SECTION IX

Qualifying A Welding Procedures Essential Variables All Referenced Section IX Pages are from the 2001 Edition with Addenda through 03

SECTION IX
When qualifying a welding procedure you must first determine the important properties of the planned weldment which then become the essential variables. The basic ones are; Base metal to be welded and thickness (T) required. Process (es) to be used including filler metal (s). Preheat. Postweld heat treatment or the lack of. Various others based on welding process used.

For this instruction we will use the SMAW Process. The a brief of Essential, Supplementary Essential and Non-Essential Variables for the SMAW process are listed in table QW-253. However this part of the course will only cover Essential Variables not the supplementary or non-essentials. Those will be covered latter. A definition of these variables follows.

Essential Variable A variable that if changed requires requalification of the procedure by the welding and testing of a new coupon or support from a previously qualified Procedure Qualification Record (PQR), i.e. a change in the base metal thickness (T) qualified.
Supplementary Essential An essential variable that is used only when impact testing of a base metal is required by a construction code, i.e. a change from one P-No. Group to another such as P1 Gr.1 to Gr.2.

Non-Essential A variable that can be changed as needed to suit production requirements without requalification.

QW-253 SMAW Brief of Variables Page 21 We will start our discussion with the top half of the SMAW brief of variables, beginning with the first two Essential Variables, Base Metal and Filler Metal.

Defining Each Essential Variable

Base Metals QW-403.7 Pages 21,58 &159 T/t Limits > 8 inches - this rule only applies at thickness greater than 8 inches (203 mm) . Unless you will be welding something over 8 inches this is of little concern. The rule for most welding procedures is the maximum that can be welded is 2 times T (the coupon). If you are welding a coupon over 8 inches you are restricted to 1.33T or 1.33t, as applicable. 1.33t is the weld metal thickness, it matters when mixing welding processes and/or filler metal F-Numbers.

Defining Each Essential Variable

Quiz 1. An 8-1/2 T coupon was welded to produce a PQR to support welding of a reactor shell course. The maximum T qualified with this coupon is ___.

Defining Each Essential Variable

Quiz 1. An 8.5 T coupon was welded to produce a PQR to support welding of a reactor shell course. The maximum T qualified with this coupon is 11.305. 8.5 X 1.33 = 11.305

Defining Each Essential Variable

Base Metals Pgs. 21, 58,159, &16 Change in Thickness (T) qualified. QW-403.8 A change in base metal thickness beyond
the range qualified in QW-451, except as otherwise permitted by QW-202.4(b) (different thickness at joint) Of concern is the thickness range qualified by the supporting PQR (s) for the WPS, from less than a 1/16 to less than 1-1/2 it is 2 x T. To weld a thickness outside the range supported by the PQR the WPS production welding changes must be supported by providing an additional PQR from file or by welding a new PQR test coupon.

Defining Each Essential Variable

Base Metals

Quiz 1. A 1 to 1 P-No.1 coupon was welded entirely by the SMAW process. The minimum thickness qualified is ___ and the maximum is ___

Defining Each Essential Variable

Base Metals

Quiz 1. A 1 to 1 P-No.1 coupon was welded entirely by the SMAW process. The minimum thickness qualified is 3/16 and the maximum is 2.

Defining Each Essential Variable

Base Metals t (weld metal) pass greater than 1/2 Pages 21 & 58 QW-403.9 For single-pass or multi-pass welding in which any pass (means layer of weld metal) is greater than 1/2 in. (13 mm) thick, an increase in base metal thickness beyond 1.1 times that of the qualification test coupon. The thickness range is affected. It will be restricted to 1.1 T as given above if you deposit more than 1/2 of weld metal in a single pass (layer). This has to do with heat input.

Defining Each Essential Variable

A single pass refers to the number of weld beads required to fill up a layer of weld metal in the joint. If the single layer/pass, t (deposited weld metal), exceeds 1/2 in thickness the WPS will be restricted to 1.1 x T in production welding.

Defining Each Essential Variable

Quiz A PQR coupon is 1-1/4(1.250) thick (T). The weld will be made in two passes, the root pass/layer will be 1/4 (.250) thick and second and third layers/passes will be each be 1/2(.500) thick. The maximum range of thickness for this qualification will be ________.

Defining Each Essential Variable

Quiz A PQR coupon is 1-1/4(1.250) thick (T). The weld will be made in three passes, the root pass/layer will be 1/4 (.250) thick and second and third layers/passes will be each be 1/2(.500) thick. The maximum range of thickness for this qualification will be 2-1/2 (2.500). Read closely, the rule states it must exceed 1/2 to be limited to 1.1 x T.

Defining Each Essential Variable Alternate Base Metals for Procedures

QW-403.11 Pages 21 & 58

Base metals specified in the WPS shall be qualified by a procedure qualification test which was made using base metals in accordance with QW-424.

QW 424 Turn to Page 131 Base Metal (s) Used for Procedure Qualification Test Coupon Versus Base Metal Qualified for production

Lets examine some of the items on the table.

One Metal From A P-No. To Any Metal From The Same P-No. Such as P1 to P1

One metal from a P-No. To any metal from any Other P-No. We will Use P No.1 to P No.8 as an example. Other combinations are possible, P Nos. 1 to 3, P Nos.3 to 4 etc.

One metal from P-No. 3 To any other metal from P-No. 3

One metal from P No. 3 to any other metal from P No. 3 Also qualifies P No. 3 to P No. 1

However one metal from P No. 3 to any metal from P No. 3 does not qualify P No. 1 to P No. 1

One metal from P-No. 4 to any other metal from P-No. 4

One metal from P No.4 to any other metal from P No.4 also qualifies P No.4 to 4, 3 and, 1

It qualifies one metal from P No. 4 to any metal from P No. 4, 3 or 1. but does not qualify P No. 3 to P No. 3 or P No. 1 to P No.1

Quiz

Using the table list the base metals qualified if we successfully weld a procedure coupon joining P No. 5A to No. P 5A

Quiz # 1 - P No. 5A to P No. 5A Qualifies?

P No. 5A to __, __,__, or __. It does not qualify __, __, or __ to each other or to their selves.

P- No. 5A to P- No. 5A Qualifies?

P- No. 5A to 5A, 4, 3, or 1. It does not qualify 4 , 3, or 1 to each other or to their selves.

Quiz # 2 - P No. 5A to P No. 4, 3, or 1 Qualifies?

P No. 5A to any metal assigned __,__, or __. It does not qualify __, __, or __ to each other or to their selves.

Quiz # 2 - P No. 5A to P No. 4, 3, or 1 Qualifies?

P No. 5A to any metal assigned 4,3, or 1. It does not qualify 4, 3, or 1 to each other or to their selves.

Defining Each Essential Variable

Base Metals Pages 21 & 58 Change of P-No. 5/9/10 QW-403.13 A change from one P No. 5 to any other P-No. 5 (P No. 5A to P No. 5B or P No. 5C or vice versa). A change from P No. 9A to P No. 9B but, not vice versa. A change from one P No.10 to any other P No.10 (P No.10A to P No.10B or P No.10C, etc., or vice versa). Simple, P-No. 5/9/10 - A,B,C.., are different PNumbers and require individual qualifications, (with the exception of 9B to 9A)

Defining Each Essential Variable Filler Metals

Change of F-Number Pages 21 & 59 QW-404.4 A change from one F-Number in QW432 to any other F-Number or to any other filler metal not listed in QW-432. Changing the F-Number to one other than that used for the procedure test coupon, during the creation the of the Procedure Qualification Record (PQR). Such as changing from F-No. 1 to F-No. 3. This rule also applies to a welders qualification test by the way.

Defining Each Essential Variable Filler Metals

QW- 404.5 Change of A-Number Pages 21,59 & 138 A-Nos. are the chemical analysis of the ferrous weld metal deposits produced by a given filler metal. Changing A numbers can change the chemistry and possibly the mechanical properties of the weld metal. This occurs by changing filler metals. It also changes the weld add mixture, that part that contains both base metal and weld metal. Changing the A No. to one other than that used to qualify requires a new test or additional PQR (s) from a file (with one exception).

The below indicates trace amounts ,single values are maximums. i.e. C = 0.20 % max.

Filler Metals
Consider the following filler metals for the SMAW process. 1. E-7018 which has an A-Number of 1. 2. E-7018 A1 which has an A-Number of 2 Lets compare the chemistry tables from Section II Part C Filler Metals for these two AWS Classification SMAW Electrodes/Filler Metals to the A Numbers of Section IX.

From Section IX QW-442 A No. 1 contains by % C 0.20/ Cr --/ Mo --/ Ni --/ Mn 1.60/ Si 1.00 From Section II Part C / E-7018 SFA 5.1

From the Section IX QW-442 A No. 2 contains by % C 0.15 / Cr 0.50/ Mo 0.40 0.65/ Ni --/ Mn 1.60/ Si 1.00 From Section II Part C / E-7018-A1 SFA 5.5

A note on the API Exams

If you are taking any of the three API Exams you will be required to review a WPS and PQR. Part of that review might be a question about the A-Number listed for the filler metal on the documents. This is a protest question. You would need ASME Section II Part C to answer that question. Sect. II Part C is listed as required for the exam. You have no way of answering!

For our example we find the following rule, proving you must read Section IX carefully! QW-404.5 (Applicable only to ferrous metals.) A change in the chemical composition of the weld deposit from one ANumber to any other A-Number in QW- 442. Qualification with A-No. 1 shall qualify for A-No. 2 and vice versa. (Note: all other ANo. changes will force re-qualification).

Defining Each Essential Variable Filler Metals

Change t deposited Pages 21 & 61 QW-404.30 A change in deposited weld metal thickness beyond the range qualified in QW-451 for procedure qualification. Example: In a SMAW procedure 1/4 of E-6010 was qualified on the PQR by depositing 1/8 in the coupon (2t), the balance of the coupon was filled with E 7018. The need arises to increase the E6010 t to 3/8 in production. This would require a new coupon or an existing PQR.

Defining Each Essential Variable

Preheat - Turn to Page 21

Defining Each Essential Variable

Preheat - Pages 21 & 62 A decrease in preheat greater than 100 o F

QW-406.1 A decrease of more than 100F (56C) in the preheat temperature qualified. The minimum temperature for welding shall be as specified in the WPS. Example: A PQR coupon was welded using a preheat of 250 F but the WPS requires a preheat of only 100 F. This is a 150 F decrease below that qualified and will require a new PQR or one from your files to support the lower temperature.

Defining Each Essential Variable PWHT

Change in PWHT Pages 21 & 62

QW-407.1 This long paragraph specifies what is considered a change in post weld heat treatments. The changes are P-Number specific with 5 different conditions of PWHT for P Nos. 1,3, 4, 5, 6, 9,10 and, 11. For all other materials there are two conditions 1. NO PHWT 2. The specified PWHT for the P No. used

Defining Each Essential Variable PWHT

T Limits (Thickness Limits) Pages 21 & 63

QW-407.4 For a procedure qualification test coupon receiving a post weld heat treatment in which the upper transformation temperature is exceeded, the maximum qualified thickness for production welds is 1.1 times the thickness of the test coupon.
This rule only applies when a production weld will undergo heat treatment at temperature that will alter the base metals physical properties, such as tempering, etc.

Producing The PQR

We have looked at all of the essential variables for the SMAW process. Lets put it all together by filling out a SMAW PQR to support a Welding Procedure Specification (WPS). To do this it will be necessary to specify a list of the essential variables for the welding we have planned.

Producing The PQR

From QW-253 we need to address the basic essential variables and they will be:
1. Base Metal (s) 2 SA-516 Gr. 70 Norm. P-No. 1 2. Filler Metal (s) E-7018 Only 3. Preheat 175 o F for P-No.1 (from Sect. VIII Div. 1 non-mandatory Appendix R) 4. PWHT 1100 o F Minimum per inch of thickness for P-No. 1 (from Sect. VIII Div. 1 UCS-56)

Producing The PQR

Next we define the ranges of the variables:
Base Metal SA-516 Gr.70 Normalized (2max.) Preheat 175 o F Then PWHT based on 2 per UCS-56 shall be 1 hour per inch, which in this example = 2 hours. The next step is to start filling out a Procedure Qualification Record as if we had actually welded the coupon. Here is the front of a blank PQR form.

First we will fill out the top half of the PQR from the company name to the base metal information on the left side and include a graphic of the joint design used to weld the coupon.

Next we will fill out the bottom half of the PQR with the filler metal and preheat on the left side. While not required on the PQR by Section IX the Non-Essential variables will be entered as well.

Now we will fill out the upper half of the PQR with the PWHT metal on the right side. Making the comment Not Applicable in the box for Gas, since the SMAW process does not use shielding gasses.

Finally the bottom right which consists of all non-essential variables. Once again these are not required by Section IX, but may be helpful for meeting a construction code requirement, i.e. Section VIII Div. 1 or B31.3.

Now we start completing the back of the PQR. To do so we need some test results for our required tension and bend tests. The tension test specimens are fabricated as given in Section IX QW-462.1(a). Page 152 .

The required number of tension test specimens are 2 as shown in Section IX QW-451.1 Page 139. The required number of tension specimens are always two, unless your coupon exceeds 1, then you are allowed divide the two specimens into multiple pieces. (see QW-151.1 (c) and (d) )

The ultimate strength of the tension specimens must be computed as described in below in QW-152. QW-152 Tension Test Procedure The tension test specimen shall be ruptured under tensile load. The tensile strength shall be computed by dividing the ultimate total load by the least cross sectional area of the specimen as calculated from actual measurements made before the load is applied.

We must measure each specimens width and thickness after machining as shown in QW-462.1(a). Section IX requires two specimens be tested. The data for our specimens was; TS1 - width = .750 thickness = .453 TS2 - width = .753 thickness = .456 Area for each specimen. TS1= .750 x.453 = .340 in.2 TS2= .753 x.456 = .343 in.2 We put the specimens in a tensile tester like this and pull each one apart;

The specimens were broke in the tensile tester and the breaking forces as read from the gage on the machine were recorded as follows ; TS1 = 25,010 Lbs. TS2 = 24,050 Lbs. Computing the ultimate strength for 1 square inch for each specimen; Load divided by Area 25,010/.340 = 73,558 PSI 24,050/.343 = 70,116 PSI We now evaluate the specimens;

Load divided by Area 25,010/.340 = 73,558 PSI 24,050/.343 = 70,116 PSI Observing the character and location of the specimen failures, it was noted that both failed in the base metal outside of the weld heat affected zones and in a ductile manner. We can now record this information on the back side of the our Procedure Qualification Record.

But First We must determine the required minimum specified strength from Section IX in the P-Number listings. Turn to Page 96 of Section IX We find that SA-516 Grade 70 has a Minimum Specified Tensile Strength of: 70 KSI = 70,000 Pounds Per Square Inch.

Our tensile specimens exceeded the minimum. Now we have one more task to complete. We must do 4 side bend tests. This requirement is found in Section IX along with the accept/reject values for all bend tests. Turn now to Page 139 again.

The required type and number of bend tests based on a 1 thick coupon are 4 Side Bend tests. Remember side bends are mandatory after the coupon thickness reaches 3/4 or larger.

We must evaluate the bend specimens to section IX QW-163. Turn now to Page 6.

QW-163 - The guided-bend specimens shall have no open discontinuity in the weld or heat-affected zone exceeding 1/8 in. (3.2 mm), measured in any direction on the convex surface of the specimen after bending. Open discontinuities.etc. To see the details for making the bend specimens look at QW-462.2 Page 156.

We evaluated the bend specimens to section IX and had the following comments. Side Bend S1. No open defects acceptable Side Bend S2. 1/32 acceptable Side Bend S3. No open defects acceptable Side Bend S4. No open defects acceptable We have the correct type based on the coupon thickness and the correct number of acceptable side bend tests.

We can now fill out the top back of the PQR.

All that is left is to fill out the bottom of the back of the PQR. This will be easy, just a few housekeeping items to complete.

Here is the front side of the complete Procedure Qualification Record

Here is the back side of the complete Procedure Qualification Record

The WPS
We have completed the Procedure Qualification Record, which is a laboratory report of the welding and testing of a coupon. From this we will write a Welding Procedure Specification. It must be in complete agreement concerning Essential Variables with the PQR.

The WPS
The Welding Procedure Specification, must be complete. You must address all of the essential, supplementary essential (if Notch toughness testing is required), and non-essential variables. The best approach is through the use of the Brief of Variables found in QW-253 on Page 21 as an item check list. We will go line by line and address all of the Essential and Non-Essential variables since our WPS will not require Notch toughness testing.

The WPS
Starting in box QW-402 we will address each of the non-essential variables. Groove Design Backing Root Spacing Retainers The following is how it was completed.

The WPS
In box QW-402 we have addressed each of the non-essential variables as follows; Groove Design Single Vee, Double Vee, JGroove and, U-Groove Backing The X in both the Yes and No boxes denotes that this WPS may be used with or without backing. Root Spacing This is given below Details. Retainers Same as Root Spacing

The WPS
Since we have addressed each of the nonessential variables and thereby giving all the needed Joint information for making a weldment. It is complete for joint design and no one should have to ask what is allowed when using this WPS.

The WPS

Next QW-403 Base Metals

The WPS
We have addressed each of the essential variables under Base Metal QW-403.
It is complete for P-No., Thickness range and the restriction of No t Pass > 1/2 has been addressed. Supplementary Essentials need not be addressed, no impact testing is required of this weldment.

The WPS

Next QW-403 Filler Metals

The WPS
We have addressed each of the essential variables under Filler Metal QW-404. It is complete for AWS Classification, F-No., A-No., Size of Filler Metals, and Weld Metal Thickness Range. Again no impact testing is required so the Supplementary Essentials do not apply.

The WPS
Next the back and top of the WPS We will now complete the Positions, Preheat, Electrical, and Postweld Heat Treatment on the WPS.

The WPS
1. The Positions for use with this WPS are, Flat, Horizontal, Vertical and, Overhead. This instructs that this WPS can be used with all positions. 2. The Preheat minimum is set at 100 o F which is within 100 o F of the PQR actual value of 175 o F. 3. The Preheat Maintenance specified as none required.

The WPS
The Electrical Characteristics are; 1. Direct Current Electrode Positive. 2. Amps are set to a range of 90-190 and the Volts are set to a range of 15-25, these values are normally obtained from the filler metal manufacturers literature or from actual experience. 3. The rest are not required for SMAW.

The WPS
The Postweld Heat Treatment values are; 1. 1150 +/- 50 o F Which is in agreement with the PQR minimum value of 1100 o F 2. Time at temperature is 1 hour, also in agreement with the PQR. 3. Gas variables are not required for SMAW.

The WPS

We will now complete the bottom half of the back of the WPS. Which consists of the Technique box QW-410 only.

The WPS
1. String or Weave, restricted from 2 to 3 core diameters (core wire exclusive of any coating). 2. Cleaning is limited to Brushing or Grinding. Back Gouging will be by Air Carbon Arc. 3. Multiple Pass, Manual is entered in the heading and Peening is not allowed. 4. All others are not SMAW variables.

The Complete WPS Front

The Complete WPS Back