ASME SEC 9

(1)

ASME SEC IX

-Welding

Welding

Procedure

Procedure and

and

performance qualification

(2)

What is the need for WPS &

performance qualification?

•

• To ensure the safety of the weldedTo ensure the safety of the welded

constructions constructions

•

• Bhopal tragedy,three mile islandBhopal tragedy,three mile island accident, Chernbyl accident,

accident, Chernbyl accident, Breakage

(3)

Why

ASME

ASME qualification

qualification &

&

certification?

•

• To ensure that design practices,To ensure that design practices,

manufacturing practices, fabrication manufacturing practices, fabrication

techniques, & inspection techniques are techniques, & inspection techniques are performed by personnel who are

performed by personnel who are

qualified in accordance with good engg. qualified in accordance with good engg. practices and standards

(4)

Selecting Your Welding Process

1.

1. The joThe joint tint to be o be welded welded is anis analyzed ialyzed in tern terms of ms of itit

requirements.

2. The joint requirements are matched with the

capabilities of available processes. One or more

of the processes are selected for further

examination.

3. A checklist of variables is used to determine the

ability of the selected processes(s) to meet the

particular application

4. Finally, the proposed process or processes

deemed most efficient are reviewed

(5)

Step 1 - Analysis of Joint Requirements

The first thing to look at is whether your weld joint is

large or small, whether the joint is out-of-position or not,

and whether the base metal is thick or thin.

In welding, the needs of any joint are

expressed in four terms:

expressed in four terms: Fast-Fill Fast-Fill (high (high

deposition rate),

deposition rate), Fast-Freeze Fast-Freeze (the joint is (the joint is

out-of-position - overhead or vertical),

Fast-Follow

Fast-Follow (high arc speed and very small (high arc speed and very small

welds), and

welds), and Penetration Penetration (the depth the (the depth the

weld

(6)

Fast-Fill is required when a large

amount of weld metal is needed

to fill the joint. A heavy weld bead

can only be laid down in minimum

arc time with a high deposition rate.

However, Fast-Fill becomes a minor

consideration when the weld is small.

Fast-Freeze implies that a joint is

out-of-position, and therefore requires

quick solidification of the molten crater.

Not all semiautomatic processes can

be used on fast-freeze joints.

Step 1

(7)

Fast-Follow suggests that the molten metal follows the

arc at rapid travel speed, giving continuous, well-shaped

beads, without "skips" or islands. This trait is especially

desirable on relatively small single-pass welds, such as

those used in joining sheet metal.

Penetration varies with the joint. With

some joints, penetration must be deep

to provide adequate mixing of the weld

and base metal and with others it must

be limited to prevent burnthrough or

Cracking.

Analysis of Joint Requ

(8)

Step 2 - Matching Joint Requirements

With Processes

Information (on the deposition rate and

arc-speed characteristics of each process

from literature)on the ability of various

processes to fulfill the needs of the joint

(9)

Step 3 - The Checklist

•

• Volume Volume of of ProductionProduction •

• Weld Weld SpecificationsSpecifications •

• Operator Operator SkillSkill •

• Auxiliary Auxiliary EquipmentEquipment

•

• Accessory Accessory EquipmentEquipment

•

• Base-Metal Base-Metal ConditionsConditions •

• Arc Arc VisibilityVisibility •

• Fixturing Fixturing RequirementsRequirements

•

(10)

Step 4 - Review of the Application by

Manufacturer's Representative

(11)

WPS

–

Welding Procedure

Specification

PQR

–

Procedure Qualification

Record

(12)

What is a WPS?

A WPS is a "Welding Procedure Specification"

or

or "Welding "Welding Procedure" Procedure" as as it it is is commonlycommonly

called.

called. It It contains contains the the combination combination of of variablesvariables

used

used to to make make a a certain certain weld. weld. This This includes theincludes the

process (SMAW, FCAW etc.), the electrode type,

electrical characteristics, base metal used,

preheat

preheat and and interpass interpass temperatures, temperatures, travel travel speedspeed

and position, post weld heat treatment, shielding

gas and flow rate, and the type of joint being

welded.

(13)

(14)

What is WPS in a layman view

point

•

• WPS lists all the parameters required to produce aWPS lists all the parameters required to produce a

sound weld to the specific code

•

• Specific parameters such as process,Specific parameters such as process,

technique,filler,current,voltage,etc., to be included

•

• It should list a range on each parameter such asIt should list a range on each parameter such as

amps = 110-150, voltage =17-22 with the more

essential or critical parameters more closely defined

or limited

•

• It It should give should give enough details enough details so so that any that any qualifiedqualified

welder could follow and produce the desired weld.

(15)

Purpose of WPS Qualification

To determine that the weldment is To determine that the weldment is capable of providing the required capable of providing the required

properties for the intended application. properties for the intended application. WPS establishes the properties of the WPS establishes the properties of the weldment and not the skill of the

weldment and not the skill of the welder.

(16)

Welding Procedure Specification

It is a written document that provides It is a written document that provides direction to the welder for making

direction to the welder for making

production welds in accordance with production welds in accordance with code requirements.

code requirements.

Any WPS must be qualifi

Any WPS must be qualified by theed by the manufacturer.

manufacturer.

WPS specifies the condition (ranges) WPS specifies the condition (ranges)

under which welding must be performed under which welding must be performed called variables.

called variables.

WPS addresses essential, supplementary WPS addresses essential, supplementary essential and non essential variables

(17)

Procedure Qualification Record

It documents what occurred during It documents what occurred during

welding the test coupon and the results welding the test coupon and the results of the test coupon.

of the test coupon.

PQR documents the essential variables PQR documents the essential variables and other specific information and the and other specific information and the results of the required

results of the required testing. Intesting. In addition, when notch toughness is addition, when notch toughness is

required for procedure qualification, the required for procedure qualification, the applicable supplementary essential

applicable supplementary essential variables shall be recorded.

(18)

Points to be considered for

establishing WPS

• • Code ofCode of construction construction •

• Detailed drawingDetailed drawing

of weldment of weldment • • MaterialMaterial • • ThicknessThickness • • ConfigurationConfiguration • • ProcessProcess • • Contract/Customer/Contract/Customer/ Code/TPI Code/TPI • • Preheat/Postheat/Preheat/Postheat/ PWHT requirements PWHT requirements •

• Skilled welderSkilled welder

•

• Good welding m/cGood welding m/c

with accessories with accessories

•

(19)

Variables

• • PreheatPreheat • • PWHTPWHT •

• Joint designJoint design •

• Backing materialBacking material •

• P NumberP Number •

• Welding ProcessWelding Process •

• Filler metalFiller metal •

• ElectrodeElectrode •

• Method of backMethod of back

gauging gauging • • EssentialEssential • • Non-essentialNon-essential • • SupplementalSupplemental essential essential

(20)

Essential Variables

A

A change change in in welding welding condition condition whichwhich will affect the mechanical properties will affect the mechanical properties of the weldment.

of the weldment.

(Change in base metal, welding (Change in base metal, welding process, Filler metal, Electrode, process, Filler metal, Electrode, Pre-heat, PWHT, etc.)

(21)

Non Essential Variables

A

A change change in in welding welding condition condition whichwhich will NOT affect the mechanical will NOT affect the mechanical properties of the weldment.

properties of the weldment.

(Change in Joint Design, Methods of (Change in Joint Design, Methods of Back gauging, Cleaning, etc.)

(22)

Supplementary Essential

Variables

A

A change change in in welding welding conditioncondition which will affect the which will affect the Notch-Toughness (Impact) properties of Toughness (Impact) properties of the weldment.

the weldment.

(Change in Heat input, Uphill or (Change in Heat input, Uphill or Down Vertical welding, Diameter Down Vertical welding, Diameter of Electrode, Position, etc.)

(23)

Joints(QW:402)

•

• Joint DesignJoint Design •

• BackingBacking •

• Baking MaterialBaking Material

Type Type

(24)

Base Metal Classification

Why P numbers?

To reduce the number of welding procedure To reduce the number of welding procedure

qualifications, base metals have been assigned qualifications, base metals have been assigned P-nos and for ferrous base metals which have P-nos and for ferrous base metals which have specified

specified impact impact test test requirements, requirements, groupgroup numbers within P-nos are again given

numbers within P-nos are again given

P nos depend on composition, weldability &

mechanical properties.

•

•Group nos classify metals within P nos forGroup nos classify metals within P nos for

procedure qualification where notch toughness

requirements are specified.

•

•The above assignments do not imply that baseThe above assignments do not imply that base

metals can be substituted without consideration

of metallurgical

(25)

Examples of P

Examples of P numbersnumbers

P1 P1 C C SteelSteel P3 P3 1/2 1/2 Mo Mo steelssteels P4 P4 1 1 Cr Cr 1/2 1/2 Mo Mo steelssteels P5A

P5A 2 2 1/4 1/4 Cr Cr 1 1 Mo Mo steelssteels

P6 P6 13 13 Cr Cr steelsteel P7 P7 17 17 Cr Cr steelsteel P8 Austenitic P8 Austenitic StainlessSteel StainlessSteel P9A

P9A 2 2 1/2 1/2 Ni Ni steelssteels

P10A

P10A Mn Mn - - 1/2 1/2 Ni Ni - - V V steelssteels

P11

P11 9 9 Ni Ni steelssteels

Base Metal P Numbers

P1 P1 P11 P11 SteelSteel P21 P21 P25 P25 Al Al alloysalloys P31 P31 P35 P35 Cu Cu alloysalloys P41 P41 P47 P47 Ni Ni alloysalloys P51 P51 P53 P53 Ti Ti alloysalloys P61 P61 P62 P62 Zr Zr alloysalloys

(26)

Base Metal for WPS

Test

Test Coupon Coupon Base Base Metal Metal qualifiedqualified

Px Px - - Px Px PxPx Px Px - - Py Py Px Px - - PyPy P3 P3 - - P3 P3 P3P3 – – ( P3 / P1) ( P3 / P1) P4 P4 - - P4 P4 P4P4 – – ( P4 / P3 / P1) ( P4 / P3 / P1) P5A

P5A - - P5A P5A P5AP5A – – ( P5A / P4 / P3 / P1) ( P5A / P4 / P3 / P1) P5A

P5A – – (P4 / P3 / P1) P5A (P4 / P3 / P1) P5A – – (P4 / P3 / P1) (P4 / P3 / P1) P4

(27)

Base

Metal(QW-403

)

•

• P. NumberP. Number •

• Group NumberGroup Number •

• SpecificationSpecification •

• Chemical Analysis & MechanicalChemical Analysis & Mechanical

Properties Properties

•

• Thickness RangeThickness Range •

(28)

(29)

P1/Group 1

Carbon Steel

T

Tubes ubes Pipes Pipes Plates Plates Forgings Forgings CastingCastingss

SA179 SA179 SA192 SA192 SA210GrA1 SA210GrA1 SA334Gr1 SA334Gr1 SA334Gr6 SA334Gr6 SA106GrB SA106GrB SA333Gr1 SA333Gr1 SA333Gr6 SA333Gr6 SA36 SA36 SA515Gr55 SA515Gr55 SA515Gr60 SA515Gr60 SA515Gr65 SA515Gr65 SA516Gr55 SA516Gr55 SA516Gr60 SA516Gr60 SA516Gr65 SA516Gr65 SA266CL1 SA266CL1 SA350LF1 SA350LF1 SA216WCA SA216WCA SA352LCA SA352LCA SA352LCB SA352LCB

(30)

P1/Group 2

Carbon Steel

Tubes

Tubes Pipes Pipes Plates Plates Forgings Forgings CastingsCastings

SA210GrC SA106GC

SA210GrC SA106GC SA515Gr70SA515Gr70

SA516Gr70 SA516Gr70 SA299 SA299 SA105 SA105 SA266CL2 SA266CL2 SSA350LF SSA350LF 2 2 SA216WC SA216WC B B SA216WC SA216WC C C SA352LCC SA352LCC

(31)

Other Specification

Carbon Steel

Tubes

Tubes Pipes Pipes Plates Plates Forgings Forgings CastingsCastings

IS1239

IS1239 API5LGrB API5LGrB IS226IS226

IS2062 IS2062 BMC10 BMC10 BMC16 BMC16 BMC20 BMC20

(32)

P3/Group 1

T

SA209T1

SA209T1 SA335P1 SA335P1 SA204GrA SA204GrA SA217WC1SA217WC1

½ Cr ½ Mo - P3 Group 2

T

SA213T2

SA213T2 SA335Gr2 SA335Gr2 SAA387Gr2SAA387Gr2

½

(33)

P4/Group 1

T

SA213T12

SA213T12 SA335P12 SA335P12 SA387Gr12 SA387Gr12 SA182F12 SA182F12 SA217WC6SA217WC6

1¼ Cr ½ Mo

T

SA213T11

SA213T11 SA335P11 SA335P11 SA387Gr11 SA387Gr11 SA182F11SA182F11

1Cr ½ Mo

(34)

P5A/Group 1

2¼Cr 1Mo

T

SA213T22

(35)

P5B/Group 1

T

SA213T5

SA213T5 SA335P5 SA335P5 SA387Gr5 SA387Gr5 SA182F5SA182F5

SA336Cl F5 SA336Cl F5 SA217C5 SA217C5

9Cr 1Mo

T

SA213T9

SA213T9 SA335P9 SA335P9 SA182F9SA182F9

SA336Cl F9 SA336Cl F9 SA217C9 SA217C9

5Cr ½ Mo

(36)

P5B/Group 2

9Cr 1Mo ¼ V

T

SA213T91

SA199T91

SA335P91

(37)

P8/Group 1

18Cr 8Ni

T

Tubes ubes Pipes Pipes Plates Plates Forgings Forgings CastingsCastings

SA213TP304 SA213TP304 SA213TP304H SA213TP304H SA213TP316 SA213TP316 SA213TP321 SA213TP321 SA213TP347 SA213TP347 SA213TP347H SA213TP347H SA376TP304 SA376TP304 SA376TP304H SA376TP304H SA376TP316 SA376TP316 SA376TP321 SA376TP321 SA376TP347 SA376TP347 SA376TP347H SA376TP347H SA240TP304 SA240TP304 SA240TP321 SA240TP321 SA240TP347 SA240TP347 SA182F304 SA182F304 SA182F321 SA182F321 SA182F347 SA182F347 SA336F304 SA336F304 SA336F321 SA336F321 SA336F347 SA336F347 SA351CF3 SA351CF3 SA351CF8 SA351CF8 SA351CF3M SA351CF3M SA351CF8M SA351CF8M SA351CF10 SA351CF10 SA351CF10M SA351CF10M

(38)

P8/Group 2

25Cr 20Ni (Type 310)

Tubes

Tubes Plates Plates Forgings Forgings CastingsCastings

SA213TP310H SA240TP310 SA182F310 SA351CK20

(39)

Filler Metals(QW-404)

•

• AWS Number AWS Number •

• SFA NumberSFA Number •

• F. NumberF. Number •

• A. Number A. Number

•

• Size of Filler metalSize of Filler metal

•

• Flux trade nameFlux trade name

•

• Consumable insertConsumable insert

•

• Electrode flux classElectrode flux class

•

(40)

Filler Metal F Numbers

Based on usability characteristics i.e Based on usability characteristics i.e ability of welders to make satisfactory ability of welders to make satisfactory welds with given filler

welds with given filler F1 F1 E E XX20,XX24,XX27XX20,XX24,XX27 F2 F2 E E XX12, XX12, E E XX13,XX14XX13,XX14 F3 F3 E E XX10, XX10, E E XX11XX11 F4 F4 E E XX15,XX16,XX18XX15,XX16,XX18 F5

F5 ASS, ASS, Duplex Duplex SSSS F6

(41)

Filler Metal A Numbers

Based on chemical composition

A1

A1 Mild steeMild steell

A2

A2 C - Mo steelC - Mo steel

A3

A3 Cr - Mo steCr - Mo steel (Cr 0.4 - 2%)el (Cr 0.4 - 2%)

A4

A4 Cr - Mo steCr - Mo steel (Cr 2 - 6%)el (Cr 2 - 6%)

A5

A5 Cr - Mo steCr - Mo steel (Cr 6 - 10.5%el (Cr 6 - 10.5%))

A6

A6 Cr MarteCr Martensiticnsitic

A7

A7 Cr FerriCr Ferritictic

A8

A8 Cr Ni steeCr Ni steelsls (Cr 14.5 - 30% Ni 7.5 - 15%)(Cr 14.5 - 30% Ni 7.5 - 15%)

A9

A9 Cr Ni steeCr Ni steelsls (Cr 19 - 30% Ni 15 - 37%)(Cr 19 - 30% Ni 15 - 37%)

A10

A10 Ni steels (Ni Ni steels (Ni 0.8 - 4%)0.8 - 4%)

A11

A11 Mn Mo steels(Mn 1.25-2.25 Mo 0.25-0.75%)Mn Mo steels(Mn 1.25-2.25 Mo 0.25-0.75%)

A12

A12 Ni Cr Mo stNi Cr Mo steelseels (Cr 1.5% Mo 0.25-0.8%(Cr 1.5% Mo 0.25-0.8%

Ni 1.25 -2.8%)

(42)

Preheat(QW:406)

•

• Preheat temperature (Preheat temperature (Minimum)Minimum)

•

• Interpass tempInterpass temp.(Maximum).(Maximum)

•

(43)

PWHT(QW:407)

•

• Temperature rangeTemperature range •

• Time rangeTime range

•

(44)

Gas(QW:408)

•

• Gases Gases Mixture Mixture % % Flow Flow raterate

(

(e.g. 75% Ar 25%COe.g. 75% Ar 25%CO₂₂)) • • ShieldingShielding • • TrailingTrailing • • BackingBacking Trail shield Trail shield

(45)

Electrical

Characteristics(QW-409)

•

• Current (AC/DC)Current (AC/DC) •

• Polarity (EP/EN)Polarity (EP/EN)

•

• Amps & Volts Amps & Volts

•

• W-Electrode type & sizeW-Electrode type & size •

• Mode of Metal TransferMode of Metal Transfer •

• Electrode Wire Feed Speed rangeElectrode Wire Feed Speed range

•

(46)

(47)

METAL TRANSFER IN GMAW

Application

Thin

Thin sheet sheet &&

all position welding

capability

Globular transfer

Short circuit transfer

Spray transfer

Medium voltage & current

Low voltage & current

High voltage & current

Applications

Down hand position welding

Sheet thickness > 2 mm

(48)

Techniques(QW-410)

•

• Stringer or Weave BeadStringer or Weave Bead

•

• Orifice/Gas Cup SizeOrifice/Gas Cup Size

•

• Initial or Interpass CleaningInitial or Interpass Cleaning •

• Method of Back GaugingMethod of Back Gauging

•

• OscillationOscillation

•

• Contact Tip to Work DistanceContact Tip to Work Distance

•

• Multiple or Single PassMultiple or Single Pass •

• Multiple Or Single ElectrodeMultiple Or Single Electrode

•

• Electrode SpacingElectrode Spacing

•

• PeeningPeening

•

(49)

Procedure Qualification

PQR is a record of we

PQR is a record of welding data to weldlding data to weld a test coupon. It also contains test

a test coupon. It also contains test results.

results.

Completed PQR shall document all Completed PQR shall document all essential variables including ranges. essential variables including ranges.

PQR to be certified accurate and s

PQR to be certified accurate and shallhall not be subcontracted.

not be subcontracted.

If more than one process then weld If more than one process then weld

deposit thickness for each process and deposit thickness for each process and filler metal to be recorded.

(50)

Procedure Qualification

Several WPSs may be prepared from one Several WPSs may be prepared from one PQR.

PQR.

eg. 1G plate PQR may support WPSs eg. 1G plate PQR may support WPSs inin 2G, 3G, 4G, pipe 5G, 6G etc p

2G, 3G, 4G, pipe 5G, 6G etc providedrovided other parameters are kept same.

other parameters are kept same. A single WPS may co

A single WPS may cover several PQRsver several PQRs eg. A single WPS may cover

eg. A single WPS may cover 1.6 mm to1.6 mm to 32 mm thickness if PQRs for 1.6 to 32 mm thickness if PQRs for 1.6 to 4.84.8 mm and 4.8 mm to 32 mm thickness mm and 4.8 mm to 32 mm thickness ranges. ranges.

(51)

Weld Orientation

Plate groove positions 1G, 2G, 3G, 4G Plate groove positions 1G, 2G, 3G, 4G Pipe groove positions 1G, 2G, 5G, 6G Pipe groove positions 1G, 2G, 5G, 6G Plate fillet positions 1F, 2F, 3F, 4F

Plate fillet positions 1F, 2F, 3F, 4F Pipe

Pipe fillet fillet positions positions 1F, 1F, 2F, 2F, 2FR, 2FR, 4F, 4F, 5F5F 1F - 0 to 30 1F - 0 to 30 2F - +15 -10 wrt 45 2F - +15 -10 wrt 45 4F - 0 - 125 4F - 0 - 125 3F - 125 - 235 3F - 125 - 235

(52)

Procedure Qualification

When two or more

When two or more procedures (diffprocedures (diff

processes or other essential variables) are

used in one joint, use

used in one joint, use table for determiningtable for determining

the applicable range of

the applicable range of thickness qualified.thickness qualified.

Carry out tension test for

Carry out tension test for each weld metal.each weld metal.

One or more processes from a

combination may be

combination may be deleted provideddeleted provided

remaining metal meets the requirements.

(53)

Procedure Qualification Thickness limits Procedure Qualification Thickness limits

T

T Range Range of of T T max max t t Tests Tests (transverse(transverse

bend) bend) <1/16” <1/16” _T_T_-_-_2T_2T _2t_2t _2T,_2T,₂₂_FB,_FB,₂₂_RB_RB 1/16-1/16-3/8” 1/163/8” 1/16 _-_-_2T_2T _2t_2t _-do- -do- 3/8-3/8-3/4” 3/163/4” 3/16 _-_-_2T_2T _2t_2t _-do- -do- 3/4-3/4-1.5” 3/161.5” 3/16 _-_-_2T_2T _2t_2t_if_if_t<3/4_t<3/4 _2T,_2T,₄₄_SB_SB 2T if t>3/4 2T if t>3/4 >1.5” >1.5” _3/16_3/16_-_- 8”8” 2t if t<3/4”2t if t<3/4” _-do- -do-8 if t>3/4” 8 if t>3/4”

(54)

Procedure Qualification Thickness limits Procedure Qualification Thickness limits

T

T Range Range of of T T max max t t Tests Tests (longtl(longtl

bend) bend) <1/16” <1/16” T T - - 2T 2T 2t 2t 2T, 2T, 2 2 FB, FB, 2 2 RBRB 1/16-1/16-3/8” 1/163/8” 1/16 - - 2T 2T 2t 2t -do- -do-> > 3/8” 3/8” 3/163/16 - - 2T 2T 2t 2t -do-

(55)

-do-WPS for SMAW WPS for SMAW

Essential variables

Change in

Change in qualified Thicknessqualified Thickness

Change in P no

Change in F no of filler metal

Change in A no of filler metal

Change in

Change in deposited metal thicknessdeposited metal thickness

Decrease of more than 100 F in

preheat

Change in PWHT

(56)

WPS for SMAW WPS for SMAW

Supplementary Essential variables

Change in Group no of

Change in Group no of base metalbase metal

Change in T limits for impact test

Change in dia of filler metal > 1/4”

Change in AWS class of filler metal

Change in welding position

Increase of more than 100 F in preheat

Change in PWHT Time

Change in PWHT Time and temp rangeand temp range

Change in current or

(57)

WPS for SMAW WPS for SMAW

Non Essential variables

Change in Groove design, backing, root

spacing, retainers etc

Change in dia of filler

Change in dia of filler metalmetal

Change in AWS class of

Change in AWS class of filler metalfiller metal

Change in preheat

Change in preheat maintenancmaintenancee

Change in current or polarity

Change in

Change in string/weavestring/weave, cleaning, back, cleaning, back

gouging, peening,

(58)

WPS for GTAW WPS for GTAW

Essential variables

Change in

Change in qualified Thicknessqualified Thickness

Change in P no

Change in F no & A

Change in F no & A no of filler metalno of filler metal

Addition/dele

Addition/deletion of tion of filler metalfiller metal

Change in size of filler

Change in size of filler metal, productmetal, product

form

Decrease of more than 100 F in preheat

Change in PWHT

(59)

WPS for GTAW WPS for GTAW Essential variables (cond) Essential variables (cond)

Change in single, mixture % gas Change in single, mixture % gas Deletion of backing gas

Deletion of backing gas

Change in shielding / trailing gas Change in shielding / trailing gas Change in Closed to out chamber Change in Closed to out chamber technique

(60)

WPS for GTAW WPS for GTAW

Supplementary Essential variables Supplementary Essential variables

Change in Group no of base metal Change in Group no of base metal Change in T limits

Change in T limits

Change in AWS class of filler

Change in AWS class of filler metalmetal Change in welding position

Increase of more than 100 F in preheat Increase of more than 100 F in preheat Change in PWHT Time and temp range Change in PWHT Time and temp range Change in current/polarity, incr. in

Change in current/polarity, incr. in heat input

heat input

Change in multi to single pass, Change in multi to single pass, electrodes

(61)

Welding Conditions

Specification,

Specification, type type and and grade grade of of Base Base Metal(s): Metal(s): SA106 SA106 Gr Gr BB

To

To Specification, Specification, type type and and grade grade of of Base Base Metal(s): Metal(s): SA106 SA106 Gr Gr BB

Base

Base Metal Metal P P or or S-number S-number 1 1 to to Base Base Metal Metal P P or or S-number S-number 1 1 Thickness:Thickness:

0.218

Welding

Welding Process(esProcess(es) ) used: used: GTAW GTAW followed followed by by SMAWSMAW

Plate

Plate X X Pipe Pipe (enter (enter diameter diameter if if pipe pipe or or tube): NPS tube): NPS 2, 2, Sch Sch 8080

Groove

Groove type type (Single (Single V, V, Double Double V, V, Single Single U, U, etc): etc): Single Single VeeVee

Initial

Initial cleaning cleaning method: method: Solvent Solvent wipe wipe and and grindinggrinding

Backing

Backing (metal, (metal, weld weld metal, metal, backwelded, backwelded, etc): etc): None None / / Weld Weld metalmetal

Filler

Filler Metal Metal (SFA) (SFA) Specification: Specification: 5.18 5.18 / / 5.15.1

Filler

Filler Metal Metal or or Electrode Electrode Classification: Classification: ER70S-2 ER70S-2 / / E7018E7018

Filler

Filler Metal Metal or or Electrode Electrode Trade Trade Name: Name: Linde Linde 65, 65, Lincoln Lincoln 7018+7018+

Tungsten electrode ty

Tungsten electrode type and size for GTApe and size for GTAW: W: EWTh-2, 3/32"EWTh-2, 3/32"

Consumable Inse

Consumable Insert Class rt Class and size and size for GTAW for GTAW or PAor PAW: W: NoneNone

Backing Gas composition and Flow rate for GTAW, PAW, GMAW: Not Used

Preheat

Preheat Temperature Temperature ((°°F): F): 7575

Position

(62)

Interpass

Interpass cleaning cleaning method: method: Wire Wire brushingbrushing

Measured interpass temperature (

Measured interpass temperature (°°F): F): less less than than 400400

Approxim

Approximate Deposit Thickneate Deposit Thickness for each filler ss for each filler metal or electrode metal or electrode type (in.): type (in.): 0.093 (3/32) / 0.1250.093 (3/32) / 0.125

Current

Current TType/Polaritype/Polarity y (AC, (AC, DCEPDCEP, , DCEN): DCEN): DCEN/DCEP DCEN/DCEP PostwelPostweld d HeatHeat

Treatment

Treatment Time Time and and tempertemperature: ature: 1100-12001100-1200°°F, 65 hr.F, 65 hr.

Visual

Visual Examination Examination of of Completed Completed Weld: Weld: Acceptable Acceptable Date Date of of TTest: est: 12/25/0112/25/01

Bend

Bend TTest est X X TranTransverse sverse Root Root and and Face Face (QW-462.3(a)) (QW-462.3(a)) Side Side (QW-462.2)(QW-462.2)

T

Type ype Result Result TType ype Result Result TType ype ResultResult

Face

Face Acceptable Acceptable Root Root AcceptableAcceptable

Face

Face Acceptable Acceptable Root Root AcceptableAcceptable

Alternative

Alternative Radiographic Radiographic Examination Examination Results: Results: N/AN/A

Specimens

Specimens EvaluateEvaluated d By: By: Dianna Dianna Ross Ross Title: Title: Leader Leader Company: Company: The The Best Best TTestingesting

Company Ever

Welding

Welding SuperviseSupervised d By: By: James James Brown Brown Title Soloist Title Soloist Company: Company: Joe-Bob's Joe-Bob's B&NPW B&NPW ShopShop

Welder’s Name:

Welder’s Name: Wolfgang Wolfgang Amadeus Amadeus Mozart Mozart Stamp Stamp No: No: A1A1

We certify that the statements in this record are correct and that the weld described above was prepared,

welded and tested in accordance with the r

(63)

(64)

(65)

(66)

(67)

Performance Qualification

The basic criterion for welder’s

The basic criterion for welder’s qualification is to determine the qualification is to determine the

welder’s ability to deposit sound weld

welder’s ability to deposit sound weld metal.

metal.

The purpose of performance The purpose of performance

qualification test is to determine the qualification test is to determine the

welding operator’s mechanical ability to

welding operator’s mechanical ability to operate the welding equipment

(68)

Fillet

Fillet welding welding of of plateplate

Vertical Vertical Horizontal Horizontal Flat Flat overhead overhead 1F 1F 2F 2F 3F 3F 4F 4F

GMAW

(69)

(70)

(71)

(72)

(73)

(74)

(75)

Welders Performance Qualification

The performance qualification tests are The performance qualification tests are intended to determine the ability of

intended to determine the ability of welders to make sound welds

welders to make sound welds A welder is qualified

A welder is qualified by radiography of aby radiography of a test coupon or by radiography of initial test coupon or by radiography of initial production welding or by bend tests

production welding or by bend tests taken from a test coupon

(76)

Variables affecting the

welders qualification

Welding conditions that affect the Welding conditions that affect the

ability of welder to produce sound ability of welder to produce sound welds are qualification variables welds are qualification variables

•

• Welding processWelding process

•

• Filler metalFiller metal •

• Welding positionWelding position •

• Joint backingJoint backing •

(77)

Welding process

•

• A change in welding A change in welding processprocess – –fromfrom

SMAW

SMAW to to GTAW, GTAW, for for eg.,requires eg.,requires thethe requalification of the welder since

requalification of the welder since skill required to use one process is skill required to use one process is different from another one.

(78)

Filler metals

•

• Filler metals used in welding areFiller metals used in welding are grouped based on their usability grouped based on their usability

characteristics. These are assigned characteristics. These are assigned F-numbers

numbers

•

• Ordinarily welder is qualified for a F noOrdinarily welder is qualified for a F no and do the same in production

and do the same in production

•

• SAW :F1-F4: Qualification in higher FnoSAW :F1-F4: Qualification in higher Fno

entails qualfication for lower F nos of entails qualfication for lower F nos of electrodes

(79)

Backing

•

• Joint backing includes any material placed atJoint backing includes any material placed at

the root of the weld to support the liquid

metal

metal(e.g backing strip,non fusing bars, root(e.g backing strip,non fusing bars, root

weld with another process,etc)

•

• If a welder qualifies using a backing on theIf a welder qualifies using a backing on the

test coupon but the backing is removed for the

production welding for a joint made from one

side, then he must requalify

•

• If a welder qualifies using without a backing,If a welder qualifies using without a backing,

for a joint with backing he is automatically

qualified

(80)

Welders Performance Qualification

Welded Qualified Welded Qualified Without Backing Without Backing Fx Fx Fx Fx With Backing With Backing F1 F1 F1 F1 F2 F2 F2, F2, F1F1 F3 F3 F3, F3, F2, F2, F1F1 F4 F4 F4, F4, F3, F3, F2, F2, F1F1 F5 F5 F5, F5, F1F1

(81)

Welders Performance Qualification Welders Performance Qualification

F No qualification with backing

F1

F1 with with backing backing F1 F1 with with backingbacking

F1

F1 without without backing backing F1 F1 with with & & without without backingbacking

F2

F2 with with backing backing F1 F1 & & F2 F2 with with backingbacking

F2 without

F2 without backing backing F2 witF2 with & h & without bwithout backing, Facking, F1 with 1 with backingbacking

F3

F3 with with backing backing F1, F1, F2 F2 & & F3 F3 with with backingbacking

F3 without

F3 without backing backing F3 wF3 with & ith & without bwithout backing, Facking, F1, F2 1, F2 withwith

backing

F4

F4 with with backing backing F1, F1, F2, F2, F3 F3 & & F4 F4 with with backingbacking

F4 without

F4 without backing backing F4 with F4 with & without & without backing, Fbacking, F1, F2, 1, F2, F3 withF3 with

backing

F5

F5 with with backing backing F1 F1 & & F5 F5 with with backingbacking

F5 without

(82)

Welding

position(QW-405

)

•

• Welding test positions are defined differently forWelding test positions are defined differently for

plate and pipe

•

• A change i A change in welding posn welding position from thaition from that qualifit qualifieded

may require requalification

•

• Certain test position qualify for more than oneCertain test position qualify for more than one

production welding position

(E.g.qualification in 3G position qualifies the welder

for vertical and flat positions)

•

• In vertical position welding, a change in weldingIn vertical position welding, a change in welding

progression from uphill to downhill would require

requalification

•

• Qualification in difficult position qualifies for lessQualification in difficult position qualifies for less

difficult

(83)

(84)

(85)

(86)

Welders Performance Qualification

Weld

Weld Plate Plate & & pipe pipe Pipe Pipe of of OD OD FilletFillet

>24”OD >24”OD 2 2 7/8 7/8 -- 24” 24” Plate Plate 1F 1F FF Plate Plate 2F 2F F, F, HH Plate Plate 3F 3F F, F, H, H, VV Plate Plate 4F 4F F, F, H, H, OO 3F

(87)

Welders Performance Qualification

Weld

Weld Plate Plate & & pipePipe pipePipe of of OD OD FilletFillet

>24”OD >24”OD 2 2 7/8 7/8 -- 24” 24” Plate Plate 1G 1G F F F F FF Plate Plate 2G 2G F, F, H H F, F, H H F, F, HH Plate Plate 3G 3G F, F, V V F F F, F, H, H, VV Plate Plate 4G 4G F, F, O O F F F, F, H, H, OO

(88)

Welders Performance Qualification

Weld

>24”OD >24”OD 2 2 7/8 7/8 -- 24” 24” Pipe Pipe 1G 1G F F F F FF Pipe Pipe 2G 2G F, F, H H F, F, H H F, F, HH Pipe

Pipe 5G 5G F, F, V, V, O O F, F, V, V, O O AllAll

Pipe

Pipe 6G 6G All All All All AllAll

Pipe

(89)

Welders Performance Qualification

Weld

>24”OD >24”OD 2 2 7/8 7/8 -- 24” 24” Pipe Pipe 1F 1F FF Pipe Pipe 2F 2F F, F, HH Pipe Pipe 2FR 2FR F, F, HH Pipe Pipe 4F 4F F, F, H, H, OO Pipe

(90)

Test coupon thickness

•

• The thickness of the production workThe thickness of the production work

determines the thickness of the plate or pipe

test

test coupon coupon to to be be weldedwelded

•

• Thumb rule is a welder is qualified to depositThumb rule is a welder is qualified to deposit

in production welding two times the thickness

of the weld deposited on the test coupon (e.g.

test coupon of 9 mm qualifies a person to weld

upto 19mm thick production weld)

•

• Some code makes once a weld of 1 inch isSome code makes once a weld of 1 inch is

made, the welder is qualified to weld all

thickness

(91)

Test coupon

thickness(contd.)

•

• The weld deposit thickness(t) determines theThe weld deposit thickness(t) determines the thickness of the weld metal the welder is

thickness of the weld metal the welder is

allowed to use in production not the thickness allowed to use in production not the thickness of the base metal in the test coupon.

of the base metal in the test coupon.

•

• When welding a test coupon using more thanWhen welding a test coupon using more than one process or filler metal, the thickness of one process or filler metal, the thickness of

the weld in production depends on the deposit the weld in production depends on the deposit thickness

thickness for for the the process and process and the the type type of of testtest of filler metal that was used on the test

of filler metal that was used on the test coupon.

(92)

Thk

Thk Max Max tk tk of of dep. dep. Metal Metal TestTest

<3/8”

<3/8” 2t 2t 1FB, 1FB, 1RB1RB

>3/8”

>3/8” 2t 2t 1FB, 1FB, 1RB1RB

>1/2”

>1/2” Max Max to to be be welded welded 2SB2SB

OD

OD of of test test coupon coupon Range Range of of OD OD qualifiedqualified

<1”

<1” Size Size welded welded - - unlimitdunlimitd

1

-1 - 2 7/8” 2 7/8” 1”1” - unlimited- unlimited

> 2 7/8”

(93)

Welders Performance Qualification Welders Performance Qualification Test coupon More than 2 welders

Test coupon More than 2 welders different

different procedure procedure can can do do a a single single testtest coupon. Failure then both are failed.

coupon. Failure then both are failed. Retest - 2 consecutive test coupons to Retest - 2 consecutive test coupons to pass

pass

Renewal if no welding for 6 months. Renewal if no welding for 6 months. Single test coupon plate/pipe, any Single test coupon plate/pipe, any

thickness, material, position. If passed thickness, material, position. If passed then complete previous qualification is then complete previous qualification is restored.

(94)

Welders Performance Qualification Welders Performance Qualification Variables for SMAW

Variables for SMAW

Removal of backing Removal of backing

Change in Pipe diameter Change in Pipe diameter Change in P number

Change in P number Change in F Number Change in F Number

Change in thickness of weld deposit Change in thickness of weld deposit Change in welding position

(95)

Variables for GTAW Variables for GTAW

Removal of backing Removal of backing

Change in Pipe diameter Change in Pipe diameter

Addition / deletion of filler

Addition / deletion of filler metalmetal Addition / deletion of insert

Addition / deletion of insert Change in P number

Change in P number Change in F Number Change in F Number

Change in solid filler to flux cored filler metal Change in solid filler to flux cored filler metal Change in thickness of weld deposit

Change in thickness of weld deposit Change in welding position

Change in welding position Removal of inert gas backing Removal of inert gas backing Change in current or polarity Change in current or polarity

(96)

Tests for Qualification Tests for Qualification Tension

Tension test test Minimum Minimum values values for for specifiedspecified

tensile strength

For dissimilar joint, lesser of the

two values

If break outside weld, if tensile st.

value not < 5% of the base

value not < 5% of the base metalmetal

Bend test

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

direction

Impact

(97)

Tests for Qualification

Radiography

Radiography No No crack crack or or LOP LOP or or LOFLOF

Any elongated

Any elongated slag >1/8” for t slag >1/8” for t <3/8” <3/8”

1/3 t for t 3/8

-1/3 t for t 3/8 - 2 1/4” 2 1/4”

3/4 “ for t>2 1/4”

Any group of slag in a line w

Any group of slag in a line with aggregateith aggregate

length t in 12 t unless

length t in 12 t unless separated by 6Lseparated by 6L

Max permissible dimension for rounded

indication

indication smaller of smaller of 20% 20% of t of t or 1or 1/8”/8”

For thickness<1/8”, max no

For thickness<1/8”, max no of acceptedof accepted

rounded indication 12 in 6”

rounded indication 12 in 6” lengthlength

For thickness>1/8”, charts for max

acceptable types of rounded indication

(98)

A 106 Gr B, A 106 Gr B, Sch 160Sch 160 C. R. Ratheeskumar C. R. Ratheeskumar FCAW(S) FCAW(S) 8" 8" P No.:1 Gr.:1 P No.:1 Gr.:1 Yes(Root) Yes(Root) E71T8-K6 E71T8-K6 66 66 F

FCCAAWW((SS) ) --119 9 mmmm UUpptto o MMaax x tto o bbe e wwee FCAW(S)

FCAW(S)

2 7/8" & Above 2 7/8" & Above

With

With babackingcking P 1 - P 11 P 1 - P 11

A

(99)

A 106 Gr B, Sc A 106 Gr B, Sc h 160h 160 P No.:1 Gr.:1 P No.:1 Gr.:1 Yes(Root) Yes(Root) E71T8-K6 E71T8-K6 6 6 ₆₆ F

FCCAAWW((SS) ) --119 9 mmmm UUpptto o MMaax x tto o bbe e wweellddeedd

6G

6G All P All Positionsositions Down Hill Down Hill NA NA DC DC Electrode Negative Electrode Negative Acc Acceptedepted NA NA NA NA NA NA NA NA With backing With backing Down Hill Down Hill NA NA DC DC NA NA Welding Resear

Welding Research Institute, ch Institute, BHEL, Trichy, BHEL, Trichy, IndIndia.ia. P 1 - P 11 P 1 - P 11 NDT NDT / / 250A 250A / / 03 03 Dt.23.2.Dt.23.2.04.04. Electrode Negative Electrode Negative

(100)

(101)

(102)

(103)

(104)

(105)

(106)

(107)

(108)

Welder’s Performance

Qualification as per

Indian Boiler Regulations

(109)

Welder’s Performance

Qualification as per IBR

Initial qualification of welders Initial qualification of welders

-Certificate valid for 24 months provided Certificate valid for 24 months provided welder has been employed with

welder has been employed with reasonable continuity

reasonable continuity

If preceding three months, no welding If preceding three months, no welding carried out or if there is

carried out or if there is any doubt onany doubt on

welder’s stability then requalification

welder’s stability then requalification needed

(110)

Welder’s Performance

Qualification as per IBR

Requalification of welders must for the Requalification of welders must for the following

following

Omission of backing strip Omission of backing strip

Change in class of electrode Change in class of electrode Change in base metal to be Change in base metal to be welded(CS or AS)

welded(CS or AS)

Change in welding process Change in welding process

Change from dc to ac and vice versa Change from dc to ac and vice versa

(111)

Tests for Initial Qualification

•

• Theoretical examinationTheoretical examination

•

• Groove welds in plate - single or double vee Groove welds in plate - single or double vee 299 x 381 x 16 mm min size in flat, horizontal 299 x 381 x 16 mm min size in flat, horizontal or vertical. Vertical or horizontal position also or vertical. Vertical or horizontal position also qualifies for all

qualifies for all

•

•Fillet weld in plate - 16 x 381 mm min in flat,Fillet weld in plate - 16 x 381 mm min in flat,

horizontal, vertical or overhead. horizontal, vertical or overhead. Horizontal

Horizontal or or vertical vertical also also qualifies qualifies for for flat.flat. Vertical position also qualifies

Vertical position also qualifies for flat,for flat, horizontal or vertical.

(112)

Tests for Initial Qualification

Pipe welding in the following positions (i) Pipe welding in the following positions (i)

Horizontally rolled (ii) Horizontal turned (iii) Horizontally rolled (ii) Horizontal turned (iii) Vertical fixed (iv) Horizontal fixed.

Vertical fixed (iv) Horizontal fixed.

Qualification in (ii) or (iii) also qualifies (i). Qualification in (ii) or (iii) also qualifies (i). Qualification in (iv) also qualifies (i) or (ii). Qualification in (iv) also qualifies (i) or (ii). Branch to pipe welding

Branch to pipe welding

Pipe size 127 OD x 10 tk. Tube 89 OD x 6 tk. Pipe size 127 OD x 10 tk. Tube 89 OD x 6 tk. Tube welding with axis vertical and tubes of Tube welding with axis vertical and tubes of same size fixed in adjoining positions.

(113)

Tests for Requalification

•

• No No theoretical theoretical examinationexamination •

• Plate Plate welding welding 152 152 length length x x 229 229 x x 16 16 tk tk inin

45

45 deg deg position. position. Weld Weld to to be be done done fromfrom underside.

underside.

•

• Pipe Pipe welding welding with with axis axis of of pipe pipe horizontal.horizontal. •

• Branch Branch to to pipe pipe as as earlierearlier

•

• Tube Tube welding welding axis axis vertical vertical and and tubes tubes ofof

same

same size size in in adjoining adjoining position.position.

•

• Regular Regular production production weld weld to to thethe satisfaction

satisfaction of of competent competent authorityauthority may

may be be accepted accepted as as alternative alternative to to thethe above tests

(114)

Examination of the weld for initial

Qualification

PLATE QUALIFICATION (Groove weld) PLATE QUALIFICATION (Groove weld)

•

• Visual Visual examinationexamination

•

• RadiographyRadiography

•

• 2 2 no no of of Tensile Tensile testtest •

• 2 2 no no each each of of Bend Bend test test - - face face and and rootroot bend

bend ( ( 3t 3t for for both both C C steel steel and and alloy alloy steelsteel 180 deg bend)

180 deg bend)

•

• 1 1 no no Micro Micro examinationexamination

•

(115)

Examination of the weld for

initial Qualification

PLATE QUALIFICATION (Fillet weld) PLATE QUALIFICATION (Fillet weld)

•

• Specimen shall not fracture during loadSpecimen shall not fracture during load application

application

•

• If fractures, no evidence of cracks / ICP / If fractures, no evidence of cracks / ICP / sum

sum of of inclusions inclusions and and gas gas pockets pockets < < 51 51 mmmm

•

• Macro examination shall show complete Macro examination shall show complete

fusion fusion

•

• concavity / convexity < 1.6 mm concavity / convexity < 1.6 mm

•

(116)

(117)

Examination of the weld for initial

Qualification

PIPE QUALIFICATION PIPE QUALIFICATION

•

• Visual Visual examinationexamination

•

• Macro Macro examinationexamination

•

bend ( ( 3t 3t for for C C steel steel and and 4t 4t for for alloyalloy `steel 90 deg bend)

(118)

Examination of the weld for

Requalification

PLATE QUALIFICATION PLATE QUALIFICATION • • RadiographyRadiography •

bend

•

• 2 2 no no of of macro macro examinationexamination

PIPE QUALIFICATION PIPE QUALIFICATION

•

• 1 1 no no each each of of bend bend test test - - face face and and rootroot

bend bend Macro

(119)

(120)

(121)

(122)

(123)

(124)

(125)

A 106 Gr B, S A 106 Gr B, S ch 160ch 160 FCAW(S) FCAW(S) 8" 8" P No.:1 Gr.:1 P No.:1 Gr.:1 Yes(Root) Yes(Root) E71T8-K6 E71T8-K6 6 6 FCAW(S) -19 mm FCAW(S) -19 mm 6G 6G Down Hill Down Hill NA NA DC DC Electrode Negative Electrode Negative ACTUAL VALUE ACTUAL VALUE

(126)

(127)

(128)

(129)

(130)

(131)

Steps involved in qualifying the

welding process & welder/

operator

•

• A tentative welding procedure is p A tentative welding procedure is preparedrepared •

• Test samples welded with the above andTest samples welded with the above and parameters recorded on PQR

parameters recorded on PQR

•

• Tested Tested as as per per required required codescodes

•

• If test is passed, the procedure hasIf test is passed, the procedure has completed qualification.

completed qualification.

•

• If test is not passed, the tentative WPSIf test is not passed, the tentative WPS value of the parameters are changed as value of the parameters are changed as deemed feasible

(132)

welding process & welder/

operator

•

• The welder making the test samples to be used inThe welder making the test samples to be used in

qualifying the procedure is normally considered

qualified.

•

• Other welder Other welder to to be be qualified qualified weld weld test test samplessamples

as per WPS and the samples are tested as per

applicable requirements.

•

• A qualifie A qualified WPS is usabd WPS is usable for an ile for an indefinitndefinite lengthe length

of time

•

• The welder’s qualification is normally consideredThe welder’s qualification is normally considered

effective for an indefinite period of time, unless

the welder is not engaged in the specific process

of welding for which she is qualified for a period

of exceeding 6 months

(133)

Case study

Objective

Objective : : To develop a WPS for pipeTo develop a WPS for pipe

to pipe butt joint( dia. 406 *

to pipe butt joint( dia. 406 * 12mm)12mm) of

of SA SA 106 106 GrCGrC – – SA106 GrC as per SA106 GrC as per ASME sec IX

ASME sec IX

•

• Requirement of mechanical property:Requirement of mechanical property: Impact toughness at room

Impact toughness at room temperature

temperature

Tensile strength Tensile strength

(134)

Filling up of WPS- Draft

•

• WPS: WPS: No: No: Date:Date: •

• Supporting PQRSupporting PQR

•

• Welding process :Welding process :

•

• Type : Manual/ Machine/Auto/Type : Manual/ Machine/Auto/

Semi Auto Semi Auto

•

(135)

Joints(QW:402)

•

• Joint DesignJoint Design •

• BackingBacking

•