PQR Asme
PQR Asme
PQR Asme
Module 7
Module 7 Summary
Module 7 Summary
7A ASME Section IX Weld Procedure Qualification
7B ASME Section IX Welder Qualification
7-2
Module 7 Summary
7-3
Module 7 Summary
Understand the intended application for which the WPS will be used
Develop a draft procedure
Make a qualification weld
Test the qualification weld
Write up the WPS
7-5
Module 7 Summary
7-6
Module 7 Summary
7-7
Module 7 Summary
7-8
Module 7 Summary
7-9
Module 7 Summary
7-10
Module 7 Summary
QW-402
Joints
Brief of Variables
Essential
Supplementary
Essential
Nonessential
.1
Groove Design
.4
- Backing
.10
Root Spacing
.11
Retainers
included angle
QW-402.4 There was a backing bar used
QW-402.10 The root spacing was 1/8-in.
QW-402.11 Nonmetallic or nonfusing retainers were not
used
7-11
Module 7 Summary
Note: The weld was both GTAW and GMAW with 1/4-in. deposited with
GTAW and 1/2-in. deposited with GMAW
7-12
Module 7 Summary
Brief of Variables
.5
Group No.
.11
P-No. Qualified
Essential
Supplementary
Essential
Nonessential
X
X
Table QW-422
Spec. No.
Type/Grade
UNS No.
P-No.
Group
No.
SA-36
K02600
Nominal
Composition
Product Form
C-Mn-Si
7-13
Module 7 Summary
QW-403
Base
Materials
Brief of Variables
Essential
.6
T Limits
.8
T Qualified
.9
.10
Supplementary
Essential
Nonessential
was 0.75-in.
QW-403.9 No single weld pass in the qualification weld was
greater than 1/2-in.
GMAW only
7-14
Module 7 Summary
7-15
Module 7 Summary
Brief of Variables
Essential
Supplementary
Essential
Nonessential
.3
Size
.6
Diameter
.23
GTAW only
GMAW only
7-16
Module 7 Summary
Brief of Variables
.4
Essential
F-No.
Supplementary
Essential
Nonessential
ASME Section II, SFA 5.28 specifies low-alloy steel electrodes for gas
shielded arc welding
ASME Section II, SFA 5.18 specifies carbon steel electrodes for gas
shielded arc welding
Table QW-432
F-No.
ASME Specification
AWS Classification
SFA-5.28
All Classifications
SFA-5.18
All Classifications
7-17
Module 7 Summary
Brief of Variables
.5
Essential
A-No.
Supplementary
Essential
Nonessential
A-No.
Weld Deposit
Cr
Mo
Ni
Mn
Si
11
Mn Mo
0.17
0.25 0.75
0.85
1.25 2.25
1.00
0.07 0.12
0.4-0.6
0.15
1.60 2.10
0.5 0.8
0.20
1.60
1.00
0.06 0.15
0.15
0.15
0.15
1.40 1.85
0.80 1.15
Mild Steel
7-18
Module 7 Summary
QW-404
Filler
Metals
Brief of Variables
Essential
Supplementary
Essential
Nonessential
.12
Classification
.14
Filler
.33
Classification
.50
Flux
GTAW only
GTAW only
7-19
Module 7 Summary
QW-404
Filler
Metal
Brief of Variables
Essential
.22
Consumable Insert
.24
or Supplemental
.27
Alloy Elements
.30
.32
Supplementary
Essential
Nonessential
X
GTAW only
GMAW only
7-20
Module 7 Summary
Other:
7-21
Module 7 Summary
Brief of Variables
.1
+ Position
.2
Position
.3
Vertical Welding
Essential
Supplementary
Essential
Nonessential
X
X
X
7-22
Module 7 Summary
Flat
N/A
7-23
Module 7 Summary
Brief of Variables
.1
.2
Preheat Maintenance
.3
Increase >100F
Essential
Supplementary
Essential
Nonessential
X
X
X
7-24
Module 7 Summary
Ambient (70F)
450F
7-25
Module 7 Summary
Brief of Variables
.1
PWHT
.2
.4
T Limits
Essential
Supplementary
Essential
Nonessential
X
X
X
7-26
Module 7 Summary
7-27
Module 7 Summary
QW-408
Gas
Brief of Variables
Essential
Supplementary
Essential
Nonessential
.1
Trail or Composition
.5
or Backing Gas
.9
- Backing or Composition
.10
Shielding or Trailing
7-28
Module 7 Summary
Brief of Variables
.2
Single, Mixture or %
.3
Flow Rate
Essential
Supplementary
Essential
Nonessential
X
X
7-29
Module 7 Summary
Shielding
Trailing
Backing
Percent Composition
Gas(es)
Mixture
GTAW - Argon
100%
GMAW - Argon/CO2
75%/25%
N/A
N/A
N/A
N/A
Flow Rate
15 25 cfh
25 35 cfh
N/A
N/A
7-30
Module 7 Summary
Procedure Qualification
Electrical Characteristics Variables
Brief of Variables
.1
QW-409
.2
Electrical
Characteristics .3
Essential
Supplementary
Essential
Nonessential
X
X
Pulsing I
GMAW only
GTAW only
7-31
Module 7 Summary
Procedure Qualification
Electrical Characteristics Variables
Paragraph
Brief of Variables
.4
Current or Polarity
QW-409
.8
I or E Range
Electrical
Characteristics .12 Tungsten Electrode
Essential
Supplementary
Essential
Nonessential
X
X
X
GTAW only
7-32
Module 7 Summary
Procedure Qualification
Electrical Characteristics Variables
7-33
Module 7 Summary
Procedure Qualification
Technique Variables
QW-410
Technique
Brief of Variables
Essential
Supplementary
Essential
Nonessential
.1
Stringer/Weave
.3
.5
Method of cleaning
.6
stringer beads
QW-410.3 GTAW weld was made with a 5/8-in. cup size
and the GMAW weld was made with a 1-in. nozzle size
QW-410.5 Cleaning was done using a wire brush
QW-410.6 No back gouging was performed
7-34
Module 7 Summary
Paragraph
QW-410
Technique
Procedure Qualification
Technique Variables
Brief of Variables
Essential
Supplementary
Essential
Nonessential
.7
Oscillation
.8
Tube-work Distance
.9
.11
GMAW only
GTAW only
7-35
Module 7 Summary
Paragraph
QW-410
Technique
Procedure Qualification
Technique Variables
Brief of Variables
Essential
Supplementary
Essential
Nonessential
.26 Peening
.64
7-36
Module 7 Summary
Procedure Qualification
Electrical Characteristics Variables
Technique (QW-410)
Travel Speed:
1 to 5 ipm
Stringer or Weave Bead:
Manual Stringer Bead
Oscillation:
No Oscillation
Multi/Single Pass per Side: Multiply Passes per Side
Multi/Single Electrode:
Single Electrode
Other:
1. No peening was used
2. CTWD was 1/2 3/4-in.
3. Cleaning with a wire brush
4. GTAW gas cup was 5/8-in.
5. GMAW nozzle size was 1-in.
7-37
Module 7 Summary
Side Bend,
QW-160
1/16-in. to 3/8-in.
(5)
(5)
2 (4)
1 1/2-in. to 6-in.
2 (4)
7-38
Module 7 Summary
7-39
Module 7 Summary
QW-422
7-40
Module 7 Summary
No open discontinuities in
the weld or HAZ greater
than 1/8-in.
Provides some leeway
7-41
Module 7 Summary
7-42
Module 7 Summary
7-43
Module 7 Summary
7-44
Module 7 Summary
Width
Thickness
Area
Ultimate
Load, lb
Ultimate Stress,
psi
Type of Failure
and Location
Tensile 1
Tensile 2
Results
Side Bend 1
Side Bend 2
Side Bend 3
Side Bend 4
Module 7 Summary
7-46
Module 7 Summary
Company Name:
By:
WPS No.:
Supporting PQR No.(s)
Nuclear Construction
Joe Welder
NRC-WPS-1
Date:
NRC-PQR-1
7-47
Module 7 Summary
Brief of Variables
Essential
Sup. Essential
Nonessential
7-48
Module 7 Summary
QW-402
Joints
Brief of Variables
Essential
Sup. Essential
Nonessential
.1
Groove Design
.4
- Backing
.10
Root Spacing
.11
Retainers
Joint Design:
Backing:
Backing Material:
Root Spacing:
Retainers:
Module 7 Summary
Brief of Variables
.5
Group No.
.11
P-No. Qualified
Essential
Sup. Essential
Nonessential
X
X
Module 7 Summary
Brief of Variables
.8
Essential
T Qualified
Sup. Essential
Nonessential
Table QW-451
Max.
1/16-in. to 3/8-in.
1/16-in.
2T
3/16-in.
2T
3/16-in.
2T
1 1/2-in. to 6-in.
3/16-in.
8-in.
Note (3) of Table QW-451 calls out QW-202.2 which defines thickness
ranges for fillet welds when qualifying with a groove weld
All material thicknesses when depositing fillet welds
7-51
Module 7 Summary
Brief of Variables
Essential
.6
T Limits
.9
.10
Sup. Essential
Nonessential
QW-403.9 limits the maximum thickness to 1.1T when any single weld
pass greater than 1/2-in.
QW-403.10 limits maximum thickness to 1.1T when the qualification
thickness is less than 1/2-in. when welding with short circuit GMAW
7-52
Module 7 Summary
7-53
Module 7 Summary
Brief of Variables
.4
F-No.
.12
Classification
.33
Classification
Essential
Sup. Essential
Nonessential
X
X
X
SFA Classification:
AWS Classification:
F-No.:
GMAW
SFA 5.18
ER70S-6
6
SFA Classification:
AWS Classification:
F-No.:
GMAW
SFA 5.18
ER70S-6
6
7-54
Module 7 Summary
Brief of Variables
.3
Size
.5
A-No.
.6
Diameter
Essential
Sup. Essential
Nonessential
X
X
X
A-No.:
Size of Filler Metal:
A-No.:
Size of Filler Metal:
GMAW
1
0.035-in.
7-55
Module 7 Summary
QW-404
Filler
Metals
Brief of Variables
Essential
.14
Filler
.23
.24
or Supplemental
.27
Alloy Elements
Sup. Essential
Nonessential
GMAW
Solid Wire
None Used
GMAW
Solid Wire
None Used
7-56
Module 7 Summary
Brief of Variables
.30
.32
Essential
Sup. Essential
Nonessential
X
X
Table QW-451
1/16-in. to 3/8-in.
2t
2t
2t
t1 1/2-in. to 6-in.
Note (3) of Table QW-451 calls out QW-202.2 which defines fillet weld
sizes when qualifying with a groove weld
All fillet weld sizes
7-57
Module 7 Summary
Weld Thickness:
GMAW
1/2-in.
GMAW
1-in.
Unlimited
7-58
Module 7 Summary
Brief of Variables
Essential
Sup. Essential
Nonessential
.22
Consumable Insert
.50
Flux
Electrode/Flux:
Flux Type:
Flux Trade Name;
Consumable Insert:
GMAW
N/A
N/A
N/A
N/A
Electrode/Flux:
Flux Type:
Flux Trade Name:
Consumable Insert:
GMAW
N/A
N/A
N/A
N/A
7-59
Module 7 Summary
Brief of Variables
.1
+ Position
.2
Position
.3
Vertical Welding
Essential
Sup. Essential
Nonessential
X
X
X
Position of Groove:
Weld Progression:
7-60
Module 7 Summary
Brief of Variables
.1
.2
Preheat Maintenance
.3
Essential
Supplementary
Essential
Nonessential
X
X
X
7-61
Module 7 Summary
Brief of Variables
.1
PWHT
.2
.4
Temperature:
Time:
T Limits
Essential
Sup. Essential
Nonessential
X
X
X
7-62
Module 7 Summary
Brief of Variables
.2
Single, Mixture or %
.3
Flow Rate
Shielding:
Shielding:
Essential
Sup. Essential
Nonessential
X
X
Flow Rate
15 25 cfh
25 35 cfh
Flow Rate
10 40 cfh
10 45 cfh
7-63
Module 7 Summary
QW-408
Gas
Brief of Variables
Essential
Sup. Essential
Nonessential
.1
Trail or Composition
.5
or Backing Gas
.9
- Backing or Composition
.10
Shielding or Trailing
Trailing:
Backing:
Flow Rate
None Used
None Used
Trailing:
Backing:
Flow Rate
15-35 cfh
N/A
7-64
Module 7 Summary
Welding Procedure
Electrical Characteristics Variables
Paragraph
.1
QW-409
.2
Electrical
Characteristics .3
Heat Input:
Transfer Mode:
Pulsing Current:
Brief of Variables
Essential
Sup. Essential
Nonessential
X
X
Pulsing I
GMAW
45 kJ/in.
Globular
N/A
Module 7 Summary
Welding Procedure
Electrical Characteristics Variables
Paragraph
Brief of Variables
.4
Essential
Sup. Essential
Nonessential
Current or Polarity
QW-409
.8
I or E Range
Electrical
Characteristics .12 Tungsten Electrode
X
X
Process
1-3
GTAW
ER80S-D2
4-10
GMAW
ER70S-6
Other:
Filler Metal
Class.
Dia.
1/8-in.
Current
Type/Polarity
Volts
Travel Speed
Amps
DCEP
175 200
10 14
Not Recorded
0.035-in. DCEN
170 200
24 28
Not Recorded
7-66
Module 7 Summary
Welding Procedure
Electrical Characteristics Variables
Procedure Qualification Record
Weld
Pass
Process
Filler Metal
1-3
GTAW
ER80S-D2
4-10
GMAW
ER70S-6
Class.
Other:
Dia.
1/8-in.
Current
Type/Polarity
Volts
Travel Speed
Amps
DCEP
175 200
10 14
1-5
0.035-in. DCEN
170 200
24 28
1-5
Volts
Travel Speed
Weld
Pass
Process
1-3
GTAW
ER80S-D2
3/32-in.
DCEP
150 300
5 25
1-10
1-3
GTAW
ER80S-D2
1/8-in.
DCEP
175 200
10 14
1-10
Fill
GMAW
ER70S-6
0.035-in. DCEN
150 250
20 30
5-20
Fill
GMAW
ER70S-6
0.045-in. DCEN
200 400
20 30
5-20
Other:
Filler Metal
Class.
Dia.
Current
Type/Polarity
Amps
7-67
Module 7 Summary
Brief of Variables
Essential
Sup. Essential
Nonessential
.1
Stringer/Weave
.3
.5
Method of Cleaning
GMAW
Stringer
1-in.
Wire Brush
Module 7 Summary
Brief of Variables
Essential
Sup. Essential
Nonessential
.7
Oscillation
.8
Tube-work Distance
.9
GMAW
None Used
1/2 3/4-in.
Multiply Pass
Module 7 Summary
Brief of Variables
Essential
Sup. Essential
.11
Nonessential
GMAW
Single
None Used
N/A
Module 7 Summary
Brief of Variables
Essential
Sup. Essential
Nonessential
.26 Peening
.64
X
X
GMAW
None Used
None Used
7-71
Welder Qualification
Module 7B
Module 7 Summary
Welder Qualification
Welder Qualification
Primary purpose for performance qualification
7-73
Module 7 Summary
7-74
Module 7 Summary
Linear Indications
Rounded Indications
Characterization charts
7-75
Module 7 Summary
7-76
Module 7 Summary
7-77
Module 7 Summary
Welder Qualification
Welders were qualified with backing so they are only allowed to weld
on backing
7-78
Module 7 Summary
Welders were qualified with filler metal so they are only allowed to
weld with filler metal
Welders were qualified with F-No. 6 so they are only allowed to weld
with F-No. 6
7-79
Module 7 Summary
Welders were qualified using a solid wire so they can only weld with a
solid wire
Welders deposited 1/4-in. GTA weld and 1/2-in. of GMA weld so they
are qualified to deposit an 1/2-in. GTA weld and unlimited GMA weld
7-80
Module 7 Summary
Welders were qualified in the flat (1F) position so they can only weld
in the 1F position
Welders were qualified in the flat (1F) position so they can weld in the
vertical direction
7-81
Module 7 Summary
7-82
Module 7 Summary
Welders were qualified with backing so the variable does not apply
Welders were qualified using globular transfer so they can only weld
with globular, spray or pulsed transfer modes
Welders were qualified using DCEP so they can only weld using
DCEP
7-83
Module 7 Summary
Welder Qualification
When the welder has not welded with the process within 6 months
When there is a specific reason to question his ability to make welds
that met the specifications
7-84