ASME Section IX.updated

An introduction to ASME & ASME SEC IX

QA/QC DEPARTMENT

Contents

The ASME SystemIntroduction to Section IXOrganization and Use Section IXSection IX ResponsibilitiesResponsibilities of the Authorized Inspector or Owner User Inspector Responsibilities of the Manufacturer Welding Processes and weld types Section II, Part C Welding MaterialsWelding Procedure Specification QW-200Procedure Qualification Record (PQR)Qualifying a WPSMiscellaneous ApplicationWelding VariablesWelder performance Qualification QW-300Welder Essential Variables SMAW

The ASME System

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Outline

The ASME System ASME Boiler & Pressure Vessel Codes Section IX Subcommittee Organization

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The ASME

The American Society of Mechanical EngineersProvides minimum safety rules for Construction

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The Members

The American Society of Mechanical Engineers (ASME)

Manufacturer/Certificates Holders Owners/Users Authorized Inspection Agencies Jurisdiction/Regulatory Agencies Members voluntarily supported by their organizations

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Manufacturers

AIAsOwner/Users

Voluntary Members Jurisdictions

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Boiler & Pressure Vessel Committee

1911: ASME establishes a committee for the purpose of formulating standard rules for the construction of power boilers and other pressure vessels.

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Construction Codes

Section I – Power Boilers Section III – Divs. 1 & 2 – Nuclear Components Section IV – Heating Boilers Section VIII, Divs. 1, 2 & 3 Pressure Vessels Section X – Fiberglass Reinforced Plastic Pressure Vessels

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History of Construction Codes

1914: Section I – Power Boilers 1923: Section IV – Heating Boilers 1928: Section VIII – Unrefined Pressure Vessels 1965: Section III- Nuclear Power Plant Components.

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History of Construction Codes

1968: Renamed Section VIII, Div. 1 PressureVessel Code 1968: Section VIII, Div. 2 Alternate Rules for Pressure Vessels 1969: Section X – Fiberglass Reinforced Plastic Pressure Vessels

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Reference Codes

Section II – Materials Section V - Nondestructive Examination Section IX - Welding & Brazing Qualification

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History of Reference Codes

1924: Section II - Material 1937: Section IX – Welding Qualification

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Subgroup Organization

Section IX Committee

Subgroup BrazingSubgroup General

Requirements

Subgroup MaterialsSubgroup Strength

of Weldment

Subgroup ProceduresSubgroup Performance

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Introduction to Section IX

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Outline

Foreword WPS/PQR Qualifications Addenda Organization and Use of Section IX

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Foreword

Foreword covers topics such as: History of ASME Committee Submitting interpretations to ASME as referenced in Appendix A

Effect date of Addenda Addenda may be used upon issuance although it is not mandatory six month after issue Material requiremen

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ASME Code Section IX

Qualification Standard for Welding and Brazing Procedures Welders, Braziers, Welding and Brazing Operators.

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WPS/PQR Qualification

Article I Paragraph QW-100.2 discusses “OLD” procedures and Welders Qualifications Qualification prior to 1962:

Requires updating to a later edition or discard as valid After 1962, the Procedures and Welders are good forever

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Addenda

Changes to the Code Issued annually Mandatory use six months after issue May be used upon issue

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Reference Code

Section IX is a reference Code and may be used only when referenced and as it is referenced by the Construction or Governing Code

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Organization and Use Section IX

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Organization

Part QW Article 1 – General Requirements Article 11 – Welding Procedure Qualification Article 111 – Welding Performance Qualification Article IV – Welding Variables Article V – Standard Welding Procedure (AWS)

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Article I

General Requirements QW-100 General QW-110 Weld Ordination QW-120 Test Position for Groove welds QW-130 Test Position for Fillet Welds QW-140 Types and purpose of test and examinations

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Article I

General Requirements QW-150 Tension Test QW-160 Guided bend test QW-170 Notch Toughness Test QW-180 Fillet Weld Test QW-190 Other test & examinations

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Article II

Welding Procedure Qualification QW-200 General QW-210 Preparation of test coupon QW-250 Welding Variables

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Article III

Welding Performance Qualification QW-300 General QW-310 Qualification test coupon QW-320 Reset and renewal of qualification QW-350 Welding variables for welders QW-360 Welding variable for welding Operators QW-380 Special processes

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Article IV

Welding Data QW-400 Variables QW-410 Techniques QW-320 P-Number QW-430 F- Numbers QW-440 Weld metal chemical composition QW-450 Specimens QW-460 Graphics QW-470 Etching process and reagents QW-490 Definitions

Section IX Responsibilities

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Outline

Responsibilities Authorized Inspector Manufacturer

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Responsibilities of the Authorized Inspector or Owner User Inspector

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Before Construction

Verify that Procedure comply with procedure Procedure have been properly qualified Welding and Operators are properly qualified QC Manual has been followed

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During Construction

Make sure welding is preformed within the parameters of the welding procedure Verify welder qualification limits are neither exceeded nor expired

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Responsibilities of the

Manufacturer

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Qualification of Procedure

Establish a QC program to control qualification List parameters for construction Prepare a written WPS Assure metallurgical compatibility between filler and base metal Prepare and certify PQR based upon recorded data

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Recommended that each Manufacturer has, or has access to, a welding metallurgist QW-200.3 Hold the manufacturer responsible for assuring that material are compatible when welded

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Qualification of Welders

Establish QC program to control welder qualification Qualify each welder to the process being used Weld the test coupon in accordance with a written WPS

Cont’d…

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Qualification of Welder

Control and supervise during the welding of coupon Maintain welder identification Document welder qualification

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Subcontracted Welding Procedures

Applicable to Section I only when using “PP” stamp to ASME/ ANSI B31.1 Code The National Certified Pipe Welder’s Bureau (NCPWB), a national organization made up of member companies, provides welding procedures to its members.

Cont’d…

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Subcontracted Welding Procedures

The member company must Sign each WPS and PQR Accept responsibility for its use and Code compliance

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Subcontracted Welding

Allowed by the construction Code, provided; Use is described in the QC Manual Work performed within the scope of the Certificate of Authorization Certificate holder has contractual control over the Welders.

Cont’d…

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Subcontracted Welding

Certificate Holder has final responsibility for the welding Welder is under subcontract to the Certificate holder Welder are qualified by the Certificate Holder

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Inter – Company Procedures QW-201

Welding procedure may be used among different companies, provided they are within the same corporate structure Each company must state how they control such procedure in their QC Manual and satisfy the ASME during joint review

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Example

Company “A” qualifies and files several PQRs Company “B” files their own PQR and combines with the PQRs from company “A” to develop a WPS The PQR from company “A” was not qualified. Is this permissible?

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Allows to use the Welders amongst different companies without prequalification, provided both companies are within the same corporate structure Each company must satisfy the ASME requirements during the joint review and incorporate the necessary control in the QC Manual

Inter – Company Procedures QW-300.2

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Welding Processes and Weld Types

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Outline

Welding Processes Weld Types

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Welding Processes

OFW Oxyfuel Welding

SMAW Shield Metal Arc Welding

SAW Submerge Arc Welding

GMAW Gas Metal Arc Welding

FCAW Flux-Core Arc Welding

GTAW Gas Tungsten Arc Welding

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Welding Processes

PAW Plasma Arc Welding

ESW Electro Slag Welding

EGW Electro Gas Welding

EBW Electro Beam Welding

LBW Laser Beam Welding

Stud Welding

Inertia and Continuous Friction

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Special Processes

Corrosion resistance overlay and hard surface overlay welding Qualification requirement: QW-453 Essential variables: QW-250

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Weld Types

Three types of welds covered in Section IX Groove Weld

U Groove J Groove V Groove Partial Penetration

Fillet Welds Stud Welds

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‘J’ and ‘U’ Preparations

Root radius“U” preparation

Double “U” butt

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Groove Weld

Cont’d……

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Groove Weld

Groove Angle

Cont’d……

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Groove Weld

Cont’d……

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Groove Weld

Cont’d……

Bevel Angle

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Groove Weld

Cont’d……

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Groove Weld

Cont’d……

Groove Face

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Groove Weld

Cont’d……

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Groove Weld

Cont’d……

Root Face

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Groove Weld

Cont’d……

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Groove Weld

Cont’d……

Root Gap

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Groove Weld

Groove Angle

Groove Face

Bevel Angle

Root Face

Root Gap

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Fillet Weld

Cont’d……

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Fillet Weld

Cont’d……

Toe of Weld

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Fillet Weld

Cont’d……

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Fillet Weld

Cont’d……

Weld Face

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Fillet Weld

Cont’d……

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Fillet Weld

Cont’d……

Weld Size

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Fillet Weld

Cont’d……

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Fillet Weld

Cont’d……

Weld Leg

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Fillet Weld

Cont’d……

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Fillet Weld

Cont’d……

Weld Root

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Fillet Weld

Cont’d……

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Fillet Weld

Cont’d……

Weld Throat

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Fillet Weld

Root Throat

Face Weld Size

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Stud Welding

Cont’d……

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Stud Welding

Cont’d……

Work Piece

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Stud Welding

Cont’d……

Work Piece?

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Stud Welding

Cont’d……

Work Piece

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Stud Welding

Cont’d……

Work Piece

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Stud Welding

Cont’d……

Work Piece

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Section II, Part C Welding Material

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Outline

Scope of Section II, Part C Electrode Identification

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ASME Section II, Part C

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Section II- material specifications referenced in the fabrication Code. Part C – Material Specification for welding materials

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Information includes: Processes that may be used with various electrodes Recommended storage requirements AWS marking Recommended electrode positions Recommended polarity Information on “how” to meet SFA specification

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Table of Contents

SFA-5.1 Carbon Steel covered arc welding electrodes. SFA-5.4 Corrosion resistance Cr and Cr-Ni steel covered electrodes SFA- 5.5 Low alloy steel-covered arc welding electrodes SFA-2.18 Carbon steel filler metals for Gas Shielded Arc Welding

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Specification SFA-5.1

Requirements for classifying carbon steel electrodes used for Shielded Metal Arc Welding (SMAW) Example:

E6010, E6011, E7018 and E7028

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Requirement for classifying stainless steel-covered electrodes used for SMAW Example:

E308H, E309L, E317L and E317L

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Requirements for classifying low alloy steel-covered electrodes used for SMAW Example:

E7018-A1, E8016-B2, E9015-B3 and E9018-B3L

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Requirements for classifying carbon steel electrodes and rods used for Gas Shielded Arc Welding (GSAW) Examples:

ER70S2, ER70S3, ER70SG and ER70CGM.

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Electrode Identification

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Marking Requirements

SFA-5.1 requires marking on both the package and electrode

Package• AWS classification and class• Supplier’s name and trade designation• Size and net weight• Lot, control or heat number

Electrode• Classification must be within 2.5” of grip end• Prefix “E” may be omitted

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Classification SFA-5.1

PositionElectrode

Minimum tensile strength (ksi)

Type of coating and recommended current

For 018Electrodes, “1” indicates that charpy values of 20 ft-lbs at -50 F have been met

EXXXX- 1

Cont’d……

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PositionElectrode

Minimum tensile strength 70 ksi

For 016 E7016 & E7018 Electrodes, “1” indicates that charpy values of 20 ft-lbs at -50 F have been met

EXXYY- 1

Cont’d……

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PositionElectrode

For E7016 & E7018 Electrodes, “1” indicates that charpy values of 20 ft-lbs at -50 F have been met

EXXYY-1

Cont’d……

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Cont’d……

All PositionElectrode

EXX18- 1

Low Hydrogen, Potassium, Iron powder and use for AC

or DCEP

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PositionElectrode

EXXYY-1

Cont’d……

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Example of SFA-5.1 Electrode

E6010, E7018, E7024 Note: Only 60 ksi and 70 ksi tensile electrode are covered by this specification

Cont’d……

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Requirements for classifying corrosion-resistant and chromium nickel steel-covered arc welding electrodes used for SMAW

Cont’d……

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Electrode

Chemical Composition (first three digits)

Usability (Position & Current type

E-XXX-XXX-XX

One or more letters indicating modification of basic composition

Cont’d……

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Cont’d……

Electrode

E-XXX-YYY-XX

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Electrode

19 Cr, 10 Ni

E-308-YYY-XX

Cont’d……

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Cont’d……

Electrode

E-XXX-L-XX

Low carbon contents 0.04% max

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Cont’d……

Electrode

DCEP or AC/ all position

E-XXX-YYY-16

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Example of SFA-5.4

E308L, E308L-16, E309Cb

Legend

L Low Carbon

Cb Addition of columbium, Reduction of Carbon

Mo Addition of molybdenum, reduction of carbon

15 Lime covering, use DCEP

16 Lime or titania, use with DCEN or DCEP

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Requirements for classifying low-alloy steel electrode used for SMAW

Cont’d……

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Cont’d……

Electrode

One or more letters & number indicating

chemical composition of deposited metal

EXX (X) XX-XXX

Type of coating & recommended current

Position

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Cont’d……

Electrode

EXX (X) YY-XXX

Position

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Cont’d……

Electrode

Minimum tensile strength

100 ksi

E 100 XX-XXX

Position

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Cont’d……

Electrode

EXX (X) 16-XXX

Low hydrogen Potassium AC/DCEP

All Position

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Cont’d……

Electrode

EXX (X) 16-B2L

Low hydrogen Potassium AC/DCEP

All Position

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Cont’d……

Electrode

Chromium- molybdenum steel electrode

EXX (X) YY-B2L

Position

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Example of SFA-5.5

E7012, E7013-B3“A” Chemical Composition Number

A1- C Mo (1/2 % Mo) B1- Cr Mo (1/2%Cr,1/2%Mo) B2- Cr Mo (1-1/4%Cr, 1/2%Mo) B3- Cr Mo (2-1/4%Cr, 1/2%Mo)

“A” 2 3 3 4

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Requirements for classifying carbon steel electrodes and rods used with the following welding methods:

Gas Metal Arc GMAW) Gas Tungsten Arc (GTAW) Plasma Arc (PAW)

Cont’d……

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Cont’d……

Electrode

Suffix relating to manufacture chemical

composition

ERXXS-X(XX)

Bare, Solid wire or rod

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Cont’d……

Electrode

composition

ERXXC-X(XX)

Composite wire

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Cont’d……

Electrode

Minimum tensile strength 70ksi

composition

ER70S-X

Bare, Solid wire or rod

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Cont’d……

Electrode

composition

ERXXS-X(XX)

Solid Wire

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Cont’d……

Electrode

Low carbon with trace of Ti, Zr and Al content

ERXXS-2(XX)

Bare, Solid Wire or rod

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ER70S-2, ER70S-3

Suffix "A" Shielding Gas

2 1 Ar/O2, Ar, Ar/CO2

3 1 Ar/CO2, CO2

4 1 CO2

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Welding Procedure Specification QW-200

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Outline

Weld Procedure Specification (WPS) qualification Procedure Qualification Record (PQR) Writing a WPS Qualifying a WPS Testing weld specimens Groove weld Qualifications Miscellaneous applications Welding variables

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WPS Qualification

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What is a WPS?

A document that has been prepared by qualification and is used to provide necessary direction and control for making a weld joint

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Contents of a WPS

A WPS must address: Essential and Non-essential variables in QW-250 Supplemental variables, when impact testing required Acceptance qualification ranges Other information

Category of Variables

Essential Must be qualified when a change occur

Non- Essential Must be addressed in the WPS

Supplementary Essential Must be requalified when notch toughness is involved

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Considerations

Joint designs Weld and base metal compatibility Heat treatment Metallurgical properties Desired mechanical properties Service requirements Welders’ ability Equipment availability Weld location Economy

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Procedure Qualification Record(PQR)

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Record of welding data used to weld a test coupon Modifies or justifies the WPS Supporting document that includes the results of welding and testing a coupon

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Contents of PQR

Essential variables (as a minimum) Supplemental Essential Variables (When impact testing required) Other information, if desired

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WPS/PQR Forms

Recommended, non-mandatory sample forms in QW-482 and QW-483

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Multiple PQRs Supporting One WPS

Example PQR No. 1 with PWHT and PQR No. 2 without PWHT supports a WPS with and without PWHT

It is possible to have one WPS that covers all possible welding circumstances

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Single PQR Supporting Multiple WPS

Example

A PQR is qualified for F4 and F6 electrodes. This PQR can be used to support a WPS using F4 electrodes and the second WPS using the F6 electrodes

QW-200.2 allows the use of one PQR to support several WPS

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Permitted Change without Requalification

Changes in non-essential variable Corrections or update, supported by an exciting PQR

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Permitted Changes to a PQR

Obvious errors or changes supported by data recorded during test coupon welding

Example: Code- driven material specification change in a later edition

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Example of a Revised RQR

A section IX revision assigns a P-number to a material previously qualified by material specifications The PQR may now be revised to identify a P-number rather than just a specific material

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PQR Review

PQRs may be written but Always maintain the original Never White-out or pencil-in an original PQR Always rectify a PQR if revised and note reason for revision

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Combining Welding Procedures

Several welding processes may be included in one WPS (qualified separated or combined) Section IX treats the following combination procedures:

More than one welding process used More than one F-No. filler metal More than one A-No. electrode, except A-1 and A-2

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Examples of Combination Procedures

WPS with ¼” GTAW and ¾” SMAW WPS with ½” SMAW (F-1) and ½” SMAW (F-4) GTAW WPS and SMAW WPS used to make the same weld WPS with E7018-A1 and E8018-B2 (A-No. difference)

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Qualifying a WPS

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Six steps to Qualify a WPS

Review Essential Variables Write Draft WPS Weld the test coupon using the WPS Prepare test specimens Evaluate test results Document results on a PQR and certify

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Writing a WPS

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Writing a WPS

What base material will be welded? What filler material will be used? What welding processes will be used? What service or production restriction (s) will be required?

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Base Material

P-Number: QW-422 Substitute most economical material for testing: QW-424

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Filler Material

F-Number: QW-432 A-Number: QW-442 Shielding (Gas, Flux) Position restriction

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Processes to be used

Required variables: QW-250 Production joint types Welder technique Equipment available

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Service Requirements

Code/Customer Preheat/PWHT Corrosion Notch toughness (supplemental variable)

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Qualifying a WPS

Write an unqualified WPS around job parameters.

Watch variables QW-250 and QW-260

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Qualifying a WPS

Weld the test coupon using unqualified parameters QW-250, QW-260

Monitor all essential variables and record the actual values on the PQR Recommended also recording non-essential variables Record supplementary variables if required

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Qualifying a WPS

Prepare the test coupon into specimens per QW-462, QW-463

Cut test coupon to size per QW-451, QW-462, QW463 Make the required test per QW-451

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Qualifying a WPS

Evaluate results against Article 1 standards, QW-150 to QW-260 Compare unqualified WPS (essential and supplementary if required) Variable with results of the PQR Assure compliance to section IX

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Qualifying a WPS

When acceptable, certify the PQR The Certificate Holder

• Approves WPS• Develops WPS and file• Uses the WPS for production welding

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Additional Qualification

An Additional PQR is required when: An essential variable changes The validity of the procedure is in doubt

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A manufacturer must have a WPS that describes the welding parameters The WPS may reference production drawings to covers some variables The WPS may be pieces of paper or documents The WPS documentation must be controlled

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How to Change WPS

Amendment (i. e additional PQR’s) New (Including Revision)

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Groove Weld Qualification Thickness Limits and Test Specimens

See reference table QW-451

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QW- 451.1: Example 1

T= .062” to 0.20” t= 0.20” max

T= 0.10” GTAW

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T= 1/16” to 1/2” t= 1/2” max

T= 1/4” SMAW

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T= 3/16” to 1” t= 1” max

T= 1/2” SMAW

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T= 3/16” to 1”

GTAW t= 1/4” max SMAW t=3/4” max

T= 1/2”

SMAW = 3/8”

GTAW = 1/8”

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T= 3/16” to 2”

GTAW t= 1/2” max SMAW t=2” max

T= 1”

SMAW = 3/8”

GTAW = 1/4”

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T= 3/16” to 2”

F-4 SMAW = 2” max F-3 SMAW t=1/2” max

T= 1”

3/4“ SMAW F-4

1/4” SMAW F-3

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T= 3/16” to 8”

GTAW t= 8” max SMAW t=8” max

1-1/2”

SMAW = 3/4”

GTAW = 3/4”

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T= 3/16” to 8”

F-4 SMAW t= 8” max F-1 SMAW t=1/2” max

1-1/2”

1-1/4“ SMAW F-4

1/4” SMAW F-1

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Observation

If the welding material is less than 8” thick, a test coupon greater than 1-1/2” is not required. A weld-deposited metal of 3/4” thick qualifies the weld to be deposited on maximum thickness. Filler metal is still limited to 8” maximum.

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Miscellaneous Application

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WPS for Root Pass or Tack Welding

QW-200.4(b) allows special qualification for root deposit or tack welds only. Deposit filler metal on a 1/2” minimum base metal; the base metal qualification thickness range is unlimited. “t” deposit is limited to 2t

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General VariablesQW-202.2

Variables that may be applicable or may reduce the number of procedures qualified.

Partial penetration welds Groove and filler weld relationship P-11 requirement Weld metal repair and build-up Dissimilar base material thickness

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Full Penetration Groove Welds QW-202.2(a)

Full Penetration Groove Welds shall qualify for both base metal and deposited metal used in production

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Qualification for Filler Welds QW-202.2(c) Groove weld test coupon qualifies for all fillet welds:

Thickness Sizes Pipe Diameter Within essential variables

Note: exemption is P-11A groups 3,4,5 and P-11B which requires special qualification

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Fillet Weld Qualification QW-202.2(c) Table QW-451.3: information for types of tests that must be performed Fillet weld qualification may not be used for pressure-retaining welds

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Welding Variables

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QW-253: All Welding Variables (SMAW)

QW-402: Joints QW-403: Base Metal QW-404: Filler Metals QW-405: Positions QW-406: Preheat QW-407: PWHT Qw-409: Electrical QW-410: Technique

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Essential Variables: SMAW

QW-403.7: T/t limits>8" QW-404.5 Ø A No.

QW-403.8:Ø T qualified QW-404.30: Ø t

QW-403.9: t pass > 1/2"QW-406.1 Decrease > 100

QW-403.11: Ø P-No. qualified QW-407.1 Ø PWHT

QW-403.13: Ø P-No. 9/10 QW-407.4: T limits

QW-404.4: Ø F-No.

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QW-403.7: T/t Limits > 8”

For thickness > 8”, the procedure test coupon thickness shall not be less than the thickness of the joint to be welded in production weld divided by 1.33, and the maximum thickness of deposited weld metal qualified is 1.33 or 1.33t as applicable.

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PWHTQW-407.1

A separate PQR is required for each of the following conditions:

For P-No. 1,3,4,5,6,9,10 and 11 materials, the following PWHT conditions apply:

• No PWHT• PWHT below the lower transformation temperature

Cont’d……

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• PWHT above the upper transformation temperature (e.g. Normalizing)• PWHT above the upper transformation temperature followed by heat treatment below the lower transformation temperature (e.g. Normalizing or quenching, followed by Tempering)• PWHT between the upper and lower transformation temperatures

Cont’d……

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For all other materials, the following condition apply: No PWHT PWHT within a specified temperature range

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Alternative Preheat

For thickness over 1-1/4 to 1-1/2” thick, you may preheat at 200 ºF

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Non-Essential Variable

QW-402.1 Ø Groove designQW-402.4 – BackingQW-402.10 Ø Root SpacingQW-402.11 ± RetainersQW-404.6 Ø DiameterQW-404.33 Ø AWS ClassQW-405.1 + PositionQW-405.3 Ø Vertical up or down

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Non-Essential Variable

QW-406.2 Ø Preheat maintenanceQW-409.8 Ø Type I or I & E rangeQW-410.1 Ø String/WeaveQW-410.5 Ø Method CleaningQW-410.5 Ø Method back gougingQW-410.25 Ø Manual or AutomaticQW-410.26 ± Peening

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QW-402.1

Change in type of groove Vee-groove U-groove Single bevel Double bevel

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QW- 402.4

Deletion of backing in single welded grove welds Double welded groove welds are considered welding with backing

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QW-402.10

A change in specified root spacing.

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QW-402.11

The addition or deletion of nonmetallic retainers or nonfusing metal retainers

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QW-404.6

A change in the nominal size of the electrode or e electrodes specified in WPS

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QW-404.33

A change in the SFA specification filler metal classification; or, if not conforming to an AWS filler metal classification, a change in the manufacturer’s trade name for the electrode or filler metal

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QW-405.1

The addition of the welding position than those already qualified (See QW-120, QW-130 and QW- 303)

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Limits of Position

Electrode must be suitable for the position to be used.

Example: E7024 May not be used for vertical welding without special qualification Section II only recognize E7024 for flat groove and horizontal fillet welds

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QW-405.3

A change from upward to downward, or from downward to upward in the progression specified for any pass of a vertical weld (the cover or wash pass may be up or down) A change in the range of electrode wire feed speed may be used as an alternative to amperage

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QW-406.2

A change in the maintenance or reduction of preheat upon completion or welding prior to any required post- weld heat treatment

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QW-409.8

A change in the type of current or polarity, a change in the range of amperage, except for SMAW and GTAW welding, a change in the range of voltage A change in the range of electrode wire feed speed may be used as an alternative to amperage

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QW-410.1

A change from the stringer bead technique to the weave bead technique, or vice versa

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QW-410.5

A change in the method of initial and inter-pass cleaning, (brushing, grinding, etc.)

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QW-410.6

A change in the method of back gouging

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QW-410.25

A change from the manual or semi-automatic to machine or automatic welding and vice versa

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QW-410.26

Addition or deletion of peening

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Non-Essential Variables

Must be addressed on the WPS but do not require qualification

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Welder performanceQualification

QW-300

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Outline

Rules & Definitions Welders’ Performance Qualification Record Welder/Operator Record Test Coupons:

Mechanical Testing Radiography

Essential Variables (SMAW)

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Rules and Definitions

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Use QW-300, Article III to qualify

welder plus: Applicable QW-100 paragraphs Applicable QW-100 paragraphs

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Define a Welder

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A Welder is…

One who performs a manual or semi-automatic welding operations

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A Welder Operator…

… is one who operates machineor automatic welding equipment

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Purpose of Qualifying a Welder Operator

To determine the operator’s ability to operate the welding equipment

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Welders’ PerformanceQualification Record A document used to record the Welder and Welding operator qualification

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Contents of the WPQ

All applicable variables used by the Welder to make a test coupon Results of test Ranges of qualification (same variables only have minimum or maximum values)

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Essential Variables

For Welders see QW-350 For Welding Operators see QW-360 Performance Qualification Record only has essential variables

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Welder/Operator Records

QW-103.2 requires the Manufacturer to maintain a record for the results obtained in performance qualificationRecords must be certified by the Manufacturer

See non-mandatory Appendix A forSample from QW-484

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Welder/Operator Records

Welder’s Continuity Log: used by Manufactures to comply with QW-322.1

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Test Coupons

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Welding of Test Coupon

Must use a WPS (qualified or not) Each coupon must be stamped with the number, symbol or letter assigned to identify the welder Preheat nor PWHT is not required WPS qualification may be used for the welder who made the weld

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Visual ExaminationQW-302.4

Plate coupon: Shall be performed on all surfaces (not marked “discard”) Pipe: Shall be performed over the entire circumference, inside and out. Visual examination shall be per QW-194

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Qualification by Radiography

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Visual ExaminationQW-302.4

Plate coupon: Shall be performed on all surfaces (not marked “discard”) Pipe: Shall be performed over the entire circumference inside and out. Visual examination shall be per QW-194

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Qualification by Radiography

Radiography may be used in-lieu of mechanical testing as permitted in QW-304 and QW-305 Only limited to the following processes

SMAW, SAW, PAW, GTAW (except for P-6X materials) GMAW (except short circuit)

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Welder Qualification by RadiographyQW-304, QW-302

Test coupon: 6” min. weld length Production weld: 6” min. weld length Qualification on pipe shall include the entire weld circumference

Small dia. pipe may require multiple coupons – the quantity need not exceed four

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Test coupon: 6” min. weld length Production weld: 6” min. weld length Qualification on pipe shall include the entire weld circumference

Small dia. pipe may require multiple coupons – the quantity need not exceed four coupons

Welder Operator Qualification by Radiography QW-304, QW-302

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Requirements of RadiographyQW-191

Technique must meet ASME Code Section V, Article 2 Acceptance Criteria per QW-191.2

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Welding Operator RadiographicAcceptance Criteria

Same as welder as using test coupons Same as Construction Code acceptance criteria on production test coupon (QW-191.2.3)

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Failure of Test Coupon

Immediate retest using same method Mechanical: Two consecutive test coupons Radiography: Two consecutive test coupons (NOT 12” in one coupon)

With additional training, just start over No specific requirements for training in Section IX

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WPS Exceptions

Examples of welding variables with no impact for performance qualification

Preheat and PWHT Substitution of base material per QW-423 Possible substitution of filler metal Impact testing

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Requirements of RadiographyQW-191

Not welding with a process during a six month period Specific reason to question ability

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Renewal of QualificationQW-322.2

For each process One test Any material, thickness, plate or pipe Any position

Requalifies all previous qualifications

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Welder Essential VariablesSMAW

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QW-353: SMAW

Ø P-No.

Brief of Variables

QW-402Joints

QW-403Base Material

Paragraph

Deletion of Backing.4

QW-404Filler metals

QW-405Position

Ø Pipe Diameter

Ø F-No.

Ø t weld deposit

Ø position

Ø ↑↓ Vertical Welding

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QW-402.4

The deletion of the backing in single welded groove joints Double- welded groove welds are considered welding with backing

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QW-353: SMAW

Brief of Variables

QW-402Joints

QW-403Base Material

Paragraph

QW-404Filler metals

QW-405Position

Ø Pipe Diameter

Ø P-No.

Ø F-No.

Ø t weld deposit

Ø position

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QW-403.16

A change in pipe diameter beyond the range qualified in QW-452, except as otherwise permitted in QW-303.1 and QW-303.2

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QW-353: SMAW

Ø t weld deposit

Brief of Variables

QW-402Joints

QW-403Base Material

Paragraph

QW-404Filler metals

QW-405Position

Ø Pipe Diameter

Ø P-No.

Ø F-No.

Ø position

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QW-403.18

A change from one P-Number to another P-Number or to a base metal not listed in QW-422, except as permitted in QW-423 and QW- 420.2 (S-Number)

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QW-353: SMAW

Brief of Variables

QW-402Joints

QW-403Base Material

Paragraph

QW-404Filler metals

QW-405Position

Ø Pipe Diameter

Ø P-No.

Ø F-No.

Ø t weld deposit

Ø position

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QW-404.15

A change from one F-Number in QW-432 to any F- Number or to any other filler metal, except as permitted in QW-433

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QW-353: SMAW

Brief of Variables

QW-402Joints

QW-403Base Material

Paragraph

QW-404Filler metals

QW-405Position

Ø Pipe Diameter

Ø P-No.

Ø F-No.

Ø t weld deposit

Ø position

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QW-404.30

A change in deposited weld metal thickness beyond the range qualified in QW-452, except as otherwise permitted in QW-303.31 and QW-303.2 When a welder is qualified using Radiography, the thickness range of QW-452.1 apply

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Deposited Metal ThicknessQW-452.1

Max. to be Welded1/2" and OverGroove

2 t Over 3/8" Groove

2 t Up to 3/8" Groove

Thickness "t" of deposited weld metal qualified

Thickness of test Coupon Welded

Type of

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Test Positions

Four positions for welding with plate IG, 2G, 3G, 4G

Four positions for welding with pipe IG, 2G, 5G, 6G

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Groove Weld in Plate Test Positionback to contents

Groove Weld in Plate Test Position back to contents

Groove Welds Pipe Test Positionback to contents

Fillet Weld Plate Test Positionback to contents

Limits of Qualified Position and Diameter

Welders qualified in the grooves position in QW-461.9 shall be qualified to weld for that position in both groove and fillet welds Welders shall also be qualified to make fillet welds in all thickness and pipe diameter

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Qualification Test Position and type Weld Qualified [Note 1]

Groove Fillet

Plate and Pipe Pipes ≤ 24" OD Plate and Pipe

Plate – Groove 1G F F [Note 2] F

2G F,H F,H [Note 2] F,H

3G F,V F [Note 2] F,H,V

4G F,O F [Note 2] F,H,O

3G and 4G F,V,O F [Note 2] All

2G, 3G and 4G All F,H [Note 2] All

Special Positions SP SP [Note 2] SP,F

Pipe – Filter 1F . . . . . . F [Note 2]

2F . . . . . . F,H [Note 2]

3F . . . . . . F,H,V [Note 2]

4F . . . . . . F,H,O [Note 2]

3F and 4F . . . . . . All [Note 2]

Special Positions . . . . . . SP,F [Note 2]

Pipe – Groove 1G F F F

2G F,H F,H F,H

5G F,V,O F,V,O All

6G All All All

2G and 5G All All All

Special Positions SP SP SP,F

Plate - Fillet 1F . . . . . . F

[Note 3] 2F . . . . . . F,H

2FR . . . . . . F,H

4F . . . . . . F,H,O

5F . . . . . . All

Special Positions . . . . . . SP,F

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Position Qualification

The Welder is qualified to weld Vertical Overhead Flat Positions

For both Pipe Plate

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The Welder Welded in Position 5G Pipe.

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The Welder Welded in Position: 2G Pipe.

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The Welder Welded 2G, 3G & 4G Plate

2G 3G 4G

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The Welder is qualified to weld in both horizontal and flat positions

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The Welder is qualified to all positions in both plate and pipe, NPS 24 and over Is the Welder qualified to weld all positions on an NPS 10 pipe

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QW-353: SMAW

Brief of Variables

QW-402Joints

QW-403Base Material

Paragraph

Deletion of Backing

QW-404Filler metals

QW-405Position

Ø Pipe Diameter

Ø P-No.

Ø F-No.

Ø t weld deposit

Ø position

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QW-405.3

A change from upward to downward, or from downward to upward, in the progression specified for any pass of a vertical weld, except that the cover or wash pass may be up or down The root pass may be run either up or down when the root pass is removed to sound weld metal in preparation for welding the second side

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THE END

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ASME Section IX.updated

Documents

Transcript of ASME Section IX.updated

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