NCPWBulletin

February 2000 The Newsletter of the National Certified Pipe Welding Bureau

News from the Joint Meeting of the Board and Tripartite Committee
The Board approved the distribution of a Model Specification for HVAC Piping Fabrication and Installation.The model provides the requirements for materials, fabrication, installation, examination, testing, quality control and documentation for HVAC piping systems.This document will be printed and distributed to Bureau chapters by late May 2000. On the code activities regarding ASME Section IX, the Board discussed the subject of simultaneous testing of welders under paragraph QW 300.3.A recent inquiry to ASME Boiler and Pressure Vessel Code Section IX still remains unanswered.The inquiry sought clarification as to whether or not an employee who is responsible for welder performance qualification can be contracted to represent the organization solely for the purpose of simultaneous welding.This issue will be discussed at the Technical Committee meeting in April 2000. s

Status of Welder Database

The new NCPWB Welder Certification Database is currently undergoing development. In order to accommodate each chapters reporting needs, a survey has been conducted.The results will be used to develop a series of reports from which a user can select. To circumvent the development of a new program and to ensure 100% compatibility with the UA welder database, the Bureau has requested and received UA program codes for their new database. In addition the Bureau has purchased a server, which would be dedicated solely to the NCPWB database clearinghouse. The MCAA computer department has outsourced the development of the new database. It is important to note that the new database will be totally "Web based" meaning all data will be entered onto our secure server over the Internet. Local affiliates of the NCPWB will then be able to select from a series of standard reports to download or create their own based on the data they submit to their own private area of the Web site. The new system is anticipated to be ready for general use after testing this spring. s

National Certified Pipe Welding Bureau

1385 Piccard Drive Rockville, MD 20850-4340 (301) 869-5800

CHAIRMANS CORNER
The Tripartite Committee (TPC) continues to promote the joint UA/NCPWB certification program. In 1999, the members of the TPC visited a number of UA locals and NCPWB Chapters in Washington, D.C., Michigan, Pittsburgh, Kentucky and Wisconsin to promote the Joint UA/NCPWB welder certimust work very closely to insure that tests are scheduled in a timely manner, to insure NCPWB member contractors are present at the test site, and to complete the proper joint performance qualification test (JPQT) records. Over the course of the last year, we have worked hard to reach an agreement on the development of JPQT that encompasses all UA existing tests.Twentyseven procedures have been developed and soon will be distributed to chapter members.These forms will eliminate any confusion and will assist NCPWB chapters when joint qualification forms are needed. It should be clear that these joint procedures are used solely for the purpose of testing welders and should never be offered to the contractors as welding procedures. Each contractor must

In order to truly have an effective program, both UA locals and NCPWB chapters must work very closely to insure that tests are scheduled in a timely manner
fication program and to educate local authorities.The TPC members provide the history and development of the joint program, as well as code references and acceptances by various states and users in other parts of the country.These are important promotional activities to which the TPC is committed.With all of these promotions, we must work hard to insure that we, at the local level, also promote the program. In order to truly have an effective program, both UA locals and NCPWB chapters

Robert B. Waddy NCPWB Chairman

have his own Welding Performance Specification that matches the JPQTs (All NCPWB contractors meet this requirement).We are still faced with the challenge of promoting the joint programs in areas where there are no NCPWB chapters.We are open to any ideas and suggestions that could provide a solution to this issue. s

Meeting in Western Pennsylvania: From left to right, Randy Ward, UA Special Representative; Regis Claus, Executive Director of Western Pennsylvania NCPWB Chapter; Bill Spohn, Chairman of the NCPWB Technical Committee.

February 2000

Joint UA/NCPWB Qualification Program

In an agreement that was signed on September 28, 1999, the UA and the Bureau outlined a process by which a welder can obtain joint procedures qualification test (JPQT) records.The agreement provides for the process that allows the issuance of JPQTs.The respective parties have recognized that each organization should maintain the integrity of its own program.The agreement provides for issuance of JPQTs under the following conditions: The five-year re-qualification required by the NCPWB program would include the local UA ATR.The presence of an agent of the UA and the NCPWB will warrant the issuance of applicable joint welder qualifications. The UA and NCPWB will jointly administer (witness) new welder qualification tests performed by either organization. The updating of welder test qualifications through the maintenance of continuity records will be accomplished in a similar fashion. Welders, with UA weld test qualifications, working for contractor members of the NCPWB, can be issued joint UA/NCPWB welder qualifications.This assumes that the process performed by the welder is applicable to weld test procedures common to both the UA and the NCPWB. s

New and Revised WPSs Have Been Distributed

Recently the Bureau distributed a package of updated Welding Procedure Specifications (WPSs) and accompanying Welding Performance Qualification records in addition to two updated Brazing Procedures. There were a total of 48 updated/new procedures and supporting documents distributed among the members. If you have not received your copy, please give us a call.

Membership Certificate
By now members of the Bureau should have received their membership certificates. The new certificate replaces the old plastic plaque which had to be renewed every year. The new certificate is a paper type and does not have to be renewed every year.

American Welding Society Publications

Filler Metal Comparison Chart FMC: 2000. This is a collection of over 80 producers and marketers of filler metals providing trade names of thousands of products conforming to AWS filler metal classifications. Guide to Weld Discoloration Levels on Inside of Austenitic Stainless Steel Tube, D18.2: 1999. This standard provides a visual comparison guide that can be used to specify surface discoloration (heat-tint) criteria for sanitary (hygienic) welds in austenitic stainless steel tube. Specification for Resistance Welding of Carbon and Low-Alloy Steels, C1.4M/C1.4: 1999. This specification provides for a quality program covering the minimum shear strength and weld button diameter requirements for carbon steel and low-alloy steel. Process Specification for Electron Beam Welding C7.3: 1999. This specification on electron beam welding discusses applicable specifications, safety requirements, fabrication, quality examination, equipment calibration and maintenance, approval of work, and delivery of work.
These publications can be ordered directly from the AWS by calling (800) 443-9353. s

NCPWBulletin
is published periodically by the National Certified Pipe Welding Bureau at its national office. 1385 Piccard Drive Rockville, MD 20850-4340 (301) 869-5800 Dariush Nikpourfard, Editor

NCPWBulletin

Development of Joint Welder and Brazer Qualification Procedures

The Bureau has developed joint procedures that cross-reference the UAs entire welder qualification procedures with the Bureaus procedures.There are a number of UA procedures that are repeated when cross-referenced with the Bureau procedures.The following is a list of cross-referenced procedures that soon will be distributed to Bureau chapters.

CROSS-REFERENCED JOINT UA/NCPWB WELDER QUALIFICATION PROCEDURES PROCESS NCPWB WPS UA WPS NCPWB/UA JPQT SMAW SMAW/SMAW SMAW/SMAW GTAW/SMAW SMAW/SMAW GTAW/ SMAW GTAW/SMAW GTAW GTAW GTAW/SMAW GTAW/SMAW GTAW/SMAW GTAW/SMAW/SMAW SMAW/SMAW SMAW/SMAW SMAW/SMAW GTAW/SMAW GTAW/SMAW GTAW/SMAW GMAW-S/GMAW-FC (FCAW) GMAW-S/GMAW-FC (FCAW) GMAW-S/GMAW-FC (FCAW) GTAW - Automatic GTAW - Automatic GTAW GTAW GTAW - Automatic 1-1-3 1-12-1 1-12-1 1-32-1 1-12-1 1-32-1 1-32-1 8-32-1 8-32-1 8-32-1 8-32-1 1-32-1 1-32-1 & 8-2-1 1-12-1 1-12-1 1-12-1 1-32-1 1-32-1 1-32-1 1-57-1 1-57-1 1-57-1 8-3-4 & 8-3-3 8-3-4 & 8-3-3 1-32-1 1-32-1 8-3-4 UA-1 UA-2 UA-2 UA-2 UA-2 UA-3 UA-3 UA-4 UA-4 UA-4 UA-4 UA-5 UA-6 UA-7S & UA-21SM-d UA-8 UA-9S UA-9T UA-10 UA-11 UA-12 UA-12 UA-12 UA-13 UA-14 UA-15 UA-16 UA-20 JPQT STD-01 JPQT STD-02 JPQT STD-21SM-d JPQT STD-22GT/SM-d JPQT STD-23SM-D JPQT STD-03 JPQT STD-07T JPQT STD-04 JPQT STD-41GT/SM-d JPQT STD-42GT/SM-d JPQT STD-43GT/SM-d JPQT STD-05 JPQT STD-06 JPQT STD-07S JPQT STD-08 JPQT STD-09S JPQT STD-09T JPQT STD-10 JPQT STD-11 JPQT STD-12 JPQT STD-17 JPQT STD-17A JPQT STD-13 JPQT STD-14 JPQT STD-15 JPQT STD-16 JPQT STD-20

CROSS-REFERENCED JOINT UA/NCPWB BRAZER QUALIFICATION PROCEDURES PROCESS NCPWB BPS UA BPS NCPWB/UA JPQT Torch (diameter if pipe or tube: 3/4 in) Torch (diameter if pipe or tube: 1-1/2 in.) 107A-1 107A-1 UA-TB7-BPS UA-TB7-BPS JBPQT 44 JBPQT 45

February 2000

A MESSAGE FROM THE CONSULTANT

A SUMMARY OF THE ACTIVITIES OF ASME SUBCOMMITTEE IX DECEMBER OF 1999
The following is a summary of the changes that will appear in the 2000 Addend of ASME Section IX. These changes and related discussion are reported by Walter J. Sperko, P.C., vice-chairman of Subcommittee IX; readers are advised that the opinions expressed in this article are those of Mr. Sperko and not the official opinion of Subcommittee IX.
Walter Sperko NCPWB Technical Consultant

Two major changes to Section IX that have been in the works for some time will appear in the 2000 Addenda.Although these items only drew one negative at Subcommittee level, they drew three at the Main Committee; four negatives at Main Committee would have killed these items. The changes are:
AWS Standard Welding Procedures (SWPS) will be permitted to be used without qualification. The thickness of weld that a welder will have to deposit to be qualified for unlim-ited thickness is reduced from 3/4 to 1/2 inch.

Use of AWS Standard Welding Procedures (SWPS) will be permitted without qualification by each contractor. Instead of qualification, each contractor will have to perform a demonstration test weld following a typical SWPS and document it.The purpose of this test weld is to demonstrate and document that the contractor knows enough about welding to follow the SWPS.After one demonstration, most other SWPSs may be used without further demonstration. Smart contractors will do this demonstration weld in conjunction with a welder test. SWPSs that fall into this program are those for welding P/S-1 and P/S-8 metals using SMAW, GTAW and GMAW-FC.Typical thickness ranges are 1/8 to 1-1/2 inches, and both as-welded and postweld heat treated procedures (for P/S-1 metals) are available.The permitted SWPSs will be listed in Article V of Section IX; contractors who

elect to use them will have to purchase them from AWS (1-800-443-9373). Site license purchase arrangements are available in addition to individual SWPSs.As it stands,ASME will not reproduce SWPSs as part of the Code as it has the filler metal specifications. WPSs qualified by NCPWB or other technically competent groups or agencies do not fall under these new rules of Section IX; only AWS-published,ANSI-approved SWPSs may be used under these provisions.This change does not affect the use of NCPWB WPSs for B31 construction in any way except that contractors may also use the SWPSs. NCPWB WPSs are still valid and useful; in fact, NCPWB WPSs cover more materials, more processes and greater thickness ranges than the SWPS do or likely ever will. A form is included with the changes to make it easy to document the demonstration test. The benefit that the writer sees for piping contractors from SWPSs is that they are industry standards that a contractor should not have trouble getting approval by cus-tomers (i.e., a reduction in hassle-factor) if they are submitted. Also, permission of the owner is not required. The thickness that a welder will have to deposit to be qualified for unlimited thickness will be reduced from 3/4 to 1/2 inch provided the welder deposits at least 3 layers of weld metal with the process.
Continued on next page

NCPWBulletin

Readers are reminded that the thickness of weld deposit t used in determining the thickness that a welder is qualified to deposit is limited to a single welding process and single set of variables. See QW-306. That is, if a welder tests using GTAW and SMAW, the approximate thickness of GTAW is measured and that thickness is used to determine the thickness that the welder is qualified to deposit using GTAW. Similarly, the approximate thickness of SMAW (excluding reinforcement) is determined, and that thickness is used to deter-mine the thickness that the welder is qualified to deposit using SMAW. If the test coupon is welded using E6010 (F-3 electrode) followed by E7018 (F-4 elec-trode), the thickness that a welder is qualified to deposit is determined in the same manner.That is, the approximate thickness of E6010 is measured and that thickness is used to determine the thickness that the welder is qualified to deposit using F-3 electrodes. Similarly, the approximate thickness of E7018 is measured and that thickness is used to determine the thickness that the welder is qualified to deposit using F-4 electrodes. If the test coupon is welded using GMAW-S and the root is made using downhill progression and the fill passes are made using uphill progression, the thickness of each progression direction must be determined and used separately to determine the thick-ness that the welder is qualified to deposit downhill and the thickness that he is quali-fied to deposit uphill. It should be noted that, when two processes or variations of processes are used, other variables, such as backing, backing gas, filler metal type, transfer mode, etc. may be different for each process and should be documented separately for each process and variation of process. A workable method for doing this is to separate variations on a line by a slash (/). For example, one might record backing on the above E6010/E7018 test as:
Variable Actual Value Range Qualified Backing: None/Used Optional/Required

Although this change should reduce testing cost somewhat, it will probably not result in an industry-wide switch to thinner test coupons. This is because an NPS 6 XXS (0.864 wall) coupon after counterboring is only 0.756 inches thick. If a counterbored coupon is used, it cannot be used for a combination process qualification under the 3/4 inch rule to get unlimited thickness for the welder; it can be used for unlimited thick-ness under the 1/2 inch rule. In other less dramatic matters, a Code Case was passed to permit use of ultrasonic ex-amination in lieu of radiography for welder qualification.The Case is complex and limited. Size limits are that the thickness must be 0.20 inches minimum, and, if pipe, not less than 4.5 inches outside diameter and, the thickness may not exceed 0.062 times the pipe outside diameter. NPS 6 Schedule 40 (0.218 wall) pipe fits these criteria but Schedule 80 and heavier do not. Its not much use, but the NDE guys wanted to be sure that the procedures and techniques were clearly defined and able to be used without state-of-theart (i.e., expensive) equipment. Three columns will be deleted from the nonferrous portion of QW/QB-422 (the P/S-number table), allowing the font to be increased making the table easier to read. Editorially, the column for Alloy was combined with the Type and Grade column and the Thickness column was combined with the Product Form column. Of greater consequence, the column Condition was also deleted.This column identified heat treatment conditions such as annealed, hot worked, cold worked, solution hardened, etc. Many lines of materials where multiple conditions were possible were deleted, such as in the copper and aluminum alloys; the only line for any specification, type and grade that was left in the table was for the annealed or hot rolled condition material.The tensile strength shown in this remaining line in QW/QB-422 is the annealed or hot rolled tensile strength.This tensile strength is the minimum tensile strength that tension test specimens must meet to be acceptable. See QW-153 for the specifics on tensile test acceptance criteria. Some editorial changes are still in process to clean up details in

February 2000

QW-150 resulting from this change, but those changes will not appear until the next addenda. There will be a major format change to QW432, the F-number table. Each AWS classification of electrode will be listed on its own line and assigned its F-number.Where all classifications within an SFA Specification are the same F-number, such as in SFA5.18, the AWS classification will simply be All Classifications.This will make the table longer but easier to read, and it will eliminate constant corrections that the Subcommittee has to make to the number of XXXs for SAW and FCAW filler metals. Those who weld aluminum using SMAW will be ecstatic to know that the latest version of AWS A5.3, Specifications for Aluminum and Aluminum-Alloy Electrodes for Shielded Metal Arc Welding has been approved.Thats right. Aluminum SMAW. Go figure. The terminology for acceptance criteria for bend, section, peel and other tests in Section IX has been revised. Many years ago,ASME recognized that part of the legal definition of the term defect was that a part with a defect was unacceptable.When this was recognized, various acceptance standards, particularly those associated with nondestructive examination and inspection, were changed to recognize that flaws and discontinuities in materials could be acceptable if they did not exceed certain acceptance criteria, but that a defect wasby definition rejectable.Accordingly, the term defect was purged from all acceptance criteria and the terms flaw and discontinuity were promulgated to describe conditions that may or may not be acceptable. Section IX is catching up to that change by eliminating the term defect from all acceptance criteria, such as QW-163 for bend tests, and replacing it with discontinuity.This is not a technical change except in a purely legal sense. (I know.An oxymoron. Legal Sense ). The radiographic method requirements in QW-191 have been revised No longer will a written radiography procedure be required. Instead of a procedure, demonstration of the density, penetrameter image and essential hole size requirements of Section V on the film are required.

The use of penetration-enhancing flux (ITWs FasTIG) is going to become a nones-sential variable for GTAW. For those who do machine welding, the term oscillation and weave and stringer have not been used consistently.As it stands, the Subcommittee will review the use of these terms and apply oscillation to machine and automatic welding and weave or stringer to manual and semi-automatic welding. It may turn out that both terms will appear in the same variable for some applications. Regrettably, the action to create separate forms for welder qualification and welding operator qualification has been hung up in the Subgroup on General Requirements.These new forms, which will make it easier to document what welding operators actually did, should be in the 2001 addenda. There is an effort to bring all requirements for temper bead welding in Section IX.Temper bead rules are currently found in Sections III, XI,VIII and the National Board Inspection Code.Temper bead welding is used in lieu of postweld heat treatment (PWHT) where heat treatment is impractical or impossible; it involves very closed con-trol of welding heat input and bead placement, particularly near the base metal. It is anticipated that temper bead techniques could replace PWHT for carbon steel of great thickness and alloy steels. Using temper bead in lieu of for field welds on piping could save the industry a lot of money. Section IX users should be aware that ASME has adopted two filler metal specifica-tions that are not required to be followed by may prove useful.These are SFA 5.32, Specification for Welding Shielding Gases, and SFA 5.31, Specification for Fluxes for Brazing and Braze Welding.The shielding gas specification gives standard designations for shielding gas that will be found on gas bottles in the future.The specification contains purity limits, dew point limits and, for mixed gases, composition limits. Examples of classifications are:

Continued on next page

NCPWBulletin

SG-A SG-AC-25 SG-AO-8 SG-ACO-10/2

Argon Argon, 25% CO2 Argon, 8% Oxygen Argon, 10% CO2, 2% Oxygen

Welcome New Members

Since the last publication of the newsletter, nine new contractors have joined the Welding Bureau. We welcome these new members. The Bureau ended 1999 with 30 new members. Chicago Arctic Engineering Co. Quality Control Systems Cincinnati Cincy Mechanical, Inc. Detroit E. L. Pipe, Inc Kentucky Piping Specialties, Inc. F. S. Schardein & Sons, Inc. Rochester Finger Lakes Piping, Inc. Tennessee T.W. Fondren Co., Inc. W. Michigan Pressures & Pipes, Inc. Northeastern PA Construction Unlimited, Inc. National Marelich Mechanical Co., Inc.

It is not required that one uses these classifications yet. But if gas suppliers start to use them, these designations would be a good way to identify shielding gas on a WPS. For brazing fluxes, there is a table of flux classifications that can be used to identify fluxes. Present Section IX rules require that a BPS be requalified if the composition of the flux is changed.The only way to meet these requirements is to qualify and stick with one brand name. One could reasonably argue that the classification controls the flux chemistry as well as the brand name.The Subgroup on brazing is working on incorporating the brazing flux classifications into Section IX. The Subcommittee answered an interesting inquiry about diameter qualification for welders of small nozzle welds. Is it necessary to qualify a welder on NPS 2 or smaller pipe if he is going to groove weld a 3/4 inch class 3000 coupling (about 1-1/2 inch OD) to an NPS 24 header? The reply was that it depends on which is beveled. If the coupling is beveled, the answer was yes. If the header is beveled, the answer is no.The difference is easy to understand if one recognizes that, when the fitting is beveled, the resulting groove is similar to a pipe butt weld, but when the header is beveled, the re-sulting groove is like a solid bar inserted into a hole.This inquiry is of little interest to piping contractors since the branch pipe is customarily beveled, but for vessel fabricators, beveling the header (or the vessel wall) is common practice.This distinction is not covered per se in Section IX; the inquiry is and old one, IX-80-67. s

NCPWB Calendar
2000 April 1619 Technical Committee Meeting Westin La Paloma Tucson,AZ

October 1517 Board of Trustees Meeting The Broadmoor Colorado Spring, CO 2001 March 1822

Technical Committee Meeting Amelia Island Plantation, FL

October 1417 Board of Trustees Meeting Diplomat Hotel Hollywood, FL

February 2000