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Inspector Certification
Course.
INTRODUCTION …
1
INTRODUCTION …
Section IX Relates To :
Qualification Of:
¾ Welders
¾ Welding Operators
¾ Brazers
¾ 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
¾ General Requirements
¾ Procedure Qualification
¾ Performance Qualification
¾ Data
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INTRODUCTION …
INTRODUCTION …
3
INTRODUCTION …
WELDING PROCESS …
INTRODUCTION …
4
INTRODUCTION …
INTRODUCTION …
5
INTRODUCTION …
INTRODUCTION …
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ARTICLE I. GENERAL REQUIREMENTS …
PART QW WELDING
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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ARTICLE I. RESPONSIBILITY …
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IF YOU QUALIFY ON GROOVES DO YOU STILL HAVE
TO QUALIFY ON FILLETS ?
¾ Tension Tests:
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ARTICLE I. TENSILE TESTS …
Maximum Load
Tensile Strength =
Minimum Cross Sectional Area
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ARTICLE I. TURNED SAMPLES …
QW153.1
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ARTICLE I. P. NUMBERS …
ARTICLE I. SOLVE …
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ARTICLE I. SOLVE …
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ARTICLE I. GUIDED BEND TEST …
The Weld & Heat Affected Zone Must Be Within The Bent Area.
10 mm
50 mm
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ARTICLE I. OTHER MECHANICAL TESTS …
ARTICLE I. QW-190 …
Radiographic Examination
Requirements of Article 2, Section V to be used. Written procedure not required nor is personnel
qualification required.
The acceptance standard for welding operators who qualify on production welds shall be that specified
in the referencing Code Section.
The acceptance standard for welders who qualify on production welds shall be per QW-191.2.2.
Performance coupons shall show complete joint penetration with complete fusion of weld metal and
base metal.
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ARTICLE I. QW-192 STUD WELD TEST…
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ARTICLE II. WELDING PROCEDURE
QUALIFICATIONS…
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ARTICLE II. QW-201 WPS. VARIABLES…
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ARTICLE II. QW-202 PQR. PROCEDURE QUALIFICATION RECORD…
CHANGES
Are Not Allowed Except For Editorial Mistakes And Then
Must Be Certified.
PQR MUST Be Certified Accurate By
Manufacturer/Contractor.
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ARTICLE II. QW-202 PQR. PROCEDURE QUALIFICATION RECORD…
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.
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ARTICLE II. QW-211. BASE METALS…
The base metals may consist of either plate, pipe, or other product forms. Qualification
in plate also qualifies for pipe welding and vice versa.
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ARTICLE II. QW-250. VARIABLES PER EACH PROCESS…
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
Nonessential variables are those in which a change as described in specific variables, may be made in
the WPS without requalification.
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ARTICLE III. Welding Performance Qualifications…
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
The performance qualification tests are intended to determine the ability of welders and welding
operators to make sound welds.
The performance qualification shall be welded in accordance with qualified WPS's. Identification
of Welders and Welding Operators
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ARTICLE III. QW-300.2…
Reading Carefully
Passes).
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ARTICLE III. QW-301.3. Identification Of Welders…
¾ Type Of Test
¾ Test Results
¾ Range Qualified
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ARTICLE III. QW-304. Welders …
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.
Test Coupons:
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ARTICLE III. QW-304.1 Welders Examination…
Welding Operators:-
What is Difference?
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ARTICLE III. QW-320 Retest and Renewal of Qualification…
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ARTICLE III. QW-322 Expiration & Renewal of Qualifications…
Ability is Questioned.
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-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.
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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.
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.
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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ARTICLE IV. Welding Data
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
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.
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.
QW-442 A-NUMBERS
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
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.
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ARTICLE IV. Welding Data
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.
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.
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ARTICLE IV. Welding Data
Unless a minimum, maximum, or tolerance is given in the figures, the dimensions are to be
considered approximate.
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.
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.
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ARTICLE IV. Welding Data
QW-462.2 SIDE BEND
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(b) PLATES -3/4 in. AND OVER THICKNESS AND ALTERNATE FROM 3/8 in. BUT LESS THAN 3/4
in. THICKNESS PROCEDURE QUALIFICATION
QW-463.2(b) PLATES –3/4 in. AND OVER THICKNESS AND ALTERNATE FROM 3/8 in. BUT LESS THAN
3/4 in. THICKNESS PERFORMANCE QUALIFICATION
QW-490 DEFINITIONS
These are definitions related to welding/brazing and may be helpful in answering some questions.
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