Manufacturing Technology- I

Introduction to
ASME Sec. IX
S.C.Ghosh
5-Oct. 2006
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ASME Sec. IX
General

guide

lines

for

procedure

and

performance

qualification
Referenced by all ASME code of construction
Covers welding as well as Brazing operations

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Welding procedure specification (WPS)

Procedure Qualification Records (PQR)
WPS:
It is a written procedure prepared to provide welding parameters for
making welds as per code requirement.
Can be used on production only after successful qualification of
supporting PQR(s).
A WPS can be supported by one or multiple PQR(s).

PQR:
Record of the actual welding data used to weld a test coupon.
Also contains test results (Mechanical, Chemical & Non Destructive Test)
of the test coupon.

One PQR can support one or multiple WPS(es).

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Different types of variables in WPS

Essential variable:
A change in welding condition which will affect the mechanical
properties other than toughness of weldment
Any change in this variable calls for re-qualification of PQR

Supplementary essential variable:

A Change in welding condition which will affect impact toughness of
weldment
Change in this variable calls for re-qualification of PQR in case there is
requirement of impact toughness for the vessel

Non - essential variable:

No change in mechanical properties is expected

A WPS shall record all essential, supplementary essential &

non essential variables
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Different types of variables in WPS

Grouping of Base Material:
To reduce number of qualification, materials are grouped
into P Numbers or Parent metal numbers and Group
numbers
List of most commonly used P Nos is given in next slide

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P Numbers of Commonly Used Materials

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P Numbers of Commonly Used Materials

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Different types of variables in WPS

F numbers:

Grouping of electrode on their usability characteristics

Determine the ability of welder to deposit sound weld.

List of most commonly used F Numbers is given in next

slide

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F Numbers of Commonly Used Consumables

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Different types of variables in WPS

A-No:
Identification of weld metal chemical composition.
To reduce the no of qualification
List of most commonly used A-No is given in next
slide

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A Number

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Different types of variables in WPS

QW 402: Joints
Non essential variables Groove design,
Backing,
Root gap,
Retainers

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Different types of variables in WPS

QW 403: Base metals
Essential variables P No,
Thickness of base material qualified,
Thickness of each pass beyond 13 mm for multipass welding

Supplementary essential variables Group no for base material

Minimum thickness of base material qualified

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Different types of variables in WPS

QW 404: Filler Metals
Essential variables

F no,
A no,
Thickness of deposited weld metal
Flux / wire class,
Alloy addition through flux (SAW),
Re-crushed slag (SAW)

Supplementary essential variables Electrode Diameter > 6 mm for SMAW

Non essential Variables

Change of Electrode Diameter for SAW

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Different types of variables in WPS

QW 405: Positions
Supplementary essential variables Change from any position to vertical uphill progression for SMAW.

Non essential variables

Change in position.

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Different types of variables in WPS

QW 406: Preheat
Essential variables

Decrease of more than 55C in the preheat temperature qualified.

Supplementary essential variables

Increase of more than 55C in the interpass temperature qualified.

Non essential variables

Change of preheat maintenance i.e. Dehydrogenation Treatment (DHT) etc.

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Different types of variables in WPS

QW 407: PWHT (Post Weld Heat
Treatment)
Essential variables Any change in the following conditions:

No PWHT,
PWHT below lower transformation temperature,
PWHT above upper transformation temperature,
PWHT between upper & lower transformation temperature.

Supplementary essential variables

Increase in job PWHT soaking time beyond 20% of the
soaking time qualified in PQR.
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Different types of variables in WPS

QW 408 : Gas
Essential variables Single shielding gas to mixture of gasses,
Different types of mixed gasses,
Percentage composition of gasses for GMAW, FCAW, GTAW process

Non essential variables

Flow rate,
Backing gas flow rate
Backing gas composition

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Different types of variables in WPS

QW 409: Electrical Characteristics
Supplementary essential variables Increase in heat input ,
Change in current type ( AC / DC),
Change in Polarity (DCEN / DCEP)

Non essential variables

Change in current range,
Change in range of voltage (except SMAW & GTAW)

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Different types of variables in WPS

QW 410: Technique
Supplementary essential variables Change in multiple to single pass per side .
Change of Single to multi electrode for SAW

Non essential variables

Change of Stringer bead to Weave bead technique or vice versa,
Method of cleaning,
Method of back gouging,

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Standard WPS Format (sheet 1 of 2)

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Standard WPS Format (sheet 2 of 2)

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Standard PQR Format (sheet 1 of 3)

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Standard PQR Format (sheet 2 of 3)

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Standard PQR Format (sheet 3 of 3)

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Welder Performance Qualification

Purpose
To validate the capability of an welder to deposit sound weld metal
following a qualified welding Procedure
Establish the range of qualification to minimize the number of
qualification
Guide line for renewal of qualification

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Welder Performance Qualification

Welder
Person performing welding by manipulating arc by hand

Welding Operator
Person performing welding by controlling the manipulation of arc
by machine

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Welder Performance Qualification

Requirement for Welder Qualification:
A welder qualified by a company cannot be used by another
company
When a welder changes a company fresh qualification is
mandatory

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Welder Performance Qualification

Essential variable:
A change in welding condition which will affect the ability
of welder to deposit sound weld metal
Any change in this variable calls for re-qualification

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Welder Performance Qualification

Essential variable for SMAW, GTAW as per Sec.
IX
QW 353, 356
A change in welding condition which will affect the ability
of welder to deposit sound weld metal
Any change in this variable calls for re-qualification

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Welder Performance Qualification

Essential variable for SMAW, GTAW as per Sec. IX
QW 353, 356

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Welder Performance Qualification

Essential variable for Machine welding ( SAW), QW 361.2
A change in welding condition which will affect the ability of
welder to deposit sound weld metal
Any change in this variable calls for re-qualification
Essential Variables

Change in welding Process

Change from direct to remote visual control
Deletion of Auto joint tracking
Addition of welding position not qualified
Deletion of consumable inserts
Deletion of backing
Single pass per side to multi pass per side

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Welder Performance Qualification

Welding Position for joints : QW 405.1, .3

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Welder Performance Qualification

Welding Position for joints : QW 461

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Welder Performance Qualification

Qualification Range

Thickness of weld metal

Position
Pipe diameter
Filler metal
Base metal (for manual or semiautomatic processes)

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Welder Performance Qualification

Qualification Range- Thickness of weld metal

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Welder Performance Qualification

Qualification Range- Position

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Welder Performance Qualification

Qualification Range- Pipe diameter
OD of Test coupon,mm
Less than 25 mm
25 to 73,mm
Over 73 mm

Minimum OD Qualified, mm
Size welded
25 mm
73 mm

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Welder Performance Qualification

Qualification Range- Filler metal

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Welder Performance Qualification

Qualification Range- Base metal , QW 425

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Welder Performance Qualification

Test for qualification Butt Joints

Mechanical test: Visual Examination and bend

test (QW302.1 &.4)

NDT: RT , 150mm length (QW304)

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Welder Performance Qualification

Test for qualification: Weld overlay

Mechanical test: Side bend

NDT: PT
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Welder Performance Qualification

QW322
Renewal of qualification: After every six month based on production
work, or welding a separate test coupon

Suspension of Qualification:
- If process is not used in last six month
- If there is specific reason for doubting the skill

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Welder Performance Qualification

Record of Qualification

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Welder Performance Qualification

List of reference:
ASME Section IX,Edition 2004

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