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S.SINGARAVELU
SM/ WTC
QUALIFICATION STANDARD FOR
WELDING AND BRAZING
PROCEDURES,WELDERS,BRAZERS,
AND WELDERS AND BRAZING
OPERATORS.
BOARDBOARD
OF
COMMITTEES
GOVERNORS
OF TECHNICAL
& TECHNICAL
GROUPS DIVISIONS
(37)
SUB
SUB GROUP ONMEMBER
COMMITTEE
HONORARY ON WELDING (SC IX)
CONTENTS
PART QW : WELDING
PART QB : BRAZING
APPENDICES:
- A : Mandatory Submittal of Tech enquiry
- B : Non Mandatory- Welding & Brazing Forms
- D : Non Mandatory P number Listing
- E : Mandatory- Permitted SWPSs
-F : Mandatory -Standard units used in equations
- G : Non Mandatory- Guidance for use of US
Customary & SI units in ASME code.
TITLE QW WELDING QB BRAZING
1. Application needs
Essential
Non-essential
Supplementary
essential
Essential variables
Essential variables are those in which a change,as
described in specific variables,is considered to affect
mechanical properties of the weldment and shall require
requalification of the WPS.
Supplementary Essential variables
Supplementary Essential variables are those variables
which are also to be considered essential variables when
other sections of the code call for notch toughness
testing.
Non Essential variables
Non Essential variables are those in which a change,as
described in specific variables, may be made in the WPS
with out requalification.
Essential Variables
C) Diameter of Electrode
D) Position, etc.
Points to be considered for
establishing WPS
Code Contract/Customer/
of construction
Code/TPI
Detailed drawing of
Preheat/Postheat/ PWHT
weldment requirements
Material Skilled welder
Thickness Good welding m/c with
Configuration accessories
Application
Process
WPS FLOW DIAGRAM
Release PQR(QW483)
Selection of PQR from past records Select a PQR from the past data matching essential /
supplementary essential variables of the job
Preparation of draft WPS (QW482) Release of draft WPS-R0 with out PQR
Release of WPS Rev 1 for work Release of WPS R1 with all essential, supplementary
essential and non essential variables
OF
WPS / PQR
IX recommends formats for WPS in QW 482 wherein the
following details shall be filled in:
1.Joints QW 402
2.Base metals QW 403
3.Filler metals QW 404
4.Positions QW 405
5.Preheat QW 406
6.Post weld heat treatment QW 407
7.Gas QW 408
8.Electrical characteristics QW 409
9.Techniques QW 410
The details are to be filled in depending on applicability to
the particular welding process selected in the WPS.
Joints (QW-402)
Joint Design
(V-groove, U-groove, Single-bevel
etc.)
Backing
(YES/NO)
Thickness Range
Groove : ______ Fillet:______
PipeDiameter Range
Groove : ______ Fillet :_______
Thickness Range
Range of Thickness T of Base Metal,
Thickness T of Test Coupon, Qualified (mm) Maximum Thickness t of Deposited
Welded, (mm) Weld Metal, Qualified, (mm)
Min. Max.
2T when t > 19
Position Of Fillet
Others
Preheat (QW-406)
Preheat Temperature (min.)
Preheat Maintenance
Others
PWHT (QW-407)
Temperature Range
Time Range
Others
Preheat & PWHT requirement
based on Diameter, Thickness
and Composition of
Base Material
GAS (QW-408)
Gas Mix % Flow Rate
Shielding
Trailing
Backing
Electrical Characteristics (QW-409)
Current (AC/DC)
Polarity (EP/EN)
Amps & Volts
W-Electrode type & size
Mode of Metal Transfer (GMAW)
Electrode Wire Feed Speed range
Techniques (QW-410)
Stringer or Weave Bead
Orifice/Gas Cup Size
Initial or Interpass Cleaning
Method of Back Gauging
Oscillation
Contact Tip to Work Distance
Multiple or Single Pass (per side)
Multiple or Single Electrode
Electrode Spacing
Peening
Others
BHARAT HEAVY ELECTRICALS LIMITED Form No.
TIRUCHIRAPALLI-620014 101-403
WELDING TECHNOLOGY CENTRE
PROCEDURE QUALIFICATION RECORD
Page 1 of 2
OTHER TESTS
Type of Test :
Result :
Report No. :
Deposit analysis :
Others :
Approved by : Prepared by :
(XXXXXXXX) (XXXXXXXX)
XXXXXXX XXXXXXXXX
BHARAT HEAVY ELECTRICALS LIMITED Form No.
TIRUCHIRAPPALLI-620014 101 - 401
WELDING TECHNOLOGY CENTRE
WELDING PROCEDURE SPECIFICATION
Page 1 of 2
JOINTS (QW-402)
Joint Design :.
Backing (Yes/No) :
Backing Material (Type) :
Metal/Non fusing metal
Non metallic/Others
TECHNIQUES (QW-410)
String or Weave Bead
Orifice or Gas cup size :
Initial and Interpass Cleaning : Brushing / Chipping / Grinding.
Method of Back Gouging : .
Oscillation :
Contact tube to work distance :
Multiple or single pass (per side) :
Multiple or single Electrode :
Electrode spacing : .
Peening :
Others : Nil
Filler Current Others (Hot
Weld Process Class Dia. Type Amps. Voltage Travel speed wire,Torch
Layer mm. Range Range angle,ROL.)
Root &
Capping
Others
-- do --
Approved by : Prepared by :
(xxxxxxxxx) (xxxxxxxxxxxx)
xxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxx
Weldgroove
Plate Orientation
positions 1G, 2G, 3G,
4G
Pipe groove positions 1G, 2G, 5G,
6G
Plate fillet positions 1F, 2F, 3F, 4F
Pipe fillet positions 1F, 2F, 2FR, 4F,
5F
1F - 0 to 30
2F - +15 -10 wrt 45
4F - 0 - 125
3F - 125 - 235
GMAW in different
positions
1F
2F
Flat Horizont
Fillet welding of plate al
3F
4F overhead
Vertical
Base Metal Classification
P nos depend on composition,
weldability & mechanical
properties.
Group nos classify metals within P
nos for procedure qualification
where notch toughness
requirements are specified. But
base metals can not be
indiscriminately substituted.
P. No. & COMMON TUBES PIPES PLATES FORGINGS CASTINGS
Gr. No NAME
P1 Gr1 CARBON SA179 SA106GrB SA36 SA266CL1 SA216WCA
STEELS SA192 SA333Gr1 SA515Gr55 SA350LF1 SA352LCA
SA210GrA1 SA333Gr6 SA515Gr60 SA352LCB
SA334Gr1 SA515Gr65
SA334Gr6 SA516Gr55
SA516Gr60
SA516Gr65
P1 Gr2 -do- SA210GrC SA106GrC SA515Gr70 SA105 SA216WCB
SA516Gr70 SA266CL2S SA216WCC
SA299 SA350LF2 SA352LCC
OTHER -do- IS1239 API5LGrB IS226
SPEC. IS2062
BMC10
BMC16
BMC20
P3 Gr1 C Mo SA209T1 SA335P1 SA204GrA SA217WC1
Cr 1/2Mo SA213T2 SA335Gr2 SAA387Gr2
P4 Gr1 1Cr MO SA213T12 SA335P12 SA387Gr12 SA182F12 SA217WC6
1Cr Mo SA213T11 SA335P11 SA387Gr11 SA182F11
P5A Gr1 2, Cr 1Mo SA213T22 SA335P22 SA387Gr22 SA182F22 SA217WC9
P5B Gr2 9Cr1Mo V SA213T91 SA335P91 SA387Gr91 SA182F91
SA199T91
P8 Gr1 18Cr 8Ni SA213TP304 SA376TP304 SA240TP304 SA182F304 SA351CF3
SA213TP304H SA376TP304H SA240TP321 SA182F321 SA351CF8
SA213TP316 SA376TP316 SA240TP347 SA182F347 SA351CF3M
SA213TP321 SA376TP321 SA336F304 SA351CF8M
SA213TP347 SA376TP347 SA336F321 SA351CF10
SA213TP347H SA376TP347H SA336F347 SA351CF10M
P8 Gr2 25Cr-20Ni SA213TP310H SA240TP310 SA182F310 SA351CK20
(Type 310)
Base Metal P Numbers
P1 - P11 Steel
P21 - P25 Al alloys
P31 - P35 Cu alloys
P41 - P47 Ni alloys
P51 - P53 Ti alloys
P61 - P62 Zr alloys
Base Metal P Numbers
Examples of P nos
P1 C Steel
P3 1/2 Mo steels
P4 1 Cr 1/2 Mo steels
P5A 2 1/4 Cr 1 Mo steels
P6 13 Cr steel
P7 17 Cr steel
P8 ASS
P9A 2 1/2 Ni steels
P10A Mn - 1/2 Ni - V steels
P11 9 Ni steels
Base Metal P Numbers
Examples of P nos
P1 C Steel
P3 1/2 Mo steels
P4 1 Cr 1/2 Mo steels
P5A 2 1/4 Cr 1 Mo steels
P6 13 Cr steel
P7 17 Cr steel
P8 ASS
P9A 2 1/2 Ni steels
P10A Mn - 1/2 Ni - V steels
P11 9 Ni steels
Base Metal for WPS
Test Coupon Base Metal
qualified
Px - Px Px
Px - Py Px - Py
P3 - P3 P3 ( P3 / P1)
P4 - P4 P4 ( P4 / P3 / P1)
P5A - P5A P5A ( P5A / P4 / P3 / P1)
P5A (P4 / P3 / P1) P5A (P4 / P3 / P1)
P4 (P3 / P1) P4 (P3 / P1)
BM used for procedure qualification coupon Base Metals Qualified
One metal from a P-No. to any metal from the Any metal assigned that P or S No.
same P-No.
One metal from a P-No. to any metal from the Any metal assigned the 1st P or S No. to any
any other P-No. metal assigned the 2nd P or S No.
One metal from P-No. 3 to any metal from P-No. Any P or S No. 3 metal to any metal
3 assigned P or S No. 3 or 1
One metal from P-No. 4 to any metal from P-No. Any P or S No. 4 metal to any metal
4 assigned P or S No. 4, 3 or 1
One metal from P-No. 5A to any metal from P- Any P or S No. 5A metal to any metal
No. 5A assigned P or S No. 5A, 4, 3 or 1
One metal from P-No. 5A to any metal from P- Any P or S No. 5A metal to any metal
No. 4, 3 or 1 assigned P or S No. 4, 3 or 1
One metal from P-No. 4 to any metal from P-No. Any P or S No. 4 metal to any metal
3 or 1 assigned P or S No. 3 or 1
Any unassigned metal to the same unassigned The unassigned metal to itself
metal
Any unassigned metal to any P-No. metal The unassigned metal to any metal assigned
to the same P or S No. as the qualified metal
Any unassigned metal to any other unassigned The first unassigned metal to the second
metal unassigned metal
S - Number
They are mostly ASTM specification
materials that have not been adopted within
Section II, Part D but that are referred within
Code Cases and the ASME B31 Code.
e.g. A 588 Gr A S-No. 3
Group No. 1
A 576 G10100 S-No. 1
Group No. 1
SFA NO. DESCRIPTION
5.01 Filler Metal Procurement Guidelines
5.1 Carbon Steel Electrodes for Shielded Metal Arc Welding
5.2 Carbon and Low Alloy Steel Rods for Oxy Fuel Gas Welding
5.3 Aluminum and Aluminum Alloy Electrodes for Shielded Metal Arc Welding
5.4 Stainless Steel Electrodes for Shielded Metal Arc Welding
5.5 Low Alloy Steel Electrodes for Shielded Metal Arc Welding
5.6 Covered Copper and Copper Alloy Arc Welding Electrodes
5.7 Copper and Copper Alloy Bare Welding Rods and Electrodes
5.8 Filler Metal for Brazing and Braze Welding
5.9 Bare Stainless Steel Welding Electrodes and Rods
5.10 Bare Aluminum and Aluminum Alloy Welding Electrodes and Rods
5.11 Nickel and Nickel Alloy Welding Electrodes for Shielded Metal Arc Welding
5.12 Tungsten and Tungsten Alloy Electrodes for Arc Welding and Cutting
5.13 Solid Surfacing Welding Rods and Electrodes
5.14 Nickel and Nickel Alloy Bare Welding Electrodes and Rods
5.15 Welding Electrodes and Rods for Cast Iron
5.16 Titanium and Titanium Alloy Welding Rods and Electrodes
5.17 Carbon Steel Electrodes and Fluxes for Submerged Arc Welding
5.18 Carbon Steel Filler Metals for Gas Shielded Arc Welding
5.19
5.20 Carbon steel Electrodes for Flux Cored Arc Welding
5.21 Composite Surfacing Welding Rods and Electrodes
5.22 SS Electrodes for FCAW and SS Flux Cored Rods for Gas Tungsten Arc Welding
5.23 Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding
5.24 Zirconium and Zirconium Alloy Welding Electrodes and Rods
5.25 Carbon and Low Alloy Steel Electrodes and Fluxes for Electro-slag Welding
5.26 Carbon and Low Alloy Steel Electrodes for Electro-gas Welding
5.27
5.28 Low Alloy Steel Electrodes and Rods for Gas Shielded Arc Welding
5.29 Low Alloy Steel Electrodes for Flux Cored Arc Welding
5.30 Consumable Inserts
5.31 Fluxes and Brazing and Braze Welding
5.32 Welding Shielding Gases
F-Number Description
1 CS, LAS and certain SS (EXX2X) electrodes
2 CS titania-coated (EXX12, EXX13, EXX14 & EXX19)
electrodes
3 CS cellulose-coated (EXX10 & EXX11) electrodes
4 CS & LAS all position, low hydrogen (EXX15, EXX16,
EXX18 & EXX48) electrodes & martensitic, ferritic &
ppt. hardening SS all position (EXX15, EXX16 &
EXX17) electrodes
5 Austenitic and duplex SS all-position (EXX15, EXX16
& EXX17) electrodes
6 Solid, Flux-cored & composite ferrous electrodes & rods
--- ---
Filler Metal F Numbers
Based on usability characteristics
i.e ability of welders to make
satisfactory welds with given filler
F1 E XX20
F2 E XX12, E XX13
F3 E XX10, E XX11
F4 E XX18
F5 ASS, Duplex SS
F6 Bare rods
F - NUMBERS (QW - 432)
Steel and Steel Alloys
F-No. ASME Classification AWS Classification F-No. ASME Classification AWS Classification
Nickel-Chrome-
12 0.15 1.50 0.25-0.80 1.25-2.80 0.75-2.25 1.00
Molybdenum
Selection of Filler Metal
Tube
P1/Gr1,2 P3/Gr1 P4/Gr1 P5A/Gr1 P5B/Gr2 P8/Gr1,2
Material
ER80S-G ER80S-G ER80S-G ER80S-G
ERNiCr-3
P1/Gr1,2 (RT Mo) (RT Mo) (RT Mo) (RT Mo)
ENiCrFe-3
E7018-1 E7018-1 E7018-1 E7018-1
ER80S-G ER80S-G ER80S-G
P3/Gr1 (RT Mo) (RT Mo) (RT Mo)
E7018-A1 E7018-A1 E7018-A1
ER80S-G ER80S-G ER80S-G
ERNiCr-3
P4/Gr1 (1Cr Mo) (1Cr Mo) (1Cr Mo)
ENiCrFe-3
E8018-B2 E8018-B2 E8018-B2
ER90S-G ER90S-G
ERNiCr-3
P5A/Gr1 (2Cr1Mo) (2Cr1Mo)
ENiCrFe-3
E9018-B3 E9018-B3
ER90S-B9 ERNiCr-3
P5B/Gr2
E9018-B9 ENiCrFe-3
Filler metals suitable for welding joints between
dissimilar austenitic stainless steels
Base Metal 304L 308 309 309S 310 310S 316,316H 316L 317 321,321H 347,347H,348,348H
304,304H,305 308L 308L 308,309 308,309 308,309, 310 308,309, 310 308,316 308,316 308,316, 317 308 308
304L 308L 308,309 308,309 308,309, 310 308,309, 310 308,316 308L,316L 308,316, 317 308L,347 308L,347
308 308,309 308,309 308,309, 310 308,309, 310 308,316 308,316 308,316, 317 308 308,347
321,321H 308L,347
Procedure Qualification
2T when t > 19
Essential variables
Essential variables
Preparation Welder / Operator Preparation of specimen for the test using materials of
Qualification Tests compatible quality
Plate 1F F
Plate 2F F, H
Plate 3F F, H, V
Plate 4F F, H, O
Welders Performance Qualification
>24OD 2 7/8 - 24
Plate 1G F F F
Plate 2G F, H F, H F, H
Plate 3G F, V F F, H, V
Plate 4G F, O F F, H, O
Welders Performance Qualification
Pipe 1G F F F
Pipe 2G F, H F, H F, H
Pipe 5G F, V, OF, V, O All
Pipe 6G All All All
Pipe 2G + 5GAll All All
Welders Performance Qualification
Pipe 1F F
Pipe 2F F, H
Pipe 2FR F, H
Pipe 4F F, H, O
Pipe 5F All
Welders Performance Qualification
Removal of backing
Change in Pipe diameter
Change in P number
Change in F Number
Change in thickness of weld
deposit
Change in welding position
Welders Performance Qualification
Variables for GTAW
Removal of backing
Change in Pipe diameter
Addition / deletion of filler metal
Addition / deletion of insert
Change in P number
Change in F Number
Change in solid filler to flux cored filler
metal
Change in thickness of weld deposit
Change in welding position
Removal of inert gas backing
Change in current or polarity
Welders Performance Qualification
Welded Qualified
Without Backing
Fx Fx
With Backing
F1 F1
F2 F2, F1
F3 F3, F2, F1
F4 F4, F3, F2, F1
F5 F5, F1
Welders Performance Qualification
F No qualification with backing
F1 with backing F1 with backing
F1 without backing F1 with & without backing
F2 with backing F1 & F2 with backing
F2 without backing F2 with & without backing, F1 with
backing
F3 with backing F1, F2 & F3 with backing
F3 without backing F3 with & without backing, F1, F2
with backing
F4 with backing F1, F2, F3 & F4 with backing
F4 without backing F4 with & without backing, F1, F2,
F3 with backing
F5 with backing F1 & F5 with backing
F5 without backing F5 with & without backing, F1 with
backing
Tests for Qualification
Tension test Minimum values for specified
tensile strength
For dissimilar joint, lesser of the
two values
If break outside weld, if tensile st.
value not < 5% of the base metal
QUESTIONS PLEASE