aws cwi exam guide

8/2/2019 Aws CWI Exam Guide

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READ and UNDERSTAND VERY IMPORTANTNOW let us deal with the SCOPE of WPS , PQR and WPQ

Welding WPSto PQRto WPQtoApplication SPECIFY RECORD , Actual Record - Value

Veriable ranges , Veriables , Essential TestedEssential variables , Veriahles , Test and Specify - RangeNon essential Results. Qualifiedvariables - Record--


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1. WPS = Welding Procedure Specification, it is a document written by the welding engineerwhich states all the requirements to get the weld done in proper and correct manner

2. . PQR = Procedure Qualification Records, as the names suggests these are RECORDS of theTests done to verify and validate that weld produced using the WPS is of GOOD QUALITY. IT is intended to prove weldablity of the base metal, tiller metal and welding process

(SMAW, GTAW eet.) combination.3. WPQ = Welder Performance Qualification, as the name suggests it is the qualification of thewelder to give GOOD/Sound WELD.

FOR Production purpose on the shop floor or weld site or welder WPS is required to beavailable, PQR is not required or given to shop floor or weld site or welder.

FOR TIlE PURPOSE OF THE EXAM YOU HAVE TO FOCUS ONLY ON 'SMAW, GTAW,GMAW, SAW' PROCESS, AS SUCH YOU NEED NOT READ THE SECTION IXCOMPLETELY,JUST FOCUS ON WHAT, IS SENT TO YOU.ALSO PULL OUT THE 'WELD ROAD MAP' FLOW CHART I SENT YOU EARLIER, THATONE IS THE KEY , WRITE DOWN THAT FLOW CHART SOME WHERE IN SECTION IXPREFEREABLY NEAR THE TABLE QW 253 , OR QW 254 OR QW 255 OR QW 256 Theseare the tables you need for the exam. These tables give you in tabular form and in simpler way, whatis written in the standard in ENGLISH, so don't read the ENGLISH understand the table. NOTREQUIRED TO REMEMVER BY HEART.

So let us start.

Although WPS is written before the POR is done, its approval and authorization is done onlv afterPOR is completed, that is why the Date Of Approval Or Authorization On The WPS Will Always BeAfter The PQR Dates.

Before you start 1 ust tell you the definition of the VERlABLE, as you will come across termsESSENTIAL VERlABLE, NON ESSENTIAL VARiABLE, SUPPLIMENTAL VARlABLE

ESSENTIAL VARIALBLE :- is dimension or a property or an method, which i(changed will have animpact on the property of the weld and any change in these require a WPS MUST BE REVISEDANDRE-QUAliFIED Wl11l NEW PQR OR SUPPORTED BY AN EXISTING VALID PQR

NON ESSENTIAL VARIABLE:- as the word states it is a non-essential part, which ifchanged doesnot require to have a REQUALIFICATION OF WPS. but needs a mandatory Revision

SUPPLIMENTARY ESSENTIAL VARlABLE:- Whe!l NOTCH- TOUGHNES is required by the codeEITHER AMSE OR API 510, these become ADDITIONAL ESSENTIAL VARIABLES, AND WILLFOLLOW THE RULES OF ESSENTIAL VARIABLE FOR ANY CHANGES. (In short if notch-toughness is not required by the code these have no effect and can be treated as non-essential)

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BASICS BEFORE YOU START WELDING OR STRIKE AN ARC

If you get bored read quickly and move to the next section

1. Prepare WPS , in which SPECIFY Variable ranges(tolarence) , Essential variables, Nonessential variables2. Perform PQR, in which RECORD, Actual Variables, Essential Variables, Test and Results

3. Perform WPQ, in which RECORD, Variables, Specify Ranges, Qualified.Example for above

Step I :- Welding shall me made using the directions of WPS. EACH contractor shall preparehis own WPS to cover EACH application of Welding , QW 250 (start QW 251 to QW 264), giveyou all the ESSENTIAL, NON ESSENTIAL , and any SUPPLIMENTAL VARIABLES forEACH OF THE PROCESS , (UNDERSTAND only the tables, HERE on the side of anyone table

WRITE DOWN THE ' ROAD MAP for the WELD SPECIFICTION SENT TO YOU BY MEEARLIER)

for our EXAM focus only on the process required in the BODY of KNOWLEDGE ,

Step 2:- QW 250 and its sub -sections till QW 264 lists the variables for Qualifying a WPS foreach Welding process. USER must supervise the welding of a test coupon following thevariables of a WPS. USER must RECORD All the Variables, TESTS, and TEST RESULTS on aPQRFORM.EACH WPS MUST BE SUPPORTED BY AN INDEPENTENT PQR.

Step 3 :- WPQ QW - 350 lists variables for qualifying the welders m for each process, Weldersget qualified using TEST Coupons which follow the directions of WPS . USER must RECORD Allthe Variables, TESTS, and TEST RESULTS on a WPQ FORM.Step 4:- USER is defmed as Manufactures, contractor, assembler, or installer, the ownerluser or the Repair ffrm responsible for controlling the welding , on the pressure retainingitems. VERY IMPORTANT to Remember that CODE DEMANDS EACH USER has hisown independent WPS, PQR,

That means WPS from Bectel cannot be used by OXY , if oxy if responsible for welding, OROXY WPS cannot be used by OXY sub-contractor, (remember this statement for EXAMpurpose, real life situation can be different)

Step 5:- USER must describe on an WPS the details to control how each weld is to be made , TheWPS shall specify an allowable RANGE for each variable. THIS WPS shall be used to providedirection/guidance to WELDER

Step 6 :- USER may perform the test himself or subcontract it to a testing lab, howere USER has toCERTIFY THE PQR in EACH case there by accepting the RESPONSIBILITY for the RESULTSof the TESTS.


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Step 7 :- Test coupon shall be mechanically Tested or examined by Radiograph, Tests may besubcontracted, but WPQ must be CERTIFIED by the USER.

USER TO maintain EACH welders Qualification using a RECORD which verifies the welder hasused the process every SIX months.

Step 8 :- AUTHORISED INSPECTOR (here in this case either API or ASME certified) shallverify that each WPS is supported by valid PQR Records and is Properly prepared and isValid according to section IX. Or api 510Authorized inspector to document his concurrence prior to the start of any new construction orrepairs by welding on Pressure retaining item.


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U R NOT REomRED TO READ THE WHOLE SECTION IX, focus on following

READ andlor understand following in Section IX (to start FIRST bighUght what is stated belowand then start reading/understanding)

1. QW 100.1 Full every line read and understand.2. QW 100.2 Full every line read and understand.3. QW 100.3 Full every line read and understand.4. QW 142 Full every line read and understand.5. QW 151.1 sub section 'c' and'd'6. QW 153.1 sub section 'd' ,7. QW 161.2 first sentence of para8. QW 161.3 first sentence of para.9. QW 161.5 full section10. QW 161.6 first sentence11. QW 161.7 first sentence

12. QW 163 second para full13. QW 171 remember the standard ref to SA 370 for Charpy V notch test14. QW 172 remember the standard refto ASTM E 208 for notch test by Drop Weight15. QW 183 last para16. QW 191.2.1 full understand the liner and rounded indication definition17. QW 191.2.2 Understand that this is the specification for Welder Performance test

Radiograpy and how will you accept the radiographs to qualify the welder.18. QW 200.1 full understand, remember sub section 'e'19. QW 200.2 sub section 'a' and subsection 'b' and first two sentences and last sentence of

subsection 'c', and sub section 'e' and sub section 'f'20. QW 200.3 understand the definition of P numbers in the first two sentences of para,

remember the 1 sentence of 2 nd para.21. QW 203 understand first sentence, PROCEDURE QUALIFICATION in ANY positon

qualify for ALL position , except if Procedure requires impact testing then it is aESSENTIAL VARIABLE

22. QW 210 remember that PQR made on Plate can be qualified for PIPE23. QW 211 fullpara24. QW 253 Table not required to remember just remember where to locate25. QW 254 Same as Above26. QW 255 Same as Above27. QW 256 Same as Above28. QW 300.1 full para , but last sententence is of importance.29. QW 301.1 full para30. QW 302.1 first sentence31. QW 302.2 full para32. QW 302.3 full para33. QW 303 you will have to read QW 461 for this34. QW 304 second statement starting 'Alternatively, welders may be tested35. QW 322.1 sub section 'a' and 'b'36. QW 322.2 sub section 'a first sentence37. QW 353 ,354,356, are tables for variables for welder qualifcaiton understand them do not

Remember.


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38. QW 409.1 remember the formula for heat input39. QW 416 Understand the table but not required to be remembered.40. QW 420.1 second sentence starting' these assignment are based on ' here go the the body of

knowledge and you will see that it restricts to P 1 to P11 and P 5A and 5B & 5C you have tolink this to API 510 requiremnts for welding, understanding to requirements of welding in

API 510 is VERY IMPORTANT.41. QW/QB 422 Develop ability to quickly trace the minimum Specified Tensile Ksi ,P No ,

Group No., S No. Based on SPEC No. Any time in exam you have question linked to thewelding first check the P no and S no of the metal from this table and then apply therequirements of API 510 VERY IMPORTANT. (it has been found that they select verypeculiar metal SPEC NO, which we feel is normal but according to API 510 might needNOTCH TEST, and hence will require to have SUPPLIMENTRY ESSENTIALVARIALBES CONVERTED TO ESSSENTIAL VARIABLES plus some other additionalrequiremtns )

42. QW 423.1 understand the requirement43. QW 431 understand! remember the definition ofF numbers from the 1 st para

44. QW 432 understand the table and remember to check in case of any doubt.45. QW 441 understand the A numbers46. QW 451 UNDERSTAND AND REMEMBER THE TABLE That it is (APPLICABLE TO

PROCEDURE QUALIFICATION (write this on the comer of the page)47. QW 452.1(a) Understand this table for TEST SPECIMENNS remember that it is applicable

for WELDER QUALIFICATION, (write this on the comer of the page)48. QW 452.1 (B) Understand this table for WELD METAL QUALIFCATION remember that it

is applicable for WELDER QUALIFICATION, (write this on the comer of the page)49. QW 461.9 Position and diameter table VERY IMPORTANT,50. QW 462.2 Remember the dimension of the test specimen 3/8" is taken as 10 mm51. QW 463 remember the way specimens are cut for test. Procedure Qualification52. QW 463.1 & 2 Same as above53. QW 463.1 (f) Remember the location for Notch toughness specimen for Procedure

Qualification

ONCE YOU HIGHLIGHT THE REQUIRMENTS YOU WILL SEE THAT VERY LITLIE ISLEFT FOR STUDY.

FINALLY VERY IMPORTANT TO REMEMBER THAT ANY REQIDREMTNS OF API510 ON WELDING WILL SUPERCEEDI OVER RULE THE ASME REQUIREMNETSFOR THE PURPOSE OF EXAM AND IN REAL LIFE INSPECTION AS WELL SOJUST MAKE IS SURE THAT YOU HAVE UNDERSTOOD THE API 510 WELDINGREQUIREMENTS.

If yon have any questions once you read write back to me

I HAVE DRAWN THESE NOTES FROM MY NOTES AND HIGHLIGHTS FOR STUDY. SOMAY GOD ASSIST YOU NOW.

aws cwi exam guide

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