ASME SEC. IX Overview

1. Introduction to ASME Sec. IX

2.  General guide lines for procedure and
performance qualification referenced by
all ASME code of construction
 Covers welding as well as Brazing
operations

3.  A Mandatory Requirement from Codes /Stds / Regulations
 Qualification Tests in accordance with the Applicable Code
/ Standard / Regulation.
 Acceptance Criteria of Test Results as per the Code of
Construction
 Qualification Records and Test Results to be Documented

4.  Welding Procedure Qualification
 Welders’ or Welding Operators’
Performance Qualification

5.  Proves the Quality & Properties of Weld Joint Prepared by a set of
welding variables
 Welding Process
 Base Material
 Welding consumable
 Welding Parameters & Techniques ( Position, Polarity, Preheat, Inter
Pass Temp. Back Gouging--)
 PWHT
 Qualification limited to the essential variables of the Specific Process

6. WPS:
 It is a written procedure prepared to provide welding parameters for making
welds as per code requirement.
 Can be used on production only after successful qualification of supporting
PQR(s).
 A WPS can be supported by one or multiple PQR(s).
PQR:
 Record of the actual welding data used to weld a test coupon.
 Also contains test results (Mechanical, Chemical & Non Destructive Test) of
the test coupon.
 One PQR can support one or multiple WPS(es).

7. Essential variable:
◦ A change in welding condition which will affect the mechanical
properties other than toughness of weldment
◦ Any change in this variable calls for re-qualification of PQR
 Supplementary – essential variable:
• Change in this variable calls for re-qualification of PQR in case
there is requirement of impact toughness for the vessel
• A Change in welding condition which will affect impact
toughness of weldment
 Non - essential variable:
• No change in mechanical properties is expected
 A WPS shall record all essential, supplementary essential & non
essential variables

8.  Read & Understand ASME Sec. IX - Welding Data - Essential, Non
Essential & Supplementary Essential Variables.
 Test Requirements
 Testing Procedures
 ASME Sec.II Part C.
Classification of Welding Consumable
Properties of Consumables

9. Write A Welding Procedure Specification –WPS
 WPS Provides Direction for A Specific Welding
 WPS Shall Include All Essential, Supplementary
Essential & Non Essential Variables
 WPS Format Available in ASME Sec. IX.
 Each WPS Shall be Assigned with A Unique Number.

10. NDT Of Weld Coupon - Optional
 X-Ray / Radiograph the Weld Joint ( Not a Code Requirement )
 Mark Transverse Tensile & Guided Bends As Per QW461
 Eliminate Defective Weld Portion If Any, While marking the Test
Specimens
 Preserve RT Report & X-Ray Film as Annexure to PQR

11. Mechanical Tests – Qw 451, Groove Weld.
 Up to 9 mm Thickness
- Transverse Tensile :– 2No
- Root Bend :- 2No
- Face Bend :- 2No
 Over 9 mm Thickness
-Transverse Tensile :- 2No
- Side Bend :- 4No

12. Acceptance Criteria for Test Results.
 Tensile Strength (Qw / QB-422)
- Minimum Tensile Strength of Material Used
 Bend Test (Qw 163)
-Opening Not More Than 3.2 mm in Any Direction on Convex
Surface Within the Weld & HAZ

13.  PQR – Procedure Qualification Record
- PQR Format Available in Sec. IX
- Record All Relevant Data in the Format.
-Record All Mechanical Test Results
-Attach All Test Reports & Welding Parameters Used
as Annexure to PQR
-Assign Unique Number to Each PQR
-WPS No Shall be Referred in PQR

14. A WPS Remains Qualified When
 A Procedure Qualification Coupon Is Welded As Per WPS
 All Mechanical Tests of The Coupon Are Completed
 All Test Results Are Within The Acceptable Limit
And
 The Supporting PQR No Is Referred In The WPS

15.  To reduce number of qualification, materials
are grouped into ‘P’ Numbers or Parent metal
numbers and Group numbers
 List of most commonly used P Nos is given in
next slide

16. ‘P’ Number (Base Metal) Details
‘P’ No. Example Type
P1
SA-515 Gr. 60/70 (Plate)
C-Mn Steel
SA-537 CL .2 (Plate)
SA-105 (Forging)
SA-106 Gr. B (Pipe)
P3
SA-204 Gr. B (Plate)
0.5 Mo SteelSA-302 Gr. A/B (Plate)
SA-336 F1 (Forging)
SA-182 F1 (Forging)
SA-335 P1/2 (Pipe)
SA-209 T1(Tube)

17. ‘P’ Number (Base Metal) Details
‘P’ No. Example Type
P4
SA-387 Gr. 11/12 CL1/CL.2
(Plates)
1Cr-0.5 Mo Steel
SA-182 F 11/ F12
SA-336 F22 (Forging)
SA-335 P11(Pipe)
SA-199 T11 (Tubes)

18. ‘P’ Number (Base Metal) Details
‘P’ No. Example Type
P5-A
SA-387 Gr. 22 CL.1 / 2 (Plates)
Low Alloy Steel
SA-182 F22 (Forging)
SA-336 F22 (Forging)
SA-335 P22 (Pipe)
SA-199 T22 (Tube)
SA-250 T22 (Tube)
P5-B
SA-387 Gr. 5 CL.1/2 (Plates) 5Cr-0.5 Mo
SA-387 Gr. 91 CL.2 (Plates) 9Cr-1Mo
SA-335 P5 (Pipes) 5Cr-0.5 Mo

19. ‘P’ Number (Base Metal) Details
‘P’ No. Example Type
P6
SA-240 TP410(Plates) Martensitic SS 13Cr
SA-182 F6B (Forging)
P7 SA-240 TP 405/410S/430 Ferritic SS 13-17 Cr
P8
SA-240 (Plates) Austenitic SS
SA-312 (Pipes) TP304L/316L/317L/321/347 18-Cr-8Ni
SA-213 (Tubes)
P9 A/B
SA-203 Gr. B (Plates) 2.5 % Ni
Nickel Steel
SA-203 Gr. E (Plates) 3.5 % Ni
SA-350 LF-3 (Forging) 3.5 % Ni

20. ‘P’ Number (Base Metal) Details
‘P’No. Example Type
P10
SA-225 Gr. C (Plate) Mn-0.5 Ni-V Quenched & tempered
SA-182 F50 (Forging) 25Cr-6Ni-Mo-V Alloy Steel
P11A
SA-353 (Plates) 9 % Ni Quenched &
SaA-533 Type B CL.3 (Plates) Mn-Mo-
Ni tempered
SA-522 Type 1/2 (Forging) 9% Ni Steel
P11B SA-517 Gr. F (Plate) Ni-Cr-Mo-V
Quenched & tempered
Steel

21. ‘P’ Number (Base Metal) Details
‘P’ No. Example Type
P21-25 Aluminium & its alloys
P31-35 Copper its alloys
P41-47 Nickel & Nickel based alloys
P51-53 Titanium & Titanium Based alloys
P61-62 Zirconium & Zirconium based alloys

22. F numbers:
 Grouping of electrode on their usability characteristics
 Determine the ability of welder to deposit sound weld.
 List of most commonly used F Numbers is given in next
slide

23. F' Number (Filler Metal) Details
'F' No. Process Type Of Consumable Example
F1 SMAW Iron Oxide Rutile E6020, E7024
F2 SMAW Rutile (Titania)
E6012, E6013,
E7014
F3 SMAW Cellulose E6010, E6011
F4 SMAW Low Hydrogen
E7018/-1/A1, E8018-
B2/C1/C2/D3,
E9018 B3/M,
E11018M
F5 SMAW
SS Austenitic Titania /
Silica
E308L-16

24. 'F' No. Process Type Of Consumable Example
F6 GTAW Bare Wires
ER70 S2/S6, ER80
SD2/B2/Ni2,
ER308L/316L
GMAW Bare Wires ER70 S6, ER308L/ER316
FCAW Flux Cored Wires
E71 T-1, E70 T-5, E308LT-
1, E316LT1, E309LT-1,
E347LT-1
SAW SAW Wires
EH 14, S3,
EA3,EA4,EB2/EB3,
ER308L/309L

25. 'F' No. Process
Type Of
Consumable Example
F21-24 Al & Al based Alloys
F31-37 Cu & Cu based Alloys
F41-45 Ni & Ni based Alloys
F51-54 Ti & Ti based Alloys
F61 Zr & Zr based Alloys
F71-72 Hard Facing

26. A-No.
 Identification of weld metal chemical
composition.
 To reduce the no of qualification
 List of most commonly used A-No is given in
next slide

28. QW 402: Joints
Non essential variables -
 Groove design,
 Backing,
 Root gap,
 Retainers

29. QW 403: Base metals
Essential variables -
 P No,
 Thickness of base material qualified,
 Thickness of each pass beyond 13 mm for
multipass welding
 Supplementary essential variables -
 Group no for base material
 Minimum thickness of base material qualified

30. QW 404: Filler Metals
Essential variables -
 F no,
 A no,
 Thickness of deposited weld metal
 Flux / wire class,
 Alloy addition through flux (SAW),
 Re-crushed slag (SAW)
 Supplementary essential variables -
 Electrode Diameter > 6 mm for SMAW
 Non essential Variables –
 Change of Electrode Diameter for SAW

31. QW 405: Positions
Supplementary essential variables -
 Change from any position to vertical uphill
progression for SMAW.
 Non essential variables –
 Change in position.

32. QW 406: Preheat
Essential variables -
 Decrease of more than 55ºC in the preheat temperature qualified.
Supplementary essential variables -
 Increase of more than 55ºC in the interpass temperature qualified.
Non essential variables –
 Change of preheat maintenance i.e. Dehydrogenation Treatment
(DHT) etc.

33. QW 407: PWHT (Post Weld Heat Treatment)
Essential variables -
 Any change in the following conditions:
 No PWHT,
 PWHT below lower transformation temperature,
 PWHT above upper transformation temperature,
 PWHT between upper & lower transformation temperature.
Supplementary essential variables –
 Increase in job PWHT soaking time beyond 20% of the
soaking time qualified in PQR.

34. QW 408 : Gas
Essential variables -
 Single shielding gas to mixture of gasses,
 Different types of mixed gasses,
 Percentage composition of gasses for GMAW, FCAW,
GTAW process
Non essential variables –
 Flow rate,
 Backing gas flow rate
 Backing gas composition

35. QW 409: Electrical Characteristics
Supplementary essential variables -
 Increase in heat input ,
 Change in current type ( AC / DC),
 Change in Polarity (DCEN / DCEP)
Non essential variables –
 Change in current range,
 Change in range of voltage (except SMAW & GTAW)

36. QW 410: Technique
Supplementary essential variables-
 Change in multiple to single pass per side .
 Change of Single to multi electrode for SAW
Non essential variables –
 Change of Stringer bead to Weave bead
technique or vice versa,
 Method of cleaning,
 Method of back gouging,

37. Purpose
 To validate the capability of an welder to deposit
sound weld metal following a qualified welding
Procedure
 Establish the range of qualification to minimize the
number of qualification
 Guide line for renewal of qualification

38. Welder
 Person performing welding by manipulating arc by
hand
Welding Operator
 Person performing welding by controlling the
manipulation of arc by machine

39. Requirement for Welder Qualification:
 A welder qualified by a company cannot be used by
another company
 When a welder changes a company fresh qualification
is mandatory

40. Essential variable:
 A change in welding condition which will affect the
ability of welder to deposit sound weld metal
 Any change in this variable calls for re-qualification

41. Essential variable for SMAW, GTAW as per Sec. IX
 QW 353, 356
 A change in welding condition which will affect the ability of
welder to deposit sound weld metal
 Any change in this variable calls for re-qualification

42. Essential variable for SMAW, GTAW as per Sec. IX QW
353, 356

43. Essential variable for Machine welding ( SAW), QW 361.2
A change in welding condition which will affect the ability of welder
to deposit sound weld metal
Any change in this variable calls for re-qualification
Essential Variables
 Change in welding Process
 Change from direct to remote visual control
 Deletion of Auto joint tracking
 Addition of welding position not qualified
 Deletion of consumable inserts
 Deletion of backing
 Single pass per side to multi pass per side

45.  Qualification Range
 Thickness of weld metal
 Position
 Pipe diameter
 Filler metal
 Base metal (for manual or semiautomatic processes)

46.  Read ASME Sec. IX - Welding Performance
Qualifications
 Variables For Different Processes – QW 350
 Limits Of Positions Qualified & Dia – QW 461
 Testing Requirements – QW 304-1

47.  Train The Welder For The Process To Be Qualified
 Welder Shall Posses Adequate Skill In Performing the Process.
 He Shall have Necessary Knowledge In Operation Of Machine,
Precautions In Storage & Usage Of Consumable, Defects In
Welding, Their Causes And Remedy.
 He Shall Practice Welding In The Particular Position In Which He Is
To Be Tested / Qualified

48. Preparation Of Test Coupon
 Prepare A Test Coupon Out of 300 х 150 х 20 mm CS
Plates Or As Per Applicable WPS.
 WEP ( Angle, Root Face & Root Opening ) Shall Be As
Per The WPS
 Provide Run in & Run Out plate & Fix the Test Coupon
In In Any One Of The Positions To Be Qualified.
 Weld The Groove Fully In The Position
 All Welding Variables Shall be Strictly Within The
Qualified WPS

49. Type Of Test Required On Welded Coupon (QW-302)
 Visual Examination – Qw 302.4
 Completed Coupon Shall be Subjected To Visual
Inspection
 Mechanical Test - QW 452
 Root Bend :- 1 No, Face Bend :- 1 No
Or
 Side Bend :- 2 No
 Alternate to Mechanical Tests, Radiograph the Coupon
– 6 ” Minimum Length

50. Acceptability Criteria For Tests
 Visual Examination – Qw 302.4
 Free From Incomplete Fusion / Penetration and Surface
Defect
 Bend Test - QW 163
 Opening not more than 3.2 mm in any direction on
Convex Surface Within the Weld & HAZ
 R T – Qw 191.2
 No Crack, L/F & Incomplete Penetration
 No Slag, Cluster Of Porosity & Other Inclusions Beyond
Specified Limit

51. Qualification Test Position & Type of Weld Qualified
Weld Position
Plate & Pipe
Over 610mm
Pipe ≤ 610mm
Fillet Plate &
Pipe
Plate
Groove
1G
2G
3G
4G
2G, 3G &4G
Spcl. Position
F
F, H
F,V
F,O
ALL
SP & F
F*
F*&H*
F*
F*
F*&H*
SP & F
F
F,H
F,H,V
F,H,O
ALL
SP & F
Pipe$
Groove
1G
2G
5G
6G
2G &5G
Spcl. Position
F
F,H
F,V,O
ALL
ALL
SP,F
F
F,H
F,V,O
ALL
ALL
SP,F
F
F,H
ALL
ALL
ALL
SP&F
Pipe 73mm OD and Over
$ Pipe OD Restrictions As Per QW 452.3, 452.4 and 452.6

52. Out Side Dia. Of Test Coupon
in mm ( in)
Out Side Dia. Qualified
Min. Max.
Less Than 25 (1”) Size Welded Unlimited
25 (1”) to 73 (2⅞”) 25 (1”) Unlimited
Over 73 (2⅞”) 73 (2⅞”) Unlimited
Notes:-
1) Type & Number of Tests as per QW-452.1
2) 73 mm OD is equivalent to 2½” NB Pipe
3) Welders Qualified on Groove, Are Also Qualified for making Fillets of all Sizes on Any
Thickness & Any Pipe Dia.

53. ANY QUESTION?