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WPS-PQR-WELDER QUALIFICATION.PPT.pdf.pdf

The document outlines the qualification requirements for welding procedures, emphasizing the necessity of compliance with codes and standards, particularly ASME specifications. It details the processes for qualifying welding procedures and welders, including essential and nonessential variables, and the documentation of qualification records. Additionally, it describes the systematic approach to testing and the acceptance criteria for welds, ensuring that they meet predetermined mechanical properties.

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1 WELDING QUALIFICATION
2 Welding Qualifications • 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 Range & Limits as per Code / Std / Regulation • Qualification Records and Test Results to be Documented
3 Welding Qualifications Qualification Requirements For Equipments to be Made as per ASME Boiler & Pressure Vessel Code • ASME Sec IX + Applicable Design Code (Sec.VIII Div I or II, Sec. I, Sec. III)
4 Welding Qualifications • Welding Procedure Qualification • Welders’ or Welding Operators’ Performance Qualification
5 Welding Procedure Qualification • 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 Welding Procedure Qualification • WELDING DATA - A set of Welding Variables involved in Preparing a Weld Joint. • ESSENTIAL VARIABLE - A change in welding condition which will affect the mechanical properties (Other than notch toughness) of weld joint . • SUPPLEMENTARY ESSENTIAL VARIABLE - A change in welding condition which will affect the notch toughness properties of weld joint • NONESSENTIAL VARIABLE - A Change in welding condition which will not affect the mechanical properties of the weld joint
7 Welding Performance Qualification • Ascertain the skill of a welder or a welding operator to Produce defect free/Sound weld  Makes A Weld Coupon Using an Approved WPS of a Qualified Procedure.  Weld Coupon Undergoes Soundness Test  Each Qualified Welder Shall be Assigned by A Unique Welder Number  Welders’ Qualifications Records Are Documented • Performance Qualification limited to the essential variables of the Specific Process
8 Welding Performance Qualification • WELDING DATA - A set of Welding Variables involved in Performing a Weld Joint. • ESSENTIAL VARIABLE - A change in welding condition which will affect the ability of welder to deposit sound weld metal. • NONESSENTIAL VARIABLE - A Change in welding condition which will not affect the ability of welder to deposit sound weld metal
9 How To Qualify Groove Butt Weld Procedure? 1) Understand ASME Sec. IX Classifications & Requirements - Welding Data - Essential, Non Essential & Supplementary Essential Variables. – QW-251, 400 - Parent Metal Grouping - “P” No / S No; Group No – QW-420 & 422 - Filler Metal Grouping – “ F” No – QW-431,432, 433 - Weld Metal Composition Grouping (For Ferrous Metal) – “A” No – QW- 440, 441, 442 - Welding Positions, Groove & Fillet – QW-461 - Types of Tests & Acceptance Limits – Tension, Guided Bend, Notch Toughness – QW-141, 451, 153, 163, 171, 172, 462, 463 - Test Requirements – QW-451, - Test Specimen – Location, Dimension & Testing Procedure – QW-462,463, 464, 466 - Qualifications – Range in Thickness - QW-451, - Record & Documentation of WPS & PQR
10 How To Qualify Groove Butt Weld Procedure? • 2) Understand ASME Sec.II Part C. - Specification for Filler Analysis – SFA No - AWS Classification of Welding Consumable - Limits for Chemical Composition & Mechanical Properties of Consumables
11 How To Qualify Groove Butt Weld Procedure? 3) 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.
12 How To Qualify Groove Butt Weld Procedure? 4) Prepare A Test Coupon As Per WPS - Coupon Size: Pair of 300 mm X 150 mm Plates Or Pipes 150 mm long as Specified in WPS - All Other Details as per Written WPS - Complete the Welding by Reasonably Skilled Welder - All Welding Variables Shall be Used Within the Limit Specified in WPS. - All Variables Actually Used Shall be Documented as Annexure to PQR ( Procedure Qualification Record)
13 How To Qualify Groove Butt Weld Procedure? 5) NDT Of Weld Coupon - Optional - X-Ray / Radiograph the Weld Joint ( Not a Code Requirement ) - Mark Transverse Tensile & Guided Bends As Per QW463 - Eliminate Defective Weld Portion If Any, While Marking the Test Specimens - Preserve RT Report & X-Ray Film as Annexure to PQR
14 6) Mechanical Tests – Qw 451, Groove Weld. • Up to 19 mm in Thickness - Transverse Tensile :– 2No - *Root Bend :- 2No - *Face Bend :- 2No • 19 mm and above in Thickness - Transverse Tensile :- 2No - Side Bend :- 4No * For material 10 mm and above in thickness, 4 side bend Tests may be substituted for Face & Root bends How To Qualify Groove Butt Weld Procedure?
18 How To Qualify Groove Butt Weld Procedure? Location of Test Specimens From Test coupon – QW 463.1 Plates thickness less than 19 mm Root Bend 2No Face Bend 2No Reduced Section Tensile 2No * * * * * * <19 mm Balance Plate Discard Discard
19 How To Qualify Groove Butt Weld Procedure? Location of Test Specimens From Test coupon – QW 463.1 Plates thickness 19 mm and above Side Bend 4No Reduced Section Tensile 2No * * * * >19 mm Balance Plate Discard Discard * *
20 How To Qualify Groove Butt Weld Procedure? Location of Test Specimens From Test coupon QW 463.1 Pipe When Pipe Thickness is 19 mm or more, In place of Root & Face, 4 Side Bends shall be Taken Horizontal Plane Pipe is welded in Horizontal fixed position @ = Reduced section Tensile 2No £ £ £ £ @ @ £ = Bends - Root & Face or Side Root Bend Face Bend Root Bend Face Bend 45˚- 60˚ 45˚ - 60˚
23 How To Qualify Groove Butt Weld Procedure? 7) 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 mm in Any Direction on Convex Surface Within the Weld & HAZ
24 How To Qualify Groove Butt Weld Procedure? 8) 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
25 Qualified WPS • 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
26 Thickness Limit For Groove Butt Weld Procedure.QW451 Thickness “T” Of Test Coupon Welded in mm Range Of Thickness “T” of BM Qualified in mm Thickness “t”of Deposited Weld metal Qualified in mm Mini Max Max Less Than 1.5 (1/16”) T 2T 2t 1.5 to 10 (1/16” to” ⅜”) Incl 1.5 (1/16”) 2T 2t Over 10 to below 19 (⅜” to ¾ ) 5 (3/16”) 2T 2t 19 to below 38 ( ¾ ” to 1 ½”) 5 (3/16”) 2T 2t When t < 19 19 to below 38 ( ¾ ” to 1 ½”) 5 (3/16”) 2T 2T When t ≥19 38 (1 ½”) and over 5 (3/16”) 200 ( 8” ) 2t When t < 19 38 (1 ½”) and over 5 (3/16”) 200 ( 8” ) 200 When t ≥19 Over 200 (8”) – QW 403.7 5 (3/16”) 1.33 T 1.33 t
27 Minimum Base Metal Thickness Limit For Butt Weld Procedure With Impact .QW403.6 Thickness “T” Of Test Coupon Welded in mm Range Of Thickness “T” of BM Qualified in mm Thickness “t”of Deposited Weld metal Qualified in mm Mini Max Max Below 6 1/2T 2T 2t 6 to 16 (1/4” to” 5/8”) Incl T 2T 2t Over 16 to below 19 (5/8” to ¾’’ ) 16 (5/8”) 2T 2t 19 to below 38 ( ¾ ” to 1 ½”) 16 (5/8”) 2T 2t When t < 19 19 to below 38 ( ¾ ” to 1 ½”) 16 (5/8”) 2T 2T When t ≥19 38 (1 ½”) and over 16 (5/8”) 200 ( 8” ) 2t When t < 19 38 (1 ½”) and over 16 (5/8”) 200 ( 8” ) 200 When t ≥19 Over 200 (8”) – QW 403.7 16 (5/8”) 1.33 T 1.33 t
28 Impact Testing – UG 84 Qualification With Supplementary Essential Variable. A) Weld Joint Thickness 38 mm ( 1½ “) And Below Two Sets Of Charpy V Notch Impact Specimens • One Set Of 3 Nos. Each From HAZ – Within 1.5 from Any Surface • One Set Of 3 Nos. Each From Weld – Within 1.5 from Any Surface B) Weld Joint Thickness Above 38 mm ( 1½ “) Three Sets Of Charpy V Notch Impact Specimens • One Set Of 3Nos. Each From HAZ – Within 1.5 from First Half Surface • One Set Of 3 Nos. Each From Weld – Within 1.5 from Any Surface • One Set Of 3 Nos. Each From Weld – Midway In Second Half
31 Procedure Qualification - QW-253 SMAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 402 Joints Change in Groove Design --- --- * Addition / Deletion of Backing --- --- * QW 403 Base Metals Change in group Of P No --- * --- T Limits Impact --- * --- T/t Limits  200 mm * --- --- Change in T Qualified * --- --- “t” pas  13 mm * --- --- Change of P Number Qualified * --- --- QW 404 Filler Metals Change in F No * --- --- Change in A No * --- --- Change in Dia --- --- * Change in Dia  6 mm --- * --- Change in AWS classification --- * --- Change in t qualified * --- ---
32 Procedure Qualification - QW-253 SMAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 405 Positions Addition of Position --- --- * Change in Position --- * --- QW 406 Preheat Decrease  56°C * --- --- Increase  56°C IP --- * --- QW 407 PWHT Addition / Deletion of PWHT * --- --- Change in Time & Temp. Qualified --- * --- QW 409 Electrical Characteristics Increase in Heat Input --- * --- Change in Current / Polarity --- * --- Change in Current / Voltage --- --- * QW 410 Technique Change from String / Weave --- --- * Method of Cleaning --- --- * Method of Back Gouging --- --- * Change From Multiple to Single Pass --- * ---
33 Procedure Qualification - QW-254 SAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 402 Joints Change in Groove Design --- --- * Addition / Deletion of Backing --- --- * QW 403 Base Metals Change in group Of P No --- * --- T Limits Impact --- * --- T/ t Limits  203 mm * --- --- Change in T Qualified * --- --- “t” pas  13 mm * --- --- Change of P Number Qualified * --- --- QW 404 Filler Metals Change in F No * --- --- Change in A No * --- --- Change in Dia --- --- * Change in Wire & Flux Combination * --- --- Change in Alloyed Flux * --- ---
34 Procedure Qualification - QW-254 SAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 404 Filler Metal Alloy Elements / supplemental Wire * --- --- Change in Flux Type * --- --- Change in “t” Qualified * --- --- QW 405 Positions Addition of Position --- --- * QW 406 Preheat Decrease  56°C * --- --- Increase  56°C IP --- * --- QW 407 PWHT Addition / Deletion of PWHT * --- --- Change in Time & Temp. Qualified --- * --- T Limits * --- --- QW 409 Electrical Characteristics Increase in Heat Input --- * --- Change in Current / Polarity --- * --- Change in Current / Voltage --- --- *
35 Procedure Qualification - QW-256 GTAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 402 Joints Change in Groove Design --- --- * Addition / Deletion of Backing --- --- * QW 403 Base Metals Change in group Of P No --- * --- T Limits Impact --- * --- T / t Limits  203 mm * --- --- Change in T Qualified * --- --- Change From T Qualified * --- --- Change From P Number Qualified * --- --- QW 404 Filler Metals Change in F No * --- --- Change in A No * --- --- Change in AWS Classification --- * --- Addition / Deletion of Filler * --- --- Addition / Deletion of Consumable Insert --- -- * Change From Solid – Flux / Powder Cored * --- ---
36 Procedure Qualification - QW-256 GTAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 405 Positions Addition of Position --- --- * Change in Position --- * --- QW 406 Preheat Decrease  56°C * --- --- Increase  56°C IP --- * --- QW 407 PWHT Addition / Deletion of PWHT * --- --- Change in Time & Temp. Qualified --- * --- Change in T thickness Qualified * --- --- QW 408 Gas Addition / Deletion / Change in Trailing Gas --- --- * Addition / Deletion / Change in Shielding Gas * --- -- Change in Flow Rate of Shielding / Backing Gas --- --- * Deletion of Backing Gas * --- ---
37 Procedure Qualification - QW-256 GTAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 409 Electrical Characteristics Increase in Heat Input --- * --- Change in Tungsten Electrode Size --- --- * Addition / Deletion of Pulsing --- --- * Change in Current or Polarity --- * --- QW 410 Technique Change in Nozzle / Gas Cup Size --- --- * Method of Cleaning --- --- * Change in Oscillation --- --- * Method of Back Gouging --- --- * Change From Single to Multi Electrode --- * --- Change From Closed Chamber to Out Side * --- --- Change From Manual to Auto / Auto to Manual --- --- * Addition or Deletion of Preening --- --- *
38 Procedure Qualification - QW-255 GMAW & FCAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 402 Joints Change in Groove Design --- --- * Addition / Deletion of Backing --- --- * QW 403 Base Metals Change in group Of P No --- * --- T / t Limits  200 mm * --- --- Change From T Qualified * --- --- When “ t” in Single Pass  13 mm * --- --- T Qualified Limit for Short Circ. Transfer * --- --- Change From P Number Qualified * --- --- QW 404 Filler Metals Change in F No * --- --- Change in A No * --- --- Change in AWS Classification --- * --- Change from solid - Flux Cored / Powder Cored * --- --- Addition / Deletion of Alloy Elements * --- --- “t” Qualified Limit for Short Circ. Transfer * --- ---
39 Procedure Qualification - QW-255 GMAW & FCAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 405 Positions Addition of Position --- --- * Change in Position --- * --- QW 406 Preheat Decrease  56°C * --- --- Increase  56°C IP --- * --- QW 407 PWHT Addition / Deletion of PWHT * --- --- Change in Time & Temp. Qualified * --- --- Change in T thickness Qualified * --- --- QW 408 Gas Addition / Deletion / Change in Trailing Gas --- --- * Addition / Deletion / Change in Shielding Gas * --- -- Change in Flow Rate of Shielding / Backing Gas --- --- * Deletion of Backing Gas * --- ---
40 Procedure Qualification - QW- 255 GMAW & FCAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 409 Electrical Characteristics Increase in Heat Input --- * --- Change in Metal Transfer Mode * --- --- Change in Wire feed & Voltage --- --- * Change in Current or Polarity --- * --- QW 410 Technique Change in Nozzle / Gas Cup Size --- --- * Method of Cleaning --- --- * Change in Oscillation --- --- * Method of Back Gouging --- --- * Change From Single to Multi Electrode --- * --- Change From Multiple to Single Pass per Side --- * --- Change From Manual to Auto / Auto to Manual --- --- * Addition or Deletion of Preening --- --- *
41 P Number & Group Number • P Numbers assigned to all Materials Listed in ASME Sec. II – Part A & B. (P1, P3, P4, P5 ----) • S Numbers are assigned to materials not listed in ASME Sec. II, but permitted to use in ASME jobs - ASTM Material (S1,S3, S4, S5 --) • Assignment of P or S Number is based on Characteristic – Composition, Weldability & Mechanical Properties • Ferrous materials (ASME Sec II – A & ASTM) further grouped to Sub Group Numbers based on impact properties (P1- Gr.2, P4 - Gr. 1, S8 - Gr. 2 ---) • Grouping of Parent materials to P No or S No reduces the number of welding qualifications.
42 P – Number & Group Number (Base Metal For Qualification) P- No Group No Met. Spec. Grade Met. Quality & Form P1 1 2 SA 515 / SA 516 SA 515 / SA 516 60 70 CS – Plate CS – Plate P1 1 2 SA 106 SA 106 A / B C CS – Pipe CS - Pipe P1 1 3 SA333 SA 333 6 10 CS – Pipe CS - Pipe P1 1 2 SA 234 SA 234 WPB WPC CS Pipe Fitting CS Pipe Fitting P1 1 SA 285 C / B CS Plate P1 1 SA 179 --- CS Tube P1 1 2 SA 105 SA 181 --- Cl 70 CS Forging CS Forging QW-422
43 P – Number & Group Number (Base Metal For Qualification) • QW-422 P- No Group No Met. Spec. Grade Met. Quality & Form P3 2 3 SA 302 SA 302 A B,C,D Mn – 0.5 Mo – Plate Mn – 0.5 Mo – Plate P3 1 SA 335 P1 / P2 C – 0.5 Mo – Pipe P3 3 SA 533 TP- B, Cl- 1 or 2 C – 0.5 Mo – Plate P3 1 SA 209 T1, T1a, T1b C – 0.5 Mo – Tube P3 2 SA 282 F1 C – 0.5 Mo – Forging
44 P – Number & Group Number (Base Metal For Qualification) • QW-422 P- No Group No Met. Spec. Grade Met. Quality & Form P4 1 3 SA 387 SA 387 12, Cl –1 / 2 11, Cl –1 / 2 1Cr. 0.5 Mo – Plate 1.25 Cr. 0.5 Mo – Plate P4 1 SA 335 P12 / P11 1Cr (1.25 Cr) – 0.5 Mo – Pipe P4 2 SA 423 TP - 1 / 2 1.25 Cr. 0.5 Mo – Tube P4 1 SA 282 SA 336 F12, Cl- 1 / 2 F11, Cl –1 / 2 / 3 1. Cr – 0.5 Mo – Forging 1.25 Cr – 0.5 Mo – Forging
45 P – Number & Group Number (Base Metal For Qualification) • QW-422 P- No Group No Met. Spec. Grade Met. Quality & Form P5A P5B 1 1 SA 387 SA 387 22, Cl –1 / 2 5, Cl - 2 2. 25 Cr. 1 Mo – Plate 5 Cr. 0.5 Mo - Plates P5A 1 SA 335 P22 2. 25 Cr. 1 Mo – Pipe P5A 1 SA 213 TP - 22 2. .25 Cr. 1 Mo – Tube P5B P5C P5A 1 1 1 SA 182 SA 182 SA 336 F5 F22V F22, Cl –1 / 3 5 Cr – 0.5 Mo – Forging 2. 25 Cr – 1 Mo,V – Forging 2. 25 Cr – 1 Mo – Forging
46 P – Number & Group Number (Base Metal For Qualification) • QW-422 P- No Group No Met. Spec. Grade Met. Quality & Form P6 2 SA 240 TP 429 15Cr. – Plate P6 4 SA 731 S41500 13Cr., 4.5 Ni, Mo - Pipe P6 1 SA 268 TP410 13Cr. – Tube P6 3 SA 336 F6 13Gr.– Forging P7 2 SA182 F430 17Cr. - Forging P7 2 SA 240 TP 430 17Cr. - Plate P7 2 SA 268 TP430 17Cr. Tube P7 2 SA 731 TP439 18Cr., Ti – Pipe
47 P – Number & Group Number (Base Metal For Qualification) • QW-422 P- No Group No Met. Spec. Grade Met. Quality & Form P8 1 1 SA 312 SA 312 TP321 TP347 18Cr., 10Ni, Ti - Pipe 18Cr., 10Ni, Cb - Pipe P8 1 1 SA336 SA 336 TP316 TP310 18Cr., 8 Ni, 2Mo -Forging 25Cr., 20 Ni, Forging P8 1 2 SA 240 SA 204 TP304 TP309S 18Cr, 8Ni - Plates 23Cr. 12Cr. - Plates P8 1 1 SA 249 SA 249 TP317 TP316L 18Cr, 13Ni, 3Mo –Tube 16Cr, 12Ni, 2Mo - Tube
48 P – Number & Group Number (Base Metal For Qualification) • QW-422 P- No Group No Met. Spec. Grade Met. Quality & Form P9B 1 SA 333 3 3.5Ni - Pipe P9A 1 SA334 7 2.5Ni - Tube P9A P9B 1 1 SA 350 SA 350 LF5, Cl. 2 LF3 1.5Ni - Forging 3.5Ni. - Forging P9A P9B 1 1 SA 203 SA 203 A E 2.5Ni. - Plate 3.3Ni. - Plate
49 P – Number & Group Number (Base Metal For Qualification) • QW-422 P- No Group No Met. Spec. Grade Met. Quality & Form P10H 1 SA240 S31803 22Cr, 5Ni, 3Mo, N - Plate P10H 1 SA240 S32550 25Cr, 5Ni, 3Mo, 2Cu - Plate P11A 1 SA 333 8 9Ni - Pipe P11A 1 SA334 8 9Ni - Tube P11A P11A 5 5 SA 508 SA 508 4N, Cl. 2 5, Cl. 2 3.5Ni –1.75 Cr.-0.5Mo.- V, Forging 3.5Ni –1.75 Cr.-0.5Mo.- V, Forging P11A P11A 4 4 SA 533 SA 533 TP B, Cl. 3 TP C, Cl. 3 Mn, 0.5 Mo, 0.5Ni – Plate Mn, 0.5 Mo, 0.75Ni - Plate
50 How To Qualify A Welder 1) Understand ASME Sec. IX - Welding Performance Qualifications - Variables For Different Processes – QW 350 - Limits Of Positions Qualified & Dia – QW 461 - Testing Requirements – QW 304-1
51 How To Qualify A Welder 2) 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
52 How To Qualify A Welder 3) Preparation Of Test Coupon - Prepare A Test Coupon Out of 300 х 150 х 20 mm Plates Or Pipe Of 150mm long As Per Applicable WPS. - WEP ( Angle, Root Face & Root Opening ) Shall Be As Per The WPS - Provide Run in & Run Out Coupons on 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
53 How To Qualify A Welder 4) 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 Nos (For 5G / 6G – 2 Face & 2 Root Or 4 Side Bends) • Alternate to Mechanical Tests, Radiograph the Coupon – 6 ” Minimum Length < 19 mm Thick ≥ 19 mm Thick
54 Location of Test Specimens From Test coupon – QW 463.2 Plates Less Than 19 mm How To Qualify A Welder Root Bend 1No Face Bend 1No * * <19 mm Discard Discard 300 mm ( 150 mm Minimum)
55 Location of Test Specimens From Test coupon – QW 463.2 Plates -Thickness 19 mm & more How To Qualify A Welder Side Bend 2No * Discard Discard 300 mm ( 150 mm Minimum) ≥19 mm * Balance Material *
56 Location of Test Specimens From Test coupon – QW 463.2 Pipe in 5G or 6G Position How To Qualify A Welder Horizontal Plane Pipe is welded in Horizontal fixed position £ £ £ £ £ = Bends - Root & Face or Side Root Bend Face Bend Root Bend Face Bend 45˚- 60˚ 45˚ - 60˚ When Pipe Thickness is 19 mm or more, In place of Root & Face, 4 Side Bends shall be Taken
57 Location of Test Specimens From Test Pipe 6 NPS Welded in Combination of 5G & 2G – QW 463.2 How To Qualify A Welder 270˚Welded in 5G Pipe is welded in Horizontal fixed position 0˚ = 5G Weld = 2G Weld Root Bend Face Bend Root Bend Face Bend When Pipe Thickness is 19 mm or more, In place of Root & Face, Side Bends shall be Taken Welded in 2G 90˚ 270˚ 180˚ 90˚ Face Bend Root Bend 50˚ 130˚ 202.5˚ 247.5˚ 292.5˚ 337.5˚
58 How To Qualify A Welder 5) 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 mm in any direction on Convex Surface Within the Weld & HAZ • R T – Qw 91.2 No Crack, L/F & Incomplete Penetration No Slag, Cluster Of Porosity & Other Inclusions Beyond Specified Limit
59 Performance Qualification Thickness Limits – QW 452.1(b) Thickness “t” of Weld Metal in the Coupon in mm ( in) Thickness of Weld metal Qualified All 2t 13 (1/2) and Over With Minimum Three Layers Maximum To Be Welded
60 Groove Weld Positions – QW461 Sr No. Groove Position Base Metal Position Inclination of Axis in ° Plate Pipe 1 1G Flat Horizontal Pipe Axis Horizontal – in Rotation 0 -15 2 2G Horizontal Vertical Pipe Axis Vertical 0 - 15 3 3G Vertical Vertical NA 80 – 90 15 - 80 4 4G Over Head Horizontal NA 0 - 80 5 5G NA Pipe Axis Fixed Horizontally 0 -15 6 6G NA Pipe Axis Fixed 45° inclined + or - 5
61 Performance Qualification Position & Dia Limits- QW461.9 Qualification Test Position & Type of Weld Qualified Weld Position Plate & Pipe Over 24” Pipe ≤ 24” 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 2 ⅞” OD and Over, $ Pipe OD Restrictions As Per QW 452.3, 452.4 & 452.6
62 Performance Qualification Groove-Weld, Pipe Dia. Limits QW 452.3 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.
63 Welding Variables- Qw 416 Performance Qualification Group of Variables Brief Of Variables Essential Variables SMAW QW -353 SAW. QW-354 GMAW QW-355 GTAW QW-356 QW 402 Joints Deletion of Backing + + + + QW 403 B M Change in Pipe Dia. + + + + Change in P Number + + + + QW 404 Filler Metal Deletion /Addition of FM --- --- --- + Change in F Number + + + + Dele. /Addi. of Consumable Insert --- --- --- + Solid – Metal/Flux Cored --- --- --- + Change in t deposit Qualified + + + + “t” deposit for Short Cir.Transfer --- --- + ---
64 Welding Variables- Qw 416 Performance Qualification Group of Variables Brief Of Variables Essential Variables SMAW QW -353 SAW. QW-354 GMAW QW-355 GTAW QW-356 QW 405 Position Addition of New Position + + + + Change from up hill to Down hill –3G + --- + + QW 408 Gas Deletion of Inert Gas Backing --- --- + + QW 409 Electric Charact. Change in Mode of Metal Transfer --- --- + --- Change in Type of Current / Polarity --- --- --- +

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WPS-PQR-WELDER QUALIFICATION.PPT.pdf.pdf

  • 1.
  • 2.
    2 Welding Qualifications • AMandatory 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 Range & Limits as per Code / Std / Regulation • Qualification Records and Test Results to be Documented
  • 3.
    3 Welding Qualifications Qualification Requirements ForEquipments to be Made as per ASME Boiler & Pressure Vessel Code • ASME Sec IX + Applicable Design Code (Sec.VIII Div I or II, Sec. I, Sec. III)
  • 4.
    4 Welding Qualifications • WeldingProcedure Qualification • Welders’ or Welding Operators’ Performance Qualification
  • 5.
    5 Welding Procedure Qualification •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.
    6 Welding Procedure Qualification •WELDING DATA - A set of Welding Variables involved in Preparing a Weld Joint. • ESSENTIAL VARIABLE - A change in welding condition which will affect the mechanical properties (Other than notch toughness) of weld joint . • SUPPLEMENTARY ESSENTIAL VARIABLE - A change in welding condition which will affect the notch toughness properties of weld joint • NONESSENTIAL VARIABLE - A Change in welding condition which will not affect the mechanical properties of the weld joint
  • 7.
    7 Welding Performance Qualification • Ascertainthe skill of a welder or a welding operator to Produce defect free/Sound weld  Makes A Weld Coupon Using an Approved WPS of a Qualified Procedure.  Weld Coupon Undergoes Soundness Test  Each Qualified Welder Shall be Assigned by A Unique Welder Number  Welders’ Qualifications Records Are Documented • Performance Qualification limited to the essential variables of the Specific Process
  • 8.
    8 Welding Performance Qualification • WELDINGDATA - A set of Welding Variables involved in Performing a Weld Joint. • ESSENTIAL VARIABLE - A change in welding condition which will affect the ability of welder to deposit sound weld metal. • NONESSENTIAL VARIABLE - A Change in welding condition which will not affect the ability of welder to deposit sound weld metal
  • 9.
    9 How To QualifyGroove Butt Weld Procedure? 1) Understand ASME Sec. IX Classifications & Requirements - Welding Data - Essential, Non Essential & Supplementary Essential Variables. – QW-251, 400 - Parent Metal Grouping - “P” No / S No; Group No – QW-420 & 422 - Filler Metal Grouping – “ F” No – QW-431,432, 433 - Weld Metal Composition Grouping (For Ferrous Metal) – “A” No – QW- 440, 441, 442 - Welding Positions, Groove & Fillet – QW-461 - Types of Tests & Acceptance Limits – Tension, Guided Bend, Notch Toughness – QW-141, 451, 153, 163, 171, 172, 462, 463 - Test Requirements – QW-451, - Test Specimen – Location, Dimension & Testing Procedure – QW-462,463, 464, 466 - Qualifications – Range in Thickness - QW-451, - Record & Documentation of WPS & PQR
  • 10.
    10 How To QualifyGroove Butt Weld Procedure? • 2) Understand ASME Sec.II Part C. - Specification for Filler Analysis – SFA No - AWS Classification of Welding Consumable - Limits for Chemical Composition & Mechanical Properties of Consumables
  • 11.
    11 How To QualifyGroove Butt Weld Procedure? 3) 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.
  • 12.
    12 How To QualifyGroove Butt Weld Procedure? 4) Prepare A Test Coupon As Per WPS - Coupon Size: Pair of 300 mm X 150 mm Plates Or Pipes 150 mm long as Specified in WPS - All Other Details as per Written WPS - Complete the Welding by Reasonably Skilled Welder - All Welding Variables Shall be Used Within the Limit Specified in WPS. - All Variables Actually Used Shall be Documented as Annexure to PQR ( Procedure Qualification Record)
  • 13.
    13 How To QualifyGroove Butt Weld Procedure? 5) NDT Of Weld Coupon - Optional - X-Ray / Radiograph the Weld Joint ( Not a Code Requirement ) - Mark Transverse Tensile & Guided Bends As Per QW463 - Eliminate Defective Weld Portion If Any, While Marking the Test Specimens - Preserve RT Report & X-Ray Film as Annexure to PQR
  • 14.
    14 6) Mechanical Tests– Qw 451, Groove Weld. • Up to 19 mm in Thickness - Transverse Tensile :– 2No - *Root Bend :- 2No - *Face Bend :- 2No • 19 mm and above in Thickness - Transverse Tensile :- 2No - Side Bend :- 4No * For material 10 mm and above in thickness, 4 side bend Tests may be substituted for Face & Root bends How To Qualify Groove Butt Weld Procedure?
  • 15.
    18 How To QualifyGroove Butt Weld Procedure? Location of Test Specimens From Test coupon – QW 463.1 Plates thickness less than 19 mm Root Bend 2No Face Bend 2No Reduced Section Tensile 2No * * * * * * <19 mm Balance Plate Discard Discard
  • 16.
    19 How To QualifyGroove Butt Weld Procedure? Location of Test Specimens From Test coupon – QW 463.1 Plates thickness 19 mm and above Side Bend 4No Reduced Section Tensile 2No * * * * >19 mm Balance Plate Discard Discard * *
  • 17.
    20 How To QualifyGroove Butt Weld Procedure? Location of Test Specimens From Test coupon QW 463.1 Pipe When Pipe Thickness is 19 mm or more, In place of Root & Face, 4 Side Bends shall be Taken Horizontal Plane Pipe is welded in Horizontal fixed position @ = Reduced section Tensile 2No £ £ £ £ @ @ £ = Bends - Root & Face or Side Root Bend Face Bend Root Bend Face Bend 45˚- 60˚ 45˚ - 60˚
  • 18.
    23 How To QualifyGroove Butt Weld Procedure? 7) 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 mm in Any Direction on Convex Surface Within the Weld & HAZ
  • 19.
    24 How To QualifyGroove Butt Weld Procedure? 8) 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
  • 20.
    25 Qualified WPS • AWPS 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
  • 21.
    26 Thickness Limit ForGroove Butt Weld Procedure.QW451 Thickness “T” Of Test Coupon Welded in mm Range Of Thickness “T” of BM Qualified in mm Thickness “t”of Deposited Weld metal Qualified in mm Mini Max Max Less Than 1.5 (1/16”) T 2T 2t 1.5 to 10 (1/16” to” ⅜”) Incl 1.5 (1/16”) 2T 2t Over 10 to below 19 (⅜” to ¾ ) 5 (3/16”) 2T 2t 19 to below 38 ( ¾ ” to 1 ½”) 5 (3/16”) 2T 2t When t < 19 19 to below 38 ( ¾ ” to 1 ½”) 5 (3/16”) 2T 2T When t ≥19 38 (1 ½”) and over 5 (3/16”) 200 ( 8” ) 2t When t < 19 38 (1 ½”) and over 5 (3/16”) 200 ( 8” ) 200 When t ≥19 Over 200 (8”) – QW 403.7 5 (3/16”) 1.33 T 1.33 t
  • 22.
    27 Minimum Base MetalThickness Limit For Butt Weld Procedure With Impact .QW403.6 Thickness “T” Of Test Coupon Welded in mm Range Of Thickness “T” of BM Qualified in mm Thickness “t”of Deposited Weld metal Qualified in mm Mini Max Max Below 6 1/2T 2T 2t 6 to 16 (1/4” to” 5/8”) Incl T 2T 2t Over 16 to below 19 (5/8” to ¾’’ ) 16 (5/8”) 2T 2t 19 to below 38 ( ¾ ” to 1 ½”) 16 (5/8”) 2T 2t When t < 19 19 to below 38 ( ¾ ” to 1 ½”) 16 (5/8”) 2T 2T When t ≥19 38 (1 ½”) and over 16 (5/8”) 200 ( 8” ) 2t When t < 19 38 (1 ½”) and over 16 (5/8”) 200 ( 8” ) 200 When t ≥19 Over 200 (8”) – QW 403.7 16 (5/8”) 1.33 T 1.33 t
  • 23.
    28 Impact Testing –UG 84 Qualification With Supplementary Essential Variable. A) Weld Joint Thickness 38 mm ( 1½ “) And Below Two Sets Of Charpy V Notch Impact Specimens • One Set Of 3 Nos. Each From HAZ – Within 1.5 from Any Surface • One Set Of 3 Nos. Each From Weld – Within 1.5 from Any Surface B) Weld Joint Thickness Above 38 mm ( 1½ “) Three Sets Of Charpy V Notch Impact Specimens • One Set Of 3Nos. Each From HAZ – Within 1.5 from First Half Surface • One Set Of 3 Nos. Each From Weld – Within 1.5 from Any Surface • One Set Of 3 Nos. Each From Weld – Midway In Second Half
  • 24.
    31 Procedure Qualification -QW-253 SMAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 402 Joints Change in Groove Design --- --- * Addition / Deletion of Backing --- --- * QW 403 Base Metals Change in group Of P No --- * --- T Limits Impact --- * --- T/t Limits  200 mm * --- --- Change in T Qualified * --- --- “t” pas  13 mm * --- --- Change of P Number Qualified * --- --- QW 404 Filler Metals Change in F No * --- --- Change in A No * --- --- Change in Dia --- --- * Change in Dia  6 mm --- * --- Change in AWS classification --- * --- Change in t qualified * --- ---
  • 25.
    32 Procedure Qualification -QW-253 SMAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 405 Positions Addition of Position --- --- * Change in Position --- * --- QW 406 Preheat Decrease  56°C * --- --- Increase  56°C IP --- * --- QW 407 PWHT Addition / Deletion of PWHT * --- --- Change in Time & Temp. Qualified --- * --- QW 409 Electrical Characteristics Increase in Heat Input --- * --- Change in Current / Polarity --- * --- Change in Current / Voltage --- --- * QW 410 Technique Change from String / Weave --- --- * Method of Cleaning --- --- * Method of Back Gouging --- --- * Change From Multiple to Single Pass --- * ---
  • 26.
    33 Procedure Qualification -QW-254 SAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 402 Joints Change in Groove Design --- --- * Addition / Deletion of Backing --- --- * QW 403 Base Metals Change in group Of P No --- * --- T Limits Impact --- * --- T/ t Limits  203 mm * --- --- Change in T Qualified * --- --- “t” pas  13 mm * --- --- Change of P Number Qualified * --- --- QW 404 Filler Metals Change in F No * --- --- Change in A No * --- --- Change in Dia --- --- * Change in Wire & Flux Combination * --- --- Change in Alloyed Flux * --- ---
  • 27.
    34 Procedure Qualification -QW-254 SAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 404 Filler Metal Alloy Elements / supplemental Wire * --- --- Change in Flux Type * --- --- Change in “t” Qualified * --- --- QW 405 Positions Addition of Position --- --- * QW 406 Preheat Decrease  56°C * --- --- Increase  56°C IP --- * --- QW 407 PWHT Addition / Deletion of PWHT * --- --- Change in Time & Temp. Qualified --- * --- T Limits * --- --- QW 409 Electrical Characteristics Increase in Heat Input --- * --- Change in Current / Polarity --- * --- Change in Current / Voltage --- --- *
  • 28.
    35 Procedure Qualification -QW-256 GTAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 402 Joints Change in Groove Design --- --- * Addition / Deletion of Backing --- --- * QW 403 Base Metals Change in group Of P No --- * --- T Limits Impact --- * --- T / t Limits  203 mm * --- --- Change in T Qualified * --- --- Change From T Qualified * --- --- Change From P Number Qualified * --- --- QW 404 Filler Metals Change in F No * --- --- Change in A No * --- --- Change in AWS Classification --- * --- Addition / Deletion of Filler * --- --- Addition / Deletion of Consumable Insert --- -- * Change From Solid – Flux / Powder Cored * --- ---
  • 29.
    36 Procedure Qualification -QW-256 GTAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 405 Positions Addition of Position --- --- * Change in Position --- * --- QW 406 Preheat Decrease  56°C * --- --- Increase  56°C IP --- * --- QW 407 PWHT Addition / Deletion of PWHT * --- --- Change in Time & Temp. Qualified --- * --- Change in T thickness Qualified * --- --- QW 408 Gas Addition / Deletion / Change in Trailing Gas --- --- * Addition / Deletion / Change in Shielding Gas * --- -- Change in Flow Rate of Shielding / Backing Gas --- --- * Deletion of Backing Gas * --- ---
  • 30.
    37 Procedure Qualification -QW-256 GTAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 409 Electrical Characteristics Increase in Heat Input --- * --- Change in Tungsten Electrode Size --- --- * Addition / Deletion of Pulsing --- --- * Change in Current or Polarity --- * --- QW 410 Technique Change in Nozzle / Gas Cup Size --- --- * Method of Cleaning --- --- * Change in Oscillation --- --- * Method of Back Gouging --- --- * Change From Single to Multi Electrode --- * --- Change From Closed Chamber to Out Side * --- --- Change From Manual to Auto / Auto to Manual --- --- * Addition or Deletion of Preening --- --- *
  • 31.
    38 Procedure Qualification -QW-255 GMAW & FCAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 402 Joints Change in Groove Design --- --- * Addition / Deletion of Backing --- --- * QW 403 Base Metals Change in group Of P No --- * --- T / t Limits  200 mm * --- --- Change From T Qualified * --- --- When “ t” in Single Pass  13 mm * --- --- T Qualified Limit for Short Circ. Transfer * --- --- Change From P Number Qualified * --- --- QW 404 Filler Metals Change in F No * --- --- Change in A No * --- --- Change in AWS Classification --- * --- Change from solid - Flux Cored / Powder Cored * --- --- Addition / Deletion of Alloy Elements * --- --- “t” Qualified Limit for Short Circ. Transfer * --- ---
  • 32.
    39 Procedure Qualification -QW-255 GMAW & FCAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 405 Positions Addition of Position --- --- * Change in Position --- * --- QW 406 Preheat Decrease  56°C * --- --- Increase  56°C IP --- * --- QW 407 PWHT Addition / Deletion of PWHT * --- --- Change in Time & Temp. Qualified * --- --- Change in T thickness Qualified * --- --- QW 408 Gas Addition / Deletion / Change in Trailing Gas --- --- * Addition / Deletion / Change in Shielding Gas * --- -- Change in Flow Rate of Shielding / Backing Gas --- --- * Deletion of Backing Gas * --- ---
  • 33.
    40 Procedure Qualification -QW- 255 GMAW & FCAW Variable Group of Variables Brief Of Variables Essential Supplementary Essential Nonessential QW 409 Electrical Characteristics Increase in Heat Input --- * --- Change in Metal Transfer Mode * --- --- Change in Wire feed & Voltage --- --- * Change in Current or Polarity --- * --- QW 410 Technique Change in Nozzle / Gas Cup Size --- --- * Method of Cleaning --- --- * Change in Oscillation --- --- * Method of Back Gouging --- --- * Change From Single to Multi Electrode --- * --- Change From Multiple to Single Pass per Side --- * --- Change From Manual to Auto / Auto to Manual --- --- * Addition or Deletion of Preening --- --- *
  • 34.
    41 P Number &Group Number • P Numbers assigned to all Materials Listed in ASME Sec. II – Part A & B. (P1, P3, P4, P5 ----) • S Numbers are assigned to materials not listed in ASME Sec. II, but permitted to use in ASME jobs - ASTM Material (S1,S3, S4, S5 --) • Assignment of P or S Number is based on Characteristic – Composition, Weldability & Mechanical Properties • Ferrous materials (ASME Sec II – A & ASTM) further grouped to Sub Group Numbers based on impact properties (P1- Gr.2, P4 - Gr. 1, S8 - Gr. 2 ---) • Grouping of Parent materials to P No or S No reduces the number of welding qualifications.
  • 35.
    42 P – Number& Group Number (Base Metal For Qualification) P- No Group No Met. Spec. Grade Met. Quality & Form P1 1 2 SA 515 / SA 516 SA 515 / SA 516 60 70 CS – Plate CS – Plate P1 1 2 SA 106 SA 106 A / B C CS – Pipe CS - Pipe P1 1 3 SA333 SA 333 6 10 CS – Pipe CS - Pipe P1 1 2 SA 234 SA 234 WPB WPC CS Pipe Fitting CS Pipe Fitting P1 1 SA 285 C / B CS Plate P1 1 SA 179 --- CS Tube P1 1 2 SA 105 SA 181 --- Cl 70 CS Forging CS Forging QW-422
  • 36.
    43 P – Number& Group Number (Base Metal For Qualification) • QW-422 P- No Group No Met. Spec. Grade Met. Quality & Form P3 2 3 SA 302 SA 302 A B,C,D Mn – 0.5 Mo – Plate Mn – 0.5 Mo – Plate P3 1 SA 335 P1 / P2 C – 0.5 Mo – Pipe P3 3 SA 533 TP- B, Cl- 1 or 2 C – 0.5 Mo – Plate P3 1 SA 209 T1, T1a, T1b C – 0.5 Mo – Tube P3 2 SA 282 F1 C – 0.5 Mo – Forging
  • 37.
    44 P – Number& Group Number (Base Metal For Qualification) • QW-422 P- No Group No Met. Spec. Grade Met. Quality & Form P4 1 3 SA 387 SA 387 12, Cl –1 / 2 11, Cl –1 / 2 1Cr. 0.5 Mo – Plate 1.25 Cr. 0.5 Mo – Plate P4 1 SA 335 P12 / P11 1Cr (1.25 Cr) – 0.5 Mo – Pipe P4 2 SA 423 TP - 1 / 2 1.25 Cr. 0.5 Mo – Tube P4 1 SA 282 SA 336 F12, Cl- 1 / 2 F11, Cl –1 / 2 / 3 1. Cr – 0.5 Mo – Forging 1.25 Cr – 0.5 Mo – Forging
  • 38.
    45 P – Number& Group Number (Base Metal For Qualification) • QW-422 P- No Group No Met. Spec. Grade Met. Quality & Form P5A P5B 1 1 SA 387 SA 387 22, Cl –1 / 2 5, Cl - 2 2. 25 Cr. 1 Mo – Plate 5 Cr. 0.5 Mo - Plates P5A 1 SA 335 P22 2. 25 Cr. 1 Mo – Pipe P5A 1 SA 213 TP - 22 2. .25 Cr. 1 Mo – Tube P5B P5C P5A 1 1 1 SA 182 SA 182 SA 336 F5 F22V F22, Cl –1 / 3 5 Cr – 0.5 Mo – Forging 2. 25 Cr – 1 Mo,V – Forging 2. 25 Cr – 1 Mo – Forging
  • 39.
    46 P – Number& Group Number (Base Metal For Qualification) • QW-422 P- No Group No Met. Spec. Grade Met. Quality & Form P6 2 SA 240 TP 429 15Cr. – Plate P6 4 SA 731 S41500 13Cr., 4.5 Ni, Mo - Pipe P6 1 SA 268 TP410 13Cr. – Tube P6 3 SA 336 F6 13Gr.– Forging P7 2 SA182 F430 17Cr. - Forging P7 2 SA 240 TP 430 17Cr. - Plate P7 2 SA 268 TP430 17Cr. Tube P7 2 SA 731 TP439 18Cr., Ti – Pipe
  • 40.
    47 P – Number& Group Number (Base Metal For Qualification) • QW-422 P- No Group No Met. Spec. Grade Met. Quality & Form P8 1 1 SA 312 SA 312 TP321 TP347 18Cr., 10Ni, Ti - Pipe 18Cr., 10Ni, Cb - Pipe P8 1 1 SA336 SA 336 TP316 TP310 18Cr., 8 Ni, 2Mo -Forging 25Cr., 20 Ni, Forging P8 1 2 SA 240 SA 204 TP304 TP309S 18Cr, 8Ni - Plates 23Cr. 12Cr. - Plates P8 1 1 SA 249 SA 249 TP317 TP316L 18Cr, 13Ni, 3Mo –Tube 16Cr, 12Ni, 2Mo - Tube
  • 41.
    48 P – Number& Group Number (Base Metal For Qualification) • QW-422 P- No Group No Met. Spec. Grade Met. Quality & Form P9B 1 SA 333 3 3.5Ni - Pipe P9A 1 SA334 7 2.5Ni - Tube P9A P9B 1 1 SA 350 SA 350 LF5, Cl. 2 LF3 1.5Ni - Forging 3.5Ni. - Forging P9A P9B 1 1 SA 203 SA 203 A E 2.5Ni. - Plate 3.3Ni. - Plate
  • 42.
    49 P – Number& Group Number (Base Metal For Qualification) • QW-422 P- No Group No Met. Spec. Grade Met. Quality & Form P10H 1 SA240 S31803 22Cr, 5Ni, 3Mo, N - Plate P10H 1 SA240 S32550 25Cr, 5Ni, 3Mo, 2Cu - Plate P11A 1 SA 333 8 9Ni - Pipe P11A 1 SA334 8 9Ni - Tube P11A P11A 5 5 SA 508 SA 508 4N, Cl. 2 5, Cl. 2 3.5Ni –1.75 Cr.-0.5Mo.- V, Forging 3.5Ni –1.75 Cr.-0.5Mo.- V, Forging P11A P11A 4 4 SA 533 SA 533 TP B, Cl. 3 TP C, Cl. 3 Mn, 0.5 Mo, 0.5Ni – Plate Mn, 0.5 Mo, 0.75Ni - Plate
  • 43.
    50 How To QualifyA Welder 1) Understand ASME Sec. IX - Welding Performance Qualifications - Variables For Different Processes – QW 350 - Limits Of Positions Qualified & Dia – QW 461 - Testing Requirements – QW 304-1
  • 44.
    51 How To QualifyA Welder 2) 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
  • 45.
    52 How To QualifyA Welder 3) Preparation Of Test Coupon - Prepare A Test Coupon Out of 300 х 150 х 20 mm Plates Or Pipe Of 150mm long As Per Applicable WPS. - WEP ( Angle, Root Face & Root Opening ) Shall Be As Per The WPS - Provide Run in & Run Out Coupons on 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
  • 46.
    53 How To QualifyA Welder 4) 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 Nos (For 5G / 6G – 2 Face & 2 Root Or 4 Side Bends) • Alternate to Mechanical Tests, Radiograph the Coupon – 6 ” Minimum Length < 19 mm Thick ≥ 19 mm Thick
  • 47.
    54 Location of TestSpecimens From Test coupon – QW 463.2 Plates Less Than 19 mm How To Qualify A Welder Root Bend 1No Face Bend 1No * * <19 mm Discard Discard 300 mm ( 150 mm Minimum)
  • 48.
    55 Location of TestSpecimens From Test coupon – QW 463.2 Plates -Thickness 19 mm & more How To Qualify A Welder Side Bend 2No * Discard Discard 300 mm ( 150 mm Minimum) ≥19 mm * Balance Material *
  • 49.
    56 Location of TestSpecimens From Test coupon – QW 463.2 Pipe in 5G or 6G Position How To Qualify A Welder Horizontal Plane Pipe is welded in Horizontal fixed position £ £ £ £ £ = Bends - Root & Face or Side Root Bend Face Bend Root Bend Face Bend 45˚- 60˚ 45˚ - 60˚ When Pipe Thickness is 19 mm or more, In place of Root & Face, 4 Side Bends shall be Taken
  • 50.
    57 Location of TestSpecimens From Test Pipe 6 NPS Welded in Combination of 5G & 2G – QW 463.2 How To Qualify A Welder 270˚Welded in 5G Pipe is welded in Horizontal fixed position 0˚ = 5G Weld = 2G Weld Root Bend Face Bend Root Bend Face Bend When Pipe Thickness is 19 mm or more, In place of Root & Face, Side Bends shall be Taken Welded in 2G 90˚ 270˚ 180˚ 90˚ Face Bend Root Bend 50˚ 130˚ 202.5˚ 247.5˚ 292.5˚ 337.5˚
  • 51.
    58 How To QualifyA Welder 5) 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 mm in any direction on Convex Surface Within the Weld & HAZ • R T – Qw 91.2 No Crack, L/F & Incomplete Penetration No Slag, Cluster Of Porosity & Other Inclusions Beyond Specified Limit
  • 52.
    59 Performance Qualification Thickness Limits– QW 452.1(b) Thickness “t” of Weld Metal in the Coupon in mm ( in) Thickness of Weld metal Qualified All 2t 13 (1/2) and Over With Minimum Three Layers Maximum To Be Welded
  • 53.
    60 Groove Weld Positions– QW461 Sr No. Groove Position Base Metal Position Inclination of Axis in ° Plate Pipe 1 1G Flat Horizontal Pipe Axis Horizontal – in Rotation 0 -15 2 2G Horizontal Vertical Pipe Axis Vertical 0 - 15 3 3G Vertical Vertical NA 80 – 90 15 - 80 4 4G Over Head Horizontal NA 0 - 80 5 5G NA Pipe Axis Fixed Horizontally 0 -15 6 6G NA Pipe Axis Fixed 45° inclined + or - 5
  • 54.
    61 Performance Qualification Position &Dia Limits- QW461.9 Qualification Test Position & Type of Weld Qualified Weld Position Plate & Pipe Over 24” Pipe ≤ 24” 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 2 ⅞” OD and Over, $ Pipe OD Restrictions As Per QW 452.3, 452.4 & 452.6
  • 55.
    62 Performance Qualification Groove-Weld, PipeDia. Limits QW 452.3 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.
  • 56.
    63 Welding Variables- Qw416 Performance Qualification Group of Variables Brief Of Variables Essential Variables SMAW QW -353 SAW. QW-354 GMAW QW-355 GTAW QW-356 QW 402 Joints Deletion of Backing + + + + QW 403 B M Change in Pipe Dia. + + + + Change in P Number + + + + QW 404 Filler Metal Deletion /Addition of FM --- --- --- + Change in F Number + + + + Dele. /Addi. of Consumable Insert --- --- --- + Solid – Metal/Flux Cored --- --- --- + Change in t deposit Qualified + + + + “t” deposit for Short Cir.Transfer --- --- + ---
  • 57.
    64 Welding Variables- Qw416 Performance Qualification Group of Variables Brief Of Variables Essential Variables SMAW QW -353 SAW. QW-354 GMAW QW-355 GTAW QW-356 QW 405 Position Addition of New Position + + + + Change from up hill to Down hill –3G + --- + + QW 408 Gas Deletion of Inert Gas Backing --- --- + + QW 409 Electric Charact. Change in Mode of Metal Transfer --- --- + --- Change in Type of Current / Polarity --- --- --- +