T$aiMoobDy INTERNATIONAL API 510 EXAMINATION PREPARATORY TRAINING SEMINAR REVIEW OF ASME SECTION IX Notice to readers: This guide has been prepared for use by customers of Moody International, and is intended to be used only by those attending the Moody International ‘API 510 Examination Preparation Course. Use, reproduction or distribution by anyone, for any purpose other than that approved by Moody International is prohibited by copyright laws of the United States of America, Canada and ‘other global trade partners. Individuals and companies failing to respect, these provisions shall face clear and certain legal proceedings in the United ‘States and their domiciled country. REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 - MOODY INTERNATIONAL - ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROMITED 1C TSAiMooDy INTERNATIONAL REVIEW OF ASME SECTION IX OBJECTIVE © FAMILIARIZE CANDIDATES FOR THE CERTIFICATION TEST WITH TYPES AND FORMS OF INFORMATION CONCERNING WELDING PROCEDURE QUALIFICATION AND WELDER QUALIFICATIONS, IN WHICH THEY MUST BE KNOWLEDGEABLE. REFERENCES © BODY OF KNOWLEDGE, API AUTHORIZED PRESSURE VESSEL INSPECTOR CERTIFICATION EXAMINATION © ASME CODE SECTION IX INTRODUCTION ASME Section IX relates to the qualification of; © Welders © Welding Operators + Brazers + Brazing Operators ‘+ Welding/Brazing Procedures Of personnel employed in welding or brazing in accordance with the: © ASME Boiler and Pressure Vessel Code * ASME Piping Codes PURPOSE ‘The Welding Procedure Specification (WPS) and the Procedure Qualification Record (PQR) are used to determine that the weldment proposed for construction is capable of having the required properties. ‘The procedure qualification testis to establish the properties of the weldmenVbrazement, NOT. the skill of the welder/brazer. REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 - MOODY INTERNATIONAL - ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROHIBITED 2ORGANIZATION Section IX is divided into two parts: + Welding, identified as QW © Brazing, identified as QB ‘These two parts are further divided into four Articles: ‘+ General Requirements © Procedure Qualification + Performance Qualification + Data PROCEDURE QUALIFICATION Each process is listed separately with the applicable essential and non-essential variables © Change in an ESSENTIAL variable requites requalification © Change in a NON-ESSENTIAL variable requires a revision to WPS/BPS * Change in a SUPPLEMENTARY ESSENTIAL variable requires requalification ADDITIONAL RULES In addition to covering various joining processes, rules also exist for special processes: ‘© Corrosion Resistance Weld Metal Overlay ‘+ Hard-Facing Weld Metal Overlay PERFORMANCE QUALIFICATION Each process is listed separately with the applicable essential variables ‘+ Welder/Welding Operator can be qualified by: Mechanical Tests 1 Radiography of the Test Plate/pipe Radiography of initial Production Weld ‘+ Brazer/Brazing Operators CANNOT be qualified by radiography REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2008 - MOODY INTERNATIONAL -ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROHIBITED 3ARTICLE! WELDING GENERAL REQUIREMENTS QW-100.1 A WPS js a written document that provides direction to the welder or operator for making production welds. The WPS must be qualified by the manufacturer or it shal be a Standard Welding Procedure Specification (SWPS) listed in Appendix E. QW-100.2 The purpose of the performance test for a welder is to determine her ability to deposit sound weld metal. The purpose of the operator's test is fo determine his/her ability to operate the equipment. QW-100.3 WPS, PQR, and Records of Performance Qualification can be used for construction built according to either the: ‘+ ASME Boiler and Pressure Vessel Code, or the ASME B31 Code for Pressure Piping Providing it meets the requirements of either the ‘+ 1962, or later, editions of Section IX ‘+ Pre-1962 Edition of Section IX meeting ALL requirements of 1982, or later, editions A Quaiification/requalification of WPS MUST conform with the current Edition and Addenda of Section IX ‘Scope: Rules in this section apply to QW-101 ‘+ preparation of WPS © qualication of welding procedures, welders, and welding operator for ‘ALL manual/machine welding processes permitted in other sections Responsibility: Manufacturer/contractor is responsible for welding QW-103 ‘+ MUST conduct tests to qualify Welding Procedure and Welders! Welding Operators + Test resuits MUST be kept by manufacturercontractor © MUST be certified by Manufacturer/contractor ‘Types and P\ ‘Tests and Examinations (QW-140) Mechanical Tests Qw-144 Tension Tests Determine the ultimate strength of groove-weld joints Qw-141.1 Guided-Bend Tests Determine the degree of soundness and ductility of groove-weld joints Qw.141.2 FilletWeld Tests Determine the size, contour, and degree of soundness of filet welds Qw.141.3 REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 - MOODY INTERNATIONAL - ALL RIGHTS RESERVED - COPY OR DISTRIGUTION PROMITED ‘4TAT MOoRY Notch-Toughness _Determine the notch toughness of the weldment, Tests aweta14 Stud-Weld Tests Determine the accepiabilty of stud welds Qw-141.5 Tension Test To determine the ultimate strength ofa joint, expose sample to stress aw-1s0 levels exceeding stated limitations Tension Test ‘Sample shall be ruptured under tensile load Procedure Qw.182 + Calculation: Tensile Strength = Maximum Load Minimum Cross Sectional Area Cc = Measurements MUST be taken before load is applied Acceptance Criteria Tension Tests Qw-1s3 Tensile Strength Minimum tensile strength requirements: aw-15341 ‘+ Stated base metal limitation, or ‘+ Stated base metal limitation of WEAKEST specimen when two different strength levels are present, or ‘+ Stated weld metal limitation when the applicable Section requires use of ‘weld metal with a lower room temperature strength than the base metal ‘+ Strength is NOT MORE than 5% below the stated base metal limitation IF the specimen breaks outside the Fusion Zone and weld in the base material Guided Bend Tests Using a test jig, bend the sample into a"U" shape Qw.160 Types of Guided Bend Tests awet61 Transverse Side Bend Weld is transverse to the longitudinal axis of the specimen Qw-t614 Side surface of the weld becomes the convex surface ofthe specimen Transverse Face Weld is transverse to the longitudinal axis ofthe specimen Bend Qw 161.2 Face surface of the weld becomes the convex surface of the specimen REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 - MOODY INTERNATIONAL -ALL RIGHTS RESERVED -COPY OR DISTRIBUTION PROHIBITED 5IMTS eRy Transverse Root Bend Qw-161.3, QWw-161.6 Longitudinal Root Bend Qw-161.7 Acceptance Criteria Qw-163 Notch Toughness. Tests Qw-170 Weld is transverse to the longitudinal axis of the specimen Root surface of the weld becomes the convex surface of the specimen Longitudinal Face Bend Weld is parallel to the longitudinal axis of the specimen Face surface of the weld becomes the convex surface of the specimen Weld is parallel to the longitudinal axis of the specimen Root surface of the weld becomes the convex surface of the specimen Weld and heat affected zone MUST BE ENTIRELY within the bent area of the specimen ‘Specimen MUST NOT have any defects greater than 1/8 inch ‘+ Measurements taken anywhere on rounded surface ‘+ Comer cracks discounted unless evidence of intemal defects are present Corrosion Resistant Weld Overiay Cladding requirements: + No defects greater than 1/16 inch (cladding) ‘+ No defects greater than 1/8 inch (bond line) When required by the Code, one of the following tests MUST be conducted: © Charpy Venotch * Drop Weight Impact Other Tests and Examinations Qw-1s0 Radiographic Examination Qw-191 awi9t.23 Visual examination of welder/operator qualification test is required May be substituted for mechanical testing for weldershwelding operators MUST meet requirements of Article 2, Section V ~ Except that a written RT procedure is not required, MUST meet acceptance criteria of QW-191.2 Acceptance standards for operators that qualify on production welds shall be the referencing code section. The acceptance standard for welders on production welds shall be QW 191.22. REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 ~ MOODY INTERNATIONAL -ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROHIBITEDTIATMS Rx RTICLE It WELDING PROCEDURE QUALIFICATIONS General QW-200 Welding Procedure Written directions for the welder/welding operator making production welds Specification (WPS) describing all variables involved QWw-200.1 * ESSENTIAL VARIABLE Welding specification change affecting mechanical properties of the weldment Requires specification requalification ‘* SUPPLEMENTARY ESSENTIAL VARIABLE ‘Welding specification change affecting notch toughness properties of the ‘weldment ce Requires specification requalification (if impact testis required) * NON-ESSENTIAL VARIABLE Welding specification change NOT affecting the mechanical or notch toughness properties of the weldment. Requalification NOT required providing WPS is amended Essential variable for one process may be non-essential for another or may not be required at all for a third process Non-essential variables can be changed without requaiification ‘Change MUST be documented by variable on either a new, or amended original, WPS Procedure Tests to determine that the weld can provide the required (PR) properties Qualification for the intended application aw-2002 Allvariables of the WPS MUST be followed Base metal of the specimen can be in any form * Procedure qualification transferable between plate and pipe welding PQR contents: * All essential and supplementary essential variables used during test ‘coupon welding MUST be recorded * Any non-essential or other variables option, be recorded at manufacturer's ‘© Any variables recorded MUST be the actual variable Variables not monitored MUST NOT be recorded If more than one processffller metal is employed, RECORD the approximate deposit weld thickness of each REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 - MOODY INTERNATIONAL -ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROHIBITED 1‘Changes; ‘+ REQUIRES recertification Muttiple WPS's with Several WPS's may be prepared from data on one POR, ‘One POR/Muttiple PR's with one (One WPS may cover numerous essential variable changes providing a POR WPS: exists for all essential and supplementary essential variables aw-200.4 Combination welding procedures (more than one process) are allowed; however ALL variables and ranges for each process shall be applied and identified. Note: Restriction on GMAW-S C arc. aw-201 Manutacturers/Contractors responsibilty to conduct tests, document results, ‘and maintain records. NOT permissible to sub-contract welding of coupons, but al other work in preparing coupons and testing can be subcontracted, ‘Table QW 252 -Variable Tables per process QW 265 - REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2008 - MOODY INTERNATIONAL -ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROMIBITEDQa TNA;MOODY INTERNATIONAL ARTICLE, WELDING PERFORMANCE QUALIFICATIONS General QW-300 Qw-300.1 Welder qualification is limited by the essential variables given for each process. Welder/welding operator can be qualified by: ‘+ Radiography of test coupon ‘+ Radiography of intial production welding ‘+ Bend tests taken from test coupon Visual examination of all tests is required Qw-300.2 Manufacturer/contractor MUST conduct tests to qualify welders/welding operators in accordance with a qualified WPS. + This is to ensure that weldersiwelding operators can develop the ‘minimum requirements specified for an acceptable weldment. Intent of Tests Determine the ability of the weldersiwelding operators to make sound welds Qw.301.1 Qualification of Tests Performance qualification tests MUST be welded in accordance with qualified QW-301.2 wes, Welder/Welding operator who prepares the WPS qualification test coupon is ‘also qualified within the performance qualification range of the performance variables. Identification of Must be assigned an individual identifying: WeldersWelding number, Operators ~or~ Qw.301.3 ‘= symbol ALL work must be identified in this manner Record of Tests WP record MUST include: QWw-301.4 « Essential variables » Type of test # Test results * Qualified range of welderiwelding operator Use form QW-484 or equivalent REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 - MOODY INTERNATIONAL - AL RIGHTS RESERVED - COPY OR DISTRIBUTION PRONIBITEDTALMOODY INTERNATIONAL Welders aw-304 Examination Qw-304.1 Failure to Meet Radiographic Standards QW-304.2 Welding Operators Qw-305 Examination QW-305.1 Failure to Meet Radiographic ‘Standards Qw-305.2 Combination of Qw-308 Welding Processes Welders MUST pass the mechanical test prescribed in QW-302.1 + Exception: special requirements Welder making groove-welds using ‘sMAW SAW GTAW PAW GMAW (except short-ircuiting mode) Or a combination of these Can be qualified by radiographic examination ~- Exception: P-21 - 25, P-51 -53 and P-61 -62 metals Welders making groove-welds in P-21 - 25 and P-51 - 53 metals using GTAW process may be qualified by radiographic examination Welders qualified with one WPS are likewise qualified with another WPS Providing the same welding process is used within the applicable range of essential variables of QW-350 Shall be examined by either: ‘* Mechanical Tests (QW-302.1) sore Radiography (QW-302.2) IF the production weld selected for welder performance qualification DOES NOT meet the radiographic standards the welder has FAILED. If the entire production weld had been made by this welder, it MUST be radiographed and repaired by a qualifed welderhwelding operator Same as QW-304 ‘Same as QW-304.1 ‘* Exception: for the production weld being radiographed, a three foot length MUST be examined Same as QW-304.2 Welder MUST be qualified for the welding process(es) used in production Welder can be qualified by making tests with the: ‘© Individual welding process REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 - MOODY INTERNATIONAL - ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROHIBITED 10Retests and Renewal of Qualifications Qw.320 Retests Qw-32t Immediate Retest Qwa21.4 Immediate Retest Qw-321.2 Further training aw.a2t4 Renewal of Qualification Qw-322 ‘+ combination of welding processes in one test coupon(s) Thickness limits of which the welder will be qualified depend upon the thickness of the deposited weld metal of each welding process. Failure of ANY portion of a combination test in a test coupon fails the entire combination, Welderiwelding operator can be retested per the conditions of: © owsztt © QW321.2 MUST make two consecutive test coupons for each Mechanical Testing position failed. All coupons must pass the required tests. Retest must be two 6 inch plate coupons or using Radiography Pipe: © Two pipes, totaling 12 inches of welds, that MUST include the entire weld circumference ‘Small Diameter Pipe. * Perform no more than eight consecutively made test coupons ‘Production Welds: ‘© Can be retested by an additional 12 inch length of the SAME weld -+ Iflength PASSES, the welder is qualified -- If length FAILS, all production welds must be completely radiographed and repaired. ‘A welding operator who has failed can retest by submitting an additional six foot length of the same production weld ~~ Iflength PASSES, the welding operator is qualified -+ If length FAILS, all production welds must be completely radiographed and repaired, when the welder or welding operator has had further training, anew test shall be made for each position on which he failed. Welderiwelding operator performance qualifications will be affected by these conditions + Not welding with a specific process during six month or greater period of time: + Qualifications for that process have expired * Specific reason to doubt that the welds meet required specifications: ~- Qualifications for those processes MUST be revoked When qualifications have expired it can be renewed by welding one test ‘coupon and testing it as specified in QW-301 and QW-302 for each process: qualified. REVIEW OF ASME SECTION RO ‘COPYRIGHT 2006 - MOODY INTERNATIONAL -ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROHIBITED "TATMQORY eeneererd + This process renews the welder/welding operator's previous qualifications, When qualifications have been revoked a welder/welding operator can be requalified by welding and testing a test coupon representative of the work that person will be doing + Test MUST be in accordance with QW-301 and QW-302 + Test MUST be completed prior to performing any work ‘Table QW-352-357 Variable tables for WELDERS - all essential variables. aws6o Variables for machine/automatic OPERATORS -all essential variables aw-380 ‘Special process requirements for welders/operators - includes corrosion- resistant weld metal overlay and hard facing weld metal overiay ARTICLE IV WELDING DATA This Article contains many - Tables, Graphs, and other mandatory information that is referenced throughout Articles |, Il, and Il Many of the Tables (such as QW 451.1, QW 452.1(a) and 452.1(b)) will be used to determine the allowable ranges for the WPS or WPQ, such as: Allowable Base Metal Ranges for WPS (QW 451.1) Allowable Deposited Weld Metal Ranges for WPS (QW 451.1) Allowable Deposited Weld Metal Ranges for Welders (QW 452.1(b)) Allowable Pipe Diameter Qualification Ranges for Welders (QW 452.3) Allowable Position Qualifications for Welders (QW 461.7) Allowable P# Qualification ranges for Welders and WPS (QW 423 and 424, respectively) ‘The candidate must become familiar with the Tables, and know where to go to obtain the correct information. After several practice sessions these Tables become quite easy to master, and can be accessed rather quickly. ARTICLE V STANDARD WELDING PROCEDURE SPECIFICATIONS (SWPS) aw-sto The SWP's listed in Appendix E (approximately 17) are only allowed. Prior to use @ laundry list of items must be completed by the user of the SWPs, including the following a. _Enterthe name of the user (manufacturer); b. The SWPs must be certified; The applicable referencing code sections must be met; d. The user (manufacturer) must weld and test one groove weld using the ‘SWPS and record 15 items. Then the coupon must be visually examined and bend tested or radiographed, REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 ~ MOODY INTERNATIONAL - ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROMITED 2Qw-520 Once the above coupon passes all similar SWP’s may be used without the demonstration in (d), above. The list of changes that will require additional discreet demonstrations are listed inthis paragraph. aw-s40 All production welding must be done in strict accordance to the SWP’s, other rules for utilizing SWP's are provided in the paragraph. REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 - MOODY INTERNATIONAL - ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROHIBITED 2TSATMS.ORY QW-462.2 SIDE BEND SIDE BENDS EXPOSE THE FULL CROSS SECTION OF THE WELD TO THE 180° BEND VERSUS ‘THE FACE OR ROOT BENDS. Qw-483 TENSILE TEST 5° SCHEDULE 80 3/8" SA-108 GR B w t A Loap Pst loc. 5 0.695 0.249 0.173 11,000 63,583 wu 6 0.785 0.220 0.173 9,878 57,098 BM REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 - MOODY INTERNATIONAL -ALL RIGHTS RESERVED -COPY OR DISTRIBUTION PROHIBITED “ ‘Acceptable Ref. QW- 153.1(0) Acceptable Ref. QW- 153.4(d)TATMOORy w-483 TENSILE TEST ‘These two specimens represent one specimen. Another set of two is needed to meet Procedure Qualifications Requirements. --- -73 —= a ——S 2° SA-537 CLASS 2 (MIN. SPECIFIED TENSILE = 80,000) WH T x 1b PSI To. ja ‘1500 0.984 Ta 176,000 60,220. WM “Acceptable Ref. QW- 153.1(a) tb 1.490 0.997 1.486 114,000 76,720. PM Acceptable Ref. QW- 153.1(a) 2a 1.497 0.950 1.437 91,200 80,000 WM ‘Acceptable Ref, QW- 153.1(a) 2 = 4.250 0.981 1.226 98,000 79,934 = WM. Unacceptable Ref. QW- 153.1(a) NOTE: Full set unacceptable because of 2b. Reference QW-151.1(c) SPECIAL NOTE: The math is incorrect on 1a. The area is 1.476 which makes the PSI 78,590 which is unacceptable. (Reference QW-153.1) REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 MOODY INTERNATIONAL -ALL RIGHTS RESERVED -COPY OR DISTRIBUTION PROMBITED roQw-150 TENSILE TEST “TURNED SPECIMENS” “0.508” EXAMPLE: Base Metal Tensile Strengt 5,000 NOTE: EACH PROCESS OR PROCEDURE SHALL BE INCLUDED IN THE TENSION, BEND OR IMPACT TEST SPECIMEN. REF. QW-200.4(a) w T A LoaD Psi Loc. 1 0.511D 0.205 15570 75,950 BM 2 0.501D 0.197 14,520 73,750 wm NOTE: Turned Specimens(QW-151.3) *REF. QW-462.41(d) “Ref. QW-153.1(a) D=0.500 + 0.010 In. REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2008 - MOODY INTERNATIONAL -ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROMIBITED 6TMATMQORY WELDING DOCUMENTATION AND WELDING REQUIREMENTS |. Introduction This session will deal with the welding documentation and welding requirements for fabrication to the ASME Boiler and Pressure Vessel Code, Section Vill, Division 1. The reader should come away with an understanding of what will be needed regarding welding documents and what parameters these documents must contain in order to prove qualification in accordance with ASME Section IX and Section Vill In all sections of the ASME Code the responsibilty for construction and documentation is placed with the manufacturer or contractor. This is true with welding documentation also. The ASME Code requires that a writen procedure be available prior to construction and that the procedure contain directions for the welder and the supervisor to insure that a weld meeting the mechanical property requirements of the ASME Code are met. In a welding procedure three distinct types of variables must be addressed. The first is an essential variable, which is a variable that if changed will cause a change in the mechanical properties of the weldment. Anytime an essential variable is changed outside of the range specified on the welding Procedure specification, the procedure must be requalified by performing mechanical testing on weldment made with the new parameters. The second type of variable that must be addressed on every welding procedure specification is called a nonessential variable. Changes in these variables can be made without requalifcation of the welding procedure; however, the welding procedure must be revised to reflect these changes, The third type of variable to be addressed on a welding procedure specification is called a supplementary essential variable. These supplementary essential variables must be addressed on a welding procedure specification only when impact properties are required of the weldment. When impact properties are required then the supplementary essential variables become essential variables and the welding must be done within the specified range of these variables. Any changes outside of the range specified on a welding procedure specification must be requalified by mechanical and impact testing, The purpose of this handout is not to instruct the API 510 Candidate in every welding process recognized by the ASME Boiler and Pressure Vessel Code. What is attempted is a recap of those Variables that must be addressed when writing and qualifying a welding procedure for the shielded metal arc welding (SMAW) process. Il, Preparing or Reviewing a Welding Procedure Specification (WPS) ‘The best way to start writing or reviewing a welding procedure specification is to refer to Article 2 in ASME Section IX. In this instance we will refer specifically to paragraph QW-253 which is a table that Specifies the essential, supplementary essential, and nonessential variables for the SMAW process. This table refers us to eight categories that must be addressed on a welding procedure specification. The first category is welding joints, QW-402, From QW-263, there are no essential or supplementary essential variables for joints. However, there are four nonessential variables and as previously stated all the variables specified for a particular Process must be addressed on the welding procedure specification. Taking the first nonessential variable, the X in the column indicates that we must refer to QW-402.1. QW-402.1 states that a change in the type of groove is a nonessential variable. This means that a change from a V groove to U groove, is a change in a nonessential variable. As previously stated, the welding procedure specification must be revised to indicate this change. When writing or reviewing a welding procedure specification, there is a chance that more than one joint design will be used in a weldment. Therefore, the welding procedure specification can simply specify that all types of joint design will be used, not restrict the document to any unique joint design REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 - MOODY INTERNATIONAL -ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROHIBITED 7Mi MOODY INTERNATIONAL The next variable in the joints category, is the deletion of backing. This is specified in QW-402.4, Again, as in the joint design, if restrictions are not needed on our production facilities, the WPS can simply specify that the joint can be made with or without backing. Ifthe WPS states that the weld is to be made with backing, that is what must happen in production until the welding procedure is revised. The next variables in QW-253, are a change in the root spacing and the addition or deletion of retainers. Because these are nonessential variables, a welding procedure specification should have as wide tolerances as possible for these categories. Because the addition or deletion of retainers is a nonessential variable forthe shielded metal arc welding process, it must also be addressed. if you are not going to use retainers, you should state this on your welding procedure specification. ‘The second category for variables is base metal. These variables are addressed in paragraph QW- 403. In this category there are no nonessential variables, and all the variables that are listed are either essential variables or supplementary essential variables, {As stated earlier, supplementary essential variables apply only if impact properties are required ofthe weldment. Supplementary essential variables have some restrictions on the base material that can only be qualified with a single procedure qualification record. it also puts restrictions on the base ‘metal thickness range that is qualified when qualifying a procedure qualification The list of essential variables starts with the base material and weld metal thickness limitations when trying to qualify for thicknesses greater than 8 inches. The reader is advised that when impact properties are required the supplementary essential variables take precedence for welding procedure qualifications. ‘The next essential variable addresses whenever there is a change in the base material thickness qualified. Essentially it stipulates that the welding procedure depending on the thickness of the ‘coupon used in the procedure qualification is qualified for a range of base metal thicknesses. if base metal thickness goes beyond the range of qualification another test plate must be welded and tested to ascertain that the welding procedure develops the required mechanical properties in the new thickness range. One essential variable that is often overlooked on welding procedure specifications is that a single pass of weld material that is more than % inch thick has a range of qualification different from that when using weld passes of less than % inch thick. This % inch limitation must be addressed somewhere on the welding procedure specification. If you are not going to allow welding greater than % inch thickness in one pass, you must state this on your welding procedure specification, The last two essential variables listed for the shielded metal arc welding process have to do with base ‘material P-numbers. Qualifying for P1 material, does not qualify for any other P-number material If it is desired to weld on other P-numbers, qualification tests must be performed on materials listed in the P-numbers for which qualifications are sought. QW 424 allows some alternatives to be used when Qualifying on P-5, P-4, or P-3 materials The third category of variables listed is for filer metals QW-404. In this category all three variable types are applicable. The first two have to do with the chemistry and the types of electrodes used in the welding process. The F-number is a grouping of electrodes that have similar characteristics in the way that they produce mechanical properties and they have similar deposition characteristics. The other property that is dealt with as an essential variable is the A-number. This is a chemical limitation in that electrodes that fall within a particular A-number category have similar chemical properties. ‘Changes in either of these variables will require requalification of the procedure. The diameter of the electrode is listed as a nonessential variable. The welding procedure should list ‘as many diameters of electrodes to be used as possible to preclude problems in production. if the writer of the welding procedure lists just one diameter of electrode, before a different diameter of electrode may be used in production, the weld procedure must be revised to include these new diameters. Two supplementary essential variables are listed under filer metals. One refers to QW-404.7 and deals with large diameter electrodes. It states that if impact properties are required and the use of an electrode diameter of greater than a quarter of an inch is necessary, the specific electrode diameter must be qualified for impact values. REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 - MOODY INTERNATIONAL -ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROMIBITED 2TSZiMOODY INTERNATIONAL The other supplementary essential variable listed in QW-404.12 is the AWS classification. All filer metal specifications (SFA) presently recognized as standard filer metal by the ASME Code are listed in ASME Section I! part C. This supplementary essential requires that a change in the electrode SFA number requires requalifcation of the welding procedure if impact values are required. ‘QW 404.30 deals with deposited weld metal thickness (or DWM). This variable is sometimes overlooked, but must be addressed, especialy if restrictions are placed on the DWM, or if partial penetration welds are used. ‘The next category for variables for the shielded metal arc welding process is position QW-405. There are three variables listed and, without going into detail, the reader should know that when impact values are not required, the position of the welding is a nonessential variable, meaning that a welding procedure can be qualified by running a test plate or pipe in any position and the procedure is then qualified to be used in all positions. When impact values are required for the qualification of the welding procedure, position becomes an essential variable when changed from any position to the vertical uphill progression. Further, if you change from a stringer bead in the vertical uphill progression to a weave bead, this would also require requalification for impact properties. PWHT above the upper critical temperature (ie., annealing) will negate thi limitation. AA fifth category of variables for the shielded metal arc welding process is preheat. There is one essential variable, one supplementary essential variable, and one nonessential variable listed in this table. The essential variable is that if a procedure is qualified at a given preheat value, the preheat may not be decreased more than 100 degrees F from that qualified without requalification of the procedure. The nonessential variable for preheat has to do with the maintenance of the preheat temperature when post -weld heat treatment is required. The maintenance that is addressed in Section IX is the continuance of the preheat temperature after the completion of welding. The preheat ‘temperature is going to be maintained after completion of welding for a period of time or if it will be allowed to cool in air and not monitored after the completion of welding. The supplemental essential variable mentioned in this category of variables deals with interpass temperature and not with preheat temperature. When a welding procedure requires impact testing, the interpass temperature must be monitored and must be maintained below a maximum value. The supplemental essential variable for interpass temperature states that ifthe interpass temperature is increased by more than 100 degrees over that Qualified, the procedure must be requalified. The next category of variables is postweld heat treatment QW-407. The first variable listed is a change in postweld heat treatment and this is classified as an essential variable. Itis not always necessary to postweld heat treat base material. The construction or repair code will dictate when this is necessary. However, the Code does specify that a change in the postweld heat treatment is an essential variable and therefore must be addressed on the welding procedure. The PWHT treatment variables must be watched closely, as upper/lower critical temperatures on each ‘material may differ, and this may have a bearing on what can be done in production. To state that postweld heat treatment is not applicable is not correct. If there is to be no postweld heat treatment then the welding procedure specification should state "No Postweld Heat Treatment” ‘or somehow indicate that no postweld heat treatment will be performed. ‘The next supplementary variable listed for postweld heat treatment deals with a change in the time ‘and temperature range for the postweld heal treatment. Whenever the time at temperature or the temperature range itself is changed, (outside of the range initially written and qualified) the procedure must be requalified whenever impact properties are required, ‘The last variable has to do with the thickness of the base metal qualified. The variable is stated in QW-407.4 and requires that whenever the upper transformation temperature for the alloy is exceeded, the maximum thickness that is qualified with that post-weld heat treatment is 1.1 times the thickness of the test coupon. This is a restriction over the normal 2 X base metal thickness that can bbe qualified ifthe upper transformation temperature has not been exceeded, REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 - MOODY INTERNATIONAL - ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROMIBITED 9TNATMQORY The next variable category in QW-253 is electrical characteristics. Both variables listed in this category deal with current and voltage. The first variable listed is a change in the current or an increase in the heat input and this classified as a nonessential variable, which can have an effect on impact values. When qualifying a welding procedure with impact values the amount of heat input due to the welding process must be controlled. This variable stated in QW-409.1 requires that when the type of current or the polarity of the current are changed, ifthe heat input is increased, or ifthe volume of weld metal deposited per unit length of weld is increased, the procedure must be requalified for impact values, ‘The other variable listed in electrical characteristics is a change in the type of current or a change in the current and voltage range. This is a nonessential variable. Referring to QW.408.8, if the type of current or polarity is changed or the range of amperage is outside the range initially listed on the welding procedure specification, then the welding procedure must be revised to indicate this new range of welding parameters. Voltage for shielded metal arc welding is not a variable, and therefore it is not necessary to list the voltage range on a SMAW weld procedure specification. Usually the electrode manufacturer's recommendation for amperage is adequate and many manufacturers use this range on their welding procedure specification. The last category of variables for the shielded metal arc welding process is titled “technique QW-410". ‘Such things as string or weave bead, the method of cleaning, whether manual or automatic weldi peening, and the method of back gouging a joint must be addressed on the welding procedure specification. Since these are nonessential variables, a change may be made without requalifcation of the procedure. However, the Code is very specific in requiring that they must be addressed on the welding procedure specification. Ill Preparation/Review of a Procedure Qualification Record (POR) ‘The next document that the ASME Code requires for welding is the procedure qualification record (POR). The purpose of this document is to record the essential variables used during the welding of a test coupon, and to record the values of the mechanical properties obtained when testing the welded ‘coupon (bend tests, tensile tests, notch toughness tests, or filet weld tests, as applicable). The ASME recommended form (QW-483), has spaces to list all essential, nonessential, and supplementary ‘essential variables for the various recognized welding processes. ‘The only information required to be on the PGR is the listing of the values for the essential variables used while welding the test plate and the mechanical values obtained when doing the testing on the test coupons. If the manufacturer or contractor voluntarily wishes to list the nonessential variables on this form, the values that are to be listed are those that were actually used or obtained during the welding of the test coupon. For example, the same range of amperage that is specified on the welding procedure should not be listed on the procedure quaiffcation record, unless that entire range was used during the welding of the test coupon. When qualifying welding procedures, two of the primary areas are the base material thickness qualified and the deposited weld metal thickness qualified. The ASME Code allows a range of thickness qualification when welding a specific thickness of base material for the procedure qualification. As an example, when the test coupon is made from a 1” thick plate, the welding procedure is qualified to be used on a range of base metal thicknesses ftom 3/16 inch to 2 inches. ‘When qualifying welding procedures the manufacturer or contractor should ensure that the thickness. of the test coupon will qualify the welding procedure over the range of base metal thicknesses that will be needed in production When using a combination of welding processes or a combination of filer materials, each filler or process will have a range of qualification. The thickness deposited by the different processes or the thicknesses deposited by different filer metals must be measured when welding the test coupon for procedure qualification. These thicknesses then must be documented on the procedure qualification record. These values will determine the welding procedure range of qualification, As an example, if 2 manufacturer were to use gas tungsten arc welding to run the first 1/4” of weld in a % inch thick piate, and then use shielded metal arc welding to finish the weld, each process would be qualified to deposit inch of metal and the procedure would be qualified to weld on base metal up to 1 inch thick Neither of the welding processes is qualified to weld a 1 inch thick deposit in a 1 inch thick plate, but together they can be used to weld a 1 inch thick plate. REVIEW OF ASME SECTION IX_RO ‘COPYRIGHT 2006 - MOODY INTERNATIONAL - ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROHIBITED Ey‘The physical testing criteria should be closely reviewed. The number, type and results of the tests, should be compared with the applicable acceptance criteria in Artie 1 and the requirements of AAticle 4 for the test involved. All PR's must be certified (by signature) by the Manufacturer or Contractor. IV Preparation/Review of a Welders Performance Qualification (WPQ) The last document to be discussed will be the welder performance qualification record. The purpose of this document is to list the actual values used by the welder when welding a test coupon and also to lst the thickness ranges for which the welder is qualified. Using the table in paragraph QW-353 of Section IX, the essential variables for welder qualfications, are variables that affect welders ability or skill and whenever any one of these variables is changed the welder must be requalifed. The frst essential variable in this table has to do with joints and states that if a welder is qualified to weld with backing and that backing is deleted, the welder must requalify to perform an open butt joint. Variables, regarding base metal that affect welder qualifications are pipe diameter and a change in the P number material Paragraph QW.423 allows a range of P-number qualifications by welding on one P-number for welder qualification, only. As can be seen, it requires a very drastic change in base material before a welder has to requalify due to this essential variable. ‘Two variables are listed for filer metal. The first variable deals with all other electrodes and limits the range of qualifications for the various F-numbers. The most commonly used range is when a welder qualifies with an F4 electrode. He is then qualified to weld with F3, F2, and F1 electrodes with backing only. Any electrodes used above an F4 only qualify for that F-number, and F1, F2, and F3 do not qualify up for F4 deposits. (See Table QW-433) The second essential variable for filer metals isthe thickness of the weld deposit and this chart refers to the variable QW-404.30 which limits the welder to the range of thickness qualifications as shown in aw-452 The next category of variables for welder qualification is position. The manufacturer or contractor should watch this variable closely. As an example, if a welder takes a qualifying test in the horizontal Position he is also qualified to weld in the flat position. There are several other combinations that can be obtained ifthe proper position for qualification is selected. Table QW 461.9 is often overlooked and misunderstood, in this context ‘The last variable mentioned in QW-383 is a change from vertical up to vertical down welding, and refers to paragraphs QW.405.3 ‘As previously stated, whenever any one of these variables is changed outside the range of qualification, the welder must requaiify for the new range. Itis the responsibilty of the manufacturer or contractor to insure that welders are qualified for the production welds made. This has been a brief review of the three welding documents that are required by the ASME Boller and Pressure Vessel Code. The reader is advised to thoroughly research the requirements of Section IX before undertaking the process of writing or reviewing a welding procedure. The reader is further advised that many of the construction codes (Section I, IV, Vill, Il, 83a) can further restrict welding requirements. Many companies are in compliance with the requirements of Section IX, but not using @ welding procedure that is in compliance to the Construction Code Sections of ASME, or other repairiateration codes. REVIEW OF ASME SECTION IX_RO (COPYRIGHT 2008 - MOODY INTERNATIONAL -ALL RIGHTS RESERVED - COPY OR DISTRIBUTION PROMIBITED a