Post on 21-Apr-2017
API 510 Course
(Calculations – Internal and External Inspection Intervals)
I.
Able to calculate;
NOTE: These calculations can be open and/or closed book exams.
II. Joint Efficiencies
Determine;
2
3
API 510 Calculations
Required Thickness
=
MinimumThickness
=
Short Term Corrosion Rate
CRST =tprevious tactual
# of years between tprevious & tactual
Long Term Corrosion Rate
CRLT =tinitial tactual
# of years between tprevious & tactual
Remaining Life
RL =tactual trequired
Corrosion Rate
Internal Inspection Interval
=
Internal or Onstream IntervalLesser of 10 yrs or ½ Remaining life
if remaining life is less than 4 yrs, full lifeup to 2 years
Remaining life is 2 years or less, intervalis FULL LIFE
Section 7, par7.1.1
External Inspection Interval
=
5
Short Term Corrosion Rate
CRST =tprevious tactual_LAST
# of years between tprevious & tactual _LAST
Variables for Thickness Calcs
Long Term Corrosion Rate
CRLT =tinitial tactual_LAST
# of years between tInitial & tactual_LAST
6
7
8
9
10
tinitial tlast=# of years between tinitial & tlast
11
tprevious tlast=# of years between tprevious & tlast
Corrosion rate
Section 7, par7.1.1
12
Section 7, par7.1.1
13
0.875 0.865
5=
tprevious = 0.875
tlast = 0.865
tprevious tlast=# of years between tprevious & tlast
Corrosion rate
inch/yr= 0.002
Section 7, par7.1.1
14
Thickness Years of service
Determined by SHORT term or Long Term Calculations (API 510, par 7.1.1.2)
Newly installed or Change in Service (API 510, par 7.1.2)
1. Calculated from data of vessels in similar service.2. Estimated from Owner-User experience3. Published Data4. On-stream determination after 1000 hrs of service.
May have different corrosion-rates for large vessels with multiple zones. (API 510, par 6.5.3)
19
Mechanical fatigue is caused by;
What material does not have an endurance limit?
24
Variables for Remaining Life Calcs
Remaining Life
RL =tactual_Last trequired
Corrosion Rate
Section 7, par7.2.1
25
Section 7, par7.2.1
26
tlast trequired=Corrosion rate
tprevious 0.625
tlast 0.600
= ?????Corrosion rate
Since the “CORROSION RATE is unknown, the 1st Step is to determine theCorrosion rate.
Section 7, par7.2.1
27
tprevious tlast=# of years between tprevious & tlast
0.625 0.600
8=
= 0.003
tprevious 0.625
tlast 0.600
tlast trequired=Corrosion rate
28
tlast trequired=Corrosion rate
0.600 0.575=0.003
= 8yrs
trequired = 0.575
tlast = 0.600
= 0.003Corrosion rate
29
(API 510 par 6.5.1.1)
Internal or on-stream inspections shall not exceed oone half the remaining life of the vessel or 10 years, whichever is less. Whenever the remaining life is less than four years, the inspection interval may be the full remaining life up to a maximum of two years.
(API 510 par 6.5.1.1)
Interval not exceed the llesser of 5 years or the internal/on-stream interval..
Thickness Inspection IntervalsShould be part of the inspection plan, but no interval requirements mentioned in API-510 (API 510 par 5.5.1)
CUI Inspection IntervalsShould be part of the inspection plan, but no interval requirements mentioned in API-510 (API 510 par 5.5.1)
“SHALL” be considered for insulated vessels in “intermittent” service or operates between;
10oF and 350oF for carbon steel and alloy steels140oF and 400oF for austenitic stainless steels
31
Section 6, par6.5.1v
Section 5, par5.5.1
32
Section 6, par6.5.1v
33
tlast trequired=Corrosion rate
tprevious 0.625
tlast 0.600
= ?????Corrosion rate
Since the “CORROSION RATE is unknown, the 1st Step is to determine theCorrosion rate.
Section 7, par7.2.1
34
tprevious tlast=# of years between tprevious & tlast
0.625 0.600
8=
= 0.003
tprevious 0.625
tlast 0.600
tlast trequired=Corrosion rate
Section 7, par7.1.1
35
tlast trequired=Corrosion rate
0.600 0.575=0.003
= 8yrs
trequired = 0.575
tlast = 0.600
= 0.003Corrosion rate
Section 7, par7.2.1
36
Internal Inspection Interval = 4 years
37
Section 6, par6.4.1
HEAD
BANGER
What is the temperature range that temper embrittlement occursin low alloy steels ?
Next inspection date = Last inspection date +interval
42
Practice for “Simple” calculation
43
44
RemainingLife (yr)
March 2000 March 1995
16 .324 .356
Widely scattered pits can be ignored, if;
45
Vessel Thickness = 2.0”
Depth of Pit = 1.06”
Corrosion Allowance = 0.250
Retirement Thickness = 1.75”
Remaining Thickness below pit is greater than ½½ the Required Thickness
Rule # 1
Section 7, par7.4.3
Widely scattered pits can be ignored, if;
46
Area of the pitting below thecorrosion allowance has anarea less than 7 in2 within an8” diameter circle.
Rule # 2
Section 7, par7.4.3
Widely scattered pits can be ignored, if;
47
Rule # 3Sum of the length of pits within any 8” line, must be less than 2”
Section 7, par7.4.3
48
Section 7, par7.4.3
49
“Minimum allowed remaining thickness below the pit is ½ the required thickness”,
Therefore, the minimum thickness allowed at the deepest pit is;
( ½ required thickness = 1.250”/2 = 0.625”)
Corrosion allowance
RequiredThickness
½ of RequiredThickness
Remaining thicknessbelow pit
Section 7, par7.4.3
a. Pits can be ignoredb. Pits are unacceptable based on sum of the pit dimensions along a 8” straight line.c. Pits are unacceptable due to total area of pitting within an 8” diameter circle.d. Pits are unacceptable due to insufficient remaining thickness below the deepest pit.
Section 7, par7.4.3
Section 7, par7.4.3
HEAD
BANGER
53
54
55
56
57
pH Scale
Acidity Basic / Akalinity /Caustic
StrongAcidity
StrongAlkalinity
NeutralW
eakAcidity
Weak
Alkalinity
58
pH Scale
Acidity Basic / Akalinity /Caustic
StrongAcidity
StrongAlkalinity
NeutralW
eakAcidity
Weak
Alkalinity
A. Inspection plan must be established for all pressure vessels and pressure-relieving devices.
B. Inspection plan developed by inspector or engineer.
C. Corrosion-specialist must be consulted for inspection plan for vessels operating above 750oF.
D. Inspection plan shall be evaluated based on present or possible types of damage mechanisms.
E. Methods and extent of NDE shall be evaluated to assure they can adequately identify the damage mechanism and severity of damage.
59
Section 5, par5.1
F. Examinations must be scheduled at intervals that consider;A. Type of damageB. Rate of damageC. Tolerance of equipment to the damageD. Probability of the NDE methods to detect the damageE. Maximum intervals as defined in API 510
G. Minimum Contents of Inspection PlanA. Type of inspection neededB. Next inspection date for each type inspection (internal,
external, etc)C. Describe inspection and NDE techniquesD. Describe extent and locations of inspection and NDEE. Describe the cleaning requirementsF. Describe the requirements of any needed pressure testG. Describe any required repairs
60
Section 5, par5.1
A. General
Inspections should be conducted in accordance with the inspection plan
Prior to performing an inspection, the inspector should be familiar with;
Thorough understanding of the inspection plan
Operating conditions since the last inspection (API 572 par 9.1)
Applicable damage mechanisms
Prior history
New inspection intervals shall be established if operating temp increases, operating pressure increases or process fluid changes. (API 510 par. 6.2.2)
61
Section 5
Interval is lesser of ½ remaining life or 10 years. If remaining life is LESS than 4 years, interval can be the full remaining life up to max of 2 years. (API 510 par 6.5.1.1).
SHALL be conducted by the inspector (API 510 par 5.5.2.1)
Primary reason for internal inspection is to find damage that cannot be found by external CML’s (API 510 par 5.5.2.1)
Internal inspection performed inside the vessel (API 510 par 5.5.2.1)
Internals may need to be removed to facilitate the internal inspection. Likely will not need to remove 100% of the internals. (API 510 par 5.5.2.2)
Inspector should consult with Corrosion Specialist to determine if it is necessary to remove any linings and/or deposits (API 510 par 5.5.2.3)
Vessels in non-continuous service, the interval is based on number of years of actual service, instead of calendar years, provided the vessel when idled is separated from process stream & not exposed to corrosive streams.
62
C. On-stream Inspection
Interval same as INTERNAL inspection.
Should be conducted by either an inspector or examiner. (API 510 par 5.5.3.1)
On-stream inspections performed by examiners shall be authorized/approved by the inspector (API 510 par 5.5.3.1)
Inside of vessel inspected from outside vessel. (API 510 par 5.5.3.2)
63
D. External Inspection
Performed by inspector or qualified others (qualified with appropriate training). (API 510 par 5.5.4.1.1)
Interval is lesser of 5 years or the internal interval.External inspections check; (API 510 par 5.5.4.1.2)
Condition of Outside surface of vesselCondition of Insulation systemCondition of Coating systemCondition of SupportsFor leaksHot spotsVibration damageAllowance for expansionBulging, misalignment, distortion, etc
Conditions discovered by others, must be reported to inspector. (API 510 par 5.5.4.1.3)
64
E. Thickness Inspection
Performed by inspector or examiner. (API 510 par 5.5.5.1)
No required interval.
Inspector should consult with corrosion-specialist when short term corrosion-rate changes significantly. (API 510 par 5.5.5.3)
Owner-user is responsible for assuring individuals taking thickness readings are trained and qualified (API 510 par 5.5.5.4)
F. CUI InspectionPerformed by inspector or other qualified personnel (i.e. same as external)Shall be considered for; (API 510 par 5.5.6.1)
Carbon steel and low alloy operating between 10oF and 350oF.Stainless steel operating between 140oF and 400oF.
Usually causes localized corrosion damage (API 510 par 5.5.6.2)Susceptible locations include; (API 510 par 5.5.6.2)
Insulation or stiffening ringsNozzles and manwaysStructural penetrations (ladder clips, pipe supports, etc)Damage insulationInsulation with failed caulkingTop and bottom heads
CUI inspection may require some or all insulation (API 510 par 5.5.6.3)Insulation may not need to be removed if; (API 510 par 5.5.6.3)
Insulation is in good condition and there is no reason to suspect damage behind the insulation;
CUI inspection can be performed with UT from ID of vessel.66
67
Weld Joint CATERGORY is the ”location” of a “joint” in a pressure vessel
Category A:All longitudinal welds in shell and nozzlesAll welds in heads, Hemi head to shell weld joint
Category B:All circumferential welds in shell and nozzlesHead to shell joint (other than Hemispherical.)
Category C and D are flange welds and nozzle attachment welds respectivelyLongitudinal welds (Category A) are more critical than Circumferential welds (Category B)because they are under double stress.This the reason why in different part of ASME code we have stringent rules in category Ajoint compared to category B joint.
Sub Section B,UW, General,
UW 3
Weld Joint Types
68
Sub Section B,UW, Design,
UW 12
Weld Joint Types
69
Sub Section B,UW, Design,
UW 12
70
Type of RadiographyFull – as required by the Code (see UW 11(a)), and UCS 57Spot – Category B and C welds that are not required to be
radiographed by UW 11(a)(5)(b).None
Code Required RT (UW 11(a) and UW 11(b)
Based on Service, Thickness or Welding Process
User Specified RTThe user can establish the type of joint and degree of examination whenthe rules of Code does not require radiography (see UW 12)
Sub Section B,UW, Design,
UW 11
Sub Section C,CCS, Design,
UCS 57
FULL RT – Required by CODE
71
FULL RTAll butt welds in shell & heads in lethal serviceAll butt welds in shell & heads with thickness >11/2 or per UCS 57All butt welds in shell & heads of unfired boilers with;
Pressure exceeding 50 psig or thickness > 1 1/2 or per UCS 57Butt welds in nozzles >10 NPS or > 1 1/8” thicknessCategory “A” and “D” welds in shells and heads, where jointefficiency is based on Table UW 12Butt welds made using Electro gas & Electro slag process
Spot RTCategory B and C butt welds intersecting Cat A welds in shells and headsCategory B and C butt welds connecting seamless heads or shells
Sub Section B,UW, Design,
UW 11a
72
When and where is there a code requirement for full radiography?
Item 1:
Item 2:
Item 3:
Item 4:
The point is this: items 1, 2 and 3 are similar, but item 4 is completely different. In items 1, 2 and 3 it is mandated bycode; to do full radiography in all butt welds in vessel so it means it is mandatory for designer to select column (a) inUW 12 table.
But in item 4, there is no mandating rule. A manufacturer with its own decision has chosen to use column (a) in tableUW 12 for full radiography.
All butt welds in vessels used to contain a lethal substance (UW 11(a)).Lethal substances have specificdefinitions in ASME Code in UW 2 and it is the responsibility of the end user to determine if they ordereda vessel that contains lethal substances.
All butt welds in vessels in which the nominal thickness exceeds specified values (UW 11(a). You can findthese values in subsection C, in UCS 57. For example, this value for P No.1 in UCS 57 is 1 ¼ inch. Nozzleslarger than 10 NPS or thickness greater than 1 1/8”.
All butt welds in an unfired steam boiler with design pressure > 50 psi (UW 11(a)).
All category A and D butt welds in vessel when “Full Radiography” optionally selected from table UW12(column (a) in this table is selected); and categories B and C which intersect Category A shall meet thespot radiography requirement (UW 11(a) (5) (b)).
Sub Section B,UW, Design,
UW 11
Sub Section C,UCS, Design,
UCS 57
73
a. Items 1, 2 and 3 from the previous slide; RT is related to the type of welds andservices.
b. Pressure vessels in these items are critical from a safety point of view, onecontains a lethal substance, the other one has a high thickness, whichimplicates high pressure, and the last one is an unfired steam boiler
c. Item 4 has no criticality like the other items have.d. But you should note all 4 items have been categorized in full radiography
clause( U 11(a)), so to differentiate item 1, 2 and 3 from item 4, the RTsymbols are used in Code (UG 116).
74
RT 1: Items 1, 2 and 3, (E=1), All butt welds full length radiography
RT 2: Item 4 (E=1), Category A and D butt welds full length radiographyand category B and C butt welds spot Radiography
RT 3: (E=0.85), Spot radiography butt welds
RT 4: (E=0.7), Partial / No radiography
You need to consider the hemispherical head joint to shell as category A, but ellipsoidaland torispherical head joint to shell as category B;
Do you know why? Why ASME considered the stringent rule for pressure vessel RT test inhemispherical head joint?
It is because this joint is more critical, because the thickness obtained from theformula for hemispherical head approximately would be half of the shell thickness;It means if the shell thickness is 1 inch, the hemispherical head thickness would be0.5 inch.
Sub SectionA, UG, Design,
UG 116
Spot RT – Required by CODEB and C welds that are not required to be radiographed by UW-11(a)(5)(b)Type 1 and Type 2 butt welds that are not required to be radiographed by UW-11(a).
RT MarkingsRT 1 and RT 2 - FULL RadiographyRT 3 - Spot RadiographyRT 4 - Combo Radiography
RT markings are located on Nameplate
75
Sub Section B,UW, Design,
UW 11
Sub SectionA, UG, Design,
UG 116
HEAD
BANGER
Joint Efficiency is based on;
80
Sub Section B,UW, Design,Table UW 12
81
E = 1RT 1
E = 1RT 2 E = 1
E = 0.85RT 3 E = 1
E = 0.70RT 4 E = 0.85
Sub SectionA, UG, Design,
UG 116
Joint Efficiency based on RadiographyRT 1 – Full RT per UW 11(a), except UW(a)(5)
Use Column “a” of Table UW 12For Seamless heads & shells E = 1
RT 2 Full RT per UW 11(a)(5)Use Column “a” of Table UW 12For seamless heads and shells E = 1
RT 3 Spot radiography per UW 11(b)Use Column “b” of Table UW 12For seamless heads & shells E = 1
RT 4 Combination of RT 1, RT 2 and RT 3
No RT no radiography at allUse Column “c” of Table UW 12For seamless shells and heads E = 0.85
82RT Stamping
Sub Section B,UW, Design,Table UW 12
Sub SectionA, UG, Design,
UG 116
83
RT 1orRT 2 RT 3 RT 4
NOTE: For Weld types 3, 4, 5, and 6, RT cannot be used to increase the joint efficiency.
Sub Section B,UW, Design,Table UW 12
84
Joint Efficiency For Seamless Parts
Weld Type Spot RT No RT1 1.0 0.852 1.0 0.853 0.85 0.854 0.85 0.855 0.85 0.856 0.85 0.85
Sub Section B,UW, Design,
Par UW11(a)(5)(a)& (b)
Sub Section B,UW, Design, Par
UW 12d
85
A pressure vessel shell with TYPE 1 longitudinal seams and circumferential welds thatare single full fillet lap joints without plug welds. The vessel is stamped No RT. Whatis the joint efficiency for;
Vessel shell ?
A seamless head _________?
Sub Section B, UW,Design, Par UW
11(a)(5)(a)& (b) andTable UW 12
Sub Section B,UW, Design, Par
UW 12d
86
Sub Section B, UW,Design, Par UW
11(a)(5)(a)& (b) andTable UW 12
Sub Section B,UW, Design, Par
UW 12d
87
Sub Section B, UW,Design, Par UW
11(a)(5)(a)& (b) andTable UW 12
Sub Section B,UW, Design, Par
UW 12d
88
Sub Section B, UW,Design, Par UW
11(a)(5)(a)& (b) andTable UW 12
Sub Section B,UW, Design, Par
UW 12d
89
ouble full fillet lap joint we
Sub Section B, UW,Design, Par UW
11(a)(5)(a)& (b) andTable UW 12
Sub Section B,UW, Design, Par
UW 12d
90
Sub Section B, UW,Design, Par UW
11(a)(5)(a)& (b) andTable UW 12
Sub Section B,UW, Design, Par
UW 12d
(Calculations – Static Head, Internal and External Pressure)
1
(Calculations – Static Head and Internal Pressure
2
(Calculations – Static Head and Internal Pressure
3
4
ASME Sec VIII, UG 98
5
1 ft
0.433 psi(at bottom of the water column)
ASME Section VIIISubsection A, UG,
Inspection and Testing,UG 98(a)(b)
6
ASME Sec VIII, UG 98
44 ft8 ft
What is MAWP of each component for a 48 ft tallvertical vessel with ellipsoidal heads and a MAWPof 500 psig?
2 ft
2 ft6 ft
6 ft
36 ftVessel MAWP = 500 psig
Vessel MAWP is the gage pressure at the “TOP” ofthe vessel, including Static head pressure. ReferenceUG 98(a)(b)
N1
N2
MAWP of N1 = ________
MAWP of N2 = _________
MAWP of Top head = _________
MAWP of Btm head = _________
MAWP of the shell = _________
ASME Section VIIISubsection A, UG,
Inspection and Testing,UG 98(a)(b)
7
ASME Sec VIII, UG 98
44 ft8 ft
What is MAWP of each component for a 48 ft tallvertical vessel with ellipsoidal heads and a MAWPof 500 psig?
2 ft
2 ft6 ft
6 ft
36 ftVessel MAWP = 500 psig
Vessel MAWP is the gage pressure at the “TOP” ofthe vessel, including Static head pressure. ReferenceUG 98(a)(b)
N1
N2
MAWP of N1 = ________
MAWP of N2 = _________
MAWP of Top head = _________
MAWP of Btm head = _________
MAWP of the shell = _________
500 psig + (6 x 0.433) = 500 + 2.6 = 502.60 psig
500 psig + (42 x 0.433) = 500 + 18.19 = 518.19 psig
500 psig + (2 x 0.433) = 500 + 0.87 = 500.87 psig
500 psig + (48 x 0.433) = 500 + 20.78 = 520.78 psig
500 psig + (46 x 0.433) = 500 + 19.92 = 519.92 psig
ASME Section VIIISubsection A, UG,
Inspection and Testing,UG 98(a)(b)
8
ASME Sec VIII, UG 98
42 ft
10 ft
What is MAWP of this vessel?
2 ft
50 ft
48 ft
0 ft
8 ftN1
N2
Part PartMAWP
StaticHead
Pressure atTop ofVessel
Tophead 510 psig
N1 500 psigN2 495 psig
Shell 510 psigBtmHead 507 psig
ASME Section VIIISubsection A, UG,
Inspection and Testing,UG 98(a)(b)
9
66 ft8 ft
Practice Question # 12 ft
2 ft6 ft
6 ft
58 ft
If this vessel is being hydrostatically tested at 200psig, what is the pressure at the bottom of thevessel?
N1
N2Practice Question # 2If the MAWP of the vessel is 550 psig, what is theMAWP of N2?
Practice Question # 3
If the MAWP of the shell of the vessel is 564 psig,what is the MAWP of N1?
Use this vessel to answerthese practice questions
ASME Section VIIISubsection A, UG,
Inspection and Testing,UG 98(a)(b)
10
66 ft8 ft
Practice Question # 4 2 ft
2 ft6 ft
6 ft
58 ft
If a vessel is being hydrostatically tested at 400psig, what is the pressure at N2?
N1
N2Practice Question # 5
During a hydrotest of a vessel, if the pressure at thebottom of the vessel is 635 psig, what is thepressure at N1?
Practice Question # 6During a hydrotest of a vessel, if the pressure at N2is 528 psig, what is the pressure at the top of thevessel? Use this vessel to answer
these practice questions
NOTE: Per ASME Section VIII, UG 99(c.), the hydrotest pressure is the pressure at the top of the vessel.
ASME Section VIIISubsection A, UG,
Inspection and Testing,UG 98(a)(b)
11
ASME Sec VIII, UG 21 and Appendix 3 (par 3 2)
Design pressure is the pressure used in the design of a vessel componenttogether with coincident temperature for the purpose of determining theminimum permissible thickness for each component. Design pressureincludes static head pressure.
NOTE: Design pressure is the minimum pressure used to design the vessel (i.e. used to determine the “requiredthickness” of each component.
Maximum allowable working pressure (MAWP) is the maximum pressurepermissible at the top of the vessel in its normal operating position. MAWP isadjusted for the difference in static head that may exist between for the partconsidered and the top of the vessel.
Design pressure is the pressure for the process (process pressure plusstatic head). MAWP is the maximum pressure rating for each partand/or vessel.
ASME Section VIIISubsection A, UG,
Inspection and Testing,UG 98(a)(b)
t = PR/ (SE) (0.6P)
12
ASME Sec VIII, UG 27(c.)(1)
Variablest = required thicknessP = Design PressureR = Inside Radius of shellS = Allowable StressE = Joint Efficiency
inchespsi
psi
inches
ASME Section VIIISubsection A, UG,
Design, UG 27( c.)(1)
13
Practice Question # 7A 60’ tall vertical vessel has an inside diameter of 8’ and designed for 300 psig @ 450 degF. Allowable stress of the material of construction is 17,500 psi and the joint efficiency is0.85. What is the minimum required thickness?
ASME Section VIIISubsection A, UG,
Design, UG 27( c.)(1)
14
Variablest = required thicknessP = Design PressureR = Inside Radius of shellS = Allowable StressE = Joint Efficiency
Practice Question # 7A 60’ tall vertical vessel has an inside diameter of 8’ and designed for 300 psig @ 450 degF. Allowable stress of the material of construction is 17,500 psi and the joint efficiency is0.85. What is the minimum required thickness?
inchespsi
psi
inches
ASME Section VIIISubsection A, UG,
Design, UG 27( c.)(1)
t = PR
(SE) (0.6P)
t =300 x 48
( 17500 x 0.85 ) ( 0.6 x 300 )
t = 14400
( 14875 ) ( 180 )
t = 14400
14695
t = 0.980 inches
15
Practice Question # 8A vessel has an inside diameter of 60” and designed for 150 psig @ 350 deg F.Allowable stress of the material of construction is 18,000 psi and the jointefficiency is 1.0 What is the minimum required thickness?
ASME Section VIIISubsection A, UG,
Design, UG 27( c.)(1)
16
Practice Question # 9A vessel has an inside radius of 48” and designed for 250 psig @ 500 deg F.Allowable stress of the material of construction is 17,000 psi and the jointefficiency is .90 What is the minimum required thickness?
ASME Section VIIISubsection A, UG,
Design, UG 27( c.)(1)
17
t =PR
(2SE) (0.2P)Variables
t = required thicknessP = Design PressureR = Inside Radius of shellS = Allowable StressE = Joint Efficiency
inchespsi
psi
inches
ASME Section VIIISubsection A, UG,Design, UG 27(d)
18
Practice Question # 10A sphere has an inside radius of 12 ft and designed for 250 psig @ 500 deg F.Allowable stress of the material of construction is 17,000 psi and the welds aresingle butt welded with backing and vessel is stamped RT 2. What is theminimum required thickness?
ASME Section VIIISubsection A, UG,Design, UG 27(d)
19
Practice Question # 11A sphere has an ID of 36 ft and designed for 30 psig @ 400 deg F. Allowablestress of the material of construction is 15,000 psi and the joint efficiency is 0.80What is the minimum required thickness?
ASME Section VIIISubsection A, UG,Design, UG 27(d)
ShortAxis
20
h = 1/4D
D = Inside diameter
L = inside radius
D = Inside diameter
Ellipsoidal heads are known as 2 to 1 heads. 2 to 1 comesfrom the fact that an ellipsoidal head is 1/2 of a ellipse. Anellipse has a long axis that is 2 x the short axis.
Long Axis
ASME Section VIIISubsection A, UG,Design, UG 32(d)
ASME Section VIIISubsection A, UG,Design, UG 32(f)
21
Minimum Required Thickness of an Ellipsoidal Head
Minimum Required Thickness of a Hemispherical Head
x L2 [( S x E ) ( X )]
tP
0.2 P=
Px D2 [( S x E ) ( X )]
t =0.2 P
t = minimum required thicknessP = Design PressureD = Inside DiameterS = Allowable StressE = Joint Efficiency
t = minimum required thicknessP = Design PressureL = Inside RadiusS = Allowable StressE = Joint Efficiency
ASME Section VIIISubsection A, UG,Design, UG 32(d)
ASME Section VIIISubsection A, UG,Design, UG 32(f)
22
Practice Question # 12What is the minimum required thickness for the head of a 30’ tall vertical vesselwith ellipsoidal heads, inside diameter of 72”, allowable stress of 16,500 psi,MAWP of 120 psig, and welds that are double welded butt welds and Spot RT’d?
ASME Section VIIISubsection A, UG,Design, UG 32(d)
23
Practice Question # 13
What is the minimum required thickness for the head of a seamless horizontal vesselwith ellipsoidal heads, inside diameter of 96”, allowable stress of 18,000 psi, MAWPof 200 psig, and welds that are double full fillet welded lap joints and RT 1?
ASME Section VIIISubsection A, UG,Design, UG 32(d)
24
Practice Question # 14
What is the minimum required thickness for the head of a 30’ tall vertical vesselwith hemispherical heads, inside diameter of 72”, allowable stress of 16,500 psi,MAWP of 320 psig, and welds that are double welded butt welds and Spot RT’d?
ASME Section VIIISubsection A, UG,Design, UG 32(f)
25
Practice Question # 15
What is the minimum required thickness for the heads of a horizontal vessel withhemispherical heads, inside diameter of 96”, allowable stress of 18,000 psi, MAWP of200 psig, and welds that are double full fillet welded lap joints and RT 1?
ASME Section VIIISubsection A, UG,Design, UG 32(f)
HEAD
BANGER
I. MAWP of Ellipsoidal Heads
II. MAWP of Hemispherical Heads
29
2 SEt( D + 0.2t)
P =t = minimum required thicknessD = Inside DiameterS = Allowable StressE = Joint Efficiency
t = minimum required thicknessL = Inside RadiusS = Allowable StressE = Joint Efficiency
( L + 0.2t)P =
2 Set
ASME Section VIIISubsection A, UG,Design, UG 32(d)
ASME Section VIIISubsection A, UG,Design, UG 32(f)
30
Practice Question # 16
During an inspection of a vertical vessel thickness measurements taken on the bottom ellipsoidalhead was found to be 0.785. The inside diameter of the vessel is 96”, allowable stress is 17,000psi, and welds that are double welded butt weld joints and the vessel is stamped RT 1. What isthe maximum allowable working pressure for this seamless ellipsoidal head?
ASME Section VIIISubsection A, UG,Design, UG 32(d)
2 SEt( D + 0.2t)
2 ( x x )( + ( x )
2 x+
P =
P =
1 0.7850.2 0.7996
P =17000
P =13345
96 0.157
277.57
P =2669096.157
31
Practice Question # 16
During an inspection of a vertical vessel thickness measurements taken on the bottom ellipsoidalhead was found to be 0.785. The inside diameter of the vessel is 96”, allowable stress is 17,000psi, and welds that are double welded butt weld joints and the vessel is stamped RT 1. What isthe maximum allowable working pressure for this seamless ellipsoidal head?
t = 0.785”D = 96”S = 17,000E = 1
Note:Read the question closely, in this question there is no mentionif the vessel has long seams or not. Therefore, assume the vesselhas long seams. You go to Table UW 12 and find the joint efficiencyto be “1” for “double welded butt welds”. The “seamless” head,does not change the joint efficiency.
ASME Section VIIISubsection A, UG,Design, UG 32(d)
32
Practice Question # 17
A horizontal vessel with an outside diameter of 72” and ellipsoidal heads. Shell thickness is0.750” and the heads are 0.500” thick. The allowable stress is 16,000 psi. Welds are double fullfillet lap joints and the vessel is stamped RT 1. The corrosion allowance for the entire vessel is0.125”. What is the maximum allowable working pressure for the ellipsoidal head?
32
ASME Section VIIISubsection A, UG,Design, UG 32(f)
33
Practice Question # 18During an inspection of a vertical vessel thickness measurements taken on the bottomhemispherical head was found to be 0.785. The inside diameter of the vessel is 96”, allowablestress is 17,000 psi, and welds that are double welded butt weld joints and the vessel is stampedRT 1. What is the maximum allowable working pressure for this hemispherical head?
ASME Section VIIISubsection A, UG,Design, UG 32(f)
34
Practice Question # 19A horizontal vessel with an outside diameter of 72” and hemispherical heads. Shell thickness is0.750” and the heads are 0.500” thick. The allowable stress is 16,000 psi. Welds are double fullfillet lap joints and the vessel is stamped RT 1. The corrosion allowance for the entire vessel is0.125”. What is the maximum allowable working pressure for the Hemispherical head?
34
ASME Section VIIISubsection A, UG,Design, UG 32(f)
35
Practice Question # 20
During a recent inspection of a horizontal vessel with an inside diameter of 72”and hemispherical heads, shell thickness was recorded as 0.625”. The allowablestress is 16,000 psi. Welds are double full fillet lap joints and the vessel isstamped RT 1. The corrosion rate is 0.006”/yr. Required thickness is 0.588”.Vessel is in corrosive service. Next inspection is in 5 years. What is themaximum allowable working pressure for this vessel?
ASME Section VIIISubsection A, UG,
Design, UG 27( c.)(1)
API 510, Section 7, Subpar 7.3.3
36
There are three factors that can effect the resistance ofcrushing due external pressure.
1. Stiffeners2. Thickness – thicker materials resist crushing3. Diameter – increasing diameter, increases susceptibility of crushing
ASME Section VIIISubsection A, UG,Design, UG 28( c.)
I. Formula and variables
37
A = Factor based on ratio of L/Do and Do/t. (Get it from ASME Sec II, Part D, Fig G.)B = Factor based on “A” Factor and design Temperature (Get if from ASME Sec II,
Part D, Tables CS 1 or CS 2)Do = Outside Diametert = Minimum required thickness
4B[ 3 ( Do / t ) ]
Pa =
“B” factor will be given to you in the question.
ASME Section VIIISubsection A, UG,Design, UG 28( c.)
38
Practice Question # 21
A horizontal vessel has an outside diameter of 60”. The distance betweensupports is 15’ ft. The wall thickness is 0.625”. Material of construction is SA516 Gr 70. This vessel has a “B” factor of 3500 and is designed for 250 psig @500 deg F. Allowable stress is 16,500. What is the maximum external pressurefor this vessel?
ASME Section VIIISubsection A, UG,Design, UG 28( c.)
39
Practice Question # 21
A horizontal vessel has an outside diameter of 60”. The distance betweensupports is 15’ ft. The wall thickness is 0.625”. Material of construction is SA516 Gr 70. This vessel has a “B” factor of 3500 and is designed for 250 psig @500 deg F. Allowable stress is 16,500. What is the maximum external pressurefor this vessel?
B = 3500Do = 60”t = 0.625
4B[ 3 ( Do / t ) ]
4 x[ 3 x ( / 0.625 ) ]
Pa = 3 x ( )
Pa = psi
Pa =
Pa =60
3500
96
14000
48.611
ASME Section VIIISubsection A, UG,Design, UG 28( c.)
40
Practice Question # 22
During an external inspection of a vessel with an outside diameter of 48”uniform corrosion damage was discovered. The thickness in this area of shellwas found to be 0.425”. This vessel is designed for 35 psi external pressure andhas a B factor of 1800. Can this vessel operate at 35 psi external pressure ordoes it need to be rerated?
ASME Section VIIISubsection A, UG,Design, UG 28( c.)
41
Practice Question # 23
A 20 ft long exchanger tube has an outside diameter of 2” and nominalthickness of 0.083”. Material of construction is SA 283 Gr D and designtemperature is 600 deg F. The “B” factor for the tube is 1500. What is themaximum allowed external pressure for this tube?
ASME Section VIIISubsection A, UG,Design, UG 28( c.)
(Calculations – Impact Testing, Weld Size and NozzleReinforcement)
1
(Calculations – Impact Testing, Weld Size and Nozzle Reinforcement)
I. Impact TestingA. The inspector should understand impact testing requirements and impact testing procedure (UG 84)B. The inspector should be able to determine the minimum metal temperature of a material which is exempt from impact testing (UG 20 (f), UCS 66,
UCS 68(c).)
II. WELD SIZE FOR ATTACHMENT WELDS AT OPENINGMust be able to determine if the weld size meets Code requirements.
A. Convert a fillet weld throat dimension to leg dimension or visa versa, using conversion factor (0.707);B. Determine the required size of welds at openings (UW-16)
III. Nozzle Reinforcement
A. Understand the key concepts of reinforcement, such as replacement of strength removed and limits of reinforcement.Credit can be taken for extra metal in shell and nozzle
B. Be able to calculate the required areas for reinforcement or check to ensure that a designed pad is large enough. Tosimplify the problem:
All fr = 1.0All F = 1.0All E = 1.0
C. There will be no nozzle projecting inside the shellD. Be able to compensate for corrosion allowancesE. Weld strength calculations are excluded
2
I. What does Impact Testing Determine?
II. What is MDMT?
III. Why does the Code worry about MDMT?
IV. What are some factors that affect brittleness of materials?
V. What is the opposite of brittleness?
.
3
(ASME VIII UG 20 (f), UG 84 UCS 66, UCS 68(c).)
I. How does ASME Section VIII manage Brittle Fracture
a. By Material Selection (P1 Group 1 and 2 see Fig. UCS 66)
b. Provides a method for determining MDMT
1. Curves for material groupings (Fig. UCS 66)
2. Initial impact testing exempt temperature based on material (curveletter) and thickness (Table UCS 66 1)
3. Stress Reduction Ratio factor [(tr x E)/(tn c)]. (Fig UCS 66.1)Note: This ratio will be provided on the test.
4. PWHT Reduction (residual stress reduction allowed when PWHT is performed and is not requiredby the Code) see (par. UCS 68(c.))
c. Temperature limited by UCS 66(b)(2)&(3) and UCS 68(c.)
a) UCS 66(b)(2) – no colder than 55oF, unless ;
1) Stress reduction ratio is 0.35 or less, then temperature can bebetween 55oF and 155oF. (UCS 66(b)(3)
2) PWHT performed when not required by Code, temperature canbe below 55oF. (UCS 68(c.)
4
ASME VIII,
ASME VIII,
Practice Question # 1A horizontal vessel constructed from SA-516 Gr 65 plate (not normalized). Designed for 350 psig @ 650oF. Wall thickness is 1.5”, with a 1/16” corrosion allowance and reduction ratio is .80. Nameplate is stamped RT-1 and HT. What is the lowest possible MDMT for this vessel?
5
Practice Question # 1A horizontal vessel constructed from SA-516 Gr 65 plate (not normalized). Designed for 350 psig @ 650oF. Wall thickness is 1.5”, with a 1/16” corrosion allowance and reduction ratio is .80. Nameplate is stamped RT-1 and HT. What is the lowest possible MDMT for this vessel?
6
Step 1: Find material Curve Letter;Curve letter is “B” from Fig. UCS 66
Step 2: Initial MDMT;51oF from Table UCS 66
Step 3: MDMT reduction (stress ratio reduction);20oF reduction allowed, thereforeReduced MDMT = 51oF 20oF = + 31oF (from Fig. UCS 66.1)
Step 4: PWHT reduction (not allowed)PWHT reduction is not allowed because PWHT was requiredby Code (i.e. nameplate stamped “HT”) see Par. UCS 68(c.)
Lowest MDMT = + 31oF
ASME VIII,
ASME VIII,
ASME VIII,
ASME VIII,
Practice Question # 2A horizontal vessel constructed from SA-516 Gr 50N plate. Designed for 300 psig @ 600oF. Wall thickness is 0.25”, with a 1/32” corrosion allowance and reduction ratio is .80. Nameplate is stamped RT-1. Vessel was PWHT’d. What is the lowest possible MDMT for this vessel?
7
(ASME VIII UG 20 (f), UG 84 UCS 66, UCS 68(c).)
Practice Question # 3A horizontal vessel constructed from SA 178 Gr A plate. Designed for 200psig @ 500oF. Wall thickness is 0.500”, with a 1/8” corrosion allowanceand reduction ratio is .80. Vessel was PWHT’d. Nameplate is stamped RT2. What is the lowest possible MDMT for this vessel?
(ASME VIII UG 20 (f), UG 84 UCS 66, UCS 68(c).)
Practice Question # 4A horizontal vessel constructed from SA-516 Gr 60 plate. Designed for 200 psig @ 500oF. Wall thickness is 0.750”, with a 1/8” corrosion allowance and reduction ratio is .88. Nameplate is stamped RT-2 and vessel was PWHT’d for environment cracking. What is the lowest possible MDMT for this vessel?
(ASME VIII UG 20 (f), UG 84 UCS 66, UCS 68(c).)
Charpy Impact Test
Each Specimen shall consist of three specimens ASME VIII UG 84
Specimen thickness is 0.394” Fig. UG 84
10
ASME VIII,
Charpy Impact Test
11
(a) Interpolation between yield strengths shown is permitted.
(b) The minimum impact energy for one specimen shall not be less than 2 3 of the average energy requiredfor three specimens. The average impact energy value of the three specimens may be rounded to thenearest ft lb.
ASME VIII,
Practice Question # 5What is the required average and minimum charpy impact values for a material with 50 ksiMSYS and is 1.0 thick?
12
ASME VIII,
13
(ASME VIII UG 84
50 Ksi
1.0 thickness
15 ft lbs
ANSWER:Average = 15 ft lbsMin. Value = 2/3 x 15 = 10 ft lbs
Practice Question # 6What is the required average and minimum charpy impact values for a material with 55 ksiMSYS and is 2.0 thick?
14
(ASME VIII UG 84
Practice Question # 7During impact testing of a 1 ½” thick material with a MSYS of 45,000 psi, the impacttesting values for the specimens were 17, 12, and 11? Are the results of these impacttests acceptable?
15
(ASME VIII UG 84
16
Leg
Throat
Leg
Fillet weld size is normally described by the “leg” size.
Calculating fillet weld size;
Throat size = 0.707 x leg size
Leg size = throat size / 0.707
Per Fig. UW 16.1;Throat size = ½ tmin
orThroat size = tc
or
Throat size = tw
ASME VIII,
17
Leg
Throat
Leg
Calculating the size of fillet welds;
Practice Question # 5An equal leg fillet weld has a throat of 0.375”.What is leg size for this fillet weld?
Leg size = throat size / 0.707= 0.375 / 0.707= 0.530”
Practice Question # 6A fillet weld with a leg size of 0.250”.What is throat size for this fillet weld?
Practice Question # 7A 45o fillet weld has a leg size of 0.125”.What is throat size for this fillet weld?
ASME VIII,
18
tn
tc
d
te
t
a 11 /2 tmin
Per par. UW 16(b);Fillet weld size, must be converted from throat size (½ tmin or tc) to leg size.
tmin = lesser of ¾” or members joined
Assume, the repad is 0.375” thick, the vesselshell is 0.500” thick and the nozzle is 0.432”.What is the required fillet weld size attachingthe repad to the vessel shell?
Step 1: Go to the sketch (UW 16.1(a 1).
Step 2: Calculate throat size ( ½ tmin)½ tmin = ½ x (less
= ½ x (lesser of (0.75”, _____, _____,____)= ½ x (lesser of (0.75”, 0.375”, 0.500”, 0.423”)= ½ x 0.375”= 0.1875”
Step 3: Calculate weld size (Fillet weld Leg size);Leg = ½ tmin / 0.707 = 0.1875 / 0.707 = 0.265” , rounded to next 1/16” = 0.3125”
ASME VIII,
19
Per par. UW 16(b);Fillet weld size for nozzles without repads must be calculated by converting throat size (tc), to leg size.
tc = not less than smaller of ¼” or 0.707 x tmin
Assume, the vessel shell is 0.500” thick and the nozzle is 0.432”. What is the required fillet weld size for this branch connection?
Step 1: Find correct sketch (UW-16.1(a).
Step 2: Calculate the throat size (tc)tc = lesser of ¼” or 0.707 x tmin
= lesser of ¼” or 0.707 x (lesser of 0.750, 0.423, 0.500)= lesser of ¼” or (0.707 x 0.432)= lesser of ¼” or 0.305”= 0.250”
Step 3: Calculate weld size (Fillet weld Leg size);Leg = tc / 0.707 = 0.250 / 0.707 = 0.357”, rounded to next 1/16” = 0.375”
tn
tc
d
t
a
20
tc =
0.375”
0.3125”
0.250”
21
tn
tc
d
t
a
Practice Question # 8A branch connection is being installed without a reinforcement pad.The nozzle thickness is 0.625” and the vessel shell is 0.875” thick. What sizefillet weld should be used for this branch connection?
ASME VIII par. UW 16(b);
22
Practice Question # 9A branch connection is being installed with a reinforcement pad.The nozzle thickness is 0.625”, repad is 0.750” thick and thevessel shell is 0.875” thick. What size fillet weld should beused to attach the repad to the vessel shell?
ASME VIII par. UW 16(b);
tn
tc
d
te
t
a 11 /2 tmin
23
Practice Question # 10
tn
tc
d
t
a
A nozzle is installed in a vessel per Fig. UW 16.1(a). The vessel wall thicknessis 0.325” and the nozzle wall thickness is 0.375”. What is the minimum filletWeld size for the nozzle to shell fillet weld?
ASME VIII par. UW 16(b), Fig. UW 16.1(a)
24
Practice Question # 11
tn
tc
d
t
a
A nozzle is installed in a vessel per Fig. UW 16.1(a). The vessel wall thicknessis 0.325” and the nozzle wall thickness is 0.375”. What is the minimum filletweld size for the nozzle to shell fillet weld?
ASME VIII par. UW 16(b), Fig. UW 16.1(a)
25
ASME VIII par. UG 37
Practice Question # 12
A new 8 NPS nozzle is installed in a vessel per Fig. UW 16.1(h). Shell required thickness is1.125”. Nominal shell thickness is 1.250”. Nominal thickness for the nozzle is 0.875”.The repad thickness is 0.500”.
1) What is the minimum fillet weld size for the nozzle to repad fillet weld?2) What is the minimum fillet weld size for the shell to repad fillet weld?
tc
d
t
Fig. UW 16 1(h)
tn
tw= 0.7tmin
tc
HEAD
BANGER
I. Nozzle Reinforcement
29
ASME VIII par. UG 37
Replacing area lost by cutting hole in vessel (cross sectional area)Strength of the material lost, must be replacedStrength lost = diameter of hole x shell tmin
Limits of reinforcementExtra metal must be near the nozzle
Strength of reinforcementReinforcement must be equal to the strength removedAdditional reinforcement must be added
Reinforcement can come from multiple sourcesShell, nozzle, repad and fillet weldsCorrosion allowance cannot be used
30
Variables for nozzles wwith repads
A = d x tr
A1 = d (t-tr) or 2(t + tn)(t-tr) , larger of these two
A2 = 5t(tn-trn) or 5tn (tn-trn) , smaller of these two
A41 = Leg2
A42 = Leg2
A5 = (Dp – d – 2tn)te
Variables for nozzles wwithout repads
A = d x tr
A1 = d (t-tr) or 2(t + tn)(t-tr) , extra shell area, larger of these two
A2 = 5t(tn-trn) or 5tn (tn-trn) , extra nozzle area, smaller of these two
A41 = leg2
Notes:A. There will be no nozzle projecting inside the shell
B. Be able to compensate for corrosion allowances
C. Weld strength calculations are excluded
d = diameter of nozzle in corroded conditiont = shell thickness in the corroded conditiontr = shell required thicknesstn = nozzle thickness in the corroded conditiontrn = nozzle required thicknessDp = outside diameter of repadte = repad thicknessLimits of reinforcement = greater of d or Rn+tn_t
Nozzle Reinforcement Variables
tn
tc
d
te
t
a 11 /2 tmin
tn
tc
d
t
a
ASME VIII, Subsection A, Part UG, UG 37
31
Practice Question # 13
tn
tc
d
t
a
A 12 NPS nozzle is being installed on a vessel. The corroded ID of the nozzle is12.0”. Shell thickness is 0.750”. Corrosion allowance is 1/16”. Required thicknessfor the shell is 0.625”. The area that must be replaced is;
ASME VIII, Subsection A, Part UG, UG 37
32
ASME VIII par. UG 37
Practice Question # 13
tn
tc
d
t
a
A 12 NPS nozzle is being installed on a vessel. The corroded ID of the nozzle is12.0”. Shell thickness is 0.750”. Corrosion allowance is 1/16”. Required thicknessfor the shell is 0.625”. The area that must be replaced is;
ASME VIII, Subsection A, Part UG, UG 37
33
ASME VIII par. UG 37
Practice Question # 14
tn
tc
d
t
a
A 8 NPS nozzle is being installed on a vessel. The corroded ID of the nozzle is8.0”. Nozzle thickness is 0.250”. Required thickness for the nozzle is 0.100”Shell thickness is 0.450”. Required thickness for the shell is 0.400”.Fillet weld size is 0.375”.
1. What is the area lost?2. What is the limits of reinforcement?3. What is the extra area provided by shell?4. What is the extra area provided by the nozzle?
Practice Question # 15
tn
tc
d
te
t
Fig. UW 16.1(a 1)
1 /2 tmin
A 12 NPS nozzle is being installed in a vessel as indicated by Fig. UW 16.1(a 1). The vesselwall thickness is 0.825” thick. Vessel required thickness is 0.625”. The nozzle wallthickness is 0.500”. Required nozzle thickness is 0.375”. The repad is 0.375” thick.Corrosion allowance is 0.125”.
1) What is the limits of reinforcement (edge to edge)?
2) What is the area lost?
1
Exam Restrictions/Exclusions:
2
1. No more than one process (SMAW, GTAW or SAW).
2. One filler metal per process
3. PQR will be the supporting PQR for the WPS (only one WPS and one PQR).
4. Base metal limited to P1, P3, P4, P5 and P8
5. Dissimilar metals and/or thicknesses are excluded from exam
6. Corrosion-resistant weld overlay, hard-facing overlay, and dissimilar metal welds with buttering of ferritic member is excluded from exam
7. P1, P3, P4 & P5 lower transition temperature will be 1330 F and 1600 F upper transformation
8. Editorial and non-technical requirements are excluded (i.e. Revision #, Company Name, WPS number, WPS Date, and Name of testing lab).
9. Supplemental Variables are excluded from Exam.
Body of Knowledge
I. WPS/PQR/WPQ – BODY OF KNOWLEDGE
3
Layout of the ASME Section IX Code Book
Divided into 2 partsQW – WELDING QB - BRAZING (pages 204 – 243 is not on exam)
QW – Divided into 5 ArticlesArticle I – Welding general requirements (13 pages) QW100
Article II – Welding Procedure Qualifications (WPS/PQR) QW200
Article III – Welding Performance Qualifications (WPQ) QW300
Article IV – Welding Data QW400
Article V - Standard WPS Specifications (NOT ON TEST) QW500
4
Purpose of ASME Section IX
5
Section IX is focused on THREE things;
1. WPS - (Welding Procedure Specification)
2. PQR - (Procedure Qualification Record)
3. WPQ - (Welder Performance Qualification)
Directions to welder to for making production welds
Qualifies that the WPS can be used to make a quality weld
Qualifies that the WELDER can make quality welds with a Welding Process (i.e. SMAW, GTAW, SAW).
General requirements of ASME Section IX
QW100.1 (page 1)
a. Provides directions to welder for making production welds in accordance with CODE requirements.
b. WPS shall be qualified by Manufacturer/Contractorc. WPS specifies conditions which welding must be performed d. WPS must address eessential and non-essential variables and supplemental
variables when applicable (supplemental variables are not on API 510 exam).
e. PQR establishes the properties of the weld, “not the skill of welder’.f. PQR must address eessential variables and and supplemental variables
when applicable (supplemental variables are not on API 510 exam).
QW100.2 (page 2)
a. WPQ determines welder’s ability to make sound welds.
6
General requirements of ASME Section IX (cont)
QW100.3a. WPS qualified per Section IX, can be used to make welds in accordance
with Section VIIIb. WPS qualified in accordance with Section IX 1962 or later can be used.c. WPS qualified in accordance with Section IX prior to 1962, can be used, if
all the 1962 requirements are met.d. Prior to 2009, Section IX used “S” numbers. The 2010 Section IX
eliminated the “S” numbers. WPS’s created using “S” numbers must be revised to show correct “P” number, but not RE-QUALIFIED.
e. New WPS’s and Welder Qualifications, must be per 2010 Edition of Section IX
QW-101a. Section IX applies to preparation of WPS, PQR, WPQ for all types of
manual & machine welding processes
7
General requirements of ASME Section IX (cont)
QW102 (Definitions) (see QW492, page 193)a. Groove Weld – weld made in a groove formed within a single or two members.b. Heat-affected zone – base metal that was not melted, but whose mechanical
properties were altered during weldingc. Interpass temperature – highest temperature allowed in weld or weld joint prior
to welding. d. Lower Transformation Temperature 1330oF – Ferrite begins to transform into
Austenite (P1, P3, P4, P5)e. Macro-Examination - Observing a cross-section of a specimen by the unaided eye
or low magnification with or without etching.f. Performance Qualification – welder’s ability to produce welds meeting prescribed
standards.g. Preheating – heat applied prior to weldingh. Upper Transformation temperature 1600oF – Transformation from ferrite to
austenite is completed. (P1, P3, P4, P5)i. Welder – one who performs manual or semi-automatic welding.
8
General requirements of ASME Section IX (cont)
QW103.1 - Responsibilitya. Manufacturer is responsible for and shall conduct testing required to Qualify
WPS’s and Welders.
QW103.2 - Recordsa. Manufacturer shall maintain a record of the results of WPS and Welder
Qualifications (i.e. PQR and WPQ).
QW110 – Weld Orientationa. Weld orientations used for WPS and WPQ test are as indicated in figure QW
461.1 or QW 461.2 (page 151).
9
Understanding P-Number
14
Understanding P-Number
15
Example - What is the P-Number for SA 285 Gr C?
Answer - Find SA 285 Gr C in table QW/QB 422 (page 76). It is P1 Gr 1.
Understanding F-Numbers
16
Understanding F-Numbers
17
Example - What is the F-Number for E8018?
Answer - Find AWS classification in Table QW 432 (page 134), then go horizontally to lefttill you get to the F-No column. F4 is answer
P-Number and F-Number Practice Questions
18
Material P Number
SA 240 Type 304
SA 217 Type WC1
UNS S31000
Filler Metal Classification and/or Specification F Number
E7024
E8018
SFA 5.18
Test positions for Groove Welds (plate)
19
QW120 – Test Positionsa. Test coupons may be oriented in any position indicate in figures QW 461.3 (plate) or QW
461.4 (pipe) …..see page 153
15 deg15 deg
Test positions for Groove Welds (Pipe)
20
15 deg15 deg
21
“FIELD” Weld Orientations (QW110 page 151)
0o
to 360o
280o
ROTATION of FACE
INCLINATION of AXISTabulation of Positions of GROOVE WELDS
Diagram Inclination RotationPosition Reference of Axis of FaceFlat A 0 to 15o 150 to 210o
Horizontal B 0 to 15o 80 to 150o
210 to 280o
Overhead C 0 to 80o 0 to 80o
210 to 360o
Vertical D 15 to 80o 80 to 280o
E 80 to 90o 0 to 360o
22
Groove Weld – POSITION of Field Welds
Tabulation of Positions of GROOVE WELDS
Diagram Inclination RotationPosition Reference of Axis of FaceFlat A 0 to 15o 150 to 210o
Horizontal B 0 to 15o 80 to 150o
210 to 280o
Overhead C 0 to 80o 0 to 80o
210 to 360o
Vertical D 15 to 80o 80 to 280o
E 80 to 90o 0 to 360o
“FIELD” Weld Orientations (QW110 page 151)
23
“FIELD” Weld Orientations (QW110 page 151)
24
Tabulation of Positions of GROOVE WELDS
Diagram Inclination RotationPosition Reference of Axis of FaceFlat A 0 to 15o 150 to 210o
Horizontal B 0 to 15o 80 to 150o
210 to 280o
Overhead C 0 to 80o 0 to 80o
210 to 360o
Vertical D 15 to 80o 80 to 280o
E 80 to 90o 0 to 360o
Tabulation of Positions of GROOVE WELDS
Diagram Inclination RotationPosition Reference of Axis of FaceFlat A 0 to 15o 150 to 210o
Horizontal B 0 to 15o 80 to 150o
210 to 280o
Overhead C 0 to 80o 0 to 80o
210 to 360o
Vertical D 15 to 80o 80 to 280o
E 80 to 90o 0 to 360o
“FIELD” Weld Orientations (QW110 page 151)
25
Tabulation of Positions of GROOVE WELDS
Diagram Inclination RotationPosition Reference of Axis of FaceFlat A 0 to 15o 150 to 210o
Horizontal B 0 to 15o 80 to 150o
210 to 280o
Overhead C 0 to 80o 0 to 80o
210 to 360o
Vertical D 15 to 80o 80 to 280o
E 80 to 90o 0 to 360o
“FIELD” Weld Orientations (QW110 page 151)
26
Practice Questions for
Weld Orientations
27
Practice Questions for
Weld Orientations
28
Practice Questions for
Weld Orientations
29
Practice Questions for
Weld Orientations
QW141.1 – Tension Test A. Used to determine “ultimate strength” of groove weld joints (TENSILE STRENGTH).B. Types of Test - Reduced Section, Round (Turned), Full SectionC. Tensile Strength = Load/Area in lbs/in2 (psi)
QW141.2 – Guided Bend Test A. Used to determine “degree of soundness and ductility” of groove weld joints.B. Types - Root, Face and Side bend
QW141.3 – Fillet Weld TestA. Used to determine “size, contour & degree of soundness ” of fillet welds.
QW141.4 – Charpy Impact A. Used to determine “notch toughness” of the welds
QW142 – Special examination for welders A. RT or UT may be substituted for mechanical test (bends) for welders.
QW144 – Visual examination A. Used to determine welds meet “quality standards”
30
31
QW141.1 – Tension Test A. Used to determine “ultimate strength” of groove weld joints (TENSILE STRENGTH).B. Types of Test - Reduced Section, Round (Turned), Full SectionC. Tensile Strength = Load/Area in lbs/in2 (psi)
QW151 – Tension TestQW 151.1 - Reduced section “may be” used for all thicknesses of pplates
QW 151.1(a) - For thicknesses 1” “SHALL” be FULL thickness specimensQW 151.1(b) - For thicknesses > 1” “may be” FULL thickness or multiple specimens
QW 151.2 - Reduced section “may be” used for all thicknesses of ppipe > 3” diameter.QW 151.2(a) - For pipe thickness 1” “SHALL” be FULL thickness specimensQW 151.2(b) - For thicknesses > 1” “may be” FULL thickness or multiple specimens
QW153 – Tension Test – Acceptance Criteria
32
In order for a Tension test to pass, the specimen shall have a tensile strength of not less than;
a) MSTS of the base metal (when it fails in weld)b) MSTS of the weaker of the two metals joined together (when it fails in
the weld)c) 95% of the MSTS of base metal (when it fails in the base metal).
38
Failure Stress or Ultimate Stress = Load/Area
Area of a tensile specimen is the width x thickness
Load is the amount of stress required to pull the tensile specimens apart
39
40
Bend Test - Specimens
41
Bend TestQW141.2 – Bend Test
A. Used to determine “degree of soundness and dductility” of groove weld joints.B. Types of Test - Face, Root, and Side bends (determined by which face is on “Convex” side)
Face and Root Bend TestThese two test are always done together. Therefore, what ever # of face bends are required, the same number of root bends are also required.
Side Bend TestSide bends are only performed with other side bends (i.e. you will never see face, root AND side bends required). Side bends are only required for “THICKER” materials (i.e. ¾” or greater in thickness). See Table QW 451.1(a) on page 147.
Acceptance Criteria1. Weld and Haz must be in the bent portion of bend.2. No open discontinuity in weld or HAZ > 1/8” in any direction on convex surface3. Open discontinuity at the corners are acceptable,unless result from LOF, slag or internal
discontinuities
43
Figure “A”Figure “B” Figure “C”
44
Figure “A”
Figure “B” Figure “C”
Visual Examinations
QW144 – Visual ExaminationA. Used to determine if welds meet “qquality standards”B. Required for “PERFORMANCE” test, not PQR.
QW-194 Acceptance Criteria1. Welds must be inspected after welding is complete and before specimens
are removed (see QW-302.4)2. Must have complete Joint penetration3. Must have complete fusion of weld metal and base metal
Radiography
QW142 – Radiography1. May be substituted for Groove weld Mechanical
Test for WELDERS.
QW-191 Acceptance Criteria1. No cracks, Lack of Fusion (LOF) or Incomplete Penetration (IP)2. Elongated slag inclusions (i.e. indication is 3 times longer than width), max
size permitted;1. Max length of 1/8” - for t up to 3/8”2. Max length of 1/3 t - for t > 3/8” but < 2 ¼”3. Max length ¾” - for t > 2 ¼”4. Aligned inclusions with aggregate length > t in 12t length of weld
3. Rounded Indications 1. Smaller of 20% of t oor 1/8”2. For clustered, assorted or randomly dispersed configurations, see
Appendix I
Welder Qualification RecordWelder Performance Qualification (WPQ)
1. Coupon or production for each welding process (SMAW, GTAW, SAW, etc)
2. Qualified by; a. Production weld must be examined by RT or UTb. Coupon can be examined by VT and Mechanical or RT/UT See QW-300.1
NOTE: GMAW S “short circuiting mode” welds cannot be qualified by RT
3. If examination is acceptable, welder is qualified within the limits of QW-304
4. WPQ is welded in accordance with a WPS. Preheat & PWHT required by WPS can be omitted for WPQ
51
Welder Qualification RecordPractice Question # 14
Which of the following cannot be used to qualify a welder?1. VT & Bend Test2. RT of 1st Production weld3. RT of test coupon4. Tension Test
52
WPQ Bend Specimen Requirements
53
Bends
1. Number of bends? AND
Bend Specimen Requirementsfor “Performance Qualification”
54
Bends2. Dimensions?
WPQ Bend Specimens
55
Bends
Where to remove the specimens?
Alternative Inspection (RT/UT) for WPQ
56
RequirementsNDE – Alternative Inspection (RT/UT in lieu of BENDS
1. Minimum Length of weld?
2. Pipe?
1. Minimum Length of weld?
2. Welder Operator?
RT cannot be used to test a welder for either of the following;
57
2. Any of the bend test fail;
3. Fails RT exam;
1. Welder has not used the Process for 6 months
2. Reason to question welder’s ability to make sound weld
1. Fails Visual test;
Qualify by; retest and RT twice the required length of weld
Qualify by: making 2 coupons, both must pass mechanical test.
Qualify by: making 2 coupons, both must pass VT and 1 picked for mechanical testing (bend)
Qualified by; Welding single coupon, plate or pipe, any thickness/diameter/position, VT/Bend or RT.
Practice Questions for WelderQualificationPractice Question # 15
RT can be used to qualify a welder, except for the following?1. Welding P21 material with GTAW process2. SAW process3. SMAW Process4. GMAW process in Short-circuiting mode
Practice Question # 16 A welder is being qualified by welding using ½” thickA106B pipe coupon in 5G position. How many face bends are required?
1. 22. 13. 34. 0
Practice Question # 17A welder is being qualified for 2G and 5G on a single pipe 1” thick coupon (A240 type 304L coupon). How many side bends are required?
1. 62. 23. 44. 0
58
Practice Questions for WelderQualification
Practice Question # 18Which of the following is the manufacturer/contractor prohibited from delegating to another organization?
1. Preparing test coupons2. Performing mechanical or NDE inspection of specimens3. Witnessing the welder making the weld coupon4. Developing the WPQ record
Practice Question # 19A welder was making test coupons for a 2G and 5G pipe qualification test and the 2G coupon failed VT examination. In order for the welder to be qualified, which of the following must occur?
1. Make another 1G coupon and either RT or Mechanical Test the coupon2. Make two 1G coupons and VT and RT examine both coupons 3. Make two 1G coupons and VT both coupons, but only RT one coupon4. Make two 2G coupons and VT both coupons, but only Mechanical test one coupon
Practice Question # 20A 6G qualification coupon failed the mechanical testing (one of the bends failed), In order for the welder to be qualified, which of the following is required?
1. Two more coupons have to be welded and all 4 bends for each of the coupons have to pass mechanical test2. Two more coupons have to be welded and only one coupon has to pass the required mechanical test3. Another coupon has to be welded and all 4 bends has to pass mechanical test4. Two more coupons have to be welded and both coupons must be either pass mechanical testing or RT examined .
59
WPQ “P” Number Qualification Range
60
“P” numberof testcouponwelded
“P” numberRange
qualified toweld inFIELD
Answer:
WPQ “F” Number Qualification Range
61
Qualifiedwith
“F” numberRange
qualified toweld inFIELD
Answer:
WPQ # of Bend Specimens
62
Answer:
WPQ # of Bend Specimens
63
Answer:
WPQ Thickness Limits
64
Answer:
WPQ Diameter Limits
65
Answer:
WPQ Position Limits
66
Answer:
Welder Qualification Record
67
WPQ Record
1. Variables used (i.e. process, type(manual/automatic, with/without backing, P-No, F-No, etc)
2. Essential Variables (i.e. joints, Base metal, Filler Metal, Position, etc)
3. Type of Test (i.e. VT, Bends and/or RT/UT)
4. Test Results (i.e. Acceptable or Failed)
5. Ranges Qualified – (i.e. thickness range, Positions, Diameters, fillet welds)
6. Certification (i.e. signature of Manufacturer/Contractor)
WPQ – Essential Variables
68
Essential Variables
Paragraph VariableProcess
SAW SMAW GTAW
QW402Joints .4 Backing X X
QW 403Base Metals
.16 Ø Pipe Diameter X X X
.18 Ø P Number X X X
QW 404 FillerMetals
.14 ± Filler X
.15 Ø F Number X X X
.22 ± Inserts X
.23 Ø Solid or metal cored toflux core X
.30 Ø t Weld deposit X X X
QW 405Positions
.1 X X X
.3 + Position X X
QW 408Gas .8 Ø Ver cal welding X
QW 409Electrical .4 Ø Current or polarity X
69
Determine What welding PROCESS and TYPE used to make test couponStep 1 SMAW and Manual
Find the “Essential” variables for the welding process used in ASME IX.Step 2 QW 353 for SMAW
Complete Testing Variables and Qualification Limits (“Range Qualified” section)Step 3
Welding Variables (QW 350) Actual Variables Range Qualified
1. Welding Process(es) SMAW
2. Type (i.e. manual, semi-automatic) used Manual .
3. Backing (with or without) (QW 402.4) None
4. Test Coupon Production Weld (dia if pipe) (QW 403.16 Base) 6” NPS
5. Base metal P-Number to P-Number (QW 403.18 P-Number) P1 to P1
6. Filler Metal or Electrode Spec (SFA) 5.1
7. Filler Metal F-Number (QW 404.15 F-Number) F3
8. Consumable Insert (GTAW or PAW) N/A
9. Filler Metal Type (solid/metal or flux cored/powder) N/A
QW 353 for SMAW
SMAW
Manual
_F1,F2, and F3
P1-P15F,P34,P41-49
2 7/8” OD
F1 to F3 with,F3 wo
Page 57
These are set by WPS
--------
------------
------------
x
Welding Variables (QW 350) Actual Variables Range Qualified
10. Deposited Thickness for each process (QW 403.30)
a. Process 1: SMAW 3 layers minimum Yes No . .
b. Process 2: SMAW 3 layers minimum Yes No . ------ .
11. Position qualified (1G,2G,3G,4G,5G,6G, etc) . .
12. Vertical progression (uphill or downhill) .
13. Inert Gas Backing (GTAW, PAW, GMAW) .
14. GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit) .
15. GTAW Current type/polarity (AC,DCEP,DCEN) .
________________________________________________________________________________________________________________
70
x
Complete “Results: section and then Sign and Date FormStep 4
That’s IT, you just completed a WPQ RECORD
n/a horz
F,H
------------
------------
------------
------------
.280”
2G
Uphill
N/A
N/A
N/A
71
Determine if Essential Variables are “Correct”Practice Question#28Welding Variables (QW 350) Actual Variables Range Qualified
1. Welding Process(es) . .. .2. Type (i.e. manual, semi-automatic) used . .3. Backing (with or without) .
4. Test Coupon Production Weld (dia if pipe) . .5. Base metal P-Number to P-Number . .6. Filler Metal or Electrode Spec (SFA) . .7. Filler Metal F-Number .8. Consumable Insert (GTAW or PAW) . .9. Filler Metal Type (solid/metal or flux cored/powder) . .10. Deposited Thickness for each process
a. Process 1: SMAW 3 layers minimum Yes No .b. Process 1: SMAW 3 layers minimum Yes No .
11. Position qualified (1G,2G,3G,4G,5G,6G, etc) .12. Vertical progression (uphill or downhill) .13. Inert Gas Backing (GTAW, PAW, GMAW) .
14. GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit) .15. GTAW Current type/polarity (AC,DCEP,DCEN) .
x
x
Downhill only
ALL
Max of .600”
--------
--------
--------
--------
SMAWManual
F1,F2, and F3
P1-P15F,P34,P41-492 7/8” Min to Unlimited
F1, F2 & F3 with
---------
----------------
SMAWManualWith3”P3
5.4F3
N/AN/A
.300”
-------6G
DownhillN/AN/AN/A
WPQ Welding Variables
72
X
XX
X
X
XX
73
WPQ Welding Variables
74
WPQ Welding VariablesReference WPQ MR. ROD BURNER to answer the following questions;
Welding Procedure - Requirements (WPS)
1. WPS requirements (QW-200.1, page 14)
a. WPS provides directions for making production welds.b. Must contain essential, nonessential and when required
supplementary variables.1) Must reference the supporting PQR
c. Changes can be made to “nonessential” variables withoutrequalification. Changes to “essential or supplementary” variablesrequire requalification.
d. Format of WPS may be any format as long as every essential,nonessential and supplementary variable is included.
e. WPS must be readily available at the fabrication site for review bywelder and inspector.
79
Welding Procedure – Requirements (PQR)
a. Is a Record of the welding data used to make the test coupon andmechanical test results.
a. Must;1) Contain essential and supplementary variables (supplemental is not API 570 Exam).2) Record range of variables used to make the coupon must be included3) Be certified by the manufacturer/contractor (i.e. signed and dated).
b. Changes to the PQR are not allowed, except for editorial type changes (i.e. P# enteredincorrectly, or Code changes the F# for the materials used, etc.) All changes to a PQR,require recertification (i.e. signed and dated by manufacturer/contractor).
c. Format may be any format as long following are included;a. Essential and supplementary variablesb. Type of mechanical test, number of tests and test results
d. PQR must be available for the AI, but not the welder.e. There could be multiple PQR’s supporting one WPS or multiple WPS’s for a single PQR.
80
1. WPS is prepared for production welds that are to be made.
2. Welder (employee or contracted out), makes a Test Coupon using directions fromthe WPS.
3. The coupon is mechanically tested - Bends and Tension test (RT is not allowed).
4. If mechanical testing is acceptable, WPS is Qualified within ranges set by variablesused to make the test coupon.
5. PQR is a record created based on variables used to make the test coupon andsubsequent mechanical testing results.
81
NOTE: PQR “Must” be signed and dated to be CERTIFIED.
(QW-201)
(QW-100)
(QW-202.2)
1. What is the difference between the Procedure QUALIFICATION andWelder QUALIFICATION?
82
A. Procedure qualification requires TWO documents (WPS/PQR).
B. Examinations are different;
C. WPQ only requires “Essential” variables to be recorded,while the WPS must record “Essential, Non-Essential and Supplementary(when required) variables”.PQR must record “Essential and Supplementary” variables.
WPS/PQR – requires Bends/Tension test and Charpy test when notchtoughness is required. Also, Hardness when PWHT’d.
1)
WPQ – requires VT and Bend test or RT/UT examination.2)
1. Verify WPS has been properly completed and addresses requirementsof Section IX (for API Exam, means Essential Variables and Non-Essential variables areaddressed) API 577 par 6.4 page 18
2. Verify PQR has been properly completed and addresses requirementsof Section IX (for API Exam, means Essential Variables are addressed and PQR is signed anddated) API 577 par 6.4 page 18
3. Verify PQR essential variables properly support the range specified inWPS (for API Exam, means Essential Variables are addressed and PQR is signed and dated) API 577
par 6.4 page 18
83
84
INSTRUCTIONS for Checking WPS and PQR
STEP 1 Locate the appropriate “Welding Variables Chart” for the Welding PROCESS (i.e. SMAW– QW 253, SAW-QW 254 or GTAW -QW 256……these are the only three that will be on the API Exam).
STEP 2 Verify PQR is signed by Manufacture/Contractor – QW202(b).
STEP 3 Verify WPS references the supporting PQR – QW201(b).
STEP 4 Verify all Non-Essential variables are addressed on the WPS, and validate that on the checklist (e.g. enter “OK” or “ERROR” inthe VALIDATE column) - QW201(b).
STEP 5 List values for all “ESSENTIAL” variables on Checklist from the PQR – QW202(b).
STEP 6 List values for all “ESSENTIAL” variables on Checklist from the WPS – QW201(b).
STEP 7 Use Section IX to determine and list the “ACCEPTABLE” range for all essential variables (based on the PQR results)
STEP 8 Compare the “Acceptable” range against the WPS values and document the findings in the “VALIDATE” column.
STEP 9 Check TESTING data on PQR and verify correct type/number of BEND specimens (i.e. 2 face & 2 Root, etc) were tested andresults are acceptable or rejectable. Record answer in “Validate” column of checklist.
STEP 10 Check TESTING data on PQR and verify correct type/number of TENSILE specimens (i.e. 2 or more, depending on thickness)were tested and results are acceptable or rejectable. Record answer in “Validate” column of checklist.
STEP 11 Check for P-No and/or F-No mistakes.
Practice Question for Reviewing WPS/PQR
85
1.) Is the PQR signed & dated?
2.) Now check the Essential, Non-essential variables and ranges qualified
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
86
WPS/PQR “Review” ResultsReview of WPS# Rev# Dated:
Supporting PQR# Rev# Dated:
STEP 4 STEP 5 STEP 6 STEP 7 Validate
Paragraph Brief of Variables Essential Non Essential PQR WPS Qualified For? OK or Error
QW 402 Joints
.1 Groove Design NE
.4 - Backing NE
.10 Root spacing NE
.11 Retainers NE
QW 403Base Metals
.8 T qualified E
.9 t Pass > ½ inch E
.11 P No. qualified E
QW 404 FillerMetals
.4 F Number E
.5 A Number E
.6 Diameter NE
.30 t E
.33 AWS Classification NE
QW 405 Positions.1 + Position NE
.3 Vertical welding NE
QW 406 Preheat1. Decrease > 100oF E
.2 Preheat maintenance NE
QW 407 PWHT.1 PWHT E
.4 T limits E
QW 409 Electric.4 Current or polarity NE
.8 I & E range NE
QW 410Technique
.1 String/Weave NE
.5 Method of cleaning NE
.6 Method back gouge NE
.9 Multi to single pass/side NE
.25 Manual or automatic NE
.26 Peening NE
.64 Use of Thermal Processes E
JCP P101
JCP PQ101
0
0
9/11/2001
9/12/2001
--------------------
----------
-----
-----
-----
--------------------
-----
-----
-----
--------
½”½” thk
SA53 Gr B (P1_)F-4
1
½”
50oF
None-----
1/16” to 1”½” thkP1F31
1/16” to 1”
50oF
None
None
3/16” to 1”½” plate N/A
P1F31
Max of 1”
50oF
None----- -----
None
ERROR – should be F3
None
PQR should be 1/16” to 1”
Par
Par
Par
Par
Par
Par
ParOK
87
WPS/PQR “Review” ResultsBEND SPECIMENS
Number of bends ResultsValidate
(Ok or Error)Required(# & Type)
On PQR(# & Type)
Allowable Defects On PQR
NOTE: 1. Open discontinuity in weld or HAZ < 1/8” (See QW-163, page 6)2. Ignore open discontinuity on corners, unless result from LOF, Slag or internal discontinuity
TENSILE SPECIMENSNumber of Tensile Specimens Compare Results
Validate(Ok or Error)# Required # on PQR
MSTS of BaseMetal
UltimateFailureStress
Check for P-No, F-No and/or Specification mistakes on the WPS/PQR.Results - No F-No or P-No errors.
NOTE: 1. Failure Stress (failed in “Base Metal”) must be .95% of MSTS (see QW-153, page 4)2. Failure Stress (failed in “WELD”) must be MSTS (QW-153)3. Verify that the “Ultimate Failure Stress” is calculated properly (S=Load/Area) – (see QW-152, page 4)
2F & 2R OR 4S 4 SIDES 1/8” OK OK
2 2 60,000 PSI57,038 Base66,158 Weld OK
Practice Questions for Reviewing WPS/PQR
88
Is the P# qualified in accordance with ASME Section IX?Result – Yes, P8
Practice Question # 30
If you don’t know SA 240 Type 304 is P8, then look it up at P-No Tab
Practice Questions for Reviewing WPS/PQR
89
Is the base metal thickness in accordance with ASME Section IX?
Result – No, PQR coupon was ½” which qualifies thk range of 3/16” to 1”,WPS indicated 1/16” to 1”
Practice Question # 31
Practice Questions for Reviewing WPS/PQR
90
Is the shielding gas in accordance with ASME Section IX?
Result – NO, WPS is for single gas (argon) and PQR is for 75/25 mix
Practice Question # 32
Essential
Practice Questions for Reviewing WPS/PQR
91
Is the F# qualified in accordance with ASME Section IX?
Result – NO, ER304 is F6 & E7018 is a F4
Practice Question # 33
Practice Questions for Reviewing WPS/PQR
92
Are the tensile test in accordance with ASME Section IX?
Practice Question # 34
93
WPS/PQR
94
WPS/PQR
PQR JCP PQ101
95
WPS/PQR
2T = 2 x ½” = 1”
96
WPS/PQR
97
WPS/PQR
PQR JCP PQ101 SA 53B is “P 1
98
WPS/PQR
Welded P 1 Welded P 1
99
WPS/PQR
100
WPS/PQR
PQR JCP PQ101
101
WPS/PQR
Go to par404.4
102
WPS/PQR
WPS
PQR
103
WPS/PQR
104
WPS/PQR
PQR JCP PQ101
105
WPS/PQR
106
WPS/PQR
107
WPS/PQR
PQR JCP PQ101
108
WPS/PQR
109
WPS/PQR
110
WPS/PQR
PQR JCP PQ101
111
WPS/PQR
112
WPS/PQR
PQR JCP PQ101
113
WPS/PQR
Par
Par
1
PWHT temps, see Table UCS-56Partial HT requires 5 ft overlap for each successive heats (partial means part cannot fit into furnace) per par UW-40(a)(2).HT of welds includes a zone extend 1t or 2”, whichever is less, beyond each side of the weld (par UW-40(a)No control of temperature up to 800oF. Par UCS-56(c.)Heating rate above 800oF shall not be more than 400oF per hr/max metal thickness. Par UCS-56(d)(1)(2).Variation in temperature cannot exceed 250oF in any 15 ft length of vessel. Par UCS-56(d)(2)Holding time is per Table UCS-56During holding time, temperature cannot vary by more than 150oF. Par UCS-56(d)(3).Cool down rate shall not be more than 500oF per hr/max metal thickness. No control necessary below 800oF. Par UCS-56(d)(5).
2
3
A 2” thick vessel fabricated from SA-516-70N was repaired and PWHT’d at 1000o F. How long should the vessel be maintained at this PWHT temperature?
4
A 2” thick vessel fabricated from SA-516-70N was repaired and PWHT’d at 1000o F. How long should the vessel be maintained at this PWHT temperature?
5
ANSWER 4 hrs & 15 min
A 3” thick vessel fabricated from SA-516-70 was repaired and PWHT’d at 950o F. How long should the vessel be maintained at this PWHT temperature?
6
Post Weld Heat Treatment (PWHT)( API 510)
API 510PWHT should be made as required by ASME Code (Par 8.1.6.4)Local PWHT may be substituted for 360 degree banding on local repairs (Par8.1.6.4.1)
If approved by the engineer.A preheat of 300oF or higher is maintained during weldingPWHT temperature maintained for a distance not less than 2 x t, from the toe of the weld.At least two thermocouples must be used.Metallurgist approves the PWHT procedure if it is performed for environmental assistedcracking resistance.
7
If a repair is made to a vessel after PWHT. A Minimum preheat of 200oF shall bemaintained during the repair for P1 materials. And 350oF for P3 materials. Par UCS-56(f)(4)(b).
No welding recommended at temperatures lower than 0oF. Temperatures between 32oFand 0oF, surfaces within 3” of the weld should be heated to a minimum of 60oF. Par.UW-30.
PWHT can be avoided for certain thickness. Example: P1 between 1 ¼” & 1 ½” doesn’trequired PWHT if a minimum of a 200oF preheat is applied during welding.
8
Preheat in lieu of PWHT for P1 and P3 materials, provided;1. Preheat temperature maintained at a minimum of 300oF.2. Preheat temperature maintained at a distance of 4” or 4t, whichever is
greater, on each side of weld3. Maximum interpass temperature of 600oF
9
10
11
Weld Process Schematics
12
13
Welding Process Productivity
14
15
16
21
22
23
24
25
26
27
Vessel thickness of 1.125”, using a SWE/SWV technique and technicianhas access to the ID of the vessel.
28
Vessel thickness of 1.125”, using a SWE/SWV technique and technicianhas access to the ID of the vessel.
29
Vessel thickness of 1.125”, using a SWE/SWV technique and techniciandoes not have access to the ID of the vessel.
30
Vessel thickness of 1.125”, using a SWE/SWV technique and techniciandoes not have access to the ID of the vessel.
31
Welding Procedure (WPS),
Procedure Qualification Record (PQR)
and
Welder Performance Qualification (WPQ)
Forms
Index
WPS JCP-P101 PQR JCP-PQ101 WPS JCP-P201 PQR JCP-PQ201 WPS JCP-P301 PQR JCP-PQ301 Rod Burner WPQ Form – with qualified range Rod Burner WPQ Form – without qualified range Blank WPS Form Blank PQR Form Blank WPQ Form
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS) (See Section IX QW-200.1)
Company Name JC Penny By Mr. Penny Welding Procedure Specification No. JCP-P101 Date 9/11/2001 Supporting PQR No.(s)JCP-PQ101 Revision No. 0 Date 9/11/2001
Welding Process(es) SMAW Type(s) Manual
Test Description
Joints (QW 402) Joint Design Single V Groove and Fillets Root Spacing .0625” to 1.250” Backing: Yes x No x Backing Material (Type) Metal (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified. (At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)). Base Metals (QW 403) P-No. 1 Group No. to P-No. 1 Group No. OR Specification and type/grade to Specification and type/grade OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum pass thickness ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All 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 Type_ _ _ _ _ _ _ _ _ _ _ _ _ Consumable Insert_ _ _ _ _ _ _ _ _ Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
1st Filler Metal 5.1 E-7018 3 1 3/32”, 1/8”, 5/16” .0625” to 1.0” .250” to 1.0” N/A N/A N/A
2nd Filler Metal
Page of 2 WPS No. JCP-P101 Rev.# 0
Positions (QW 405) Position(s) of Groove ALL Welding Progression: UP X Down Position(s) of fillet ALL
Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other
Preheat (QW 406) Preheat Temp, Min 50oF Interpass Temp, Max 350oF Preheat Maintenance None (Continuous or special heating, where applicable, should be recorded.
Gas (QW 408) Percent Composition Gases Mixtures Flow Rate Shielding N/A Trailing Backing Other
Electrical Characteristics (QW 409)
Weld Pass(es)
Process
Filler Metal Current Type and
Polarity
Amps (Range)
Wire Feed Speed (Range)
Energy or Power (Range)
Volts (Range)
Travel Speed (Range)
Other (e.g Remarks, Com-ments, Hot Wire
Addition, Technique, Torch
Angle, etc)
Classifi-cation
Diameter
All
SMAW
E-7018
1/8”
DCEP
70 to 200
N/A
N/A
19 - 25
5 to 7
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current N/A Heat Input (max.) N/A Tungsten Electrode Size and Type N/A (Pure Tungsten, 2% Thoriated, etc)
Mode of Metal Transfer for GMAW or FCAW N/A (Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410) String or Weave Bead String or Weave Orifice, Nozzle, or Gas Cup Size N/A Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping or Wire Brush Method of Back Gouging Grinding Oscillation N/A Contact Tube to Work Distance N/A Multiple or Single Pass (per side) Multiple or Single Multiple of Single Electrodes Single Peening N/A Other
Page 2 of 2
ASME Section IX –PQR
QW-483 Suggested Format For Procedure Qualification Record (PQR) (See Section IX QW-200.2)
Company Name JC Penny PQR No. JCP-PQ101 WPS # JCP-P101 Date 9/12/2001
Welding Process(es) SMAW Type(s) Manual
Joints (QW 402)
Groove Design of Test Coupon
Base Metals (QW 403) Material Spec. SA-53 Gr B P-No. to P-No. Thickness of Test Coupon ½” Diameter of Test Coupon 6” Other
Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other
Gas (QW 408) Percent Composition
Gases Mixtures Flow RateShielding N/A TrailingBacking
Filler Metals (QW 404) SFA Specification 5.1 AWS Classification E-7018 Filler Metal F-No. 4 Weld Metal Analysis A-No. 1 Size of Filler Metal 5/32” Other Weld Metal Thickness
Electrical Characteristics (QW 409) Current DC Polarity Straight Amps: 150-300 Volts 20-28 Tungsten Electrode Size N/A Other
Positions (QW 405) Position of Groove ALL Weld Progression (Uphill, Downhill) Other
Technique (QW 410) Travel Speed 3”/min String or Weave Bead StringerOscillation Multipass or Single Pass (per side) Multiple Single or Multiple Electrodes SingleOther
Preheat (QW 406) Preheat Temp 50oF Interpass Temp Other
G D i f T C
QW 483 (back)
PQR No. JCP-PQ101
Tensile Test (QW -150)
Specimen No. Width (inch)
Thickness (inch)
Area (sq. inches)
Ultimate Load (lbs)
Ultimate Stress (psi)
Type of Failure & Location
T1 .750 .455 .341 19,450 57,038 Pass - Base T2 .756 .451 .341 22,560 66,158 Pass - Weld
Guided Bend Tests (QW -160)
Type and Figure No. Results SIDE # 1 Pass SIDE # 2 Pass SIDE # 3 Pass SIDE # 4 Pass
Notch Toughness Tests (QW -170)
Specimen No.
Notch Location
Notch Type
Test Temp
Impact Values
Lateral Exp Drop Weight % Shear Mils Break No Break
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 Jack Shift Jr Clock No. Stamp No. B2 Test 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 ASME Section IX. Manufacturer JC Penny Date 9/11/2001 By: Jack Shift Sr
Page 2 of 2
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS) (See Section IX QW-200.1)
Company Name JC Penny By Mr. Penny Welding Procedure Specification No. JCP-P201 Date 8/11/2001 Supporting PQR No.(s)JCP-PQ201 Revision No. 0 Date 8/11/2001
Welding Process(es) GTAW Type(s) Manual
Test Description
Joints (QW 402) Joint Design Single V Groove Root Spacing 1.250” Backing: Yes x No x Backing Material (Type) Solid Metal or weld metal (Refers to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified. (At the option of the manufacturer, sketches may be attached to illustrate 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 and type/grade SA 240 Type 304 to Specification and type/grade SA 240 Type 304 OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum pass thickness ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All Filler Metals (QW 404) Spec. No. (SFA): 5.9 AWS No. (Class): ER304 F-No.: F-6 A-No.: A-8 Size of Filler Metals: 3/32”, 1/8”,5/16” Weld MetalThickness Range: Groove: .0625” to 1.0” Fillet: No limit Electrode-Flux (Class): N/A Flux Type: N/A Consumable Insert: None Other: N/A
No single pass > ½”
Page of 2
WPS No. JCP-P201 Rev.# 0 Positions (QW 405) Position(s) of Groove ALL Welding Progression: UP X Down Position(s) of fillet ALL
Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other
Preheat (QW 406) Preheat Temp, Min 80oF Interpass Temp, Max 350oF Preheat Maintenance None (Continuous or special heating, where applicable, should be recorded.
Gas (QW 408) Percent Composition Gases Mixtures Flow Rate Shielding Argon Trailing None Backing None Other
Electrical Characteristics (QW 409)
Weld Pass(es)
Process
Filler Metal Current Type and
Polarity
Amps (Range)
Wire Feed Speed (Range)
Energy or Power (Range)
Volts (Range)
Travel Speed (Range)
Other
(e.g Remarks,
Comments,
Hot Wire Addition,
Technique, Torch
Angle, etc)
Classifi-cation
Diameter
All GTAW ER304 3/32” DCSP 60-100 N/A N/A N/A N/A
All GTAW ER304 1/8” DCSP 70-110 N/A N/A N/A N/A
All GTAW ER304 5/16”” DCSP 90-160 N/A N/A N/A N/A
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current N/A Heat Input (max.) N/A Tungsten Electrode Size and Type 2% Thoriated (EWTh-2) or Cesium Stablilized (EWCe-2) (Pure Tungsten, 2% Thoriated, etc)
Mode of Metal Transfer for GMAW or FCAW N/A (Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410) String or Weave Bead String or Weave Orifice, Nozzle, or Gas Cup Size 3/8” to ¾” diameter shielding gas cup size Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping, Wire Brush or Thermal process Method of Back Gouging Grinding or thermal process Oscillation N/A Contact Tube to Work Distance N/A Multiple or Single Pass (per side) Multiple Multiple of Single Electrodes Single Peening None Other
Page 2 of 2
ASME Section IX –PQR
QW-483 Suggested Format For Procedure Qualification Record (PQR) (See Section IX QW-200.2)
Company Name JC Penny PQR No. JCP-PQ201 WPS # JCP-P201 Date 8/12/2001
Welding Process(es) GTAW Type(s) Manual
Joints (QW 402)
Groove Design of Test Coupon
Base Metals (QW 403) Material Spec. SA-240 Type 304 P-No. 8 to P-No. 8 Thickness of Test Coupon ½” Diameter of Test Coupon Plate Other
Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other
Gas (QW 408) Percent Composition
Gases Mixtures Flow RateShielding Argon/CO 75%/25% 15-25 Trailing NoneBacking None
Filler Metals (QW 404) SFA Specification 5.18 AWS Classification E-7018 Filler Metal F-No. 6 Weld Metal Analysis A-No. 8 Size of Filler Metal N/A Other Weld Metal Thickness ½”
Electrical Characteristics (QW 409) Current DC Polarity Straight Amps: 90-100 Volts 20-28 Tungsten Electrode Size 1/8” Other
Positions (QW 405) Position of Groove 1G Weld Progression (Uphill, Downhill) N/A Other
Technique (QW 410) Travel Speed 5”/min String or Weave Bead WeaveOscillation Multipass or Single Pass (per side) Multiple Single or Multiple Electrodes SingleOther
Preheat (QW 406) Preheat Temp 50oF Interpass Temp 250oF Other
G D i f T C
QW 483 (back)
PQR No. JCP-PQ101
Tensile Test (QW -150)
Specimen No. Width(W) (inch)
Thickness(y) (inch)
Area (sq. inches)
Ultimate Load (lbs)
Ultimate Stress (psi)
Type of Failure & Location
T1 .750 .440 .330 24,450 74,090 Pass - Weld T2 .750 .449 .337 24,000 71,216 Pass - Base
Guided Bend Tests (QW -160)
Type and Figure No. Results Face # 1 Pass Face # 2 Pass Root # 3 Pass Root # 4 Pass
Notch Toughness Tests (QW -170)
Specimen No.
Notch Location
Notch Type
Test Temp
Impact Values
Lateral Exp Drop Weight % Shear Mils Break No Break
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 Jack Shift Jr Clock No. Stamp No. B2 Test conducted by: Shear Metal Testing Lab Laboratory Test No. SM-1001 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 ASME Section IX. Manufacturer JC Penny Date 8/12/2001 By: Jack Shift Sr
Page 2 of 2
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS) (See Section IX QW-200.1)
Company Name JC Penny By Mr. Penny Welding Procedure Specification No. JCP-P301 Date 9/11/2001 Supporting PQR No.(s)JCP-PQ301 Revision No. 0 Date 9/11/2001
Welding Process(es) SMAW Type(s) Manual
Test Description
Joints (QW 402) Joint Design Single V Groove and Fillets Root Spacing .0625” to 1.250” Backing: Yes x No x Backing Material (Type) Metal (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified. (At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)). Base Metals (QW 403) P-No. 1 Group No. to P-No. 1 Group No. OR Specification and type/grade to Specification and type/grade OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum pass thickness ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All 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 Type_ _ _ _ _ _ _ _ _ _ _ _ _ Consumable Insert_ _ _ _ _ _ _ _ _ Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
1st Filler Metal 5.1 E-7018 3 1 3/32”, 1/8”, 5/16” .0625” to 1.0” .250” to 1.0” N/A N/A N/A
2nd Filler Metal
Page 1 of 2 WPS No. JCP-P301 Rev.# 0
Positions (QW 405) Position(s) of Groove ALL Welding Progression: UP X Down Position(s) of fillet ALL
Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other
Preheat (QW 406) Preheat Temp, Min 50oF Interpass Temp, Max 350oF Preheat Maintenance None (Continuous or special heating, where applicable, should be recorded.
Gas (QW 408) Percent Composition Gases Mixtures Flow Rate Shielding N/A Trailing Backing Other
Electrical Characteristics (QW 409)
Weld Pass(es)
Process
Filler Metal Current Type and
Polarity
Amps (Range)
Wire Feed Speed (Range)
Energy or Power (Range)
Volts (Range)
Travel Speed (Range)
Other (e.g Remarks, Com-ments, Hot Wire
Addition, Technique, Torch
Angle, etc)
Classifi-cation
Diameter
All
SMAW
E-7018
1/8”
DCEP
70 to 200
N/A
N/A
19 - 25
5 to 7
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current N/A Heat Input (max.) N/A Tungsten Electrode Size and Type N/A (Pure Tungsten, 2% Thoriated, etc)
Mode of Metal Transfer for GMAW or FCAW N/A (Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410) String or Weave Bead String or Weave Orifice, Nozzle, or Gas Cup Size N/A Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping or Wire Brush Method of Back Gouging Grinding Oscillation N/A Contact Tube to Work Distance N/A Multiple or Single Pass (per side) Multiple or Single Multiple of Single Electrodes Single Peening N/A Other
Page 2 of 2
ASME Section IX –PQR
QW-483 Suggested Format For Procedure Qualification Record (PQR) (See Section IX QW-200.2)
Company Name JC Penny PQR No. JCP-PQ301 WPS # JCP-P301 Date 9/12/2001
Welding Process(es) SMAW Type(s) Manual
Joints (QW 402)
Groove Design of Test Coupon
Base Metals (QW 403) Material Spec. SA-53 Gr B P-No. to P-No. Thickness of Test Coupon ½” Diameter of Test Coupon 6” Other
Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other
Gas (QW 408) Percent Composition
Gases Mixtures Flow RateShielding N/A TrailingBacking
Filler Metals (QW 404) SFA Specification 5.1 AWS Classification E-7018 Filler Metal F-No. 4 Weld Metal Analysis A-No. 1 Size of Filler Metal 5/32” Other Weld Metal Thickness
Electrical Characteristics (QW 409) Current DC Polarity Straight Amps: 150-300 Volts 20-28 Tungsten Electrode Size N/A Other
Positions (QW 405) Position of Groove ALL Weld Progression (Uphill, Downhill) Other
Technique (QW 410) Travel Speed 3”/min String or Weave Bead StringerOscillation Multipass or Single Pass (per side) Multiple Single or Multiple Electrodes SingleOther
Preheat (QW 406) Preheat Temp 50oF Interpass Temp Other
G D i f T C
QW 483 (back)
PQR No. JCP-PQ301
Tensile Test (QW -150)
Specimen No. Width (inch)
Thickness (inch)
Area (sq. inches)
Ultimate Load (lbs)
Ultimate Stress (psi)
Type of Failure & Location
T1 .750 .455 .341 19,450 57,038 Pass - Base T2 .756 .451 .341 22,560 66,158 Pass - Weld
Guided Bend Tests (QW -160)
Type and Figure No. Results SIDE # 1 Pass SIDE # 2 Pass Face # 1 Pass Face # 2 Pass
Notch Toughness Tests (QW -170)
Specimen No.
Notch Location
Notch Type
Test Temp
Impact Values
Lateral Exp Drop Weight % Shear Mils Break No Break
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 Jack Shift Jr Clock No. Stamp No. B2 Test 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 ASME Section IX. Manufacturer JC Penny Date 9/11/2001 By: Jack Shift Sr
Page 2 of 2
ASME Section IX – Welder Qualification Homework – WPQ’s
QW-484A Suggested Format For Welder Performance Qualification (WPQ)
(See Section IX QW-301)
Welder(s) Name Mr. Rod Burner Identification Number A11
Test Description
Identification of WPS followed WPS 101 Test Coupon Production Weld
Specification and Type/Grade or UNS Number of base metal(s) A 106B to A106B Thickness .280
Testing Variables and Qualification Limits
Welding Variables (QW350) Actual Values Range Qualified
Welding Process(es) SMAW SMAW
Type (i.e. manual, semi-automatic) used Manual Manual
Backing (with or without) None F1 to F3 with,F3 wo
Test Coupon Production Weld (dia if pipe) 6” NPS __ 2 7/8” OD
Base metal P-Number to P-Number P-1 to P-1 P1-P15F, P34, P41-P49
Filler Metal or Electrode Spec (SFA) 5.1 -------
Filler Metal F-Number F 3 F1,F2, & F3
Consumable Insert (GTAW or PAW) N/A -------
Filler Metal Type (solid/metal or flux cored/powder) N/A -------
Deposited Thickness for each process
Process 1: SMAW 3 layers minimum Yes No .280” .560
Process 2: 3 layers minimum Yes No ---- -------
Position qualified (1G,2G,3G,4G,5G,6G, etc) 2G F, H
Vertical progression (uphill or downhill) Uphill Uphill
Inert Gas Backing (GTAW, PAW, GMAW) N/A -------
GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit) N/A -------
GTAW Current type/polarity (AC,DCEP,DCEN) N/A -------
RESULTS
Visual examination of completed weld (QW 302.4) Acceptable
Transverse face and root bends (QW 462.3(a) Longitudinal bends (QW 462.3(b) Side bends (QW 462.2)
Type Results Type Results
Face No defects – Acceptable
Root No defects - Acceptable
Alternative Volumetric Examination Results (QW 191) N/A RT or UT
Fillet weld – fracture test (QW 181.2) N/A Length and percent of defects N/A
Macro examination (QW 184) Fillet size (in.) x Concavity/convexity (in.)
Other tests
Film or specimens evaluated by Company
Mechanical tests conducted by Ben Tension Laboratory test no. 123 Welding supervised by Red Eye
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the
requirements of Section IX of the ASME Code. Organization Worlds Best Fabricator
Date April 7, 2010 By John Doe
Welding Procedure (WPS),
Procedure Qualification Record (PQR)
and
Welder Performance Qualification (WPQ)
Forms
Index
WPS JCP-P101 PQR JCP-PQ101 WPS JCP-P201 PQR JCP-PQ201 WPS JCP-P301 PQR JCP-PQ301 Rod Burner WPQ Form – with qualified range Rod Burner WPQ Form – without qualified range Blank WPS Form Blank PQR Form Blank WPQ Form
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS)(See Section IX QW-200.1)
Company Name JC Penny By Mr. Penny Welding Procedure Specification No. JCP-P101 Date 9/11/2001 Supporting PQR No.(s)JCP-PQ101 Revision No. 0 Date 9/11/2001
Welding Process(es) SMAW Type(s) Manual
Test Description
Joints (QW 402) Joint Design Single V Groove and Fillets Root Spacing .0625” to 1.250” Backing: Yes x No x Backing Material (Type) Metal
(Refer to both backing and retainers)
Metal Nonfusing Metal Nonmetallic Other
Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified.
(At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)).
Base Metals (QW 403) P-No. 1 Group No. to P-No. 1 Group No.
OR Specification and type/grade to Specification and type/grade
OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop.
Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum pass thickness ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All
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 Type_ _ _ _ _ _ _ _ _ _ _ _ _ Consumable Insert_ _ _ _ _ _ _ _ _ Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
1st Filler Metal 5.1 E-70 3 1
3/32”, 1/8”, 5/16”
.0625” to 1.0”
.250” to 1.0” N/A N/A N/A
2nd Filler Metal
Page of 2 WPS No. JCP-P101 Rev.# 0
Positions (QW 405) Position(s) of Groove ALL Welding Progression: UP X Down Position(s) of fillet ALL
Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other
Preheat (QW 406) Preheat Temp, Min 50oF Interpass Temp, Max 350oF Preheat Maintenance None
(Continuous or special heating, where applicable, should be recorded.
Gas (QW 408) Percent Composition
Gases Mixtures Flow Rate Shielding N/A Trailing Backing Other
Electrical Characteristics (QW 409)
Weld Pass(es)
Process
Filler Metal Current Type and
Polarity
Amps (Range)
Wire Feed Speed (Range)
Energy or Power (Range)
Volts (Range)
Travel Speed (Range)
Other (e.g Remarks, Com-ments, Hot Wire
Addition, Technique, Torch
Angle, etc)
Classifi-cation
Diameter
All SMAW E-7018 1/8” DCEP 70 to 200
N/A N/A 19 - 25 5 to 7
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current N/A Heat Input (max.) N/A Tungsten Electrode Size and Type N/A
(Pure Tungsten, 2% Thoriated, etc)
Mode of Metal Transfer for GMAW or FCAW N/A (Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410) String or Weave Bead String or Weave Orifice, Nozzle, or Gas Cup Size N/A Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping or Wire Brush
Method of Back Gouging Grinding Oscillation N/A Contact Tube to Work Distance N/A Multiple or Single Pass (per side) Multiple or Single Multiple of Single Electrodes Single Peening N/A Other
Page 2 of 2
ASME Section IX –PQR
QW-483 Suggested Format For Procedure Qualification Record (PQR)(See Section IX QW-200.2)
Company Name JC Penny PQR No. JCP-PQ101 WPS # JCP-P101 Date 9/12/2001
Welding Process(es) SMAW Type(s) Manual
Joints (QW 402)
Groove Design of Test Coupon
Base Metals (QW 403) Material Spec. SA-53 Gr B P-No. to P-No. Thickness of Test Coupon ½” Diameter of Test Coupon 6” Other
Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other
Gas (QW 408) Percent Composition
Gases Mixtures Flow RateShielding N/A TrailingBacking
Filler Metals (QW 404) SFA Specification 5.1 AWS Classification E-7018 Filler Metal F-No. 4 Weld Metal Analysis A-No. 1 Size of Filler Metal 5/32” Other
Weld Metal Thickness
Electrical Characteristics (QW 409) Current DC Polarity Straight Amps: 150-300 Volts 20-28 Tungsten Electrode Size N/A Other
Positions (QW 405) Position of Groove ALL Weld Progression (Uphill, Downhill) Other
Technique (QW 410) Travel Speed 3”/min String or Weave Bead StringerOscillation Multipass or Single Pass (per side) Multiple Single or Multiple Electrodes SingleOther
Preheat (QW 406) Preheat Temp 50oF Interpass Temp Other
G D i f T C
QW 483 (back)
PQR No. JCP-PQ101
Tensile Test (QW -150)
Specimen No. Width (inch)
Thickness (inch)
Area (sq. inches)
Ultimate Load (lbs)
Ultimate Stress (psi)
Type of Failure & Location
T1 .750 .455 .341 19,450 57,038 Pass - BaseT2 .756 .451 .341 22,560 66,158 Pass - Weld
Guided Bend Tests (QW -160)
Type and Figure No. ResultsSIDE # 1 PassSIDE # 2 PassSIDE # 3 PassSIDE # 4 Pass
Notch Toughness Tests (QW -170)
Specimen No.
Notch Location
Notch Type
Test Temp
Impact Values
Lateral Exp Drop Weight% Shear Mils Break No Break
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 Jack Shift Jr Clock No. Stamp No. B2 Test 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 ASME Section IX.
Manufacturer JC Penny
Date 9/11/2001 By: Jack Shift Sr
Page 2 of 2
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS) (See Section IX QW-200.1)
Company Name JC Penny By Mr. Penny Welding Procedure Specification No. JCP-P201 Date 8/11/2001 Supporting PQR No.(s)JCP-PQ201 Revision No. 0 Date 8/11/2001
Welding Process(es) GTAW Type(s) Manual
Test Description
Joints (QW 402) Joint Design Single V Groove Root Spacing 1.250” Backing: Yes x No x Backing Material (Type) Solid Metal or weld metal (Refers to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified. (At the option of the manufacturer, sketches may be attached to illustrate 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 and type/grade SA 240 Type 304 to Specification and type/grade SA 240 Type 304 OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum pass thickness ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All Filler Metals (QW 404) Spec. No. (SFA): 5.9 AWS No. (Class): ER304 F-No.: F-6 A-No.: A-8 Size of Filler Metals: 3/32”, 1/8”,5/16” Weld MetalThickness Range: Groove: .0625” to 1.0” Fillet: No limit Electrode-Flux (Class): N/A Flux Type: N/A Consumable Insert: None Other: N/A
No single pass > ½”
Page of 2
WPS No. JCP-P201 Rev.# 0 Positions (QW 405) Position(s) of Groove ALL Welding Progression: UP X Down Position(s) of fillet ALL
Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other
Preheat (QW 406) Preheat Temp, Min 80oF Interpass Temp, Max 350oF Preheat Maintenance None (Continuous or special heating, where applicable, should be recorded.
Gas (QW 408) Percent Composition Gases Mixtures Flow Rate Shielding Argon Trailing None Backing None Other
Electrical Characteristics (QW 409)
Weld Pass(es)
Process
Filler Metal Current Type and
Polarity
Amps (Range)
Wire Feed Speed (Range)
Energy or Power (Range)
Volts (Range)
Travel Speed (Range)
Other
(e.g Remarks,
Comments,
Hot Wire Addition,
Technique, Torch
Angle, etc)
Classifi-cation
Diameter
All GTAW ER304 3/32” DCSP 60-100 N/A N/A N/A N/A
All GTAW ER304 1/8” DCSP 70-110 N/A N/A N/A N/A
All GTAW ER304 5/16”” DCSP 90-160 N/A N/A N/A N/A
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current N/A Heat Input (max.) N/A Tungsten Electrode Size and Type 2% Thoriated (EWTh-2) or Cesium Stablilized (EWCe-2) (Pure Tungsten, 2% Thoriated, etc)
Mode of Metal Transfer for GMAW or FCAW N/A (Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410) String or Weave Bead String or Weave Orifice, Nozzle, or Gas Cup Size 3/8” to ¾” diameter shielding gas cup size Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping, Wire Brush or Thermal process Method of Back Gouging Grinding or thermal process Oscillation N/A Contact Tube to Work Distance N/A Multiple or Single Pass (per side) Multiple Multiple of Single Electrodes Single Peening None Other
Page 2 of 2
ASME Section IX –PQR
QW-483 Suggested Format For Procedure Qualification Record (PQR) (See Section IX QW-200.2)
Company Name JC Penny PQR No. JCP-PQ201 WPS # JCP-P201 Date 8/12/2001
Welding Process(es) GTAW Type(s) Manual
Joints (QW 402)
Groove Design of Test Coupon
Base Metals (QW 403) Material Spec. SA-240 Type 304 P-No. 8 to P-No. 8 Thickness of Test Coupon ½” Diameter of Test Coupon Plate Other
Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other
Gas (QW 408) Percent Composition
Gases Mixtures Flow RateShielding Argon/CO 75%/25% 15-25 Trailing NoneBacking None
Filler Metals (QW 404) SFA Specification 5.18 AWS Classification E-7018 Filler Metal F-No. 6 Weld Metal Analysis A-No. 8 Size of Filler Metal N/A Other Weld Metal Thickness ½”
Electrical Characteristics (QW 409) Current DC Polarity Straight Amps: 90-100 Volts 20-28 Tungsten Electrode Size 1/8” Other
Positions (QW 405) Position of Groove 1G Weld Progression (Uphill, Downhill) N/A Other
Technique (QW 410) Travel Speed 5”/min String or Weave Bead WeaveOscillation Multipass or Single Pass (per side) Multiple Single or Multiple Electrodes SingleOther
Preheat (QW 406) Preheat Temp 50oF Interpass Temp 250oF Other
G D i f T C
QW 483 (back)
PQR No. JCP-PQ 01
Tensile Test (QW -150)
Specimen No. Width(W) (inch)
Thickness(y) (inch)
Area (sq. inches)
Ultimate Load (lbs)
Ultimate Stress (psi)
Type of Failure & Location
T1 .750 .440 .330 24,450 74,090 Pass - WeldT2 .750 .449 .337 24,000 71,216 Pass - Base
Guided Bend Tests (QW -160)
Type and Figure No. ResultsFace # 1 PassFace # 2 PassRoot # 3 PassRoot # 4 Pass
Notch Toughness Tests (QW -170)
Specimen No.
Notch Location
Notch Type
Test Temp
Impact Values
Lateral Exp Drop Weight% Shear Mils Break No Break
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 Jack Shift Jr Clock No. Stamp No. B2 Test conducted by: Shear Metal Testing Lab Laboratory Test No. SM-1001
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 ASME Section IX.
Manufacturer JC Penny
Date 8/12/2001 By: Jack Shift Sr
Page 2 of 2
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS)(See Section IX QW-200.1)
Company Name JC Penny By Mr. Penny Welding Procedure Specification No. JCP-P301 Date 9/11/2001 Supporting PQR No.(s)JCP-PQ301 Revision No. 0 Date 9/11/2001
Welding Process(es) SMAW Type(s) Manual
Test Description
Joints (QW 402) Joint Design Single V Groove and Fillets Root Spacing .0625” to 1.250” Backing: Yes x No x Backing Material (Type) Metal
(Refer to both backing and retainers)
Metal Nonfusing Metal Nonmetallic Other
Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified.
(At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)).
Base Metals (QW 403) P-No. 1 Group No. to P-No. 1 Group No.
OR Specification and type/grade to Specification and type/grade
OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop.
Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum pass thickness ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All
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 Type_ _ _ _ _ _ _ _ _ _ _ _ _ Consumable Insert_ _ _ _ _ _ _ _ _ Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
1st Filler Metal 5.1 E-7018 3 1
3/32”, 1/8”, 5/16”
.0625” to 1.0”
.250” to 1.0” N/A N/A N/A
2nd Filler Metal
Page 1 of 2 WPS No. JCP-P301 Rev.# 0
Positions (QW 405) Position(s) of Groove ALL Welding Progression: UP X Down Position(s) of fillet ALL
Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other
Preheat (QW 406) Preheat Temp, Min 50oF Interpass Temp, Max 350oF Preheat Maintenance None (Continuous or special heating, where applicable, should be recorded.
Gas (QW 408) Percent Composition Gases Mixtures Flow Rate Shielding N/A Trailing Backing Other
Electrical Characteristics (QW 409)
Weld Pass(es)
Process
Filler Metal Current Type and
Polarity
Amps (Range)
Wire Feed Speed (Range)
Energy or Power (Range)
Volts (Range)
Travel Speed (Range)
Other (e.g Remarks, Com-ments, Hot Wire
Addition, Technique, Torch
Angle, etc)
Classifi-cation
Diameter
All
SMAW
E-7018
1/8”
DCEP
70 to 200
N/A
N/A
19 - 25
5 to 7
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current N/A Heat Input (max.) N/A Tungsten Electrode Size and Type N/A (Pure Tungsten, 2% Thoriated, etc)
Mode of Metal Transfer for GMAW or FCAW N/A (Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410) String or Weave Bead String or Weave Orifice, Nozzle, or Gas Cup Size N/A Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping or Wire Brush Method of Back Gouging Grinding Oscillation N/A Contact Tube to Work Distance N/A Multiple or Single Pass (per side) Multiple or Single Multiple of Single Electrodes Single Peening N/A Other
Page 2 of 2
ASME Section IX –PQR
QW-483 Suggested Format For Procedure Qualification Record (PQR) (See Section IX QW-200.2)
Company Name JC Penny PQR No. JCP-PQ301 WPS # JCP-P301 Date 9/12/2001
Welding Process(es) SMAW Type(s) Manual
Joints (QW 402)
Groove Design of Test Coupon
Base Metals (QW 403) Material Spec. SA-53 Gr B P-No. to P-No. Thickness of Test Coupon ½” Diameter of Test Coupon 6” Other
Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other
Gas (QW 408) Percent Composition
Gases Mixtures Flow RateShielding N/A TrailingBacking
Filler Metals (QW 404) SFA Specification 5.1 AWS Classification E-7018 Filler Metal F-No. 4 Weld Metal Analysis A-No. 1 Size of Filler Metal 5/32” Other Weld Metal Thickness
Electrical Characteristics (QW 409) Current DC Polarity Straight Amps: 150-300 Volts 20-28 Tungsten Electrode Size N/A Other
Positions (QW 405) Position of Groove ALL Weld Progression (Uphill, Downhill) Other
Technique (QW 410) Travel Speed 3”/min String or Weave Bead StringerOscillation Multipass or Single Pass (per side) Multiple Single or Multiple Electrodes SingleOther
Preheat (QW 406) Preheat Temp 50oF Interpass Temp Other
G D i f T C
QW 483 (back)
PQR No. JCP-PQ301
Tensile Test (QW -150)
Specimen No. Width (inch)
Thickness (inch)
Area (sq. inches)
Ultimate Load (lbs)
Ultimate Stress (psi)
Type of Failure & Location
T1 .750 .455 .341 19,450 57,038 Pass - Base T2 .756 .451 .341 22,560 66,158 Pass - Weld
Guided Bend Tests (QW -160)
Type and Figure No. Results SIDE # 1 Pass SIDE # 2 Pass Face # 1 Pass Face # 2 Pass
Notch Toughness Tests (QW -170)
Specimen No.
Notch Location
Notch Type
Test Temp
Impact Values
Lateral Exp Drop Weight % Shear Mils Break No Break
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 Jack Shift Jr Clock No. Stamp No. B2 Test 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 ASME Section IX. Manufacturer JC Penny Date 9/11/2001 By: Jack Shift Sr
Page 2 of 2
ASME Section IX – Welder Qualification Homework – WPQ’s
QW-484A Suggested Format For Welder Performance Qualification (WPQ)
(See Section IX QW-301)
Welder(s) Name Mr. Rod Burner Identification Number A11
Test Description
Identification of WPS followed WPS 101 Test Coupon Production Weld
Specification and Type/Grade or UNS Number of base metal(s) A 106B to A106B Thickness .280
Testing Variables and Qualification Limits
Welding Variables (QW350) Actual Values Range Qualified
Welding Process(es) SMAW SMAW
Type (i.e. manual, semi-automatic) used Manual Manual
Backing (with or without) None F1 to F3 with,F3 wo
Test Coupon Production Weld (dia if pipe) 6” NPS __ 2 7/8” OD
Base metal P-Number to P-Number P-1 to P-1 P1-P15F, P34, P41-P49
Filler Metal or Electrode Spec (SFA) 5.1 -------
Filler Metal F-Number F 3 F1,F2, & F3
Consumable Insert (GTAW or PAW) N/A -------
Filler Metal Type (solid/metal or flux cored/powder) N/A -------
Deposited Thickness for each process
Process 1: SMAW 3 layers minimum Yes No .280” .560
Process 2: 3 layers minimum Yes No ---- -------
Position qualified (1G,2G,3G,4G,5G,6G, etc) 2G F, H
Vertical progression (uphill or downhill) Uphill Uphill
Inert Gas Backing (GTAW, PAW, GMAW) N/A -------
GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit) N/A -------
GTAW Current type/polarity (AC,DCEP,DCEN) N/A -------
RESULTS
Visual examination of completed weld (QW 302.4) Acceptable
Transverse face and root bends (QW 462.3(a) Longitudinal bends (QW 462.3(b) Side bends (QW 462.2)
Type Results Type Results
Face No defects – Acceptable
Root No defects - Acceptable
Alternative Volumetric Examination Results (QW 191) N/A RT or UT
Fillet weld – fracture test (QW 181.2) N/A Length and percent of defects N/A
Macro examination (QW 184) Fillet size (in.) x Concavity/convexity (in.)
Other tests
Film or specimens evaluated by Company
Mechanical tests conducted by Ben Tension Laboratory test no. 123 Welding supervised by Red Eye
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the
requirements of Section IX of the ASME Code. Organization Worlds Best Fabricator
Date April 7, 2010 By John Doe
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS) (See Section IX QW-200.1)
Company Name By Welding Procedure Specification No. Date Supporting PQR No.(s) Revision No. Date
Welding Process(es) Type(s)
TTest Description
Joints (QW 402) Joint Design Root Spacing Backing: Yes No Backing Material (Type) (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified. (At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)). BBase Metals (QW 403) P-No. Group No. to P-No. Group No. OR Specification and type/grade to Specification and type/grade OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop. Thickness Range: Base Metal: Groove Fillet Maximum pass thickness ≤ ½” (yes) (no) FFiller Metals (QW 404) Spec. No. (SFA) _ _ _ _ _ _ _ _ _ AWS No. (Class) _ _ _ _ _ _ _ _ _ F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ Size of Filler Metals_ _ _ _ _ _ _ _ Filler Metal Product Form_ _ _ _ _ Weld Metal: Thickness Range: Groove_ _ _ _ _ _ _ _ _ _ _ Fillet_ _ _ _ _ _ _ _ _ _ _ _ Electrode-Flux (Class) _ _ _ _ _ _ _ Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _ Consumable Insert_ _ _ _ _ _ _ _ _ Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
1sst FFiller Metal
2nnd Filler Metal
Page 1 of 2
WPS No. Rev.# PPositions ((QW 405)) Position(s) of Groove Welding Progression: UP Down Position(s) of fillet
PPostweld Heat Treatment ((QW 407)) Temperature Range Time Range Other
PPreheat ((QW 406)) Preheat Temp, Min Interpass Temp, Max Preheat Maintenance (Continuous or special heating, where applicable, should be recorded.
GGas ((QW 408)) Percent Composition Gases Mixtures Flow Rate Shielding Trailing Backing Other
EElectrical Characteristics (QW 4099)
Weld Pass(es)
Process
Filler Metal Current Type and
Polarity
Amps (Range)
Wire Feed Speed (Range)
Energy or Power (Range)
Volts (Range)
Travel Speed (Range)
Other (e.g Remarks, Com-ments, Hot Wire
Addition, Technique, Torch
Angle, etc)
Classifi-cation
Diameter
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current Heat Input (max.) Tungsten Electrode Size and Type (Pure Tungsten, 2% Thoriated, etc)
Mode of Metal Transfer for GMAW or FCAW (Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410) String or Weave Bead Orifice, Nozzle, 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 of Single Electrodes Electrode Spacing Peening Other
Page 2 of 2
ASME Section IX – PQR
QW-483 Suggested Format For Procedure Qualification Record (PQR)(See Section IX QW-200.2)
Company Name PQR No. WPS # Date
Welding Process(es) Type(s)
Joints (QW 402)
Groove Design of Test Coupon
Base Metals (QW 403) Material Spec. P-No. to P-No. Thickness of Test Coupon Diameter of Test Coupon Other
Postweld Heat Treatment (QW 407) Temperature Range Time Range Other
Gas (QW 408) Percent Composition
Gases Mixtures Flow Rate Shielding N/A Trailing Backing
Filler Metals (QW 404) SFA Specification AWS Classification Filler Metal F-No. Weld Metal Analysis A-No. Size of Filler Metal Other
Weld Metal Thickness
Electrical Characteristics (QW 409) Current Polarity Amps: Volts Tungsten Electrode Size Other
Positions (QW 405) Position of Groove ALL Weld Progression (Uphill, Downhill) Other
Technique (QW 410) Travel Speed String or Weave Bead Oscillation Multipass or Single Pass (per side) Single or Multiple Electrodes Other
Preheat (QW 406) Preheat Temp 50oF Interpass Temp None Other
.375"
QW 483 (back)
PQR No.
Tensile Test (QW -150)
Specimen No. Width (inch)
Thickness (inch)
Area (sq. inches)
Ultimate Load (lbs)
Ultimate Stress (psi)
Type of Failure & Location
Guided Bend Tests (QW -160)
Type and Figure No. Results
Notch Toughness Tests (QW -170)
Specimen No.
Notch Location
Notch Type
Test Temp
Impact Values
Lateral Exp Drop Weight% Shear Mils Break No Break
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. Test 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 ASME Section IX.
Manufacturer
Date By:
Page 2 of 2
ASME Section IX – Welder Qualification Homework – WPQ’s
QW-484A Suggested Format For Welder Performance Qualification (WPQ)
(See Section IX QW-301)
Welder(s) Name Identification Number
TTest Description
Identification of WPS followed Test Coupon Production Weld
Specification and Type/Grade or UNS Number of base metal(s) Thickness
Testing Variables and Qualification Limits
Welding Variables (QW350) AActual Values Range Qualified
Welding Process(es)
Type (i.e. manual, semi-automatic) used
Backing (with or without)
Test Coupon Production Weld (dia if pipe)
Base metal P-Number to P-Number
Filler Metal or Electrode Spec (SFA)
Filler Metal F-Number
Consumable Insert (GTAW or PAW)
Filler Metal Type (solid/metal or flux cored/powder)
Deposited Thickness for each process
Process 1: 3 layers minimum Yes No
Process 2: 3 layers minimum Yes No
Position qualified (1G,2G,3G,4G,5G,6G, etc)
Vertical progression (uphill or downhill)
Inert Gas Backing (GTAW, PAW, GMAW)
GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit)
GTAW Current type/polarity (AC,DCEP,DCEN)
RESULTS
Visual examination of completed weld (QW 302.4)
□ Transverse face and root bends (QW 462.3(a) Longitudinal bends (QW 462.3(b) Side bends (QW 462.2)
Type Results Type Results
Alternative Volumetric Examination Results (QW 191) RT or UT
Fillet weld – fracture test (QW 181.2) Length and percent of defects
Macro examination (QW 184) Fillet size (in.) x Concavity/convexity (in.)
Other tests
Film or specimens evaluated by Company
Mechanical tests conducted by Laboratory test no. Welding supervised by
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the
requirements of Section IX of the ASME Code. Organization
Date By