Asme sec. ix bkr - 051010
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Introduction to ASME Sec. IX
5-Oct. 2006
Manufacturing Technology- I
S.C.Ghosh
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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 WPSEssential 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:F numbers:• Grouping of electrode on their usability characteristicsGrouping of electrode on their usability characteristics
• Determine the ability of welder to deposit sound weld. Determine the ability of welder to deposit sound weld.
• List of most commonly used F Numbers is given in next List of most commonly used F Numbers is given in next slideslide
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F Numbers of Commonly Used Consumables
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• Identification of weld metal chemical composition.• To reduce the no of qualification• List of most commonly used A-No is given in next
slide
Different types of variables in WPS
A-No:
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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 WPSQW 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 55ºC in the preheat temperature qualified.
• Supplementary essential variables - • Increase of more than 55ºC in the interpass temperature qualified.
• Non essential variables – • Change of preheat maintenance i.e. Dehydrogenation Treatment (DHT) etc.
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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.
Different types of variables in WPS
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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 QualificationPurpose
• 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 QualificationWelder
• 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 Minimum OD Qualified, mm
Less than 25 mm Size welded
25 to 73,mm 25 mm
73 mmOver 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
QW322Renewal 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