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Abstract
This section describes the development of a welding procedure specification, the
qualification of that specification, and the qualification of the welder using that
specification. It focuses on the ASME Boiler and Pressure Vessel Code, Section IX,
because this code is most frequently used for qualifying weld procedures and
welders (except for pipelines, offshore structures and shipbuilding).
Contents Page
210 Introduction
It is often mandatory to use qualified welders and procedures to meet codes and
standards. Even when not required, this practice is advisable. Qualifying welders
and procedures provides a standard for quality as well as agreement between the
fabricator and the user, whether welding is done by an outside contractor or by
Company personnel.
Figure 200-1 shows the relationships between various Company welding applica-
tions, their appropriate fabrication code, and the document that therefore governs
the welding qualification. Figure 200-2 illustrates the steps necessary to qualify
welding procedures and welders, and where to find this information within the
section.
This section discusses welding qualifications using ASME Code Section IX as the
model. For a discussion of welding qualification for pipelines, see Section 600 of
the Pipeline Manual. For offshore structures, see Section 600 of this manual.
Fig. 200-2 Flow Chart for Qualification of Welding Procedures and Welders
process. For a blank WPS form, see Appendix D; for an example of a completed
form, see Section 271.
Each WPS must list the supporting PQR; more than one PQR may be used for each
WPS to increase its range of application. This is done because recorded welding
variables in the PQR normally only fall within a small range of the actual variables
that may be used in production. Therefore, in order to use a single WPS, it may be
necessary to develop more than one PQR. For example, if more than one welding
process is needed for a production joint, separate PQRs can be prepared for each
process and combined into one WPS.
PQRs are required to be certified by the manufacturer or contractor as a true record
of the welding variables, and must certify that the test results are in compliance with
Section IX. Changes to PQRs are normally not permitted except for editorial
changes that do not require recertification.
241 Variables
Welding variables in Section IX are categorized as being one of three types: essen-
tial, nonessential, and supplementary essential. Changes in essential variables
require that the welding procedure be requalified. Changes in nonessential vari-
ables require only that the WPS be amended to reflect the change. Supplementary
essential variables cover impact testing requirements and are considered essential
variables when those tests are required; otherwise, they are considered to be nones-
sential.
To determine the variable type, consult the ASME Code Section IX, Tables QW-
252 through QW-262. (See Figure 200-3 and Figure 200-4 for examples of Tables
QW-253 and QW-253.1.)
Variables include things like base metal type, filler metal type, thickness, welding
position, electrical characteristics, joint type, heat treatment, etc. They are placed in
one of the three categories, based on the welding process used. A more detailed
description of each variable is given in the paragraph in the Code that is referenced
by the table.
Several variables, such as groove design, filler metal diameter, and welding posi-
tion, are listed in the table as nonessential (as long as impact tests are not required).
Any of these nonessential variables may be changed without requalifying the
welding procedure. However, should an essential variable be changed, then a new
WPS must be developed and qualified.
Fig. 200-3 Essential, Nonessential, and Supplementary Essential Variables for the SMAW Process (Table QW-253,
ASME Section IX) (Courtesy of ASME)
QW-253WELDING VARIABLES PROCEDURE SPECIFICATIONS (WPS)
Shielded Metal Arc Welding (SMAW)
Supplementary
Paragraph Brief of Variables Essential Essential Nonessential
.1 Groove design X
.4 Backing X
QW-402
Joints .10 Root spacing X
.11 Retainers X
.5 Group Number X
.6 T Limits impact X
QW-404 .6 Diameter X
Filler metals .7 Diam. > 1/4 in. X
.12 AWS class X
.30 t X
.33 AWS class X
.1 + Position X
QW-405
.2 Position X
Positions
.3 Vertical welding X
.1 Decrease > 100F X
QW-406
.2 Preheat maint. X
Preheat
.3 Increase > 100F (IP) X
.1 PWHT X
QW-407
.2 PWHT (T & T range) X
PWHT
.4 T Limits X
QW-409 Electrical .1 or > heat input X
characteristics
.4 Current or Polarity X X
.8 Type or & E range X
.1 String/weave X
.5 Method cleaning X
QW-410
Technique .6 Method backgouge X
.25 Manual or automatic X
.26 Peening X
Legend: Change
+ Addition Deletion
> Increase/greater than < Decrease/less than
Uphill Downhill
Forehand Backhand
Fig. 200-4 Welding Variables Procedure Specifications (WPS) Shielded Metal-Arc (SMAW) (Table QW-253.1, ASME
Section IX) (Courtesy of ASME)
QW-253.1WELDING VARIABLES PROCEDURE SPECIFICATIONS (WPS)
Shielded Metal-Arc (SMAW)
Special Process Essential Variables
Hardfacing Overlay Corrosion-Resistant Overlay
Paragraph (QW-216) (QW-214)
QW-402 Joints .16 < Finished t < Finished t
QW-403 .20 P-Number P-Number
Base Metals .23 T Qualified T Qualified
.12 AWS class
QW-404
.37 A-Number
Filler Metals
.38 Dia. (1st layer) Dia. (1st layer)
QW-405 .4 + Position + Position
Positions
QW-406 .4 Dec. > 100F preheat Dec. > 100F preheat
Preheat > Interpass > Interpass
QW-407 .6 PWHT PWHT
PWHT
QW-409 Electrical .4 Current or polarity Current or polarity
Characteristics
.22 Inc. > 10% 1st layer Inc. > 10% 1st layer
QW-410 .38 Multi- to single-layer Multi- to single-layer
Technique
Legend:
+ Addition
- Deletion
> Increase/greater than
< Decrease/less than
Change
Group Numbers. Group numbers are assigned for steel and steel alloys for proce-
dure qualifications where notch toughness requirements are specified.
F-numbers. F-numbers have been developed to categorize filler metals. F-number
groupings are based primarily on usability characteristics. For example, E6010 elec-
trodes have F-number 3 while E7018 (low hydrogen) electrodes have F-number 4,
because different welder abilities are required for each of these filler metals. A
complete listing of F-numbers appears in QW-432.
A-numbers. A-numbers have also been developed to categorize filler metals.
A-number groupings are based on chemical composition. For example, A-number 1
is for mild steel filler metal, A-number 2 is for carbon-molybdenum steel,
A-number 3 is for low chromium-molybdenum steel, etc. A-numbers are listed in
QW-442.
1/2 inches in the flat and horizontal positions. Groove weld qualifications also
qualify for fillet welding but not vice versa. Test coupon thickness less than 3/4 inch
qualifies for welding on thicknesses up to two times the thickness of the test
coupon, but test coupon thicknesses 3/4 inch and over qualify for the maximum
thickness to be welded.
If complete welding procedures are needed for a job or for review by a National
Board Inspector in connection with Code work, copies of individual procedures can
be obtained from the Engineering Technology Department (ETD) Materials Divi-
sion at Richmond. A complete set of qualified procedures can be obtained through
ETDs Technical Standards Division, San Ramon, CA.
Often, Company welding procedures must be altered slightly to be applicable for a
specified welding job. (Refer to the earlier discussion of nonessential and essential
variables, Section 240.)
H. Preheat and Postweld Heat Treatment. This procedure does not require
preheat or PWHT. If preheat were to be added, the procedure would not need to
be requalified, but if PWHT was added, requalification would be necessary.
Consult the Code, QW-406 and QW-407 for more information on heat treat-
ment.
I. Gas. Because this procedure is for the SMAW process, there are no require-
ments for gas. Consult the Code for procedures that require gas (GMAW,
GTAW, etc.).
J. Electrical Characteristics. This section lists the current, polarity, amperage,
and voltage used. These variables are nonessential for SMAW unless impact
tests are required. Consult the Code if impact tests are needed.
K. Technique. These variables are all nonessential for SMAW. They can there-
fore be varied without requalification.