asme ix presentation summary oct 2007

1

API 510 Pressure Vessel Inspector Certification Course.

Venezuela October 2007.

Review ASME Section IX

The main key is:

“Keep separate variables for

Procedure and Performance”

INTRODUCTION …

2

Section IX Relates To :

Qualification Of:

Welders

Welding Operators

Brazers

Welding/Brazing Procedures

Who Are Employed In Welding & Brazing In Accordance

With ASME BOILER & Pressure Vessel Code / API Code and Standards.

INTRODUCTION …

Welding Identified As QW

Brazing Identified As QB (no in the BOK)

What Does The Q Signify ?

The Two Parts Are Further Divided Into Four Articles

General Requirements

Procedure Qualification

Performance Qualification

Data

The Section Is Divided Into Two Parts:INTRODUCTION …

3

Weld Deposit Material Properties Are Controlled Through – Procedure Qualification.

Welder Skill Is Controlled Through – Performance Qualification.

An Understanding of Essential, Non-Essential And Supplementary Essential Variables Is Required.

INTRODUCTION …

INTENTIONALLY Essentials, non-Essentials and Essentials Supplementary variables are not discussed now, but we will need talk about it forward…

INTRODUCTION …

4

WELDING PROCESS …

INTRODUCTION …

SMAW – SHIELDED METAL ARC WELDING

INTRODUCTION …

5

GMAW – GAS METAL ARC WELDING

INTRODUCTION …

GTAW – GAS TUNGSTEN ARC WELDING

INTRODUCTION …

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SAW – SUBMERGED ARC WELDING

INTRODUCTION …

INTRODUCTION …

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ARTICLE I. GENERAL REQUIREMENTS …

PART QW WELDING

ARTICLE I - WELDING GENERAL REQUIREMENTS

QW-100.1 A welding procedure is a written document that provides direction to the welder or welding operator for making production welds.

When prepared by the manufacturer or contractor, it must address, as a minimum, the specific variables, both essential and nonessential, as provided in Article II. When notch toughness is required the applicable supplementary essential variables must be addressed in the WPS.

The Procedure Qualification Record (PQR) documents what occurred during welding of the test coupon and the results of testing of the coupon:

As a minimum the PQR shall document the essential variables and other specific information identified in Article II. When notch toughness is required the applicable supplementary essential variables shall be recorded.

WPS's, PQR's and WPQ's made in accordance with the 1962 Edition or any later edition may be used in any construction built to the ASME B&PV Code or the ASME 831 Code for Pressure Piping.

WPS's, PQR's and WPQ's made in accordance with Editions prior to 1962 may be used if all the requirements of the 1962 Edition or later Editions are met.

WPS's and WPQ's meeting the above requirements do not need to be amended to include any variables required by later 'Editions or Addenda.

Qualification of new WPS's or WPQ's and requalification of existing WPS's and WPQ's shall be in accordance with the current Edition and Addenda of Section IX.

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Important Points QW-103

Manufacturer/Contractor Is Responsible For Welding

He MUST Conduct Tests To Qualify Welding Procedure And Welders/Welding Operators.

Test Results MUST be kept by Manufacturer/Contractor

MUST Be Certified By Manufacturer/Contractor

What Constitutes Certification ?

ARTICLE I. RESPONSIBILITY …

“READ 04 EDT & ADD-05 - 06”

QW-120 To QW-132 WITH GRAPHICS IN QW-461 REFER.ARTICLE I. WELDING POSITIONS …

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IF YOU QUALIFY ON GROOVES DO YOU STILL HAVE

TO QUALIFY ON FILLETS ?

DOES THE REVERSE APPLY ?. (see table QW-451.4)

THEN IS BAD IDEA QUALIFY USING FILLETS

Mechanical Tests (Destructive)

Tension Tests:

Guided Bend Tests:

Fillet Weld Tests:

Notch Toughness Tests:

Stud Weld Tests:

ARTICLE I. QW-140 TYPES & PURPOSE OF TEST …

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Specimen Ruptured Under Tensile Load

ARTICLE I. TENSILE TESTS …

Maximum Load

Minimum Cross Sectional Area

Width x Thickness = Cross Sectional Area

i.e. 0.500” Wide x 0.265” Thick

Locate Dimensions Of A Sample – QW 462.1 (a)

ARTICLE I. “DOG BONE SAMPLES” (HUESO DE PERRO) …

Tensile Strength =

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Cross Sectional Area Is

πr2 Where

r = Radius Of Specimen

Be Cautious Code Sets Tolerance On Machined Specimens – QW-462.1 (d)

ARTICLE I. TURNED SAMPLES …

QW153.1

Minimum Of Weakest Base Metal

Can Be 5% Under If Breaks In Base Metal.

Tensile Strength Is Laid Out In Code.

Where Find Now: QW 422

ARTICLE I. TENSION TEST ACCEPTANCE …

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Contained In Tables Under QW/QB-422

Base Metals Are Grouped Based On Characteristics,

Composition, Weldability, Mechanical Properties.

Additionally Group Numbers Are Assigned Where Notch

Toughness Is Required.

This Saves A Large Number Of PQR Tests.

ARTICLE I. P. NUMBERS …

T1= 0.285 x 0.748 What Is CSA?

If It Fails At 17821 Lbs What is Tensile Strength?

If It Fails In Weld Metal And Material Is A-139

Gr.A Has It Passed?

If the Failure Is In The Base Metal Has It Passed?

ARTICLE I. SOLVE …

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T1= 0.495” Diameter What Is CSA?

If It Fails At 20921 Lbs What is Tensile Strength?

If It Fails In Weld Metal And Material Is

SA-182 Gr.F55 Has It Passed?

If the Failure Is In The Base Metal Has It Passed?

ARTICLE I. SOLVE …

Dimensions As Code QW-160 refer to QW-466.X:

Caution – Type Of Tests Based On Thickness Of Sample.

Multiple Samples For Thick Sections.

Bent through 180 Degrees On Jig As Per Code

ARTICLE I. GUIDED BEND TEST …

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Acceptance Criteria (QW-163):

The Weld & Heat Affected Zone Must Be Within The Bent Area.

No Open Defects In Weld Or HAZ Exceeding 1/8” In Any Direction.

Open Defects At Edge Shall Be Discarded Unless There Is Clear Evidence Of Welding Defect.

For Corrosion Resistant Cladding No Defect Exceeding 1/8” On Bond Line Or 1/16” Elsewhere.

ARTICLE I. GUIDED BEND TEST …

Charpy V Notch Test In Accordance With SA-370

Acceptance Standards Are Complex And Will Be Covered Under ASME Section VIII / API-653, ETC.

Drop Weight Tests May be Required By Other Sections

10 mm

50 mm

ARTICLE I. QW-170. NOTCH TOUGHNESS TESTS

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Be Aware That There Are Requirements For:

Fillet Weld Bends & Fracture Tests

Macro Etch Examinations

ARTICLE I. OTHER MECHANICAL TESTS …

ARTICLE I. QW-190 …

QW-190 OTHER TESTS AND EXAMINATIONS

Radiographic ExaminationRequirements of Article 2, Section V to be used. Written procedure not required nor is personnel qualification required.

Radiographic Acceptance CriteriaAcceptance criteria for welders and welding operators performance tests of welds in test assemblies.

QW-191 READ THE CODE BOOK NOW

QW-191.2.3 Production Welds

The acceptance standard for welding operators who qualify on production welds shall be that specifiedin the referencing Code Section.

The acceptance standard for welders who qualify on production welds shall be per QW-191.2.2.

QW-194 Visual Examination – Performance

Performance coupons shall show complete joint penetration with complete fusion of weld metal and base metal.

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QW-192 TEN TESTS PER PROCEDURE

FIVE HAMMERED FLAT - 1/4 OF LENGTH OR 15% ANGLE AND STRAIGHTENED

FIVE TORQUE TESTED OR TENSILE TESTED

TORQUE AS PER QW-192.3

TENSILE MUST MEET 35000 - 30000 PSI

FOR PERFORMANCE FIVE STUDS HAMMERED FLAT

MUST SHOW NOR CRACKING OR LACK OF FUSION.

ARTICLE I. QW-192 STUD WELD TEST…

PQR – Procedure Qualification Record

WPS – Welding Procedure Specification

WPQ – Welder Performance Qualification Record

ARTICLE I. THREE CRITICAL DOCUMENTS …

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ARTICLE II. WELDING PROCEDURE

QUALIFICATIONS…

QW-200-1 WPS WELDING PROCEDURE

SPECIFICATION

Written Directions For The Welder/Welding Operator

Making Production Welds Describing All Variables Involved.

Describes All Essential, Non Essential And When Required

Supplementary Variables Listed In QW-250 Thru. QW-280

ARTICLE II. QW-201 WPS. WELDING PROCEDURE SPECIFICATION…

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Essential Variable - Change Affecting Mechanical Properties -Requires Specification Re-qualification

Supplementary Essential Variable - Change Affecting Notch Toughness Properties - Requires Specification Re-qualification

Non Essential Variable - Does Not Affect Mechanical or Notch Toughness- Re-qualification Not Required.

ARTICLE II. QW-201 WPS. VARIABLES…

Essential Variable For One Process May Be Non Essential For Another - Work The Tables.

Non Essential Variable Can Be Changed Without Re-qualification But Must Be Recorded On A New Or Amended WPS Form.

WPS form May Be In Any Format As Long As All Information is Covered.

WPS Must Be Available For Reference And Review By The AI.

ARTICLE II. QW-201 WPS. VARIABLES…

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A Record Of What Actually Occurred During Welding And The Subsequent Mechanical Tests.

Intent Is To Determine That the Required Mechanical Properties Can Be Achieved.

All Variables In the WPS MUST Be Followed.

Base Metal Used In The Test Can Be In Any Form -Qualification Is Transferable Between Plate & Pipe.

All Essential And Supplementary Essential Variables Must Be Recorded.

Any Non Essential Variables Can be Recorded At A Later Date.

ARTICLE II. QW-202 PQR. PROCEDURE QUALIFICATION RECORD…

Any Variables Recorded MUST Be The Actual Variable.

Variables Not Recorded MUST NOT Be Recorded.

If More Than One Process Or Filler Metal Is Employed RECORD The Approximate Deposit Thickness.

CHANGES

Are Not Allowed Except For Editorial Mistakes And Then Must Be Certified.

PQR MUST Be Certified Accurate By Manufacturer/Contractor.


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QW-201 Manufacturer's or Contractor's Responsibility

Each manufacturer or contractor shall qualify the WPS by the welding of test coupons and the testing of specimens and, the recording of the welding data and test results in a document known as a PQR.

The welders or welding operators used to produce weldments to be tested for qualification of procedures shall be under the full supervision and control of the manufacturer or contractor during the production of these test weldments.

The weldments to be tested for qualification of procedures shall be welded either by direct employees or by individuals engaged by contract for their services as welders or welding operators under the full supervision and control of the manufacturer or contractor.

FROM QW-202.2 (b) PQR MUST Be Certified Accurate By Manufacturer/Contractor.

WHAT HAPPEN WITH AWS-CWI?


Format May Be Any As Long As Required Information Is Present.

PQR Must Be Available To The AI But Does Not Have To Be Available To The Welders.

More Than One WPS Can Be Prepared From The Same PQR.

One WPS May Cover Multiple Essential Variable Changes Providing The PQR Exists For All Essential & Supplementary Variables.

More Than One PQR Can Be Used to Prepare The Same WPS.

See example for WPS’s from one PQR


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ARTICLE II. QW-211. BASE METALS…

QW-211 Base Metal

The base metals may consist of either plate, pipe, or other product forms. Qualification

in plate also qualifies for pipe welding and vice versa.

Read now from codebook…

Source Of Guidance On Which Variable Apply To Which Process.

Which Are Essential, Non Essential & Supplementary Essential.

Know How To Find And Use These Tables :-

ARTICLE II. QW-250. VARIABLES PER EACH PROCESS…

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QW-250 WELDING VARIABLES

QW-250.2 Essential Variables

Essential variables are those in which a change, as described in the specific variables, is considered to affect the mechanical properties of the weldment, and shall require requalification of the WPS.QW-251.3

QW-250.3 Nonessential Variables

Nonessential variables are those in which a change as described in specific variables, may be made in the WPS without requalification.

WELDING VARIABLES PROCEDURE SPECIFICATIONS (WPS)

QW-253 Shielded Metal-Arc (SMAW)

QW-254 Submerged-Arc Welding (SAW)

QW-255 Gas Metal-Arc Welding (GMAW and FCAW)

QW-256 Gas Tungsten-Arc Welding (GTAW)

ARTICLE II. QW-250. VARIABLES PER EACH PROCESS…

ARTICLE III. WELDING PERFORMANCE

QUALIFICATIONS…

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Qualification Of The Man.

Limited By Essential Variable For Each Process – Different From Procedure Qualification – QW-352 Onwards

Visual Examination Always Required.

Qualification By:

Guided Bend Tests Of Test Coupon

Radiography Of – Test Coupon or

First Production Weld

ARTICLE III. Welding Performance Qualifications…

ARTICLE III

WELDER PERFORMANCE QUALIFICATIONS

QW- 300 GENERAL

QW-301.1 A welder or welding operator may be qualified by radiography of a test coupon, radiography of his initial production welding, or by bend tests taken from a test coupon except as stated in QW-304 and QW-305.

QW-300.2 The welders or welding operators used to produce such weldments shall be tested under the full supervision and control of the manufacturer, contractor, assembler, or installer during the production of these test weldments.

QW-301 Tests

QW-301.1 Intent of Tests

The performance qualification tests are intended to determine the ability of welders and welding operators to make sound welds.

Qw-301.2 Qualification Tests

The performance qualification shall be welded in accordance with qualified WPS's. Identification of Welders and Welding Operators

ARTICLE III. Welding Performance Qualifications…

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Manufacturer/Contractor MUST Conduct Tests To Qualify Welders

ARTICLE III. QW-300.2…

More than one manufacturer/contractor conducting only one tests for qualification procedure

Reading Carefully

Performance Tests Must Be Done To A Qualified WPS.

Welder Who Prepares The WPS Qualification Test

Coupon is Qualified Within Those Limitations (If It

Passes).

Caution It May Limit His Range Of Qualification

ARTICLE III. QW-301..2…

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Each Welder Must Be Assigned Unique Identification.

Identify All Work With This.

Does Not Have To Hard Stamp!!!

ARTICLE III. QW-301.3. Identification Of Welders…

WPQ Must Record:

Essential Variables

Type Of Test

Test Results

Range Qualified

ARTICLE III. QW-301.4. Record Of Tests…

QW-301.4 Record of Tests

The record of Welder/Welding Operator Performance Qualification (WPQ) tests shall include the essential variables (QW-350 or QW-360), the type of test and test results, and the ranges qualified in accordance with QW-452 for each welder and welding operator.

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Shall Pass Mechanical And Visual Requirements.

Qualification Using Radiography

Allowed Using: SMAW, SAW, GTAW, PAW

GMAW Except in Short

Circuiting Mode

Except P-21 Through P-25, P-51 Through P-53 & P-61, P-62 Materials.

P-21Through P-25, P-51 Through P-53 Using GTAW Are Allowed.

ARTICLE III. QW-304. Welders …

Test Coupons:

Mechanical (Bend ) Tests Or Radiography.

If Qualified On Production Weld:

Radiography Of First 6” Of Weld (for welder)

ARTICLE III. QW-304.1 Welders Examination…

QW-304.1 Examination

Welds made in test coupons may be examined by visual and mechanical examinations, or by radiography.

Alternatively a 6 in. length of the first production weld made by a welder may be qualified by radiography.

Acceptance criteria? QW-191.2.2

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If Radiography On A Production Weld Is Unacceptable

Then The Welder Has Failed.

Entire Production Weld Must Then Be Radiographed And

Repaired By A Qualified Welder.

ARTICLE III. QW-304.1 Welders Examination…

Welding Operators:-What is Difference?

ARTICLE III. QW-305 Welding Operators…

Much The Same Rules Apply However:

If Qualifying By Radiography On Production Weld The

First Three Feet Of Weld Must be Examined.

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A Welder Or Operator Who Fails May Be Retested.

If Fails Visual – Shall Make Two Consecutive Test Coupons And Then Pass Visual & Mechanicals.

If Fails Mechanicals – Shall Make Two Consecutive Test Coupons And Then Pass Mechanicals.

If Fails Radiography –

Coupons Make Two 6” Inch Plates Or Two pipes Totalling 12” Of Weld. Small Diameter Pipe Need Not Exceed Eight Pipes.

ARTICLE III. QW-320 Retest and Renewal of Qualification…

If Production Weld Fails Radiography:

Radiograph 12” Of Same Production Weld. If Passes He Is Qualified And Can Repair the Earlier Failed Part. If Not He Has Failed.

Welding Operator - Radiograph 6’ Of Weld.

This is The Two For One Rule.

ARTICLE III. QW-320 Retest and Renewal of Qualification…

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Renewal & Expiration of Qualifications.

Expires If Does Not Weld for Six Months or

Ability is Questioned.

Expired Qualifications May Be Renewed By Welding One Test Coupon And Successfully Testing.

Renewal May Be Done On Production Work.

Revoked Qualifications Must Be Tested On A Test Coupon.

ARTICLE III. QW-322 Expiration & Renewal of Qualifications…

ARTICLE III. QW-350 Welding Variables for Welders…

QW-350 WELDING VARIABLES FOR WELDERS

QW-351 General

A welder shall be requalified whenever a change is made in one or more of the essential variables listed for each process in QW-352 thru QW-357.In any given production weldment, welders may not deposit a thickness greater than permitted by QW-452 for each welding process in which they are qualified.

QW-360 WELDING VARIABLES FOR WELDING OPERATORS

QW-361 General

A welding operator shall be requalified whenever a change is made in one of the essential variables listed for each process in QW-361.1 or QW-361.2.

Check out tables from QW-350 / QW-360 from codebook…

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ARTICLE IV. WELDING DATA…

ARTICLE IV. Welding Data

QW-400 VARIABLES

These are the complete wording of the variables that are listed under "Brief of Variables" in the checklists QW-252 thru QW-264.

When answering any questions regarding the WPS/PQR combination it is very important to read each of the required variables before answering any questions.

QW-422 FERROUS P-NUMBERS AND S-NUMBERS

Grouping of Base Metals for Qualification

This is a listing of all the SA and SB base metal specification numbers in ascending order which are used to determine the minimum specified tensile strength and P-No's of the. base metals shown on the PQR.

QW-423 Alternate Base Metals for Welder Qualification

Base material used for welder qualification (Column 1) may be substituted for the P-Number material specified in the WPS (Column 2) .

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QW-424 Base Metals Used for Procedure Qualification

Base metals used for the Procedure Qualification (Column 1) qualify the base metals listed in (Column 2).

Note that qualification using one P-No. to the same P-No. may permit the welding of that P-No. to other lower P-No's.

QW-432 F-NUMBERS

Grouping of Electrodes and Welding Rods by Qualification

For the API Examination we are only interested in F-No's 1 thru 6 Steel and Steel Alloys with their corresponding ASME Specifications and A WS Classifications.

QW-433 Alternate F-Numbers for Welder Performance Qualification

This Table identifies the filler metal or electrode F-Number used during qualification testing as "Qualified With" and the electrode or filler metal that the welder is qualified to use in production as "Qualified For". This Table is referenced from Welding Data Variable QW-404.15.

Note that although a welder who qualifies on a higher F-Number without backing is also qualified to weld lower F-Numbers, he/she are not permitted to weld without backing for the lower F-Numbers.


QW-442 A-NUMBERS

Classification of Ferrous Weld Metal Analysis for Procedure QualificationThis Table is used to identify the weld metal chemical composition designated on the PQR and WPS per QW-404.5 for ferrous weld metal deposits.

NOTE: For GMAW a weld metal deposit analysis from the PQR may be required if the shielding gas used to weld the procedure qualification test coupon was not the same used by the SFA Specification.

QW-450 SPECIMENS

QW-451 Procedure Qualification Thickness Limits and Test Specimens

QW-451.1 GROOVE WELD TENSION TESTS AND TRANSVERSE-BEND TESTS

This Table is used each time the thickness range T of base metals qualified and maximum thickness t of deposited weld metal on the WPS is being verified based on the thickness T of the test coupon welded during PQR qualification.

The Table also shows for the thickness T of the test coupon welded, the number of tension tests required and the type and number of bend tests required.

It is also important to read the applicable notes as there may be permitted variations in the thickness limits and types of test specimens.


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QW-452 Performance Qualiificati.on Thickness Limits and Test Specimens

QW-452.1 TRANSVERSE-BEND TESTS

This table is used to determine the maximum thickness of deposited weld metal qualified for a welder or welding operator.

Note that the 2000 addenda reduced the deposited weld metal thickness from 3/4 in. to 1/2 in. to give the welder/welding operator the maximum to be welded qualification. Also a minimum of three layers must be deposited.

QW-452.3 GROOVE WELD DIAMETER LIMITS

In order for a welder/welding operator to weld small diameter pipe/tube this table is used to determine the outside diameter of the test coupon.

This Table in conjunction with QW-461.9 is used to determine performance position and diameter limitations.

QW-461.9 PERFORMANCE QUALIFICATION - POSITION AND DIAMETER LIMITATIONS

Extremely important that this Table be thoroughly understood and unfortunately to be memorized since recent API Examinations have had questions taken from it in the closed book portion of the examination.


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QW-463 Test Specimens

Unless a minimum, maximum, or tolerance is given in the figures, the dimensions are to be considered approximate.

QW-462.1(a) TENSION - REDUCED SECTION – PLATE

Width of specimen regardless of thickness is 3/4 in.

QW-462.1(b) TENSION - REDUCED SECTION – PIPE

Width of specimen regardless of thickness is 3/4 in.

QW-462.1(c ) TENSION - REDUCED SECTION - ALTERNATE FOR PIPE

Per QW-151.2 pipe having an outside diameter of 3 in. or less may use this alternate reduced section specimen which has a width of 1/2 in.

TENSION - REDUCED SECTION - TURNED SPECIMENS

These are round specimens that come in four different diameters.

NOTE: The C dimension or grip end for each of the four specimens is larger than the diameter D. It is therefore not possible to obtain. as an example. a 0.505 in. diameter specimen from less than 3/4 in. thick plate because the grip end is 0.750 in.


ARTICLE IV. Welding Data. QW-461.9

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QW-462.2 SIDE BEND

Dimensions for side bend specimens

QW-462.3(a) FACE AND ROOT BENDS – TRANSVERSE

Dimensions of face and root bend specimens.

These are the only ones covered by the API Examination.

QW-463 Order of Removal

The following are the order of removal sketches that must be followed by those organizations that prepare the test specimens for procedure and performance qualification.

QW-463.1(a) PLATES - LESS THAN 3/4 in. THICKNESS PROCEDURE QUALIFICATION

QW-463.1(b) PLATES -3/4 in. AND OVER THICKNESS AND ALTERNATE FROM 3/8 in. BUT LESS THAN 3/4 in. THICKNESS PROCEDURE QUALIFICATION

QW-463.1(d) PROCEDURE QUALIFICATION PIPE UP TO 3/4 in. THICKNESS

QW-463.1(e) PROCEDURE QUALIFICATION PIPE 3/4 in. AND OVER THICKNESS

QW-463.2(a) PLATES - LESS THAN 3/4 in. THICKNESS PERFORMANCE QUALIFICATION


QW-463.2(b) PLATES –3/4 in. AND OVER THICKNESS AND ALTERNATE FROM 3/8 in. BUT LESS THAN 3/4 in. THICKNESS PERFORMANCE QUALIFICATION

QW-463.2(d) PERFORMANCE QUALIFICATION PIPE UP TO 3/4 in. THICKNESS

QW-463.2(e) PERFORMANCE QUALIFICATION PIPE 3/4 in. AND OVER THICKNESS

QW-463.2((f) PIPE-10 in. ASSEMBLY PERFORMANCE QUALIFICATION

QW-463.2(g) 6 in. OR 8 in. ASSEMBLY PERFORMANCE QUALIFICATION

QW-490 DEFINITIONS

These are definitions related to welding/brazing and may be helpful in answering some questions.


asme ix presentation summary oct 2007

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