What is required from a company performing welded repairs on Boiler Proper or BEP. Where is this documented
This information is documented Section IX of the ASME Boiler and Pressure Vessel Code (BPVC), on:
1. Welding Procedure Specification (WPS)
2. Welding Procedure Qualification Record (WPQR)
3. Welding Performance Qualification (WPQ)
What is a welding procedure qualification
The Welding Procedure Specification is a required document for all code welding. Your customer either directly or indirectly specifies to what code your company must qualify. The WPS outlines all of the parameters required to perform your welding operation.
In short the WPS is the recipe for your welding operation. It describes the welding process or processes used, the base materials used, the joint design and geometry, gases and flow rates, welding position and includes all of the process conditions and variables. Each code has a recommended format.
What is a Welding Procedure Qualification Record
The Welding Procedure Qualification Record is the document that qualifies the Welding Procedure Specification. In order to qualify your WPS, a procedure qualification plate is welded the code requirements. The actual test parameters are recorded at the time of welding to ensure the WPS was being followed. Generally any supporting documentation, such as material specifications, electrode specifications and shielding gas specifications, are included as part of the WPQR. All required testing, both non-destructive and destructive, is recorded as well. These tests typically include X-Ray examinations, ultrasonic examinations, tensile testing, bend testing and when required impact testing.
The WPQR combines all of the information of the WPS and adds the test results to provide a complete document that certifies the welding specification. This document is also required by all codes unless you are qualifying under American Welding Society (AWS) specifications. Under certain conditions the WPS may be considered prequalified in which the WPQR is not required.
What is a Welder Performance Qualification
This document is required by all codes for all welders. It details and summarizes the following information: Indicates the WPS referenced during the qualification test Identifies the welder by name and/or clock number Lists what the essential parameters were during this test Reports the results of the required qualification tests Specifies qualified limits for welder For most codes there is a time limit associated with the welder qualification test.
However, the American Welding Society provides an unlimited qualification period if certain conditions are met. As with the WPS and WPQR, each code has a recommended format.
What is the procedure that a company hired to perform a welded repair on a boiler follow when no WPS exists
- Your welding company is hired to do a job for a power plant.
- The job requires that two unusual types of metal be joined. No WPS exist for this job.
- Your welders must create a test coupon and record the exact essential, non-essential, and supplementary variables from which the coupon was created (the PQR).
- The test coupon must be mechanically examined by non-destructive and destructive examination to determine whether its mechanical properties are sufficient.
- If the test coupon and proposed WPS are approved and certified by a signature. The welding Companies welding engineer or senior inspector could sign, but typically it’s specified by the company’s policy. Once certified and approved the WPS may be used again in the future by your company.
- The welders that will be performing this new WPS need to be qualified under this procedure’s corresponding p#?
WQT/WPQ- Welder Qualification Test/Welder Performance Qualification
used to test the actual welder’s skill- The welder completes a test coupon under supervision, following a WPS. The weld is then tested using the standard’s prescribed methods. Minimum visual examination, but may also require Bending, Macro Test (cross sectional view of the weld) break test, Radiographic examination, etc.
Welder qualification tests are approved by the welding company as specified by their quality management system, and qualification tests are carried out in accordance with ASME Section 9 part QG-103 or QG-104; performance qualification & performance qualification records.
Standards for ASME Code welders can bound found in ASME IX.
pWPS- Proposed Welding Procedure Specification
Instructions for the welder on how to create the test coupon that will be analyzed in the creation of a WPS. PWPS is submitted to the client for their approval. This is not always required, ensures the client is happy with your method before you go through the trouble of making a coupon.
WPQR- Welding Procedure Qualification Record-
A record of the actual recorded variables during the making of the test coupon (amperage, process, travel speed, filler metal, etc). This record also contains test results of the tested specimen. These records are considered with relevant codes and standards to make the new WPS.
WPS- Weld Procedure Specification
The recipe for the weld; written welding procedure prepared to provide directions to the welder or welding operator while performing code welds. WPS shall describe in detail all of the variables which are essential, supplementary, and non-essential to the procedure. WPS shall list the P#, filler metal to be used, base metals, pre-heat treatment, post-heat treatment, base metal thickness, process type, etc.
What is a bridge gauge used for?
For welding inspection;
Angle 0-60*
Excess weld reinforcement
Depth of undercut
Fillet throat size
Fillet leg length
Misalignment
For radial bearings;
Radial clearance measurement
Explain post-weld heat treatment.
ASME I PW-39 REQUIREMENTS FOR POSTWELD HEAT TREATMENT
PW-39.3 The weldment shall be heated slowly to the temperature specified in Table PW-39 and held for the specified time, and shall be allowed to cool slowly in a still atmosphere to a temperature not exceeding 800°F. Several weldments of varied thickness may be postweld heat treated in the same furnace at the same time. Nominal thickness in Table PW-39 is the thickness of the weld, pressure retaining material, or the thinner of the sections being joined, whichever is least. For fillet welds, the nominal thickness is the throat thickness, and for partial penetration and material repair welds, the nominal thickness is the depth of the weld groove or preparation. For combination groove and fillet welds, nominal thickness is the total combined thickness of the deposited weld, groove depth plus fillet weld throat. The holding time at temperature as specified in Table PW-39 need not be continuous. It may be an accumulation of time of multiple postweld heat treat cycles.
Explain WPS, PQR, and WPQ. (AMSE IX & packet)
Prior to performing any welds on an ASME pressure vessel, a Welding Procedure Specification (WPS), a Performance Qualification Record (PQR), and a Welder Procedure Qualification (WPQ) must be produced. The purpose of the WPS and PQR is to determine that the weldment proposed for construction is capable of providing the required properties for its intended application. The WPS is intended to provide direction for the welder or welding operator. The PQR lists what was used in qualifying the WPS and the test results. WPQ is issued to determine the ability of welders and welding operators to make sound welds. Each manufacturer or contactor shall qualify each welder or welding operator for each process to be used. A record of the tests as well as the test coupons and any destructive or nondestructive test records shall be maintained by the manufacturer or contractor. If a welder has not welded for a period of greater than six months, his qualifications for the process shall expire, and a new WPQ must be produced.
How does a welder become qualified?
A qualified welder is a person who has satisfactorily passed (as prescribed in ASME IX) for the type of filler metal to be used for each position in which he will be called upon to operate in making the repair or alteration.
This test is administered by a manufacturer or contractor who has been approved by the ASME. Upon successful completion of welding tests, the manufacturer or contractor will make out the form “Manufacturer’s record of welder or welding operator qualification tests form,” upon which will describe the positions and type of welding the welder is authorized to perform.
A welding rod has a stamping of E7011. What do these designations mean?
E designates an electrode. The first two digits (70) designate the minimum tensile strength in Kpsi of the deposited metal. The third digit (1) designates the position of the weld. The fourth digit (1) designates the type of covering of the electrode (flux).
Name some positions used in welding.
- Flat position. 2. Horizontal position. 3. Vertical position. 4. Overhead position. 5. Horizontal fixed position. 6. Inclined fixed position.
