asme sec. ix bkr - 051010

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Introduction to ASME Sec. IX

5-Oct. 2006

Manufacturing Technology- I

S.C.Ghosh

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ASME Sec. IX

General guide lines for procedure and performance

qualification

Referenced by all ASME code of construction

Covers welding as well as Brazing operations

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Welding procedure specification (WPS) Procedure Qualification Records (PQR)

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).

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Different types of variables in WPSEssential 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:• A Change in welding condition which will affect impact toughness of

weldment

• Change in this variable calls for re-qualification of PQR in case there is requirement of impact toughness for the vessel

Non - essential variable:• No change in mechanical properties is expected

A WPS shall record all essential, supplementary essential & non essential variables

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Different types of variables in WPS

Grouping of Base Material: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

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P Numbers of Commonly Used Materials

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P Numbers of Commonly Used Materials

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Different types of variables in WPS

F numbers:F numbers:• Grouping of electrode on their usability characteristicsGrouping of electrode on their usability characteristics

• Determine the ability of welder to deposit sound weld. Determine the ability of welder to deposit sound weld.

• List of most commonly used F Numbers is given in next List of most commonly used F Numbers is given in next slideslide

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F Numbers of Commonly Used Consumables

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

slide

Different types of variables in WPS

A-No:

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A Number

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Different types of variables in WPS

QW 402: Joints• Non essential variables -

• Groove design,

• Backing,

• Root gap,

• Retainers

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Different types of variables in WPS 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

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Different types of variables in WPSQW 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

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Different types of variables in WPS

QW 405: Positions• Supplementary essential variables -

• Change from any position to vertical uphill progression for SMAW.

• Non essential variables – • Change in position.

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Different types of variables in WPS

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.

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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.

Different types of variables in WPS

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Different types of variables in WPS

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

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Different types of variables in WPS

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)

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Different types of variables in WPS

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,

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Standard WPS Format (sheet 1 of 2)

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Standard WPS Format (sheet 2 of 2)

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Standard PQR Format (sheet 1 of 3)

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Standard PQR Format (sheet 2 of 3)

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Standard PQR Format (sheet 3 of 3)

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Welder Performance QualificationPurpose

• 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

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Welder Performance QualificationWelder

• Person performing welding by manipulating arc by hand

Welding Operator

• Person performing welding by controlling the manipulation of arc

by machine

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Welder Performance Qualification

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

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Welder Performance Qualification

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

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Welder Performance Qualification

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

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Welder Performance Qualification

Essential variable for SMAW, GTAW as per Sec. IX

QW 353, 356

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Welder Performance Qualification

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

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Welder Performance Qualification

Welding Position for joints : QW 405.1, .3

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Welder Performance Qualification

Welding Position for joints : QW 461

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Welder Performance Qualification

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

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Welder Performance Qualification

Qualification Range- Thickness of weld metal

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Welder Performance Qualification

Qualification Range- Position

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Welder Performance Qualification

Qualification Range- Pipe diameter

OD of Test coupon,mm Minimum OD Qualified, mm

Less than 25 mm Size welded

25 to 73,mm 25 mm

73 mmOver 73 mm

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Welder Performance Qualification

Qualification Range- Filler metal

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Welder Performance Qualification

Qualification Range- Base metal , QW 425

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Welder Performance Qualification

Test for qualification Butt Joints

Mechanical test: Visual Examination and bend test (QW302.1 &.4)

NDT: RT , 150mm length (QW304)

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Welder Performance Qualification

Test for qualification: Weld overlay

Mechanical test: Side bend

NDT: PT

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Welder Performance Qualification

QW322Renewal of qualification: After every six month based on

production work, or welding a separate test coupon

Suspension of Qualification: - If process is not used in last six month- If there is specific reason for doubting the skill

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Welder Performance Qualification

Record of Qualification

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Welder Performance Qualification

List of reference: ASME Section IX,Edition 2004