Professional Documents
Culture Documents
Lesson 14 WelderQuals New2
Lesson 14 WelderQuals New2
Lesson 14
Welders Qualification
SECTION IX
Welders Qualifications / Essential Variables
QW-353
Shielded Metal-Arc Welding (SMAW)
Essential Variables
Paragraph
QW 402
Joints
QW 403
Base Metals
QW 404
Filler Metals
QW 405
Positions
Brief of Variables
.4
Deletion of Backing
.16
.18
.15
.30
Change in F Number
Change in weld t deposited
.1
.3
Addition of a position
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
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 ________.
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 PNo. 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 FNumber 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
Notice that the large table only addresses FNumbers 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-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
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
QW-452.1 (b)
Thickness Of Weld Metal Deposit
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 FNo.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
QW-353
Shielded Metal-Arc Welding (SMAW)
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 QW353?
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
Warning
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!
Suppose a welder qualifies with SMAW using an FNo.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 FNo.41 filler metal. He would have to prove his skill
with the F-No.41 filler metal.
QW-353
Shielded Metal-Arc Welding (SMAW)
Essential Variables
Paragraph
QW 402
Joints
QW 403
Base Metals
QW 404
Filler Metals
QW 405
Positions
.4
Brief of Variables
Deletion of Backing
.16
.18
.15
.30
.1
.3
Change in F Number
Change in weld metal t deposited
Addition of a position
Change from vertical Up to Down
or Down to UP progression
A welder is limited by, process, pipe diameter, PNumber, F- Number, weld metal thickness,
position, backing and progression.
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.