ASME SEC IX Welding Procedure and
performance qualification
What is the need for WPS &
performance qualification?
• To ensure the safety of the welded
constructions
• Bhopal tragedy,three mile island
accident, Chernbyl accident,
Breakage of ship in the midsea
Why ASME qualification &
certification?
• To ensure that design practices,
manufacturing practices, fabrication
techniques, & inspection techniques are
performed by personnel who are
qualified in accordance with good engg.
practices and standards
Selecting Your Welding Process
1. The joint
joint to
to be welded is analyzed
analyzed in
in terms
terms of it
requirements.
2. The joint requirements are matched with the
capabilities of available processes. One or more
of the processes are selected for further
examination.
3. A checklist of variables is used to determine the
ability of the selected processes(s) to meet the
particular application
4. Finally, the proposed process or processes
deemed most efficient are reviewed
Step 1 - Analysis of Joint Requirements
The first thing to look at is whether your weld joint is
large or small, whether the joint is out-of-position or not,
and whether the base metal is thick or thin.
In welding, the needs of any joint are
expressed in four terms: Fast-Fill (high
deposition rate), Fast-Freeze (the joint is
out-of-position - overhead or vertical),
Fast-Follow (high arc speed and very small
welds), and Penetration (the depth the
weld
the base metal
Step 1 - Analysis of Joint Requirements
Requirements
Fast-Fill is required when a large
amount of weld metal is needed
to fill the joint. A heavy weld bead
can only be laid down in minimum
arc time with a high deposition rate.
However, Fast-Fill becomes a minor
consideration when the weld is small.
Fast-Freeze implies that a joint is
out-of-position, and therefore requires
quick solidification of the molten crater.
Not all semiautomatic processes can
be used on fast-freeze joints.
Analysis of Joint Requirements
Requirements
Fast-Follow suggests that the molten metal follows the
arc at rapid travel speed, giving continuous, well-shaped
beads, without "skips" or islands. This trait is especially
desirable on relatively small single-pass welds, such as
those used in joining sheet metal.
Penetration varies with the joint. With
some joints, penetration must be deep
to provide adequate mixing of the weld
and base metal and with others it must
be limited to prevent burnthrough or
Cracking.
Step 2 - Matching Joint Requirements
With Processes
Information (on the deposition rate and
arc-speed characteristics of each process
from literature)on the ability of various
processes to fulfill the needs of the joint
Step 3 - The Checklist
•
•
•
•
•
•
•
•
•
Volume of Production
Weld Specifications
Operator Skill
Auxiliary Equipment
Accessory Equipment
Base-Metal Conditions
Arc Visibility
Fixturing Requirements
Production Bottlenecks
Step 4 - Review of the Application by
Manufacturer's Representative
WPS – Welding Procedure
Specification
PQR – Procedure Qualification
Record
What is a WPS?
A WPS is a "Welding Procedure Specification"
or "Welding Procedure" as it is commonly
called. It contains the combination of variables
used to make a certain weld. This includes the
process (SMAW, FCAW etc.), the electrode type,
electrical characteristics, base metal used,
preheat and interpass temperatures, travel speed
and position, post weld heat treatment, shielding
gas and flow rate, and the type of joint being
welded.
What is WPS in a layman view
point
• WPS lists all the parameters required to produce a
sound weld to the specific code
• Specific parameters such as process,
technique,filler,current,voltage,etc., to be included
• It should list a range on each parameter such as
amps = 110-150, voltage =17-22 with the more
essential or critical parameters more closely defined
or limited
• It should give enough details so that any qualified
welder could follow and produce the desired weld.
Purpose of WPS Qualification
To determine that the weldment is
capable of providing the required
properties for the intended application.
WPS establishes the properties of the
weldment and not the skill of the
welder.
Welding Procedure Specification
It is a written document that provides
direction to the welder for making
production welds in accordance with
code requirements.
Any WPS must be qualified
qualified by the
manufacturer.
WPS specifies the condition (ranges)
under which welding must be performed
called variables.
WPS addresses essential, supplementary
essential and non essential variables
Procedure Qualification Record
It documents what occurred during
welding the test coupon and the results
of the test coupon.
PQR documents the essential variables
and other specific information and the
results of the required testing. In
addition, when notch toughness is
required for procedure qualification, the
applicable supplementary essential
variables shall be recorded.
Points to be considered for
establishing WPS
• Code of
• Contract/Customer/
construction
• Detailed drawing
of weldment
• Material
• Thickness
• Configuration
• Process
Code/TPI
• Preheat/Postheat/
PWHT requirements
• Skilled welder
• Good welding m/c
with accessories
• Application
Variables
• Preheat
• PWHT
• Joint design
• Backing material
• P Number
• Welding Process
• Filler metal
• Electrode
• Method of back
gauging
• Essential
• Non-essential
• Supplemental
essential
Essential Variables
A change in welding condition which
will affect the mechanical properties
of the weldment.
(Change in base metal, welding
process, Filler metal, Electrode, Preheat, PWHT, etc.)
Non Essential Variables
A change in welding condition which
will NOT affect the mechanical
properties of the weldment.
(Change in Joint Design, Methods of
Back gauging, Cleaning, etc.)
Supplementary Essential
Variables
A change in welding condition
which will affect the NotchToughness (Impact) properties of
the weldment.
(Change in Heat input, Uphill or
Down Vertical welding, Diameter
of Electrode, Position, etc.)
Joints(QW:402)
• Joint Design
• Backing
• Baking Material
Type
Base Metal Classification
Why P numbers?
To reduce the number of welding procedure
qualifications, base metals have been assigned
P-nos and for ferrous base metals which have
specified impact test requirements, group
numbers within P-nos are again given
P nos depend on composition, weldability &
mechanical properties.
•Group nos classify metals within P nos for
procedure qualification where notch toughness
requirements are specified.
•The above assignments do not imply that base
metals can be substituted without consideration
of metallurgical properties
properties,etc.,
,etc.,
Base Metal P Numbers
Examples of P numbers
P1
C Steel
P3
1/2 Mo steels
P4
1 Cr 1/2 Mo steels
P5A
2 1/4 Cr 1 Mo steels
P6
13 Cr steel
P7
17 Cr steel
P8
Austenitic
StainlessSteel
P9A
2 1/2 Ni steels
P10A
Mn - 1/2 Ni - V steels
P11
9 Ni steels
Base Metal for WPS
Test Coupon
Base Metal qualified
Px - Px
Px
Px - Py
Px - Py
P3 - P3
P3 – ( P3 / P1)
P4 - P4
P4 – ( P4 / P3 / P1)
P5A - P5A
P5A – ( P5A / P4 / P3 / P1)
P5A – (P4 / P3 / P1) P5A – (P4 / P3 / P1)
P4 – (P3 / P1)
P4 – (P3 / P1)
Base Metal(QW-403
Metal(QW-403))
• P. Number
• Group Number
• Specification
• Chemical Analysis & Mechanical
Properties
• Thickness Range
• Pipe Diameter Range
P1/Group 1
Carbon Steel
Tubes
Pipes
SA179
SA106GrB
SA192
SA333Gr1
SA210GrA1 SA333Gr6
SA334Gr1
SA334Gr6
Plates
Forgings
Castingss
Casting
SA36
SA266CL1
SA515Gr55 SA350LF1
SA515Gr60
SA515Gr65
SA516Gr55
SA516Gr60
SA516Gr65
SA216WCA
SA352LCA
SA352LCB
P1/Group 2
Carbon Steel
Tubes
Pipes
Plates
SA210GrC SA106GC SA515Gr70
SA516Gr70
SA299
Forgings Castings
SA105
SA266CL2
SSA350LF
2
SA216WC
B
SA216WC
C
SA352LCC
Other Specification
Carbon Steel
Tubes
IS1239
Pipes
Plates
API5LGrB IS226
IS2062
BMC10
BMC16
BMC20
Forgings Castings
P3/Group 1
½ Mo (C–MOLY STEELS)
STEELS)
Tubes
Pipes
Plates
SA209T1
SA335P1
SA204GrA
Forgings
Castingss
Casting
SA217WC1
½ Cr ½ Mo - P3 Group 2
Tubes
Pipes
Plates
SA213T2
SA335Gr2
SAA387Gr2
Forgings
Castingss
Casting
P4/Group 1
1Cr ½ Mo
Tubes
Pipes
SA213T12
SA335P12
Plates
Forgings
Castingss
Casting
SA387Gr12 SA182F12
SA217WC6
1¼ Cr ½ Mo
Tubes
Pipes
SA213T11
SA335P11
Plates
Forgings
SA387Gr11 SA182F11
Castingss
Casting
P5A/Group 1
2¼Cr 1Mo
Tubes
Pipes
SA213T22
SA335P22
Plates
Forgings
Castingss
Casting
SA387Gr22 SA182F22
SA217WC9
P5B/Group 1
5Cr ½ Mo
Tubes
Pipes
Plates
SA213T5
SA335P5
SA387Gr5
Forgings
Castingss
Casting
SA182F5
SA217C5
SA336Cl F5
9Cr 1Mo
Tubes
Pipes
SA213T9
SA335P9
Plates
Forgings
Castingss
Casting
SA182F9
SA217C9
SA336Cl F9
P5B/Group 2
9Cr 1Mo ¼ V
Tubes
Pipes
SA213T91
SA199T91
SA335P91
Plates
Forgings
SA387Gr91 SA182F91
Castingss
Casting
P8/Group 1
18Cr 8Ni
Tubes
Pipes
Plates
Forgings
Castings
SA213TP304
SA213TP304H
SA213TP316
SA213TP321
SA213TP347
SA213TP347H
SA376TP304
SA376TP304H
SA376TP316
SA376TP321
SA376TP347
SA376TP347H
SA240TP304
SA240TP321
SA240TP347
SA182F304
SA182F321
SA182F347
SA336F304
SA336F321
SA336F347
SA351CF3
SA351CF8
SA351CF3M
SA351CF8M
SA351CF10
SA351CF10M
P8/Group 2
25Cr 20Ni (Type 310)
Tubes
Plates
Forgings
Castings
SA213TP310H SA240TP310 SA182F310 SA351CK20
Filler Metals(QW-404)
• AWS Number
• SFA Number
• F. Number
• A. Number
•
• Size of Filler metal
• Flux trade name
• Consumable insert
• Electrode flux class
Deposited Metal thickness range
Filler Metal F Numbers
Based on usability characteristics i.e
ability of welders to make satisfactory
welds with given filler
F1
E XX20,XX24,XX27
F2
E XX12, E XX13,XX14
F3
E XX10, E XX11
F4
E XX15,XX16,XX18
F5
ASS, Duplex SS
F6
Bare rods ERXX
Filler Metal A Numbers
Based on chemical composition
A1
Mild steel
steel
A2
C - Mo steel
A3
Cr - Mo steel
steel (Cr 0.4 - 2%)
A4
Cr - Mo steel
steel (Cr 2 - 6%)
A5
Cr - Mo steel
steel (Cr 6 - 10.5%)
10.5%)
A6
Cr Martensitic
Martensitic
A7
Cr Ferritic
Ferritic
A8
Cr Ni steels
steels (Cr 14.5 - 30% Ni 7.5 - 15%)
A9
Cr Ni steels
steels (Cr 19 - 30% Ni 15 - 37%)
A10
Ni steels (Ni 0.8 - 4%)
Mn Mo steels(Mn 1.25-2.25 Mo 0.25-0.75%)
A11
A12
Ni Cr Mo steels
steels (Cr 1.5% Mo 0.25-0.8%
Ni 1.25 -2.8%)
Preheat(QW:406)
• Preheat temperature (Minimum)
• Interpass temp.(Maximum)
• Preheat maintenance
PWHT(QW:407)
• Temperature range
• Time range
• Thickness range
Gas(QW:408)
• Gases
Mixture %
Flow rate
(e.g. 75% Ar 25%CO2)
• Shielding
• Trailing
• Backing
Trail shield
Electrical
Characteristics(QW-409)
• Current (AC/DC)
• Polarity (EP/EN)
• Amps & Volts
• W-Electrode type & size
• Mode of Metal Transfer
• Electrode Wire Feed Speed range
• Pulsing Current
METAL TRANSFER IN GMAW
Short circuit transfer
Low voltage & current
Application
Thin sheet &
all position welding
capability
Globular transfer
Medium voltage & current
Spray transfer
High voltage & current
Applications
Down hand position welding
Sheet thickness > 2 mm
Techniques(QW-410)
• Stringer or Weave Bead
• Orifice/Gas Cup Size
• Initial or Interpass Cleaning
• Method of Back Gauging
• Oscillation
• Contact Tip to Work Distance
• Multiple or Single Pass
• Multiple Or Single Electrode
• Electrode Spacing
• Peening
• Others
Procedure Qualification
PQR is a record of welding
we lding data to weld
a test coupon. It also contains test
results.
Completed PQR shall document all
essential variables including ranges.
PQR to be certified accurate and shall
s hall
not be subcontracted.
If more than one process then weld
deposit thickness for each process and
filler metal to be recorded.
Procedure Qualification
Several WPSs may be prepared from one
PQR.
eg. 1G plate PQR may support WPSs in
2G, 3G, 4G, pipe 5G, 6G etc provided
p rovided
other parameters are kept same.
A single WPS may cover
cover several PQRs
eg. A single WPS may cover 1.6 mm to
32 mm thickness if PQRs for 1.6 to 4.8
mm and 4.8 mm to 32 mm thickness
ranges.
Weld Orientation
Plate groove positions 1G, 2G, 3G, 4G
Pipe groove positions 1G, 2G, 5G, 6G
Plate fillet positions 1F, 2F, 3F, 4F
Pipe fillet positions 1F, 2F, 2FR, 4F, 5F
1F - 0 to 30
2F - +15 -10 wrt 45
4F - 0 - 125
3F - 125 - 235
Procedure Qualification
When two or more procedures (diff
processes or other essential variables) are
used in one joint, use table for determining
the applicable range of thickness qualified.
Carry out tension test for each weld metal.
One or more processes from a
combination may be deleted provided
remaining metal meets the requirements.
Procedure Qualification Thickness limits
T
Range of T
max t
Tests (transverse
bend)
2t
2T, 2 FB, 2 RB
1/16-3/8” 1/16 - 2T
2t
-do-
3/8-3/4”
3/16 - 2T
2t
-do-
3/4-1.5”
3/16 - 2T
2t if t<3/4
2T, 4 SB
<1/16”
T - 2T
2T if t>3/4
>1.5”
3/16 - 8”
2t if t<3/4”
8 if t>3/4”
-do-
Procedure Qualification Thickness limits
T
Range of T
<1/16”
T - 2T
max t Tests (longtl
bend)
2t
2T, 2 FB, 2 RB
1/16-3/8”
1/163/8” 1/16 - 2T
2t
-do-
> 3/8”
2t
-do-
3/16 - 2T
WPS for SMAW
Essential variables
Change in qualified Thickness
Change in P no
Change in F no of filler metal
Change in A no of filler metal
Change in deposited metal thickness
Decrease of more than 100 F in
preheat
Change in PWHT
WPS for SMAW
Supplementary Essential variables
Change in Group no of base metal
Change in T limits for impact test
Change in dia of filler metal > 1/4”
Change in AWS class of filler metal
Change in welding position
Increase of more than 100 F in preheat
Change in PWHT Time and temp range
Change in current or polarity
WPS for SMAW
Non Essential variables
Change in Groove design, backing, root
spacing, retainers etc
Change in dia of filler metal
Change in AWS class of filler metal
Change in welding position
Change in preheat maintenanc
maintenance
e
Change in current or polarity
Change in string/weave
string/weave,, cleaning, back
gouging, peening, manual/autom
manual/automatic
atic
WPS for GTAW
Essential variables
Change in qualified Thickness
Change in P no
Change in F no & A no of filler metal
Addition/deletion
Addition/dele
tion of filler metal
Change in size of filler metal, product
form
Decrease of more than 100 F in preheat
Change in PWHT
WPS for GTAW
Essential variables (cond)
Change in single, mixture % gas
Deletion of backing gas
Change in shielding / trailing gas
Change in Closed to out chamber
technique
WPS for GTAW
Supplementary Essential variables
Change in Group no of base metal
Change in T limits
Change in AWS class of filler metal
Change in welding position
Increase of more than 100 F in preheat
Change in PWHT Time and temp range
Change in current/polarity, incr. in
heat input
Change in multi to single pass,
electrodes
Welding Conditions
Specification, type and grade of Base Metal(s):
To Specification, type and grade of Base Metal(s):
Base Metal P or S-number
0.218
1
X
SA106 Gr B
to Base Metal P or S-number
Welding Process(es
Process(es)) used:
Plate
SA106 Gr B
1 Thickness:
GTAW followed by SMAW
Pipe (enter diameter if pipe or tube): NPS 2, Sch 80
Groove type (Single V, Double V, Single U, etc):
Initial cleaning method:
Single Vee
Solvent wipe and grinding
Backing (metal, weld metal, backwelded, etc):
Filler Metal (SFA) Specification:
5.18 / 5.1
None / Weld metal
Filler Metal or Electrode Classification:
ER70S-2 / E7018
Filler Metal or Electrode Trade Name:
Linde 65, Lincoln 7018+
Tungsten electrode type
type and size for GTAW:
GTAW: EWTh-2, 3/32"
Consumable Insert
Insert Class and size for GTAW or PAW:
PAW: None
Backing Gas composition and Flow rate for GTAW, PAW, GMAW: Not Used
Preheat Temperature ( F):
75
°
Position (F, V, OH, H or 5G, 3G, etc.) of weld:
5G
Interpass cleaning method:
Wire brushing
Measured interpass temperature ( F):
less than 400
°
Approximate
Approxim
ate Deposit Thickness
Thickness for each filler metal or electrode type (in.): 0.093 (3/32) / 0.125
Current Type/Polarit
ype/Polarity
y (AC, DCEP
DCEP,, DCEN): DCEN/DCEP
Treatment Time
and temper
temperature:
ature:
1100-1200 F, 65 hr.
Postweld
Postwel
d Heat
°
Visual Examination of Completed Weld:
Bend Test X
Acceptable
Date of Test:
12/25/01
Transverse
Tran
sverse Root and Face (QW-462.3(a))
Side (QW-462.2)
Type
Result
Result
Face
Face
Type
Result
Type
Acceptable
Root
Acceptable
Acceptable
Root
Acceptable
Alternative Radiographic Examination Results:
N/A
Specimens Evaluate
Evaluated
d By:
Company Ever
Dianna Ross
Title: Leader
Company:
The Best Testing
Welding Supervise
Supervised
d By:
James Brown
Title
Company:
Joe-Bob's B&NPW Shop
Welder’s Name:
Wolfgang Amadeus Mozart
Soloist
Stamp No:
A1
We certify that the statements in this record are correct and that the weld described above was prepared,
welded and tested in accordance with the r equirements of Section IX of the ASME Code.
Performance Qualification
The basic criterion for welder’s
qualification is to determine the
welder’s ability to deposit sound weld
metal.
The purpose of performance
qualification test is to determine the
welding operator’s mechanical ability to
operate the welding equipment.
GMAW in different positions
1F
2F
Flat
Fillet welding of plate
3F
Vertical
4F
Horizontal
overhead
Welders Performance Qualification
The performance qualification tests are
intended to determine the ability of
welders to make sound welds
A welder is qualified by radiography of a
test coupon or by radiography of initial
production welding or by bend tests
taken from a test coupon
Variables affecting the
welders qualification
Welding conditions that affect the
ability of welder to produce sound
welds are qualification variables
• Welding process
• Filler metal
• Welding position
• Joint backing
• Thickness of test coupon
Welding process
• A change in welding process –from
SMAW to GTAW, for eg.,requires the
requalification of the welder since
skill required to use one process is
different from another one.
Filler metals
• Filler metals used in welding are
grouped based on their usability
characteristics. These are assigned Fnumbers
• Ordinarily welder is qualified for a F no
and do the same in production
• SAW :F1-F4: Qualification in higher Fno
entails qualfication for lower F nos of
electrodes
Backing
• Joint backing includes any material placed at
the root of the weld to support the liquid
metal(e.g backing strip,non fusing bars, root
weld with another process,etc)
• If a welder qualifies using a backing on the
test coupon but the backing is removed for the
production welding for a joint made from one
side, then he must requalify
• If a welder qualifies using without a backing,
for a joint with backing he is automatically
qualified
Welders Performance Qualification
Welded
Without Backing
Fx
With Backing
F1
F2
F3
F4
F5
Qualified
Fx
F1
F2, F1
F3, F2, F1
F4, F3, F2, F1
F5, F1
Welders Performance Qualification
F No qualification with backing
F1 with backing
F1 with backing
F1 without backing F1 with & without backing
F2 with backing
F1 & F2 with backing
F2 without backing F2 with
with & without backing,
backing, F1
F1 with backing
F3 with backing
F1, F2 & F3 with backing
F3 without backing F3 with
with & without backing,
backing, F1,
F1, F2 with
backing
F4 with backing
F1, F2, F3 & F4 with backing
F4 without backing F4 with & without backing, F1,
F1, F2, F3 with
backing
F5 with backing
F1 & F5 with backing
F5 without backing F5 with
with & without backing,
backing, F1
F1 with backing
Welding
position(QW-405)
position(QW-405
)
• Welding test positions are defined differently for
plate and pipe
in welding position
position from that
that qualified
qualified
• A change in
may require requalification
• Certain test position qualify for more than one
production welding position
(E.g.qualification in 3G position qualifies the welder
for vertical and flat positions)
• In vertical position welding, a change in welding
progression from uphill to downhill would require
requalification
• Qualification in difficult position qualifies for less
difficult positions: E.g 6 G qualifies for all positions
Welders Performance Qualification
Weld
Plate 1F
Plate 2F
Plate 3F
Plate 4F
3F &4 F
Plate & pipe
>24”OD
Pipe of OD
2 7/8 - 24”
Fillet
F
F, H
F, H, V
F, H, O
All
Welders Performance Qualification
Weld Plate & pipePipe of OD
Fillet
2 7/8 - 24”
>24”OD
Plate 1G
Plate 2G
Plate 3G
Plate 4G
F
F, H
F, V
F, O
F
F, H
F
F
F
F, H
F, H, V
F, H, O
Welders Performance Qualification
Weld
Plate & pipe
>24”OD
Pipe 1G
Pipe 2G
Pipe 5G
Pipe 6G
Pipe 2G + 5G
F
F, H
F, V, O
All
All
Pipe of OD
2 7/8 - 24”
F
F, H
F, V, O
All
All
Fillet
F
F, H
All
All
All
Welders Performance Qualification
Weld
Pipe 1F
Pipe 2F
Pipe 2FR
Pipe 4F
Pipe 5F
Plate & pipe
>24”OD
Pipe of OD
2 7/8 - 24”
Fillet
F
F, H
F, H
F, H, O
All
Test coupon thickness
• The thickness of the production work
determines the thickness of the plate or pipe
test coupon to be welded
• Thumb rule is a welder is qualified to deposit
in production welding two times the thickness
of the weld deposited on the test coupon (e.g.
test coupon of 9 mm qualifies a person to weld
upto 19mm thick production weld)
• Some code makes once a weld of 1 inch is
made, the welder is qualified to weld all
thickness
Test coupon
thickness(contd.)
• The weld deposit thickness(t) determines the
thickness of the weld metal the welder is
allowed to use in production not the thickness
of the base metal in the test coupon.
• When welding a test coupon using more than
one process or filler metal, the thickness of
the weld in production depends on the deposit
thickness for the process and the type of test
of filler metal that was used on the test
coupon.
Welders Performance Qualification
Thk
<3/8”
>3/8”
>1/2”
Max tk of dep. Metal
Test
2t
1FB, 1RB
2t
1FB, 1RB
Max to be welded 2SB
OD of test coupon
<1”
1 - 2 7/8”
> 2 7/8”
Range of OD qualified
Size welded - unlimitd
1” - unlimited
2 7/8” - unlimited
Welders Performance Qualification
Test coupon More than 2 welders
different procedure can do a single test
coupon. Failure then both are failed.
Retest - 2 consecutive test coupons to
pass
Renewal if no welding for 6 months.
Single test coupon plate/pipe, any
thickness, material, position. If passed
then complete previous qualification is
restored.
Welders Performance Qualification
Variables for SMAW
Removal of backing
Change in Pipe diameter
Change in P number
Change in F Number
Change in thickness of weld deposit
Change in welding position
Welders Performance Qualification
Variables for GTAW
Removal of backing
Change in Pipe diameter
Addition / deletion of filler metal
Addition / deletion of insert
Change in P number
Change in F Number
Change in solid filler to flux cored filler metal
Change in thickness of weld deposit
Change in welding position
Removal of inert gas backing
Change in current or polarity
Tests for Qualification
Tension test
Minimum values for specified
tensile strength
For dissimilar joint, lesser of the
two values
If break outside weld, if tensile st.
value not < 5% of the base metal
Bend test
No open discontinuity > 1/8” in any
direction
Impact test
In accordance with the section
Tests for Qualification
Radiography
No crack or LOP or LOF
Any elongated slag >1/8” for t <3/8”
1/3 t for t 3/8 - 2 1/4”
3/4 “ for t>2 1/4”
Any group of slag in a line with
with aggregate
length t in 12 t unless separated by 6L
Max permissible dimension for rounded
indication smaller of 20% of t or 1/8”
1/8”
For thickness<1/8”, max no of accepted
rounded indication 12 in 6” length
For thickness>1/8”, charts for max
acceptable types of rounded indication
C. R. Ratheeskumar
ACTUAL VALUE
RANGE QUALIFIE
FCAW(S)
FCAW(S)
8"
2 7/8" & Above
A 106 Gr B, Sch 160
P No.:1 Gr.:1
Yes(Root)
E71T8-K6
6
FCAW (S) -19 mm
P 1 - P 11
With backing
backing
6
Upto Max to be we
A 106 Gr B, Sc h 160
P No.:1 Gr.:1
P 1 - P 11
With backing
Yes(Root)
E71T8-K6
6
6
FCAW (S) -19 mm
Upto Max to be welded
6G
All Positions
P ositions
Down Hill
Down Hill
NA
NA
DC
Electrode Negative
DC
Electrode Negative
Accepted
Acc epted
NDT / 250A / 03
Dt.23.2.04.
Dt.23.2. 04.
NA
NA
NA
NA
Welding Research
Research Institute, BHEL, Trichy, India.
India.
NA
Welder’s Performance
Qualification as per
Indian Boiler Regulations
Welder’s Performance
Qualification as per IBR
Initial qualification of welders Certificate valid for 24 months provided
welder has been employed with
reasonable continuity
If preceding three months, no welding
carried out or if there is any doubt on
welder’s stability then requalification
needed
Welder’s Performance
Qualification as per IBR
Requalification of welders must for the
following
Omission of backing strip
Change in class of electrode
Change in base metal to be
welded(CS or AS)
Change in welding process
Change from dc to ac and vice versa
Tests for Initial Qualification
• Theoretical examination
• Groove welds in plate - single or double vee
299 x 381 x 16 mm min size in flat, horizontal
or vertical. Vertical or horizontal position also
qualifies for all
•Fillet weld in plate - 16 x 381 mm min in flat,
horizontal, vertical or overhead.
Horizontal or vertical also qualifies for flat.
Vertical position also qualifies for flat,
horizontal or vertical.
Tests for Initial Qualification
Pipe welding in the following positions (i)
Horizontally rolled (ii) Horizontal turned (iii)
Vertical fixed (iv) Horizontal fixed.
Qualification in (ii) or (iii) also qualifies (i).
Qualification in (iv) also qualifies (i) or (ii).
Branch to pipe welding
Pipe size 127 OD x 10 tk. Tube 89 OD x 6 tk.
Tube welding with axis vertical and tubes of
same size fixed in adjoining positions.
Tests for Requalification
•
•
•
•
•
•
No theoretical examination
Plate welding 152 length x 229 x 16 tk in
45 deg
position. Weld to be done from
underside.
Pipe welding with axis of pipe horizontal.
Branch to pipe as earlier
Tube welding axis vertical and tubes of
same size in
adjoining position.
Regular production weld to the
satisfaction of
competent authority
may be accepted as alternative
to the
above tests
Examination of the weld for initial
Qualification
PLATE QUALIFICATION (Groove weld)
•
•
•
•
•
•
Visual examination
Radiography
2 no of Tensile test
2 no each of Bend test - face and root
bend ( 3t for both C steel and alloy steel
180 deg bend)
1 no Micro examination
1 no Macro examination
Examination of the weld for
initial Qualification
PLATE QUALIFICATION (Fillet weld)
• Specimen shall not fracture during load
application
• If fractures, no evidence of cracks / ICP /
sum of
inclusions and gas pockets < 51 mm
• Macro examination shall show complete
fusion
• concavity / convexity < 1.6 mm
• difference in leg length < 1.6 mm
Examination of the weld for initial
Qualification
PIPE QUALIFICATION
•
•
•
Visual examination
Macro examination
2 no each of Bend test - face and root
bend ( 3t for C steel and 4t for alloy
`steel 90 deg bend)
Examination of the weld for
Requalification
PLATE QUALIFICATION
•
Radiography
1 no each of Bend test - face and root
•
bend
2 no of macro examination
•
PIPE QUALIFICATION
1 no each of bend test - face and root
•
bend
Macro examination
ACTUAL VALUE
FCAW(S)
8"
A 106 Gr B, S ch 160
P No.:1 Gr.:1
Yes(Root)
E71T8-K6
6
FCAW(S) -19 mm
6G
Down Hill
NA
DC
Electrode Negative
Steps involved in qualifying the
welding process & welder/
operator
p repared
• A tentative welding procedure is prepared
• Test samples welded with the above and
parameters recorded on PQR
• Tested as per required codes
• If test is passed, the procedure has
completed qualification.
• If test is not passed, the tentative WPS
value of the parameters are changed as
deemed feasible
welding process & welder/
operator
• The welder making the test samples to be used in
qualifying the procedure is normally considered
qualified.
• Other welder to be qualified weld test samples
as per WPS and the samples are tested as per
applicable requirements.
• A qualified
qualified WPS is usable
usable for an indefinit
indefinite
e length
of time
• The welder’s qualification is normally considered
effective for an indefinite period of time, unless
the welder is not engaged in the specific process
of welding for which she is qualified for a period
of exceeding 6 months
Case study
Objective : To develop a WPS for pipe
to pipe butt joint( dia. 406 * 12mm)
of SA 106 GrC – SA106 GrC as per
ASME sec IX
• Requirement of mechanical property:
Impact toughness at room
temperature
Tensile strength
Filling up of WPS- Draft
Date:
• WPS: No:
• Supporting PQR
• Welding process :
• Type : Manual/ Machine/Auto/
Semi Auto
• Application:
Joints(QW:402)
• Joint Design
• Backing
• Baking Material Type
Base Metal(QW-403
Metal(QW-403))
• P. Number
• Group Number
• Specification
• Chemical Analysis & Mechanical
Properties
• Thickness Range
• Pipe Diameter Range
Filler Metals(QW-404)
• AWS Number
• SFA Number
• F. Number
• A. Number
•
• Size of Filler metal
• Flux trade name
• Consumable insert
• Electrode flux class
Deposited Metal thickness range
Welding position(QW-405
position(QW-405))
• Welding test positions are defined
differently for plate and pipe
Preheat(QW:406)
• Preheat temperature Min
• Interpass temp.(Max.)
• Preheat maintenance
PWHT(QW:407)
• Temperature range
• Time range
• Thickness range
Gas(QW:408)
Mix %
• Gases
• Shielding
• Trailing
• Backing
Flow rate
Electrical
Characteristics(QW-409)
• Current (AC/DC)
• Polarity (EP/EN)
• Amps & Volts
• W-Electrode type & size
• Mode of Metal Transfer
• Electrode Wire Feed Speed range
• Pulsing Current
Techniques(QW-410)
• Stringer or Weave Bead
• Orifice/Gas Cup Size
• Initial or Interpass Cleaning
• Method of Back Gauging
• Oscillation
• Contact Tip to Work Distance
• Multiple or Single Pass
• Multiple Or Single Electrode
• Electrode Spacing
• Peening
• Others
Filling up of WPS-Joints(QW:402)