ASME :

ASME

WPS - PQR - WPQ Based on ASME Code Section IX

:

1 07

ASME :

. . 001 . . . . . . WTO . . ... . ) (Welding Procedure Specification WPS ) (Procedure Qualification Record PQR WPQ Welder Performance Qualification. ASME Sec. IX 1.1AWS D . . . 58765242190 kkhodaparasti@yahoo .com . 6831

2 07

ASME :

)( WPS

3 07

ASME :

. . WPS . WPS WPS WPS PQR . ) test plate test coupon ( . ) (specimen . . WPS WPS . WPS . . . Welder Performance Qualification WPQ . . WPQ WQR Welder Qualification Record . :)ASME Sec.IX (Boiler and Pressure Vessel Code )ASME B31.1(Power Piping )ASME B31.3 (Process Piping )AWS D1.1 (Structural Welding Code-Steel )API 650 (Welded Steel Tanks for Oil Storage )API 1104 (Welding of Pipelines and Related Facilities )EN 288 (Specification and Approval of Procedures for Welding Metallic Materials

PQR ,WPS WPQ . )( . . . . )CEN ( 4991 927 EN . EN 927 . ) ISO ( 927 EN 4383 ISO 5002 . ) EWF ( 927 EN

4 07

ASME :

4383 ISO EN . 927 EN 0784 BS . 4383 EN 729/ISO . 1009 ISO . WPS . ASME " WPS ". WPS . . . WPS . WPS

WPS 1 4 . . .

5 07

ASME :

1- WPS 1.1AWS D

6 07

ASME :

2- WPS 4011 API

7 07

ASME :

3- WPS 2-882 EN

8 07

ASME :

4- WPS ASME Sec.IX

9 07

ASME :

WPS 4 . WPS. 284- QW . ASME Section IX QW QB QW Article ) Q Qualification ( :.QW-100 General introduction to testing requirements etc .QW-200 Procedure qualification details .QW-300 Performance qualifications (welder approvals) details QW-400 Welding data .This is the biggest section of the code and covers data for both procedure and :performance qualification.It includes -Material and consumable data -Approval range for thickness, diameter, joint .-Configuration and welding positions .-Definitions used in code )QW-500 Standard Welding Procedure Specifications (SWPSs ) QW-200.1(d ASME Section IX B WPS

WPS ASME Sec.IX

) Nonmandatory Appendix B ( SMAW, SAW, GMAW GTAW . ) SAW ( ) GTAW SMAW ( . )(Company Name . WPS . )(By ASME Section IX ) (authorization or certification WPS . By WPS ) (Prepared by ) (Checked by ) (Approved by . (WPS No.) WPS ASME Section IX WPS WPS ) (unique WPS . WPS . 431 :)1 = ASME P-No. 1 (Carbon Steel Base Metals 3 = F-No. 3 (E6010) SMAW 4 = F-No. 4 (E7018) SMAW

2- T 11- P Piping. WPS . . 01 07

ASME :

)(Date WPS . )(Revision WPS 0 . WPS WPS . 1 . ) QW-200.1(c . )(Revision Date WPS . WPS . (Supporting PQR No.(s)) PQR ) QW-200.1(b PQR WPS . ) (essential variable PQR . ))(Welding Process(es 352- QW ) (essential variable 104- QW . WPS . . 5 . 1 . . ) ( . . . 4 : : . 4 : ) ( ) ( ) ( ) (. . . . ) ( . . . . . 4 . : . . . 11 07

ASME :

: . . . . : . . : . : . . : . . : . : . . : . . : ) ( . : . . . : . . : . 6 .

21 07

ASME :

5-

31 07

ASME :

Letter Designation )SMAW(USA )MMA(UK

Welding Process Shielded Metal Arc Welding Manual Metal Arc Welding Stick Welding

)2(CO

)GMAW(USA )MIG(UK )MAG(UK GTAW )TIG(UK FCAW PAW OFW ESW EGW EBW SAW

Gas Metal Arc Welding Metal Inert Gas Welding Metal Active Gas Welding Gas Tungsten Arc Welding Tungsten Inert Gas Welding Flux Cored Arc Welding Plasma Arc Welding Oxy-Fuel Gas Welding Electro Slag Welding Electro Gas Welding Electron Arc Welding Submerged Arc Welding

1-

41 07

ASME :

6- )(Type

) (Manual) (Automatic ) (Semi-Automatic ) (Machine. ) ( . FCAW GMAW . 2 .

51 07

ASME :

2- )(Joint Design

WPS . ) (Joint . 7 . : ) (Butt joint ) (Lap joint ) .(T joint ) (Groove Weld ) .( Fillet Weld 8 .

7 -

61 07

ASME :

8 - . ) (Bevel . . . ) (Single sided ) (Double Sided . . ) (Distortion . 9 .

71 07

ASME :

9 - . 01

.

01 - . . WPS WPS . 81 07

ASME :

. 11 . . 4.2 AWS A . : 3552 . BS 499-2 ,EN 22553,ISO . 21 . 31 .

11

21 -

91 07

ASME :

31 - )(Backing

. 41 . ))(Backing Material (Type . : - - - - 2CO

02 07

ASME :

41 - WPS ) (Bead. ) (Distortion . ) 51(. WPS .

51 - )(Base Metals

WPS. . (P-No.) P WPS PQR P . . Group No . . P . Gr . 3 .P No

12 07

ASME :

. . P No 224- QW .) 71 224- QW ( P No 5 9 01 31.304- QW . 61 . ) 2 . P No !!( P 11-1 52-12 53-13 74-14 26-16

ASME IX11.224- QW 1.224-QW 52.224- QW 12.224-QW 53.224- QW 13.224-QW 74.224- QW 14.224-QW 26.224- QW 16.224-QW

Al Cu Ti Zr

3- P

61 - P

22 07

ASME :

71 - 224-QW

71 ASME SA . :ASME Boiler and Pressure Vessel Code, Section II, Part A and B

ASTM ASME " " S ASTM ASME. Part A Section II ASME Part B . ASME ASTM . ASME SA 516/SA-516M-01 Grade 70 - Pressure Vessel Plates, Carbon Steel, for Moderate - and Lower Temperature Service 07 ASTM A 516/516-01 Grade " " SA ASME

. 2.024- QW . S No . 13 ASME B ASME Section II ASME . S No . Appendix D ASME Sec. IX . P No . ) (Specification ) (Type & Grade ) (Chemical Analysis ) (Mechanical Properties WPS .

32 07

ASME :

. 1.154- QW WPS :- )1/16 in. (1.6mm - ) 3/8 in. (10mm < )1/16 in. (1.6mm - )< 3/4 in. (19mm < )3/8 in. (10mm - )< 1 in. (38mm )3/4in. (19mm - ) 1 in. (38mm )(Pipe Diameter Range

)(Thickness Range

WPS . .O.D I.D . 3.254- QW .- )1 in. (25mm - )< 27/8 in. (73mm )1 in. (25mm - ) 27/8 in. (73mm )(Filler Metals

. . . : ( ( ( ( ( ) ( ( ( ( ) (Electrode ) (Rod . Filler Metal AWS 1.5 A 13.5 A . ASME AWS SF 21.5 AWS A 21.5 SFA Part C Section II ASME. 81 Filler Metals . Filler Metals ) 0652 .(EN 12072,EN 785,EN 499,ISO

42 07

ASME :

81 - Filler Metals

: - E 70xx 6.4mm 6.4mm. - E 7x 8mm. - - E 70S-x 8mm. - E 70T-x 8mm.

52 07

ASME :

- . . 1.5 AWS A . 5.5 AWS A 1 2 ) 350-430C ( 120-150C . 2 . . 404- QW WPS . (F-No) F

F-No 234- QW . WPS PQR . 4 F-No 91 . Al Cu Ni Ti Zr 4- F-No

QW

F-No 6-1 42-12 73-13 54-14 15 16 27-17

1.234 2.234 3.234 4.234 5.234 6.234 7.234

91 - F-No 62 07

ASME :

A-No . 5.404- QW A . ) 5( - SMAW, GTAW, PAW . . - ESW GMAW . . - SAW .

(A-No) A

5- A-No ).(Spec. No

AWS . ASME SF . 81 02 .

72 07

ASME :

)(Solid Surfacing )(Composite Surfacing

1.5-SFA 2.5-SFA 3.5-SFA 4.5-SFA 5.5-SFA 6.5-SFA 7.5-SFA 8.5-SFA 9.5-SFA 01.5-SFA 11.5-SFA 21.5-SFA 31.5-SFA 41.5-SFA 51.5-SFA 61.5-SFA 71.5-SFA 81.5-SFA 02.5-SFA 12.5-SFA 22.5-SFA 32.5-SFA 42.5-SFA 52.5-SFA 62.5-SFA 82.5-SFA 92.5-SFA 03.5-SFA 13.5-SFA

02 - Filler Metals AWS )).(AWS No. (Class No

. 1.5 A E xxxx . E . E ksi ) ( E 11013G:

82 07

ASME :

: - : E xx1x ) (OH,H,V,F . - : E xx2x ) (H,F . - : E xx3x ) (F . AWS 0 8 6 . 4.5 A ASTM E . 61- E 316 L 013 E 403 E OFW E G 613 G AWS .

E 60xx, E 70xx, E 80xx, E90xx, E 110xx, E120xx

12 - )( )(

)( ) (

0 1 2 3 4 5 6 7 8 9

6- 92 07

ASME :

)(Size of Electrode ) ( . : . . . V K . . : 1- 52/3 . 4 5 . 5/2 52/3 4 . 2- V 4 5 . 3- 5 . 52/3 4 . 01 52/3 4 . )(Deposited Weld Metal Thickness Range

WPS 154- QW . ) ( ) )( Electrode- Flux (Calss

71.5- SFA 32.5- SFA . . 4 22 . 32 .

03 07

ASME :

22 - 4

32 -

13 07

ASME :

. 03.5 ASME Sec.ll, Part C, SFA . 03.5 SFA F.No 234- QW . )( Other

)( Consumable insert

. ) ( Positions 1( Flat 2( Horizontal 3( Vertical 4( Overhead

:

504- QW . ASME Sec. IX 164- QW . : )(Position(s) of Groove / Position(s) of Fillet

7 42 .) ( : .

7-

23 07

ASME :

42 - )(Welding Progression

) (Upward . ) (Preheat

... . - ) - (Tempering . . . . 18 0C . 67 ) 3 ( . 604- QW . :

33 07

ASME :

. . :1.ASME B31.1 ASME B31.3 table 330.1.1 AWS D1.1 table 3.2 ASME Sec. Vlll Div

) )( Preheat Temp.(min

. ) (IIW ) (CE 8 .) K ( 8 : ) 62.304- QW (

8- IIW CE 3.1.6 API 5L . ) )( Interpass Temp.(max

2.3 AWS D1.1 table . ) (Tempering . P No. l 300 0C .

43 07

ASME :

) (Preheat Maintenance WPS . ) ( )(Post Weld Heat Treatment 704- QW . P.No 01 , 9 , 6 , 5 , 4 , 3 , 1 11 : - PWHT - PWHT - PWHT ) ( - PWHT ) ( - PWHT . WPS . . ) ( Temperature Range

) ( . : - )590 0C (1100 0F - )650 0C (1100-1200 0F - ) 600 0F(315 0C . - 315 0C 220 0C/hr . 220/t t . 0 - 4.6m 140 C . - 83 0C . - 260 0C/hr . 260/t t . 2- 021/0721+ D D . :1.1.133 AWS D1.1 item 5.8 , ASME B31.3 table

) (Time Range . - . .

53 07

ASME :

WPS WPS . )(Gas

)(Other

. WPS 804- QW . : 1( 2( 3( ))(Shielding Gas(es 2 Ar CO2 He N . . . .) ( . ) (OFW : . 9 .

9- ))(Percent Composition (Mixture

. . : %99-2 Co %08- .Co2-20% + Ar WPS OFW . .) 01 (

63 07

ASME :

) (Flow Rate . . 5-15 lit/ min. 11 .

01-

11- )( Electrical Characteristics . . 904- QW . :

73 07

ASME :

: )(Current AC or DC

DC AC . DC . . AC . ) (Polarity

DC . . . . ( : DCDCEP: Direct Current Electrode Positive DCRP: Direct Current Reverse Polarity

( : DCDCEN: Direct Current Electrode Negative DCSP: Direct Current Straight Polarity ) )(Amps ( Range

.... . SMAW 1 03- 54 .) 21 31 (GTAW )Tungsten Size (mm 1 6.1 4.2 2.3 0.4 )Current(A 08-05 041-06 061-08 003-051 005-052 )Volts(v 31-7 31-7 31-7 31-7 31-7 ).Travel Speed (Cm/min 01-5 01-5 01-5 01-5 01-5

21-

83 07

ASME :

SMAW Position Diameter Polarity )Current(A )Volts(v Travel Speed ).(Cm/min 02-01 02-01 02-01 02-01 31-8 31-8 31-8 31-8

5.2 & Flat Horizontal 2.3 0.4 0.5 & Vertical Overhead 5.2 2.3 0.4 0.5 AC or DCRP AC or DCRP

021-08 051-011 002-051 052-002 001-08 021-08 061-001 022-061

02-61 22-81 52-91 52-91 02-61 22-81 52-91 52-91

31- ))(Volts ( Range

. 42-02 06-05 ) 04-03 (. . 41 .

93 07

ASME :

41- ) (Tungsten Electrode Size and Type

. . ) 21.5 AWS A 84862 EN (. 51 .

GTAW . . : - - . - 8.0 2.2

51-

04 07

ASME :

(Mode of Metal Transfer for GMAW) GMAW GMAW . : ) (Short Circuiting ) (Spray ) (Globular ... . . . . . . 52 .

52 - ) (Eloctrode Wire Feed Speed Range

. )(Technique

014- QW . : 1. ) ( ) ( 2. 3. 4. 5. 6. 7. 8. 9. 01.

14 07

ASME :

) ( . . 8 . ) 62 (

) (String or Weave Bead

62 - ) (Orifice or Gas Cup Size

. ) .....(),(Initial and Interpass Cleaning (Brushing , Grinding

) ( . ... . ) (Method of Back Gouging : ( Electric Arc gouging Oxyfuel gouging ( Grinding and Chipping ( )(Oscillation

. ... .

24 07

ASME :

GMAW SAW . ESO

)(Contact Tube toWork Distance

Electrical Stick-Out. TWD Tip to Work Distance .) 72 (

72- ))( Multiple or Single Pass(per side

. )(Multiple or Single Electrode

SAW . . ))(Travel Speed(range

.

.

)(Peening

34 07

ASME :

WPS WPS . ASME : .a .b .c ) : ( Essential Variables WPS PQR . ) : (Supplementary Essential Variables WPS PQR . ) : ( Nonessential Variables WPS PQR . ASME Sec.IX 252- QW 262- QW . WPS WPS. PQR WPS . )(Standard WPSs

. ) (WPS . WPS WPS PQR. PQR . .!! . ) (PreQualified WPSs 1.1 AWS D . WPS . AWS . . WPS PQR . WPS PQR . ) 3 AWS D1.1 Section ( ASME AWS ASME IX Article V . ) 0002 ( AWS PQR . ASME PQR . )) QW-510(d (

44 07

ASME :

AWS . . ... . . : 8 . 4/6 4/6 . 4 41 EXX . 4 . 4/6 . : 5/9 . 8 . 7/21 . : 3 . 4 . 210C . . . .... . . . . . 8 . 4/6 . 7/21 .

54 07

ASME :

9/51 . . 006 . 0001 . ) ( 4 4/2 2 . 7/21 5/9 8 . GMAW 4/ 6 . 7/21 . 9/51 . FCAW 4/6 . 7/21 . 9/51 . . . . . 210C . . . .... . GMAW . 5 . ... . .

64 07

ASME :

)(PQR

74 07

ASME :

) (WPS . ) (PQR . 102- QW . PQR

PQR 82 03 . . .

82- PQR 1.1AWS D

84 07

ASME :

92- PQR 4011 API

94 07

ASME :

03- PQR ASME Sec.IX

PQR

) test plate sample test coupon ( . ) (specimen . . WPS WPS . PQR : 1- 2- 3- 4- ) ( . WPS )112- .(QW ) ...( . PQR .

05 07

ASME :

)154- (QW . ) 61( 1.364-) QW 13( . ) (fillet ) QW-202.2(c ) QW-202.2(d .

61-

13- 61 ) (transverse. 1.202- QW 2.154- QW . ) ( . : ) (Visual Inspection 15 07

ASME :

)(Tensile test )( Side Bend test )( )( Face Bend test )(Root Bend test

EGW(All weld metal tension test) ESW )(Macroetch test )(Non destructive test :RT, UT )( Impact test

) (Fillet : ) ( Visual Inspection )(Macroetch test ) ( Side Bend test )(All weld metal tension test . 4.4 1.1 AWS D ) 33 43( . . . :)1.8.4 (1) Visual Inspection (see )2.8.4 (2) NDT (see )1.3.8.4 (3) Face, root and side bend (see )4.3.8.4 (4) Reduced Section Tension (see )6.3.8.4 (5) All-Weld-Metal Tension (see )4.8.4 (6) Macroetch (see

71 4011 API .

71- 4011 API

25 07

ASME :

ASME Sec.IX ) 3.171- (QW-171.1, QW-171.2, QW ) ( . . piping 3.13 ASME B 323.2.2A 23 . 1.1 AWS D Annex III .

23- 323.2.2A 3.13 ASME B

35 07

ASME :

33- PQR 1.1 AWS D

45 07

ASME :

43- PQR 1.1 AWS D 01 : 0 0 : ASME Sec. IX )( ) 081( ) 081( : AWS D l.l )( )0 081( ) 0081(

55 07

ASME :

AWS D 1.l : ( ) ( ASW.DI.l .Sec 6 Part C, E,F . ( : )( ) (Quantitative ) .(Qualitative . 81 .

81- . . . . ) ( ) (Elongation .

65 07

ASME :

:2986 ASTM E 8, DIN 50 125, EN 10 002, ISO

53- )( )(

75 07

ASME :

. : ( . ( . ( . U . ) (HAZ . 53 . 32 ASTM E . 3 5 . 63 .

63- Fillet weld fracture testing Butt weld Nick-break testing 73 83 .

85 07

ASME :

73- Fillet weld fracture testing

83- Butt weld Nick-break testing

. . ) (Etchant 074- QW . :388 ASTM E 340, ASTM E 7, ASTM E

95 07

ASME :

93 .

93- )1.351-(QW

: . . . . 59 % . )361-(QW

: 2/3 )( ) (HAZ . . )2.171-(QW

.

: HAZ .

06 07

ASME :

3 . ) - (

191- QW . 191- QW .

PQR . 03 PQR . PQR WPS : ..... . PQR ... . ( 051- QW . . . . . . . ) ( . . . ( 061- QW . ) ( 264- QW . :Acceptable No open defect Satisfactory Good

Satisfactory Good . ( 071- QW . . . . B.M. H.A.Z. W.M . . ) ( Charpy ) ( Izod ) ( Key hole . . ) ( lb-ft . . . ) ( .

16 07

ASME :

. .) ) (Drop-weight test (Pellini test 802 ASTM E ) (. . ( 081- QW . Satisfactory . ( Penetration into Parent Metal Macro-result . ( ) (WM ) (BM ) (HAZ . ) (Type of Test ) ...( . . ) (Deposit Analysis . ) (Other . ( PQR . PQR . PQR . PQR . ) PQR ( PQR . WPS PQR . 002- QW WPS WPS ) (PQR . WPS PQR . 252- QW 262- QW PQR WPS . 262- QW 252- QW ) ( . 002- QW 812- QW PQR .

26 07

ASME :

)(WPQ

36 07

ASME :

. . Welder Performance Qualification WPQ . . WPQ WQR Welder Qualification Record . 04 WPQ ASME Sec.IX .

04- WPQ ASME Sec.IX WPQ : )053-(QW

. . 46 07

ASME :

) (test plate WPS . ) ( . WPQ . ASME Sec.IX . 1. P No 11. P No .)1.324- QW ( . F No . SMAW . F No 1 4 . F No ) ( )11.404- QW ( . A No . 253- QW 753- QW PQR. . 3.254- QW . . . . 5.254- QW 8/4 . 9.164- QW .

. 56 07

ASME :

. )1.003- (QW . .)2.103-( QW ) (All Position Qualification 2G 5G 6G . . . PQR 503- QW-303,QW-304,QW .)2.103-(QW )254-(QW : 5G 6G 4 ) 1.254- QW ( 5/9 . 664- QW . GMAW ) 403-( QW )5.254-(QW

)481- (QW ) (QW-182)(Fracture test . 364- QW .)191-(QW

51 . 51 ) 4 ( )2.203-(QW )091-(QW-302.2,QW

. corrosion resistant overlay hard facing 183- QW-453, QW-252, QW-380, QW-402.16, QW-405.4, QW .

66 07

ASME :

. . . . . 51 03 . 03 . )( . 03 . )( . . )(QW-322.2)(Expiration and renewal

: ( 6 ( . . . 1.1 AWS D . 1.1 AWS D 14 24 .

76 07

ASME :

14- 1.1AWS D

86 07

ASME :

24- 1.1AWS D

96 07

ASME :

) (123457002 ,ASME Boiler and Pressure Vessel Code, Section IX, Welding and Brazing Qualifications 4002 ,AWS D1.1, Structural Welding Code-Steel 4002 ,International Welding Engineer (IWE) Course Book, SLV Duisbug 4991,.The Procedure Handbook of Arc Welding, The Lincoln Electric Company, 13 th ed 7991 ,Jefferson's Welding Encyclopedia, AWS Publications 6- 7- 6831 8- 1 2 6831 9- 51 61 4831

07 07