WELDER
QUALIFICATON PROCEDURE (FOR PLATE &PIPING)
1.
Test positions for performance qualification
1.1 Positions
(Groove weld) plate & pipe: - An angular deviation of plus or minus 15°
From specified horizontal and vertical planes is permitted during welding. Position for
qualification as per ASME IX QW-461.3 & QW-461.4
Table. 1
|
Plate Positions |
Pipe Positions |
|
a)
Vertical
Position 3G (Fig.1a) |
b)
Overhead
Positions 6G- (Fig.1b) |
|
b) Overhead Position 4G (Fig.1a) |
|
1.2 Test Positions for Fillet Welds: - An angular deviation of plus or minus 15° from the specified horizontal and vertical planes is permitted during welding. Position for qualification as per ASME QW-461.5
Table.2
|
Fillet joint Positions |
|
a) Vertical 3F |
|
b) Overhead
4F |
Fig.2 Position of test plate for fillet weld
2. Dimension
of test piece for performance qualification
2.1 Plate & Pipe (Groove
weld)
1. The dimensions of the test
piece is given below
a)
Minimum length of test piece for pipe is 150mm (6
in) (for each piece of pipe) fig.4
ASME Sec IX QW 302.3 &
QW 462.2, QW 462.3(a) & (b),
b) The width for plate is 150mm (for each
piece of plate) & length is 300mm Fig. no. 3 or as required (as
per AWS D1.1 2000_ 4.23.2 Fig 4.22)
Fig.3 Plate test piece
Fig.4 Pipe test piece
2.2 Fillet
Weld
1.
As per ASME Sec IX QW 462.4(a) Test
Coupon Requirement, for Fillet weld procedure qualification.
Required two no. piece with
Length=300mm & width=150mm minimum thickness .
Fig.5 Dimension of test plate for fillet weld
3.Performance qualification thickness limits (As per ASME Sec IX QW-452)
Groove weld (Plate)
Fillet weld (See Fig. 3)
Fig. 6 Performance qualification thickness limit
2.Position Qualified
As per AWS D1.1 table 4.1 & 4.2 the position qualified by
Plate, Pipe, Box tube & range of thickness and diameter qualified is shown
in fig. 3 See notes of Table 4.1 also.
Fig. 7 Position qualified for Plate, Pipe and Tube
3.
WEP specification
(SMAW/GTAW)
Table no. 3
|
Thk.(mm) |
Angle |
Root gap (mm) |
Root face (mm) |
|
3 |
- |
- |
- |
|
5 |
60° |
1.6 |
1.6 |
|
6 |
60° |
1.6 |
1.6 |
|
10 |
60°-70° |
1.6 |
1.6 |
|
12.5 |
60°-70° |
2.4 |
2.4 |
|
19 |
60°-70° |
3.2 |
3.2 |
|
25 |
60°-70° |
3.2 |
3.2 |
|
38* |
60°-70° |
3.2 |
3.2 |
|
75** |
20° |
3.2 |
- |
Note-1.* Double V-type joint recommended 2.**Double U-type joint recommended
4. Base metal selection for procedure qualification
5.
P‐Numbers are assigned to base metals for the purpose of reducing
the number of welding and brazing procedure qualifications required. Base metals are assigned P‐Numbers in Table.4 (ASME SEC IX 2013,QW
-420 & 424.1)
Table. 4
|
Sr. no. |
Base Metal(s) Used for Procedure Qualification Coupon |
Base Metals Qualified |
|
1 |
One metal from a P‐Number to any metal from the same P‐Number |
Any metals assigned that P‐Number |
|
2 |
One metal from P‐No. 15E to any metal from P‐No. 15E |
Any P‐No. 15E or 5B metal to any metal assigned P‐No. 15E or 5B |
|
3 |
One metal from a P‐Number to any metal from any other P‐ Number |
Any metal assigned the first P‐Number to any metal assigned
the second P‐Number |
|
4 |
One metal from P‐No. 15E to any metal from any other P‐Number |
Any P‐No. 15E or 5B metal to any metal assigned the second P‐Number |
|
5 |
One metal from P‐No. 3 to any metal from P‐No. 3 |
Any P‐No. 3 metal to any metal assigned P‐No. 3 or 1 |
|
6 |
One metal from P‐No. 4 to any metal from P‐No. 4 |
Any P‐No. 4 metal to any metal assigned P‐No. 4, 3, or 1 |
|
7 |
One metal from P‐No. 5A to any metal from P‐No. 5A |
Any P‐No. 5A metal to any metal assigned P‐No. 5A, 4, 3, or 1 |
|
8 |
One metal from P‐No. 5A to a metal from P‐No. 4, or P‐No. 3, or P‐No. 1 |
Any P‐No. 5A metal to any metal assigned to P‐No. 4, 3, or 1 |
|
9 |
One metal from P‐No. 4 to a metal from P‐No. 3 or P‐No. 1 |
Any P‐No. 4 metal to any metal assigned to P‐No. 3 or 1 |
|
10 |
Any unassigned metal to the same unassigned metal |
The unassigned metal to itself |
|
11 |
Any unassigned metal to any P‐Number metal |
The unassigned metal to any metal assigned to the
same P‐Number
as the qualified metal |
|
12 |
Any unassigned metal to any metal from P‐No. 15E |
The unassigned metal to any metal assigned P‐No. 15E or 5B |
|
13 |
Any unassigned metal to any other unassigned metal |
The first unassigned metal to the second
unassigned metal |
3.14 Type of test during /after qualification
The type and number of qualification tests required to
qualify a WPS for a given thickness, diameter, or both, shall conform to Table
4.2 (CJP), Table 4.3 (PJP). Details on the individual NDT and mechanical test
requirements are found in the following subsections (As per AWS D1.1)
(1) Visual Inspection (100%) (2)
Non-destructive(100%)
(3) Face, root and side bend (4) Reduced Section
(5) All-Weld-Metal Tension (6)
Macroetch
(1)
Visual examination: All welds shall be visually inspected and shall be
acceptable if
the criteria of given table are satisfied. (Table no. 5)
Qualifications,
personnel qualifications, and operating methods shall be in accordance
With AWS D1.1
SEC-6, for radiography inspection AWS
D1.1 SEC 6.12,for Ultrasonic
examination AWS D1.1 SEC 6.13.1
(3) Macro examination: The test specimens are to be prepared and
etched on one side to
clearly reveal the weld metal, the fusion line and the
heat affected zone. Macro examination
is to include about 10 mm unaffected base examination
is to reveal a regular weld profile,
through fusion between adjacent layers of weld and
base metal and the absence of defects
such as cracks, lack of fusion etc.
Refer AWS D1.1,Table-6.1
|
Discontinuity Category and
Inspection Criteria |
Statically Loaded Non
tubular Connections |
Cyclically Loaded Non
tubular Connections |
Tubular Connections (All
Loads) |
|
Crack
Prohibition Any crack is unacceptable, regardless of size or location. |
X |
X |
X |
|
Weld/Base-Metal
Fusion Thorough fusion
shall exist between adjacent layers of weld metal and between weld metal and
base metal. |
X |
X |
X |
|
Crater
Cross Section All craters
shall be filled to provide the specified weld size, except for the ends of
intermittent fillet welds outside of their effective length. |
X |
X |
X |
|
Weld
Profiles Weld profiles
shall be in conformance with 5.24. of AWS D1.1 |
X |
X |
X |
|
Time
of Inspection Visual
inspection of welds in all steels may begin immediately after the completed
weldshave cooled to ambient temperature. Acceptance criteria for ASTM A 514,
A 517, and A 709 Grade 100 and 100 W steels shall be based on visual
inspection performed not less than 48 hours after completion of the
weld. |
X |
X |
X |
|
Undersized
Welds The size of a
fillet weld in any continuous weld may be less than the specified nominal
size {L)
without
correction b~
the
following amounts {U): L
U Specified
nominal weld size, in. {mm)Allowable decrease from L, in. (mm) <3/16 (5) <1/16(2) 1/4 (6) <3/32 (2.5) > 5/16
(8)
<1/8 (3) In all cases,
the undersize portion shall not exceed 10% of the weld length. On
web-to-f1ange welds on girders, no underrun is permitted at the ends for a
length equal to twice the width of the flange. |
X |
X |
X |
|
Undercut (A) For
material less than 1 in. (25 mm) thick, undercut shall not exceed 1/32 in. (1
mm), except that a maximum 1/16 in. (2 mm) is permitted for an accumulated
length of 2 in. (50 mm) in any 12 in. (300 mm). For material equal to or
greater than 1 in. thick, undercut shall
not exceed 1/16 in. (2 mm) for any length of weld. |
X |
|
|
|
(B) In primary
members, undercut shall be no more than 0.01 in. (0.25 mm) deep when the weld
is transverse to tensile stress under any design loading condition. Undercut
shall be no more than 1/32 in. (1 mm) deep for all other cases. |
|
X |
X |
|
Porosity (A) Complete
joint penetration groove welds in butt joints transverse to the direction of computed
tensile stress shall have no visible piping porosity. For all other groove
welds and for fillet welds, the sum of the visible piping porosity 1/32 in.
(1 mm) or greater in diameter shall not exceed 3/8 in. (10 mm) in any linear
inch of weld and shall not exceed 3/4 in. (20 mm) in any 12 in. (300 mm)
length of weld. |
X |
|
|
|
(B) The
frequency of piping porosity in fillet welds shall not exceed one in each 4
in.(100 mm) of weld length and the maximum diameter shall not exceed 3/32 in.
(2.5 mm). Exception: for fillet welds connecting stiffeners to web, the sum
of the diameters of piping porosity
shall not exceed 3/8 in. (10 mm) in any linear inch of weld and shall not
exceed 3/4 in. (20 mm) in any 12 in. (300 mm) length of weld. |
|
X |
X |
|
(C) Complete
joint penetration groove welds in butt joints transverse to the direction of
computed tensile stress shall have no piping porosity. For all other groove
welds, the frequency of piping porosity shall not exceed one in 4 in. (100
mm) of length and the Maximum
diameter shall not exceed 3/32 in. (2.5 mm). |
|
X |
X |
An "X"
Indicates applicability for the connection type.
If the test piece fails to comply with any of the
requirements for visual or non-destructive testing one further test piece is to
be welded and subjected to the same examination.
Welding conditions for test assemblies and test
results are to be recorded in welding
procedure test record. A statement of the results of assessing each test piece, including repeat tests, is to be made for each welding procedure test As per ASME Sec IX 2019,QW 484A & QW-301
.........................
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