Weld Reference for Section 9

8/16/2019 Weld Reference for Section 9

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Welding QualificationsWelding Procedures, Welder Approvals and Welding Procedure Specifications explained.

• European Standards

An introduction toEuropean WeldingStandards. (427Kb pdf

ile!• Basic Guide

A basic introduction toWelding "ualifications

and #$% t$e% arere"uiredWelding Procedure

Specifications(WPS)

Welding ProcedureSpecifications to E&'S )*+-) (for/erl%E&200 Part 2!. W$%

are t$e% re"uired and#$at s$ould t$e%include.

•

ASME Section IX

1uidance on t$e "ualification of #elding procedures and t$e perfor/ance testing of #elders to section -of t$e ASE boiler and pressure vessel code. Approval 3ange alculator.

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• European & ISO Welding Standards

5$ese ne# standards are renu/bered and updated versions of t$e old E&200 series. 'nfor/ation is also provided about t$e older standards. &EW Approval 3ange alculator.

• Autoatic!Mac"ine Welding

1uidance on t$e "ualification of #elding operators to E& and ASE 3ules• Independant Inspection Aut"orit#

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Please ote' #$ilst ' a/ prepared to ans#er %our "uestions, ' cant suppl% copies or extracts of standards because t$e% are all sub8ect to cop%rig$t la#. 9o#ever copies of /ost standards can be purc$ased online

fro/ t$e various standards aut$orities, see :'&KS for t$eir #eb site addresses.Page last updated 2)

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5$e re"uire/ent for #eld procedures and t$e coding of #elders is specified in application standards suc$ as;

• <S 2-7) lass 2 Arc Welding of arbon Steel Pipe#or= >1as Pressures less t$an )7 barg?

• <S 2+@@ lass ) Arc Welding of arbon Steel Pipe#or=• <S 4+77 Arc Welding f Austenitic Steel Pipe#or=.

•

<S 0+ <oiler Pipe Wor= (3efers to <S 2-7) and <S 2+@@!• P ** Bnfired Pressure Cessels (or/all% <S**!• <S 27- S$ell <oilers

• <S )))@ Water 5ube <oilers

• <S *)+- Air 3eceivers

Application Standards

All t$e above application standards re"uire #elding procedures to E& 'S )*+)4 Part ) (or/erl% <SE& 200@! and#elders coded to <SE& 207 Part ). So/e applications of <S 2-7) and <S *)+- per/it #elders to be "ualified

#it$out procedures to <S 4072, a less stringent standard.

5$e application standard /a% re"uire tests in addition to t$ose re"uired b% #elding standards, for exa/ple /ost BK

boiler and pressure vessel codes re"uire all #eld tensile tests for plate "ualification above )//.

pressure s#stes regulations

'te/s t$at co/e under t$e BK pressure s%ste/s regulations /ust be properl% designed and constructed so as to prevent danger, and ite/s t$at are repaired or /odified s$ould not give rise to danger. 5$e 9ealt$ and Safet%Executive 1uidance <oo=let to t$e regulations interprets t$is state/ent as /eaning t$e /anufacture or repair of an%

ite/ s$ould be carried out to suitable codes and reco//ends t$e use of <ritis$ Standards or ot$er e"uivalent &ationalStandards.

European Pressure E*uipent +irecti,e

or inspection categor% 2 and above all #elding procedures and #elder "ualifications $ave to be approved b% a &otified <od% (an 'nspection Aut$orit% &otified b% a European /e/ber countr% under t$e irective!, or a 5$ird Part%

rganisation si/ilarl% approved under t$e irective. All "ualifications approved b% t$ese organisations $ave to be



accepted b% all parties for #or= carried out under t$e directive providing t$e% are suitable for t$e application andtec$nicall% correct.

Welding Procedure Specifications

5$is is a si/ple instruction s$eet giving details of $o# t$e #eld is to be perfor/ed, its purpose is to aid t$e planningand "ualit% control of t$e #elding operation. E& 'S )*+- (for/erl% E&200 Part 2! specifies t$e contents of suc$ aspecification in t$e for/ of a list of ite/s t$at s$ould be recorded, $o#ever onl% relevant infor/ation need bespecified, for exa/ple onl% in t$e case of a procedure re"uiring $eat input control #ould t$ere be a necessit% to "uotetravel speed or run out lengt$ for /anual processes.

A #eld procedure specification /a% cover a range of t$ic=nesses, dia/eters and /aterials, but t$e range /ust bespecified and be co/patible #it$ t$e rest of t$e para/eters on t$e docu/ent. ' suggest t$at %ou produce a ne# WPS

for eac$ t%pe of 8oint and =eep to t$e ranges of t$ic=ness and dia/eters specified in t$e #elding procedure standard.

Welding Procedures

Welding procedures are re"uired #$en it is necessar% to de/onstrate t$at %our co/pan% $as t$e abilit% to produce

#elds possessing t$e correct /ec$anical and /etallurgical properties.

A #elding procedure /ust "ualified in accordance #it$ t$e re"uire/ents of an appropriate #elding procedurestandard suc$ as E& 'S )*+)4 Part ) as follo#s;

). Produce a #elding procedure specification as stated above.

2. Weld a test piece in accordance #it$ t$e re"uire/ents of %our specification. 5$e 8oint set up, #elding and visualexa/ination of t$e co/pleted #eld s$ould be #itnessed b% an 'nspection <od%. 5$e details of t$e test suc$ ast$e #elding current, pre$eat etc., /ust be recorded during t$e test.

@. nce t$e #elding is co/plete t$e test piece /ust be sub8ect to destructive and non destructive exa/ination suc$



as radiograp$% and /ec$anical tests as defined b% t$e #elding procedure standard. 5$is #or= can be carried outin an% laborator% but t$e 'nspection <od% /a% re"uire to #itness t$e tests and vie# an% radiograp$s.

4. 'f t$e test is successful %ou or t$e test bod% co/plete t$e appropriate docu/ents #$ic$ t$e test bodies surve%or

signs and endorses. 5$e necessar% docu/ents are as follo#s;

E- Welding Procedure Appro,al %est .ertificate

5$is is t$e front s$eet and onl% gives details of #$at t$e procedure can be used for. i.e. its range of approval.

E/ +etails Of Weld %est

5$is gives details of #$at actuall% too= place during t$e test #eld it is si/ilar to a WPS but s$ould not include

ranges of #elding para/eters.

E0 %est $esults

etails of &5 and ec$anical testing 3esultsE1 Welder Appro,al %est .ertificate2

5$is is t$e #elder approval part of t$e "ualification.

ote 5$e E), E2, E@, E4 designations are used b% so/e 'nspection Aut$orities to refer to t$e individual for/s.Exa/ples of t$ese for/s are given in annexes of E& 'S )*+)4 and E&207.

or/s E), E2, E@ /a% be referred to as t$e WPA3 (Welding Procedure Approval 3ecord! or WPD3 (Weld Procedure

Dualification 3ecord!.

'n general a ne# #elding procedure /ust be "ualified for eac$ of t$e follo#ing c$anges sub8ect to t$e individual

re"uire/ents of t$e appropriate standard used;

• $ange in parent /aterial t%pe.• $ange of #elding process



• 5$e dia/eter range for pipe given b% t$e #elding standard is exceeded. 5%picall% .*x to 2x.

• 5$e t$ic=ness range is exceeded. 5%picall% .*xt to 2xt.

• An% ot$er c$ange re"uired b% t$e #elding standard.

Welder Appro,al

nce t$e procedure is approved it is necessar% to de/onstrate t$at all %our #elders #or=ing to it $ave t$e re"uired

=no#ledge and s=ill to put do#n a clean sound #eld. 'f t$e #elder $as satisfactoril% co/pleted t$e procedure test t$en$e is auto/aticall% approved but eac$ additional #elder /ust be approved b% co/pleting an approval test to anappropriate standard suc$ as E& 207 part ) as follo#s;

o/plete a #eld test as stated in 2! above. 5$e test s$ould si/ulate production conditions and t$e #elding position s$ould be t$e position t$at t$e production #elds are to be /ade in or one /ore severe

or /axi/u/ positional approval a pipe inclined at 4* degrees (referred to as t$e +1 position! approves all

positions except vertical do#n.

5est t$e co/pleted #eld in accordance #it$ t$e relevant standard to ensure t$at t$e #eld is clean and full%fused. or a butt #eld t$is is nor/all% a visual exa/ination follo#ed b% radiograp$%.

nce t$e test is co/pleted t$e E4 for/ $as to be co/pleted b% %ou or t$e test bod% and signed b% t$e test bodies surve%or.

&ote 5$e above c$anges t$at re"uire a ne# #elding procedure /a% also appl% to t$e #elders approval, refer tot$e standard for precise details.

ASME 3

ASE - as far as t$e pressurised s%ste/s regulations are concerned can be considered as e"uivalent to E& 'S)*+)4) E& 207. 9o#ever it /a% not be contractuall% acceptable. 5$e advantage in using ASE is t$at generall%fe#er procedure tests are re"uired particularl% #$en #elding pipe#or=.



Welder Appro,al Wit"out A procedure

<S 4072 is for t$e "ualification of #elders #$ere a #eld procedure is not re"uired eit$er b% t$e application standardt$at governs t$e "ualit% of production #elds or b% contractual agree/ent. 5%picall% applied per <S2-7) for #elding of

boiler pipe#or= less t$an )7 bar g and 2F. <asicall% t$e sa/e rules /entioned above for t$e #elder approvalappl%.

Acceptance Standards

'n general #elds /ust s$o# a neat #or=/an li=e appearance. 5$e root /ust be full% fused along t$e entire lengt$ oft$e #eld, t$e profile of t$e cap s$ould blend in s/oot$l% #it$ t$e parent /aterial and t$e #eld s$ould be significantl%

free fro/ i/perfections. 3eference s$ould be /ade to t$e acceptance standard for precise details.

'ts a good idear to ensure t$at %ou can ac$ieve t$e appropriate standard before %ou call in an 'nspection <od%.

Penetration defects and lac= of fusion can often be easil% detected b% sectioning #elds and bending t$e/.

Welding Procedure Specifications

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Welding Procedure Specification E4aple

A WPS is a docu/ent t$at describes $o# #elding is to be carried out in production. 5$e% are reco//ended for all

#elding operations and /an% application codes and standards /a=e t$e/ /andator%

W$at infor/ation s$ould t$e% includeG

Sufficient details to enable an% co/petent person to appl% t$e infor/ation and produce a #eld of acceptable "ualit%.5$e a/ount of detail and level of controls specified on a WPS is dependant on t$e application and criticalit% of t$e 8ointto be #elded.

or /ost applications t$e infor/ation re"uired is generall% si/ilar to t$at recorded on a Procedure Dualification3ecord (PD3! or Welding Procedure Approval 3ecord (WPA3!, except t$at ranges are usuall% per/itted on

t$ic=nesses, dia/eters, #elding current, /aterials, 8oint t%pes etc.

'f a WPS is used in con8unction #it$ approved #elding procedures t$en t$e ranges stated s$ould be in accordance #it$t$e approval ranges per/itted b% t$e #elding procedure.

9o#ever careful consideration s$ould be given to t$e ranges specified to ensure t$e% are ac$ievable, as t$e rangesgiven b% #elding procedure standards do not al#a%s represent good #elding practice. or exa/ple #elding positions per/itted b% t$e #elding procedure standard /a% not be ac$ievable or practical for certain #elding processes or

consu/ables.

E ISO -56738- (forall# E /99 Part /) European Standard :or Welding Procedure Specifications

E& 'S )*+- efines t$e contents of a Welding Procedure Specification in t$e for/ of a list of infor/ation t$at s$ould be recorded. or so/e applications it /a% be necessar% to supple/ent or reduce t$e list. or exa/ple onl% in t$e caseof a procedure re"uiring $eat input control #ould t$ere be a necessit% to "uote travel speed or runout lengt$ for /anual

processes.

ASME IX Aerican Boiler and Pressure ;essel .ode





DW 2* :ists t$e variables for eac$ #elding process, all t$e variables stated s$ould be addressed. 5$e range per/itted b% t$e WPS isdictated b% t$e PD3 or PD3Hs used to "ualif% it.

5%pical 'te/s 5$at S$ould <e 3ecorded n W.P.S;

.oon to all Processes .

• Procedure nu/ber

• Process t%pe

• onsu/able SiIe, 5%pe and full odification. • onsu/able <a=ing 3e"uire/ent if applicable

• Parent /aterial grade and spec. • 5$ic=ness range.

• Plate or Pipe, ia/eter range

• Welding Position

• Joint it Bp, Preparation, leaning, i/ensions etc. • <ac=ing Strip, <ac= 1ouging infor/ation.

• Pre9eat (in 5e/p and et$od!

• 'nterpass 'f 3e"uired (axi/u/ 5e/perature recorded !

• Post Weld 9eat 5reat/ent. 'f 3e"uired (5i/e and 5e/p!

• Welding 5ec$ni"ue (#eaving,/ax run #idt$ etc.!

• Arc Energ% :i/its s$ould be stated if i/pact tests are re"uired or if t$e /aterial being #elded is sensitive to $eatinput.

Specific %o Welding Processes MMA %IG

MIG

MAG :.AW

SB

A$.

Welding current %es %es %es %es



5%pe of Welding current A Polarit% %es %es %es %es

Arc voltage 'f Auto %es %es

Pulse para/eters (Pulse ti/e and pea= 6 bac=gound current! 'f Bsed 'f Bsed

Welding Speed 'f ec$anised %es %es %es

Wire configuration %es

S$ielding gas (co/p,flo# rate! %es %es

Purge gas (co/p 6 flo# rate! 'f Bsed 'f Bsed

5ungsten electode ia/eter and t%pe. %es

&oIIle dia/eter %es %es

5%pe of lux odification 6 <rand &a/e %es

&oIIle Stand ff istance (istance fro/ tip of noIIle to#or=piece!.

%es

S<etc"es

A s=etc$ of t$e 8oint configuration is re"uired #$ic$ s$ould include t$e basic di/ensions of t$e #eld preparation. So/e

indication of t$e run se"uence is also beneficial, particularl% if t$e correct se"uence is essential to ensure t$e propertiesof t$e #eld are /aintained.

Production Se*uence

W$ilst t$is is good practice it is not a re"uire/ent of eit$er ASE - or E&200 Part 2 it could be issued as a separate

DA procedure if preferred.



on +estructi,e %esting A WPS is pri/aril% concerned #it$ #elding not & 5, t$is activit% s$ould be covered b% separate & 5 procedures.

Welding Procedure Specification:- Example

Weld Procedure u=er @ P) 5'1 ) 'ssue A

>ualif#ing Welding Procedure (WPA$) WP 5)7A

anufacturer; &ational abs :td2* :ane End

<ir=ens$a#:eeds

:ocation; Wor=s$op

Welding Process; anual 5'1 Joint 5%pe; Single Sided <utt Weld

et$od f Preparationand leaning;

ac$ine and egrease

Parent etal Specification; 1rade @4: Stainless Steel

Parent etal 5$ic=ness @ to 0// Wall

Pipe utside ia/eter 2* to )//

Welding Position; All Positions

Welding Progression; Bp#ards

$e,ision ?istor#

+ate Issue ."anges Aut"ori@ation

2+))2 A irst 'ssue Jac= Stra# Jack Straw

• Welding Procedure Specifications

ASME - !ntroduction

5$ese articles are intended as a ver% general guide to ASE -. 5$e% are a collection of /% o#n personal notes #$ic$

#ere #ritten to aid /% understanding of t$e code. 5$eir are certain exceptions in t$e code t$at are not covered in t$esearticles, t$erefore %ou are urged to stud% t$e code carefull% before using its rules to carr% out an% #elding





"ualifications.• <rief 'ntroduction

• o#nload ASE suggested for/s

• Procedure Dualification 3ecord (PD3!

• Welding Perfor/ance Dualification (WPD!

• ASE definitions for #elding processes, consu/ables and #elding positions • ASE Approval 3ange alculator • ASE P aterial &u/bers

• 1rap$ic 3epresentation of Welding Positions

Brief Introduction

Welding "ualifications to ASE - are for use #it$ t$e ASE boiler and pressure vessel code or t$e ASE pipe#or=codes. or use #it$ an% ot$er code or standard agree/ent bet#een all contracting parties s$ould be obtained.

5$e ASE boiler and pressure vessel code e/braces its o#n DA s%ste/ #$ic$ revolves around satisf%ing t$e rules oft$e code. 5$is de/onstrates t$at an accredited fabricator $as so/e degree of co/petence per/itting t$e/ to perfor/ alarge a/ount of t$eir o#n inspection #it$out t$e involve/ent of an 'ndependent 'nspection <od%, #$ic$ #ould be

re"uired b% ot$er standards for si/ilar inspections.

5$is is #$% #elding "ualifications carried out under t$e ASE code do not re"uire 'ndependent 'nspection, a fabricator can "ualif% $is o#n procedures and #elders using t$e ASE code rules. 9o#ever t$is /a% not be acceptable to t$eEuropean Pressure E"uip/ent irective #$ic$ re"uires all #elding "ualifications in inspection categories t#o andabove to be approved b% a &otified <od%.

9o#ever t$ere is not$ing stopping an%bod% using an% of t$e rules of t$e ASE code #it$out being ASE approved,

but to prove %our co/petence in #elding an 'ndependent 'nspection <od% is reco//ended to approve %our #eldingtests.

5$e advantage of ASE - is t$at its ver% #or=able and ver% co/pre$ensive, if %ou $ave a "uestion %ou #ill al/ostcertainl% find an ans#er so/e#$ere in t$e code, #$ic$ is /ore t$an can be said for its European e"uivalent E& 'S

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5$e /ain proble/ #it$ t$e ASE code is t$at it treats all #elding processes separatel% and i/poses separate

restrictions for eac$ on bot$ procedures and approvals. 't is t$erefore prudent to c$ec= #$at t$e code sa%s about t$e#elding process %ou intend to use before %ou carr% out an% #elding tests.

5$e ASE code covers a ver% #ide range of #elding processes and applications suc$ as $ard facing, stud #elding, braIing etc.

Application standards suc$ as t$e <@) pipe#or= code /a% i/pose additional re"uire/ents and li/itations in so/e

cases.

5$e code is divided into 4 parts as follo#s;

DW) 1eneral introduction to testing re"uire/ents etc.

DW2 Procedure Dualification details.

DW@ Perfor/ance Dualifications (Welder Approvals! details.

DW4 Welding ata. 5$is is t$e biggest section of t$e code and covers data for bot$ procedure and perfor/ance "ualifications. 't includes ;

• aterial and consu/able data

• 5est re"uire/ents.

• Approval ranges for t$ic=ness, dia/eter, 8oint configuration and #elding positions

• efinitions used in t$e code.










• ASE definitions for #elding processes, consu/ables and #elding positions

Procedure Dualification 3ecord (PD3!

PD3s are not re"uired if Standard Welding Procedures are used, see belo# for details.

5$is docu/ent contains details of t$e #elding test, it /ust include details of all t$e para/eters listed as variables in tables DW2* to

DW2+* for eac$ process involved and all t$e destructive test results.5$e relevant variables for eac$ t%pe of #elding process are clearl% defined in tables DW2* to DW2+*. 5$e left $and colu/n of eac$

table defines t$e section and paragrap$ #$ere eac$ variable and its application to t$e table is explained in t$e code.Welding Cariables

Cariables used in a #elding procedure test are divided into @ categories ;• Essential Cariables Are variables t$at $ave a significant affect on t$e /ec$anical properties of a 8oint. 5$e% /ust not be

c$anged except #it$in t$e li/its specified b% t$is code. e.g. aterial t$ic=ness range, aterial 1roup etc.

• &onEssential Cariables Are variables t$at $ave no significant affect on /ec$anical properties. 5$e% can be c$anged #it$out re

"ualification of t$e PD3.

• Supple/entar% Cariables Are variables t$at $ave an affect on t$e i/pact properties of a 8oint. 5$e% are classed as &onEssential

if i/pact testing is not re"uired

All variables listed as essential, nonessential or supple/entar% s$ould be addressed on bot$ t$e WPS and t$e PD3. 'f an% of t$e

variables do not appl% to t$e particular application t$en t$e% s$ould be specified as not applicable.

Joint onfigurationEit$er plate or pipe can be used for t$e test piece (plate approves pipe and vice versa ref. DW2))!, an% #elding position approves all

positions providing no i/pact tests are re"uired ref. tables DW2* to DW2+* and an% 8oint geo/etr% approves all geo/etr%s, e.g.single C, double C, B prep, bac=ed or unbac=ed.

A butt or groove #eld approves branc$ and fillet #elds but not t$e converse, ref. DW22. &on pressure retaining fillet #elds in pipe or

plate can be tested but t$e% /ust be double sided if plate and at least t$e di/ensions illustrated in DW4+2.4a, ref. DW22.2c. Pressureretaining branc$ #elds /ust be "ualified b% groove (butt! #elds.

aterial 1roupingaterials are assigned P nu/bers in DW42 a test in one P nu/ber approves all /aterials listed under t$at P nu/ber, except #$ere

i/pact tests are re"uired t$en approval is restricted to /aterials listed in t$e group nu/ber #it$in t$e P nu/ber. t$er P nu/bergroupings are per/issible ref. DW424.) for details. 3ef DW 424.) for furt$er details.

't is nor/all% per/issible if t$e /aterial is not listed in DW422 to assign it to a P nu/ber #$ic$ lists /aterials #it$ t$e sa/e





/etallurgical and /ec$anical properties alt$oug$ t$is is not in strict confor/ance #it$ t$e code. 5%picall% <S)*) )*) 4@A lo#carbon steel could be regarded as P) and stainless steels suc$ as @)+, @4 as P0.

&ote P*, - 6 ) are divided into sub groups eg *A,*< etc., 5reat eac$ sub group li=e a separate P &u/ber

issi/ilar /aterials are acceptable providing t$e% are co/patible. or exa/ple P) to P0, but t$is does not cover P) to P) or P0 to P0. &ote S nu/bers are for pipe#or= to <@), a P nu/ber covers an S nu/ber but not t$e converse

onsu/ables

5$e ASE code uses its o#n specifications for consu/ables SA. #$ic$ is al/ost identical to t$e AWS specification. &5E A c$ange in consu/able is onl% per/issible providing it $as t$e sa/e nu/ber and A nu/ber (if applicable! as t$e P.D.3..

5$ic=ness :i/its

5$ic=ness li/its 1roove #elds. See DW4*) for precise details.• W$en '/pact tests are re"uired t$e /ini/u/ t$ic=ness approved is restricted. See DW4@.+

• ore t$an one PD3 /a% be re"uired to "ualif% dissi/ilar t$ic=ness

5$e t$ic=ness little t of deposited #eld /etal for eac$ process involved is approved fro/ to 2xt except;

• '1A1 (1AWAW! dip transfer #eld of deposited t$ic=ness less t$an NO approves /axi/u/ t$ic=ness of ).) x t onl%

3ef; DW2** (DW4@.)!

• 'f an% Pass in a single or /ultipass #eld NO t$en t$e t$ic=ness approval e"uals ).)x5

issi/ilar 5$ic=ness DW22.4; 5$e t$ic=er and t$inner part /ust be "ualified, Except P0 and P4Q t$e t$inner part can be "ualified if

no '/pacts and test coupon +// t$ic=.

5$ic=ness li/its for fillet #elds as per DW4+2.4a or DW4+2.4d "ualif% all fillet #eld siIes on all base /aterial t$ic=nesses and alldia/eters in one test.

5esting 3e"uire/ents (3ef DW 4+@ for location of speci/ens!

Bnli=e E&200 t$ere is no re"uire/ent for an% nondestructive testing suc$ as radiograp$% or P'P', alt$oug$ ' #ould reco//endradiograp$% for butt #elds.

5$e testing re"uire/ent for groove #elds are as follo#s;• 5#o 5ransverse tensile tests (DW)*!.

• 5#o 3oot bends and 5#o face bends unless t$e plate t$ic=ness exceeds @0O t$en 4 side bends are re"uired. All bend tests

s$ould be done to DW)+ using t$e correct for/er ref. DW4++ to an angle of )0 degrees. :ongitudinal (all #eld! bend tests

are not reco//ended unless t$e base#eld /aterials differ /ar=edl% in bending properties. See DW 4++ for exceptions and



precise details.

5$e testing re"uire/ent for fillet #elds on plate is * /acro sections onl%, for Pipe fillet #elds 4 /acro sections. &o fracture testre"uired.

Welding Procedure Specifications (WPS)

5$is docu/ent details t$e practical application of t$e Procedure Dualification 3ecord (PD3!. 't s$ould contain enoug$ infor/ation to

give direction to t$e #elder and s$ould address all variables associated #it$ t$e #elding process defined in DW2* including nonessential and supple/entar%.

A WPS can co/bine #elding processes fro/ ot$er PD3s but all t$e relevant variables /ust be addressed including parent /etal

t$ic=ness. 5$ere is an exception to t$is rule for root runs fro/ PD3s t$at are greater t$an ).* inc$es t$ic= (@0.)//!, see code fordetails.

Standard Welding Procedures Specifications (SWPs!Standard #elding procedures listed in annex E of ASE 'Q can be purc$ased fro/ t$e A/erican Welding Societ% and used #it$out"ualif%ing a PD3. Section C of ASE 'Q gives details of essential variables and restrictions. A successful #elder perfor/ance

"ualification /ust be carried out to de/onstrate t$e SWPs before a /anufacturer can use it.

• <rief 'ntroduction



• ASE definitions for #elding processes, consu/ables and #elding positions

Welder Perforance >ualification (WP>!

aterials

5$e purpose of t$is test is to deter/ine t$e #elders abilit% to deposit a sound #eld t$erefore t$e base /aterial is not considered ascritical as it is in t$e PD3. 9ence a perfor/ance test on an% /aterial in P groups ) to )) approves all t$ose groups and sub groups, also

P@4 and P4Q (P4P4-!. Providing a co/patible consu/able exists #it$ t$e sa/e nu/ber used in t$e "ualification test. (DW42@.)! &ote a single sided #eld is classed as a #eld #it$out bac=ing and a double sided #eld or #eld #it$ sealing run is classed as a #eld











'f t$e #elder does not use t$e #elding process for #$ic$ $e is "ualified for a period of + /ont$s or /ore t$en $e /ust perfor/ a ne#test in pipe or plate, an% parent /aterial, t$ic=ness and position, if successful all t$e #elder approvals for t$at #elding process are

rene#ed in one test.

5esting 3e"uire/ents5est re"uire/ents for groove #elds DW4*2 consists of eit$er;

• ne face bend and one root bend except for #elding positions *1 6 +1 #$ic$ re"uire 4 bends (3ef DW4*2.) &ote 4!. 'f t$e

plate exceeds @0O side bends /a% be used. See DW 4++ for precise details and exceptions. &ote; <end 5ests can in /ost cases be replaced b% 3adiograp$% >See <elo#?.

• 3adiograp$% is optional and /ust be supple/ented b% bend tests #$en using 1AW ('1A1! #it$ dip transfer (S$ort

ircuiting Arc! or #$en #elding so/e special /aterials. 3ef. DW@4. &ote; Bltrasonic Exa/ination in lieu of 3adiograp$% is not per/itted

5est re"uire/ents for fillet #elds in plate ref. DW4*2.*;• ne /acro section (DW )04! and ne fracture test (DW)02!.

5$e location #$ere eac$ speci/en $as to be ta=en is defined in DW4+@3adiograp$% 3ef DW )-)

• A lengt$ of at least +O /ust be exa/ined for plate or t$e entire circu/ference for pipe.

• 'f t$e pipe circu/ference is less t$an +O t$en /ore sa/ples /ust be #elded up to a /axi/u/ of 4. 3ef DW @2.2.

Cisual Exa/ination 3ef DW @2.2 6 DW )-

Perfor/ance test coupons /ust s$o# co/plete 8oint penetration #it$ full fusion of t$e #eld /etal and base /etal.

5$e #elder perfor/ance test /ust follo# a properl% "ualified W.P.S. nce "ualified t$e #elder /ust al#a%s #or= #it$in t$e extent ofapproval of an% properl% "ualified W.P.S. and $is W.P.D.

5$e #elder #$o "ualifies t$e P.D.3. is auto/aticall% approved #it$in t$e li/its specified in DW@4, DW@* and DW@@. 3ef

DW@).2.Specialist ProcessesSuc$ as corrosion resistant overla% or $ard facing are covered in DW 4*@.

Procedure variables are defined #it$ all procedure variables in DW2*2 and in DW@0 for #elder approval.

in base t$ic=ness approved R siIe #elded or )O, DW 4*@in eposit SiIe Approved; Point W$ere $e/ical anal%sis ta=en &o upper li/it DW42.)+ (4+2.*a! Welding Positions DW4*.4

Perfor/ance Dualification approves all deposit t$ic=nessH &o /in.DW@0)



ASE efinitions, onsu/ables, Welding Positions

ASME P Material u=ers E4plained

ASE $as adopted t$eir o#n designation for #elding processes, #$ic$ are ver% different fro/ t$e 'S definitions adopted b%

E&24+@.

+esignation +escription

W x%fuel 1as Welding

SAW S$ielded etal Arc Welding (A!

SAW Sub/erged Arc Welding

1AW 1as etal Arc Welding ('1A1!

AW lux ored Wire

15AW 1as 5ungsten Arc Welding (5'1!

PAW Plas/a Arc Welding

Straig$t polarit% R Electrode ve

3everse polarit% R Electrode ve

ASME : u=ers

&u/ber 1eneral escription

) 9eav% rutile coated iron po#der electrodes ; A*.) ; E724

2 ost 3utile consu/ables suc$ as ; A*.) ; E+)@

@ ellulosic electrodes suc$ as ; A*.) ; E+))

4 <asic coated electrodes suc$ as ; A*.) ; E7)+ and E7)0

* 9ig$ allo% austenitic stainless steel and duplex ; A*.4 ; E@)+:)+

+ An% steel solid or cored #ire (#it$ flux or /etal!







Pipe ixed U 4* degrees o#n#ards +1 J:4*

Welding Positions :or :illet elds8

Welding Position %est Position ISO and E

lat (Weld flat 8oint at 4* degrees! ) PA

9oriIontal 2 P<

9oriIontal 3otated 23 P<

Certical Bp#ards Progression @ P

Certical o#n#ards Progression @ P1

ver$ead 4 P

Pipe ixed 9oriIontal * P

Welding Positions DW4@).) and DW4+).2

<asicall% t$ere are t$ree inclinations involved.• lat, #$ic$ includes fro/ to )* degrees inclination

• )* 0 degrees inclination

• Certical, 0 - degrees

or eac$ of t$ese inclinations t$e #eld can be rotated fro/ t$e flat position to 9oriIontal to over$ead.





Welder Performance Qualification "WPQ#

Materials

5$e purpose of t$is test is to deter/ine t$e #elders abilit% to deposit a sound #eld t$erefore t$e base /aterial is

not considered as critical as it is in t$e PD3. 9ence a perfor/ance test on an% /aterial in P groups ) to ))approves all t$ose groups and sub groups, also P@4 and P4Q (P4P4-!. Providing a co/patible consu/ableexists #it$ t$e sa/e nu/ber used in t$e "ualification test. (DW42@.)!

&ote a single sided #eld is classed as a #eld #it$out bac=ing and a double sided #eld or #eld #it$ sealing run

is classed as a #eld #it$ bac=ing

.onsua=les

5$e nu/ber cannot be c$anged #it$out re "ualification of t$e #elder except t$at for perfor/ance "ualification

onl% using SAW (A! nu/bers up to and including 4 approve all lesser nu/bers for double sided or#elds #it$ bac=ing onl#. ne onsu/able fro/ 4) 5o 4* approves an% of t$ese consu/ables, except SAW.3ef. >W1712--.

&ote A nu/bers do not appl% to #elder approval tests.

;aria=les

or eac$ #elding process t$ere is a list of essential variables in DW@*2 to DW@*7 and DW@+ for #eldingoperators, t$ese are not necessaril% t$e sa/e as t$e ones for t$e PD3. Essential variables cannot be c$anged.

Explanations of all t$ese variables is given in section 'C of t$e code.

+iaeter and %"ic<ness $anges

ia/eter li/its for all circular #elds including groove #elds, branc$ #elds and fillet #elds is given inDW4*2.@. t$ere are no upper li/its on dia/eters approved and pipe covers plate

&ote for branc$ #elds t$e dia/eter considered for t$e above li/its is t$e one containing t$e #eld preparation.



5$ic=ness li/its, groove #elds.5$e t$ic=ness li/it onl% applies to t$e deposited #eld /etal t$ic=ness not t$e plate t$ic=ness and an% groove#eld approves all fillet #eld siIes. or t greater t$an )2.*// t$ere is no restriction on t$e siIe t$at can be #elded (Providing t$e test #eld deposit

contains at least @ la%ers of #eld!.

5$ic=ness li/its, fillet #elds.

A test on plate greater t$an @)+O approves all base /etal t$ic=nesses and fillet #eld siIes ref. DW4*2.*. (&otet$e above dia/eter li/its appl% unless t$e fillet #eld is "ualified b% a groove #eld!

Coint .onfiguration

Joint geo/etr%, a double C (or B! is considered t$e sa/e as a 8oint #it$ bac=ing and does not "ualif% a single C(or B! #it$out bac=ing, but a single full penetration 8oint #it$out bac=ing "ualifies all 8oint configurations.

Appro,al $ange

Extent of approval is ver% #ell explained in DW4+).-. 5a=e particular note of #elding positions #$ic$ are alsoexplained in DW4+), for exa/ple to "ualif% a fillet #eld in t$e nor/al $oriIontalvertical position #it$ a groove#eld, t$e groove #eld /ust be "ualified in at least t$e 21 position. 5$e #elding positions defined inDW4+).).6 DW4+).2 s$ould be referred to in t$e WPS. 5$e position designations; )1 ,21 ,@1 ,41 ,*1 ,+1

(1roove Welds! and ) ,2 ,@ ,4 (illet Welds! are test positions

Period of ;alidit#!$eneal of >ualifications (>W 0//2/)

Providing t$e #elder uses t$e process for #$ic$ $e is "ualified and t$ere is no reason to "uestion $is abilit% t$en$is "ualification lasts indefinitel%.

'f t$e #elder does not use t$e #elding process for #$ic$ $e is "ualified for a period of + /ont$s or /ore t$en $e/ust perfor/ a ne# test in pipe or plate, an% parent /aterial, t$ic=ness and position, if successful all t$e #elder

approvals for t$at #elding process are rene#ed in one test.



%esting $e*uireents

5est re"uire/ents for groove #elds DW4*2 consists of eit$er;

• ne face bend and one root bend except for #elding positions 5G & 6G #$ic$ re"uire 1 =ends (3efDW4*2.) &ote 4!. 'f t$e plate exceeds @0O side bends /a% be used. See DW 4++ for precise details andexceptions. ote8 Bend %ests can in ost cases =e replaced =# $adiograp"# DSee Belo2

• $adiograp"# is optional and /ust be supple/ented b% bend tests #$en using 1AW ('1A1! #it$dip transfer (S$ort ircuiting Arc! or #$en #elding so/e special /aterials. 3ef. DW@4.

ote8 ltrasonic E4aination in lieu of $adiograp"# is not peritted

5est re"uire/ents for fillet #elds in plate ref. DW4*2.*;• ne /acro section (DW )04! and ne fracture test (DW)02!.

5$e location #$ere eac$ speci/en $as to be ta=en is defined in DW4+@

$adiograp"# $ef >W -3-

• A lengt$ of at least +O /ust be exa/ined for plate or t$e entire circu/ference for pipe.

• 'f t$e pipe circu/ference is less t$an +O t$en /ore sa/ples /ust be #elded up to a /axi/u/ of 4. 3ef

DW @2.2.

;isual E4aination $ef >W 07/2/ & >W -37

Perfor/ance test coupons /ust s$o# co/plete 8oint penetration #it$ full fusion of t$e #eld /etal and base

/etal.

5$e #elder perfor/ance test /ust follo# a properl% "ualified W.P.S. nce "ualified t$e #elder /ust al#a%s



#or= #it$in t$e extent of approval of an% properl% "ualified W.P.S. and $is W.P.D.

5$e #elder #$o "ualifies t$e P.D.3. is auto/aticall% approved #it$in t$e li/its specified in DW@4, DW@*and DW@@. 3ef DW@).2.

Specialist Processes

Suc$ as corrosion resistant overla% or $ard facing are covered in DW 4*@.Procedure variables are defined #it$ all procedure variables in DW2*2 and in DW@0 for #elder approval.

in base t$ic=ness approved R siIe #elded or )O, DW 4*@

in eposit SiIe Approved; Point W$ere $e/ical anal%sis ta=en &o upper li/it DW42.)+ (4+2.*a! Welding

Positions DW4*.4 Perfor/ance Dualification approves all deposit t$ic=nessH &o /in.DW@0)

ASME P Material $um%ers

5$is is a general guide ASE P nu/bers and t$eir e"uivalent E&200 groupings. 1roups referred to in t$e <aseetal colu/n are ASE sub groups. E&200 /aterial groups are included for co/parison onl%.

P o2 E/99 Base Metal

) )

arbon anganese Steels, 4 Sub 1roups• 1roup ) up to approx +* =si

• 1roup 2 Approx 7=si

• 1roup @ Approx 0=si

• 1roup 4 G

2 &ot Bsed

@ 4 @ Sub 1roups; 5%picall% $alf /ol% and $alf c$ro/e $alf /ol%



4 * 2 Sub 1roups; 5%picall% one and a "uarter c$ro/e $alf /ol%

*A * 5%picall% t#o and a "uarter c$ro/e one /ol%

*< * 2 Sub 1roups; 5%picall% five c$ro/e $alf /ol% and nine c$ro/e one /ol%

* + * Sub 1roups; $ro/e /ol% vanadiu/

+ 0 + Sub 1roups; artensitic Stainless Steels 5%picall% 1rade 4)7 0 erritic Stainless Steels 5%picall% 1rade 4-

0 -

Austenitic Stainless Steels, 4 Sub groups

• 1roup) 5%picall% 1rades @4, @)+, @47

• 1roup 2 5%picall% 1rades @-, @)

• 1roup @ 9ig$ /anganese grades

• 1roup 4 5%picall% 2*4 S t%pe steels

-A, <, 7 5%picall% t#o to four percent &ic=el Steels

)A,<,,,1 G ixed bag of lo# allo% steels, )1 @+ &ic=el Steel

) 9 ) uplex and Super uplex 1rades @)0@, @27*

)J G 5%picall% 2+ $ro/e one /ol%

))A 1roup ) 7 - &ic=el Steels

)) A 1roups

2 to *G ixed bag of $ig$ strengt$ lo# allo% steels.

))< G ) Sub 1roups; ixed bag of $ig$ strengt$ lo# allo% steels.

)2 to 2 &ot Bsed

2) 2) Pure Alu/iniu/

22 22a Alu/iniu/ agnesiu/ 1rade *

2@ 2@ Alu/iniu/ agnesiu/ Silicone 1rade +

24 &ot Bsed

2* 22b Alu/iniu/ agnesiu/ anganese 5%picall% *0@, *0+

2+ to @ &ot used







Automatic&Mac'ine Welding

+efinitions

• ec$anised #elding ; Ad8ust/ent during #elding possible

• Auto/atic Welding ; Ad8ust/ent during #elding not re"uired

European Standards

Dualif% procedure using an appropriate part of E& 'S )+)4 (for/erl% E&200!, or E& 'S )*+)@ (for/erl%E&200 Part 0! if t$e 8oint geo/etr% is co/plex. A /anual #eld /a% "ualif% a /ac$ine #eld using t$e sa/e

#elding process as /ec$anisation s$ould not significantl% affect t$e /ec$anical properties of t$e #eld, $o#evert$is #ill be sub8ect to agree/ent bet#een contracting parties.

5$e "ualification of #elding operators s$ould use E& )4)0 MApproval of #elding operators ; usion and

3esistance WeldingH. 5$is standard can also be used for testing t$e person #$o sets up t$e #elding /ac$ine ift$e% $ave /ore influence on #eld "ualit% t$an t$e operator. perators t$at canHt ad8ust t$e e"uip/ent. i.e. <utton pus$ers, donHt need testing.

E& )4)0 offers four different /et$ods of "ualification;

• Adopt E& 'S )*+)4 for testing, but approval range for t$ic=ness and dia/eter based on capacit% of

e"uip/ent used. A WPS /ust be follo#ed.

• Pre Production test to E& 'S )*+)@ or e"uivalent. ust follo# a WPS and approval range sa/e asabove



• Production sa/pling, Set up e"uip/ent and sa/ple test production #elds. 5est /et$od sub8ect toagree/ent bet#een contracting parties.

• unction 5est, n t$e 8ob Job Kno#ledge test;

•

Kno#ledge of #elding • Para/eters C #elding results

• Setting up e"uip/ent to WPS

• 5est e"uip/ent to WPS

• Kno#ledge of /alfunctions

ASME 3

'n general a /anuall% "ualified PD3 #ill support a WPS for a Auto/aticac$ine #eld. 9o#ever addition or

deletion of filler #ill re"uire re"ualification.

Welder perfor/ance is a gre% area $o#ever #e #ould argued t$at t$e definition in DW 4- for a Welder and aWelding operator are different t$erefore /anual #elders canHt operate /ec$anised #elding #it$out being retested.

An operator does one test and $e is "ualified for all t$ic=nessH and dia/eters as per DW @+. 9o#ever t$eapproval range for #elding position is t$e sa/e as /anual #elding.

Documents

Weld Reference for Section 9