A comparison of ISO 15614 Part 1 and ASME IX

The question is sometimes asked Can I use our existing welding procedure qualifications? where the qualification specification required by the contract is one that has not previously been used by the organisation This is particularly relevant when substantial costs and!or delays will be incurred if re"qualification of the welding procedures is necessary The two most frequently encountered specifications are I#$ %&'%( )art % and *#+, I- and whilst these are written with the same purpose .that of giving assurance that a welding procedure will provide the desired /oint properties0 there are ma/or differences between the two specifications that mean that they are not equivalent It will not be possible in this short article to cover every welding variable and its range of approval in the two specifications 1here compliance is required then reference +2#T be made to the appropriate specification 1ith respect to *#+, I- the specification requirements can be applied in two ways3 *#+, intent and *#+, stamp If the welded item is to be *#+, stamped this can only be done by a manufacturer who has a quality system accredited by *#+, and who holds an appropriate stamp4 5 stamp for nuclear components4 2 for unfired pressure vessels4 # for power boilers etc *ll the requirements of the *#+, specifications +2#T be complied with4 even to the extent of dimensions of the mechanical test pieces and the calibration of testing equipment *#+, intent is used where the item is not to be code stamped but is perhaps only designed to the relevant *#+, code and some flexibility is possible with respect to the manufacturing aspects of specification compliance #uch flexibility may allow the manufacturer to submit to the client or inspecting authority procedure qualification records .)670 to I#$ %&'%( )art % for approval that can be shown to be technically equivalent to an *#+, )67 *#+, I- covers the qualification of welders and welding operators4 welding procedures4 bra8ing operatives and bra8ing procedures for the complete range of ferrous and non"ferrous engineering metals .steels4 copper4 nickel4 aluminium4 titanium and 8irconium alloys0 and oxy"gas4 arc4 power beam4 resistance and solid phase welding processes I#$ %&'%( )t% covers the welding procedure qualification of arc and gas welds in steel and nickel alloys only $ther alloys and /oining processes are covered by additional specifications within the I#$ %&'%( series 9oth specifications identify essential variable .although I#$ %&'%( )t% does not describe them as such0 to each of which is assigned a range of approval * change to an essential variable outside of its range of approval requires the welding procedure to be re"qualified *#+, I- in addition identifies supplementary and non"essential variables #upplementary variables are only invoked when toughness requirements are specified by the application

code4 eg *#+, :III or *#+, 9;% ; 5on"essential variables4 as the name suggests4 are those variables that are not regarded as affecting the quality or mechanical properties of the welded /oint and comprise such variables as the weld preparation4 shield gas flow rate4 method of back gouging4 shield gas no88le si8e etc *lthough these variables are non"essential it is a requirement that they should be referenced on the welding procedure It is therefore 5$T acceptable to use a butt welding procedure to specify how a fillet weld should be made I#$ %&'%( )t% does not identify any variables as non"essential3 where a variable is not regarded as significant it is simply not referenced in the specification There are several variables in both specifications where there is no range of approval3 the manufacturer4 the welding process and the application or deletion of post weld heat treatment .)1<T0 for example In order to reduce the amount of qualification testing4 both specifications group alloys of similar characteristics together 6ualifying the welding of one alloy within the group allows the other alloys within the group to be welded *#+, I- assigns the groups numbers with steels being numbered )% to )%&= *ny alloy that does not have a ) number is regarded as unassigned3 a procedure qualification carried out using an unassigned alloy qualifies only that specific designation of alloy 2ntil recently only alloys that complied with the *#+, and!or *#T+ material specifications and!or had a 25# number were assigned ) numbers <owever4 a limited number of ,54 Canadian4 Chinese and >apanese alloys have now been introduced into the list of assigned alloys I#$ %&'%( )t % also groups steel and nickel alloys into families with similar properties but is somewhat less prescriptive than the *#+, code in that4 provided alloys have similar chemical compositions and mechanical properties4 the material specification is not relevant ? for example a plain carbon steel with less than @ A&BC and a minimum specified yield strength less than ('@+)a falls into Croup % irrespective of whether or not it is a pressure vessel or structural steel or supplied in accordance with ,5 or *#T+ material specifications To determine into which group the alloy falls reference should be made to I#$!T7 %&'@D4 the specification that lists both ferrous and non"ferrous alloys and assigns them a group number $ther significant differences between the two specifications with respect to the arc welding processes areE" *#+, I- requires only tensile and bend tests to qualify a butt weld I#$ %&'%( )t% requires a far more extensive test programme of visual inspection4 radiography or ultrasonic examination4 surface crack detection4 tensile and bend tests and macro" examination In certain circumstances Charpy": impact tests and hardness surveys are also required *#+, I- specifies that the tensile strength of the cross /oint tensile specimen shall be at least that of the minimum specified for the parent metal and that bend test coupons should have no discontinuity greater than ;mm I#$ %&'%( )t% has identical requirements for these mechanical tests but in addition specifies an acceptance standard for the non"destructive testing3 impact test results4 when required4 that match the parent material toughness and hardness limits when hardness testing is required I#$ %&'%( )t % requires Charpy": impact testing for steels over %Amm thick when the material specification requires it *#+, requires impact testing only when specified in the application standard This requirement makes heat input a supplementary essential variable in *#+, I- but an essential variable in I#$ %&'%( )t% <ardness testing is required by I#$ %&'%( )t% for all ferritic steels with a specified minimum yield strength greater than AF&+)a * maximum hardness for /oints in

either the as"welded of )1<Td condition is specified *#+, I- does not require hardness testing *#+, I- allows a reduction in preheat of &&$C before requalification is required I#$ %&'%( )t% does not permit any reduction in preheat from that used in the qualification test *#+, allows the maximum interpass temperature to be &&$C above that measured in the qualification test I#$ %&'%( )t % permits no such increase *#+, I- requires pressure containing fillet welds to be qualified by a butt weld procedure qualification test 5on"pressure retaining fillet welds may be qualified by a fillet weld test only I#$ %&'%( )t% requires a fillet weld to be qualified by a butt weld when mechanical properties G are relevant to the application H i e when it is a load carrying fillet weld In addition4 whilst a butt weld will qualify a fillet weld G fillet weld tests shall be required where this is the predominant form of production welding H i e an I#$ compliant welding procedure where the ma/ority of the welding is of load carrying fillet welds must reference both a butt weld and a fillet weld procedure qualification 1eld metal transfer mode4 where relevant4 is an essential variable in both I#$ %&'%( )t% and *#+, I- but the current type is an essential variable in I#$ %&'%( )t% and a supplementary essential variable in *#+, I* change from manual to automatic welding is an essential variable in I#$ %&'%( )t% but a non"essential variable in *#+, I-

1hilst there are several other variables in the two specifications that have substantially different ranges of approval there are many that have ranges that are very similar ? material thickness being but one example This article has highlighted some of the significant differences but to ensure that the welding procedure and its supporting procedure qualification record are compliant the specifications must be referred to The answer to the question posed at the start of this article is therefore ? it depends upon what you can persuade the client and inspecting authority to acceptI