.10 - General Welding Fabrication and Testing
Juan Velasquez Serna
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Abstract
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The document outlines the specifications and requirements for general welding fabrication and testing, emphasizing the importance of Welding Procedure Specifications (WPS) and Procedure Qualification Test Records (PQR) in ensuring compliance prior to any welding activities. It details the responsibilities of vendor and subvendor compliance, material selection criteria for various welding processes, production test requirements including chemical analysis and hardness testing, as well as quality assurance procedures through inspections and testing methods. Key acceptance criteria and corrective actions for non-compliance are systematically defined.
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General Welding Fabrication and Test
This Standard covers the minimum welding requirements, for welding of shop and field fabrications and the weld inspection of the following: 1. Pressure containing equipment and piping, whether code stamped or not, including but not limited to: rotating equipment, boilers, pressure vessels, heat exchangers, air coolers, shop and field fabricated piping, fired heater tubes, storage tanks, stacks and their attachments. 2. Equipment or piping containing toxic or corrosive materials. 3. Structural Steel 4. Other fabrications where specified. B. This Standard modifies the requirements of applicable ASME, AWS, API and ANSI codes and standards in effect at the revision date. C. Conflicts between requirements of this Standard, related specifications, standards, codes, purchase orders or drawings shall be clarified with Client or Client's Engineer (designated Contractor) prior to proceeding with the fabrication of the affected parts. Regarding conflicts, the Client reserves the right of final decision. D. Where conflicts exist between this Engineering Standard and other POLARIS Engineering Standards and/or applicable codes or regulations, the more stringent requirement shall govern. All conflicts shall be brought to the Client's attention for resolution. The Client shall be the sole arbiter of any conflicts. II. REFERENCES This POLARIS Standard is to be used in conjunction with the latest revision of the standards and codes listed below, unless specifically noted. The terminology "latest revision" shall be interpreted as the revision in effect at the time of contract award. This POLARIS Standard may reference specific sections of some of these codes and standards. The revision of the codes and standards being referenced is noted below in parenthesis. This information is provided to identify the subject matter being referenced. Changes or exceptions made to the referenced code or standard shall apply to later revisions as applicable. A.
PART QW WELDING ARTICLE I WELDING GENERAL REQUIREMENTS QW-100 GENERAL
Section IX of the ASME Boiler and Pressure Vessel Code relates to the qualification of welders, welding operators, brazers, and brazing operators, and the procedures that they employ in welding and brazing according to the ASME Boiler and Pressure Vessel Code and the ASME B31 Code for Pressure Piping. It is divided into two parts: Part QW gives requirements for welding and Part QB contains requirements for brazing. The purpose of the Welding Procedure Specification (WPS) and Procedure Qualification Record (PQR) is to determine that the weldment proposed for construction is capable of providing the required properties for its intended application. It is presupposed that the welder or welding operator performing the welding procedure qualification test is a skilled workman. That is, the welding procedure qualification test establishes the properties of the weldment, not the skill of the welder or welding operator. In addition to this general requirement, special considerations for notch toughness are required by other Sections of the Code. Briefly, a WPS lists the variables, both essential and nonessential, and the acceptable ranges of these variables when using the WPS. The WPS is intended to provide direction for the welder /welding operator. The PQR lists what was used in qualifying the WPS and the test results. In performance qualification, the basic criterion established for welder qualification is to determine the welder's ability to deposit sound weld metal. The purpose of the performance qualification test for the welding operator is to determine the welding operator's mechanical ability to operate the welding equipment. 1 QW-100.3 Welding Procedure Specifications (WPS) written and qualified in accordance with the rules of this Section, and welders and welding operators of automatic and machine welding equipment also qualified in accordance with these rules may be used in any construction built to the requirements of the ASME Boiler and Pressure Vessel Code or the ASME B31 Code for Pressure Piping. However, other Sections of the Code state the conditions under which Section IX requirements are mandatory, in whole or in part, and give additional requirements. The reader is advised to take these provisions into consideration when using this Section. Welding Procedure Specifications, Procedure Qualification Records, and Welder /Welding Operator Performance Qualification made in accordance with the requirements of the 1962 Edition or any later Edition of Section IX may be used in any construction built to the ASME Boiler and Pressure Vessel Code or the ASME B31 Code for Pressure Piping. Welding Procedure Specifications, Procedure Qualification Records, and Welder /Welding Operator Performance Qualification made in accordance with the requirements of the Editions of Section IX prior to 1962, in which all of the requirements of the 1962 Edition or later Editions are met, may also be used. Welding Procedure Specifications and Welder/Welding Operator Performance Qualification records meeting the above requirements do not need to be amended to include any variables required by later Editions and Addenda. Qualification of new Welding Procedure Specifications or Welders /Welding Operators and requalification of existing Welding Procedure Specifications or Welders /Welding Operators shall be in accordance with the current Edition (see Foreword) and Addenda of Section IX. A99 A99 QW-101 1998 SECTION IX QW-123.1 The rules in this Section apply to the preparation of Welding Procedure Specifications and the qualification of welding procedures, welders, and welding operators for all types of manual and machine welding processes permitted in this Section. These rules may also be applied, insofar as they are applicable, to other manual or machine welding processes permitted in other Sections. Terms and Definitions Some of the more common terms relating to welding and brazing are defined in QW-492. Wherever the word pipe is designated, tube shall also be applicable. Responsibility QW-103.1 Welding. Each manufacturer 1 or contractor 1 is responsible for the welding done by his organization and shall conduct the tests required in this Section to qualify the welding procedures he uses in the construction of the weldments built under this Code, and the performance of welders and welding operators who apply these procedures. Each manufacturer or contractor shall maintain a record of the results obtained in welding procedure and welder and welding operator performance qualifications. These records shall be certified by the manufacturer or contractor and shall be accessible to the Authorized Inspector. Refer to recommended Forms in Nonmandatory Appendix B. The orientations of welds are illustrated in QW-461.1 or QW-461.2. Groove welds may be made in test coupons oriented in any of the positions in QW-461.3 or QW-461.4 and 2 as described in the following paragraphs, except that an angular deviation of Ϯ15 deg. from the specified horizontal and vertical planes, and an angular deviation of Ϯ5 deg. from the specified inclined plane are permitted during welding. Plate Positions QW-121.1 Flat Position 1G. Plate in a horizontal plane with the weld metal deposited from above. Refer to QW-461.3 sketch (a). QW-121.2 Horizontal Position 2G. Plate in a vertical plane with the axis of the weld horizontal. Refer to QW-461.3 sketch (b). QW-121.3 Vertical Position 3G. Plate in a vertical plane with the axis of the weld vertical. Refer to QW-461.3 sketch (c). QW-121.4 Overhead Position 4G. Plate in a horizontal plane with the weld metal deposited from underneath. Refer to QW-461.3 sketch (d). Pipe Positions QW-122.1 Flat Position 1G. Pipe with its axis horizontal and rolled during welding so that the weld metal is deposited from above. Refer to QW-461.4 sketch (a). Position 2G. Pipe with its axis vertical and the axis of the weld in a horizontal plane. Pipe shall not be rotated during welding. Refer to QW-461.4 sketch (b). QW-122.3 Multiple Position 5G. Pipe with its axis horizontal and with the welding groove in a vertical plane. Welding shall be done without rotating the pipe. Refer to QW-461.4 sketch (c). QW-122.4 Multiple Position 6G. Pipe with its axis inclined at 45 deg. to horizontal. Welding shall be done without rotating the pipe. Refer to QW-461.4 sketch (d). Test Positions for Stud Welds QW-123.1 Stud Welding. Stud welds may be made in test coupons oriented in any of the positions as described in QW-121 for plate and QW-122 for pipe (excluding QW-122.1). In all cases, the stud shall be QW-123.1 QW-143 perpendicular to the surface of the plate or pipe. See QW-461.7 and QW-461.8. Fillet welds may be made in test coupons oriented in any of the positions of QW-461.5 or QW-461.6, and as described in the following paragraphs, except that an angular deviation of Ϯ15 deg. from the specified horizontal and vertical planes is permitted during welding. Plate Positions QW-131.1 Flat Position 1F. Plates so placed that the weld is deposited with its axis horizontal and its throat vertical. Refer to QW-461.5 sketch (a). Plates so placed that the weld is deposited with its axis horizontal on the upper side of the horizontal surface and against the vertical surface. Refer to QW-461.5 sketch (b). Plates so placed that the weld is deposited with its axis vertical. Refer to QW-461.5 sketch (c). Plates so placed that the weld is deposited with its axis horizontal on the underside of the horizontal surface and against the vertical surface. Refer to QW-461.5 sketch (d). Pipe Positions QW-132.1 Flat Position 1F. Pipe with its axis inclined at 45 deg. to horizontal and rotated during welding so that the weld metal is deposited from above and at the point of deposition the axis of the weld is horizontal and the throat vertical. Refer to QW-461.6 sketch (a). (a) Position 2F. Pipe with its axis vertical so that the weld is deposited on the upper side of the horizontal surface and against the vertical surface. The axis of the weld will be horizontal and the pipe is not to be rotated during welding. Refer to . (b) Position 2FR. Pipe with its axis horizontal and the axis of the deposited weld in the vertical plane. The pipe is rotated during welding. Refer to QW-461.6 sketch (c). 3 QW-132.3 Overhead Position 4F. Pipe with its axis vertical so that the weld is deposited on the underside of the horizontal surface and against the vertical surface. The axis of the weld will be horizontal and the pipe is not to be rotated during welding. Refer to . QW-132.4 Multiple Position 5F. Pipe with its axis horizontal and the axis of the deposited weld in the vertical plane. The pipe is not to be rotated during welding. Refer to QW-461.6 sketch (e). Mechanical tests used in procedure or performance qualification are as follows. 141.1 Tension Tests. Tension tests as described in QW-150 are used to determine the ultimate strength of groove-weld joints. QW-141.2 Guided-Bend Tests. Guided-bend tests as described in QW-160 are used to determine the degree of soundness and ductility of groove-weld joints. QW-141.3 Fillet-Weld Tests. Tests as described in QW-180 are used to determine the size, contour, and degree of soundness of fillet welds. QW-141.4 Notch-Toughness Tests. Tests as described in QW-171 and QW-172 are used to determine the notch toughness of the weldment. QW-141.5 Stud-Weld Test. Deflection bend, hammering, torque, or tension tests as shown in QW-466.4, , and a macro-examination performed in accordance with QW-202.5, respectively, are used to determine acceptability of stud welds. Radiographic examination may be substituted for mechanical testing of QW-141 for groove-weld performance qualification as permitted in QW-304 to prove the ability of welders to make sound welds. An examination of a weld by radiography may be substituted for mechanical testing of QW-141 for groove weld performance qualification as permitted in QW- 305 to prove the ability of welding operators...
CASTI Guidebook to ASME Section IX -Welding Qualifications
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