ASME SEC IX -

Welding Procedure and

performance qualification
 What is the need for WPS &
performance qualification?

• To ensure the safety of the welded

constructions
• Bhopal tragedy,three mile island
accident, Chernbyl accident,
Breakage of ship in the midsea
 Why ASME qualification &
certification?

• To ensure that design practices,

manufacturing practices, fabrication
techniques, & inspection techniques are
performed by personnel who are
qualified in accordance with good engg.
practices and standards
Selecting Your Welding Process
1. The joint to be welded is analyzed in terms of its
requirements.

2. The joint requirements are matched with the

capabilities of available processes. One or more
of the processes are selected for further
examination.
3. A checklist of variables is used to determine the
ability of the selected processes(s) to meet the
particular application

4. Finally, the proposed process or processes

deemed most efficient are reviewed
Step 1 - Analysis of Joint Requirements

The first thing to look at is whether your weld joint is

large or small, whether the joint is out-of-position or not,
and whether the base metal is thick or thin.

In welding, the needs of any joint are

expressed in four terms: Fast-Fill (high
deposition rate), Fast-Freeze (the joint is
out-of-position - overhead or vertical),
Fast-Follow (high arc speed and very small
welds), and Penetration (the depth the
weld penetrates the base metal)
Step 1 - Analysis of Joint Requirements

Fast-Fill is required when a large

amount of weld metal is needed
to fill the joint. A heavy weld bead
can only be laid down in minimum
arc time with a high deposition rate.
However, Fast-Fill becomes a minor
consideration when the weld is small.

Fast-Freeze implies that a joint is

out-of-position, and therefore requires
quick solidification of the molten crater.
Not all semiautomatic processes can
be used on fast-freeze joints.
 Analysis of Joint Requirements

Fast-Follow suggests that the molten metal follows the

arc at rapid travel speed, giving continuous, well-shaped
beads, without "skips" or islands. This trait is especially
desirable on relatively small single-pass welds, such as
those used in joining sheet metal.

Penetration varies with the joint. With

some joints, penetration must be deep
to provide adequate mixing of the weld
and base metal and with others it must
be limited to prevent burnthrough or
Cracking.
Step 2 - Matching Joint Requirements
With Processes

Information (on the deposition rate and

arc-speed characteristics of each process
from literature)on the ability of various
processes to fulfill the needs of the joint
Step 3 - The Checklist

• Volume of Production
• Weld Specifications
• Operator Skill
• Auxiliary Equipment
• Accessory Equipment
• Base-Metal Conditions
• Arc Visibility
• Fixturing Requirements
• Production Bottlenecks
Step 4 - Review of the Application by
Manufacturer's Representative
 WPS – Welding Procedure
Specification

PQR – Procedure Qualification

Record
What is a WPS?
A WPS is a "Welding Procedure Specification"
or "Welding Procedure" as it is commonly
called. It contains the combination of variables
used to make a certain weld. This includes the
process (SMAW, FCAW etc.), the electrode type,
electrical characteristics, base metal used,
preheat and interpass temperatures, travel speed
and position, post weld heat treatment, shielding
gas and flow rate, and the type of joint being
welded.
What is WPS in a layman view
point
• WPS lists all the parameters required to produce a
sound weld to the specific code
• Specific parameters such as process,
technique,filler,current,voltage,etc., to be included
• It should list a range on each parameter such as
amps = 110-150, voltage =17-22 with the more
essential or critical parameters more closely defined
or limited
• It should give enough details so that any qualified
welder could follow and produce the desired weld.
 Purpose of WPS Qualification
To determine that the weldment is
capable of providing the required
properties for the intended application.

WPS establishes the properties of the

weldment and not the skill of the
welder.
 Welding Procedure Specification
It is a written document that provides
direction to the welder for making
production welds in accordance with
code requirements.
Any WPS must be qualified by the
manufacturer.
WPS specifies the condition (ranges)
under which welding must be performed
called variables.
WPS addresses essential, supplementary
essential and non essential variables
 Procedure Qualification Record
It documents what occurred during
welding the test coupon and the results
of the test coupon.
PQR documents the essential variables
and other specific information and the
results of the required testing. In
addition, when notch toughness is
required for procedure qualification, the
applicable supplementary essential
variables shall be recorded.
 Points to be considered for
establishing WPS
• Code of • Contract/Customer/
construction Code/TPI
• Detailed drawing • Preheat/Postheat/
of weldment PWHT requirements
• Material • Skilled welder
• Thickness • Good welding m/c
with accessories
• Configuration
• Application
• Process
 Variables
• Preheat
• PWHT • Essential
• Joint design
• Backing material • Non-essential
• P Number
• Welding Process • Supplemental
• Filler metal essential
• Electrode
• Method of back
gauging
 Essential Variables

A change in welding condition which

will affect the mechanical properties
of the weldment.
(Change in base metal, welding
process, Filler metal, Electrode, Pre-
heat, PWHT, etc.)
 Non Essential Variables

A change in welding condition which

will NOT affect the mechanical
properties of the weldment.
(Change in Joint Design, Methods of
Back gauging, Cleaning, etc.)
 Supplementary Essential
Variables

A change in welding condition

which will affect the Notch-
Toughness (Impact) properties of
the weldment.
(Change in Heat input, Uphill or
Down Vertical welding, Diameter
of Electrode, Position, etc.)
 Joints(QW:402)

• Joint Design
• Backing
• Baking Material
Type
 Base Metal Classification
Why P numbers?
To reduce the number of welding procedure
qualifications, base metals have been assigned
P-nos and for ferrous base metals which have
specified impact test requirements, group
numbers within P-nos are again given
P nos depend on composition, weldability &
mechanical properties.
•Group nos classify metals within P nos for
procedure qualification where notch toughness
requirements are specified.
•The above assignments do not imply that base
metals can be substituted without consideration
of metallurgical properties,etc.,
 Base Metal P Numbers

Examples of P numbers
P1 C Steel

P1 - P11 Steel P3 1/2 Mo steels

P4 1 Cr 1/2 Mo steels
P21 - P25 Al alloys
P5A 2 1/4 Cr 1 Mo steels
P31 - P35 Cu alloys P6 13 Cr steel

P41 - P47 Ni alloys P7 17 Cr steel

P8 Austenitic
P51 - P53 Ti alloys StainlessSteel

P61 - P62 Zr alloys 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)
 Base Metal(QW-403)

• P. Number
• Group Number
• Specification
• Chemical Analysis & Mechanical
Properties
• Thickness Range
• Pipe Diameter Range
 P1/Group 1
Carbon Steel
Tubes Pipes Plates Forgings Castings
SA179 SA106GrB SA36 SA266CL1 SA216WCA
SA192 SA333Gr1 SA515Gr55 SA350LF1 SA352LCA
SA210GrA1 SA333Gr6 SA515Gr60 SA352LCB
SA334Gr1 SA515Gr65
SA334Gr6 SA516Gr55
SA516Gr60
SA516Gr65
 P1/Group 2
Carbon Steel
Tubes Pipes Plates Forgings Castings
SA210GrC SA106GC SA515Gr70 SA105 SA216WC
SA516Gr70 SA266CL2 B
SA299 SSA350LF SA216WC
2 C
SA352LCC
 Other Specification
Carbon Steel

Tubes Pipes Plates Forgings Castings

IS1239 API5LGrB IS226
IS2062
BMC10
BMC16
BMC20
 P3/Group 1
½ Mo (C–MOLY STEELS)
Tubes Pipes Plates Forgings Castings
SA209T1 SA335P1 SA204GrA SA217WC1

½ Cr ½ Mo - P3 Group 2
Tubes Pipes Plates Forgings Castings
SA213T2 SA335Gr2 SAA387Gr2
 P4/Group 1
1Cr ½ Mo
Tubes Pipes Plates Forgings Castings
SA213T12 SA335P12 SA387Gr12 SA182F12 SA217WC6

1¼ Cr ½ Mo
Tubes Pipes Plates Forgings Castings
SA213T11 SA335P11 SA387Gr11 SA182F11
 P5A/Group 1
2¼Cr 1Mo
Tubes Pipes Plates Forgings Castings
SA213T22 SA335P22 SA387Gr22 SA182F22 SA217WC9
 P5B/Group 1
5Cr ½ Mo
Tubes Pipes Plates Forgings Castings
SA213T5 SA335P5 SA387Gr5 SA182F5 SA217C5
SA336Cl F5

9Cr 1Mo
Tubes Pipes Plates Forgings Castings
SA213T9 SA335P9 SA182F9 SA217C9
SA336Cl F9
 P5B/Group 2
9Cr 1Mo ¼ V
Tubes Pipes Plates Forgings Castings
SA213T91 SA335P91 SA387Gr91 SA182F91
SA199T91
 P8/Group 1
18Cr 8Ni
Tubes Pipes Plates Forgings Castings
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/Group 2
25Cr 20Ni (Type 310)

Tubes Plates Forgings Castings

SA213TP310H SA240TP310 SA182F310 SA351CK20
 Filler Metals(QW-404)

• AWS Number • Size of Filler metal

• Flux trade name
• SFA Number
• Consumable insert
• F. Number
• Electrode flux class
• A. Number

• Deposited Metal thickness range

 Filler Metal F Numbers
Based on usability characteristics i.e
ability of welders to make satisfactory
welds with given filler
F1 E XX20,XX24,XX27
F2 E XX12, E XX13,XX14
F3 E XX10, E XX11
F4 E XX15,XX16,XX18
F5 ASS, Duplex SS
F6 Bare rods ERXX
 Filler Metal A Numbers
Based on chemical composition
A1 Mild steel
A2 C - Mo steel
A3 Cr - Mo steel (Cr 0.4 - 2%)
A4 Cr - Mo steel (Cr 2 - 6%)
A5 Cr - Mo steel (Cr 6 - 10.5%)
A6 Cr Martensitic
A7 Cr Ferritic
A8 Cr Ni steels (Cr 14.5 - 30% Ni 7.5 - 15%)
A9 Cr Ni steels (Cr 19 - 30% Ni 15 - 37%)
A10 Ni steels (Ni 0.8 - 4%)
A11 Mn Mo steels(Mn 1.25-2.25 Mo 0.25-0.75%)
A12 Ni Cr Mo steels (Cr 1.5% Mo 0.25-0.8%
Ni 1.25 -2.8%)
 Preheat(QW:406)

• Preheat temperature (Minimum)

• Interpass temp.(Maximum)
• Preheat maintenance
 PWHT(QW:407)

• Temperature range
• Time range
• Thickness range
 Gas(QW:408)

• Gases Mixture % Flow rate

(e.g. 75% Ar 25%CO2)
• Shielding
• Trailing
• Backing

Trail shield
 Electrical
Characteristics(QW-409)

• Current (AC/DC)
• Polarity (EP/EN)
• Amps & Volts
• W-Electrode type & size
• Mode of Metal Transfer
• Electrode Wire Feed Speed range
• Pulsing Current
 METAL TRANSFER IN GMAW
Short circuit transfer
Low voltage & current Application
Thin sheet &
all position welding
capability

Globular transfer Spray transfer

Medium voltage & current High voltage & current

Applications
Down hand position welding
Sheet thickness > 2 mm
 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
• Multiple Or Single Electrode
• Electrode Spacing
• Peening
• Others
 Procedure Qualification
PQR is a record of welding data to weld
a test coupon. It also contains test
results.
Completed PQR shall document all
essential variables including ranges.
PQR to be certified accurate and shall
not be subcontracted.
If more than one process then weld
deposit thickness for each process and
filler metal to be recorded.
 Procedure Qualification
Several WPSs may be prepared from one
PQR.
eg. 1G plate PQR may support WPSs in
2G, 3G, 4G, pipe 5G, 6G etc provided
other parameters are kept same.
A single WPS may cover several PQRs
eg. A single WPS may cover 1.6 mm to
32 mm thickness if PQRs for 1.6 to 4.8
mm and 4.8 mm to 32 mm thickness
ranges.
 Weld Orientation
Plate groove 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
 Procedure Qualification
When two or more procedures (diff
processes or other essential variables) are
used in one joint, use table for determining
the applicable range of thickness qualified.
Carry out tension test for each weld metal.
One or more processes from a
combination may be deleted provided
remaining metal meets the requirements.
Procedure Qualification Thickness limits

T Range of T max t Tests (transverse

bend)
<1/16” T - 2T 2t 2T, 2 FB, 2 RB
1/16-3/8” 1/16 - 2T 2t -do-
3/8-3/4” 3/16 - 2T 2t -do-
3/4-1.5” 3/16 - 2T 2t if t<3/4 2T, 4 SB
2T if t>3/4
>1.5” 3/16 - 8” 2t if t<3/4” -do-
8 if t>3/4”
Procedure Qualification Thickness limits

T Range of T max t Tests (longtl

bend)

<1/16” T - 2T 2t 2T, 2 FB, 2 RB

1/16-3/8” 1/16 - 2T 2t -do-
> 3/8” 3/16 - 2T 2t -do-
 WPS for SMAW
Essential variables

Change in qualified Thickness

Change in P no
Change in F no of filler metal
Change in A no of filler metal
Change in deposited metal thickness
Decrease of more than 100 F in
preheat
Change in PWHT
 WPS for SMAW
Supplementary Essential variables
Change in Group no of base metal
Change in T limits for impact test
Change in dia of filler metal > 1/4”
Change in AWS class of filler metal
Change in welding position
Increase of more than 100 F in preheat
Change in PWHT Time and temp range
Change in current or polarity
 WPS for SMAW
Non Essential variables
Change in Groove design, backing, root
spacing, retainers etc
Change in dia of filler metal
Change in AWS class of filler metal
Change in welding position
Change in preheat maintenance
Change in current or polarity
Change in string/weave, cleaning, back
gouging, peening, manual/automatic
 WPS for GTAW
Essential variables

Change in qualified Thickness

Change in P no
Change in F no & A no of filler metal
Addition/deletion of filler metal
Change in size of filler metal, product
form
Decrease of more than 100 F in preheat
Change in PWHT
 WPS for GTAW
Essential variables (cond)

Change in single, mixture % gas

Deletion of backing gas
Change in shielding / trailing gas
Change in Closed to out chamber
technique
 WPS for GTAW
Supplementary Essential variables
Change in Group no of base metal
Change in T limits
Change in AWS class of filler metal
Change in welding position
Increase of more than 100 F in preheat
Change in PWHT Time and temp range
Change in current/polarity, incr. in
heat input
Change in multi to single pass,
electrodes
Welding Conditions
Specification, type and grade of Base Metal(s): SA106 Gr B
To Specification, type and grade of Base Metal(s): SA106 Gr B
Base Metal P or S-number 1 to Base Metal P or S-number 1 Thickness:
0.218
Welding Process(es) used: GTAW followed by SMAW
Plate X Pipe (enter diameter if pipe or tube): NPS 2, Sch 80
Groove type (Single V, Double V, Single U, etc): Single Vee
Initial cleaning method: Solvent wipe and grinding
Backing (metal, weld metal, backwelded, etc): None / Weld metal
Filler Metal (SFA) Specification: 5.18 / 5.1
Filler Metal or Electrode Classification: ER70S-2 / E7018
Filler Metal or Electrode Trade Name: Linde 65, Lincoln 7018+
Tungsten electrode type and size for GTAW: EWTh-2, 3/32"
Consumable Insert Class and size for GTAW or PAW: None
Backing Gas composition and Flow rate for GTAW, PAW, GMAW: Not Used
Preheat Temperature (°F): 75
Position (F, V, OH, H or 5G, 3G, etc.) of weld: 5G
Progression (Uphill or Downhill): Uphill GTAW / downhill SMA
Interpass cleaning method: Wire brushing
Measured interpass temperature (°F): less than 400
Approximate Deposit Thickness for each filler metal or electrode type (in.): 0.093 (3/32) / 0.125

Current Type/Polarity (AC, DCEP, DCEN): DCEN/DCEP Postweld Heat

Treatment Time and temperature: 1100-1200°F, 65 hr.

Visual Examination of Completed Weld: Acceptable Date of Test: 12/25/01

Bend Test X Transverse Root and Face (QW-462.3(a)) Side (QW-462.2)

Type Result Type Result Type Result

Face Acceptable Root Acceptable
Face Acceptable Root Acceptable

Alternative Radiographic Examination Results: N/A

Specimens Evaluated By: Dianna Ross Title: Leader Company: The Best Testing
Company Ever
Welding Supervised By: James Brown Title Soloist Company: Joe-Bob's B&NPW Shop

Welder’s Name: Wolfgang Amadeus Mozart Stamp No: A1

We certify that the statements in this record are correct and that the weld described above was prepared,
welded and tested in accordance with the requirements of Section IX of the ASME Code.
 Performance Qualification
The basic criterion for welder’s
qualification is to determine the
welder’s ability to deposit sound weld
metal.

The purpose of performance

qualification test is to determine the
welding operator’s mechanical ability to
operate the welding equipment.
GMAW in different positions

1F

2F
Flat Horizontal
Fillet welding of plate

3F
Vertical overhead
4F
 Welders Performance Qualification
The performance qualification tests are
intended to determine the ability of
welders to make sound welds

A welder is qualified by radiography of a

test coupon or by radiography of initial
production welding or by bend tests
taken from a test coupon
 Variables affecting the
welders qualification

Welding conditions that affect the

ability of welder to produce sound
welds are qualification variables
• Welding process
• Filler metal
• Welding position
• Joint backing
• Thickness of test coupon
 Welding process

• A change in welding process –from

SMAW to GTAW, for eg.,requires the
requalification of the welder since
skill required to use one process is
different from another one.
 Filler metals
• Filler metals used in welding are
grouped based on their usability
characteristics. These are assigned F-
numbers
• Ordinarily welder is qualified for a F no
and do the same in production
• SAW :F1-F4: Qualification in higher Fno
entails qualfication for lower F nos of
electrodes
 Backing

• Joint backing includes any material placed at

the root of the weld to support the liquid
metal(e.g backing strip,non fusing bars, root
weld with another process,etc)
• If a welder qualifies using a backing on the
test coupon but the backing is removed for the
production welding for a joint made from one
side, then he must requalify
• If a welder qualifies using without a backing,
for a joint with backing he is automatically
qualified
 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
•
Welding position(QW-405)
Welding test positions are defined differently for
plate and pipe
• A change in welding position from that qualified
may require requalification
• Certain test position qualify for more than one
production welding position
(E.g.qualification in 3G position qualifies the welder
for vertical and flat positions)
• In vertical position welding, a change in welding
progression from uphill to downhill would require
requalification
• Qualification in difficult position qualifies for less
difficult positions: E.g 6 G qualifies for all positions
Welders Performance Qualification

Weld Plate & pipe Pipe of OD Fillet

>24”OD 2 7/8 - 24”

Plate 1F F
Plate 2F F, H
Plate 3F F, H, V
Plate 4F F, H, O
3F &4 F All
Welders Performance Qualification

Weld Plate & pipePipe of OD Fillet

>24”OD 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

Weld Plate & pipe Pipe of OD Fillet

>24”OD 2 7/8 - 24”

Pipe 1G F F F
Pipe 2G F, H F, H F, H
Pipe 5G F, V, O F, V, O All
Pipe 6G All All All
Pipe 2G + 5G All All All
 Welders Performance Qualification

Weld Plate & pipe Pipe of OD Fillet

>24”OD 2 7/8 - 24”

Pipe 1F F
Pipe 2F F, H
Pipe 2FR F, H
Pipe 4F F, H, O
Pipe 5F All
 Test coupon thickness

• The thickness of the production work

determines the thickness of the plate or pipe
test coupon to be welded
• Thumb rule is a welder is qualified to deposit
in production welding two times the thickness
of the weld deposited on the test coupon (e.g.
test coupon of 9 mm qualifies a person to weld
upto 19mm thick production weld)
• Some code makes once a weld of 1 inch is
made, the welder is qualified to weld all
thickness
 Test coupon
thickness(contd.)
• The weld deposit thickness(t) determines the
thickness of the weld metal the welder is
allowed to use in production not the thickness
of the base metal in the test coupon.

• When welding a test coupon using more than

one process or filler metal, the thickness of
the weld in production depends on the deposit
thickness for the process and the type of test
of filler metal that was used on the test
coupon.
 Welders Performance Qualification
Thk Max tk of dep. Metal Test
<3/8” 2t 1FB, 1RB
>3/8” 2t 1FB, 1RB
>1/2” Max to be welded 2SB

OD of test coupon Range of OD qualified

<1” Size welded - unlimitd
1 - 2 7/8” 1” - unlimited
> 2 7/8” 2 7/8” - unlimited
 Welders Performance Qualification
Test coupon More than 2 welders
different procedure can do a single test
coupon. Failure then both are failed.

Retest - 2 consecutive test coupons to

pass
Renewal if no welding for 6 months.
Single test coupon plate/pipe, any
thickness, material, position. If passed
then complete previous qualification is
restored.
 Welders Performance Qualification

Variables for SMAW

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
 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

Bend test No open discontinuity > 1/8” in any

direction

Impact test In accordance with the section

 Tests for Qualification

Radiography No crack or LOP or LOF

Any elongated slag >1/8” for t <3/8”
1/3 t for t 3/8 - 2 1/4”
3/4 “ for t>2 1/4”
Any group of slag in a line with aggregate
length t in 12 t unless separated by 6L

Max permissible dimension for rounded

indication smaller of 20% of t or 1/8”
For thickness<1/8”, max no of accepted
rounded indication 12 in 6” length
For thickness>1/8”, charts for max
acceptable types of rounded indication
C. R. Ratheeskumar
ACTUAL VALUE RANGE QUALIFIED
FCAW(S) FCAW(S)
8" 2 7/8" & Above
A 106 Gr B, Sch 160

P No.:1 Gr.:1 P 1 - P 11
Yes(Root) With backing
E71T8-K6
6 6

FCAW(S) -19 mm Upto Max to be we

 8" 2 7/8" & Above
A 106 Gr B, Sch 160

P No.:1 Gr.:1 P 1 - P 11
Yes(Root) With backing
E71T8-K6
6 6
FCAW(S) -19 mm Upto Max to be welded

6G All Positions
Down Hill Down Hill
NA NA
DC DC
Electrode Negative Electrode Negative

Accepted
NDT / 250A / 03 Dt.23.2.04.

NA

NA
NA
NA
Welding Research Institute, BHEL, Trichy, India.
NA
 Welder’s Performance
Qualification as per

Indian Boiler Regulations

 Welder’s Performance
Qualification as per IBR
Initial qualification of welders -
Certificate valid for 24 months provided
welder has been employed with
reasonable continuity

If preceding three months, no welding

carried out or if there is any doubt on
welder’s stability then requalification
needed
 Welder’s Performance
Qualification as per IBR
Requalification of welders must for the
following
Omission of backing strip
Change in class of electrode
Change in base metal to be
welded(CS or AS)
Change in welding process
Change from dc to ac and vice versa
 Tests for Initial Qualification
• Theoretical examination
• Groove welds in plate - single or double vee
299 x 381 x 16 mm min size in flat, horizontal
or vertical. Vertical or horizontal position also
qualifies for all
•Fillet weld in plate - 16 x 381 mm min in flat,
horizontal, vertical or overhead.
Horizontal or vertical also qualifies for flat.
Vertical position also qualifies for flat,
horizontal or vertical.
 Tests for Initial Qualification
Pipe welding in the following positions (i)
Horizontally rolled (ii) Horizontal turned (iii)
Vertical fixed (iv) Horizontal fixed.
Qualification in (ii) or (iii) also qualifies (i).
Qualification in (iv) also qualifies (i) or (ii).

Branch to pipe welding

Pipe size 127 OD x 10 tk. Tube 89 OD x 6 tk.

Tube welding with axis vertical and tubes of

same size fixed in adjoining positions.
 Tests for Requalification
• No theoretical examination
• Plate welding 152 length x 229 x 16 tk in
45 deg position. Weld to be done from
underside.
• Pipe welding with axis of pipe horizontal.
• Branch to pipe as earlier
• Tube welding axis vertical and tubes of
same size in adjoining position.
• Regular production weld to the
satisfaction of competent authority
may be accepted as alternative to the
above tests
 Examination of the weld for initial
Qualification
PLATE QUALIFICATION (Groove weld)

• Visual examination
• Radiography
• 2 no of Tensile test
• 2 no each of Bend test - face and root
bend ( 3t for both C steel and alloy steel
180 deg bend)
• 1 no Micro examination
• 1 no Macro examination
 Examination of the weld for
initial Qualification
PLATE QUALIFICATION (Fillet weld)

• Specimen shall not fracture during load

application
• If fractures, no evidence of cracks / ICP /
sum of inclusions and gas pockets < 51 mm
• Macro examination shall show complete
fusion
• concavity / convexity < 1.6 mm
• difference in leg length < 1.6 mm
 Examination of the weld for initial
Qualification
PIPE QUALIFICATION

• Visual examination
• Macro examination
• 2 no each of Bend test - face and root
bend ( 3t for C steel and 4t for alloy
`steel 90 deg bend)
 Examination of the weld for
Requalification
PLATE QUALIFICATION
• Radiography
• 1 no each of Bend test - face and root
bend
• 2 no of macro examination

PIPE QUALIFICATION
• 1 no each of bend test - face and root
bend
• Macro examination
ACTUAL VALUE
FCAW(S)
8"

A 106 Gr B, Sch 160

P No.:1 Gr.:1

Yes(Root)
E71T8-K6
6

FCAW(S) -19 mm

6G
Down Hill
NA
DC
Electrode Negative
Steps involved in qualifying the
welding process & welder/
operator
• A tentative welding procedure is prepared
• Test samples welded with the above and
parameters recorded on PQR
• Tested as per required codes
• If test is passed, the procedure has
completed qualification.
• If test is not passed, the tentative WPS
value of the parameters are changed as
deemed feasible
Steps involved in qualifying the
welding process & welder/
operator
• The welder making the test samples to be used in
qualifying the procedure is normally considered
qualified.
• Other welder to be qualified weld test samples
as per WPS and the samples are tested as per
applicable requirements.
• A qualified WPS is usable for an indefinite length
of time
• The welder’s qualification is normally considered
effective for an indefinite period of time, unless
the welder is not engaged in the specific process
of welding for which she is qualified for a period
of exceeding 6 months
 Case study
Objective : To develop a WPS for pipe
to pipe butt joint( dia. 406 * 12mm)
of SA 106 GrC – SA106 GrC as per
ASME sec IX
• Requirement of mechanical property:
Impact toughness at room
temperature
Tensile strength
 Filling up of WPS- Draft

• WPS: No: Date:

• Supporting PQR
• Welding process :
• Type : Manual/ Machine/Auto/
Semi Auto
• Application:
 Joints(QW:402)

• Joint Design
• Backing
• Baking Material Type
 Base Metal(QW-403)

• P. Number
• Group Number
• Specification
• Chemical Analysis & Mechanical
Properties
• Thickness Range
• Pipe Diameter Range
 Filler Metals(QW-404)

• AWS Number • Size of Filler metal

• Flux trade name
• SFA Number
• Consumable insert
• F. Number
• Electrode flux class
• A. Number

• Deposited Metal thickness range

 Welding position(QW-405)
• Welding test positions are defined
differently for plate and pipe
 Preheat(QW:406)

• Preheat temperature Min

• Interpass temp.(Max.)
• Preheat maintenance
 PWHT(QW:407)

• Temperature range
• Time range
• Thickness range
 Gas(QW:408)

• Gases 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
• Electrode Wire Feed Speed range
• Pulsing Current
 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
• Multiple Or Single Electrode
• Electrode Spacing
• Peening
• Others
Filling up of WPS-Joints(QW:402)