SECTION IX

Welder’s Qualifications / Essential Variables

We will discuss all of the welder’s essential
variables listed in QW-353 for the SMAW
process. So here goes, turn to page 52 of
Section IX.
 QW-353
Shielded Metal-Arc Welding (SMAW)
Essential Variables

Paragraph Brief of Variables

QW 402
Joints .4 Deletion of Backing
QW 403
Base Metals .16 Change Pipe Diameter
.18 Change in P Number
QW 404
Filler Metals .15 Change in F Number
.30 Change in weld t deposited
QW 405
Positions .1 Addition of a position
.3 Change from vertical Up to Down
or Down to UP progression
 QW-353
Shielded Metal-Arc Welding (SMAW)
Welder Essential Variables
The first essential variable listed is – Backing (Removal of).
If a welder is qualified using any type of backing, and asked
to perform an open root weld he must retest without backing
to be qualified to perform the welding.
The Code definition of backing is welding with a backing bar
or retainer, welding double sided welds where the weld metal
of the first pass is used after gouging/grinding as weld metal
backing for the balance of the weld.
Fillet and partial penetration welds are also considered
welding with backing.
 QW-353
Shielded Metal-Arc Welding (SMAW)
Welder Essential Variables
The next inline is change in Pipe Diameter
qualified. As pipe diameters become smaller the
difficulty for a welder is increased resulting in a
higher skill level requirement.
So this translates to a change in diameter to one
smaller than qualified by the welder’s pipe
coupon on a previous test with this process.
The ranges of pipe diameters qualified are given
in Section IX, turn to page 143 in Section IX.
QW-452.3 GROOVE-WELD DIAMETER LIMITS
QW-452.3 GROOVE-WELD DIAMETER LIMITS

As we can see:
1. Under 1 inch (25mm) qualifies the diameter
down to the size welded to unlimited
diameter, because it is only easier for the
welder as the diameter of the Pipe welded
increases.
2. From 1 inch (25mm) to 2-7/8 inch (73mm)
qualifies 1 inch to unlimited.
3. Over 2-7/8 inch (73mm) qualifies 2-7/8 inch
to unlimited.
QW-452.3 GROOVE-WELD DIAMETER LIMITS

Quiz
1. If a welder qualified on a NPS 6 inch pipe
coupon the range of diameter qualifications
in production with the WPS he tested to will
be _________.
2. If tested with a NPS 2 inch coupon what is
his minimum and maximum diameter range
is ________
QW-452.3 GROOVE-WELD DIAMETER LIMITS

Quiz
1. If a welder qualified on a NPS 6 inch pipe
coupon the range of diameter qualifications
in production with the WPS he tested to will
be 2-7/8” to unlimited.
2. If tested with a NPS 2 inch coupon what is
his minimum and maximum diameter range
is 1” to unlimited.
 QW-353
Welder Essential Variables

P-Numbers. P-Numbers serve to group metals

by mechanical and chemical properties. So it is
reasonable to think that not all metals can be
welded using the same technique, or have the
same level of difficulty for welders.
There are three basic P-No. groupings for
welder qualifications. If a welder changes to a P-
No. group that he/she has not qualified for then a
retest is required. We will have a more
thorough lesson on Alternate Base Metals later
in this course.
 QW-432
F Numbers

We have now arrived at the Filler Metal Number

or F Number. F Numbers are a grouping of
electrodes and filler metals that weld in a
similar way and in general present more or less
difficulty for a welder. In other words some F-
Number filler metals require different skills than
others.
Turn now to Page 132 of Section IX
 QW-433 Alternate F-Numbers for Welder
Performance Qualifications

Changing the F Number for a welder may affect

his ability to weld and require re-qualification.
There are some provisions for using lower F-
Numbers when qualifying with numbers 2 to 4
but, there are restrictions on those qualifications.

Turn now to Page 137 of Section IX

 QW-433 Alternate F-Numbers for Welder
Performance Qualifications

Examples
1. Using the table QW-433, if a welder qualifies
with or without backing with a filler metal or
electrode assigned to F-Number 4. What F-
Numbers can he use with backing in a
production weld?

2. What F Numbers can he weld without

backing?
 QW-433 Alternate F-Numbers for Welder
Performance Qualifications
Solution
1. He can weld F-Numbers 1 through 4 with
backing. Going right across the row titled
“Qualified With” to F-Number 4 without
backing then down to each x in the boxes, then
left to read the “Qualified For” Column we find
F Numbers 1, 2, 3 and 4 with backing.
2. Also the “Qualified For” F Number 4 without
backing is included which makes sense as he
performed that weld for his test.
 QW-433 Alternate F-Numbers for Welder
Performance Qualifications

Notice that the large table only addresses F-

Numbers 1 through 5. The rest of the F-Numbers
are in a small table along with notes beneath
the large table. Let’s have a look at those.
QW-433 Alternate F-Numbers for Welders
 QW-452.1 (b)
Thickness Of Weld Metal Deposit

The fifth essential variable listed is change in

thickness of Weld deposit.
A welder is restricted by the amount of weld
metal he deposits during his performance
qualification test with a particular, welding
process, electrode/filler metal F-number in a
P-Number base metal combination. We will now
have a look at those rules.
Turn to Page 142 of Section IX
 QW-452.1 (b)
Thickness Of Weld Metal Deposit

The column ‘Thickness t, of weld metal in the

coupon’ refers to the amount of weld metal from
a process or a filler metal. Perhaps a bit of E-
6010 and the rest E-7018 or GTAW root and
SMAW fill and cap.
 QW-452.1 (b)
Thickness Of Weld Metal Deposit

Example
Assume one welding process, SMAW and one
electrode E-7018 using a P-No.1 pipe.
A coupon thickness of 3/8 inch was welded
using E-7018. In the column on the right titled
‘Thickness of weld metal qualified’ we see 2t,
so 2 x 3/8” = 3/4” this is the maximum amount
of E-7018 (F-No. 4) , that the welder can
deposit in production.
 QW-452.1 (b)
Thickness Of Weld Metal Deposit

Suppose now the coupon is 1/2” thick and a

welder welds it with 100% E-7018 using 3 weld
layers, we see that welder’s limit of deposited
weld metal with an F-No.4 is the maximum to be
welded.
 QW-452.1 (b)
Thickness Of Weld Metal Deposit

Another combination in the 1/2” coupon.

1/8” of E-6010 (F-No.3) and 3/8” of E-7018. By

the first column 2 x 1/8” = 1/4” of E-6010 (F-
No.3) and 2 x 3/8” = 3/4” of 7018 (F-No.4). The
welder can deposit up to 1/4” of any F-No.3 and
3/4” of any F-No.4 with any production WPS he
is otherwise fully qualified for, meaning position,
diameter, P-No., backing, progression etc.
 QW-452.1 (b)
Thickness Of Weld Metal Deposit

Quiz
How can we qualify a welder for unlimited
thickness with both F-No.3 and 4 in a single
coupon?
If he or she welds a coupon that is at least ___
thick and deposits at least___” of E-6010 and at
least ___” of E-7018 using a minimum of ____
layers of each filler metal.

* Hint See Note 1 of table QW-452.1(b)

 QW-452.1 (b)
Thickness Of Weld Metal Deposit

Solution
If he or she welds a coupon that is at least 1”
thick and deposits at least 1/2” of E-6010 and at
least 1/2” of E-7018 using a minimum of three
weld layers for each filler metal.
The welder can deposit unlimited t with any F-
No.3 and/or F-No.4 with any production WPS he
is otherwise fully qualified for such as, position,
P-No., backing, diameter, progression etc.
 QW-353
Welder Essential Variables

The next essential variable listed is Position.

Consider the welding positions versus the welder
test positions for a moment. We will use pipe test
coupons. Positions for pipe tests are designated
such as 1G, 1 designates the coupon orientation, in
this example the pipe is on the horizontal and is
rotated/rolled beneath the welder and is considered
to be flat welding. The G means a groove butt
weld. The others are 2G, 5G and, 6G.
Turn to Page 148 QW-461.4 in Section IX.
 QW-461.4
Groove Welds in Pipe – Test Positions

The more difficult the test position, the more

positions a welder can apply. The four positions
for welding are Flat, Horizontal, Vertical and
Overhead.
These are referred to as:
F,H,V,O
 QW-461.4
Groove Welds in Pipe – Test Positions
There are corresponding pipe and plate test
positions that qualify a welder for F,V,H, and O.
We will use pipe in the examples.
1G qualifies F (Rotated)
2G qualifies H
5G qualifies F, V, and O
6G qualifies F, V, H and, O (this yields all
positions)
 QW-461.4
Groove Welds in Pipe – Test Positions

Section IX allows combing test positions to

produce an all position welder. Therefore if a
welder tests in 2G and 5G he/she was tested for
all positions.
2G covers H and 5G covers F, V, and O
Which is equal to 6G that qualifies F, V, H and,
O. Either of these two yields an all positions
welder.
 QW-469.1
Performance Qualifications - Position and
Diameter Limitations
All of this information is compiled into one table.

In this way you can go straight to a one page

table and review a Welder Performance
Qualification (WPQ) for position and diameter
qualifications.
Turn to Page 151 Section IX
Notice the entry on the top row right
Position and Type Weld Qualified. [Note (1) ]
Below that Groove
Below Groove exists two sub-headings
Plate and Pipe Over 24 inches and Pipe less than or
equal to 24 inches. Ignoring Fillets because any welder
qualified for groove 1G is qualified for the same fillet 1F.
To the left we have Qualification Test

Which has the sub-headings Weld and Position

We will use the Pipe-Groove [ Note (3)] row. Starting at
the top of the table in the Qualification Test column
move down and stop at the 1G entry below. To the right
we see the entries F F F  ignore fillets.
Move up at the first F and find Plate and Pipe Over 24 in.
O.D. is qualified
Move up from the second F and find Pipe less than or
equal to 24 in. O.D. is qualified. See [ Note (3)]
Pipe less than or equal to 24 in. O.D. is
qualified. See [ Note (3)]

Note (3) See diameter restrictions in QW-452.3, QW-

452.4, and QW-452.6
Notice that while the welder can weld on pipe in
the FLAT position he or she is still restricted by
the diameters given in the table below on,
Pipe less than or equal to 24 in. O.D..
 QW-353
Shielded Metal-Arc Welding (SMAW)

The last essential variable listed is Progression.

This as simple as it gets.
If a welder welds Vertically Up (Uphill) during a
particular test he is only qualified for Vertically Up.
Should the welder be required to weld Vertically Down
(Downhill) it is required to test a coupon (keeping other
variables the same) welding Vertically Down.
The reverse is also true, qualify Downhill and you must
weld another coupon to qualify Uphill.
 QW-353
(SMAW) Welder Essential Variables
Quiz
A welder performs a test on a NPS 4” (4.5”) pipe
coupon in the 6G position. The coupon is Schedule
160 and has a wall T of 0.531”. The welder will use
SMAW with E-6010 for the root pass for a total weld
deposit t of .125” (1/8”). The balance of the weld
deposit t (.401”) will be performed using 3 weld
layers of E-7018 filler metal. No backing will be
used. All welding will be uphill during the test. What
are his qualifications as listed in table QW-353?
 (SMAW) Welder Essential Variables
Continued
The test qualifies ___ positions with a minimum
diameter of ______ and a maximum of _______.
The test also qualifies the welder to deposit ___
inches of F- No. 3 and ____inches of F-No.4.
The welder will also be qualified to weld _____or
_______backing. The thickest weld he can make
using this combination in production is__________.
The welder’s production welds must made using
_______ progression.
 (SMAW) Welder Essential Variables

Solutions
The test qualifies all positions with a minimum
diameter of 2-7/8” and a maximum of unlimited.
The test also qualifies the welder to deposit .250”
inches of F- No. 3 and .812” inches of F-No.4.
The welder will also be qualified to weld with or
without backing. The thickest weld he can make
using this combination in production is .250 +.812
or 1.062”. The welder’s production welds must be
made using uphill progression.
 QW-353
Shielded Metal-Arc Welding (SMAW)
Welder Essential Variables

The next series of slides address the alternate

base materials for welder qualifications. As you
will see a welder can test for example on a P-No.
1 base material with a selected F-No. filler metal
and, under the rules of Section IX he can weld
many other P-Numbers using the F-No. selected
for the test, maintaining all the other essential
variables for the welder, position, diameter, etc.