IT A € Inspection Training And Consulting Chapter Nne ASME Section IX Procedures & Qualifications Summary and Notes Inspection Training And Consulting, 2003API570 ASME Section IX ASME Section IX was developed to provide a common location for welding qualifications for the ASME Codes. ‘The intent of Section IX is to provide information on the qualifications of welding procedures and welding personnel for the new construction of boilers and pressure vessels. Section IX is now referenced by other codes such as API 570 and most other API Standards. The organization of Section IX is described in the introduction. Article Tis the general article and contains information relative to the remainder of the book. The paragraphs in Article I are numbered QW-100. Article I contains the acceptance criteria, types of tests, etc. Article II deals with welding procedure qualifications. The paragraphs in Article IL are numbered QW-200. Article III provides the information needed to qualify welders and operators. The paragraphs in Article III are numbered QW-300. Article IV is titled Welding Data, this article contains the variables, tables and figures used to qualify personnel and procedures. NOTE: Do not go to Article IV unless me of other articles ref there Article V, Standard Welding Procedure Specifications (SWPS). This section gives the details for allowing the use of prequalified procedures , as outlined by the American Welding Society. The forward of Section IX contains the following information: Directions for submitting interpretations to ASME, the effective dates of addenda, (Addenda becomes mandatory six months after issue.) and Code cases. Section IX is used to qualify procedures and personnel. The following welding processes are addressed by Section IX: OFW Oxyfuel Welding SMAW _ Shielded Metal Arc Welding SAW Submerged Arc Welding GMAW _ Gas Metal Arc Welding FCAW Flux Core Arc Welding GIAW Gas Tungsten Arc Welding PAW Plasma Arc Welding ESW Electroslag Welding EGW Electrogas Welding EBW Electron Beam Welding sw Stud Welding ITAC ASME 1X Surnmary (API570), Spring, 2008 Page 9-1Section II, Part C is the part of Section II that describes welding materials. Section Il, Part C, describes: ‘The Processes that may be used with each electrode, recommended storage information, an explanation of the AWS symbols, positions to be used with electrodes and recommended polarity and current. A welding procedure shows compatibility of: Base metals Filler metals Processes Technique When writing a procedure, a good method to use would be to write a sample procedure, weld.a test coupon, prepare the test specimen and test them, evaluate \ the results and document them on and certify the PQR. Considerations involved ‘when writing a procedure include: Economy, the compatibility of the base and weld metal, metallurgical and mechanical properties of the weld, heat treatment requirements, service requiremenis, welder’s ability and equipment available. The manufacturer must qualify the WPS, maintain the WPS and PQR while welding is being performed and provide a listing of all procedures that may be used on code items. The code forms provided in Section IX are not mandatory, any form may be used provided all the required variables are addressed. The general approaches to procedure qualification is usually in one of two forms: Prequalified procedures These are AWS welding procedures used only for structural welding and do not require testing. The user is limited to specific weld joints and specific weld processes (see AWS D 1.1). ASME Section IX, 2001 Edition, Paragraph QW-100.1 now allows AWS Standard Welding Procedure Specifications (SWPS), as listed in Appendix E or in accordance with Article V. Procedure qualification testing These are API and ASME requirements. Both require actual welding to be performed and destructively tested. ASME procedure qualification testing uses a listing of essential variables in the creation of weld procedures. Essential variables are those in which a change is considered to affect the mechanical properties of the weldment, and shall require requalification of the WPS, ASME IX Paragraph QW - 251.2. Under ASME rules the welding procedure begins with the creation of the WPS. This information is taken from ASME IX and outlines the ranges of materials, electrodes and other general aspects. Then the PQR is created, performed and tested and used as proof for the WPS. The WPS can have many supporting PORs. ITAC ASME IX Summary (API 570), Spring, 2003 Page 9-2The basic steps in qualifying a WPS are as follows: * Write a sample around construction parameters and Code variables (QW-250) + Establish a test coupon size (QW-451) «Weld the test coupon using the parameters established. * Monitor all variables and record at least the essential variables on the PQR. If notch toughness is a requirement, a supplementary essential variable must be recorded. Cut the coupons into specimens (QW-462). Make the required tests per QW-451 Evaluate the results against the appropriate criteria found in Article I. If acceptable, certify the POR ‘Approve the WPS for use on Code piping or other Code applications. Release the approved WPS and POR for production. The required tests for procedure qualifications are described in QW-202. This paragraph requires 2 tensile tests and 4 bend tests minimum for groove weld qualification. Table QW-451 provides information on coupon size, ranges and test requirements for groove weld qualification. QW-451.1 GROOVE-WELD TENSION TESTS AND TRANSVERSE-BEND TESTS Tange of ThainesT Siachical ‘Thicknesst of Deposited Typeand Number of Tests Required Guilfelin Wed Meat Guach in. "Yerson and Gided Bend Tests Rotel Nate) Nene Thickness T of Test Tori Side end Face end Rot Bend Eigowaled in Min, Mex. Max wi Gwe, Gweleo™ ait Less than 1/16 Toa 24 2 2 1/16109/8 include. 1/1627 2 2 Noes) 2 2 Overs/Sbutisotan3/4 3/162 2t 2 Note) 2 2 S/Atolesttanti/2 3/167 aewhent<3/4 26) 4 Stole thanti2 37s Fr Hanes 3G od 1 1/and over a6 8 aewhentes/t 26) 4 11/2and over Bis 8) Bowness 26) 4 Noves: UY See QW-408 (2,3, 6,9, 10), QW-404.32, and QW-4074 for further limits on range of thickness qualified. Sete GW 208 (5. ay octal crcetons = fs (2) For the welding processes of QW-103/7 only otherwise per Note (1) or 7T, or 2, whichever is applicable 6 Four side bend ts ay be baat forthe requ ocean rot brides, when cine T 83/8 in (4) For combination of welding procedures, see QW-2004. Oe a natn ot as re oa nips Specimens when coupon thicknesoes are over 1 in ITAC ASME IX Summary (API570),Spring, 2003 Page 9-3,Locations of weld specimens from plate procedure qualification. Discard this piece Reduced-section| —_hensie specimen -—-—--|-P—--—— Discard Root bend specimen Face-bond spect pecimen Longitudinal Gee ee eet (eet cee teeta Face-bend Root-bend ‘specimen ‘Specimen Face-bend specimen t—---|-p--- Reduced-section| || | tensile specimen Resicedsecion] ens specimen ~ [Discard this piece Longitudinal Root-bend Vv Specimen QW-463.1 (a) Plates-Less than 3/4 in. alban Longitudinal Thicknesses Procedure Qualification {stag TEE ‘Specimen Discard this piece FReduced-section | || | tensile specimen Side-bend specimen die ae | eens fPedicedsecton | fost specimen Longitudinal Root-bend BeeieecsrieeeerescresesQerercse@eeeieecsciierecitestse ‘Specimen Side-bend specimen dice aaa eee Discard Reduced-section| _fensile specimen TZ end specimen Discard this piece ‘QW-463.1 (c) Plates-Longitudinal Procedure Qualification QW-463.1 (b) Plates- 9/4 in. and over Thickness and altemate from 3/8 in. but less than 3/4 in. Thicknesses Procedure Qualification TTAC ASME IX Summary (API570),Spring, 2003 Page 9-4Locations of weld specimens from pipe procedure qualification. QW-463.1 (d) Procedure Qualification Redvoet secon ‘ensio, Face bend Root bend Root bend Face bon Recuoad ection oe JReduced-section Pipes - Less than 3/4 In. thickness ry aaa ise ido bends ida bends side Rdueed-scton ‘eneie Pipes -S/4 In. and over thickness and Aiternate trom 3/8 in, but less than 2/4 In. ‘thickness ‘QW-463.1 (e) Procedure Qualification ITAC ASME IX Surmmary (API570), Spring, 2008 Page 9-5,Weld procedure specimens, guided bends are also used for welder qualification tests. Guided Bends Face Side Root TTAC ASME IX Summary (API570), Spring, 2003 Page 9-6The tests commonly required by ASME Section IX are: Tensile Bends Face Root Side Table QW -451 is the Procedure qualification thickness limits and test specimens requirements. Each groove weld must pass tension tests and transverse bend tests. This table is where the requirements for testing are listed... After the procedure qualification testing the Welding Inspector must check production welding fo ensure welds are being made in compliance with the approved and tested weld procedure. Remember the weld procedure is proof that the weld can be successfully made. The general sequence for procedure qualification testing is as follows: * Select welding variables (write the WPS and POR) * Check equipment and materials for suitability + Monitor weld joint fit-up as well as actual welding, recording all important variables and observations * Select, identify and remove required test specimens « Test and evaluate specimens * Review test results for compliance with applicable code requirements * Release approved procedure for production * Qualify individual welders in accordance with this procedure * Monitor production welding for procedure compliance ITAC ASME IX Summary (API570),Spring, 2003 Page 9-7,QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS) (See QW-200.1, Section IX, ASME Boller and Pressure Vessel Code) Company Name: Welding Procedure Specification No. Date: ‘Supporting POR No(s) Revision No. Date: Welding Process(os): Tie ‘Automatic, Manué Machine, or Semi-Auto ils Joint Design Backing (Yes) (Woy Backing Material (Type). (Floferto both backing and retainers) Metal) Nonfusing Meal OF Nonmetaic other ‘Sketches, Production Drawings, Weld Symbols or Written Des- ‘tiption should show the general arrangement of the parts to be welied. Where applicable, the root spacing and the details of ‘wold groove may be specified. (At the option of the Migr., sketches may be attached to illus trate joint design, weld layers and bead sequence, e.g. for notch toughness procedures, for multiple process procedures, ate.) “BASE METALS (QW-403) P-No. Group No. toP-No, Group No. oR Specification type and grade to Specification type and grade OR Chem. Analysis and Mech. Prop. to Chem. Analysis and Mech. Prop. ‘Thickness Range: Base Metal: Groove Fillet Pipe Dia. Range: Groove Fillet Other: FILLER METALS (QW-404) ‘Spec. No. (SFA) AWS No. (Ciass) FNo. A-No. Size of Filer Metals Weld Metal Thickness Range: Groove Flot Electrode-Flux (Class) Flux Trade Name Consumable Insert Other “Each base metaliler metal combination should be recorded individually TTAC ASME IX Summary (API570) Spring, 2008 Page 98Sample Procedure Using SMAW variables the following represents a sample welding procedure. This procedure will be written under “ideal conditions”. The production information is as follows: + A piping system is under construction using welding procedures qualified to ‘ASME Section IX. «The pipe wall is 1 inch thick. + The base material is SA-106-B. © Filler material will be F-3 for the root pass and F-4 for the fill. There are no special service restrictions The first part is general information supplied by the writer. a detailed sketch of the joint should be included in the space provided or on attached sheets. (QW402.1) «Base Metals The P-No. is 1to1 (See QW-403.1) The Specification, Type and Grade: SA 106 Grade B (Supplied Example) Thickness Range: (QW-403.7 and QW-403.8) Pipe Diameter Range: 27/8 inch Outside Diameter and over (QW-452.3) Filler Metals (QW-404.4) SFA-5.1 &5.5 (QW-432) ‘AWS No. E-6010 (Supplied Example) AWS No. E-7018 (Supplied Example) F-No: 3 (QW-432) F-No.:4 (QW-432) Weld Metal Thickness Range: (QW-451.1) TTAC ASME IX Summary (API570), Spring, 2003 Page 9-9QW-482 (Back) WPS No. Rev, [POSITIONS (QW-405) POSTWELD HEAT TREATMENT (QW-407) Position(s) of Groove Temperature Range Welding Progression: Up ‘Time Range Position(s) of Fillet GAS (QW-408) JPREHEAT (QWw-406) Percent Composition Prohoat Temp. - Min. Gast (Modure) Flow Rate Interpass Temp. - Max Preheat Maintenance | Shielding (Contruous or special hosting whore appeabe shoul be reccréed) | Traling Backing [ELECTRICAL CHARACTERISTICS (QW-409) Curent AG or OC Polarity ‘Amnps (Range) ‘Volts (Range) | (Amps and vots range should be recorded for each postion, and thickness, efc. This information may Delisted in a tabular form simierto that shown below. ‘Tungsten Electrode Size and Type (Pure Tungsten, 2% Thorated, etc.) Mode of Metal Transfer for GMAW. ‘(Spray are, short-cireuting are, etc.) Electrode Wire feed speed range TECHNIQUE (QW-410) Sting or Weave Bead Orifice or Gas Cup Size Intial and intorpass Cleaning (Brushing, Grinding, ete.) Method of Back Gouging eel ease teaneanreeeereneeeeeaeseeceeeiaes nf henna Contact Tube to Work Distance Moc gl ato tivor oii ttsecaceceeraeeeetrnctearneeeearneeeeeeeee cece Ii, ite cron ae csnacncnatcsnetanurnecnennre nnn nine er ceeeeTce Travel Speed (Range) Peering Other Filler Metal Current Other Travel | (0.9, Remarks, Comments, Wild Type | Amp Speed | Hot Wire Addin Tectniqus, Layer(s)| Process | Class | Dia.) Polar fs Range Torch Angle, Etc) ITAC ASME Ix Summary (API570), Spring, 2003 Page 9-10«Positions (QW-405.1) Welding Progression: (QW-405.3) «Preheat (QW-406.1) QW-407.1 Special requirements for preheating «Postweld heat treatment (QW-407) none required «Gas (QW-408) none required «Electrical Characteristics (QW-409.4) Current: DC Polarity: DCRP Amps: (QW-409.8) «Technique (QW410.1) String or Weave Bead: Stringer / Weave Cleaning: (QW-410.5) Brush or grind as necessary Method of Back Gouging: (QW-410.6) ACA-A or grind as necessary Peening: (QW-410.26) None allowed TTAC ASME 1X Summary (API570) Spring, 2003. Page 9-11QW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR) (See QW-200.2, Section IX, ASME Boller and Pressure Vessel Code) Record Actual Conditions Used to Weld Test Coupon ‘Company Name. Procedure Qualification Record No. Date WPS No, Welding Process(es) Types (Manual, Automatic, Semi-Auto.) JOINTS (QW-402) Groove Design of Test Coupon [For combination qualifications, the deposited weld metal thickness will be requifed for each filler metal or process used. eee eee een ee OST WELD HEAT TREATMENT CMaG7) Material Spec. Temperature ype or Grade Time IP. No. DPN. Ober hickness of Test Coupon jameter of Test Coupon GAS(QW-408) Percent Composition Gasles) _(MPtyre) Flow Fate Shiokding ILLER METALS (QW-404) Tag FA Specification Backing WS Classification ler Metal F-No, | | _ ELECTRICAL CHARACTERISTICS (QW-409) Current jokd Meal Analysis A-No. EET ze of Filer Metal Polarity er Amps. Volts ‘Tungsten Electrode Size ed Metal Thickness Other. POSITION (GW-405) TECHNIQUE (GW-470) Position of Groove ‘Travel Spoed fold Progression (Uphil, Downhill) ‘Sting or Weave Bead fotner Osailation ‘Multipass of Single Pass (per side) Single or Multiple Electrodes PREHEAT (QW-406) Other Preheat Temp. linterpass Temp. jother = ITAC ASME Ix Summary (API570), Spring, 2003 Page 9-12QW-483 (Back) PQR No. Tensile Test (QW-150) Utimate Unimate Type of Spocimen Total Load | Unit Stress Falure & No. wath | Thickness | Area b. psi Location Guided-Bend Tests (QW-160) “Type and Figure No. Toughness Tests (QW-170) [Specimen] Notch] Noich [Test [impact Lateral Bp. Drop Weight No. Location | Type | Temp. | Values [~vesnear—] tis BroaK] Fillet-Weld Test (QW-180) Result Satisfactory: Yes No Penetration into Parent Metal: Yes No Macro - Results Other Tests ‘Type of Tost Doposit Analysis Other Welders Name Tests conducted by: ‘Stamp No, Laboratory Test No. \We ceriy that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code. Manufacturer Date By {Data of record of ests ar Hlustratve only and may be maxed to conform tothe type and number of tt required bythe Code) ITAC ASME IX Summary (API.570),Spring, 2003 Page9-13,ASME Section IX Welder Qualification Welder qualification establishes the skill level for the welder. The test positions are similar to the welding procedure positions. The essential variables for welder qualification are as follows: © Position Base Metal Type Joint Configuration Base Metal Thickness Electrode Type and Size Technique (Up-hill or Dowr-hill) * Process (a) 4G ~ (a) 1G (b) 2G ° (©) 3G QW-461.3 Groove Welds in Plate -- Test Positions (a) 1G Rotated (©) 5G (@) 6G QW-461.4 Groove Welds in Pipe -- Test Positions Throat of weld Axis of weld Axis of weld AC horizontal vertical ee 45 deg. (a) 1F (b) 2F (a) aF (9 3F QW-461.5 Fillet Welds in Plate - Test Positions TAC ASME IX Summary (API570), Spring 2003, Page 9-14PERFORMANCE QUALIFICATION - POSITION AND DIAMETER LIMITATIONS (Within the Other Limitations of QW-303) Position and Type Weld Qualified [Note (1)] Qualification Test Groove Fillet Plate and Pipe Pipe Plate Weld Position Over 24 in. O.D. —-< 24 in. OD. and. Pipe Plate - Groove 1G F F [Note (2)] F 2G FH FH [Note (2)] FH 3G RV F [Note (2)] RAV 4G FO F [Note (2)] FO 3G and 4G FY,0 F [Note (2)] All 2G, 3G and 4G All FH [Note (2)] All Special Positions m(SP) SPF SPF SPF Plate - Fillet IF F [Note (2)] oF BH [Note (2)] 3F BLY [Note (2)] 4aF EHO [Note (2)] 3F and 4F All (Note (2)] Special Positions (SP) SP, F [Note (2)] Position and Type Weld Qualified [Note (1)] Qualification Test Groove Fillet Plate and Pipe Pipe Plate Weld Position Over 24 in. O.D. —< 24 in. OD. and Pipe Pipe - Groove [Note (3)] 1G F F F 2G BH FH RH 5G RV.O FV,0 All 6G All All All 2G and SG All All All Special Positions (SP) SPF SPF SPF Pipe - Fillet (Note G)]) IF F 2F FH 2FR FH 4aF FHO SF All Special Positions (SP) SPF NOTES: (1) Positions of welding as shown in QW-461.1 and QW-461.2, F = Flat H = Horizontal V = Vertical O = Overhead (2) Pipe 2 7/8 in. O.D. and over. (3) See diameter restrictions in QW-452.3, QW-452.4 and QW-452.6 ITAC ASME IX Summary (API570), Spring, 2003 Page 9-15,~The general sequence for Welder qualification testing is as follows: © Identify essential variables * Check equipment and materials for suitability * Check test coupon configuration and position * Monitor actual welding, to assure that it complies with applicable welding procedure * Select, identify and remove required test specimens * Test and evaluate specimens * Complete necessary paperwork ~ * Monitor production welding ITAC ASME IX Summary (API 570), Spring, 2003 Page 9-16QW-484 SUGGESTED FORMAT FOR MANUFACTURER'S RECORD OF WELDER OR WELDING OPERATOR QUALIFICATION TESTS (WPQ) See QW-301, Section IX, ASME Boiler and Pressure Vessel Code Welder’s name Clock no. Stamp no. Welding process(es) used ‘Type Identification of WPS followed by welder during welding of test coupon Base materials) welded Thick Manual or Semiautomatic Variables for Each Process (QW-350) ‘Actual Values Range Qualified Backing (metal, weld metal, welded from both sides, ux, ec.) (QW-402) ‘ASME P-No, to ASME P-No, (QW-403) (_) Plate ()_ Pipe (enter diameter, it pipe) Filler metal specification (SFA): Classification (QW-404) Filler metal F-No. Consumable insert for GTAW or PAW Weld deposit thickness for each welding process Welding position (16, 5G, ote) (QW-405) Progression (uphil/downthil) Backing gas for GTAW, PAW or GMAW, fuel gas for OFW (QW-408) GMAW transfor mode (AW-408) GTAW welding current type/polarty Machine Welding Variables for the Process Used (QW-360) ‘Actual Values Range Qualified Direct/remote visual control ‘Automatic voltage control (GTAW) ‘Automatic joint tracking ‘Welding position (1G, 8G, ete.) Consumable insert Backing (metal, weld met welded from back sides, flux, ete.) Guided-Bend Test Results (Guided Bond Tests Typo { JOW-4E22 (Sid) Rosas —{ YOW-#6I5(e) (Trane. REF) Type —( JOWAEESIS (Long AS Fy Resulis Visual examination results (QW-302.4) Radiographic test results (QW-304 and QW-305) (For alternative qualification of groove welds by radiography) Filet Weld - Fracture test Length and percent of defects in Maoro test fusion Filletleg size in.x In. Coneavity/convexity in, Welding test conducted by Mechanical tests conducted by Taboratory test no. We cortty thatthe statements in this record are correct and that the test coupons were prepared, welded and tested in accordance with the requirements of Section IX of the ASME Code. Organization Date By TTAC ASME IX Summary (API570), Spring, 2003 Page 9-17