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&RUURVLRQ5DWH&DOFXODWLRQV Section7,par 7.1.1

6KRUWWHUPFRUURVLRQUDWH CorrosionͲrate

=

tprevious Ͳ tlast #ofyearsbetweentprevious&tlast

/RQJWHUPFRUURVLRQUDWH /RQJ7HUP = &RUURVLRQUDWH

tinitial Ͳ tlast #ofyearsbetweentinitial &tlast 11

&RUURVLRQ5DWH&DOFXODWLRQV 3UDFWLFH4XHVWLRQ

Section7,par 7.1.1

‡ $YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDV´DQG)XOO57ZDV SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV´ /DVWPHDVXUHGWKLFNQHVVWDNHQ\HDUV DJRLQGLFDWHGDUHPDLQLQJWKLFNQHVVRI´:KDWLV6KRUW7HUPFRUURVLRQUDWH"

12

&RUURVLRQ5DWH&DOFXODWLRQV Section7,par 7.1.1

3UDFWLFH4XHVWLRQ

‡ $YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDV´DQG)XOO57ZDV SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV´ /DVWPHDVXUHGWKLFNQHVVWDNHQ\HDUV DJRLQGLFDWHGDUHPDLQLQJWKLFNQHVVRI´:KDWLV6KRUW7HUPFRUURVLRQUDWH" &DOFXODWH6KRUWWHUPFRUURVLRQUDWH :KDWLV.QRZQ" CorrosionͲrate

=

tprevious Ͳ tlast

tprevious = 0.875

#ofyearsbetweentprevious&tlast

tlast = 0.865 =

0.875 Ͳ 0.865 5

= 0.002 inch/yr

+RZPDQ\\HDUVEHWZHHQUHDGLQJV"

3UHYLRXVUHDGLQJLVWKH25,*,1$/WKLFNQHVVLH =(52\HDUVRIVHUYLFH

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Thickness

LQFKPP LQFKPP LQFKPP

Yearsofservice

1HZ &XUUHQW

‡ :KDWLVWKHFRUURVLRQUDWHIRUWKLVFRQGLWLRQPRQLWRULQJORFDWLRQ"

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&RUURVLRQUDWH'HWHUPLQDWLRQ ‡ Determined by SHORT term or Long Term Calculations (API 510, par 7.1.1.2)

‡ Newly installed or Change in Service (API 510, par 7.1.2) 1. 2. 3. 4.

Calculated from data of vessels in similar service. Estimated from Owner- experience Published Data On-stream determination after 1000 hrs of service.

‡ May have different corrosion-rates for large vessels with multiple zones. (API 510, par 6.5.3)

19

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5HPDLQLQJ/LIH&DOFXODWLRQV ‡ 5HPDLQLQJ/LIHHTXDWLRQ

Section7,par 7.2.1 Remaining Life

RL =

tactual_Last

Ͳ trequired

CorrosionͲRate

Variables forRemainingLifeCalcs WDFWXDO WUHTXLUHG

DFWXDORU/$67 WKLFNQHVVPHDVXUHG WKLFNQHVVUHTXLUHGIRULQWHUQDOSUHVVXUHDVFDOFXODWHGE\GHVLJQ IRUPXODVEHIRUHFRUURVLRQDOORZDQFHDQGPDQXIDFWXUHU WROHUDQFHVDUHDGGHG

F &RUURVLRQ5DWH 127( &RUURVLRQUDWHLVWKH UDWHLH6KRUWRU/RQJWHUPUDWH ZKLFKUHVXOWV LQVKRUWHVWUHPDLQLQJOLIH

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Section7,par 7.2.1

‡ $YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDV´DQG)XOO57ZDV SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV´&XUUHQWPHDVXUHGWKLFNQHVVLQGLFDWHV DUHPDLQLQJWKLFNQHVVRI´:KDWLV5HPDLQLQJOLIH"

25

5HPDLQLQJ/LIH&DOFXODWLRQV Section7,par 7.2.1

3UDFWLFH4XHVWLRQ

‡ $YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDV´DQG)XOO57ZDV SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV´&XUUHQWPHDVXUHGWKLFNQHVVLQGLFDWHV DUHPDLQLQJWKLFNQHVVRI´:KDWLV5HPDLQLQJOLIH" /RRNLQJDWWKHIRUPXODIRU³5HPDLQLQJ/LIH´ZKDWLV81.2:1"

5HPDLQLQJ/LIH =

Ͳ trequired tlast CorrosionͲrate

:KDWLV.QRZQ"

tprevious

0.625

tlast

0.600

8QNQRZQ"

CorrosionͲrate = ?????

Sincethe“CORROSIONͲRATEisunknown,the1st Stepistodeterminethe CorrosionͲrate. 26

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5HPDLQLQJ/LIH =

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=

=


tprevious

0.625

tlast

0.600

0.625 Ͳ 0.600 8

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= 0.003 27

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=

tlast

Ͳ trequired

:KDWLV.QRZQ"

CorrosionͲrate

trequired = 0.575 =

=

0.600 Ͳ 0.575 0.003

8 yrs

tlast = 0.600

CorrosionͲrate = 0.003

28

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,QVSHFWLRQ,QWHUYDOVDQG1H[W,QVSHFWLRQ'DWH ‡ ,QWHUQDO,QVSHFWLRQ,QWHUYDOV(API 510 par 6.5.1.1)

Section6,par 6.5.1v

‡ Internal or on-stream inspections shall not exceed one half the remaining life of the vessel or 10 years, whichever is less. ‡ Whenever the remaining life is less than four years, the inspection interval may be the full remaining life up to a maximum of two years.

‡ ([WHUQDO,QVSHFWLRQ,QWHUYDOV(API 510 par 6.5.1.1) ‡ Interval not exceed the lesser of 5 years or the internal/on-stream interval..

‡ ThicknessInspectionIntervals ‡ Should be part of the inspection plan, but no interval requirements mentioned in API510 (API 510 par 5.5.1)

‡ CUIInspectionIntervals

Section5,par 5.5.1

‡ Should be part of the inspection plan, but no interval requirements mentioned in API510 (API 510 par 5.5.1) ‡ “SHALL” be considered for insulated vessels in “intermittent” service or operates between; ‡ ‡

10oF and 350oF for carbon steel and alloy steels 140oF and 400oF for austenitic stainless steels 31

,QWHUQDO,QVSHFWLRQ,QWHUYDO 3UDFWLFH4XHVWLRQ

Section6,par 6.5.1v

‡ $YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDV´DQG)XOO57ZDV SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV´&XUUHQWPHDVXUHGWKLFNQHVVLQGLFDWHV DUHPDLQLQJWKLFNQHVVRI´:KDWLV,QWHUQDO,QVSHFWLRQ,QWHUYDO"

32

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5HPDLQLQJ/LIH =

Ͳ trequired tlast CorrosionͲrate

tprevious

0.625

tlast

0.600

Section7,par 7.2.1 8QNQRZQ"

CorrosionͲrate = ?????

Sincethe“CORROSIONͲRATEisunknown,the1st Stepistodeterminethe CorrosionͲrate. 33

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5HPDLQLQJ/LIH =

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=

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tprevious

0.625

tlast

0.600

0.625 Ͳ 0.600

= 0.003

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Section7,par 7.1.1

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Section7,par 7.2.1

6WHS± &DOFXODWHWKH5(0$,1,1*/,)( 5HPDLQLQJ/LIH

=

tlast

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CorrosionͲrate

trequired = 0.575 =

=

0.600 Ͳ 0.575 0.003

8 yrs

tlast = 0.600

CorrosionͲrate = 0.003

35


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InternalInspectionInterval=4years

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Whatisthetemperaturerangethattemperembrittlementoccurs inlowalloysteels? :KHQVKRXOGDFRUURVLRQVSHFLDOLVWEHFRQVXOWHGZKLOH GHYHORSLQJDQLQVSHFWLRQSODQ" $WZKDWWHPSHUDWXUHGRHV6XOILGDWLRQEHJLQRQLURQEDVHGVWHHOV" :KDWLVWKHPD[LPXPWHPSHUDWXUHIRUWDNLQJ87WKLFNQHVV PHDVXUHPHQWV" :KDWLVWKH3:+7WHPSHUDWXUHIRUFDUERQVWHHO"

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Remaining Life(yr)

March2000

March 1995

16

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44

(YDOXDWLRQRI3LWWLQJ $3,3DUD

‡ Widely scattered pits can be ignored, if;

Section7,par 7.4.3

Rule#1 Remaining Thickness below pit is greater than ½ the Required Thickness

Vessel Thickness

= 2.0”

Depth of Pit

= 1.06”

Corrosion Allowance = 0.250 Retirement Thickness = 1.75”

45



Section7,par 7.4.3

Rule#2 Areaofthepittingbelowthe corrosionallowancehasan arealessthan7in2withinan 8”diametercircle.

46



Section7,par 7.4.3

Rule#3 Sumofthelengthofpitswithinany8”line,mustbelessthan2”

47

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Section7,par 7.4.3

‡ $UHFHQWLQVSHFWLRQGLVFRYHUHGLVRODWHGSLWWLQJLQWKHYHVVHOZDOO0LQLPXPUHTXLUHGZDOO WKLFNQHVVLV´&XUUHQWWKLFNQHVVRIWKHYHVVHOLV´ :KDWLVWKHPLQLPXP DOORZHGUHPDLQLQJWKLFNQHVVDOORZHGDWWKHGHHSHVWSLW"

48

(YDOXDWLRQRI3LWWLQJ Section7,par 7.4.3

3UDFWLFH4XHVWLRQ

‡ $UHFHQWLQVSHFWLRQGLVFRYHUHGLVRODWHGSLWWLQJLQWKHYHVVHOZDOO0LQLPXPUHTXLUHGZDOO WKLFNQHVVLV´&XUUHQWWKLFNQHVVRIWKHYHVVHOLV´ :KDWLVWKHPLQLPXP DOORZHGUHPDLQLQJWKLFNQHVVDOORZHGDWWKHGHHSHVWSLW" “Minimum allowed remaining thickness below the pit is ½ the required thickness”, Therefore, the minimum thickness allowed at the deepest pit is; ( ½ required thickness = 1.250”/2 = 0.625”) Corrosionallowance

Required Thickness

Remainingthickness belowpit

½

ofRequired Thickness

49


Section7,par 7.4.3

‡ 'XULQJDUHFHQWLQWHUQDOLQVSHFWLRQRID´,'YHVVHOZLWK´ZDOOWKLFNQHVVWKUHH LVRODWHGSLWVZHUHGLVFRYHUHG7KHSLWVDUHZLWKLQD´GLDPHWHUFLUFOHZLWKWKHVXPRI WKHLUGLPHQVLRQVDORQJDVWUDLJKWOLQHLV´9HVVHOKDVDUHTXLUHGWKLFNQHVVLV´ DQGFRUURVLRQDOORZDQFHRI´'LPHQVLRQVRIWKHSLWVDUHDVIROORZV 3LW± ´[´[´GHHS 3LW ´[[´GHHS 3LW ´[´[´GHHS :KLFKRIWKHIROORZLQJLVWUXH"

a. b. c. d.

Pitscanbeignored Pitsareunacceptablebasedonsumofthepitdimensionsalonga8”straightline. Pitsareunacceptableduetototalareaofpittingwithinan8”diametercircle. Pitsareunacceptableduetoinsufficientremainingthicknessbelowthedeepestpit.


Section7,par 7.4.3

‡ 'XULQJDUHFHQWLQWHUQDOLQVSHFWLRQRID´,'YHVVHOZLWK´ZDOOWKLFNQHVVWKUHH LVRODWHGSLWVZHUHGLVFRYHUHG7KHSLWVDUHZLWKLQD´GLDPHWHUFLUFOH/HQJWKRIWKHSLWV GLPHQVLRQVDORQJDVWUDLJKWOLQHLV´´DQG´9HVVHOKDVDUHTXLUHG WKLFNQHVVLV´DQGFRUURVLRQDOORZDQFHRI´&DQWKHVHSLWVEHLJQRUHG",IQRW ZK\QRW"'LPHQVLRQVRIWKHSLWVDUHDVIROORZV 3LW± ´[´[´GHHS 3LW ´[[´GHHS 3LW ´[´[´GHHS

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Section5,par 5.1

A. Inspection plan must be established for all pressure vessels and pressure-relieving devices. B. Inspection plan developed by inspector or engineer. C. Corrosion-specialist must be consulted for inspection plan for vessels operating above 750oF. D. Inspection plan shall be evaluated based on present or possible types of damage mechanisms. E. Methods and extent of NDE shall be evaluated to assure they can adequately identify the damage mechanism and severity of damage. 59

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Section5,par 5.1

F. Examinations must be scheduled at intervals that consider; A. Type of damage B. Rate of damage C. Tolerance of equipment to the damage D. Probability of the NDE methods to detect the damage E. Maximum intervals as defined in API 510 G. Minimum Contents of Inspection Plan A. Type of inspection needed B. Next inspection date for each type inspection (internal, external, etc) C. Describe inspection and NDE techniques D. Describe extent and locations of inspection and NDE E. Describe the cleaning requirements F. Describe the requirements of any needed pressure test G. Describe any required repairs 60

7\SHVRI,QVSHFWLRQ

Section5

A. General ‡ Inspections should be conducted in accordance with the inspection plan ‡ Prior to performing an inspection, the inspector should be familiar with; ‡ Thorough understanding of the inspection plan ‡ Operating conditions since the last inspection (API 572 par 9.1) ‡ Applicable damage mechanisms ‡ Prior history ‡ New inspection intervals shall be established if operating temp increases, operating pressure increases or process fluid changes.

(API

510 par. 6.2.2) 61

7\SHVRI,QVSHFWLRQ % ,QWHUQDO,QVSHFWLRQ ‡ Interval is lesser of ½ remaining life or 10 years. If remaining life is LESS than 4 years, interval can be the full remaining life up to max of 2 years. (API 510 par 6.5.1.1). ‡ SHALL be conducted by the inspector (API 510 par 5.5.2.1) ‡ Primary reason for internal inspection is to find damage that cannot be found by external CML’s (API 510 par 5.5.2.1) ‡ Internal inspection performed inside the vessel (API 510 par 5.5.2.1) ‡ Internals may need to be removed to facilitate the internal inspection. Likely will not need to remove 100% of the internals. (API 510 par 5.5.2.2) ‡ Inspector should consult with Corrosion Specialist to determine if it is necessary to remove any linings and/or deposits (API 510 par 5.5.2.3) ‡ Vessels in non-continuous service, the interval is based on number of years of actual service, instead of calendar years, provided the vessel when idled is separated from process stream & not exposed to corrosive streams. 62

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C. On-stream Inspection ‡ Interval same as INTERNAL inspection. ‡ Should be conducted by either an inspector or examiner. (API 510 par 5.5.3.1)

‡ On-stream inspections performed by examiners shall be authorized/approved by the inspector (API 510 par 5.5.3.1) ‡ Inside of vessel inspected from outside vessel. (API 510 par 5.5.3.2)

63

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D. External Inspection

‡ Performed by inspector or qualified others (qualified with appropriate training). (API 510 par 5.5.4.1.1) ‡ Interval is lesser of 5 years or the internal interval. ‡ External inspections check; (API 510 par 5.5.4.1.2) ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡ ‡

Condition of Outside surface of vessel Condition of Insulation system Condition of Coating system Condition of s For leaks Hot spots Vibration damage Allowance for expansion Bulging, misalignment, distortion, etc

‡ Conditions discovered by others, must be reported to inspector. (API 510 par 5.5.4.1.3) 64

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E. Thickness Inspection ‡ Performed by inspector or examiner. (API 510 par 5.5.5.1) ‡ No required interval. ‡ Inspector should consult with corrosion-specialist when short term corrosion-rate changes significantly. (API 510 par 5.5.5.3) ‡ Owner- is responsible for assuring individuals taking thickness readings are trained and qualified (API 510 par 5.5.5.4)

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F. CUI Inspection ‡ Performed by inspector or other qualified personnel (i.e. same as external) ‡ Shall be considered for; (API 510 par 5.5.6.1) ‡ Carbon steel and low alloy operating between 10oF and 350oF. ‡ Stainless steel operating between 140oF and 400oF. ‡ Usually causes localized corrosion damage (API 510 par 5.5.6.2) ‡ Susceptible locations include; (API 510 par 5.5.6.2) ‡ Insulation or stiffening rings ‡ Nozzles and manways ‡ Structural penetrations (ladder clips, pipe s, etc) ‡ Damage insulation ‡ Insulation with failed caulking ‡ Top and bottom heads ‡ CUI inspection may require some or all insulation (API 510 par 5.5.6.3) ‡ Insulation may not need to be removed if; (API 510 par 5.5.6.3) ‡ Insulation is in good condition and there is no reason to suspect damage behind the insulation; ‡ CUI inspection can be performed with UT from ID of vessel. 66

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WeldtCATERGORY isthe”location”ofa“t”inapressurevessel SubͲSectionB, UW,General, UWͲ3

Category A: ‡ Alllongitudinalweldsinshellandnozzles ‡ Allweldsinheads,HemiͲheadtoshellweldt Category B: ‡ Allcircumferentialweldsinshellandnozzles ‡ Headtoshellt(otherthanHemispherical.) Category C and D are flange welds and nozzle attachment welds respectively Longitudinal welds (Category A) are more critical than Circumferential welds (Category B) because they are under double stress. This the reason why in different part of ASME code we have stringent rules in category A t compared to category B t. 67

:HOG-RLQW7\SHV

SubͲSectionB, UW,Design, UWͲ12

‡ Weld t Types ‡ 7\SH± 'RXEOHZHOGHGEXWWMRLQWV

‡ 7\SH± 6LQJOHZHOGHGZLWKEDFNLQJ

‡ 7\SH 6LQJOHZHOGHGZLWKRXWEDFNLQJ

68

:HOG-RLQW7\SHV


‡ Weld t Types ‡ 7\SH± 'RXEOH)XOO)LOOHW/DS-RLQW ‡ 7\SH± 6LQJOH)XOO)LOOHW/DS-RLQW ZLWKSOXJZHOG

‡ 7\SH 6LQJOH)XOO)LOOHW/DS-RLQW ZLWKRXWSOXJZHOG

69

5DGLRJUDSK\ TypeofRadiography

SubͲSectionB, UW,Design, UWͲ11 SubͲSectionC, CCS,Design, UCSͲ57

‡ Full– asrequiredbytheCode(seeUWͲ11(a)),andUCS57 ‡ Spot– CategoryBandCweldsthatarenotrequiredtobe radiographedbyUWͲ11(a)(5)(b). ‡ None

CodeRequiredRT(UWͲ11(a)andUWͲ11(b) ‡ BasedonService,ThicknessorWeldingProcess

SpecifiedRT ‡ Thecanestablishthetypeoftanddegreeofexaminationwhen therulesofCodedoesnotrequireradiography(seeUWͲ12) 70

5DGLRJUDSK\

SubͲSectionB, UW,Design, UWͲ11a

‡ FULLRT– RequiredbyCODE ‡ FULLRT ‡ Allbuttweldsinshell&headsinlethalservice ‡ Allbuttweldsinshell&headswiththickness>11/2orperUCSͲ57 ‡ Allbuttweldsinshell&headsofunfiredboilerswith; ‡ Pressureexceeding50psigorthickness>11/2orperUCS57 ‡ Buttweldsinnozzles>10NPSor>11/8”thickness ‡ Category“A”and“D”weldsinshellsandheads,wheret efficiencyisbasedonTableUWͲ12 ‡ ButtweldsmadeusingElectroͲgas&ElectroͲslagprocess ‡ SpotRT ‡ CategoryBandCbuttweldsintersectingCatAweldsinshellsandheads ‡ CategoryBandCbuttweldsconnectingseamlessheadsorshells 127(&DWHJRU\ $ %ZHOGVPXVWEH7\SHRU7\SHZHOGVVHH7DEOH8: 71

5DGLRJUDSK\ When and where is there a code requirement for full radiography?


Item 1: Allbuttweldsinvesselsusedtocontainalethalsubstance(UWͲ11(a)).Lethalsubstanceshavespecific definitionsinASMECodeinUWͲ2anditistheresponsibilityoftheendtodetermineiftheyordered avesselthatcontainslethalsubstances.

Item 2: All butt welds in vessels in which the nominal thickness exceeds specified values (UWͲ11(a). You can find these values in subsection C, in UCSͲ57. For example, this value for PͲNo.1 in UCSͲ57 is 1 ¼ inch. Nozzles larger than 10 NPS or thickness greater than 1 1/8”. SubͲSectionC,

Item 3: All butt welds in an unfired steam boiler with design pressure > 50 psi (UWͲ11(a)).

UCS,Design, UCSͲ57

Item 4: All category A and D butt welds in vessel when “Full Radiography” optionally selected from table UWͲ 12(column (a) in this table is selected); and categories B and C which intersect Category A shall meet the spot radiography requirement (UWͲ11(a) (5) (b)). The point is this: items 1, 2 and 3 are similar, but item 4 is completely different. In items 1, 2 and 3 it is mandated by code; to do full radiography in all butt welds in vessel so it means it is mandatory for designer to select column (a) in UWͲ12 table. But in item 4, there is no mandating rule. A manufacturer with its own decision has chosen to use column (a) in table UWͲ12 for full radiography. 72

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‡ 7KHUH LV D FRQFHVVLRQ RU ERQXV WR PDQXIDFWXUHUV IRU FDWHJRULHV % DQG & ‡ :KDW LV FRQFHSW EHKLQG WKLV FRQFHVVLRQ RU ERQXV LQ SUHVVXUH YHVVHO 57 WHVW" a. Items 1, 2 and 3 from the previous slide; RT is related to the type of welds and services. b. Pressure vessels in these items are critical from a safety point of view, one contains a lethal substance, the other one has a high thickness, which implicates high pressure, and the last one is an unfired steam boiler c. Item 4 has no criticality like the other items have. d. But you should note all 4 items have been categorized in full radiography clause( UͲ11(a)), so to differentiate item 1, 2 and 3 from item 4, the RT symbols are used in Code (UGͲ116).

73

5DGLRJUDSK\

SubͲSection A,UG,Design, UGͲ116

RT1: Items1,2and3,(E=1),AllbuttweldsͲfulllengthradiography RT2: Item4(E=1),CategoryAandDbuttweldsfulllengthradiography andcategoryBandCbuttweldsspotRadiography RT3: (E=0.85),Spotradiographybuttwelds RT4: (E=0.7),Partial/Noradiography You need to consider the hemispherical head t to shell as category A, but ellipsoidal and torispherical head t to shell as category B; Do you know why? Why ASME considered the stringent rule for pressure vessel RT test in hemispherical head t? It is because this t is more critical, because the thickness obtained from the formula for hemispherical head approximately would be half of the shell thickness; It means if the shell thickness is 1 inch, the hemispherical head thickness would be 0.5 inch. 74

5DGLRJUDSK\


‡ SpotRT– RequiredbyCODE ‡ B and C welds that are not required to be radiographed by UW11(a)(5)(b) ‡ Type 1 and Type 2 butt welds that are not required to be radiographed by UW-11(a).

‡ RTMarkings ‡ RT 1 and RT 2 - FULL Radiography ‡ RT 3 - Spot Radiography ‡ RT 4 - Combo Radiography

SubͲSection A,UG,Design, UGͲ116

‡ RTmarkingsarelocatedonNameplate 75

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-RLQW(IILFLHQF\

SubͲSectionB, UW,Design, TableUWͲ12

‡ t Efficiency is based on; ‡ :HOG-RLQW7\SH7\SHV ‡ :HOG&DWHJRU\$%&'EXWPDLQO\RQ$ % ‡ 5DGLRJUDSK\575757DQG57 ‡ 9HVVHOVZLWKORQJLWXGLQDOVHDPVRUVHDPOHVV

80

5DGLRJUDSK\ -RLQW(IILFLHQF\ SubͲSection A,UG,Design, UGͲ116

RTͲ1

E=1

RTͲ2

E=1

E=1

RTͲ3

E=0.85

RTͲ4

E=0.70

E=1

E=0.85

81

-RLQW(IILFLHQF\ ‡ tEfficiencybasedonRadiography ‡ RTͲ1– FullRTperUWͲ11(a),exceptUW(a)(5)

‡ UseColumn“a”ofTableUWͲ12 ‡ ForSeamlessheads&shellsE=1

SubͲSection A,UG,Design, UGͲ116 SubͲSectionB, UW,Design, TableUWͲ12

‡ RTͲ2Ͳ FullRTperUWͲ11(a)(5)

‡ UseColumn“a”ofTableUWͲ12 ‡ ForseamlessheadsandshellsE=1

‡ RTͲ3Ͳ SpotradiographyperUWͲ11(b)

‡ UseColumn“b”ofTableUWͲ12 ‡ Forseamlessheads&shellsE=1

‡ RTͲ4Ͳ CombinationofRTͲ1,RTͲ2andRTͲ3 ‡ NoRTͲ noradiographyatall

‡ UseColumn“c”ofTableUWͲ12 ‡ ForseamlessshellsandheadsE=0.85

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RT3

RT4

SubͲSectionB, UW,Design, TableUWͲ12

NOTE:ForWeldtypes3,4,5,and6,RTcannotbeusedtoincreasethetefficiency.

83

-RLQW(IILFLHQF\ t Efficiency For Seamless Parts WeldType

Spot RT

NoRT

1

1.0

0.85

2

1.0

0.85

3

0.85

0.85

4

0.85

0.85

5

0.85

0.85

6

0.85

0.85

SubͲSectionB, UW,Design, ParUWͲ 11(a)(5)(a)&(b) SubͲSectionB, UW,Design,Par UWͲ12d

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‡ A seamless head _________?

SubͲSectionB,UW, Design,ParUWͲ 11(a)(5)(a)&(b)and TableUWͲ12 SubͲSectionB, UW,Design,Par UWͲ12d

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6WDWLF+HDG ASMESecVIII,UGͲ98

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6WDWLF+HDG

ASMESectionVIII SubsectionA,UG, InspectionandTesting, UGͲ98(a)(b)

, 6WDWLF+HDG D 6WDWLF+HDG IRRWFROXPQRIZDWHULVHTXDOWRSVLDWWKHERWWRPRI WKHFROXPQ RIZDWHU,QRWKHUZRUGVWKHZHLJKWRIWKHZDWHU DSSOLHVDIRUFHOEV SUHVVXUHSVL

1ft

0.433psi (atbottomofthewatercolumn)

5

6WDWLF+HDG , 3DUW6WDWLF+HDG

ASMESectionVIII SubsectionA,UG, InspectionandTesting, UGͲ98(a)(b) ASMESecVIII,UGͲ98

2ft

WhatisMAWPofeachcomponentfora48ft tall verticalvesselwithellipsoidalheadsandaMAWP of500psig?

N1

6 ft

44ft 8ft

36ft

VesselMAWP=500psig VesselMAWPisthegagepressureatthe“TOP”of thevessel,includingStaticheadpressure.Reference UGͲ98(a)(b)

N2 2ft

6 ft

MAWPofN1=________ MAWPofN2=_________ MAWPofTophead=_________ MAWPofBtm head=_________ MAWPoftheshell=_________ 6

6WDWLF+HDG , 3DUW6WDWLF+HDG


2ft

WhatisMAWPofeachcomponentfora48ft tall verticalvesselwithellipsoidalheadsandaMAWP of500psig?

N1

6 ft

44ft 8ft

36ft

VesselMAWP=500psig VesselMAWPisthegagepressureatthe“TOP”of thevessel,includingStaticheadpressure.Reference UGͲ98(a)(b)

N2 2ft

6 ft

500psig+(6x0.433)=500+2.6=502.60psig MAWPofN1=________ 500psig+(42x0.433)=500+18.19=518.19psig MAWPofN2=_________ 500psig+(2x0.433)=500+0.87=500.87psig MAWPofTophead=_________ 500psig+(48x0.433)=500+20.78=520.78psig MAWPofBtm head=_________ 500psig+(46x0.433)=500+19.92=519.92psig MAWPoftheshell=_________ 7


6WDWLF+HDG , 3DUW6WDWLF+HDG WhatisMAWPofthisvessel? Part

Part MAWP

Top head

510psig

N1

500psig

N2

495psig

Shell

510psig

Btm Head

507psig

Static Head

0ft 2ft

Pressureat Topof Vessel

N1

8ft

10ft N2

42ft 48ft 50ft

8

9HVVHO0$:3YV 3DUW0$:3 ASMESectionVIII SubsectionA,UG, InspectionandTesting, UGͲ98(a)(b)

, 9HVVHO 3DUW0$:3 PracticeQuestion#1 Ifthisvesselisbeinghydrostaticallytestedat200 psig,whatisthepressureatthebottomofthe vessel?

2ft 6 ft

N1 66ft 8ft

PracticeQuestion#2 IftheMAWPofthevesselis550psig,whatisthe MAWPofN2?

58ft N2 6 ft

2ft

PracticeQuestion#3 IftheMAWPoftheshellofthevesselis564psig, whatistheMAWPofN1?

Usethisvesseltoanswer thesepracticequestions 9

7RWDO3UHVVXUH


, 7RWDO3UHVVXUH PracticeQuestion#4

2ft

Ifavesselisbeinghydrostaticallytestedat400 psig,whatisthepressureatN2?

6 ft

N1 66ft 8ft

PracticeQuestion#5

58ft N2

Duringahydrotest ofavessel,ifthepressureatthe bottomofthevesselis635psig,whatisthe 2ft pressureatN1?

6 ft

PracticeQuestion#6 Duringahydrotest ofavessel,ifthepressureatN2 is528psig,whatisthepressureatthetopofthe vessel?

Usethisvesseltoanswer thesepracticequestions 10

NOTE:PerASMESectionVIII,UGͲ99(c.),thehydrotest pressureisthepressureatthetopofthevessel.

,QWHUQDO3UHVVXUH ASMESecVIII,UGͲ21andAppendix3(par3Ͳ2)


, 'HVLJQ3UHVVXUH Designpressureisthepressureusedinthedesignofavesselcomponent togetherwithcoincidenttemperatureforthepurposeofdeterminingthe minimumpermissiblethicknessforeachcomponent.Designpressure includesstaticheadpressure. NOTE:Designpressureistheminimumpressureusedtodesignthevessel(i.e.usedtodeterminethe“required thickness”ofeachcomponent.

,, 0$:3 Maximumallowableworkingpressure(MAWP)isthemaximumpressure permissibleatthetopofthevesselinitsnormaloperatingposition.MAWPis adjustedforthedifferenceinstaticheadthatmayexistbetweenforthepart consideredandthetopofthevessel.

,,, 'HVLJQ3UHVVXUHYV 0$:3 Designpressureisthepressurefortheprocess(processpressureplus statichead).MAWPisthemaximumpressureratingforeachpart and/orvessel. 11

6KHOO0LQLPXP5HTXLUHG7KLFNQHVV ASMESecVIII,UGͲ27(c.)(1)

, 7KHUHTXLUHGWKLFNQHVVRIDF\OLQGULFDOVKHOO EDVHGRQFLUFXPIHUHQWLDOVWUHVVJLYHQD SUHVVXUH8*F Variables

t=PR/(SE)Ͳ(0.6P)

ASMESectionVIII SubsectionA,UG, Design,UGͲ27(c.)(1)

t=requiredthickness inches P=DesignPressure psi R=InsideRadius ofshell inches S=AllowableStress psi E=tEfficiency

12

6KHOO0LQLPXP5HTXLUHG7KLFNQHVV PracticeQuestion#7


A60’tallverticalvesselhasaninsidediameterof8’anddesignedfor300psig@450deg F.Allowablestressofthematerialofconstructionis17,500psiandthetefficiencyis 0.85.Whatistheminimumrequiredthickness?

13

6KHOO0LQLPXP5HTXLUHG7KLFNQHVV ASMESectionVIII SubsectionA,UG, Design,UGͲ27(c.)(1)

PracticeQuestion#7

A60’tallverticalvesselhasaninsidediameterof8’anddesignedfor300psig@450deg F.Allowablestressofthematerialofconstructionis17,500psiandthetefficiencyis 0.85.Whatistheminimumrequiredthickness? t

PR

=

(SE)Ͳ(0.6P)

t

300

= (

t

17500

x

(

=

48

) Ͳ (

14400

=

t

0.85

x

14875

)

14400

Ͳ

(

180 )

0.6

x

300

)

Variables t=requiredthickness inches P=DesignPressure psi R=InsideRadius ofshell inches S=AllowableStress psi E=tEfficiency

14695

t

=

0.980

inches

14



Avesselhasaninsidediameterof60”anddesignedfor150psig@350deg F. Allowablestressofthematerialofconstructionis18,000psiandthet efficiencyis1.0Whatistheminimumrequiredthickness?

15



Avesselhasaninsideradiusof48”anddesignedfor250psig@500deg F. Allowablestressofthematerialofconstructionis17,000psiandthet efficiencyis.90Whatistheminimumrequiredthickness?

16

6SKHUH0LQLPXP5HTXLUHG7KLFNQHVV ASMESectionVIII SubsectionA,UG, Design,UGͲ27(d)

,

7KHUHTXLUHGWKLFNQHVVRID6SKHUHLVJLYHQE\8*G

PR t = (2SE)Ͳ(0.2P)

Variables inches t=requiredthickness P=DesignPressure psi R=InsideRadius ofshell inches psi S=AllowableStress E=tEfficiency

17

6SKHUH0LQLPXP5HTXLUHG7KLFNQHVV PracticeQuestion#10

ASMESectionVIII SubsectionA,UG, Design,UGͲ27(d)

Aspherehasaninsideradiusof12ft anddesignedfor250psig@500deg F. Allowablestressofthematerialofconstructionis17,000psiandtheweldsare singlebuttweldedwithbackingandvesselisstampedRTͲ2.Whatisthe minimumrequiredthickness?

18

6SKHUH0LQLPXP5HTXLUHG7KLFNQHVV PracticeQuestion#11


AspherehasanIDof36ft anddesignedfor30psig@400deg F.Allowable stressofthematerialofconstructionis15,000psiandthetefficiencyis0.80 Whatistheminimumrequiredthickness?

19

9HVVHO+HDGV h=1/4D


D=Insidediameter LongAxis

Ellipsoidalheadsareknownas2to1heads.2to1comes fromthefactthatanellipsoidalheadis1/2ofaellipse.An ellipsehasalongaxisthatis2xtheshortaxis.

L=insideradius

Short Axis

ASMESectionVIII SubsectionA,UG, Design,UGͲ32(f)

D=Insidediameter

20

+HDGV0LQLPXP5HTXLUHG7KLFNQHVV MinimumRequiredThicknessofanEllipsoidalHead

t =

Px D 2 [( S x E ) Ͳ ( 0.2 X

P

)]

t=minimumrequiredthickness P=DesignPressure D=InsideDiameter S=AllowableStress E=tEfficiency

MinimumRequiredThicknessofaHemisphericalHead

t =

P x L 2 [( S x E ) Ͳ ( 0.2 X

P

)]



t=minimumrequiredthickness P=DesignPressure L=InsideRadius S=AllowableStress E=tEfficiency 21

+HDGV0LQLPXP5HTXLUHG7KLFNQHVV PracticeQuestion#12


Whatistheminimumrequiredthicknessfortheheadofa30’tallverticalvessel withellipsoidalheads,insidediameterof72”,allowablestressof16,500psi, MAWPof120psig,andweldsthataredoubleͲweldedbuttweldsandSpotRT’d?

22



Whatistheminimumrequiredthicknessfortheheadofaseamlesshorizontalvessel withellipsoidalheads,insidediameterof96”,allowablestressof18,000psi,MAWP of200psig,andweldsthataredoubleͲfullfilletweldedlaptsandRTͲ1?

23



Whatistheminimumrequiredthicknessfortheheadofa30’tallverticalvessel withhemisphericalheads,insidediameterof72”,allowablestressof16,500psi, MAWPof320psig,andweldsthataredoubleͲweldedbuttweldsandSpotRT’d?

24



Whatistheminimumrequiredthicknessfortheheadsofahorizontalvesselwith hemisphericalheads,insidediameterof96”,allowablestressof18,000psi,MAWPof 200psig,andweldsthataredoubleͲfullfilletweldedlaptsandRTͲ1?

25

HEAD BANGER

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0$:3IRU+HDGV ASMESectionVIII SubsectionA,UG, Design,UGͲ32(d)

I. MAWPofEllipsoidalHeads 2 SEt P = ( D + 0.2t)

t=minimumrequiredthickness D=InsideDiameter S=AllowableStress E=tEfficiency

II. MAWPofHemisphericalHeads 2Set P = ( L + 0.2t)


t=minimumrequiredthickness L=InsideRadius S=AllowableStress E=tEfficiency

29

0$:3 PracticeQuestion#16


Duringaninspectionofaverticalvesselthicknessmeasurementstakenonthebottomellipsoidal headwasfoundtobe0.785.Theinsidediameterofthevesselis96”,allowablestressis17,000 psi,andweldsthataredoubleweldedbuttweldtsandthevesselisstampedRTͲ1.Whatis themaximumallowableworkingpressureforthisseamlessellipsoidalhead?

30

0$:3 ASMESectionVIII SubsectionA,UG, Design,UGͲ32(d)

PracticeQuestion#16

Duringaninspectionofaverticalvesselthicknessmeasurementstakenonthebottomellipsoidal headwasfoundtobe0.785.Theinsidediameterofthevesselis96”,allowablestressis17,000 psi,andweldsthataredoubleweldedbuttweldtsandthevesselisstampedRTͲ1.Whatis themaximumallowableworkingpressureforthisseamlessellipsoidalhead?

P =

P =

P =

2 SEt ( D + 0.2t) 2 ( 17000 x 1 x 0.785 ) ( 96 + ( 0.2 x 0.79 )

t=0.785” D=96” S=17,000 E=1

2 x 13345 96 + 0.157

P =

26690 96.157

P =

277.57

Note: Readthequestionclosely,inthisquestionthereisnomention ifthevesselhaslongseamsornot.Therefore,assumethevessel haslongseams.YougotoTableUWͲ12andfindthetefficiency tobe“1”for“doubleͲweldedbuttwelds”.The“seamless”head, doesnotchangethetefficiency. 31



Ahorizontalvesselwithanoutsidediameterof72”andellipsoidalheads.Shellthicknessis 0.750”andtheheadsare0.500”thick. Theallowablestressis16,000psi.Weldsaredoublefull filletlaptsandthevesselisstampedRTͲ1.Thecorrosionallowancefortheentirevesselis 0.125”.Whatisthemaximumallowableworkingpressurefortheellipsoidalhead?

32



Duringaninspectionofaverticalvesselthicknessmeasurementstakenonthebottom hemisphericalheadwasfoundtobe0.785.Theinsidediameterofthevesselis96”,allowable stressis17,000psi,andweldsthataredoubleweldedbuttweldtsandthevesselisstamped RTͲ1.Whatisthemaximumallowableworkingpressureforthishemisphericalhead?

33



Ahorizontalvesselwithanoutsidediameterof72”andhemisphericalheads.Shellthicknessis 0.750”andtheheadsare0.500”thick. Theallowablestressis16,000psi.Weldsaredoublefull filletlaptsandthevesselisstampedRTͲ1.Thecorrosionallowancefortheentirevesselis 0.125”.WhatisthemaximumallowableworkingpressurefortheHemisphericalhead?

34

0$:3

9HVVHOLQ&RUURVLYH6HUYLFH

PracticeQuestion#20

ASMESectionVIII SubsectionA,UG, Design,UGͲ27(c.)(1) API510,Section7,SubͲ par7.3.3

Duringarecentinspectionofahorizontalvesselwithaninsidediameterof72” andhemisphericalheads,shellthicknesswasrecordedas0.625”.Theallowable stressis16,000psi.Weldsaredoublefullfilletlaptsandthevesselis stampedRTͲ1.ThecorrosionͲrateis0.006”/yr.Requiredthicknessis0.588”. Vesselisincorrosiveservice.Nextinspectionisin5years.Whatisthe maximumallowableworkingpressureforthisvessel?

35

([WHUQDO3UHVVXUH

ASMESectionVIII SubsectionA,UG, Design,UGͲ28(c.)

Therearethreefactorsthatcaneffecttheresistanceof crushingdueexternalpressure. 1. Stiffeners 2. Thickness– thickermaterialsresistcrushing 3. Diameter– increasingdiameter,increasessusceptibilityofcrushing

36

([WHUQDO3UHVVXUH&DOFXODWLRQV I. Formulaandvariables Pa =

4B [ 3 ( Do /


t )]

A=FactorbasedonratioofL/DoandDo/t.(GetitfromASMESecII,PartD,FigG.) B=Factorbasedon“A”FactoranddesignTemperature(GetiffromASMESecII, PartD,TablesCSͲ1orCSͲ2) Do =OutsideDiameter t=Minimumrequiredthickness

“B”factorwillbegiventoyouinthequestion.

37

([WHUQDO3UHVVXUH&DOFXODWLRQV PracticeQuestion#21


Ahorizontalvesselhasanoutsidediameterof60”.Thedistancebetween sis15’ft.Thewallthicknessis0.625”.MaterialofconstructionisSAͲ 516Gr70.Thisvesselhasa“B”factorof3500andisdesignedfor250psig@ 500deg F.Allowablestressis16,500.Whatisthemaximumexternalpressure forthisvessel?

38

([WHUQDO3UHVVXUH&DOFXODWLRQV ASMESectionVIII SubsectionA,UG, Design,UGͲ28(c.)

PracticeQuestion#21

Ahorizontalvesselhasanoutsidediameterof60”.Thedistancebetween sis15’ft.Thewallthicknessis0.625”.MaterialofconstructionisSAͲ 516Gr70.Thisvesselhasa“B”factorof3500andisdesignedfor250psig@ 500deg F.Allowablestressis16,500.Whatisthemaximumexternalpressure forthisvessel? Pa =

Pa =

4B [ 3 ( Do /

t )]

4 x 3500 60 / [ 3x (

B=3500 Do =60” t=0.625 0.625 ) ]

14000 Pa = Pa =

3x (

96

48.611 psi

) 39



Duringanexternalinspectionofavesselwithanoutsidediameterof48” uniformcorrosiondamagewasdiscovered.Thethicknessinthisareaofshell wasfoundtobe0.425”.Thisvesselisdesignedfor35psiexternalpressureand hasaBfactorof1800.Canthisvesseloperateat35psiexternalpressureor doesitneedtobererated?

40



A20ft longexchangertubehasanoutsidediameterof2”andnominal thicknessof0.083”.MaterialofconstructionisSAͲ283GrDanddesign temperatureis600deg F.The“B”factorforthetubeis1500.Whatisthe maximumallowedexternalpressureforthistube?

41

/HVVRQ3ODQ,,, (Calculations– ImpactTesting,WeldSizeandNozzle Reinforcement)

1

/HVVRQ3ODQ,,, (Calculations– ImpactTesting,WeldSizeandNozzleReinforcement)

I.

Impact Testing A. B.

Theinspectorshouldunderstandimpacttestingrequirementsandimpacttestingprocedure(UGͲ84) Theinspectorshouldbeabletodeterminetheminimummetaltemperatureofamaterialwhichisexemptfromimpacttesting(UGͲ20(f),UCSͲ66, UCSͲ68(c).)

II. WELD SIZE FOR ATTACHMENT WELDS AT OPENING MustbeabletodetermineiftheweldsizemeetsCoderequirements.

A. B.

Convertafilletweldthroatdimensiontolegdimensionorvisaversa,usingconversionfactor(0.707); Determinetherequiredsizeofweldsatopenings(UW-16)

III. Nozzle Reinforcement A. B.

C. D. E.

Understandthekeyconceptsofreinforcement,suchasreplacementofstrengthremovedandlimitsofreinforcement. Creditcanbetakenforextrametalinshellandnozzle Beabletocalculatetherequiredareasforreinforcementorchecktoensurethatadesignedpadislargeenough.To simplifytheproblem: Allfr =1.0 AllF=1.0 AllE=1.0

Therewillbenonozzleprojectinginsidetheshell

Beabletocompensateforcorrosionallowances Weldstrengthcalculationsareexcluded

2

,PSDFW7HVWLQJ0'07 (ASMEVIIIUGͲ20(f),UGͲ84UCSͲ66,UCSͲ68(c).)

I.

WhatdoesImpactTestingDetermine?

II.

WhatisMDMT?

III. WhydoestheCodeworryaboutMDMT?

IV. Whataresomefactorsthataffectbrittlenessofmaterials?

V. Whatistheoppositeofbrittleness? ‡

. 3

0'07 I.

ASMEVIII, 6XEVHFWLRQ$3DUW8*'HVLJQ8* 6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH 2SHUDWLRQ8&6D E 8&6F

HowdoesASMESectionVIIImanageBrittleFracture a.

ByMaterialSelection(P1Group1and2Ͳ

b.

ProvidesamethodfordeterminingMDMT

c.

seeFig.UCSͲ66)

ASMEVIII, 6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH 2SHUDWLRQ8&6SDJHGRZQWLPHV

1.

Curvesformaterialgroupings(Fig.UCSͲ66)

2.

Initialimpacttestingexempttemperaturebasedonmaterial(curve letter)andthickness(TableUCSͲ66Ͳ1)

3.

StressReductionRatiofactor[(tr xE)/(tnͲc)].(FigUCSͲ66.1)

4.

PWHTReduction(residualstressreductionallowedwhenPWHTisperformedandisnotrequired bytheCode)see(par.UCSͲ68(c.))

Note:Thisratiowillbeprovidedonthetest.

TemperaturelimitedbyUCSͲ66(b)(2)&(3)andUCSͲ68(c.) a)

UCSͲ66(b)(2)– nocolderthanͲ55oF,unless ; 1) 2)

Stressreductionratiois0.35orless,thentemperaturecanbe betweenͲ55oFandͲ155oF.(UCSͲ66(b)(3) PWHTperformedwhennotrequiredbyCode,temperaturecan bebelowͲ55oF.(UCSͲ68(c.) 4

0'07 PracticeQuestion#1 A horizontal vessel constructed from SA-516 Gr 65 plate (not normalized). Designed for 350 psig @ 650oF. Wall thickness is 1.5”, with a 1/16” corrosion allowance and reduction ratio is .80. Nameplate is stamped RT-1 and HT. What is the lowest possible MDMT for this vessel?

5

0'07 PracticeQuestion#1 A horizontal vessel constructed from SA-516 Gr 65 plate (not normalized). Designed for 350 psig @ 650oF. Wall thickness is 1.5”, with a 1/16” corrosion allowance and reduction ratio is .80. Nameplate is stamped RT-1 and HT. What is the lowest possible MDMT for this vessel? ASMEVIII,

Step1:FindmaterialCurveLetter; Curveletteris“B”fromFig.UCSͲ66

6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH 2SHUDWLRQ8&6SDJHGRZQWLPHV

ASMEVIII,

6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH Step2:InitialMDMT; 2SHUDWLRQ8&6SDJHGRZQWLPHV 51oF fromTableUCSͲ66 ASMEVIII, Step3:MDMTreduction(stressratioreduction); 6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH 20oF reductionallowed,therefore 2SHUDWLRQ8&6SDJHGRZQWLPHV ReducedMDMT=51oFͲ 20oF=+31oF (fromFig.UCSͲ66.1) Step4:PWHTreduction(notallowed) PWHTreductionisnotallowedbecausePWHTwasrequired byCode(i.e.nameplatestamped“HT”)seePar.UCSͲ68(c.)

ASMEVIII,

LowestMDMT=+31oF

6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH 2SHUDWLRQ8&6SDJHGRZQWLPHV

6

0'07 (ASMEVIIIUGͲ20(f),UGͲ84UCSͲ66,UCSͲ68(c).)

PracticeQuestion#2 A horizontal vessel constructed from SA-516 Gr 50N plate. Designed for 300 psig @ 600oF. Wall thickness is 0.25”, with a 1/32” corrosion allowance and reduction ratio is .80. Nameplate is stamped RT-1. Vessel was PWHT’d. What is the lowest possible MDMT for this vessel?

7


PracticeQuestion#3 AhorizontalvesselconstructedfromSAͲ178GrAplate.Designedfor200 [email protected]”,witha1/8”corrosionallowance andreductionratiois.80.VesselwasPWHT’d.NameplateisstampedRTͲ 2.WhatisthelowestpossibleMDMTforthisvessel?


PracticeQuestion#4 A horizontal vessel constructed from SA-516 Gr 60 plate. Designed for 200 psig @ 500oF. Wall thickness is 0.750”, with a 1/8” corrosion allowance and reduction ratio is .88. Nameplate is stamped RT-2 and vessel was PWHT’d for environment cracking. What is the lowest possible MDMT for this vessel?

&KDUS\,PSDFWV CharpyImpactTest

ASMEVIII, 6XEVHFWLRQ$3DUW8*)DEULFDWLRQ8*

‡ EachSpecimenshallconsistofthreespecimensASMEVIIIUGͲ84 ‡ Specimenthicknessis0.394”Fig.UGͲ84

10

&KDUS\,PSDFWV CharpyImpactTest

ASMEVIII, 6XEVHFWLRQ$3DUW8*)DEULFDWLRQ8* SDJHGRZQWLPHV

(a)Interpolationbetweenyieldstrengthsshownispermitted. (b)Theminimumimpactenergyforonespecimenshallnotbelessthan2Ш3oftheaverageenergyrequired forthreespecimens.Theaverageimpactenergyvalueofthethreespecimensmayberoundedtothe nearestftͲlb.

11

&KDUS\,PSDFWV ASMEVIII, 6XEVHFWLRQ$3DUW8*)DEULFDWLRQ8* SDJHGRZQWLPHV

PracticeQuestion#5 ‡

Whatistherequiredaverageandminimumcharpy impactvaluesforamaterialwith50ksi MSYSandis1.0thick?

12

&KDUS\,PSDFWV

(ASMEVIIIUGͲ84

ANSWER: Average=15ft lbs Min.Value=2/3x15=10ft lbs

50Ksi

15ft lbs

1.0thickness

13

&KDUS\,PSDFWV (ASMEVIIIUGͲ84


Whatistherequiredaverageandminimumcharpy impactvaluesforamaterialwith55ksi MSYSandis2.0thick?

14

&KDUS\,PSDFWV (ASMEVIIIUGͲ84


Duringimpacttestingofa1½”thickmaterialwithaMSYSof45,000psi,theimpact testingvaluesforthespecimenswere17,12,and11?Aretheresultsoftheseimpact testsacceptable?

15

)LOOHW:HOGV

ASMEVIII, 6XEVHFWLRQ%3DUW8:'HVLJQ8:E DQGSDJHGRZQRQFHIRU)LJ8:

Filletweldsizeisnormallydescribedbythe“leg”size. Calculatingfilletweldsize; Throatsize=0.707xlegsize Legsize=throatsize/0.707 PerFig.UWͲ16.1; Throatsize=½tmin or Throatsize=tc or

Throat Leg

Leg

Throatsize=tw 16

)LOOHW:HOGV


Calculatingthesizeoffilletwelds; Throat Leg

PracticeQuestion#5 Anequallegfilletweldhasathroatof0.375”. Whatislegsizeforthisfilletweld?

Leg

Legsize=throatsize/0.707 =0.375/0.707 = 0.530” PracticeQuestion#6 Afilletweldwithalegsizeof0.250”. Whatisthroatsizeforthisfilletweld?

PracticeQuestion#7 A45o filletweldhasalegsizeof0.125”. Whatisthroatsizeforthisfilletweld?

17

)LOOHW:HOG6L]H


Perpar.UWͲ16(b);

Filletweldsize,mustbeconvertedfromthroatsize(½tmin ortc)tolegsize.

tmin =lesserof¾”ored Assume,therepadis0.375”thick,thevessel shellis0.500”thickandthenozzleis0.432”. Whatistherequiredfilletweldsizeattaching therepadtothevesselshell?

tn d

t

Step1: Gotothesketch(UWͲ16.1(aͲ1). 1/2tmin

Step2: Calculatethroatsize(½tmin)

tc

te

aͲ1

½tmin =½x(less =½x(lesserof(0.75”,_____,_____,____) =½x(lesserof(0.75”,0.375”,0.500”,0.423”) =½x0.375” =0.1875”

Step3:Calculateweldsize(FilletweldLegsize); Leg=½tmin /0.707=0.1875/0.707=0.265”,roundedtonext1/16”=0.3125”

18

)LOOHW:HOG6L]H Perpar.UWͲ16(b); Fillet weld size for nozzles without repads must be calculated by converting throat size (tc), to leg size. tc = not less than smaller of ¼” or 0.707 x tmin

tn d

Assume, the vessel shell is 0.500” thick and the nozzle is 0.432”. What is the required fillet weld size for this branch connection? Step1: Find correct sketch (UW-16.1(a).

tc t

Step2: Calculate the throat size (tc) tc = lesser of ¼” or 0.707 x tmin = lesser of ¼” or 0.707 x (lesser of 0.750, 0.423, 0.500) = lesser of ¼” or (0.707 x 0.432) = lesser of ¼” or 0.305” = 0.250”

a

Step 3: Calculate weld size (Fillet weld Leg size); Leg = tc / 0.707 = 0.250 / 0.707 = 0.357”, rounded to next 1/16” = 0.375” 19

tc = 0.375” 0.3125” 0.250”

20

)LOOHW:HOG6L]H

ASMEVIIIpar.UWͲ16(b);

PracticeQuestion#8 Abranchconnectionisbeinginstalledwithoutareinforcementpad. Thenozzlethicknessis0.625”andthevesselshellis0.875”thick.Whatsize filletweldshouldbeusedforthisbranchconnection?

tn d

tc t a

21

)LOOHW:HOG6L]H

ASMEVIIIpar.UWͲ16(b);

PracticeQuestion#9 Abranchconnectionisbeinginstalledwithareinforcementpad. Thenozzlethicknessis0.625”,repadis0.750”thickandthe vesselshellis0.875”thick.Whatsizefilletweldshouldbe usedtoattachtherepad tothevesselshell? tn d tc

te t 1/2tmin

aͲ1

22

)LOOHW:HOG6L]H ASMEVIIIpar.UWͲ16(b),Fig.UWͲ16.1(a)

Practice Question # 10 AnozzleisinstalledinavesselperFig.UWͲ16.1(a).Thevesselwallthickness is0.325”andthenozzlewallthicknessis0.375”.Whatistheminimumfillet WeldsizeforthenozzleͲtoͲshellfilletweld? tn

d tc t a

23

)LOOHW:HOG6L]H ASMEVIIIpar.UWͲ16(b),Fig.UWͲ16.1(a)

Practice Question # 11 AnozzleisinstalledinavesselperFig.UWͲ16.1(a).Thevesselwallthickness is0.325”andthenozzlewallthicknessis0.375”.Whatistheminimumfillet weldsizeforthenozzleͲtoͲshellfilletweld? tn d tc t a

24

)LOOHW:HOG6L]H ASMEVIIIpar.UGͲ37

Practice Question # 12 Anew8NPSnozzleisinstalledinavesselperFig.UWͲ16.1(h).Shellrequiredthicknessis 1.125”.Nominalshellthicknessis1.250”.Nominalthicknessforthenozzleis0.875”. Therepadthicknessis0.500”. 1) WhatistheminimumfilletweldsizeforthenozzleͲtoͲrepadfilletweld? 2) WhatistheminimumfilletweldsizefortheshellͲtoͲrepadfilletweld?

tn d tw=0.7tmin

tc t

tc

25 Fig.UWͲ16Ͳ1(h)

HEAD BANGER

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1R]]OH5HLQIRUFHPHQW ASMEVIIIpar.UGͲ37

I. Nozzle Reinforcement ‡ Replacingarealostbycuttingholeinvessel(crossͲsectionalarea) ‡ Strengthofthemateriallost,mustbereplaced ‡ Strengthlost=diameterofholexshelltmin ‡ Limitsofreinforcement ‡ Extrametalmustbenearthenozzle ‡ Strengthofreinforcement ‡ Reinforcementmustbeequaltothestrengthremoved ‡ Additionalreinforcementmustbeadded ‡ Reinforcementcancomefrommultiplesources ‡ Shell,nozzle,repadandfilletwelds ‡ Corrosionallowancecannotbeused

29

1R]]OH5HLQIRUFHPHQW ASMEVIII,SubsectionA,PartUG,UGͲ37

Nozzle Reinforcement Variables

6XEVHFWLRQ%3DUW8:'HVLJQ8:E DQGSDJH GRZQRQFHIRU)LJ8:

Variables for nozzles without repads

Variables for nozzles with repads

tn

d

A = d x tr

t a

A1 = d (t-tr) or 2(t + tn)(t-tr) , extra shell area, larger of these two A2 = 5t(tn-trn) or 5tn (tn-trn) , extra nozzle area, smaller of these two A41 = leg2 d = diameter of nozzle in corroded condition t = shell thickness in the corroded condition tr = shell required thickness tn = nozzle thickness in the corroded condition trn = nozzle required thickness Dp =outsidediameterofrepad te = repad thickness Limits of reinforcement = greater of d or Rn+tn_t

tc

te

tc

A = d x tr

tn

d

t 1/2tmin

aͲ1

A1 = d (t-tr) or 2(t + tn)(t-tr) , larger of these two A2 = 5t(tn-trn) or 5tn (tn-trn) , smaller of these two A41 = Leg2 A42 = Leg2 A5 = (Dp – d – 2tn)te

Notes:

A.

Therewillbenonozzleprojectinginsidetheshell

B.

Beabletocompensateforcorrosionallowances

C.

Weldstrengthcalculationsareexcluded

30

1R]]OH5HLQIRUFHPHQW ASMEVIII,SubsectionA,PartUG,UGͲ37

Practice Question # 13

6XEVHFWLRQ%3DUW8:'HVLJQ8:E DQGSDJH GRZQRQFHIRU)LJ8:

A12NPSnozzleisbeinginstalledonavessel.ThecorrodedIDofthenozzleis 12.0”.Shellthicknessis0.750”.Corrosionallowanceis1/16”.Requiredthickness fortheshellis0.625”.Theareathatmustbereplacedis; tn d tc t a

31


Practice Question # 13 A12NPSnozzleisbeinginstalledonavessel.ThecorrodedIDofthenozzleis 12.0”.Shellthicknessis0.750”.Corrosionallowanceis1/16”.Requiredthickness fortheshellis0.625”.Theareathatmustbereplacedis; tn d tc t a

ASMEVIII,SubsectionA,PartUG,UGͲ37 6XEVHFWLRQ%3DUW8:'HVLJQ8:E DQGSDJH GRZQRQFHIRU)LJ8:

32


Practice Question # 14 A8NPSnozzleisbeinginstalledonavessel.ThecorrodedIDofthenozzleis 8.0”.Nozzlethicknessis0.250”.Requiredthicknessforthenozzleis0.100” Shellthicknessis0.450”.Requiredthicknessfortheshellis0.400”. Filletweldsizeis0.375”. 1.Whatisthearealost? 2.Whatisthelimitsofreinforcement? 3.Whatistheextraareaprovidedbyshell? 4.Whatistheextraareaprovidedbythenozzle?

tn d tc t a

33

1R]]OH5HLQIRUFHPHQW Practice Question # 15 A12NPSnozzleisbeinginstalledinavesselasindicatedbyFig.UWͲ16.1(aͲ1).Thevessel wallthicknessis0.825”thick.Vesselrequiredthicknessis0.625”.Thenozzlewall thicknessis0.500”.Requirednozzlethicknessis0.375”.Therepadis0.375”thick. Corrosionallowanceis0.125”. 1) What is the limits of reinforcement (edge to edge)?

tn

d

2) What is the area lost?

tc

te t 1/2tmin

Fig.UWͲ16.1(aͲ1)

/HVVRQ3ODQ,9 $60(6HFWLRQ,; :36345:34

1

ExamRestrictions/Exclusions: 1.

No more than one process (SMAW, GTAW or SAW).

2.

One filler metal per process

3.

PQR will be the ing PQR for the WPS (only one WPS and one PQR).

4.

Base metal limited to P1, P3, P4, P5 and P8

5.

Dissimilar metals and/or thicknesses are excluded from exam

6. 7. 8. 9.

Corrosion-resistant weld overlay, hard-facing overlay, and dissimilar metal welds with buttering of ferritic member is excluded from exam P1, P3, P4 & P5 lower transition temperature will be 1330 F and 1600 F upper transformation Editorial and non-technical requirements are excluded (i.e. Revision #, Company Name, WPS number, WPS Date, and Name of testing lab). Supplemental Variables are excluded from Exam.

2

BodyofKnowledge I. WPS/PQR/WPQ – BODY OF KNOWLEDGE $ 'HWHUPLQHLISURFHGXUHDQGTXDOLILFDWLRQUHFRUGVDUHLQFRPSOLDQFHZLWK$60( &RGHDQG$3, % 'HWHUPLQHLIDOOHVVHQWLDODQGQRQHVVHQWLDOYDULDEOHVKDYHEHHQDGGUHVVHG & 'HWHUPLQHQXPEHUDQGW\SHRIPHFKDQLFDOWHVWVWKDWDUHOLVWHGLQ345DUHWKH SURSHUWHVWVDQGZKHWKHUWKHUHVXOWVDUHDFFHSWDEOH 127(0XVWNQRZWKDWWKH345 PXVWEHVLJQHGDQGGDWHG

3

Layout of the ASME Section IX Code Book ‡ Divided into 2 parts ‡ QW – WELDING ‡ QB - BRAZING (pages 204 – 243 is not on exam)

‡ QW – Divided into 5 Articles ‡ ‡ ‡ ‡ ‡

Article I – Welding general requirements (13 pages) QW100 Article II – Welding Procedure Qualifications (WPS/PQR) QW200 Article III – Welding Performance Qualifications (WPQ) QW300 Article IV – Welding Data QW400 Article V - Standard WPS Specifications (NOT ON TEST) QW500

4

Purpose of ASME Section IX Section IX is focused on THREE things; 1. WPS - (Welding Procedure Specification) ‡ Directions to welder to for making production welds 2. PQR - (Procedure Qualification Record) ‡ Qualifies that the WPS can be used to make a quality

weld

3. WPQ - (Welder Performance Qualification) ‡ Qualifies that the WELDER can make quality welds

with a Welding Process (i.e. SMAW, GTAW, SAW).

5

General requirements of ASME Section IX

$UWLFOH,

‡ QW100.1 (page 1) a. Provides directions to welder for making production welds in accordance with CODE requirements. b. WPS shall be qualified by Manufacturer/Contractor c. WPS specifies conditions which welding must be performed d. WPS must address essential and non-essential variables and supplemental variables when applicable (supplemental variables are not on API 510 exam). e. PQR establishes the properties of the weld, “not the skill of welder’. f. PQR must address essential variables and and supplemental variables when applicable (supplemental variables are not on API 510 exam).

‡

QW100.2 (page 2) a. WPQ determines welder’s ability to make sound welds.

6

General requirements of ASME Section IX (cont)

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QW100.3 a. WPS qualified per Section IX, can be used to make welds in accordance with Section VIII b. WPS qualified in accordance with Section IX 1962 or later can be used. c. WPS qualified in accordance with Section IX prior to 1962, can be used, if all the 1962 requirements are met. d. Prior to 2009, Section IX used “S” numbers. The 2010 Section IX eliminated the “S” numbers. WPS’s created using “S” numbers must be revised to show correct “P” number, but not RE-QUALIFIED. e. New WPS’s and Welder Qualifications, must be per 2010 Edition of Section IX

‡

QW-101 a. Section IX applies to preparation of WPS, PQR, WPQ for all types of manual & machine welding processes

7


$UWLFOH,

‡

QW102 (Definitions) (see QW492, page 193) a. b.

Groove Weld – weld made in a groove formed within a single or two . Heat-affected zone – base metal that was not melted, but whose mechanical

properties were altered during welding c. Inter temperature – highest temperature allowed in weld or weld t prior to welding. o d. Lower Transformation Temperature 1330 F – Ferrite begins to transform into Austenite (P1, P3, P4, P5) e. Macro-Examination - Observing a cross-section of a specimen by the unaided eye or low magnification with or without etching. f. Performance Qualification – welder’s ability to produce welds meeting prescribed standards. g. Preheating – heat applied prior to welding o h. Upper Transformation temperature 1600 F – Transformation from ferrite to austenite is completed. (P1, P3, P4, P5) i. Welder – one who performs manual or semi-automatic welding.

8


$UWLFOH,

‡

QW103.1 - Responsibility a.

‡

QW103.2 - Records a.

‡

Manufacturer is responsible for and shall conduct testing required to Qualify WPS’s and Welders.

Manufacturer shall maintain a record of the results of WPS and Welder Qualifications (i.e. PQR and WPQ).

QW110 – Weld Orientation a.

Weld orientations used for WPS and WPQ test are as indicated in figure QW 461.1 or QW 461.2 (page 151).

9

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14

Understanding P-Number Example -

WhatistheP-NumberforSA285GrC?

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Answer- FindSA285GrCintableQW/QB422(page76).ItisP1Gr1.

15

Understanding F-Numbers %)1XPEHU 4:SDJH :K\DUH)1XPEHUVXVHG"

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16

Understanding F-Numbers Example - WhatistheF-NumberforE8018?

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Answer- FindAWSclassificationinTableQW432(page134),thengohorizontallytoleft tillyougettotheF-Nocolumn.F4isanswer

17

P-Number and F-Number Practice Questions 31XPEHU 3UDFWLFH± ZKDW LVWKH3IRUIROORZLQJ" Material

PͲNumber

SA240Type 304 SA217TypeWC1 UNSS31000

)1XPEHU 3UDFWLFH± ZKDWLVWKH)IRUWKHIROORZLQJ" Filler MetalClassificationand/orSpecification

FͲNumber

E7024

E8018

SFA5.18 18

Test positions for Groove Welds (plate) QW120 – Test Positions a.

Test coupons may be oriented in any position indicate in figures QW 461.3 (plate) or QW 461.4 (pipe) …..see page 153

$UWLFOH,94: 4: 3DJHGRZQWLPHV

r 15deg

r 15deg

19

Test positions for Groove Welds (Pipe) $UWLFOH,94: 4: 3DJHGRZQWLPHV

r 15deg

r 15deg

20

“FIELD” Weld Orientations $UWLFOH,9 4: 4:

(QW110 page 151)

Tabulation of Positions of GROOVE WELDS

INCLINATION of AXIS Position Flat

Diagram Reference A

Inclination of Axis 0 to 15o

Rotation of Face 150 to 210o

Horizontal

B

0 to 15o

80 to 150o 210 to 280o

Overhead

C

0 to 80o

0 to 80o 210 to 360o

Vertical

D E

15 to 80o 80 to 90o

80 to 280o 0 to 360o

o

280 o

0 to o 360 ROTATION of FACE

21

“FIELD” Weld Orientations

(QW110 page 151)

Groove Weld – POSITION of Field Welds Tabulation of Positions of GROOVE WELDS

6WHS

6WHS

6WHS

Position Flat

Diagram Reference A



Horizontal

B

0 to 15o

80 to 150o 210 to 280o

Overhead

C

0 to 80o

0 to 80o 210 to 360o

Vertical

D E

15 to 80o 80 to 90o

80 to 280o 0 to 360o

3RVLWLRQ RULHQWDWLRQRIWKH³:(/'´ ‡ 7KHUHDUHRQO\³´SRVLWLRQV ‡ )ODW$ ‡ +RUL]RQWDO% ‡ 9HUWLFDO& ‡ 2YHUKHDG' 1RWH( LVIRU)LOOHWZHOGVDQGWKLVZLOOQRWEHRQ([DP 22


(QW110 page 151)

3UDFWLFH4XHVWLRQ $JURRYH ZHOGLVLQFOLQHGGHJUHHVIURPKRUL]RQWDODQGWKHIDFHRIWKHZHOGLVDWGHJUHHVSPFORFNSRVLWLRQ :KDW LVWKHZHOGLQJSRVLWLRQRIWKLVZHOG"

23

“FIELD” Weld Orientations 3UDFWLFH4XHVWLRQ $JURRYH ZHOGLVLQFOLQHGGHJUHHVIURPKRUL]RQWDO DQGWKHIDFHRIWKHZHOGLVDWGHJUHHVSPFORFN SRVLWLRQ :KDWLVZHOGLQJSRVLWLRQRIWKLVZHOG"

6WHS

6WHS 0DWFKWKH3RVLWLRQ IURP6WHSWRWKHIDFH URWDWLRQ 7KLVZLOOJLYH\RXWKH3RVLWLRQV IRUWKLVSURGXFWLRQ ZHOG Tabulation of Positions of GROOVE WELDS

'HWHUPLQHZKLFKSRVLWLRQ WKLV³LQFOLQDWLRQRIZHOGD[LV´ WKLVZHOGFRXOGSRVVLEO\EHLH$%&RU'

Tabulation of Positions of GROOVE WELDS

6WHS Position Flat

Diagram Reference A



Horizontal

B

0 to 15o

80 to 150o 210 to 280o

Overhead

C

0 to 80o

0 to 80o 210 to 360o

Vertical

D E

15 to 80o 80 to 90o

80 to 280o 0 to 360o

(QW110 page 151)

6WHS Position Flat

Diagram Reference A



Horizontal

B

0 to 15o

80 to 150o 210 to 280o

Overhead

C

0 to 80o

0 to 80o 210 to 360o

Vertical

D E

15 to 80o 80 to 90o

80 to 280o 0 to 360o

/RRNLQJDWWKHFKDUW GHJUHHVFDQEH³$´ ³%´³&´RU³'´

24


(QW110 page 151)

3UDFWLFH4XHVWLRQ $JURRYH ZHOGLVLQFOLQHGGHJUHHVIURPKRUL]RQWDO DQGWKHIDFHRIWKHZHOGLVDWGHJUHHVSPFORFN SRVLWLRQ :KDWLVZHOGLQJSRVLWLRQRIWKLVZHOG"

6WHS 0DWFK WKH³,QFOLQDWLRQ´WRWKH³)DFH5RWDWLRQ´WR GHWHUPLQHWKH326,7,21RIWKH:(/' Tabulation of Positions of GROOVE WELDS

Position Flat

Diagram Reference A



Horizontal

B

0 to 15o

80 to 150o 210 to 280o

Overhead

C

0 to 80o

0 to 80o 210 to 360o

Vertical

D E

15 to 80o 80 to 90o

80 to 280o 0 to 360o

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25

Practice Questions for Weld Orientations

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26


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27



28



29

7\SHVRI7HVW([DPV $UWLFOH,

‡

QW141.1 – Tension Test A. B. C.

‡

QW141.2 – Guided Bend Test A. B.

‡

Used to determine “notch toughness” of the welds

QW142 – Special examination for welders A.

‡

Used to determine “size, contour & degree of soundness ” of fillet welds.

QW141.4 – Charpy Impact A.

‡

Used to determine “degree of soundness and ductility” of groove weld ts. Types - Root, Face and Side bend

QW141.3 – Fillet Weld Test A.

‡

Used to determine “ultimate strength” of groove weld ts (TENSILE STRENGTH). Types of Test - Reduced Section, Round (Turned), Full Section 2 Tensile Strength = Load/Area in lbs/in (psi)

RT or UT may be substituted for mechanical test (bends) for welders.

QW144 – Visual examination A.

Used to determine welds meet “quality standards”

30

7(16,217(67 $UWLFOH,94: 4:SDJH GRZQWLPHV

31

7(16,217(67 QW141.1 – Tension Test

‡

A. B. C.

QW151 – Tension Test

‡

QW 151.1 - Reduced section “may be” used for all thicknesses of plates

‡ ‡ ‡

QW 151.1(a) - For thicknesses ” 1” “SHALL” be FULL thickness specimens QW 151.1(b) - For thicknesses > 1” “may be” FULL thickness or multiple specimens

QW 151.2 - Reduced section “may be” used for all thicknesses of pipe > 3” diameter.

‡ ‡ ‡

‡

Used to determine “ultimate strength” of groove weld ts (TENSILE STRENGTH). Types of Test - Reduced Section, Round (Turned), Full Section 2 Tensile Strength = Load/Area in lbs/in (psi)

QW 151.2(a) - For pipe thickness ” 1” “SHALL” be FULL thickness specimens QW 151.2(b) - For thicknesses > 1” “may be” FULL thickness or multiple specimens

QW153 – Tension Test – Acceptance Criteria

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In order for a Tension test to , the specimen shall have a tensile strength of not less than; a) MSTS of the base metal (when it fails in weld) b) MSTS of the weaker of the two metals ed together (when it fails in the weld) c) 95% of the MSTS of base metal (when it fails in the base metal). 127(/2$'LVDPHDVXUHRIWKHVWUHVV QHHGHGWRSXOOWKH7(16,21VSHFLPHQDSDUWLHIDLOXUH

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Bend Test - Specimens

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41

Bend Test ‡

QW141.2 – Bend Test A. B.

‡

Face and Root Bend Test ‡

‡

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These two test are always done together. Therefore, what ever # of face bends are required, the same number of root bends are also required.

‡

Side bends are only performed with other side bends (i.e. you will never see face, root AND side bends required). Side bends are only required for “THICKER” materials (i.e. ¾” or greater in thickness). See Table QW 451.1(a) on page 147.

Acceptance Criteria 1. 2. 3.

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Side Bend Test ‡

‡

4:SDJH $UWLFOH, Used to determine “degree of soundness and ductility” of groove weld ts. Types of Test - Face, Root, and Side bends (determined by which face is on “Convex” side)

4:SDJH

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Weld and Haz must be in the bent portion of bend. No open discontinuity in weld or HAZ > 1/8” in any direction on convex surface Open discontinuity at the corners are acceptable,unless result from LOF, slag or internal discontinuities 127('XFWLOLW\LVDPDWHULDOVDELOLW\WREHVKDSHGZLWKRXWEUHDNLQJ

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Figure“A” Figure“B”

Figure“C”

43

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Figure“A” Figure“B”

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44

Visual Examinations ‡

QW144 – Visual Examination A. Used to determine if welds meet “q quality standards” B. Required for “PERFORMANCE” test, not PQR. 4:SDJH

‡

QW-194 Acceptance Criteria 1. Welds must be inspected after welding is complete and before specimens are removed (see QW-302.4) $UWLFOH,,, 2. Must have complete t penetration 3. Must have complete fusion of weld metal and base metal

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Radiography ‡ QW142 – Radiography

4:SDJH

1. May be substituted for Groove weld Mechanical Test for WELDERS.

‡ QW-191 Acceptance Criteria

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4:SDJH

1. No cracks, Lack of Fusion (LOF) or Incomplete Penetration (IP) 2. Elongated slag inclusions (i.e. indication is 3 times longer than width), max size permitted; 1. 2. 3. 4.

Max length of 1/8” - for t up to 3/8” Max length of 1/3 t - for t > 3/8” but < 2 ¼” Max length ¾” - for t > 2 ¼” Aligned inclusions with aggregate length > t in 12t length of weld

3. Rounded Indications

1. Smaller of 20% of t or 1/8” 2. For clustered, assorted or randomly dispersed configurations, see Appendix I

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Welder Qualification Record ‡ WelderPerformanceQualification(WPQ) 1.

Coupon or production for each welding process (SMAW, GTAW, SAW, etc) 4:SDJH

2.

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Qualified by; a. b.

Production weld must be examined by RT or UT Coupon can be examined by VT and Mechanical or RT/UT See QW-300.1

NOTE:GMAWͲS“shortͲcircuitingmode”weldscannotbequalifiedbyRT

3.

If examination is acceptable, welder is qualified within the limits of QW-304

4.

WPQ is welded in accordance with a WPS. Preheat & PWHT required by WPS can be omitted for WPQ 4:SDJH

51

Welder Qualification Record Practice Question # 14 Which of the following cannot be used to qualify a welder? 1. 2. 3. 4.

VT & Bend Test RT of 1st Production weld RT of test coupon Tension Test

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52

WPQ Bend Specimen Requirements Bends

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1. Number of bends?

AND

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53

Bend Specimen Requirements for “Performance Qualification” $UWLFOH,9

Bends

4: 4:

2. Dimensions? )LJXUHV4: D E SDJH VLGHEHQG

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WPQ Bend Specimens Bends

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Where to remove the specimens? 4: FWRJ

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Alternative Inspection (RT/UT) for WPQ $UWLFOH,,,VFUROO WR4: 4:

Requirements NDE – Alternative Inspection

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(RT/UT in lieu of BENDS

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1. Minimum Length of weld? ´

1. Minimum Length of weld? ´XQOHVV*RU*

2. Pipe? )XOO&LUFXPIHUHQFH

2. Welder Operator? 0LQLPXPRIIW

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RT cannot be used to test a welder for either of the following;

‡ ‡

4:SDJH

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4:SDJH

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1. Fails Visual test; 4:SDJH Qualify by: making 2 coupons, both must VT and 1 picked for

mechanical testing (bend)

2. Any of the bend test fail; 4:SDJH Qualify by: making 2 coupons, both must mechanical test. 3. Fails RT exam; 4:SDJH Qualify by; retest and RT twice the required length of weld

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1. Welder has not used the Process for 6 months 2. Reason to question welder’s ability to make sound weld Qualified by;

Welding single coupon, plate or pipe, any thickness/diameter/position, VT/Bend or RT. 57

Practice Questions for Welder Qualification Practice Question # 15 RT can be used to qualify a welder, except for the following? 1. 2. 3. 4.

Welding P21 material with GTAW process SAW process SMAW Process GMAW process in Short-circuiting mode

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Practice Question # 16 A welder is being qualified by welding using ½” thickA106B pipe coupon in 5G position. How many face bends are required? 1. 2. 3. 4.

2 1 3 0


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A welder is being qualified for 2G and 5G on a single pipe 1” thick coupon (A240 type 304L coupon). How many side bends are required? 1. 2. 3. 4.

6 2 4 0

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Practice Questions for Welder Qualification Practice Question # 18 Which of the following is the manufacturer/contractor prohibited from delegating to another organization? 1. 2. 3. 4.

Preparing test coupons Performing mechanical or NDE inspection of specimens Witnessing the welder making the weld coupon Developing the WPQ record


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A welder was making test coupons for a 2G and 5G pipe qualification test and the 2G coupon failed VT examination. In order for the welder to be qualified, which of the following must occur? 1. 2. 3. 4.

Make another 1G coupon and either RT or Mechanical Test the coupon Make two 1G coupons and VT and RT examine both coupons Make two 1G coupons and VT both coupons, but only RT one coupon Make two 2G coupons and VT both coupons, but only Mechanical test one coupon

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Practice Question # 20 A 6G qualification coupon failed the mechanical testing (one of the bends failed), In order for the welder to be qualified, which of the following is required?

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1. 2. 3. 4.

Two more coupons have to be welded and all 4 bends for each of the coupons have to mechanical test Two more coupons have to be welded and only one coupon has to the required mechanical test Another coupon has to be welded and all 4 bends has to mechanical test Two more coupons have to be welded and both coupons must be either mechanical testing or RT examined . 59

WPQ “P” Number Qualification Range 4XHVWLRQ

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“P”number oftest coupon welded

“P”number Range qualifiedto weldin FIELD

Answer: 31RWKUX) WKUX 60

WPQ “F” Number Qualification Range 4XHVWLRQ $UWLFOH,9 4: SDJHXS WLPH

“F”number Range qualifiedto weldin FIELD

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Qualified with

Answer: )1R

61

WPQ # of Bend Specimens 4XHVWLRQ :KDWW\SHEHQGDQGKRZPDQ\EHQGVDUHUHTXLUHGIRUD ZHOGHUWHVWPDGHRQD´[´SLSHFRXSRQZHOGHGLQWKH*SRVLWLRQ" $UWLFOH,9 4: SDJHGRZQ WLPHV

Answer: IDFHDQGURRWRUVLGHEHQGV 62

WPQ # of Bend Specimens 4XHVWLRQ :KDWW\SHEHQGDQGKRZPDQ\EHQGVDUHUHTXLUHGIRUD ZHOGHUWHVWPDGHRQD´[´SLSHFRXSRQZHOGHGLQWKH*SRVLWLRQ" $UWLFOH,9 4: SDJHGRZQ WLPHV

Answer: IDFHDQGURRWRUVLGHEHQGVWKLVLVDVLQGLFDWHGLQSDU4:SDJH 63

WPQ Thickness Limits 4XHVWLRQ :KDWWKLFNQHVVLVDZHOGHUTXDOLILHGIRULIWKHTXDOLILFDWLRQFRXSRQLV PDGHRQD´[´SLSHFRXSRQZHOGHGLQWKH*SRVLWLRQ" $UWLFOH,9 4: SDJHGRZQ WLPHV

Answer: ´XQOHVVWKHZHOGLVPDGHLQOD\HUVWKHQWKLFNQHVVLV³8QOLPLWHG´ 64

WPQ Diameter Limits 4XHVWLRQ :KDWGLDPHWHULVDZHOGHUTXDOLILHGIRULIWKHTXDOLILFDWLRQFRXSRQLV PDGHRQD136[´SLSHFRXSRQZHOGHGLQWKH*SRVLWLRQ" $UWLFOH,9 4: SDJHGRZQ WLPHV

Answer: ´2'WR8QOLPLWHG´ 65

WPQ Position Limits 4XHVWLRQ :KDWSRVLWLRQLVDZHOGHUTXDOLILHGIRULIWKHTXDOLILFDWLRQFRXSRQLV PDGHRQD136[´SLSHZHOGHGLQYHUWLFDOSRVLWLRQ" $UWLFOH,9 4:SDJH GRZQWLPHV

Answer: )9DQG2

66

Welder Qualification Record WPQ Record 0XVWFRQWDLQIROORZLQJ

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1. Variables used (i.e. process, type(manual/automatic, with/without backing, P-No, F-No, etc)

2. Essential Variables (i.e. ts, Base metal, Filler Metal, Position, etc)

3. Type of Test (i.e. VT, Bends and/or RT/UT) 4. Test Results (i.e. Acceptable or Failed) 5. Ranges Qualified – (i.e. thickness range, Positions, Diameters, fillet welds)

6. Certification (i.e. signature of Manufacturer/Contractor)

67

WPQ – Essential Variables Essential Variables

Paragraph QW402 ts QW403 BaseMetals

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QW405 Positions

Variable

Process SAW

SMAW

GTAW

X

X

.4

Ͳ Backing

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ØPipeDiameter

X

X

X

.18

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X

X

.14

± Filler

.15

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± Inserts

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X

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X X

X

X

X

X

X

X

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X

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&RPSOHWLQJD:345HFRUG Step1

DetermineWhatweldingPROCESSandTYPEusedtomaketestcoupon SMAWandManual

ThesearesetbyWPS

Step2

Findthe“Essential”variablesfortheweldingprocessusedinASMEIX.

Page57

Step3

CompleteTestingVariablesandQualificationLimits(“RangeQualified” section) QW353forSMAW

WeldingVariables(QW350)

WeldingProcess(es) Type(i.e.manual,semi-automatic)used 3. Backing(withorwithout) (QW402.4) 4. x TestCouponProductionWeld(dia ifpipe) (QW403.16Base) 5. BasemetalP-NumbertoP-Number (QW403.18P-Number) 6. FillerMetalorElectrodeSpec(SFA) 7. FillerMetalF-Number(QW404.15F-Number) 8. ConsumableInsert(GTAWorPAW) 9. FillerMetalType(solid/metalorfluxcored/powder) 1. 2.

ActualVariables SMAW Manual None

6”NPS P1toP1 5.1 F3 N/A N/A

QW353forSMAW

RangeQualified

SMAW . Manual F1toF3with,F3wo

• 27/8”OD P1-P15F,P34,P41-49 -------_F1,F2,andF3 ------------

------------

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69

&RPSOHWLQJD:345HFRUGFRQW WeldingVariables(QW350)

10. DepositedThicknessforeachprocess(QW403.30) a. b.

11.

Process1: SMAW 3layersminimumYesNo x Process2: SMAW 3layersminimumYesNo

Positionqualified(1G,2G,3G,4G,5G,6G,etc)

ActualVariables . .280” . ------

.

2G

RangeQualified ” . ------------ . F,H

12. Verticalprogression(uphillordownhill)

. Uphill

n/ahorz

13. InertGasBacking(GTAW,PAW,GMAW)

. N/A

------------

14. GMAWTransfermode(Spray,Globular,Pulse,orShortCircuit) 15. GTAWCurrenttype/polarity(AC,DCEP,DCEN)

N/A N/A . .

------------

.

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________________________________________________________________________________________________________________ Step4

Complete“Results:sectionandthenSignandDateForm That’sIT,youjustcompletedaWPQRECORD

70

3UDFWLFH4XHVWLRQ IRU :HOGHUV4XDOLILFDWLRQ5HFRUG PracticeQuestion#28 WeldingVariables(QW350)

DetermineifEssential Variablesare“Correct”

1. WeldingProcess(es) 2. Type(i.e.manual,semi-automatic)used 3. Backing(withorwithout) 4. xTestCouponProductionWeld(dia ifpipe) 5. BasemetalP-NumbertoP-Number 6. FillerMetalorElectrodeSpec(SFA) 7. FillerMetalF-Number 8. ConsumableInsert(GTAWorPAW) 9. FillerMetalType(solid/metalorfluxcored/powder) . 10. DepositedThicknessforeachprocess x a. Process1: SMAW 3layersminimumYesNo b. Process1: SMAW 3layersminimumYesNo 11. Positionqualified(1G,2G,3G,4G,5G,6G,etc) 12. Verticalprogression(uphillordownhill) 13. InertGasBacking(GTAW,PAW,GMAW) 14. GMAWTransfermode(Spray,Globular,Pulse,orShortCircuit) 15. GTAWCurrenttype/polarity(AC,DCEP,DCEN)

ActualVariables . SMAW . Manual

. . . .

With 3” P3 5.4 F3 N/A N/A .300”

------6G Downhill N/A N/A N/A

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RangeQualified .. SMAW . . Manual . F1,F2&F3with 27/8”MintoUnlimited . P1-P15F,P34,P41-49 . . --------. F1,F2,andF3 . -------. -------. Max of .600” . -------ALL . . Downhill only . -------. -------. --------

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6HH4: RQ 3DJH 71

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WPQ WeldingVariables

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X $UWLFOH,9 4:

X $UWLFOH,9 4: SDJH83 WLPHV $UWLFOH,9 4: SDJHGRZQ WLPHV

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WPQ WeldingVariables 5HIHUHQFH:34 IRU³0U52'%851(5´WRDQVZHUWKHIROORZLQJTXHVWLRQV

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73

WPQ WeldingVariables ReferenceWPQ Ͳ MR.RODBURNERtoanswerthefollowingquestions; :KDW³)´QXPEHUVLV0U5RG%XUQHUTXDOLILHGIRU"

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Welding Procedure - Requirements (WPS) 1. WPSrequirements (QW-200.1,page14) a. WPSprovidesdirectionsformakingproductionwelds. b. Mustcontainessential,nonessentialandwhenrequired supplementaryvariables. 1)

$UWLFOH,,

MustreferencetheingPQR

c. Changescanbemadeto“nonessential”variableswithout requalification.Changesto“essentialorsupplementary”variables requirerequalification. d. FormatofWPSmaybeanyformataslongaseveryessential, nonessentialandsupplementaryvariableisincluded. e. WPSmustbereadilyavailableatthefabricationsiteforreview by welderandinspector.

79

Welding Procedure – Requirements (PQR) 345UHTXLUHPHQWV4:SDJH $UWLFOH,,

a. IsaRecordoftheweldingdatausedtomakethetestcouponand mechanicaltestresults. a. Must; 1) Containessential andsupplementaryvariables(supplementalisnotAPI570Exam). 2) Recordrangeofvariablesusedtomakethecouponmustbeincluded 3) Becertifiedbythemanufacturer/contractor(i.e.signedanddated). b. ChangestothePQRarenotallowed,exceptforeditorialtypechanges(i.e.P#entered incorrectly,orCodechangestheF#forthematerialsused,etc.)AllchangestoaPQR, requirerecertification(i.e.signedanddatedbymanufacturer/contractor). c. Formatmaybeanyformataslongfollowingareincluded; a. Essentialandsupplementaryvariables b. Typeofmechanicaltest,numberoftestsandtestresults d. PQRmustbeavailablefortheAI,butnotthewelder. e. TherecouldbemultiplePQR’singoneWPSormultipleWPS’sforasinglePQR. 80

6WHSVWR48$/,)<D:HOGLQJ3URFHGXUH 1. WPS ispreparedforproductionweldsthataretobemade. (QW-100) 2. Welder(employeeorcontractedout),makesaTestCouponusingdirectionsfrom theWPS. (QW-201) 3. Thecouponismechanicallytested- BendsandTensiontest (RTisnotallowed). 4. Ifmechanicaltestingisacceptable,WPSisQualifiedwithinrangessetby variables

usedtomakethetestcoupon. (QW-202.2)

5. PQRisarecordcreatedbasedonvariablesusedtomakethetestcouponand subsequentmechanicaltestingresults. NOTE:PQR“Must” besignedanddatedtobeCERTIFIED.

81

'LIIHUHQFHEHWZHHQ:36345 DQG:34 1. WhatisthedifferencebetweentheProcedureQUALIFICATIONand WelderQUALIFICATION? A. ProcedurequalificationrequiresTWOdocuments(WPS/PQR). B. Examinationsaredifferent; 1)

WPS/PQR– requiresBends/TensiontestandCharpy testwhennotch toughnessisrequired.Also,HardnesswhenPWHT’d.

2) WPQ– requiresVTandBendtestorRT/UTexamination.

C. WPQonlyrequires“Essential”variablestoberecorded,

whiletheWPSmustrecord“Essential,Non-EssentialandSupplementary (whenrequired)variables”. PQRmustrecord“EssentialandSupplementary”variables. 82

%DVLF6WHSVRI5HYLHZLQJ:36345 1. WPShasbeenproperlycompletedandaddressesrequirements ofSectionIX (forAPIExam,meansEssentialVariablesandNon-Essentialvariablesare addressed)API577par6.4page18

2. PQRhasbeenproperlycompletedandaddressesrequirements ofSectionIX (forAPIExam,meansEssentialVariablesareaddressedandPQRissignedand dated)API577par6.4page18

3. PQRessentialvariablesproperlytherangespecifiedin WPS (forAPIExam,meansEssentialVariablesareaddressedandPQRissignedanddated)API577 par6.4page18

83

:363455HYLHZ,QVWUXFWLRQV INSTRUCTIONSforCheckingWPSandPQR STEP1 Locatetheappropriate“WeldingVariablesChart”fortheWeldingPROCESS(i.e.SMAW– QW253,SAW-QW254orGTAWQW256……thesearetheonlythreethatwillbeontheAPIExam). STEP2 PQRissignedbyManufacture/Contractor– QW202(b). STEP3 WPSreferencestheingPQR– QW201(b). STEP4 allNon-EssentialvariablesareaddressedontheWPS,andvalidatethatonthechecklist(e.g.enter“OK”or“ERROR”in theVALIDATEcolumn)- QW201(b). STEP5 Listvaluesforall“ESSENTIAL”variablesonChecklistfromthePQR– QW202(b). STEP6 Listvaluesforall“ESSENTIAL”variablesonChecklistfromtheWPS– QW201(b). STEP7 UseSectionIXtodetermineandlistthe“ACCEPTABLE”rangeforallessentialvariables(basedonthePQRresults) STEP8 Comparethe“Acceptable”rangeagainsttheWPSvaluesanddocumentthefindingsinthe“VALIDATE”column. STEP9 CheckTESTINGdataonPQRandcorrecttype/numberofBENDspecimens(i.e.2face&2Root,etc)weretestedand resultsareacceptableorrejectable.Recordanswerin“Validate”columnofchecklist. STEP10 CheckTESTINGdataonPQRandcorrecttype/numberofTENSILEspecimens(i.e.2ormore,dependingonthickness) weretestedandresultsareacceptableorrejectable.Recordanswerin“Validate”columnofchecklist. STEP11 CheckforP-Noand/orF-Nomistakes. 84

Practice Question for Reviewing WPS/PQR 3UDFWLFH4XHVWLRQ 5HYLHZ:36-&33DQG345-&334 1.)IsthePQRsigned&dated?

2.)NowchecktheEssential,Non-essentialvariablesandrangesqualified

85

WPS/PQR“Review”Results $UWLFOH,9JP101 4: JPQ101

ReviewofWPS#

Rev#

0

Dated:

ingPQR#

Rev#

0

Dated:

Paragraph

BriefofVariables

Essential

Par4: QW402ts

$UWLFOH,9 QW403 4: BaseMetals Par4: QW404Filler Metals

Par4: QW405Positions

4:

QW406Preheat

QW407PWHT

Par4: QW409Electric

Par4: Par4: QW410 Technique

Par4:

9/11/2001 9/12/2001 STEP4

STEP5

NonͲEssential

PQR

.1

I GrooveDesign

NE

Ͳ

.4

-

NE

Ͳ

.10

I Rootspacing

NE

Ͳ

.11

r Retainers

NE

Ͳ

Backing

.8

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E

.9

t>½inch

E

.11

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E

.4

I FͲNumber

E

.5

I AͲNumber

E

.6

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STEP6

WPS

½” ½”thk

1/16”to1” ½”thk P1 SA53GrB(P1_) F3 F-4 1 1 NE

.30

It

.33

I AWSClassification

NE

E

Ͳ

½” Ͳ

1/16”to1”

Ͳ

STEP7

Validate

QualifiedFor?

OKorError

----------------3/16”to1” ½”plateN/A P1 F3 1 ----Maxof1” ---------

OK OK OK OK

PQRshouldbe1/16”to1” OK OK

ERROR– shouldbeF3 OK OK OK OK OK

.1

+Position

NE

.3

I np Verticalwelding

NE

1.

Decrease>100oF

.2

I Preheatmaintenance

.1

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E

.4

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E

.4

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NE

Ͳ

.8

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NE

Ͳ

.1

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NE

Ͳ

.5

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NE

Ͳ

.6

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NE

Ͳ

-----

.9

I Multitosingle/side

NE

Ͳ

-----

OK

-----

OK

Ͳ

50oF

E NE

-----

.25

I Manualorautomatic

NE

Ͳ

.26

r Peening

NE

Ͳ

.64

UseofThermalProcesses

E

None

OK

50oF

OK

None

None

OK

Ͳ

None

-----

50oF -----

None

-----

-----

-----------------

-------None

OK OK OK

OK OK OK

OK

OK OK

86

WPS/PQR“Review”Results Numberofbends Required OnPQR (#&Type) (#&Type) 2F&2ROR4S 4SIDES NOTE:

BENDSPECIMENS

Results

AllowableDefects

OnPQR

1/8”

OK

Validate (OkorError) OK

1.OpendiscontinuityinweldorHAZ<1/8”(SeeQW-163,page6) 2.Ignoreopendiscontinuityoncorners,unlessresultfromLOF,Slagorinternaldiscontinuity

TENSILESPECIMENS CompareResults Ultimate MSTSofBase Failure #onPQR Metal Stress

NumberofTensileSpecimens #Required 2

2

60,000PSI

57,038Base 66,158Weld

$UWLFOH,9 4:

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NOTE:1.FailureStress(failedin“BaseMetal”)mustbe• .95%ofMSTS(seeQW-153,page4) 2.FailureStress(failedin“WELD”)mustbe• MSTS(QW-153) 3.thatthe“UltimateFailureStress” iscalculatedproperly(S=Load/Area)– (seeQW-152,page4)

CheckforP-No,F-Noand/orSpecificationmistakesontheWPS/PQR. Results- NoF-NoorP-Noerrors. 87

Practice Questions for Reviewing WPS/PQR Practice Question # 30

IstheP#qualifiedinaccordancewithASMESectionIX? Result– Yes,P8 (VVHQWLDO

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$UWLFOH,9 4:

IsthebasemetalthicknessinaccordancewithASMESectionIX? Result– No,PQRcouponwas½”whichqualifiesthk rangeof3/16”to1”, WPSindicated1/16”to1”

89


IstheshieldinggasinaccordancewithASMESectionIX? Result– NO,WPSisforsinglegas(argon)andPQRisfor75/25mix

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3UDFWLFH4XHVWLRQ ‡ A 2” thick vessel fabricated from SA-516-70N was repaired and PWHT’d at 1000o F. How long should the vessel be maintained at this PWHT temperature?

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ANSWER 4hrs &15min 5


3UDFWLFH4XHVWLRQ ‡ A 3” thick vessel fabricated from SA-516-70 was repaired and PWHT’d at 950o F. How long should the vessel be maintained at this PWHT temperature?

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31

Welding Procedure (WPS), Procedure Qualification Record (PQR) and Welder Performance Qualification (WPQ) Forms

Index x WPS J-P101 x PQR J-PQ101 x WPS J-P201 x PQR J-PQ201 x WPS J-P301 x PQR J-PQ301 x Rod Burner WPQ Form – with qualified range x Rod Burner WPQ Form – without qualified range x Blank WPS Form x Blank PQR Form x Blank WPQ Form

ASME Section IX – WPS

QW-482 Suggested Format For Welding Procedure Specification (WPS) (See Section IX QW-200.1) Company Name JC Penny By Mr. Penny Welding Procedure Specification No. J-P101 Date 9/11/2001 ing PQR No.(s)J-PQ101 Revision No. 0 Date 9/11/2001 Welding Process(es)

SMAW

Type(s)

Manual

Test Description

ts (QW 402) t Design Single V Groove and Fillets Root Spacing .0625” to 1.250” Backing: Yes x No x Backing Material (Type) Metal (Refer to both backing and retainers) Metal Nonmetallic

Nonfusing Metal Other

Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified. (At the option of the manufacturer, sketches may be attached to illustrate t design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)). Base Metals (QW 403) P-No. 1 Group No. to P-No. 1 Group No. OR Specification and type/grade to Specification and type/grade OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum thickness ” ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All Filler Metals (QW 404) Spec. No. (SFA) _ _ _ _ _ _ _ _ _ AWS No. (Class) _ _ _ _ _ _ _ _ _ F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ Size of Filler Metals_ _ _ _ _ _ _ _ Weld Metal: Thickness Range: Groove_ _ _ _ _ _ _ _ _ _ _ Fillet_ _ _ _ _ _ _ _ _ _ _ _ Electrode-Flux (Class) _ _ _ _ _ _ _ Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _ Consumable Insert_ _ _ _ _ _ _ _ _ Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

1st Filler Metal 5.1 E-7018 3 1 3/32”, 1/8”, 5/16”

.0625” to 1.0” .250” to 1.0” N/A N/A N/A

2nd Filler Metal

Positions (QW 405) Position(s) of Groove ALL Welding Progression: UP X Position(s) of fillet ALL Preheat (QW 406) Preheat Temp, Min Inter Temp, Max Preheat Maintenance

WPS No. J-P101 Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other

Down

Gas (QW 408)

50oF 350oF None

(Continuous or special heating, where applicable, should be recorded.

Percent Composition Mixtures Flow Rate

Gases N/A

Shielding Trailing Backing Other

Page of 2 Rev.# 0

Electrical Characteristics (QW 409)

Filler Metal Weld (es)

Process

Classifi -cation

Diameter

All

SMAW

E-7018

1/8”

Current Type and Polarity

DCEP

Amps (Range)

70 to 200

Wire Feed Speed (Range)

Energy or Power (Range)

Volts (Range)

Travel Speed (Range)

N/A

N/A

19 - 25

5 to 7

Other (e.g Remarks, Comments, Hot Wire Addition, Technique, Torch Angle, etc)

NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc

Pulsing Current N/A Tungsten Electrode Size and Type

N/A

Mode of Metal Transfer for GMAW or FCAW

Heat Input (max.) (Pure Tungsten, 2% Thoriated, etc)

N/A

(Spray Arc, Short Circuiting Arc, Globular Arc, etc)

Technique (QW 410) String or Weave Bead String or Weave Orifice, Nozzle, or Gas Cup Size N/A Initial and Inter cleaning (Brushing, Grinding, etc Method of Back Gouging Grinding Oscillation N/A Tube to Work Distance N/A Multiple or Single (per side) Multiple of Single Electrodes Peening N/A Other

N/A

Grinding, Chipping or Wire Brush

Multiple or Single Single

Page 2 of 2

ASME Section IX –PQR

QW-483 Suggested Format For Procedure Qualification Record (PQR) (See Section IX QW-200.2) Company Name JC Penny PQR No. J-PQ101 WPS # J-P101 Date 9/12/2001 Welding Process(es) SMAW Type(s) Manual ts (QW 402)

G D i off TTest C Groove Design Coupon Base Metals (QW 403) Material Spec. SA-53 Gr B P-No. to P-No. Thickness of Test Coupon ½” Diameter of Test Coupon 6” Other

Postweld Heat Treatment (QW 407) Temperature Range None Time Range Other

Gas (QW 408) Filler Metals (QW 404) SFA Specification 5.1 AWS Classification E-7018 Filler Metal F-No. 4 Weld Metal Analysis A-No. 1 Size of Filler Metal 5/32” Other Weld Metal Thickness Positions (QW 405) Position of Groove ALL Weld Progression (Uphill, Downhill) Other Preheat (QW 406) Preheat Temp 50oF Inter Temp Other

Shielding Trailing Backing

Gases N/A


Electrical Characteristics (QW 409) Current DC Polarity Straight Amps: 150-300 Volts 20-28 Tungsten Electrode Size N/A Other Technique (QW 410) Travel Speed 3”/min String or Weave Bead Stringer Oscillation Multi or Single (per side) Multiple Single or Multiple Electrodes Single Other

QW 483 (back) PQR No. J-PQ101 Specimen No.

Width (inch) .750 .756

T1 T2

SIDE SIDE SIDE SIDE

# # # #

Specimen No.

Thickness (inch) .455 .451

Type and Figure No.

1 2 3 4

Notch Location

Area (sq. inches) .341 .341

Ultimate Load (lbs) 19,450 22,560

Guided Bend Tests (QW -160)

Ultimate Stress (psi) 57,038 66,158

Test Temp

No

Impact Values

Type of Failure & Location - Base - Weld

Results

Notch Toughness Tests (QW -170)

Notch Type

Result – Satisfactory: YES Macro Results

Tensile Test (QW -150)

Lateral Exp % Shear Mils

Fillet Weld Test (QW -180)

Penetration into Parent Metal YES

Drop Weight Break No Break

No

Other Tests

Type of Test Deposit Analysis Other …………………………………………………………………………………………………………………………………………………………………………………. Welder’s Name Jack Shift Jr Test conducted by:

Clock No.

Stamp No. Laboratory Test No.

B2

We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in accordance with the requirements of ASME Section IX. Manufacturer Date

9/11/2001

By:

JC Penny

Jack Shift Sr Page 2 of 2



GTAW

Type(s)

Manual

Test Description

ts (QW 402) t Design Single V Groove Root Spacing 1.250” Backing: Yes x No x Backing Material (Type) Solid Metal or weld metal (Refers to both backing and retainers) Metal Nonmetallic


Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified. (At the option of the manufacturer, sketches may be attached to illustrate t design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)). Base Metals (QW 403) P-No. Group No. to P-No. Group No. OR Specification and type/grade SA 240 Type 304 to Specification and type/grade SA 240 Type 304 OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum thickness ” ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All Filler Metals (QW 404) Spec. No. (SFA): 5.9 AWS No. (Class): ER304 F-No.: F-6 A-No.: A-8 Size of Filler Metals: 3/32”, 1/8”,5/16” Weld MetalThickness Range: Groove: .0625” to 1.0” Fillet: No limit Electrode-Flux (Class): Flux Type: Consumable Insert: Other:

N/A N/A None N/A

No single > ½”


Page of 2 Rev.# 0


Down

Gas (QW 408)

80oF 350oF None


Gases Argon None None



Electrical Characteristics (QW 409) Filler Metal


Amps (Range)



Volts (Range)


Weld (es)

Process

Classifi -cation

Diameter

All

GTAW

ER304

3/32”

DCSP

60-100

N/A

N/A

N/A

N/A

All All

GTAW GTAW

ER304 ER304

1/8” 5/16””

DCSP DCSP

70-110 90-160

N/A N/A

N/A N/A

N/A N/A

N/A N/A




Heat Input (max.) N/A 2% Thoriated (EWTh-2) or Cesium Stablilized (EWCe-2)


(Pure Tungsten, 2% Thoriated, etc)

N/A


Technique (QW 410) String or Weave Bead String or Weave Orifice, Nozzle, or Gas Cup Size 3/8” to ¾” diameter shielding gas cup size Initial and Inter cleaning (Brushing, Grinding, etc Grinding, Chipping, Wire Brush or Thermal process Method of Back Gouging Grinding or thermal process Oscillation N/A Tube to Work Distance N/A Multiple or Single (per side) Multiple Multiple of Single Electrodes Single Peening None Other Page 2 of 2


QW-483 Suggested Format For Procedure Qualification Record (PQR) (See Section IX QW-200.2) Company Name JC Penny PQR No. J-PQ201 WPS # J-P201 Date 8/12/2001 Welding Process(es) GTAW Type(s) Manual ts (QW 402)

G D i off TTest C Groove Design Coupon Base Metals (QW 403) Material Spec. SA-240 Type 304 P-No. 8 to P-No. 8 Thickness of Test Coupon ½” Diameter of Test Coupon Plate Other


Gas (QW 408) Filler Metals (QW 404) SFA Specification 5.18 AWS Classification E-7018 Filler Metal F-No. 6 Weld Metal Analysis A-No. 8 Size of Filler Metal N/A Other Weld Metal Thickness

Electrical Characteristics (QW 409) Current DC Polarity Straight Amps: 90-100 Volts 20-28 Tungsten Electrode Size 1/8” Other

½”

Positions (QW 405) Position of Groove 1G Weld Progression (Uphill, Downhill) Other Preheat (QW 406) Preheat Temp 50oF Inter Temp 250oF Other


Percent Composition Gases Mixtures Flow Rate Argon/CO 75%/25% 15-25 None None

N/A

Technique (QW 410) Travel Speed 5”/min String or Weave Bead Weave Oscillation Multi or Single (per side) Multiple Single or Multiple Electrodes Single Other

QW 483 (back) PQR No. J-PQ101 Specimen No. T1 T2

Face # 1 Face # 2 Root # 3 Root # 4

Specimen No.

Width(W) (inch) .750 .750

Thickness(y) (inch) .440 .449

Type and Figure No.

Notch Location





Test Temp

No

Impact Values

Type of Failure & Location - Weld - Base

Results


Notch Type







No

Other Tests

Type of Test Deposit Analysis Other …………………………………………………………………………………………………………………………………………………………………………………. Welder’s Name Jack Shift Jr Clock No. Test conducted by: Shear Metal Testing Lab


B2 SM-1001


8/12/2001

By:

JC Penny




SMAW

Type(s)

Manual

Test Description




1st Filler Metal 5.1 E-7018 3 1 3/32”, 1/8”, 5/16”

.0625” to 1.0” .250” to 1.0” N/A N/A N/A

2nd Filler Metal



Down

Gas (QW 408)

50oF 350oF None



Gases N/A


Page 1 of 2 Rev.# 0



Process

Classifi -cation

Diameter

All

SMAW

E-7018

1/8”


DCEP

Amps (Range)

70 to 200



Volts (Range)


N/A

N/A

19 - 25

5 to 7




N/A



N/A



N/A



Page 2 of 2







Gases N/A





T1 T2

Type and Figure No.

SIDE # 1 SIDE # 2 Face # 1 Face # 2

Specimen No.


Notch Location





Test Temp

No

Impact Values


Results


Notch Type







No

Other Tests


Clock No.


B2


9/11/2001

By:

JC Penny


ASME Section IX – Welder Qualification Homework – WPQ’s QW-484A Suggested Format For Welder Performance Qualification (WPQ) (See Section IX QW-301) Welder(s) Name

Mr. Rod Burner

Identification Number

A11

Test Description Identification of WPS followed

WPS 101

Test Coupon

Production Weld

Specification and Type/Grade or UNS Number of base metal(s) A 106B to A106B

Thickness

.280

Testing Variables and Qualification Limits Welding Variables (QW350)

Actual Values

Welding Process(es) Type (i.e. manual, semi-automatic) used

Manual

Backing (with or without)

None

Test Coupon

Range Qualified

SMAW

Production Weld (dia if pipe)

SMAW Manual F1 to F3 with,F3 wo __

6” NPS

• 2 7/8” OD

Base metal P-Number to P-Number

P-1 to P-1

P1-P15F, P34, P41-P49

Filler Metal or Electrode Spec (SFA)

5.1

-------

Filler Metal F-Number

F3

F1,F2, & F3

Consumable Insert (GTAW or PAW)

N/A

-------

Filler Metal Type (solid/metal or flux cored/powder)

N/A

-------

Deposited Thickness for each process Process 1:

SMAW

3 layers minimum

Process 2:

Yes

3 layers minimum

No Yes

.280” No

Position qualified (1G,2G,3G,4G,5G,6G, etc)

” .560

----

-------

2G

F, H

Vertical progression (uphill or downhill)

Uphill

Uphill

Inert Gas Backing (GTAW, PAW, GMAW)

N/A

-------

GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit)

N/A

-------

GTAW Current type/polarity (AC,DCEP,DCEN)

N/A

-------

RESULTS Visual examination of completed weld (QW 302.4)

Acceptable

Transverse face and root bends (QW 462.3(a) Type

Longitudinal bends (QW 462.3(b) Results

Side bends (QW 462.2)

Type

Face

No defects – Acceptable

Root

No defects - Acceptable

Results

Alternative Volumetric Examination Results (QW 191)

N/A

Fillet weld – fracture test (QW 181.2)

Length and percent of defects

N/A

Fillet size (in.)

Concavity/convexity (in.)

N/A

Macro examination (QW 184)

RT or x

UT

Other tests Film or specimens evaluated by

Company

Mechanical tests conducted by Ben Tension

Laboratory test no. 123

Welding supervised by Red Eye

We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Code.

Organization

Date

By

April 7, 2010

Worlds Best Fabricator

John Doe

Welding Procedure (WPS), Procedure Qualification Record (PQR) and Welder Performance Qualification (WPQ) Forms

Index x WPS J-P101 x PQR J-PQ101 x WPS J-P201 x PQR J-PQ201 x WPS J-P301 x PQR J-PQ301 x Rod Burner WPQ Form – with qualified range x Rod Burner WPQ Form – without qualified range x Blank WPS Form x Blank PQR Form x Blank WPQ Form



SMAW

Type(s)

Manual

Test Description




1st Filler Metal 5.1 E-70 3 1 3/32”, 1/8”, 5/16”

.0625” to 1.0” .250” to 1.0” N/A N/A N/A

2nd Filler Metal



Down

Gas (QW 408)

50oF 350oF None



Gases N/A


Page of 2 Rev.# 0



Process

Classifi -cation

Diameter

All

SMAW

E-7018

1/8”


DCEP

Amps (Range)

70 to 200



Volts (Range)


N/A

N/A

19 - 25

5 to 7




N/A



N/A



N/A



Page 2 of 2



Groove D G Design i off TTest C Coupon Base Metals (QW 403) Material Spec. SA-53 Gr B P-No. to P-No. Thickness of Test Coupon ½” Diameter of Test Coupon 6” Other




Gases N/A





T1 T2

SIDE SIDE SIDE SIDE

# # # #

Specimen No.


Type and Figure No.

1 2 3 4

Notch Location





Test Temp

No

Impact Values


Results


Notch Type







No

Other Tests


Clock No.


B2


9/11/2001

By:

JC Penny




GTAW

Type(s)

Manual

Test Description

ts (QW 402) t Design Single V Groove Root Spacing 1.250” Backing: Yes x No x Backing Material (Type) Solid Metal or weld metal (Refers to both backing and retainers) Metal Nonmetallic


Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified. (At the option of the manufacturer, sketches may be attached to illustrate t design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)). Base Metals (QW 403) P-No. Group No. to P-No. Group No. OR Specification and type/grade SA 240 Type 304 to Specification and type/grade SA 240 Type 304 OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop. Thickness Range: Base Metal: Groove 1/16” to 1” Fillet All Maximum thickness ” ½” (yes) x (no) Pipe Diameter (Groove) 2 7/8” (Fillet) All Filler Metals (QW 404) Spec. No. (SFA): 5.9 AWS No. (Class): ER304 F-No.: F-6 A-No.: A-8 Size of Filler Metals: 3/32”, 1/8”,5/16” Weld MetalThickness Range: Groove: .0625” to 1.0” Fillet: No limit Electrode-Flux (Class): Flux Type: Consumable Insert: Other:

N/A N/A None N/A

No single > ½”


Page of 2 Rev.# 0


Down

Gas (QW 408)

80oF 350oF None


Gases Argon None None



Electrical Characteristics (QW 409) Filler Metal


Amps (Range)



Volts (Range)


Weld (es)

Process

Classifi -cation

Diameter

All

GTAW

ER304

3/32”

DCSP

60-100

N/A

N/A

N/A

N/A

All All

GTAW GTAW

ER304 ER304

1/8” 5/16””

DCSP DCSP

70-110 90-160

N/A N/A

N/A N/A

N/A N/A

N/A N/A




Heat Input (max.) N/A 2% Thoriated (EWTh-2) or Cesium Stablilized (EWCe-2)


(Pure Tungsten, 2% Thoriated, etc)

N/A


Technique (QW 410) String or Weave Bead String or Weave Orifice, Nozzle, or Gas Cup Size 3/8” to ¾” diameter shielding gas cup size Initial and Inter cleaning (Brushing, Grinding, etc Grinding, Chipping, Wire Brush or Thermal process Method of Back Gouging Grinding or thermal process Oscillation N/A Tube to Work Distance N/A Multiple or Single (per side) Multiple Multiple of Single Electrodes Single Peening None Other Page 2 of 2


QW-483 Suggested Format For Procedure Qualification Record (PQR) (See Section IX QW-200.2) Company Name JC Penny PQR No. J-PQ201 WPS # J-P201 Date 8/12/2001 Welding Process(es) GTAW Type(s) Manual ts (QW 402)

G D i off TTest C Groove Design Coupon Base Metals (QW 403) Material Spec. SA-240 Type 304 P-No. 8 to P-No. 8 Thickness of Test Coupon ½” Diameter of Test Coupon Plate Other


Gas (QW 408) Filler Metals (QW 404) SFA Specification 5.18 AWS Classification E-7018 Filler Metal F-No. 6 Weld Metal Analysis A-No. 8 Size of Filler Metal N/A Other Weld Metal Thickness

Electrical Characteristics (QW 409) Current DC Polarity Straight Amps: 90-100 Volts 20-28 Tungsten Electrode Size 1/8” Other

½”

Positions (QW 405) Position of Groove 1G Weld Progression (Uphill, Downhill) Other Preheat (QW 406) Preheat Temp 50oF Inter Temp 250oF Other


Percent Composition Gases Mixtures Flow Rate Argon/CO 75%/25% 15-25 None None

N/A

Technique (QW 410) Travel Speed 5”/min String or Weave Bead Weave Oscillation Multi or Single (per side) Multiple Single or Multiple Electrodes Single Other

QW 483 (back) PQR No. J-PQ01 Specimen No. T1 T2

Face # 1 Face # 2 Root # 3 Root # 4

Specimen No.

Width(W) (inch) .750 .750

Thickness(y) (inch) .440 .449

Type and Figure No.

Notch Location





Test Temp

No

Impact Values

Type of Failure & Location - Weld - Base

Results


Notch Type







No

Other Tests

Type of Test Deposit Analysis Other …………………………………………………………………………………………………………………………………………………………………………………. Welder’s Name Jack Shift Jr Clock No. Test conducted by: Shear Metal Testing Lab


B2 SM-1001


8/12/2001

By:

JC Penny




SMAW

Type(s)

Manual

Test Description




1st Filler Metal 5.1 E-7018 3 1 3/32”, 1/8”, 5/16”

.0625” to 1.0” .250” to 1.0” N/A N/A N/A

2nd Filler Metal



Down

Gas (QW 408)

50oF 350oF None



Gases N/A


Page 1 of 2 Rev.# 0



Process

Classifi -cation

Diameter

All

SMAW

E-7018

1/8”


DCEP

Amps (Range)

70 to 200



Volts (Range)


N/A

N/A

19 - 25

5 to 7




N/A



N/A



N/A



Page 2 of 2







Gases N/A





T1 T2

Type and Figure No.

SIDE # 1 SIDE # 2 Face # 1 Face # 2

Specimen No.


Notch Location





Test Temp

No

Impact Values


Results


Notch Type







No

Other Tests


Clock No.


B2


9/11/2001

By:

JC Penny


ASME Section IX – Welder Qualification Homework – WPQ’s QW-484A Suggested Format For Welder Performance Qualification (WPQ) (See Section IX QW-301) Welder(s) Name

Mr. Rod Burner

Identification Number

A11


WPS 101

Test Coupon

Production Weld

Specification and Type/Grade or UNS Number of base metal(s) A 106B to A106B

Thickness

.280


Actual Values

Welding Process(es) Type (i.e. manual, semi-automatic) used

Manual

Backing (with or without)

None

Test Coupon

Range Qualified

SMAW


SMAW Manual F1 to F3 with,F3 wo __

6” NPS

• 2 7/8” OD

Base metal P-Number to P-Number

P-1 to P-1

P1-P15F, P34, P41-P49

Filler Metal or Electrode Spec (SFA)

5.1

-------

Filler Metal F-Number

F3

F1,F2, & F3

Consumable Insert (GTAW or PAW)

N/A

-------

Filler Metal Type (solid/metal or flux cored/powder)

N/A

-------

Deposited Thickness for each process Process 1:

SMAW

3 layers minimum

Process 2:

Yes

3 layers minimum

No Yes

.280” No

Position qualified (1G,2G,3G,4G,5G,6G, etc)

” .560

----

-------

2G

F, H

Vertical progression (uphill or downhill)

Uphill

Uphill

Inert Gas Backing (GTAW, PAW, GMAW)

N/A

-------

GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit)

N/A

-------

GTAW Current type/polarity (AC,DCEP,DCEN)

N/A

-------

RESULTS Visual examination of completed weld (QW 302.4)

Acceptable

Transverse face and root bends (QW 462.3(a) Type



Type

Face

No defects – Acceptable

Root

No defects - Acceptable

Results


N/A

Fillet weld – fracture test (QW 181.2)

Length and percent of defects

N/A

Fillet size (in.)


N/A

Macro examination (QW 184)

RT or x

UT


Company

Mechanical tests conducted by Ben Tension

Laboratory test no. 123

Welding supervised by Red Eye


Organization

Date

By

April 7, 2010

Worlds Best Fabricator

John Doe


QW-482 Suggested Format For Welding Procedure Specification (WPS) (See Section IX QW-200.1) Company Name By Welding Procedure Specification No. Date ing PQR No.(s) Date Revision No. Welding Process(es) ts (QW 402) t Design Root Spacing Backing: Yes Backing Material (Type) Metal Nonmetallic

Type(s) Test Description

No (Refer to both backing and retainers) Nonfusing Metal Other

Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts to be welded. Where applicable, the details of weld groove may be specified. (At the option of the manufacturer, sketches may be attached to illustrate t design, weld layers, and bead sequence (e.g. for notch toughness procedures, for multiple process procedures, etc)). Base Metals (QW 403) P-No. Group No. to P-No. Group No. OR Specification and type/grade to Specification and type/grade OR Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop. Thickness Range: Base Metal: Groove Fillet Maximum thickness ≤ ½” (yes) (no) Filler Metals (QW 404) Spec. No. (SFA) _ _ _ _ _ _ _ _ _ AWS No. (Class) _ _ _ _ _ _ _ _ _ F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ Size of Filler Metals_ _ _ _ _ _ _ _ Filler Metal Product Form_ _ _ _ _ Weld Metal: Thickness Range: Groove_ _ _ _ _ _ _ _ _ _ _ Fillet_ _ _ _ _ _ _ _ _ _ _ _ Electrode-Flux (Class) _ _ _ _ _ _ _ Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _ Consumable Insert_ _ _ _ _ _ _ _ _ Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _

1st Filler Metal

2nnd Filler Metal

Page 1 of 2

Positions (QW 405)) Position(s) of Groove Welding Progression: UP Position(s) of fillet

WPS No. Postweld Heat Treatment (QW 407)) Temperature Range Time Range Other

Down

Preheat (QW 406)) Preheat Temp, Min Inter Temp, Max Preheat Maintenance

Gas (QW 408)) Gases



Rev.#




Process

Classifi -cation

Diameter


Amps (Range)



Volts (Range)




Pulsing Current Tungsten Electrode Size and Type Mode of Metal Transfer for GMAW or FCAW

Heat Input (max.) (Pure Tungsten, 2% Thoriated, etc) (Spray Arc, Short Circuiting Arc, Globular Arc, etc)

Technique (QW 410) String or Weave Bead Orifice, Nozzle, or Gas Cup Size Initial and Inter cleaning (Brushing, Grinding, etc Method of Back Gouging Oscillation Tube to Work Distance Multiple or Single (per side) Multiple of Single Electrodes Electrode Spacing Peening Other Page 2 of 2

ASME Section IX – PQR

Company Name PQR No. Welding Process(es)

QW-483 Suggested Format For Procedure Qualification Record (PQR) (See Section IX QW-200.2)

ts (QW 402)

WPS # Type(s)

Date

.375"

Groove Design of Test Coupon Base Metals (QW 403) Material Spec. P-No. to P-No. Thickness of Test Coupon Diameter of Test Coupon Other

Postweld Heat Treatment (QW 407) Temperature Range Time Range Other

Gas (QW 408) Filler Metals (QW 404) SFA Specification AWS Classification Filler Metal F-No. Weld Metal Analysis A-No. Size of Filler Metal Other Weld Metal Thickness Positions (QW 405) Position of Groove ALL Weld Progression (Uphill, Downhill) Other Preheat (QW 406) Preheat Temp 50oF Inter Temp None Other


Gases N/A


Electrical Characteristics (QW 409) Current Polarity Amps: Volts Tungsten Electrode Size Other Technique (QW 410) Travel Speed String or Weave Bead Oscillation Multi or Single (per side) Single or Multiple Electrodes Other

QW 483 (back) PQR No. Specimen No.

Width (inch)

Thickness (inch)

Type and Figure No.

Specimen No.

Notch Location

Area (sq. inches)

Ultimate Load (lbs)


Ultimate Stress (psi)

Test Temp

No

Impact Values



Type of Failure & Location

Results


Notch Type





No

Other Tests

Type of Test Deposit Analysis Other …………………………………………………………………………………………………………………………………………………………………………………. Welder’s Name Test conducted by:

Clock No.



By: Page 2 of 2

ASME Section IX – Welder Qualification Homework – WPQ’s QW-484A Suggested Format For Welder Performance Qualification (WPQ) (See Section IX QW-301) Identification Number

Welder(s) Name


Test Coupon

Production Weld

Specification and Type/Grade or UNS Number of base metal(s)

Thickness


Actual Values

Range Qualified

Welding Process(es) Type (i.e. manual, semi-automatic) used Backing (with or without) Test Coupon


Base metal P-Number to P-Number Filler Metal or Electrode Spec (SFA) Filler Metal F-Number Consumable Insert (GTAW or PAW) Filler Metal Type (solid/metal or flux cored/powder) Deposited Thickness for each process Process 1:

3 layers minimum

Yes

No

Process 2:

3 layers minimum

Yes

No

Position qualified (1G,2G,3G,4G,5G,6G, etc) Vertical progression (uphill or downhill) Inert Gas Backing (GTAW, PAW, GMAW) GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit) GTAW Current type/polarity (AC,DCEP,DCEN)

RESULTS Visual examination of completed weld (QW 302.4) □ Transverse face and root bends (QW 462.3(a) Type


Type


Results

RT or

Fillet weld – fracture test (QW 181.2) Macro examination (QW 184)


UT

Length and percent of defects Fillet size (in.)

x



Company

Mechanical tests conducted by

Laboratory test no.

Welding supervised by


Organization

Date

By

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