asme section ix.updated
TRANSCRIPT
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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ASME
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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Notes
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
Land
Root radius“U” preparation
Double “U” butt
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Groove Weld
1?
Cont’d……
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Groove Weld
1
Groove Angle
Cont’d……
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Groove Weld
1?
Cont’d……
2
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Groove Weld
Cont’d……
1
Bevel Angle
2
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Groove Weld
1
3
?
Cont’d……
2
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Groove Weld
1
3
Cont’d……
2
Groove Face
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Groove Weld
1
3
Cont’d……
2
?4
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Groove Weld
1
3
Cont’d……
2
4
Root Face
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Groove Weld
1
5
3
Cont’d……
2
?
4
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Groove Weld
1
5
3
Cont’d……
2
4
Root Gap
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Groove Weld
Groove Angle
Groove Face
Bevel Angle
Root Face
Root Gap
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Fillet Weld
1?
Cont’d……
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Fillet Weld
1?
Cont’d……
Toe of Weld
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Fillet Weld
1
?2
Cont’d……
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Fillet Weld
12
Cont’d……
Weld Face
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Fillet Weld
1 ?32
Cont’d……
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Fillet Weld
132
Cont’d……
Weld Size
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Fillet Weld
1
?
32
4
Cont’d……
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Fillet Weld
132
4
Cont’d……
Weld Leg
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Fillet Weld
1
?
32
5
4
Cont’d……
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Fillet Weld
132
5
4
Cont’d……
Weld Root
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Fillet Weld
1
?
32
65
4
Cont’d……
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Fillet Weld
132
65
4
Cont’d……
Weld Throat
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Fillet Weld
Leg
Root Throat
Face Weld Size
Toe
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Stud Welding
Cont’d……
?1
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Stud Welding
Cont’d……
1
Work Piece
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Stud Welding
Cont’d……
2
1
Work Piece?
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Stud Welding
Cont’d……
2
1
Work Piece
Stud
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Stud Welding
Cont’d……
2
31
Work Piece
Stud
?
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Stud Welding
Cont’d……
2
31
Work Piece
Stud
Weld
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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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Scope
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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Specification SFA-5.4
Requirement for classifying stainless steel-covered electrodes used for SMAW Example:
E308H, E309L, E317L and E317L
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Specification SFA-5.5
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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Specification SFA-5.18
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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Classification SFA-5.1
PositionElectrode
Minimum tensile strength 70 ksi
Type of coating and recommended current
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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Classification SFA-5.1
PositionElectrode
Minimum tensile strength 70 ksi
For E7016 & E7018 Electrodes, “1” indicates that charpy values of 20 ft-lbs at -50 F have been met
EXXYY-1
Type of coating and recommended current
Cont’d……
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Classification SFA-5.1
Cont’d……
All PositionElectrode
Minimum tensile strength 70 ksi
For E7016 & E7018 Electrodes, “1” indicates that charpy values of 20 ft-lbs at -50 F have been met
EXX18- 1
Low Hydrogen, Potassium, Iron powder and use for AC
or DCEP
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Classification SFA-5.1
PositionElectrode
Minimum tensile strength 70 ksi
For E7016 & E7018 Electrodes, “1” indicates that charpy values of 20 ft-lbs at -50 F have been met
EXXYY-1
Type of coating and recommended current
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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Specification SFA-5.4
Requirements for classifying corrosion-resistant and chromium nickel steel-covered arc welding electrodes used for SMAW
Cont’d……
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Classification SFA-5.4
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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Classification SFA-5.4
Cont’d……
Electrode
Chemical Composition (first three digits)
Usability (Position & Current type
E-XXX-YYY-XX
One or more letters indicating modification of basic composition
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Classification SFA-5.4
Electrode
19 Cr, 10 Ni
Usability (Position & Current type
E-308-YYY-XX
One or more letters indicating modification of basic composition
Cont’d……
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Classification SFA-5.4
Cont’d……
Electrode
Chemical Composition (first three digits)
Usability (Position & Current type
E-XXX-L-XX
Low carbon contents 0.04% max
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Classification SFA-5.4
Cont’d……
Electrode
Chemical Composition (first three digits)
DCEP or AC/ all position
E-XXX-YYY-16
One or more letters indicating modification of basic composition
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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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Specification SFA-5.5
Requirements for classifying low-alloy steel electrode used for SMAW
Cont’d……
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Classification SFA-5.5
Cont’d……
Electrode
Minimum tensile strength (ksi)
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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Classification SFA-5.5
Cont’d……
Electrode
Minimum tensile strength (ksi)
One or more letters & number indicating
chemical composition of deposited metal
EXX (X) YY-XXX
Type of coating & recommended current
Position
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Classification SFA-5.5
Cont’d……
Electrode
Minimum tensile strength
100 ksi
One or more letters & number indicating
chemical composition of deposited metal
E 100 XX-XXX
Type of coating & recommended current
Position
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Specification SFA-5.5
Cont’d……
Electrode
Minimum tensile strength (ksi)
One or more letters & number indicating
chemical composition of deposited metal
EXX (X) 16-XXX
Low hydrogen Potassium AC/DCEP
All Position
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Classification SFA-5.5
Cont’d……
Electrode
Minimum tensile strength (ksi)
One or more letters & number indicating
chemical composition of deposited metal
EXX (X) 16-B2L
Low hydrogen Potassium AC/DCEP
All Position
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Classification SFA-5.5
Cont’d……
Electrode
Minimum tensile strength (ksi)
Chromium- molybdenum steel electrode
EXX (X) YY-B2L
Position
Type of coating & recommended current
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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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Specification SFA-5.18
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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Classification SFA-5.18
Cont’d……
Electrode
Minimum tensile strength (ksi)
Suffix relating to manufacture chemical
composition
ERXXS-X(XX)
Bare, Solid wire or rod
Rod
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Classification SFA-5.18
Cont’d……
Electrode
Minimum tensile strength (ksi)
Suffix relating to manufacture chemical
composition
ERXXC-X(XX)
Composite wire
Rod
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Classification SFA-5.18
Cont’d……
Electrode
Minimum tensile strength 70ksi
Suffix relating to manufacture chemical
composition
ER70S-X
Rod
Bare, Solid wire or rod
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Classification SFA-5.18
Cont’d……
Electrode
Minimum tensile strength (ksi)
Suffix relating to manufacture chemical
composition
ERXXS-X(XX)
Solid Wire
Rod
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Classification SFA-5.18
Cont’d……
Electrode
Minimum tensile strength (ksi)
Low carbon with trace of Ti, Zr and Al content
ERXXS-2(XX)
Bare, Solid Wire or rod
Rod
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Classification SFA-5.18
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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PQR
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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Notes
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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QW- 451.1: Example 2
T= 1/16” to 1/2” t= 1/2” max
T= 1/4” SMAW
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QW- 451.1: Example 3
T= 3/16” to 1” t= 1” max
T= 1/2” SMAW
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QW- 451.1: Example 4
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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QW- 451.1: Example 5
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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QW- 451.1: Example 6
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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QW- 451.1: Example 7
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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QW- 451.1: Example 8
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
ºF
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
• 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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PWHT
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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Rule
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.
.30
.18
Brief of Variables
QW-402Joints
QW-403Base Material
Paragraph
Deletion of Backing.4
.16
QW-404Filler metals
QW-405Position
.15
.1
.3
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
.30
.18
Brief of Variables
QW-402Joints
QW-403Base Material
Paragraph
Deletion of Backing.4
.16
QW-404Filler metals
QW-405Position
.15
.1
.3
Ø Pipe Diameter
Ø P-No.
Ø F-No.
Ø t weld deposit
Ø position
Ø ↑↓ Vertical Welding
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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
.16
.15
Brief of Variables
QW-402Joints
QW-403Base Material
Paragraph
Deletion of Backing.4
.18
QW-404Filler metals
QW-405Position
.30
.1
.3
Ø Pipe Diameter
Ø P-No.
Ø F-No.
Ø position
Ø ↑↓ Vertical Welding
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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
Deletion of Backing.4
.16
.18
QW-404Filler metals
QW-405Position
.15
.30
.1
.3
Ø Pipe Diameter
Ø P-No.
Ø F-No.
Ø t weld deposit
Ø position
Ø ↑↓ Vertical Welding
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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
Deletion of Backing.4
.16
.18
QW-404Filler metals
QW-405Position
.15
.30
.1
.3
Ø Pipe Diameter
Ø P-No.
Ø F-No.
Ø t weld deposit
Ø position
Ø ↑↓ Vertical Welding
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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
Max
Thickness "t" of deposited weld metal qualified
Thickness of test Coupon Welded
Type of
Joint
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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 Positionback to contents
Groove Weld in Plate Test Positionback to contents
Groove Weld in Plate Test Position back to contents
Groove Welds Pipe Test Positionback to contents
Groove Welds Pipe Test Positionback to contents
Groove Welds Pipe Test Positionback 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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Position Qualification
The Welder Welded in Position 5G Pipe.
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Position Qualification
The Welder Welded in Position: 2G Pipe.
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Position Qualification
The Welder Welded 2G, 3G & 4G Plate
2G 3G 4G
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Position Qualification
The Welder is qualified to weld in both horizontal and flat positions
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Position Qualification
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
.4
Brief of Variables
QW-402Joints
QW-403Base Material
Paragraph
Deletion of Backing
.16
.18
QW-404Filler metals
QW-405Position
.15
.30
.1
.3
Ø Pipe Diameter
Ø P-No.
Ø F-No.
Ø t weld deposit
Ø position
Ø ↑↓ Vertical Welding
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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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