ASNE SEC !

X
Welding Procedure and
performance qualification
What is the need for WPS S
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 ASNE qualification S
certification?
- To ensure that design practices,
manufacturing practices, fabrication
techniques, S inspection techniques are
performed by personnel who are
qualified in accordance with good engg.
practices and standards
&electing Your Welding Process
1. The joint to be welded is analyzed in terms of its
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
&tep 1 Analysis of ]oint Requirements
The first thing to look at is whether your weld joint is
large or small, whether the joint is outofposition or not,
and whether the base metal is thick or thin.
!n welding, the needs of any joint are
expressed in four terms: FastFill (high
deposition rate), FastFreeze (the joint is
outofposition overhead or vertical),
FastFollow (high arc speed and very small
welds), and Penetration (the depth the
weld penetrates the base metal)
FastFill 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, FastFill becomes a minor
consideration when the weld is small.
FastFreeze implies that a joint is
outofposition, and therefore requires
quick solidification of the molten crater.
Not all semiautomatic processes can
be used on fastfreeze joints.
&tep 1 Analysis of ]oint Requirements
FastFollow suggests that the molten metal follows the
arc at rapid travel speed, giving continuous, wellshaped
beads, without "skips" or islands. This trait is especially
desirable on relatively small singlepass 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.
Analysis of ]oint Requirements
Step 2 - Matching Joint Requirements
With Processes
!nformation (on the deposition rate and
arcspeed characteristics of each process
from literature)on the ability of various
processes to fulfill the needs of the joint
Step 3 - The Checklist
W Volume of Production
W Weld Specifications
W Operator Skill
W Auxiliary Equipment
W Accessory Equipment
W Base-Metal Conditions
W Arc Visibility
W Fixturing Requirements
W Production Bottlenecks
Step 4 - Review of the Application by
Manufacturer's Representative
WP& - Welding Procedure
&pecification
PQR - Procedure Qualification
Record
What is a WP&
A WP& is a "Welding Procedure &pecification"
or "Welding Procedure" as it is commonly
called. !t contains the combination of variables
used to make a certain weld. This includes the
process (&AW, 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 WP& in a layman view
point
- WP& lists all the parameters required to produce a
sound weld to the specific code
- &pecific parameters such as process,
technique,filler,current,voltage,etc., to be included
- !t should list a range on each parameter such as
amps = 1101S0, voltage =1722 with the more
essential or critical parameters more closely defined
or limited
- !t should give enough details so that any qualified
welder could follow and produce the desired weld.
Purpose of WP& Qualification
To determine that the weldment is
capable of providing the required
properties for the intended application.
WP& establishes the properties of the
weldment and not the skill of the
welder.
Welding Procedure &pecification
!t is a written document that provides
direction to the welder for making
production welds in accordance with
code requirements.
Any WP& must be qualified by the
manufacturer.
WP& specifies the condition (ranges)
under which welding must be performed
called variables.
WP& addresses essential, supplementary
essential and non essential variables
Procedure Qualification Record
!t 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. !n
addition, when notch toughness is
required for procedure qualification, the
applicable supplementary essential
variables shall be recorded.
Points to be considered for
establishing WP&
- Code of
construction
- Detailed drawing
of weldment
- aterial
- Thickness
- Configuration
- Process
- Contract/Customer/
Code/TP!
- Preheat/Postheat/
PWHT requirements
- &killed welder
- Cood welding m/c
with accessories
- Application
ariables
- Preheat
- PWHT
- ]oint design
- Backing material
- P Number
- Welding Process
- Filler metal
- Electrode
- ethod of back
gauging
- Essential
- Nonessential
- &upplemental
essential
Essential ariables
A change in welding condition which
will affect the mechanical properties
of the weldment.
(Change in base metal, welding
process, Filler metal, Electrode, Pre
heat, PWHT, etc.)
Non Essential ariables
A change in welding condition which
will NOT affect the mechanical
properties of the weldment.
(Change in ]oint Design, ethods of
Back gauging, Cleaning, etc.)
&upplementary Essential
ariables
A change in welding condition
which will affect the Notch
Toughness (!mpact) properties of
the weldment.
(Change in Heat input, Uphill or
Down ertical welding, Diameter
of Electrode, Position, etc.)
]oints(QW:402)
- ]oint Design
- Backing
- Baking aterial
Type
Base etal Classification
Why P numbers
To reduce the number of welding procedure
qualifications, base metals have been assigned
Pnos and for ferrous base metals which have
specified impact test requirements, group
numbers within Pnos are again given
P nos depend on composition, weldability S
mechanical properties.
-Croup 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,etc.,
P1 - P11 8teel
P21 - P25 Al alloys
P31 - P35 Cu alloys
P41 - P47 Ni alloys
P51 - P53 Ti alloys
P61 - P62 Zr alloys
Examples of P numbers
P1 C &teel
P3 1/2 o steels
P4 1 Cr 1/2 o steels
PSA 2 1/4 Cr 1 o steels
P6 13 Cr steel
P7 17 Cr steel
P8 Austenitic
&tainless&teel
P3A 2 1/2 Ni steels
P10A n 1/2 Ni steels
P11 3 Ni steels
Examples of P numbers
P1 C &teel
P3 1/2 o steels
P4 1 Cr 1/2 o steels
PSA 2 1/4 Cr 1 o steels
P6 13 Cr steel
P7 17 Cr steel
P8 Austenitic
&tainless&teel
P3A 2 1/2 Ni steels
P10A n 1/2 Ni steels
P11 3 Ni steels
ase Netal P Numbers ase Netal P Numbers
Base etal for WP&
Test Coupon Base etal qualified
Px Px Px
Px Py Px Py
P3 P3 P3 - ( P3 / P1)
P4 P4 P4 - ( P4 / P3 / P1)
PSA PSA PSA - ( PSA / P4 / P3 / P1)
PSA - (P4 / P3 / P1) PSA - (P4 / P3 / P1)
P4 - (P3 / P1) P4 - (P3 / P1)
Base etal(QW403)
- P. Number
- Croup Number
- &pecification
- Chemical Analysis S echanical
Properties
- Thickness Range
- Pipe Diameter Range
P1/Croup 1
Carbon &teel
'ubes Pipes Plates Forgings Castings
SA173
SA132
SA210CrA1
SA334Cr1
SA334Cr6
SA106Cr
SA333Cr1
SA333Cr6
SA36
SAS1SCrSS
SAS1SCr60
SAS1SCr6S
SAS16CrSS
SAS16Cr60
SAS16Cr6S
SA266CL1
SA3S0LF1
SA216WCA
SA3S2LCA
SA3S2LC
P1/Croup 2
Carbon Steel
Tubes Pipes Plates Forgings Castings
&A210CrC &A106CC
&AS1SCr70
&AS16Cr70
&A233
&A10S
&A266CL2
&&A3S0LF
2
&A216WC
B
&A216WC
C
&A3S2LCC
Other &pecification
Carbon &teel
Tubes Pipes Plates Forgings Castings
!&1233 AP!SLCrB !&226
!&2062
BC10
BC16
BC20
P3/Croup 1
'ubes Pipes Plates Forgings Castings
SA203'1 SA33SP1 SA204CrA SA217WC1
Cr o P3 Croup 2
'ubes Pipes Plates Forgings Castings
SA213'2 SA33SCr2 SAA387Cr2
o (C-OLY &TEEL&)
P4/Croup 1
'ubes Pipes Plates Forgings Castings
SA213'12 SA33SP12 SA387Cr12 SA182F12 SA217WC6
1 Cr o
'ubes Pipes Plates Forgings Castings
SA213'11 SA33SP11 SA387Cr11 SA182F11
1Cr o
PSA/Croup 1
2Cr 1o
'ubes Pipes Plates Forgings Castings
SA213'22 SA33SP22 SA387Cr22 SA182F22 SA217WC3
PSB/Croup 1
'ubes Pipes Plates Forgings Castings
SA213'S SA33SPS SA387CrS SA182FS
SA336Cl FS
SA217CS
3Cr 1No
'ubes Pipes Plates Forgings Castings
SA213'3 SA33SP3 SA182F3
SA336Cl F3
SA217C3
SCr No
PSCroup 2
3Cr 1o
'ubes Pipes Plates Forgings Castings
SA213'31
SA133'31
SA33SP31 SA387Cr31 SA182F31
P8Croup 1
18Cr 8Ni
'ubes Pipes Plates Forgings Castings
&A213TP304
&A213TP304H
&A213TP316
&A213TP321
&A213TP347
&A213TP347H
&A376TP304
&A376TP304H
&A376TP316
&A376TP321
&A376TP347
&A376TP347H
&A240TP304
&A240TP321
&A240TP347
&A182F304
&A182F321
&A182F347
&A336F304
&A336F321
&A336F347
&A3S1CF3
&A3S1CF8
&A3S1CF3
&A3S1CF8
&A3S1CF10
&A3S1CF10
P8Croup 2
2SCr 20Ni (Type 310)
Tubes Plates Forgings Castings
&A213TP310H &A240TP310 &A182F310 &A3S1CK20
Filler etals(QW404)
- AW& Number
- &FA Number
- F. Number
- A. Number
- &ize of Filler metal
- Flux trade name
- Consumable insert
- Electrode flux class
W Deposited etal thickness range
Filler etal 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 XX1S,XX16,XX18
FS A&&, Duplex &&
F6 Bare rods ERXX
Filler etal A Numbers
Based on chemical composition
A1 ild steel
A2 C o steel
A3 Cr o steel (Cr 0.4 2)
A4 Cr o steel (Cr 2 6)
AS Cr o steel (Cr 6 10.S)
A6 Cr artensitic
A7 Cr Ferritic
A8 Cr Ni steels (Cr 14.S 30 Ni 7.S 1S)
A3 Cr Ni steels (Cr 13 30 Ni 1S 37)
A10 Ni steels (Ni 0.8 4)
A11 n o steels(n 1.2S2.2S o 0.2S0.7S)
A12 Ni Cr o steels (Cr 1.S o 0.2S0.8
Ni 1.2S 2.8)
Preheat(QW:406)
- Preheat temperature (inimum)
- !nterpass temp.(aximum)
- Preheat maintenance
PWHT(QW:407)
- Temperature range
- Time range
- Thickness range
Cas(QW:408)
- Cases ixture Flow rate
(e.g. 7S Ar 2SCO
2
)
- &hielding
- Trailing
- Backing
Trail shield
Electrical
Characteristics(QW403)
- Current (AC/DC)
- Polarity (EP/EN)
- Amps S olts
- WElectrode type S size
- ode of etal Transfer
- Electrode Wire Feed &peed range
- Pulsing Current
METAL TRANSFER IN GMAW
Application
Thin sheet S
all position welding
capability
Clobular transfer Clobular transfer
&hort circuit transfer &hort circuit transfer
&pray transfer &pray transfer
edium voltage S current
Low voltage S current
High voltage S current
Applications
Down hand position weIding
Sheet thickness > 2 mm
Techniques(QW410)
- &tringer or Weave Bead
- Orifice/Cas Cup &ize
- !nitial or !nterpass Cleaning
- ethod of Back Cauging
- Oscillation
- Contact Tip to Work Distance
- ultiple or &ingle Pass
- ultiple Or &ingle Electrode
- Electrode &pacing
- Peening
- Others
Procedure Qualification
PQR is a record of welding data to weld
a test coupon. !t also contains test
results.
Completed PQR shall document all
essential variables including ranges.
PQR to be certified accurate and shall
not be subcontracted.
!f more than one process then weld
deposit thickness for each process and
filler metal to be recorded.
Procedure Qualification
&everal WP&s may be prepared from one
PQR.
eg. 1C plate PQR may support WP&s in
2C, 3C, 4C, pipe SC, 6C etc provided
other parameters are kept same.
A single WP& may cover several PQRs
eg. A single WP& 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 1C, 2C, 3C, 4C
Pipe groove positions 1C, 2C, SC, 6C
Plate fillet positions 1F, 2F, 3F, 4F
Pipe fillet positions 1F, 2F, 2FR, 4F, SF
1F 0 to 30
2F +1S 10 wrt 4S
4F 0 12S
3F 12S 23S
Procedure Qualification
When two or more procedures (diff
processes or other essentiaI variabIes) are
used in one joint, use tabIe for determining
the appIicabIe range of thickness quaIified.
Carry out tension test for each weId metaI.
One or more processes from a
combination may be deIeted provided
remaining metaI meets the requirements.
Procedure Qualification Thickness limits
T Range of T max t Tests (transverse
bend)
<1/16 T - 2T 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
2T if t>3/4
>1.5 3/16 - 8 2t if t<3/4 -do-
8 if t>3/4
Procedure Qualification Thickness limits
T Range of T max t Tests (IongtI
bend)
<1/16" T - 2T 2t 2T, 2 FB, 2 RB
1/16-3/8" 1/16 - 2T 2t -do-
> 3/8" 3/16 - 2T 2t -do-
WP& for &AW
EssentiaI variabIes
Change in quaIified Thickness
Change in P no
Change in F no of fiIIer metaI
Change in A no of fiIIer metaI
Change in deposited metaI thickness
Decrease of more than 100 F in
preheat
Change in PWHT
WP& for &AW
SuppIementary EssentiaI variabIes
Change in Group no of base metaI
Change in T Iimits for impact test
Change in dia of fiIIer metaI > 1/4"
Change in AWS cIass of fiIIer metaI
Change in weIding position
Increase of more than 100 F in preheat
Change in PWHT Time and temp range
Change in current or poIarity
WP& for &AW
Non EssentiaI variabIes
Change in Groove design, backing, root
spacing, retainers etc
Change in dia of fiIIer metaI
Change in AWS cIass of fiIIer metaI
Change in weIding position
Change in preheat maintenance
Change in current or poIarity
Change in string/weave, cIeaning, back
gouging, peening, manuaI/automatic
WP& for CTAW
EssentiaI variabIes
Change in quaIified Thickness
Change in P no
Change in F no & A no of fiIIer metaI
Addition/deIetion of fiIIer metaI
Change in size of fiIIer metaI, product
form
Decrease of more than 100 F in preheat
Change in PWHT
WP& for CTAW
Essential variables (cond)
Change in single, mixture gas
Deletion of backing gas
Change in shielding / trailing gas
Change in Closed to out chamber
technique
WP& for CTAW
&upplementary Essential variables
Change in Croup no of base metal
Change in T limits
Change in AW& class of filler metal
Change in welding position
!ncrease 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 Welding Conditions
&pecification, type and grade of Base etal(s): &A106 Cr B
To &pecification, type and grade of Base etal(s): &A106 Cr B
Base etal P or &number 1 to Base etal P or &number 1 Thickness:
0.218
Welding Process(es) used: CTAW followed by &AW
Plate X Pipe (enter diameter if pipe or tube): NP& 2, &ch 80
Croove type (&ingle , Double , &ingle U, etc): &ingle ee
!nitial cleaning method: &olvent wipe and grinding
Backing (metal, weld metal, backwelded, etc): None / Weld metal
Filler etal (&FA) &pecification: S.18 / S.1
Filler etal or Electrode Classification: ER70&2 / E7018
Filler etal or Electrode Trade Name: Linde 6S, Lincoln 7018+
Tungsten electrode type and size for CTAW: EWTh2, 3/32"
Consumable !nsert Class and size for CTAW or PAW: None
Backing Cas composition and Flow rate for CTAW, PAW, CAW: Not Used
Preheat Temperature (SF): 7S
Position (F, , OH, H or SC, 3C, etc.) of weld: SC
Progression (Uphill or Downhill): Uphill CTAW / downhill &A
Interpass cIeaning method: Wire brushing
Measured interpass temperature (SF): Iess than 400
Approximate Deposit Thickness for each fiIIer metaI or eIectrode type (in.): 0.093 (3/32) / 0.125
Current Type/PoIarity (AC, DCEP, DCEN): DCEN/DCEP PostweId Heat
Treatment Time and temperature: 1100-1200SF, 65 hr.
VisuaI Examination of CompIeted WeId: AcceptabIe Date of Test: 12/25/01
Bend Test X Transverse Root and Face (QW-462.3(a)) Side (QW-462.2)
Type ResuIt Type ResuIt Type ResuIt
Face AcceptabIe Root AcceptabIe
Face AcceptabIe Root AcceptabIe
AIternative Radiographic Examination ResuIts: N/A
Specimens EvaIuated By: Dianna Ross TitIe: Leader Company: The Best Testing
Company Ever
WeIding Supervised By: James Brown TitIe SoIoist Company: Joe-Bob's B&NPW Shop
WeIder's Name: WoIfgang Amadeus Mozart Stamp No: A1
We certify that the statements in this record are correct and that the weId described above was prepared,
weIded and tested in accordance with the requirements 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
Fillet welding of plate
ertical
Horizontal
Flat
overhead
1F
2F
3F
4F
CAW in different positions
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
ariables 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
- ]oint backing
- Thickness of test coupon
Welding process
- A change in welding process -from
&AW to CTAW, 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 F
numbers
- Ordinarily welder is qualified for a F no
and do the same in production
- &AW :F1F4: Qualification in higher Fno
entails qualfication for lower F nos of
electrodes
Backing
- ]oint 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)
- !f 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
- !f a welder qualifies using without a backing,
for a joint with backing he is automatically
qualified
Welders Performance Qualification
Welded Qualified
Without acking
Fx Fx
With acking
F1 F1
F2 F2, F1
F3 F3, F2, F1
F4 F4, F3, F2, F1
FS FS, F1
Welders Performance Qualification
F No qualification with backing
F1 with backing F1 with backing
F1 without backing F1 with S without backing
F2 with backing F1 S F2 with backing
F2 without backing F2 with S without backing, F1 with backing
F3 with backing F1, F2 S F3 with backing
F3 without backing F3 with S without backing, F1, F2 with
backing
F4 with backing F1, F2, F3 S F4 with backing
F4 without backing F4 with S without backing, F1, F2, F3 with
backing
FS with backing F1 S FS with backing
FS without backing FS with S without backing, F1 with backing
Welding position(QW40S)
- Welding test positions are defined differently for
plate and pipe
- A change in welding position from that qualified
may require requalification
- Certain test position qualify for more than one
production welding position
(E.g.qualification in 3C position qualifies the welder
for vertical and flat positions)
- !n 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 C qualifies for all positions
Welders Performance Qualification
Weld Plate S pipe Pipe of OD Fillet
>24"OD 2 78 24"
Plate 1F F
Plate 2F F, H
Plate 3F F, H, v
Plate 4F F, H, O
3F S4 F All
Welders Performance Qualification
Weld Plate S pipePipe of OD Fillet
>24"OD 2 7/8 24"
Plate 1C F F F
Plate 2C F, H F, H F, H
Plate 3C F, F F, H,
Plate 4C F, O F F, H, O
Welders Performance Qualification
Weld Plate S pipe Pipe of OD Fillet
>24"OD 2 78 24"
Pipe 1C F F F
Pipe 2C F, H F, H F, H
Pipe SC F, v, O F, v, O All
Pipe 6C All All All
Pipe 2C + SC All All All
Welders Performance Qualification
Weld Plate S pipe Pipe of OD Fillet
>24"OD 2 78 24"
Pipe 1F F
Pipe 2F F, H
Pipe 2FR F, H
Pipe 4F F, H, O
Pipe SF 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 3 mm qualifies a person to weld
upto 13mm thick production weld)
- &ome 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
'hk Nax tk of dep. Netal 'est
<38" 2t 1F, 1R
>38" 2t 1F, 1R
>12" Nax to be welded 2S
OD of test coupon Range of OD qualified
<1" Size welded unlimitd
1 2 78" 1" unlimited
> 2 78" 2 78" unlimited
Welders Performance Qualification
Test coupon ore 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.
&ingle test coupon plate/pipe, any
thickness, material, position. !f passed
then complete previous qualification is
restored.
Welders Performance Qualification
ariables for &AW
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
ariables for CTAW
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
'ension test Ninimum values for specified
tensile strength
For dissimilar joint, lesser of the
two values
!f break outside weld, if tensile st.
value not < S of the base metal
end test No open discontinuity > 18" in any
direction
!mpact test !n accordance with the section
'ests for Qualification
Radiography No crack or LOP or LOF
Any elongated slag >18" for t <38"
13 t for t 38 2 14"
34 for t>2 14"
Any group of slag in a line with aggregate
length t in 12 t unless separated by 6L
Nax permissible dimension for rounded
indication smaller of 20 of t or 18"
For thickness<18", max no of accepted
rounded indication 12 in 6" length
For thickness>18", charts for max
acceptable types of rounded indication
106 Gr B, Sch 160
C. R. Ratheeskumar
FC(S)
8"
P No.:1 Gr.:1
Yes(Root)
E71T8-K6
6 6
FC(S) -19 mm Upto Max to be weld
FC(S)
2 7/8" & bove
ith backing
P 1 - P 11
ACTUAL VALUE RANGE QUALIFIED
106 Gr B, Sch 160
8"
P No.:1 Gr.:1
Yes(Root)
E71T8-K6
6
6
FC(S) -19 mm Upto Max to be welded
6G
ll Positions
Down Hill
N
DC
Electrode Negative
ccepted
N
N
N
N
2 7/8" & bove
ith backing
Down Hill
N
DC
N
elding Research nstitute, BHEL, Trichy, ndia.
P 1 - P 11
NDT / 250 / 03 Dt.23.2.04.
ASME BPV Code Section IX. WeIder Identity Card issued
Electrode Negative
Welder's Performance
Qualification as per
!ndian oiler Regulations
Welder's Performance
Qualification as per !R
!nitial qualification of welders
Certificate valid for 24 months provided
welder has been employed with
reasonable continuity
!f 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 !R
Requalification of welders must for the
following
Omission of backing strip
Change in class of electrode
Change in base metal to be
welded(C& or A&)
Change in welding process
Change from dc to ac and vice versa
Tests for !nitial Qualification
- Theoretical examination
- Croove welds in plate single or double vee
233 x 381 x 16 mm min size in flat, horizontal
or vertical. ertical 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.
ertical position also qualifies for flat,
horizontal or vertical.
Tests for !nitial Qualification
Pipe welding in the following positions (i)
Horizontally rolled (ii) Horizontal turned (iii)
ertical 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 83 OD x 6 tk.
Tube welding with axis vertical and tubes of
same size fixed in adjoining positions.
'ests for Requalification
- No theoretical examination
- Plate welding 1S2 length x 223 x 16 tk in
4S 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 QUAL!F!CAT!ON (Croove weld)
- isual 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 icro examination
- 1 no acro examination
Examination of the weld for
initial Qualification
PLATE QUAL!F!CAT!ON (Fillet weld)
- &pecimen shall not fracture during load
application
- !f fractures, no evidence of cracks / !CP /
sum of inclusions and gas pockets < S1 mm
- acro examination shall show complete
fusion
- concavity / convexity < 1.6 mm
- difference in leg length < 1.6 mm
Examination of the weld for initial
Qualification
P!PE QUAL!F!CAT!ON
- isual examination
- acro examination
- 2 no each of Bend test face and root
bend ( 3t for C steel and 4t for alloy
`steel 30 deg bend)
Examination of the weld for
Requalification
PLATE QUAL!F!CAT!ON
- Radiography
- 1 no each of Bend test face and root
bend
- 2 no of macro examination
P!PE QUAL!F!CAT!ON
- 1 no each of bend test face and root
bend
- acro examination
106 Gr B, Sch 160
FC(S)
8"
P No.:1 Gr.:1
Yes(Root)
E71T8-K6
6
FC(S) -19 mm
6G
Down Hill
N
DC
Electrode Negative
ACTUAL VALUE
&teps involved in qualifying the
welding process S welder/
operator
- A tentative welding procedure is prepared
- Test samples welded with the above and
parameters recorded on PQR
- Tested as per required codes
- !f test is passed, the procedure has
completed qualification.
- !f test is not passed, the tentative WP&
value of the parameters are changed as
deemed feasible
&teps involved in qualifying the
welding process S 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 WP& and the samples are tested as per
applicable requirements.
- A qualified WP& is usable for an indefinite 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 WP& for pipe
to pipe butt joint( dia. 406 * 12mm)
of &A 106 CrC - &A106 CrC as per
A&E sec !X
- Requirement of mechanical property:
!mpact toughness at room
temperature
Tensile strength
Filling up of WP& Draft
- WP&: No: Date:
- &upporting PQR
- Welding process :
- Type : anual/ achine/Auto/
&emi Auto
- Application:
]oints(QW:402)
- ]oint Design
- Backing
- Baking aterial Type
Base etal(QW403)
- P. Number
- Croup Number
- &pecification
- Chemical Analysis S echanical
Properties
- Thickness Range
- Pipe Diameter Range
Filler etals(QW404)
- AW& Number
- &FA Number
- F. Number
- A. Number
- &ize of Filler metal
- Flux trade name
- Consumable insert
- Electrode flux class
W Deposited etal thickness range
Welding position(QW40S)
- Welding test positions are defined
differently for plate and pipe
Preheat(QW:406)
- Preheat temperature in
- !nterpass temp.(ax.)
- Preheat maintenance
PWHT(QW:407)
- Temperature range
- Time range
- Thickness range
Cas(QW:408)
- Cases ix Flow rate
- &hielding
- Trailing
- Backing
Electrical
Characteristics(QW403)
- Current (AC/DC)
- Polarity (EP/EN)
- Amps S olts
- WElectrode type S size
- ode of etal Transfer
- Electrode Wire Feed &peed range
- Pulsing Current
Techniques(QW410)
- &tringer or Weave Bead
- Orifice/Cas Cup &ize
- !nitial or !nterpass Cleaning
- ethod of Back Cauging
- Oscillation
- Contact Tip to Work Distance
- ultiple or &ingle Pass
- ultiple Or &ingle Electrode
- Electrode &pacing
- Peening
- Others
Filling up of WPS]oints(QW:402)