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API 510 Course

/HVVRQ3ODQ
(Calculations InternalandExternalInspectionIntervals)
I. &RUURVLRQ5DWHVDQG,QVSHFWLRQ,QWHUYDOV
Able to calculate;
D 0HWDO/RVV LQFOXGLQJFRUURVLRQDYHUDJLQJ  $3,3DUD
E &RUURVLRQ5DWHV $3,3DUD
F 5HPDLQLQJ&RUURVLRQ$OORZDQFH $3,3DUD
G 5HPDLQLQJ6HUYLFH/LIH $3,3DUD
H ,QVSHFWLRQ,QWHUYDO $3,6HFWLRQ
NOTE: These calculations can be open and/or closed book exams.

II. Joint Efficiencies


Determine;
D :HOG-RLQW&DWHJRULHV $60( 6HFWLRQ9,,,8: 
E 7\SHRIUDGLRJUDSK\ IXOOVSRWRUQRQH SHUIRUPHGEDVLVWKHQDPHSODWHPDUNLQJV 5757HWF  8:
F

-RLQWHIILFLHQF\E\UHDGLQJ7DEOH8:

G -RLQWHIILFLHQF\IRUVHDPOHVVKHDGVDQGYHVVHOV6HFWLRQVSHU8: G DQG
H -RLQWHIILFLHQF\IRUZHOGHGSLSHDQGWXELQJSHU8: H 
127(

'HWHUPLQLQJMRLQWHIILFLHQF\PD\EHSDUWRIWKHLQWHUQDOSUHVVXUHSUREOHPVLQFHMRLQWHIILFLHQF\(LVXVHGLQWKHIRUPXODVIRUGHWHUPLQLQJUHTXLUHG
WKLFNQHVVRU9HVVHO3DUW0$:3

+RZWR6ROYH0$7+HTXDWLRQV"
+RZ7R%UHDN0$7+4XHVWLRQV"






:KDWDQVZHUGR,QHHG"
:KDWZLOO,1(('WRVROYHHTXDWLRQ"
:KDWLV.12:1"
:KDWLV81.12:1"
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API510 Calculations
ShortTermCorrosionRate

LongTermCorrosionRate

tprevious tactual
CRST = #ofyearsbetweentprevious &tactual
Remaining Life
tactual

RL =

Section7,par
7.1.1

tinitial tactual
CRLT = #ofyearsbetweentprevious &tactual
InternalInspectionInterval

,QWHUYDO=

trequired

/HVVHU RIRI5/RU \HDUV

CorrosionRate
ExternalInspectionInterval

RequiredThickness

W=

Minimum
Thickness

35
> 6(  3 @

,QWHUYDO=

/HVVHU RI\HDUVRU,QWHUQDO,QWHUYDO

InternalorOnstream Interval
Lesserof10yrs orRemaininglife

WP =

WF

ifremaininglifeislessthan4yrs,fulllife
upto2years
Remaininglifeis2yearsorless,interval
isFULLLIFE

&RUURVLRQ5DWH&DOFXODWLRQV

&RUURVLRQUDWHHTXDWLRQV

ShortTermCorrosionRate
CRST =

tprevious tactual_LAST
#ofyearsbetweentprevious &tactual_LAST

LongTermCorrosionRate
tinitial tactual_LAST
CRLT = #ofyearsbetweentInitial &tactual_LAST

Variables forThicknessCalcs

WLQLWLDO

WDFWXDO

 DFWXDO RU/$67 WKLFNQHVVPHDVXUHG

WSUHYLRXV

 WKLFNQHVVUHFRUGHGGXULQJSUHYLRXVLQVSHFWLRQV

WUHTXLUHG

 WKLFNQHVVUHTXLUHGIRULQWHUQDOSUHVVXUHDVFDOFXODWHGE\GHVLJQ
IRUPXODV EHIRUHFRUURVLRQDOORZDQFHDQGPDQXIDFWXUHU
WROHUDQFHVDUHDGGHG

<HDUV

 <HDUVEHWZHHQWKLFNQHVVUHDGLQJV

WKLFNQHVVDWLQLWLDOLQVWDOODWLRQ RUEHJLQQLQJRIDQHZFRUURVLRQ
UDWHHQYLURQPHQW

127( /7DQG67FRUURVLRQUDWHVPXVWEHFRPSDUHGWRVHHZKLFKUDWHUHVXOWVLQVKRUWHVWUHPDLQLQJOLIH

8QLIRUP&RUURVLRQ

8QLIRUP&RUURVLRQ

3LWWLQJ&RUURVLRQ

3LWWLQJ&RUURVLRQ

3LWWLQJ&RUURVLRQ

10

&RUURVLRQ5DWH&DOFXODWLRQV
Section7,par
7.1.1

6KRUWWHUPFRUURVLRQUDWH
Corrosionrate

tprevious tlast
#ofyearsbetweentprevious&tlast

/RQJWHUPFRUURVLRQUDWH
/RQJ7HUP
=
&RUURVLRQUDWH

tinitial tlast
#ofyearsbetweentinitial &tlast
11

&RUURVLRQ5DWH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ

Section7,par
7.1.1

$YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDVDQG)XOO57ZDV
SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV /DVWPHDVXUHGWKLFNQHVVWDNHQ\HDUV
DJRLQGLFDWHGDUHPDLQLQJWKLFNQHVVRI:KDWLV6KRUW7HUPFRUURVLRQUDWH"

12

&RUURVLRQ5DWH&DOFXODWLRQV
Section7,par
7.1.1

3UDFWLFH4XHVWLRQ

$YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDVDQG)XOO57ZDV
SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV /DVWPHDVXUHGWKLFNQHVVWDNHQ\HDUV
DJRLQGLFDWHGDUHPDLQLQJWKLFNQHVVRI:KDWLV6KRUW7HUPFRUURVLRQUDWH"
&DOFXODWH6KRUWWHUPFRUURVLRQUDWH
:KDWLV.QRZQ"
Corrosionrate

tprevious tlast

tprevious = 0.875

#ofyearsbetweentprevious&tlast

tlast = 0.865
=

0.875 0.865
5

= 0.002 inch/yr

+RZPDQ\\HDUVEHWZHHQUHDGLQJV"


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



/DVWUHDGLQJWDNHQDIWHU\HDUVRIVHUYLFH   

13

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3UDFWLFH4XHVWLRQ
$YHVVHOKDVEHHQLQVHUYLFHIRU\HDUVDQGWKHFXUUHQWWKLFNQHVVRIWKHVKHOOLV,QVSHFWLRQ
UHFRUGVLQGLFDWHGDQRULJLQDOWKLFNQHVVRI:KDWLVFRUURVLRQUDWH"

14

&RUURVLRQ5DWH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
$YHVVHOZDVSODFHGLQVHUYLFHLQ,QLWLDOWKLFNQHVVPHDVXUHPHQWWDNHQEHIRUHWKHYHVVHOZDV
SODFHGLQWRVHUYLFHLQGLFDWHGDVKHOOWKLFNQHVVRILQFK PP 7KLFNQHVVPHDVXUHPHQWV
WDNHQLQLQGLFDWHGDVKHOOWKLFNQHVVLQFK PP 7KHUHTXLUHGWKLFNQHVVRIWKHVKHOOLV
LQFK PP 7KHPRVWUHFHQWWKLFNQHVVPHDVXUHPHQWIRUWKHVKHOOZDVWDNHQLQDQG
LQGLFDWHGDUHPDLQLQJWKLFNQHVVRILQFK PP :KDWLVFRUURVLRQUDWH"

&RUURVLRQ5DWH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
,QVSHFWLRQUHFRUGVFRQWDLQWKHIROORZLQJLQIRUPDWLRQIRUDSDUWLFXODUFRQGLWLRQ
PRQLWRULQJORFDWLRQ

Thickness

LQFK PP
LQFK PP
LQFK PP

Yearsofservice

 1HZ 

 &XUUHQW

:KDWLVWKHFRUURVLRQUDWHIRUWKLVFRQGLWLRQPRQLWRULQJORFDWLRQ"

&RUURVLRQ5DWH&DOFXODWLRQV
5HPDLQLQJ&RUURVLRQ$OORZDQFH

3UDFWLFH4XHVWLRQ
$IWHU\HDUVRIEHLQJLQVHUYLFHDYHVVHOLVLQVSHFWHGDQGWKHWKLQQHVWVKHOOVHFWLRQLVIRXQGWREH
LQFK PP ,IWKHRULJLQDOWKLFNQHVVZDVDQGWKHUHTXLUHGWKLFNQHVVLVLQFK
PP ZKDWWKLFNQHVVRIPDWHULDOLVDYDLODEOHIRUFRUURVLRQDOORZDQFH"

&RUURVLRQ5DWH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
$YHVVHOZDVSODFHGLQVHUYLFHLQ,QLWLDOWKLFNQHVVPHDVXUHPHQWWDNHQEHIRUHWKHYHVVHOZDV
SODFHGLQWRVHUYLFHLQGLFDWHGDVKHOOWKLFNQHVVRILQFK PP 7KLFNQHVVPHDVXUHPHQWV
WDNHQLQLQGLFDWHGDVKHOOWKLFNQHVVLQFK PP 7KHUHTXLUHGWKLFNQHVVRIWKHVKHOOLV
LQFK PP 7KHPRVWUHFHQWWKLFNQHVVPHDVXUHPHQWIRUWKHVKHOOZDVWDNHQLQDQG
LQGLFDWHGDUHPDLQLQJWKLFNQHVVRILQFK PP :KDWLVFRUURVLRQUDWH"

&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-User 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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 :KDWFRGHSURYLGHVJXLGDQFHIRULQVSHFWLRQWHVWLQJDQGPDLQWHQDQFHRI
UHOLHIYDOYHV"

 7KHUPDOIDWLJXHLVVXVSHFWHGZKHQWHPSHUDWXUHVZLQJVH[FHHG

 :KDWPDWHULDOVDUHDIIHFWHGE\PHFKDQLFDOIDWLJXH"

 Mechanicalfatigueiscausedby;

 Whatmaterialdoesnothaveanendurancelimit?

 3HU$60(6HFWLRQ9,,,ZKHQLVZHOGLQJQRWUHFRPPHQGHG"

 :KHQLVLWUHFRPPHQGHGWRZDUPWKHEDVHPHWDOWRR)"
 &8,7HPSHUDWXUH5DQJHIRU&DUERQ6WHHO

 6WDQGDUGWHPSHUDWXUHUDQJHIRUD37H[DP
 7HPSHUDWXUHZKHUH&RROLQJ:DWHUFRUURVLRQVWDUWVWRVLJQLILFDQWO\
LQFUHDVH

 7HPSHUDWXUHZKHUH&KORULGH6&&EHFRPHVDFRQFHUQ

 &8,7HPSHUDWXUH5DQJHIRU6WDLQOHVV6WHHO
 7HPSHUDWXUHWKDWVSHFLDOSURFHGXUHVDUHQHHGHGIRU87
WKLFNQHVVUHDGLQJV
 7KHUPDOIDWLJXHPD\EHVXVSHFWHGLIWKHWHPSHUDWXUHVZLQJV
 :KDWLVWKHPLQLPXPSUHKHDWWHPSHUDWXUHIRUXVLQJSUHKHDWLQ
OLHXRI3:+7
 :KDWLVWKHPLQLPXPSUHKHDWWHPSHUDWXUHZKHQSHUIRUPLQJDORFDO
3:+7LQOLHXRIDIXOOHQFLUFOHPHQW3:+7

 $WZKDWWHPSHUDWXUHGRHV6XOILGDWLRQEHJLQRQ&DUERQ6WHHO
PDWHULDOV"

5HPDLQLQJ/LIH&DOFXODWLRQV
5HPDLQLQJ/LIHHTXDWLRQ

Section7,par
7.2.1
Remaining Life

RL =

tactual_Last

trequired

CorrosionRate

Variables forRemainingLifeCalcs
WDFWXDO
WUHTXLUHG

DFWXDO RU/$67 WKLFNQHVVPHDVXUHG


 WKLFNQHVVUHTXLUHGIRULQWHUQDOSUHVVXUHDVFDOFXODWHGE\GHVLJQ
IRUPXODV EHIRUHFRUURVLRQDOORZDQFHDQGPDQXIDFWXUHU
WROHUDQFHVDUHDGGHG 

F  &RUURVLRQ5DWH
127( &RUURVLRQUDWHLVWKH UDWH LH6KRUWRU/RQJWHUPUDWH ZKLFKUHVXOWV
LQVKRUWHVWUHPDLQLQJOLIH

24

5HPDLQLQJ/LIH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ

Section7,par
7.2.1

$YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDVDQG)XOO57ZDV
SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV&XUUHQWPHDVXUHGWKLFNQHVVLQGLFDWHV
DUHPDLQLQJWKLFNQHVVRI:KDWLV5HPDLQLQJOLIH"

25

5HPDLQLQJ/LIH&DOFXODWLRQV
Section7,par
7.2.1

3UDFWLFH4XHVWLRQ

$YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDVDQG)XOO57ZDV
SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV&XUUHQWPHDVXUHGWKLFNQHVVLQGLFDWHV
DUHPDLQLQJWKLFNQHVVRI:KDWLV5HPDLQLQJOLIH"
/RRNLQJDWWKHIRUPXODIRU5HPDLQLQJ/LIHZKDWLV81.2:1"

5HPDLQLQJ/LIH =

trequired
tlast
Corrosionrate

:KDWLV.QRZQ"

tprevious

0.625

tlast

0.600

8QNQRZQ"

Corrosionrate = ?????

SincetheCORROSIONRATEisunknown,the1st Stepistodeterminethe
Corrosionrate.
26

5HPDLQLQJ/LIH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
$YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDVDQG)XOO57ZDV
SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV&XUUHQWPHDVXUHGWKLFNQHVVLQGLFDWHV
DUHPDLQLQJWKLFNQHVVRI:KDWLV5HPDLQLQJOLIH"
trequired
tlast
Corrosionrate

5HPDLQLQJ/LIH =

:KDWLV.QRZQ"
6WHS &DOFXODWHWKH&25526,215$7(
&RUURVLRQUDWH

tprevious tlast
#ofyearsbetweentprevious&tlast

tprevious

0.625

tlast

0.600

0.625 0.600
8

RI\HDUVEHWZHHQ
3UHYLRXVDQG/DVW

 \HDUV

= 0.003
27

5HPDLQLQJ/LIH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ

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

tlast

trequired

:KDWLV.QRZQ"

Corrosionrate

trequired = 0.575
=

0.600 0.575
0.003

8 yrs

tlast = 0.600

Corrosionrate = 0.003

28

5HPDLQLQJ/LIH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
$YHVVHOKDVDVLQJOHFRUURVLRQUDWHRISHU\HDU PP\U 7KHUHTXLUHGWKLFNQHVVIRUWKH
VKHOODQGKHDGVLVLQFK PP 7KHDFWXDOWKLFNQHVVRIWKHKHDGLVLQFKDQGVKHOOLV
LQFK:KDWLVWKHUHPDLQLQJOLIHRIWKHYHVVHO"

29

5HPDLQLQJ/LIH&DOFXODWLRQV
3UDFWLFH4XHVWLRQ
$YHVVHOZDVSODFHGLQVHUYLFHLQ,QLWLDOWKLFNQHVVPHDVXUHPHQWWDNHQEHIRUHWKHYHVVHOZDV
SODFHGLQWRVHUYLFHLQGLFDWHGDVKHOOWKLFNQHVVRILQFK PP 7KLFNQHVVPHDVXUHPHQWV
WDNHQLQLQGLFDWHGDVKHOOWKLFNQHVVLQFK PP 7KHUHTXLUHGWKLFNQHVVRIWKHVKHOOLV
LQFK PP 7KHPRVWUHFHQWWKLFNQHVVPHDVXUHPHQWIRUWKHVKHOOZDVWDNHQLQDQG
LQGLFDWHGDUHPDLQLQJWKLFNQHVVRILQFK PP :KDWLVUHPDLQLQJOLIH"

,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\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDVDQG)XOO57ZDV
SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV&XUUHQWPHDVXUHGWKLFNQHVVLQGLFDWHV
DUHPDLQLQJWKLFNQHVVRI:KDWLV,QWHUQDO,QVSHFWLRQ,QWHUYDO"

32

,QWHUQDO,QVSHFWLRQ,QWHUYDO
3UDFWLFH4XHVWLRQ
$YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDVDQG)XOO57ZDV
SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV&XUUHQWPHDVXUHGWKLFNQHVVLQGLFDWHV
DUHPDLQLQJWKLFNQHVVRI:KDWLV,QWHUQDO,QVSHFWLRQ,QWHUYDO"
:KDWLV.QRZQ"
,QWHUQDO,QVSHFWLRQ,QWHUQDO OHVVHURI5/RU\HDUV

5HPDLQLQJ/LIH =

trequired
tlast
Corrosionrate

tprevious

0.625

tlast

0.600

Section7,par
7.2.1
8QNQRZQ"

Corrosionrate = ?????

SincetheCORROSIONRATEisunknown,the1st Stepistodeterminethe
Corrosionrate.
33

,QWHUQDO,QVSHFWLRQ,QWHUYDO
3UDFWLFH4XHVWLRQ
$YHVVHOKDVEHHQLQVHUYLFHIRU\HDUV7KHRULJLQDOVKHOOWKLFNQHVVZDVDQG)XOO57ZDV
SHUIRUPHGGXULQJIDEULFDWLRQ7KHUHTXLUHGWKLFNQHVVLV&XUUHQWPHDVXUHGWKLFNQHVVLQGLFDWHV
DUHPDLQLQJWKLFNQHVVRI:KDWLV5HPDLQLQJOLIH"
trequired
tlast
Corrosionrate

5HPDLQLQJ/LIH =

$Q\8QNQRZQV"
'RQWNQRZWKH&RUURVLRQUDWH

:KDWLV.QRZQ"
6WHS &DOFXODWHWKH&25526,215$7(
&RUURVLRQUDWH

tprevious tlast
#ofyearsbetweentprevious&tlast

tprevious

0.625

tlast

0.600

0.625 0.600

= 0.003

Section7,par
7.1.1

RI\HDUVEHWZHHQ
3UHYLRXVDQG/DVW

 \HDUV
34

,QWHUQDO,QVSHFWLRQ,QWHUYDO
3UDFWLFH4XHVWLRQ

Section7,par
7.2.1

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

tlast

trequired

:KDWLV.QRZQ"

Corrosionrate

trequired = 0.575
=

0.600 0.575
0.003

8 yrs

tlast = 0.600

Corrosionrate = 0.003

35

,QWHUQDO,QVSHFWLRQ,QWHUYDO
3UDFWLFH4XHVWLRQ

6WHS &DOFXODWHWKH,QVSHFWLRQ,QWHUYDO
,QVSHFWLRQLQWHUYDO OHVVHURI5/RU\HDUV
OHVVHURI \HDUV RU\HDUV
OHVVHU\HDUVRU\HDUV \HDUV

InternalInspectionInterval=4years

36

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3UDFWLFH4XHVWLRQ
$YHVVHOKDVDVLQJOHFRUURVLRQUDWHRISHU\HDU PP\U 7KHUHTXLUHGWKLFNQHVVIRUWKH
VKHOODQGKHDGVLVLQFK PP 7KHDFWXDOWKLFNQHVVRIWKHKHDGLVLQFKDQGVKHOOLV
LQFK:KDWLVWKHQH[WRQVWUHDPLQVSHFWLRQLQWHUYDO"

37

([WHUQDO,QVSHFWLRQ,QWHUYDO
3UDFWLFH4XHVWLRQ

Section6,par
6.4.1

$YHVVHOZLWKDUHTXLUHGWKLFNQHVVRIWKDWRSHUDWHVDWR)DWSVLJZDVSODFHGLQVHUYLFHLQ-XO\
7KLFNQHVVUHDGLQJVWDNHQSULRUWRSODFLQJWKLVYHVVHOLQVHUYLFHLQGLFDWHGDWKLFNQHVVRI
7KLFNQHVVGDWDWDNHQ-XO\LQGLFDWHGDWKLFNQHVVRI:KDWVKRXOGWKHH[WHUQDOLQVSHFWLRQ
LQWHUYDOEH"

HEAD
BANGER

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

 :KDWLVWKHPLQLPXPEDVHPHWDOWHPSHUDWXUHZKHQ
K\GURWHVWLQJ YHVVHOVWKLFN"

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LV"
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1H[W,QVSHFWLRQ
$3,3DUDDQG

Nextinspectiondate =Lastinspectiondate+
interval
$TXHVWLRQUHTXLULQJ\RXWRFDOFXODWHQH[WLQVSHFWLRQGDWHPD\EH
FRPSOH[RUVLPSOH
 6LPSOHTXHVWLRQZRXOGRQO\UHTXLUH\RXWRGHWHUPLQHLQVSHFWLRQLQWHUYDODQG
WKHQQH[WGDWH
 &RPSOH[TXHVWLRQZRXOGUHTXLUH\RXWRFDOFXODWHFRUURVLRQUDWHUHPDLQLQJOLIH
LQVSHFWLRQLQWHUYDOWKHQQH[WLQVSHFWLRQGDWH

42

1H[W,QVSHFWLRQ

$3,3DUDDQG

PracticeforSimplecalculation
3UDFWLFH4XHVWLRQ
$YHVVHOWKDWKDVDUHPDLQLQJOLIHFDOFXODWHGIURPWKHWKLFNQHVVGDWD
WDNHQ0DUFK7KHUHPDLQLQJOLIHRIWKHYHVVHOLV\HDUV:KDW
LVQH[W([WHUQDOLQVSHFWLRQGDWH"

43

1H[W,QVSHFWLRQ

$3,3DUDDQG

3UDFWLFH4XHVWLRQ
:KDWLVWKH1H[W,QWHUQDO,QVSHFWLRQGDWH ZLWKWKHIROORZLQJ
LQIRUPDWLRQ"

Remaining
Life(yr)

March2000

March 1995

16

.324

.356

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 the Required Thickness

Vessel Thickness

= 2.0

Depth of Pit

= 1.06

Corrosion Allowance = 0.250


Retirement Thickness = 1.75

45

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$3,3DUD

Widely scattered pits can be ignored, if;

Section7,par
7.4.3

Rule#2
Areaofthepittingbelowthe
corrosionallowancehasan
arealessthan7in2withinan
8diametercircle.

46

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$3,3DUD

Widely scattered pits can be ignored, if;

Section7,par
7.4.3

Rule#3
Sumofthelengthofpitswithinany8line,mustbelessthan2

47

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3UDFWLFH4XHVWLRQ

Section7,par
7.4.3

$UHFHQWLQVSHFWLRQGLVFRYHUHGLVRODWHGSLWWLQJLQWKHYHVVHOZDOO0LQLPXPUHTXLUHGZDOO
WKLFNQHVVLV&XUUHQWWKLFNQHVVRIWKHYHVVHOLV :KDWLVWKHPLQLPXP
DOORZHGUHPDLQLQJWKLFNQHVVDOORZHGDWWKHGHHSHVWSLW"

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Section7,par
7.4.3

3UDFWLFH4XHVWLRQ

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

Required
Thickness

Remainingthickness
belowpit

ofRequired
Thickness

49

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3UDFWLFH4XHVWLRQ

Section7,par
7.4.3

'XULQJDUHFHQWLQWHUQDOLQVSHFWLRQRID,'YHVVHOZLWKZDOOWKLFNQHVVWKUHH
LVRODWHGSLWVZHUHGLVFRYHUHG7KHSLWVDUHZLWKLQDGLDPHWHUFLUFOHZLWKWKHVXPRI
WKHLUGLPHQVLRQVDORQJDVWUDLJKWOLQHLV9HVVHOKDVDUHTXLUHGWKLFNQHVVLV
DQGFRUURVLRQDOORZDQFHRI'LPHQVLRQVRIWKHSLWVDUHDVIROORZV
3LW [[GHHS
3LW [[GHHS
3LW [[GHHS
:KLFKRIWKHIROORZLQJLVWUXH"

a.
b.
c.
d.

Pitscanbeignored
Pitsareunacceptablebasedonsumofthepitdimensionsalonga8straightline.
Pitsareunacceptableduetototalareaofpittingwithinan8diametercircle.
Pitsareunacceptableduetoinsufficientremainingthicknessbelowthedeepestpit.

(YDOXDWLRQRI3LWWLQJ
3UDFWLFH4XHVWLRQ

Section7,par
7.4.3

'XULQJDUHFHQWLQWHUQDOLQVSHFWLRQRID,'YHVVHOZLWKZDOOWKLFNQHVVWKUHH
LVRODWHGSLWVZHUHGLVFRYHUHG7KHSLWVDUHZLWKLQDGLDPHWHUFLUFOH/HQJWKRIWKHSLWV
GLPHQVLRQVDORQJDVWUDLJKWOLQHLVDQG9HVVHOKDVDUHTXLUHG
WKLFNQHVVLVDQGFRUURVLRQDOORZDQFHRI&DQWKHVHSLWVEHLJQRUHG",IQRW
ZK\QRW"'LPHQVLRQVRIWKHSLWVDUHDVIROORZV
3LW [[GHHS
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3LW [[GHHS

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WeakAcidity

StrongAcidity


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Basic/Akalinity /
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WeakAlkalinity

WeakAcidity

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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

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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

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% ,QWHUQDO,QVSHFWLRQ
Interval is lesser of 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 CMLs (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 Supports
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-user 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 supports, 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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WeldJointCATERGORY isthelocationofajointinapressurevessel
SubSectionB,
UW,General,
UW3

Category A:
Alllongitudinalweldsinshellandnozzles
Allweldsinheads,Hemiheadtoshellweldjoint
Category B:
Allcircumferentialweldsinshellandnozzles
Headtoshelljoint(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
joint compared to category B joint.
67

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SubSectionB,
UW,Design,
UW12

Weld Joint Types


7\SH 'RXEOHZHOGHGEXWWMRLQWV

7\SH 6LQJOHZHOGHGZLWKEDFNLQJ

7\SH 6LQJOHZHOGHGZLWKRXWEDFNLQJ

68

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SubSectionB,
UW,Design,
UW12

Weld Joint 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

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TypeofRadiography

SubSectionB,
UW,Design,
UW11
SubSectionC,
CCS,Design,
UCS57

Full asrequiredbytheCode(seeUW11(a)),andUCS57
Spot CategoryBandCweldsthatarenotrequiredtobe
radiographedbyUW11(a)(5)(b).
None

CodeRequiredRT(UW11(a)andUW11(b)
BasedonService,ThicknessorWeldingProcess

UserSpecifiedRT
Theusercanestablishthetypeofjointanddegreeofexaminationwhen
therulesofCodedoesnotrequireradiography(seeUW12)
70

5DGLRJUDSK\

SubSectionB,
UW,Design,
UW11a

FULLRT RequiredbyCODE
FULLRT
Allbuttweldsinshell&headsinlethalservice
Allbuttweldsinshell&headswiththickness>11/2orperUCS57
Allbuttweldsinshell&headsofunfiredboilerswith;
Pressureexceeding50psigorthickness>11/2orperUCS57
Buttweldsinnozzles>10NPSor>11/8thickness
CategoryAandDweldsinshellsandheads,wherejoint
efficiencyisbasedonTableUW12
ButtweldsmadeusingElectrogas&Electroslagprocess
SpotRT
CategoryBandCbuttweldsintersectingCatAweldsinshellsandheads
CategoryBandCbuttweldsconnectingseamlessheadsorshells
127(&DWHJRU\ $ %ZHOGVPXVWEH7\SHRU7\SHZHOGV VHH7DEOH8:
71

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

SubSectionB,
UW,Design,
UW11

Item 1: Allbuttweldsinvesselsusedtocontainalethalsubstance(UW11(a)).Lethalsubstanceshavespecific
definitionsinASMECodeinUW2anditistheresponsibilityoftheendusertodetermineiftheyordered
avesselthatcontainslethalsubstances.

Item 2: All butt welds in vessels in which the nominal thickness exceeds specified values (UW11(a). You can find
these values in subsection C, in UCS57. For example, this value for PNo.1 in UCS57 is 1 inch. Nozzles
larger than 10 NPS or thickness greater than 1 1/8.
SubSectionC,

Item 3: All butt welds in an unfired steam boiler with design pressure > 50 psi (UW11(a)).

UCS,Design,
UCS57

Item 4: All category A and D butt welds in vessel when Full Radiography optionally selected from table UW
12(column (a) in this table is selected); and categories B and C which intersect Category A shall meet the
spot radiography requirement (UW11(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
UW12 table.
But in item 4, there is no mandating rule. A manufacturer with its own decision has chosen to use column (a) in table
UW12 for full radiography.
72

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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( U11(a)), so to differentiate item 1, 2 and 3 from item 4, the RT
symbols are used in Code (UG116).

73

5DGLRJUDSK\

SubSection
A,UG,Design,
UG116

RT1: Items1,2and3,(E=1),Allbuttweldsfulllengthradiography
RT2: Item4(E=1),CategoryAandDbuttweldsfulllengthradiography
andcategoryBandCbuttweldsspotRadiography
RT3: (E=0.85),Spotradiographybuttwelds
RT4: (E=0.7),Partial/Noradiography
You need to consider the hemispherical head joint to shell as category A, but ellipsoidal
and torispherical head joint to shell as category B;
Do you know why? Why ASME considered the stringent rule for pressure vessel RT test in
hemispherical head joint?
It is because this joint 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\

SubSectionB,
UW,Design,
UW11

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

SubSection
A,UG,Design,
UG116

RTmarkingsarelocatedonNameplate
75

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SubSectionB,
UW,Design,
TableUW12

Joint Efficiency is based on;


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5DGLRJUDSK\ 575757DQG57
9HVVHOVZLWKORQJLWXGLQDOVHDPVRUVHDPOHVV

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SubSection
A,UG,Design,
UG116

RT1

E=1

RT2

E=1

E=1

RT3

E=0.85

RT4

E=0.70

E=1

E=0.85

81

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JointEfficiencybasedonRadiography
RT1 FullRTperUW11(a),exceptUW(a)(5)

UseColumnaofTableUW12
ForSeamlessheads&shellsE=1

SubSection
A,UG,Design,
UG116
SubSectionB,
UW,Design,
TableUW12

RT2 FullRTperUW11(a)(5)

UseColumnaofTableUW12
ForseamlessheadsandshellsE=1

RT3 SpotradiographyperUW11(b)

UseColumnbofTableUW12
Forseamlessheads&shellsE=1

RT4 CombinationofRT1,RT2andRT3
NoRT noradiographyatall

UseColumncofTableUW12
ForseamlessshellsandheadsE=0.85

RTStamping
82

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RT1
or
RT2

RT3

RT4

SubSectionB,
UW,Design,
TableUW12

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

83

-RLQW(IILFLHQF\
Joint Efficiency For Seamless Parts
WeldType

Spot RT

NoRT

1.0

0.85

1.0

0.85

0.85

0.85

0.85

0.85

0.85

0.85

0.85

0.85

SubSectionB,
UW,Design,
ParUW
11(a)(5)(a)&(b)
SubSectionB,
UW,Design,Par
UW12d

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ApressurevesselshellwithTYPE1longitudinalseamsandcircumferentialweldsthat
aresinglefullfilletlapjointswithoutplugwelds.ThevesselisstampedNoRT.What
isthejointefficiencyfor;
Vessel shell

A seamless head _________?

SubSectionB,UW,
Design,ParUW
11(a)(5)(a)&(b)and
TableUW12
SubSectionB,
UW,Design,Par
UW12d

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Design,ParUW
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SubSectionB,
UW,Design,Par
UW12d

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SubSectionB,UW,
Design,ParUW
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TableUW12
SubSectionB,
UW,Design,Par
UW12d

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SubSectionB,UW,
Design,ParUW
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TableUW12
SubSectionB,
UW,Design,Par
UW12d

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Design,ParUW
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SubSectionB,
UW,Design,Par
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Design,ParUW
11(a)(5)(a)&(b)and
TableUW12
SubSectionB,
UW,Design,Par
UW12d

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ASMESecVIII,UG98

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4

6WDWLF+HDG

ASMESectionVIII
SubsectionA,UG,
InspectionandTesting,
UG98(a)(b)

, 6WDWLF+HDG
D 6WDWLF+HDG IRRWFROXPQRIZDWHULVHTXDOWRSVLDWWKHERWWRPRI
WKHFROXPQ RIZDWHU,QRWKHUZRUGVWKHZHLJKWRIWKHZDWHU
DSSOLHVDIRUFH OEV  SUHVVXUH SVL

1ft

0.433psi
(atbottomofthewatercolumn)

6WDWLF+HDG
, 3DUW6WDWLF+HDG

ASMESectionVIII
SubsectionA,UG,
InspectionandTesting,
UG98(a)(b)
ASMESecVIII,UG98

2ft

WhatisMAWPofeachcomponentfora48ft tall
verticalvesselwithellipsoidalheadsandaMAWP
of500psig?

N1

6 ft

44ft
8ft

36ft

VesselMAWP=500psig
VesselMAWPisthegagepressureattheTOPof
thevessel,includingStaticheadpressure.Reference
UG98(a)(b)

N2
2ft

6 ft

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

6WDWLF+HDG
, 3DUW6WDWLF+HDG

ASMESectionVIII
SubsectionA,UG,
InspectionandTesting,
UG98(a)(b)
ASMESecVIII,UG98

2ft

WhatisMAWPofeachcomponentfora48ft tall
verticalvesselwithellipsoidalheadsandaMAWP
of500psig?

N1

6 ft

44ft
8ft

36ft

VesselMAWP=500psig
VesselMAWPisthegagepressureattheTOPof
thevessel,includingStaticheadpressure.Reference
UG98(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

ASMESectionVIII
SubsectionA,UG,
InspectionandTesting,
UG98(a)(b)
ASMESecVIII,UG98

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

9HVVHO0$:3YV 3DUW0$:3
ASMESectionVIII
SubsectionA,UG,
InspectionandTesting,
UG98(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

ASMESectionVIII
SubsectionA,UG,
InspectionandTesting,
UG98(a)(b)

, 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,UG99(c.),thehydrotest pressureisthepressureatthetopofthevessel.

,QWHUQDO3UHVVXUH
ASMESecVIII,UG21andAppendix3(par32)

ASMESectionVIII
SubsectionA,UG,
InspectionandTesting,
UG98(a)(b)

, 'HVLJQ3UHVVXUH
Designpressureisthepressureusedinthedesignofavesselcomponent
togetherwithcoincidenttemperatureforthepurposeofdeterminingthe
minimumpermissiblethicknessforeachcomponent.Designpressure
includesstaticheadpressure.
NOTE:Designpressureistheminimumpressureusedtodesignthevessel(i.e.usedtodeterminetherequired
thicknessofeachcomponent.

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

,,, 'HVLJQ3UHVVXUHYV 0$:3


Designpressureisthepressurefortheprocess(processpressureplus
statichead).MAWPisthemaximumpressureratingforeachpart
and/orvessel.
11

6KHOO0LQLPXP5HTXLUHG7KLFNQHVV
ASMESecVIII,UG27(c.)(1)

, 7KHUHTXLUHGWKLFNQHVVRIDF\OLQGULFDOVKHOO
EDVHGRQFLUFXPIHUHQWLDOVWUHVVJLYHQD
SUHVVXUH 8* F  
Variables

t=PR/(SE)(0.6P)

ASMESectionVIII
SubsectionA,UG,
Design,UG27(c.)(1)

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

12

6KHOO0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#7

ASMESectionVIII
SubsectionA,UG,
Design,UG27(c.)(1)

A60tallverticalvesselhasaninsidediameterof8anddesignedfor300psig@450deg
F.Allowablestressofthematerialofconstructionis17,500psiandthejointefficiencyis
0.85.Whatistheminimumrequiredthickness?

13

6KHOO0LQLPXP5HTXLUHG7KLFNQHVV
ASMESectionVIII
SubsectionA,UG,
Design,UG27(c.)(1)

PracticeQuestion#7

A60tallverticalvesselhasaninsidediameterof8anddesignedfor300psig@450deg
F.Allowablestressofthematerialofconstructionis17,500psiandthejointefficiencyis
0.85.Whatistheminimumrequiredthickness?
t

PR

(SE)(0.6P)

300

=
(

17500

48

) (

14400

0.85

14875

14400

180 )

0.6

300

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

14695

0.980

inches

14

6KHOO0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#8

ASMESectionVIII
SubsectionA,UG,
Design,UG27(c.)(1)

Avesselhasaninsidediameterof60anddesignedfor150psig@350deg F.
Allowablestressofthematerialofconstructionis18,000psiandthejoint
efficiencyis1.0Whatistheminimumrequiredthickness?

15

6KHOO0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#9

ASMESectionVIII
SubsectionA,UG,
Design,UG27(c.)(1)

Avesselhasaninsideradiusof48anddesignedfor250psig@500deg F.
Allowablestressofthematerialofconstructionis17,000psiandthejoint
efficiencyis.90Whatistheminimumrequiredthickness?

16

6SKHUH0LQLPXP5HTXLUHG7KLFNQHVV
ASMESectionVIII
SubsectionA,UG,
Design,UG27(d)

,

7KHUHTXLUHGWKLFNQHVVRID6SKHUHLVJLYHQE\ 8* G 

PR
t =
(2SE)(0.2P)

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

17

6SKHUH0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#10

ASMESectionVIII
SubsectionA,UG,
Design,UG27(d)

Aspherehasaninsideradiusof12ft anddesignedfor250psig@500deg F.


Allowablestressofthematerialofconstructionis17,000psiandtheweldsare
singlebuttweldedwithbackingandvesselisstampedRT2.Whatisthe
minimumrequiredthickness?

18

6SKHUH0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#11

ASMESectionVIII
SubsectionA,UG,
Design,UG27(d)

AspherehasanIDof36ft anddesignedfor30psig@400deg F.Allowable


stressofthematerialofconstructionis15,000psiandthejointefficiencyis0.80
Whatistheminimumrequiredthickness?

19

9HVVHO+HDGV
h=1/4D

ASMESectionVIII
SubsectionA,UG,
Design,UG32(d)

D=Insidediameter
LongAxis

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

L=insideradius

Short
Axis

ASMESectionVIII
SubsectionA,UG,
Design,UG32(f)

D=Insidediameter

20

+HDGV0LQLPXP5HTXLUHG7KLFNQHVV
MinimumRequiredThicknessofanEllipsoidalHead

t =

Px D
2 [( S x E ) ( 0.2 X

)]

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

MinimumRequiredThicknessofaHemisphericalHead

t =

P x L
2 [( S x E ) ( 0.2 X

)]

ASMESectionVIII
SubsectionA,UG,
Design,UG32(d)

ASMESectionVIII
SubsectionA,UG,
Design,UG32(f)

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

+HDGV0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#12

ASMESectionVIII
SubsectionA,UG,
Design,UG32(d)

Whatistheminimumrequiredthicknessfortheheadofa30tallverticalvessel
withellipsoidalheads,insidediameterof72,allowablestressof16,500psi,
MAWPof120psig,andweldsthataredoubleweldedbuttweldsandSpotRTd?

22

+HDGV0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#13

ASMESectionVIII
SubsectionA,UG,
Design,UG32(d)

Whatistheminimumrequiredthicknessfortheheadofaseamlesshorizontalvessel
withellipsoidalheads,insidediameterof96,allowablestressof18,000psi,MAWP
of200psig,andweldsthataredoublefullfilletweldedlapjointsandRT1?

23

+HDGV0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#14

ASMESectionVIII
SubsectionA,UG,
Design,UG32(f)

Whatistheminimumrequiredthicknessfortheheadofa30tallverticalvessel
withhemisphericalheads,insidediameterof72,allowablestressof16,500psi,
MAWPof320psig,andweldsthataredoubleweldedbuttweldsandSpotRTd?

24

+HDGV0LQLPXP5HTXLUHG7KLFNQHVV
PracticeQuestion#15

ASMESectionVIII
SubsectionA,UG,
Design,UG32(f)

Whatistheminimumrequiredthicknessfortheheadsofahorizontalvesselwith
hemisphericalheads,insidediameterof96,allowablestressof18,000psi,MAWPof
200psig,andweldsthataredoublefullfilletweldedlapjointsandRT1?

25

HEAD
BANGER

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0$:3IRU+HDGV
ASMESectionVIII
SubsectionA,UG,
Design,UG32(d)

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

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

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

ASMESectionVIII
SubsectionA,UG,
Design,UG32(f)

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

29

0$:3
PracticeQuestion#16

ASMESectionVIII
SubsectionA,UG,
Design,UG32(d)

Duringaninspectionofaverticalvesselthicknessmeasurementstakenonthebottomellipsoidal
headwasfoundtobe0.785.Theinsidediameterofthevesselis96,allowablestressis17,000
psi,andweldsthataredoubleweldedbuttweldjointsandthevesselisstampedRT1.Whatis
themaximumallowableworkingpressureforthisseamlessellipsoidalhead?

30

0$:3
ASMESectionVIII
SubsectionA,UG,
Design,UG32(d)

PracticeQuestion#16

Duringaninspectionofaverticalvesselthicknessmeasurementstakenonthebottomellipsoidal
headwasfoundtobe0.785.Theinsidediameterofthevesselis96,allowablestressis17,000
psi,andweldsthataredoubleweldedbuttweldjointsandthevesselisstampedRT1.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.YougotoTableUW12andfindthejointefficiency
tobe1fordoubleweldedbuttwelds.Theseamlesshead,
doesnotchangethejointefficiency.
31

0$:3
PracticeQuestion#17

ASMESectionVIII
SubsectionA,UG,
Design,UG32(f)

Ahorizontalvesselwithanoutsidediameterof72andellipsoidalheads.Shellthicknessis
0.750andtheheadsare0.500thick. Theallowablestressis16,000psi.Weldsaredoublefull
filletlapjointsandthevesselisstampedRT1.Thecorrosionallowancefortheentirevesselis
0.125.Whatisthemaximumallowableworkingpressurefortheellipsoidalhead?

32

0$:3
PracticeQuestion#18

ASMESectionVIII
SubsectionA,UG,
Design,UG32(f)

Duringaninspectionofaverticalvesselthicknessmeasurementstakenonthebottom
hemisphericalheadwasfoundtobe0.785.Theinsidediameterofthevesselis96,allowable
stressis17,000psi,andweldsthataredoubleweldedbuttweldjointsandthevesselisstamped
RT1.Whatisthemaximumallowableworkingpressureforthishemisphericalhead?

33

0$:3
PracticeQuestion#19

ASMESectionVIII
SubsectionA,UG,
Design,UG32(f)

Ahorizontalvesselwithanoutsidediameterof72andhemisphericalheads.Shellthicknessis
0.750andtheheadsare0.500thick. Theallowablestressis16,000psi.Weldsaredoublefull
filletlapjointsandthevesselisstampedRT1.Thecorrosionallowancefortheentirevesselis
0.125.WhatisthemaximumallowableworkingpressurefortheHemisphericalhead?

34

0$:3

9HVVHOLQ&RUURVLYH6HUYLFH

PracticeQuestion#20

ASMESectionVIII
SubsectionA,UG,
Design,UG27(c.)(1)
API510,Section7,Sub
par7.3.3

Duringarecentinspectionofahorizontalvesselwithaninsidediameterof72
andhemisphericalheads,shellthicknesswasrecordedas0.625.Theallowable
stressis16,000psi.Weldsaredoublefullfilletlapjointsandthevesselis
stampedRT1.Thecorrosionrateis0.006/yr.Requiredthicknessis0.588.
Vesselisincorrosiveservice.Nextinspectionisin5years.Whatisthe
maximumallowableworkingpressureforthisvessel?

35

([WHUQDO3UHVVXUH

ASMESectionVIII
SubsectionA,UG,
Design,UG28(c.)

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

36

([WHUQDO3UHVVXUH&DOFXODWLRQV
I. Formulaandvariables
Pa =

4B
[ 3 ( Do /

ASMESectionVIII
SubsectionA,UG,
Design,UG28(c.)

t )]

A=FactorbasedonratioofL/DoandDo/t.(GetitfromASMESecII,PartD,FigG.)
B=FactorbasedonAFactoranddesignTemperature(GetiffromASMESecII,
PartD,TablesCS1orCS2)
Do =OutsideDiameter
t=Minimumrequiredthickness

Bfactorwillbegiventoyouinthequestion.

37

([WHUQDO3UHVVXUH&DOFXODWLRQV
PracticeQuestion#21

ASMESectionVIII
SubsectionA,UG,
Design,UG28(c.)

Ahorizontalvesselhasanoutsidediameterof60.Thedistancebetween
supportsis15ft.Thewallthicknessis0.625.MaterialofconstructionisSA
516Gr70.ThisvesselhasaBfactorof3500andisdesignedfor250psig@
500deg F.Allowablestressis16,500.Whatisthemaximumexternalpressure
forthisvessel?

38

([WHUQDO3UHVVXUH&DOFXODWLRQV
ASMESectionVIII
SubsectionA,UG,
Design,UG28(c.)

PracticeQuestion#21

Ahorizontalvesselhasanoutsidediameterof60.Thedistancebetween
supportsis15ft.Thewallthicknessis0.625.MaterialofconstructionisSA
516Gr70.ThisvesselhasaBfactorof3500andisdesignedfor250psig@
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

([WHUQDO3UHVVXUH&DOFXODWLRQV
PracticeQuestion#22

ASMESectionVIII
SubsectionA,UG,
Design,UG28(c.)

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

40

([WHUQDO3UHVVXUH&DOFXODWLRQV
PracticeQuestion#23

ASMESectionVIII
SubsectionA,UG,
Design,UG28(c.)

A20ft longexchangertubehasanoutsidediameterof2andnominal
thicknessof0.083.MaterialofconstructionisSA283GrDanddesign
temperatureis600deg F.TheBfactorforthetubeis1500.Whatisthe
maximumallowedexternalpressureforthistube?

41

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

/HVVRQ3ODQ,,,
(Calculations ImpactTesting,WeldSizeandNozzleReinforcement)

I.

Impact Testing
A.
B.

Theinspectorshouldunderstandimpacttestingrequirementsandimpacttestingprocedure(UG84)
Theinspectorshouldbeabletodeterminetheminimummetaltemperatureofamaterialwhichisexemptfromimpacttesting(UG20(f),UCS66,
UCS68(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

,PSDFW7HVWLQJ0'07
(ASMEVIIIUG20(f),UG84UCS66,UCS68(c).)

I.

WhatdoesImpactTestingDetermine?

II.

WhatisMDMT?

III. WhydoestheCodeworryaboutMDMT?

IV. Whataresomefactorsthataffectbrittlenessofmaterials?

V. Whatistheoppositeofbrittleness?

.
3

0'07
I.

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

HowdoesASMESectionVIIImanageBrittleFracture
a.

ByMaterialSelection(P1Group1and2

b.

ProvidesamethodfordeterminingMDMT

c.

seeFig.UCS66)

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

1.

Curvesformaterialgroupings(Fig.UCS66)

2.

Initialimpacttestingexempttemperaturebasedonmaterial(curve
letter)andthickness(TableUCS661)

3.

StressReductionRatiofactor[(tr xE)/(tnc)].(FigUCS66.1)

4.

PWHTReduction(residualstressreductionallowedwhenPWHTisperformedandisnotrequired
bytheCode)see(par.UCS68(c.))

Note:Thisratiowillbeprovidedonthetest.

TemperaturelimitedbyUCS66(b)(2)&(3)andUCS68(c.)
a)

UCS66(b)(2) nocolderthan55oF,unless ;
1)
2)

Stressreductionratiois0.35orless,thentemperaturecanbe
between55oFand155oF.(UCS66(b)(3)
PWHTperformedwhennotrequiredbyCode,temperaturecan
bebelow55oF.(UCS68(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?

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;
CurveletterisBfromFig.UCS66

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

ASMEVIII,

6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH
Step2:InitialMDMT;
2SHUDWLRQ8&6SDJHGRZQWLPHV
51oF fromTableUCS66
ASMEVIII,
Step3:MDMTreduction(stressratioreduction);
6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH
20oF reductionallowed,therefore
2SHUDWLRQ8&6SDJHGRZQWLPHV
ReducedMDMT=51oF 20oF=+31oF (fromFig.UCS66.1)
Step4:PWHTreduction(notallowed)
PWHTreductionisnotallowedbecausePWHTwasrequired
byCode(i.e.nameplatestampedHT)seePar.UCS68(c.)

ASMEVIII,

LowestMDMT=+31oF

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

0'07
(ASMEVIIIUG20(f),UG84UCS66,UCS68(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 PWHTd. What is the lowest possible MDMT for
this vessel?

0'07
(ASMEVIIIUG20(f),UG84UCS66,UCS68(c).)

PracticeQuestion#3
AhorizontalvesselconstructedfromSA178GrAplate.Designedfor200
psig@500oF.Wallthicknessis0.500,witha1/8corrosionallowance
andreductionratiois.80.VesselwasPWHTd.NameplateisstampedRT
2.WhatisthelowestpossibleMDMTforthisvessel?

0'07
(ASMEVIIIUG20(f),UG84UCS66,UCS68(c).)

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 PWHTd for environment cracking. What is
the lowest possible MDMT for this vessel?

&KDUS\,PSDFWV
CharpyImpactTest

ASMEVIII,
6XEVHFWLRQ$3DUW8*)DEULFDWLRQ8*

EachSpecimenshallconsistofthreespecimensASMEVIIIUG84
Specimenthicknessis0.394Fig.UG84

10

&KDUS\,PSDFWV
CharpyImpactTest

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

(a)Interpolationbetweenyieldstrengthsshownispermitted.
(b)Theminimumimpactenergyforonespecimenshallnotbelessthan23oftheaverageenergyrequired
forthreespecimens.Theaverageimpactenergyvalueofthethreespecimensmayberoundedtothe
nearestftlb.

11

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

PracticeQuestion#5

Whatistherequiredaverageandminimumcharpy impactvaluesforamaterialwith50ksi
MSYSandis1.0thick?

12

&KDUS\,PSDFWV

(ASMEVIIIUG84

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

50Ksi

15ft lbs

1.0thickness

13

&KDUS\,PSDFWV
(ASMEVIIIUG84

PracticeQuestion#6

Whatistherequiredaverageandminimumcharpy impactvaluesforamaterialwith55ksi
MSYSandis2.0thick?

14

&KDUS\,PSDFWV
(ASMEVIIIUG84

PracticeQuestion#7

Duringimpacttestingofa1thickmaterialwithaMSYSof45,000psi,theimpact
testingvaluesforthespecimenswere17,12,and11?Aretheresultsoftheseimpact
testsacceptable?

15

)LOOHW:HOGV

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

Filletweldsizeisnormallydescribedbythelegsize.
Calculatingfilletweldsize;
Throatsize=0.707xlegsize
Legsize=throatsize/0.707
PerFig.UW16.1;
Throatsize=tmin
or
Throatsize=tc
or

Throat
Leg

Leg

Throatsize=tw
16

)LOOHW:HOGV

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

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

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

Perpar.UW16(b);

Filletweldsize,mustbeconvertedfromthroatsize(tmin ortc)tolegsize.

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

tn
d

Step1: Gotothesketch(UW16.1(a1).
1/2tmin

Step2: Calculatethroatsize(tmin)

tc

te

a1

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

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

18

)LOOHW:HOG6L]H
Perpar.UW16(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 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 or 0.707 x tmin
= lesser of or 0.707 x (lesser of 0.750, 0.423, 0.500)
= lesser of or (0.707 x 0.432)
= lesser of or 0.305
= 0.250

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.UW16(b);

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

tn
d

tc
t
a

21

)LOOHW:HOG6L]H

ASMEVIIIpar.UW16(b);

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

te
t
1/2tmin

a1

22

)LOOHW:HOG6L]H
ASMEVIIIpar.UW16(b),Fig.UW16.1(a)

Practice Question # 10
AnozzleisinstalledinavesselperFig.UW16.1(a).Thevesselwallthickness
is0.325andthenozzlewallthicknessis0.375.Whatistheminimumfillet
Weldsizeforthenozzletoshellfilletweld?
tn

d
tc
t
a

23

)LOOHW:HOG6L]H
ASMEVIIIpar.UW16(b),Fig.UW16.1(a)

Practice Question # 11
AnozzleisinstalledinavesselperFig.UW16.1(a).Thevesselwallthickness
is0.325andthenozzlewallthicknessis0.375.Whatistheminimumfillet
weldsizeforthenozzletoshellfilletweld?
tn
d
tc
t
a

24

)LOOHW:HOG6L]H
ASMEVIIIpar.UG37

Practice Question # 12
Anew8NPSnozzleisinstalledinavesselperFig.UW16.1(h).Shellrequiredthicknessis
1.125.Nominalshellthicknessis1.250.Nominalthicknessforthenozzleis0.875.
Therepadthicknessis0.500.
1) Whatistheminimumfilletweldsizeforthenozzletorepadfilletweld?
2) Whatistheminimumfilletweldsizefortheshelltorepadfilletweld?

tn
d
tw=0.7tmin

tc
t

tc

25
Fig.UW161(h)

HEAD
BANGER

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ASMEVIIIpar.UG37

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

29

1R]]OH5HLQIRUFHPHQW
ASMEVIII,SubsectionA,PartUG,UG37

Nozzle Reinforcement Variables

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

Variables for nozzles without repads

Variables for nozzles with repads

tn

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

t
1/2tmin

a1

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,UG37

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

1R]]OH5HLQIRUFHPHQW
ASMEVIIIpar.UG37

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

ASMEVIII,SubsectionA,PartUG,UG37
6XEVHFWLRQ%3DUW8:'HVLJQ8: E DQGSDJH
GRZQRQFHIRU)LJ8:

32

1R]]OH5HLQIRUFHPHQW
ASMEVIIIpar.UG37

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.UW16.1(a1).Thevessel
wallthicknessis0.825thick.Vesselrequiredthicknessis0.625.Thenozzlewall
thicknessis0.500.Requirednozzlethicknessis0.375.Therepadis0.375thick.
Corrosionallowanceis0.125.
1) What is the limits of reinforcement (edge to edge)?

tn

2) What is the area lost?

tc

te
t
1/2tmin

Fig.UW16.1(a1)

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

ExamRestrictions/Exclusions:
1.

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

2.

One filler metal per process

3.

PQR will be the supporting 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.

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

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

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).

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 welders ability to make sound welds.

General requirements of ASME


Section IX (cont)

$UWLFOH,

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. WPSs created using S numbers must be
revised to show correct P number, but not RE-QUALIFIED.
e. New WPSs 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

General requirements of ASME


Section IX (cont)

$UWLFOH,

QW102 (Definitions) (see QW492, page 193)


a.
b.

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

properties were altered during welding


c. Interpass temperature highest temperature allowed in weld or weld joint 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 welders 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.

General requirements of ASME


Section IX (cont)

$UWLFOH,

QW103.1 - Responsibility
a.

QW103.2 - Records
a.

Manufacturer is responsible for and shall conduct testing required to Qualify


WPSs 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).

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Understanding
P-Number
$31XPEHU 4:SDJH
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4:

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14

Understanding
P-Number
Example -

WhatistheP-NumberforSA285GrC?

$UWLFOH,9
4:

Answer- FindSA285GrCintableQW/QB422(page76).ItisP1Gr1.

15

Understanding
F-Numbers
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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

PNumber

SA240Type 304
SA217TypeWC1
UNSS31000

)1XPEHU 3UDFWLFH ZKDWLVWKH)IRUWKHIROORZLQJ"


Filler MetalClassificationand/orSpecification

FNumber

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

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4:
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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
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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

0 to 15o

80 to 150o
210 to 280o

Overhead

0 to 80o

0 to 80o
210 to 360o

Vertical

D
E

15 to 80o
80 to 90o

80 to 280o
0 to 360o

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

Inclination
of Axis
0 to 15o

Rotation
of Face
150 to 210o

Horizontal

0 to 15o

80 to 150o
210 to 280o

Overhead

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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22

FIELD Weld Orientations

(QW110 page 151)

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LVWKHZHOGLQJSRVLWLRQRIWKLVZHOG"

23

FIELD Weld Orientations


3UDFWLFH4XHVWLRQ 
$JURRYH ZHOGLVLQFOLQHGGHJUHHVIURPKRUL]RQWDO
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6WHS

6WHS
0DWFKWKH3RVLWLRQ IURP6WHSWRWKHIDFH URWDWLRQ
7KLVZLOOJLYH\RXWKH3RVLWLRQ V IRUWKLVSURGXFWLRQ
ZHOG
Tabulation of Positions of GROOVE WELDS

'HWHUPLQHZKLFKSRVLWLRQ WKLVLQFOLQDWLRQRIZHOGD[LV
WKLVZHOGFRXOGSRVVLEO\EH LH$%&RU' 

Tabulation of Positions of GROOVE WELDS

6WHS 
Position
Flat

Diagram
Reference
A

Inclination
of Axis
0 to 15o

Rotation
of Face
150 to 210o

Horizontal

0 to 15o

80 to 150o
210 to 280o

Overhead

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

Inclination
of Axis
0 to 15o

Rotation
of Face
150 to 210o

Horizontal

0 to 15o

80 to 150o
210 to 280o

Overhead

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 GHJUHHVFDQEH$
%&RU'

24

FIELD Weld Orientations

(QW110 page 151)

3UDFWLFH4XHVWLRQ 
$JURRYH ZHOGLVLQFOLQHGGHJUHHVIURPKRUL]RQWDO
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6WHS
0DWFK WKH,QFOLQDWLRQWRWKH)DFH5RWDWLRQWR
GHWHUPLQHWKH326,7,21RIWKH:(/'
Tabulation of Positions of GROOVE WELDS

Position
Flat

Diagram
Reference
A

Inclination
of Axis
0 to 15o

Rotation
of Face
150 to 210o

Horizontal

0 to 15o

80 to 150o
210 to 280o

Overhead

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

Practice Questions
for
Weld Orientations

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SRVLWLRQRIWKLVZHOG"

27

Practice Questions
for
Weld Orientations

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28

Practice Questions
for
Weld Orientations

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29

7\SHVRI7HVW([DPV
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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 joints.


Types - Root, Face and Side bend

QW141.3 Fillet Weld Test


A.

Used to determine ultimate strength of groove weld joints (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
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4:SDJH
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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 joints (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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7(16,217(67

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In order for a Tension test to pass, 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 joined 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(16,21VSHFLPHQDSDUW LHIDLOXUH

FailureStressorUltimateStress=Load/Area
Load istheamountofstressrequiredtopullthetensilespecimensapart
Area ofatensilespecimenisthewidthxthickness
38

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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

4: D SDJHIRU:36345DQG4: D SDJH:34

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. 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
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Used to determine degree of soundness and ductility of groove weld joints.
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
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FigureA
FigureB

FigureC

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FigureB

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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)
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2. Must have complete Joint penetration
3. Must have complete fusion of weld metal and base metal

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4:SDJH

Radiography
QW142 Radiography

4:SDJH

1. May be substituted for Groove weld Mechanical


Test for WELDERS.

QW-191 Acceptance Criteria

$UWLFOH,

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
Max length - for t > 2
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.

$UWLFOH,,,

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:GMAWSshortcircuitingmodeweldscannotbequalifiedbyRT

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

$UWLFOH,,,
4:SDJH

52

WPQ Bend Specimen Requirements


Bends

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1. Number of bends?

AND

4:SDJH

D 3ODWHSHU)LJXUH

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53

Bend Specimen Requirements


for Performance Qualification
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Bends

4:
4:

2. Dimensions?
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54

WPQ Bend Specimens


Bends

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Where to remove the specimens?


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4:
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SDJHV

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Alternative Inspection
(RT/UT) for WPQ
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Requirements
NDE Alternative Inspection

7HVW&RXSRQ

(RT/UT in lieu of BENDS

4:SDJH

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1. Minimum Length of weld? 

1. Minimum Length of weld? XQOHVV*RU*

2. Pipe? )XOO&LUFXPIHUHQFH 

2. Welder Operator? 0LQLPXPRIIW

SRVLWLRQWKHQ

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

4:SDJH

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56

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4:SDJH

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4:

1. Fails Visual test; 4:SDJH


Qualify by: making 2 coupons, both must pass VT and 1 picked for

mechanical testing (bend)

2. Any of the bend test fail; 4:SDJH


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

%4XDOLILFDWLRQ([SLUHV

4:SDJH

1. Welder has not used the Process for 6 months


2. Reason to question welders 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

$UWLFOH,,,
4:
:HOGHU

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

2
1
3
0

Practice Question # 17

$UWLFOH,9
4:
SDJHGRZQ
SDJHV

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

$UWLFOH,9
4:
SDJHGRZQ
SDJHV
58

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

Practice Question # 19

$UWLFOH,,,
3DU4:


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

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

WPQ
P Number Qualification Range
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Pnumber
oftest
coupon
welded

Pnumber
Range
qualifiedto
weldin
FIELD

Answer:
31RWKUX)
 WKUX
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F Number Qualification Range
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Qualified
with

Answer:
)1R 

61

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# of Bend Specimens
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Answer:
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63

WPQ
Thickness Limits
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Answer:
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Answer:
2'WR8QOLPLWHG
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Position Limits
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Answer:
)9DQG2

66

Welder Qualification Record


WPQ Record
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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. joints, 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
Joints
QW403
BaseMetals

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QW404Filler
Metals

QW405
Positions

Variable

Process
SAW

SMAW

GTAW

.4

Backing

.16

PipeDiameter

.18

PNumber

.14

Filler

.15

FNumber

.22

Inserts

.23

Solidormetalcoredto
fluxcore

.30

tWelddeposit

.1

X
X

.3

+Position

QW408
Gas

.8

Vercalwelding

QW409
Electrical

.4

Currentorpolarity

X
68

&RPSOHWLQJD:345HFRUG
Step1

DetermineWhatweldingPROCESSandTYPEusedtomaketestcoupon SMAWandManual

ThesearesetbyWPS

Step2

FindtheEssentialvariablesfortheweldingprocessusedinASMEIX.

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

6NPS
P1toP1
5.1
F3
N/A
N/A

QW353forSMAW

RangeQualified

SMAW
. Manual
F1toF3with,F3wo

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

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

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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

CompleteResults:sectionandthenSignandDateForm
ThatsIT,youjustcompletedaWPQRECORD

70

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PracticeQuestion#28
WeldingVariables(QW350)

DetermineifEssential VariablesareCorrect

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
27/8MintoUnlimited
.
P1-P15F,P34,P41-49
.
. --------. F1,F2,andF3
. -------. -------. Max of .600
. -------ALL
.
. Downhill only
. -------. -------. --------

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WPQ WeldingVariables

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X

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X

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WPQ WeldingVariables
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73

WPQ WeldingVariables
ReferenceWPQ MR.RODBURNERtoanswerthefollowingquestions;
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Welding Procedure - Requirements (WPS)


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

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MustreferencethesupportingPQR

c. Changescanbemadetononessentialvariableswithout
requalification.Changestoessentialorsupplementaryvariables
requirerequalification.
d. FormatofWPSmaybeanyformataslongaseveryessential,
nonessentialandsupplementaryvariableisincluded.
e. WPSmustbereadilyavailableatthefabricationsiteforreview by
welderandinspector.

79

Welding Procedure Requirements (PQR)


 345UHTXLUHPHQWV 4: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. TherecouldbemultiplePQRssupportingoneWPSormultipleWPSsforasinglePQR.
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:PQRMust besignedanddatedtobeCERTIFIED.

81

'LIIHUHQFHEHWZHHQ :36345 DQG :34


1. WhatisthedifferencebetweentheProcedureQUALIFICATIONand
WelderQUALIFICATION?
A. ProcedurequalificationrequiresTWOdocuments(WPS/PQR).
B. Examinationsaredifferent;
1)

WPS/PQR requiresBends/TensiontestandCharpy testwhennotch


toughnessisrequired.Also,HardnesswhenPWHTd.

2) WPQ requiresVTandBendtestorRT/UTexamination.

C. WPQonlyrequiresEssentialvariablestoberecorded,

whiletheWPSmustrecordEssential,Non-EssentialandSupplementary
(whenrequired)variables.
PQRmustrecordEssentialandSupplementaryvariables.
82

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

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

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

83

:363455HYLHZ,QVWUXFWLRQV
INSTRUCTIONSforCheckingWPSandPQR
STEP1 LocatetheappropriateWeldingVariablesChartfortheWeldingPROCESS(i.e.SMAW QW253,SAW-QW254orGTAWQW256thesearetheonlythreethatwillbeontheAPIExam).
STEP2 VerifyPQRissignedbyManufacture/Contractor QW202(b).
STEP3 VerifyWPSreferencesthesupportingPQR QW201(b).
STEP4 VerifyallNon-EssentialvariablesareaddressedontheWPS,andvalidatethatonthechecklist(e.g.enterOKorERRORin
theVALIDATEcolumn)- QW201(b).
STEP5 ListvaluesforallESSENTIALvariablesonChecklistfromthePQR QW202(b).
STEP6 ListvaluesforallESSENTIALvariablesonChecklistfromtheWPS QW201(b).
STEP7 UseSectionIXtodetermineandlisttheACCEPTABLErangeforallessentialvariables(basedonthePQRresults)
STEP8 ComparetheAcceptablerangeagainsttheWPSvaluesanddocumentthefindingsintheVALIDATEcolumn.
STEP9 CheckTESTINGdataonPQRandverifycorrecttype/numberofBENDspecimens(i.e.2face&2Root,etc)weretestedand
resultsareacceptableorrejectable.RecordanswerinValidatecolumnofchecklist.
STEP10 CheckTESTINGdataonPQRandverifycorrecttype/numberofTENSILEspecimens(i.e.2ormore,dependingonthickness)
weretestedandresultsareacceptableorrejectable.RecordanswerinValidatecolumnofchecklist.
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/PQRReviewResults
$UWLFOH,9JCPP101
4: JCPPQ101

ReviewofWPS#

Rev#

Dated:

SupportingPQR#

Rev#

Dated:

Paragraph

BriefofVariables

Essential

Par4:
QW402Joints

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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

NonEssential

PQR

.1

I GrooveDesign

NE

.4

NE

.10

I Rootspacing

NE

.11

r Retainers

NE

Backing

.8

I Tqualified

.9

tPass>inch

.11

I PNo.qualified

.4

I FNumber

.5

I ANumber

.6

I Diameter

STEP6

WPS

thk

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

.30

It

.33

I AWSClassification

NE

1/16to1

STEP7

Validate

QualifiedFor?

OKorError

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

OK
OK
OK
OK

PQRshouldbe1/16to1
OK
OK

ERROR shouldbeF3
OK
OK
OK
OK
OK

.1

+Position

NE

.3

I np Verticalwelding

NE

1.

Decrease>100oF

.2

I Preheatmaintenance

.1

I PWHT

.4

Tlimits

.4

I Currentorpolarity

NE

.8

I I&Erange

NE

.1

I String/Weave

NE

.5

I Methodofcleaning

NE

.6

I Methodbackgouge

NE

-----

.9

I Multitosinglepass/side

NE

-----

OK

-----

OK

50oF

E
NE

-----

.25

I Manualorautomatic

NE

.26

r Peening

NE

.64

UseofThermalProcesses

None

OK

50oF

OK

None

None

OK

None

-----

50oF
-----

None

-----

-----

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

-------None

OK
OK
OK

OK
OK
OK

OK

OK
OK

86

WPS/PQRReviewResults
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

60,000PSI

57,038Base
66,158Weld

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(OkorError)
OK

NOTE:1.FailureStress(failedinBaseMetal)mustbe .95%ofMSTS(seeQW-153,page4)
2.FailureStress(failedinWELD)mustbe MSTS(QW-153)
3.VerifythattheUltimateFailureStress 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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(VVHQWLDO

345-&334

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88

Practice Questions
for Reviewing WPS/PQR
8VH:36-&33DQG345-&334WRDQVZHUWKHIROORZLQJTXHVWLRQV
Practice Question # 31

$UWLFOH,9
4:

IsthebasemetalthicknessinaccordancewithASMESectionIX?
Result No,PQRcouponwaswhichqualifiesthk rangeof3/16to1,
WPSindicated1/16to1

89

Practice Questions
for Reviewing WPS/PQR
8VH:36-&33DQG345-&334WRDQVZHUWKHIROORZLQJTXHVWLRQV
Practice Question # 32

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

Essential

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IRU*7$:
RQ3DJH

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90

Practice Questions
for Reviewing WPS/PQR
8VH:36-&33DQG345-&334WRDQVZHUWKHIROORZLQJTXHVWLRQV
Practice Question # 33

IstheF#qualifiedinaccordancewithASMESectionIX?
Result NO,ER304isF6&E7018isaF4

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3DU4:
7DEOH4:

(LV)

(5LV)
91

Practice Questions
for Reviewing WPS/PQR
8VH:36-&33DQG345-&334WRDQVZHUWKLVTXHVWLRQ
Practice Question # 34

ArethetensiletestinaccordancewithASMESectionIX?
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Partial HT requires 5 ft overlap for each successive heats (partial means part cannot fit
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HT of welds includes a zone extend 1t or 2, whichever is less, beyond each side of the
weld (par UW-40(a)
No control of temperature up to 800oF. Par UCS-56(c.)
Heating rate above 800oF shall not be more than 400oF per hr/max metal thickness. Par
UCS-56(d)(1)(2).
Variation in temperature cannot exceed 250oF in any 15 ft length of vessel. Par UCS56(d)(2)
Holding time is per Table UCS-56
During holding time, temperature cannot vary by more than 150oF. Par UCS-56(d)(3).
Cool down rate shall not be more than 500oF per hr/max metal thickness. No control
necessary below 800oF. Par UCS-56(d)(5).
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Ifapprovedbytheengineer.
Apreheatof300oForhigherismaintainedduringwelding
PWHTtemperaturemaintainedforadistancenotlessthan2xt,fromthetoeoftheweld.
Atleasttwothermocouplesmustbeused.
MetallurgistapprovesthePWHTprocedureifitisperformedforenvironmentalassisted
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31

Welding Procedure (WPS),


Procedure Qualification Record (PQR)
and
Welder Performance Qualification
(WPQ)
Forms

Index
x WPS JCP-P101
x PQR JCP-PQ101
x WPS JCP-P201
x PQR JCP-PQ201
x WPS JCP-P301
x PQR JCP-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. JCP-P101
Date 9/11/2001
Supporting PQR No.(s)JCP-PQ101
Revision No. 0
Date 9/11/2001
Welding Process(es)

SMAW

Type(s)

Manual

Test Description

Joints (QW 402)


Joint 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 joint 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 pass thickness (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
Interpass Temp, Max
Preheat Maintenance

WPS No. JCP-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
Pass(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 Interpass cleaning (Brushing, Grinding, etc
Method of Back Gouging
Grinding
Oscillation
N/A
Contact Tube to Work Distance
N/A
Multiple or Single Pass (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.
JCP-PQ101
WPS # JCP-P101
Date 9/12/2001
Welding Process(es)
SMAW
Type(s)
Manual
Joints (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
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
Interpass Temp
Other

Shielding
Trailing
Backing

Gases
N/A

Percent Composition
Mixtures
Flow Rate

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
Multipass or Single Pass (per side)
Multiple
Single or Multiple Electrodes Single
Other

QW 483 (back)
PQR No. JCP-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
Pass - Base
Pass - Weld

Results
Pass
Pass
Pass
Pass

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
.
Welders 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

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. JCP-P201
Date 8/11/2001
Supporting PQR No.(s)JCP-PQ201
Revision No. 0
Date 8/11/2001
Welding Process(es)

GTAW

Type(s)

Manual

Test Description

Joints (QW 402)


Joint 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

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 joint 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 pass thickness (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 pass >

Positions (QW 405)


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

Page  of 2
Rev.# 0

WPS No. JCP-P201


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

Down

Gas (QW 408)

80oF
350oF
None

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

Gases
Argon
None
None

Shielding
Trailing
Backing
Other

Percent Composition
Mixtures
Flow Rate

Electrical Characteristics (QW 409)


Filler Metal

Current
Type
and
Polarity

Amps
(Range)

Wire
Feed
Speed
(Range)

Energy or
Power
(Range)

Volts
(Range)

Travel
Speed
(Range)

Weld
Pass(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

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

Heat Input (max.)


N/A
2% Thoriated (EWTh-2) or Cesium Stablilized (EWCe-2)

Mode of Metal Transfer for GMAW or FCAW

(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
3/8 to diameter shielding gas cup size
Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping, Wire Brush or Thermal process
Method of Back Gouging
Grinding or thermal process
Oscillation
N/A
Contact Tube to Work Distance
N/A
Multiple or Single Pass (per side)
Multiple
Multiple of Single Electrodes
Single
Peening
None
Other
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.
JCP-PQ201
WPS # JCP-P201
Date 8/12/2001
Welding Process(es)
GTAW
Type(s)
Manual
Joints (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
Diameter of Test Coupon Plate
Other

Postweld Heat Treatment (QW 407)


Temperature Range
None
Time Range
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

Positions (QW 405)


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

Shielding
Trailing
Backing

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
Multipass or Single Pass (per side)
Multiple
Single or Multiple Electrodes Single
Other

QW 483 (back)
PQR No. JCP-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

Area
(sq. inches)
.330
.337

Ultimate Load
(lbs)
24,450
24,000

Guided Bend Tests (QW -160)

Ultimate Stress
(psi)
74,090
71,216

Test
Temp

No

Impact
Values

Type of Failure
& Location
Pass - Weld
Pass - Base

Results
Pass
Pass
Pass
Pass

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
.
Welders Name Jack Shift Jr
Clock No.
Test conducted by: Shear Metal Testing Lab

Stamp No.
Laboratory Test No.

B2
SM-1001

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

8/12/2001

By:

JC Penny

Jack Shift Sr
Page 2 of 2

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. JCP-P301
Date 9/11/2001
Supporting PQR No.(s)JCP-PQ301
Revision No. 0
Date 9/11/2001
Welding Process(es)

SMAW

Type(s)

Manual

Test Description

Joints (QW 402)


Joint 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 joint 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 pass thickness (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
Interpass Temp, Max
Preheat Maintenance

WPS No. JCP-P301


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 1 of 2
Rev.# 0

Electrical Characteristics (QW 409)

Filler Metal
Weld
Pass(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 Interpass cleaning (Brushing, Grinding, etc
Method of Back Gouging
Grinding
Oscillation
N/A
Contact Tube to Work Distance
N/A
Multiple or Single Pass (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.
JCP-PQ301
WPS # JCP-P301
Date 9/12/2001
Welding Process(es)
SMAW
Type(s)
Manual
Joints (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
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
Interpass Temp
Other

Shielding
Trailing
Backing

Gases
N/A

Percent Composition
Mixtures
Flow Rate

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
Multipass or Single Pass (per side)
Multiple
Single or Multiple Electrodes Single
Other

QW 483 (back)
PQR No. JCP-PQ301
Specimen No.

Width
(inch)
.750
.756

T1
T2

Type and Figure No.

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

Specimen
No.

Thickness
(inch)
.455
.451

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
Pass - Base
Pass - Weld

Results
Pass
Pass
Pass
Pass

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
.
Welders 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

ASME Section IX Welder Qualification


Homework WPQs
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 JCP-P101
x PQR JCP-PQ101
x WPS JCP-P201
x PQR JCP-PQ201
x WPS JCP-P301
x PQR JCP-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. JCP-P101
Date 9/11/2001
Supporting PQR No.(s)JCP-PQ101
Revision No. 0
Date 9/11/2001
Welding Process(es)

SMAW

Type(s)

Manual

Test Description

Joints (QW 402)


Joint 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 joint 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 pass thickness (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-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

Positions (QW 405)


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

WPS No. JCP-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
Pass(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 Interpass cleaning (Brushing, Grinding, etc
Method of Back Gouging
Grinding
Oscillation
N/A
Contact Tube to Work Distance
N/A
Multiple or Single Pass (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.
JCP-PQ101
WPS # JCP-P101
Date 9/12/2001
Welding Process(es)
SMAW
Type(s)
Manual
Joints (QW 402)

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
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
Interpass Temp
Other

Shielding
Trailing
Backing

Gases
N/A

Percent Composition
Mixtures
Flow Rate

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
Multipass or Single Pass (per side)
Multiple
Single or Multiple Electrodes Single
Other

QW 483 (back)
PQR No. JCP-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
Pass - Base
Pass - Weld

Results
Pass
Pass
Pass
Pass

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
.
Welders 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

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. JCP-P201
Date 8/11/2001
Supporting PQR No.(s)JCP-PQ201
Revision No. 0
Date 8/11/2001
Welding Process(es)

GTAW

Type(s)

Manual

Test Description

Joints (QW 402)


Joint 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

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 joint 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 pass thickness (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 pass >

Positions (QW 405)


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

Page  of 2
Rev.# 0

WPS No. JCP-P201


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

Down

Gas (QW 408)

80oF
350oF
None

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

Gases
Argon
None
None

Shielding
Trailing
Backing
Other

Percent Composition
Mixtures
Flow Rate

Electrical Characteristics (QW 409)


Filler Metal

Current
Type
and
Polarity

Amps
(Range)

Wire
Feed
Speed
(Range)

Energy or
Power
(Range)

Volts
(Range)

Travel
Speed
(Range)

Weld
Pass(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

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

Heat Input (max.)


N/A
2% Thoriated (EWTh-2) or Cesium Stablilized (EWCe-2)

Mode of Metal Transfer for GMAW or FCAW

(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
3/8 to diameter shielding gas cup size
Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping, Wire Brush or Thermal process
Method of Back Gouging
Grinding or thermal process
Oscillation
N/A
Contact Tube to Work Distance
N/A
Multiple or Single Pass (per side)
Multiple
Multiple of Single Electrodes
Single
Peening
None
Other
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.
JCP-PQ201
WPS # JCP-P201
Date 8/12/2001
Welding Process(es)
GTAW
Type(s)
Manual
Joints (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
Diameter of Test Coupon Plate
Other

Postweld Heat Treatment (QW 407)


Temperature Range
None
Time Range
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

Positions (QW 405)


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

Shielding
Trailing
Backing

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
Multipass or Single Pass (per side)
Multiple
Single or Multiple Electrodes Single
Other

QW 483 (back)
PQR No. JCP-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

Area
(sq. inches)
.330
.337

Ultimate Load
(lbs)
24,450
24,000

Guided Bend Tests (QW -160)

Ultimate Stress
(psi)
74,090
71,216

Test
Temp

No

Impact
Values

Type of Failure
& Location
Pass - Weld
Pass - Base

Results
Pass
Pass
Pass
Pass

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
.
Welders Name Jack Shift Jr
Clock No.
Test conducted by: Shear Metal Testing Lab

Stamp No.
Laboratory Test No.

B2
SM-1001

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

8/12/2001

By:

JC Penny

Jack Shift Sr
Page 2 of 2

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. JCP-P301
Date 9/11/2001
Supporting PQR No.(s)JCP-PQ301
Revision No. 0
Date 9/11/2001
Welding Process(es)

SMAW

Type(s)

Manual

Test Description

Joints (QW 402)


Joint 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 joint 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 pass thickness (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
Interpass Temp, Max
Preheat Maintenance

WPS No. JCP-P301


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 1 of 2
Rev.# 0

Electrical Characteristics (QW 409)

Filler Metal
Weld
Pass(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 Interpass cleaning (Brushing, Grinding, etc
Method of Back Gouging
Grinding
Oscillation
N/A
Contact Tube to Work Distance
N/A
Multiple or Single Pass (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.
JCP-PQ301
WPS # JCP-P301
Date 9/12/2001
Welding Process(es)
SMAW
Type(s)
Manual
Joints (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
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
Interpass Temp
Other

Shielding
Trailing
Backing

Gases
N/A

Percent Composition
Mixtures
Flow Rate

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
Multipass or Single Pass (per side)
Multiple
Single or Multiple Electrodes Single
Other

QW 483 (back)
PQR No. JCP-PQ301
Specimen No.

Width
(inch)
.750
.756

T1
T2

Type and Figure No.

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

Specimen
No.

Thickness
(inch)
.455
.451

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
Pass - Base
Pass - Weld

Results
Pass
Pass
Pass
Pass

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
.
Welders 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

ASME Section IX Welder Qualification


Homework WPQs
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

ASME Section IX WPS

QW-482 Suggested Format For Welding Procedure Specification (WPS)


(See Section IX QW-200.1)
Company Name
By
Welding Procedure Specification No.
Date
Supporting PQR No.(s)
Date
Revision No.
Welding Process(es)
Joints (QW 402)
Joint 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 joint 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 pass thickness (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
Interpass Temp, Max
Preheat Maintenance

Gas (QW 408))


Gases

Shielding
Trailing
Backing
Other

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

Rev.#

Percent Composition
Mixtures
Flow Rate

Electrical Characteristics (QW 4099)

Filler Metal
Weld
Pass(es)

Process

Classifi
-cation

Diameter

Current
Type
and
Polarity

Amps
(Range)

Wire
Feed
Speed
(Range)

Energy or
Power
(Range)

Volts
(Range)

Travel
Speed
(Range)

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
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 Interpass cleaning (Brushing, Grinding, etc
Method of Back Gouging
Oscillation
Contact Tube to Work Distance
Multiple or Single Pass (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)

Joints (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
Interpass Temp None
Other

Shielding
Trailing
Backing

Gases
N/A

Percent Composition
Mixtures
Flow Rate

Electrical Characteristics (QW 409)


Current
Polarity
Amps:
Volts
Tungsten Electrode Size
Other
Technique (QW 410)
Travel Speed
String or Weave Bead
Oscillation
Multipass or Single Pass (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)

Guided Bend Tests (QW -160)

Ultimate Stress
(psi)

Test
Temp

No

Impact
Values

Lateral Exp
% Shear
Mils

Fillet Weld Test (QW -180)

Type of Failure
& Location

Results

Notch Toughness Tests (QW -170)

Notch
Type

Result Satisfactory: YES


Macro Results

Tensile Test (QW -150)

Penetration into Parent Metal YES

Drop Weight
Break
No Break

No

Other Tests

Type of Test
Deposit Analysis
Other
.
Welders Name
Test conducted by:

Clock No.

Stamp No.
Laboratory Test No.

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

By:
Page 2 of 2

ASME Section IX Welder Qualification


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

Welder(s) Name

Test Description
Identification of WPS followed

Test Coupon

Production Weld

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

Thickness

Testing Variables and Qualification Limits


Welding Variables (QW350)

Actual Values

Range Qualified

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

Production Weld (dia if pipe)

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

Longitudinal bends (QW 462.3(b)


Results

Type

Alternative Volumetric Examination Results (QW 191)

Results

RT or

Fillet weld fracture test (QW 181.2)


Macro examination (QW 184)

Side bends (QW 462.2)

UT

Length and percent of defects


Fillet size (in.)

Concavity/convexity (in.)

Other tests
Film or specimens evaluated by

Company

Mechanical tests conducted by

Laboratory test no.

Welding supervised by

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