MSTS Visual Exam (QW-194) ¥ Checks for External defects v Exam prior to other additional tests v Acceptance Standards " No incomplete penetration * No lack of fusion | * No cracks ery | “Gorilla welds” ~ Your call v Overheard in the last class concerning the instructor, "He certainly takes a long time to make his pointless“. \ a Did you ever meet this type of inspector? @ "When his IQ reaches 50, he should sell!" < Or how about this guy, a real team player? "This inspector should go far, and the sooner the better" @.MSTS i iL ASME Sect IX-- Welding Radiography (Qw-191) ¥ Checks for Internal defects Y Performed to ASME Section V V Acceptance Standards = No Cracks, LOF, IP = Elongated - depends on weld thickness = Rounded - size and density limitations (see Appendix I) 4g)Welder Qualification ‘Make Tost ep] tex Sm} te Coupon Coupon Joe Welder 4 Visual + Position, Bend or RT fy tlckness 6 / ge weg Posiions, Pot Fb, Pipe Diameter, thickness, ee ‘Ifyou understand this proces, ad the details. yon understand all you need to know about Welder Qualification it Welder Qualification Steps 1. Qualified by weld Process (SMAW, GTAW,...) 2. Welder makes a “Test Weld” 3. The “test weld” is Tested (Bend Tests or RT) 4. If the “test weld” passes, the Welder is qualified. WITHIN CERTAIN LIMITS 11! Data from this qualification process is recorded on the WPQ (welder’s paper) “ Welder Qualification Methods Per QW-300.1 A welder or welding operator may be qualified by: 1) radiography of a test { ae Qeode 2) radiography of his initial weld 3) or by bend tests taken from a test__ Coo MSTS 19fy tt a | i rm SS Welder Qualification - The Test Weld | Y Test Coupon - Bend Tests QW-302.1/3 "= Number and Type of Bends - At least 2 bends. QW-452 * Specimen shape & locations QW- 463.2 (a-h) Y Test Coupon - Radiography QW-302.2 * Minimum length - 6” = For pipe - Full circumference ¥ 1 Production Weld - Radiography " Welders - Minimum length - 6 inch QW=304.1 " Welding Operators - Min length - 3 ft QW-305.1 3S Test Coupons cam either be late of Pipe i! + Welder Qualification Details 1. Ist - Visual Exam performed prior to Bend Test 2. Awelder may have multiple WPQ's. 4) Different WPQs for different welding process; SMAW, GMAW, ete b) Multiple WPQ’s for same welding process. No one test qualifies the welder for all materials, F-#'s, etc. Note! Radiography can not always be used to qualify a welder, but ..bend tests always can |!! See QW-304 RT is not allowed when using: 1) GMAW short-circuit mode — 2) Some materials: P-21 thru 25, P-51 thru P53, ete.Y Expiration of Qualification QW-322.1 *" Welder has not used the Process for 6 months = Reason to question welder’s ability Y Fail a Qualification Test QW-321.1/2/3 = Retest using same test - Flunked bends, then” g must pass bends - can't substitute RT " Do twice as much - Originally 6” weld tested, now have to pass 12” weld . Code Quotes QW-321.1 “When the qualification coupon has failed the visual examination cnn Fetesting shall be by ° examination before conducting the mechanical testing. When an immediate retest is made, the welder ... shall make consecutive test coupons ..."" QW-321.2. “When the qualification coupon has failed the mechanical testing sun Fetesting shall be by testing. When an immediate retest is made, the welder ... shall make consecutive test coupons ...”” | QW-321.3 “When the qualification coupon has failed the radiographic examination ..., the immediate retest shall be by the examination method.” @) For plate: plate coupons, each at least long b) For pipe: pipe coupons, a total of weld including the entire circumference ©) For welding operator: an addition production weld of the same STS 21ASME Sect IX- Welding Welder Qualification - The WPO The WPQ (welder’s papers) records: 1. Welder data - Name, Stamp # 2. “Actual Values” - Data about the Test Weld * Process Used, Weld Procedure Used «Essential Variables (thickness, position, etc.) 3. Test Results = Type of tests performed, pass vs. fail 4. “Ranges Qualified” - Limits on Field Welds 5. Certification - Authorizing Signature Fg D Exercise W-7 Reviewing a WPQ Let's review our first WPQ. Find Doug Tozel's WPQ at the end of this section. (pg. WA-1) Remove it and find the five major sections of the WPQ! + What is the maximum thickness Doug can weld? + What type coupon did Doug use? Pipe or Plate + What type of test(s) were performed? + List one weld discontinuity that was not in this weld. + Who certified this WPQ? + What F-Number was used for this test? + What test position did Doug use? + Doug is qualified for what field positions? + Doug is qualified for what maximum pipe diameter? Range Qualified - During production welds, the welder must stay within this range? Section IX species the manimanceceptable range, based on what wes done diving the welders ad) “west el For example: Ifthe Actual Value (the est weld) isin the 1G position, per Seetion IX the Range Qualified is Flat. This welder ean only make produetion welds in the lat position! MSTS 22Welder Qualification - The WPQ Essential Variables Y Factors with Significant Impact on Weld Y Defined by Welding Process (QW-350 or QW-416) ¥ Must be recorded on the WPO = “Actual Value” data about the “test weld” = “Ranges Qualified” limits for field welds f Essential Variable - If a production weld is outside ‘that allowed by the WPQ's range qualified, it is Essential that the welder be requalified! QW-353 SHIELDED METAL-ARC WELDING (SMAW) Essential Variables & Paragraph Briefof Variables | Reference/Comment W402 Joints 4 | = Backing Testking sae es wor QW-403 Base Metals [16 | Pipediameter | _QW-4523 18 | 6 PNumber Qwe423.1 Qw-aoe Filer Metals [15 | ¢ F-Number was 30_| @ 1Welddepost | QW-AS21 QW-405 Positions 1 + Position QW-461,9 3 | ON Vertical welding | Same as tested Ly site tn yout Cote Time to Highlight! Highlight SMAW, SAW, GMAW, GTAW MSTS 234 ASME B&PV Section IX — Welder Qualification Exercise W-8 > Reviewing a WPO QW-484 SUGGESTED FORMAT FOR WELDER OR WELDING OPERATOR PERFORMANCE QUALIFICATION (WPQ) (See QW-301, Section IX, ASME Boiler and Pressure Vessel Code) Welders name _Doug Toc (Clock number_ABCI25, Stamp no._NC#32 Welding proces(s)used_SMA\ Type _ Manual denttcation of WPS fllowed by welder during welding of test coupon _WPS-HARS Base materials) welded _SA-106 ta $8106 “Thickness _ 0.218" 7 F anual or Semiautomatle Variables for Each Process (QW’380) ‘Actual Values Range Qualified Backing (metal, weld metal, welded from both sides, x, et.) (QW-A02) Nene. With or Wi ASME PXNo._1 _10 ASME Po, (QW-403) P:ltoP-1 PL foPI1, P34, psx ( )Phte (3 )Pipe (enter diameter, i pps) anes Pore OD. Filler meta spesitiation (SFA): Classification (QW-408) su Fille metal No, 3 E.LtoF:3 wi Bask Filler metal variety for GTAW, PAW (QW-204) Consumable inser for GTAW or PAW Weld deposi thickness fr each welding process Welding position (1G, 6, et.) (QW-405) Progression (upiliowahil) Backing gos for GTAW, PAW, or GMAW fuel gas for OFW (QW=408) GMAW transfer mode (QW-409) GTAW welding curent typefplaity Machine Welding Varlabes forthe Process Used (QW-360) Actual Values Direevremete visual contol ‘Automatic votage contol (GTAW) ‘Automatic joint racking Welding position (1, $6, et) Consumable insert, Backing (mel, we metal, welded from both sides, fx, et) ‘Guided Bend Test Result Guided Bend Tests Type ( )QW-462.2 (Sie) Resuls——( JQW-A52a) Tans RAF) ) QW-ASD30 (Long RAF) ‘Visual examination results (QW-3024) OK Radiographic test results (QW.304 and QW-305) _ OK (oralrerative qualiteation of groove welds by radiograpy) Fillet Weld - Fracture test Length and percent of detects in ‘Maco test fasion Fillet legsize nx In. Concavitylanvexity in Welding test conducted by _ ACME Fabrcstors Mechanica ests conducted by _Usoh Lats Laboratory test na. 201.08 ‘We certify thatthe statements in this record are corset and that te test coupons were prepared, welded and tested in cordance with ‘the requirements of Section IX ofthe ASME Code, Organization _ACME Fs eee ae _ 226001 _ wy Rb Ready (Copies from ASME BRPY Code Setien IX - 42000 - MSTS) MSTS WA-LASME Sect IX- Weldinj Essential Variable Process | i Lol se | ae || en | ine Qualified Weld a test weld Can Don make a specific production weld? It depends on his “Range Qualified” ! Exercise W-8 Completing a WPQ Let's complete a WPQ. Find Don Aucoin’s WPQ at the end of this section. (pg. WB-9) Remove it and we'll add the right data in the Range Qualified column, Keep your Section IX open to the Welder’s Essential Variables. Note! For future reference, this exercise is worked out on pages WB-I thru 8. STS 24ASME B&PV Section IX — Welder Qualification Exercise W-9 — Completing a WPQ QW-484 SUGGESTED FORMAT FOR WELDER OR WELDING OPERATOR PERFORMANCE QUALIFICATION (WPQ) (Gee QW-301, Section IX, ASME Boiler and Pressure Vessel Code) Weide nme on Aven Clocemumber _ABCESS Samp o._Wxk Wetgngprossis(s) wed _SMAW “ype ee enfcaton of WPS followed by welder ring welding oft coupon _WES-777 Basse mse) welded SAc10910 SAO eke 0.288" “Manual or Semiautomatic Variables for ach Process (QW-880) Actual Values Range Qualified Backing et, weld neta, welded from both sides, fx, 2) (QW-#02) None oa pul ASMEP-No._1 19ASMEPNo. (QW-A03) PeLio { (yet COC) Pipe ener diameter tie) arg 7 3 er etal specication (SFA): Clssiaion (QW-408) 5 i Filer etal NO. Ha ? ile etal arity for GTAW, PAW (QW-404) NA Consumable insert for GTAW or PAW NA Wal deposit ticks foreach weding process (HOSS? 288 5 Tee Weidng poten (16, 5G, e6) (QW-403) TGRowed = Progression upifdowailh wa WR Backing gs for GTAW, PAW, or GMAW: ul gs fr OFW (QW-08) (GMAW waster made (QW-408) COTAW welding cure ypptrty Machine Welding Variables forthe Proves Used (QW) Range Qualified Direcveemote visual contrat ‘Automatic voltage control (GTAW) ‘Avtomati joint tacking ‘Welding position (16, 5G, et) Consumable insert, ‘Booking (metal, wed metal, welded from both sides, fet) Guided Bend Test Resa Guided Bend Tests Type ( )QW622(SileyResela —(XJQWHELK)CTme REA () QN-KOINY (Lone REF) Root Te Linear Fave None l ‘Gini gammcimtcveansnowanmay gy Radiographic test results (QW-304 and QW:305) _NW/A (Foralerative qualification of groove welds by radiography) Fillet Weld - Fracture wst Length and percent of defects in Macro ts fusion Fillet Teg size in in. Concavtylonvexity in Welding test conducted by ACMEFabriators “Mectanica tests conducted by _Uyoh Las Laboratory test no. 299-08, ‘We cetfy that the statements in this record are core and ha the est coupons were prepared, welded and tested in accordance with the quirements of Section IX ofthe ASME Code. COrganiration _ACME Fabsicaors Date _ 2/189 ast By {Copied srom ASME BALPV Code Section IX -4/2000 - MST) MSTS WB-9MSTS Weld Procedure Qualification Data recorded on POR ‘you understand this proces, and the details. you understand ‘all you need to huow about Held Procedure. Quallfeaton {12 Weld Procedure Qualification Steps 1. Aweld procedure (WPS) is developed pd ftp 2. Welder makes a “Test Weld” using the WPS. 4) Coupon can be either plate or pipe. Normally they use plate 3. The “test weld” is Tested - Tension Tests & Bend Tests, (No RT) a) QW-451.1 Specifies number and type of tests 4. Ifthe “test weld” passes, the WPS is qualified. WITHIN CERTAIN LIMITS !!! 5. Data from this qualification process is recorded on the POR (Procedure Qualification Record) 4) The POR supports the WPS. 4) Sometimes multiple POR’s are required to support a single WPS. What's different between this and qualifying a welder ? 1) Two Documents - WPS & POR 2) Different type of tests are performed 3) Addition of “Non-Essential” variables 25@ ThewPS&POR & ¥ Why 2 documents? = Too much info, doesn’t fit on 1 sheet of paper v POR - Data about Test Weld = Similar to WPQ’s “Actual Values” = Test Results = Certification (Signature) Y WPS - Recipe for Production Welds = Similar to WPQ’s “Range Qualified” we * Places limits for production welds Exercise 9 Reviewing a WPS & POR ? Let's look at a WPS & POR and find some data. Find WPS-225 & POR— 321 on pages WC-I thru 4. For the WPS determine the following: 1) What Rod Diameters are allowed? ly! 2) Is PWHT required? 3) What positions are allowed? 4) What base metal thicknesses are allowed? 5) Can this WS be used for square-bevel joints? 6) What materials can be welded? For the POR determine the following: 1) What base metal thicknesses was used? 2) What was the F-Number used? 3) What welding position was used? Notice how the WPS and PQR are divided into blocks by subject matter; Joints, Base Metal, Filler Metal, Positions, ... This makes it easier to find data! : fannie tal MSTS 26ASME Sect IX - Weldin Procedure Variables L_ a Variables listed by Welding Process (QW-25X) Y Essential Variables ® Significantly affect weld's mechanical properties * Must be recorded on both the WPS & POR: = POR Value must support the WPS value Y Non-Essential Variables = Don't significantly affect weld’s mechanical properties = Must be recorded on the WPS only Y Supplement Essential Variable - Not on API exam © Become essential only if impact testing of weld is req'd Welding Variable Notes 1. When reviewing the WPS & POR, what's the Number I mistake? Confusion about the Essential & Non-essential Variables! 2. References in Section IX determine how the POR must support the WPS. 3. Sometimes the POR supports a range of values on the WPS. 4. Which variables must the welder follow? Both essential and non- essential! The welder must follow everything on the WPS! 5. What if qualified welder makes a weld outside of the ranges allowed by _y y WPS? It’s a Non-Code weld ... REJECTABLE! pee RD 6. What if a non-qualified welder makes a weld within the ranges allowed by WPS? It’s a Non-Code weld .., REJECTABLE! Essential Variables - When changing an essential variable on the WPS beyond the range qualified, IT IS ESSENTIAL to requalify the weld procedure. Non-essential Variables - When changing a non-essential variable on the WPS, IT IS NOT ESSENTIAL to requalify the weld procedure. As a result these variables do not need to be recorded on the POR, the qualification record! 27MSTS 2POR-100%F Same on? 2308 32F FS Pa @e 6 Note! In the review - start with the POR! Exercise 10 Evaluating a WPS & POR In this exercise we will review a WPS & it’s supporting POR and find any ‘mistakes. Remove WPS-225 and POR-321 from the manual. (pages WC-1 thru 4). On page WD-1 is a detailed procedure for evaluating a WPS. Also a checklist will be handed out in class, The secret to getting this right? Use the methodically process on WD-1. Note! For future reference, this exercise is worked out on pages WD-2 thru 4. The Essential Variable Roadmap awe WWM 7 Tinea | On api ai RA 7 alien Sew Genel ne ars area [a _[ oP | Na Se 3 [6 RNa | Ma Sine AAT Ea er eT generar [a | bsaes iar | wre ro ‘owaor evant [a | pwr Sie PT fay 4 [aims 11 | onsen leona LL tein your Code 28WPS # WPS-POR Checklist (SMAW Process) A, Checking Essential Variables 1) Turn to the list of Variable - For SMAW turn to QW-253 2) On the POR - Find the value for each essential variable and list this value in the POR Value colunn of the chart. When complete, put the POR away! ¥ On the WPS - Find the value for each essential variable and list this value in the WPS Value column of the chart. When complete, put the WPS away! 4) Start at the top of the chart. For the first essential variable, find the Section IX rules and determine the appropriate acceptance standard. List this value in the Accept Stds colunin. 3) Compare the WPS Value to the Accept Stds value and determine if it is acceptable, Write either Yes or No in the Ok? Column. 9) Repeat steps 4 & 5 for each of the essential variables. Complete the Essential Table Below (this is for the SMAW process) ey POR Aecept ; Essential Variate | POR Section IX Rule ia on Ti Limits > 8 inch Only applies for thick conponens | — Yes T (Base Metal) Qualified PerQW-4sia-(he tort) Meio e c 7Pass> inch Generally not ficor = fava P-Number Qualified Per QW-424.1— > q es P-Namber 5/9710 Adiional Limits ~ Read Reference F-Number vs Must be the Same 7) ma ‘Same, but Al & AZ are ml AeNuniber! eel interchangeable : ( ¥ \ t (Weld thickness) 7 Per QW-451.1 - t oy ‘he No Preheat Decrease > 10°F S€ |2P0R-100°F 53-15 > - 408 Tau PWHT Q ‘Same PWHT family iF yes Limit == | Only applies for thick components | = = [oe B. Checking Nou-Essentials C. Checking Testing (WPS Only —Are they Addressed?) (Specimens and. Acceptance Criteria) Ty Ne REL no y Wack. Goce yan A © 3) 3) “Tensew, 1 = det 4) 4) MSTS 5/2003(QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS) (See QW-200.1, Section IX, ASME Boiler and Pressure Vessel Code) Company Name __PRO-SPECT FABRICATORS, By __Joe Joe Byrant Welding Procedure Spec. No. __225 ___ Date__s719/1999 Supporting POR Nos)_321 Revision No. _ 0 _ Date Welding Process(es) __ SMAW. ‘Type(s) _ MANUAL. (Automate, Manual, Machine, or Semi-Auto) JOINTS (QW-402) c Details Joint Design __Double-Vee or Single-Vi Backing (Yes)__X (Na) _ xg ‘Backing Material (Type) ___ WELD META Sea ‘Rete toboh bosking dreary ©) Meat (©) Nonsing Meta No Retainers ©) Noumeatic —( ) Ober Mowed ‘Sketches, Production Drawings, Wel Symbols o Writen Description shoud show the gereral arrangement ofthe pars tobe welded Where applicable, the or spacing and the details of weld groove may be specified t (A¢ the option ofthe Mit, sketches may be attached to illistate joint design, weld ayers and bead sequen, “BASE METALS (QW-403) P.No, 1 GroupNo.___ to P-No. Group No.___ oR Specification type and grade on Chem, Analysis and Mech. Prop, ‘Thickness Range: to Specification type and grade to Chem, Analysis and Mech. Prop. Base Metal: Groove 1/16" Fillet__Same a Pipe Dia, Range: Groove __Greater than 1 NPS Fillet Same Other “FILLER METALS (QW-404) ‘Spec. No. (SFA)_$.1 AWS No. (Class) _E-6010, ENo. Fd ANo.___AlL Size of Filler Metals__1/8”, 5/32", or 3/16” Weld Metal Thickness Range: Groove__1/16" to 4" Fillet___ Sam Flectrode-Fiux (Class) Flux Trade Name Consumable Insert, Other “Each base metal-filler metal combination shouldbe recorded individually. MSTS (Copied from ASME B&PV Code Section IX - 4/2000 - MSTS) We-l‘QW-183 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR) (See QW=200.2, Section IX, ASME Boller and Pressure Vessel Code) Record Actual Conditions Used to Weld Test Coupon ‘Company Name __PRO-SPECT FABRICATORS __ PQR No. 321 WPS No. Date 5/19/99 Welding Process(es) __ SMAW. “Types (Manual, Automatic, Semi-Auto.) MANUAL JOINTS (QW-402) ‘a es, oo Groove Design of Test Coupon, (For combination qualifications, the deposited weld metal thickness shall be recorded foreach filler meal or process used.) BASE METALS (QW.403) POSTWELD HEAT TREATMENT (QW-407) Material Spee. _ SA-516 t0 $A-SI6 ‘Temperature 1175 #/-25 °F ‘Type or Grade ‘Time 15 minutes P-No,_1 toP-No._1 ther Thickness of Test Coupon 3/16 Diaineter of Test Coupon _ PLATE. Other GAS (QW-408) Percent Composition Gasfes)__(Mixture) __Flow Rete Shielding FILLER METALS (QW-404) ‘Trlling Backing SPA Specification __$.1 AWS Classification F-6010 :CTRICAL CHARACTERISTICS (QW-409) Filler Metal FNo.___F-3. Current DC Weld Metal Analysis A-No. Az Polarity Reverse Size of Filler Metal i ‘Amps 125-145 Volts Other ‘Tungsten Electrode Size ther Weld Metal Thickness POSITION (QW-405) TECHNIQUE (QW-410) Position of Groove _1G. ‘Travel Speed Weld Progression (Uphill, Downhill) String or Weave Bead Weave Other Oscillation Multipass or Single Pass (per side) Multiple Single oF Multiple Electrodes PREHEAT (QW-406) Other: Preheat Temp. 70°F Interpass Temp. _ Not Monitored Other MSTS (Copied from ASME B&PV Code Section IX - 4/2000 - MSTS) WC-3an ASME Sect IX- Weldin; | Practical Checking When checking on a welding job V Is the welder following the procedure? Y Check the WPQ - Is the welder qualified for this specific weld? (position, thickness, backing, etc.) ¥ Check the WPS - Is this procedure ok for the specific weld (P-#, F-i, preheat, thickness, etc.) Y Check the PQR(s) - Does it support the Weld Procedure Si Exercise W-11 Qualification Review! 1. On the WPS which variables does the welder need to follow? @) Essential Only b) Non-Essential Only ©) Both Essential & Non-Essential @) Neither - Qualified welders can be creative 2. Ona bend test, open defects should not be wider than 3. A welder is tested in 3G position on a coupon %4” thick @) IfRT is used, the max length of a slag inclusion is_% “t' b) IfRT is used, the max size of a single porosity indication is _\- C1" ©) Ibend tests are used, how many must be performed? d) What type of bend tests must be done? { 4. What happens if a welder makes a weld outside the following limits specified on the WPS? ? a) Outside Essential Variable limits b) Outside Non-essential Variable limits Inspector Joe says, “I wonder if Lean ‘get my old welding job back?” MSTS 29ASME P&PV Section IX Welding Module Appendixes Page # Appendix A - Sample WPQ WA-1 Appendix B - Process for completing a WPQ WB-1 Appendix C - Sample WPS & POR WC-1 Appendix D - Process to reviewing a WPS & POR WD-IASME B&PV Section IX — Welder Qualification Exercise W-9 — Completing a WPQ Supposed you are qualifying welders for an upcoming turnaround. Don Aucoin has just completed a “test weld”. The weld passed both the visual and bend test inspections. You need to fill-in the appropriate values for WPO’s Range Qualified datafields. The WPO is given on Page WB-9. Here’s our work process for this exercise. 1) Determine which Welding Process is used for the “Test Weld” 2) Check the appropriate list of Essential Variable 3) Find the appropriate Section 9 reference 4) Determine acceptable Range Qualified & complete the WPO WPO Defini Actual Values — What was done during the “test weld” Range Qualified — Limits on the welder's production welds. ms production welds in the “Overhead” position. If this welder needs to make an Overhead 7 Note! Ifa welder has a Range Qualified of “Flat”, this welder is not qualified to make production weld, it is ESSENTIAL that the welder be requalified. The Foreman should always make sure that the welder is qualified for the specific Production weld. MSTS WB-1