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Welder qualification procedure as per ASME Sec IX

 

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)

 

 

        

Fig. 1 Position of test peace for Groove weld (Plate & Pipe).

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

 Note: - The fillet shall show fusion at the root of the weld but not necessarily beyond the root. The weld metal and heat affected zone shall be free of crack.

3.Performance qualification thickness limits (As per ASME Sec IX QW-452)

Groove weld (Plate)



                                                                 Groove weld (Pipe)


                                                                          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)

           (2) Non-destructive test: All NDT methods including equipment requirements and  

 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

 Visual Inspection Acceptance Criteria (Table no. -5)

 

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.

 3.15 Re-testing

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.

 3.16 Test record

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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