WELDING QUALIFICATIONBy L D Poyyara

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

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Welding QualificationsQualification Requirements For Equipments to be Made as per ASME Boiler & Pressure Vessel Code

ASME Sec IX + Applicable Design Code (Sec.VIII Div I or II, Sec. I, Sec. III)

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Welding QualificationsWelding Procedure Qualification

Welders or Welding Operators Performance Qualification

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Welding Procedure QualificationProves the Quality & Properties of Weld Joint Prepared by a set of welding variables

Welding Process Base MaterialWelding consumableWelding Parameters & Techniques ( Position, Polarity, Preheat, Inter Pass Temp. Back Gouging--)PWHTQualification limited to the essential variables of the Specific Process

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Welding Performance QualificationAscertain the skill of a welder or a welding operator to Produce defect free/Sound weld

Makes A Weld Coupon Using an Approved WPS of a Qualified Procedure.Weld Coupon Undergoes Soundness TestEach Qualified Welder Shall be Assigned by A Unique Welder Number Welders Qualifications Records Are DocumentedPerformance Qualification limited to the essential variables of the Specific Process

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How To Qualify Groove Butt Weld Procedure?1) Read & Understand ASME Sec. IX

- Welding Data - Essential, Non Essential & Supplementary Essential Variables. - Test Requirements - Testing ProceduresASME Sec.II Part C.

Classification of Welding Consumable -Properties of Consumables

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How To Qualify Groove Butt Weld Procedure?2) Write A Welding Procedure Specification WPS - WPS Provides Direction for A Specific Welding - WPS Shall Include All Essential, Supplementary Essential & Non Essential Variables - WPS Format Available in ASME Sec. IX. - Each WPS Shall be Assigned with A Unique Number.

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How To Qualify Groove Butt Weld Procedure?3) Prepare A Test Coupon As Per WPS - Coupon Size: Pair of 300 mm X 150mm Plate Or as Specified in WPS - All Other Details as per Written WPS -Complete the Welding by Reasonably Skilled Welder - All Welding Variables Shall be Used Within the Limit Specified in WPS. - All Variables Actually Used Shall be Documented as Annexure to PQR ( Procedure Qualification Record)

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How To Qualify Groove Butt Weld Procedure?4) NDT Of Weld Coupon - Optional - X-Ray / Radiograph the Weld Joint ( Not a Code Requirement ) -Mark Transverse Tensile & Guided Bends As Per QW461 - Eliminate Defective Weld Portion If Any, While Marking the Test Specimens -Preserve RT Report & X-Ray Film as Annexure to PQR

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How To Qualify Groove Butt Weld Procedure?5) Mechanical Tests Qw 451, Groove Weld. Up to 9 mm Thickness

- Transverse Tensile : 2No -Root Bend :- 2No - Face Bend :- 2NoOver 9 mm Thickness

Transverse Tensile :- 2NoSide Bend :- 4No

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How To Qualify Groove Butt Weld Procedure?6) Acceptance Criteria for Test Results. Tensile Strength (Qw / QB-422)

- Minimum Tensile Strength of Material Used Bend Test (Qw 163)

Opening Not More Than 3.2 mm in Any Direction on Convex Surface Within the Weld & HAZ

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How To Qualify Groove Butt Weld Procedure?7) PQR Procedure Qualification Record - PQR Format Available in Sec. IX - Record All Relevant Data in the Format. -Record All Mechanical Test Results -Attach All Test Reports & Welding Parameters Used as Annexure to PQR -Assign Unique Number to Each PQR -WPS No Shall be Referred in PQR

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Qualified WPSA WPS Remains Qualified When

A Procedure Qualification Coupon Is Welded As Per WPSAll Mechanical Tests of The Coupon Are CompletedAll Test Results Are Within The Acceptable Limit AndThe Supporting PQR No Is Referred In The WPS

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Thickness Limit For Groove Butt Weld Procedure.

Thickness T Of Test Coupon Welded in mmRange Of Thickness T of BM Qualified in mmThickness tof Deposited Weld metal Qualified in mmMiniMaxMaxLess Than 1.6 (1/16)T2T2t1.6 to 10 (1/16 to )1.5 (1/16) 2T2t10 to 19 ( to )5 (3/16)2T2t19 to 38 ( to 1 )5 (3/16)2T2t When t < 1919 to 38 ( to 1 )5 (3/16)2T2T When t 1938 (1 ) and over5 (3/16)200 ( 8 )2t When t < 1938 (1 ) and over5 (3/16)200 ( 8 )200 When t 19

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Procedure Qualification - QW-253SMAW Variable

Group of VariablesBrief Of Variables EssentialSupplementary EssentialNonessential QW 402JointsChange in Groove Design------*Addition / Deletion of Backing------*QW 403Base MetalsChange in group Of P No---*---T Limits Impact---*---T/t Limits 203 mm*------Change in T Qualified*------t pas 13 mm*------Change of P Number Qualified*------QW 404Filler MetalsChange in F No*------Change in A No*------Change in Dia------*Change in Dia 6 mm---*---Change in AWS classification---*---Change in t qualified*------

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Procedure Qualification - QW-253SMAW Variable

Group of VariablesBrief Of Variables EssentialSupplementary EssentialNonessential QW 405PositionsAddition of Position------*Change in Position---*---QW 406PreheatDecrease 56C*------Increase 56C IP---*---QW 407 PWHTAddition / Deletion of PWHT*------Change in Time & Temp. Qualified---*---QW 409Electrical CharacteristicsIncrease in Heat Input ---*---Change in Current / Polarity---*---Change in Current / Voltage------*QW 410TechniqueChange from String / Weave------*Method of Cleaning------*Method of Back Gouging------*Change From Multiple to Single Pass---*---

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Procedure Qualification - QW-254SAW Variable

Group of VariablesBrief Of Variables EssentialSupplementary EssentialNonessential QW 402JointsChange in Groove Design------*Addition / Deletion of Backing------*QW 403Base MetalsChange in group Of P No---*---T Limits Impact---*---T/ t Limits 203 mm*------Change in T Qualified*------t pas 13 mm*------Change of P Number Qualified*------QW 404Filler MetalsChange in F No*------Change in A No*------Change in Dia------*Change in Wire & Flux Combination*------Change in Alloyed Flux*------

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Procedure Qualification - QW-254SAW Variable

Group of VariablesBrief Of Variables EssentialSupplementary EssentialNonessential QW 404 Filler Metal Alloy Elements / supplemental Wire*------Change in Flux Type*------Change in t Qualified*------QW 405PositionsAddition of Position------*QW 406PreheatDecrease 56C*------Increase 56C IP---*---QW 407 PWHTAddition / Deletion of PWHT*------Change in Time & Temp. Qualified---*---T Limits*------QW 409Electrical CharacteristicsIncrease in Heat Input ---*---Change in Current / Polarity---*---Change in Current / Voltage------*

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Procedure Qualification - QW-256GTAW Variable

Group of VariablesBrief Of Variables EssentialSupplementary EssentialNonessential QW 402JointsChange in Groove Design------*Addition / Deletion of Backing------*QW 403Base MetalsChange in group Of P No---*---T Limits Impact---*---T / t Limits 203 mm*------Change in T Qualified*------Change From T Qualified*------Change From P Number Qualified*------QW 404Filler MetalsChange in F No*------Change in A No*------Change in AWS Classification ---*---Addition / Deletion of Filler*------Addition / Deletion of Consumable Insert-----* Change From Solid Flux / Powder Cored*------

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Procedure Qualification - QW-256GTAW Variable

Group of VariablesBrief Of Variables EssentialSupplementary EssentialNonessential QW 405PositionsAddition of Position------*Change in Position---*---QW 406PreheatDecrease 56C*------Increase 56C IP---*---QW 407 PWHTAddition / Deletion of PWHT*------Change in Time & Temp. Qualified---*---Change in T thickness Qualified*------QW 408 GasAddition / Deletion / Change in Trailing Gas------*Addition / Deletion / Change in Shielding Gas*-----Change in Flow Rate of Shielding / Backing Gas------*Deletion of Backing Gas*------

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Procedure Qualification - QW-256GTAW Variable

Group of VariablesBrief Of Variables EssentialSupplementary EssentialNonessential QW 409Electrical CharacteristicsIncrease in Heat Input ---*---Change in Tungsten Electrode Size------*Addition / Deletion of Pulsing------*Change in Current or Polarity---*---QW 410TechniqueChange in Nozzle / Gas Cup Size------*Method of Cleaning------*Change in Oscillation------*Method of Back Gouging------*Change From Single to Multi Electrode---*---Change From Closed Chamber to Out Side*------Change From Manual to Auto / Auto to Manual------*Addition or Deletion of Preening------*

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Procedure Qualification - QW-255GMAW & FCAW Variable

Group of VariablesBrief Of Variables EssentialSupplementary EssentialNonessential QW 402JointsChange in Groove Design------*Addition / Deletion of Backing------*QW 403Base MetalsChange in group Of P No---*---T / t Limits 200 mm*------Change From T Qualified*------When t in Single Pass 13 mm*------T Qualified Limit for Short Circ. Transfer*------Change From P Number Qualified*------QW 404Filler MetalsChange in F No*------Change in A No*------Change in AWS Classification ---*---Change from solid - Flux Cored / Powder Cored*------Addition / Deletion of Alloy Elements* ------t Qualified Limit for Short Circ. Transfer*------

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Procedure Qualification - QW-255GMAW & FCAW Variable

Group of VariablesBrief Of Variables EssentialSupplementary EssentialNonessential QW 405PositionsAddition of Position------*Change in Position---*---QW 406PreheatDecrease 56C*------Increase 56C IP---*---QW 407 PWHTAddition / Deletion of PWHT*------Change in Time & Temp. Qualified*------Change in T thickness Qualified*------QW 408 GasAddition / Deletion / Change in Trailing Gas------*Addition / Deletion / Change in Shielding Gas*-----Change in Flow Rate of Shielding / Backing Gas------*Deletion of Backing Gas*------

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Procedure Qualification - QW- 255 GMAW & FCAW Variable

Group of VariablesBrief Of Variables EssentialSupplementary EssentialNonessential QW 409Electrical CharacteristicsIncrease in Heat Input ---*---Change in Metal Transfer Mode*------Change in Wire feed & Voltage------*Change in Current or Polarity---*---QW 410TechniqueChange in Nozzle / Gas Cup Size------*Method of Cleaning------*Change in Oscillation------*Method of Back Gouging------*Change From Single to Multi Electrode---*---Change From Multiple to Single Pass per Side---*---Change From Manual to Auto / Auto to Manual------*Addition or Deletion of Preening------*

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P Number Grouping(Base Metal For Qualification)

P- NoGroup NoMet. Spec.GradeMet. Quality & FormP112SA 515 / SA 516 SA 515 / SA 51660 70CS Plate CS PlateP112SA 106 SA 106A / BCCS PipeCS - PipeP113SA333 SA 333610CS PipeCS - PipeP112SA 234SA 234WPBWPCCS Pipe FittingCS Pipe FittingP11SA 285C / BCS PlateP11SA 179 ---CS TubeP112SA 105SA 181---Cl 70CS ForgingCS Forging

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P Number Grouping(Base Metal For Qualification)

P- NoGroup NoMet. Spec.GradeMet. Quality & FormP323SA 302SA 302AB,C,DMn 0.5 Mo PlateMn 0.5 Mo PlateP31SA 335 P1 / P2C 0.5 Mo PipeP33SA 533 TP- B, Cl- 1 or 2C 0.5 Mo PlateP31SA 209T1, T1a, T1bC 0.5 Mo TubeP32SA 282F1C 0.5 Mo Forging

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P Number Grouping(Base Metal For Qualification)

P- NoGroup NoMet. Spec.GradeMet. Quality & FormP413SA 387SA 38712, Cl 1 / 211, Cl 1 / 21Cr. 0.5 Mo Plate1.25 Cr. 0.5 Mo PlateP41SA 335 P12 / P111Cr (1.25 Cr) 0.5 Mo PipeP42SA 423TP - 1 / 21.25 Cr. 0.5 Mo TubeP41SA 282SA 336F12, Cl- 1 / 2 F11, Cl 1 / 2 / 3 1. Cr 0.5 Mo Forging1.25 Cr 0.5 Mo Forging

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P Number Grouping(Base Metal For Qualification)

P- NoGroup NoMet. Spec.GradeMet. Quality & FormP5AP5B11SA 387SA 38722, Cl 1 / 25, Cl - 22. 25 Cr. 1 Mo Plate5 Cr. 0.5 Mo - PlatesP5A1SA 335 P22 2. 25 Cr. 1 Mo PipeP5A1SA 213TP - 222. .25 Cr. 1 Mo TubeP5BP5CP5A111SA 182SA 182SA 336F5 F22VF22, Cl 1 / 3 5 Cr 0.5 Mo Forging2. 25 Cr 1 Mo,V Forging2. 25 Cr 1 Mo Forging

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P Number Grouping(Base Metal For Qualification)

P- NoGroup NoMet. Spec.GradeMet. Quality & FormP62SA 240TP 42915Cr. PlateP64SA 731S4150013Cr., 4.5 Ni, Mo - PipeP61SA 268 TP41013Cr. TubeP63SA 336F613Gr. ForgingP72SA182F43017Cr. - ForgingP72SA 240 TP 43017Cr. - PlateP72SA 268TP43017Cr. TubeP72SA 731TP43918Cr., Ti Pipe

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P Number Grouping(Base Metal For Qualification)

P- NoGroup NoMet. Spec.GradeMet. Quality & FormP811SA 312SA 312TP321TP34718Cr., 10Ni, Ti - Pipe18Cr., 10Ni, Cb - PipeP811SA336 SA 336TP316TP31018Cr., 8 Ni, 2Mo -Forging25Cr., 20 Ni, ForgingP812SA 240SA 204TP304TP309S18Cr, 8Ni - Plates23Cr. 12Cr. - PlatesP811SA 249SA 249TP317TP316L18Cr, 13Ni, 3Mo Tube16Cr, 12Ni, 2Mo - Tube

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P Number Grouping(Base Metal For Qualification)

P- NoGroup NoMet. Spec.GradeMet. Quality & FormP9B1SA 33333.5Ni - PipeP9A1SA33472.5Ni - TubeP9AP9B11SA 350SA 350LF5, Cl. 2LF31.5Ni - Forging3.5Ni. - ForgingP9AP9B11SA 203SA 203AE2.5Ni. - Plate3.3Ni. - Plate

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P Number Grouping(Base Metal For Qualification)

P- NoGroup NoMet. Spec.GradeMet. Quality & FormP11A1SA 33389Ni - PipeP11A1SA33489Ni - TubeP11AP11A55SA 508SA 5084N, Cl. 25, Cl. 23.5Ni 1.75 Cr.-0.5Mo.- V, Forging3.5Ni 1.75 Cr.-0.5Mo.- V, ForgingP11AP11A44SA 533SA 533TP B, Cl. 3TP C, Cl. 3Mn, 0.5 Mo, 0.5Ni PlateMn, 0.5 Mo, 0.75Ni - Plate

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How To Qualify A Welder 1) Read ASME Sec. IX - Welding Performance QualificationsVariables For Different Processes QW 350Limits Of Positions Qualified & Dia QW 461Testing Requirements QW 304-1

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How To Qualify A Welder 2) Train The Welder For The Process To Be QualifiedWelder Shall Poses Adequate Skill In Performing the Process.He Shall have Necessary Knowledge In Operation Of Machine, Precautions In Storage & Usage Of Consumable, Defects In Welding, Their Causes And Remedy. He Shall Practice Welding In The Particular Position In Which He Is To Be Tested / Qualified

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How To Qualify A Welder 3) Preparation Of Test CouponPrepare A Test Coupon Out of 300 150 20 mm CS Plates Or As Per Applicable WPS.WEP ( Angle, Root Face & Root Opening ) Shall Be As Per The WPSProvide Run in & Run Out Coupon & Fix the Test Coupon In In Any One Of The Positions To Be Qualified. Weld The Groove Fully In The PositionAll Welding Variables Shall be Strictly Within The Qualified WPS

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How To Qualify A Welder 4) Type Of Test Required On Welded Coupon (QW-302)Visual Examination Qw 302.4Completed Coupon Shall be Subjected To Visual InspectionMechanical Test - QW 452 Root Bend :- 1 No, Face Bend :- 1 NoOrSide Bend :- 2 NoAlternate to Mechanical Tests, Radiograph the Coupon 6 Minimum Length

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How To Qualify A Welder 5) Acceptability Criteria For TestsVisual Examination Qw 302.4Free From Incomplete Fusion / Penetration and Surface DefectBend Test - QW 163 Opening not more than 3.2 mm in any direction on Convex Surface Within the Weld & HAZR T Qw 191.2No Crack, L/F & Incomplete PenetrationNo Slag, Cluster Of Porosity & Other Inclusions Beyond Specified Limit

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Performance QualificationThickness Limits QW 452.1(b)

Thickness t of Weld Metal in the Coupon in mm ( in)Thickness of Weld metal Qualified All2t13 (1/2) and Over With Minimum Three Layers Maximum To Be Welded

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Groove Weld Positions QW461

Sr No.Groove PositionBase Metal PositionInclination of Axis in PlatePipe11G FlatHorizontalPipe Axis Horizontal in Rotation0 -1522G HorizontalVerticalPipe Axis Vertical0 - 1533GVerticalVerticalNA80 9015 - 8044GOver HeadHorizontalNA0 - 8055GNAPipe Axis Fixed Horizontally0 -1566GNAPipe Axis Fixed 45 inclined+ or - 5

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Performance QualificationPosition & Dia Limits- QW461.9

Qualification TestPosition & Type of Weld QualifiedWeldPositionPlate & Pipe Over 24Pipe 24Fillet Plate & PipePlate Groove1G2G3G4G2G, 3G &4GSpcl. PositionFF, HF,VF,OALLSP & FF*F*&H*F*F*F*&H*SP & FFF,HF,H,VF,H,OALLSP & FPipe$ Groove1G2G5G6G2G &5G Spcl. PositionFF,HF,V,OALLALLSP,FFF,HF,V,OALLALLSP,FFF,HALLALLALLSP&FPipe 2 OD and Over$ Pipe OD Restrictions As Per QW 452.3, 452.4 and 452.6

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Performance QualificationGroove-Weld, Pipe Dia. Limits QW 452.3

Out Side Dia. Of Test Coupon in mm ( in)Out Side Dia. QualifiedMin.Max.Less Than 25 (1) Size Welded Unlimited25 (1) to 73 (2)25 (1)UnlimitedOver 73 (2) 73 (2)UnlimitedNotes:-Type & Number of Tests as per QW-452.173 mm OD is equivalent to 2 NB Pipe Welders Qualified on Groove, Are Also Qualified for making Fillets of all Sizes on Any Thickness & Any Pipe Dia.

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Welding Variables- Qw 416 Performance Qualification

Group of VariablesBrief Of VariablesEssential VariablesSMAW QW -353SAW.QW-354GMAWQW-355GTAW QW-356QW 402 JointsDeletion of Backing++++QW 403B MChange in Pipe Dia.++++Change in P Number++++QW 404Filler MetalDeletion /Addition of FM---------+Change in F Number++++Dele. /Addi. of Consumable Insert---------+Solid Metal/Flux Cored---------+Change in t deposit Qualified++++t deposit for Short Cir.Transfer---------+

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Welding Variables- Qw 416 Performance Qualification

Group of VariablesBrief Of VariablesEssential VariablesSMAW QW -353SAW.QW-354GMAWQW-355GTAW QW-356QW 405 PositionAddition of New Position++++Change from up hill to Down hill 3G+---++QW 408GasDeletion of Inert Gas Backing------++QW 409Electric Charact.Change in Mode of Metal Transfer------+---Change in Type of Current / Polarity---------+

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Thank You

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