Wal Introduction Course Objectives Y Pass the API exam! Y Understand common piping terms Y Perform required calculations Y Be able to use codes to find needed information Y Evaluate WPS/POR & WPQ Y Re familiar with API exam format : Y Increase your inspection knowledge & skills a Class Administration A. Schedule Class Time: Starts at 7:30.a.m. Ends at 5:00 — 6:30 p.m. Breaks: About every 1-1/4 hour, break for 10 minutes Lunch: Break at about 11:30 a.m. for I hour B, Snacks & Drinks GC. Restrooms vl iN D. Your keys to class success: ) 1. Ask questions; We're here to learn! 2. Participate in the discussion, 3. Refrain from profanity, 4, Each night review concepts covered in class during that day. 5. Each night do your homework! You won't have time to “catch-up”! 6. Get to know others in class and treat them right! E. MSTS Guarantee: If you don’t pass the API exam, you can repeat our class within the next 12 months for $200. Provided you: 1) attended al of the ‘class, 2) completed the class exam, 3) completed the Study Guide "The Inspector's Cale's" Welcome to this certification clas: that this will be a profitable and special week for you! API 570 Certification - Copyright MSTSIntroduction Course Content Y Review of all documents covered by the Exam. ® API 570, API 574, API 578 " ASME B16.5, 31.3, B&PV Code V & IX Y Special emphasis on Calculations and Key Charts Y Special emphasis on how codes are organized ¥ Some emphasis on the principles behind the code Y Homework Y Sample API 570 Exam API Body of Knowledge (BOK) - Indicates what materials are covered on the API exam, API 570 Publications Effectivity Sheet - Indicates which editions of the codes are covered on the exam. A copy of each of these is found in Section 8 of your manual APIS70 Certification ~ Copyright MSTSEquipment in Major Losses Pipe Tanks Reactors « Drums ‘Pumps/Comp. Heat Exch, Towers Hurs/Boilers Misc. ih ; Introduction — | Why API 570? ¥ Most common type of pressure equipment. How do we inspect? From the outside. Wide range process operating conditions. ™ Temperature: Lowers strength, causes thermal growth ™ Pressure: Increases internal stresses ™ Velocity: Often increases corrosion ™ Process Fluids: Vapors, liquids & solids; multiphase Y It's an abused equipment type! ™ Design requirements minimized, "it's just piping” & ™ Stepped on, used as a rigging location ™ Repairs - often temporary Mech.Failure) Oper. Err Process Upset Natural Haz, Design Error | Sabotage | Misc, Cause of Major Losses 0 5 10 15 20 25 30 35 0 10 20 30 Percent of Losses API S70 Certification - Copyright MSTS Percent of Losses 40 50i -_ = — Character to Live By | wa, Orderliness vs. Confusion: Arranging myself and my surroundings so that I will achieve greater efficiency. Y Thoroughness vs. Incompleteness: Understanding what areas of knowledge wil diminish my test score if neglected. VY Attentiveness ys. Distraction: « Showing the worth of this class by giving undivided attention to the discussion and study exercises. Punctuality vs, Tardiness Showing esteem for others by doing the right thing at the right time. Responsibility vs. Unreliability Knowing and doing what is expected of me, Diligence vs. Slothfulness Investing my time and energy to complete each task. Endurance vs. Discouragement é& ‘The inward strength to withstand stress and do my best. Truthfulness vs, Deception Earning future trust by accurately reporting past facts. Gentleness vs. Harshness Showing consideration by personal consideration a personal concern for others. API 570 Certification - Copyright MSTSily ig Components Module Objectives | Y Know the types of pipe & piping components Have an understanding of piping specs Y Understand the pro's and con's of pipe joining methods Y Successfully use the B16.5, the Flange Standard Y Solve flange rating problems @ Y Determine the maximum hydrotest pressure for a flange PR API 574 Sections 4.1.1 & 4.1.2 provide a great summary about pipe. These sections discuss pipe schedules, sizes, forming methods, tolerances, etc. RN Be sure to read and study this section! A-tol bus % ORAS tanto Cae Dy 09 fanny. APL 570 Certification - Copyright MSTS.Piping Components Pipe Specifications | Y Pipe and piping components are built in the pipe mill to a spec, like ASTM A106 (CS pipe) Y These manufacturing specs cover items likes " Materials ™ Inspection requirements ™ Minimum tensile strength " Fabrication process Y Note! For most Spec #'s like A-106, the actual number does not have special significance. It just refers to a section in a code, % Surefire Pipe Specs All pipe is to be made of a long hole, surrounded by metal around the hole. All pipe is to be hollow through-out the entire length. The pipe and the hole must be the same length. The pipe ID must not exceed the pipe OD, otherwise the hole will be on the outside, Flanges must have holes for bolis. These holes must be quite separate From: the big hole in the middle of the pipe. All pipe must be roundular & tubular, All pipe over 6" diameter must have the words "large pipe" painted on it We don't want the contractor to mistake it for a small pipe. All pipe is to be supplied without rust, Rust will be more readily applied at ihe job site, (Some vendors are now able to supply pre-rusied pipe - saves work in the field!) For an example of areal” spec, see ASTM A-106 at end of this section APL-570 Certification - Copyright MSTSManufacturing of Pipe V Seamless (drawn through dies) ery ™ Used the most in our petrochemical plants " Tolerance: -12.5% BL tawemyt (inatignt ). Y Welded (plate that is rolled and welded) ™ Most piping greater than 16 NPS is rolled & welded (0:24) ™ Tolerance: -0.010” Cton wins ) ¥ Cast (and machined) ® Not used ofien * Tolerance: -0.00 + 1/16” Ly Definition: NPS - Nominal Pipe Size Seamless Pipe: The Advantage = Fewer welds! Welds are generally places for potential leaks and failures. * No longitudinal welds! In all cylinders, the stresses on longitudinal welds are twice that of circumferential welds. (Covered further in Module 2) APIS74 Table 3 [AST Nominal Pipe Size Diameter”) Thichiess Pipe Tolerances | Material |... (NPS) <= Tolerance Tolerance 6] tatty ‘433 U2 NPS ~1i32" + 16i" “12.5% i ABS = T-IR NPS =1% “12.5% 106 | _W8NPSio -TRNPS |= 1D” > Wt" | 13.5% | | [A106 | > Ti NBS 4 NPS 21a “123% | AISA All |Gireunference £ 05% Tolerance of plate of diameter standard ADS All + 1% of nominal “125% | B58 ail E05% ~ oor” For more information on pipe diameter and wall thickness tolerances, see API 574 Table 3. Caution: Some of the diameter tolerances are a little hard to read in API S74! API $70 Certification - Copyright MSTSPiping Components Y Diameters - standardized through 48" " Up to 12 NPS, size refers to pipe ID ™ Above 12 NPS, size refers to the pipe OD Y Thicknesses standardized through 36" ® Thicker pipe has smaller ID; OD stays the same " Traditional: Std. weight, extra strong, double extra strong ™ Schedules: 10, 40, 80, etc. + BIG Annex C or APIST4 Table 1 Pipe Schedules ending in S” (Le. 108) refers to Stainless Steel (SS) pipe schedule chart, The ‘88 charts are not shown in B16.5 or API S74, During projects & repairs, new pipe is ordered. Inspectors should measure the wall thickness of new pipe to determine if the thickness meets minimum code requirements. ‘The tolerance for seamless is ~12.59%, This means it ean be 12.5% thinner than what is listed in the pipe schedule. Or, the pipe has to be at least 87.5% as thick as the nominal thickness. Since ‘our UT instruments measure wall thickness, we need to know the minimum allowed thickness €' Here's the formula: iggy ~ 9875 X oy Example: Determine minimum wall thickness of a new 6 NPS seamless pipe. From pipe schedule chart: ty, = 0.250" yin ney = 9875 x 0.280 = 0,245" New pipe below 0.245" is rejectable! Minimum Thickness for New Welded Pipe Since the mill tolerance for rolied and welded pipe is. - 0.010", this is much easier to calculate. Here's the formula: yay 0-019 Examples Determine minimum wall thickness of a new 6 NPS welded pipe. 0.280” From pipe schedule chart? thoy yin ny = 0.280 - 0.010 = 0.270” New pipe below 0.270" is rejectable! APL 570 Certification - Copyright MSTSPiping Components | Other Piping | Y Tubing ™ Stated size is the actual outside diameter. ® Not generally used for piping, ™ Applications; furnace & heat exchanger tubes Y Cast Iron Piping ® Sizes are different than the sizes for steel piping ® Susceptible to brittle failures ® Not used for hydrocarbon services e Exercise 1-1 Pipe Dimensions ) 4 3% 4 Py) 9 What is the nominal wall thickness of a 6 NPS, Schedule 80 pipe? What is the nominal wall thickness of a 2 NPS Schedule 40 pipe? Ose What is the OD of a 4 NPS furnace tube? (tube is made to a pipe spec) What is the OD of a 4” furnace tube? (tube is made to a tube spec) What is the mininum allowed thickness of a new 8 NPS Schedule 80 seamless pipe? (show your calculation) Os K Oda = 0.4 S78 What is the minimum allowed thickness of a new 8 NPS Schedule 80 welded pipe? (show your calculation) APL 570 Certification - Copyright MSTSPiping Components | Joining Method - Threaded Y Limitations Y Disadvantages " Non-critical service * A significant portion of * 2NPS or smaller the pipe has been Advantages removed in the threading * Quick installation process !!! * No "hot work" required "Susceptible to fatigue ® Lower eraftsman skill cracks level required a Bde Wat ea Tapered Threads API 570 Certification » Copyright MSTSPiping Components Y Purpose for flanges * Disconnect or isolate piping & equipment * Connect to other equipment, e.g. pumps, exchangers " Install piping in areas where welding is not permitted ¥ Codes ™ B16.5: % thru 24 NPS " B16.47: 26-60 NPS ® API Sid 605 ¥ Classes: 150, 300, 400, .. Y Types: Weldneck, Slip-On, etc. Every flange is a potential leak. During design, the number of flanges are usually minimized. In high pressure units, there are very few flanges. This reduces cost and minimizes the potential for serious leaks. Often, even welded valves are used. Welding-Neck Lap-Joint Socket-Welded Flange Flange Flange ‘Slip-On Welded Blind Flange Threaded Flange Flange APL 570 Certification - Copyright MSTSPiping Components Joining Method - Welding The primary joining method for permanent petrochemical piping, Fewer leaks & repairs required with this joining method, ¥ Socket-weld ™ Generally limited to pipe <2.NPS tne“ ™ Watch out for "the gap" = Advantages: Quick, less skill required " Potential crevice corrosion Y Buit-welded ® Used on all line sizes == " High Strength PP spect with RT: the “meat & potatoes NDE" — == 4. The “gap” The Gap ‘ Why is “the gap” needed on socket welded pipe? Thermal expansion! If there is not a gap, and if pipe grows more than the socket welded fitting, then the fillet weld may crack. How could this occur? L 3 During fabrication: If the pipe wall is thinner than the SW futing, then the pipe will become hotter than the fitting during welding. Hot services: If the line is uninsulated, the socket will not heat up as much as the pipe. Hot eyclie conditions During in-service inspections using profile RT, occasionally a SW fiuting ts found without a gap. If this pipe has withstood the “test of time”, usually there is no reason to repair and add “the gap”. However, if operating temperature or eyclic conditions increase, then discuss this situation with a pressure equipment engineer. APL 570 Certification - Copyright MSTSSocreet -uaerk . > Coren rry RE HAUL pee SZ NES, v ep Ween Ae "Gee @ —P Phrentoyee Quine, to slain for ae D> Ryuatu Greve corsbier. —_— Eee - a =e A ar. GH. Rat wad & SP voek on an Ce bye son se nee aHeSHde “> ny Srey APL S70 Certification - Copyright MSTS 7Piping Components Y Flange Selection - Appropriate Strength * Must know material temp and pressure ratings Y The Gasket | ® Appropriately compressed, no blowouts The Bolting - Provides the “Squeeze” | ® Bolting Strength | ® Bolting Stretch Y The Assembler * Correct torquing procedure ot " Larger flanges are more difficult to assemble The Weak Link What's the weak link on a flange? The bolts! The bolts are like monster springs. As the nuts are tightened, the bolts stretch. This creates a squeeze on the gasket. If there is not enough “stretch”, then there is not enough “squeeze” and the gasket will leak. Also, the pressure from the process creates a force trying to pull apart the flanges, If the force from the process exceeds the bolt force (squeeze), the flange will leak. F, "PROCESS A leak occurs when Frrocess> Fyonts API 570 Certification - Copyright MSTSPiping Comp B16.5 - The Flange Standard ents Y Scope of B16.5 Y Raised face vs. Flat face ® Figs & flange fittings ¥ Flange Markings Y Types of Material Y Flange Dimensions ® Steels and alloys Y Flange Facings Y Fab Methods ® Visual Comparator * Castings = Norm Finish * Forgings + 125-250 micro-inch © 45-55 grooves/inch | * Plate (only blind fe) a Note ! B16.5 is over 150 pages long. But only 9 pager are “real” text. The rest is ‘charts and sketches. As you prepare for the tet, overview all 9 pages. Dimensions - flange dimensions do not change with different flange metallurgies. For example, all 6 NPS, Class 300 flanges have exactly the same dimensions. Flange Faces Raised Face Flat Face Ring Joint Face APL 570 Certification - Copyright MSTSPiping Components Flange Calculation. Types of Flange Calcs Factors for Calcs Y Maximum Flange Pressure ¥ Max Pressure Y Maximum Flange Temp ¥ Max Temp Y Select most cost effective Y Flange Class Flange Class Y Flange Metallurgy Y Maximun Hydrotest " Metallurgy is always Pressure provided in the API exam ® This is normally higher than questions the B31.3 system hydrotest a pressure, [e When ave flange calculations performed? 1. Rerates: If either the pressure or temperature is being raised the flange “rating” must be checked 2, New Construction or Alterations: The appropriate flange class must be selected based on the design conditions. 3. New Construction, Alterations, or Repairs: If hydrotesting is performed on the equipment or pipe, the maximum allowed flange hydrotest pressure must not be exceeded. Note! On most piping systems the flanges are usually the limiting component. This may not be the case on large diameter pipe. API 570 Certification ~ Copyright MSTS 1é B16.5 Table 1A Find Material Groups Piping Components Y Pressure-Temperature Charts needed because: ™ Flange dimensions are based on class not metallurgy ™ Some materials are stronger than others ™ As operating temperature increases, material strength decreases Y Key Flange Charts ™ Material Group: Table 1A * Pressure-Temperature Ratings; Table 2.x.x Material Group Number Materiat| Nominal | Press.-Temp Applicable ASTM Specifications Group | Designation | Rating Forgings | Castings | Plates ta esi aaa | Atos A216 Gr. Wo | A515 Ge. 70 CMnsi 4350 Gr. LF2 A516. 70, ASSTCLI 12 | eMnsi 22 ‘A216 Gr, WOC A382Gr. LOC 212 Ni A352Gr.LC2 | A203Gr.B BU Ni ABDGRLFS | A352GcLC3 | A2036n8 13 213 A352GeLCB | ASIS Gr. 65 A S16 Gr. 65 4203 Gr. A ‘4203 Gr. D 14 24 A515 Gr. 60 A 350Gr. LFICL A516 Gr. 60 15 | CAM 24s | A1s2Ge Ft 4217 Ge. WI | A208 Gr. A assaGr ici | 420668 APL S70 Certification - Copyright MSTS. I2Piping Components Flange - Max Pressure Step I: At Table 1A determine Material Group # * Based on flange metallurgy Step 2: Go to correct P-T Rating chart = “xx” represents material group number, * Validate material is listed on top of chart * Check appropriate footnotes é@ Step 3: Find intersection of Design Temp row and Designated Flange Class column Example - Determining Maximum Flange Pressure A rerate is being performed on a piping system. Determine the maxinum pressure rating for the existing Class 300 flanges. The flanges have a maximum operating temperature of SOO°F. The flange material is ASTM A182 gr. F316, Step 1: At Table 1A, determine the Material Group Number of the flange. * Material Group # for A182 gr, F316 is 2.2 (Stainless Steel forging) Step 2: Go to Table 2-2.2. Validate material is listed at top. Check footnotes. Step 3; Find intersection of temperature (500°F) in Temperature Column and Designated Flange Class (Class 300). @ * Maximum Pressure is 480 psig. Your done! Temperature _| Class 150 | Class 300 | Class 400 | Class 600 -20 10 100 200 300 00 S 0 —|——> ane 1-3 Maximum Operating Pressure Determine the maximum pressure of a Class 600 flange that has a maximum design £2 temperature of 75°F. Flange material is A103. Maximum allowable pressure: _[9 | es) 5. APL S70 Certification - Copyright MSTS 13Step I: At Table 1A determine Material Group # Step 2: Go to correct P-T Rating chart = “xx” represents material group number * Validate material listed * Check appropriate footnotes Step 3: At designated flange class column, drop down until finding design pressure. If exact pressure is not listed, stop at the closest higher pressure @ Step 4: At this pressure, run left along same row to the Temp column. This is your max temperature Example - Determining Maximum Temperature Rating A piping system with A105 flanges is being rerated for the Class 600 flanges. The piping system has a new design pressure of 1000 psig. Determine maxinum temperature, Step I: At Table 1A, determine the Material Group Number of the flange. 4 * Material Group Number for A105 is LI (Carbon Steel forging) Step 2: Goto Table 2-1.1. Yalidate material is listed at top. Cheek footnotes. Step 3: At the Class 600 Column, drop down the column until you find the Design Pressure. If the exact design pressure of the flange is not listed, stop at the next higher number. * Design Pressure is 1000 psig. Select the listed value of 1010 psig. Step 4 At this pressure rating run horizontally (to the lef)) to the Temperature Column. G The maximum design temperature is the temperature for this row. + Temperature Rating is 750°F. Your done! Temperature | Class 150 | Class 300 | Class 400 | Class 600 -20;0 160 630 700 1065 psig Se TAI0 psig $00 $25 psig GTO Exercise 1-4 Determine the maximum allowed temperature of a Class 300 flange that has a maximum { design pressure of 400 psig. Flange material is A182 gr. 304 0 Maximum allowed temperature APL 570 Certification - Copyright MSTS 14Piping Components Flange - Flange Class Step I: At Table 1A determine Material Group # Step 2: Go to correct P-T Rating chart * “cx” represents material group number * Validate material listed ™ Check appropriate footnotes ‘Step 3: In the temp column find the design temp Step 4: At this vow move right to find the first pressure that & | exceeds the design pressure Step 5: At this pressure move straight up to flange class Lede E SSE EERE LAER EMER] Example - Determining Most Cost Effective Flange Class A new piping system is being installed. Determine the most cost effective flange class for this system, The pipe has a design pressure of 700 psig and a design temperature of 650°F. The Hlange material is ASTM A182 gr. FS. Step 1: At Table 14, determine the Material Group Number of the flange. "Material Group Number for A182 gr. FS is 1.13 (5% Chrome forging) Step 2: Go to Table 2-1.13, Validate material is listed at top. Check footnotes. Step 3: At the Temperature Column, find the Design Temperature. * Design Temperature is 650°F. Siep 4: At this vow, move directly to the right to find the first Maximum Pressure that exceeds our Design Pressure of 700 pst & * 1 Column - 125 psig, 2“ Column - 590 psig, 3°¢ Column - 785 psig Step : Go up the top of this column and read the Flange Class. = Flange Class is Class 400. You're done! Temperature _| Class 150 | Class 300 | Class400 ~20t0 100 200 400 600 eo psig 78S psi A new pipe is being installed. Determine the most cost effective flange class. Flange material is A105. Design Temperature is 600°F and the Design Pressure is 950 psig. Most cost effective flange class: _€ 80 API 570 Certification - Copyright MSTS. 15Piping Components Flange - Max Hydro Pressure Maximum allowed flange hydrotest pressure (Pypgy ) te Round upto Prnsr = 15 Parooor | next 25 psig Peron or = The pressure rating of the flange at 100°F. (found on P-T Rating charts) t next 25 psig = AM answers need to end in; “00, 25, 50, 75” All flange fitings must be hydrotested at the mill. Flanges are not hydrotested at the mill. Usually the flanges are the limiting component. Often the fabrication hydrotest is based on this flange hydro calculation instead of the B31.3 piping system hydro calculation. (e.g. all A105 CS Class 150 flanges are tested at 450 psig regardless of the design pressure) Example - Determining Maximum Hydrotest Pressure Determine the maxinum hydrotest pressure for a Class 300 flange that has a maximum operating temperature of 500°F. The flange material is ASTM A182 gr. F316. Step I: Determine the Material Group Number of the flange, * Material Group Number for A182 gr. F316 is 2.2 (316 SS forging) ‘Step 2: At Table 2-2, validate the material is listed in the top chart. on Step 3: In the Temperature Column, find the Hydvotest Temperature. a * Hydrotest Temperature is 10°F, Step 4: At this row, move directly to the right to find the Class 300 column, Read the maimum pressure, “Maximum Pressure is 720 psig. Step 5: Caleulate the hydrotest pressure per formula given in paragraph 2.5 System Hydrotest. The fornvula is: Prysp= 15% Prep T Round up to next 25 psig. Prysp= 15x 720= 1080 1 Round up to 1100 psig. Exercise 1-6 Determine the maximum hydrotest, preaue for a Class 600 flange made of A105. 2 Maximum hydrotest pressure: 92-25 ee LS 7 API 570 Certification » Copyright MSTS ye 16ey API 570 Certification | API 570 Certification | B31.3 - Pipe Design . “And I'm supposed to inspect this?” “The wise man will hear and increase in knowledge” API 570 Certification - Copyright MSTSB31,3 - Pipe Design Y Understand B31.3’s scope and organization Y Know the three needed B31.3 piping classes Y Determine the allowable stress “S” Y Determine the Quality Factor “E” Y Calculate pipe thickness Y Calculate blank (blind) thickness Y Familiarize yourself with basic design issues Definitions Examination; NDE Testing: Pressure test (hydro, pneumatic) ES SaaS bee ote 0 BIL] or BIL. Check S Stereofan Tubes Internat Crossovers Boiler Proper ‘Heat exchangers Air-coolers Internal piping Heaters eal a‘ - Packaged Equipment Legend som Piping within the seope of B31,3 Piping outside the scope Other B31’s 831.1 ~ Power Piping (Boiler) B31.2— Fuel Gas Piping B31.4— Pipeline Systems for Liguids 31.5 — Refigeration Piping B31.8~ Pipeline Systems for Gases B31.9 — Building Services 31.11 ~ Shur Piping Systems API-S70 Certification - Copyright MSTS31,3 - Pipe Desig B31.3 Piping Classes Y Normal Service Y Category M 1) * Majority of plant piping * Very Toxic ‘Severe Cyclic Service Y Nonmetallic ™ High stress Y High Pressure | ® Over 7000 stress cycles © Excess of Flange | Y¥ Category D Cusivity.) . Class 2500 ™ Not damaging to hubs © Pressure Limits < 150 psig Caetano * Temp: -20 thru 366°F the API 570 exam! * “Duh Utility Piping” fe | | Normal or Severe Cycle 150 psig — Opsig — -20°F None Code & Category D * Non-Toxie + Non-Hazardous |__* Non-Fiammable APL S70 Certification - Copyright MSTS 3B31.3 - Pipe Design ¥ Table of Contents Y Chapters VII - IX Y Chapter I * Three Piping Services * Nonmetaic * Category it © igh Presse ™ Scope * Definitions Y Chapters I-VI V Appendix A-Z ® Three Piping Services * App A: "5" & "ER" * Normal Service ™ App C: Thermal Growth + Sore Cyc Service tae Index a ‘wo important tools for finding open book info... | ‘the Table of Contents and the Index!! You must understand how B31.3 is organized, Here's the basic concepts. Z._What piping classes are covered in Chapters IT— VI? Only Normal Service, Severe Cyclic and Category D, The other three B31.3 piping classes | ‘are covered in chapters VII IX. (These last three are not on the API exam!) How are Chapters U- VI Organized? By sequence of the project activity. DESIGN the pipe ... then BUILD the pipe ... then INSPECT the pipe ...then TEST the pipe. II}. How are the 3 piping classes (Severe, Normal, Cat. D) identified in Chapters I~ 1V? Rule 1: If code mentions a piping elass then rule applies only to that piping class. Rule 2; If code does not mention piping classes, then the rule applies to all 3 piping classes. (Severe, Normal, Category D) | Examples: 304.1.2 Wall Thickness Cales (class not mentioned) 341.4 Required Examinations 341.42 Category D 3414.7, Nominal Service 341.43. Severe Cyclic aay Iv, All paragraphs in B31.3 are 3x. The “3” stands for B31. ‘3” API 570 Certification » Copyright MSTS 4B31,3 - Pipe Design The B31.3 Players Y Owner Y Manufacturer = Overall responsibilty for * Provides materials & compliance with the Code ‘workmanship that complies Designer ‘with the Code * Design complies with Code Ovner's Inspector ™ Assure that the Code requirements for inspection, examination and testing are met (TIE) * Full access to all piping work Exercise 2-1 Let’s Practice!! Oy 1) What are the qualification requirements for NDE personnel? SNT-TO1A g 2) What are the requiremen' for the weld metal of tack welds? 3) The Owner's Inspector must have how many years of related inspection experience? or 4) A hydrotest must be held for at least__\ © - _ minutes, 5). Describe the heat treatment called “Normalizing”. ) ty APL 570 Certification - Copyright MSTSB13 - Pipe Design Retirement Thickness | | The Formula PD 2 (SE+ PY) 3041.2 P = design pressure (psig) D = outside diameter (inch) see B16.5 Table @ S = allowable stress (psi) E = quality factor Y = coefficient from Table 304,1.1 | Thickness Terms Thickness terms have not been standardized throughout different codes, As a result, the terms used can be very confusing. 1, Retirement Thickness (this term is not used in code). The minimum thickness allowed. If the component is below this thickness, the component should be repaired or replaced. + In B31.3 this is called “pressure design thickness” + In API 570 this is called “required thickness” + Many call it “minimum thickness” or “min” er 2. Retirement Thickness plus Corrosion Allowance When ordering new pipe, you always need to add the appropriate corrosion allowance + In B31.3 this is called “minimum required thickness” Coefficient ¥ This factor is given in B31.3 Table 3041.1 This factor produces a very minor affect on the calculated thickness. Generally it reduces the retirement thickness by about 16, The Coefficient Y for all our calculations will be 0.4, APL S70 Certification - Copyright MSTSad) 31,3 - Pipe Design Strength & Stress | Types of Loads/Stresses Y Stress Measures Strength 7 » Net fate ee Com erred fue Tone * Sra Za Aran * Units: pst (Ibs per sq. in.) gf Y Ultimate Tensile Strength Compressive ry * Stress at which failure occurs si * Determined by Tension Test | ee ® Also called SMTS Strength - the ability to withstand an applied load Definition SMTS: Specified Minimum Tensile Strength. This is also called Ultimate Tensile Strength. This is the failure stress of a material. The Formula: Stress = Load / Area » Py 5000 lbs 5000 Ibs 10,000 lbs S.,= 10,000 / (2x1) = 5000 psi Sp & Sc= 5,000 / (Ix1) = 5000 psi Different loads, but same stress! APL-S70 Certification - Copyright MSTSB31.3 - Pipe Design Y Elastic Properties Y Plastic Properties * Metals stretch when loaded . * Metals return wo original shape | 4 shen load is removed * Swretch is proportional to load. Higher load ” more stretch High Siress, metal saetches Iabove Yield Siress, it does not return to original shape when load is removed! eee ‘Permanent deformation 7 = po rae tr Be tnt peed iad fife ete | e alto Al Wool | Original — peste eta ae Se eee pore ssa ‘load Definitions Yield Strength: the stress level where the material behaves plastically, No longer in the elastic range Elastic: the deformation of a metal under a load which causes no permanent deformation. Elastic behavior is considered to be linear (the greater the pull the greater the growth/stretch,) Plastic: © stressed beyond the elastic limit and results in permanent deformation. Strength of a plate can vary significantly depending on the orientation. The strength is best in the direction of the roll. Transverse to the rolling direction the strength can be reduced by 30%. In the through-thickness direction it can even be less: API570 Certification - Copyright MSTSB31.3- Pipe Design Y Allowable Stress Sample Failure Stress ; A106 * What the designer is ua yy er “allowed to use in | 50,00 bt in = 60,000 pst thickness cates Bae * Based on Code Sofety Factor Tint + S= SMISSafey Ractor ‘Stress vs. Temperature ‘Allowable Stress | 8 = SMTS/Safely Factor 60,000 psi/ 3 = 20,000 psi "As the temp increases, the strength decreases * Also “S" decreases 60,0000, Failure Load es 2 B31.3 Safety Factor: 3 to 1 & 2 Allowable Stress “S" and SMIS are given in B31.3 Appendix A-1, You do not have to caleulate "S”! ‘The materials ave listed by Spec #'s (eg. A106 gr. B) using the following methodology. 1. Grouped by Material Families: Carbon Steel, Low & Intermediate Alloy, Stainless Steel, ..ete. 2. Within Material Famities, materials are listed by Components: Pipe ek Tubes, Pipes (Structural) Plaies & Sheets, Forgings & Fittings, Castings 3. Within Components materials are listed by SITS (Tensile Strength) Material Spec. No. P-No. Grade _<100_ 200 300 400 00 600 650 700 750 ~ LAI06 1B 200200 200 20.0 189 173 17.0 165 13.0 | A$16Gr65_A671 1 21.7 213 207 20.0 18.9 17.3 17.0 16.8 1 a OR EP Notes! 1 Asi = 1000 psi, s0 20 ksi = 20,000 psi, A-106 isa very common CS pipe used in petrochemical plants. Highlight the stresses of 106 gr. A, B & C across both pages Why do some of the listed pipe have a Material Number? This is Rolled & Welded pipe. The Material # lists the spee of the plate used to make the pipet Exercise 2-2 Are You Stressed? 1. What is the allowable stress for a A106 gr. B pipe that has a design temperature of 70°F? \G-S \ex\ 2. What is the allowable stress for a A671 gr. CC70 that has a max, operating temp of 40°F? DA. \e-4} 3. What is SMTS of A106 gr. C pipe? Ho esj 4. Inthe stress tables what do single bars represent? Ste ve wot, fae res 5. In the stress tables what do double bars represent? POW tet elms oc ator A eget, APL 570 Certification - Copyright MSTS ¥B31.3 - Pipe Design [ Stresses on Welds Cire Weld Pressurein a cylinder always creates Both cir. & long. stress Long Welds | Circumferential Stress affects: (oy welds Longitudinal Stress affects: Clee welds | Cylinder ® & 5 — 33 3 Pressure gs : Be 3 8 g Circumferential Stress Longitudinal Stress Also called Hoop Stress What increases the Stress on the Cylind 1 Lorvaswre 2 Dereers 3 stress. So. long welds are usually more critical than cire welds!!! PD API 570 Certification ~ Copyright MSTS re 10 otB31.3 - Pipe Design Quality Factor “E” Y What is “E"? Y Factors " Additional “safety factor” * Seamless Pipe + For long weld or Castings * B= 1.0, no Long welds Y Determine “E” ™ Rolled & Welded Pipe a * Type of weld * If given a pipe description rips rh 30234 * Amount of NDE (RT) * Ifgiven Material Spec Cast Pipe ‘ * Material ALA & 1B ae Table &L * Casting Method < | Note! In ASME Section VII, “E” is called “Joint Effi Same concept, just a different term Class or inti App. A Spec # a Description Epes ASME 831.3 | 453 | Types | Seaniess Pipe 1.00 - Table A-1b AS3 Type E | Electric resistance welded pipe 0.85 | “EY 453 | TypeF | Furnace butt welded pipe 0.60 Se A105 w | Forgings and fittings 100 | 4106 Seamless pipe 1.00 fe A134 w | Blectric fusion welded pipe, single| 0.80 | er bidt, straight or spiral seam 2+ Exercise 2-3 Quality Factor wes 1. What is “E” for A333 ERW pipe? Oks 2, What is the quality factor for AS3 Type S? ies 3. What is “E” for a pipe with a long weld that is double-butt-welded using the Electric Fusion process? ORS API 570 Certification = Copyright MSTS uB31.3 ~Pipe Design Performing Calculations | Successful inspectors use a disciplined approach in problem é solving. Here’s how to solve a calculation, 1) Copy formuta from Code (leave space above formuta for Step 2) 2) List data above the formula (list data in order of formula, ie. P= ey DF oy Soy B sey VE os) 3) Solve problem (input numbers) below the formula 4) Work problem vertically down on your paper. Don’t jump all over the paper. 5) Highlight your answer, (Don’t forget the u ny @ Example: Sample Calculation (Note the Format!) Determine the retirement thickuess of a seamless 14 NPS pipe _@. 14” OD). Design pressure is 500 psig and allowable stress is 15,000 ps at design temperature. Y= 0.4 e P=S00 psig Apisja E=1.0 (seamless) 8 2m Step D=14" (from BES) = -Y=04 $= 15,000 psi The problem is PD 1 eee worked straight fe (= AGH PM down the pagel 3" Step 7a 500x14 At this point learn @ 2TS,000x 1.0) + (0.4.x 50) ‘how to solve quickly? 4 Step t= 0.230” Vv This should be your Format | \p 2-4 Pipe Minimum Thickness & Determine the minimum allowed thickness for an 8 NPS pipe. The pipe is A53 Gr. B Type E (ERW). Design pressure is 400 psig and design temperature is 700°F F= Ano Poy E-0-€5 de 8" C3-f9s) Ye og, &= [b,x tooo. API570 Certification - Copyright MSTS ao ¢ & 62s) ord ta BEL E eee eb eeee Ba 2 Gesvo x ossy+(O.4 x ae) | “os So 14 99S (= D> or lrzieB31.3 - Pipe Design | Pipe - Minimum Thickness Exercise 2-4 Practice “The Format” 400 psig S= 16,500 Y= 04 A. Second y= 8695” B= 0.85 i PD. me BE POT Third (400 x 8.625) 1 = 36,500 x 0.85) + (400 x OA) Pow 4 = 122 oe ye A “Problem” with Seamless Pipe Suppose you have to order some new pipe, The ty, is calculated to be 0.875" and the specified corrosion allowance is 0.125”. What thickness is needed? tues = 0.875 + 0.125 = 1.000” So you want to order 1.0” thick pipe Suppose one of the nominal thicknesses for your needed pipe’diameter is exactly is 1.000”. So you order 1.000” thick seamless pipe. Later, the pipe is delivered and you inspect it. You check the metallurgy, the condition, and the thickness. What's the thinnest it eould be? The seamless mill tolerance is ~12.5%, so the minimum wall thickness for the new Pipe is 0.875 x 1.000” = 0.875". You take some readings and find portions of the Pipe at 0.880”. These are acceptable based on your order and the mill tolerance of seamless pipe. But you have lost all your corrosion allowance! This is a big problem! API S70 Contifieation ~ Copyright MSTS 1331.3 - Pipe Design Pipe - Ordered Thickness Rolled & Welded Seamless Pipe D) Calculate trin A) Caleulate tin 2) Add Corrosion Allowance 7) Add Corrosion Allowance twicd = tin + CA buica = tnin + CA 3) Adjust for mill tolerance 3) Select nominal thickness t wicA tom 2b wea faa 2 “E375 @ 2 4) Select nominal thickness ¥ bnominad > tadj Why divide toca by 0.8752 Suppose you make $100/tr, but the boss says you'll have to take a 10% pay ext. You will be making 902% of what you made before or $90/hr. (0.9 x 100 = 90) A year later the boss comes in and says you'll be getting a 10% pay raise. What's your nevw pay? How come you are not back to the $100/ir? How do you mathematically get back to the original $100/hr? Divide by 0.9 (90/0.9 = 100) With seamless the mill tolerance ts 12.5 % or you have 0.875 ¥ ty left, When ordering new pipe, divide the needed thickness (tice ) By 0.875. tyy = (lca) / 0.875 I you order this adjusted thickness, the new pipe can never be less than “ics” vercise 2-5. Let’s Order Pipe An 8 NPS A-106 Gr. B pipe has a caleulated ty, of 0.182". The specified corrosion allowance is 0.125”. What pipe schedule pipe should be ordered? 2. 44 NPS piping system has a design pressure of 800 psig at 60°F. Pipe material is 4-106 Gr. C. Specified corrosion allowance is 0.125”. What pipe schedule should be ordered? 3. A “rolled and welded” 12 NPS pipe has a renewal thickness of 0.218” and a x] corrosion allowance of 0.100”. What pipe schedule pipe should be ordered? APIS70 Certfieation « Coppright MSS “B31.3 - Pipe Design Pipe - Structural Minimum Y The caleulated tuin'is based Real Steps to Order Pipe only on pressure loadings 1. Caleutate tniy V Other loadings must be 2. Compare to structural tyin considered during design Pick larger value. | * Deed Loeds: weight ofpive 3, Add eorrosion allowance * Live Loads: weight of 4. Adjust for mill tolerance process, snowlce, personnel S, Pick appropriate pipe Specific strnetural minimums schedule. ¢ are not listed in the codes, toa tne I frgot © Usualy provided by Owner eerie © Usually a list o chart Why Structural Minimums? Check the calculated tpis for a 2 NPS A-106 Gr. B pipe. The design pressure is 100 psig and design temperature is 20°F. 7 PD 100 x 2.375 Lea here SE) + POI ~ Fe0.000x1) + aaoxoay ~ ™ de That's only 6 mits! If this 2 NPS pipe was 100% supported, like laying on the floor, then 6 mils would hold € the 100 psig of pressure. And this is with a 3 to 1 safety factor! But it certainly wouldn't hold up in the pipe rack, especially with a “fat-boy” standing on it! Structural minimum thicknesses are not on the API exam since they are supplied by the ownerfuser and are not provided by either the ASME or API Codes. Other Names for Structural Minimum «Arbitrary Minimum Thickness * Mechanical Minimum Thickness || Piping Inspectors should always have quick access to ‘the owner/user's ist of structural toixl API 570 Certification - Copyright MSTS ISPipe Design Blanks - Thicknesses Y Pressure-rated blinds Calculation Steps (blanks) are thick 1) Multipte “3 x P” * Flats the worse shape for 2) Divide by “16” pressure containment 3) Divide by “S", select “equals” Y Formula - Retirement 4) Select square root Thickness 3) Muttiply by “dy” | 6) If need to order plate: = aN as @) dé Corrosion Allowance d,~ inside diameter of gasker ©) Select toom = 1.0 sfno weld toon > tin + CA Work this problem on the calculator without writing doven each step! Exercise 2-6 Blanks 1. Determine the retirement thickness of a blank installed in a 6 NPS line. Design pressure is 300 psig with a design temperature of 900°F. The blank is made from stainless steel material A240 gr. 316L. The gasket ID is 6.620”. © * 6 pf BceBe> = 11800 psi IbUige) oO) h 20-45) 2. Determine the nominal plate thickness to order for a blind. The design pressure is 325 psig at 400°F. The material is A516 gr. 70 (carbon steel), The gasket ID is 8.625". The specified corrosion allowance is 0.200”. = Boos | BORS) B= NFS par iL@rayan eee’ OW 2 dbs ( TS BUA. n API 570 Certification - Copyright MSTS > OHSF qe. TaHEOE 6s2!31.3 - Pipe Design Fluid Service - Limits Y Pipe Materials (305) Y Socket WelWls (311.2.4) * Cat D-All listed materials * Normal Service ~All listed materials except those limited * Avoid in crevice eorrosion or erosion services materials * Severe Cyelic < 2NPS © Severe Cyclic - short list Y Threaded Joints (310) Y Miter Ends (306.3) * Avoid in crevice corrosion or Flanges (308.2) erosion services ™ Slip-on limits * Avoid in cyelie loadings @ ® Severe Cyelic - Weld Neck * Severe Cyclic Not allowed Bolting (309.2) except no-load items like * Low sirength « Only for Class thermowelds 2 150 & 300 flanges Definit Listed Materials: Materials listed in the Appendix A stress charts Mite Elbow fabricated from pipe using pie shaped sections, Ofien used on large diameter pipe. Straight Thread: Non-tapered threads. Used in threaded pipe unions. A Miter Elbow API 570 Certification - Copyright MSTS rdB31.3 ~ Pipe Design Pipe Flexi | ip A piping system will grow or shrink when the | temperature changes | Notice “F"@ 10°F. The _ Fxb ‘chavt is based on the pipe G= Foo itsintetere 70. G = Growth in inches € F = factor from B31.3 Table C-1 L = length of pipe in feet ‘An Bxpansion Loop Example: Thermal Growth Determine the total growth of @ 800" carbon steel line. The line operates at 400°F. Steps of A Step 1: From B31,3 Table C-1, determine the Thermal Expansion Factor “P”. F=270 Step 2: Calculate total Thermal Growth “G”, G=(PxLN00 G= (2,70x 800/100 G= 21.6 inches Watch Outs 1! + Negative temps this is how much cold pipe shrinks + Don’tuse Table C-3 Exercise 2-7 Thermal Growth 1. Determine growth of a 400° SS line that operates at 70°F. 2. Awheelwright is making a 5’ diameter stagecoach wheel. Before placing the carbon steel rim. on the wooden wheel, the rim is heated to 1400°F. How much does the diameter of the rim grow? 3. A 12” diameter carbon steel tube is welded to a 12” SS tube. The tube operates at 800°F. a. How much does the diameter of the CS tube grow? 2. 083") ” b, How much does the diameter of the SS tube grow? Ovo” c. Describe the condition of this dissimilar weld, A Oly Ser» APIS70 Certification - Copyright MSTS 18Y Ways to inerease flexibility ™ Make changes in direction ™ Expansion loops ® Suitable anchors and guides * Expansion joints @ VY Watch out for branch connections Y Stresses relax over time Definitions Anchors: Prevents movement in all 3 di Pipe Flexibility 331.3 - Pipe Design Y Components " Anchors and Guides ™ Hangars ® Sliding Supports (shoes) ® Spring Supports (Constant and Variable) * Counterweights cctions (‘x”. “y”, and “2”). a Guides: Prevents movement in 1 or 2 directions. Allows movement in only 1 or 2 directions. € 2 ypical Guide Restricts movement up/down and sideways APIS70 Certification - Copyright MSTS Concrete Counterweight Sometimes used on large lines. Important to cheek cables and pulleys! 19B31.3 - Pipe Design Pipe Flexibility Thermal growth puts a tremendous torque (also called a moment) on the pump 6] Hot Piping systens inst be adequately 5 ‘Mechanical equipment and pressure relief devices are very sensitive 10 2 Both have very smooth sealing surfaces? ON Pipe Support This needs major design ro rH changes! ON LEN Now installation. The support carries When hot, the pipe grows ani does not rest on ‘most of the weight of the pipe. support. The pump carries all the load. Also the Loricontal growth of the pipe twists the pump. anchor anchor support ©) @) Spring Can Variable Support ££ £=\ To solve the above problem, the designer could add a Spring Support and an Anchor. A spring support will continue to hold “the load” as the pipe grows. The anchor will keep the twisting off the pump. Note! This must be thoroughly designed. APIS70 Ceniification « Copyright MSTS 20B31.3 - Pipe Design Pressure Protection | Y Most piping is protected ¥ Fabrication of Devices by relief devices that are po aeygy «; designed to protect other Ey ateealtaatee equipment (e.g. vessels) : Y Full area stop valves can V Set Pressure be used on inlet and " Per ASME Sect. VII | outlet of relief device Div. 1 * Thermal relief valves cant be set at 120% of e ED, Design Pressure Et Definition Stop Valve: A block valve Swe KS Thermal Relief Device ao Thermal Relief Valves are typically needed on long runs of pipe that can be blocked in (typically found in a tank farm). “Heat from the sun warms the lines. As the produ teniperature increases, the pressure builds in “blocked-in" lines. A small thermal relief valve usually with 4 NPS connections is installed to protect the pipe. Normaily the thermal relief outlet just bypasses one of the closed valves. API570 Certification - Copyright MSTS 21API 570 Certification B31.3 - Pipe Fabrication + Ee pe “And Pm supposed to inspect this?” fe “The wise man will hear and increase in knowledge” APT570 Centification - Copyright MSTS31.3 - Pipe Fabrication 9 Module Objectives Y Determine the Minimum Design Metal Temp ” W Familiar with welding restrictions Y Familiar with basic fabrication requirements Y Determine Preheat & PWHT temperatures Y Know the NDE requirements for new pipe a Y Evaluate weld discontinuities Y Culeulate hydro and pneumatic test pressures This module will cover Chapter Il, V & VI in B31.3 \ydlow toot SK, Vert ta rene lar dtl foeert NIE Beer On tare Reale 4 mC Wrst owget 4 Sbeera> ow v a API S70 Certification ~ Copyright MSTSB31,3 - Pipe Fabrication Material: | V Listed Materials: Material "listed" in B31.3 in either; Table A-1 or Table 326.1. Y Unlisted Materials: Mat'ls not "listed" in B313 ® Use only if they meet the material property | requirements of the Code Y Unknown Materials @ * Can not be used for pressure containing components Y Selection of material to resist corrosion is not within the Scope of the Code. (323.5) API S70 Certification - Copyright MSTSB31.3 - Pipe Fabrication Low Temperature Limits Y Brittleness of a material is a major design issue for all types of pressure equipment, A brittle material can fail catastrophically I! Y Some of the factors that affect brittleness of a material include: ® Material * Temperature 1 " Stress Level * Thickness The opposite of britleness is “Toughness”. Brittle materials have low toughness. Ashland Oil's Brittle Failure - 120° Tank Points 4 & 5 used to be connected? cl ee ) -& ae Si en Geootinnte in Wore: Classic Brittle Failures: J. The Titanic 2. World War I - Convey Ships in North Atlantic 3. Kuwait Refinery - Leveled a 400,000 barrel refinery APL 570 Certification - Copyright MSTSY Minimum Temp per Code Hen ttl Tee + hn 68 Le Care Ler V het is enperaare "ater * thematerl mn be tnget tote a dhe epee oa “Neel Reends ‘Seite 1. Find Curve Letter - Table A-T 2. Find Initial Min, Temp Use Table 323.224 (tyennad © Check Notes - Fig.3232.24 3. Uf Stress Ratio ' Fig.323.2.28 Reduction Temp Batra be (Ses Rat ArGurse go vera eRe Temp * Subtract Reduction from Step 2 Impact Test Acceptance Criteria 1% Bach set has 3 bars 2. Average > Table 323.3. | 3. Minimum > Table 323.3.5 4 Only I specimen < Table Ave | | | Carbon Steel Low Temp Process we : He : 2y° Exercise 3-1 Minimum Design Temperatures!! or i By 1) What is the minimum design temperature for 4-335-P5? (5% Cr) —_ 2. - 2) What is the minimum design temperature for A-358 Type 304L? Hos OF 3) What is the minimum design temperature for a 0.750" pipe that is made from A-106-B? 4) What is the minimum design temperature for a 0.500" pipe that is made from A-516-60 plate, and is normalized? ~ 5) What is the minimum design temperature for a 0.625" pipe that is made from A-106-C and has a Stress Ratio of 0.90? 6) If the designer wants to use a pipe material below the minimum temperature allowed by the B31.3, then the material must be: _(wpaet -Coateel _ 2) Impacting testing is performed on an pipe made from A-106-C. (a fully deoxidized steel). Determine the following: Sees a. The impact procedure must follow what ebdes? A- StotAs2 b. The set consists of how many bars? 3 ¢. ‘The minimum average for the set is: 1S tet d. The mininun value for a single bar is: 1D ib € How many bar(s) can be below the required average? Lec API-570 Certification - Copyright MSTS3831.3 - Pipe Fabrication Fabrication - Welding Y Qualified Weld Procedure V Welder Idemtfication * ASME B&PY Section IX * Unique ID or Symbol * Can accept some Procedures qualified by Others Y Welder Qualification * Stamp each weld, or; Use weld maps + ASME BaP Secon ix Tacks weld * Can ascept Qualifications by Fused withthe oot pass others © Made by a qualified welder : Y Welding Records Y Bad weather - don’t weld * Bnpioyer maintain Y Fillet weld staing procedures and performance records * Figure 3285.2 Min. weld size 1/8" Other Miscellaneous Requirements 1. excessive misalignment, taper with a maximum angle of 30 degrees, 2. Peening is prohibited on the root & final pass. 3. Seal welds allowed, but must cover all exposed threads, 4. Flange Alignment a, Parallel within 1/16” per foot (diameter) b. Bolt holes aligned within 1/3” “m 5. Bolt Length: Bolts should extend completely through the nut. If not, has to be within one thread of complete engagement 6. Gaskets: Only 1 per flange assembly APL 570 Certification - Copyright MSTS9g 331.3 - Pipe Fabrication Welding & Distortion Y The Principles "Thermal Growth - As metals heat up they expan When cooked, they shrine ¥ A meta’s strength decreases wih Increasing tomperatires Y How Distortion Occurs 1. The are is initiated. 2. Hot surface expands & distorts the plate + Not much since the hor sie is much weaker than the cool side 3. Completed weld, as heat moves essay from wold, Weld contracts 4. Completed weld is distorted & has residual stresses Notes! Stresses from Welding D 4 3) When we apply heat in a non-uniform method (welding) the result is a dimensional change causing the part to be distorted or warped ‘The Principle - As the metals cool they shrink, A CS weld that is %” wide will shrink about 10 mils, + The base meial is “anchored”. As the weld shrinks, the base pulls the cooling weld. (Tensile Stress) + Athigher temperatures, the weld metal is weak and ductile, It can be pulled and reshaped to account for shrinkage. + Atlow temperature, the weld metal is stronger and less ductile, It is not easily “reshaped”. + Remaining pull on the weld once cool - “Residual Stresses” + If Residual Stresses exceed, strength of weld — Crack Residual stresses can be reduced or eliminated by: + Preheat : + Thermal heat treatment + Peening - pnewnatic hammer used fo pound on welds, e.g, jitterbug type of equipment API S70 Certification - Copyright MSTSB31.3 - Pipe Fabrication Preheat & PWHT Y Preheating (330) * Used to minimize detrimental effeets caused from welding " Preheat temperatures; Use Table 330.1.1 ® Preheat zone shall extend at least 1” from toe of weld Y Post Weld Heat Treating (331) * Used to relieve detrimental effects caused from welding " PWHT temperatures: Use Table 331,11 PWHT zone shall extend at least 1” from toe of weld Partial HT: Minimum overlap of I’ Local HT: Full circumference Hardness Testing: + Wert 125 of Furnace wll, 1% of dls ‘cise 3-2. Pre-Heat and PWHT!! 1) Determine the minimum preheat temperatures for the following situations. Circle whether > y 3» ye 4 3 9 the pre-heat is required (Req'd) or recommended (Rec). a. 0.750" thick, P-1 material, SMTS = 65 ksi Req'd or Ree b. 0.250" thick, P-8 material Req'd or Rec . 0.500" thick, P-1 material, SMTS = 75 ksi Req'd or Ree d. 0,325” thick, P-5C material Req'd or Rec e. 1.250" thick, P-l material, SMTS = 70 ksi Req'd or Rec At whet base metal temperature, do all the recommended preheat temps became regiired preheat temperatures? Determine the PWHT temperatures for the following situations a. 0.730" thick, P-1 material, SMTS = 65 ksi b. 0.250” thick, P-8 material © 0.875" thick, P-I material, SMTS d, 0,325" thick, 3% Cr material 70 ksi What is the mininuon holding time a PWHT conducted on an a Carbou Steel pipe that is 1.500” thick? ’ What is the minimum holding time a PWHT conducted on ana Carbon Steel pipe that is 0.875” thick? What is the minim holding time a PWVHT conducted on an a 9% Cr Carbon Steel pipe that is 0.750” thick? APL 570 Certification - Copyright MSTSB31.3 - Pipe Fabrication | Examination Y Category D Y RE Criteria; Table $41.3.2 = Some visual "Tw wall thickness ‘Normal Service nd” means "Teser of vais” * Some visual: maierials, ¥ Progressive Sampling fabrication & assembly Random Exam Reject » Visual: 5% of all © Take? more Visual: 5% of alt welds * If these are OK, repair & stop Vg BE 50f cia weld Be eet ‘Severe Cyclic Take 2 mare for each reject pater Seoceuta e Fabrication & assembly yam al or Repair all ee odes ay cine welds: * Only those represented by ® MTIPT: All socket-welds ‘thi Randou cam oe Exercise 3-3 NDE!! 1) Anew Normal Service pipe is fabricated. The wall thickness is 0.500” Determine the maximun allowed dimension for the following discontinuities a. Crack ° b. Lack of fusion ¢. Length of slag inclusion d. Width of a slag inclusion e. Cunmulative Length of slag inclusions £ Depth of Undercut g Length of Undereut A Maximum Cap Height 2). AUNDE methods shall be performed in accordance with ne _E : 2) AIINDE personnel should be qualified in accordance with _ QA 1p NDE Definitions - Texas Style 100% Examination: “All of Al” , Random Examination. “All of Some” ‘Spot Examination: “Some of ll” Random Spot Examination: “Some of Some” APL 570 Certification - Copyright MSTSPressure Testing * Minimize the visk of britle V All new pipe is tested ® CatD - Service Test Pr AP ¢ Y Minimum Hold Time Y Joints - Uninsulated — Pees B31.3 - Pipe Fabrication Y Purpose of testing Hydrotes * Find teas in joins Sree * Greate higher stress than LSP xSr the operation stress Pr 5 fracture vwhilei-service Pneumatic test 0.5 Pr or 25 psig essen) * 10 minaes Pry = LAPr or Pr +50 psig (essex) Sx Allowable Stress at Test Temperature (Usually @ 100°F. ) Why Sr/S? Note that Sr/S will always be> 1.0. If greater than 1.0, then the pipe will be tested at a pressure higher than 1.5 x Pr. A pipe will abvays be tested at or near ambient temperatures. But at ambient temperature, a material is stronger than at some elevated temperature. So, for pipe that is designed for elevated temperatures, Sr/S adjusts the test pressure upward, recognizing that the material is stronger at test temperature (Actually (P x Sr/ 8 ) is basically the pressure this pipe is “good for” if it was revated to a design temperature of 100 °F.) Exercise 3-4 Pressure Test!! 1) Determine the required hydrotest pressure for a 8 NPS pipe. The design pressure is 500 psig at 600°F. The pipe is made of A-106 Gr A material. P= LS (600) * Veood VA ROD Determine the following pressures, a. Test Pressure b. Initial System Pressure c. Maximum Relief Valve Pressure d._Inspeetion Pressure API 570 Certification - Copyright MSTS \ 10.8) psi 2) A pneumatic pressure test is going to be performed on a 16 NPS piping system. The design pressure is 100 psig at 300°F. The pipe is made of A-106 Gr C material. DS asia, wloo = Wopa 10i Module Objectives At the end of this module you should know: v The purpose of Section V Y How Section V is organized v Specific NDE Terms | ~ VY Know how to quickly find exam : answers Inspector Joe .."E think T can, I think Fan, I think 1 can, leara NDE!" Time to Tab ! Tab the Table of Contents for the Various Articles Article 2- “RT” Article 6- “PT” Article 7- “M1” Article 23-797 “UT” MSTSMSTS ASME Section V-NDE The Code’s Purpose Section V sets requirements to assure that a | “quality” NDE examination is conducted ® Guidance on NDE method "Limits placed on NDE method " Acceptance Criteria for Evaluating NDE Exam ™ Documentation requirements Y it does not establish: | = The Acceptance Criteria for a weld or component ® Qualifications for the those performing the NDE Examination Examples of Section V 1) Guidance on NDE method a) When using a Black light for PT or MT exams, the light should warm up for 5 minutes prior to the exam b) A lead letter “B" shall be placed on the backside of a fibn when shooting a radiograph 2) Limits placed on NDE method @ When performing radiography, only use ASME hole-type or wire- type penetrameters 3) Acceptance Criteria for Evaluating NDE Exam @ RI Film density in the Area-of-Interest must be between 2.04.0. 4) Documentation requiremems @ On radiographs - Film ID & Location markers are required 2 Pagp, The Section V Key - Did the NDE technician perform a quality exam!!!MSTS ASME Section V- NDE Organization of the Code | Y¥ Two major Subsections © Subsection A: Provides guidance for each Method ® Subsection B: Non mandatory practices Y Subsection A - NDE Articles | ® Scope & General ® Equipment * Calibration All Articles are similarly organized ® Examination ® Evaluation ® Documentation LE Eee eee ee Sree eee eee ree PeEE aH Note! Notice that the Organization of each Section V Article is the same, it follows the steps of an NDE exam. First, .. get the equipment, then ... perform any required calibrations, then ... perform the exam, then ...perform the evaluation, and ...finally document the results !!! For example, an IOI (penetrameter) is used in radiography. You will not find @ single paragraph in Section V that discusses all the important information concerning the IQI. The IQI is discussed in which RT paragraphs? 1) Equipment: What type of IIs can be used? 2) Examination: Which size of IQI should be used for a specific RT exposur 3) Evaluation: When evaluating a RT, what's ihe role of the IOI? Also ... Section Vis a “referenced” Code. It only applies if it is referenced by the Primary Code.WN MSTS ill ASME Section V~ Article 2 - Radiography Our focus will primarily be on Radiography. There a number of concepts you need to know: = Basic RT Principles Examination technique (single or double wall) Viewing mode (single or double wall) Selection, Placement & Evaluation of the IQI Backscatter Prevention & Evaluations Film Density Evaluations Film Identification | Geometric Unsharpness There are a number of important steps the radiographer must do during the examination. When evaluating the film quality, the inspector must know what was required. Once upon a time ... a RT tech radiographed a 6 NPS pipe weld in the pipe rack (wall thickness was 0.400"). The tech did not have access to the inside part of the pipe. The fabrication Code was ASME B31.3. For this examination, the radiographer did one exposure using the elliptical method. During the examination setup, the tech used a #17 hole-type penetrameter and placed the penetrameter on top of the weld, parallel with the weld, The tech also placed a lead letter "B” between the pipe and film. No other markings were used. Later, ... you, the seasoned inspector, reviewed the film, ... the weld looked good, ... but you still rejected the film. Why? ... only because the tech did at least 8 things wrong, and many of these affect the film quality!!! At the conclusion of this module you should be able to pinpoint each of these errors made!MSTS ASME Section V-NDE | RT Setup Technique Y Single-wall Technique * Radiation only passes through I wall (1-271.1) " This is a preferred method (1-271) ™ Must have access to both sides of the part = With a single exposure, can RT with a single film or with multiple film - a" panoramic” Y Double-wall Technique *" Radiation passes through 2 walls (1-271.2) ® Used only when access is not available to both sides of the part Note! All References in this section refer to ASME B&PV Section V Fill-in the blanks Fen Film Side 3 The “Panoramic” Shot The “Contact” Shot stl - wall Technique {_- wall Technique etl - wall Viewing - wall Viewing Application: Application: Source Side Film Side laASME Section V-NDE Y DW Tech - Single Wall Viewing ¢-211.20) ™ Source is placed on one side of pipe, and the film is wrapped around other " “Blow away” the wall where the source is placed = A minimum of 3 exposures - 120 degrees apart Y DW Tech - Double Wall Viewing (7-271 20) ‘Elliptical shot” which is similar to a “Profile RT” ¢ ® Source is placed away from pipe, and film is left flat * Only for outside diameters < 3-1/2” ® Requires 2 exposures 90 degrees offset Time to Think 11! Why is it called single-vall viewing even though the radiation passes through 2 walls? Ore rath 2 eloaecl Cera Fill-in the blanks Optional OMe ag The “Contact” Shot The “Elliptical” Shot S.___- wall Technique - wall Technique - wall Viewing = wall Viewing Application: MSTS 7MSTS ASME Section V-NDE i = | Penetrameters - IQTs Y The function of the Penetrameter 1 1's how the sensitivity of RT is validated 8 If the “essential” hole/vire can be seen, then any discontinuity the same size or greater should be visible in the RT Penetrameter Types (0233) ® Hole-type - small plate with 3 different sized holes (Table T-233.1) ® Wire-type - plastic holder with 6 different sized wires (Table T-233.2) What are the other names for the Penetrameter? ASTM SE-747 Wire-type IOIASME Section V-NDE | IQIs - Material & Placement Y Penetrameter Material 7276.) * The same alloy material group as the part being RT'd *» Material Groups ate listed in SE-1025, * The material groups are based on material density Y Penetrameter Placement 277.) | ® Ifaccess permits - place IQT on the source side (4) e@ "If IQL is on film side - indicate with a lead “F” (b) ™ Hole-type IQI - adjacent and parallel to the weld (c) ype IOI - perpendicular across the weld (d) ee = “only the “ZT hole? was es oom O-o this easy to see on the RT it!” ee this esy se on the RT LED : | raztien sna | eeepc: "2 ul ——— our Oe i919) Xo. | See | an Ko. SitSoeme LX ASTM SE-1025 Hole-type IQU I tH SeZeinm py O°} Time to check Section V: Ko. | evar ay 1) Can a hole-type IQI ever be placed on the weld ? Peete ons Kos | ee, flo? | 2) What does the “2T” represent? ASTM SE-1025 Hole Type IL - Material Groupings MSTS 84 MSTS ASME Section V-NDE IQIs - Size & Number Y Penetrameter Size * Use Table T-276 to select IOT = Watch out {!! * Source side vs. Film side + Hole Type vs. Wire type v Number of Penetrameters 7-277. ™ one per film, except ... ® for panoramic shots - 3 IOI’s placed 120 degrees apart ™ other exceptions ... “Source side or Film side, Hole-type or wire-type 2: ae > TABLE T2765 ral SELECTION Penetroreter 2 nin Sere Sie Fl Sie Sele Hat a NateralTlekees ole Tipe Ese wee I Hoietype Essent Whe avg, Sesion Hole —_Diamet ta {ff Onan -_ Mle Dinter, tpi 025, B ra 2.008 7 ar ra er 0. beh 0.378 35 ar Soro % ar o.ace fv 0375 tron 080, ” ar sons 5 ar oie er 050 bru 075, 2 ar oo D Ey dos O.e 075 tee 1.09 B a S20 2% ar oie 1.0 reuph30 x ar o.oas = ar Saxe e150 may 200 3s ar fiona 4 or fines e200 tau 250, 2 ar 080 x a ose ‘ne 250 tra 4.00, 0 ar dios % ar ote Sie 400 tram 6.0 @ ar ous 0 ar 050 6.00 teu 8.00 = ar ai & ar O83 ther 800 trash 1000 109 ar as 2° ar e300 Se 1900 Uren 1209 20 2 aso wo ar oa Ove 1200 wash 16.09 160 ar 0250 20 ar 80 Deer 160g 20.00 200, ar e320 10 ar 250 Notes “Through” means “including” 10ASME Section V-NDE IQIs - Selection Exercise NDE-1 Aweld side. I) Which sice of wire-type IOT should be used? _ £5. 2) What ASTM set would be used for this wire? __& 3) Which size of hole-type IQI would be used? _[ 4) What else should be visible in the RT? lottec'F 0.375” thick and a IQI is placed on the film Exercise NDE-2. Select your IQT A vessel circumferential weld is being RT’d with a single exposure using 21 film wrapped around the weld. (This would be the panoramic shot!) The weld thickness is 0.800". ? I) Which size of wire-type IOI would be use a 2) What ASTM set would be used for this wire? B 3) Which size of hole-type IOI would be used? 2S 4) What diameter is the 2T-hole? Cosd 5) What's the minimum: number of IQI’s to be used? 6) What type of technique is used? 7) What is the viewing mode? MSTS OT) gea(r) os (sd rr; 4 ASME Section V- NDE IQIs - Miscellaneous Y Reminder !1! The 11 checks RT sensitivity Y The filin density at the IQI and weld should be similar, The weld density should not be less than % of the IOI. With a weld cap, these densities will differ significantly (the weld will have a lower density) | A shim under the IQT can be used to assure the | densities between the IQI und weld are similar | ¢ ® Use radiographically similar material * Shim must be bigger than IQI, at least____sides visible on RT Ifa hole-type 101 is placed on the weld, IQI & Shim Placement the IOI munbers “XX” must be outside the Area of Interest NAAN ANANANS SS aim im (b) Doublo.Wall Technique, Single-Wall Viewing, Wall Reinforcement, No BackUp Strip MSTS 12MSTS ASME Section V- NDE Backscatter Backscatter definition ® Radiation bounces off an obstruction and strikes the back-side of the film. (Yes this exposes the film!) ® Backscatter will decrease the RT quality Y How to handle " [fin a congested area, most iechs place a lead screen on the back of the film to prevent backscatter * Place a lead letter "B” on the back of the film (1-223) ® A light image of a “B” on the RT indicates backscatter 13ASME Section V- NDE RT Markings | Y RT Identification - Each RT marked: 7-229 = Contract = Weld Number ™ Manufacturer’s Name or Symbol ™ Date Y Location Markings are used to identify specific locations on a specific weld 7.275) " Marked on Weld ™ Marked of Film Exercise NDE-3 Time to Think! ? 1. When are RT Idemtification and Location Markers very important? 2, Answer the questions based on the illustrated RT examination, Dov a) What technique is being used? 4) What type of viewing is this? Dulps 4 ) What's the maximum pipe size for this RT? Zz Alyy @ How many exposures are required? - MSTS 14MSTS et anaseee eee aanasee eee anceeEE EE HSCoeEEEEESSCCeEEEETGEE | ASME Section V-NDE Film Evaluation ~ Overview | | | Previously we have focused on performing the RT examination, now it’s time to evaluated the RT film. The evaluation includes reviewing: = Film density "= IQT (Penetrameter) = Backscatter "Geometric Unsharpness *™ Other There are two primary steps in performing Film Interpretation, 1) Evaluate the Film Quatity 2) Evaluate the Weld (Area of Interest) Quality This module will cover the first step - Film Quality Note! Many inspectors miss this step. They go directly to Step Two. But ... if the film quality does not meet the acceptance criteria, defects will be missed! The Codes uses the term “Area of Interest” (Aol), We're using RT to evaluate weld quality. So for our purposes the “Area of Interest” is the weld. This Code is also used for RT’ing castings. With castings the “Area of Interest” is some specific part of the casting. 15Film Density is the darkness of the fi Y Density is measured with either: ® Calibrated step wedge film (1-225) v Density acceptance standards 282.) e ™ Aol is within -15% to +30% of the IOL 282.2) ASME Section V- NDE | Evaluation - Film Density | lm, ® Densitometer (most accurate way!) (1-225) ™ For Gamma Ray, IOI & Aol - 2.0 io 4.0 (r- a SEER EEd ECCS ASEH Film Density is the darkness of the film. It is based on how mucl through a film th light passes High film density is__2~® Low film density is YU, What is the technical meaning of the density numbers? Density Amount of Light Passes Through Filo 10 10% 20 1% 30 0.19% 40 0.01% Why are there density limits? 1) Film too dark or too light can defects! 2) Since the IQT is used to determine the sensitivity of the RT. the IOI and weld should be similar! MSTS | the density of 16MSTS ASME Section V= NDE Evaluation - Film Density _ | OL Example Ifthe IOI density is 3.0, what is the minimum and maximum density allowed in the Area of Interest? (that's the weld!) Min Density = 0.85 x IT = 0.85 x 3.0 = 2.55 Max Density = 1.30.x IOI = 1.30 x 3.0 = 3.90 Copy these formulas in your Code To determine the acceptable density of the Aol: Minimum Density of Aol (Area of Interest) Aol Density = 100% of IQI Density - 15% = 85% (or 0. 85) of IOL Maximum Density of Aol (Area of Interest) Aol Density = 100% of IOI Density + 30% = 130% (or 1.30) of IO Exercise NDE-4 Area of Interest Density Afthe IOI density is 3.8, what is the minimun and maximum density allowed in the weld? Min Density = ORs ~ Br Max Density = HEHE (st sate test 7¢ MSTS ASME Section V-NDE Evaluation - IOT Check IQI Placement * Hole-type IOI - adjacent to weld or across the weld | ® Wire-type IOI - perpendicular across the weld | Acceptance Standards " Correct IO used (Table 7-276) ™ Hole-type IOI - * Mast see 2T hole (1-283 & Table T-276) + If shim is used, must see 3 edges of IQI. 1-277.) " Wire-type IOT- Must see designated wire (7-283) * Lead letter “F” used if IOL was placed on the film side 18MSTS Backscatter definition | " Radiation bounces off of obstructions and strikes the back-side of the film. (Yes this exposes the film!) * Backscatter will decrease the RT quality Backscatter’s acceptance standard 7-234) 4 Rejectable film - A light “B” appearing in a dark area " Acceptable film - A dark “B” appearing in a light area | Here’s Backscatter Note! How do you get a dark “B”? The radiation bounces off of the __Gz ASME Section V-NDE ‘ — aa Evaluation - Geometric Unsharpness Y Geometric Unsharpness is the shadow that can be seen around the image edges. Y Factors affecting Unsharpness include: * Diameter of the RT Source ® Source to Object distance ; ® Object to Film distance : Y Unsharpness is usuglly not an oO issue with weld quality shots! Acceptance Criteria (7.285) y Exer ise NDE-5 Unsharpness! Fill in the blanks on the sketch with the appropriate letter. \o A, Unsharpness B. Source to Object Distance C. Object to Film Distance itv __ D. Source Diameter “~ Time to Think! The Geometric Unsharpness increas 1. The Source diameter _P__ 2. The Source to Object distance g 3. The Object to Film distance >. MSTS 20ASME Section V-NDE [~ Eyaluation - Other | Y No film artifacts that affect the IOL or Aol. (e.g. fogging, streaks) (7.281) Vv RT identification (7-224) ™ Weld tt ™ Date > ® Etc, Y Location Markers: cr27 Time to Think! What if the RT film quality does not meet the Aeceptance Criteria? Generally, it needs to be reshot! Usually the NDE company should not charge the location for weld quality reshots Go back to page 5 of this module and try to idemify the errors made in the 2) Story of “Once Upon a Time”. Answers below (don't cheat, God is watching “e you!) Moy one ope af epeure 3) rons lcaon or “B* 2) Wrong # of exposures 8) Missing "F" 3) Wrong 1 2) Missing Location Markers 4). Wrong 1QK placement 8). Missing Film Identifteation MSTS 21MSTS : Other NDE Methods The other NDE Articles are organized similarly to RT. Equipment ... Calibration ... Examination ... Evaluation ... Documentation, — Most of the terms will be familiar. VY Ultrasonics - Article 5 "Very technical - questions limited Y Liquid Penetrant - Article 6 Y Magnetic Particle - Article 7 Visual - Article 9 (API 570 Only) Y Leak Testing - Article 10 (API 570 Only) Use Section V's Index & your knowledge of the Code's organization to answer exam questions. For example; How is an AC MT yoke calibrated? 1) What method? Magnetic Particle — Article 7 2) What section of the Article? This is a calibration issue, Per Index see; T-760 Bingo !!! Even though Section V is over 700 pages long, you have the answer narrowed down to Paragraph T-760 which is less than I page long! That’s how you use the tool to your advantage! A Section V quiz, which is included in the Manual, will give you practice at answering these type of questions. 22ASME Sect IX - Welding At the end of this module you should know: Y The purpose of Section IX Y How Section IX is organized Y Specific Section IX terms; positions, P#, SMTS, ete v How to evaluate a WPQ3 weider’s papers @ v How to evaluate a WPS/POR3 wetd procedure ¥ How to quickly find exam answers — nue A ‘ i: FP Pacemf ‘ WPQ - Welder Performance Qualification — WPS - Weld Procedure Specification POR - Procedure Qualification Record Welding Webster “Two “P's” with a Rod” Performance - Welder Procedure - Weld Recipe CP MSTSASME Sect IX - Welding Purpose of Section IX Quality Welds y A fine welder using a fine weld ge procedure with an appropriate environment results in an good weld. f . ‘Much of Section IX is best understood by the analogy of Baking. ‘The Welder isthe Baker, and the Weld Procedure isthe Reclpel Practical definition 2, Fine - One who has been approved by testing, one ov Good - One which meets the Arcegetinom__ Stnrrcha AS Exercise W-1 Which Code? (Sect. IX or Primary Code) Specifies how to Qualify a Welder Specifies how to Qualify a Weld Procedure e& Specifies the acceptance ria for fabrication welds A&M Specifies restrictions on the fabrication welding, Pray _oohe ie, welding processes, temperature, joint design, ... The Ke; Section IX only provides directions on how to qualify awelder or a weld procedure, All other welding directions are given in the Primary Code, eg. B31.3, ASME Sect, VII, API 650, .... MSTSwes Welder uated & FH" Qualified & Fis Primary Code Acceptance Criteria Primary Code Limitation The — Quality Welds 1. WPS - Weld Procedure Specification “the recipe” 4, Must be Qualified - Tested and passed the test Inspector - Check if WPS was correctly qualified. This usually is not the inspector's role. (This is covered in API classes) 5, WPS must “fit” the production weld being made. (CS weld requires a CS weld procedure) Inspector - Check that the WPS 2 Welder/Welding Operator a. Musi be Qualified - Tested and passed the test € Inspector - Check if Welder was correctly qualified. This usually is not the inspector's role. (This is covered in APL classes) 4, Welder must “fit” the production weld being made. (Overhead weld requires a welder qualified for overhead welds) Inspector - Check that the Welder is appropriate for the weld 3. Primary Code - Limitations a. Weld must satisfy limitations of Primary Code (Vessel Fab ~ CS over 1.5” must be PWHT) Inspector - Check that the weld design meets Primary Code limitations. This is one reason why inspectors need to be familiar with the Codes !! 4, Primary Code - Acceptance Criteria a, Weld must meet acceptance criteria of Primary Code Inspector - Inspect weld and review NDE results. Assure weld meets Primary Code acceptance criteria, is appropriate for the weld MSTS i.a 0 ASME Sect IX - Welding A . Qualifications | Y Qualification of Others « Lawyers - Training & Pass State Bar * Nurses - Training & Pass State Boards «API Inspectors - Experience & Pass API Exam * Welder - Make a weld & test it Y Qualification of Procedures Cowiseto a) » Betty Crocker - Use a new recipe & test it e ® Operating Procedure - Develop & extensive review * * Weld Procedure - Make a weld coupon & test it Data recorded on WPQ AN A Qualifying Joe Welder Qualifying the Weld Procedure MSTS Make Test test the ‘Pass Test?) Weld Weld Non-qualified welder Data recorded on POR Make Test test ==] the Coupon CouponCode Quotes € MSTS f h ASME Sect IX- Welding Why Section IX Why is Section IX used to qualify welders and procedures? Because it is REFERENCED by the Primary Codes. OU ee x“ “There are other Welding Codes; AWS Dl.ty API 1104, ete. Hut the one primarily used inside Petrochemical Facilities is ASME Section IX, Piping “Qualification of the welding procedures to be used and of the performance of welders ... shall conform to the requirements of BPV Code Section IX, ...” B31.3 - 328.2.1(w) Vessels “The procedure used in welding ... shall be qualified in accordance with Section IX.” ASME B&PY Section VII - UW-28 “The welders used ... shall be qualified in accordance with Section IX.” Section IX.” ASME B&PY Section VIII - UW-29 Tanks “The erection manufacturer and the fabrication manufacturer,...shall prepare welding procedure specifications and shall perform tests .. as required by Section IX of the ASME Code...” API 650- 7.2.1.1 “The welders ... shall be qualified in accordance with Section 1X of the ASME Code” API 650- 7.3.2 Similar text is in the Inspection Codes for Repairs & Alterations welding.MSTS ASME Sect D Organization of Code Y Article 2 - QW-2xx Procedures (text) Y Article 3 QW-3xx Welders (tex VY Article 1 OW-Ixx Testing (text) VY Article 4 QW-dxx Misc, (chars, tables) Organization Aids "Table of Contents (Front of Code) = Index (Back of Code) "Definitions (QW-492) The book is divided into two Pants: Part 1~ Welding (he QW portion) Part 2 - Brazing (the OB portion) Brazing is not commonly used in the petrochemical business and is not part of the API exam, Suggestion: Read all the appropriate text in the Section IX. The welding portion consists of about 175 pages, but... there are only about 25 pages of text Every Paragraph starts with a “Q”. The “Q” represents ! You may want to move the Index to the front of the book.Solving Welding Questions ‘START HERE Qw. if W432 ” QW-461.172 Pastens Article? Article 3 One of the most common mistakes ... thinking all welding questions are answered in Section IX. This flow diagram should be your “Thought Process” ‘on determining whether the answer is in Section IX or the Primary Code. MSISY P-Number - Parent Material All ASME recognized materials are assigned a P-#. ‘Similar materials are given the same P-#. VY SMTS - Specified Minimum Tensile Strength Each ASTM/ASME material is assigned a SMTS. This indicates the STRENGTH of the material. A material's P-# & SMTS is listed in Table QW-422 ‘Similar materials are given the same P-#. Carbon Steels are classified as P-1 materials. Generally, the higher the alloy, the higher the P-i. P-1 Carbon Steel P-3 Carbon - 9 Moly Ped 14% - 2% Chrome PS 2U0%5-996 Chrome P-6 12%. 18% Chrome (low or no nickel) P-8 ChromeiNickel Alloys (e.g. 18% chrome, 8% nickel) ercise W-2 P-Numbers & SMTS Find the P-#, MTS and Product Form for each of the following materials, Material P-Number | SMTS (psi) | Product Form SA-556.A2 7 d 4-4 fesn |S beige SA-351 CF3 - do Wey pee b ley 1 Sets -lu bey MSTS 9ASME Sect IX- Welding | Code-ology Y F-Number: Filler Material & V A-Number: Analysis of Weld Metal Y Welder vs. Welding Operator = Welder - Manual Welding # Welding Operator - Runs a welding machine @ A filler rod’s F-# is listed in Table QW-432 Weld analysis A-t is listed in Table QW-442 fe What F-# is an B-7018 electrode? awase Faburaens Grouping of Elects and Weldg Rods or alfeton a Te TSE atin Ke 7s cast es € shel an el le saa 1 stesatss x,t, 004 ena, 8 : Suse boas, ence : teasiess Bem E403, ext 0 ‘ stasa uss bons, extn, 8, exes 7 SFA. er than ara dil Bae) eae ea? 5 S54 este ad det foo, e106, x07 : Seabar owen, extox $ Sinaa Ena eee c00t : Age Er S00, CHAE AK Note! “XX” represents any number, “EXX1O” represents E-6010, E-7010, or E-8010 MSIS 10Y Field Positions _ast- = Flat (F) ae " Horizontal (H) A welder must be qualified * Vertical (V) to meld tthe poston) required by the field weld! ® Overhead (O) See @ Exercise W-3 A groove weld is inclined 20 degrees from horizontal. The weld cap is facing directly toward the side. What is this welding position? Now c« Solution Steps A puains Waa adn - - Cente Step 2- Which Leter? 2, Determine Letter (A thru E), based |} ei net orerasaen eee QW-461.1 POSITIONS OF WELDS - GROOVE WELDS Step 1 - Which Weld, 1,2 or 3? Based on angie. MSTS ilMSTS Et is ASME Sect IX - Weldin ! Welding Positions Y Qualification Test Positions Positions used during the Welder's Qualification testing ® Plate or Pipe ® Orientation (1, 2, 3, 4...) * Groove or Fillet (G or F) Welder Welk Mlustrates the Positions “Ahh 1, Ahh 2, Ahh 3, and Ahh 4” Plate Positionsf MSTS V Tension Test - strength of weld/HAZ * Pulls the specimen apart Y Bend Tests - “Soundness” of weld "= Take a specimen & make a “horseshoe” Y Visual * Surface weld defects VY Radiography = Internal weld defects Testing is done when qualifying a: 1 Weller 2 _ Prriedunrr . Note! These tests and their acceptance criteria are used only when qualifying aweider or a weld procedure. These acceptance standards are not used to evaluate a fabrication or repair weld. Fabrication and repair acceptance standards are found in the fabrication and repair Codes!i M ASME Sect IX - Weldin; | Tension Test (QW-150) Y Purpose - Determines weld strength VT; rypes of tests = Reduced Section & | ® Round/turned » Full Section Failure stress “S,” calculated b, S,;=Load/Area bh /in? (psi) Acceptance criteria QW-153 Weld Breaks Materials joined - Same strength Sz Materials joined - Different strengths Sj> _wrtnleoe i Abe Base Metal Breaks Materials Se Other types are acceptabl sketches in Q) MSTSMSTS | 4 ASME Sect IX- Welding Tension Test (QW-150) Exercise W-4 Failure Stress 1. A reduced section tension test specimen breaks in the weld at 22,000 Ibs. The specimen is %” wide x 14” thick, What is the Failure Stress for this specimen? Sp= Load/Area = 22,000/(0.5 x 0,75) = 58666 i 2. Both of the parts joined by the weld were SA-106 Gr B. What is the minimum allowed Failure Stress for this tension test? Go, >" psi e As 3. Did this tension test pass? Yes or No § 2 Exer ise W-5 Another Failure Stress & A reduced section tension test specimen breaks in the weld at 18,200 Ibs. The specimen is 0.75” wide x 0.375” thick. What is the Failure Stress for this specimen? 7 NYA 5 GuAlt psi Exercise W-6 Minimum Acceptable Failure Stress A reduced section tension test specimen breaks in the base metal. What is the minimum acceptable failure stress if the specimen joins two pieces of SA-285 Gr C? 3 PA Minimum acceptable Failure Stress = 59,900 __ psi . 52250 psi 4a 7 = 52,250 es 15i ASME Sect IX Welding Bend Test (QW-160) | ¥ Determines whether a weld has ductility, any internal flaws, etc. | ¥ Types of Bends = Root Bend = Face Bend = Side Bend Bend Test Acceptance criteria QW-163 1) The No-Brainer Criteria - The Weld and HAZ shall completely be in the bent portion of the specimen. 2) No open defeet exceeding 1/8”. 3) Open defects exceeding 1/8” in the corners are ok as long as they are not the result of a problem in the weld, e.g, slag. mS MSTS 16MSTS Visual Exam (OW-194) ¥ Checks for External defects Y Exam prior to other additional tests VA cceptance Standards = No incomplete penetration | * No lack of fusion | " No cracks = “Gorilla welds” — Your call Strow, o¢ ayy é J Overheard in the last class concerning the instructor, "He certainly takes a long time to make his pointless“. . Did you ever meet this type of inspector? co "When his IQ reaches 50, he should sell!" Or how about this guy, a real team player? "This inspector should go far, and the sooner the better” A ME Sect IX - Weldin YMSIS Radiography (QW-191) | ASME Sect IX- Weldin, ¥ Checks for Internal defects Y Performed to ASME Section V Acceptance Standards = No Cracks, LOF, IP = Elongated - depends on weld thickness ® Rounded - size and density limitations (see Appendix I)Welder Qualificat ication he-ZHEr Joe Welder Be Coupon, oe Bend oF RT Py yo yon uaderstond hs proces a the det, | wre _indeand igo nett ea Welder Qifton 1 | Positions, Pt, FP, Pipe Diameter, thickness e0. Welder Qualification Steps 1. Qualified by weld Process (SMAW, GTAW....) 2. Welder makes a “Test Weld” 3. The “test weld” is Tested (Bend Tests or RT) 4 Uf the “test weld” passes, the Welder is qualified. WITHIN CERTAIN LIMITS |!) Data from this qualification process is recorded on the WPQ (welder's paper) w Welder Qualification Methods Per QW-300.1 A welder or welding operator may be qualified by: LD) radiography of a test _Couger 2) radiography of his initial produ flor weld 3) oF by bend tests taken from a test CO. eo 19ASME Sect IX- Weldin Y Test Coupon - Bend Tests QW-302.1/3 * Number and Type of Bends - At least 2 bends. QW-452 * Specimen shape & locations QW- 463.2 (a-h) | Test Coupon - Radiography QW-302.2 = Minimum length - 6” | ® For pipe - Pull circumference | @ ¥ I Production Weld - Radiography * Welders - Minimum length - 6 inch QW-304.1 | * Welding Operators - Min length - 3 ft QW-305.1 Test Coupons can either be Plate of Pipe {lt Welder Qualification Details 1. Ist Visual Exam performed prior to Bend Test 2. Awelder may have multiple WPQ's. a) Different WPQs for different welding process; SMAW, GMAW, etc 3b) Multiple WPQ's for same welding process. No one test qualifies the welder for all materials, F-#'s, etc. Note! Radiography can not always be used to qualify a welder, but ...bend fests alvays can ti! See QW-30d Ris nor allowed when using: ¥ 1). GMAW short-circuit mode 2) Some materials: P-21 thru 25, P-51 thru P53, ete, Ce Lee 8” MSTS 20€ is made, the welder ... shall make 2. _ consecutive test coupons Y Expiration of Qualification QW-322.1 = Welder has not used the Process for 6 months ™ Reason to question welder’s ability VY Fail a Qualification Test QW-321.1/2/3 > * Retest using same test - Flunked bends, then must pass bends - can’t substitute RT € * Do twice as much - Originally 6” weld tested, now have to pass 12” weld Code Quotes QW-321.1 “When the qualification coupon has failed the visual examination , retesting shall be by _Viswael examination before conducting the mechanical testing. When an immediate retest is made, the welder ... shall make 2 consecutive test coupons ...”” QW-321.2. “When the qualification coupon has failed the mechanical testing , retesting shall be by _twLeaher sical testing. When an immediate retest QW-321.3 “When the qualification coupon has failed the radiographic examination ..., the immediate retest shall be by the __ RT. examination method.” @ For plate: _Q__ plate coupons, each at least long 2) For pipe: _2._ pipe coupons, a total of 12" weld including the entire circumference ©) For welding operator: an addition 2 proce of the same production weld MSTS 21ASME B&PV Section IX — Welder Qualification Exercise W-8 — Reviewing a WP¢ QW-484 SUGGESTED FORMAT FOR WELDER OR WELDING OPERATOR PERFORMANCE QUALIFICATION (WPQ) (See QW-301, Section IX, ASME Boiler and Pressure Vessel Cotte) Welders name Doug Touel___ Clos mumber_aBCI23 ___Sumpno,_NceR Welding proces) useh_ SAW “ype Maal enitcaon of WPS fed by wel dung woking otxtcouen WESAMRS Bae rata) weed SAlO6 0 84106 ‘eles 0218 The ctext — Fieteh Mav or Senitomatc Variables for Bach Process (QWVS389) Atta Values Range uaifed Backing neta ed mot, welded fan Bots, (QW02) With Wit ASMEP-ND Le ASME, (Q¥A0 (Plate (X )Pipe (enter damon, pipe) illor mata spositication (SEA Classification (QW-404) Filler metal No, Filer metal yarety for GTAW, PAW (QW-404) (Consumable iaset for GTAW or PAN ‘Weld deposit thickness fr each wing process Welding position (16,56, a.) (QW405) Progression (pillow) Backing gs for OTAW, PAW, oF GMAW fuel gas for OFW (QW-408) GMAW tranate ruade (QW-409) GTAW welding cucen typefpolty Machine Welding Variables forthe Process Uset (QW-360) Range Qualified Diresvremote visual conta ‘Automate vltag conl (OTAW) Automat joint racking ‘Welding position (1G, $6, et) CConsunebla insert Bachng (etl, wold real welded from both sides, fx et) Geld Bend Tot Results | Guided Bend Tests Type ( )QW-A502 (Si) Reawls—( YQW-423G) aK REF) — () OW-4ERINY(Lone RAF) rm Visual eaination results (QW-202.4) _OK | aiographi test results (QW-304 and QW-305) _ OK (or aleratve qualification of groove welds by redingsaphy) Filet Weld - Frecue test, ‘Length nd percent of defects in ‘Macro ast fsion lle Teg size inx in. Concavitylcnvesity in ‘Welding st conducted by _ ACME Fabricator ‘Mechanical ests conducted by _ Uva abs Laborstory testo, 201-08 ‘We cetity that the statements in tis ecord rs comes and that he test coupons were prepared, welded, and tested in sevordenee With ‘he requiements of Section 1X ofthe ASME Code Onanaion ACME Dave _20 3 RoC Ready (Copied ftom ASME: RPV Case Sesion IX - 4/2000 - MTS) MSTS WA-1& MSTS a ASME, Seo IX - Welding sel Welder Qualification - The WPQ The WPQ (welder’s papers) records: 1. Welder data - Name, Stamp # 2, “Actual Values” - Data about the Test Weld + Process Used, Weld Procedure Used + Essential Variables (thickness, position, etc.) 3. Test Results + Dye of tests performed, pass vs. fail 4, “Ranges Qualified” - Limits on Field Welds 5. Certification - Authorizing Signature eg oS) Exercise W-7 Reviewing a WPQ Let's review our first WPQ. Find Doug Tozel's WPQ at the end of this section. (pg. WA-1) Remove it and find the five major sections of the WPQ! + What is the maximum thickness Doug can weld? + What ype coupon did Doug use? Pipe or Plate + What type of test(s) were performed? + List one weld discontinuity that was not in this weld. * Who certified this WPQ? + What F-Number was used for this test? + What test position did Doug use? + Doug is qualified for what field positions? + Doug is qualified for what maximum pipe diameter? Laat lca. Range Qualified - During production welds, the welder must stay within this range! Section IX? specifies the maximum acceptable range, based on what was done during the welder's “test weld”. For example: Ifthe Actual Value (the test weld) isin the 1G position, per Section IX the Range Quaiified is Flat. This welder can only make production welds in the flat position! 22Welder Qualification - The WPQ | Essential Variables Y Factors with Significant Impact on Weld Y Defined by Welding Process (QW-350 or QW-416) Y Must be recorded on the WPQ * “Actual Value” data about the “test weld” = “Ranges Qualified” limits for field welds Essential Variable - If a production weld is outside that allowed by the WPQ's range qualified, it is Essential that the welder be requalified! | QW-353 SHIELDED METAL-ARC WELDING (SMAW) Essential Variables | Paragraph Brief of Variables Reference/Comment | QW-A02 Joints 4 | - Backing “est bekng an tt weiter | Qwa03 Base Meats [16 | 6 Pipe diameter | qw-ase | 18 6 P-Number QW.423.1 Qw-404 Filler Meats [15 | 6 F-Number Qw.433 30 | 6 tWeld deposit | Qwe452.1 | QwWw-A0S Positions [1 | + Position Qwetels | 3 | ANY Vertical welding [Samo as tesed Ly tritein your Code Time to Highlight! Highlight SMAW, SAW, GMAW, GTAW MSTS 23MSTS ASME Sect IX- Welding Essential Variable Process Acwat The 5 Range Vatues |oe| Seer IX male Qualified production weld? Ir depends on his “Range Quatified” | Data about test weld Can Don make a specific Exercise W-8 Completing a WPQ Let's complete a WPQ. Find Don Aucoin's WPQ at the end of this section, (pg. WB-9) Remove it and we'll add the right data in the Range Qualified column. Keep your Section IX open to the Weider’s Essential Variables. Note! For future reference, this exercise is worked out on pages WB-1 thru 8. 24MSTS 4 Make Test ‘exmb| text Em} the So | Cenpon Coupon yon underond hs proces and be dale you ndetand | “allyon nood to kow about Weld Procedure Qualification 1! | Weld Procedure Qualification Steps 1. A weld procedure (WPS) is developed Py é * 5 2, Welder makes a “Test Weld” using the WPS. @) Coupon can be either plate or pipe. Normally they use plate 3. The “test weld" is Tested - Tension Tests & Bend Tests. (No RT) a) QW-451.1 Specifies number and type of tests 4. Ifthe “test weld” passes, the WPS is qualified, WITHIN CERTAIN LIMITS Ill : 5. Data from this qualification process is recorded on the POR (Procedure Qualification Record) 4) The POR supports the WPS, 4) Sometimes multiple POR's are required to support a single WPS. What's different between this and qualifying a welder ? 1) Two Documents - WPS & POR 2) Different type of tests are performed 3) Addition of “Non-Essential” variables 25MSTS ASME Sect IX- Welding The wPS& POR (@ v Why 2 documents? = Too much info, doesn’t fit on 1 sheet of paper v POR - Data about Test Weld * Similar to WPQ's “Actual Values” " Test Results " Certification (Signature) VY WPS - Recipe for Production Welds | * Similar to WPQ’s “Range Qualified” @ " Places limits for production welds Exercise 9 Reviewing a WPS & POR Let's look at a WPS & POR and find some data. Find WPS-225 & POR ~ 321 on pages WC-1 thru 4. For the WPS determine the following: DL). What Rod Diameters are allowed? Ye Shr 3c 2) Is PWHT required? Yeo. 3). What positions are allowed? 4) What base metal thicknesses are allowed? 5) Can shis WPS be used for square-bevel joints? 6) What materials can be welded? For the POR determine the following. 1) What base metal thicknesses was used? 2) What was the F-Number used? 3) What welding position was used? Notice how the WPS and PQR are divided into blocks by subject matter; Joints, Base Metal, Filler Metal, Positions, ... This makes it easier to find data! . deanna ial 26ASME B&PV Section IX — Welder Qualification Exercise W-9 — Completing a WPQ QW-484 SUGGESTED FORMAT FOR WELDER OR WELDING OPERATOR PERFORMANCE QUALIFICATION (WPQ) (See QW-301, Section IX, ASME Boiler and Pressure Vessel Code) Welders ame_Don Anson Cost mmber_ABCHSE stomp no. _Wx8 ‘Wein process) sed_SMANL “ype Mand \Retiston of WPS followed ty wel ang weiding Fest coupon ZERIT ase sas) weled $4106 1084-106 “hicness_ 2a Tose Fiecd Actual Values “Manual or Semiautomatic Variables for Each Peocsss (QW-350) Backing (ctl, wold meal, welded from both sides, uxt) (QWW-402) ASME PANO. 1 1 ASMEP-No. (QW-409}/Q 492) (Pn COC pe enter dimer pipe) Filer meta! spesfeation (SFA Cassicaton (QW-404) Fie eta No File meta variety for GTANW, PAW (QW-404) ‘Consumable inst for GTAW or PAW Weld deposit thickness for each welding process © ASO - 1 Cl) ‘Welding position 16, $6, <4) (QW=405) CA.) Prosession apilifdownbtl) ‘Backing gs for GTAW, PAW, or GMAW fel gs for OBW (QW08) (GMAW tantarmode (QW-409) GTA welling curent ypfpotrity ‘Machine Welding Variables forthe Process Used (QW-360) Actual Values Range Qual Direcviemote visual contol -Aomatie voltage contra (GTAW) Autor joist raking Welding poston (16, 56, ee) Consumable insert, Backing (melt, wel meta, welded from both sides, fox, et) Gulded Bend Test Results Guided Bend Tests Type ( YQW-MI(SIAD Rens — (CX JQW.AMAGYCTTaM RRA —_ (QUENT (Lone REF) Root WAG Linear Fee Nove ‘Visual examination resus (QW-3024) _OK Radiographic test results (QW-308 and QW-305) _NUA (or aerate qualifeation of groove welds by mdiography) Fille Wold - Facts test Lengoh and percent of defects in (Macro tet fon Filet leg size nx Jn. Concavityfconvexiy in Welling est conducted by _ ACME Fabricators ‘Mochaniest sts conducted by _ Uyoh Laba Laboraay estr0. 299-08 ‘We cst th stamens in his record are core and tat he et coupons ware prepared, welded and este in accordance Witt ‘ho requtements of Seelion of he ASAE Code Oreanienion ACME Fabricators Date _ 2/1899 By {Copied fom ASME BAPY Code Section 1X - 42000 - MSS) MSTS WB-9a) MSTS ASME Sect IX- Welding Procedure Variables Variables listed by Welding Process (QW-25X) V Essential Variables | * Significantly affect weld’s mechanical properties * Must be recorded on both the WPS & PQR * POR Value must support the WPS value Y Non-Essential Variables * Don't significantly affect weld’s mechanical properties "Must be recorded on the WPS only ¥ Supplement Essential Variable - Not on API exam = Become essential only if impact testing of weld is req'd Welding Variable Notes 1. When reviewing the WPS & POR, what's the Number 1 mistake? Confusion about the Essential & Non-essential Variables! 2. References in Section IX determine how the POR must support the WPS. 3. Sometimes the POR supports a range of values on the WPS. 4. Which variables must the welder follow? Both essential and non- essential! The welder must follow everything on the WPS! 5. What ifa qualified welder makes a weld outside of the ranges allowed bY y 4 4 WPS? It’s a Non-Code weld ... REJECTABLE! a fk by i J 6. What if'a non-qualified welder makes a weld within the ranges allowed by * WPS? It’s a Non-Code weld ... REJECTABLE! Essential Variables - When changing an essential variable on the WPS beyond the range qualified, IT IS ESSENTIAL to requalify the weld procedure. Non-essential Variables - When changing a non-essential variable on the WPS, IT IS NOT ESSENTIAL to requalify the weld procedure, As a result these variables do not need io be recorded on the POR, the qualification record! 2ASME B&PV Section IX — Procedure Qualification Exercise W-11 — Reviewing WPS & POR Here's our work process for evaluating a WPS & POR 1 Determine if Impact Testing is required (If yes, the Supplemental Essential Variables will be required) Not! P5. 2. Verify the POR is signed by the Manufacture. 7 yr = 3. Verify the WPS references the supporting POR number Yes 4, Check Non-Essential Variables \/ a. Turn to the appropriate QW-25x Chart for the specifie Welding Process b. Look only on the WPS ~ Validate that the non-essentials have been adequately addressed $. Check Bssential Variables @ Twn to the appropriate QW-25x Chart for the specific Welding Process b.— Onthe POR- Find and list the vatue for each essential c. Review the Section IX rules, determine and list the Acceptable Range for each essential d. Compare the values on the WPS to the Acceptable Range 6. Check Testing Data @ Look only at the POR - Verify that the correct type and the correct number of tests were conducted (See QW 451.1) b. Verify the calculation of the Ultimate Stress. ($= Load/Area) -e Verify the test results meet the QW-Ixx Acceptance Standards 7. Check for mistakes. e.g, do the P-number, F-number, and A-number match their respective material specification number? MSTS WD-1ASME B&PV Section IX — Procedure Qualification Exercise W-11 — Reviewing WPS & POR Step 1 Determine if Impact Testing is required (If yes, the Supplemental Bssential Variables will be required) There is no mention of Impact Testing, ...$0 ... or this WPS the Supplemental Essential variables are... nota factor. Step 2 Verify the POR is signed by the Manufacturer POR 321 is signed by: Joe Joe Bryant OK Step 3 Verify the WPS references the supporting POR number WPS 225 References ~ POR 321 OK Step 4 Check Non-Kssential Variables @) For SMAW turn to QW-253 b) Determine that each Non-Essential Variable is appropriately addressed on the WPS Non-Essential Variable Ok on WPS? Groove Design we Backing w Root Spacing Retainers Filler Rod Size (Diameter) Filler Rod AWS Classification Position Vertical Welding (Uphill or Downhill) Preheat Maintenance (Hold temp after weld completed) Current or polarity (AC or DC, for DC indicate Polarity) T&E Range (For SMAW — Only Amps are needed) String or weave Method of cleaning Method of back gouge Manual or automatic method Peening Not Addressed: Root Spacing & Method of Back Gouge Error MSTS WD-2ASME B&PV Section IX — Procedure Qualification Exercise W-11 — Reviewing WPS & POR Step 5 Check Essential Variables a. For SMAW turn to QW-253 b.— Onthe POR - Find and list the value for each essential & Review the Section IX rules, determine and list the Acceptable Range for each essential Compare the values on the WPS to the Acceptable Range Complete the Essential Table Below [pte varaaie [POR Seton 1X ate WT on | ir ients > 8 inch = _| Only applies for thick components - Yes | F (ase Metal) Qualified Per QW.ASLA- if 1Pass> Winch <= __ | Generally not fitor | Yes | P-Number Qualified Per QW-424.1 — ow | P-Numnber 59/10 ‘Additional Limits ~ Read Reference F-Number Must be the Same ok ‘(Weld thickness) Per QW-4S1.1 - x Preheat Decrease > 100 °F JVPS > PQR - 100°F | WHT Same PIETY family Limits a Only applies for thick components = a ‘Yes MSTS WD-3ASME B&PV Section IX — Procedure Qualification Exercise W-1]_ — Reviewing WPS & POR Essential Table Completed (The Answers) : POR ; Accept | WPS 7 Essential Variable va Section IX Rule tccep Hs ok? ‘TM Limits > 8 inch = (Only applies for thick components == = ‘Yes T(Base Metal) Qualified | 36" — | Per QW-451.1- 1/16" 027° miortows | Vie | Nor Pass > inch Generally not a factor = = Yes P-Number Qualified Plto Pl Per QW-424.1 — Same to Same PltoP1 PitoPt Ok ‘Additional Limits Read P-Number 5/9/10 NA Sete NA NA NIA Number F3 | Must be the Same i) F4 | NO! ‘Same, but AT & AB are | ANamber At | iencgaatte Atora2 | Ad | Yes 1 (Weld thickness) 3/16" | Per QW-451.1- WPS <2t <3 | AN | Nor | [PechearDecrease>100°%F | 70°F _| WPS = POR-100°F 330% | 32 | Yes Yes : Below PWHT pei arr | Séme PHT famity BelowLtt | BIW | yes T Limits = Only applies for thick components = = Yes | | Step 6 Check Testing Data | a. Look only at the POR - Verify that the correct type and the correct mumber | of tests were conducted (See QW 451.1) Per Chart— 2 Face Bends & 2 Root Bends required | On WPS ~2 Side Bends & 2 Roots provided Error b. Verify the calculation of the Ultimate Stress. ($= Load/Area) go Specimen 1 & 2 Cales are ok. i c. Verify the test results meet the OW-Iax Acceptance Standards Tension Specimen #1 (Base Metal Break) Failure Stress > 0.95 SMIS Failure Stress > 0.95 x 55,000 = 52,250 But Breaks at 51,900 Error Bend Test #4 ~ 5/32” Linear Defect exceeds the 1/8” Error Step 7 Check for mistakes. (P-number, F-number) On WPS — AWS F-6010 Rod is a F-3 not an F-4 Evvor MSTS WD-4ASME Sect IX - Welding | Evaluating Essential Variables ihe Tet sat, Z| te ne | @ Weld fromm) Seton Klee - Ix wes | ep Rules Range POR Pret | 70%" | 2P0R-10-F | 3-300F ar | 8 Pe Fa Same Fs ra lp Note! In the review - start with the POR! Exercise 10 Evaluating a WPS & POR In this exercise we will review a WPS & it's supporting POR and find any mistakes, Remove WPS-225 and POR-321 from the manual. (pages WC-1 thru 4). On page WD-1 is a detailed procedure for evaluating a WPS. Also a checklist will be handed out in class. The secret to getting this right? Use the methodically process on WD-1. Note! For future reference, this exercise is worked out on pages WD-2 thru 4. a Q The Essential Variable Roadmap | v8 SHBLDED NTAL-Ane WRLDING AW Passat ee Waa [A [ aa Te Onl a be RR eee [wear | § PReGater | mr is [9 PNOSSI0 | Altes as Reece GeweraeTas [ao PR | Mae S| & ANenis: | Mon ts Sans ba ATR ABE | ster Bes ‘Waawiiaen [a _|_bam or | is Pen ‘evaorpwar La [ 9 Pen ‘Suge ey | Fhinie ‘eine nceeompnene LL. write in your cote MSTSASME Sect IX- Welding | Practical Checking When checking on a welding job V Is the welder following the procedure? ¥ Check the WPQ - Is the welder qualified for this specific weld? (position, thickness, backing, etc.) Y Check the WPS - Is this procedure ok for the specific weld (P-#, F-#, preheat, thickness, ete.) ¢ V Check the POR(s) - Does it support the Weld Procedure 1. Onthe WPS which variables does the welder need to follow? @) Essential Only 5) Non-Essential Only e)” Both Essential & Non-Essential @) Neither - Qualified welders can be creative : \ 2. Ona bend test, open defects should not be wider than 7B. 3, A welder is tested in 3G position on a coupon %" thick, \ a) IfRT is used, the max length of a slag inclusion is_ V4. b) IfRT is used, the max size of a single porosity indication is my 2. ©) Abend tests are used, how many must be performed? {Ve d) What type of bend tests must be done? 4. What happens ifa welder makes a weld outside the following limits specified on the WPS? ? a) Outside Essential Variable limits 5) Outside Non-essential Variable limits Inspector Joe says, “I wonder if Tcan ‘get my old welding job back?” MSTS 29ae e ASME P&PY Section IX Welding Module Appendixes Appendix A - Sample WPQ Appendix B - Process for completing a WPQ Appendix C - Sample WPS & POR Appendix D - Process to reviewing a WPS & PORASME B&PV Section IX — Welder Qualification Exercise W-9 ~ Completing a WPt Supposed you are qualifying welders for an upcoming turnaround. Don Aucoin has just completed a “test weld”, The weld passed both the visual and bend test inspections. You need to fill-in the appropriate values for WPQ’s Range Qualified datafields. The WPO is given on Page WB-9. Here's our work process for this exercise. i 1) Determine which Welding Process is used for the “Test Weld” ¢. 2) Check the appropriate list of Essential Variable 3) Find the appropriate Section 9 reference 4) Determine acceptable Range Qualified & complete the WPQ WPO Definitions Actual Values — What was done during the “test weld”. Range Qualified — Limits on the welder's production welds i Note! Ifa welder has a Range Qualified of “Flat”, this welder is not qualified to make production welds in the “Overhead” position. If this welder needs to make an Overhead production weld, it is ESSENTIAL that the welder be requalified, The Foreman should always make sure that the welder is qualified for the specific Production weld. MSTS WB-1a ASME B&PV Section IX — Welder Qualification Exercise W-9 — Completing a WPQ We will work this one out step-by-step. Let's get started! Step 1: Determine which Welding Process is used for the “Test Weld” Answer: The 2" Line of WPQ— Welding Process ~ Manual SMAW ‘Step 2: Check the list of Essential Variable Answer: Go to QW-353 for SMAW Welder Performance Essential Variables Add these references QW-353 SHIFLDED METAL-ARC WELDING (SMAW) to you Table Essential Variables Paragraph Briefof Variables | Reference/Comment QW-402 Joins 4 | Backing ‘Test backing sams est wo ter Qw-403 Base Metals [16 [9 Pipe diameter Qw.4s23 18 | ¢ PNamber QW-423.1 QWw.404 Filler Metas | 15 | y FANamber Qwea33 30 | @ 1Welddeposie | Qw-a521 QW-405 Positions 1 | + Position QW-4619) 3 [ON Verial welding |” Same steed Steps 3 & 4: Find the appropriate Section 9 reference Determine the acceptable Range Qualified & complete the WPQ Step 44: QW-402.4 Deletion of backing Which weld is easier to make? With or without backing? The answer ~ With Backing Ifa welder’s “test weld” is made with backing, the welder is only qualified for welds with backing Ifthe “test weld” is made without backing (a mare difficult weld), the welder is qualified for welds with or without backing. Don made the test weld without backing. He is qualified for either with or without backing. Fill-in the appropriate Range Qualified: _w/ or w/o Backing Note! Ifa SMAW welder qualified with Backing, the “deletion of Backing” is an ESSENTIAL variable. ‘Meaning ..if this welder needs to make a production weld without Backing itis ESSENTIAL for the welder to requalify without Backing? Step 4B: QW-403.16 Change in pipe diameter (see QW-452.3) MSTS WB-2ASME B&PV Section IX — Welder Qualification Exercise W-9 ~ Completing a WPQ Why this chart? The smaller the diameter, the more dij ow.452.3, GROOVE.WELD DIAMETER LIMITS * The “Actual Value” on the WPQ Outside Diameter Qualified in, ™ Outside Diameter BEE eee eeeeee Steer | of Test Coupon, in Minin Maxim Less than 1 ize welded Unlimited | 1 to less than 2-7/8 \ Unlimited | 2-7/8 and over 2-1/8 Unlimit | NOTES e (0) Type and uber of ess equ shal be scordanoe with QW-ASE. (2)2-78 in. 0.D. isthe equivalent of NPS 2-1/2, The “Range Qualified” on the WPQ Don made the test weld using 4 NPS pipe (4.5” O.D.). Per the chart, he is qualified for any pipe diameter > 2-7/8" O.D. Fill-in the appropriate Range Qualified: > 2-7/8” 0.D or > 2-1/2 NPS e MSTS WB-3ASME B&PYV Section IX — Welder Qualification Exercise W-9 — Completing a WPO Step 4C: QW-403.18 Change in P-Number (see QW-423.1) Why this chart? Some materials are more difficult to weld, ‘QW.-423.1 Base material used for welder qualification The “Range Qualified” may be substituted for the P-Number material specified on the WPO The “Actual Value” in the WPS in accordance with the following. on the WPQ aaa Base Metal(s) for Qualified Production Welder Qualification Base Metals) | P-No. | through P-No. 11, P-No. 1 through P-No. 11, P.No, 34, of PINo, 4X P-No. 34, P-No. 4X and ‘unassigned metals of similar ‘chemical composition ,., e P.No,21 through P-No, 25 P-No, 21 through P-No. 25 P.No, Sx or P-No. 6x P-No. 5x and P-No, 6x Don made the test weld using SA-106 pipe, a P-1 material. (See QW-422 to determine the P-Number for a specific material.) A test weld using P-1 material qualifies a P-1 through P-11, P-34 & P-4X materials, Wow! This is a very large range qualified! A carbon steel test coupon qualifies; carbon steel, chrome, stainless steel, and other materials. But ...we do have to take credit for the full range. In this case, Don's company believes that the welder is only qualified for materials welded. So they are only going to give Don credit for Carbon Steels — P-1 materials. e e- Fill-in the appropriate Range Qualified: P-1 Section 9 - Definitions PAX = P-40, P-41, P-42, ... (Big X) P.5x P-Sa, P-Sb, ... (Little x)_ MSTS WB-4ASME B&PV Section IX — Welder Qualification Exercise W-9 — Completing a WPQ Step 4D: QW-404.15 Change in F-Number (see QW-433) Why this chart? Different skills are required for different electrodes. The “Actual Value” on the WPQ ere Qquifeawik| Fi ] pi | ra | r2 | rs [ps | ea | pa | ps | ps with | withour | wi | withour | with | witout | win | without | with | without Qualiticd For || ooking | Backing | Backing | Backing | Bscking | Backing | Backing | Backing | Backing | Booking Fi iia x x x x x x x x x x Ri Without Backing 7 F2 ‘With Backing Pa Without Becking FS ‘With Backing, Fs ‘Without Backing Pa ‘With Backing. Fd Without Backing The “Range Qualified” on the W™® PS With Backing FS ‘Without Backing a Don made the test weld using a F-3 Rod without Backing. He is qualified for; F-l, 2 & 3 with Backing and F-3 without Backing. O__ Fittin the appropriate Range Qualified: Backing F-1 to 3, No Backing F-3 MSTS WB-SASME B&PV Section IX — Welder Qualification Exercise W-9 — Completing a WPO Step 4E: OW-404.30 Change in “t” Weld Deposit Thickness (see QW-452.1) Why this chart? Thicker materials pose more welding problems, The “Actual Value” on the WPQ QWwe452.1 ‘TRANSVERSE-BEND TESTS The “Range Qualified” Thickness ¢of Deposited Weld Metat on the WPO, Qualified, in. Thickness of ‘Type of Joint “Test Coupon Welded, in. Maxieoorn Groove Up to 3/8, incl a Groove ‘Over 3/8 but less than 3/4 a Max. to be welded Groove 3/4 and over Don made the test weld having a deposited weld metal thickness of 0.288". Use Line 1 of this chart. Qualified thickness would be up to 2t = 0,576”. | Fill-in the appropriate Range Qualified: < 0.576” MSTS WB-6ASME B&PY Section IX - Welder Qualification Exercise W-9 — Completing a WPQ Step 4F: QW-405.1 Add a Position (see QW-461.9) Why this chart? Some positions are more difficult to weld, Draw this Line Qw.46.9 PERFORMANCE QUALIFICATION - POSITION AND DIAMETER LIMITATIONS, (Within the Other Limitations of QW-303) Data 2y2 uo ,, parfipong} aBuvy,, ayy ___ Position and Type Weld Qualified - Note 1 ulifcation Test Groove Fillet Plats and Pipe Pipe Pte Weld Position Over? in.0D —<24 in. OD snd Pipe @ Plate - Groove 16 F F Note 2 F 26 BH F,H-Note2 BH 36 RY F-Note2 RAY 4G FO F-Note? RHO ey and 40 Yo F-Note2 Al g 16,36, 7 EWN? ai 8 Special Positions (SP) SP, SRF srr S Phate- Fillet IF F-Note 2 7 3 : 3 FyH- Note 2 3 : ; ; “Note? 3 2 7 BH,Y-Not = a ; FH, 0-Note? 3 3P and 4 All Note 2 = Special Positions ($P) SP, F Note 2 B Bie-crore ? 7 ? Note3 BH RH Fu e RY0 Fv,0 at i ‘a ‘Ail ‘All ail all al Ser SPF SE Don made the test weld in the 1G position with a pipe. Notice the Qualified positions may depend on the Produet form (plate or pipe). For Groove Plates, Groove Pipes and all Fillets, Don is limited to the Flat Position. Fill-in the appropriate Range Qualified: Flat Grooves & Fillets Note! Groove test welds qualify some fillet welds, but... fllet weld tests do not qualify any groove welds. MSTS WB-7ASME B&PV Section IX — Welder Qualification Exercise W-9 — Completing a WPO Step 4G: QW-405.1 Change in Vertical Welding - Welding Progression Don made the test weld in the 1G position. He is not qualified for vertical welding based on this test weld, So vertical welding (welding progression — uphill or downhill) is not applicable, The rule is ...whatever progression was used on the test weld, the Range Qualified is the same. Tested Uphill - Qualified Uphill Tested Downhill — Qualified Uphill qt” Fill-in the appropriate Range Qualified: N/A When finished sign the WPQ! This completes this WPQ! ® MSTS WB-8WPS #. WPS-POR Checklist (SMAW Process) A, Checking Essential Variables » 2 3) gy dy ¢ e Turn to the list of Variable - For SMAW turn to QW-253 On the POR - Find the value for each essential variable and list this value in the POR Value column of the chart. When complete, put the POR away! On the WPS - Find the value for each essential variable and list this value in the WPS Value column of the chart. When complete, put the WPS away! Start at the top of the chart. For the first essential variable, find the Section IX rules and determine the appropriate acceptance standard, List this value in the Accept Stdls column, Compare the WPS Value to the Accept Stds value and determine if itis acceptable, Write either Yes or No in the OK? Column. Repeat steps 4 & 5 for each of the essential variables, Complete the Essential Table Below (this is for the SMAW process) \ POR i Aocept | WPS z | Essential Variable | POR Section IX Rute | ate | OR? TH Limits > 8 inch <= __| Only applies for thik components s | ves | T (Base Metal) Qualified Per QW-451.1 - | Pass > ¥2 inch == | Generally nota factor a = Yes P-Namber Qualified Per QW-#24.1 ~ P-Number 5/9/10 Additional Limits — Read Reference | Number ‘Must be the Same | Fecal Same, but At & AB are interchangeable | ‘(Weld thickness) Per QW-ASI.t- Prebieat Decrease > 100°F = POR- 10°F ¢. PwAT ‘Same PWHT family Phimits “=| Only applies for thick components 7 = | Ye B. Checking Non-Essentials C. Checking Testing | (WPS Only ~Are they Addressed?) (Specimens and Acceptance Criteria) D D ! 2 2 y v 4) 4) MSTS 5/2003WPS # WPS-POR Checklist (SMAW Process) A, Checking Essential Variables Dy a d a » e 9 Turn to the list of Variable - For SMAW turn to QW-253 On the POR - Find the value for each essential variable and list this value in the POR Value column of the chart. When complete, put the POR away! On the WPS - Find the value for each essential variable and list this value in the WPS Value column of the chart. When complete, put the WPS away! Start at the top of the chart. For the first essential variable, find the Section LX rules and determine the appropriate acceptance standard. List this value in the Accept Stdls colunn. Compare the WPS Value to the Accept Stds value and determine if itis acceptable, Write either Yes or No in the Ok? Column. Repeat steps 4 & 5 for each of the essential variables. Complete the Essential Table Below (this is for the SMAW process) : POR ‘i Accept | WPS Fi Essential Vartable ata Section IX Rule Sue | ane | OF? it Limits > 8 inch <-=___| Only applies for thick components = - Yes 7 (Base Metal) Qualified Per QW-451.1- Pass % inch —__| Generally nota factor = = ‘Yes P-Namber Qualified Per QW-424,1 — P-Number 5/9/10 ‘Additional Limits — Read Reference Number ‘Must be the Same ‘Same, but Ai & A2 are ee interchangeable (Weld thickness) Per QW-451.1- Preheat Decrease > 100°F =POR- 10°F , PWAT ‘Same PWAL family T Limits =| Only applies for thick components = = Yes B. Checking Non-Essentials C. Checking Testing (WPS Only ~Ave they Addressed?) (Specimens and Acceptance Criteria) D oy] » 2) x x 4) 4) MSTS 5/2003WPS # WPS-PQR Checklist (SMAW Process) A. Checking Essential Variables D 2 yd 4) yd Turn to the list of Variable - For SMAW turn to QW-253 On the POR - Find the value for each essential variable and list this value in the POR Value colunn of the chart. When complete, put the POR away! On the WPS- Find the value for each essential variable and list this value in the WPS Value column of the chart. When complete, put the WPS away! Start at the top of the chart. For the first essential variable, find the Section IX rules and determine the appropriate acceptance standard, List this value in the Accept Stdls colunmn. Compare the WPS Value to the Accept Stds value and determine if itis acceptable, Write either Yes or No in the Ok? Column * ©) Repeat steps 4 & 5 for each of the essential variables. Complete the Essential Table Below (this is for the SMAW process) FOR ; Aecept [WPS Essential Vartable FoR Section IX Rule us| Vaiue_|_O% | Ti Limite> Bnch =| Oniy applies for thick components s — | ve j T (Base Metal Qualified Per QW-45T.1- | 7Pass> % inch <= | Generally nota fctor = =| Yes P-Nmber Qualified Per QW-424.1~ PoNamber 58/10 ‘Aditional Limits Read Reference | FNumber ‘Must be the Same Same, butt & AP are sited interchangeable i 1 eld thickness) Per QW-A5i.1- | Preheat Decrease > 100 °F = POR-100°F i PWAT Same PIVAT family | Pimis “=| Only applies for tick components = =| ves B. Checking Non-Essentials C. Checking Testing (WPS Only Are they Addressed?) (Specimens and Acceptance Criteria) | Db 1) y 2 | d dy 4) 9 MSTS 5/2003ASME B&PY Section IX — Welder Qualification Practice WPQ QW-484 SUGGESTED FORMAT FOR WELDER OR WELDING OPERATOR PERFORMANCE QUALIFICATION (WPQ) (See QW-301, Section IX, ASME Boiler and Pressure Vessel Code) Welles ame_Rawhide Amedee Clockmumber_ Con 326 Stamp no._ 27, Welling proses(es) tee __SMAW-Manua Te entifcation of WPS folowed by welder ding Welding of test eoupon _WPS-A5RS Dase teil’) welded _SA285C Thickness 0.625" Mani or Semiautomatic Variables for Each Process (QNV260)—Aetual Values ‘Raa Quai Backing (meta) weld neta, welded from both sides, flux, ec.) (QW-402) Dbl.Vee - Yes ita Asi Po. ASME DN (QW03) Tose FE PU, PSE, PALS pat (Pla (Pe earns ip) Piste pete” Filer ml speciation GFA) Csiteaton (QWv.40) Filer tal FN E. Fir fant, Fy ul Cur wackine Filler metat variety for GTAW, PAW (QW-404) = c Conse ise or TAN or PAW MA ‘Weld deposit thicknes fo och welding process ‘panes nes" atlas ‘Welding position (1G, 5G, ete.) (QW-405) 40, — ae, Pier + plete Progression (opi) WA ee Bucking go for GUAW, PAW, or GMAW ful gas for OFW (QW-408) ite ay x au OMAN tear mode (QW-40) E "FAW linge: bpepla eee ee Fitted Machine Welding Vaal fr the Process Used (QN960) Actual Vales ange Quatinea Fy 31, © Directtemote visual contol ‘Atomic votoge conel (GTAW) ‘Automat joint waeking Welding positon (16, 56, et.) ‘Consumable inser, ‘Racking (metal, weld meal, welded from both side, fn et.) Gulded Bend Test Results Guided Bend Tess Type CC) QHAEDD SEE) Rete (QW TanL RAF (_) QW-462.30) (Long RAF) Sie Z 6" Linear Side UB" Lines Visual examination ress (Q\W-302.4) _OK. Radiographic test results (QW-304 and QW.305) _ Ni (For alreative quatcaion of groove welde by zadiogrphy) Fillet Weld Fracture tst Length and percent of defeats a, ‘Mero at fsion| ite ins in. Cancavityfoonventy fn Welding test conducted by Convent Refinery Mectanical esis conducted by _ Shokey Breaky Labs Laboratory estno, _SBL328 ‘We certify thatthe stareoensin this record are coe and ha he est eoupons were prepared, welded, an tested in accordance wilh the equiements of Section IX ofthe ASME Code, Organization _Convant Refingsy ate angi By (Copied from ASME B&PY Code Section IX- 4/2000 - MSTS) MSTS Welding Quiz 1ASME B&PV Section IX — Welder Qualification Practice WP QW-484 SUGGESTED FORMAT FOR WELDER OR WELDING OPERATOR PERFORMANCE QUALIFICATION (WPQ) {See QW-301, Section IX, ASME Boiler and Pressure Vessel Code) Welders name_Lusky lone (Cee mamber 131912. Sump no. _Z Welding proces(es) used SMAW.Manusl ‘Type. ldentestion af WPS fllowed by welder during welding of test coupon _WPS-23R2 ose eri) wele_AsSRo AIO “Thine Ost anal or Smisutomate Variables for Bach Process (QW.380) Actes Values Range Qualified Backing ret weld me els rom ots, fae) (QW02) Yes ether sitio X ASMEPNo._L WASP. (W403) Times Pimp, 34, Al-Doct (Plate OX) Pipe enter dase i pis) Ns EP pianee bok nes Filer met speciation ($A): Casiotion QW-400 Filler tl No. PI ELIE wa Itc Fier salve foe GTAW, PAW (QUK408) a ~v Consumabi nse or GTA or PAW Na Wel eps iskess oreach weing proces Sse 950 nid ‘Welding position (1G, 5G, e2) (QW-405) Progression (wpilldooriil) pm iat Backing gus for GTA, PAW, or GMAW; fos gas for OFW (QW-608) GMAW earster mage (QW-409) Machine Welding Variables (or the Process Used (QW-360) ‘Actual Values Range Quaifed Directhemote visual contol ‘Avtomatie voltage control (QTAW) Avtomatc joint racking Welling position (26, $0, te) Consumable insert Gulded Bend Test Results Guided Bend Tests Type ( )QW.AED2 (Sie) Resula (QW) Tame RAY) QW) Lane RAD Rost ot Ono Ying near 77 ace oo iS" Liner 7 pall pia Visual examination results (QW-302.4) __OK Rediographic test results (QW-304 and QW305) (or atlernative qualation of groove welds by sadiography) Filet Weld - Pragtre test Length and percent of detest in Macrotes fin ‘een sie in.x __in. Corcavtyleonvexity fn ‘Welding test condicted by _ Muenstrman Fab Mechanical tests conducted by __Shakey Brey Lah Laboratory testno, _SBI320 ‘We cent that th statements in his record ate coect and tha the est coupons were prepared, welded, and tested in accordece with the requirements of Seaton IX of the ASME Code Organization __Muensterman Fahrsation Date anon »y Candi Kane (Copied from ASME B&PY Code Section IX- 4/2000 - MSTS) MSTS Welding Quiz 2API Certification Homework WPQ 1 - Rawhide Amedee Ranges Qualified Backing P-Number Pipe Diameter F-Number Weld Deposit Thickness Welding Positions Progression WPQ 2- Lucky Jones Variables Backing P-Number Pipe Diameter F-Number Weld Deposit Thickness Welding Positions Progression Testing ‘Type of Tests Number of Tests Acceptance Criteria Other Module 6 ASME Section IX With only PI - PIL, P34, P41-47 > 2-7/8" OD. WI thru F4 Unlimited Grooves - Plate & Pipe > 24” ~ Grooves ~ Pipe < 24” -——- F All Fillets --- F, H, O NA. Dou’t forget to sign the WPQ Error - With only OK - They could allowed a larger range (P34, P41-47) but it is not an error to limit a range. Error - > 2-7/8” O.D. OK OK OK. Enror - Uphill only, OK Error - For 5G Test, four Bend tests are required Error - Face Bend failed (3/16” is greater than 1/8") AS3 & A106 are both P1 materials, neither are P3. 13 MSTSAPI Certification Homework ASME Section IX WPS/PQR - Big Cookie Fabricators WPS # BCF16 Non-Essential Variables a 2 3. 4. AWS Classification Missing Pre-heat Maintenance Missing String or Weave Technique Missing Polarity Missing Essential Variables 5. 6. Testing 7 8 Module 6 WPS - Base Metal Thickness Range not supported by PQR - Maximum thickness allowed is only 1” WPS - No PWHT is not supported by PQR. WPS must requite PWHT Bend Test #1 not acceptable 1/6” exceeds 1/8” Bend Test #3 not acceptable 3/16” exceeds 1/3” 4 MSTSwes4¢_& &t 1G WPS-POQR Checklist (SMAW Process) A, Checking Essential Variables 1) Turn to the list of Variable - For SMAW turn to QW-253 2) On the POR - Find the value for each essential variable and list this value in the POR Value colunn of the chart, When complete, put the POR away! 3) On the WPS - Find the value for each essential variable and list this value in the WPS Value column of the chart. When complete, put the WPS away! # Start at the top of the chart. For the first essential variable, find the Section IX rules and determine the appropriate acceptance standard. List this value in the Accept Stds colunmn, 5) Compare the WPS Value to the Accept Stds value and determine if it is acceptable. Write either Yes or No in the Ok? Column, | @ 6) Repeat steps 4 & 5 for each of the essential variables. Complete the Essential Table Below (this is for the SMAW process) POR an Accept | WPS Value eee Sus | Value Te Limits > 8 inch <=" _| Only applies for thick components T(Base Metal) Qualified | OS" [PerQwasii- 3 — 2%. Essential Variable Pass > inch Generally nota factor | PNumber Qualified Per QW.424.1— P-Number 59/10 ~~ _| Additional Limits Read Reference | PNumber Z| Must bethe Sume AcNamber 1 tegen 1 (Held thickness) os" | Per Qweastt- Preheat Decrease > 100°F | =/o°F | >POR-100°F “VO — 109" | > PWHT Same PWHT family Limits Only applies for thiek components B. Checking Non-Essentials C. Checking Testing (WPS Only —Are they Addressed?) (Specimens and Acceptance Criteria) a D No _aveore clea yr DY _Mide Wend lated 24s Y File Aw clessficedion 2 Ve. | 3) Bev ch Vingind tinance 3) | 4) Qalocrtur 4 Bey [Ric art 7 MSTS 5/2003QW-483. (Back) PQRNo._BCRQ26 Tensile Test (QW-150) Spevimen No, | With “Thickness Area Ubimate Load] Ultimate Stress ‘Type of Failure (inch) (inch) (69: nches) (bs) (si) & Location 1 7 |__ 0750 0.500 0375 23,250 62,000 | Base Ductile 2 0.750 0.500 0375 25,500 68,000___| Weld -Ductle Guided-Bend Tests (QW-160) ‘Type and Figure No. Result HT -Side - QW-4622_ 7 UG? Linear Tear ® Vide-QWitea2 No Linear @ side QW:46R2 36” Wide Tear ‘No Linear HA Side QW-462.2 ‘Toughness Tests (QW-170) Specimen | Notch Noteh Test pact Lateral Bxp. Drop Weight } No Location Type ‘Temp. feGnees % Shear Mils, Break No Break j Fillet-Weld Test (QW-180) | Result Satistactory: Yes No. Penetcation into Parent Metal: Yes No. Macro-Results Other Tests Type of Test Deposit Analy, thee Welders Name _Ken Shook ClockNo.__IBB#} Stamp No,_$431. “ents conductedby:_D.Kimlabe Laboratory Test No.__DK-321 ‘We certify that the statements inthis record are correct and thatthe test welds were prepared, welded, and tested in accordance with the equitements of Section IX ofthe ASME Code. ‘Manufacturer RICATORS, Date__10/12/1998 By. (Dexa oF record of tests ae iluseative only and may be mositied to confer to the type and umber f test required by the Coe) MSTS (Copied ftom ASME B&PV Code Section IX - 4/2000 - MSTS) Welding Quiz 6(QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS) (See QW-200.1, Section IX, ASME Boiter and Pressure Vessel Code) CompanyName _BIG COOKIE FABRICATORS By Pres. Thomas Uyoh, ‘Welding Procedure Spee. No. __BCFIG Date _11/20/1998. Supporting PQR No.(s) __BCP-Q26 Revision No. Date 216/199 Welding Process(es) _SMAW Type) MANUAL. (Avtorsats, Menus, Machine, or Semi-Auto) JOINTS (QW.402) Details Joint Design| All Grooves & lets Backing (Yes) J (Wo) Backing Material (Type) Metal (Refer to both basking and vouiners) W) Mata ©) Nontusing Metal Seaiibils: () Nonmesatie —() Other ‘Mlowed ‘Stetehes, Production Drawings, Weld Symbols or Write Description lptene show te geveral amrangement of the parts to be welded. Where ‘plicable he rot spacing and the details of weld groove may be speife, ur enteetic ee aner -Acthe option of tho Mi, skotes may be sllached toils ont design, Weld layers and bes sequence. “BASE METALS (QW-403) PNo. 1 GroupNo. to P.No. Group No, on Specification type and grade to Specification type and grade OR ‘Chem. Anelysis and Mech. Pro. ‘Thickness Range: to Chem, Analysis and Mech, Prop. Base Metal Groove 1a" Fillet at -2" Pipe Dia. Range: Groove _2NPS to unlimited Filet Other “FILLER METALS (QW-404) Sans ersicn ace Pine 5 Sa ermiewead eae Walnuen Tce es fie "urea Sits Gey mae cae oe "Bach base metal-filer metal combination should be recorded individually. MSTS (Copied from ASME B&PY Code Section 1X - 4/2000 - MSTS) Welding Quiz 3(QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATION (WPS) (See QW-200.1, Section IX, ASME Boiler and Pressure Vessel Code) Company Name __PRO-SPECT FABRICATORS. By |__Joe Joe Byrant_) Welding Procedure Spee. No, 225 Date ___sit9/1999 Supporting PQR Nos) 321 Revision No, 0 Date ‘Welding Process(es) _SMAW_ Su z ‘Type(s)_MANUAL, (Automats, Manual, Machine, or Sens-Asto) JOINTS (QW-402) Details: Ton Design Dosecor Sig-ve Backing (Yes)__X_ (No) See / . Backing Material (Type) ___ WELD METAL. Hae fk (Beomrye. wenctiion © vent) rata ‘No Retainers () Nonmetatis (Other Mloved Sketies, Production Drawings, Weld Symbols or Wrien Description should [Sp Srowite sect arongeent ofthe pars foe welded, Whe apace he (> socsptcng an he dt of weld groove maybe specif. (At the option ofthe Mir, skethes may be atached toile joint desi, ‘eld ayes and bea sequence, “DASE METALS (QW-403) PANO. GroupNo,_toP.Ne, GrowNo___E oR no 5 Specifienton type ad page to Speciation type and grade on Chem, Ansys nd Meh, Pop to Chem, Ansys and Mesh, Prop. “Thikess Rang: Base Meta Groove_1/16"= 18" Fiet__som PipeDia Range: Groove Greater NPS Fils otter “FILLER METALS (@WV-409 : som Spee. No. (SFA)_ 5,1. ze AWS Wo. (Cis) E6010 F-No. Fa 3" F323 AeNo__ el Size of Filer Meals _1/8", 5/32", or 316" Weld Metal Thickness Range: __ Grove. (1/160 Fillet___‘Same ~~" Blectrode-Fux (Cass) Flux Trade Name. Consumable nse. Other ‘Bach base metal-filer metal combination should be recorded i MSTS (Copied from ASME B&PV Code Section IX - 4/2000 - MSTS) WO-LQW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORD (PQR) (Se QW-200.2, Section IX, ASME Boiler and Pressure Vessel Code) Record Actual Conditions Used to Weld Test Coupon, Company Name __PRO-SPECT FABRICATORS. PQR No, 321 WPS No, ate _ 5/19/99, ‘Welding Process(es) _SMAW. ‘Types (Manual, Automatic, Semi-Auto.) MANUAL. JOINTS (QW-402) 3/6” Groove Design of Test Coupon ir (For combination qualifications, tke deposited weld metal thickness shall be recorded for each filler metal or proces used.) BASE METALS (QW-403) POSTWELD HEAT TREATMENT (QW.407) Material Spec. __$A:516 10 SA-516 ‘Temperature 1175. 4f.25 °F. ‘Type or Grade ‘Time _15 minut P-No,_1 toP-No._1 Other "Thickness of Tesi Coupon _[3/16" Diaineter of Test Coupon — PLATE. Other GAS (QW-408) Percent Composition Gast (ovinture) _Hlow Rate Shielding FILLER METALS (QW-404) ‘Tailing Backing SFA Specification _$.1 AWS Classification 10 ELECTRICAL CHARACTERISTICS (QW-409) Filler Metal F-No, Fe Current__DC. ‘Weld Metal Analysis A-No,—_AcL Polarity Reverse I Sze oF Filer Met Amps. 125-14 Volts Other ‘Tungsten Blectrode Size Other ‘Weld Metal Thiokness POSITION (QW-405) ‘TECHNIQUE (QW-410) Position of Groove _16 ‘Travel Speed ‘Weld Progression (Uphill, Downhill) String or Weave Beas Weave, ther Oscillation ‘Multipass or Single Pass (per side) Multiple Single or Multiple Blectrodes PREHEAT (QW-406) Other Preheat Temp. _70°R Interpass Temp. _ Not Monitored Other MSTS (Copied from ASME B&PV Code Section IX - 4/2000 - MSTS) WO-3west O28 WPS-POR Checklist (SMAW Process) A, Checking Essential Variables 1) Turn to the list of Variable - For SMAW turn to QW-253 2) On the POR - Find the value for each essential variable and list this value in the POR Value column of the chart. When complete, put the POR away! 3) On the WPS - Find the value for each essential variable and list this value in the WES Value colunn of the chart. When complete, put the WPS away! 4) Start at the top of the chart. For the first essential variable, find the Section IX rules and determine the appropriate acceptance standard. List this value in the Accept Stds column. 5) Compare the WPS Value to the Accept Stds value and determine if it is acceptable. Write either Yes or No in the Ok? Column. 6) Repeat steps 4 & 5 for each of the essential variables. Complete the Essential Table Below (this is for the SMAW process) POR Accept | WPS Essential Variable ae Seetion IX Rule cco | WS | one TA Limits > 8 inch, —~__| Only applies for thick components a Yes T (Base Metal Quatified [SA Q" | Pr Qw-asli-, oT Mo 2 Ke @"| No # Pass > % inch as Generally not a factor ee Yes P-Number Qualified Pt Py | Per QW-424.1— P- Py [re] y. P2Number 5/9/10 —_| Additional Limits— Read Reference _|_-— = fle F-Numiber 3 Must be the Same FS ey Alo A.Number Ate |eeepeneemenine AverAd yes «(Weld thickness) BAe" | Per QW-451.1-¢9 + 0 3k" Mo~ 2K| No Preheat Decrease > 100°F | Fo°e | =POR-100°F “% Fo 100: ~ 30] % ~30%| 3a°F | ved PwaT Yes __| Same PIVET family Yes. > TLimits —-__| Only applies for thick components = = Yes B. Checking Non-Essentials C. Checking Testing (WPS Only -Are they Addressed?) (Specimens and Acceptance Criteria) Aawre D heak Spin 1 2 Lory bends (oa ive Wend) 2) Weted Vesti your 2 #4 Rect wad Aailed S/a" >" » 3) £1 Tonite toot failest 4) 4) MSTS 5/2003