1 < Size welded - unlimtd
2 - 1 ”7/8 unlimited - ”1
”7/8 2 > unlimited - ”7/8 2
Welding Performance Qualification
Test coupon More than 2 welders different
procedure can do a single test coupon. then
.Failure 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
 Welding Performance Qualification

Variables for SMAW

Removal of backing
Change in Pipe diameter
Change in P number F
Change in Number
Change in thickness of deposit
Change in weld welding
position
Welding Performance Qualification
Variables for GTAW
Removal of backing
Change in Pipe diameter
Addition / deletion of filler metal
/ Addition deletion of insert
Change in P number
Change in F Number
Change in solid filler to flux cored filler metal
Change in thickness of weld deposit
Change in welding position
Removal of inert gas backing
Change in current or polarity
 Welding Performance Qualification
F No qualification with backing
F1 with backing F1 with backing
F1 without backing F1 with & without backing
F2 with backing F1 & F2 with backing
F2 without backing F2 with & without backing, F1 with
F3 with backing backing
F3 without backing F3 F1, F2 & F3 with backing
with & without backing, F1, backing
F2 with
F4 with backing F1, F2, F3 & F4 with backing
F4 without backing F4 with & without backing, F1, F2, F3 with
backing
F5 with backing F1 & F5 with backing
F5 without backing F5 with & without backing, F1 with
backing
 Tests for Qualification
Tension test Minimum values for specified
tensile strength
For dissimilar joint, lesser of the two
values
If break outside weld, if tensile st.
value not < 5% of the base metal

Bend test No open discontinuity > 1/8” in any

direction

Impact test In accordance with the section

 Tests for Qualification

Radiography No crack or LOP or LOF

Any elongated slag ”for t <3/8
”>1/8
t for t 3/8 - 2 1/4”
1/3
”“ for t>2 1/4
Any group of slag in a3/4
line with aggregate
length t in 12 t unless separated by 6L

Max permissible dimension for rounded

”indication smaller of 20% of t or 1/8
For thickness<1/8”, max no of accepted
rounded indication 12 in 6” length
For thickness>1/8”, charts for max
acceptable types of rounded indication
 Welder’s Performance
Qualification as per

Indian Boiler Regulations

 Welder’s Performance
Qualification as per
IBR
Initial qualification of welders - Certificate valid
for 24 months provided welder has been
employed with reasonable continuity

If preceding three months, no welding carried out

or if there is any doubt on welder’s stability then
requalification needed
 Welder’s Performance
Qualification as per IBR
Requalification of welders must for the following

Omission of backing strip

Change in class of electrode
Change in base metal to be
Change in welded welding
Change from dc to ac and vice versa
process
 Tests for Initial Qualification
• Theoretical examination
• Groove welds in plate - single or double vee 299 x
x 16 mm min size in flat, horizontal or 381
Vertical or horizontal position also qualifies.vertical
for all
• Fillet weld in plate - 16 x 381 mm min in flat,
,horizontal vertical or overhead. Horizontal or
vertical also qualifies for flat. Vertical position also
.qualifies for flat, horizontal or vertical
 Tests for Initial Qualification
Pipe welding in the following positions (i)
Horizontally rolled (ii) Horizontal turned (iii) Vertical
fixed
Horizontal fixed. Qualification in (ii) or (iii) also (iv)
qualifies
.Qualification in (iv) also qualifies (i) or (ii) .)i(

Branch to pipe welding

Pipe size 127 OD x 10 tk. Tube 89 OD x 6
.tk
Tube welding with axis vertical and tubes of same size
.fixed in adjoining positions
 Tests for Requalification
• No theoretical examination
• Plate welding 152 length x 229 x 16 tk in deg
45 position. Weld to be done from
• .underside
• Pipe welding with axis of pipe horizontal.
• Branchand
Tube welding axis vertical to pipe asof
tubes earlier
same size in
.adjoining position
• Regular production weld to the satisfaction of
competent authority may be accepted as
alternative to the above tests
Examination of the weld for
initial Qualification
PLATE QUALIFICATION

• Visual examination
• Radiography
• no 2 of Tensile test
• no 2 each of Bend test face and root bend - ( 3t for
both )C steel and alloy steel 180 deg bend
• no 1 Micro examination
• no 1 Macro examination
 Examination of the weld for
initial Qualification
PIPE QUALIFICATION

• Visual examination
• Macro examination
• no each of Bend test 2 face and root bend - ( 3t for
)C steel and 4t for alloy steel 90 deg bend
Examination of the weld for
Requalification
PLATE QUALIFICATION
• Radiography
• no each of Bend test 1 face and root - bend

PIPE QUALIFICATION
• no each of bend test - face and root 1
• bend
Macro examination