API 510 Preparatory Class

Lesson 14
Welders Qualification
 SECTION IX

Welders Qualifications / Essential Variables

We will discuss all of the welders essential
variables listed in QW-353 for the SMAW
process. Please turn to page 52 of Section
IX.
 QW-353
Shielded Metal-Arc Welding (SMAW)
Essential Variables

Paragraph Brief of Variables

QW 402
Joints .4 Deletion of Backing
QW 403
Base Metals .16 Change Pipe Diameter
.18 Change in P Number
QW 404
Filler Metals .15 Change in F Number
.30 Change in weld t deposited
QW 405
Positions .1 Addition of a position
.3 Change from vertical Up to Down
or Down to UP progression
 QW-353
Shielded Metal-Arc Welding (SMAW)
Welder Essential Variables
The first essential variable listed is Backing (Removal of).

If a welder is qualified using any type of backing, and asked

to perform an open root weld he must retest without backing
to be qualified to perform the welding.

The Code definition of backing is welding with a backing bar

or retainer, welding double sided welds where the weld metal
of the first pass is used after gouging/grinding as weld metal
backing for the balance of the weld. Fillet and partial
penetration welds are also considered welding with backing.
 QW-353
Shielded Metal-Arc Welding (SMAW)
Welder Essential Variables
The next inline is a change in Pipe Diameter
qualified. As pipe diameters become smaller the
difficulty for a welder is increased resulting in a
higher skill level requirement.
So this translates to a change in diameter to
one smaller than qualified by the welders pipe
coupon on a previous test with this process.
The ranges of pipe diameters qualified are given
in Section IX, turn to page 143 in Section IX.
 QW-452.3 GROOVE-WELD DIAMETER
LIMITS

As we can see:
1. Under 1 inch (25mm) qualifies the diameter
down to the size welded to unlimited
diameter, because it is only easier for the
welder as the diameter of the Pipe welded
increases.
2. From 1 inch (25mm) to 2-7/8 inch (73mm)
qualifies 1 inch to unlimited.
3. Over 2-7/8 inch (73mm) qualifies 2-7/8 inch
to unlimited.
QW-452.3 GROOVE-WELD DIAMETER
LIMITS

Quiz
1. If a welder qualified on a NPS 6 inch pipe
coupon the range of diameter qualifications
in production with the WPS he tested to will
be _________.
2. If tested with a NPS 2 inch coupon what is
his minimum and maximum diameter range
is ________.
QW-452.3 GROOVE-WELD DIAMETER
LIMITS

Quiz
1. If a welder qualified on a NPS 6 inch pipe
coupon the range of diameter qualifications
in production with the WPS he tested to will
be 2-7/8 to unlimited.
2. If tested with a NPS 2 inch coupon what is
his minimum and maximum diameter range
is 1 to unlimited.
 QW-353
Welder Essential Variables

P-Numbers. P-Numbers serve to group metals

by mechanical and chemical properties. So it is
reasonable to think that not all metals can be
welded using the same technique, or have the
same level of difficulty for welders.
There are three basic P-No. groupings for
welder qualifications. If a welder changes to a P-
No. group that he/she has not qualified for then a
retest is required. We will have a more
thorough lesson on Alternate Base Metals later
in this course.
 QW-432
F Numbers

We have now arrived at the Filler Metal Number

or F- Number. F- Numbers are a grouping of
electrodes and filler metals that weld in a
similar way and in general present more or less
difficulty for a welder. In other words some F-
Number filler metals require different skills than
others and must be qualified individually in most
cases.
 QW-432
F Numbers

The table of F Numbers coming up is read in the

following way
EXX18 stands for all SMAW electrodes ending
in 18 such as E-7018, E-7018-A1, 8018-B1 etc..
So all of the above are F-Number 4
EXX10 would be E-6010 with an F-Number of 3
The XX is the tensile strength 70,000 PSI ect.
Turn now to Page 132 of Section IX
 QW-433 Alternate F-Numbers for Welder
Performance Qualifications

Changing the F Number for a welder may affect

his ability to weld and require requalification.
There are some provisions for using lower F-
Numbers when qualifying with numbers 2 to 4
but, there are restrictions on those qualifications.

Turn now to Page 137 of Section IX

 QW-433 Alternate F-Numbers for Welder
Performance Qualifications

Examples
1. Using the table QW-433, if a welder qualifies
without backing with an electrode assigned to
F-Number 4. What F-Numbers can he use with
backing in a production weld?

2. What F Numbers can he weld without

backing?
 QW-433 Alternate F-Numbers for Welder
Performance Qualifications
Solution
1. He can weld F-Numbers 1 through 4 with
backing. Going right across the row titled
Qualified With to F-Number 4 without
backing then down to each x in the boxes, then
left to read the Qualified For Column we find
F Numbers 1, 2, 3 and 4 with backing.
2. Also the Qualified For F Number 4 without
backing is included which makes sense as he
performed that weld for his test.
 QW-433 Alternate F-Numbers for Welder
Performance Qualifications

Notice that the large table only addresses F-

Numbers 1 through 5. The rest of the F-Numbers
are in a small table along with notes beneath
the large table. Lets have a look at those.
QW-433 Alternate F-Numbers for Welders
 QW-452.1 (b)
Thickness Of Weld Metal Deposit

The fifth essential variable listed is change in

thickness of Weld deposit.

A welder is restricted by the amount of weld

metal he deposits during his performance
qualification test with a particular, welding
process, electrode/filler metal F-number in a
P-Number base metal combination. We will now
have a look at those rules.
Turn to Page 142 of Section IX
 QW-452.1 (b)
Thickness Of Weld Metal Deposit

The column Thickness t, of weld metal in the

coupon refers to the amount of weld metal from
a process or a filler metal. Perhaps a bit of E-
6010 and the rest E-7018. Perhaps GTAW root
and SMAW fill passes and cap.
 QW-452.1 (b)
Thickness Of Weld Metal Deposit

Example
Assume one welding process, SMAW and one
electrode E-7018 using a P-No.1 pipe.
A coupon thickness of 3/8 inch was welded
using E-7018. In the column on the right titled
Thickness of weld metal qualified we see 2t,
so 2 x 3/8 = 3/4 this is the maximum amount
of E-7018 (F-No. 4) , that the welder can
deposit in production.
 QW-452.1 (b)
Thickness Of Weld Metal Deposit

Suppose now the coupon is 1/2 thick and a

welder welds it with 100% E-7018 using 3 weld
layers, we see that welders limit of deposited
weld metal with an F-No.4 is the maximum to be
welded.
 QW-452.1 (b)
Thickness Of Weld Metal Deposit

Another combination in the 1/2 coupon.

1/8 of E-6010 (F-No.3) and 3/8 of E-7018. By

the first column 2 x 1/8 = 1/4 of E-6010 (F-
No.3) and 2 x 3/8 = 3/4 of 7018 (F-No.4). The
welder can deposit up to 1/4 of any F-No.3 and
3/4 of any F-No.4 with any production WPS he
is otherwise fully qualified for, meaning position,
diameter, P-No., backing, progression etc.
 QW-452.1 (b)
Thickness Of Weld Metal Deposit

Quiz
How can we qualify a welder for unlimited
thickness with both F-No.3 and 4 in a single
coupon?
If he or she welds a coupon that is at least ___
thick and deposits at least___ of E-6010 and at
least ___ of E-7018 using a minimum of ____
layers of each filler metal.

* Hint See Note 1 of table QW-452.1(b)

 QW-452.1 (b)
Thickness Of Weld Metal Deposit

Solution
If he or she welds a coupon that is at least 1
thick and deposits at least 1/2 of E-6010 and at
least 1/2 of E-7018 using a minimum of three
weld layers for each filler metal.
The welder can deposit unlimited t with any F-
No.3 and/or F-No.4 with any production WPS he
is otherwise fully qualified for such as, position,
P-No., backing, diameter, progression etc.
 QW-353
Welder Essential Variables

The next essential variable listed is Position.

Consider the welding positions versus the welder
test positions for a moment. We will use pipe test
coupons. Positions for pipe tests are designated by
an alphanumeric such as 1G, 1 designates the
coupon orientation, in this example the pipe is on
the horizontal and is rotated/rolled beneath the
welder and is considered to be flat welding. The G
means a groove butt weld. The others are 2G, 5G
and, 6G.
Turn to Page 148 QW-461.4 in Section IX.
 QW-461.4
Groove Welds in Pipe Test Positions

The more difficult the test position, the more

positions a welder can perform. The four
positions for welding are Flat, Horizontal, Vertical
and Overhead.
These are referred to as:
F,H,V,O
 QW-461.4
Groove Welds in Pipe Test Positions
There are corresponding pipe and plate test
positions that qualify a welder for F,V,H, and O.
We will use pipe in the examples.
1G qualifies F (Rotated)
2G qualifies H
5G qualifies F, V, and O
6G qualifies F, V, H and, O (this yields all
positions)
 QW-461.4
Groove Welds in Pipe Test Positions

Section IX allows combining test positions to

produce an all position welder. Therefore if a
welder tests in 2G and 5G he/she was tested for
all positions.
2G covers H and 5G covers F, V, and O
Which is equal to 6G that qualifies F, V, H and,
O. Either of these two yields an all positions
welder.
 QW-469.1
Performance Qualifications - Position and
Diameter Limitations
All of this information is compiled into one table.

In this way you can go straight to a one page

table and review a Welder Performance
Qualification (WPQ) for position and diameter
qualifications.
Turn to Page 151 Section IX
Notice the entry on the top row right
Position and Type Weld Qualified. [Note (1) ]
Below that Groove
Below Groove exists two sub-headings
Plate and Pipe Over 24 inches and Pipe less than or
equal to 24 inches. Ignoring Fillets because any welder
qualified for groove 1G is qualified for the same fillet 1F.
To the left we have Qualification Test

Which has the sub-headings Weld and Position

We will use the Pipe-Groove [ Note (3)] row. Starting at
the top of the table in the Qualification Test column
move down and stop at the 1G entry below. To the right
we see the entries F F F ignore fillets.
Move up at the first F and find Plate and Pipe Over 24 in.
O.D. is qualified
Move up from the second F and find Pipe less than or
equal to 24 in. O.D. is qualified. See [ Note (3)]
Pipe less than or equal to 24 in. O.D. is
qualified. See [ Note (3)]

Note (3) See diameter restrictions in QW-452.3, QW-

452.4, and QW-452.6
Notice that while the welder can weld on
pipe in the position qualified he or she is
still restricted by the diameters given in the
table below on,
Pipe less than or equal to 24 in. O.D..
 QW-353
Shielded Metal-Arc Welding (SMAW)

The last essential variable listed is Progression.

This is as simple as it gets.
If a welder welds Vertically Up (Uphill) during a
particular test he is only qualified for Vertically Up.
Should the welder be required to weld Vertically Down
(Downhill) he will be required to weld a test coupon
(keeping other variables the same) welding Vertically
Down.
The reverse is also true, qualify Downhill and you must
weld another coupon to qualify Uphill.
 QW-353
(SMAW) Welder Essential Variables
Quiz
A welder performs a test on a NPS 4 (4.5) pipe
coupon in the 6G position. The coupon is Schedule
160 and has a wall T of 0.531. The welder will use
SMAW with E-6010 for the root pass for a total weld
deposit t of .125 (1/8). The balance of the weld
deposit t (.406) will be performed using 3 weld
layers of E-7018 filler metal. Obviously no backing
will be used. All welding will be uphill during the test.
What are his qualifications as listed in table QW-
353?
 (SMAW) Welder Essential Variables
Continued
The test qualifies ___ positions with a minimum
diameter of ______ and a maximum of _______.
The test also qualifies the welder to deposit ___
inches of F- No. 3 and ____inches of F-No.4.
The welder will also be qualified to weld _____or
_______backing. The thickest weld he can make
using this combination in production is__________.
The welders production welds must made using
_______ progression.
 (SMAW) Welder Essential Variables

Solutions
The test qualifies all positions with a minimum
diameter of 2-7/8 and a maximum of unlimited.
The test also qualifies the welder to deposit .250
inches of F- No. 3 and .812 inches of F-No.4.
The welder will also be qualified to weld with or
without backing. The thickest weld he can make
using this combination in production is .250 +.812
or 1.062. The welders production welds must be
made using uphill progression.
 QW-353
Shielded Metal-Arc Welding (SMAW)
Welder Essential Variables

The next series of slides address the alternate

base materials for welder qualifications. As you
will see a welder can test for example on a P-No.
1 base material with a selected F-No. filler metal
and, under the rules of Section IX he can weld
many other P-Numbers using the F-No. used for
the test, maintaining all the other essential
variables for the welder, position, diameter, etc.
 SECTION IX
QW 423 Turn to Page 131
Alternate Base Materials for Welder
Qualification
Versus
Base Metal Qualified
 QW-423 Alternate Base Metals for
Welder Qualification

Base metals used for welder qualification may be

substituted for the metal specified in the WPS in
accordance with the following in-text table.

When a base metal in the left column is used

for welder qualification, the welder is qualified
to weld all combinations of base metals in
the right column. Including unassigned metals
of similar composition to these metals.
Warning
Base Metal (s) Used for Base Metal (s) for
Welder Qualification which the Welder is Qualified

P-No. 1 through P-No. 11, P- P-No. 1 through P-No. 11, P-

No. 34, or P-No. 41 through No. 34, or P-No. 41 through
P-No. 47 P-No. 47

P-No. 21 through P-No. 25 P-No. 21 through P-No. 25

P-No. 51 through P-No. 53 or P- P-No. 51 through P-No. 53 or P-

No. 61 through P-No. 62 No. 61 through P-No. 62
 QW-423 Alternate Base Metals for
Welder Qualification

So, all we need to do is qualify a welder to

weld any P-No. from the list and he can
weld all of the others. This would be great!
There is however a problem with this
theory. Welders are also limited by the
Filler Metal Number (F-No.) used during a
test.
If a welder qualifies on any P-Number from
P 1 through P 11, P 34 or P 41 through P47
he/she is qualified to weld any of those
metals together. Be warned this is further
limited by the F-number (s)!
If a welder qualifies on P 21 to P 25 he/she is
qualified to weld any of these metals together
or any combination of these aluminum alloys
together!
If a welder qualifies on P 51 to P 53 or P 61 to 62
he/she is qualified to weld any of these metals
together or in any combination of Titanium or
Zirconium alloy!
In theory a welder could be qualified for all the listed
base materials by welding just three (3) coupons.
Remember our lesson on Filler Metal Numbers (F-
Numbers). This is where the welders limitations
become very important.

One of the essential variables for a welder is the F-

Number of the electrode he qualifies with during a
given test.
Suppose a welder qualifies with SMAW using an F-
No.4 electrode the test coupon is a P-No.1 base
material.

The welder has qualified to weld P No. 1 to 11, 34

or 41 through 47. So lets have him weld one of the
nickels, a P-No.41. Assume it will be required to
make the weld with a filler metal that is designated
as a F-No.41 in Section IX. There is a problem ,
he has not qualified any of those metals with a F-
No.41 filler metal. He would have to prove his skill
with the F-No.41 filler metal.
He is qualified for SMAW using a F-No.4 electrode
not F-No.41. The welder will have to test again on
any of those metals using a SMAW electrode
designated as a F-No.41, why because the F-
Numbers 4 and 41 are considered to require
different skill levels to weld. The F-Number is a
welders essential variable as well as a
procedures.
Welders are limited by all of the following essential
variables (skill issues), which are in Section IX
for the welding processes listed on page 52.
 QW-353
Shielded Metal-Arc Welding (SMAW)
Essential Variables
Paragraph Brief of Variables
QW 402 .4 Deletion of Backing
Joints
QW 403 .16 Change Pipe Diameter
Base Metals .18 Change in P Number
QW 404
Filler Metals .15 Change in F Number
.30 Change in weld metal t deposited
QW 405 .1 Addition of a position
Positions .3 Change from vertical Up to Down
or Down to UP progression
Simply put the welder must qualify all of his/her
essential variables, not just be qualified to weld a
particular P-Number. In our example he/she is
disqualified for the nickel alloy weld because of the
required F-Number qualification being F-No.41 as
listed on the WPS/PQR.
A welder is limited by, process, pipe diameter, P-
Number, F- Number, weld metal thickness,
position, backing and progression.

All of these Essential Variables must meet the

requirements of the WPS to be used in the
production weld.
 Destructive Testing of Welders
Qualification Coupons

There are three items that must be

addressed when performing destructive
testing of a welders test coupon.
1. The type of the specimens required.
2. How many specimens are required.
3. Where in the test coupon specimens shall
be taken from.
These items are listed in Article IV
Welding Data of Section IX in a tabular
form, 452.1(a) and are accompanied by
notes referencing paragraphs found in
Article III, of Section IX .The type and
number a listed in that paragraph.
Turn now to Page 142 of Section IX.
Notice that the notes underneath the table do the
following things:
General Note: Defines the Thickness of the Weld
Metal and disallows using the reinforcement as part of
the thickness deposited.
Note 1. Specifies the number of coupons used for the
listed welder pipe groove test positions, and thereby
differentiates pipe from plate coupons.
Note 2. Coupons tested by face and root bends. Limits
the type of weld bend coupons that can be used when
doing combination welder or process tests a single
coupon. Combinations outside of this description will
require side bends.
Note 3. Allows the substitution of side bends for face
and root when the coupon is 3/8 to less than 3/4.
We will now examine the figures referenced in
QW-452.1(a) for removal of Welders
Performance Coupons.

Turn to Page 173

Next an example of the coupons required
for a 2G and 5G test in a single coupon
which will qualify a welder for all four of the
positions, Flat, Horizontal, Vertical and,
Overhead just the same as the single 6G
test.
This coupon requires 6 bend specimens
instead of the usual 4, taken from the
locations indicated in the graphic.
We will now examine the figures
referenced in QW-452.1(b) for
Welders Thickness of Weld Metal (t)
Qualified.

Turn to Page 142

Notice that the welder must deposit at least
1/2 in a minimum of three layers/passes to
be qualified for unlimited thickness in
production. All thickness below 1/2 follow
the 2 x t rule.
Example:

The welder deposits 3/8 he is qualified to

weld up to 3/4 in production welding with
the process and filler metal used during his
test. Also, as stated previously in addition
he will be limited by diameter, progression,
backing and, position.
Combination tests are described in notes 1, 2, and,
3.
Example:
Note 1: Two welders deposit 1/2 each, both used
three layers in a single 10 Schedule 140, 1 thick
coupon with SMAW F-No. 4 electrodes. They will
each be qualified to weld unlimited thickness in
production with that process and F-No. using the
position, progression, backing and, diameter used
during the test. They could also have used different
F-No.s and/or processes and could have been
qualified unlimited thickness based on the test they
performed.
Example:
Note 2: Two welders deposit 1/2 each, both
used three layers in a single 1 thick coupon
with SMAW F-No. 4 electrodes. They will
each be qualified to weld unlimited
thickness in production with that process
and F-No. using the position, progression,
backing and, diameter used during the test.
They could also have used different F-No. s
and/or processes and would have been
qualified unlimited thickness base on the
test they performed.
Example:
Note 3: Two welders deposit 1/2 each, both
used three layers in a single 1 thick coupon
with SMAW F-No. 4 electrodes. They will
each be qualified to weld unlimited
thickness in production with that process
and F-No. using the position, progression,
backing and, diameter used during the test.
They could also have used different F-No. s
and/or processes and would have been
qualified unlimited thickness base on the
test they performed.
Example - Billy Bob Welders
performance test was made under the
following conditions using Big Welding
Companys WPS CW-1010 :

1. P-Number 1 pipe coupon

2. Pipe diameter NPS 8 (8.625)
3.Thickness 0.500
4. 6G test position
5. Uphill progression
6. F-No.4 (SFA 5.1) 3 layers of weld metal
7. Process SMAW Only
Next we fill out the of Welders
Performance Qualification Form QW-
484 (WPQ) for Billy Bob Welder.
Remember, a welder has only Essential
Variables and for SMAW they are:
1. P-Number
2. F-Number
3. Diameter
4. Backing, with or without and, without qualifies
both for a given F-Number and lower F-
Numbers in some instances.
5. Vertical Progression (Uphill or Downhill)
6. Position
7. Weld Metal thickness