Chap.

Chapters 3 4. 5. and 6 wlll cover Article I1 of Section IX. This Article is veIy important because . it sets the standards for the qualification of a l welding procedure specincations WPS) for the l welding processes of Section I X
Chapter 3 addresses items that are generic to all welding procedure specifications. Chapters 4.5, and 6 include specific information relatlng to the use of the variables for a specinc process. There

will be a short test at the end of each section.

(This page intentionally left blank)

8 1992 H d o r d Steam Boiler hspction and Insurance Company

. ..

1.

Facts About the WPS. Read QW-200.1 According to Section K. a WPS is required to be prepared by the manufacturer or contractor. Suppose at this point we state that the WPS may be compikd rather than prepared. that i i to say that it may be more than a piece of paper. Previously. the Code indicated that a WPS was the h t t i g that occurred in t e ASME hn h system when qualifying a welding procedure. Section L has clarlfled that the PQR is X the Arst document that occurs in the ^Code" system. While you may have a wrlttm WPS to use or refer to when qualifying the PQR it is not necessary to retain that WPS nor to evm follow that WPS when qualifying the PQR The PQR is the first document that falls under the rules of Section DL
.. .

Another c h a n g e ' ~ 6 m , p y e \ r i d u ~ , C o r l ~ e r e q 1 ~ ~ ~ ~ &:~.:.the.WPSis~ olearly for the use of those individuals r e s p o n s i b ~ & ~ a m p ~ ~ t b ~ ~ u . l i ~ m e g @ & ~ i o n l y :.for *e, .. . - ... .. . welders and welding opetitotsi:.Tt~s WPS-d~aiy:& spdni+&eh:tir lafhc@&ssion.' ' b i t h e 1: :.. l .. ,welding foreman. The necessary information which is ne;d;h- by -thew&der or '' weldkg operator is all that need be given. . .
. .

The WPS is not required to be supplied to the welder or welding operator.. . .. ..

All essential, supplementary essential. and nonessential variables that apply to a qualified procedure are contained in the WPS. Only those variables listed in QW-250 through QW-264 for a specific process are requiredl to be addressed in the WPS. Additional variables are strictly for the use of the manufacturer or . contractor and should not be the basis for anyone citing noncompliance wlth Section DL

QW-250 through 264. which wlll be discussed later. arc listlngs of those variables that X apply to each welding process addressed by Sectlon l. The WPS, as a minimum. must address all of those W b l e s Micated as e s d vwiables. Additionally. those items indicated as non eswntkd variables are also required to be addressed on the WPS. If notch toughness applies. supphmntaq essential turfablesmust also be addressed on the WPS. Many times other information is listed on the WPS for the use of those responsible for welding. When a WPS is considered to be in compliance with Section IX this additional information should be reviewed; however, rejection of the WPS cannot be made when using Section K as a rejection criteria. Coanmon sense and metallurgical on side rations may dictate rejection of a specific WPS on items that are not mentioned in the variables r e q u i d by the Code.

There is no required format for the VIES. However. Fonn QW-482in Section K can be used as a sample for the convenience of the rnanufactu~r contractor. It is located in or

8 1992 Hanford Stnm Boikr Inspection and InsuranceCompany

The Form QW-482. like the other nonmandatory fonns in Section K,does not have to be completed in any specific manner. As long as the essential. nonessential and supplementary essential (if they a ply) variables arc addressed, the forms can be used in any manner suitable to the man cturer's needs. Some people would have you believe that each blank must be completed. This is not generally true. Recent interpretations from Section M indicate that compliance with Section M does not rest upon properly completing the form. Section M has stated that they have no rules for completing the form. therefore Section M cannot be violated by cornpletlng the form in a specific manner suitable to the manufacturer or contractor's needs.

&

The WPS should be available to the AuthorJzed Inspector (not a Section M nquimncnt but rather an ASME Fabrication Code requirement) and the welder or welding operator. An ofRcial intupretatiop states that the welder/welding operator needs to be informed o f those things he has control over when maldng a weld. This information could be on the drawings.
A WPS was created and it contained all essential. supplementary essential. and

nonessential variables required for the process being used. It also contained two variables not required by Section DL The WPS was recorded on form QW-482. Is this WPS valid if it has additional information that may be confusing to the welder? (Yes/No?)

Answer: Yes.

As long &the minimum requirements of Section M are met. any additional information can be added.

Read QW-200.2 - The Procedure Quallflcation Record (PQRJ. The PQR is the most mportant document required by Section M and is prepared and certified by the manufacturer or contractor. The PQR is the governing document for welding procedure qualifications. Without a properly qualified and certifled PQR there can may be several unqualiiked WPSs used to qualify the be no Section M qualified WPS. PQR but they do not fall within Ue ASME system or Section M until they arc properly supported by a PQR Again, keep in mind that the word prepared should probably be the word comptled for the same reason as stated for the WPS. It may be more than one piece of paper.

men

Additionally. the PQR may be welded by anyone, pmvlded a representative from the manufacturer's (contractor or fabncatod organization is present to witness the welding of the test coupon. The words in Section M are sllghtiy vague in this area. A welding procedure can be qualified by a robot, therefore it does not make sense to requin the welder making the procedure quallffcation to be in the employment of the manufacturer who will use the procedure. Homer. Fabrication Codes may supersede the minimums of Section M. To date. there are no Fabrication Codes that do thls. Be aware that there are several indMduals who feel that the welder must be in the employment of the organization that is qualifying the PQR or WPS.

O 1992 Hartford Steam Boiler Inspccticn d Insurance Company

The PQR is the document that jusiMes or supports the WPS or WPS's. The WPS is dependent on the PQR for its validity. Each WPS must have one or more supporting PQRs to just@ that the WPS was properly qualified. However. a single PQR can support more than one WPS. A PQR that was qualified some time after 1962 is still valid today to support a WPS that is certified to meet the latest uue Code requirements. However, to avoid any questions or f t r problems, it would be a good idea to update or rwlse the PQR to meet the requirements of the Code for these cases. , One should be very careful because the essential variables that an required to be listed on the PQR may not be changed or alter4 however. it is possible to revise the PQR As you may note from QW-200.2(c) changes tn the PQR must be recertified and dated by the manufacturer. '
A PQR documenting what happened during a qualification must indicate the date of qualification. The PQR must be certified by the manufacturer or contractor who will use it. Please remember that the PQR should only list what was witnessed durlng a test and not anything else. For example. if the amperage and voltage were not witnessed durlng

the test. they cannot be entered on the PQR Generally the amperage and voltage is considered a non-essential varlable and are notnqulred to be recorded on thrPQR-

The PQR must con

.

(a)The essential.varl through QW-2

ses.(& listch in.~N!-250.. ._.~: . qualify the test weld.

:. .

. .

..

..
, ;

., . : .,>.

. :

...

..

(b) The number and results of the tests performed on the test specimens.
(c) Certification. including date. by the manufacturer or contractor. The certification of the

PQR may not be done by the test lab. The test lab may certify the results of thelr testing (the manufacturer need not m e s s the actual tenslle, bend tests or other tcsts): however. the manufacturer must make an additional certificatfon that these tests comply wlth Section I of the ASME Code and that the test results are amptable to Section DL X Any changes in an essential or supptementary essential variable require that the procedure be requalified. Essential variables should not be estimated. m y o b d data shodd be recorded. There is no mandatory form for the PQR just as there was none for the WPS. Form QW-483 is provided as a guide. but it is not necessarily applicable for all situations.
A PQR was made in the following manna: it was prepared by recording data during the wdding of a test coupon. The PQR addressed every essential variable for the pmcess used that is listed in QW250. All subsequent test result data was recorded on the PQR It was then cerUfied by the

manufacturer and made availabk for examination by the Authorized Inspector. Is this the correct methodology for documenting a PQR? Wes/No?)

0 1996 Haftford a r m Boiler Inspsnim nd Imurarue Company

Chap. 3 -Items Generic to all Welding

Procedure Soeeifications

P-Numbers Read QW-200.3. P-Numbers are for the convenience of the manufacturer and contractor. These n u m b permit classification of a group of base materlals having similar metallurgical structures and weldability properties (See QW-422for P-Number listings). The base material must be distlngufshed from filler metal which wlll be discussed later (Refer to QW-432for filler metal F-Numbers). P-Numbers cannot be assigned by a manufacturer or a contractor. If the P-Number for a specific material and grade of material is not listed in QW-422. material must have a WPS quallfted with the specific material the and the resulting WPS wlll only be acceptable when welding that base material. Not all materials found in Section 1 of the ASME Codes are listed in QW422. I many cases 1 n Section IX has considered certain materials not weldable or the referencing fabrication Code does not permit the welding of certain materials. Some examples are those materials that have a carbon content in excess of 0 3 % AU of the ASME Codes prohibit welding materfals .5. with a carbon content of 0.35% or greater. * Section IX d o t assign P-Numbers to any mate* ,the ASME code (the materials specification Code).

that is notfound-in Section I1 of ~ . .

~

. . ... - . ~.~ .
6 8 ,

Because a base material is listed with other base materials under a single P-Number. it cannot be assumed that any other base m a t e e w i t h the same P-Number may be substituted for it in production. Different base materials have different metallurgical properties and therefore should not be indiscriminately substituted without consideration of their compatibility and intended service. Material that may be acceptable for an air tank may not be satisfactory for a hot water storage tank. Section IX makes the assumption that each manufacturer or contractor has on his staff a welding engineer or someone familiar with welding metallurgy. The ASME Codes are primarily safety codes and not necessarily operational codes. They do not consider all of the different metallurgical combinations that may be possible for fabricating boilers and pressure vessels. Therefore. it is incumbent upon the users of Section I to make sure X that the materials they are welding. are metallurgically compatible with respect to postweld heat treatment. weld design. mechanical properties and service requirements.
A manufacturer finds that a particular stkctural A S I M material has identical chemical and physical requirements as a comparable P-Number 1 material found in QW-422.The manufacturer assigns this material a P-Number 1 designation and proceeds to weld it

Rd

using a qualified procedure that indicate P-Number 1 material must be used. Is it acceptable?

Answer: No. The manufacturer may not assign P-Numbers to materials that are not found in QW422 and no materials other than SA or SB materlals are listed in this table. Note that the SA specification is indicative of a ferrous material and the SB indicates a nonferrous material.

8 1996 Hartford Sleam Bollcr Inspection and Insurance Company

-- -

4.

?he P-Numbers of QW-422 also. in most cases have a Group Number. This Group Number is usually not relevant However. when notch toughness is a consideraton, a change in P-Number and Group Number may require requaMcation of the welding procedure. ?huefore. it is very important to indicate the P-Number and Group Number on the PQR and on the WPS. If a WPS is limited to PNumber 1. Group Number 1 materials. it may not be used to weld P-Number 1. Group Number 3 materials wlthout a revision or requalification. Without knowing the spedec circumstances (whether or not notch toughr~ess a requirement) we cannot tell whether or not the WPS has to be requalified is or revised based on the given information. Ftnd SA-285. Grade C in the P-Number table of QW-422. What is i s P-Number and Group Number? t

Answer: P-Number 1. Group Number 1

...

5.

In some cases. there are some materials that have a letter designattop in addition to.@v.P-Number. designation. For -p1ee7efer $P-,Number l O ~ l.l,:*-%422. You can q t&qs.tlyre ..... d .: 6.p- .., :" ::' Number 1 0 A. B. C. etd. Thc$km&q~&'iilbb tia$:a ~ u @ M ~ ~ ; - . & : ~ i i j r :' :~-- ~ ...... . the p-Number on the WPS &d pQR ifi sdme dase;a & *d& & mate,&& Pr 22. for example. Refer to P-Number 5A. Group Number 1material SA-335 which-hw a w d e P 2 1 and P22. At times, we have found that WES and PQR.$+pn+us& .indtcate~t?Wwis-&:P,~~~ . ... .!::. :.I-. .- -:.. . .. . . - . . . : ..::., ..~ . 77+ -., . . . , :-:. .:.'".; . .: . .. ,. Number when it is really thegrade6fmaterlal. ,. . . :.:..., . ~. . .

.!

'af,&-&&@
L'2

-1.

.Find SA-240 grade S44700. What is its P-Nurnber and Group Number'?

Answer: P-Number 10J. Group Number

5 .

Read QW-200.4 This particular paragraph has been revised many times. Additions were made to the paragraph including the transfer of many of the notes from QW-45 1.1 and QW-45 1.2 . One particular item to uramine is the second sentence of paragraph (a). Please note that combination processes or comb,ination procedures refer to those situations when there are more than one welding process or more than one filler material in a particular test coupon or l production weld. A l essential variables apply to each of the processes and ffller materials. A WPS is pretty straight forward as long a s there is not a combination process or combination welding procedure involved. However. this is not the general rule. More than one WPS may be used in a single production joint. For wrrimple. a GTAW procedure may be used for the initial weld deposit or root pass. Then the fill passes'may be with a SMAW procedure.

0 1996 Hanford Steam Boiler Inspection and ins^ Company

When two or more pmedures (or different processes, Nler metals. etc.1 are used. the qualified ranges of the base materials and fffler metals for each process or procedure is determined from QW-451. One of the exceptions is for root deposits qualified per QW200.4(bl. The purpose of this additional paragraph is to permit the qualUlcaWn of a very small deposit of filler material on a large thickness of base matertal when used for tacklng or the root pass only (one pass). This paragraph has no benefit to base materials that arc less than one inch thick for the actual production welding. Later we will discuss QW-451.1.

--

For example: If we wished to only tack weld an 8" thick mat&, at least a 1-1/2" thick test coupon would be required for qualification. Tl paragraph permits you to use only a hs 1 / 2 t i k test coupon. It has very limited use and it should not be misused or hc misinterpreted to apply to something it was not intended for. When this paragraph was placed into Section pC. much consideration was ghrm to providing a true evaluauon of the
heat sink effect caused by a small amount of filler metal and a large thickness of base material. It was felt that the 1/2" thick test coupon adequately represented the heat sink that is evldent in large cross sections of material. Deposited weld metal from each procedure or process must be included in the requked tension and bend specimens. I some instances, the turned tension specimens of QWn 462 may not be used because the first few passes will be machined off when the tensile specimen is tumed. In general, the tumed specimens should not be used when combination processes or procedures are used in a test coupon * P r- e s s e s - q u ~ d a c o b l ~ t i o n $ m M d u r C o in kg.. GTAW root, S A balance) may be M W used separately. provided the applicable variables and thiclmess limits of QW-451.1 or QW-45 1.2 (asappkable) are applied to each process. Note that the parentmses relating to the short;cimuIUng mode-af arc transfer (GMAW) may provide additional Wts. This is simply to remind the mader of the 1.1 times the thickness llmit for this particular type of GWW mode of arc transfer referred to in QW-404.32. an essential -able for the G A process. If a 1 / 2 thick (or thicker) test coupon l used to quallfy the MW s G A short-circuit process. the 1.1 limit disappears and the range of thickness is taken from MW QW-451. Therefore. one could assume that if you use any welding process and a 1 / 2 thick test coupon. that this would qualify for that particular welding process or mode of transfer to be used for root passes and tack welding on all thickness of base material including G A short-circuit MW mode.
A manufacturer or contractor has a quallfled WPS which specifies the G A process for the weld TW

root pass and the SMAW process for the balance of the weld. Can thIs procedure be used to make a production weld using only the G A process? TW

Answer:

Yes. provided the thickness of metal deposited by each process during qualification was documented and the applicable qualified llmlts are not exceeded. By documented, we mean that when the PQR was qualified. the amount of filler materhl for each process was recorded on the PQR In other words. the PQR is not satisfactory if it does not specify the thickness of each fIller metal deposited.

8 1992 Hardord Steam Boiler Iwpection and Insurance Company

.

7.

A manufacturer or contractor has a WPS which was qualified using a 1 . 8 7 5 thick test plate using only the SMAW process. He intends to use this WPS to make a production weld with base material 3 thick However. the fabrication requirements necessitate the use of a GTAW root deposit. It will be necessary to quallfy a separate GTAW procedurr to make the root depostt.

What is the minimum test coupon thickness that can be used?

Answer:

1/2". provided the quallflcation is for root deposit only [see QW-200.41bll.

3.

What is the smallest test coupon thickness that could be used if the manufactuxw wanted to make 2 passes using GTAW for the 1.875" thick test plate of question 77

Answer: 0.9375"(112 i 1.875, puQW-451.1) whlchlen have not covered yet

keep in mind that the 2 and 2t values of Q W 4 5 1 govern-if more than the root pass T or a small tack weld i involved. s

At Ulls timeJust

3.

Read QW-202.1. Throughout QW-202 the term %ase metal' is used. For the purposes of this course we will use the term base material to dfstinguish It from filler metal. To aid in your understanding. we will use the term base material to mean the matcrlals being joined and filler metal to mean the deposited weld metal or filler metal Joining the base materials.
This paragraph distinguishes between tests required for groove welds and tests required for fillet welds. Required tests for groove welds arc specified as be- addressed in QW-451. The reference to QW-45 1 includes QW-45 1.1 through Q W 4 5 1.4. QW-45 1 then nfas back to QW-202 in case you incorrectly went to QW-451 first.

Referring to QW-451.1. we can see that there are two tension tests and four bend tests required for each of the test coupon thicknesses. Suppose we had a situation where the two tension tests passed the acceptance crfteria and only one of the bend tests failed the acceptance crltaia. The i one fatled test. in this case. obviously fafled because of moisture in the a r during the final few minutes of the quallflcation test welding. Therefore. the manufacturer wishes to only retest that one bend test and accept the welding procedure quallflcation if it passes. Is this acceptable?

Answer: No.

If any of the tests fall. the entire test coupon must be -kIed

and retested.

I I/

Read QW-202.2ua). Groove weld procedure qualification base material thickness ranges are given in QW-451. The ranges are from a certain rnlnimum thickness to a certain maximum thickness. Ranges for filler metal are also given for a certaln maximum thickness. The minImum thickness restriction for deposited filler metal was deleted from Section I with the Winter. 1982 Addenda to the 1980 Code X and is therefore not required to be addressed. The provisions of QW-202.2(a)apply to all P-Numbers. Remember that there are only five types of welds discussed in Section DL These are: (1) Groove Welds

() 2 Fillet Welds (3) Stud Welds (4) Corrosion-Resistant-Weld Metal Overlay

(5) Hardfacing-Weld Metal Overlay In paragraph QW-202.2(a) the-term groove weld is used. In paragraph QW-202.m) one type o grooveweld f (partla1 penetration groove weld) is addressed. From the standpoint of Section I a partial penetration weld X is a groove weld by definltion. Therefore, QW-202.2(a) still applies to al types of groove welds. l May a groove weld test coupon be qualified by guided bend tests and reduced-section tension tests if it is constructed of P-Number 1 (assuming all other factors are in compliance with the Code)? (Yes/No?)

Answer:

Yes. (See QW-451.1 or 45 1.2 for required tests for groove welds.)

Read QW-202.2b). There are two distinct provisions in this paragraph: Groove welds that have only partM penetration must sttll be quallfled in accordance wlth the requirements of QW-451 for both the base matedal and deposited Nler metal thickness. Generally, a full penetration groove weld test coupon is used to qualify a partial penetration, production groove weld. The alternative is to partially R11 a test coupon groove and machine the remaining base material immediately prior to the actual testing (not before welding). A partial penetration groove weld is a weld where the deposited weld metal does not penetrate the full base metal thickness such a s in some nozzle attachments to a boiler or vessel wall.

O 1996 Hartford Learn Boiler Inspection and Insurance Company

Assuming it passes all required tests. the test coupon for a m a 1 penetration groove weld 1-1/2 thick or greater will have no upper thickness limit for the base material thickness range. This conforms to QW-451.1 except that the maximum 8" thickness limitation is not imposed for base material thickness range. Use of QW-451.1 will follow later. but briefly look at it now. particularly the last two ltnes (1-1/2 thick and greater test coupon thickness) and the T range and 7"maxlmum columns. The Mer metal stlll has the upper limit. Paragraph QW-202.2(b) like QW-202.3 and QW-202.4 will not apply to situations where base metal thicknesses less than 3"thick are to be welded. If your shop does not weld over 3 thick material, you may ignore these paragraphs.
A partial penetration groove weld test coupon i prepared. The test coupon is 2 thick. s

Welding is done by depositing filler metal 1/2" from each side. There is a 1 thick non" filled portion in the middle. Is this acceptable for a test coupon?

Answer: No. The test coupon must be a full pknetration weld if welding from both sides. The
code does not state '&is but it is the intent The machined tens!oti testf wauldd .. . never pass. DO NOT ASSUME THAT THE CODE COVERS EVERYTHING. Read QW-202 . 2 (c) Notice that this paragraph is applicable to all P-Numbers except P-Number 11A. Groups 1. 2. and 5 and P-Number 11B materials. The particular paragraph has a double negative as it addresses the exceptions for materlals exceptfor. To turn that around. it is really addressing the materials mentioned in the introductory sentence of QW-202(c]. N t weld quaMcatton test e coupons are not acceptable when groove welds or pressure retaining Wet welds will be made in production. In effect. a manufacturer cannot use a procedure qualified by toting a fillet weld test coupon (no fracture test - See QW- 182) for pressure rrtatnlng Wet welds on a boiler or pressure vessel. However, this does not .mean that welding procedures qualified with fillet weld test coupons prior to the Summer. 1981 Addenda arc no longer valid. As mentioned previously. in this course once a welding procedure is qualified it remains quallfled. unless someone wlshes to update the procedure or requalify it. This is hue wen if the Code becomes more restrictive. To avoid questions from customers, inspectors or auditors it is a good idea to meet the latest Code requirements. but it is not mandatory unless a fabrication Code nquirrs i t TOdate, we are not aware of any fabrication Code that requires this. According to QW-202.2[c),non-pressure retaW.ng fillet weld procedure qualification tests must be made in accordance with what paragraph of Section I? X
. .. .

Answer: QW- 180 in Article 1. Specifically paragraphs QW-18 1.1 and QW-183.

8 1996 Hanford Steam Boiler l n s p n i o n and lnsunnee Company

If a manufacturer wishes to weld a pressure vessel together using only flllet welds. qualified wlth a fillet weld pmcedun test coupon. using the QW-181.1 tesUng and QW-183 acceptance criteria. is it acceptable? (Yes/No?l

Answer:

No. The manufacturer must test using a groove weld test coupon even if all welds yill be Nlet welds.

If the manufacturer qualitled a Nlet welding procedure prior to the Summer. 1981 Addenda being efZective January 1, 1982. may the procedure be used to weld the pressure vessel of question 13 above? IYes/No?l

Answer: Yes. The procedm-e was acceptable for production Nlet welds when it was qualified.

l (See QW-100.3.) Once a WPS is qualified, it remains qualified. A l new quaUflcaUons and requaltflcations must be to the latest Code Edltion and Addenda.

Read QW-202.2(dl.

This paragraph contains the requirements for t e P-Number 11A (Group 3. 4. and 5) and Ph Number 11B materials which are excluded from QW-202.2(c). There are two important dlffennces between QW-202.2(d) and the prcvlous paragraphs, (a). Ib).and (cl.
1. With the P-Numbers of QW-202.2(d), a single groove weld test cannot qua* the WPS for both groovc welds and fillet welds. 2. Fillet welds, using these P-Numbers,must be quallfled with both a groovc weld coupon and a met weld test coupon with the appropriate test for each type of test coupon. The reason for the severe treatment of these groups of material is that these materials arc very heat sensitive. Improper heating during the weld will usually resuit in cracks. Therefore. Section l believes that a more severe test is called for. X
A manufacturer desires to make a pmductton weld. using a Nlet weld to attach two pieces of pressure retatning SA-517 grade A material. A procedure test coupon is prepared by maklng a groove weld test coupon in accordance wlth the requirements of Section I . This test coupon is X

then tested and passes. Does this qua@ the procedum for maklng the fillet welds? (Yes/No?l

Answer:

No. Qualification also requires a Nlet weld test coupon. It is P-11B material.

Chap. 3

- Items Generic to all Weldin

addresses minimum and maximum base material thickness requirements when qualirytng test coupons. for weld repair, and for weld metal buildup. Tlw paragraph is limited to npalrs to welds and weld metal buildup such as on comded or eroded steel. As mentioned in numb& 11 in this chapter, QW-202.3 provides the manufacturer a n exemption if the base matatal that is being repalred exceeds 8". This paragtaph only applies to those situations where the base matatal is thicker than 8": othcrprise. QW-451 applles. The illler metal maximum of QW-451 sUll applies. There is no minimum depth of deposited weld metal q&ed.
451.1.
A qualified groove weld test coupon also applies for fillet weld repairs. This is consistent with QW-202.2(a) and QW-45 1.1.

This paragraph covers some important arcepuons to some of the provisions of Article I. It I

This is consistent with QW-

Test coupons less than 1 - 1 / 2 thick are qualltled within the thickness ranges of QW451.1. QW-202.3 also permits the maximum base material qualification thickness to be greater than the 8 limit of QW-451.1 base materlal. Under that circumstance. there is no maximum placed on the qualified base materlal range. The maximum 8 limit on the flller materlal still applies. .You may not deposit filler material exceeding 8" in thichess by this paragraph.
A contractor wants to qualify a test coupon for weld repair and buildup to castings that range up to 1 2 thick A test coupon 1-1/2" thick is prepared and welded. The test coupon is tested and passes. Can the contractor use the resulting PQR to justify a WPS coverkg 3 / 1 V to 12" thick

base materlal repairs? Cles/No?)

Answer: Yes. however the filler material thickness range will sUll be limited to a maxlmum of
8" only.

It is important to recognize that this paragraph addresses dirsfmffar thickneues of base material not dissimilar compositions of base material. It addresses the quallRcaUon of welds that join Merent thicknesses of base material (e.g.
2 to 1/4" such as welding a 1/4" thick nozzle to a 2"thick vessel).

It determines the qualificauon of such things as thin wall nozzles welded to thick wall shells and pressure vessel jackets or items only several thousandths of an inch thick to thick wall vessels.

-Already-quallfled" groove welded PQRs may be used for a production weld jolning two dissimilar base materlal thlclmesses provfded no essential variables change. The thinner of the two pieces of base materlal must be wlthin the qualified range on the WPS. as specified in QW-451. The weld f w . a metal thickness must also be wfthin the thlckness range specifled in QW-451. There is no maxtmum thicknesses for the thicker of the two base materials so long as the qualification was made on base material 1-1/2" thick or more. More than one PQR may be required to quallfy for some dissirrmar thickness combinattons to gain the full range of thicknesses desired.

s A WPS i q U e d for a base m a t d thiclmess range of 1/16" to 3 / 4 . The qualified maxlmum thickness of the d e p t t e d weld metal ts 3/4". The holda of the qualified WPS intends to make a pruJuction weld joining base material 3/16" thick to base materlal 1" thick. The welded joint will be 3/ 16" thick. Will the WPS support the production joint of 3/ 16" thick base materlal to 1" thick base materlal? (Yes/No?l

Answer:

No. The thickness of both materials being joined must be within the range qualified by the PQRs. T i will become clearer as we dlscuss the limitations o QW-451.1. hs f

Read QW-202.5. Notice that studs welded to other than P-Number 1 base metals must have five additional test wtlds made and a m a ~ ~ ~ - c m w n a U o n be performed. Studs used for heatkg surfaces only must (no load] need not be subjected to the extra five tests when two dlffercnt P-Number materials are involved. Be sure to note that thls requirement is over and above what QW-192 q u i r e s and if a person had started in QW-192 he would have missed the proper requlmncnts hex. BE SURE TO READ ARTICLE U FIRST FOR WELDING PROCEDURE QUALIFICATIONS AND REFERENCE ALL OF THE APPLICABLE PARAGRAPHS. DO NOT READ ARTICLE I OR ARTICLE IV AND EXE'ECT TO FULFILL YOUR OBUCAllON IN MEETING SECnON D REQUIREMENTS. THE [ TERMINOLOGY m N D E D HEATING SURFACES' I USED WHEN STUDS ARE PLACED O AN S N OBJECT NEXT TO EACH OTHER SIMPLY FOR ADDITIONAL HEATING SURFACE WHICH Several studs am going to be stud welded to SA-672 grade L70 pipe. Procedure quallflcation tests are made in accordance with QW-192. The welding procedure qualification tests quallfled the welding p m d u r e for use wlthin the range of essential variables of QW-261. -Isthls testing correct? (Yes/No?)

Answer: No. This is a P-3. Gmup 2 materlal and 5 additional macroetch tests are required.
This assumes the studs are not for heatlng surface.

8 1992 Hartford Steam Boiler Jnspction and Insurance Company

-

3. Read QW-203.

Note the following about this paragraph: Unless QW-250 states otherwise. a weld test coupon made in any position quallfles the WPS for al positions. TMs was a revision made in the 1974 Edition of Section I . Several conditions l X may arise that invalidate the first sentence. One is that the weld must be made in one of the positions recommended for the electrode by the electrode manufacturer or the Wer metal specifications. These positions are found in Section 11. Part C and most electrode manufahrer's literature. If, however, the weld is made in an unrecommended position. it is still quallfled for that position if all the required procedure tests pass.
A welder or weldinioperator making the test coupon is also automatically qualified to use that procedure except in some cases of fillet welds. Refer to Chapter 2 for a discussion on QW- 180 and the difference in the performance and procedure test coupons. The welder who quallfles a fillet welding procedure is quallfled to make only non-pressure retainlng fillet welds. 'This has been confirmed by two interpretations from Section IX in the past few years. To avoid problems. it is our suggestion that you think of the welder as not being qualikd therefore, you do not have a welder quallfled for non-pressure retainlng and pressure retaining f i e t welds. Also. keep in mind that a welder who qualifies a welding procedure in one position may not be qualified to use that welding procedure in all positions. As stated in Article I 1 of Section IX. the welder is 1 restricted by the position he quallfled in.

. Welding position is a nonessential variable.

For example:
A welder who qualifies a welding procedure in the flat position is only qualified to use that

welding procedure in a flat position. However. by Section IX. the welding procedure itself usually is qualiRed for use in all positions.
A groove weld test coupon is prepared. The sample WPS calls for the SMAW process. using E70 14 electrodes. The welder makes the weld in the vertical position. The test coupon is tested and it passes. The manufacturer wishes to use that WPS for a production weld using

E7014 electrodes in the flat position on a groove weld. They also want to use the welder. who made the test weld. without requiring another test. Can the manufacturer do both of these things and be in compliance with Section I ? X (Yes/No?)

Answer: Yes. However. the welder's position will be limited to that qualified for the WPS. Thls will
be discussed in a later Chapter when we discuss Article 1 1 1.

0 19% Hanford Skam Boiler lnspcccion and insurance Company

Read QW-2 11. The use of the word "pipe" also means tubing, fittings, or other similar shapes. Prior to the 1974 Edition of Section IX,qualification on plate did not q u a w for pipe. but it does today. Section IX is now written under the premise that when qualifying a weldtng procedure. the manufacturer is trying to verlfy that materials and welding filler metals used are compatible. One is trying to evaluate the skill that a welder needs to posxss to weld different types of product forms.
A pipe test coupon was large enough to provlde all required test specimens to qualify SA-106 gr. B using E7010 and E7018 electrodes. Can this WPS be used to weld two piece of SA515 gr. 70 plate to get he^ assuming no other variables are changed? (Yes/No?)

Answer: Yes. This may not be fully clear a t this point but both are P-1 materials.

* Welding grooves may exist in slightly different shapes. According to QW-212. the test coupon must be welded using one of the shapes (types) of groove proposed for use in actual fabrication. Unless QW-250 through QW-264 has a speciilc provision to the contrary. the type and dimensions of the welding groove are considered nonessential variables. Therefore. the WPS qualified with the test coupon may be used when welding other types of grooves. The only requirement is that the groove (or 5UeU type to be used. be indicated on the WPS or as an attachment to the procedure or referenced by the WPS. Acceptability of a weld in production may depend on a welding engineer choosing the correct Joint type. However, with the many varied types of grooves that may be required to make a n acceptable weld. Section IX leaves the decision up to the manufacturer's personnel. Section IX assumes the manufacturer's personnel are well versed in weld design. Because of the approach Section IX uses in qualifcations. the selection of a joint type or design is considered nonessential to the weld qualification. The weld Joint design wlll make a difference in whether the production weld was good or bad in some cases. Selection of an improper design may put undue stress on the weld which could result in failure depending on the service of the boiler or pressure vessel.
Read QW-2 12.
A WPS qualified with a single bevel joint generally qualifies for a double welded joint

(True or False?)

fmswer: True.

.-.

O 1996 Hanford Steam Boiler Inspection and Insurance Company

22. ' ~ e a d QW-213. The key words in this paragraph are P-Number11 and therrnaL If the vessel: is to be constructed of P-Number 11 material:
wlll use construction pmctices that require groove preparation by back gouging or a specific thermal cuttlng: and

the weld groove will be less than 5/8" thick: Test coupons must be thermally cut in the same manner as the construction base materials. and the weld test growe must be back-gouged when production welding will encounter thermal backgouging between passgs. Later we will see that back-gouging ir a nonessential variable but in this special case. for P-11 materials. the addition of back-gouging may actually require requalification of a procedure if the test coupon did not include back-gouging.
A manufacturer proposes to make a production weld that uses oxy-acetylene cutting to prepare

the base material and back-gouging for the double welded joint (welded from both sides). The total filler material deposited will be 1/2" thick with SA-645 plate. Must the manufacturer use thermal back gouging in his test coupon? Ws/No?)

M e r : Yes. It is a P-Number 1l Group 2 base material. k

13.

Read QW-2 14.1 and QW-453. and QW-462.5. Notice the following about these paragraphs: It applies to corrosion resistant filler metal deposited on the base material by welding. Unfortunately. Section U does not tell you but. It is applied for non-strength considerations. If the deposited Wer metal is used for strength in the design. treat the deposited filler metal as a groove weld qualiEcation and this paragraph does not apply. To obtaln qualification for a thiCkness below 1".the test coupon shall not be larger than the desired thickness. Naturally you need not qualify a test coupon for under 1" thick Wler metal if you wlll not overlay (less than 1" thick) base materials with a corrosion mistant Aller metal. (See QW-453) Section U does not consider the werlayed filler metal to be a co~wkleration the vessel's of overall strength, but other sections of the ASME Code permit you to consider the overlay as part of the vessel's total strength. There is no filler metal thickness h i t . The tests required by this paragraph are not the same as those required by other Code Sections. They were added as QW- 195. Four guided side bend tests ue required.
I

I/

Previous editions of Section I indicated that bend tests were required. ASME inquiries and a X revision to Section I have c l d e d that side bends were always intended. X Tensile testing is not required for any corrosion resistant weld metal overlay test coupons. (Also remember that to establish a minimum thickness of overlay, it is very important to record where the chemical analysis was taken.) Refer to QW-462.5. While it may seem pretty easy from the sketch to determine exactly what the minimum thickness qualified would be. it is not nearly as easy using a real test sample. The rough surface created by the weld fusion line can vary as much as 0.03 inches in some cases. When you consider that the entire deposit of cladding (another term for corrosion-resistant , overlay), may be as small as 0.05 in. you can appreciate the fact that this may create a problem. While Section l does not specify measuring at the lowest point, or the highest point. our X suggestion is to take yle worst case and measure the smallest distance h~twcen bond line the and the sample or take an average. In most cases it d not make any difference because you l wlll not usually measure it in production. The closer you can take your chemical sample to the weld fusion line, the less you have to justify your 'rninimum thickness qualIiled" to auditors or Inspectors. A weld overlay surface was examined by the liquid penetrant method. in accordance wlth Appendix 8 of Section VIII. Division 1. Following the Iiquid penetrant test, four side bend tests w&e made, all from test specimens cut perpendicular the direction of welding. 1s this test procedure in accordance with QW-2 14.27 (Yes/No?)

Answer: No. LP shall be performed per QW-195.1. See QW-453. Note 4.

A manufacturer wants to qua@ for a range of thicknesses 1 / 2 to 5 thick production base materlal that will be overlayed with a noncorrosive lining. The manufacturer quallfles on a test coupon that i 1 / 4 thick. Does this test coupon qus the manufacturer for a thickness range of 1 / 2 minimum to a 6 maximum? Wes/No?)
-

Answer: Yes. It would be qualieed for thickness 1 / 4 to unlimited

On what does the minimum and maximum thickness of qurillfied overlay thickness depend?

Answer: The distance from the sample to the bond h e . The minimum is dependent on where
you take the chemical analysis. There is no maximum.

24.

Read QW-2 14.2. Review QW-462.5. The essential variables for Procedure Qualification are addressed for corrosion redstance weld metal overlays established in QW-250 through QW-264 for the specific welding process.
0 1996 Hartford Steam Boiler Impect~on insurance Company and

C-,

!5. Read QW-215.

QW-215 indicates that joint geometry is an essential variable for electron beam welding and laser beam welding.
A contractor qualifies a procedure cslng electron beam welding wlth an open-square-butt-groovcjoint. Later.in production. the contractor wants to use a U-joint. Can the cn ouse the U-joint if the WPS is only revlsed and not requalified?

Answet: No. Joint geometry is an essential varlable and cannot be changed for producUon
welds without requalincation.

! . Read QW-2 16 .1 and QW-453. 6

UnWce QW-214(corrosion-resistant weld material werlay). QW-216 (hard-facing weld material overlay) specifies a mtnimum range of possible test coupon sizes for t i t i k c s width and I-. hchcas. QW-2 1 only addresses the wear-resistant overlay that is deposited by welding. The qtdifbtion 6 may be performed on a test sample that is the size of the actual production part. or the premibed minimum sjzc of test coupon This is prlrnarily to address the cases where hard facing i s performed on a very small surface. If the production base material is less than 1"thick. the test coupon base material must be less than or the same thickness to quai@ for production weldments.
'

Notice the following about the above:

Them must be a liquid penetrant test of the hard facing test coupon

After liquid penetrant testing. the test coupon shall be sectioned. and the hard facing shaU be sub ected to macro-camlmtion with an etcfiant. A macro-examination with 5X ma cation is required. Higher magnification and radiography may be used but you may not be able to meet the acceptance criteria. If radiography or higher than 5X magnification is used and defects an IdrntUled in the hard fadug. such d e f d should be recorded but would not necessarily be cause for rejection of the test coupon We are not t y n for 100%quality. we only wish to attain an acceptable level of quality. rig

In addition to the visual tests. a minimum of three hardness readings must be made. and the results must meet the hardness requirements specified in the WPS. One standard method is to use the Brhell Test. but others are also acceptable.

Finally. in addition to the hardness and visual tests. the weld metal overlay must be chemically analyzed.

The chemical analysis that is required by QW-453. Note 9 can be limited to the chemical elements that are indicated on the welding procedures specification. A full chemical analysis of all trace elements need not be performed. With the Winter. 1979 Addenda, the depth from which the chemical analysis is taken was changed. Hard-facing welding procedures quaW1ed prior to the Winter. 1979 Addenda are still valid and may be used for new construction. If you read all of QW-453. Note 3 carefully you will note that there is no acceptance standard for the liquid penetrant examination required. It states that the acceptance criteria is to be specified in the WPS. Unfortunately this has been missing for some time and we can supply you with no definite answer of what should be used for the acceptance criteria. We also cannot definitely tell you what type of procedure to use. Our suggestion. and we feel it is the intent of Section I .1s. X that the same procedure referenced in QW-453. Note 4 for corrosion-resistant overlay procedures be used for hard-facing overlay procedures.

17.

What is the maxtmum thickness of a coupon would be required to qualify hard-facing on 1 / 2 thick base material?

Answer: 1 / 2

A manufacturer prepares a base material test coupon for hard-facing weld metal overlay qUalIfication. It is cut to be 1 - l / 2 thick.2 wide. and 15" long. 'Ibe weld metal is deposited over the entire surface of the base material test coupon. Is this test coupon properly stzed to meet Section I standards for qualifying a procedure for hard facing 1" thick base material? X (Yes/No?')

6 ..&

Answer: Yes.

28.

A hard facing weld material overlay test coupon was welded and subjected to the following tests: a chemical analysis, a liquid penetrant test. four hardness tests and a radiography test. Has the test coupon been tested sufficiently? Wes/No?)

Answer:

No. It still must have macro-examination under 5X or greater magnltlcation.

29.

QW-2 16.2. Review QW-462.5. The essential variables for procedure qualification are addressed for hard-facing overlay (wear resistant) are established in QW-250 through QW-264 for the specific welding process.

0 1996 Hartford Steam Boilcr Inspeclion and Insurance Company

3.

Read QW-2 17 (1st paragraph). Clad metals refer to Wetal sandwiches.' (e.g. a carbon steel base material clad with P-Number8 metal for corrosive protection). This paragraph points out a critical distinction:
If the cladding metal's thickness ls included in the Fabrication Code design then subparagraph (a)must be used.

~~.

If the clad metal'has NOT been included in design calculations. then either (a) or Ib)must be used
pressure but it Design calculations generaw refer to the strength needed to could also refer to strength due to internal or external loads on an object. I thls case. n the cladding or part of the cladding thiclmess ls used to withstand design pressure.

If the metal is bonded onto the base materlal and is intended to contribute to the vessers integral strength. then subparagraph (a) is mandatory. *

This is one particular welding subject that definitely requlrcs some compe$emc in the Beld of welding metallurgy and welding technology. For example, Section M does not specify that the cladding must be stripped back f o the weld groove when welding a vessel joint of carbon steel rm clad with stainless steel. In general, carbon steel electrodes are used to weld the carbon steel portion and statnless steel electrodes are used to weld the cladding. If this ls done, the carbon steel electrodes (if they come in contact with the stainless steel cladding) wlll lnitiate cracks in the weld. The cracking wFU be so severe that the testing wlll usually fail visually without any additional tests in most cases. Carbon steel electrodes in contact with staJnless steel ls much like hot water in contact with ice.
A vessel is designed using clad carbon steel. The designers intend to calculate the vessel's total strength. required to hold the pressure. by calculating the strength of the clad metal and the

strength of the base materlal. Which subparagraph of QW-217 must the designers use for qualIficaUon?

Answer: QW-2 17(a)

Notice the following about this subparagraph: For welding clad metals. the essential variables include using the same P-Number base materlal. cladding. welding process. and filler material combination that will be used in production.
If the base metal. proposed for production, is not ltsted in the P-Number table QW422. the test plate may still be qualified. but only within the range of chemical composition for the production base metals. This presents a problem in most cases because many materials do not have ranges (only mintmums or maximums).

Therefore, in many canes qupllfication I limited to the base matcrial(s) welded. . Thickness range quaUIlcations is not based on the thickness o the entire test coupon. but f on each of the different thickncsss of base materlal, cladding, and Nler metal. The minimum thickness of the mer metal used when joiaing the clad porUon of t e weld shall h be based on a chemical analysis of the weldment. (See QW-453) Tensile and bend tests shall be made on the final test specimens. as nquired in QW-451. Each t s spectmen shalbhave afull thickness qfcladd67g through the test spedmen's et reduced section No machlnlng of the clad surface is pormittcd; this does n t however. o. prohibit the macNning off of the weld reinforcement that may have been deposited so that 'approximately parallel surfaces" may be obtained. The type of bend tests is based on the Combined thiclmess of base materlal and cladding. However. side bends are used most often for practical purposes. Remember that for thickmsses less than 318'. QW-451does not permit side bends. The reference to 'cladding applied by a process other than fusion weldtug' refers to processes such as explosive bondlng. An explosive charge is used to force the molecules of the base material and the cladding material together. This obviously is done at a ml il rather than at a manufacturer's shop in most cases: however there have been cases where explosively bonded tubing has been manufactured at a job site.
A contractor wlshes to qualify a weld joint that includes clad metal. The contractor prepares a test coupon for a groove weld by obtaining clad base material and flller metal that wlll be used in

the proposed production weld. The contractor prepares a groove weld test coupon with the base materials and makes the groove weld with the welding process that will be used in production. After welding, the test coupon is sectioned into test specimens and subjected to 2 tensile and 4 side bend tests. When the test coupon passes the quallficatton testing. the contractor t e uses hn the same clad base material and filler metal. but changes the welding process for a production weld. Can the contractor do this. or is it necessary to requalify the procedure?

Answer: The contractor must requallfy the procedure if the process is changed. This should be
obvious for any welding, not Just clad materials.

0 1992 Hartford Steam Boiler Inspection m d Insurance Company

32.

Read QW-217(b).
QW-2 1 7 (b)makes a distinction between qualifying a procedure for welding the base materials

and qualifying a procedure for welding the cladding. The essential and nonessential variables of QW-250 through QW-264 apply for joining the base materlal portion of the weldment. While the essential and nonessential variables of QW-250 apply to the overlay portion of the weld. The WPS may have two separate supporting PQRs for welding the clad materlal.
THE F R T RULE FOR USING SECT'ION DL ARllCLE I1 IS: IS

n WHEN

NEVER USE ANY PARAGRAPH IN SECTION I THAT IS NOT REFERENCED FROM ARTICLE X QUALIFYING WELDING PROCEDURES.

The last sentence of QW-217(b) seems to be a little ambiguous. The reference to the WPS is intended to mean the qu&ed WPS. When the sl~ength portion of the weld i qualitled s separately from the cladding portion of the weld. the WPS should be clear enough to prohiblt deposition of cladding filler metal below the surface of the base material. To assure the full strength of the weld Reep in mInd that the cladding in this partlcular case is not part of the strength of the weld) the WPS should not permit the RUer metal joining the cladding to be deposited below the surface the strength weld. Even though some filler metal deposition may be unavoidable, the designer should definitely spec@ the maximum depth. In most cases. no depth + is permitted.
If a manufacturer already has a PQR quallfylng the welding with the SMAW process as the base material of a proposed clad metal for production, to what paragraph of Section I must the X manufacturer turn to find the essential and nonessential variables for the cladding?

Answer: QW-253

0 19% Hartford Steam Boiler tnspeaion and Insurance Company

~..

Read QW-218. QW-218 generally applies to manufacturers who wish to attach a metal liner to a vessel for corrosion or erosion purposes. The form (plate. tube. etc.) and amangemat used in c o n a t r u e arc essential variables. They must be duplicated for the qualUkation test. The test coupon must also be made of base material. Ilninz. and weld metal within the range of the chemical composition of metals to be used in construction. The chemical composttion is established by the welding . engineer on the WPS. This is not covered in Section M The welding varlables of QW-250 shall also apply.
A qualification test inust be performed using each position that will be used in production.

One test spcdmrn from each position must be sectioned. polished. and etched to show the fusion zone. Even though it is not dcrcnced. we believe the M e n t is to use a macro-etch procedure in compliance wIth the nconrmendationa of QW470. The acceptance criteria. unlike other arcas of Section M is stated in this paragraph. To pass, the test specimen .must haw complete fusion in the fusion zone and have no cracks in the fusion and heat affected zones. N mechanical testing is required. o The requtrcd macro--tion test is to be done without magmflcation. If magnification is used. Any defects noted which would not be vlsible without magnification must still be recorded. Thb does not mean that the test fails. (See QW470 for itching.)
A

manufacturer is attempting to q u a w a welding procedure for applied linings. The manufacturer complies with all welding variables of QW-250 and makes a test coupon for each I welding position that will be used ~ I production. One test specfmen from each test coupon is sectioned. pollshed, and etched. Visual inspecuon wlth 2X magnifkation shows no defects. When the test coupon was prepared. the manufacturer was unable to obtain metals with the same chemical composition a s those proposed for production Other metals with the same P-Number were substituted. Does this invalidate the qualification attempt?

- ' 3

Answer: Yes,if the tested metals were not in the same chemical range as the production
As mentioned earlier. establishing a chemical range can be difficult.

metals. the test is invalid..The P-Number has no bearing on the validity of the test.

Thls completes Chapter 3 regarding items that arc generic to all WPSs. The next Chapters will describe how to use and interpret the essential. supplanentary essential and nonessential varlab1es of Section M for the SMAW welding process. However. Section M SMAW variables also

apply to many other welding processes. Therefore. approach the next few sedions with an open mind even if you are not using the SMAW welding process. The information you learn will be useful to evaluate other welding processes. Most of the examples used in the following sections also apply to other welding processes.
NOW PROCEED WITH TEE CHAPTER 3 TEST

8 1992 Hutford Stcrm Boiler Inspection and

..

IruMnce Company

CPIX ANSWER SHEET CHAPTER 3 TEST

ANSWERS SHOULD BE BASED ON THE 1995 EDITION, WITH THE 95 ADDENDA OF SECTION IX.

WHEN COMPLETED. CHECK YOUR ANSWERS IN CHAPTER 12

Chapter 3 Answer Sheet

(1)
(2)

A. A.
*

B. B.

(3)
(4) (5)

Cl A.
A.

CI B.
B .

CI A. CI A.
A.

Cl B .
B .
*

(6)
(7)
(8)

Cl B. Cl
B.
B.

CI A.
A.
A.

(9) (10) (11)

(12)
,

B.

A.

CI B. CI B. CI B.
B .
B.

CI A.
A.

(13)

(14) (15) (16)

(1'1)

CI A.
A.

A.

'. B

CI A.
A.
A.

CI B.
B.
B .
B.

(18) (19)
(20)

A.

Chap. 3

- Items Generic to all Weldin

CHAPTER 3 TEST

The following questions are designed to measure your understanding of the lnfomtion presented in Chapter Three. Then fs only one correct answer for the multiple-choice questions. In some cases. where more than one answer is correct, there will be a choice similar to 'AU of the above' or 'Both A and B.' Choose only one answer. Read each question carefully. then mark your answer on the answer sheet prwided for this unit. When you have finished. you may check your answers in Chapter 12.
A manufacturer has qualified welding procedure specification to the 1992 Edition of Section M. It is supported by a PQR that was properly quallfled in 1973. With only this ldormation. what

a'

must the manufacturer do to meet minimum Section DL requirements?

@
C.

Qualtfy a new PQR to the 1989 Edition of Section M . Evaluate the p-nt PQR to see ffit complies with the 1992 Edition of Section D and ( possibly no quallflcation is required. Nothing is required. The WPS does meet Section M without any necessary revisions or requalifications.
*

The procedure qualification record PQR) is a document of what happened at a specific point in m e ; and it may never be revised to include data not observed during the test. If a revlsion is necessary. the entire PQR must be requalified with a new test coupon.
B.

True False

3.

A procedure qualification record was evaluated and it was determined that it did not include

the positton of the test coupon. For a SMAW welding process, position I a nonessential variable. s . Which of the following is true? The manufacturer must reaualify the PQR in the position that he wishes to use in production. The manufacturer must add the position used for qualification to the PQR before it I s acceptable. Nonessential variables are not required to be listed on the PQR. It depends upon the date the PQR is qualified. Not untll 1989 was it required to put nonessential variables on the PQR

A.

B.

B 1992 H d o r d Seam Boiler Inspection and h y l c e Company

-

'
t

The forms QW-482and QW-483must be used for compliance wlth Section M minimum requirements.

The WPS and the PQR must be available to the welder.

A.

True

Which of the following welding procedures. uslog these welding processes. may be qualified by radiography?
A.

B.
C.

The SMAW welding process. The GMAW short circulbg transfer method. All welding processes. N welding processes. o

to repair weld l materlaI that is n He has a qualified 3 A manufacturer wlshesprocedure aspecinfation &as qualified14" thick.1-1/2-thickmaxlmum of flller weldine ~rocedure that lists a rase of 3/16" to 8" of base material uslrUE 8" mate&: The welding using a test coupon
UD

What must the manufacturer do to the WPS, if an . to meet Section I minimum X requirements and repair the 14" thick weld to a depth of 5 maxlmum?
A.

C.

D.

The manufacturer's welding procedure is qualified and need not be revised or requallffed to perform the repair. The flller material Is acceptable for a maxjmum depth of 8". A manufacturer must revise the weldlng procedure spedlcation to p e m t the welded repair m unlimited base msterlal thlclmeu. Requalification Is not required. The manufacturer must qualify a new weldlng procedure for the maximum base materlal thicluless of 14". None of the above are correct.

8 1992 Hartford Stum Boila Inrpcction and IIISWMCC Company

..

Chap. 3

- Items Centric to all Weldin

A production weld on 3" thick m a t e d wlll be made using a partial penetration groove weld. The weldlng wlll be 1" deep &om both sides. Must the manufacturer qualify this wClding procedure using a full penetration groove weld or may he qualify the procedure using a 3" thick test coupon with 1" of filler metal deposited from each side to represent the actual weld to be made?

9
C.

The manufacturer must qualifl using a full penetration groove weld. The manufacturer may use a 3" thick test coupon with 1- Nlcr zxaterial deposited from both sides. Either of the above will be acceptable.

>.R( Q & .

that was qualtiled using plate matin the flat position, welding procedure specification for weldlng pipe in all positions.
B.

be used to s u p n a

A.

True False

10.

A welding procedure. qualified using one P-Number b&e material. not the two materials are metallurgically compatible in all cases.

d determine whether or

b
4
A

True False

11. P-Number 11 A. Group 1 material using a groove weld wlll qualify that welding procedure for welding fillet welds without an additional qualification. True False

1 . A flllet weld qualification test coupon using P-Number 5 base rnatcrhl may only be used to 2

support productton welding for nonpressure-retaining flllet welds. True False

w B .

O 1992 H d o r d S t e m Boiler Inrpacion ud Insurance Can-

-. -

Chap. 3

- Item

The GMAW welding process will be used to tack weld the flrst pass of a joint that is 4 thick. What is the m u m thiclmess of the test coupon that may be used to support the required welding procedure specification? The SMAW weldlng process will be used to complete the joint.

Who is responsible for wqtching the test coupon being welded?

A.

C .

Anyone the manufacturer or contractor subcontracts to through a contractual agreement. The manufacturer or contractor who arill use the welding procedure spcdkatlon. The test lab that will do the testing has responsibilities for the acceptance of the test coupon.

A welding procedure specification was q u a l a d in 1975. The Nler materlal that was used

in the pmedure was not included in Section II. Part C at that time. The 1992 Edition adopted that particular classification of filler material. May a manufacturer M e . not requallfy. his welding procedure specification and FQR to indicate that the matefil now has a speclflcation and classification number7
B.

Yes No

Section M requires that the Authorized Inspector accept all welding procedure specifications made by the manufacturer.
A.

True

7.

manufacturer has lncluded a requinment for the welding procedure specification that states that the welder must be left handed to perform the welding procedure. Considering that this is obviously not a variable for welding as outlined in Section M and considerJng Section M minimum requirements only. may a right handed welder use this weldtng procedure without nvision to the welding procedure or requaliflcation of the procedure? yes No

Q B .

8 Supplementary essential variables must be addressed on the PQR even if notch toughness . does not apply?

* . . The PQR must be certified by both the testing laboratory and the manufactureror contractor 9 (who will use the PQR) to be in compliance with Section M.

4
!O.

True False

A manufacturer wishes to qualify three welding processes in the same test coupon. The test coupon will be 1 / 2 t i k plate. What type of tests will be required as a minimum? hc

@
D.

2 face bend. 2 root bend. 2 tension tests.

4 side bend. 2 tension tests.

Either 2 face bend and 2 root bend or 4 side bend; and 1 tension tests. 2 face bend. 2 root bend. 4 side bend. and 2 tension tests.
NOW PROCEED WITH CFIAPTER 4

8 1992 Hndord S t e m Boiler LIJPCChn Od humnee Campmy