qualification standard for welding and brazing procedures, welders ...
Qualification of Welding Procedure Specification Fc
-
Upload
mister-pogi -
Category
Documents
-
view
114 -
download
12
description
Transcript of Qualification of Welding Procedure Specification Fc
1 / 13
TABLE OF CONTENTS
1.0 SCOPE
2.0 REFERENCE
3.0 RESPONSIBILITY
4.0 DEFINITION
5.0 PROCEDURE
6.0 ATTACHMENTS
Attachment 1A Welding Procedure Specification
Attachment 1B Welding Procedure Specification (Continuation)
Attachment 2A Procedure Qualification Record
Attachment 2B Procedure Qualification Record (Continuation)
Attachment 3 Welding Procedure Qualification Test Plan
Attachment 4 Index of WPS
2 / 13
1. SCOPE
This procedure applies to the instruction for qualification and control method of the Welding
Procedures Specification (WPS) and Procedure Qualification Record (PQR) in order that the
welding work conforms to the requirements of the applicable codes and standards
2.0 REFERENCE
2.1 Site Quality Plan (6423DA060-00-00200 00)
2.2 Document Control Procedure (6423MJ050-00-00010 00)
2.3 Welding and Brazing Qualification (ASME Section IX)
2.4 Structural Welding Code-Steel (AWS D1.1)
2.5 Power Piping (ASME B31.1)
2.6 Process Piping (ASME B31.3)
3.0 RESPONSIBILITY
3.0 The Construction Manager is responsible for ;
(1) Requesting the Quality Manager to provide the required WPS.
(2) Supporting PQ Test performed by the Quality Team.
3.1 The Quality Manager is responsible for ;
(1) Ensuring that all procedure qualifications are carried out in accordance with this
procedure.
(2) Approval of WPS and certification of PQR
3.2 The Welding Engineer is responsible for ;
(1) Preparation of Welding Procedure Qualification Test Plan
(2) Preparation and maintenance of WPS and PQR
(3) Manufacturing of test specimen and request of test
(4) Preparation of test report
3 / 13
(5) Review of Subcontractor’s WPS & PQR.
4.0 DEFINITION
4.1 WPS : Welding Procedure Specification.
4.2 PQR : Welding Procedure Qualification Record
4.3 PQT : Welding Procedure Qualification Test
4.4 Welder : Welder or Welding Machine Operator
5.0 PROCEDURE
5.1 Establishment of Welding Procedure Qualification Test Plan
5.1.1 The Welding Engineer shall prepare the Welding Procedure Qualification Test Plan
(Attachment 3) through review of technical specifications and drawings in order to prepare
the WPS to be applied for construction work.
5.1.2 Attention shall be paid to the following during review of the technical specifications and
drawings:
(1) Limitation for the welding process
(2) Base metal
(3) Limitation for the welding material
(4) Preheat and post weld heat treatment
(5) Welding position
(6) Gas
(7) Electrical characteristic
(8) Joint design
(9) Reference to applicable approval code, i.e. ASME IX, AWS D1.1
5.1.3 The Welding Engineer shall prepare the draft WPS with all the information in accordance
with applicable Code and Standards. The WPS (Attachment 1A & 1B) shall be approved
when the procedure qualification testing is completed and a PQR (Attachment 2A & 2B) is
certified by Quality Manager and accepted by OWNER.
5.2 The Numbering System is as follows.
4 / 13
5.2.1 Welding Procedure Specification (WPS)
DZ01- 1 2 3 - 4 5 - 6 7
Where
DZ01 : Project Identification
1 : P-No of Base Metal (refer to ASME Sec. IX)
2 : Classification of PWHT (A: No heat treatment, P: Heat treatment)
3 : P-No of Base Metal (refer to ASME Sec. IX)
4 5 : Classification of welding process (refer to following abbreviation)
SM : Shielded Metal Arc Welding (SMAW)
GT : Gas Tungsten Arc Welding (GTAW)
GS : GTAW + SMAW
FC : Flux Cored Arc Welding (FCAW)
TG : TGX + GTAW
TS : TGX + SMAW
ST : Stud Welding
6 7 : Serial number (Issue order of WPS, ex. : 01, 02,........)
5.2.2 Welding Procedure Qualification Record (PQR)
DZ01 - PQR -
Where
DZ01 : Project Identification
PQR : Welding Procedure Qualification Report
1 2 : Serial number (ex.: 01, 02,........)
1 2
5 / 13
5.2.3 Tension Test, Bend Test, Notch-toughness Test and Hardness Test shall be performed in
accordance with ASME Sec. IX QW-150, QW-160 and QW-171.
5.3. Test Preparation
5.3.1 The Welding Engineer shall review contractual documentation and applicable Code
requirements to identify those design and material requirements necessitating the
preparation of new welding procedure qualification.
5.3.2 The Quality Team shall give a minimum formal notice of two (2) days to OWNER prior to
commencing welding of the test coupon.
5.3.3 The PQ Test shall be performed by the skilled Welder or Welding Machine Operator.
5.3.4 The Construction Team shall prepare the test coupon for Welding Procedure Qualification Test.
5.4 Performance of Test
5.4.1 The welder performing welding work for the PQ Test shall be under the supervision
of the Welding Engineer, and the welding work performed by other personnel shall not
be permitted in the test area.
5.4.2 The Procedure qualification test may be witnessed by OWNER.
5.4.3 The completed procedure qualification test welds shall first be subjected to visual
inspection by Welding Engineer and OWNER.
5.4.4 The test specimens to be tested for PQ Test shall be prepared by the same method as the
applicable codes and standards by the Quality Team. The type and quantity of test
specimens shall be prepared in accordance with the requirements of applicable code,
standard and technical specification.
5.4.5 The test method and acceptance criteria shall comply with the requirements of applicable
code, standard and technical specification. If any test specimen required by applicable codes
and standards does not conform to applicable acceptance criteria, the test coupon shall be
regarded as rejected and a new test coupon shall be prepared.
5.4.6 Welded test coupons shall show complete joint penetration with complete fusion of weld
metal and base metal in accordance with the applicable code requirements.
6 / 13
5.4.7 Welder who is involved in the welding of a procedure qualification which is subsequently
proved to be acceptable will automatically be qualified to carry out that procedure weld
requirements/criteria/range.
5.5 Welding Procedure Qualification Record (PQR)
5.5.1 The PQR shall be prepared by the Welding Engineer who supervised the PQ Test
and the test results. The original reports of the WPS and PQR which ha recorded test results
shall be submitted to OWNER for approval.
5.5.2 The actual variables used during the welding of the test coupons are recorded on a
PQR. The completed PQR shall be documented with all essential and supplementary
essential variables (when required) for each welding process. A separate data run
sheet shall be attached to PQR as applicable.
5.5.3 The nonessential or other variables used during welding of test coupon may be recorded
on the PQR.
5.5.4 Variables shall be followed as required by the code and technical specification.
5.5.5 The PQR shall be certified by the Quality Manager.
5.5.6 Any other Daewoo E&C’s PQR’s that meet the contract criteria and applicable code
requirements shall be considered acceptable for this project..
5.6 Welding Procedure Specification (WPS)
5.6.1 The Welding Engineer shall prepare the WPS to be used for the permanent welding
based on the PQR certified. The WPS shall be submitted to OWNER for approval.
5.6.2 The WPS shall describe all essential, supplementary essential (if required) and
non-essential variables for each welding process specified in applicable code and standard
and all requirements of the technical specification. The WPS shall include supporting
PQR number(s).
5.6.3 The Welding Engineer shall prepare and maintain an Index of Welding Procedure
Specification (Attachment 4) which identifies qualified Welding Procedure Specification
7 / 13
5.6.4 All WPS and Index of Welding Procedure Specification shall be distributed in accordance
with the Document Control Procedure.
5.6.5 When there is a specific reason to question the Welding Procedure Specification, the
Quality Manager or the OWNER representative may require re-qualification.
5.7 Records
5.7.1 All WPS and PQR and related data of qualification shall be maintained on file by the
Welding Engineer.
5.7.2 All WPS and PQR and related data of qualification shall be controlled as QA Records in
accordance with the Quality Records Control Procedure.
6.0 ATTACHMENTS
Attachment 1A Welding Procedure Specification (WPS)
Attachment 1B Welding Procedure Specification (WPS) - Continuation
Attachment 2A Welding Procedure Qualification Record (PQR)
Attachment 2B Welding Procedure Qualification Record (PQR) - Continuation
Attachment 3 Welding Procedure Qualification Test Plan
Attachment 4 Index of Welding Procedure Specification
8 / 13
Attachment 1A
6423DA060-005-01A(0)
WELDING PROCEDURE SPECIFICATION(WPS))))
Project name AOFP
Project NO. DZ01
Prepared by
Checked by
Approved by
WPS No.: Rev: Date
Supporting PQR No(s)
Welding Process(es) Type(s)
Applicable Code
Joints (QW–402)
JOINT DETAIL (TYPICAL
Joint Design:
Backing:□ Yes □ No Backing Material
Other
Base Metal (QW-403)
P. No.: Group No: to P. No Group No:
Specification Type & Grade to
Chem. Analysis & Mech. Prop. to
Thickness Range: Fillet
Pipe Dia. Range:
Other
Filler Metals (QW-404) Root / Fill
F. No: /
A. No. /
Spec No. (SFA) /
AWS. No. (Class) /
JIS No. /
Size:
Deposited Weld Metal
Brand Name of Electrode or Filler Metal
Wire Type for GMAW
Electrode-Flux (Class)
Brand Name of Flux
Drying Condition: Temp oC Time hours
Other
Position (QW-405)
Position of Groove
Welding Progression : ■ Up � Down Position of Fillet
Other
9 / 13
Attachment 1B
6423DA060-005-01B(0)
WELDING PROCEDURE SPECIFICATION (WPS) -
Contd/... Project name AOFP
WPS NO
Preheat:(QW-406)
�Yes ■No
Post Weld Heat Treatment ;(QW-407)
�Yes ■No
Preheat Temp: oC Post Heat Temp
oC
Interpass Temp; oC Holding Time min
Method oC Method
Other: Other
Gas (QW-408)
Shielding Gas(es) Flow Rate:
L /min
Percent Composition
% Gas Backing �Yes ■No
Trailing Shielding Gas Composition
%
Other
Electrical Characteristics & Technique (QW-409)
Tungsten Electrode Size mm Type
Mode of Metal Transfer for GMAW
Electrode Wire Feed Speed Range
Technique (QW-410)
Bead: ■ String ■ Weave Orifice or Gas Cup Size mm
Initial & Interpass Cleaning: ■ Brushing ■ Grinding � Other
Pass (per side ) ■ Multi � Single Electrode: � Multi ■ Singl
Method of Back Gouging Other
Weld Layer
Welding
Process
Filler Metal Current Travel Speed
Range
(cm/min)
Brand Class Dia: (mm) Type Polarity Amperage Range
Voltage Range
10 / 13
: Attachment 2A
6423DA060-005-02A(0)
WELDING PROCEDURE QUALIFICATION RECORD
(PQR)
Project name AOFP
Project NO DZ01
Prepared by
Checked by
Certified by
PQR No. Date:
WPS No. Date:
Welding Process(es)
Type (Manual, Automatic, Semi-Auto.)
Applicable Code
Joint/ Design of Test Coupon (QW-402)
Backing No Yes
Material
BASE METALS (QW-403) POSTWELD HEAT TREATMENT (QW-407)
Material Spec Temperature
Type of Grade Time
P. No to P. No Other
Thickness mm
Diameter
Other
FILLER METALS (QW-404) GAS (QW-408)
Weld Metals Analysis A. No. Shielding Trailing Backing
Size of Electrode Type of Gas or Gases
Filler Metal F. No. Flow Rate
SFA Specification Composition of Gas Mixture
AWS Classification Other
Brand Name
POSITION (QW-405) ELECTRICAL CHARACTERISTICS (QW-409)
Position of Groove Current
Weld Progression (Uphill, Downhill) Polarity
Other Amps. Volts
Tungsten Electrode Type Size
PREHEAT (QW-406) TECHNIQUE (QW-410)
Travel Speed
Preheat Temp String or Weaver Bead
Oscillation
Interpass Temp. Multiple or Single Pass (per side)
Single of Multiple Electrode
Other Other
11 / 13
Attachment 2B
(QW-483)
PQR No. :
Tensile Tests (QW-150)
Specimen
No.
Width
mm
Thickness
mm
Area
mm2
Ultimate
Total Load
Kg
Ultimate
unit Stress
kg/mm2
Character of
Failure &
Location
Guided Bend Tests (QW-160)
Type & Specimen No. Result
Toughness Tests (QW-170)
Specimen
No.
Notch
Location
Notch Type Test Temp. Impact
Values
Lateral Exp. Drop Weight
% Shear mm Break No Break
Fillet Weld Test (QW-180)
Result-Satisfactory : Yes No Penetration into Parent Metal : Yes No
Macro-Result
Other Test
Type of Test
Deposit Analysis
Welder Name Stamp No.
Tests conducted by Laboratory Test No.
Witnessed
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 _______________________________________
(Applicable Code)
6423DA060-005-02B(0)
12 / 13
Attachment 3
6423DA060-005-03(0)
Welding Procedure Qualification Test Plan
Seq.
No PQR No Base Metals(ASTM) P-No
Group
No
Filler
metals
(AWS)
PWHT
(time)
Impact
( )℃℃℃℃
Qualified thickness (mm) Type and number of tests required
Remarks Material GTAW SMAW
GTAW +
SMAW Tension
Face
bend Root bend Impact(B/W/H)
13 / 13
Attachment 4
INDEX OF WPS
S/N WPS No. Supporting
PQR No.
P-NO
(GR No.)
Thickness
Range (mm) Base Metal Filler Metal PWHT
Impact
Temp.( )℃ Remarks
6423DA060-005-04(0)