asme ix presentation summary oct 2007
TRANSCRIPT
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API 510 Pressure Vessel Inspector Certification Course.
Venezuela October 2007.
Review ASME Section IX
The main key is:
“Keep separate variables for
Procedure and Performance”
INTRODUCTION …
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Section IX Relates To :
Qualification Of:
Welders
Welding Operators
Brazers
Welding/Brazing Procedures
Who Are Employed In Welding & Brazing In Accordance
With ASME BOILER & Pressure Vessel Code / API Code and Standards.
INTRODUCTION …
Welding Identified As QW
Brazing Identified As QB (no in the BOK)
What Does The Q Signify ?
The Two Parts Are Further Divided Into Four Articles
General Requirements
Procedure Qualification
Performance Qualification
Data
The Section Is Divided Into Two Parts:INTRODUCTION …
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Weld Deposit Material Properties Are Controlled Through – Procedure Qualification.
Welder Skill Is Controlled Through – Performance Qualification.
An Understanding of Essential, Non-Essential And Supplementary Essential Variables Is Required.
INTRODUCTION …
INTENTIONALLY Essentials, non-Essentials and Essentials Supplementary variables are not discussed now, but we will need talk about it forward…
INTRODUCTION …
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WELDING PROCESS …
INTRODUCTION …
SMAW – SHIELDED METAL ARC WELDING
INTRODUCTION …
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GMAW – GAS METAL ARC WELDING
INTRODUCTION …
GTAW – GAS TUNGSTEN ARC WELDING
INTRODUCTION …
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SAW – SUBMERGED ARC WELDING
INTRODUCTION …
INTRODUCTION …
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ARTICLE I. GENERAL REQUIREMENTS …
PART QW WELDING
ARTICLE I - WELDING GENERAL REQUIREMENTS
QW-100.1 A welding procedure is a written document that provides direction to the welder or welding operator for making production welds.
When prepared by the manufacturer or contractor, it must address, as a minimum, the specific variables, both essential and nonessential, as provided in Article II. When notch toughness is required the applicable supplementary essential variables must be addressed in the WPS.
The Procedure Qualification Record (PQR) documents what occurred during welding of the test coupon and the results of testing of the coupon:
As a minimum the PQR shall document the essential variables and other specific information identified in Article II. When notch toughness is required the applicable supplementary essential variables shall be recorded.
WPS's, PQR's and WPQ's made in accordance with the 1962 Edition or any later edition may be used in any construction built to the ASME B&PV Code or the ASME 831 Code for Pressure Piping.
WPS's, PQR's and WPQ's made in accordance with Editions prior to 1962 may be used if all the requirements of the 1962 Edition or later Editions are met.
WPS's and WPQ's meeting the above requirements do not need to be amended to include any variables required by later 'Editions or Addenda.
Qualification of new WPS's or WPQ's and requalification of existing WPS's and WPQ's shall be in accordance with the current Edition and Addenda of Section IX.
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Important Points QW-103
Manufacturer/Contractor Is Responsible For Welding
He MUST Conduct Tests To Qualify Welding Procedure And Welders/Welding Operators.
Test Results MUST be kept by Manufacturer/Contractor
MUST Be Certified By Manufacturer/Contractor
What Constitutes Certification ?
ARTICLE I. RESPONSIBILITY …
“READ 04 EDT & ADD-05 - 06”
QW-120 To QW-132 WITH GRAPHICS IN QW-461 REFER.ARTICLE I. WELDING POSITIONS …
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IF YOU QUALIFY ON GROOVES DO YOU STILL HAVE
TO QUALIFY ON FILLETS ?
DOES THE REVERSE APPLY ?. (see table QW-451.4)
THEN IS BAD IDEA QUALIFY USING FILLETS
Mechanical Tests (Destructive)
Tension Tests:
Guided Bend Tests:
Fillet Weld Tests:
Notch Toughness Tests:
Stud Weld Tests:
ARTICLE I. QW-140 TYPES & PURPOSE OF TEST …
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Specimen Ruptured Under Tensile Load
ARTICLE I. TENSILE TESTS …
Maximum Load
Minimum Cross Sectional Area
Width x Thickness = Cross Sectional Area
i.e. 0.500” Wide x 0.265” Thick
Locate Dimensions Of A Sample – QW 462.1 (a)
ARTICLE I. “DOG BONE SAMPLES” (HUESO DE PERRO) …
Tensile Strength =
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Cross Sectional Area Is
πr2 Where
r = Radius Of Specimen
Be Cautious Code Sets Tolerance On Machined Specimens – QW-462.1 (d)
ARTICLE I. TURNED SAMPLES …
QW153.1
Minimum Of Weakest Base Metal
Can Be 5% Under If Breaks In Base Metal.
Tensile Strength Is Laid Out In Code.
Where Find Now: QW 422
ARTICLE I. TENSION TEST ACCEPTANCE …
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Contained In Tables Under QW/QB-422
Base Metals Are Grouped Based On Characteristics,
Composition, Weldability, Mechanical Properties.
Additionally Group Numbers Are Assigned Where Notch
Toughness Is Required.
This Saves A Large Number Of PQR Tests.
ARTICLE I. P. NUMBERS …
T1= 0.285 x 0.748 What Is CSA?
If It Fails At 17821 Lbs What is Tensile Strength?
If It Fails In Weld Metal And Material Is A-139
Gr.A Has It Passed?
If the Failure Is In The Base Metal Has It Passed?
ARTICLE I. SOLVE …
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T1= 0.495” Diameter What Is CSA?
If It Fails At 20921 Lbs What is Tensile Strength?
If It Fails In Weld Metal And Material Is
SA-182 Gr.F55 Has It Passed?
If the Failure Is In The Base Metal Has It Passed?
ARTICLE I. SOLVE …
Dimensions As Code QW-160 refer to QW-466.X:
Caution – Type Of Tests Based On Thickness Of Sample.
Multiple Samples For Thick Sections.
Bent through 180 Degrees On Jig As Per Code
ARTICLE I. GUIDED BEND TEST …
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Acceptance Criteria (QW-163):
The Weld & Heat Affected Zone Must Be Within The Bent Area.
No Open Defects In Weld Or HAZ Exceeding 1/8” In Any Direction.
Open Defects At Edge Shall Be Discarded Unless There Is Clear Evidence Of Welding Defect.
For Corrosion Resistant Cladding No Defect Exceeding 1/8” On Bond Line Or 1/16” Elsewhere.
ARTICLE I. GUIDED BEND TEST …
Charpy V Notch Test In Accordance With SA-370
Acceptance Standards Are Complex And Will Be Covered Under ASME Section VIII / API-653, ETC.
Drop Weight Tests May be Required By Other Sections
10 mm
50 mm
ARTICLE I. QW-170. NOTCH TOUGHNESS TESTS
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Be Aware That There Are Requirements For:
Fillet Weld Bends & Fracture Tests
Macro Etch Examinations
ARTICLE I. OTHER MECHANICAL TESTS …
ARTICLE I. QW-190 …
QW-190 OTHER TESTS AND EXAMINATIONS
Radiographic ExaminationRequirements of Article 2, Section V to be used. Written procedure not required nor is personnel qualification required.
Radiographic Acceptance CriteriaAcceptance criteria for welders and welding operators performance tests of welds in test assemblies.
QW-191 READ THE CODE BOOK NOW
QW-191.2.3 Production Welds
The acceptance standard for welding operators who qualify on production welds shall be that specifiedin the referencing Code Section.
The acceptance standard for welders who qualify on production welds shall be per QW-191.2.2.
QW-194 Visual Examination – Performance
Performance coupons shall show complete joint penetration with complete fusion of weld metal and base metal.
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QW-192 TEN TESTS PER PROCEDURE
FIVE HAMMERED FLAT - 1/4 OF LENGTH OR 15% ANGLE AND STRAIGHTENED
FIVE TORQUE TESTED OR TENSILE TESTED
TORQUE AS PER QW-192.3
TENSILE MUST MEET 35000 - 30000 PSI
FOR PERFORMANCE FIVE STUDS HAMMERED FLAT
MUST SHOW NOR CRACKING OR LACK OF FUSION.
ARTICLE I. QW-192 STUD WELD TEST…
PQR – Procedure Qualification Record
WPS – Welding Procedure Specification
WPQ – Welder Performance Qualification Record
ARTICLE I. THREE CRITICAL DOCUMENTS …
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ARTICLE II. WELDING PROCEDURE
QUALIFICATIONS…
QW-200-1 WPS WELDING PROCEDURE
SPECIFICATION
Written Directions For The Welder/Welding Operator
Making Production Welds Describing All Variables Involved.
Describes All Essential, Non Essential And When Required
Supplementary Variables Listed In QW-250 Thru. QW-280
ARTICLE II. QW-201 WPS. WELDING PROCEDURE SPECIFICATION…
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Essential Variable - Change Affecting Mechanical Properties -Requires Specification Re-qualification
Supplementary Essential Variable - Change Affecting Notch Toughness Properties - Requires Specification Re-qualification
Non Essential Variable - Does Not Affect Mechanical or Notch Toughness- Re-qualification Not Required.
ARTICLE II. QW-201 WPS. VARIABLES…
Essential Variable For One Process May Be Non Essential For Another - Work The Tables.
Non Essential Variable Can Be Changed Without Re-qualification But Must Be Recorded On A New Or Amended WPS Form.
WPS form May Be In Any Format As Long As All Information is Covered.
WPS Must Be Available For Reference And Review By The AI.
ARTICLE II. QW-201 WPS. VARIABLES…
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A Record Of What Actually Occurred During Welding And The Subsequent Mechanical Tests.
Intent Is To Determine That the Required Mechanical Properties Can Be Achieved.
All Variables In the WPS MUST Be Followed.
Base Metal Used In The Test Can Be In Any Form -Qualification Is Transferable Between Plate & Pipe.
All Essential And Supplementary Essential Variables Must Be Recorded.
Any Non Essential Variables Can be Recorded At A Later Date.
ARTICLE II. QW-202 PQR. PROCEDURE QUALIFICATION RECORD…
Any Variables Recorded MUST Be The Actual Variable.
Variables Not Recorded MUST NOT Be Recorded.
If More Than One Process Or Filler Metal Is Employed RECORD The Approximate Deposit Thickness.
CHANGES
Are Not Allowed Except For Editorial Mistakes And Then Must Be Certified.
PQR MUST Be Certified Accurate By Manufacturer/Contractor.
ARTICLE II. QW-202 PQR. PROCEDURE QUALIFICATION RECORD…
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QW-201 Manufacturer's or Contractor's Responsibility
Each manufacturer or contractor shall qualify the WPS by the welding of test coupons and the testing of specimens and, the recording of the welding data and test results in a document known as a PQR.
The welders or welding operators used to produce weldments to be tested for qualification of procedures shall be under the full supervision and control of the manufacturer or contractor during the production of these test weldments.
The weldments to be tested for qualification of procedures shall be welded either by direct employees or by individuals engaged by contract for their services as welders or welding operators under the full supervision and control of the manufacturer or contractor.
FROM QW-202.2 (b) PQR MUST Be Certified Accurate By Manufacturer/Contractor.
WHAT HAPPEN WITH AWS-CWI?
ARTICLE II. QW-202 PQR. PROCEDURE QUALIFICATION RECORD…
Format May Be Any As Long As Required Information Is Present.
PQR Must Be Available To The AI But Does Not Have To Be Available To The Welders.
More Than One WPS Can Be Prepared From The Same PQR.
One WPS May Cover Multiple Essential Variable Changes Providing The PQR Exists For All Essential & Supplementary Variables.
More Than One PQR Can Be Used to Prepare The Same WPS.
See example for WPS’s from one PQR
ARTICLE II. QW-202 PQR. PROCEDURE QUALIFICATION RECORD…
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ARTICLE II. QW-211. BASE METALS…
QW-211 Base Metal
The base metals may consist of either plate, pipe, or other product forms. Qualification
in plate also qualifies for pipe welding and vice versa.
Read now from codebook…
Source Of Guidance On Which Variable Apply To Which Process.
Which Are Essential, Non Essential & Supplementary Essential.
Know How To Find And Use These Tables :-
ARTICLE II. QW-250. VARIABLES PER EACH PROCESS…
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QW-250 WELDING VARIABLES
QW-250.2 Essential Variables
Essential variables are those in which a change, as described in the specific variables, is considered to affect the mechanical properties of the weldment, and shall require requalification of the WPS.QW-251.3
QW-250.3 Nonessential Variables
Nonessential variables are those in which a change as described in specific variables, may be made in the WPS without requalification.
WELDING VARIABLES PROCEDURE SPECIFICATIONS (WPS)
QW-253 Shielded Metal-Arc (SMAW)
QW-254 Submerged-Arc Welding (SAW)
QW-255 Gas Metal-Arc Welding (GMAW and FCAW)
QW-256 Gas Tungsten-Arc Welding (GTAW)
ARTICLE II. QW-250. VARIABLES PER EACH PROCESS…
ARTICLE III. WELDING PERFORMANCE
QUALIFICATIONS…
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Qualification Of The Man.
Limited By Essential Variable For Each Process – Different From Procedure Qualification – QW-352 Onwards
Visual Examination Always Required.
Qualification By:
Guided Bend Tests Of Test Coupon
Radiography Of – Test Coupon or
First Production Weld
ARTICLE III. Welding Performance Qualifications…
ARTICLE III
WELDER PERFORMANCE QUALIFICATIONS
QW- 300 GENERAL
QW-301.1 A welder or welding operator may be qualified by radiography of a test coupon, radiography of his initial production welding, or by bend tests taken from a test coupon except as stated in QW-304 and QW-305.
QW-300.2 The welders or welding operators used to produce such weldments shall be tested under the full supervision and control of the manufacturer, contractor, assembler, or installer during the production of these test weldments.
QW-301 Tests
QW-301.1 Intent of Tests
The performance qualification tests are intended to determine the ability of welders and welding operators to make sound welds.
Qw-301.2 Qualification Tests
The performance qualification shall be welded in accordance with qualified WPS's. Identification of Welders and Welding Operators
ARTICLE III. Welding Performance Qualifications…
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Manufacturer/Contractor MUST Conduct Tests To Qualify Welders
ARTICLE III. QW-300.2…
More than one manufacturer/contractor conducting only one tests for qualification procedure
Reading Carefully
Performance Tests Must Be Done To A Qualified WPS.
Welder Who Prepares The WPS Qualification Test
Coupon is Qualified Within Those Limitations (If It
Passes).
Caution It May Limit His Range Of Qualification
ARTICLE III. QW-301..2…
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Each Welder Must Be Assigned Unique Identification.
Identify All Work With This.
Does Not Have To Hard Stamp!!!
ARTICLE III. QW-301.3. Identification Of Welders…
WPQ Must Record:
Essential Variables
Type Of Test
Test Results
Range Qualified
ARTICLE III. QW-301.4. Record Of Tests…
QW-301.4 Record of Tests
The record of Welder/Welding Operator Performance Qualification (WPQ) tests shall include the essential variables (QW-350 or QW-360), the type of test and test results, and the ranges qualified in accordance with QW-452 for each welder and welding operator.
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Shall Pass Mechanical And Visual Requirements.
Qualification Using Radiography
Allowed Using: SMAW, SAW, GTAW, PAW
GMAW Except in Short
Circuiting Mode
Except P-21 Through P-25, P-51 Through P-53 & P-61, P-62 Materials.
P-21Through P-25, P-51 Through P-53 Using GTAW Are Allowed.
ARTICLE III. QW-304. Welders …
Test Coupons:
Mechanical (Bend ) Tests Or Radiography.
If Qualified On Production Weld:
Radiography Of First 6” Of Weld (for welder)
ARTICLE III. QW-304.1 Welders Examination…
QW-304.1 Examination
Welds made in test coupons may be examined by visual and mechanical examinations, or by radiography.
Alternatively a 6 in. length of the first production weld made by a welder may be qualified by radiography.
Acceptance criteria? QW-191.2.2
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If Radiography On A Production Weld Is Unacceptable
Then The Welder Has Failed.
Entire Production Weld Must Then Be Radiographed And
Repaired By A Qualified Welder.
ARTICLE III. QW-304.1 Welders Examination…
Welding Operators:-What is Difference?
ARTICLE III. QW-305 Welding Operators…
Much The Same Rules Apply However:
If Qualifying By Radiography On Production Weld The
First Three Feet Of Weld Must be Examined.
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A Welder Or Operator Who Fails May Be Retested.
If Fails Visual – Shall Make Two Consecutive Test Coupons And Then Pass Visual & Mechanicals.
If Fails Mechanicals – Shall Make Two Consecutive Test Coupons And Then Pass Mechanicals.
If Fails Radiography –
Coupons Make Two 6” Inch Plates Or Two pipes Totalling 12” Of Weld. Small Diameter Pipe Need Not Exceed Eight Pipes.
ARTICLE III. QW-320 Retest and Renewal of Qualification…
If Production Weld Fails Radiography:
Radiograph 12” Of Same Production Weld. If Passes He Is Qualified And Can Repair the Earlier Failed Part. If Not He Has Failed.
Welding Operator - Radiograph 6’ Of Weld.
This is The Two For One Rule.
ARTICLE III. QW-320 Retest and Renewal of Qualification…
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Renewal & Expiration of Qualifications.
Expires If Does Not Weld for Six Months or
Ability is Questioned.
Expired Qualifications May Be Renewed By Welding One Test Coupon And Successfully Testing.
Renewal May Be Done On Production Work.
Revoked Qualifications Must Be Tested On A Test Coupon.
ARTICLE III. QW-322 Expiration & Renewal of Qualifications…
ARTICLE III. QW-350 Welding Variables for Welders…
QW-350 WELDING VARIABLES FOR WELDERS
QW-351 General
A welder shall be requalified whenever a change is made in one or more of the essential variables listed for each process in QW-352 thru QW-357.In any given production weldment, welders may not deposit a thickness greater than permitted by QW-452 for each welding process in which they are qualified.
QW-360 WELDING VARIABLES FOR WELDING OPERATORS
QW-361 General
A welding operator shall be requalified whenever a change is made in one of the essential variables listed for each process in QW-361.1 or QW-361.2.
Check out tables from QW-350 / QW-360 from codebook…
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ARTICLE IV. WELDING DATA…
ARTICLE IV. Welding Data
QW-400 VARIABLES
These are the complete wording of the variables that are listed under "Brief of Variables" in the checklists QW-252 thru QW-264.
When answering any questions regarding the WPS/PQR combination it is very important to read each of the required variables before answering any questions.
QW-422 FERROUS P-NUMBERS AND S-NUMBERS
Grouping of Base Metals for Qualification
This is a listing of all the SA and SB base metal specification numbers in ascending order which are used to determine the minimum specified tensile strength and P-No's of the. base metals shown on the PQR.
QW-423 Alternate Base Metals for Welder Qualification
Base material used for welder qualification (Column 1) may be substituted for the P-Number material specified in the WPS (Column 2) .
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QW-424 Base Metals Used for Procedure Qualification
Base metals used for the Procedure Qualification (Column 1) qualify the base metals listed in (Column 2).
Note that qualification using one P-No. to the same P-No. may permit the welding of that P-No. to other lower P-No's.
QW-432 F-NUMBERS
Grouping of Electrodes and Welding Rods by Qualification
For the API Examination we are only interested in F-No's 1 thru 6 Steel and Steel Alloys with their corresponding ASME Specifications and A WS Classifications.
QW-433 Alternate F-Numbers for Welder Performance Qualification
This Table identifies the filler metal or electrode F-Number used during qualification testing as "Qualified With" and the electrode or filler metal that the welder is qualified to use in production as "Qualified For". This Table is referenced from Welding Data Variable QW-404.15.
Note that although a welder who qualifies on a higher F-Number without backing is also qualified to weld lower F-Numbers, he/she are not permitted to weld without backing for the lower F-Numbers.
ARTICLE IV. Welding Data
QW-442 A-NUMBERS
Classification of Ferrous Weld Metal Analysis for Procedure QualificationThis Table is used to identify the weld metal chemical composition designated on the PQR and WPS per QW-404.5 for ferrous weld metal deposits.
NOTE: For GMAW a weld metal deposit analysis from the PQR may be required if the shielding gas used to weld the procedure qualification test coupon was not the same used by the SFA Specification.
QW-450 SPECIMENS
QW-451 Procedure Qualification Thickness Limits and Test Specimens
QW-451.1 GROOVE WELD TENSION TESTS AND TRANSVERSE-BEND TESTS
This Table is used each time the thickness range T of base metals qualified and maximum thickness t of deposited weld metal on the WPS is being verified based on the thickness T of the test coupon welded during PQR qualification.
The Table also shows for the thickness T of the test coupon welded, the number of tension tests required and the type and number of bend tests required.
It is also important to read the applicable notes as there may be permitted variations in the thickness limits and types of test specimens.
ARTICLE IV. Welding Data
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ARTICLE IV. Welding Data
QW-452 Performance Qualiificati.on Thickness Limits and Test Specimens
QW-452.1 TRANSVERSE-BEND TESTS
This table is used to determine the maximum thickness of deposited weld metal qualified for a welder or welding operator.
Note that the 2000 addenda reduced the deposited weld metal thickness from 3/4 in. to 1/2 in. to give the welder/welding operator the maximum to be welded qualification. Also a minimum of three layers must be deposited.
QW-452.3 GROOVE WELD DIAMETER LIMITS
In order for a welder/welding operator to weld small diameter pipe/tube this table is used to determine the outside diameter of the test coupon.
This Table in conjunction with QW-461.9 is used to determine performance position and diameter limitations.
QW-461.9 PERFORMANCE QUALIFICATION - POSITION AND DIAMETER LIMITATIONS
Extremely important that this Table be thoroughly understood and unfortunately to be memorized since recent API Examinations have had questions taken from it in the closed book portion of the examination.
ARTICLE IV. Welding Data
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QW-463 Test Specimens
Unless a minimum, maximum, or tolerance is given in the figures, the dimensions are to be considered approximate.
QW-462.1(a) TENSION - REDUCED SECTION – PLATE
Width of specimen regardless of thickness is 3/4 in.
QW-462.1(b) TENSION - REDUCED SECTION – PIPE
Width of specimen regardless of thickness is 3/4 in.
QW-462.1(c ) TENSION - REDUCED SECTION - ALTERNATE FOR PIPE
Per QW-151.2 pipe having an outside diameter of 3 in. or less may use this alternate reduced section specimen which has a width of 1/2 in.
TENSION - REDUCED SECTION - TURNED SPECIMENS
These are round specimens that come in four different diameters.
NOTE: The C dimension or grip end for each of the four specimens is larger than the diameter D. It is therefore not possible to obtain. as an example. a 0.505 in. diameter specimen from less than 3/4 in. thick plate because the grip end is 0.750 in.
ARTICLE IV. Welding Data
ARTICLE IV. Welding Data. QW-461.9
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QW-462.2 SIDE BEND
Dimensions for side bend specimens
QW-462.3(a) FACE AND ROOT BENDS – TRANSVERSE
Dimensions of face and root bend specimens.
These are the only ones covered by the API Examination.
QW-463 Order of Removal
The following are the order of removal sketches that must be followed by those organizations that prepare the test specimens for procedure and performance qualification.
QW-463.1(a) PLATES - LESS THAN 3/4 in. THICKNESS PROCEDURE QUALIFICATION
QW-463.1(b) PLATES -3/4 in. AND OVER THICKNESS AND ALTERNATE FROM 3/8 in. BUT LESS THAN 3/4 in. THICKNESS PROCEDURE QUALIFICATION
QW-463.1(d) PROCEDURE QUALIFICATION PIPE UP TO 3/4 in. THICKNESS
QW-463.1(e) PROCEDURE QUALIFICATION PIPE 3/4 in. AND OVER THICKNESS
QW-463.2(a) PLATES - LESS THAN 3/4 in. THICKNESS PERFORMANCE QUALIFICATION
ARTICLE IV. Welding Data
QW-463.2(b) PLATES –3/4 in. AND OVER THICKNESS AND ALTERNATE FROM 3/8 in. BUT LESS THAN 3/4 in. THICKNESS PERFORMANCE QUALIFICATION
QW-463.2(d) PERFORMANCE QUALIFICATION PIPE UP TO 3/4 in. THICKNESS
QW-463.2(e) PERFORMANCE QUALIFICATION PIPE 3/4 in. AND OVER THICKNESS
QW-463.2((f) PIPE-10 in. ASSEMBLY PERFORMANCE QUALIFICATION
QW-463.2(g) 6 in. OR 8 in. ASSEMBLY PERFORMANCE QUALIFICATION
QW-490 DEFINITIONS
These are definitions related to welding/brazing and may be helpful in answering some questions.
ARTICLE IV. Welding Data