API 510 Course
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(Calculations– InternalandExternalInspectionIntervals)
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Able to calculate;
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H ,QVSHFWLRQ,QWHUYDO $3,6HFWLRQ
NOTE: These calculations can be open and/or closed book exams.
II. Joint Efficiencies
Determine;
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3
API510Ͳ Calculations
ShortTermCorrosionRate
LongTermCorrosionRate
tprevious Ͳ tactual
CRST = #ofyearsbetweentprevious &tactual
Remaining Life
tactual
RL =
Section7,par
7.1.1
tinitial Ͳ tactual
CRLT = #ofyearsbetweentprevious &tactual
InternalInspectionInterval
,QWHUYDO=
Ͳ trequired
/HVVHU RIòRI5/RU \HDUV
CorrosionͲRate
ExternalInspectionInterval
RequiredThickness
W=
Minimum
Thickness
35
> 6( 3 @
,QWHUYDO=
/HVVHU RI\HDUVRU,QWHUQDO,QWHUYDO
InternalorOnstream Interval
Ͳ Lesserof10yrs or½Remaininglife
WP =
WF
Ͳ ifremaininglifeislessthan4yrs,fulllife
upto2years
Ͳ Remaininglifeis2yearsorless,interval
isFULLLIFE
&RUURVLRQ5DWH&DOFXODWLRQV
‡
&RUURVLRQUDWHHTXDWLRQV
ShortTermCorrosionRate
CRST =
tprevious Ͳ tactual_LAST
#ofyearsbetweentprevious &tactual_LAST
LongTermCorrosionRate
tinitial Ͳ tactual_LAST
CRLT = #ofyearsbetweentInitial &tactual_LAST
Variables forThicknessCalcs
‡
WLQLWLDO
WDFWXDO
DFWXDO RU/$67 WKLFNQHVVPHDVXUHG
WSUHYLRXV
WKLFNQHVVUHFRUGHGGXULQJSUHYLRXVLQVSHFWLRQV
WUHTXLUHG
WKLFNQHVVUHTXLUHGIRULQWHUQDOSUHVVXUHDVFDOFXODWHGE\GHVLJQ
IRUPXODV EHIRUHFRUURVLRQDOORZDQFHDQGPDQXIDFWXUHU
WROHUDQFHVDUHDGGHG
<HDUV
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WKLFNQHVVDWLQLWLDOLQVWDOODWLRQ RUEHJLQQLQJRIDQHZFRUURVLRQ
UDWHHQYLURQPHQW
127( /7DQG67FRUURVLRQUDWHVPXVWEHFRPSDUHGWRVHHZKLFKUDWHUHVXOWVLQVKRUWHVWUHPDLQLQJOLIH
5
8QLIRUP&RUURVLRQ
6
8QLIRUP&RUURVLRQ
7
3LWWLQJ&RUURVLRQ
8
3LWWLQJ&RUURVLRQ
9
3LWWLQJ&RUURVLRQ
10
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Section7,par
7.1.1
6KRUWWHUPFRUURVLRQUDWH
CorrosionͲrate
=
tprevious Ͳ tlast
#ofyearsbetweentprevious&tlast
/RQJWHUPFRUURVLRQUDWH
/RQJ7HUP
=
&RUURVLRQUDWH
tinitial Ͳ tlast
#ofyearsbetweentinitial &tlast
11
&RUURVLRQ5DWH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
Section7,par
7.1.1
‡ $YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDV´DQG)XOO57ZDV
SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV´ /DVWPHDVXUHGWKLFNQHVVWDNHQ\HDUV
DJRLQGLFDWHGDUHPDLQLQJWKLFNQHVVRI´:KDWLV6KRUW7HUPFRUURVLRQUDWH"
12
&RUURVLRQ5DWH&DOFXODWLRQV
Section7,par
7.1.1
3UDFWLFH4XHVWLRQ
‡ $YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDV´DQG)XOO57ZDV
SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV´ /DVWPHDVXUHGWKLFNQHVVWDNHQ\HDUV
DJRLQGLFDWHGDUHPDLQLQJWKLFNQHVVRI´:KDWLV6KRUW7HUPFRUURVLRQUDWH"
&DOFXODWH6KRUWWHUPFRUURVLRQUDWH
:KDWLV.QRZQ"
CorrosionͲrate
=
tprevious Ͳ tlast
tprevious = 0.875
#ofyearsbetweentprevious&tlast
tlast = 0.865
=
0.875 Ͳ 0.865
5
= 0.002 inch/yr
+RZPDQ\\HDUVEHWZHHQUHDGLQJV"
3UHYLRXVUHDGLQJLVWKH25,*,1$/WKLFNQHVV LH
=(52\HDUVRIVHUYLFH
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&RUURVLRQ5DWH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
‡ $YHVVHOKDVEHHQLQVHUYLFHIRU\HDUVDQGWKHFXUUHQWWKLFNQHVVRIWKHVKHOOLV´,QVSHFWLRQ
UHFRUGVLQGLFDWHGDQRULJLQDOWKLFNQHVVRI´:KDWLVFRUURVLRQUDWH"
14
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3UDFWLFH4XHVWLRQ
‡ $YHVVHOZDVSODFHGLQVHUYLFHLQ,QLWLDOWKLFNQHVVPHDVXUHPHQWWDNHQEHIRUHWKHYHVVHOZDV
SODFHGLQWRVHUYLFHLQGLFDWHGDVKHOOWKLFNQHVVRILQFK PP 7KLFNQHVVPHDVXUHPHQWV
WDNHQLQLQGLFDWHGDVKHOOWKLFNQHVVLQFK PP 7KHUHTXLUHGWKLFNQHVVRIWKHVKHOOLV
LQFK PP 7KHPRVWUHFHQWWKLFNQHVVPHDVXUHPHQWIRUWKHVKHOOZDVWDNHQLQDQG
LQGLFDWHGDUHPDLQLQJWKLFNQHVVRILQFK PP :KDWLVFRUURVLRQUDWH"
&RUURVLRQ5DWH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
‡ ,QVSHFWLRQUHFRUGVFRQWDLQWKHIROORZLQJLQIRUPDWLRQIRUDSDUWLFXODUFRQGLWLRQ
PRQLWRULQJORFDWLRQ
Thickness
LQFK PP
LQFK PP
LQFK PP
Yearsofservice
1HZ &XUUHQW
‡ :KDWLVWKHFRUURVLRQUDWHIRUWKLVFRQGLWLRQPRQLWRULQJORFDWLRQ"
&RUURVLRQ5DWH&DOFXODWLRQV
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‡ $IWHU\HDUVRIEHLQJLQVHUYLFHDYHVVHOLVLQVSHFWHGDQGWKHWKLQQHVWVKHOOVHFWLRQLVIRXQGWREH
LQFK PP ,IWKHRULJLQDOWKLFNQHVVZDVDQGWKHUHTXLUHGWKLFNQHVVLVLQFK
PP ZKDWWKLFNQHVVRIPDWHULDOLVDYDLODEOHIRUFRUURVLRQDOORZDQFH"
&RUURVLRQ5DWH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
‡ $YHVVHOZDVSODFHGLQVHUYLFHLQ,QLWLDOWKLFNQHVVPHDVXUHPHQWWDNHQEHIRUHWKHYHVVHOZDV
SODFHGLQWRVHUYLFHLQGLFDWHGDVKHOOWKLFNQHVVRILQFK PP 7KLFNQHVVPHDVXUHPHQWV
WDNHQLQLQGLFDWHGDVKHOOWKLFNQHVVLQFK PP 7KHUHTXLUHGWKLFNQHVVRIWKHVKHOOLV
LQFK PP 7KHPRVWUHFHQWWKLFNQHVVPHDVXUHPHQWIRUWKHVKHOOZDVWDNHQLQDQG
LQGLFDWHGDUHPDLQLQJWKLFNQHVVRILQFK PP :KDWLVFRUURVLRQUDWH"
&RUURVLRQUDWH'HWHUPLQDWLRQ
‡ Determined by SHORT term or Long Term Calculations
(API 510, par 7.1.1.2)
‡ Newly installed or Change in Service (API 510, par 7.1.2)
1.
2.
3.
4.
Calculated from data of vessels in similar service.
Estimated from Owner-User experience
Published Data
On-stream determination after 1000 hrs of service.
‡ May have different corrosion-rates for large vessels with
multiple zones. (API 510, par 6.5.3)
19
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LQFUHDVH
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&8,7HPSHUDWXUH5DQJHIRU6WDLQOHVV6WHHO
7HPSHUDWXUHWKDWVSHFLDOSURFHGXUHVDUHQHHGHGIRU87
WKLFNQHVVUHDGLQJV
7KHUPDOIDWLJXHPD\EHVXVSHFWHGLIWKHWHPSHUDWXUHVZLQJV
:KDWLVWKHPLQLPXPSUHKHDWWHPSHUDWXUHIRUXVLQJSUHKHDWLQ
OLHXRI3:+7
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3:+7LQOLHXRIDIXOOHQFLUFOHPHQW3:+7
$WZKDWWHPSHUDWXUHGRHV6XOILGDWLRQEHJLQRQ&DUERQ6WHHO
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5HPDLQLQJ/LIH&DOFXODWLRQV
‡ 5HPDLQLQJ/LIHHTXDWLRQ
Section7,par
7.2.1
Remaining Life
RL =
tactual_Last
Ͳ trequired
CorrosionͲRate
Variables forRemainingLifeCalcs
WDFWXDO
WUHTXLUHG
DFWXDO RU/$67 WKLFNQHVVPHDVXUHG
WKLFNQHVVUHTXLUHGIRULQWHUQDOSUHVVXUHDVFDOFXODWHGE\GHVLJQ
IRUPXODV EHIRUHFRUURVLRQDOORZDQFHDQGPDQXIDFWXUHU
WROHUDQFHVDUHDGGHG F &RUURVLRQ5DWH
127( &RUURVLRQUDWHLVWKH UDWH LH6KRUWRU/RQJWHUPUDWH ZKLFKUHVXOWV
LQVKRUWHVWUHPDLQLQJOLIH
24
5HPDLQLQJ/LIH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
Section7,par
7.2.1
‡ $YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDV´DQG)XOO57ZDV
SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV´&XUUHQWPHDVXUHGWKLFNQHVVLQGLFDWHV
DUHPDLQLQJWKLFNQHVVRI´:KDWLV5HPDLQLQJOLIH"
25
5HPDLQLQJ/LIH&DOFXODWLRQV
Section7,par
7.2.1
3UDFWLFH4XHVWLRQ
‡ $YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDV´DQG)XOO57ZDV
SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV´&XUUHQWPHDVXUHGWKLFNQHVVLQGLFDWHV
DUHPDLQLQJWKLFNQHVVRI´:KDWLV5HPDLQLQJOLIH"
/RRNLQJDWWKHIRUPXODIRU³5HPDLQLQJ/LIH´ZKDWLV81.2:1"
5HPDLQLQJ/LIH =
Ͳ trequired
tlast
CorrosionͲrate
:KDWLV.QRZQ"
tprevious
0.625
tlast
0.600
8QNQRZQ"
CorrosionͲrate = ?????
Sincethe“CORROSIONͲRATEisunknown,the1st Stepistodeterminethe
CorrosionͲrate.
26
5HPDLQLQJ/LIH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
‡ $YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDV´DQG)XOO57ZDV
SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV´&XUUHQWPHDVXUHGWKLFNQHVVLQGLFDWHV
DUHPDLQLQJWKLFNQHVVRI´:KDWLV5HPDLQLQJOLIH"
Ͳ trequired
tlast
CorrosionͲrate
5HPDLQLQJ/LIH =
:KDWLV.QRZQ"
6WHS± &DOFXODWHWKH&25526,215$7(
&RUURVLRQUDWH
=
=
tprevious Ͳ tlast
#ofyearsbetweentprevious&tlast
tprevious
0.625
tlast
0.600
0.625 Ͳ 0.600
8
RI\HDUVEHWZHHQ
3UHYLRXVDQG/DVW
\HDUV
= 0.003
27
5HPDLQLQJ/LIH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
6WHS± &DOFXODWHWKH5(0$,1,1*/,)(
5HPDLQLQJ/LIH
=
tlast
Ͳ trequired
:KDWLV.QRZQ"
CorrosionͲrate
trequired = 0.575
=
=
0.600 Ͳ 0.575
0.003
8 yrs
tlast = 0.600
CorrosionͲrate = 0.003
28
5HPDLQLQJ/LIH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
‡ $YHVVHOKDVDVLQJOHFRUURVLRQUDWHRI´SHU\HDU PP\U 7KHUHTXLUHGWKLFNQHVVIRUWKH
VKHOODQGKHDGVLVLQFK PP 7KHDFWXDOWKLFNQHVVRIWKHKHDGLVLQFKDQGVKHOOLV
LQFK:KDWLVWKHUHPDLQLQJOLIHRIWKHYHVVHO"
29
5HPDLQLQJ/LIH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
‡ $YHVVHOZDVSODFHGLQVHUYLFHLQ,QLWLDOWKLFNQHVVPHDVXUHPHQWWDNHQEHIRUHWKHYHVVHOZDV
SODFHGLQWRVHUYLFHLQGLFDWHGDVKHOOWKLFNQHVVRILQFK PP 7KLFNQHVVPHDVXUHPHQWV
WDNHQLQLQGLFDWHGDVKHOOWKLFNQHVVLQFK PP 7KHUHTXLUHGWKLFNQHVVRIWKHVKHOOLV
LQFK PP 7KHPRVWUHFHQWWKLFNQHVVPHDVXUHPHQWIRUWKHVKHOOZDVWDNHQLQDQG
LQGLFDWHGDUHPDLQLQJWKLFNQHVVRILQFK PP :KDWLVUHPDLQLQJOLIH"
,QVSHFWLRQ,QWHUYDOVDQG1H[W,QVSHFWLRQ'DWH
‡ ,QWHUQDO,QVSHFWLRQ,QWHUYDOV(API 510 par 6.5.1.1)
Section6,par
6.5.1v
‡ Internal or on-stream inspections shall not exceed one half the remaining life of the
vessel or 10 years, whichever is less.
‡ Whenever the remaining life is less than four years, the inspection interval may be the
full remaining life up to a maximum of two years.
‡ ([WHUQDO,QVSHFWLRQ,QWHUYDOV(API 510 par 6.5.1.1)
‡ Interval not exceed the lesser of 5 years or the internal/on-stream interval..
‡ ThicknessInspectionIntervals
‡ Should be part of the inspection plan, but no interval requirements mentioned in API510 (API 510 par 5.5.1)
‡ CUIInspectionIntervals
Section5,par
5.5.1
‡ Should be part of the inspection plan, but no interval requirements mentioned in API510 (API 510 par 5.5.1)
‡ “SHALL” be considered for insulated vessels in “intermittent” service or operates
between;
‡
‡
10oF and 350oF for carbon steel and alloy steels
140oF and 400oF for austenitic stainless steels
31
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3UDFWLFH4XHVWLRQ
Section6,par
6.5.1v
‡ $YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDV´DQG)XOO57ZDV
SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV´&XUUHQWPHDVXUHGWKLFNQHVVLQGLFDWHV
DUHPDLQLQJWKLFNQHVVRI´:KDWLV,QWHUQDO,QVSHFWLRQ,QWHUYDO"
32
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3UDFWLFH4XHVWLRQ
‡ $YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDV´DQG)XOO57ZDV
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:KDWLV.QRZQ"
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5HPDLQLQJ/LIH =
Ͳ trequired
tlast
CorrosionͲrate
tprevious
0.625
tlast
0.600
Section7,par
7.2.1
8QNQRZQ"
CorrosionͲrate = ?????
Sincethe“CORROSIONͲRATEisunknown,the1st Stepistodeterminethe
CorrosionͲrate.
33
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‡ $YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDV´DQG)XOO57ZDV
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DUHPDLQLQJWKLFNQHVVRI´:KDWLV5HPDLQLQJOLIH"
Ͳ trequired
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=
=
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#ofyearsbetweentprevious&tlast
tprevious
0.625
tlast
0.600
0.625 Ͳ 0.600
= 0.003
8
Section7,par
7.1.1
RI\HDUVEHWZHHQ
3UHYLRXVDQG/DVW
\HDUV
34
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Section7,par
7.2.1
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=
tlast
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CorrosionͲrate
trequired = 0.575
=
=
0.600 Ͳ 0.575
0.003
8 yrs
tlast = 0.600
CorrosionͲrate = 0.003
35
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3UDFWLFH4XHVWLRQ
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OHVVHU\HDUVRU\HDUV \HDUV
InternalInspectionInterval=4years
36
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‡ $YHVVHOKDVDVLQJOHFRUURVLRQUDWHRI´SHU\HDU PP\U 7KHUHTXLUHGWKLFNQHVVIRUWKH
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37
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‡ 3UDFWLFH4XHVWLRQ
Section6,par
6.4.1
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7KLFNQHVVUHDGLQJVWDNHQSULRUWRSODFLQJWKLVYHVVHOLQVHUYLFHLQGLFDWHGDWKLFNQHVVRI´
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HEAD
BANGER
Whatisthetemperaturerangethattemperembrittlementoccurs
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43
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$3,3DUDDQG
3UDFWLFH4XHVWLRQ
:KDWLVWKH1H[W,QWHUQDO,QVSHFWLRQGDWH ZLWKWKHIROORZLQJ
LQIRUPDWLRQ"
Remaining
Life(yr)
March2000
March 1995
16
.324
.356
44
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$3,3DUD
‡ Widely scattered pits can be ignored, if;
Section7,par
7.4.3
Rule#1
Remaining Thickness below pit is
greater than ½ the Required Thickness
Vessel Thickness
= 2.0”
Depth of Pit
= 1.06”
Corrosion Allowance = 0.250
Retirement Thickness = 1.75”
45
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$3,3DUD
‡ Widely scattered pits can be ignored, if;
Section7,par
7.4.3
Rule#2
Areaofthepittingbelowthe
corrosionallowancehasan
arealessthan7in2withinan
8”diametercircle.
46
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$3,3DUD
‡ Widely scattered pits can be ignored, if;
Section7,par
7.4.3
Rule#3
Sumofthelengthofpitswithinany8”line,mustbelessthan2”
47
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3UDFWLFH4XHVWLRQ
Section7,par
7.4.3
‡ $UHFHQWLQVSHFWLRQGLVFRYHUHGLVRODWHGSLWWLQJLQWKHYHVVHOZDOO0LQLPXPUHTXLUHGZDOO
WKLFNQHVVLV´&XUUHQWWKLFNQHVVRIWKHYHVVHOLV´ :KDWLVWKHPLQLPXP
DOORZHGUHPDLQLQJWKLFNQHVVDOORZHGDWWKHGHHSHVWSLW"
48
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Section7,par
7.4.3
3UDFWLFH4XHVWLRQ
‡ $UHFHQWLQVSHFWLRQGLVFRYHUHGLVRODWHGSLWWLQJLQWKHYHVVHOZDOO0LQLPXPUHTXLUHGZDOO
WKLFNQHVVLV´&XUUHQWWKLFNQHVVRIWKHYHVVHOLV´ :KDWLVWKHPLQLPXP
DOORZHGUHPDLQLQJWKLFNQHVVDOORZHGDWWKHGHHSHVWSLW"
“Minimum allowed remaining thickness below the pit is ½ the required thickness”,
Therefore, the minimum thickness allowed at the deepest pit is;
( ½ required thickness = 1.250”/2 = 0.625”)
Corrosionallowance
Required
Thickness
Remainingthickness
belowpit
½
ofRequired
Thickness
49
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3UDFWLFH4XHVWLRQ
Section7,par
7.4.3
‡ 'XULQJDUHFHQWLQWHUQDOLQVSHFWLRQRID´,'YHVVHOZLWK´ZDOOWKLFNQHVVWKUHH
LVRODWHGSLWVZHUHGLVFRYHUHG7KHSLWVDUHZLWKLQD´GLDPHWHUFLUFOHZLWKWKHVXPRI
WKHLUGLPHQVLRQVDORQJDVWUDLJKWOLQHLV´9HVVHOKDVDUHTXLUHGWKLFNQHVVLV´
DQGFRUURVLRQDOORZDQFHRI´'LPHQVLRQVRIWKHSLWVDUHDVIROORZV
3LW± ´[´[´GHHS
3LW ´[[´GHHS
3LW ´[´[´GHHS
:KLFKRIWKHIROORZLQJLVWUXH"
a.
b.
c.
d.
Pitscanbeignored
Pitsareunacceptablebasedonsumofthepitdimensionsalonga8”straightline.
Pitsareunacceptableduetototalareaofpittingwithinan8”diametercircle.
Pitsareunacceptableduetoinsufficientremainingthicknessbelowthedeepestpit.
(YDOXDWLRQRI3LWWLQJ
3UDFWLFH4XHVWLRQ
Section7,par
7.4.3
‡ 'XULQJDUHFHQWLQWHUQDOLQVSHFWLRQRID´,'YHVVHOZLWK´ZDOOWKLFNQHVVWKUHH
LVRODWHGSLWVZHUHGLVFRYHUHG7KHSLWVDUHZLWKLQD´GLDPHWHUFLUFOH/HQJWKRIWKHSLWV
GLPHQVLRQVDORQJDVWUDLJKWOLQHLV´´DQG´9HVVHOKDVDUHTXLUHG
WKLFNQHVVLV´DQGFRUURVLRQDOORZDQFHRI´&DQWKHVHSLWVEHLJQRUHG",IQRW
ZK\QRW"'LPHQVLRQVRIWKHSLWVDUHDVIROORZV
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Section5,par
5.1
A. Inspection plan must be established for all
pressure vessels and pressure-relieving devices.
B. Inspection plan developed by inspector or
engineer.
C. Corrosion-specialist must be consulted for
inspection plan for vessels operating above 750oF.
D. Inspection plan shall be evaluated based on
present or possible types of damage mechanisms.
E. Methods and extent of NDE shall be evaluated to
assure they can adequately identify the damage
mechanism and severity of damage.
59
,QVSHFWLRQ3ODQV
Section5,par
5.1
F. Examinations must be scheduled at intervals that consider;
A. Type of damage
B. Rate of damage
C. Tolerance of equipment to the damage
D. Probability of the NDE methods to detect the damage
E. Maximum intervals as defined in API 510
G. Minimum Contents of Inspection Plan
A. Type of inspection needed
B. Next inspection date for each type inspection (internal,
external, etc)
C. Describe inspection and NDE techniques
D. Describe extent and locations of inspection and NDE
E. Describe the cleaning requirements
F. Describe the requirements of any needed pressure test
G. Describe any required repairs
60
7\SHVRI,QVSHFWLRQ
Section5
A. General
‡ Inspections should be conducted in accordance with the inspection
plan
‡ Prior to performing an inspection, the inspector should be familiar
with;
‡ Thorough understanding of the inspection plan
‡ Operating conditions since the last inspection (API 572 par 9.1)
‡ Applicable damage mechanisms
‡ Prior history
‡ New inspection intervals shall be established if operating temp
increases, operating pressure increases or process fluid changes.
(API
510 par. 6.2.2)
61
7\SHVRI,QVSHFWLRQ
% ,QWHUQDO,QVSHFWLRQ
‡ Interval is lesser of ½ remaining life or 10 years. If remaining life is LESS than 4
years, interval can be the full remaining life up to max of 2 years. (API 510 par 6.5.1.1).
‡ SHALL be conducted by the inspector (API 510 par 5.5.2.1)
‡ Primary reason for internal inspection is to find damage that cannot be found by
external CML’s (API 510 par 5.5.2.1)
‡ Internal inspection performed inside the vessel (API 510 par 5.5.2.1)
‡ Internals may need to be removed to facilitate the internal inspection. Likely will
not need to remove 100% of the internals. (API 510 par 5.5.2.2)
‡ Inspector should consult with Corrosion Specialist to determine if it is necessary
to remove any linings and/or deposits (API 510 par 5.5.2.3)
‡ Vessels in non-continuous service, the interval is based on number of years of
actual service, instead of calendar years, provided the vessel when idled is
separated from process stream & not exposed to corrosive streams.
62
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$3,SDUSDJH
C. On-stream Inspection
‡ Interval same as INTERNAL inspection.
‡ Should be conducted by either an inspector or examiner. (API 510 par
5.5.3.1)
‡ On-stream inspections performed by examiners shall be
authorized/approved by the inspector (API 510 par 5.5.3.1)
‡ Inside of vessel inspected from outside vessel. (API 510 par 5.5.3.2)
63
7\SHVRI,QVSHFWLRQ
$3,SDUSDJH
D. External Inspection
‡ Performed by inspector or qualified others (qualified
with appropriate training). (API 510 par 5.5.4.1.1)
‡ Interval is lesser of 5 years or the internal interval.
‡ External inspections check; (API 510 par 5.5.4.1.2)
‡
‡
‡
‡
‡
‡
‡
‡
‡
Condition of Outside surface of vessel
Condition of Insulation system
Condition of Coating system
Condition of Supports
For leaks
Hot spots
Vibration damage
Allowance for expansion
Bulging, misalignment, distortion, etc
‡ Conditions discovered by others, must be reported to
inspector. (API 510 par 5.5.4.1.3)
64
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$3,SDUSDJH
E. Thickness Inspection
‡ Performed by inspector or examiner. (API 510 par 5.5.5.1)
‡ No required interval.
‡ Inspector should consult with corrosion-specialist when short term
corrosion-rate changes significantly. (API 510 par 5.5.5.3)
‡ Owner-user is responsible for assuring individuals taking thickness
readings are trained and qualified (API 510 par 5.5.5.4)
7\SHVRI,QVSHFWLRQ
$3,SDUSDJH
F. CUI Inspection
‡ Performed by inspector or other qualified personnel (i.e. same as external)
‡ Shall be considered for; (API 510 par 5.5.6.1)
‡ Carbon steel and low alloy operating between 10oF and 350oF.
‡ Stainless steel operating between 140oF and 400oF.
‡ Usually causes localized corrosion damage (API 510 par 5.5.6.2)
‡ Susceptible locations include; (API 510 par 5.5.6.2)
‡ Insulation or stiffening rings
‡ Nozzles and manways
‡ Structural penetrations (ladder clips, pipe supports, etc)
‡ Damage insulation
‡ Insulation with failed caulking
‡ Top and bottom heads
‡ CUI inspection may require some or all insulation (API 510 par 5.5.6.3)
‡ Insulation may not need to be removed if; (API 510 par 5.5.6.3)
‡ Insulation is in good condition and there is no reason to suspect damage behind
the insulation;
‡ CUI inspection can be performed with UT from ID of vessel.
66
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$60(9,,,8: D E
WeldJointCATERGORY isthe”location”ofa“joint”inapressurevessel
SubͲSectionB,
UW,General,
UWͲ3
Category A:
‡ Alllongitudinalweldsinshellandnozzles
‡ Allweldsinheads,HemiͲheadtoshellweldjoint
Category B:
‡ Allcircumferentialweldsinshellandnozzles
‡ Headtoshelljoint(otherthanHemispherical.)
Category C and D are flange welds and nozzle attachment welds respectively
Longitudinal welds (Category A) are more critical than Circumferential welds (Category B)
because they are under double stress.
This the reason why in different part of ASME code we have stringent rules in category A
joint compared to category B joint.
67
:HOG-RLQW7\SHV
SubͲSectionB,
UW,Design,
UWͲ12
‡ Weld Joint Types
‡ 7\SH± 'RXEOHZHOGHGEXWWMRLQWV
‡ 7\SH± 6LQJOHZHOGHGZLWKEDFNLQJ
‡ 7\SH 6LQJOHZHOGHGZLWKRXWEDFNLQJ
68
:HOG-RLQW7\SHV
SubͲSectionB,
UW,Design,
UWͲ12
‡ Weld Joint Types
‡ 7\SH± 'RXEOH)XOO)LOOHW/DS-RLQW
‡ 7\SH± 6LQJOH)XOO)LOOHW/DS-RLQW
ZLWKSOXJZHOG
‡ 7\SH 6LQJOH)XOO)LOOHW/DS-RLQW
ZLWKRXWSOXJZHOG
69
5DGLRJUDSK\
TypeofRadiography
SubͲSectionB,
UW,Design,
UWͲ11
SubͲSectionC,
CCS,Design,
UCSͲ57
‡ Full– asrequiredbytheCode(seeUWͲ11(a)),andUCS57
‡ Spot– CategoryBandCweldsthatarenotrequiredtobe
radiographedbyUWͲ11(a)(5)(b).
‡ None
CodeRequiredRT(UWͲ11(a)andUWͲ11(b)
‡ BasedonService,ThicknessorWeldingProcess
UserSpecifiedRT
‡ Theusercanestablishthetypeofjointanddegreeofexaminationwhen
therulesofCodedoesnotrequireradiography(seeUWͲ12)
70
5DGLRJUDSK\
SubͲSectionB,
UW,Design,
UWͲ11a
‡ FULLRT– RequiredbyCODE
‡ FULLRT
‡ Allbuttweldsinshell&headsinlethalservice
‡ Allbuttweldsinshell&headswiththickness>11/2orperUCSͲ57
‡ Allbuttweldsinshell&headsofunfiredboilerswith;
‡ Pressureexceeding50psigorthickness>11/2orperUCS57
‡ Buttweldsinnozzles>10NPSor>11/8”thickness
‡ Category“A”and“D”weldsinshellsandheads,wherejoint
efficiencyisbasedonTableUWͲ12
‡ ButtweldsmadeusingElectroͲgas&ElectroͲslagprocess
‡ SpotRT
‡ CategoryBandCbuttweldsintersectingCatAweldsinshellsandheads
‡ CategoryBandCbuttweldsconnectingseamlessheadsorshells
127(&DWHJRU\ $ %ZHOGVPXVWEH7\SHRU7\SHZHOGV VHH7DEOH8:
71
5DGLRJUDSK\
When and where is there a code requirement for full radiography?
SubͲSectionB,
UW,Design,
UWͲ11
Item 1: Allbuttweldsinvesselsusedtocontainalethalsubstance(UWͲ11(a)).Lethalsubstanceshavespecific
definitionsinASMECodeinUWͲ2anditistheresponsibilityoftheendusertodetermineiftheyordered
avesselthatcontainslethalsubstances.
Item 2: All butt welds in vessels in which the nominal thickness exceeds specified values (UWͲ11(a). You can find
these values in subsection C, in UCSͲ57. For example, this value for PͲNo.1 in UCSͲ57 is 1 ¼ inch. Nozzles
larger than 10 NPS or thickness greater than 1 1/8”.
SubͲSectionC,
Item 3: All butt welds in an unfired steam boiler with design pressure > 50 psi (UWͲ11(a)).
UCS,Design,
UCSͲ57
Item 4: All category A and D butt welds in vessel when “Full Radiography” optionally selected from table UWͲ
12(column (a) in this table is selected); and categories B and C which intersect Category A shall meet the
spot radiography requirement (UWͲ11(a) (5) (b)).
The point is this: items 1, 2 and 3 are similar, but item 4 is completely different. In items 1, 2 and 3 it is mandated by
code; to do full radiography in all butt welds in vessel so it means it is mandatory for designer to select column (a) in
UWͲ12 table.
But in item 4, there is no mandating rule. A manufacturer with its own decision has chosen to use column (a) in table
UWͲ12 for full radiography.
72
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‡ :KDW LV FRQFHSW EHKLQG WKLV FRQFHVVLRQ RU ERQXV LQ SUHVVXUH YHVVHO 57 WHVW"
a. Items 1, 2 and 3 from the previous slide; RT is related to the type of welds and
services.
b. Pressure vessels in these items are critical from a safety point of view, one
contains a lethal substance, the other one has a high thickness, which
implicates high pressure, and the last one is an unfired steam boiler
c. Item 4 has no criticality like the other items have.
d. But you should note all 4 items have been categorized in full radiography
clause( UͲ11(a)), so to differentiate item 1, 2 and 3 from item 4, the RT
symbols are used in Code (UGͲ116).
73
5DGLRJUDSK\
SubͲSection
A,UG,Design,
UGͲ116
RT1: Items1,2and3,(E=1),AllbuttweldsͲfulllengthradiography
RT2: Item4(E=1),CategoryAandDbuttweldsfulllengthradiography
andcategoryBandCbuttweldsspotRadiography
RT3: (E=0.85),Spotradiographybuttwelds
RT4: (E=0.7),Partial/Noradiography
You need to consider the hemispherical head joint to shell as category A, but ellipsoidal
and torispherical head joint to shell as category B;
Do you know why? Why ASME considered the stringent rule for pressure vessel RT test in
hemispherical head joint?
It is because this joint is more critical, because the thickness obtained from the
formula for hemispherical head approximately would be half of the shell thickness;
It means if the shell thickness is 1 inch, the hemispherical head thickness would be
0.5 inch.
74
5DGLRJUDSK\
SubͲSectionB,
UW,Design,
UWͲ11
‡ SpotRT– RequiredbyCODE
‡ B and C welds that are not required to be radiographed by UW11(a)(5)(b)
‡ Type 1 and Type 2 butt welds that are not required to be
radiographed by UW-11(a).
‡ RTMarkings
‡ RT 1 and RT 2 - FULL Radiography
‡ RT 3
- Spot Radiography
‡ RT 4
- Combo Radiography
SubͲSection
A,UG,Design,
UGͲ116
‡ RTmarkingsarelocatedonNameplate
75
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-RLQW(IILFLHQF\
SubͲSectionB,
UW,Design,
TableUWͲ12
‡ Joint Efficiency is based on;
‡ :HOG-RLQW7\SH 7\SHV
‡ :HOG&DWHJRU\ $%&'EXWPDLQO\RQ$ %
‡ 5DGLRJUDSK\ 575757DQG57
‡ 9HVVHOVZLWKORQJLWXGLQDOVHDPVRUVHDPOHVV
80
5DGLRJUDSK\ -RLQW(IILFLHQF\
SubͲSection
A,UG,Design,
UGͲ116
RTͲ1
E=1
RTͲ2
E=1
E=1
RTͲ3
E=0.85
RTͲ4
E=0.70
E=1
E=0.85
81
-RLQW(IILFLHQF\
‡ JointEfficiencybasedonRadiography
‡ RTͲ1– FullRTperUWͲ11(a),exceptUW(a)(5)
‡ UseColumn“a”ofTableUWͲ12
‡ ForSeamlessheads&shellsE=1
SubͲSection
A,UG,Design,
UGͲ116
SubͲSectionB,
UW,Design,
TableUWͲ12
‡ RTͲ2Ͳ FullRTperUWͲ11(a)(5)
‡ UseColumn“a”ofTableUWͲ12
‡ ForseamlessheadsandshellsE=1
‡ RTͲ3Ͳ SpotradiographyperUWͲ11(b)
‡ UseColumn“b”ofTableUWͲ12
‡ Forseamlessheads&shellsE=1
‡ RTͲ4Ͳ CombinationofRTͲ1,RTͲ2andRTͲ3
‡ NoRTͲ noradiographyatall
‡ UseColumn“c”ofTableUWͲ12
‡ ForseamlessshellsandheadsE=0.85
RTStamping
82
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-RLQW(IILFLHQF\
RT1
or
RT2
RT3
RT4
SubͲSectionB,
UW,Design,
TableUWͲ12
NOTE:ForWeldtypes3,4,5,and6,RTcannotbeusedtoincreasethejointefficiency.
83
-RLQW(IILFLHQF\
Joint Efficiency For Seamless Parts
WeldType
Spot RT
NoRT
1
1.0
0.85
2
1.0
0.85
3
0.85
0.85
4
0.85
0.85
5
0.85
0.85
6
0.85
0.85
SubͲSectionB,
UW,Design,
ParUWͲ
11(a)(5)(a)&(b)
SubͲSectionB,
UW,Design,Par
UWͲ12d
84
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ApressurevesselshellwithTYPE1longitudinalseamsandcircumferentialweldsthat
aresinglefullfilletlapjointswithoutplugwelds.ThevesselisstampedNoRT.What
isthejointefficiencyfor;
‡ Vessel shell
?
‡ A seamless head _________?
SubͲSectionB,UW,
Design,ParUWͲ
11(a)(5)(a)&(b)and
TableUWͲ12
SubͲSectionB,
UW,Design,Par
UWͲ12d
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‡ $ZHOGHGVKHOOBBBBBBBBBB"
‡ $VHDPOHVVKHDGBBBBBBBBB"
SubͲSectionB,UW,
Design,ParUWͲ
11(a)(5)(a)&(b)and
TableUWͲ12
SubͲSectionB,
UW,Design,Par
UWͲ12d
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‡ $VHDPOHVVKHDGBBBBBBBBB"
SubͲSectionB,UW,
Design,ParUWͲ
11(a)(5)(a)&(b)and
TableUWͲ12
SubͲSectionB,
UW,Design,Par
UWͲ12d
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SubͲSectionB,UW,
Design,ParUWͲ
11(a)(5)(a)&(b)and
TableUWͲ12
SubͲSectionB,
UW,Design,Par
UWͲ12d
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SubͲSectionB,UW,
Design,ParUWͲ
11(a)(5)(a)&(b)and
TableUWͲ12
SubͲSectionB,
UW,Design,Par
UWͲ12d
89
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SubͲSectionB,UW,
Design,ParUWͲ
11(a)(5)(a)&(b)and
TableUWͲ12
SubͲSectionB,
UW,Design,Par
UWͲ12d
90
/HVVRQ3ODQ,,
(Calculations– StaticHead,InternalandExternalPressure)
1
/HVVRQ3ODQ,,
(Calculations– StaticHeadandInternalPressure
,
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2
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/HVVRQ3ODQ,,
(Calculations– StaticHeadandInternalPressure
,,,
(;7(51$/35(6685(
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D
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3
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ASMESecVIII,UGͲ98
, 6WDWLF+HDG
D 6WDWLFKHDGSUHVVXUHFRQYHUVLRQIDFWRU SVLIW E .QRZWKHGLIIHUHQFHEHWZHHQYHVVHO0$:3DQGYHVVHOSDUW
0$:3 8* F &DOFXODWHVWDWLFKHDGSUHVVXUHRQDQ\YHVVHOSDUW
G &DOFXODWHWRWDOSUHVVXUH 0$:3VWDWLFKHDG RQDQ\YHVVHO
SDUW
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DQGHOHYDWLRQV
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LIVWDWLFKHDGGDWDLVJLYHQLQWKHH[DPLQDWLRQSUREOHP
4
6WDWLF+HDG
ASMESectionVIII
SubsectionA,UG,
InspectionandTesting,
UGͲ98(a)(b)
, 6WDWLF+HDG
D 6WDWLF+HDG IRRWFROXPQRIZDWHULVHTXDOWRSVLDWWKHERWWRPRI
WKHFROXPQ RIZDWHU,QRWKHUZRUGVWKHZHLJKWRIWKHZDWHU
DSSOLHVDIRUFH OEV SUHVVXUH SVL
1ft
0.433psi
(atbottomofthewatercolumn)
5
6WDWLF+HDG
, 3DUW6WDWLF+HDG
ASMESectionVIII
SubsectionA,UG,
InspectionandTesting,
UGͲ98(a)(b)
ASMESecVIII,UGͲ98
2ft
WhatisMAWPofeachcomponentfora48ft tall
verticalvesselwithellipsoidalheadsandaMAWP
of500psig?
N1
6 ft
44ft
8ft
36ft
VesselMAWP=500psig
VesselMAWPisthegagepressureatthe“TOP”of
thevessel,includingStaticheadpressure.Reference
UGͲ98(a)(b)
N2
2ft
6 ft
MAWPofN1=________
MAWPofN2=_________
MAWPofTophead=_________
MAWPofBtm head=_________
MAWPoftheshell=_________
6
6WDWLF+HDG
, 3DUW6WDWLF+HDG
ASMESectionVIII
SubsectionA,UG,
InspectionandTesting,
UGͲ98(a)(b)
ASMESecVIII,UGͲ98
2ft
WhatisMAWPofeachcomponentfora48ft tall
verticalvesselwithellipsoidalheadsandaMAWP
of500psig?
N1
6 ft
44ft
8ft
36ft
VesselMAWP=500psig
VesselMAWPisthegagepressureatthe“TOP”of
thevessel,includingStaticheadpressure.Reference
UGͲ98(a)(b)
N2
2ft
6 ft
500psig+(6x0.433)=500+2.6=502.60psig
MAWPofN1=________
500psig+(42x0.433)=500+18.19=518.19psig
MAWPofN2=_________
500psig+(2x0.433)=500+0.87=500.87psig
MAWPofTophead=_________
500psig+(48x0.433)=500+20.78=520.78psig
MAWPofBtm head=_________
500psig+(46x0.433)=500+19.92=519.92psig
MAWPoftheshell=_________
7
ASMESectionVIII
SubsectionA,UG,
InspectionandTesting,
UGͲ98(a)(b)
ASMESecVIII,UGͲ98
6WDWLF+HDG
, 3DUW6WDWLF+HDG
WhatisMAWPofthisvessel?
Part
Part
MAWP
Top
head
510psig
N1
500psig
N2
495psig
Shell
510psig
Btm
Head
507psig
Static
Head
0ft
2ft
Pressureat
Topof
Vessel
N1
8ft
10ft
N2
42ft
48ft
50ft
8
9HVVHO0$:3YV 3DUW0$:3
ASMESectionVIII
SubsectionA,UG,
InspectionandTesting,
UGͲ98(a)(b)
, 9HVVHO 3DUW0$:3
PracticeQuestion#1
Ifthisvesselisbeinghydrostaticallytestedat200
psig,whatisthepressureatthebottomofthe
vessel?
2ft
6 ft
N1
66ft
8ft
PracticeQuestion#2
IftheMAWPofthevesselis550psig,whatisthe
MAWPofN2?
58ft
N2
6 ft
2ft
PracticeQuestion#3
IftheMAWPoftheshellofthevesselis564psig,
whatistheMAWPofN1?
Usethisvesseltoanswer
thesepracticequestions
9
7RWDO3UHVVXUH
ASMESectionVIII
SubsectionA,UG,
InspectionandTesting,
UGͲ98(a)(b)
, 7RWDO3UHVVXUH
PracticeQuestion#4
2ft
Ifavesselisbeinghydrostaticallytestedat400
psig,whatisthepressureatN2?
6 ft
N1
66ft
8ft
PracticeQuestion#5
58ft
N2
Duringahydrotest ofavessel,ifthepressureatthe
bottomofthevesselis635psig,whatisthe
2ft
pressureatN1?
6 ft
PracticeQuestion#6
Duringahydrotest ofavessel,ifthepressureatN2
is528psig,whatisthepressureatthetopofthe
vessel?
Usethisvesseltoanswer
thesepracticequestions
10
NOTE:PerASMESectionVIII,UGͲ99(c.),thehydrotest pressureisthepressureatthetopofthevessel.
,QWHUQDO3UHVVXUH
ASMESecVIII,UGͲ21andAppendix3(par3Ͳ2)
ASMESectionVIII
SubsectionA,UG,
InspectionandTesting,
UGͲ98(a)(b)
, 'HVLJQ3UHVVXUH
Designpressureisthepressureusedinthedesignofavesselcomponent
togetherwithcoincidenttemperatureforthepurposeofdeterminingthe
minimumpermissiblethicknessforeachcomponent.Designpressure
includesstaticheadpressure.
NOTE:Designpressureistheminimumpressureusedtodesignthevessel(i.e.usedtodeterminethe“required
thickness”ofeachcomponent.
,, 0$:3
Maximumallowableworkingpressure(MAWP)isthemaximumpressure
permissibleatthetopofthevesselinitsnormaloperatingposition.MAWPis
adjustedforthedifferenceinstaticheadthatmayexistbetweenforthepart
consideredandthetopofthevessel.
,,, 'HVLJQ3UHVVXUHYV 0$:3
Designpressureisthepressurefortheprocess(processpressureplus
statichead).MAWPisthemaximumpressureratingforeachpart
and/orvessel.
11
6KHOO0LQLPXP5HTXLUHG7KLFNQHVV
ASMESecVIII,UGͲ27(c.)(1)
, 7KHUHTXLUHGWKLFNQHVVRIDF\OLQGULFDOVKHOO
EDVHGRQFLUFXPIHUHQWLDOVWUHVVJLYHQD
SUHVVXUH 8* F Variables
t=PR/(SE)Ͳ(0.6P)
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ27(c.)(1)
t=requiredthickness
inches
P=DesignPressure
psi
R=InsideRadius ofshell inches
S=AllowableStress
psi
E=JointEfficiency
12
6KHOO0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#7
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ27(c.)(1)
A60’tallverticalvesselhasaninsidediameterof8’anddesignedfor300psig@450deg
F.Allowablestressofthematerialofconstructionis17,500psiandthejointefficiencyis
0.85.Whatistheminimumrequiredthickness?
13
6KHOO0LQLPXP5HTXLUHG7KLFNQHVV
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ27(c.)(1)
PracticeQuestion#7
A60’tallverticalvesselhasaninsidediameterof8’anddesignedfor300psig@450deg
F.Allowablestressofthematerialofconstructionis17,500psiandthejointefficiencyis
0.85.Whatistheminimumrequiredthickness?
t
PR
=
(SE)Ͳ(0.6P)
t
300
=
(
t
17500
x
(
=
48
) Ͳ (
14400
=
t
0.85
x
14875
)
14400
Ͳ
(
180 )
0.6
x
300
)
Variables
t=requiredthickness
inches
P=DesignPressure
psi
R=InsideRadius ofshell inches
S=AllowableStress
psi
E=JointEfficiency
14695
t
=
0.980
inches
14
6KHOO0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#8
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ27(c.)(1)
Avesselhasaninsidediameterof60”anddesignedfor150psig@350deg F.
Allowablestressofthematerialofconstructionis18,000psiandthejoint
efficiencyis1.0Whatistheminimumrequiredthickness?
15
6KHOO0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#9
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ27(c.)(1)
Avesselhasaninsideradiusof48”anddesignedfor250psig@500deg F.
Allowablestressofthematerialofconstructionis17,000psiandthejoint
efficiencyis.90Whatistheminimumrequiredthickness?
16
6SKHUH0LQLPXP5HTXLUHG7KLFNQHVV
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ27(d)
,
7KHUHTXLUHGWKLFNQHVVRID6SKHUHLVJLYHQE\ 8* G PR
t =
(2SE)Ͳ(0.2P)
Variables
inches
t=requiredthickness
P=DesignPressure
psi
R=InsideRadius ofshell inches
psi
S=AllowableStress
E=JointEfficiency
17
6SKHUH0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#10
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ27(d)
Aspherehasaninsideradiusof12ft anddesignedfor250psig@500deg F.
Allowablestressofthematerialofconstructionis17,000psiandtheweldsare
singlebuttweldedwithbackingandvesselisstampedRTͲ2.Whatisthe
minimumrequiredthickness?
18
6SKHUH0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#11
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ27(d)
AspherehasanIDof36ft anddesignedfor30psig@400deg F.Allowable
stressofthematerialofconstructionis15,000psiandthejointefficiencyis0.80
Whatistheminimumrequiredthickness?
19
9HVVHO+HDGV
h=1/4D
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(d)
D=Insidediameter
LongAxis
Ellipsoidalheadsareknownas2to1heads.2to1comes
fromthefactthatanellipsoidalheadis1/2ofaellipse.An
ellipsehasalongaxisthatis2xtheshortaxis.
L=insideradius
Short
Axis
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(f)
D=Insidediameter
20
+HDGV0LQLPXP5HTXLUHG7KLFNQHVV
MinimumRequiredThicknessofanEllipsoidalHead
t =
Px D
2 [( S x E ) Ͳ ( 0.2 X
P
)]
t=minimumrequiredthickness
P=DesignPressure
D=InsideDiameter
S=AllowableStress
E=JointEfficiency
MinimumRequiredThicknessofaHemisphericalHead
t =
P x L
2 [( S x E ) Ͳ ( 0.2 X
P
)]
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(d)
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(f)
t=minimumrequiredthickness
P=DesignPressure
L=InsideRadius
S=AllowableStress
E=JointEfficiency
21
+HDGV0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#12
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(d)
Whatistheminimumrequiredthicknessfortheheadofa30’tallverticalvessel
withellipsoidalheads,insidediameterof72”,allowablestressof16,500psi,
MAWPof120psig,andweldsthataredoubleͲweldedbuttweldsandSpotRT’d?
22
+HDGV0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#13
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(d)
Whatistheminimumrequiredthicknessfortheheadofaseamlesshorizontalvessel
withellipsoidalheads,insidediameterof96”,allowablestressof18,000psi,MAWP
of200psig,andweldsthataredoubleͲfullfilletweldedlapjointsandRTͲ1?
23
+HDGV0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#14
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(f)
Whatistheminimumrequiredthicknessfortheheadofa30’tallverticalvessel
withhemisphericalheads,insidediameterof72”,allowablestressof16,500psi,
MAWPof320psig,andweldsthataredoubleͲweldedbuttweldsandSpotRT’d?
24
+HDGV0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#15
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(f)
Whatistheminimumrequiredthicknessfortheheadsofahorizontalvesselwith
hemisphericalheads,insidediameterof96”,allowablestressof18,000psi,MAWPof
200psig,andweldsthataredoubleͲfullfilletweldedlapjointsandRTͲ1?
25
HEAD
BANGER
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ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(d)
I. MAWPofEllipsoidalHeads
2 SEt
P =
( D + 0.2t)
t=minimumrequiredthickness
D=InsideDiameter
S=AllowableStress
E=JointEfficiency
II. MAWPofHemisphericalHeads
2Set
P =
( L + 0.2t)
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(f)
t=minimumrequiredthickness
L=InsideRadius
S=AllowableStress
E=JointEfficiency
29
0$:3
PracticeQuestion#16
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(d)
Duringaninspectionofaverticalvesselthicknessmeasurementstakenonthebottomellipsoidal
headwasfoundtobe0.785.Theinsidediameterofthevesselis96”,allowablestressis17,000
psi,andweldsthataredoubleweldedbuttweldjointsandthevesselisstampedRTͲ1.Whatis
themaximumallowableworkingpressureforthisseamlessellipsoidalhead?
30
0$:3
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(d)
PracticeQuestion#16
Duringaninspectionofaverticalvesselthicknessmeasurementstakenonthebottomellipsoidal
headwasfoundtobe0.785.Theinsidediameterofthevesselis96”,allowablestressis17,000
psi,andweldsthataredoubleweldedbuttweldjointsandthevesselisstampedRTͲ1.Whatis
themaximumallowableworkingpressureforthisseamlessellipsoidalhead?
P =
P =
P =
2 SEt
( D + 0.2t)
2 ( 17000 x 1 x 0.785 )
( 96 + ( 0.2 x 0.79 )
t=0.785”
D=96”
S=17,000
E=1
2 x 13345
96 + 0.157
P =
26690
96.157
P =
277.57
Note:
Readthequestionclosely,inthisquestionthereisnomention
ifthevesselhaslongseamsornot.Therefore,assumethevessel
haslongseams.YougotoTableUWͲ12andfindthejointefficiency
tobe“1”for“doubleͲweldedbuttwelds”.The“seamless”head,
doesnotchangethejointefficiency.
31
0$:3
PracticeQuestion#17
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(f)
Ahorizontalvesselwithanoutsidediameterof72”andellipsoidalheads.Shellthicknessis
0.750”andtheheadsare0.500”thick. Theallowablestressis16,000psi.Weldsaredoublefull
filletlapjointsandthevesselisstampedRTͲ1.Thecorrosionallowancefortheentirevesselis
0.125”.Whatisthemaximumallowableworkingpressurefortheellipsoidalhead?
32
0$:3
PracticeQuestion#18
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(f)
Duringaninspectionofaverticalvesselthicknessmeasurementstakenonthebottom
hemisphericalheadwasfoundtobe0.785.Theinsidediameterofthevesselis96”,allowable
stressis17,000psi,andweldsthataredoubleweldedbuttweldjointsandthevesselisstamped
RTͲ1.Whatisthemaximumallowableworkingpressureforthishemisphericalhead?
33
0$:3
PracticeQuestion#19
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(f)
Ahorizontalvesselwithanoutsidediameterof72”andhemisphericalheads.Shellthicknessis
0.750”andtheheadsare0.500”thick. Theallowablestressis16,000psi.Weldsaredoublefull
filletlapjointsandthevesselisstampedRTͲ1.Thecorrosionallowancefortheentirevesselis
0.125”.WhatisthemaximumallowableworkingpressurefortheHemisphericalhead?
34
0$:3
9HVVHOLQ&RUURVLYH6HUYLFH
PracticeQuestion#20
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ27(c.)(1)
API510,Section7,SubͲ
par7.3.3
Duringarecentinspectionofahorizontalvesselwithaninsidediameterof72”
andhemisphericalheads,shellthicknesswasrecordedas0.625”.Theallowable
stressis16,000psi.Weldsaredoublefullfilletlapjointsandthevesselis
stampedRTͲ1.ThecorrosionͲrateis0.006”/yr.Requiredthicknessis0.588”.
Vesselisincorrosiveservice.Nextinspectionisin5years.Whatisthe
maximumallowableworkingpressureforthisvessel?
35
([WHUQDO3UHVVXUH
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ28(c.)
Therearethreefactorsthatcaneffecttheresistanceof
crushingdueexternalpressure.
1. Stiffeners
2. Thickness– thickermaterialsresistcrushing
3. Diameter– increasingdiameter,increasessusceptibilityofcrushing
36
([WHUQDO3UHVVXUH&DOFXODWLRQV
I. Formulaandvariables
Pa =
4B
[ 3 ( Do /
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ28(c.)
t )]
A=FactorbasedonratioofL/DoandDo/t.(GetitfromASMESecII,PartD,FigG.)
B=Factorbasedon“A”FactoranddesignTemperature(GetiffromASMESecII,
PartD,TablesCSͲ1orCSͲ2)
Do =OutsideDiameter
t=Minimumrequiredthickness
“B”factorwillbegiventoyouinthequestion.
37
([WHUQDO3UHVVXUH&DOFXODWLRQV
PracticeQuestion#21
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ28(c.)
Ahorizontalvesselhasanoutsidediameterof60”.Thedistancebetween
supportsis15’ft.Thewallthicknessis0.625”.MaterialofconstructionisSAͲ
516Gr70.Thisvesselhasa“B”factorof3500andisdesignedfor250psig@
500deg F.Allowablestressis16,500.Whatisthemaximumexternalpressure
forthisvessel?
38
([WHUQDO3UHVVXUH&DOFXODWLRQV
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ28(c.)
PracticeQuestion#21
Ahorizontalvesselhasanoutsidediameterof60”.Thedistancebetween
supportsis15’ft.Thewallthicknessis0.625”.MaterialofconstructionisSAͲ
516Gr70.Thisvesselhasa“B”factorof3500andisdesignedfor250psig@
500deg F.Allowablestressis16,500.Whatisthemaximumexternalpressure
forthisvessel?
Pa =
Pa =
4B
[ 3 ( Do /
t )]
4 x 3500
60 /
[ 3x (
B=3500
Do =60”
t=0.625
0.625 ) ]
14000
Pa =
Pa =
3x (
96
48.611 psi
)
39
([WHUQDO3UHVVXUH&DOFXODWLRQV
PracticeQuestion#22
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ28(c.)
Duringanexternalinspectionofavesselwithanoutsidediameterof48”
uniformcorrosiondamagewasdiscovered.Thethicknessinthisareaofshell
wasfoundtobe0.425”.Thisvesselisdesignedfor35psiexternalpressureand
hasaBfactorof1800.Canthisvesseloperateat35psiexternalpressureor
doesitneedtobererated?
40
([WHUQDO3UHVVXUH&DOFXODWLRQV
PracticeQuestion#23
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ28(c.)
A20ft longexchangertubehasanoutsidediameterof2”andnominal
thicknessof0.083”.MaterialofconstructionisSAͲ283GrDanddesign
temperatureis600deg F.The“B”factorforthetubeis1500.Whatisthe
maximumallowedexternalpressureforthistube?
41
/HVVRQ3ODQ,,,
(Calculations– ImpactTesting,WeldSizeandNozzle
Reinforcement)
1
/HVVRQ3ODQ,,,
(Calculations– ImpactTesting,WeldSizeandNozzleReinforcement)
I.
Impact Testing
A.
B.
Theinspectorshouldunderstandimpacttestingrequirementsandimpacttestingprocedure(UGͲ84)
Theinspectorshouldbeabletodeterminetheminimummetaltemperatureofamaterialwhichisexemptfromimpacttesting(UGͲ20(f),UCSͲ66,
UCSͲ68(c).)
II. WELD SIZE FOR ATTACHMENT WELDS AT OPENING
MustbeabletodetermineiftheweldsizemeetsCoderequirements.
A.
B.
Convertafilletweldthroatdimensiontolegdimensionorvisaversa,usingconversionfactor(0.707);
Determinetherequiredsizeofweldsatopenings(UW-16)
III. Nozzle Reinforcement
A.
B.
C.
D.
E.
Understandthekeyconceptsofreinforcement,suchasreplacementofstrengthremovedandlimitsofreinforcement.
Creditcanbetakenforextrametalinshellandnozzle
Beabletocalculatetherequiredareasforreinforcementorchecktoensurethatadesignedpadislargeenough.To
simplifytheproblem:
Allfr =1.0
AllF=1.0
AllE=1.0
Therewillbenonozzleprojectinginsidetheshell
Beabletocompensateforcorrosionallowances
Weldstrengthcalculationsareexcluded
2
,PSDFW7HVWLQJ0'07
(ASMEVIIIUGͲ20(f),UGͲ84UCSͲ66,UCSͲ68(c).)
I.
WhatdoesImpactTestingDetermine?
II.
WhatisMDMT?
III. WhydoestheCodeworryaboutMDMT?
IV. Whataresomefactorsthataffectbrittlenessofmaterials?
V. Whatistheoppositeofbrittleness?
‡
.
3
0'07
I.
ASMEVIII,
6XEVHFWLRQ$3DUW8*'HVLJQ8*
6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH
2SHUDWLRQ8&6 D E 8&6 F HowdoesASMESectionVIIImanageBrittleFracture
a.
ByMaterialSelection(P1Group1and2Ͳ
b.
ProvidesamethodfordeterminingMDMT
c.
seeFig.UCSͲ66)
ASMEVIII,
6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH
2SHUDWLRQ8&6SDJHGRZQWLPHV
1.
Curvesformaterialgroupings(Fig.UCSͲ66)
2.
Initialimpacttestingexempttemperaturebasedonmaterial(curve
letter)andthickness(TableUCSͲ66Ͳ1)
3.
StressReductionRatiofactor[(tr xE)/(tnͲc)].(FigUCSͲ66.1)
4.
PWHTReduction(residualstressreductionallowedwhenPWHTisperformedandisnotrequired
bytheCode)see(par.UCSͲ68(c.))
Note:Thisratiowillbeprovidedonthetest.
TemperaturelimitedbyUCSͲ66(b)(2)&(3)andUCSͲ68(c.)
a)
UCSͲ66(b)(2)– nocolderthanͲ55oF,unless ;
1)
2)
Stressreductionratiois0.35orless,thentemperaturecanbe
betweenͲ55oFandͲ155oF.(UCSͲ66(b)(3)
PWHTperformedwhennotrequiredbyCode,temperaturecan
bebelowͲ55oF.(UCSͲ68(c.)
4
0'07
PracticeQuestion#1
A horizontal vessel constructed from SA-516 Gr 65 plate (not normalized). Designed for
350 psig @ 650oF. Wall thickness is 1.5”, with a 1/16” corrosion allowance and reduction
ratio is .80. Nameplate is stamped RT-1 and HT. What is the lowest possible MDMT for
this vessel?
5
0'07
PracticeQuestion#1
A horizontal vessel constructed from SA-516 Gr 65 plate (not normalized). Designed for
350 psig @ 650oF. Wall thickness is 1.5”, with a 1/16” corrosion allowance and reduction
ratio is .80. Nameplate is stamped RT-1 and HT. What is the lowest possible MDMT for
this vessel?
ASMEVIII,
Step1:FindmaterialCurveLetter;
Curveletteris“B”fromFig.UCSͲ66
6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH
2SHUDWLRQ8&6SDJHGRZQWLPHV
ASMEVIII,
6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH
Step2:InitialMDMT;
2SHUDWLRQ8&6SDJHGRZQWLPHV
51oF fromTableUCSͲ66
ASMEVIII,
Step3:MDMTreduction(stressratioreduction);
6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH
20oF reductionallowed,therefore
2SHUDWLRQ8&6SDJHGRZQWLPHV
ReducedMDMT=51oFͲ 20oF=+31oF (fromFig.UCSͲ66.1)
Step4:PWHTreduction(notallowed)
PWHTreductionisnotallowedbecausePWHTwasrequired
byCode(i.e.nameplatestamped“HT”)seePar.UCSͲ68(c.)
ASMEVIII,
LowestMDMT=+31oF
6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH
2SHUDWLRQ8&6SDJHGRZQWLPHV
6
0'07
(ASMEVIIIUGͲ20(f),UGͲ84UCSͲ66,UCSͲ68(c).)
PracticeQuestion#2
A horizontal vessel constructed from SA-516 Gr 50N plate. Designed for 300 psig @ 600oF.
Wall thickness is 0.25”, with a 1/32” corrosion allowance and reduction ratio is .80.
Nameplate is stamped RT-1. Vessel was PWHT’d. What is the lowest possible MDMT for
this vessel?
7
0'07
(ASMEVIIIUGͲ20(f),UGͲ84UCSͲ66,UCSͲ68(c).)
PracticeQuestion#3
AhorizontalvesselconstructedfromSAͲ178GrAplate.Designedfor200
psig@500oF.Wallthicknessis0.500”,witha1/8”corrosionallowance
andreductionratiois.80.VesselwasPWHT’d.NameplateisstampedRTͲ
2.WhatisthelowestpossibleMDMTforthisvessel?
0'07
(ASMEVIIIUGͲ20(f),UGͲ84UCSͲ66,UCSͲ68(c).)
PracticeQuestion#4
A horizontal vessel constructed from SA-516 Gr 60 plate. Designed for 200 psig @ 500oF.
Wall thickness is 0.750”, with a 1/8” corrosion allowance and reduction ratio is .88.
Nameplate is stamped RT-2 and vessel was PWHT’d for environment cracking. What is
the lowest possible MDMT for this vessel?
&KDUS\,PSDFWV
CharpyImpactTest
ASMEVIII,
6XEVHFWLRQ$3DUW8*)DEULFDWLRQ8*
‡ EachSpecimenshallconsistofthreespecimensASMEVIIIUGͲ84
‡ Specimenthicknessis0.394”Fig.UGͲ84
10
&KDUS\,PSDFWV
CharpyImpactTest
ASMEVIII,
6XEVHFWLRQ$3DUW8*)DEULFDWLRQ8*
SDJHGRZQWLPHV
(a)Interpolationbetweenyieldstrengthsshownispermitted.
(b)Theminimumimpactenergyforonespecimenshallnotbelessthan2Ш3oftheaverageenergyrequired
forthreespecimens.Theaverageimpactenergyvalueofthethreespecimensmayberoundedtothe
nearestftͲlb.
11
&KDUS\,PSDFWV
ASMEVIII,
6XEVHFWLRQ$3DUW8*)DEULFDWLRQ8*
SDJHGRZQWLPHV
PracticeQuestion#5
‡
Whatistherequiredaverageandminimumcharpy impactvaluesforamaterialwith50ksi
MSYSandis1.0thick?
12
&KDUS\,PSDFWV
(ASMEVIIIUGͲ84
ANSWER:
Average=15ft lbs
Min.Value=2/3x15=10ft lbs
50Ksi
15ft lbs
1.0thickness
13
&KDUS\,PSDFWV
(ASMEVIIIUGͲ84
PracticeQuestion#6
‡
Whatistherequiredaverageandminimumcharpy impactvaluesforamaterialwith55ksi
MSYSandis2.0thick?
14
&KDUS\,PSDFWV
(ASMEVIIIUGͲ84
PracticeQuestion#7
‡
Duringimpacttestingofa1½”thickmaterialwithaMSYSof45,000psi,theimpact
testingvaluesforthespecimenswere17,12,and11?Aretheresultsoftheseimpact
testsacceptable?
15
)LOOHW:HOGV
ASMEVIII,
6XEVHFWLRQ%3DUW8:'HVLJQ8: E DQGSDJHGRZQRQFHIRU)LJ8:
Filletweldsizeisnormallydescribedbythe“leg”size.
Calculatingfilletweldsize;
Throatsize=0.707xlegsize
Legsize=throatsize/0.707
PerFig.UWͲ16.1;
Throatsize=½tmin
or
Throatsize=tc
or
Throat
Leg
Leg
Throatsize=tw
16
)LOOHW:HOGV
ASMEVIII,
6XEVHFWLRQ%3DUW8:'HVLJQ8: E DQGSDJHGRZQRQFHIRU)LJ8:
Calculatingthesizeoffilletwelds;
Throat
Leg
PracticeQuestion#5
Anequallegfilletweldhasathroatof0.375”.
Whatislegsizeforthisfilletweld?
Leg
Legsize=throatsize/0.707
=0.375/0.707
= 0.530”
PracticeQuestion#6
Afilletweldwithalegsizeof0.250”.
Whatisthroatsizeforthisfilletweld?
PracticeQuestion#7
A45o filletweldhasalegsizeof0.125”.
Whatisthroatsizeforthisfilletweld?
17
)LOOHW:HOG6L]H
ASMEVIII,
6XEVHFWLRQ%3DUW8:'HVLJQ8: E DQGSDJHGRZQRQFHIRU)LJ8:
Perpar.UWͲ16(b);
Filletweldsize,mustbeconvertedfromthroatsize(½tmin ortc)tolegsize.
tmin =lesserof¾”ormembersjoined
Assume,therepadis0.375”thick,thevessel
shellis0.500”thickandthenozzleis0.432”.
Whatistherequiredfilletweldsizeattaching
therepadtothevesselshell?
tn
d
t
Step1: Gotothesketch(UWͲ16.1(aͲ1).
1/2tmin
Step2: Calculatethroatsize(½tmin)
tc
te
aͲ1
½tmin =½x(less
=½x(lesserof(0.75”,_____,_____,____)
=½x(lesserof(0.75”,0.375”,0.500”,0.423”)
=½x0.375”
=0.1875”
Step3:Calculateweldsize(FilletweldLegsize);
Leg=½tmin /0.707=0.1875/0.707=0.265”,roundedtonext1/16”=0.3125”
18
)LOOHW:HOG6L]H
Perpar.UWͲ16(b);
Fillet weld size for nozzles without repads must be
calculated by converting throat size (tc), to leg size.
tc = not less than smaller of ¼” or 0.707 x tmin
tn
d
Assume, the vessel shell is 0.500” thick and the
nozzle is 0.432”. What is the required fillet weld
size for this branch connection?
Step1: Find correct sketch (UW-16.1(a).
tc
t
Step2: Calculate the throat size (tc)
tc = lesser of ¼” or 0.707 x tmin
= lesser of ¼” or 0.707 x (lesser of 0.750, 0.423, 0.500)
= lesser of ¼” or (0.707 x 0.432)
= lesser of ¼” or 0.305”
= 0.250”
a
Step 3: Calculate weld size (Fillet weld Leg size);
Leg = tc / 0.707 = 0.250 / 0.707 = 0.357”, rounded to next 1/16” = 0.375”
19
tc =
0.375”
0.3125”
0.250”
20
)LOOHW:HOG6L]H
ASMEVIIIpar.UWͲ16(b);
PracticeQuestion#8
Abranchconnectionisbeinginstalledwithoutareinforcementpad.
Thenozzlethicknessis0.625”andthevesselshellis0.875”thick.Whatsize
filletweldshouldbeusedforthisbranchconnection?
tn
d
tc
t
a
21
)LOOHW:HOG6L]H
ASMEVIIIpar.UWͲ16(b);
PracticeQuestion#9
Abranchconnectionisbeinginstalledwithareinforcementpad.
Thenozzlethicknessis0.625”,repadis0.750”thickandthe
vesselshellis0.875”thick.Whatsizefilletweldshouldbe
usedtoattachtherepad tothevesselshell?
tn
d
tc
te
t
1/2tmin
aͲ1
22
)LOOHW:HOG6L]H
ASMEVIIIpar.UWͲ16(b),Fig.UWͲ16.1(a)
Practice Question # 10
AnozzleisinstalledinavesselperFig.UWͲ16.1(a).Thevesselwallthickness
is0.325”andthenozzlewallthicknessis0.375”.Whatistheminimumfillet
WeldsizeforthenozzleͲtoͲshellfilletweld?
tn
d
tc
t
a
23
)LOOHW:HOG6L]H
ASMEVIIIpar.UWͲ16(b),Fig.UWͲ16.1(a)
Practice Question # 11
AnozzleisinstalledinavesselperFig.UWͲ16.1(a).Thevesselwallthickness
is0.325”andthenozzlewallthicknessis0.375”.Whatistheminimumfillet
weldsizeforthenozzleͲtoͲshellfilletweld?
tn
d
tc
t
a
24
)LOOHW:HOG6L]H
ASMEVIIIpar.UGͲ37
Practice Question # 12
Anew8NPSnozzleisinstalledinavesselperFig.UWͲ16.1(h).Shellrequiredthicknessis
1.125”.Nominalshellthicknessis1.250”.Nominalthicknessforthenozzleis0.875”.
Therepadthicknessis0.500”.
1) WhatistheminimumfilletweldsizeforthenozzleͲtoͲrepadfilletweld?
2) WhatistheminimumfilletweldsizefortheshellͲtoͲrepadfilletweld?
tn
d
tw=0.7tmin
tc
t
tc
25
Fig.UWͲ16Ͳ1(h)
HEAD
BANGER
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ASMEVIIIpar.UGͲ37
I. Nozzle Reinforcement
‡ Replacingarealostbycuttingholeinvessel(crossͲsectionalarea)
‡ Strengthofthemateriallost,mustbereplaced
‡ Strengthlost=diameterofholexshelltmin
‡ Limitsofreinforcement
‡ Extrametalmustbenearthenozzle
‡ Strengthofreinforcement
‡ Reinforcementmustbeequaltothestrengthremoved
‡ Additionalreinforcementmustbeadded
‡ Reinforcementcancomefrommultiplesources
‡ Shell,nozzle,repadandfilletwelds
‡ Corrosionallowancecannotbeused
29
1R]]OH5HLQIRUFHPHQW
ASMEVIII,SubsectionA,PartUG,UGͲ37
Nozzle Reinforcement Variables
6XEVHFWLRQ%3DUW8:'HVLJQ8: E DQGSDJH
GRZQRQFHIRU)LJ8:
Variables for nozzles without repads
Variables for nozzles with repads
tn
d
tc
te
tc
A = d x tr
tn
d
A = d x tr
t
a
t
1/2tmin
aͲ1
A1 = d (t-tr) or 2(t + tn)(t-tr) , extra shell area, larger
of these two
A1 = d (t-tr) or 2(t + tn)(t-tr) , larger of these two
A2 = 5t(tn-trn) or 5tn (tn-trn) , extra nozzle area,
smaller of these two
A41 = Leg2
A41 = leg2
d = diameter of nozzle in corroded condition
t = shell thickness in the corroded condition
tr = shell required thickness
tn = nozzle thickness in the corroded condition
trn = nozzle required thickness
Dp =outsidediameterofrepad
te = repad thickness
Limits of reinforcement = greater of d or Rn+tn_t
A2 = 5t(tn-trn) or 5tn (tn-trn) , smaller of these two
A42 = Leg2
A5 = (Dp – d – 2tn)te
Notes:
A.
Therewillbenonozzleprojectinginsidetheshell
B.
Beabletocompensateforcorrosionallowances
C.
Weldstrengthcalculationsareexcluded
30
1R]]OH5HLQIRUFHPHQW
ASMEVIII,SubsectionA,PartUG,UGͲ37
Practice Question # 13
6XEVHFWLRQ%3DUW8:'HVLJQ8: E DQGSDJH
GRZQRQFHIRU)LJ8:
A12NPSnozzleisbeinginstalledonavessel.ThecorrodedIDofthenozzleis
12.0”.Shellthicknessis0.750”.Corrosionallowanceis1/16”.Requiredthickness
fortheshellis0.625”.Theareathatmustbereplacedis;
tn
d
tc
t
a
31
1R]]OH5HLQIRUFHPHQW
ASMEVIIIpar.UGͲ37
Practice Question # 13
A12NPSnozzleisbeinginstalledonavessel.ThecorrodedIDofthenozzleis
12.0”.Shellthicknessis0.750”.Corrosionallowanceis1/16”.Requiredthickness
fortheshellis0.625”.Theareathatmustbereplacedis;
tn
d
tc
t
a
ASMEVIII,SubsectionA,PartUG,UGͲ37
6XEVHFWLRQ%3DUW8:'HVLJQ8: E DQGSDJH
GRZQRQFHIRU)LJ8:
32
1R]]OH5HLQIRUFHPHQW
ASMEVIIIpar.UGͲ37
Practice Question # 14
A8NPSnozzleisbeinginstalledonavessel.ThecorrodedIDofthenozzleis
8.0”.Nozzlethicknessis0.250”.Requiredthicknessforthenozzleis0.100”
Shellthicknessis0.450”.Requiredthicknessfortheshellis0.400”.
Filletweldsizeis0.375”.
1.Whatisthearealost?
2.Whatisthelimitsofreinforcement?
3.Whatistheextraareaprovidedbyshell?
4.Whatistheextraareaprovidedbythenozzle?
tn
d
tc
t
a
33
1R]]OH5HLQIRUFHPHQW
Practice Question # 15
A12NPSnozzleisbeinginstalledinavesselasindicatedbyFig.UWͲ16.1(aͲ1).Thevessel
wallthicknessis0.825”thick.Vesselrequiredthicknessis0.625”.Thenozzlewall
thicknessis0.500”.Requirednozzlethicknessis0.375”.Therepadis0.375”thick.
Corrosionallowanceis0.125”.
1) What is the limits of reinforcement (edge to edge)?
tn
d
2) What is the area lost?
tc
te
t
1/2tmin
Fig.UWͲ16.1(aͲ1)
/HVVRQ3ODQ,9
$60(6HFWLRQ,;
:36345:34
1
ExamRestrictions/Exclusions:
1.
No more than one process (SMAW, GTAW or SAW).
2.
One filler metal per process
3.
PQR will be the supporting PQR for the WPS (only one WPS and one PQR).
4.
Base metal limited to P1, P3, P4, P5 and P8
5.
Dissimilar metals and/or thicknesses are excluded from exam
6.
7.
8.
9.
Corrosion-resistant weld overlay, hard-facing overlay, and dissimilar metal welds with
buttering of ferritic member is excluded from exam
P1, P3, P4 & P5 lower transition temperature will be 1330 F and 1600 F upper transformation
Editorial and non-technical requirements are excluded (i.e. Revision #, Company Name, WPS
number, WPS Date, and Name of testing lab).
Supplemental Variables are excluded from Exam.
2
BodyofKnowledge
I. WPS/PQR/WPQ – BODY OF KNOWLEDGE
$ 'HWHUPLQHLISURFHGXUHDQGTXDOLILFDWLRQUHFRUGVDUHLQFRPSOLDQFHZLWK$60(
&RGHDQG$3,
% 'HWHUPLQHLIDOOHVVHQWLDODQGQRQHVVHQWLDOYDULDEOHVKDYHEHHQDGGUHVVHG
& 'HWHUPLQHQXPEHUDQGW\SHRIPHFKDQLFDOWHVWVWKDWDUHOLVWHGLQ345DUHWKH
SURSHUWHVWVDQGZKHWKHUWKHUHVXOWVDUHDFFHSWDEOH
127(0XVWNQRZWKDWWKH345 PXVWEHVLJQHGDQGGDWHG
3
Layout of the
ASME Section IX Code Book
‡ Divided into 2 parts
‡ QW – WELDING
‡ QB - BRAZING (pages 204 – 243 is not on exam)
‡ QW – Divided into 5 Articles
‡
‡
‡
‡
‡
Article I – Welding general requirements (13 pages) QW100
Article II – Welding Procedure Qualifications (WPS/PQR) QW200
Article III – Welding Performance Qualifications (WPQ) QW300
Article IV – Welding Data QW400
Article V - Standard WPS Specifications (NOT ON TEST) QW500
4
Purpose of ASME Section IX
Section IX is focused on THREE things;
1. WPS - (Welding Procedure Specification)
‡ Directions to welder to for making production welds
2. PQR - (Procedure Qualification Record)
‡ Qualifies that the WPS can be used to make a quality
weld
3. WPQ - (Welder Performance Qualification)
‡ Qualifies that the WELDER can make quality welds
with a Welding Process (i.e. SMAW, GTAW, SAW).
5
General requirements of ASME
Section IX
$UWLFOH,
‡ QW100.1 (page 1)
a. Provides directions to welder for making production welds in accordance
with CODE requirements.
b. WPS shall be qualified by Manufacturer/Contractor
c. WPS specifies conditions which welding must be performed
d. WPS must address essential and non-essential variables and supplemental
variables when applicable (supplemental variables are not on API 510
exam).
e. PQR establishes the properties of the weld, “not the skill of welder’.
f. PQR must address essential variables and and supplemental variables
when applicable (supplemental variables are not on API 510 exam).
‡
QW100.2 (page 2)
a. WPQ determines welder’s ability to make sound welds.
6
General requirements of ASME
Section IX (cont)
$UWLFOH,
‡
QW100.3
a. WPS qualified per Section IX, can be used to make welds in accordance
with Section VIII
b. WPS qualified in accordance with Section IX 1962 or later can be used.
c. WPS qualified in accordance with Section IX prior to 1962, can be used, if
all the 1962 requirements are met.
d. Prior to 2009, Section IX used “S” numbers. The 2010 Section IX
eliminated the “S” numbers. WPS’s created using “S” numbers must be
revised to show correct “P” number, but not RE-QUALIFIED.
e. New WPS’s and Welder Qualifications, must be per 2010 Edition of Section
IX
‡
QW-101
a. Section IX applies to preparation of WPS, PQR, WPQ for all types of
manual & machine welding processes
7
General requirements of ASME
Section IX (cont)
$UWLFOH,
‡
QW102 (Definitions) (see QW492, page 193)
a.
b.
Groove Weld – weld made in a groove formed within a single or two members.
Heat-affected zone – base metal that was not melted, but whose mechanical
properties were altered during welding
c. Interpass temperature – highest temperature allowed in weld or weld joint prior
to welding.
o
d. Lower Transformation Temperature 1330 F – Ferrite begins to transform into
Austenite (P1, P3, P4, P5)
e. Macro-Examination - Observing a cross-section of a specimen by the unaided eye
or low magnification with or without etching.
f. Performance Qualification – welder’s ability to produce welds meeting prescribed
standards.
g. Preheating – heat applied prior to welding
o
h. Upper Transformation temperature 1600 F – Transformation from ferrite to
austenite is completed. (P1, P3, P4, P5)
i. Welder – one who performs manual or semi-automatic welding.
8
General requirements of ASME
Section IX (cont)
$UWLFOH,
‡
QW103.1 - Responsibility
a.
‡
QW103.2 - Records
a.
‡
Manufacturer is responsible for and shall conduct testing required to Qualify
WPS’s and Welders.
Manufacturer shall maintain a record of the results of WPS and Welder
Qualifications (i.e. PQR and WPQ).
QW110 – Weld Orientation
a.
Weld orientations used for WPS and WPQ test are as indicated in figure QW
461.1 or QW 461.2 (page 151).
9
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Understanding
P-Number
$31XPEHU 4:SDJH
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14
Understanding
P-Number
Example -
WhatistheP-NumberforSA285GrC?
$UWLFOH,9
4:
Answer- FindSA285GrCintableQW/QB422(page76).ItisP1Gr1.
15
Understanding
F-Numbers
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4:
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16
Understanding
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Example - WhatistheF-NumberforE8018?
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4:
Answer- FindAWSclassificationinTableQW432(page134),thengohorizontallytoleft
tillyougettotheF-Nocolumn.F4isanswer
17
P-Number and F-Number
Practice Questions
31XPEHU 3UDFWLFH± ZKDW LVWKH3IRUIROORZLQJ"
Material
PͲNumber
SA240Type 304
SA217TypeWC1
UNSS31000
)1XPEHU 3UDFWLFH± ZKDWLVWKH)IRUWKHIROORZLQJ"
Filler MetalClassificationand/orSpecification
FͲNumber
E7024
E8018
SFA5.18
18
Test positions for Groove Welds
(plate)
QW120 – Test Positions
a.
Test coupons may be oriented in any position indicate in figures QW 461.3 (plate) or QW
461.4 (pipe) …..see page 153
$UWLFOH,94:
4:
3DJHGRZQWLPHV
r 15deg
r 15deg
19
Test positions for Groove Welds
(Pipe)
$UWLFOH,94:
4:
3DJHGRZQWLPHV
r 15deg
r 15deg
20
“FIELD” Weld Orientations
$UWLFOH,9
4:
4:
(QW110 page 151)
Tabulation of Positions of GROOVE WELDS
INCLINATION of AXIS
Position
Flat
Diagram
Reference
A
Inclination
of Axis
0 to 15o
Rotation
of Face
150 to 210o
Horizontal
B
0 to 15o
80 to 150o
210 to 280o
Overhead
C
0 to 80o
0 to 80o
210 to 360o
Vertical
D
E
15 to 80o
80 to 90o
80 to 280o
0 to 360o
o
280
o
0
to
o
360
ROTATION of FACE
21
“FIELD” Weld Orientations
(QW110 page 151)
Groove Weld – POSITION of Field Welds
Tabulation of Positions of GROOVE WELDS
6WHS 6WHS 6WHS Position
Flat
Diagram
Reference
A
Inclination
of Axis
0 to 15o
Rotation
of Face
150 to 210o
Horizontal
B
0 to 15o
80 to 150o
210 to 280o
Overhead
C
0 to 80o
0 to 80o
210 to 360o
Vertical
D
E
15 to 80o
80 to 90o
80 to 280o
0 to 360o
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22
“FIELD” Weld Orientations
(QW110 page 151)
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23
“FIELD” Weld Orientations
3UDFWLFH4XHVWLRQ $JURRYH ZHOGLVLQFOLQHGGHJUHHVIURPKRUL]RQWDO
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Tabulation of Positions of GROOVE WELDS
'HWHUPLQHZKLFKSRVLWLRQ WKLV³LQFOLQDWLRQRIZHOGD[LV´
WKLVZHOGFRXOGSRVVLEO\EH LH$%&RU' Tabulation of Positions of GROOVE WELDS
6WHS Position
Flat
Diagram
Reference
A
Inclination
of Axis
0 to 15o
Rotation
of Face
150 to 210o
Horizontal
B
0 to 15o
80 to 150o
210 to 280o
Overhead
C
0 to 80o
0 to 80o
210 to 360o
Vertical
D
E
15 to 80o
80 to 90o
80 to 280o
0 to 360o
(QW110 page 151)
6WHS Position
Flat
Diagram
Reference
A
Inclination
of Axis
0 to 15o
Rotation
of Face
150 to 210o
Horizontal
B
0 to 15o
80 to 150o
210 to 280o
Overhead
C
0 to 80o
0 to 80o
210 to 360o
Vertical
D
E
15 to 80o
80 to 90o
80 to 280o
0 to 360o
/RRNLQJDWWKHFKDUW GHJUHHVFDQEH³$´
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24
“FIELD” Weld Orientations
(QW110 page 151)
3UDFWLFH4XHVWLRQ $JURRYH ZHOGLVLQFOLQHGGHJUHHVIURPKRUL]RQWDO
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6WHS
0DWFK WKH³,QFOLQDWLRQ´WRWKH³)DFH5RWDWLRQ´WR
GHWHUPLQHWKH326,7,21RIWKH:(/'
Tabulation of Positions of GROOVE WELDS
Position
Flat
Diagram
Reference
A
Inclination
of Axis
0 to 15o
Rotation
of Face
150 to 210o
Horizontal
B
0 to 15o
80 to 150o
210 to 280o
Overhead
C
0 to 80o
0 to 80o
210 to 360o
Vertical
D
E
15 to 80o
80 to 90o
80 to 280o
0 to 360o
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25
Practice Questions
for
Weld Orientations
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26
Practice Questions
for
Weld Orientations
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27
Practice Questions
for
Weld Orientations
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28
Practice Questions
for
Weld Orientations
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29
7\SHVRI7HVW([DPV
$UWLFOH,
‡
QW141.1 – Tension Test
A.
B.
C.
‡
QW141.2 – Guided Bend Test
A.
B.
‡
Used to determine “notch toughness” of the welds
QW142 – Special examination for welders
A.
‡
Used to determine “size, contour & degree of soundness ” of fillet welds.
QW141.4 – Charpy Impact
A.
‡
Used to determine “degree of soundness and ductility” of groove weld joints.
Types - Root, Face and Side bend
QW141.3 – Fillet Weld Test
A.
‡
Used to determine “ultimate strength” of groove weld joints (TENSILE STRENGTH).
Types of Test - Reduced Section, Round (Turned), Full Section
2
Tensile Strength = Load/Area in lbs/in (psi)
RT or UT may be substituted for mechanical test (bends) for welders.
QW144 – Visual examination
A.
Used to determine welds meet “quality standards”
30
7(16,217(67
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4:SDJH
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31
7(16,217(67
QW141.1 – Tension Test
‡
A.
B.
C.
QW151 – Tension Test
‡
QW 151.1 - Reduced section “may be” used for all thicknesses of plates
‡
‡
‡
QW 151.1(a) - For thicknesses ” 1” “SHALL” be FULL thickness specimens
QW 151.1(b) - For thicknesses > 1” “may be” FULL thickness or multiple specimens
QW 151.2 - Reduced section “may be” used for all thicknesses of pipe > 3” diameter.
‡
‡
‡
‡
Used to determine “ultimate strength” of groove weld joints (TENSILE STRENGTH).
Types of Test - Reduced Section, Round (Turned), Full Section
2
Tensile Strength = Load/Area in lbs/in (psi)
QW 151.2(a) - For pipe thickness ” 1” “SHALL” be FULL thickness specimens
QW 151.2(b) - For thicknesses > 1” “may be” FULL thickness or multiple specimens
QW153 – Tension Test – Acceptance Criteria
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‡
$60(,;
4:
In order for a Tension test to pass, the specimen shall
have a tensile strength of not less than;
a) MSTS of the base metal (when it fails in weld)
b) MSTS of the weaker of the two metals joined together (when it fails in
the weld)
c) 95% of the MSTS of base metal (when it fails in the base metal).
127(/2$'LVDPHDVXUHRIWKHVWUHVV QHHGHGWRSXOOWKH7(16,21VSHFLPHQDSDUW LHIDLOXUH
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Load isȱtheȱamountȱofȱstressȱrequiredȱtoȱpullȱtheȱtensileȱspecimensȱapart
Area ofȱaȱtensileȱspecimenȱisȱtheȱwidthȱxȱthickness
38
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40
Bend Test - Specimens
7UDQVYHUVH %HQG
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41
Bend Test
‡
QW141.2 – Bend Test 4:SDJH
A.
B.
‡
Face and Root Bend Test
‡
‡
4: D SDJHIRU:36345DQG4: D SDJH:34
These two test are always done together. Therefore, what ever # of face
bends are required, the same number of root bends are also required.
‡
Side bends are only performed with other side bends (i.e. you will never see face, root
AND side bends required).
Side bends are only required for “THICKER” materials (i.e. ¾” or greater in thickness).
See Table QW 451.1(a) on page 147.
Acceptance Criteria
1.
2.
3.
$UWLFOH,9
4:
4:
Side Bend Test
‡
‡
$UWLFOH,
Used to determine “degree of soundness and ductility” of groove weld joints.
Types of Test - Face, Root, and Side bends (determined by which face is on “Convex” side)
4:SDJH
$UWLFOH,
Weld and Haz must be in the bent portion of bend.
No open discontinuity in weld or HAZ > 1/8” in any direction on convex surface
Open discontinuity at the corners are acceptable,unless result from LOF, slag or internal
discontinuities
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Figure“B”
Figure“C”
43
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Figure“B”
Figure“C”
44
Visual Examinations
‡
QW144 – Visual Examination
A. Used to determine if welds meet “q
quality standards”
B. Required for “PERFORMANCE” test, not PQR.
4:SDJH
‡
QW-194 Acceptance Criteria
1. Welds must be inspected after welding is complete and before specimens
are removed (see QW-302.4)
$UWLFOH,,,
2. Must have complete Joint penetration
3. Must have complete fusion of weld metal and base metal
$UWLFOH,
4:SDJH
Radiography
‡ QW142 – Radiography
4:SDJH
1. May be substituted for Groove weld Mechanical
Test for WELDERS.
‡ QW-191 Acceptance Criteria
$UWLFOH,
4:SDJH 1. No cracks, Lack of Fusion (LOF) or Incomplete Penetration (IP)
2. Elongated slag inclusions (i.e. indication is 3 times longer than width), max
size permitted;
1.
2.
3.
4.
Max length of 1/8” - for t up to 3/8”
Max length of 1/3 t - for t > 3/8” but < 2 ¼”
Max length ¾” - for t > 2 ¼”
Aligned inclusions with aggregate length > t in 12t length of weld
3. Rounded Indications
1. Smaller of 20% of t or 1/8”
2. For clustered, assorted or randomly dispersed configurations, see
Appendix I
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Welder Qualification Record
‡ WelderPerformanceQualification(WPQ)
1.
Coupon or production for each welding process (SMAW,
GTAW, SAW, etc)
4:SDJH
2.
$UWLFOH,,,
Qualified by;
a.
b.
Production weld must be examined by RT or UT
Coupon can be examined by VT and Mechanical or RT/UT See QW-300.1
NOTE:GMAWͲS“shortͲcircuitingmode”weldscannotbequalifiedbyRT
3.
If examination is acceptable, welder is qualified within the limits of QW-304
4.
WPQ is welded in accordance with a WPS. Preheat & PWHT required by WPS can be
omitted for WPQ
4:SDJH
51
Welder Qualification Record
Practice Question # 14
Which of the following cannot be used to qualify a welder?
1.
2.
3.
4.
VT & Bend Test
RT of 1st Production weld
RT of test coupon
Tension Test
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52
WPQ Bend Specimen Requirements
Bends
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AND
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Bend Specimen Requirements
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Bends
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Alternative Inspection
(RT/UT) for WPQ
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Requirements
NDE – Alternative Inspection
(RT/UT in lieu of BENDS
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1. Minimum Length of weld? ´
1. Minimum Length of weld? ´XQOHVV*RU*
2. Pipe? )XOO&LUFXPIHUHQFH 2. Welder Operator? 0LQLPXPRIIW
SRVLWLRQWKHQ
RT cannot be used to test a welder for either of the following;
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1. Fails Visual test; 4:SDJH
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mechanical testing (bend)
2. Any of the bend test fail; 4:SDJH
Qualify by: making 2 coupons, both must pass mechanical test.
3. Fails RT exam; 4:SDJH
Qualify by; retest and RT twice the required length of weld
%4XDOLILFDWLRQ([SLUHV
4:SDJH
1. Welder has not used the Process for 6 months
2. Reason to question welder’s ability to make sound weld
Qualified by;
Welding single coupon, plate or pipe, any
thickness/diameter/position, VT/Bend or RT.
57
Practice Questions for Welder
Qualification
Practice Question # 15
RT can be used to qualify a welder, except for the following?
1.
2.
3.
4.
Welding P21 material with GTAW process
SAW process
SMAW Process
GMAW process in Short-circuiting mode
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Practice Question # 16
A welder is being qualified by welding using ½” thickA106B pipe coupon in 5G position. How many face bends
are required?
1.
2.
3.
4.
2
1
3
0
Practice Question # 17
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A welder is being qualified for 2G and 5G on a single pipe 1” thick coupon (A240 type 304L coupon). How
many side bends are required?
1.
2.
3.
4.
6
2
4
0
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58
Practice Questions for Welder
Qualification
Practice Question # 18
Which of the following is the manufacturer/contractor prohibited from delegating to another organization?
1.
2.
3.
4.
Preparing test coupons
Performing mechanical or NDE inspection of specimens
Witnessing the welder making the weld coupon
Developing the WPQ record
Practice Question # 19
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A welder was making test coupons for a 2G and 5G pipe qualification test and the 2G coupon failed VT examination.
In order for the welder to be qualified, which of the following must occur?
1.
2.
3.
4.
Make another 1G coupon and either RT or Mechanical Test the coupon
Make two 1G coupons and VT and RT examine both coupons
Make two 1G coupons and VT both coupons, but only RT one coupon
Make two 2G coupons and VT both coupons, but only Mechanical test one coupon
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Practice Question # 20
A 6G qualification coupon failed the mechanical testing (one of the bends failed), In order for the welder to be
qualified, which of the following is required?
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4:
1.
2.
3.
4.
Two more coupons have to be welded and all 4 bends for each of the coupons have to pass mechanical test
Two more coupons have to be welded and only one coupon has to pass the required mechanical test
Another coupon has to be welded and all 4 bends has to pass mechanical test
Two more coupons have to be welded and both coupons must be either pass mechanical testing or RT examined .
59
WPQ
“P” Number Qualification Range
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oftest
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welded
“P”number
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qualifiedto
weldin
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Qualified
with
Answer:
)1R 61
WPQ
# of Bend Specimens
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WPQ
Thickness Limits
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64
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Diameter Limits
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66
Welder Qualification Record
WPQ Record
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4:SDJH
1. Variables used (i.e. process, type(manual/automatic,
with/without backing, P-No, F-No, etc)
2. Essential Variables (i.e. joints, Base metal, Filler
Metal, Position, etc)
3. Type of Test (i.e. VT, Bends and/or RT/UT)
4. Test Results (i.e. Acceptable or Failed)
5. Ranges Qualified – (i.e. thickness range,
Positions, Diameters, fillet welds)
6. Certification (i.e. signature of
Manufacturer/Contractor)
67
WPQ – Essential Variables
Essential
Variables
Paragraph
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Joints
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BaseMetals
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Process
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Step1
DetermineWhatweldingPROCESSandTYPEusedtomaketestcoupon SMAWandManual
ThesearesetbyWPS
Step2
Findthe“Essential”variablesfortheweldingprocessusedinASMEIX.
Page57
Step3
CompleteTestingVariablesandQualificationLimits(“RangeQualified” section) QW353forSMAW
WeldingVariables(QW350)
WeldingProcess(es)
Type(i.e.manual,semi-automatic)used
3. Backing(withorwithout) (QW402.4)
4. x TestCouponProductionWeld(dia ifpipe) (QW403.16Base)
5. BasemetalP-NumbertoP-Number (QW403.18P-Number)
6. FillerMetalorElectrodeSpec(SFA)
7. FillerMetalF-Number(QW404.15F-Number)
8. ConsumableInsert(GTAWorPAW)
9. FillerMetalType(solid/metalorfluxcored/powder)
1.
2.
ActualVariables
SMAW
Manual
None
6”NPS
P1toP1
5.1
F3
N/A
N/A
QW353forSMAW
RangeQualified
SMAW
. Manual
F1toF3with,F3wo
• 27/8”OD
P1-P15F,P34,P41-49
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WeldingVariables(QW350)
10. DepositedThicknessforeachprocess(QW403.30)
a.
b.
11.
Process1: SMAW 3layersminimumYesNo
x
Process2: SMAW 3layersminimumYesNo
Positionqualified(1G,2G,3G,4G,5G,6G,etc)
ActualVariables
. .280”
.
------
.
2G
RangeQualified
” .
------------ .
F,H
12. Verticalprogression(uphillordownhill)
. Uphill
n/ahorz
13. InertGasBacking(GTAW,PAW,GMAW)
. N/A
------------
14. GMAWTransfermode(Spray,Globular,Pulse,orShortCircuit)
15. GTAWCurrenttype/polarity(AC,DCEP,DCEN)
N/A
N/A
.
.
------------
.
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Step4
Complete“Results:sectionandthenSignandDateForm
That’sIT,youjustcompletedaWPQRECORD
70
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PracticeQuestion#28
WeldingVariables(QW350)
DetermineifEssential Variablesare“Correct”
1.
WeldingProcess(es)
2. Type(i.e.manual,semi-automatic)used
3. Backing(withorwithout)
4. xTestCouponProductionWeld(dia ifpipe)
5. BasemetalP-NumbertoP-Number
6. FillerMetalorElectrodeSpec(SFA)
FillerMetalF-Number
7.
8. ConsumableInsert(GTAWorPAW)
9. FillerMetalType(solid/metalorfluxcored/powder) .
10. DepositedThicknessforeachprocess
x
a. Process1: SMAW 3layersminimumYesNo
b. Process1: SMAW 3layersminimumYesNo
11. Positionqualified(1G,2G,3G,4G,5G,6G,etc)
12. Verticalprogression(uphillordownhill)
13. InertGasBacking(GTAW,PAW,GMAW)
14. GMAWTransfermode(Spray,Globular,Pulse,orShortCircuit)
15. GTAWCurrenttype/polarity(AC,DCEP,DCEN)
ActualVariables
. SMAW
. Manual
.
.
.
.
With
3”
P3
5.4
F3
N/A
N/A
.300”
------6G
Downhill
N/A
N/A
N/A
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RangeQualified
.. SMAW
.
. Manual
. F1,F2&F3with
27/8”MintoUnlimited
.
P1-P15F,P34,P41-49
.
. --------. F1,F2,andF3
. -------. -------. Max of .600”
. -------ALL
.
. Downhill only
. -------. -------. --------
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WPQ WeldingVariables
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WPQ WeldingVariables
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WPQ WeldingVariables
ReferenceWPQ Ͳ MR.RODBURNERtoanswerthefollowingquestions;
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Welding Procedure - Requirements (WPS)
1. WPSrequirements (QW-200.1,page14)
a. WPSprovidesdirectionsformakingproductionwelds.
b. Mustcontainessential,nonessentialandwhenrequired
supplementaryvariables.
1)
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MustreferencethesupportingPQR
c. Changescanbemadeto“nonessential”variableswithout
requalification.Changesto“essentialorsupplementary”variables
requirerequalification.
d. FormatofWPSmaybeanyformataslongaseveryessential,
nonessentialandsupplementaryvariableisincluded.
e. WPSmustbereadilyavailableatthefabricationsiteforreview by
welderandinspector.
79
Welding Procedure – Requirements (PQR)
345UHTXLUHPHQWV 4:SDJH
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a. IsaRecordoftheweldingdatausedtomakethetestcouponand
mechanicaltestresults.
a. Must;
1) Containessential andsupplementaryvariables(supplementalisnotAPI570Exam).
2) Recordrangeofvariablesusedtomakethecouponmustbeincluded
3) Becertifiedbythemanufacturer/contractor(i.e.signedanddated).
b. ChangestothePQRarenotallowed,exceptforeditorialtypechanges(i.e.P#entered
incorrectly,orCodechangestheF#forthematerialsused,etc.)AllchangestoaPQR,
requirerecertification(i.e.signedanddatedbymanufacturer/contractor).
c. Formatmaybeanyformataslongfollowingareincluded;
a. Essentialandsupplementaryvariables
b. Typeofmechanicaltest,numberoftestsandtestresults
d. PQRmustbeavailablefortheAI,butnotthewelder.
e. TherecouldbemultiplePQR’ssupportingoneWPSormultipleWPS’sforasinglePQR.
80
6WHSVWR48$/,)<D:HOGLQJ3URFHGXUH
1. WPS ispreparedforproductionweldsthataretobemade. (QW-100)
2. Welder(employeeorcontractedout),makesaTestCouponusingdirectionsfrom
theWPS. (QW-201)
3. Thecouponismechanicallytested- BendsandTensiontest (RTisnotallowed).
4. Ifmechanicaltestingisacceptable,WPSisQualifiedwithinrangessetby variables
usedtomakethetestcoupon. (QW-202.2)
5. PQRisarecordcreatedbasedonvariablesusedtomakethetestcouponand
subsequentmechanicaltestingresults.
NOTE:PQR“Must” besignedanddatedtobeCERTIFIED.
81
'LIIHUHQFHEHWZHHQ :36345 DQG :34
1. WhatisthedifferencebetweentheProcedureQUALIFICATIONand
WelderQUALIFICATION?
A. ProcedurequalificationrequiresTWOdocuments(WPS/PQR).
B. Examinationsaredifferent;
1)
WPS/PQR– requiresBends/TensiontestandCharpy testwhennotch
toughnessisrequired.Also,HardnesswhenPWHT’d.
2) WPQ– requiresVTandBendtestorRT/UTexamination.
C. WPQonlyrequires“Essential”variablestoberecorded,
whiletheWPSmustrecord“Essential,Non-EssentialandSupplementary
(whenrequired)variables”.
PQRmustrecord“EssentialandSupplementary”variables.
82
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1. VerifyWPShasbeenproperlycompletedandaddressesrequirements
ofSectionIX (forAPIExam,meansEssentialVariablesandNon-Essentialvariablesare
addressed)API577par6.4page18
2. VerifyPQRhasbeenproperlycompletedandaddressesrequirements
ofSectionIX (forAPIExam,meansEssentialVariablesareaddressedandPQRissignedand
dated)API577par6.4page18
3. VerifyPQRessentialvariablesproperlysupporttherangespecifiedin
WPS (forAPIExam,meansEssentialVariablesareaddressedandPQRissignedanddated)API577
par6.4page18
83
:363455HYLHZ,QVWUXFWLRQV
INSTRUCTIONSforCheckingWPSandPQR
STEP1 Locatetheappropriate“WeldingVariablesChart”fortheWeldingPROCESS(i.e.SMAW– QW253,SAW-QW254orGTAWQW256……thesearetheonlythreethatwillbeontheAPIExam).
STEP2 VerifyPQRissignedbyManufacture/Contractor– QW202(b).
STEP3 VerifyWPSreferencesthesupportingPQR– QW201(b).
STEP4 VerifyallNon-EssentialvariablesareaddressedontheWPS,andvalidatethatonthechecklist(e.g.enter“OK”or“ERROR”in
theVALIDATEcolumn)- QW201(b).
STEP5 Listvaluesforall“ESSENTIAL”variablesonChecklistfromthePQR– QW202(b).
STEP6 Listvaluesforall“ESSENTIAL”variablesonChecklistfromtheWPS– QW201(b).
STEP7 UseSectionIXtodetermineandlistthe“ACCEPTABLE”rangeforallessentialvariables(basedonthePQRresults)
STEP8 Comparethe“Acceptable”rangeagainsttheWPSvaluesanddocumentthefindingsinthe“VALIDATE”column.
STEP9 CheckTESTINGdataonPQRandverifycorrecttype/numberofBENDspecimens(i.e.2face&2Root,etc)weretestedand
resultsareacceptableorrejectable.Recordanswerin“Validate”columnofchecklist.
STEP10 CheckTESTINGdataonPQRandverifycorrecttype/numberofTENSILEspecimens(i.e.2ormore,dependingonthickness)
weretestedandresultsareacceptableorrejectable.Recordanswerin“Validate”columnofchecklist.
STEP11 CheckforP-Noand/orF-Nomistakes.
84
Practice Question for Reviewing
WPS/PQR
3UDFWLFH4XHVWLRQ
5HYLHZ:36-&33DQG345-&334
1.)IsthePQRsigned&dated?
2.)NowchecktheEssential,Non-essentialvariablesandrangesqualified
85
WPS/PQR“Review”Results
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ReviewofWPS#
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Dated:
SupportingPQR#
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Dated:
Paragraph
BriefofVariables
Essential
Par4:
QW402Joints
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4:
BaseMetals
Par4:
QW404Filler
Metals
Par4:
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4:
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Par4:
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Par4:
Par4:
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Technique
Par4:
9/11/2001
9/12/2001
STEP4
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1
1
STEP7
Validate
QualifiedFor?
OKorError
----------------3/16”to1”
½”plateN/A
P1
F3
1
----Maxof1”
---------
OK
OK
OK
OK
PQRshouldbe1/16”to1”
.8
I Tqualified
E
.9
tPass>½inch
E
.11
I PͲNo.qualified
E
.4
I FͲNumber
E
.5
I AͲNumber
E
.6
I Diameter
.30
It
.33
I AWSClassification
NE
.1
+Position
NE
.3
I np Verticalwelding
NE
1.
Decrease>100oF
.2
I Preheatmaintenance
.1
I PWHT
E
.4
Tlimits
E
.4
I Currentorpolarity
NE
Ͳ
.8
I I&Erange
NE
Ͳ
.1
I String/Weave
NE
Ͳ
.5
I Methodofcleaning
NE
Ͳ
.6
I Methodbackgouge
NE
Ͳ
-----
.9
I Multitosinglepass/side
NE
Ͳ
-----
OK
-----
OK
NE
E
Ͳ
½”
Ͳ
Ͳ
Ͳ
50oF
E
NE
None
-----
.25
I Manualorautomatic
NE
Ͳ
r Peening
NE
Ͳ
.64
UseofThermalProcesses
None
-----
ERROR– shouldbeF3
OK
OK
OK
OK
OK
OK
50oF
50oF
OK
None
None
OK
Ͳ
.26
E
1/16”to1”
OK
OK
-----
None
-----
-----
-----------------
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OK
OK
OK
OK
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OK
OK
OK
OK
86
WPS/PQR“Review”Results
Numberofbends
Required
OnPQR
(#&Type)
(#&Type)
2F&2ROR4S
4SIDES
NOTE:
BENDSPECIMENS
Results
AllowableDefects
OnPQR
1/8”
OK
Validate
(OkorError)
OK
1.OpendiscontinuityinweldorHAZ<1/8”(SeeQW-163,page6)
2.Ignoreopendiscontinuityoncorners,unlessresultfromLOF,Slagorinternaldiscontinuity
TENSILESPECIMENS
CompareResults
Ultimate
MSTSofBase
Failure
#onPQR
Metal
Stress
NumberofTensileSpecimens
#Required
2
2
60,000PSI
57,038Base
66,158Weld
$UWLFOH,9
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Validate
(OkorError)
OK
NOTE:1.FailureStress(failedin“BaseMetal”)mustbe• .95%ofMSTS(seeQW-153,page4)
2.FailureStress(failedin“WELD”)mustbe• MSTS(QW-153)
3.Verifythatthe“UltimateFailureStress” iscalculatedproperly(S=Load/Area)– (seeQW-152,page4)
CheckforP-No,F-Noand/orSpecificationmistakesontheWPS/PQR.
Results- NoF-NoorP-Noerrors.
87
Practice Questions
for Reviewing WPS/PQR
Practice Question # 30
IstheP#qualifiedinaccordancewithASMESectionIX?
Result– Yes,P8
(VVHQWLDO
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345-&334
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88
Practice Questions
for Reviewing WPS/PQR
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Practice Question # 31
$UWLFOH,9
4:
IsthebasemetalthicknessinaccordancewithASMESectionIX?
Result– No,PQRcouponwas½”whichqualifiesthk rangeof3/16”to1”,
WPSindicated1/16”to1”
89
Practice Questions
for Reviewing WPS/PQR
8VH:36-&33DQG345-&334WRDQVZHUWKHIROORZLQJTXHVWLRQV
Practice Question # 32
IstheshieldinggasinaccordancewithASMESectionIX?
Result– NO,WPSisforsinglegas(argon)andPQRisfor75/25mix
Essential
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9DULDEOHV
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Practice Questions
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8VH:36-&33DQG345-&334WRDQVZHUWKHIROORZLQJTXHVWLRQV
Practice Question # 33
IstheF#qualifiedinaccordancewithASMESectionIX?
Result– NO,ER304isF6&E7018isaF4
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3DU4:
7DEOH4:
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(5LV)
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Practice Questions
for Reviewing WPS/PQR
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Practice Question # 34
ArethetensiletestinaccordancewithASMESectionIX?
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‡ PWHT temps, see Table UCS-56
‡ Partial HT requires 5 ft overlap for each successive heats (partial means part cannot fit
into furnace) per par UW-40(a)(2).
‡ HT of welds includes a zone extend 1t or 2”, whichever is less, beyond each side of the
weld (par UW-40(a)
‡ No control of temperature up to 800oF. Par UCS-56(c.)
‡ Heating rate above 800oF shall not be more than 400oF per hr/max metal thickness. Par
UCS-56(d)(1)(2).
‡ Variation in temperature cannot exceed 250oF in any 15 ft length of vessel. Par UCS56(d)(2)
‡ Holding time is per Table UCS-56
‡ During holding time, temperature cannot vary by more than 150oF. Par UCS-56(d)(3).
‡ Cool down rate shall not be more than 500oF per hr/max metal thickness. No control
necessary below 800oF. Par UCS-56(d)(5).
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long should the vessel be maintained at this PWHT temperature?
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long should the vessel be maintained at this PWHT temperature?
ANSWER 4hrs &15min
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long should the vessel be maintained at this PWHT temperature?
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Ifapprovedbytheengineer.
Apreheatof300oForhigherismaintainedduringwelding
PWHTtemperaturemaintainedforadistancenotlessthan2xt,fromthetoeoftheweld.
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1. Preheat temperature maintained at a minimum of 300oF.
2. Preheat temperature maintained at a distance of 4” or 4t, whichever is
greater, on each side of weld
3. Maximum interpass temperature of 600oF
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Welding Procedure (WPS),
Procedure Qualification Record (PQR)
and
Welder Performance Qualification
(WPQ)
Forms
Index
x WPS JCP-P101
x PQR JCP-PQ101
x WPS JCP-P201
x PQR JCP-PQ201
x WPS JCP-P301
x PQR JCP-PQ301
x Rod Burner WPQ Form – with qualified range
x Rod Burner WPQ Form – without qualified range
x Blank WPS Form
x Blank PQR Form
x Blank WPQ Form
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS)
(See Section IX QW-200.1)
Company Name
JC Penny
By
Mr. Penny
Welding Procedure Specification No. JCP-P101
Date 9/11/2001
Supporting PQR No.(s)JCP-PQ101
Revision No. 0
Date 9/11/2001
Welding Process(es)
SMAW
Type(s)
Manual
Test Description
Joints (QW 402)
Joint Design
Single V Groove and Fillets
Root Spacing
.0625” to 1.250”
Backing: Yes
x
No
x
Backing Material (Type)
Metal
(Refer to both backing and retainers)
Metal
Nonmetallic
Nonfusing Metal
Other
Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts
to be welded. Where applicable, the details of weld groove may be specified.
(At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence
(e.g. for notch toughness procedures, for multiple process procedures, etc)).
Base Metals (QW 403)
P-No.
1
Group No.
to P-No.
1
Group No.
OR
Specification and type/grade
to Specification and type/grade
OR
Chemical Analysis and Mech. Prop.
to Chemical Analysis and Mech. Prop.
Thickness Range:
Base Metal: Groove 1/16” to 1”
Fillet
All
Maximum pass thickness ” ½” (yes) x
(no)
Pipe Diameter (Groove)
2 7/8”
(Fillet)
All
Filler Metals (QW 404)
Spec. No. (SFA) _ _ _ _ _ _ _ _ _
AWS No. (Class) _ _ _ _ _ _ _ _ _
F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _
A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _
Size of Filler Metals_ _ _ _ _ _ _ _
Weld Metal:
Thickness Range:
Groove_ _ _ _ _ _ _ _ _ _ _
Fillet_ _ _ _ _ _ _ _ _ _ _ _
Electrode-Flux (Class) _ _ _ _ _ _ _
Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _
Consumable Insert_ _ _ _ _ _ _ _ _
Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
1st Filler Metal
5.1
E-7018
3
1
3/32”, 1/8”, 5/16”
.0625” to 1.0”
.250” to 1.0”
N/A
N/A
N/A
2nd Filler Metal
Positions (QW 405)
Position(s) of Groove
ALL
Welding Progression: UP X
Position(s) of fillet
ALL
Preheat (QW 406)
Preheat Temp, Min
Interpass Temp, Max
Preheat Maintenance
WPS No. JCP-P101
Postweld Heat Treatment (QW 407)
Temperature Range None
Time Range
Other
Down
Gas (QW 408)
50oF
350oF
None
(Continuous or special heating, where applicable, should be recorded.
Percent Composition
Mixtures
Flow Rate
Gases
N/A
Shielding
Trailing
Backing
Other
Page of 2
Rev.# 0
Electrical Characteristics (QW 409)
Filler Metal
Weld
Pass(es)
Process
Classifi
-cation
Diameter
All
SMAW
E-7018
1/8”
Current
Type
and
Polarity
DCEP
Amps
(Range)
70 to
200
Wire
Feed
Speed
(Range)
Energy or
Power
(Range)
Volts
(Range)
Travel
Speed
(Range)
N/A
N/A
19 - 25
5 to 7
Other (e.g
Remarks, Comments, Hot Wire
Addition,
Technique, Torch
Angle, etc)
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current
N/A
Tungsten Electrode Size and Type
N/A
Mode of Metal Transfer for GMAW or FCAW
Heat Input (max.)
(Pure Tungsten, 2% Thoriated, etc)
N/A
(Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410)
String or Weave Bead
String or Weave
Orifice, Nozzle, or Gas Cup Size
N/A
Initial and Interpass cleaning (Brushing, Grinding, etc
Method of Back Gouging
Grinding
Oscillation
N/A
Contact Tube to Work Distance
N/A
Multiple or Single Pass (per side)
Multiple of Single Electrodes
Peening
N/A
Other
N/A
Grinding, Chipping or Wire Brush
Multiple or Single
Single
Page 2 of 2
ASME Section IX –PQR
QW-483 Suggested Format For Procedure Qualification Record (PQR)
(See Section IX QW-200.2)
Company Name
JC Penny
PQR No.
JCP-PQ101
WPS # JCP-P101
Date 9/12/2001
Welding Process(es)
SMAW
Type(s)
Manual
Joints (QW 402)
Groove D
G
Design
i off TTest C
Coupon
Base Metals (QW 403)
Material Spec.
SA-53 Gr B
P-No.
to
P-No.
Thickness of Test Coupon ½”
Diameter of Test Coupon 6”
Other
Postweld Heat Treatment (QW 407)
Temperature Range
None
Time Range
Other
Gas (QW 408)
Filler Metals (QW 404)
SFA Specification 5.1
AWS Classification
E-7018
Filler Metal F-No.
4
Weld Metal Analysis A-No.
1
Size of Filler Metal
5/32”
Other
Weld Metal Thickness
Positions (QW 405)
Position of Groove
ALL
Weld Progression (Uphill, Downhill)
Other
Preheat (QW 406)
Preheat Temp 50oF
Interpass Temp
Other
Shielding
Trailing
Backing
Gases
N/A
Percent Composition
Mixtures
Flow Rate
Electrical Characteristics (QW 409)
Current DC
Polarity Straight
Amps: 150-300
Volts 20-28
Tungsten Electrode Size
N/A
Other
Technique (QW 410)
Travel Speed 3”/min
String or Weave Bead
Stringer
Oscillation
Multipass or Single Pass (per side)
Multiple
Single or Multiple Electrodes Single
Other
QW 483 (back)
PQR No. JCP-PQ101
Specimen No.
Width
(inch)
.750
.756
T1
T2
SIDE
SIDE
SIDE
SIDE
#
#
#
#
Specimen
No.
Thickness
(inch)
.455
.451
Type and Figure No.
1
2
3
4
Notch
Location
Area
(sq. inches)
.341
.341
Ultimate Load
(lbs)
19,450
22,560
Guided Bend Tests (QW -160)
Ultimate Stress
(psi)
57,038
66,158
Test
Temp
No
Impact
Values
Type of Failure
& Location
Pass - Base
Pass - Weld
Results
Pass
Pass
Pass
Pass
Notch Toughness Tests (QW -170)
Notch
Type
Result – Satisfactory: YES
Macro Results
Tensile Test (QW -150)
Lateral Exp
% Shear
Mils
Fillet Weld Test (QW -180)
Penetration into Parent Metal YES
Drop Weight
Break
No Break
No
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………………………………………………….
Welder’s Name Jack Shift Jr
Test conducted by:
Clock No.
Stamp No.
Laboratory Test No.
B2
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 ASME Section IX.
Manufacturer
Date
9/11/2001
By:
JC Penny
Jack Shift Sr
Page 2 of 2
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS)
(See Section IX QW-200.1)
Company Name
JC Penny
By
Mr. Penny
Welding Procedure Specification No. JCP-P201
Date 8/11/2001
Supporting PQR No.(s)JCP-PQ201
Revision No. 0
Date 8/11/2001
Welding Process(es)
GTAW
Type(s)
Manual
Test Description
Joints (QW 402)
Joint Design
Single V Groove
Root Spacing
1.250”
Backing: Yes
x
No
x
Backing Material (Type)
Solid Metal or weld metal
(Refers to both backing and retainers)
Metal
Nonmetallic
Nonfusing Metal
Other
Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts
to be welded. Where applicable, the details of weld groove may be specified.
(At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence
(e.g. for notch toughness procedures, for multiple process procedures, etc)).
Base Metals (QW 403)
P-No.
Group No.
to P-No.
Group No.
OR
Specification and type/grade SA 240 Type 304
to Specification and type/grade SA 240 Type 304
OR
Chemical Analysis and Mech. Prop.
to Chemical Analysis and Mech. Prop.
Thickness Range:
Base Metal: Groove 1/16” to 1”
Fillet
All
Maximum pass thickness ” ½” (yes) x
(no)
Pipe Diameter (Groove)
2 7/8”
(Fillet)
All
Filler Metals (QW 404)
Spec. No. (SFA):
5.9
AWS No. (Class):
ER304
F-No.:
F-6
A-No.:
A-8
Size of Filler Metals: 3/32”, 1/8”,5/16”
Weld MetalThickness Range:
Groove: .0625” to 1.0”
Fillet: No limit
Electrode-Flux (Class):
Flux Type:
Consumable Insert:
Other:
N/A
N/A
None
N/A
No single pass > ½”
Positions (QW 405)
Position(s) of Groove
ALL
Welding Progression: UP X
Position(s) of fillet
ALL
Preheat (QW 406)
Preheat Temp, Min
Interpass Temp, Max
Preheat Maintenance
Page of 2
Rev.# 0
WPS No. JCP-P201
Postweld Heat Treatment (QW 407)
Temperature Range None
Time Range
Other
Down
Gas (QW 408)
80oF
350oF
None
(Continuous or special heating, where applicable, should be recorded.
Gases
Argon
None
None
Shielding
Trailing
Backing
Other
Percent Composition
Mixtures
Flow Rate
Electrical Characteristics (QW 409)
Filler Metal
Current
Type
and
Polarity
Amps
(Range)
Wire
Feed
Speed
(Range)
Energy or
Power
(Range)
Volts
(Range)
Travel
Speed
(Range)
Weld
Pass(es)
Process
Classifi
-cation
Diameter
All
GTAW
ER304
3/32”
DCSP
60-100
N/A
N/A
N/A
N/A
All
All
GTAW
GTAW
ER304
ER304
1/8”
5/16””
DCSP
DCSP
70-110
90-160
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Other
(e.g Remarks,
Comments,
Hot Wire Addition,
Technique, Torch
Angle, etc)
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current
N/A
Tungsten Electrode Size and Type
Heat Input (max.)
N/A
2% Thoriated (EWTh-2) or Cesium Stablilized (EWCe-2)
Mode of Metal Transfer for GMAW or FCAW
(Pure Tungsten, 2% Thoriated, etc)
N/A
(Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410)
String or Weave Bead
String or Weave
Orifice, Nozzle, or Gas Cup Size
3/8” to ¾” diameter shielding gas cup size
Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping, Wire Brush or Thermal process
Method of Back Gouging
Grinding or thermal process
Oscillation
N/A
Contact Tube to Work Distance
N/A
Multiple or Single Pass (per side)
Multiple
Multiple of Single Electrodes
Single
Peening
None
Other
Page 2 of 2
ASME Section IX –PQR
QW-483 Suggested Format For Procedure Qualification Record (PQR)
(See Section IX QW-200.2)
Company Name
JC Penny
PQR No.
JCP-PQ201
WPS # JCP-P201
Date 8/12/2001
Welding Process(es)
GTAW
Type(s)
Manual
Joints (QW 402)
Groove D
G
Design
i off TTest C
Coupon
Base Metals (QW 403)
Material Spec.
SA-240 Type 304
P-No. 8
to
P-No.
8
Thickness of Test Coupon ½”
Diameter of Test Coupon Plate
Other
Postweld Heat Treatment (QW 407)
Temperature Range
None
Time Range
Other
Gas (QW 408)
Filler Metals (QW 404)
SFA Specification 5.18
AWS Classification
E-7018
Filler Metal F-No.
6
Weld Metal Analysis A-No.
8
Size of Filler Metal
N/A
Other
Weld Metal Thickness
Electrical Characteristics (QW 409)
Current DC
Polarity Straight
Amps: 90-100
Volts 20-28
Tungsten Electrode Size
1/8”
Other
½”
Positions (QW 405)
Position of Groove
1G
Weld Progression (Uphill, Downhill)
Other
Preheat (QW 406)
Preheat Temp 50oF
Interpass Temp 250oF
Other
Shielding
Trailing
Backing
Percent Composition
Gases
Mixtures
Flow Rate
Argon/CO 75%/25%
15-25
None
None
N/A
Technique (QW 410)
Travel Speed 5”/min
String or Weave Bead
Weave
Oscillation
Multipass or Single Pass (per side)
Multiple
Single or Multiple Electrodes Single
Other
QW 483 (back)
PQR No. JCP-PQ101
Specimen No.
T1
T2
Face # 1
Face # 2
Root # 3
Root # 4
Specimen
No.
Width(W)
(inch)
.750
.750
Thickness(y)
(inch)
.440
.449
Type and Figure No.
Notch
Location
Area
(sq. inches)
.330
.337
Ultimate Load
(lbs)
24,450
24,000
Guided Bend Tests (QW -160)
Ultimate Stress
(psi)
74,090
71,216
Test
Temp
No
Impact
Values
Type of Failure
& Location
Pass - Weld
Pass - Base
Results
Pass
Pass
Pass
Pass
Notch Toughness Tests (QW -170)
Notch
Type
Result – Satisfactory: YES
Macro Results
Tensile Test (QW -150)
Lateral Exp
% Shear
Mils
Fillet Weld Test (QW -180)
Penetration into Parent Metal YES
Drop Weight
Break
No Break
No
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………………………………………………….
Welder’s Name Jack Shift Jr
Clock No.
Test conducted by: Shear Metal Testing Lab
Stamp No.
Laboratory Test No.
B2
SM-1001
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 ASME Section IX.
Manufacturer
Date
8/12/2001
By:
JC Penny
Jack Shift Sr
Page 2 of 2
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS)
(See Section IX QW-200.1)
Company Name
JC Penny
By
Mr. Penny
Welding Procedure Specification No. JCP-P301
Date 9/11/2001
Supporting PQR No.(s)JCP-PQ301
Revision No. 0
Date 9/11/2001
Welding Process(es)
SMAW
Type(s)
Manual
Test Description
Joints (QW 402)
Joint Design
Single V Groove and Fillets
Root Spacing
.0625” to 1.250”
Backing: Yes
x
No
x
Backing Material (Type)
Metal
(Refer to both backing and retainers)
Metal
Nonmetallic
Nonfusing Metal
Other
Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts
to be welded. Where applicable, the details of weld groove may be specified.
(At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence
(e.g. for notch toughness procedures, for multiple process procedures, etc)).
Base Metals (QW 403)
P-No.
1
Group No.
to P-No.
1
Group No.
OR
Specification and type/grade
to Specification and type/grade
OR
Chemical Analysis and Mech. Prop.
to Chemical Analysis and Mech. Prop.
Thickness Range:
Base Metal: Groove 1/16” to 1”
Fillet
All
Maximum pass thickness ” ½” (yes) x
(no)
Pipe Diameter (Groove)
2 7/8”
(Fillet)
All
Filler Metals (QW 404)
Spec. No. (SFA) _ _ _ _ _ _ _ _ _
AWS No. (Class) _ _ _ _ _ _ _ _ _
F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _
A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _
Size of Filler Metals_ _ _ _ _ _ _ _
Weld Metal:
Thickness Range:
Groove_ _ _ _ _ _ _ _ _ _ _
Fillet_ _ _ _ _ _ _ _ _ _ _ _
Electrode-Flux (Class) _ _ _ _ _ _ _
Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _
Consumable Insert_ _ _ _ _ _ _ _ _
Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
1st Filler Metal
5.1
E-7018
3
1
3/32”, 1/8”, 5/16”
.0625” to 1.0”
.250” to 1.0”
N/A
N/A
N/A
2nd Filler Metal
Positions (QW 405)
Position(s) of Groove
ALL
Welding Progression: UP X
Position(s) of fillet
ALL
Preheat (QW 406)
Preheat Temp, Min
Interpass Temp, Max
Preheat Maintenance
WPS No. JCP-P301
Postweld Heat Treatment (QW 407)
Temperature Range None
Time Range
Other
Down
Gas (QW 408)
50oF
350oF
None
(Continuous or special heating, where applicable, should be recorded.
Percent Composition
Mixtures
Flow Rate
Gases
N/A
Shielding
Trailing
Backing
Other
Page 1 of 2
Rev.# 0
Electrical Characteristics (QW 409)
Filler Metal
Weld
Pass(es)
Process
Classifi
-cation
Diameter
All
SMAW
E-7018
1/8”
Current
Type
and
Polarity
DCEP
Amps
(Range)
70 to
200
Wire
Feed
Speed
(Range)
Energy or
Power
(Range)
Volts
(Range)
Travel
Speed
(Range)
N/A
N/A
19 - 25
5 to 7
Other (e.g
Remarks, Comments, Hot Wire
Addition,
Technique, Torch
Angle, etc)
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current
N/A
Tungsten Electrode Size and Type
N/A
Mode of Metal Transfer for GMAW or FCAW
Heat Input (max.)
(Pure Tungsten, 2% Thoriated, etc)
N/A
(Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410)
String or Weave Bead
String or Weave
Orifice, Nozzle, or Gas Cup Size
N/A
Initial and Interpass cleaning (Brushing, Grinding, etc
Method of Back Gouging
Grinding
Oscillation
N/A
Contact Tube to Work Distance
N/A
Multiple or Single Pass (per side)
Multiple of Single Electrodes
Peening
N/A
Other
N/A
Grinding, Chipping or Wire Brush
Multiple or Single
Single
Page 2 of 2
ASME Section IX –PQR
QW-483 Suggested Format For Procedure Qualification Record (PQR)
(See Section IX QW-200.2)
Company Name
JC Penny
PQR No.
JCP-PQ301
WPS # JCP-P301
Date 9/12/2001
Welding Process(es)
SMAW
Type(s)
Manual
Joints (QW 402)
Groove D
G
Design
i off TTest C
Coupon
Base Metals (QW 403)
Material Spec.
SA-53 Gr B
P-No.
to
P-No.
Thickness of Test Coupon ½”
Diameter of Test Coupon 6”
Other
Postweld Heat Treatment (QW 407)
Temperature Range
None
Time Range
Other
Gas (QW 408)
Filler Metals (QW 404)
SFA Specification 5.1
AWS Classification
E-7018
Filler Metal F-No.
4
Weld Metal Analysis A-No.
1
Size of Filler Metal
5/32”
Other
Weld Metal Thickness
Positions (QW 405)
Position of Groove
ALL
Weld Progression (Uphill, Downhill)
Other
Preheat (QW 406)
Preheat Temp 50oF
Interpass Temp
Other
Shielding
Trailing
Backing
Gases
N/A
Percent Composition
Mixtures
Flow Rate
Electrical Characteristics (QW 409)
Current DC
Polarity Straight
Amps: 150-300
Volts 20-28
Tungsten Electrode Size
N/A
Other
Technique (QW 410)
Travel Speed 3”/min
String or Weave Bead
Stringer
Oscillation
Multipass or Single Pass (per side)
Multiple
Single or Multiple Electrodes Single
Other
QW 483 (back)
PQR No. JCP-PQ301
Specimen No.
Width
(inch)
.750
.756
T1
T2
Type and Figure No.
SIDE # 1
SIDE # 2
Face # 1
Face # 2
Specimen
No.
Thickness
(inch)
.455
.451
Notch
Location
Area
(sq. inches)
.341
.341
Ultimate Load
(lbs)
19,450
22,560
Guided Bend Tests (QW -160)
Ultimate Stress
(psi)
57,038
66,158
Test
Temp
No
Impact
Values
Type of Failure
& Location
Pass - Base
Pass - Weld
Results
Pass
Pass
Pass
Pass
Notch Toughness Tests (QW -170)
Notch
Type
Result – Satisfactory: YES
Macro Results
Tensile Test (QW -150)
Lateral Exp
% Shear
Mils
Fillet Weld Test (QW -180)
Penetration into Parent Metal YES
Drop Weight
Break
No Break
No
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………………………………………………….
Welder’s Name Jack Shift Jr
Test conducted by:
Clock No.
Stamp No.
Laboratory Test No.
B2
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 ASME Section IX.
Manufacturer
Date
9/11/2001
By:
JC Penny
Jack Shift Sr
Page 2 of 2
ASME Section IX – Welder Qualification
Homework – WPQ’s
QW-484A Suggested Format For Welder Performance Qualification (WPQ)
(See Section IX QW-301)
Welder(s) Name
Mr. Rod Burner
Identification Number
A11
Test Description
Identification of WPS followed
WPS 101
Test Coupon
Production Weld
Specification and Type/Grade or UNS Number of base metal(s) A 106B to A106B
Thickness
.280
Testing Variables and Qualification Limits
Welding Variables (QW350)
Actual Values
Welding Process(es)
Type (i.e. manual, semi-automatic) used
Manual
Backing (with or without)
None
Test Coupon
Range Qualified
SMAW
Production Weld (dia if pipe)
SMAW
Manual
F1 to F3 with,F3 wo
__
6” NPS
• 2 7/8” OD
Base metal P-Number to P-Number
P-1 to P-1
P1-P15F, P34, P41-P49
Filler Metal or Electrode Spec (SFA)
5.1
-------
Filler Metal F-Number
F3
F1,F2, & F3
Consumable Insert (GTAW or PAW)
N/A
-------
Filler Metal Type (solid/metal or flux cored/powder)
N/A
-------
Deposited Thickness for each process
Process 1:
SMAW
3 layers minimum
Process 2:
Yes
3 layers minimum
No
Yes
.280”
No
Position qualified (1G,2G,3G,4G,5G,6G, etc)
” .560
----
-------
2G
F, H
Vertical progression (uphill or downhill)
Uphill
Uphill
Inert Gas Backing (GTAW, PAW, GMAW)
N/A
-------
GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit)
N/A
-------
GTAW Current type/polarity (AC,DCEP,DCEN)
N/A
-------
RESULTS
Visual examination of completed weld (QW 302.4)
Acceptable
Transverse face and root bends (QW 462.3(a)
Type
Longitudinal bends (QW 462.3(b)
Results
Side bends (QW 462.2)
Type
Face
No defects – Acceptable
Root
No defects - Acceptable
Results
Alternative Volumetric Examination Results (QW 191)
N/A
Fillet weld – fracture test (QW 181.2)
Length and percent of defects
N/A
Fillet size (in.)
Concavity/convexity (in.)
N/A
Macro examination (QW 184)
RT or
x
UT
Other tests
Film or specimens evaluated by
Company
Mechanical tests conducted by Ben Tension
Laboratory test no. 123
Welding supervised by Red Eye
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the
requirements of Section IX of the ASME Code.
Organization
Date
By
April 7, 2010
Worlds Best Fabricator
John Doe
Welding Procedure (WPS),
Procedure Qualification Record (PQR)
and
Welder Performance Qualification
(WPQ)
Forms
Index
x WPS JCP-P101
x PQR JCP-PQ101
x WPS JCP-P201
x PQR JCP-PQ201
x WPS JCP-P301
x PQR JCP-PQ301
x Rod Burner WPQ Form – with qualified range
x Rod Burner WPQ Form – without qualified range
x Blank WPS Form
x Blank PQR Form
x Blank WPQ Form
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS)
(See Section IX QW-200.1)
Company Name
JC Penny
By
Mr. Penny
Welding Procedure Specification No. JCP-P101
Date 9/11/2001
Supporting PQR No.(s)JCP-PQ101
Revision No. 0
Date 9/11/2001
Welding Process(es)
SMAW
Type(s)
Manual
Test Description
Joints (QW 402)
Joint Design
Single V Groove and Fillets
Root Spacing
.0625” to 1.250”
Backing: Yes
x
No
x
Backing Material (Type)
Metal
(Refer to both backing and retainers)
Metal
Nonmetallic
Nonfusing Metal
Other
Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts
to be welded. Where applicable, the details of weld groove may be specified.
(At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence
(e.g. for notch toughness procedures, for multiple process procedures, etc)).
Base Metals (QW 403)
P-No.
1
Group No.
to P-No.
1
Group No.
OR
Specification and type/grade
to Specification and type/grade
OR
Chemical Analysis and Mech. Prop.
to Chemical Analysis and Mech. Prop.
Thickness Range:
Base Metal: Groove 1/16” to 1”
Fillet
All
Maximum pass thickness ” ½” (yes) x
(no)
Pipe Diameter (Groove)
2 7/8”
(Fillet)
All
Filler Metals (QW 404)
Spec. No. (SFA) _ _ _ _ _ _ _ _ _
AWS No. (Class) _ _ _ _ _ _ _ _ _
F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _
A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _
Size of Filler Metals_ _ _ _ _ _ _ _
Weld Metal:
Thickness Range:
Groove_ _ _ _ _ _ _ _ _ _ _
Fillet_ _ _ _ _ _ _ _ _ _ _ _
Electrode-Flux (Class) _ _ _ _ _ _ _
Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _
Consumable Insert_ _ _ _ _ _ _ _ _
Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
1st Filler Metal
5.1
E-70
3
1
3/32”, 1/8”, 5/16”
.0625” to 1.0”
.250” to 1.0”
N/A
N/A
N/A
2nd Filler Metal
Positions (QW 405)
Position(s) of Groove
ALL
Welding Progression: UP X
Position(s) of fillet
ALL
Preheat (QW 406)
Preheat Temp, Min
Interpass Temp, Max
Preheat Maintenance
WPS No. JCP-P101
Postweld Heat Treatment (QW 407)
Temperature Range None
Time Range
Other
Down
Gas (QW 408)
50oF
350oF
None
(Continuous or special heating, where applicable, should be recorded.
Percent Composition
Mixtures
Flow Rate
Gases
N/A
Shielding
Trailing
Backing
Other
Page of 2
Rev.# 0
Electrical Characteristics (QW 409)
Filler Metal
Weld
Pass(es)
Process
Classifi
-cation
Diameter
All
SMAW
E-7018
1/8”
Current
Type
and
Polarity
DCEP
Amps
(Range)
70 to
200
Wire
Feed
Speed
(Range)
Energy or
Power
(Range)
Volts
(Range)
Travel
Speed
(Range)
N/A
N/A
19 - 25
5 to 7
Other (e.g
Remarks, Comments, Hot Wire
Addition,
Technique, Torch
Angle, etc)
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current
N/A
Tungsten Electrode Size and Type
N/A
Mode of Metal Transfer for GMAW or FCAW
Heat Input (max.)
(Pure Tungsten, 2% Thoriated, etc)
N/A
(Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410)
String or Weave Bead
String or Weave
Orifice, Nozzle, or Gas Cup Size
N/A
Initial and Interpass cleaning (Brushing, Grinding, etc
Method of Back Gouging
Grinding
Oscillation
N/A
Contact Tube to Work Distance
N/A
Multiple or Single Pass (per side)
Multiple of Single Electrodes
Peening
N/A
Other
N/A
Grinding, Chipping or Wire Brush
Multiple or Single
Single
Page 2 of 2
ASME Section IX –PQR
QW-483 Suggested Format For Procedure Qualification Record (PQR)
(See Section IX QW-200.2)
Company Name
JC Penny
PQR No.
JCP-PQ101
WPS # JCP-P101
Date 9/12/2001
Welding Process(es)
SMAW
Type(s)
Manual
Joints (QW 402)
Groove D
G
Design
i off TTest C
Coupon
Base Metals (QW 403)
Material Spec.
SA-53 Gr B
P-No.
to
P-No.
Thickness of Test Coupon ½”
Diameter of Test Coupon 6”
Other
Postweld Heat Treatment (QW 407)
Temperature Range
None
Time Range
Other
Gas (QW 408)
Filler Metals (QW 404)
SFA Specification 5.1
AWS Classification
E-7018
Filler Metal F-No.
4
Weld Metal Analysis A-No.
1
Size of Filler Metal
5/32”
Other
Weld Metal Thickness
Positions (QW 405)
Position of Groove
ALL
Weld Progression (Uphill, Downhill)
Other
Preheat (QW 406)
Preheat Temp 50oF
Interpass Temp
Other
Shielding
Trailing
Backing
Gases
N/A
Percent Composition
Mixtures
Flow Rate
Electrical Characteristics (QW 409)
Current DC
Polarity Straight
Amps: 150-300
Volts 20-28
Tungsten Electrode Size
N/A
Other
Technique (QW 410)
Travel Speed 3”/min
String or Weave Bead
Stringer
Oscillation
Multipass or Single Pass (per side)
Multiple
Single or Multiple Electrodes Single
Other
QW 483 (back)
PQR No. JCP-PQ101
Specimen No.
Width
(inch)
.750
.756
T1
T2
SIDE
SIDE
SIDE
SIDE
#
#
#
#
Specimen
No.
Thickness
(inch)
.455
.451
Type and Figure No.
1
2
3
4
Notch
Location
Area
(sq. inches)
.341
.341
Ultimate Load
(lbs)
19,450
22,560
Guided Bend Tests (QW -160)
Ultimate Stress
(psi)
57,038
66,158
Test
Temp
No
Impact
Values
Type of Failure
& Location
Pass - Base
Pass - Weld
Results
Pass
Pass
Pass
Pass
Notch Toughness Tests (QW -170)
Notch
Type
Result – Satisfactory: YES
Macro Results
Tensile Test (QW -150)
Lateral Exp
% Shear
Mils
Fillet Weld Test (QW -180)
Penetration into Parent Metal YES
Drop Weight
Break
No Break
No
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………………………………………………….
Welder’s Name Jack Shift Jr
Test conducted by:
Clock No.
Stamp No.
Laboratory Test No.
B2
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 ASME Section IX.
Manufacturer
Date
9/11/2001
By:
JC Penny
Jack Shift Sr
Page 2 of 2
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS)
(See Section IX QW-200.1)
Company Name
JC Penny
By
Mr. Penny
Welding Procedure Specification No. JCP-P201
Date 8/11/2001
Supporting PQR No.(s)JCP-PQ201
Revision No. 0
Date 8/11/2001
Welding Process(es)
GTAW
Type(s)
Manual
Test Description
Joints (QW 402)
Joint Design
Single V Groove
Root Spacing
1.250”
Backing: Yes
x
No
x
Backing Material (Type)
Solid Metal or weld metal
(Refers to both backing and retainers)
Metal
Nonmetallic
Nonfusing Metal
Other
Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts
to be welded. Where applicable, the details of weld groove may be specified.
(At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence
(e.g. for notch toughness procedures, for multiple process procedures, etc)).
Base Metals (QW 403)
P-No.
Group No.
to P-No.
Group No.
OR
Specification and type/grade SA 240 Type 304
to Specification and type/grade SA 240 Type 304
OR
Chemical Analysis and Mech. Prop.
to Chemical Analysis and Mech. Prop.
Thickness Range:
Base Metal: Groove 1/16” to 1”
Fillet
All
Maximum pass thickness ” ½” (yes) x
(no)
Pipe Diameter (Groove)
2 7/8”
(Fillet)
All
Filler Metals (QW 404)
Spec. No. (SFA):
5.9
AWS No. (Class):
ER304
F-No.:
F-6
A-No.:
A-8
Size of Filler Metals: 3/32”, 1/8”,5/16”
Weld MetalThickness Range:
Groove: .0625” to 1.0”
Fillet: No limit
Electrode-Flux (Class):
Flux Type:
Consumable Insert:
Other:
N/A
N/A
None
N/A
No single pass > ½”
Positions (QW 405)
Position(s) of Groove
ALL
Welding Progression: UP X
Position(s) of fillet
ALL
Preheat (QW 406)
Preheat Temp, Min
Interpass Temp, Max
Preheat Maintenance
Page of 2
Rev.# 0
WPS No. JCP-P201
Postweld Heat Treatment (QW 407)
Temperature Range None
Time Range
Other
Down
Gas (QW 408)
80oF
350oF
None
(Continuous or special heating, where applicable, should be recorded.
Gases
Argon
None
None
Shielding
Trailing
Backing
Other
Percent Composition
Mixtures
Flow Rate
Electrical Characteristics (QW 409)
Filler Metal
Current
Type
and
Polarity
Amps
(Range)
Wire
Feed
Speed
(Range)
Energy or
Power
(Range)
Volts
(Range)
Travel
Speed
(Range)
Weld
Pass(es)
Process
Classifi
-cation
Diameter
All
GTAW
ER304
3/32”
DCSP
60-100
N/A
N/A
N/A
N/A
All
All
GTAW
GTAW
ER304
ER304
1/8”
5/16””
DCSP
DCSP
70-110
90-160
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Other
(e.g Remarks,
Comments,
Hot Wire Addition,
Technique, Torch
Angle, etc)
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current
N/A
Tungsten Electrode Size and Type
Heat Input (max.)
N/A
2% Thoriated (EWTh-2) or Cesium Stablilized (EWCe-2)
Mode of Metal Transfer for GMAW or FCAW
(Pure Tungsten, 2% Thoriated, etc)
N/A
(Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410)
String or Weave Bead
String or Weave
Orifice, Nozzle, or Gas Cup Size
3/8” to ¾” diameter shielding gas cup size
Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping, Wire Brush or Thermal process
Method of Back Gouging
Grinding or thermal process
Oscillation
N/A
Contact Tube to Work Distance
N/A
Multiple or Single Pass (per side)
Multiple
Multiple of Single Electrodes
Single
Peening
None
Other
Page 2 of 2
ASME Section IX –PQR
QW-483 Suggested Format For Procedure Qualification Record (PQR)
(See Section IX QW-200.2)
Company Name
JC Penny
PQR No.
JCP-PQ201
WPS # JCP-P201
Date 8/12/2001
Welding Process(es)
GTAW
Type(s)
Manual
Joints (QW 402)
Groove D
G
Design
i off TTest C
Coupon
Base Metals (QW 403)
Material Spec.
SA-240 Type 304
P-No. 8
to
P-No.
8
Thickness of Test Coupon ½”
Diameter of Test Coupon Plate
Other
Postweld Heat Treatment (QW 407)
Temperature Range
None
Time Range
Other
Gas (QW 408)
Filler Metals (QW 404)
SFA Specification 5.18
AWS Classification
E-7018
Filler Metal F-No.
6
Weld Metal Analysis A-No.
8
Size of Filler Metal
N/A
Other
Weld Metal Thickness
Electrical Characteristics (QW 409)
Current DC
Polarity Straight
Amps: 90-100
Volts 20-28
Tungsten Electrode Size
1/8”
Other
½”
Positions (QW 405)
Position of Groove
1G
Weld Progression (Uphill, Downhill)
Other
Preheat (QW 406)
Preheat Temp 50oF
Interpass Temp 250oF
Other
Shielding
Trailing
Backing
Percent Composition
Gases
Mixtures
Flow Rate
Argon/CO 75%/25%
15-25
None
None
N/A
Technique (QW 410)
Travel Speed 5”/min
String or Weave Bead
Weave
Oscillation
Multipass or Single Pass (per side)
Multiple
Single or Multiple Electrodes Single
Other
QW 483 (back)
PQR No. JCP-PQ01
Specimen No.
T1
T2
Face # 1
Face # 2
Root # 3
Root # 4
Specimen
No.
Width(W)
(inch)
.750
.750
Thickness(y)
(inch)
.440
.449
Type and Figure No.
Notch
Location
Area
(sq. inches)
.330
.337
Ultimate Load
(lbs)
24,450
24,000
Guided Bend Tests (QW -160)
Ultimate Stress
(psi)
74,090
71,216
Test
Temp
No
Impact
Values
Type of Failure
& Location
Pass - Weld
Pass - Base
Results
Pass
Pass
Pass
Pass
Notch Toughness Tests (QW -170)
Notch
Type
Result – Satisfactory: YES
Macro Results
Tensile Test (QW -150)
Lateral Exp
% Shear
Mils
Fillet Weld Test (QW -180)
Penetration into Parent Metal YES
Drop Weight
Break
No Break
No
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………………………………………………….
Welder’s Name Jack Shift Jr
Clock No.
Test conducted by: Shear Metal Testing Lab
Stamp No.
Laboratory Test No.
B2
SM-1001
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 ASME Section IX.
Manufacturer
Date
8/12/2001
By:
JC Penny
Jack Shift Sr
Page 2 of 2
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS)
(See Section IX QW-200.1)
Company Name
JC Penny
By
Mr. Penny
Welding Procedure Specification No. JCP-P301
Date 9/11/2001
Supporting PQR No.(s)JCP-PQ301
Revision No. 0
Date 9/11/2001
Welding Process(es)
SMAW
Type(s)
Manual
Test Description
Joints (QW 402)
Joint Design
Single V Groove and Fillets
Root Spacing
.0625” to 1.250”
Backing: Yes
x
No
x
Backing Material (Type)
Metal
(Refer to both backing and retainers)
Metal
Nonmetallic
Nonfusing Metal
Other
Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts
to be welded. Where applicable, the details of weld groove may be specified.
(At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence
(e.g. for notch toughness procedures, for multiple process procedures, etc)).
Base Metals (QW 403)
P-No.
1
Group No.
to P-No.
1
Group No.
OR
Specification and type/grade
to Specification and type/grade
OR
Chemical Analysis and Mech. Prop.
to Chemical Analysis and Mech. Prop.
Thickness Range:
Base Metal: Groove 1/16” to 1”
Fillet
All
Maximum pass thickness ” ½” (yes) x
(no)
Pipe Diameter (Groove)
2 7/8”
(Fillet)
All
Filler Metals (QW 404)
Spec. No. (SFA) _ _ _ _ _ _ _ _ _
AWS No. (Class) _ _ _ _ _ _ _ _ _
F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _
A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _
Size of Filler Metals_ _ _ _ _ _ _ _
Weld Metal:
Thickness Range:
Groove_ _ _ _ _ _ _ _ _ _ _
Fillet_ _ _ _ _ _ _ _ _ _ _ _
Electrode-Flux (Class) _ _ _ _ _ _ _
Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _
Consumable Insert_ _ _ _ _ _ _ _ _
Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
1st Filler Metal
5.1
E-7018
3
1
3/32”, 1/8”, 5/16”
.0625” to 1.0”
.250” to 1.0”
N/A
N/A
N/A
2nd Filler Metal
Positions (QW 405)
Position(s) of Groove
ALL
Welding Progression: UP X
Position(s) of fillet
ALL
Preheat (QW 406)
Preheat Temp, Min
Interpass Temp, Max
Preheat Maintenance
WPS No. JCP-P301
Postweld Heat Treatment (QW 407)
Temperature Range None
Time Range
Other
Down
Gas (QW 408)
50oF
350oF
None
(Continuous or special heating, where applicable, should be recorded.
Percent Composition
Mixtures
Flow Rate
Gases
N/A
Shielding
Trailing
Backing
Other
Page 1 of 2
Rev.# 0
Electrical Characteristics (QW 409)
Filler Metal
Weld
Pass(es)
Process
Classifi
-cation
Diameter
All
SMAW
E-7018
1/8”
Current
Type
and
Polarity
DCEP
Amps
(Range)
70 to
200
Wire
Feed
Speed
(Range)
Energy or
Power
(Range)
Volts
(Range)
Travel
Speed
(Range)
N/A
N/A
19 - 25
5 to 7
Other (e.g
Remarks, Comments, Hot Wire
Addition,
Technique, Torch
Angle, etc)
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current
N/A
Tungsten Electrode Size and Type
N/A
Mode of Metal Transfer for GMAW or FCAW
Heat Input (max.)
(Pure Tungsten, 2% Thoriated, etc)
N/A
(Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410)
String or Weave Bead
String or Weave
Orifice, Nozzle, or Gas Cup Size
N/A
Initial and Interpass cleaning (Brushing, Grinding, etc
Method of Back Gouging
Grinding
Oscillation
N/A
Contact Tube to Work Distance
N/A
Multiple or Single Pass (per side)
Multiple of Single Electrodes
Peening
N/A
Other
N/A
Grinding, Chipping or Wire Brush
Multiple or Single
Single
Page 2 of 2
ASME Section IX –PQR
QW-483 Suggested Format For Procedure Qualification Record (PQR)
(See Section IX QW-200.2)
Company Name
JC Penny
PQR No.
JCP-PQ301
WPS # JCP-P301
Date 9/12/2001
Welding Process(es)
SMAW
Type(s)
Manual
Joints (QW 402)
Groove D
G
Design
i off TTest C
Coupon
Base Metals (QW 403)
Material Spec.
SA-53 Gr B
P-No.
to
P-No.
Thickness of Test Coupon ½”
Diameter of Test Coupon 6”
Other
Postweld Heat Treatment (QW 407)
Temperature Range
None
Time Range
Other
Gas (QW 408)
Filler Metals (QW 404)
SFA Specification 5.1
AWS Classification
E-7018
Filler Metal F-No.
4
Weld Metal Analysis A-No.
1
Size of Filler Metal
5/32”
Other
Weld Metal Thickness
Positions (QW 405)
Position of Groove
ALL
Weld Progression (Uphill, Downhill)
Other
Preheat (QW 406)
Preheat Temp 50oF
Interpass Temp
Other
Shielding
Trailing
Backing
Gases
N/A
Percent Composition
Mixtures
Flow Rate
Electrical Characteristics (QW 409)
Current DC
Polarity Straight
Amps: 150-300
Volts 20-28
Tungsten Electrode Size
N/A
Other
Technique (QW 410)
Travel Speed 3”/min
String or Weave Bead
Stringer
Oscillation
Multipass or Single Pass (per side)
Multiple
Single or Multiple Electrodes Single
Other
QW 483 (back)
PQR No. JCP-PQ301
Specimen No.
Width
(inch)
.750
.756
T1
T2
Type and Figure No.
SIDE # 1
SIDE # 2
Face # 1
Face # 2
Specimen
No.
Thickness
(inch)
.455
.451
Notch
Location
Area
(sq. inches)
.341
.341
Ultimate Load
(lbs)
19,450
22,560
Guided Bend Tests (QW -160)
Ultimate Stress
(psi)
57,038
66,158
Test
Temp
No
Impact
Values
Type of Failure
& Location
Pass - Base
Pass - Weld
Results
Pass
Pass
Pass
Pass
Notch Toughness Tests (QW -170)
Notch
Type
Result – Satisfactory: YES
Macro Results
Tensile Test (QW -150)
Lateral Exp
% Shear
Mils
Fillet Weld Test (QW -180)
Penetration into Parent Metal YES
Drop Weight
Break
No Break
No
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………………………………………………….
Welder’s Name Jack Shift Jr
Test conducted by:
Clock No.
Stamp No.
Laboratory Test No.
B2
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 ASME Section IX.
Manufacturer
Date
9/11/2001
By:
JC Penny
Jack Shift Sr
Page 2 of 2
ASME Section IX – Welder Qualification
Homework – WPQ’s
QW-484A Suggested Format For Welder Performance Qualification (WPQ)
(See Section IX QW-301)
Welder(s) Name
Mr. Rod Burner
Identification Number
A11
Test Description
Identification of WPS followed
WPS 101
Test Coupon
Production Weld
Specification and Type/Grade or UNS Number of base metal(s) A 106B to A106B
Thickness
.280
Testing Variables and Qualification Limits
Welding Variables (QW350)
Actual Values
Welding Process(es)
Type (i.e. manual, semi-automatic) used
Manual
Backing (with or without)
None
Test Coupon
Range Qualified
SMAW
Production Weld (dia if pipe)
SMAW
Manual
F1 to F3 with,F3 wo
__
6” NPS
• 2 7/8” OD
Base metal P-Number to P-Number
P-1 to P-1
P1-P15F, P34, P41-P49
Filler Metal or Electrode Spec (SFA)
5.1
-------
Filler Metal F-Number
F3
F1,F2, & F3
Consumable Insert (GTAW or PAW)
N/A
-------
Filler Metal Type (solid/metal or flux cored/powder)
N/A
-------
Deposited Thickness for each process
Process 1:
SMAW
3 layers minimum
Process 2:
Yes
3 layers minimum
No
Yes
.280”
No
Position qualified (1G,2G,3G,4G,5G,6G, etc)
” .560
----
-------
2G
F, H
Vertical progression (uphill or downhill)
Uphill
Uphill
Inert Gas Backing (GTAW, PAW, GMAW)
N/A
-------
GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit)
N/A
-------
GTAW Current type/polarity (AC,DCEP,DCEN)
N/A
-------
RESULTS
Visual examination of completed weld (QW 302.4)
Acceptable
Transverse face and root bends (QW 462.3(a)
Type
Longitudinal bends (QW 462.3(b)
Results
Side bends (QW 462.2)
Type
Face
No defects – Acceptable
Root
No defects - Acceptable
Results
Alternative Volumetric Examination Results (QW 191)
N/A
Fillet weld – fracture test (QW 181.2)
Length and percent of defects
N/A
Fillet size (in.)
Concavity/convexity (in.)
N/A
Macro examination (QW 184)
RT or
x
UT
Other tests
Film or specimens evaluated by
Company
Mechanical tests conducted by Ben Tension
Laboratory test no. 123
Welding supervised by Red Eye
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the
requirements of Section IX of the ASME Code.
Organization
Date
By
April 7, 2010
Worlds Best Fabricator
John Doe
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS)
(See Section IX QW-200.1)
Company Name
By
Welding Procedure Specification No.
Date
Supporting PQR No.(s)
Date
Revision No.
Welding Process(es)
Joints (QW 402)
Joint Design
Root Spacing
Backing: Yes
Backing Material (Type)
Metal
Nonmetallic
Type(s)
Test Description
No
(Refer to both backing and retainers)
Nonfusing Metal
Other
Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts
to be welded. Where applicable, the details of weld groove may be specified.
(At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence
(e.g. for notch toughness procedures, for multiple process procedures, etc)).
Base Metals (QW 403)
P-No.
Group No.
to P-No.
Group No.
OR
Specification and type/grade
to Specification and type/grade
OR
Chemical Analysis and Mech. Prop.
to Chemical Analysis and Mech. Prop.
Thickness Range:
Base Metal: Groove
Fillet
Maximum pass thickness ≤ ½” (yes)
(no)
Filler Metals (QW 404)
Spec. No. (SFA) _ _ _ _ _ _ _ _ _
AWS No. (Class) _ _ _ _ _ _ _ _ _
F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _
A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _
Size of Filler Metals_ _ _ _ _ _ _ _
Filler Metal Product Form_ _ _ _ _
Weld Metal:
Thickness Range:
Groove_ _ _ _ _ _ _ _ _ _ _
Fillet_ _ _ _ _ _ _ _ _ _ _ _
Electrode-Flux (Class) _ _ _ _ _ _ _
Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _
Consumable Insert_ _ _ _ _ _ _ _ _
Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
1st Filler Metal
2nnd Filler Metal
Page 1 of 2
Positions (QW 405))
Position(s) of Groove
Welding Progression: UP
Position(s) of fillet
WPS No.
Postweld Heat Treatment (QW 407))
Temperature Range
Time Range
Other
Down
Preheat (QW 406))
Preheat Temp, Min
Interpass Temp, Max
Preheat Maintenance
Gas (QW 408))
Gases
Shielding
Trailing
Backing
Other
(Continuous or special heating, where applicable, should be recorded.
Rev.#
Percent Composition
Mixtures
Flow Rate
Electrical Characteristics (QW 4099)
Filler Metal
Weld
Pass(es)
Process
Classifi
-cation
Diameter
Current
Type
and
Polarity
Amps
(Range)
Wire
Feed
Speed
(Range)
Energy or
Power
(Range)
Volts
(Range)
Travel
Speed
(Range)
Other (e.g
Remarks, Comments, Hot Wire
Addition,
Technique, Torch
Angle, etc)
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current
Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW or FCAW
Heat Input (max.)
(Pure Tungsten, 2% Thoriated, etc)
(Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410)
String or Weave Bead
Orifice, Nozzle, or Gas Cup Size
Initial and Interpass cleaning (Brushing, Grinding, etc
Method of Back Gouging
Oscillation
Contact Tube to Work Distance
Multiple or Single Pass (per side)
Multiple of Single Electrodes
Electrode Spacing
Peening
Other
Page 2 of 2
ASME Section IX – PQR
Company Name
PQR No.
Welding Process(es)
QW-483 Suggested Format For Procedure Qualification Record (PQR)
(See Section IX QW-200.2)
Joints (QW 402)
WPS #
Type(s)
Date
.375"
Groove Design of Test Coupon
Base Metals (QW 403)
Material Spec.
P-No.
to
P-No.
Thickness of Test Coupon
Diameter of Test Coupon
Other
Postweld Heat Treatment (QW 407)
Temperature Range
Time Range
Other
Gas (QW 408)
Filler Metals (QW 404)
SFA Specification
AWS Classification
Filler Metal F-No.
Weld Metal Analysis A-No.
Size of Filler Metal
Other
Weld Metal Thickness
Positions (QW 405)
Position of Groove
ALL
Weld Progression (Uphill, Downhill)
Other
Preheat (QW 406)
Preheat Temp 50oF
Interpass Temp None
Other
Shielding
Trailing
Backing
Gases
N/A
Percent Composition
Mixtures
Flow Rate
Electrical Characteristics (QW 409)
Current
Polarity
Amps:
Volts
Tungsten Electrode Size
Other
Technique (QW 410)
Travel Speed
String or Weave Bead
Oscillation
Multipass or Single Pass (per side)
Single or Multiple Electrodes
Other
QW 483 (back)
PQR No.
Specimen No.
Width
(inch)
Thickness
(inch)
Type and Figure No.
Specimen
No.
Notch
Location
Area
(sq. inches)
Ultimate Load
(lbs)
Guided Bend Tests (QW -160)
Ultimate Stress
(psi)
Test
Temp
No
Impact
Values
Lateral Exp
% Shear
Mils
Fillet Weld Test (QW -180)
Type of Failure
& Location
Results
Notch Toughness Tests (QW -170)
Notch
Type
Result – Satisfactory: YES
Macro Results
Tensile Test (QW -150)
Penetration into Parent Metal YES
Drop Weight
Break
No Break
No
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………………………………………………….
Welder’s Name
Test conducted by:
Clock No.
Stamp No.
Laboratory Test No.
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 ASME Section IX.
Manufacturer
Date
By:
Page 2 of 2
ASME Section IX – Welder Qualification
Homework – WPQ’s
QW-484A Suggested Format For Welder Performance Qualification (WPQ)
(See Section IX QW-301)
Identification Number
Welder(s) Name
Test Description
Identification of WPS followed
Test Coupon
Production Weld
Specification and Type/Grade or UNS Number of base metal(s)
Thickness
Testing Variables and Qualification Limits
Welding Variables (QW350)
Actual Values
Range Qualified
Welding Process(es)
Type (i.e. manual, semi-automatic) used
Backing (with or without)
Test Coupon
Production Weld (dia if pipe)
Base metal P-Number to P-Number
Filler Metal or Electrode Spec (SFA)
Filler Metal F-Number
Consumable Insert (GTAW or PAW)
Filler Metal Type (solid/metal or flux cored/powder)
Deposited Thickness for each process
Process 1:
3 layers minimum
Yes
No
Process 2:
3 layers minimum
Yes
No
Position qualified (1G,2G,3G,4G,5G,6G, etc)
Vertical progression (uphill or downhill)
Inert Gas Backing (GTAW, PAW, GMAW)
GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit)
GTAW Current type/polarity (AC,DCEP,DCEN)
RESULTS
Visual examination of completed weld (QW 302.4)
□ Transverse face and root bends (QW 462.3(a)
Type
Longitudinal bends (QW 462.3(b)
Results
Type
Alternative Volumetric Examination Results (QW 191)
Results
RT or
Fillet weld – fracture test (QW 181.2)
Macro examination (QW 184)
Side bends (QW 462.2)
UT
Length and percent of defects
Fillet size (in.)
x
Concavity/convexity (in.)
Other tests
Film or specimens evaluated by
Company
Mechanical tests conducted by
Laboratory test no.
Welding supervised by
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the
requirements of Section IX of the ASME Code.
Organization
Date
By