api 510 booklet

API 510 Course

(Calculations – Internal and External Inspection Intervals)

I.

Able to calculate;

NOTE: These calculations can be open and/or closed book exams.

II. Joint Efficiencies

Determine;

2

API 510 Calculations

Required Thickness

=

MinimumThickness

=

Short Term Corrosion Rate

CRST =tprevious tactual

# of years between tprevious & tactual

Long Term Corrosion Rate

CRLT =tinitial tactual

# of years between tprevious & tactual

Remaining Life

RL =tactual trequired

Corrosion Rate

Internal Inspection Interval

=

Internal or Onstream IntervalLesser of 10 yrs or ½ Remaining life

if remaining life is less than 4 yrs, full lifeup to 2 years

Remaining life is 2 years or less, intervalis FULL LIFE

Section 7, par7.1.1

External Inspection Interval

=

5

Short Term Corrosion Rate

CRST =tprevious tactual_LAST

# of years between tprevious & tactual _LAST

Variables for Thickness Calcs

Long Term Corrosion Rate

CRLT =tinitial tactual_LAST

# of years between tInitial & tactual_LAST

tinitial tlast=# of years between tinitial & tlast

11

tprevious tlast=# of years between tprevious & tlast

Corrosion rate

Section 7, par7.1.1

12

Section 7, par7.1.1

13

0.875 0.865

5=

tprevious = 0.875

tlast = 0.865


Corrosion rate

inch/yr= 0.002

Section 7, par7.1.1

Thickness Years of service

Determined by SHORT term or Long Term Calculations (API 510, par 7.1.1.2)

Newly installed or Change in Service (API 510, par 7.1.2)

1. Calculated from data of vessels in similar service.2. Estimated from Owner-User experience3. Published Data4. On-stream determination after 1000 hrs of service.

May have different corrosion-rates for large vessels with multiple zones. (API 510, par 6.5.3)

19

Mechanical fatigue is caused by;

What material does not have an endurance limit?

24

Variables for Remaining Life Calcs

Remaining Life

RL =tactual_Last trequired

Corrosion Rate

Section 7, par7.2.1

25

Section 7, par7.2.1

26

tlast trequired=Corrosion rate

tprevious 0.625

tlast 0.600

= ?????Corrosion rate

Since the “CORROSION RATE is unknown, the 1st Step is to determine theCorrosion rate.

Section 7, par7.2.1

27


0.625 0.600

8=

= 0.003

tprevious 0.625

tlast 0.600


28


0.600 0.575=0.003

= 8yrs

trequired = 0.575

tlast = 0.600

= 0.003Corrosion rate

(API 510 par 6.5.1.1)

Internal or on-stream inspections shall not exceed oone half the remaining life of the vessel or 10 years, whichever is less. Whenever the remaining life is less than four years, the inspection interval may be the full remaining life up to a maximum of two years.

(API 510 par 6.5.1.1)

Interval not exceed the llesser of 5 years or the internal/on-stream interval..

Thickness Inspection IntervalsShould be part of the inspection plan, but no interval requirements mentioned in API-510 (API 510 par 5.5.1)

CUI Inspection IntervalsShould be part of the inspection plan, but no interval requirements mentioned in API-510 (API 510 par 5.5.1)

“SHALL” be considered for insulated vessels in “intermittent” service or operates between;

10oF and 350oF for carbon steel and alloy steels140oF and 400oF for austenitic stainless steels

31

Section 6, par6.5.1v

Section 5, par5.5.1

32

Section 6, par6.5.1v

33


tprevious 0.625

tlast 0.600

= ?????Corrosion rate

Since the “CORROSION RATE is unknown, the 1st Step is to determine theCorrosion rate.

Section 7, par7.2.1

34


0.625 0.600

8=

= 0.003

tprevious 0.625

tlast 0.600


Section 7, par7.1.1

35


0.600 0.575=0.003

= 8yrs

trequired = 0.575

tlast = 0.600

= 0.003Corrosion rate

Section 7, par7.2.1

36

Internal Inspection Interval = 4 years

Section 6, par6.4.1

HEAD

BANGER

What is the temperature range that temper embrittlement occursin low alloy steels ?

Next inspection date = Last inspection date +interval

42

Practice for “Simple” calculation

43

44

RemainingLife (yr)

March 2000 March 1995

16 .324 .356

Widely scattered pits can be ignored, if;

45

Vessel Thickness = 2.0”

Depth of Pit = 1.06”

Corrosion Allowance = 0.250

Retirement Thickness = 1.75”

Remaining Thickness below pit is greater than ½½ the Required Thickness

Rule # 1

Section 7, par7.4.3


46

Area of the pitting below thecorrosion allowance has anarea less than 7 in2 within an8” diameter circle.

Rule # 2

Section 7, par7.4.3


47

Rule # 3Sum of the length of pits within any 8” line, must be less than 2”

Section 7, par7.4.3

48

Section 7, par7.4.3

49

“Minimum allowed remaining thickness below the pit is ½ the required thickness”,

Therefore, the minimum thickness allowed at the deepest pit is;

( ½ required thickness = 1.250”/2 = 0.625”)

Corrosion allowance

RequiredThickness

½ of RequiredThickness

Remaining thicknessbelow pit

Section 7, par7.4.3

a. Pits can be ignoredb. Pits are unacceptable based on sum of the pit dimensions along a 8” straight line.c. Pits are unacceptable due to total area of pitting within an 8” diameter circle.d. Pits are unacceptable due to insufficient remaining thickness below the deepest pit.

Section 7, par7.4.3

Section 7, par7.4.3

HEAD

BANGER

57

pH Scale

Acidity Basic / Akalinity /Caustic

StrongAcidity

StrongAlkalinity

NeutralW

eakAcidity

Weak

Alkalinity

58

pH Scale

Acidity Basic / Akalinity /Caustic

StrongAcidity

StrongAlkalinity

NeutralW

eakAcidity

Weak

Alkalinity

A. Inspection plan must be established for all pressure vessels and pressure-relieving devices.

B. Inspection plan developed by inspector or engineer.

C. Corrosion-specialist must be consulted for inspection plan for vessels operating above 750oF.

D. Inspection plan shall be evaluated based on present or possible types of damage mechanisms.

E. Methods and extent of NDE shall be evaluated to assure they can adequately identify the damage mechanism and severity of damage.

59

Section 5, par5.1

F. Examinations must be scheduled at intervals that consider;A. Type of damageB. Rate of damageC. Tolerance of equipment to the damageD. Probability of the NDE methods to detect the damageE. Maximum intervals as defined in API 510

G. Minimum Contents of Inspection PlanA. Type of inspection neededB. Next inspection date for each type inspection (internal,

external, etc)C. Describe inspection and NDE techniquesD. Describe extent and locations of inspection and NDEE. Describe the cleaning requirementsF. Describe the requirements of any needed pressure testG. Describe any required repairs

60

Section 5, par5.1

A. General

Inspections should be conducted in accordance with the inspection plan

Prior to performing an inspection, the inspector should be familiar with;

Thorough understanding of the inspection plan

Operating conditions since the last inspection (API 572 par 9.1)

Applicable damage mechanisms

Prior history

New inspection intervals shall be established if operating temp increases, operating pressure increases or process fluid changes. (API 510 par. 6.2.2)

61

Section 5

Interval is lesser of ½ remaining life or 10 years. If remaining life is LESS than 4 years, interval can be the full remaining life up to max of 2 years. (API 510 par 6.5.1.1).

SHALL be conducted by the inspector (API 510 par 5.5.2.1)

Primary reason for internal inspection is to find damage that cannot be found by external CML’s (API 510 par 5.5.2.1)

Internal inspection performed inside the vessel (API 510 par 5.5.2.1)

Internals may need to be removed to facilitate the internal inspection. Likely will not need to remove 100% of the internals. (API 510 par 5.5.2.2)

Inspector should consult with Corrosion Specialist to determine if it is necessary to remove any linings and/or deposits (API 510 par 5.5.2.3)

Vessels in non-continuous service, the interval is based on number of years of actual service, instead of calendar years, provided the vessel when idled is separated from process stream & not exposed to corrosive streams.

62

C. On-stream Inspection

Interval same as INTERNAL inspection.

Should be conducted by either an inspector or examiner. (API 510 par 5.5.3.1)

On-stream inspections performed by examiners shall be authorized/approved by the inspector (API 510 par 5.5.3.1)

Inside of vessel inspected from outside vessel. (API 510 par 5.5.3.2)

63

D. External Inspection

Performed by inspector or qualified others (qualified with appropriate training). (API 510 par 5.5.4.1.1)

Interval is lesser of 5 years or the internal interval.External inspections check; (API 510 par 5.5.4.1.2)

Condition of Outside surface of vesselCondition of Insulation systemCondition of Coating systemCondition of SupportsFor leaksHot spotsVibration damageAllowance for expansionBulging, misalignment, distortion, etc

Conditions discovered by others, must be reported to inspector. (API 510 par 5.5.4.1.3)

64

E. Thickness Inspection

Performed by inspector or examiner. (API 510 par 5.5.5.1)

No required interval.

Inspector should consult with corrosion-specialist when short term corrosion-rate changes significantly. (API 510 par 5.5.5.3)

Owner-user is responsible for assuring individuals taking thickness readings are trained and qualified (API 510 par 5.5.5.4)

F. CUI InspectionPerformed by inspector or other qualified personnel (i.e. same as external)Shall be considered for; (API 510 par 5.5.6.1)

Carbon steel and low alloy operating between 10oF and 350oF.Stainless steel operating between 140oF and 400oF.

Usually causes localized corrosion damage (API 510 par 5.5.6.2)Susceptible locations include; (API 510 par 5.5.6.2)

Insulation or stiffening ringsNozzles and manwaysStructural penetrations (ladder clips, pipe supports, etc)Damage insulationInsulation with failed caulkingTop and bottom heads

CUI inspection may require some or all insulation (API 510 par 5.5.6.3)Insulation may not need to be removed if; (API 510 par 5.5.6.3)

Insulation is in good condition and there is no reason to suspect damage behind the insulation;

CUI inspection can be performed with UT from ID of vessel.66

67

Weld Joint CATERGORY is the ”location” of a “joint” in a pressure vessel

Category A:All longitudinal welds in shell and nozzlesAll welds in heads, Hemi head to shell weld joint

Category B:All circumferential welds in shell and nozzlesHead to shell joint (other than Hemispherical.)

Category C and D are flange welds and nozzle attachment welds respectivelyLongitudinal welds (Category A) are more critical than Circumferential welds (Category B)because they are under double stress.This the reason why in different part of ASME code we have stringent rules in category Ajoint compared to category B joint.

Sub Section B,UW, General,

UW 3

Weld Joint Types

68

Sub Section B,UW, Design,

UW 12

Weld Joint Types

69


UW 12

70

Type of RadiographyFull – as required by the Code (see UW 11(a)), and UCS 57Spot – Category B and C welds that are not required to be

radiographed by UW 11(a)(5)(b).None

Code Required RT (UW 11(a) and UW 11(b)

Based on Service, Thickness or Welding Process

User Specified RTThe user can establish the type of joint and degree of examination whenthe rules of Code does not require radiography (see UW 12)


UW 11

Sub Section C,CCS, Design,

UCS 57

FULL RT – Required by CODE

71

FULL RTAll butt welds in shell & heads in lethal serviceAll butt welds in shell & heads with thickness >11/2 or per UCS 57All butt welds in shell & heads of unfired boilers with;

Pressure exceeding 50 psig or thickness > 1 1/2 or per UCS 57Butt welds in nozzles >10 NPS or > 1 1/8” thicknessCategory “A” and “D” welds in shells and heads, where jointefficiency is based on Table UW 12Butt welds made using Electro gas & Electro slag process

Spot RTCategory B and C butt welds intersecting Cat A welds in shells and headsCategory B and C butt welds connecting seamless heads or shells


UW 11a

72

When and where is there a code requirement for full radiography?

Item 1:

Item 2:

Item 3:

Item 4:

The point is this: items 1, 2 and 3 are similar, but item 4 is completely different. In items 1, 2 and 3 it is mandated bycode; to do full radiography in all butt welds in vessel so it means it is mandatory for designer to select column (a) inUW 12 table.

But in item 4, there is no mandating rule. A manufacturer with its own decision has chosen to use column (a) in tableUW 12 for full radiography.

All butt welds in vessels used to contain a lethal substance (UW 11(a)).Lethal substances have specificdefinitions in ASME Code in UW 2 and it is the responsibility of the end user to determine if they ordereda vessel that contains lethal substances.

All butt welds in vessels in which the nominal thickness exceeds specified values (UW 11(a). You can findthese values in subsection C, in UCS 57. For example, this value for P No.1 in UCS 57 is 1 ¼ inch. Nozzleslarger than 10 NPS or thickness greater than 1 1/8”.

All butt welds in an unfired steam boiler with design pressure > 50 psi (UW 11(a)).

All category A and D butt welds in vessel when “Full Radiography” optionally selected from table UW12(column (a) in this table is selected); and categories B and C which intersect Category A shall meet thespot radiography requirement (UW 11(a) (5) (b)).


UW 11

Sub Section C,UCS, Design,

UCS 57

73

a. Items 1, 2 and 3 from the previous slide; RT is related to the type of welds andservices.

b. Pressure vessels in these items are critical from a safety point of view, onecontains a lethal substance, the other one has a high thickness, whichimplicates high pressure, and the last one is an unfired steam boiler

c. Item 4 has no criticality like the other items have.d. But you should note all 4 items have been categorized in full radiography

clause( U 11(a)), so to differentiate item 1, 2 and 3 from item 4, the RTsymbols are used in Code (UG 116).

74

RT 1: Items 1, 2 and 3, (E=1), All butt welds full length radiography

RT 2: Item 4 (E=1), Category A and D butt welds full length radiographyand category B and C butt welds spot Radiography

RT 3: (E=0.85), Spot radiography butt welds

RT 4: (E=0.7), Partial / No radiography

You need to consider the hemispherical head joint to shell as category A, but ellipsoidaland torispherical head joint to shell as category B;

Do you know why? Why ASME considered the stringent rule for pressure vessel RT test inhemispherical head joint?

It is because this joint is more critical, because the thickness obtained from theformula for hemispherical head approximately would be half of the shell thickness;It means if the shell thickness is 1 inch, the hemispherical head thickness would be0.5 inch.

Sub SectionA, UG, Design,

UG 116

Spot RT – Required by CODEB and C welds that are not required to be radiographed by UW-11(a)(5)(b)Type 1 and Type 2 butt welds that are not required to be radiographed by UW-11(a).

RT MarkingsRT 1 and RT 2 - FULL RadiographyRT 3 - Spot RadiographyRT 4 - Combo Radiography

RT markings are located on Nameplate

75


UW 11


UG 116

HEAD

BANGER

Joint Efficiency is based on;

80

Sub Section B,UW, Design,Table UW 12

81

E = 1RT 1

E = 1RT 2 E = 1

E = 0.85RT 3 E = 1

E = 0.70RT 4 E = 0.85


UG 116

Joint Efficiency based on RadiographyRT 1 – Full RT per UW 11(a), except UW(a)(5)

Use Column “a” of Table UW 12For Seamless heads & shells E = 1

RT 2 Full RT per UW 11(a)(5)Use Column “a” of Table UW 12For seamless heads and shells E = 1

RT 3 Spot radiography per UW 11(b)Use Column “b” of Table UW 12For seamless heads & shells E = 1

RT 4 Combination of RT 1, RT 2 and RT 3

No RT no radiography at allUse Column “c” of Table UW 12For seamless shells and heads E = 0.85

82RT Stamping



UG 116

83

RT 1orRT 2 RT 3 RT 4

NOTE: For Weld types 3, 4, 5, and 6, RT cannot be used to increase the joint efficiency.


84

Joint Efficiency For Seamless Parts

Weld Type Spot RT No RT1 1.0 0.852 1.0 0.853 0.85 0.854 0.85 0.855 0.85 0.856 0.85 0.85


Par UW11(a)(5)(a)& (b)

Sub Section B,UW, Design, Par

UW 12d

85

A pressure vessel shell with TYPE 1 longitudinal seams and circumferential welds thatare single full fillet lap joints without plug welds. The vessel is stamped No RT. Whatis the joint efficiency for;

Vessel shell ?

A seamless head _________?

Sub Section B, UW,Design, Par UW

11(a)(5)(a)& (b) andTable UW 12


UW 12d

86




UW 12d

87




UW 12d

88




UW 12d

89

ouble full fillet lap joint we




UW 12d

90




UW 12d

(Calculations – Static Head, Internal and External Pressure)

1

(Calculations – Static Head and Internal Pressure

2

(Calculations – Static Head and Internal Pressure

3

4

ASME Sec VIII, UG 98

5

1 ft

0.433 psi(at bottom of the water column)

ASME Section VIIISubsection A, UG,

Inspection and Testing,UG 98(a)(b)

6


44 ft8 ft

What is MAWP of each component for a 48 ft tallvertical vessel with ellipsoidal heads and a MAWPof 500 psig?

2 ft

2 ft6 ft

6 ft

36 ftVessel MAWP = 500 psig

Vessel MAWP is the gage pressure at the “TOP” ofthe vessel, including Static head pressure. ReferenceUG 98(a)(b)

N1

N2

MAWP of N1 = ________

MAWP of N2 = _________

MAWP of Top head = _________

MAWP of Btm head = _________

MAWP of the shell = _________



7


44 ft8 ft

What is MAWP of each component for a 48 ft tallvertical vessel with ellipsoidal heads and a MAWPof 500 psig?

2 ft

2 ft6 ft

6 ft

36 ftVessel MAWP = 500 psig

Vessel MAWP is the gage pressure at the “TOP” ofthe vessel, including Static head pressure. ReferenceUG 98(a)(b)

N1

N2

MAWP of N1 = ________

MAWP of N2 = _________

MAWP of Top head = _________

MAWP of Btm head = _________

MAWP of the shell = _________

500 psig + (6 x 0.433) = 500 + 2.6 = 502.60 psig

500 psig + (42 x 0.433) = 500 + 18.19 = 518.19 psig

500 psig + (2 x 0.433) = 500 + 0.87 = 500.87 psig

500 psig + (48 x 0.433) = 500 + 20.78 = 520.78 psig

500 psig + (46 x 0.433) = 500 + 19.92 = 519.92 psig



8


42 ft

10 ft

What is MAWP of this vessel?

2 ft

50 ft

48 ft

0 ft

8 ftN1

N2

Part PartMAWP

StaticHead

Pressure atTop ofVessel

Tophead 510 psig

N1 500 psigN2 495 psig

Shell 510 psigBtmHead 507 psig



9

66 ft8 ft

Practice Question # 12 ft

2 ft6 ft

6 ft

58 ft

If this vessel is being hydrostatically tested at 200psig, what is the pressure at the bottom of thevessel?

N1

N2Practice Question # 2If the MAWP of the vessel is 550 psig, what is theMAWP of N2?

Practice Question # 3

If the MAWP of the shell of the vessel is 564 psig,what is the MAWP of N1?

Use this vessel to answerthese practice questions



10

66 ft8 ft

Practice Question # 4 2 ft

2 ft6 ft

6 ft

58 ft

If a vessel is being hydrostatically tested at 400psig, what is the pressure at N2?

N1

N2Practice Question # 5

During a hydrotest of a vessel, if the pressure at thebottom of the vessel is 635 psig, what is thepressure at N1?

Practice Question # 6During a hydrotest of a vessel, if the pressure at N2is 528 psig, what is the pressure at the top of thevessel? Use this vessel to answer

these practice questions

NOTE: Per ASME Section VIII, UG 99(c.), the hydrotest pressure is the pressure at the top of the vessel.



11

ASME Sec VIII, UG 21 and Appendix 3 (par 3 2)

Design pressure is the pressure used in the design of a vessel componenttogether with coincident temperature for the purpose of determining theminimum permissible thickness for each component. Design pressureincludes static head pressure.

NOTE: Design pressure is the minimum pressure used to design the vessel (i.e. used to determine the “requiredthickness” of each component.

Maximum allowable working pressure (MAWP) is the maximum pressurepermissible at the top of the vessel in its normal operating position. MAWP isadjusted for the difference in static head that may exist between for the partconsidered and the top of the vessel.

Design pressure is the pressure for the process (process pressure plusstatic head). MAWP is the maximum pressure rating for each partand/or vessel.



t = PR/ (SE) (0.6P)

12

ASME Sec VIII, UG 27(c.)(1)

Variablest = required thicknessP = Design PressureR = Inside Radius of shellS = Allowable StressE = Joint Efficiency

inchespsi

psi

inches


Design, UG 27( c.)(1)

13

Practice Question # 7A 60’ tall vertical vessel has an inside diameter of 8’ and designed for 300 psig @ 450 degF. Allowable stress of the material of construction is 17,500 psi and the joint efficiency is0.85. What is the minimum required thickness?



14

Variablest = required thicknessP = Design PressureR = Inside Radius of shellS = Allowable StressE = Joint Efficiency

Practice Question # 7A 60’ tall vertical vessel has an inside diameter of 8’ and designed for 300 psig @ 450 degF. Allowable stress of the material of construction is 17,500 psi and the joint efficiency is0.85. What is the minimum required thickness?

inchespsi

psi

inches



t = PR

(SE) (0.6P)

t =300 x 48

( 17500 x 0.85 ) ( 0.6 x 300 )

t = 14400

( 14875 ) ( 180 )

t = 14400

14695

t = 0.980 inches

15

Practice Question # 8A vessel has an inside diameter of 60” and designed for 150 psig @ 350 deg F.Allowable stress of the material of construction is 18,000 psi and the jointefficiency is 1.0 What is the minimum required thickness?



16

Practice Question # 9A vessel has an inside radius of 48” and designed for 250 psig @ 500 deg F.Allowable stress of the material of construction is 17,000 psi and the jointefficiency is .90 What is the minimum required thickness?



17

t =PR

(2SE) (0.2P)Variables

t = required thicknessP = Design PressureR = Inside Radius of shellS = Allowable StressE = Joint Efficiency

inchespsi

psi

inches

ASME Section VIIISubsection A, UG,Design, UG 27(d)

18

Practice Question # 10A sphere has an inside radius of 12 ft and designed for 250 psig @ 500 deg F.Allowable stress of the material of construction is 17,000 psi and the welds aresingle butt welded with backing and vessel is stamped RT 2. What is theminimum required thickness?


19

Practice Question # 11A sphere has an ID of 36 ft and designed for 30 psig @ 400 deg F. Allowablestress of the material of construction is 15,000 psi and the joint efficiency is 0.80What is the minimum required thickness?


ShortAxis

20

h = 1/4D

D = Inside diameter

L = inside radius

D = Inside diameter

Ellipsoidal heads are known as 2 to 1 heads. 2 to 1 comesfrom the fact that an ellipsoidal head is 1/2 of a ellipse. Anellipse has a long axis that is 2 x the short axis.

Long Axis


ASME Section VIIISubsection A, UG,Design, UG 32(f)

21

Minimum Required Thickness of an Ellipsoidal Head

Minimum Required Thickness of a Hemispherical Head

x L2 [( S x E ) ( X )]

tP

0.2 P=

Px D2 [( S x E ) ( X )]

t =0.2 P

t = minimum required thicknessP = Design PressureD = Inside DiameterS = Allowable StressE = Joint Efficiency

t = minimum required thicknessP = Design PressureL = Inside RadiusS = Allowable StressE = Joint Efficiency



22

Practice Question # 12What is the minimum required thickness for the head of a 30’ tall vertical vesselwith ellipsoidal heads, inside diameter of 72”, allowable stress of 16,500 psi,MAWP of 120 psig, and welds that are double welded butt welds and Spot RT’d?


23


What is the minimum required thickness for the head of a seamless horizontal vesselwith ellipsoidal heads, inside diameter of 96”, allowable stress of 18,000 psi, MAWPof 200 psig, and welds that are double full fillet welded lap joints and RT 1?


24


What is the minimum required thickness for the head of a 30’ tall vertical vesselwith hemispherical heads, inside diameter of 72”, allowable stress of 16,500 psi,MAWP of 320 psig, and welds that are double welded butt welds and Spot RT’d?


25


What is the minimum required thickness for the heads of a horizontal vessel withhemispherical heads, inside diameter of 96”, allowable stress of 18,000 psi, MAWP of200 psig, and welds that are double full fillet welded lap joints and RT 1?


HEAD

BANGER

I. MAWP of Ellipsoidal Heads

II. MAWP of Hemispherical Heads

29

2 SEt( D + 0.2t)

P =t = minimum required thicknessD = Inside DiameterS = Allowable StressE = Joint Efficiency

t = minimum required thicknessL = Inside RadiusS = Allowable StressE = Joint Efficiency

( L + 0.2t)P =

2 Set



30


During an inspection of a vertical vessel thickness measurements taken on the bottom ellipsoidalhead was found to be 0.785. The inside diameter of the vessel is 96”, allowable stress is 17,000psi, and welds that are double welded butt weld joints and the vessel is stamped RT 1. What isthe maximum allowable working pressure for this seamless ellipsoidal head?


2 SEt( D + 0.2t)

2 ( x x )( + ( x )

2 x+

P =

P =

1 0.7850.2 0.7996

P =17000

P =13345

96 0.157

277.57

P =2669096.157

31


During an inspection of a vertical vessel thickness measurements taken on the bottom ellipsoidalhead was found to be 0.785. The inside diameter of the vessel is 96”, allowable stress is 17,000psi, and welds that are double welded butt weld joints and the vessel is stamped RT 1. What isthe maximum allowable working pressure for this seamless ellipsoidal head?

t = 0.785”D = 96”S = 17,000E = 1

Note:Read the question closely, in this question there is no mentionif the vessel has long seams or not. Therefore, assume the vesselhas long seams. You go to Table UW 12 and find the joint efficiencyto be “1” for “double welded butt welds”. The “seamless” head,does not change the joint efficiency.


32


A horizontal vessel with an outside diameter of 72” and ellipsoidal heads. Shell thickness is0.750” and the heads are 0.500” thick. The allowable stress is 16,000 psi. Welds are double fullfillet lap joints and the vessel is stamped RT 1. The corrosion allowance for the entire vessel is0.125”. What is the maximum allowable working pressure for the ellipsoidal head?

32


33

Practice Question # 18During an inspection of a vertical vessel thickness measurements taken on the bottomhemispherical head was found to be 0.785. The inside diameter of the vessel is 96”, allowablestress is 17,000 psi, and welds that are double welded butt weld joints and the vessel is stampedRT 1. What is the maximum allowable working pressure for this hemispherical head?


34

Practice Question # 19A horizontal vessel with an outside diameter of 72” and hemispherical heads. Shell thickness is0.750” and the heads are 0.500” thick. The allowable stress is 16,000 psi. Welds are double fullfillet lap joints and the vessel is stamped RT 1. The corrosion allowance for the entire vessel is0.125”. What is the maximum allowable working pressure for the Hemispherical head?

34


35


During a recent inspection of a horizontal vessel with an inside diameter of 72”and hemispherical heads, shell thickness was recorded as 0.625”. The allowablestress is 16,000 psi. Welds are double full fillet lap joints and the vessel isstamped RT 1. The corrosion rate is 0.006”/yr. Required thickness is 0.588”.Vessel is in corrosive service. Next inspection is in 5 years. What is themaximum allowable working pressure for this vessel?



API 510, Section 7, Subpar 7.3.3

36

There are three factors that can effect the resistance ofcrushing due external pressure.

1. Stiffeners2. Thickness – thicker materials resist crushing3. Diameter – increasing diameter, increases susceptibility of crushing

ASME Section VIIISubsection A, UG,Design, UG 28( c.)

I. Formula and variables

37

A = Factor based on ratio of L/Do and Do/t. (Get it from ASME Sec II, Part D, Fig G.)B = Factor based on “A” Factor and design Temperature (Get if from ASME Sec II,

Part D, Tables CS 1 or CS 2)Do = Outside Diametert = Minimum required thickness

4B[ 3 ( Do / t ) ]

Pa =

“B” factor will be given to you in the question.


38


A horizontal vessel has an outside diameter of 60”. The distance betweensupports is 15’ ft. The wall thickness is 0.625”. Material of construction is SA516 Gr 70. This vessel has a “B” factor of 3500 and is designed for 250 psig @500 deg F. Allowable stress is 16,500. What is the maximum external pressurefor this vessel?


39


A horizontal vessel has an outside diameter of 60”. The distance betweensupports is 15’ ft. The wall thickness is 0.625”. Material of construction is SA516 Gr 70. This vessel has a “B” factor of 3500 and is designed for 250 psig @500 deg F. Allowable stress is 16,500. What is the maximum external pressurefor this vessel?

B = 3500Do = 60”t = 0.625

4B[ 3 ( Do / t ) ]

4 x[ 3 x ( / 0.625 ) ]

Pa = 3 x ( )

Pa = psi

Pa =

Pa =60

3500

96

14000

48.611


40


During an external inspection of a vessel with an outside diameter of 48”uniform corrosion damage was discovered. The thickness in this area of shellwas found to be 0.425”. This vessel is designed for 35 psi external pressure andhas a B factor of 1800. Can this vessel operate at 35 psi external pressure ordoes it need to be rerated?


41


A 20 ft long exchanger tube has an outside diameter of 2” and nominalthickness of 0.083”. Material of construction is SA 283 Gr D and designtemperature is 600 deg F. The “B” factor for the tube is 1500. What is themaximum allowed external pressure for this tube?


(Calculations – Impact Testing, Weld Size and NozzleReinforcement)

1

(Calculations – Impact Testing, Weld Size and Nozzle Reinforcement)

I. Impact TestingA. The inspector should understand impact testing requirements and impact testing procedure (UG 84)B. The inspector should be able to determine the minimum metal temperature of a material which is exempt from impact testing (UG 20 (f), UCS 66,

UCS 68(c).)

II. WELD SIZE FOR ATTACHMENT WELDS AT OPENINGMust be able to determine if the weld size meets Code requirements.

A. Convert a fillet weld throat dimension to leg dimension or visa versa, using conversion factor (0.707);B. Determine the required size of welds at openings (UW-16)

III. Nozzle Reinforcement

A. Understand the key concepts of reinforcement, such as replacement of strength removed and limits of reinforcement.Credit can be taken for extra metal in shell and nozzle

B. Be able to calculate the required areas for reinforcement or check to ensure that a designed pad is large enough. Tosimplify the problem:

All fr = 1.0All F = 1.0All E = 1.0

C. There will be no nozzle projecting inside the shellD. Be able to compensate for corrosion allowancesE. Weld strength calculations are excluded

2

I. What does Impact Testing Determine?

II. What is MDMT?

III. Why does the Code worry about MDMT?

IV. What are some factors that affect brittleness of materials?

V. What is the opposite of brittleness?

.

3

(ASME VIII UG 20 (f), UG 84 UCS 66, UCS 68(c).)

I. How does ASME Section VIII manage Brittle Fracture

a. By Material Selection (P1 Group 1 and 2 see Fig. UCS 66)

b. Provides a method for determining MDMT

1. Curves for material groupings (Fig. UCS 66)

2. Initial impact testing exempt temperature based on material (curveletter) and thickness (Table UCS 66 1)

3. Stress Reduction Ratio factor [(tr x E)/(tn c)]. (Fig UCS 66.1)Note: This ratio will be provided on the test.

4. PWHT Reduction (residual stress reduction allowed when PWHT is performed and is not requiredby the Code) see (par. UCS 68(c.))

c. Temperature limited by UCS 66(b)(2)&(3) and UCS 68(c.)

a) UCS 66(b)(2) – no colder than 55oF, unless ;

1) Stress reduction ratio is 0.35 or less, then temperature can bebetween 55oF and 155oF. (UCS 66(b)(3)

2) PWHT performed when not required by Code, temperature canbe below 55oF. (UCS 68(c.)

4

ASME VIII,

ASME VIII,

Practice Question # 1A horizontal vessel constructed from SA-516 Gr 65 plate (not normalized). Designed for 350 psig @ 650oF. Wall thickness is 1.5”, with a 1/16” corrosion allowance and reduction ratio is .80. Nameplate is stamped RT-1 and HT. What is the lowest possible MDMT for this vessel?

5

Practice Question # 1A horizontal vessel constructed from SA-516 Gr 65 plate (not normalized). Designed for 350 psig @ 650oF. Wall thickness is 1.5”, with a 1/16” corrosion allowance and reduction ratio is .80. Nameplate is stamped RT-1 and HT. What is the lowest possible MDMT for this vessel?

6

Step 1: Find material Curve Letter;Curve letter is “B” from Fig. UCS 66

Step 2: Initial MDMT;51oF from Table UCS 66

Step 3: MDMT reduction (stress ratio reduction);20oF reduction allowed, thereforeReduced MDMT = 51oF 20oF = + 31oF (from Fig. UCS 66.1)

Step 4: PWHT reduction (not allowed)PWHT reduction is not allowed because PWHT was requiredby Code (i.e. nameplate stamped “HT”) see Par. UCS 68(c.)

Lowest MDMT = + 31oF

ASME VIII,

ASME VIII,

ASME VIII,

ASME VIII,

Practice Question # 2A horizontal vessel constructed from SA-516 Gr 50N plate. Designed for 300 psig @ 600oF. Wall thickness is 0.25”, with a 1/32” corrosion allowance and reduction ratio is .80. Nameplate is stamped RT-1. Vessel was PWHT’d. What is the lowest possible MDMT for this vessel?

7


Practice Question # 3A horizontal vessel constructed from SA 178 Gr A plate. Designed for 200psig @ 500oF. Wall thickness is 0.500”, with a 1/8” corrosion allowanceand reduction ratio is .80. Vessel was PWHT’d. Nameplate is stamped RT2. What is the lowest possible MDMT for this vessel?


Practice Question # 4A horizontal vessel constructed from SA-516 Gr 60 plate. Designed for 200 psig @ 500oF. Wall thickness is 0.750”, with a 1/8” corrosion allowance and reduction ratio is .88. Nameplate is stamped RT-2 and vessel was PWHT’d for environment cracking. What is the lowest possible MDMT for this vessel?


Charpy Impact Test

Each Specimen shall consist of three specimens ASME VIII UG 84

Specimen thickness is 0.394” Fig. UG 84

10

ASME VIII,

Charpy Impact Test

11

(a) Interpolation between yield strengths shown is permitted.

(b) The minimum impact energy for one specimen shall not be less than 2 3 of the average energy requiredfor three specimens. The average impact energy value of the three specimens may be rounded to thenearest ft lb.

ASME VIII,

Practice Question # 5What is the required average and minimum charpy impact values for a material with 50 ksiMSYS and is 1.0 thick?

12

ASME VIII,

13

(ASME VIII UG 84

50 Ksi

1.0 thickness

15 ft lbs

ANSWER:Average = 15 ft lbsMin. Value = 2/3 x 15 = 10 ft lbs

Practice Question # 6What is the required average and minimum charpy impact values for a material with 55 ksiMSYS and is 2.0 thick?

14

(ASME VIII UG 84

Practice Question # 7During impact testing of a 1 ½” thick material with a MSYS of 45,000 psi, the impacttesting values for the specimens were 17, 12, and 11? Are the results of these impacttests acceptable?

15

(ASME VIII UG 84

16

Leg

Throat

Leg

Fillet weld size is normally described by the “leg” size.

Calculating fillet weld size;

Throat size = 0.707 x leg size

Leg size = throat size / 0.707

Per Fig. UW 16.1;Throat size = ½ tmin

orThroat size = tc

or

Throat size = tw

ASME VIII,

17

Leg

Throat

Leg

Calculating the size of fillet welds;

Practice Question # 5An equal leg fillet weld has a throat of 0.375”.What is leg size for this fillet weld?

Leg size = throat size / 0.707= 0.375 / 0.707= 0.530”

Practice Question # 6A fillet weld with a leg size of 0.250”.What is throat size for this fillet weld?

Practice Question # 7A 45o fillet weld has a leg size of 0.125”.What is throat size for this fillet weld?

ASME VIII,

18

tn

tc

d

te

t

a 11 /2 tmin

Per par. UW 16(b);Fillet weld size, must be converted from throat size (½ tmin or tc) to leg size.

tmin = lesser of ¾” or members joined

Assume, the repad is 0.375” thick, the vesselshell is 0.500” thick and the nozzle is 0.432”.What is the required fillet weld size attachingthe repad to the vessel shell?

Step 1: Go to the sketch (UW 16.1(a 1).

Step 2: Calculate throat size ( ½ tmin)½ tmin = ½ x (less

= ½ x (lesser of (0.75”, _____, _____,____)= ½ x (lesser of (0.75”, 0.375”, 0.500”, 0.423”)= ½ x 0.375”= 0.1875”

Step 3: Calculate weld size (Fillet weld Leg size);Leg = ½ tmin / 0.707 = 0.1875 / 0.707 = 0.265” , rounded to next 1/16” = 0.3125”

ASME VIII,

19

Per par. UW 16(b);Fillet weld size for nozzles without repads must be calculated by converting throat size (tc), to leg size.

tc = not less than smaller of ¼” or 0.707 x tmin

Assume, the vessel shell is 0.500” thick and the nozzle is 0.432”. What is the required fillet weld size for this branch connection?

Step 1: Find correct sketch (UW-16.1(a).

Step 2: Calculate the throat size (tc)tc = lesser of ¼” or 0.707 x tmin

= lesser of ¼” or 0.707 x (lesser of 0.750, 0.423, 0.500)= lesser of ¼” or (0.707 x 0.432)= lesser of ¼” or 0.305”= 0.250”

Step 3: Calculate weld size (Fillet weld Leg size);Leg = tc / 0.707 = 0.250 / 0.707 = 0.357”, rounded to next 1/16” = 0.375”

tn

tc

d

t

a

20

tc =

0.375”

0.3125”

0.250”

21

tn

tc

d

t

a

Practice Question # 8A branch connection is being installed without a reinforcement pad.The nozzle thickness is 0.625” and the vessel shell is 0.875” thick. What sizefillet weld should be used for this branch connection?

ASME VIII par. UW 16(b);

22

Practice Question # 9A branch connection is being installed with a reinforcement pad.The nozzle thickness is 0.625”, repad is 0.750” thick and thevessel shell is 0.875” thick. What size fillet weld should beused to attach the repad to the vessel shell?

ASME VIII par. UW 16(b);

tn

tc

d

te

t

a 11 /2 tmin

23


tn

tc

d

t

a

A nozzle is installed in a vessel per Fig. UW 16.1(a). The vessel wall thicknessis 0.325” and the nozzle wall thickness is 0.375”. What is the minimum filletWeld size for the nozzle to shell fillet weld?

ASME VIII par. UW 16(b), Fig. UW 16.1(a)

24


tn

tc

d

t

a

A nozzle is installed in a vessel per Fig. UW 16.1(a). The vessel wall thicknessis 0.325” and the nozzle wall thickness is 0.375”. What is the minimum filletweld size for the nozzle to shell fillet weld?

ASME VIII par. UW 16(b), Fig. UW 16.1(a)

25

ASME VIII par. UG 37


A new 8 NPS nozzle is installed in a vessel per Fig. UW 16.1(h). Shell required thickness is1.125”. Nominal shell thickness is 1.250”. Nominal thickness for the nozzle is 0.875”.The repad thickness is 0.500”.

1) What is the minimum fillet weld size for the nozzle to repad fillet weld?2) What is the minimum fillet weld size for the shell to repad fillet weld?

tc

d

t

Fig. UW 16 1(h)

tn

tw= 0.7tmin

tc

HEAD

BANGER

I. Nozzle Reinforcement

29


Replacing area lost by cutting hole in vessel (cross sectional area)Strength of the material lost, must be replacedStrength lost = diameter of hole x shell tmin

Limits of reinforcementExtra metal must be near the nozzle

Strength of reinforcementReinforcement must be equal to the strength removedAdditional reinforcement must be added

Reinforcement can come from multiple sourcesShell, nozzle, repad and fillet weldsCorrosion allowance cannot be used

30

Variables for nozzles wwith repads

A = d x tr

A1 = d (t-tr) or 2(t + tn)(t-tr) , larger of these two

A2 = 5t(tn-trn) or 5tn (tn-trn) , smaller of these two

A41 = Leg2

A42 = Leg2

A5 = (Dp – d – 2tn)te

Variables for nozzles wwithout repads

A = d x tr

A1 = d (t-tr) or 2(t + tn)(t-tr) , extra shell area, larger of these two

A2 = 5t(tn-trn) or 5tn (tn-trn) , extra nozzle area, smaller of these two

A41 = leg2

Notes:A. There will be no nozzle projecting inside the shell

B. Be able to compensate for corrosion allowances

C. Weld strength calculations are excluded

d = diameter of nozzle in corroded conditiont = shell thickness in the corroded conditiontr = shell required thicknesstn = nozzle thickness in the corroded conditiontrn = nozzle required thicknessDp = outside diameter of repadte = repad thicknessLimits of reinforcement = greater of d or Rn+tn_t

Nozzle Reinforcement Variables

tn

tc

d

te

t

a 11 /2 tmin

tn

tc

d

t

a

ASME VIII, Subsection A, Part UG, UG 37

31


tn

tc

d

t

a

A 12 NPS nozzle is being installed on a vessel. The corroded ID of the nozzle is12.0”. Shell thickness is 0.750”. Corrosion allowance is 1/16”. Required thicknessfor the shell is 0.625”. The area that must be replaced is;


32



tn

tc

d

t

a

A 12 NPS nozzle is being installed on a vessel. The corroded ID of the nozzle is12.0”. Shell thickness is 0.750”. Corrosion allowance is 1/16”. Required thicknessfor the shell is 0.625”. The area that must be replaced is;


33



tn

tc

d

t

a

A 8 NPS nozzle is being installed on a vessel. The corroded ID of the nozzle is8.0”. Nozzle thickness is 0.250”. Required thickness for the nozzle is 0.100”Shell thickness is 0.450”. Required thickness for the shell is 0.400”.Fillet weld size is 0.375”.

1. What is the area lost?2. What is the limits of reinforcement?3. What is the extra area provided by shell?4. What is the extra area provided by the nozzle?


tn

tc

d

te

t

Fig. UW 16.1(a 1)

1 /2 tmin

A 12 NPS nozzle is being installed in a vessel as indicated by Fig. UW 16.1(a 1). The vesselwall thickness is 0.825” thick. Vessel required thickness is 0.625”. The nozzle wallthickness is 0.500”. Required nozzle thickness is 0.375”. The repad is 0.375” thick.Corrosion allowance is 0.125”.

1) What is the limits of reinforcement (edge to edge)?

2) What is the area lost?

Exam Restrictions/Exclusions:

2

1. No more than one process (SMAW, GTAW or SAW).

2. One filler metal per process

3. PQR will be the supporting PQR for the WPS (only one WPS and one PQR).

4. Base metal limited to P1, P3, P4, P5 and P8

5. Dissimilar metals and/or thicknesses are excluded from exam

6. Corrosion-resistant weld overlay, hard-facing overlay, and dissimilar metal welds with buttering of ferritic member is excluded from exam

7. P1, P3, P4 & P5 lower transition temperature will be 1330 F and 1600 F upper transformation

8. Editorial and non-technical requirements are excluded (i.e. Revision #, Company Name, WPS number, WPS Date, and Name of testing lab).

9. Supplemental Variables are excluded from Exam.

Body of Knowledge

I. WPS/PQR/WPQ – BODY OF KNOWLEDGE

3

Layout of the ASME Section IX Code Book

Divided into 2 partsQW – WELDING QB - BRAZING (pages 204 – 243 is not on exam)

QW – Divided into 5 ArticlesArticle I – Welding general requirements (13 pages) QW100

Article II – Welding Procedure Qualifications (WPS/PQR) QW200

Article III – Welding Performance Qualifications (WPQ) QW300

Article IV – Welding Data QW400

Article V - Standard WPS Specifications (NOT ON TEST) QW500

4

Purpose of ASME Section IX

5

Section IX is focused on THREE things;

1. WPS - (Welding Procedure Specification)

2. PQR - (Procedure Qualification Record)

3. WPQ - (Welder Performance Qualification)

Directions to welder to for making production welds

Qualifies that the WPS can be used to make a quality weld

Qualifies that the WELDER can make quality welds with a Welding Process (i.e. SMAW, GTAW, SAW).

General requirements of ASME Section IX

QW100.1 (page 1)

a. Provides directions to welder for making production welds in accordance with CODE requirements.

b. WPS shall be qualified by Manufacturer/Contractorc. WPS specifies conditions which welding must be performed d. WPS must address eessential and non-essential variables and supplemental

variables when applicable (supplemental variables are not on API 510 exam).

e. PQR establishes the properties of the weld, “not the skill of welder’.f. PQR must address eessential variables and and supplemental variables

when applicable (supplemental variables are not on API 510 exam).

QW100.2 (page 2)

a. WPQ determines welder’s ability to make sound welds.

6

General requirements of ASME Section IX (cont)

QW100.3a. WPS qualified per Section IX, can be used to make welds in accordance

with Section VIIIb. WPS qualified in accordance with Section IX 1962 or later can be used.c. WPS qualified in accordance with Section IX prior to 1962, can be used, if

all the 1962 requirements are met.d. Prior to 2009, Section IX used “S” numbers. The 2010 Section IX

eliminated the “S” numbers. WPS’s created using “S” numbers must be revised to show correct “P” number, but not RE-QUALIFIED.

e. New WPS’s and Welder Qualifications, must be per 2010 Edition of Section IX

QW-101a. Section IX applies to preparation of WPS, PQR, WPQ for all types of

manual & machine welding processes

7


QW102 (Definitions) (see QW492, page 193)a. Groove Weld – weld made in a groove formed within a single or two members.b. Heat-affected zone – base metal that was not melted, but whose mechanical

properties were altered during weldingc. Interpass temperature – highest temperature allowed in weld or weld joint prior

to welding. d. Lower Transformation Temperature 1330oF – Ferrite begins to transform into

Austenite (P1, P3, P4, P5)e. Macro-Examination - Observing a cross-section of a specimen by the unaided eye

or low magnification with or without etching.f. Performance Qualification – welder’s ability to produce welds meeting prescribed

standards.g. Preheating – heat applied prior to weldingh. Upper Transformation temperature 1600oF – Transformation from ferrite to

austenite is completed. (P1, P3, P4, P5)i. Welder – one who performs manual or semi-automatic welding.

8


QW103.1 - Responsibilitya. Manufacturer is responsible for and shall conduct testing required to Qualify

WPS’s and Welders.

QW103.2 - Recordsa. Manufacturer shall maintain a record of the results of WPS and Welder

Qualifications (i.e. PQR and WPQ).

QW110 – Weld Orientationa. Weld orientations used for WPS and WPQ test are as indicated in figure QW

461.1 or QW 461.2 (page 151).

9

Understanding P-Number

14

Understanding P-Number

15

Example - What is the P-Number for SA 285 Gr C?

Answer - Find SA 285 Gr C in table QW/QB 422 (page 76). It is P1 Gr 1.

Understanding F-Numbers

16

Understanding F-Numbers

17

Example - What is the F-Number for E8018?

Answer - Find AWS classification in Table QW 432 (page 134), then go horizontally to lefttill you get to the F-No column. F4 is answer

P-Number and F-Number Practice Questions

18

Material P Number

SA 240 Type 304

SA 217 Type WC1

UNS S31000

Filler Metal Classification and/or Specification F Number

E7024

E8018

SFA 5.18

Test positions for Groove Welds (plate)

19

QW120 – Test Positionsa. Test coupons may be oriented in any position indicate in figures QW 461.3 (plate) or QW

461.4 (pipe) …..see page 153

15 deg15 deg

Test positions for Groove Welds (Pipe)

20

15 deg15 deg

21

“FIELD” Weld Orientations (QW110 page 151)

0o

to 360o

280o

ROTATION of FACE

INCLINATION of AXISTabulation of Positions of GROOVE WELDS

Diagram Inclination RotationPosition Reference of Axis of FaceFlat A 0 to 15o 150 to 210o

Horizontal B 0 to 15o 80 to 150o

210 to 280o

Overhead C 0 to 80o 0 to 80o

210 to 360o

Vertical D 15 to 80o 80 to 280o

E 80 to 90o 0 to 360o

22

Groove Weld – POSITION of Field Welds

Tabulation of Positions of GROOVE WELDS



210 to 280o


210 to 360o


E 80 to 90o 0 to 360o


23


24




210 to 280o


210 to 360o


E 80 to 90o 0 to 360o




210 to 280o


210 to 360o


E 80 to 90o 0 to 360o


25




210 to 280o


210 to 360o


E 80 to 90o 0 to 360o


26

Practice Questions for

Weld Orientations

27


Weld Orientations

28


Weld Orientations

29


Weld Orientations

QW141.1 – Tension Test A. Used to determine “ultimate strength” of groove weld joints (TENSILE STRENGTH).B. Types of Test - Reduced Section, Round (Turned), Full SectionC. Tensile Strength = Load/Area in lbs/in2 (psi)

QW141.2 – Guided Bend Test A. Used to determine “degree of soundness and ductility” of groove weld joints.B. Types - Root, Face and Side bend

QW141.3 – Fillet Weld TestA. Used to determine “size, contour & degree of soundness ” of fillet welds.

QW141.4 – Charpy Impact A. Used to determine “notch toughness” of the welds

QW142 – Special examination for welders A. RT or UT may be substituted for mechanical test (bends) for welders.

QW144 – Visual examination A. Used to determine welds meet “quality standards”

30

QW141.1 – Tension Test A. Used to determine “ultimate strength” of groove weld joints (TENSILE STRENGTH).B. Types of Test - Reduced Section, Round (Turned), Full SectionC. Tensile Strength = Load/Area in lbs/in2 (psi)

QW151 – Tension TestQW 151.1 - Reduced section “may be” used for all thicknesses of pplates

QW 151.1(a) - For thicknesses 1” “SHALL” be FULL thickness specimensQW 151.1(b) - For thicknesses > 1” “may be” FULL thickness or multiple specimens

QW 151.2 - Reduced section “may be” used for all thicknesses of ppipe > 3” diameter.QW 151.2(a) - For pipe thickness 1” “SHALL” be FULL thickness specimensQW 151.2(b) - For thicknesses > 1” “may be” FULL thickness or multiple specimens

QW153 – Tension Test – Acceptance Criteria

32

In order for a Tension test to pass, the specimen shall have a tensile strength of not less than;

a) MSTS of the base metal (when it fails in weld)b) MSTS of the weaker of the two metals joined together (when it fails in

the weld)c) 95% of the MSTS of base metal (when it fails in the base metal).

38

Failure Stress or Ultimate Stress = Load/Area

Area of a tensile specimen is the width x thickness

Load is the amount of stress required to pull the tensile specimens apart

Bend Test - Specimens

41

Bend TestQW141.2 – Bend Test

A. Used to determine “degree of soundness and dductility” of groove weld joints.B. Types of Test - Face, Root, and Side bends (determined by which face is on “Convex” side)

Face and Root Bend TestThese two test are always done together. Therefore, what ever # of face bends are required, the same number of root bends are also required.

Side Bend TestSide bends are only performed with other side bends (i.e. you will never see face, root AND side bends required). Side bends are only required for “THICKER” materials (i.e. ¾” or greater in thickness). See Table QW 451.1(a) on page 147.

Acceptance Criteria1. Weld and Haz must be in the bent portion of bend.2. No open discontinuity in weld or HAZ > 1/8” in any direction on convex surface3. Open discontinuity at the corners are acceptable,unless result from LOF, slag or internal

discontinuities

43

Figure “A”Figure “B” Figure “C”

44

Figure “A”

Figure “B” Figure “C”

Visual Examinations

QW144 – Visual ExaminationA. Used to determine if welds meet “qquality standards”B. Required for “PERFORMANCE” test, not PQR.

QW-194 Acceptance Criteria1. Welds must be inspected after welding is complete and before specimens

are removed (see QW-302.4)2. Must have complete Joint penetration3. Must have complete fusion of weld metal and base metal

Radiography

QW142 – Radiography1. May be substituted for Groove weld Mechanical

Test for WELDERS.

QW-191 Acceptance Criteria1. No cracks, Lack of Fusion (LOF) or Incomplete Penetration (IP)2. Elongated slag inclusions (i.e. indication is 3 times longer than width), max

size permitted;1. Max length of 1/8” - for t up to 3/8”2. Max length of 1/3 t - for t > 3/8” but < 2 ¼”3. Max length ¾” - for t > 2 ¼”4. Aligned inclusions with aggregate length > t in 12t length of weld

3. Rounded Indications 1. Smaller of 20% of t oor 1/8”2. For clustered, assorted or randomly dispersed configurations, see

Appendix I

Welder Qualification RecordWelder Performance Qualification (WPQ)

1. Coupon or production for each welding process (SMAW, GTAW, SAW, etc)

2. Qualified by; a. Production weld must be examined by RT or UTb. Coupon can be examined by VT and Mechanical or RT/UT See QW-300.1

NOTE: GMAW S “short circuiting mode” welds cannot be qualified by RT

3. If examination is acceptable, welder is qualified within the limits of QW-304

4. WPQ is welded in accordance with a WPS. Preheat & PWHT required by WPS can be omitted for WPQ

51

Welder Qualification RecordPractice Question # 14

Which of the following cannot be used to qualify a welder?1. VT & Bend Test2. RT of 1st Production weld3. RT of test coupon4. Tension Test

52

WPQ Bend Specimen Requirements

53

Bends

1. Number of bends? AND

Bend Specimen Requirementsfor “Performance Qualification”

54

Bends2. Dimensions?

WPQ Bend Specimens

55

Bends

Where to remove the specimens?

Alternative Inspection (RT/UT) for WPQ

56

RequirementsNDE – Alternative Inspection (RT/UT in lieu of BENDS

1. Minimum Length of weld?

2. Pipe?

1. Minimum Length of weld?

2. Welder Operator?

RT cannot be used to test a welder for either of the following;

57

2. Any of the bend test fail;

3. Fails RT exam;

1. Welder has not used the Process for 6 months

2. Reason to question welder’s ability to make sound weld

1. Fails Visual test;

Qualify by; retest and RT twice the required length of weld

Qualify by: making 2 coupons, both must pass mechanical test.

Qualify by: making 2 coupons, both must pass VT and 1 picked for mechanical testing (bend)

Qualified by; Welding single coupon, plate or pipe, any thickness/diameter/position, VT/Bend or RT.

Practice Questions for WelderQualificationPractice Question # 15

RT can be used to qualify a welder, except for the following?1. Welding P21 material with GTAW process2. SAW process3. SMAW Process4. GMAW process in Short-circuiting mode

Practice Question # 16 A welder is being qualified by welding using ½” thickA106B pipe coupon in 5G position. How many face bends are required?

1. 22. 13. 34. 0

Practice Question # 17A welder is being qualified for 2G and 5G on a single pipe 1” thick coupon (A240 type 304L coupon). How many side bends are required?

1. 62. 23. 44. 0

58

Practice Questions for WelderQualification

Practice Question # 18Which of the following is the manufacturer/contractor prohibited from delegating to another organization?

1. Preparing test coupons2. Performing mechanical or NDE inspection of specimens3. Witnessing the welder making the weld coupon4. Developing the WPQ record

Practice Question # 19A welder was making test coupons for a 2G and 5G pipe qualification test and the 2G coupon failed VT examination. In order for the welder to be qualified, which of the following must occur?

1. Make another 1G coupon and either RT or Mechanical Test the coupon2. Make two 1G coupons and VT and RT examine both coupons 3. Make two 1G coupons and VT both coupons, but only RT one coupon4. Make two 2G coupons and VT both coupons, but only Mechanical test one coupon

Practice Question # 20A 6G qualification coupon failed the mechanical testing (one of the bends failed), In order for the welder to be qualified, which of the following is required?

1. Two more coupons have to be welded and all 4 bends for each of the coupons have to pass mechanical test2. Two more coupons have to be welded and only one coupon has to pass the required mechanical test3. Another coupon has to be welded and all 4 bends has to pass mechanical test4. Two more coupons have to be welded and both coupons must be either pass mechanical testing or RT examined .

59

WPQ “P” Number Qualification Range

60

“P” numberof testcouponwelded

“P” numberRange

qualified toweld inFIELD

Answer:

WPQ “F” Number Qualification Range

61

Qualifiedwith

“F” numberRange

qualified toweld inFIELD

Answer:

WPQ # of Bend Specimens

62

Answer:

WPQ # of Bend Specimens

63

Answer:

WPQ Thickness Limits

64

Answer:

WPQ Diameter Limits

65

Answer:

WPQ Position Limits

66

Answer:

Welder Qualification Record

67

WPQ Record

1. Variables used (i.e. process, type(manual/automatic, with/without backing, P-No, F-No, etc)

2. Essential Variables (i.e. joints, Base metal, Filler Metal, Position, etc)

3. Type of Test (i.e. VT, Bends and/or RT/UT)

4. Test Results (i.e. Acceptable or Failed)

5. Ranges Qualified – (i.e. thickness range, Positions, Diameters, fillet welds)

6. Certification (i.e. signature of Manufacturer/Contractor)

WPQ – Essential Variables

68

Essential Variables

Paragraph VariableProcess

SAW SMAW GTAW

QW402Joints .4 Backing X X

QW 403Base Metals

.16 Ø Pipe Diameter X X X

.18 Ø P Number X X X

QW 404 FillerMetals

.14 ± Filler X

.15 Ø F Number X X X

.22 ± Inserts X

.23 Ø Solid or metal cored toflux core X

.30 Ø t Weld deposit X X X

QW 405Positions

.1 X X X

.3 + Position X X

QW 408Gas .8 Ø Ver cal welding X

QW 409Electrical .4 Ø Current or polarity X

69

Determine What welding PROCESS and TYPE used to make test couponStep 1 SMAW and Manual

Find the “Essential” variables for the welding process used in ASME IX.Step 2 QW 353 for SMAW

Complete Testing Variables and Qualification Limits (“Range Qualified” section)Step 3

Welding Variables (QW 350) Actual Variables Range Qualified

1. Welding Process(es) SMAW

2. Type (i.e. manual, semi-automatic) used Manual .

3. Backing (with or without) (QW 402.4) None

4. Test Coupon Production Weld (dia if pipe) (QW 403.16 Base) 6” NPS

5. Base metal P-Number to P-Number (QW 403.18 P-Number) P1 to P1

6. Filler Metal or Electrode Spec (SFA) 5.1

7. Filler Metal F-Number (QW 404.15 F-Number) F3

8. Consumable Insert (GTAW or PAW) N/A

9. Filler Metal Type (solid/metal or flux cored/powder) N/A

QW 353 for SMAW

SMAW

Manual

_F1,F2, and F3

P1-P15F,P34,P41-49

2 7/8” OD

F1 to F3 with,F3 wo

Page 57

These are set by WPS

--------

------------

------------

x

Welding Variables (QW 350) Actual Variables Range Qualified

10. Deposited Thickness for each process (QW 403.30)

a. Process 1: SMAW 3 layers minimum Yes No . .

b. Process 2: SMAW 3 layers minimum Yes No . ------ .

11. Position qualified (1G,2G,3G,4G,5G,6G, etc) . .

12. Vertical progression (uphill or downhill) .

13. Inert Gas Backing (GTAW, PAW, GMAW) .

14. GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit) .

15. GTAW Current type/polarity (AC,DCEP,DCEN) .

________________________________________________________________________________________________________________

70

x

Complete “Results: section and then Sign and Date FormStep 4

That’s IT, you just completed a WPQ RECORD

n/a horz

F,H

------------

------------

------------

------------

.280”

2G

Uphill

N/A

N/A

N/A

71

Determine if Essential Variables are “Correct”Practice Question#28Welding Variables (QW 350) Actual Variables Range Qualified

1. Welding Process(es) . .. .2. Type (i.e. manual, semi-automatic) used . .3. Backing (with or without) .

4. Test Coupon Production Weld (dia if pipe) . .5. Base metal P-Number to P-Number . .6. Filler Metal or Electrode Spec (SFA) . .7. Filler Metal F-Number .8. Consumable Insert (GTAW or PAW) . .9. Filler Metal Type (solid/metal or flux cored/powder) . .10. Deposited Thickness for each process

a. Process 1: SMAW 3 layers minimum Yes No .b. Process 1: SMAW 3 layers minimum Yes No .

11. Position qualified (1G,2G,3G,4G,5G,6G, etc) .12. Vertical progression (uphill or downhill) .13. Inert Gas Backing (GTAW, PAW, GMAW) .

14. GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit) .15. GTAW Current type/polarity (AC,DCEP,DCEN) .

x

x

Downhill only

ALL

Max of .600”

--------

--------

--------

--------

SMAWManual

F1,F2, and F3

P1-P15F,P34,P41-492 7/8” Min to Unlimited

F1, F2 & F3 with

---------

----------------

SMAWManualWith3”P3

5.4F3

N/AN/A

.300”

-------6G

DownhillN/AN/AN/A

WPQ Welding Variables

72

X

XX

X

X

XX

73

WPQ Welding Variables

74

WPQ Welding VariablesReference WPQ MR. ROD BURNER to answer the following questions;

Welding Procedure - Requirements (WPS)

1. WPS requirements (QW-200.1, page 14)

a. WPS provides directions for making production welds.b. Must contain essential, nonessential and when required

supplementary variables.1) Must reference the supporting PQR

c. Changes can be made to “nonessential” variables withoutrequalification. Changes to “essential or supplementary” variablesrequire requalification.

d. Format of WPS may be any format as long as every essential,nonessential and supplementary variable is included.

e. WPS must be readily available at the fabrication site for review bywelder and inspector.

79

Welding Procedure – Requirements (PQR)

a. Is a Record of the welding data used to make the test coupon andmechanical test results.

a. Must;1) Contain essential and supplementary variables (supplemental is not API 570 Exam).2) Record range of variables used to make the coupon must be included3) Be certified by the manufacturer/contractor (i.e. signed and dated).

b. Changes to the PQR are not allowed, except for editorial type changes (i.e. P# enteredincorrectly, or Code changes the F# for the materials used, etc.) All changes to a PQR,require recertification (i.e. signed and dated by manufacturer/contractor).

c. Format may be any format as long following are included;a. Essential and supplementary variablesb. Type of mechanical test, number of tests and test results

d. PQR must be available for the AI, but not the welder.e. There could be multiple PQR’s supporting one WPS or multiple WPS’s for a single PQR.

80

1. WPS is prepared for production welds that are to be made.

2. Welder (employee or contracted out), makes a Test Coupon using directions fromthe WPS.

3. The coupon is mechanically tested - Bends and Tension test (RT is not allowed).

4. If mechanical testing is acceptable, WPS is Qualified within ranges set by variablesused to make the test coupon.

5. PQR is a record created based on variables used to make the test coupon andsubsequent mechanical testing results.

81

NOTE: PQR “Must” be signed and dated to be CERTIFIED.

(QW-201)

(QW-100)

(QW-202.2)

1. What is the difference between the Procedure QUALIFICATION andWelder QUALIFICATION?

82

A. Procedure qualification requires TWO documents (WPS/PQR).

B. Examinations are different;

C. WPQ only requires “Essential” variables to be recorded,while the WPS must record “Essential, Non-Essential and Supplementary(when required) variables”.PQR must record “Essential and Supplementary” variables.

WPS/PQR – requires Bends/Tension test and Charpy test when notchtoughness is required. Also, Hardness when PWHT’d.

1)

WPQ – requires VT and Bend test or RT/UT examination.2)

1. Verify WPS has been properly completed and addresses requirementsof Section IX (for API Exam, means Essential Variables and Non-Essential variables areaddressed) API 577 par 6.4 page 18

2. Verify PQR has been properly completed and addresses requirementsof Section IX (for API Exam, means Essential Variables are addressed and PQR is signed anddated) API 577 par 6.4 page 18

3. Verify PQR essential variables properly support the range specified inWPS (for API Exam, means Essential Variables are addressed and PQR is signed and dated) API 577

par 6.4 page 18

83

84

INSTRUCTIONS for Checking WPS and PQR

STEP 1 Locate the appropriate “Welding Variables Chart” for the Welding PROCESS (i.e. SMAW– QW 253, SAW-QW 254 or GTAW -QW 256……these are the only three that will be on the API Exam).

STEP 2 Verify PQR is signed by Manufacture/Contractor – QW202(b).

STEP 3 Verify WPS references the supporting PQR – QW201(b).

STEP 4 Verify all Non-Essential variables are addressed on the WPS, and validate that on the checklist (e.g. enter “OK” or “ERROR” inthe VALIDATE column) - QW201(b).

STEP 5 List values for all “ESSENTIAL” variables on Checklist from the PQR – QW202(b).

STEP 6 List values for all “ESSENTIAL” variables on Checklist from the WPS – QW201(b).

STEP 7 Use Section IX to determine and list the “ACCEPTABLE” range for all essential variables (based on the PQR results)

STEP 8 Compare the “Acceptable” range against the WPS values and document the findings in the “VALIDATE” column.

STEP 9 Check TESTING data on PQR and verify correct type/number of BEND specimens (i.e. 2 face & 2 Root, etc) were tested andresults are acceptable or rejectable. Record answer in “Validate” column of checklist.

STEP 10 Check TESTING data on PQR and verify correct type/number of TENSILE specimens (i.e. 2 or more, depending on thickness)were tested and results are acceptable or rejectable. Record answer in “Validate” column of checklist.

STEP 11 Check for P-No and/or F-No mistakes.

Practice Question for Reviewing WPS/PQR

85

1.) Is the PQR signed & dated?

2.) Now check the Essential, Non-essential variables and ranges qualified

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

OK

86

WPS/PQR “Review” ResultsReview of WPS# Rev# Dated:

Supporting PQR# Rev# Dated:

STEP 4 STEP 5 STEP 6 STEP 7 Validate

Paragraph Brief of Variables Essential Non Essential PQR WPS Qualified For? OK or Error

QW 402 Joints

.1 Groove Design NE

.4 - Backing NE

.10 Root spacing NE

.11 Retainers NE

QW 403Base Metals

.8 T qualified E

.9 t Pass > ½ inch E

.11 P No. qualified E

QW 404 FillerMetals

.4 F Number E

.5 A Number E

.6 Diameter NE

.30 t E

.33 AWS Classification NE

QW 405 Positions.1 + Position NE

.3 Vertical welding NE

QW 406 Preheat1. Decrease > 100oF E

.2 Preheat maintenance NE

QW 407 PWHT.1 PWHT E

.4 T limits E

QW 409 Electric.4 Current or polarity NE

.8 I & E range NE

QW 410Technique

.1 String/Weave NE

.5 Method of cleaning NE

.6 Method back gouge NE

.9 Multi to single pass/side NE

.25 Manual or automatic NE

.26 Peening NE

.64 Use of Thermal Processes E

JCP P101

JCP PQ101

0

0

9/11/2001

9/12/2001

--------------------

----------

-----

-----

-----

--------------------

-----

-----

-----

--------

½”½” thk

SA53 Gr B (P1_)F-4

1

½”

50oF

None-----

1/16” to 1”½” thkP1F31

1/16” to 1”

50oF

None

None

3/16” to 1”½” plate N/A

P1F31

Max of 1”

50oF

None----- -----

None

ERROR – should be F3

None

PQR should be 1/16” to 1”

Par

Par

Par

Par

Par

Par

ParOK

87

WPS/PQR “Review” ResultsBEND SPECIMENS

Number of bends ResultsValidate

(Ok or Error)Required(# & Type)

On PQR(# & Type)

Allowable Defects On PQR

NOTE: 1. Open discontinuity in weld or HAZ < 1/8” (See QW-163, page 6)2. Ignore open discontinuity on corners, unless result from LOF, Slag or internal discontinuity

TENSILE SPECIMENSNumber of Tensile Specimens Compare Results

Validate(Ok or Error)# Required # on PQR

MSTS of BaseMetal

UltimateFailureStress

Check for P-No, F-No and/or Specification mistakes on the WPS/PQR.Results - No F-No or P-No errors.

NOTE: 1. Failure Stress (failed in “Base Metal”) must be .95% of MSTS (see QW-153, page 4)2. Failure Stress (failed in “WELD”) must be MSTS (QW-153)3. Verify that the “Ultimate Failure Stress” is calculated properly (S=Load/Area) – (see QW-152, page 4)

2F & 2R OR 4S 4 SIDES 1/8” OK OK

2 2 60,000 PSI57,038 Base66,158 Weld OK

Practice Questions for Reviewing WPS/PQR

88

Is the P# qualified in accordance with ASME Section IX?Result – Yes, P8


If you don’t know SA 240 Type 304 is P8, then look it up at P-No Tab


89

Is the base metal thickness in accordance with ASME Section IX?

Result – No, PQR coupon was ½” which qualifies thk range of 3/16” to 1”,WPS indicated 1/16” to 1”



90

Is the shielding gas in accordance with ASME Section IX?

Result – NO, WPS is for single gas (argon) and PQR is for 75/25 mix


Essential


91

Is the F# qualified in accordance with ASME Section IX?

Result – NO, ER304 is F6 & E7018 is a F4



92

Are the tensile test in accordance with ASME Section IX?


93

WPS/PQR

94

WPS/PQR

PQR JCP PQ101

95

WPS/PQR

2T = 2 x ½” = 1”

96

WPS/PQR

97

WPS/PQR

PQR JCP PQ101 SA 53B is “P 1

98

WPS/PQR

Welded P 1 Welded P 1

99

WPS/PQR

100

WPS/PQR

PQR JCP PQ101

101

WPS/PQR

Go to par404.4

102

WPS/PQR

WPS

PQR

103

WPS/PQR

104

WPS/PQR

PQR JCP PQ101

105

WPS/PQR

106

WPS/PQR

107

WPS/PQR

PQR JCP PQ101

108

WPS/PQR

109

WPS/PQR

110

WPS/PQR

PQR JCP PQ101

111

WPS/PQR

112

WPS/PQR

PQR JCP PQ101

113

WPS/PQR

Par

Par

PWHT temps, see Table UCS-56Partial HT requires 5 ft overlap for each successive heats (partial means part cannot fit into furnace) per par UW-40(a)(2).HT of welds includes a zone extend 1t or 2”, whichever is less, beyond each side of the weld (par UW-40(a)No control of temperature up to 800oF. Par UCS-56(c.)Heating rate above 800oF shall not be more than 400oF per hr/max metal thickness. Par UCS-56(d)(1)(2).Variation in temperature cannot exceed 250oF in any 15 ft length of vessel. Par UCS-56(d)(2)Holding time is per Table UCS-56During holding time, temperature cannot vary by more than 150oF. Par UCS-56(d)(3).Cool down rate shall not be more than 500oF per hr/max metal thickness. No control necessary below 800oF. Par UCS-56(d)(5).

2

A 2” thick vessel fabricated from SA-516-70N was repaired and PWHT’d at 1000o F. How long should the vessel be maintained at this PWHT temperature?

4

A 2” thick vessel fabricated from SA-516-70N was repaired and PWHT’d at 1000o F. How long should the vessel be maintained at this PWHT temperature?

5

ANSWER 4 hrs & 15 min

A 3” thick vessel fabricated from SA-516-70 was repaired and PWHT’d at 950o F. How long should the vessel be maintained at this PWHT temperature?

6

Post Weld Heat Treatment (PWHT)( API 510)

API 510PWHT should be made as required by ASME Code (Par 8.1.6.4)Local PWHT may be substituted for 360 degree banding on local repairs (Par8.1.6.4.1)

If approved by the engineer.A preheat of 300oF or higher is maintained during weldingPWHT temperature maintained for a distance not less than 2 x t, from the toe of the weld.At least two thermocouples must be used.Metallurgist approves the PWHT procedure if it is performed for environmental assistedcracking resistance.

7

If a repair is made to a vessel after PWHT. A Minimum preheat of 200oF shall bemaintained during the repair for P1 materials. And 350oF for P3 materials. Par UCS-56(f)(4)(b).

No welding recommended at temperatures lower than 0oF. Temperatures between 32oFand 0oF, surfaces within 3” of the weld should be heated to a minimum of 60oF. Par.UW-30.

PWHT can be avoided for certain thickness. Example: P1 between 1 ¼” & 1 ½” doesn’trequired PWHT if a minimum of a 200oF preheat is applied during welding.

8

Preheat in lieu of PWHT for P1 and P3 materials, provided;1. Preheat temperature maintained at a minimum of 300oF.2. Preheat temperature maintained at a distance of 4” or 4t, whichever is

greater, on each side of weld3. Maximum interpass temperature of 600oF

9

Weld Process Schematics

12

Welding Process Productivity

14

27

Vessel thickness of 1.125”, using a SWE/SWV technique and technicianhas access to the ID of the vessel.

28

Vessel thickness of 1.125”, using a SWE/SWV technique and technicianhas access to the ID of the vessel.

29

Vessel thickness of 1.125”, using a SWE/SWV technique and techniciandoes not have access to the ID of the vessel.

30

Vessel thickness of 1.125”, using a SWE/SWV technique and techniciandoes not have access to the ID of the vessel.

Welding Procedure (WPS),

Procedure Qualification Record (PQR)

and

Welder Performance Qualification (WPQ)

Forms

Index

WPS JCP-P101 PQR JCP-PQ101 WPS JCP-P201 PQR JCP-PQ201 WPS JCP-P301 PQR JCP-PQ301 Rod Burner WPQ Form – with qualified range Rod Burner WPQ Form – without qualified range Blank WPS Form Blank PQR Form Blank WPQ Form

ASME Section IX – WPS

QW-482 Suggested Format For Welding Procedure Specification (WPS) (See Section IX QW-200.1)

Company Name JC Penny By Mr. Penny Welding Procedure Specification No. JCP-P101 Date 9/11/2001 Supporting PQR No.(s)JCP-PQ101 Revision No. 0 Date 9/11/2001

Welding Process(es) SMAW Type(s) Manual

Test Description

Joints (QW 402) Joint Design Single V Groove and Fillets Root Spacing .0625” to 1.250” Backing: Yes x No x Backing Material (Type) Metal (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified. (At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)). Base Metals (QW 403) P-No. 1 Group No. to P-No. 1 Group No. OR Specification and type/grade to Specification and type/grade OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum pass thickness ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All Filler Metals (QW 404) Spec. No. (SFA) _ _ _ _ _ _ _ _ _ AWS No. (Class) _ _ _ _ _ _ _ _ _ F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ Size of Filler Metals_ _ _ _ _ _ _ _ Weld Metal: Thickness Range: Groove_ _ _ _ _ _ _ _ _ _ _ Fillet_ _ _ _ _ _ _ _ _ _ _ _ Electrode-Flux (Class) _ _ _ _ _ _ _ Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _ Consumable Insert_ _ _ _ _ _ _ _ _ Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

1st Filler Metal 5.1 E-7018 3 1 3/32”, 1/8”, 5/16” .0625” to 1.0” .250” to 1.0” N/A N/A N/A

2nd Filler Metal

Page of 2 WPS No. JCP-P101 Rev.# 0

Positions (QW 405) Position(s) of Groove ALL Welding Progression: UP X Down Position(s) of fillet ALL

Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other

Preheat (QW 406) Preheat Temp, Min 50oF Interpass Temp, Max 350oF Preheat Maintenance None (Continuous or special heating, where applicable, should be recorded.

Gas (QW 408) Percent Composition Gases Mixtures Flow Rate Shielding N/A Trailing Backing Other

Electrical Characteristics (QW 409)

Weld Pass(es)

Process

Filler Metal Current Type and

Polarity

Amps (Range)

Wire Feed Speed (Range)

Energy or Power (Range)

Volts (Range)

Travel Speed (Range)

Other (e.g Remarks, Com-ments, Hot Wire

Addition, Technique, Torch

Angle, etc)

Classifi-cation

Diameter

All

SMAW

E-7018

1/8”

DCEP

70 to 200

N/A

N/A

19 - 25

5 to 7

NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc

Pulsing Current N/A Heat Input (max.) N/A Tungsten Electrode Size and Type N/A (Pure Tungsten, 2% Thoriated, etc)

Mode of Metal Transfer for GMAW or FCAW N/A (Spray Arc, Short Circuiting Arc, Globular Arc, etc)

Technique (QW 410) String or Weave Bead String or Weave Orifice, Nozzle, or Gas Cup Size N/A Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping or Wire Brush Method of Back Gouging Grinding Oscillation N/A Contact Tube to Work Distance N/A Multiple or Single Pass (per side) Multiple or Single Multiple of Single Electrodes Single Peening N/A Other

Page 2 of 2

ASME Section IX –PQR

QW-483 Suggested Format For Procedure Qualification Record (PQR) (See Section IX QW-200.2)

Company Name JC Penny PQR No. JCP-PQ101 WPS # JCP-P101 Date 9/12/2001


Joints (QW 402)

Groove Design of Test Coupon

Base Metals (QW 403) Material Spec. SA-53 Gr B P-No. to P-No. Thickness of Test Coupon ½” Diameter of Test Coupon 6” Other


Gas (QW 408) Percent Composition

Gases Mixtures Flow RateShielding N/A TrailingBacking

Filler Metals (QW 404) SFA Specification 5.1 AWS Classification E-7018 Filler Metal F-No. 4 Weld Metal Analysis A-No. 1 Size of Filler Metal 5/32” Other Weld Metal Thickness

Electrical Characteristics (QW 409) Current DC Polarity Straight Amps: 150-300 Volts 20-28 Tungsten Electrode Size N/A Other

Positions (QW 405) Position of Groove ALL Weld Progression (Uphill, Downhill) Other

Technique (QW 410) Travel Speed 3”/min String or Weave Bead StringerOscillation Multipass or Single Pass (per side) Multiple Single or Multiple Electrodes SingleOther

Preheat (QW 406) Preheat Temp 50oF Interpass Temp Other

G D i f T C

QW 483 (back)

PQR No. JCP-PQ101

Tensile Test (QW -150)

Specimen No. Width (inch)

Thickness (inch)

Area (sq. inches)

Ultimate Load (lbs)

Ultimate Stress (psi)

Type of Failure & Location

T1 .750 .455 .341 19,450 57,038 Pass - Base T2 .756 .451 .341 22,560 66,158 Pass - Weld

Guided Bend Tests (QW -160)

Type and Figure No. Results SIDE # 1 Pass SIDE # 2 Pass SIDE # 3 Pass SIDE # 4 Pass

Notch Toughness Tests (QW -170)

Specimen No.

Notch Location

Notch Type

Test Temp

Impact Values

Lateral Exp Drop Weight % Shear Mils Break No Break

Fillet Weld Test (QW -180)

Result – Satisfactory: YES No Penetration into Parent Metal YES No Macro Results

Other Tests

Type of Test Deposit Analysis Other …………………………………………………………………………………………………………………………………………………………………………………. Welder’s Name Jack Shift Jr Clock No. Stamp No. B2 Test conducted by: Laboratory Test No. We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of ASME Section IX. Manufacturer JC Penny Date 9/11/2001 By: Jack Shift Sr

Page 2 of 2




Welding Process(es) GTAW Type(s) Manual

Test Description

Joints (QW 402) Joint Design Single V Groove Root Spacing 1.250” Backing: Yes x No x Backing Material (Type) Solid Metal or weld metal (Refers to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified. (At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)). Base Metals (QW 403) P-No. Group No. to P-No. Group No. OR Specification and type/grade SA 240 Type 304 to Specification and type/grade SA 240 Type 304 OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum pass thickness ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All Filler Metals (QW 404) Spec. No. (SFA): 5.9 AWS No. (Class): ER304 F-No.: F-6 A-No.: A-8 Size of Filler Metals: 3/32”, 1/8”,5/16” Weld MetalThickness Range: Groove: .0625” to 1.0” Fillet: No limit Electrode-Flux (Class): N/A Flux Type: N/A Consumable Insert: None Other: N/A

No single pass > ½”

Page of 2

WPS No. JCP-P201 Rev.# 0 Positions (QW 405) Position(s) of Groove ALL Welding Progression: UP X Down Position(s) of fillet ALL



Gas (QW 408) Percent Composition Gases Mixtures Flow Rate Shielding Argon Trailing None Backing None Other


Weld Pass(es)

Process


Polarity

Amps (Range)



Volts (Range)


Other

(e.g Remarks,

Comments,

Hot Wire Addition,

Technique, Torch

Angle, etc)

Classifi-cation

Diameter

All GTAW ER304 3/32” DCSP 60-100 N/A N/A N/A N/A


All GTAW ER304 5/16”” DCSP 90-160 N/A N/A N/A N/A


Pulsing Current N/A Heat Input (max.) N/A Tungsten Electrode Size and Type 2% Thoriated (EWTh-2) or Cesium Stablilized (EWCe-2) (Pure Tungsten, 2% Thoriated, etc)


Technique (QW 410) String or Weave Bead String or Weave Orifice, Nozzle, or Gas Cup Size 3/8” to ¾” diameter shielding gas cup size Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping, Wire Brush or Thermal process Method of Back Gouging Grinding or thermal process Oscillation N/A Contact Tube to Work Distance N/A Multiple or Single Pass (per side) Multiple Multiple of Single Electrodes Single Peening None Other

Page 2 of 2





Joints (QW 402)


Base Metals (QW 403) Material Spec. SA-240 Type 304 P-No. 8 to P-No. 8 Thickness of Test Coupon ½” Diameter of Test Coupon Plate Other



Gases Mixtures Flow RateShielding Argon/CO 75%/25% 15-25 Trailing NoneBacking None

Filler Metals (QW 404) SFA Specification 5.18 AWS Classification E-7018 Filler Metal F-No. 6 Weld Metal Analysis A-No. 8 Size of Filler Metal N/A Other Weld Metal Thickness ½”

Electrical Characteristics (QW 409) Current DC Polarity Straight Amps: 90-100 Volts 20-28 Tungsten Electrode Size 1/8” Other

Positions (QW 405) Position of Groove 1G Weld Progression (Uphill, Downhill) N/A Other

Technique (QW 410) Travel Speed 5”/min String or Weave Bead WeaveOscillation Multipass or Single Pass (per side) Multiple Single or Multiple Electrodes SingleOther

Preheat (QW 406) Preheat Temp 50oF Interpass Temp 250oF Other

G D i f T C

QW 483 (back)

PQR No. JCP-PQ101


Specimen No. Width(W) (inch)

Thickness(y) (inch)

Area (sq. inches)

Ultimate Load (lbs)



T1 .750 .440 .330 24,450 74,090 Pass - Weld T2 .750 .449 .337 24,000 71,216 Pass - Base


Type and Figure No. Results Face # 1 Pass Face # 2 Pass Root # 3 Pass Root # 4 Pass


Specimen No.

Notch Location

Notch Type

Test Temp

Impact Values




Other Tests

Type of Test Deposit Analysis Other …………………………………………………………………………………………………………………………………………………………………………………. Welder’s Name Jack Shift Jr Clock No. Stamp No. B2 Test conducted by: Shear Metal Testing Lab Laboratory Test No. SM-1001 We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of ASME Section IX. Manufacturer JC Penny Date 8/12/2001 By: Jack Shift Sr

Page 2 of 2





Test Description

Joints (QW 402) Joint Design Single V Groove and Fillets Root Spacing .0625” to 1.250” Backing: Yes x No x Backing Material (Type) Metal (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified. (At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)). Base Metals (QW 403) P-No. 1 Group No. to P-No. 1 Group No. OR Specification and type/grade to Specification and type/grade OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum pass thickness ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All Filler Metals (QW 404) Spec. No. (SFA) _ _ _ _ _ _ _ _ _ AWS No. (Class) _ _ _ _ _ _ _ _ _ F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ Size of Filler Metals_ _ _ _ _ _ _ _ Weld Metal: Thickness Range: Groove_ _ _ _ _ _ _ _ _ _ _ Fillet_ _ _ _ _ _ _ _ _ _ _ _ Electrode-Flux (Class) _ _ _ _ _ _ _ Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _ Consumable Insert_ _ _ _ _ _ _ _ _ Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

1st Filler Metal 5.1 E-7018 3 1 3/32”, 1/8”, 5/16” .0625” to 1.0” .250” to 1.0” N/A N/A N/A

2nd Filler Metal

of 2 WPS No. JCP-P301 Rev.# 0






Weld Pass(es)

Process


Polarity

Amps (Range)



Volts (Range)




Angle, etc)

Classifi-cation

Diameter

All

SMAW

E-7018

1/8”

DCEP

70 to 200

N/A

N/A

19 - 25

5 to 7





Page 2 of 2





Joints (QW 402)











G D i f T C

QW 483 (back)

PQR No. JCP-PQ301



Thickness (inch)

Area (sq. inches)

Ultimate Load (lbs)





Type and Figure No. Results SIDE # 1 Pass SIDE # 2 Pass Face # 1 Pass Face # 2 Pass


Specimen No.

Notch Location

Notch Type

Test Temp

Impact Values




Other Tests


Page 2 of 2

ASME Section IX – Welder Qualification Homework – WPQ’s

QW-484A Suggested Format For Welder Performance Qualification (WPQ)

(See Section IX QW-301)

Welder(s) Name Mr. Rod Burner Identification Number A11

Test Description

Identification of WPS followed WPS 101 Test Coupon Production Weld

Specification and Type/Grade or UNS Number of base metal(s) A 106B to A106B Thickness .280

Testing Variables and Qualification Limits

Welding Variables (QW350) Actual Values Range Qualified

Welding Process(es) SMAW SMAW

Type (i.e. manual, semi-automatic) used Manual Manual

Backing (with or without) None F1 to F3 with,F3 wo

Test Coupon Production Weld (dia if pipe) 6” NPS __ 2 7/8” OD

Base metal P-Number to P-Number P-1 to P-1 P1-P15F, P34, P41-P49

Filler Metal or Electrode Spec (SFA) 5.1 -------

Filler Metal F-Number F 3 F1,F2, & F3

Consumable Insert (GTAW or PAW) N/A -------

Filler Metal Type (solid/metal or flux cored/powder) N/A -------

Deposited Thickness for each process

Process 1: SMAW 3 layers minimum Yes No .280” .560

Process 2: 3 layers minimum Yes No ---- -------

Position qualified (1G,2G,3G,4G,5G,6G, etc) 2G F, H

Vertical progression (uphill or downhill) Uphill Uphill

Inert Gas Backing (GTAW, PAW, GMAW) N/A -------

GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit) N/A -------

GTAW Current type/polarity (AC,DCEP,DCEN) N/A -------

RESULTS

Visual examination of completed weld (QW 302.4) Acceptable

Transverse face and root bends (QW 462.3(a) Longitudinal bends (QW 462.3(b) Side bends (QW 462.2)

Type Results Type Results

Face No defects – Acceptable

Root No defects - Acceptable

Alternative Volumetric Examination Results (QW 191) N/A RT or UT

Fillet weld – fracture test (QW 181.2) N/A Length and percent of defects N/A

Macro examination (QW 184) Fillet size (in.) x Concavity/convexity (in.)

Other tests

Film or specimens evaluated by Company

Mechanical tests conducted by Ben Tension Laboratory test no. 123 Welding supervised by Red Eye

We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the

requirements of Section IX of the ASME Code. Organization Worlds Best Fabricator

Date April 7, 2010 By John Doe

Welding Procedure (WPS),

Procedure Qualification Record (PQR)

and

Welder Performance Qualification (WPQ)

Forms

Index

WPS JCP-P101 PQR JCP-PQ101 WPS JCP-P201 PQR JCP-PQ201 WPS JCP-P301 PQR JCP-PQ301 Rod Burner WPQ Form – with qualified range Rod Burner WPQ Form – without qualified range Blank WPS Form Blank PQR Form Blank WPQ Form


QW-482 Suggested Format For Welding Procedure Specification (WPS)(See Section IX QW-200.1)



Test Description

Joints (QW 402) Joint Design Single V Groove and Fillets Root Spacing .0625” to 1.250” Backing: Yes x No x Backing Material (Type) Metal

(Refer to both backing and retainers)

Metal Nonfusing Metal Nonmetallic Other

Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified.

(At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)).

Base Metals (QW 403) P-No. 1 Group No. to P-No. 1 Group No.

OR Specification and type/grade to Specification and type/grade

OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop.

Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum pass thickness ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All

Filler Metals (QW 404) Spec. No. (SFA) _ _ _ _ _ _ _ _ _ AWS No. (Class) _ _ _ _ _ _ _ _ _ F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _Size of Filler Metals_ _ _ _ _ _ _ _

Weld Metal: Thickness Range:

Groove_ _ _ _ _ _ _ _ _ _ _ Fillet_ _ _ _ _ _ _ _ _ _ _ _ Electrode-Flux (Class) _ _ _ _ _ _ _ Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _ Consumable Insert_ _ _ _ _ _ _ _ _ Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

1st Filler Metal 5.1 E-70 3 1

3/32”, 1/8”, 5/16”

.0625” to 1.0”

.250” to 1.0” N/A N/A N/A

2nd Filler Metal

Page of 2 WPS No. JCP-P101 Rev.# 0



Preheat (QW 406) Preheat Temp, Min 50oF Interpass Temp, Max 350oF Preheat Maintenance None

(Continuous or special heating, where applicable, should be recorded.


Gases Mixtures Flow Rate Shielding N/A Trailing Backing Other


Weld Pass(es)

Process


Polarity

Amps (Range)



Volts (Range)




Angle, etc)

Classifi-cation

Diameter

All SMAW E-7018 1/8” DCEP 70 to 200

N/A N/A 19 - 25 5 to 7


Pulsing Current N/A Heat Input (max.) N/A Tungsten Electrode Size and Type N/A

(Pure Tungsten, 2% Thoriated, etc)


Technique (QW 410) String or Weave Bead String or Weave Orifice, Nozzle, or Gas Cup Size N/A Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping or Wire Brush

Method of Back Gouging Grinding Oscillation N/A Contact Tube to Work Distance N/A Multiple or Single Pass (per side) Multiple or Single Multiple of Single Electrodes Single Peening N/A Other

Page 2 of 2


QW-483 Suggested Format For Procedure Qualification Record (PQR)(See Section IX QW-200.2)



Joints (QW 402)






Filler Metals (QW 404) SFA Specification 5.1 AWS Classification E-7018 Filler Metal F-No. 4 Weld Metal Analysis A-No. 1 Size of Filler Metal 5/32” Other

Weld Metal Thickness





G D i f T C

QW 483 (back)

PQR No. JCP-PQ101



Thickness (inch)

Area (sq. inches)

Ultimate Load (lbs)



T1 .750 .455 .341 19,450 57,038 Pass - BaseT2 .756 .451 .341 22,560 66,158 Pass - Weld


Type and Figure No. ResultsSIDE # 1 PassSIDE # 2 PassSIDE # 3 PassSIDE # 4 Pass


Specimen No.

Notch Location

Notch Type

Test Temp

Impact Values

Lateral Exp Drop Weight% Shear Mils Break No Break



Other Tests

Type of Test Deposit Analysis Other ………………………………………………………………………………………………………………………………………………………………………………….

Welder’s Name Jack Shift Jr Clock No. Stamp No. B2 Test conducted by: Laboratory Test No.

We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of ASME Section IX.

Manufacturer JC Penny

Date 9/11/2001 By: Jack Shift Sr

Page 2 of 2





Test Description

Joints (QW 402) Joint Design Single V Groove Root Spacing 1.250” Backing: Yes x No x Backing Material (Type) Solid Metal or weld metal (Refers to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified. (At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)). Base Metals (QW 403) P-No. Group No. to P-No. Group No. OR Specification and type/grade SA 240 Type 304 to Specification and type/grade SA 240 Type 304 OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum pass thickness ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All Filler Metals (QW 404) Spec. No. (SFA): 5.9 AWS No. (Class): ER304 F-No.: F-6 A-No.: A-8 Size of Filler Metals: 3/32”, 1/8”,5/16” Weld MetalThickness Range: Groove: .0625” to 1.0” Fillet: No limit Electrode-Flux (Class): N/A Flux Type: N/A Consumable Insert: None Other: N/A

No single pass > ½”

Page of 2

WPS No. JCP-P201 Rev.# 0 Positions (QW 405) Position(s) of Groove ALL Welding Progression: UP X Down Position(s) of fillet ALL



Gas (QW 408) Percent Composition Gases Mixtures Flow Rate Shielding Argon Trailing None Backing None Other


Weld Pass(es)

Process


Polarity

Amps (Range)



Volts (Range)


Other

(e.g Remarks,

Comments,

Hot Wire Addition,

Technique, Torch

Angle, etc)

Classifi-cation

Diameter



All GTAW ER304 5/16”” DCSP 90-160 N/A N/A N/A N/A


Pulsing Current N/A Heat Input (max.) N/A Tungsten Electrode Size and Type 2% Thoriated (EWTh-2) or Cesium Stablilized (EWCe-2) (Pure Tungsten, 2% Thoriated, etc)


Technique (QW 410) String or Weave Bead String or Weave Orifice, Nozzle, or Gas Cup Size 3/8” to ¾” diameter shielding gas cup size Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping, Wire Brush or Thermal process Method of Back Gouging Grinding or thermal process Oscillation N/A Contact Tube to Work Distance N/A Multiple or Single Pass (per side) Multiple Multiple of Single Electrodes Single Peening None Other

Page 2 of 2





Joints (QW 402)


Base Metals (QW 403) Material Spec. SA-240 Type 304 P-No. 8 to P-No. 8 Thickness of Test Coupon ½” Diameter of Test Coupon Plate Other



Gases Mixtures Flow RateShielding Argon/CO 75%/25% 15-25 Trailing NoneBacking None

Filler Metals (QW 404) SFA Specification 5.18 AWS Classification E-7018 Filler Metal F-No. 6 Weld Metal Analysis A-No. 8 Size of Filler Metal N/A Other Weld Metal Thickness ½”

Electrical Characteristics (QW 409) Current DC Polarity Straight Amps: 90-100 Volts 20-28 Tungsten Electrode Size 1/8” Other

Positions (QW 405) Position of Groove 1G Weld Progression (Uphill, Downhill) N/A Other

Technique (QW 410) Travel Speed 5”/min String or Weave Bead WeaveOscillation Multipass or Single Pass (per side) Multiple Single or Multiple Electrodes SingleOther

Preheat (QW 406) Preheat Temp 50oF Interpass Temp 250oF Other

G D i f T C

QW 483 (back)

PQR No. JCP-PQ 01


Specimen No. Width(W) (inch)

Thickness(y) (inch)

Area (sq. inches)

Ultimate Load (lbs)



T1 .750 .440 .330 24,450 74,090 Pass - WeldT2 .750 .449 .337 24,000 71,216 Pass - Base


Type and Figure No. ResultsFace # 1 PassFace # 2 PassRoot # 3 PassRoot # 4 Pass


Specimen No.

Notch Location

Notch Type

Test Temp

Impact Values




Other Tests


Welder’s Name Jack Shift Jr Clock No. Stamp No. B2 Test conducted by: Shear Metal Testing Lab Laboratory Test No. SM-1001


Manufacturer JC Penny

Date 8/12/2001 By: Jack Shift Sr

Page 2 of 2


QW-482 Suggested Format For Welding Procedure Specification (WPS)(See Section IX QW-200.1)



Test Description

Joints (QW 402) Joint Design Single V Groove and Fillets Root Spacing .0625” to 1.250” Backing: Yes x No x Backing Material (Type) Metal

(Refer to both backing and retainers)

Metal Nonfusing Metal Nonmetallic Other

Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified.

(At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)).

Base Metals (QW 403) P-No. 1 Group No. to P-No. 1 Group No.

OR Specification and type/grade to Specification and type/grade

OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop.

Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum pass thickness ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All

Filler Metals (QW 404) Spec. No. (SFA) _ _ _ _ _ _ _ _ _ AWS No. (Class) _ _ _ _ _ _ _ _ _ F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _Size of Filler Metals_ _ _ _ _ _ _ _

Weld Metal: Thickness Range:

Groove_ _ _ _ _ _ _ _ _ _ _ Fillet_ _ _ _ _ _ _ _ _ _ _ _ Electrode-Flux (Class) _ _ _ _ _ _ _ Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _ Consumable Insert_ _ _ _ _ _ _ _ _ Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

1st Filler Metal 5.1 E-7018 3 1

3/32”, 1/8”, 5/16”

.0625” to 1.0”

.250” to 1.0” N/A N/A N/A

2nd Filler Metal

of 2 WPS No. JCP-P301 Rev.# 0






Weld Pass(es)

Process


Polarity

Amps (Range)



Volts (Range)




Angle, etc)

Classifi-cation

Diameter

All

SMAW

E-7018

1/8”

DCEP

70 to 200

N/A

N/A

19 - 25

5 to 7





Page 2 of 2





Joints (QW 402)











G D i f T C

QW 483 (back)

PQR No. JCP-PQ301



Thickness (inch)

Area (sq. inches)

Ultimate Load (lbs)





Type and Figure No. Results SIDE # 1 Pass SIDE # 2 Pass Face # 1 Pass Face # 2 Pass


Specimen No.

Notch Location

Notch Type

Test Temp

Impact Values




Other Tests


Page 2 of 2




Welder(s) Name Mr. Rod Burner Identification Number A11

Test Description

Identification of WPS followed WPS 101 Test Coupon Production Weld

Specification and Type/Grade or UNS Number of base metal(s) A 106B to A106B Thickness .280


Welding Variables (QW350) Actual Values Range Qualified

Welding Process(es) SMAW SMAW

Type (i.e. manual, semi-automatic) used Manual Manual

Backing (with or without) None F1 to F3 with,F3 wo

Test Coupon Production Weld (dia if pipe) 6” NPS __ 2 7/8” OD

Base metal P-Number to P-Number P-1 to P-1 P1-P15F, P34, P41-P49

Filler Metal or Electrode Spec (SFA) 5.1 -------

Filler Metal F-Number F 3 F1,F2, & F3

Consumable Insert (GTAW or PAW) N/A -------

Filler Metal Type (solid/metal or flux cored/powder) N/A -------


Process 1: SMAW 3 layers minimum Yes No .280” .560

Process 2: 3 layers minimum Yes No ---- -------

Position qualified (1G,2G,3G,4G,5G,6G, etc) 2G F, H

Vertical progression (uphill or downhill) Uphill Uphill

Inert Gas Backing (GTAW, PAW, GMAW) N/A -------

GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit) N/A -------

GTAW Current type/polarity (AC,DCEP,DCEN) N/A -------

RESULTS

Visual examination of completed weld (QW 302.4) Acceptable

Transverse face and root bends (QW 462.3(a) Longitudinal bends (QW 462.3(b) Side bends (QW 462.2)


Face No defects – Acceptable

Root No defects - Acceptable

Alternative Volumetric Examination Results (QW 191) N/A RT or UT

Fillet weld – fracture test (QW 181.2) N/A Length and percent of defects N/A


Other tests


Mechanical tests conducted by Ben Tension Laboratory test no. 123 Welding supervised by Red Eye


requirements of Section IX of the ASME Code. Organization Worlds Best Fabricator

Date April 7, 2010 By John Doe



Company Name By Welding Procedure Specification No. Date Supporting PQR No.(s) Revision No. Date

Welding Process(es) Type(s)

TTest Description

Joints (QW 402) Joint Design Root Spacing Backing: Yes No Backing Material (Type) (Refer to both backing and retainers) Metal Nonfusing Metal Nonmetallic Other Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified. (At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)). BBase Metals (QW 403) P-No. Group No. to P-No. Group No. OR Specification and type/grade to Specification and type/grade OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop. Thickness Range: Base Metal: Groove Fillet Maximum pass thickness ≤ ½” (yes) (no) FFiller Metals (QW 404) Spec. No. (SFA) _ _ _ _ _ _ _ _ _ AWS No. (Class) _ _ _ _ _ _ _ _ _ F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ Size of Filler Metals_ _ _ _ _ _ _ _ Filler Metal Product Form_ _ _ _ _ Weld Metal: Thickness Range: Groove_ _ _ _ _ _ _ _ _ _ _ Fillet_ _ _ _ _ _ _ _ _ _ _ _ Electrode-Flux (Class) _ _ _ _ _ _ _ Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _ Consumable Insert_ _ _ _ _ _ _ _ _ Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

1sst FFiller Metal

2nnd Filler Metal

Page 1 of 2

WPS No. Rev.# PPositions ((QW 405)) Position(s) of Groove Welding Progression: UP Down Position(s) of fillet

PPostweld Heat Treatment ((QW 407)) Temperature Range Time Range Other

PPreheat ((QW 406)) Preheat Temp, Min Interpass Temp, Max Preheat Maintenance (Continuous or special heating, where applicable, should be recorded.

GGas ((QW 408)) Percent Composition Gases Mixtures Flow Rate Shielding Trailing Backing Other

EElectrical Characteristics (QW 4099)

Weld Pass(es)

Process


Polarity

Amps (Range)



Volts (Range)




Angle, etc)

Classifi-cation

Diameter


Pulsing Current Heat Input (max.) Tungsten Electrode Size and Type (Pure Tungsten, 2% Thoriated, etc)

Mode of Metal Transfer for GMAW or FCAW (Spray Arc, Short Circuiting Arc, Globular Arc, etc)

Technique (QW 410) String or Weave Bead Orifice, Nozzle, or Gas Cup Size Initial and Interpass cleaning (Brushing, Grinding, etc Method of Back Gouging Oscillation Contact Tube to Work Distance Multiple or Single Pass (per side) Multiple of Single Electrodes Electrode Spacing Peening Other

Page 2 of 2

ASME Section IX – PQR

QW-483 Suggested Format For Procedure Qualification Record (PQR)(See Section IX QW-200.2)

Company Name PQR No. WPS # Date

Welding Process(es) Type(s)

Joints (QW 402)


Base Metals (QW 403) Material Spec. P-No. to P-No. Thickness of Test Coupon Diameter of Test Coupon Other

Postweld Heat Treatment (QW 407) Temperature Range Time Range Other


Gases Mixtures Flow Rate Shielding N/A Trailing Backing

Filler Metals (QW 404) SFA Specification AWS Classification Filler Metal F-No. Weld Metal Analysis A-No. Size of Filler Metal Other

Weld Metal Thickness

Electrical Characteristics (QW 409) Current Polarity Amps: Volts Tungsten Electrode Size Other


Technique (QW 410) Travel Speed String or Weave Bead Oscillation Multipass or Single Pass (per side) Single or Multiple Electrodes Other

Preheat (QW 406) Preheat Temp 50oF Interpass Temp None Other

.375"

QW 483 (back)

PQR No.



Thickness (inch)

Area (sq. inches)

Ultimate Load (lbs)




Type and Figure No. Results


Specimen No.

Notch Location

Notch Type

Test Temp

Impact Values




Other Tests


Welder’s Name Clock No. Stamp No. Test conducted by: Laboratory Test No.


Manufacturer

Date By:

Page 2 of 2




Welder(s) Name Identification Number

TTest Description

Identification of WPS followed Test Coupon Production Weld

Specification and Type/Grade or UNS Number of base metal(s) Thickness


Welding Variables (QW350) AActual Values Range Qualified

Welding Process(es)

Type (i.e. manual, semi-automatic) used

Backing (with or without)

Test Coupon Production Weld (dia if pipe)

Base metal P-Number to P-Number

Filler Metal or Electrode Spec (SFA)

Filler Metal F-Number

Consumable Insert (GTAW or PAW)

Filler Metal Type (solid/metal or flux cored/powder)


Process 1: 3 layers minimum Yes No

Process 2: 3 layers minimum Yes No

Position qualified (1G,2G,3G,4G,5G,6G, etc)

Vertical progression (uphill or downhill)

Inert Gas Backing (GTAW, PAW, GMAW)

GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit)

GTAW Current type/polarity (AC,DCEP,DCEN)

RESULTS

Visual examination of completed weld (QW 302.4)

□ Transverse face and root bends (QW 462.3(a) Longitudinal bends (QW 462.3(b) Side bends (QW 462.2)


Alternative Volumetric Examination Results (QW 191) RT or UT

Fillet weld – fracture test (QW 181.2) Length and percent of defects


Other tests


Mechanical tests conducted by Laboratory test no. Welding supervised by


requirements of Section IX of the ASME Code. Organization

Date By

api 510 booklet

Engineering