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    102 Welding Qualifications

    Uploaded by

    dayalram
    The document discusses welding procedure and performance qualification. It describes welding procedure specifications that define required welding conditions, procedure qualification records that demonstrate acceptable test joints, and welder performance qualifications that show a welder's ability to produce sound welds. It explains essential variables that require requalification if changed and lists examples of variables that depend on the welding process and application.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    102 Welding Qualifications

    Uploaded by

    dayalram
    130 views27 pages
    The document discusses welding procedure and performance qualification. It describes welding procedure specifications that define required welding conditions, procedure qualification records that demonstrate acceptable test joints, and welder performance qualifications that show a welder's ability to produce sound welds. It explains essential variables that require requalification if changed and lists examples of variables that depend on the welding process and application.

    Original Title

    102 Welding Qualifications

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    The document discusses welding procedure and performance qualification. It describes welding procedure specifications that define required welding conditions, procedure qualification records that demonstrate acceptable test joints, and welder performance qualifications that show a welder's ability to produce sound welds. It explains essential variables that require requalification if changed and lists examples of variables that depend on the welding process and application.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    130 views27 pages

    102 Welding Qualifications

    Uploaded by

    dayalram
    The document discusses welding procedure and performance qualification. It describes welding procedure specifications that define required welding conditions, procedure qualification records that demonstrate acceptable test joints, and welder performance qualifications that show a welder's ability to produce sound welds. It explains essential variables that require requalification if changed and lists examples of variables that depend on the welding process and application.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 27
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    The key takeaways are that welding procedures need to be qualified through procedure qualification records and welders need to be qualified through welder performance qualification records. The welding procedure specification defines the essential and non-essential variables for the procedure while welder qualification depends on variables like welding process, filler metal, and position.

    The different types of welding qualification records are the welding procedure specification (WPS), procedure qualification record (PQR), and welder/welding operator performance qualification (WPQ/WOPQ). The WPS defines the procedure, the PQR qualifies the WPS, and the WPQ qualifies individual welders.

    The variables that need to be specified for a welding procedure in the WPS include welding process, joint design, base metal, filler metal, position, preheat/interpass temperatures, gas type, electrical characteristics, and welding technique.

    WELDING PROCEDURE

    AND
    PERFORMANCE
    QUALIFICATION
    WELDING PROCEDURE AND
    PERFORMANCE QUALIFICATION
    • WELDING PROCEDURE
    SPECIFICATION ( WPS )

    • PROCEDURE QUALIFICATION
    RECORD ( PQR )

    • WELDER / WELDING OPERATOR


    PERFORMANCE QUALIFICATION
    ( WPQ / WOPQ )
    WELDING PROCEDURE
    SPECIFICATION

    • Document that provides in detail


    required welding conditions to assure
    repeatability by properly trained welders
    or welding operators

    • Contains Essential Variables and non-


    essential variables
    WELDING PROCEDURE
    SPECIFICATION

    ESSENTIAL VARIABLE
    • Item in the WPS that , if changed beyond
    specific limits requires re-qualification of the
    welding procedure

    • The change beyond specific limits significantly


    affects mechanical properties of the sound
    weldment
    ( Weld Metal / HAZ / PM )
    WELDING PROCEDURE
    SPECIFICATION

    NON-ESSENTIAL VARIABLE
    • Item in the WPS that , if changed does not
    require re-qualification of the welding
    procedure
    • The change does not affect desired
    properties of the sound weldment
    ( Weld Metal / HAZ / PM )
    • The item is necessary to achieve sound
    weldment
    WELDING PROCEDURE
    SPECIFICATION

    ESSENTIAL & NON-ESSENTIAL


    VARIABLES
    • Depend upon the welding process
    • Depend upon the application
    -- Joint welding
    -- Corrosion resistant overlay
    -- Hard facing overlay
    • Additional requirements
    -- Impact toughness
    -- Hardness control
    WELDING PROCEDURE
    QUALIFICATION

    • Qualification of WPS is accomplished


    by demonstrating that joints made by
    the procedure can meet prescribed
    requirements

    • Procedure Qualification Record


    contains actual conditions used to
    produce acceptable test joint and the
    results of the qualification test
    WELDING PROCEDURE
    QUALIFICATION

    • Actual conditions used must be recorded


    in the PQR for all the essential variables of the
    WPS for procedure qualification

    • All the tests required for the application


    must be conducted to qualify the WPS
    prior to use on the job

    • Each WPS must be supported by a PQR or PQRs


    WELDING PROCEDURE
    QUALIFICATION

    • The type and number of tests depend upon the


    type of application
    --- Joint Welding
    -- Corrosion Resistant Overlay
    -- Hard facing Overlay
    WELDER /WELDING OPERATOR
    QUALIFICATION

    Accomplished through demonstration by


    the welders / welding operators of their
    ability to produce sound welds that meet
    required standards
    •
    WELDER /WELDING OPERATOR
    QUALIFICATION

    ESSENTIAL VARIABLE FOR


    WELDER / WELDING OPERATOR

    • Item in the WPS that , if changed beyond


    specific limits requires re-qualification of the
    welder or welding operator

    • The change beyond specific limits significantly


    affects welder’s or welding operator’s ability to
    deposit sound weld
    WELDER /WELDING OPERATOR
    QUALIFICATION

    ESSENTIAL VARIABLES FOR


    WELDER / WELDING OPERATOR

    • Depend upon the welding process

    • Depend upon the application


    -- Joint welding
    -- Corrosion resistant overlay
    -- Hard facing overlay
    WELDER /WELDING OPERATOR
    QUALIFICATION

    • Welder Performance Qualification Record


    ( WPQ ) contains actual conditions used to
    produce acceptable test joint and the
    results of the qualification test

    • Actual conditions used by the welder must be


    recorded in the WPQ for all the essential
    variables of the WPS for welder qualification
    WELDER /WELDING OPERATOR
    QUALIFICATION

    • All the tests required for the application


    must be conducted to qualify the Welder
    prior to use on the job

    • Each Welder / Welding Operator must be have


    a WPQ or WOPQ

    • Each WPQ / WOPQ mentions the range of


    qualification of the welder / welding operator
    WELDER /WELDING OPERATOR
    QUALIFICATION

    • The type and number of tests depend upon the


    type of application
    --- Joint Welding
    -- Corrosion Resistant Overlay
    -- Hard facing Overlay
    VARIABLES FOR
    WELDING PROCEDURE

    • Welding Process

    • Type of joint
    -Design, Backing, Backing Material

    • Base Metal
    -P.No. , Specification , Grade, Chem. /Mech. Prop
    thickness range for groove and fillet weld
    VARIABLES FOR
    WELDING PROCEDURE
    • Filler Metals
    -Spec. No, AWS No., F No. A No, Size,
    weld metal thickness range for groove and fillet
    welds , electrode –flux class, flux trade name
    • Position
    -For Groove and Fillet, Welding Progression
    • Preheat
    -Min Preheat, Max. Interpass,
    Preheat Maintenance
    VARIABLES FOR
    WELDING PROCEDURE
    • Post Weld Heat Treatment
    -Temperature range, Time range

    • Gas
    -Shielding, Trailing , Backing

    • Electrical Characteristics
    -Current, Polarity, Amps & Volt range
    Mode of Metal transfer
    VARIABLES FOR
    WELDING PROCEDURE
    • Technique
    -string or weave bead,
    orifice or gas cup size,
    initial and inter-pass cleaning,
    method of back gouging,
    oscillation,
    contact tube to work distance,
    multiple or single pass per side,
    multiple or single electrode,
    travel speed range
    VARIABLES FOR
    WELDER QUALIFICATION

    • Welding Process
    • Backing
    • Base Metal P No
    • Plate / Pipe OD
    • Filler Metal F No.
    • Filler Metal A No.
    • Filler Type
    VARIABLES FOR
    WELDER QUALIFICATION

    • Deposit Thickness
    • Position
    • Vertical Progression
    • Inert gas backing
    • Metal transfer mode
    • GTAW current polarity
    P Nos.
    ASME Section IX

    1 - 11 Steels
    21-25 Aluminum & its alloys
    31-35 Copper & its alloys
    41-45 Nickel & its alloys
    51-52 Titanium and its alloys
    61-62 Zirconium & its alloys
    P Nos.
    ASME Section IX

    P1 Carbon , Carbon-Mn Steels


    P3 Carbon- Moly Steels
    P4 Cr-Mo steels up to 2% Cr
    P5 Cr-Mo steels up to 9% Cr
    P6 Martensitic SS
    P7 Ferritic SS
    P8 Austenitic SS
    F Nos.
    ASME Section IX

    1 E XX20, 24, 27, 28


    2 E XX 12, 13, 14
    3 E XX 10, 11
    4 E XX 15, 16, 18
    5 E 3XX
    6 Continuous Consumables -Steel
    F Nos.
    ASME Section IX

    21 - 24 Al
    31 - 37 Cu
    41 - 45 Ni
    51 - Ti
    61 - Zr
    A Nos.
    ASME Section IX

    1 Mild steel
    2 Carbon Moly
    3 Cr- Mo ( Cr-0.4 to 2 %)
    4 Cr- Mo ( Cr-2 to 6 %)
    5 Cr- Mo ( Cr-6 to 10.5 %)
    A Nos.
    ASME Section IX
    6 Chrome Martensitic
    7 Chrome Ferritic
    8 Cr- Ni ( Cr-14.5 to 30 %)
    ( Ni-7.5 to 15 %)
    9 Cr- Ni ( Cr-25 to 30 %)
    ( Ni-15 to 37 %)
    10 Nickel up to 4%
    11 Mn - Mo

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