The tests commonly required by ASME Section IX are: Tensile Bends Face Root Side
Table QW -451 is the Procedure qualification thickness limits and test specimens requirements. Each groove weld must pass tension tests and transverse bend tests. This table is where the requirements for testing are listed..
After the procedure qualification testing the Welding Inspector must check production welding to ensure welds are being made in compliance with the
approved and tested weld procedure. Remember the weld procedure is proof that the weld can be successfully made.
The general sequence for procedure qualification testing is as follows: • Select welding variables (write the WPS and PQR)
• Check equipment and materials for suitability • Monitor weld joint fit-up as well as actual welding,
recording all important variables and observations
• Select, identify and remove required test specimens • Test and evaluate specimens
• Review test results for compliance with applicable code requirements
• Release approved procedure for production • Qualify individual welders in accordance with this
procedure
• Monitor production welding for procedure compliance
QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS ( W P S )
(See QW-200.1, Section IX, ASME Boiler and Pressure Vessel Code)
Company Name : By:
Welding Procedure Specification No. Date: Supporting PQR No.(s)
Revision No. Date:
Welding Process(es): Type(s):
Automatic, Manual, Machine, or Semi-Auto JOINTS (QW-402) Details Joint Design
Backing (Yes) (No)
Backing Material (Type)
(Refer to both backing and retainers) Metal Nonfusing Meal Nonmetalic Other Sketches, Production Drawings, Weld Symbols or Written Des- cription should show the general arrangement of the parts to be welded. Where applicable, the root spacing and the details of weld groove may be specified. (At the option of the Mfgr., sketches may be attached to illus- trate joint design, weld layers and bead sequence, e.g., for notch toughness procedures, for multiple process procedures, etc.) *BASE METALS (QW-403) P-No. Group No. to P-No. Group No.
OR Specification type and grade
to Specification type and grade
OR Chem. Analysis and Mech. Prop.
to Chem. Analysis and Mech. Prop.
Thickness Range: Base Metal: Groove Fillet
Pipe Dia. Range: Groove Fillet
Other:
*FILLER METALS (QW-404) Spec. No. (SFA)
AWS No. (Class)
F-No.
A-No.
Size of Filler Metals
Weld Metal Thickness Range: Groove
Fillet
Electrode-Flux (Class)
Flux Trade Name
Consumable Insert
Other
Sample Procedure
Using SMAW variables the following represents a sample welding procedure. This procedure will be written under “ideal conditions”. The production information is as follows:
• A piping system is under construction using welding procedures qualified to ASME Section IX.
• The pipe wall is 1 inch thick. • The base material is SA-106-B.
• Filler material will be F-3 for the root pass and F-4 for the fill. • There are no special service restrictions
The first part is general information supplied by the writer. a detailed sketch of the joint should be included in the space provided or on attached sheets. (QW402.1)
«
Base MetalsThe P-No. is 1 to 1 (See QW-403.1)
The Specification, Type and Grade: SA 106 Grade B (Supplied Example) Thickness Range: (QW-403.7 and QW-403.8)
Pipe Diameter Range: 2 7/8 inch Outside Diameter and over (QW-452.3)
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Filler Metals (QW-404.4) SFA-5.1 &5.5 (QW-432)AWS No. E-6010 (Supplied Example) AWS No. E-7018 (Supplied Example) F-No.: 3 (QW-432) F-No.: 4 (QW-432)
QW-482 (Back)
WPS No. Rev.
POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407) Position(s) of Groove Temperature Range
Welding Progression: Up Down Time Range
Position(s) of Fillet
GAS (QW-408) PREHEAT (QW-406) Percent Composition Preheat Temp. - Min. Gas(es) (Mixture) Flow Rate Interpass Temp. - Max.
Preheat Maintenance Shielding (Continuous or special heating where applicable should be recorded) Trailing Backing ELECTRICAL CHARACTERISTICS (QW-409) Current AC or DC Polarity
Amps (Range) Volts (Range)
(Amps and volts range should be recorded for each position, and thickness, etc. This information may be listed in a tabular form similar to that shown below. Tungsten Electrode Size and Type
(Pure Tungsten, 2% Thorated, etc.) Mode of Metal Transfer for GMAW
(Spray arc, short-circuiting arc, etc.) Electrode Wire feed speed range
TECHNIQUE (QW-410) String or Weave Bead
Orifice or Gas Cup Size
Initial and Interpass Cleaning (Brushing, Grinding, etc.)
Method of Back Gouging
Oscillation
Contact Tube to Work Distance
Multiple or Single Pass (per side)
Multiple or Single Electrodes
Travel Speed (Range)
Peening
Other
Filler Metal Current
Other
Travel (e.g., Remarks, Comments, Weld Type Amp Volt Speed Hot Wire Addition,Technique, Layer(s) Process Class Dia. Polar Range Range Range Torch Angle, Etc.)
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Positions (QW-405.1)Welding Progression: (QW-405.3)
«
Preheat (QW-406.1) QW-407.1 Special requirements for preheating«
Postweld heat treatment (QW-407) none required«
Gas (QW-408) none required«
Electrical Characteristics (QW-409.4) Current: DC Polarity: DCRP Amps: (QW-409.8)«
Technique (QW410.1)String or Weave Bead: Stringer / Weave
Cleaning: (QW-410.5) Brush or grind as necessary
Method of Back Gouging: (QW-410.6) ACA-A or grind as necessary Peening: (QW-410.26) None allowed
QW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD ( P Q R )
(See QW-200.2, Section IX, ASME Boiler and Pressure Vessel Code) Record Actual Conditions Used to Weld Test Coupon
Company Name
Procedure Qualification Record No. Date
WPS No .
Welding Process(es)
Types (Manual, Automatic, Semi-Auto.)
JOINTS (QW-402) Groove Design of Test Coupon (For combination qualifications, the deposited weld metal thickness will be required for each filler metal or process used.) BASE METALS (QW-403) POST WELD HEAT TREATMENT (QW-407) Material Spec. Temperature
Type or Grade Time
P. No. to P-No. Other
Thickness of Test Coupon
Diameter of Test Coupon
Other
GAS(QW-408) Percent Composition Gas(es) (Mixture) Flow Rate
Shielding FILLER METALS (QW-404) Trailing SFA Specification Backing AWS Classification
Filler Metal F-No. ELECTRICAL CHARACTERISTICS (QW-409) Weld Meal Analysis A-No. Current
Size of Filler Metal Polarity
Other Amps. Volts
Tungsten Electrode Size
Weld Metal Thickness Other
POSITION (QW-405) TECHNIQUE (QW-410) Position of Groove Travel Speed
Weld Progression (Uphill, Downhill) String or Weave Bead
Other Oscillation
Multipass or Single Pass (per side)
Single or Multiple Electrodes
PREHEAT (QW-406) Other
Preheat Temp.
Interpass Temp.
Other
QW-483 (Back) PQR No. Tensile Test (QW-150) Guided-Bend Tests (QW-160) Toughness Tests (QW-170) Fillet-Weld Test (QW-180) Result- Satisfactory: Yes No Penetration into Parent Metal: Yes No
Macro - Results Other Tests Type of Test Deposit Analysis Other ...
Welder’s Name Clock No. Stamp No.
Tests conducted by: Laboratory Test No.
We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code. Manufacturer
Date By
(Detail of record of tests are illustrative only and may be modified to conform to the type and number of test required by the Code.)
Ultimate Ultimate Type of
Specimen Total Load Unit Stress Failure &
No. Width Thickness Area lb. psi Location
Type and Figure No.
Specimen Notch Notch Test Impact Lateral Exp. Drop Weight No. Location Type Temp. Values % Shear Mils Break No Break
ASME Section IX Welder Qualification
Welder qualification establishes the skill level for the welder. The test positions are similar to the welding procedure positions. The essential variables for welder qualification are as follows:
• Position Base Metal Type • Joint Configuration Base Metal Thickness
• Electrode Type and Size Technique (Up-hill or Down-hill) • Process
(a) 1G (b) 2G
(c) 3G
(d) 4G
QW-461.3 Groove Welds in Plate -- Test Positions
(a) 1G Rotated
(b) 2G (c) 5G
(d) 6G
QW-461.4 Groove Welds in Pipe -- Test Positions
45 deg.
Throat of weld vertical
Axis of weld
horizontal Axis of weld
horizontal Axis of weld
vertical
QW-461.5 Fillet Welds in Plate - Test Positions
(a) 1F (b) 2F