Welder and Procedure Qualification

BY

SRSREDDY, IAU

Definitions

Welding procedure specification [WPS]:

is a written document that provides direction to the welder or welding operator for making production welds in accordance with code requirements. The completed WPS shall describe all the essential , non essential and when required supplementary essential variables for each welding process used in the WPS.

Definitions

Procedure Qualification record [PQR]:

is a record of the weld data used to weld a test coupon. It also contains the test results of the tested specimens. The completed PQR shall document all the essential when required supplementary essential variables for each welding process used during the welding of test coupon. Non essential variables used during the welding of the coupon may be recorded.

Definitions

Welder performance qualification [WPQ]:

is a record of the weld data used to weld a test coupon. It also contains the test results of the tested specimens. The completed WPQ shall document only the essential variables for each welding process used during the welding of test coupon.

A welder or welding operator may be qualified by radiography of a test coupon, radiography of his initial production welding or by bend tests taken from a test coupon

Definitions

Essential variable: are those in which a change, as described in the specific variables, is considered to affect the mechanical properties of the weldment, and shall require requalification of the WPS.

Non essential variables: are those in which a change as described in the specific variables may be made in the WPS with out requalification..

Supplementary essential variables: are required for materials for which other sections specify notch toughness tests and are in addition to the essential variables for each welding process

Definitions

Manual welding: Welding where in entire welding operation is performed and controlled by Hand [Example : SMAW]

Semi automatic welding: Welding with equipment which controls only the filler metal feed. The advance of welding is manually controlled. [Example: MIG, MAG, FCAW]

Definitions

Automatic welding: Welding with equipment which performs the welding operation with out adjustment of controls by a welding operator. The equipment may or may not perform the loading and unloading of the work

Machine welding: Welding with equipment that has controls that are manually adjusted by the welding operator in response to visual observation of the welding with the torch, gun or electrode holder by a mechanical device. [Example – SAW]

Definitions

Welder: One who performs Manual or Semi automatic welding

Welding operator: One who operates Machine or Automatic welding equipment

Definitions

P number: P numbers are assigned to base metals dependent on characteristics such as composition, weldability, and mechanical properties where this logically can be done.

Group number – are assigned additionally to P Numbers to classify the metals for the purpose of procedure qualification where notch toughness requirements are specified.

Definitions

S number: S numbers are assigned to materials that are acceptable for use by the ASME B31 code for pressure piping or by selected boiler and pressure vessel code case , but which are not included within ASME Boiler and pressure vessel code material specifications [Section II].

Qualification using a P number material qualifies corresponding S number materials; Qualification using an S number material qualifies corresponding S number materials but not corresponding P- Number materials ; qualification of welders using a P number material qualifies them to weld on corresponding S- number materials and Vice versa.

Definitions

F number: grouping of electrodes and welding rods is based on essentially on their usability characteristics. This grouping is made to reduce the number of welding procedure and performance qualifications where this can logically be done.

A number: is given based on weld metal analysis for procedure qualification.

Definitions

Position of welding: Flat, Horizotal, Overhead, Vertical

Test positions – see the figs

Procedure Qualification record

Review: Ensure that all essential and supplementary

essential variables of welding process are listed in the PQR format and the actual values are filled.

Check the type and no of tests required as per QW 451 and review test results.

Welding procedure specification

Review: Ensure that all essential, Non essential and

supplementary essential variables [when required] of welding process are listed in the WPS format and the qualified ranges of each variable are listed as per QW 451 based on the approved PQR.

Welder Performance Qualification

Review: Ensure that all essential variables are listed

and filled. Check the type and no of tests required as

per QW 452 and review test results.

Qualification Requirements

END PRODUCT / CODE / STANDARD

SPECIFIED QUALIFICATION REQUIREMENTS

ASMESection I Power Boilers‑

Section III Nuclear Components‑Section VIII Pressure Vessels‑

ASME Sec. IXASME Sec. IXASME Sec. IX

ASMEB3 1.1 Power Piping‑

B31.3 Refinery/Chemical Piping‑B31.4 Liquid Petroleum Transportation ‑

PipingB31.8 Gas Transmission Distribution ‑

Piping

ASME Sec. IXASME Sec. IX

API 1104 or ASME Section IX‑

API 1104 or ASME IX or Appendix A of B31.8API

AWSD 1.1 Structural Code Steel‑ ‑

D1.3 Sheet Steel in Structures‑DIA Structural Code Reinforcing Steel‑ ‑

D3.5 Steel Hull Welding‑

D14.1 Industrial and Mill Cranes‑D14.3 Heavy Equipment‑

D14.4 Machinery Equipment‑

Contained in D 1. 1Contained in D1.3Contained in DIA

U.S. Navy/U.S. Coast Guard/Bureau of Ships Specifications

Contained in D14.1 or may use ASME Section IXContained in D 14.3 except use AWS D 10. 9 for

Pipe/TubeContained in D14.4

Qualification requirement for different codes

Review of PQR, WPS

Review of WPQ

Validity of WPS, PQR and WPQ

WPS, PQR and WPQ made in accordance with the requirements of the 1962 edition or any later edition of ASME Section IX may be used in any construction built to the ASME Boiler and pressure vessel code or the ASME B 31 code for pressure piping.

Qualifications made in accordance with the requirements of the editions of section IX prior to 1962, in which all the requirements of the 1962 edition or later editions are met, may also be used.

Expiration and Renewal of Welder Qualification

The performance qualification of welder or welding operator shall be affected when one of the following conditions occurs:

a) When welder/ welding operator has not welded with a process during a period of 6 months or more, his qualification for that process shall expire ; unless with in the 6 months period prior to his expiration of qualification

1. A welder has welded using a manual or semi automatic welding process that will maintain his qualification for manual and semi automatic welding with that process.

2. A welding operator has welded with a machine or automatic welding process that will maintain his qualification for machine and automatic welding with that process

Expiration and Renewal of Welder Qualification

b) When there is a specific reason to question his ability to make welds that meet the specification , the qualifications that support the welding he is doing shall be revoked. All other qualifications not questioned remain in effect.

Welding repairs in service – Pressure vessels [API 510]

The welding procedures and qualified welders as per ASME Section IX can be used for repair welding.

When preheat or controlled deposition welding methods are used for repair welding, the weld procedures are required to be qualified as per API 510 Cl 7.2.3

Welding repairs in service – Piping

The welding procedures and qualified welders as per ASME B 31.3 or the code to which the piping system was built can be used to perform weld repairs

Applicable Aramco engineering procedures

SAEP 321:specifies the minimum requirements for the testing, certification and registration of Saudi Aramco welders working for Maintenance.

SAEP 323:specifies the minimum requirements for the testing, certification and registration of contract welders and brazers working directly for, and under the supervision of, Saudi Aramco Maintenance.

SAEP 324:specifies the welding requirements for certification review and registration of contract welders that will be used on new projects in Saudi Aramco.

Weld repair rate

SAES-W series standards require that the Contractor review and track project and Welder repair rates daily. PID will monitor and evaluate production weld repair rates and welder performance weekly. The target for maximum project repair rate (calculated on a joint basis) should normally not to exceed 5%.

Thank you