api 570 chapter10 asme ix rev

8/9/2019 API 570 Chapter10 Asme Ix Rev

1/50

Chapter Ten

. . . . . . . . . .

..........

ASME Section IX Procedures and

Qualifications

Do Not Duplicate

ASME IX

These course notes have been prepared by TWI, strictly for the use of attendees to this TWIAPI-

570 Examination Preparation Course. This manual is to be used as an aid to assist those persons wishingto take the API-570 Piping Inspector Certification Examination. This manual is not all-inclusive and may

not be used in place of any recognized Code or Standard. This manual may not be reproduced by any

means without the express written consent of TWI.


2/50

THE WELDING INSTITUTE

REV.005 ASME IX (570 ED) 2Copyright TWI Ltd 2008

ASME SECTION IX

Section IX covers welding and brazing. Section IX is divided into four Articles but has sixdistinct areas of information as follows:

The Forward & Introduction

Article I, Welding General Requirements

Article II, Welding Procedure Qualification

Article III, Welding Performance Qualification

Article IV, Welding Data (Variables In written paragraph format)

Article IV, Welding Data (Variables in chart and table format)

ASME SECTION IX - WELDING DOCUMENTS:

PQR: Procedure Qualification Record

Used to document welding procedure qualification and test

Is a record of the actual measurements taken and conditions observed when producingthe qualification test coupon

Documents results of subsequent qualification tests such as tensile and bends.

Must address all essential variables listed for the processes used and supplementaryessential variables when notch toughness is a consideration required by the

referencing code

Deals with the soundness of the weldment to be made

Must be signed and dated

WPS: Welding Procedure Specification

Used to provide direction to the welder Lists the ranges qualified as a result of welding the qualification coupon and

performing tests

Must address all essential and nonessential variables listed for the processes used andsupplemental essential variables when notch toughness is a consideration required by

the referencing code.

Deals with the soundness of the weldment to be made


3/50



WPQ: Welder Performance Qualification Record

Used to document welder qualification and tests Must address all essential variables listed for the processes used

Is a record of the actual measurements taken and conditions observed and the rangesqualified as a results of welding the qualification coupon

Documents the results of subsequent qualification tests such as bends and radiography

Must be signed and dated

Welding Variables:

There are three types of variables used in Section IX

Essential Variable: Applicable to the PQR, WPS & WPQ

Addresses information that must be included in the PQR, WPS or WPQ that is mandatoryto assure the soundness of the weldment (except for notch toughness properties) or skill

of the welder

Section IX gives specific ranges qualified for essential variables directly related to theactual measurements taken during production of the qualification coupon

A change in the information requires re-qualification of the WPS or welder

Nonessential Variables: Applicable to the WPS

Addresses information that is not mandatory to assure the soundness of the weldment

A change in the information does not require re-qualification of the WPS (all weldervariables are essential) but may require a new revision level of the WPS to be issued

No specific ranges are specified by Section IX for nonessential variables. (Theinformation given on a WPS to satisfy a nonessential variable requirement can be outside

anything reasonable and satisfy code requirements. For example a root gap may be 3

or a welding rod diameter 1. Although this will probably not be seen or work well in real

life there are no restrictions on nonessential variables in the ASME Section IX.

All non essential variables must be addressed on the WPS. (For example: peening is listedfor most processes but seldom used. An appropriate statement is None to be performed.

An inappropriate statement is Not applicable)

Supplemental Essential Variables: Applicable to the PQR AND WPS *

Addresses information that must be included in the PQR and WPS that is mandatory toassure the notch toughness qualities of the weldment

The construction codes which reference Section IX specify some ranges qualified forsupplemental essential variables directly related to the actual measurements taken and

information recorded during production of the qualification coupon (For example:

thickness qualified)

A change in the information requires additional testing or requalification of the WPS


4/50



NOTE: Supplemental Essential Variables are excluded from the welding

documents used on the actual 653 exam by the 653 Body of Knowledge.

ASME SECTION IX: QW-100 SERIES PARAGRAPHS: QW-100- GENERAL

QW-100.1:

1) The WPS is a written document that provides directions to the welder/operatorwhen making production welds.

2) WPSs have to be qualified by each manufacturer, or it can be an AWS StandardWPS (SWPS) shown in Article V.

3) Both list conditions allowed to weld (variables).

4) Purpose of qualifying the WPS is to prove the weldment purpose for construction iscapable of the required properties.

5) Section IX does not contain specific requirements for notch toughness. These arecontained in the referencing Codes sections.

6) The PQR lists the information recorded during qualification of the procedure.

QW-100.2:

1) Welder Performance Qualification is used to determine the welders ability todeposit sound weld metal. Operator Performance Qualification is used to determine

the operators ability to run the equipment.

QW-100.3

1) PQRs & WPQs made in accordance with the 1962 or later Editions are still valid.2) New WPSs & PQRs shall be in accordance with the current Edition and Addenda.

QW-103.1

1) Each organization is responsible for the welding they perform and must conduct thequalification tests required by Section IX.

2) However, the actual nondestructive & mechanical testing may be subcontracted

(QW-201).

QW-103.2

1) Each organization must complete and certify records of all qualification tests andthe records must be kept on file.

2) These records must be available to the Authorised Inspector.

QW-142 & QW-143:

1) When permitted by QW-304 & QW-305 radiography may substitute for mechanicaltesting.


5/50



QW-153.1: Tensile Test Criteria:

1) Specimens shall have a tensile strength not less than: Minimum tensile of the base metal.

Minimum tensile of the weaker base metal if different strengths are used.

Minimum tensile of the weld metal when allowed to have a lower roomtemperature strength than the base metal by the referencing code section.

May be 5% below the minimum strength of the base metal if the break isoutside the weld or fusion line in the base metal.

QW-191

1) Special acceptance standards for testing welders using radiography are per QW-142& 143.

2) The radiography must be performed in accordance with ASME Section V Article 2.No written procedure is required, and geometric unsharpness is not required to be

calculated. T-285 of ASME V (unsharpness) is only a guide.

QW-191.2

1) Lists the acceptance standards for welder qualification with radiography.

QW-191.2.3

1) RT qualification using production welds:

For welding operators use acceptance standard from referencing code section.

For welders use acceptance standards in QW-191.2.2 (see QW-304 for processes andmodes of transfer permitted to be qualified by RT)

QW-194 Visual Examination Performance

Performance coupon visual exam shall show complete penetration & fusion of weld & base

metals

QW-200 SERIES PARAGRAPHS:


6/50



QW-200.1 Welding Procedure Specification:

Each organization shall prepare a written document defined as:

A) WPS A written qualified welding procedure created to give guidance and directionwhen used to make production welds to code requirements.

B) The WPS shall contain:

Descriptions of all the essential, nonessential and, when required, supplementaryessential variables for each welding process used in the WPS.

Reference to the supporting PQR(S).

The WPS may include any other data considered helpful in completing the joint.C) Changes made to WPSs

Changes to nonessential variables may be made without re-qualification but mustbe documented on the WPS by revision level or by use of a new WPS.

Changes to essential or supplementary essential variables to ranges outside thoseallowed by Section IX requires re-qualification of the WPS.

D) Format of the WPS:

The WPS may be in any format.

Forms shown in Section IX are not required-only for reference & example.E) Availability:

The WPS must be available for reference and available to the AuthorisedInspector.

The WPS must be available at the fabrication site.

QW-200.2- Procedure Qualification Records:

Each organization shall prepare a written document defined as:

A) PQR A written document used to record the welding information and data usedwhen welding a test coupon for qualification of a WPS and the results of the tests

performed on specimens taken from the coupon.

B) The PQR shall contain:

Actual values observed for all the essential and, when required, supplementary

essential variables for each welding process used while welding the coupons fortesting.

Test results from tests performed on the speciemens removed from the coupon.

Other information may be included.

When values are included for other variables it must be the actual values observed not the full ranges to be used in production unless required by a specific

variables or referencing code section.

The organization qualifying the PQR shall certify the accuracy of the PQR.

Certification of the PQR may not be subcontracted.

The approximate deposited weld metal thicknesses for each filler metal or processshall be recorded separately.

C) Changes made to the PQRS - Not permitted except as follows:


7/50



Editorial changes may be made in a WPS or PQR; i.e: to correct errors or toreflect code changes.

Additional information may be added later if it can be proven to be part of theoriginal information recorded with reliable documentation such as lab test records.

D) Format of the PQR:

The PQR may be any format.

Forms shown in Section IX are not required only for reference & example.E) Availability

The PQR must be available to the Authorised Inspector upon request.F) Multiple WPSS & PQRS.

Multiple PQRS may be used to support a single WPS.

Multiple WPSS may be supported by a single PQR

Multiple WPSS may be used to complete a single joint.

QW-201: Responsibilities, Subcontracting Testing & Shared Qualifications

1) Nondestructive and mechanical testing may be subcontracted but the actual weldingmust be performed by the qualifying organization.

2) Two or more organizations may share qualification if effective operational control byboth is demonstrated and described in the quality manuals of all the organizations

involved.

QW-300 SERIES PARAGRAPHS:

QW-300.2 Responsibility

1) Each organization must tests all welders to assure they are qualified for the weldingactivities they will be assigned to perform.

2) Welders must be tested under the supervision of the qualifying organization.

QW-300.3 Shared Qualifications

1) Qualifications may be shared among two or more companies as long as the system used is

described in the companies quality systems and all other Section IX requirements aremet.

QW-301.2 Tests

1) Coupons welded for welder qualification shall be welded in accordance with aqualified WPS except that:

When preheat and PWHT are required in the WPS they may omitted during thewelding of the welders test coupon.

When a welder prepares a coupon for WPS qualification and the coupon passesthe tests for qualification the welder is also qualified within the limits specified

for welders.


8/50



Welder qualification tests may be stopped at any point at which it becomesapparent that the welder does not have the required skill.

QW-301.3

1) Each welder shall be assigned a unique identifying symbol, number or letter to usewhen stamping or recording the work performed by the welder.

QW-302.2

1) Welders may be qualified using radiography as allowed by QW-304 & QW-305.

QW-304.2

1) When a welder fails qualification using radiography the entire section of the jointmade by the welder be removed or completely radiographed and the defective areas

repaired by a qualified welder.

QW-306

1) Welders may be qualified using separate coupons for each process or by welding withmultiple processes in a single coupon as long as all the requirements of Section IX are

met.

2) Failure of any portion of a combination test in a single coupon constitutes failure of

the entire coupon.

QW-321

1) When a welder fails a qualification test he may take an immediate retest.

QW-322

A welders qualification is affected when one of the following occurs:

A) If he has not welded with a process in which he is qualified for a period of sixmonths or more his qualifications for that process expire unless within 6 months

prior to the expiration:

a welder has welded using a manual or semiautomatic process which willmaintain his qualification for manual or semiautomatic welding with that

process

a welding operator has welded using a machine or automatic process whichwill maintain his qualification for machine or automatic welding with that

process

B) Whenever there is a specific reason to question the welders ability to make weldsthat meet the specification the qualification required to make those weldments

shall be revoked.


9/50



A welders qualifications may be renewed by:

A) When the welders qualifications have expired due to not having welded with theprocess they may be renewed for all positions, diameters, thicknesses and basemetals by the welder welding a single test coupon of plate or pipe of any base

metal using any thickness, diameter or position and performing the tests required

by QW-301 & QW-302.

B) Revoked qualifications may be renewed by using a test coupon appropriate to theproduction work to be performed. The coupon shall be welded and tested as

required by QW-301 & QW-302.

QW-350

These tables list the variables for welders. They are all essential variables, and as such, mustbe addressed on the WPQ in some manner. The variables for operators are given in QW-360.

Article V This article provides rules for using AWS Prequalified Welding Procedures.

Reference is also made to Appendix E, which lists approximately 17 approved pre-qualified

welding procedures which do not have to be qualified by the Manufacturers.

ASME Section IX - Procedure Qualification Testing

Required Tests:

1. Tensile2. Bends

Face

Root

Side3. Nondestructive Testing

General sequence for Procedure Qualification Testing


10/50



1. Select welding variables.

2. Check equipment and materials for suitability.3. Monitor weld joint fit-up as well as actual welding, recording all-important variables andobservations.

4. Select, identify and remove required test specimens.5. Test and evaluate specimens.6. Review test results for compliance with applicable code requirements.7. Release approved procedure for production.8. Quality individual welders in accordance with this procedure.9. Monitor production welding for procedure compliance.


11/50




12/50




13/50



ASME Section IX - Welder Qualification

Establishes Skill

Essential Variables

Position

Joint Configuration

Electrode Type and Size

Process

Base Metal Thickness

Technique


14/50



General Sequence for Welder Qualification Testing

1. Identity essential variables.2. Check equipment and materials for suitability3. Check test coupon configuration and position.4. Monitor actual welding, to ensure that is complies with applicable welding procedure.5. Select, identify and remove required test specimens.6. Test and evaluate specimens.

7. Complete necessary paperwork.8. Monitor production welding.


15/50



ASME SECTION IX WELDING PRACTICE QUESTIONS:

1. The purpose of the WPS and PQR is to determined that:

1. the welder is qualified2. the base metals are strong enough3. the weldment has the desired properties4. the skill of the welder

2. The WPS lists:

1. nonessential variables2. essential variables

3. supplementary essential variables if required4. all of the above

3. The PQR must list:

1. essential variables and supplementary essential variables when notch toughness isrequired

2. nonessential variables3. welder qualification variables4. all of the above

4. What is the earliest Edition of Section IX recognized by the current edition?

1. 19582. 19923. 19874. 1962

5. New Welding Procedure Specifications must meet the ____________ Edition andaddenda of Section IX.

1. 1962

2. current (latest mandatory)3. Inspector4. All of the above

6. Each ______________ shall conduct the tests required by Section IX to quality theWPSs used during the construction, alteration, or repair.

1. Welder or welding operator2. Manufacturer or contractor3. Inspector4. All of the above


16/50



7. The records of procedure, welder and welding operator qualification must be available tothe ________________.

1. Manufacturer or Contractor2. Welder3. Authorized Inspector4. Foreman

8. A welder qualifying with a groove weld in plate in the 4G position is qualified to weldgroove welds in plate and pipe over 24 O.D. in the ______________ positions.

1. Overhead2. Flat and horizontal

3. Flat and overhead4. Horizontal

9. A welder qualifying with the plate fillet welds in the 3F and 4F positions is qualified toweld groove welds in plate in the ________________ positions.

1. Flat only2. Flat and horizontal3. Flat and vertical4. None of the above

10.A welder qualifying by making a groove weld on pipe with an O.D. of 3/4" in the 5Gposition is qualified to weld groove welds in:

1. 1/2" O.D. Pipe in the overhead position2. 6 O.D. Pipe in the vertical position3. 3/4" O.D. pipe in the horizontal position4. None of the above

11.In general, qualification on groove welds also qualifies a welder to make:

1. Stud welds

2. Overhead welds3. Fillet welds4. All of the above

12.Charpy V-notch tests are performed to determine a weldments

1. Tensile strength2. Ductility3. Notch toughness4. All of above


17/50



13.A welder making a groove weld using the SAW process on P1 materials may be qualifiedusing radiography.

1. True2. False

14.When a tensile specimen breaks in the metal outside of the weld or fusion line, thestrength recorded may be _______________ below the specified tensile and be accepted.

1. 3.5%2. .5%3. 5%4. All of the above

15.Guided-bend specimens shall have no open defects in the weld or heat effected zoneexceeding ____________ measured in any direction on the convex surface of the

specimen after bending.

1. 1/162. 3/323. 1/84. None of the above

16.When using radiographs to qualify welders, the acceptance standards used are found in:

1. ASME Section V2. ASME Section IX3. ASME Section VIII4. The referencing code

17.A WPS must describe:

1. Essential variables2. Nonessential variables3. Supplementary essential variables when required for notch toughness

4. All of the above

18.A PQR must describe:

1. Nonessential variables2. Essential variables3. Results of Welder Qualification tests4. Project description & NDE methods


18/50



19.The ____________________ must certify the PQR as accurate.

1. Inspector2. Manufacturer or contractor3. Welder4. All of the above

20.For the SMAW process ___________________ is an essential variable for the WPS.

1. Groove design2. Post Weld heat treatment (PWHT)3. Roof spacing4. Method of cleaning

21.For the SAW process ________________ is an essential variable for the WPS.

1. Supplemental powdered filler metal (if used)2. Filler metal diameter3. Preheat maintenance4. Addition or deletion of peening

22.The basic purpose of testing a welder is to establish the welders ______________.

1. Knowledge of welding requirements

2. Ability to deposit sound weld metal3. mechanical ability to operate equipment4. General attitude toward welding inspectors

23.The record of a welders performance tests is called a ________________.

1. PQR2. WQR3. WPS4. WPQ

24.if a welder qualified with the manual SMAW process on Jan. 1, 1997 and last weldedwith manual SMAW on March 15, 1997, would he still be qualified on October 7, 1997?

1. Yes2. No


19/50



25.A welder qualifying with the SMAW process with a double welded groove weld isqualified to weld.

1. Without backing2. With all base metals3. With backing only4. With P1 backing only

26.Immediate retests of welders qualifications coupons __________________.

1. shall use the same method2. May use any method3. Are not allowed

4. Required Inspector approval

27.Welder performance qualification records must describe all the _____________ variablesspecified.

1. Essential & nonessential2. Nonessential3. Essential4. Brazing

28.A welder depositing 1/2 of weld metal in three layers in a groove weld with the SMAWprocess is qualified to deposit up to __________________ of weld metal.

1. 82. 13. Max to be welded4. 1/2"

29.P numbers are used to designate groups of

1. Electrodes2. Flux3. Base metals

4. Joints

30.A welder qualifying with P-No.21 is qualified to weld

1. P-1 P-11 to P-1 P-112. P-8 P83. P-21 P-25 to P-21 P-254. P21 to P21 only


20/50



31.Section IX groups welding electrodes by

1. AWS class2. ASME specification3. SFA4. F number

32.Ferrous weld metal chemical composition may be designated using

1. P number2. Welder I.D.3. A number4. page number

33.For welder qualification with the SMAW process _________________ is an essentialvariable.

1. Base metal thickness2. Peening3. P-number4. Electrode diameter

34.Each welder must be assigned a(n)

1. P number2. Unique identifier3. Hood & gloves4. Inspector

35.A welder qualification coupon welded in the 2G position of 5/16 thick plate materialmust have how many root and face bends?

1. 2 1 each2. 4 2 each3. 6 2 face and 4 root

4. 8 4 each

36.A WPS shall have:

1. the welder referenced.2. the PQR referenced.3. the NACE referenced.4. the PDQ referenced.


21/50



37.Welding in the 1G position qualifies a welder in what position?

1. horizontal2. vertical3. flat4. overhead

38.Which of the following is an essential variable for qualification of an SMAW weldingprocedure?

1. F number2. joint design3. diameter of the electrode

4. pipe diameter39.A welder may be qualified by RT if:

1. The first 3 of the first production weld is radiographed.2. the first production weld passes mechanical tests.3. If the first production weld passes mechanical tests.4. If the first production weld is passes by MT examination.

40.A welder may be qualified using RT in these processes except for _______________.

1. GMAW (short-circuiting mode)

2. GMAW (pulsed-arc)3. GMAW (spray-arch)4. SMAW


22/50



ASME SECTION IX ANSWER KEY

1. 3,QW-100.1

2. 4,QW-100.1

3. 1,QW-100.1

4. 4,QW-100.3

5. 2,QW-100.3

6. 2,QW-103

7. 3,QW-103

8. 3,QW-461.9

9. 4,QW-461.9

10. 2,QW-461.9 & QW-452.3

11. 3,QW-30312. 3,QW-171

13. 1,QW-304

14. 4,QW-153

15. 3,QW-163

16. 2,QW-191

17. 4,QW-200.1

18. 2,QW-200.2

19. 2,QW-200.2

20. 2,QW-253

21. 1,QW-254

22. 2,QW-100.2 & QW-301.1

23. 4,QW-300.3 & QW-301.4

24. 2,QW-322.1

25. 3,QW-402.4 & QW-310.2

26. 1,QW-321

27. 3,QW-301.4

28. 3,QW-452.1

29. 3,QW-420

30. 3,QW-423.1

31. 4,QW-431

32. 3,QW-441

33. 3,QW-353

34. 2,QW-301.335. 1,QW-452.1

36. 2,QW-200.1 (b)

37. 3,QW-303.1 & QW-461.9

38. 1,QW-253

39. 2,QW-304

40. 1,QW-304


23/50



ASME SECTION IX WPS REVIEW AND PRACTICE QUESTIONS

STEP 1: Variables table

The welding process is SMAW therefore the brief of variables used will be those in Table

QW-253.

Look at table QW-253 and check the brief of variables for Base metals (QW-403). Note that

QW-403.8 specifies that change of thickness T qualified is an essential variable therefore

the base material thickness must be addressed on the PQR. When we read QW-403.8 in

section IX we see that it refers us to QW-451 for the thickness range qualified.

Note:

The PQR tells us under Base metals (QW-403) the coupon thickness T = 1 inch QW-451.1 tells us that for a test coupon of thickness - 1 inch the base material

range qualified on the WPS is 3/16 inch to 2T (therefore 2T = 2inches).

The correct answers to the typical question below must therefore be (c)

1. (WPS)The base metal thickness range shown on the WPS

a) Is correct

b) Is wrong it should be 1/16 1

c) Is wrong it should be 3/16 2 (QW 451.1)

d) Is wrong it should be 3/8 1

Look at Table QW-253 and note how QW-404.30 change in deposited weld metal thickness

t is an essential variables (and refers to QW-451 for the maximum thickness qualified)

therefore weld metal thickness must be addressed in the PQR.

Note:

PQR under QW-404 filler states weld metal thickness t = 1 inch

QW-451 states if t in the maximum qualified weld metal thickness = 2T where

T = base metal thickness.

The correct answers to the typical question below must therefore be (d)

2. (WPS)The deposited weld metal thickness

a) Is correct

b) Is wrong it should be unlimited

c) Is wrong it should be 8 maximum

d) Is wrong it should be 2 maximum (QW-451.1)


24/50



NEXT STEP: Check of type of consumable used

Note how QW-404.4 shows that a change in F-No from table QW-432 is an essentialvariable. This is addressed on the PQR which shows the E7018 electrode as an F-No 4. Table

QW-432 and the WPS both show the E7016 electrode is also an F-No 4.

The correct answers to the typical question below must therefore be (a)

3. (WPS) The electrode change from E7018 on the PQR to E7016 on the WPS

a) Is acceptable (QW-432)

b) Is unacceptable it can only be an E7018 on the WPS

c) Is acceptable provided the electrode is an E7016 A1

d) Is unacceptable the only alternate electrode is an E6010

NEXT STEP: Check of type of preheat

QW-406.1 shows that a decrease of preheat > 100F (55C) is defined as an essential

variable.

The PQR shows a preheat of 200F, which means the minimum shows on the WPS must be

100F and not none as shown.

The correct answers to the typical question below must therefore be (d)

4. (WPS) The preheat should read

a) 60 F minimum

b) 100 F minimum

c) 250 F minimum

d) 300 F minimum

NEXT STEP: Check of tensile test results

Note how the tensile test part of the PQR directs you to QW-150. On reading this section you

will notice that it directs you to tensile test acceptance criteria in QW-153. This says

minimum procedure qualification tensile test acceptance criteria in QW-153. This says

minimum procedure qualification tensile values are found in Table QW/QB-422. Checking

through the figures for material SA-672 Grade B70 shows a minimum specified tensile value

of 70ksi (70000 psi) but the PQR specimen T-2 shows a UTS value of 63969 psi.


25/50




5. (PQR) The tension test results are

a) Acceptable

b) Unacceptable not enough specimens

c) Unacceptable UTS does not meet ASME IX (QW-422-70ksi)

d) Unacceptable Specimen width incorrect

NEXT STEP: Check of bend test results

The PQR directs you to QW-160 for bend tests. For API exam purpose the bend tests will be

transverse tests. Notes these important sections covering bend tests

QW-163 gives acceptance criteria for bend tests

QW-451 contains PQR thickness limits and test specimens requirements,

QW-463.2 refers to performance qualifications

In relation to the question below:

6. (PQR) The bend test results are

a) Acceptable

b) Unacceptable defect size greater than permitted

c) Unacceptable wrong type and incorrect number of specimens (QW-450)

d) Unacceptable incorrect figure number should be QW-463.2

NEXT STEP: Certification of PQRs

The requirements for certifying of PQR is clearly shown in QW-201. Note how it says the

manufacturer or contractor shallcertify that he has qualified

The correct answers to the typical question below must therefore be (a)

7. (PQR)To be code legal the PQR must be

a) Certified (QW-201)

b) Notarized

c) Authorized

d) Witnessed


26/50



NEXT STEP: Check of variables shown on WPS/PQR

Note how QW-253 defines QW-403.9 t-pass as an essential variable. It must therefore beincluded on the PQR and WPS. Note how in the example it has been addressed on the WPS

(under QW-410 technique) but has not been addressed on the PQR

The correct answers to the typical question below must therefore be (b)

8. (WPS/PQR) Essential variable QW-403.9 has been

a) Correctly addressed on the WPS

b) Incorrectly addressed on the WPS

c) Not addressed on the PQR

d) Both b) and c)

NEXT STEP: Variables shown on WPS/PQR

Remember that weld positions are shown in QW-461. They are not an essential variables

however so the weld position is not required to be addressed on the PQR. If it is (optionally)

shown on he PQR it need to be checked to make sure it is correct. In this case the position

shown refers to the test position of plate, rather than pipe.


9. (PQR) The position of the groove weld is

a) Acceptable as shown

b) Unacceptable it is an essential variable not addressed

c) Unacceptable position shown is not for pipe (QW-461.4)

d) Both b) and c)

NEXT STEP: Variables shown on WPS/PQR

For SMAW, the type of weld bead used is not specified under QW-410 as an essential

variable. This means it is a non essential variable and is not required in the PQR (but can be

included by choice remember). QW-200. 1c permits changes to non essential variables of a

WPS as long as it is recorded. It is therefore acceptable to specify string bead in the PQR but

recorded it as string and weave in the WPS.


27/50



The correct answers to the typical question below must therefore be (b)

10. (PQR/WPS) PQR shows string beads but WPS shows both string and weave beads. This is:

a) Unacceptable does not meet code requirements

b) Acceptable meets code requirements (Non Ess variable QW200.1c)

c) Acceptable if string beads are only used on the root

d) Acceptable if weave beads are only used on the cap


28/50



QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECTIONS (WPS)

(See Qw-200.1, Section IX, ASME Boiler and Pressure Vessel Code)

Company Name__________TWI_________________________By________P.PAUL_________________________Welding Procedure Specification No.___SMAW-01___Date__20/08/2007__Supporting PQR No. (s)___SMAW-01____Revision no. ________0________Date_____20/08/2007______

Welding Process (es) _________SMAW_______________Type (s) __________Manual____________________(automatic, Manual, Machine, or Semi-Auto)

JOINTS (QW-402) DetailsJoint Design________Single Vee Butt________________Backing (Yes)__________________(No)______X______Backing Material (Type) ___________________________

(Refer to both backing and retainers)

Metal Nonfusing MetalNonmetalinnic Other

Sketches, Production Drawings, Weld Symbols or WrittenDescription should show the general arrangement of he partsTo be welded. Where applicable, the root spacing and the detailsof weld groove may be specified.

(at the option of the Mfgr. Sketches may be attached to illustrateJoint design, weld layers and bead sequence, e.g., for notchToughness procedures, for multiple process procedures, etc.)

__________________________________________________________________________________________

*BASE METALS(QW-403)P-No.___1___Group No.___2___to P-No.______1_______Group No. __________2____________________

ORSpecification type and grade ___________________________________________________________________To Specification type and grade_________________________________________________________________

ORChem. Analysis and Mech. Prop.________________________________________________________________To chem. Analysis and Mech Prop.______________________________________________________________Thickness range:Base Metal: Groove___________1/16 2______________Fillet_________________________________Pipe Diameter range: Groove ________All_________________ Fillet _________________All________________Other_____________________________________________________________________________________

*FILLER METALS (QW-404)

Spec. No. (SFA) SFA 5.1

AWS No. (Class) E7016

F-No. 6A-No 4

Size of filler metals All

Weld Metal

Thickness Range

Groove All

Fillet All

Electrode-Flux (Class) N/A

Flux Trade Name N/A

Consumable Insert N/A

Other

* Each base metal-filler metal combination should be recorded individually.


29/50


30/50


31/50



QW-483 (Back)PQR No.__SMAW 1

Tensil e Test (QW-150)

Specimen No. Width Thickness AreaUltimate Total

Load IbUltimate Units

Stress Psi

Type ofFailure &Location

T - 1 0.750 0.985 0.7387 54100 73236 BF/WM

T - 2 0.751 0.975 0.6253 40000 63969 BF/WM

Guided-Bead Tests (QW-160)

Type and Figure No. Result

QW-462.2 - FACE Opening 1/16 long - Acceptable

QW-462.2 - ROOT Acceptable

Toughness Tests (QW-170)

Impact Values

SpecimenNo

NotchLocation

SpecimenSize

TestTemp.

Drop WeightBreak(Y/N)

Comment: ____________________________________________________________________________________

Fillet-Weld Test (QW-180)

Result Satisfactory: Yes___________No___________Penetration into Parent Metal: Yes_________No__________

Macro Results_________________________________________________________________________________

Other TestsType of Test____________________________________________________________________________________Deposit Analysis________________________________________________________________________________Other_________________________________________________________________________________________

.

Weldders Name______Steve Francis_______Clock No.________________Stamp No._______SF3_____________Tests conducted by______Testhouse_____________Laboratory Test No._________TH 001__________________We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested inaccordance with the requirements of Section IX of the ASME Code.

Manufacturer_______________TWI______________

Date__________20/07/07___________________ By___MikeTrinidad_______

(Detail of record of tests are illustrative only and may be modified to conform to the type and number of tests required by theCode)


32/50



Please Refer to SAW-02 WPS for questions 9 to 18.

9. (WPS/PQR) An essential variable not addressed on the PQR or WPS is

a) QW-403.9

b) QW-403.13

c) QW-404.36

d) All essential variables have been addressed

10. (WPS) The deposited weld metal thickness range shown

a) Is correct

b) Is beyond the range permitted by the code

c) Should be 4 max

d) None of the above

11. (WPS) The SFA classification for the filler metal shown is

a) 5.7

b) 5.17

c) 5.20

d) 5.30

12. (WPS) The pipe diameter range listed on the WPS

a) Is incorrect

b) Is acceptable

c) Should be 24 max


13. (PQR/WPS) PWHT shown on the PQR and WPS is

a) Incorrect, all codes require PWHT at this thickness

b) Incorrect, as the PQR should have PWHT values filled in

c) Incorrect, the WPS should specify a PWHT temp for production welds

d) Acceptable it is correctly addressed


33/50




a) Sufficiently strong for code compliance

b) Not sufficiently strong for code compliance

c) 10% over rated based metal UTS and therefore out of code compliance



a) Acceptable

b) Unacceptable insufficient specimen width

c) Unacceptable multiple specimens not allowed for 1 thickness welded

d) Unacceptable insufficient number of specimens

16. (PQR) the PQR

a) Need not be signed to be properly certified

b) Must be signed by the Managing Director

c) Must be signed to be properly certified


17. (PQR) Bend test results are


b) Unacceptable incorrect type of specimens tested

c) Unacceptable incorrect figure number quoted

d) Unacceptable not enough specimens tested

18. (PQR) An essential variable(s) incorrectly omitted from the PQR is

a) QW-404.25

b) QW406.1

c) QW-407

d) QW-404.34


34/50



QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECTIONS (WPS)

(See Qw-200.1, Section IX, ASME Boiler and PressureVessel Code)

Company Name____________TWI_____________________By____________P.PAUL_______________________Welding Procedure Specification No.___SAW-02_____Date___20/08/2007___Supporting PQR No. (s)____SAW-02___Revision no. ____SAW_______Date______________________

Welding Process (es) __________________________________Type (s) _______Machine____________________(automatic, Manual, Machine, or Semi-Auto)

JOINTS (QW-402) DetailsJoint Design________Double Vee Groove________________Backing (Yes)_______X_________(No)__________________Backing Material (Type) _________Weld metal____________


Metal Nonfusing MetalNonmetalinnic Other



__________________________________________________________________________________________

*BASE METALS(QW-403)

P-No.___1___Group No.___1____to P-No.______1________Group No. _____________1_____________OR

Specification type and grade __________________SA134 SA285 C__________________________________To Specification type and grade________________SA134 SA285 C__________________________________

ORChem. Analysis and Mech. Prop.________________________________________________________________To chem. Analysis and Mech Prop.______________________________________________________________Thickness range:Base Metal: Groove__________3/16 2____________Fillet___________________________________Pipe Diameter range: Groove ______________All__________________ Fillet ____________________________Other_____________________________________________________________________________________



AWS No. (Class) F7A-EM12

F-No. 6A-No 1

Size of filler metals 1/8 1/4

Weld Metal

Thickness Range

Groove 2 max

Fillet N/A

Electrode-Flux (Class) F7A2 (neutral)

Flux Trade Name Lincoln


Other No supplemental powder



35/50



QW-482 (Back)

WPS No.__SAW-02___Rev__0___

POSITIONS (QW-405Position (s) of Groove___________1G________________Welding Progression: Up_________Down_______________Position (s) of Fillet_____________None_______________

POSTWELD HEAT TREATMENT (QW-407)TemperatureRange_____________None__________________TimeRange_____________________________________

PREHEAT (QW-406)Preheat Temp. Min _____________60F_________________Interpass Temp. Max____________650Max__________________Preheat Maintenance____________None________________(Continuous or special heating where applicable should berecorded)

GAS (QW-408)Percent Composition

Gas (es) (Mixture) FlowRateShielding ___None___ _________

__________Trailing ___None___ _________

__________

Backing ___None___ ___________________

ELECTRICAL CHARACHTERISTICS (QW-409)Current AC or DC________DC________Polarity____Reverse______

Amps (Rang)______300 - 400__Vots (Range)_____34-40_______(amps and volts range should be recorded for each electrodeSize, position, and thickness, etc. This information may beListed in a tabular form similar to that shown below)

Tungsten Electrodes Size and Type________________N/A_____________________________________________________(Pure Tungsten, 2% Thoriated, etc.)

Mode of Metal Transfer for GMAW_________________N/A_____________________________________________________(spray arc, short circuiting arc, etc.)

Electrode Wire feed speed range___________________60 -100 IPM_____________________________________________

TECHNIQUE (QW-410)String or weave Bead__________________String_____________________________________________________________Orifice or Gas Cup Size___________________________________________________________________________________Initial and Interpass Cleaning (Brushing, Grinding, etc.)_______________Brushing, grinding____________________________

______________________________________________________________________________________________________Method of Back Gouging________________Air carbon arc_______________________________________________________Oscillation____________________________None_____________________________________________________________Contact Tude to Work Distance___________1/8 ___________________________________________________________Multiple or Single Pass (per side)__________Multiple pass_______________________________________________________Multiple or single Electrodes______________Single_____________________________________________________________Travel Speed (Range)___________________27 40 IPM________________________________________________________Peening______________________________Not Allowed________________________________________________________Other__________________________________________________________________________________________________

____________________________________________________________________________________________________________________________________________________________________________________________________

Filler Metal Current

WeldLayer (s)

Process

Class Dia TypePolar

AmpRange

VoltRange

TravelSpeedRange

Other(e.gRemarks,

Comments, Hotwire Addition,

Technique, TorchAngle, Etc


36/50



QW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORDS (PQR)(See Qw-200.2, Section IX, ASME Boiler and Pressure Vessel Code)

Record Actual Conditions Used to Weld Test Coupon

Company Name______________TWI_______________________________________________________________Procedure Qualification Record No.______________SAW-02________________ Date_______20/07/07__________WPS No._______________SAW-02________________________________________________________________Welding Process (es)___________SAW____________________________________________________________Types (automatic, Manual, Machine, or Semi-Auto)__________Manual_________________________________________

JOINTS (QW-402)

Groove Design of Test Coupon(For combination qualifications, the deposited weld metal thickness shall recorded for each filler metal or process used)

POSTWELD HEAT TREATMENT( QW-407)Temperature ______None____________________Time _____________None____________________Other_____________________________________

___________________________________________________________________________________________________________________________

BASE METALS (QW-403)Material Spec._________SA-134________________Type of Grade_______SA285 GrC______________P-No_____1________to P-No._______1_________Thickness of test coupon ____________1________Diameter of Test Coupon__________24_____Other_____________________________________

_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


Gas(es) (Mixture) Flow RateShielding __None___ ________ _________Trailing __None___ ________ _________Backing __None___ ________ _________

FILLER METALS (QW-404)SFA Specification____5.7______

AWS Classification__F7A-EM12___Filler Metal F-No.______6______Weld Metal Analysis A-No.__1___Size of Filler Metal_____1/8____Other___No pass greater than ____

_____________________________Weld Metal Thickness_____1___

________________________________________________________________________________________________

ELECTRICAL CHARACTERISTCS (QW-409)

Current _______Direct______________________Polarity _______Reverse____________________

Amps______100________Volts_______________Tungsten Electrode Size ____________________Other____________________________________

________________________________________________________________________________

POSITION (QW-405)Position of Groove_______________1G_________Weld Progression (Uphill, Downhill)_____Flat____Other_____________________________________

__________________________________________

PREHEAT (QW-406)Preheat Temp__________60F min_____________Interpass Temp_________650F max___________

Other_____________________________________

TECHNIQUE (QW-410)Travel Speed_______________30 IPM__________String or Weave Bead________ String___________Oscillation__________None____________________Multipass or Single Pass(per side)____multiple____Single or Multiple Electrodes______Single________Other_____________________________________

____________________________________________________________________________________


37/50


38/50



Please refer to GMAW-03 WPS for questions 19 - 28

19. (WPS) The base material thickness range shown;

a) Is correct

b) Should be 3/16 4

c) Should be 3/16 8 max

d) Should be 3/16 2

20. (WPS) The deposited weld metal thickness range

a) Is correct

b) Is beyond the range permitted by the code

c) Is acceptable if impact testing is carried out


21. (WPS) The fillet metal shown is

a) Acceptable

b) Unacceptable ER70S-2 was qualified but ER 70S-7 is on the WPS

c) Unacceptable electrode should be 6010 on WPS

d) Correct c and d answers

22. (WPS) The mode of metal transfer is

a) Unacceptable for that qualified on the PQR

b) Is acceptable

c) Unacceptable-Should be pulsed

d) Unacceptable Should be spray

23. (WPS) The gas shielding is

a) Acceptable

b) Unacceptable composition has changed

c) Not required for GMAW



39/50



24. (PQR) The 3G position of the test pipe indicates it was

a) Welded in the horizontal position

b) Welded in the overhead position

c) Welded in the 45 fixed position

d) None of the above this is not a pipe test position


a) Acceptable

b) Unacceptable-insufficient strength

c) Unacceptable-not enough tests for thickness welded

d) Unacceptable-calculations incorrect

26. (PQR) Bend test results are


b) Unacceptable-incorrect type of specimens tested

c) Unacceptable results do not meet code

d) Unacceptable not enough specimens tested

27. (PQR) A non-essential variable incorrectly omitted from the PQR is

a) Peening

b) Electrode spacing

c) Gas nozzle size

d) None-non-essential variables do not have to be included in the PQR

28. (PQR) An essential variable(s) incorrectly omitted from the PQR is

a) QW-403.9

b) QW404.24 and QW-404.27

c) QW-402.1

d) Both a) and b)


40/50



QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECTIONS (WPS)(See Qw-200.1, Section IX, ASME Boiler and Pressure Vessel Code)

Company Name__________TWI___________________By____________P.PAUL___________________________Welding Procedure Specification No.____GMAW-03__Date_20/08/2007__Supporting PQR No. (s)____GMAW-03____Revision no. _________________Date______________________

Welding Process (es) __________GMAW_________________Type (s) ______Semi-auto____________________(automatic, Manual, Machine, or Semi-Auto)

JOINTS (QW-402) DetailsJoint Design________Single Vee Groove______________Backing (Yes)__________________(No)_____X________Backing Material (Type) ___________none____________


Metal Nonfusing Metal

Nonmetalinnic Other



__________________________________________________________________________________________

*BASE METALS(QW-403)P-No.__1___Group No.____1____to P-No._________1______Group No. __________1____________________

OR

Specification type and grade ______________SA-333_______________________________________________To Specification type and grade____________SA-333_______________________________________________

ORChem. Analysis and Mech. Prop.________________________________________________________________To chem. Analysis and Mech Prop.______________________________________________________________Thickness range:Base Metal: Groove_______1/16 2________________Fillet___________________________________Other_____________________________________________________________________________________



AWS No. (Class) E70S-7

F-No. 6

A-No 1

Size of filler metals 1/8 - 3/32

Weld Metal

Thickness Range

Groove Unlimited

Fillet Unlimited


Flux Trade Name N/A


Other



41/50



QW-482 (Back)

WPS No.__GMAW-03___Rev__0___

POSITIONS (QW-405Position (s) of Groove___________All________________Welding Progression: Up____X____Down _______________Position (s) of Fillet_____________All_______________

POSTWELD HEAT TREATMENT (QW-407)TemperatureRange_____________None__________________Time Range_____________________________________

PREHEAT (QW-406)Preheat Temp. Min _____________60F_________________Interpass Temp. Max____________650Max__________________Preheat Maintenance____________None________________(Continuous or special heating where applicable should be recorded)


Gas (es) (Mixture) Flow RateShielding ___Ar/CO2___ __80/20__ _35CFH__Trailing ___None___ _________ _______Backing ___None___ _________ _______

ELECTRICAL CHARACHTERISTICS (QW-409)

Current AC or DC________DC________Polarity____Reverse______Amps (Rang)______120 - 200__Vots (Range)_____14-18_______(amps and volts range should be recorded for each electrodeSize, position, and thickness, etc. This information may beListed in a tabular form similar to that shown below)

Tungsten Electrodes Size and Type________________N/A_____________________________________________________(Pure Tungsten, 2% Thoriated, etc.)

Mode of Metal Transfer for GMAW_________________Short circuiting____________________________________________(spray arc, short circuiting arc, etc.)

Electrode Wire feed speed range__________________________________________________________________________

TECHNIQUE (QW-410)String or weave Bead__________________String_____________________________________________________________Orifice or Gas Cup Size___________________________________________________________________________________

Initial and Interpass Cleaning (Brushing, Grinding, etc.)_______________Brushing, grinding__________________________________________________________________________________________________________________________________Method of Back Gouging________________None_______________________________________________________Oscillation____________________________Reverse____________________________________________________________Contact Tude to Work Distance___________ ___________________________________________________________Multiple or Single Pass (per side)__________Multiple pass_______________________________________________________Multiple or single Electrodes______________Single_____________________________________________________________Travel Speed (Range)___________________10 15 IPM________________________________________________________Peening ______________________________Not Allowed________________________________________________________Other__________________________________________________________________________________________________

____________________________________________________________________________________________________________________________________________________________________________________________________


WeldLayer (s)

ProcessClass Dia Type Polar

AmpRange

VoltRange

TravelSpeedRange

Other(e.gRemarks,Comments,

Hot wireAddition,Technique,Torch Angle,Etc)


42/50





Company Name___________TWI__________________________________________________________________Procedure Qualification Record No.__________GMAW-03_____________________ Date ________20/07/07_______WPS No.___________GMAW-03____________________________________________________________________Welding Process (es)______________GMAW_________________________________________________________Types (automatic, Manual, Machine, or Semi-Auto)__________Semi-Auto______________________________________

JOINTS (QW-402)

Groove Design of Test Coupon

(For combination qualifications, the deposited weld metal thickness shall recorded for each filler metal or process used)

POSTWELD HEAT TREATMENT( QW-407)Temperature _______None____________________Time _____________None____________________Other_____________________________________

___________________________________________________________________________________________________________________________

BASE METALS (QW-403)Material Spec._______SA333__________________Type of Grade_________6___________________P-No _____1__________to P-No._______1______Thickness of test coupon _________2__________Diameter of Test Coupon___________48________Other_____________________________________

____________________________________________________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________


Gas(es) (Mixture) Flow RateShielding __CO2___ __100%_ _20 CFH__Trailing __None___ ________ _________Backing __None___ ________ _________

FILLER METALS (QW-404)SFA Specification__5.18_______

AWS Classification___E70S-2___Filler Metal F-No.______6______Weld Metal Analysis A-No.___1__Size of Filler Metal_____1/8____Other______________________

___________________________Weld Metal Thickness___2____

________________________________________________________________________________________________


Current_________Direct_____________________Polarity_________Reverse____________________

Amps________130_________Volts_____17_____Tungsten Electrode Size __________N/A________Other____________________________________

________________________________________________________________________________

POSITION (QW-405)Position of Groove_________3G________________Weld Progression (Uphill, Downhill)___Downhill____Other_____________________________________

__________________________________________

PREHEAT (QW-406)Preheat Temp____________60________________Interpass Temp___________650_______________Other_____________________________________

__________________________________________

TECHNIQUE (QW-410)Travel Speed_____________12 IPM____________String or Weave Bead_______Weave___________Oscillation________________None____________Multipass or Single Pass(per side)___multiple____Single or Multiple Electrodes________Single______Other_____________________________________

____________________________________________________________________________________

__________________________________________


43/50



QW-483 (Back)PQR No.______GMAW-03__

Tensi le Test (QW-150)

Specimen No. Width Thickness AreaUltimate

Total LoadIb

UltimateUnit Stress

Psi


T 1 0.750 1 0.750 53200 70933 DF/HAZ

T 1 0.751 1 0.751 52300 69640 DF/HAZ



QW-462.2 FACE 1 Pass

QW-462.2 FACE 2 PassQW-462.2 ROOT 1 Pass

QW-462.2 ROOT 2 Pass


Impact ValuesSpecimenNo.

NotchLocation

SpecimenSize

TestTemp. Ft. ibs % Shear Mils

Drop Weight Break(Y/N)

Comment: ____________________________________________________________________________________


Result Satisfactory: Yes___________No___________Penetration into Parent Metal: Yes_________No__________

Macro Results_________________________________________________________________________________


.

Weldders Name______STEVE FRANCIS________Clock No._____________Stamp No._______SF3___________Tests conducted by________Testhouse_____________Laboratory Test No._________TH-002________________We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance withthe requirements of Section IX of the ASME Code.

Manufacturer________________TWI________________

Date__________20/07/07_____________________ By_________MikeTrinidad___

(Detail of record of tests are il lustrative only and may be modified to conform to the type and number of tests required by the Code)


44/50



Please refer to GTAW-04 WPS for questions 29-40

29. (WPS) The base material thickness range shown;

a) Is correct

b) Should be 1/16 1"

c) Should be 3/16 1/2"

d) Should be 3/16 1/4

30. (WPS) The shielding gas on the WPS

a) Is correct

b) Should be 95% argon 5% H2

c) Should be shown as 20-30 CFH

d) Both b) and c)

31. (WPS) The correct preheat on the WPS is

a) Correct as shown

b) 100 F minimum

c) 250 F maximum

d) 150 F minimum

32. (PQR/WPS)The supporting PQR

a) Is properly identified and traceable to the WPS

b) Is not properly identified and not traceable to the WPS

c) Is not traceable to the WPS

d) Must be PWHTd per ASME requirements

33. A drawing or sketch of the weld joint

a) Must be shown on the PQR

b) Must be shown on the PQR and WPS

c) Must be shown on the WPS but not the PQR



45/50



34. (PQR) The tension tests are

a) Full size pipe specimens

b) Full size reduced section specimens

c) Reduced section turned specimens

d) Not required for this PQR


a) Acceptable

b) Unacceptable-insufficient strength

c) Unacceptable-due to size of the specimens (section t)

d) Unacceptable-calculation incorrect

36. (PQR) Bend tests shown on the PQR

a) Are acceptable as shown

b) Are insufficient in number

c) Are the wrong type

d) Both b) and c)

37. (PQR) Bend test shown on the PQR

a) Are acceptable as shown

b) Do not meet ASME IX defect acceptance requirements

c) Should be listed with each specimens length

d) Need PWHT after bending

38. (PQR) The PQR is

a) Unacceptable it was welded in 2G position but WPS states all positions

b) Unacceptable it is not certified

c) Unacceptable it has a backing gas not required on WPS

d) All of the above


46/50


47/50



QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECTIONS (WPS)(See Qw-200.1, Section IX, ASME Boiler and Pressure Vessel Code)

Company Name_______________TWI_____________________By_________P.PAUL_______________________Welding Procedure Specification No.___GTAW-04___Date__20/08/2007__Supporting PQR No. (s)____GTAW-04____Revision no. ________0________Date_____20/07/2007_______

Welding Process (es) __________GTAW__________________Type (s)_______Manual_____________________(automatic, Manual, Machine, or Semi-Auto)

JOINTS (QW-402) DetailsJoint Design ______________All____________________Backing (Yes)_________X________(No)_____X________ SEE PRODUCTION DRAWINGSBacking Material (Type) _______Carbon Steel____________


Metal Nonfusing Metal Nonmetalinnic Other



__________________________________________________________________________________________

*BASE METALS(QW-403)P-No.__4___Group No.____1____to P-No._______4________Group No. ____________1__________________

ORSpecification type and grade ___________SA250 T11_______________________________________________To Specification type and grade_________SA250 T11_______________________________________________

ORChem. Analysis and Mech. Prop.________________________________________________________________To chem. Analysis and Mech Prop.______________________________________________________________Thickness range:Base Metal: Groove_________1/16 1/2"______________Fillet____________All___________________Pipe diameter range: Groove __________1/16 1/2___________Fillet ____________All_____________Other_____________________________________________________________________________________



AWS No. (Class) ER70S2

F-No. 6

A-No 3

Size of filler metals 1/16 1/8

Weld Metal

Thickness Range

Groove 1/2 max

Fillet All


Flux Trade Name N/A

Consumable Insert YES

Other



48/50



QW-482 (Back) WPS No.__GTAW-04_Rev_0_

POSITIONS (QW-405Position (s) of Groove___________All_________________Welding Progression: Up____X____Down_______________Position (s) of Fillet___________All____________________

POSTWELD HEAT TREATMENT (QW-407)TemperatureRange_______1100F_____________________Time Range_________1 Hr perinch_____________________

PREHEAT (QW-406)Preheat Temp. Min ______________60F_______________Interpass Temp. Max_____________650F max___________Preheat Maintenance_____________none_______________(Continuous or special heating where applicable should be recorded)


Gas (es) (Mixture) FlowRateShielding __Argon___ __99.9%_

____45_____Trailing __None___ _________

___________

Backing __None___ ____________________

ELECTRICAL CHARACHTERISTICS (QW-409)Current AC or DC______DC__________Polarity___Reverse_____

Amps (Rang)______110-160________Vots (Range)____12-17____(amps and volts range should be recorded for each electrodeSize, position, and thickness, etc. This information may beListed in a tabular form similar to that shown below)

Tungsten Electrodes Size and Type__________________________N/A_____________________________________________(Pure Tungsten, 2% Thoriated, etc.)

Mode of Metal Transfer for GMAW___________________________N/A____________________________________________(spray arc, short circuiting arc, etc.)

Electrode Wire feed speed range_____________________________N/A____________________________________________

TECHNIQUE (QW-410)String or weave Bead _______________________String or weave________________________________________________Orifice or Gas Cup Size_______________________________________________________________________________Initial and Interpass Cleaning (Brushing, Grinding, etc.)_____________Brushing, grinding______________________________

______________________________________________________________________________________________________Method of Back Gouging______________None_______________________________________________________________Oscillation__________________________None________________________________________________________________Contact Tude to Work Distance__________1/2________________________________________________________________Multiple or Single Pass (per side)________Multiple______________________________________________________________Multiple or single Electrodes____________Single_______________________________________________________________Travel Speed (Range)_________________20-30 IPM___________________________________________________________Peening ____________________________Not Allowed_________________________________________________________Other__________________________________________________________________________________________________

____________________________________________________________________________________________________________________________________________________________________________________________________


WeldLayer (s) Process Class Dia

Type Polar AmpRange

VoltRange

TravelSpeedRange

Other(e.g Remarks,Comments, Hot wire

Addition, Technique,Torch Angle, Etc)


49/50





Company Name___________TWI__________________________________________________________________Procedure Qualification Record No.__________GTAW-08________________________________________________WPS No._________________GTAW-04______________________________________________________________Welding Process (es) __________GTAW____________________________________________________________Types (automatic, Manual, Machine, or Semi-Auto) ____________Manual______________________________________

JOINTS (QW-402)

SEE PRODUCTION DRAWINGS

Groove Design of Test Coupon

(For combination qualifications, the deposited weld metal thickness shall recorded for each filler metal or process used)

POSTWELD HEAT TREATMENT( QW-407)Temperature_____1100F___________________Time________1 Hr_________________________Other_____________________________________

___________________________________________________________________________________________________________________________

BASE METALS (QW-403)Material Spec._____SA-250__________________Type of Grade_______T11____________________P-No_______4________to P-No.________4______Thickness of test coupon ____________1/4______Diameter of Test Coupon______2______________Other_____________________________________

__________________________________________________________________________________

_____________________________________________________________________________________________________________________________________________________________________________________________________________


Gas(es) (Mixture) Flow RateShielding __Ar/H2__ _95/5___ _20-30 CFH_Trailing ___N/A__ ________ _________Backing __Argon__ __99.9%_ _10-15 CFH_

FILLER METALS (QW-404)SFA Specification____5.9______

AWS Classification___ER70S-2_Filler Metal F-No._______6_____Weld Metal Analysis A-No.___1__Size of Filler Metal_____1/6___Other______________________

___________________________Weld Metal Thickness___1/4___

________________________________________________________________________________________________


Current _________Direct____________________Polarity _________Straight____________________

Amps________110_________Volts______15____Tungsten Electrode Size _______1/8___________Other____________________________________

________________________________________________________________________________

POSITION (QW-405)Position of Groove__________2G_______________Weld Progression (Uphill, Downhill)______N/A_____Other_____________________________________

__________________________________________

PREHEAT (QW-406)Preheat Temp________250F___________________Interpass Temp _______N/A_______________Other_____________________________________

__________________________________________

TECHNIQUE (QW-410)Travel Speed_____________10 IPM____________String or Weave Bead _____string or weave_____Oscillation_________________________________Multipass or Single Pass(per side)_____multiple___Single or Multiple Electrodes _______Multiple____Other_____________________________________

____________________________________________________________________________________

__________________________________________


50/50


QW-483 (Back)PQR No.____GTAW___

Tensi le Test (QW-150)

Specimen No. Width Thickness AreaUltimate

Total LoadIb

UltimateUnit Stress

Psi


T-1 N/A 0.495 0.190 14000 73684 DF/HAZ

T-2 N/A 0.480 0.180 13700 76111 DF/HAZ



QW-462.2- SIDE 1 Pass

QW-462.2 - SIDE 2 Linear indication - Pass

QW-462.2 SIDE 3 Pass


Impact ValuesSpecimenNo.

NotchLocation

SpecimenSize

TestTemp. Ft. ibs % Shear Mils

Drop Weight Break (Y/N)

Comment: ____________________________________________________________________________________


Result Satisfactory: Yes ___________No__________ Penetration into Parent Metal: Yes _________No_________Macro Results_________________________________________________________________________________


.

Weldders Name__________Steve Francis_______ Clock No. ________________Stamp No.__________________Tests conducted by _________Testhouse_____________ Laboratory Test No .________TH - 004_____________We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance withthe requirements of Section IX of the ASME Code.

Manufacturer _________ANZ.LTD______________________

Date____________20/07/07___________________ By______________________________________

(Detail of record of tests are il lustrative only and may be modified to conform to the type and number of tests required by the Code)