WPS DESIGN using ASME SECTION IX CODE REQUIREMENTS

Politeknik Perkapalan Negeri Surabaya Surabaya, 1 December 2010

By Condro Widiyarto

1. Flow of Welding Procedure Qualification: 2. ASME SECTION IX CODE REQUIREMENTS: 1). Article 1
2). Article 2 3). Article 3 4). Article 4

3. SPECIFIC MATERIAL Overview: 4. WPQT-WPS-PQR: 1). CS With impact requirements

1. FLOW CHART PEMBUATAN KUALIFIKASI PROSEDUR LAS DRAWING STD REFERENCE CUSTOMER SPEC WPQT PELAKSANAAN TEST PROSEDUR LAS PEMBUATAN / MACHINING TEST PIECE TEST LABORATORY
Not ok

Result

PQR

WPS Qualified for product Welder Qualified ( Certificate welder )

1.1 Customer Overview:

Code Requirements:
o International Code: ASME, API, AWS, EN, ETC o Indonesia Code: SII, SNI, ETC

Regulation:
o MIGAS, DEPNAKER, BKI, ETC.

Additional Requirements:
o Customer Data Sheet o Customer Specification

1.2 ASME Code Requirements:

o o o

ASME Section VIII Division 1 to VIII Division 3:

Section VIII Division 1: Rules for Construction of Pressure Vessels Section VIII Division 2: Alternative Rules - Rules for Construction of Pressure Vessels Section VIII Division3: Alternative rules for Construction of High Pressure Vessels

o o o o

ASME Section II Part A, B, C, D: Part A: Ferrous Material Specification Part B: Non Ferrous Material Specification Part C: Specification for Welding Rods, Electrodes and Filler Metals Part D: Properties (Customary)/(Metrics) ASME Section V: Non Destructive Examinations

ASME Section IX: Qualification standard for Welding and Brazing Procedures, Welders, Brazers, and Welding and Brazing Operator o QW- Qualification Welding o QB- Qualification Brazing

2. ASME Section IX Code Requirements:

Part QW:
o o o o

o o o o

Article 1: Welding General Requirements Article 2: Welding Procedure Qualification Article 3: Welding Performance Qualification Article 4: Welding Data
Part QB:
Article 1: Brazing General Requirements Article 2: Brazing Procedure Qualification Article 3: Brazing Performance Qualification Article 4: Brazing Data

Appendices: A to G Index

Section IX Part QW Article-1

Section IX Part QW Article-2

Section IX Part QW Article-1

It is mandatory to read every article of Section IX in order to apply the code rules QW-100.1 Purpose of WPS QW-100.3 Purpose of WPS and WPQ qualified accordance with rules of this section may be used in any construction built to the requirements of the ASME Boiler & PV or the ASME B31 code for pressure piping. QW-120, 130 & QW-132 Test position with written definition & reference to Article IV where of these position to be found QW-141. up to QW-141.5 Explanation of the various test and examination required

Test Position

Section IX Part QW Article-1

QW-142 & QW-143 Special examination for welder & welding operator and QW-144 Visual examination (See QW-194 Visual Inspection Performance). QW-150 For Tension test, QW-160 for guided bend test. Acceptance criteria are listed for each type of test described with one exception being the Notch Toughness test of QW-170 QW-190 Other type test & examination are listed. RT and PT examination referred to Section V article 2 and 6 respectively technique. Acceptance standard QW-191.2 & QW-195.2 respectively must be met the examination

Section IX Article 1: Test/Examination & Acceptance Criteria

Section IX Article 1: Test/Examination & Acceptance Criteria

Section IX Article 1: Test/Examination & Acceptance Criteria

Section IX Article 1: Test/Examination & Acceptance Criteria

Section IX Article 1: Test/Examination & Acceptance Criteria

Section IX Part QW Article-2

3 Types of variable: 1. Essential Variable: Any time an essential variable is changed of the range given in the WPS, the procedure must be re qualified by welding a new coupon and mechanical testing. You must generate a new PQR. 2. Non Essential Variable: Changes in this can be made with out requalification of the WPS, however WPS must be revised to reflect these changes. 3. Supplement Essential variable: Need only be given if the weld must have specific impact properties for low temperature services. If impact test are required they become essential variable.

Section IX Part QW Article-2

Learning the review method for SMAW process will serve to teach all process (May use SMAW, GTAW, GMAW/FCAW or SAW) Essential variable for SMAW as described on table QW-253 as follows: Joint: QW-402.1 Groove Design, 402.4 - Backing, 402.10 Root Spacing and 402.11 Retainers are Non essential variable, on the WPS do not leave blank You should indicate this variable as being By Sketch at list groove design used, With OR Without Backing, 1/32 OR 1/16 Root spacing, With OR Without Retainers or simplify place Xs in both blocks.

Section IX Part QW Article-2 Essential Variable

Section IX Part QW Article-2 Essential Variable

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Section IX Part QW Article-2 Essential Variable

Section IX Part QW Article-2

Base Metals: QW-403.5 Group no. and 403.6 T Limits Impact (Minimum thickness range qualified by impact testing) are Supplement Essential Variable, become essential variable when impact properties are required. QW-403.8 T qualified (Table QW-451.1 for maximum thickness range by qualified test coupon used in PQR), 403.9 t pass > (13 mm), 403.11 P no Qualified (See QW-424.1) and 403.13 P no. 5/9/10 are essential variable. Filler Metal:

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Section IX Part QW Article-2

2.2 Section IX - Article-2 QW-422

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2.2 Section IX Part QW Article-2 Ess. Var.: Welding Data

Section IX Part QW Article-2 Essential Variable

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Section IX Part QW Article-2 Essential Variable

2.2 Section IX Article-2 Essential Variable: QW-424.1

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2.2 Section IX Part QW Article-2 Ess. Var.: Welding Data

Section IX Part QW Article-2

QW-404.5 diameter and QW-404.33 Classification are not essential variable. QW-404.4 F No. (See QW-432), 404.5 A No. (See QW-442 except as given in QW-404.5), 404.30 t (See QW-451.1) are essential variable. QW-404.7 diameter > (6mm), QW-404.12 Classification (SFA number given in Section II of the ASME Code) are supplement essential variable. Position: QW-405.1 + Position and QW-405.3 Vertical Welding are not essential variable QW-405.2 Position ( Any position to vertical up hill but not reverse. In up hill progression, a change from stringer bead to weave bead) is supplement essential variable.

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Section IX Part QW Article-2 Essential Variable

Section IX Part QW Article-2 Essential Variable

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Section IX Part QW Article-2 Essential Variable

Section IX Part QW Article-2 Essential Variable

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Section IX Part QW Article-2

Preheat:
QW-406.1 Decrease > 100F (55C) is essential variable QW-406.2 Pre heat maintenance (This is of continuance of pre heat after completion of weld) is not essential variable QW-406.3 Increase > 100F (55C) (IP) is supplement essential variable

PWHT:
QW-407.1 PWHT(If PWHT will not performed, this should be indicated on the WPS by entering the words Not PWHT or simply none and 407.4 T limit (PWHT upper transformation temperature) are essential variable.

Section IX Part QW Article-2 Essential Variable

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Section IX Part QW Article-2

QW-407.2 PWHT (T x T range) is supplement essential variable (again when impact properties are required of a weldment, a change of the time span of PWHT or the temperature range will require re-requalification of the procedure. Electric Characteristics: QW-409.1 > Heat Input (HI = Amp x Volt/Speed) and QW-409.4 Current (AC or DC) or Polarity (EN or EP) are supplement essential variable. QW-409.8 I & E range is not essential variable.

Section IX Part QW Article-2 Essential Variable

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Section IX Part QW Article-2 Essential Variable

Section IX Part QW Article-2 Essential Variable

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Section IX Part QW Article-2 Essential Variable

Section IX Part QW Article-2

Technique: QW-410.1 String or weave, 410.5 Method cleaning. 410.6 Method back gouge, 410.25 Manual or Automatic and 410.26 Peening are not essential Variable. QW- 410.9 Multiple to Single pass/side is supplement essential variable.

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Section IX Part QW Article-2 Essential Variable

3. Base material Overview:

CS with Impact Requirements

SA516-70 N P1 Gr2

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3.1 CS overview

3.1 CS with Impact Requirements for Low Temperature

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3.1 CS with Impact Requirements for Low Temperature

3.1 CS with Impact Requirements for Low Temperature

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3.1 CS with Impact Requirements for Low Temperature

3.1 CS with Impact Requirements for Low Temperature

Cold Crack (< 200 C):
o Hydrogen (Crack and Blow Hole) o Stress Concentration o Brittle in weld

Hot Crack (Elevated Temperature): o Hydrogen (Crack and Blow Hole) o Stress Concentration o Brittle in weld o Impurities P & S
Effect Heat Input (HI): o HI Increase: Toughness decrease o SAW: HI high due to high ampere can prevent cold cracking o HI have limited value due to cause hot cracking in weld metal

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3.1 CS with Impact Requirements for Low Temperature

3.1 CS with Impact Requirements for Low Temperature

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3.1 CS with Impact Requirements for Low Temperature

3.1 CS with Impact Requirements for Low Temperature

Effect of preheating on hardness of HAZ

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3.1 CS with Impact Requirements for Low Temperature

3.1 CS with Impact Requirements for Low Temperature

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3.1 CS with Impact Requirements for Low Temperature

3.1 CS with Impact Requirements for Low Temperature

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3.1 CS with Impact Requirements for Low Temperature

3.1 CS with Impact Requirements for Low Temperature

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3.1 CS with Impact Requirements for Low Temperature

Ensuring WeldWeld-ability

Prevent Weld Defect:

Cooling Rate Restraint Intensity Amount of Hydrogen pick up Chemical composition of the steel plate (Pcm and Ceq taken into consideration) Etc (Good resistance to Lamelar tearing)

Pre - Heating PWHT Low Hydrogen filler metal Material Requisition Sheet with Normalized material & simulated PWHT NDE (UT examination) Hardness control

NOTE: Lower P content and add Ni for improving the toughness and for ensuring resistance to lamellar tearing. tearing.

4. WPQT-WPS-PQR: Engineering Drawing

WELDING JOINT NUMBER DATA SHEET

POS or PART NUMBER

GA Drawing

DETAIL JOINT

MATERIAL THICKNESS

MATERIAL SPECIFICATION

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4.1 WPQT-WPS-PQR: GA DRAWING

4.1 WPQT-WPS-PQR: DATA SHEET

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4.1 WPQT-WPS-PQR: Typical Weld Map

To Prepare WPQT for GA drawing 37-S-101 A B

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To Prepare WPQT for GA drawing 37-S-101 A B

To Prepare WPQT for GA drawing 37-S-101 A B

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To Prepare WPQT for GA drawing 37-S-101 A B

To Prepare WPQT for GA drawing 37-S-101 A B

Summary Material Spec. (P No. Gr. No.) x Thickness as follows:

Pipe 2x Schedule 160 = 8.74 mm thick x SA333-6 (P No. 1 Gr. 1) Pipe 8 x schedule 120 = 18.26 mm thick x SA333-6 (P No. 1 Gr.1) Pipe Shell 16 x Schedule 60 = 16.6 mm thick x SA333-6 (P No. 1 Gr.1) CAP (A) 16 schedule 60 = 16.6 mm thick x SA420 WPL 6 (P No.1 Gr.1) CAP (B) 16 schedule 80 = 21.4 mm thick x SA420 WPL 6 (P No.1 Gr.1) Flange x 8.74 to 21.4 mm thick x SA350 LF2 (P No. 1 Gr.2) Reinforcing Pad 12 mm thick x SA516-70 (P No.1 Gr.2) 1CW - Joint Cap to Shell Pipe: P1 Gr1 to P1 Gr1 2CW Joint Flange to Shell Pipe: P1 Gr2 to P1 Gr1 Joint Reinforcing Pad to Shell Pipe/Nozzle: P1 Gr2 to P1 Gr1

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To Prepare WPQT for GA drawing 37-S-101 A B

Essential Variable WPS P1 Gr1 to P1 Gr1 P1 Gr1 to P1 Gr2 PQR Remarks

P no. Gr No.

Thickness (mm)

8.74 - 12 16.6 21.4

PWHT Impact Welding Process

Yes Yes (- 45C) GTAW (8.74-12) GTAW+SMAW ( 16)

Others

To Prepare WPQT for GA drawing 37-S-101 A B

Essential Variable WPS P1 Gr1 to P1 Gr1 P1 Gr1 to P1 Gr2 PQR P1 Gr1 to P1 Gr1 P1 Gr1 to P1 Gr2 8 16 Yes Yes (- 45C) GTAW (8 mm) GTAW+SMAW 16 mm) Remarks

P no. Gr No.

Thickness (mm)

8.74 - 12 16.6 21.4

PWHT Impact Welding Process

Yes Yes (- 45C) GTAW (8.74-12) GTAW+SMAW ( 16)

Others 27

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WPQT GTAW with Impact Requirements of CS

PQR GTAW with Impact Requirements of CS

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PQR GTAW with Impact Requirements of CS

PQR GTAW with Impact Requirements of CS

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PQR GTAW with Impact Requirements of CS

WPS GTAW with Impact Requirements of CS

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WPQT GTAW+SMAW with Impact Requirements of CS

PQR GTAW + SMAW with Impact Requirements of CS

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PQR GTAW + SMAW with Impact Requirements of CS

PQR GTAW+SMAW with Impact Requirements of CS

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PQR GTAW+SMAW with Impact Requirements of CS

WPS with Impact Requirements of CS

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SUMMARIZED:
The accurate understanding which went into all aspect of the design and qualification welding procedures for the material/CS with impact requirements according to Section IX ASME Code requirements was presented with sample of WPQT, PQR and WPS under GTAW and SMAW process. The best way to understanding of CS Welding with impact test requirements (Toughness) is to study with CS equilibrium diagram/CCT diagram,

Condro Widiyarto condro06@yahoo.co.id 085652010809

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