Module 5 Documents Governing WI and Qualification

COMIMSA Module 5
1. Introduction
The simple statement, The welds must be good, is not sufficient
information for judging the weld quality. The WI cannot evaluate a welded
structure without information form the designer or the welding engineer.
There are numerous documents available to the designer, welding
engineer and WI that state what, when, where, and how the inspection is
to be performed. Some of the documents the welding inspector may use
include drawings, codes, standards, and specifications.

COMIMSA Module 5
2. Drawings
Drawings describe the part or structure in graphic detail. Drawings
dimensions, tolerances, notes, weld and welding details, and
accompanying documents should be reviewed by the inspector.
Dimensions
Dimensions have two basic functions:
1) Provide the sizes needed to fabricate the parts.
2) Indicate locations where the individuals components
of each part should be placed.
Both U.S. units or SI units.

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2. Drawings
Tolerances
Are the total amount of variation permitted form the design size of a part.
They may be expressed three ways:
1) As a variation between limits,
2) As the design size followed by the tolerance,
3) When only one value is given, the other
value is assumed to be zero.

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2. Drawings
Notes
Eliminate the need for repetition on the face of the drawing, such as the
size of holes to be drilled, fastener (hardware) used, machining operations,
inspection requirements and so forth.

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2. Drawings
Welding details
Shown on drawings or other documents include locations, lengths an sizes
of welds, joint configurations, material callouts, specification of
nondestructive examination, and special processing requirements.

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2. Drawings
Documents
Before welding, the WI should review welding procedures to ensure that all
combinations of material, thickness, process, and position are adequately
covered.
As well as:
1) NDE specifications (procedures)
2) Welder Certification or Qualification
3) Levels of persons performing NDE
4) Codes, Standards and Specifications.

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3. Codes
Standard
Codes Specifications
It is a standard that is suitable Describes the essential technical

for adoption by a governmental requirements for a material,
authority as a part of a law or product system or service.
regulation, or as a specified by
other mandatory documents. MANDATORY
WHEN REFERENCED BY
MANDATORY OTHER MANDATORY
DOCUMENTS
Shall Will Should Could
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3. Codes
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3. Codes
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4. Standards
Something established for use as a rule o basis of comparison in
measuring or judging capacity, quantity, content, extent, value, quality, etc.

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5. Specifications
A detailed description of the parts of a whole; statement or enumeration of
particulars, as to actual or required size, quality, performance, terms, etc.
The A5.XX series of specifications, AWS A5.1 through A5.33, cover the
requirements for various types of welding consumables and electrodes.

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Organizations
AWS American Welding Society
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
ASNT American Society for Nondestructive Testing
ANSI American National Standards Institute

COMIMSA Module 5
6. Control of materials
In many industries, an important aspect of fabrication is the identification
and traceability of materials. The documents for metals is sometimes
referred to as an MTR Material Test Report or MTC Material Test
Certificate.
For a material control program to be successful, there must be some
system whereby the received material can then be traced through the
various fabrication steps.

1) Segregation, or separation.
2) Color coding system
3) Alphanumeric code
4) Bar code
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7. Alloy identification
Alloy identifications are usually developed by industry associations such as
the Society of Automotive Engineers (SAE), American Iron and Steel
Institute (AISI), and the Copper Development Association (CDA).
The UNS (Unified Number System), establishes 18 series of primary
numbers for metals and alloys. Each number consists of a single letter
prefix, followed by five digits.

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Typical Steel Specification
The WI is sometimes required to compare actual material properties with
the requirements of the specified material specification. ASTM has
developed numerous material specifications. To become familiar with what
type of information is provided as well as how it is presented, a typical
steel specification will be discussed.

COMIMSA Module 5
ASTM A514, Standard specification for high yield strength, quenched and
tempered alloy steel plate, suitable for welding.

1) Scope
2) Applicable documents
3) General Requirements for delivery
4) Process
5) Heat Treatment
6) Chemical Requirements
7) Tensile Requirements
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ASTM A514, Standard specification for high yield strength, quenched and
tempered alloy steel plate, suitable for welding.

8) Brinell Hardness Requirements
9) Test Specimens
10) Number of tests
11) Retest
12) Marking
13) Supplemental Requeriments

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Typical Filler Metal Specification
ASTM A5.1, Specification for covered Carbon Steel Arc Welding
Electrodes.
1) Scope
Section A General Requeriments
1) Classification
2) Acceptance
3) Certification
4) Retests
5) Method of Manufacture
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Typical Filler Metal Specification
ASTM A5.1, Specification for covered Carbon Steel Arc Welding
Electrodes.
6) Marking
7) Packaging
8) Rounding-off Procedures
Section B Required Tests and Test Methods
Section C Manufacture, Packaging, and Identification
Section D Details of Tests
Appendix
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8. Qualification of Procedures and Welders

Part of every major welding project, whether completed in the shop or filed,
is the qualification of welding procedures and welders, or welding
operators.
Some codes require that the WI witness the actual qualification welding
and testing.
Most codes place the burden of responsibility for qualification on the
fabricator or contractor.
The responsibility of the WI is to review both WPS and WPQ to determine
if they are in accordance with the code and job specifications.
Some code welding are: AWS D1.1, ASME Section IX, API 1104.
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Procedure Qualification
The very first step in the qualification process is the development of the
welding procedure, and its performance within the procedure qualification.
Although most codes will consider the welder who performs the welding to
be automatically qualified.
The welding procedure qualification is performed to show the compatibility
of:
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AWS D1.1 Structural Welding Code - Steel
1) General Requirements.
2) Design of Welded Connections.
3) Prequalification of WPSs
4) Qualification
5) Fabrication
6) Inspection
7) Stud Welding
8) Strengthening and Repair of Existing Structures

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AWS D1.1 Structural Welding Code - Steel
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ASME Section IX, Welding and Brazing Qualifications, cover the
qualification of brazing as well as welding for the fabrication of pressure
vessels and piping.
API 1104, Standard for Welding of Pipelines and Related Facilities, is
primarily used by the cross-country pipeline industry for the qualification
and inspection of welding procedures and personnel.
In all documents the essential variables dictate the extent of a given
procedure qualification.
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The essential variables must be stated on a Welding Procedure
Specification (WPS). The actual test conditions are recorded on a second
document, the Procedure Qualification Record (PQR).
The test are designed to evaluate the effects of the welding techniques
and the compatibility of the base and filler metals:

1) Tensile
2) Bend
3) Nick-break
4) Macro-etch
5) Fillet break
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Procedures are welding
instructions; therefore, they
should be readily available to the
welder during production.

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Welder Qualification
Once the procedure has been qualified, it is of no use until individuals
welders have been qualified to perform welding in accordance with that
procedure.
It is now necessary to perform welder qualification tests to determine if
individual welders possess sufficient skill to produce satisfactory welds
using those procedures.
Same the WPS, there are essential variables: welding position, joint
configuration, electrode type and size, process, base metal type, base
metal thickness, and specific welding technique.

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Conform to AWS D1.1, the essential variables are:
Positions: plate grooves, plate fillets and pipe grooves.
Thickness: plate or pipe
Joint configuration
Type of electrode
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An important aspect that must be considered the WI, is the rolling direction
of the plate, during the test qualifications.
The ductility of the metal will vary depending on its rolling direction.
The welders may be qualified on test configuration joint Groove or fillet
welds.
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Position 6GR for welder qualification
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Some codes permit to use of NDE only, such as radiography, in lieu of
standard destructive tests for welder qualification.
Once properly identified, the specimens are removed and tested. If the
results are satisfactory, the welder is qualified.
The Qualification means that the welder has demonstrated skill.
The Certification means the document that support this qualification.
There are many formats for qualification: Procedure and Welder.

COMIMSA Module 5

The general sequence for the qualification of a welder is:

Module 5 Documents Governing WI and Qualification

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COMIMSA Module 5

The simple statement, The welds must be good, is not sufficient

structure without information form the designer or the welding engineer.

There are numerous documents available to the designer, welding

to be performed. Some of the documents the welding inspector may use

include drawings, codes, standards, and specifications.

dimensions, tolerances, notes, weld and welding details, and

accompanying documents should be reviewed by the inspector.

1) Provide the sizes needed to fabricate the parts.

2) Indicate locations where the individuals components

of each part should be placed.

Both U.S. units or SI units.

They may be expressed three ways:

1) As a variation between limits,

2) As the design size followed by the tolerance,

3) When only one value is given, the other

value is assumed to be zero.

size of holes to be drilled, fastener (hardware) used, machining operations,

inspection requirements and so forth.

of welds, joint configurations, material callouts, specification of

nondestructive examination, and special processing requirements.

combinations of material, thickness, process, and position are adequately

2) Welder Certification or Qualification

3) Levels of persons performing NDE

4) Codes, Standards and Specifications.

It is a standard that is suitable Describes the essential technical

measuring or judging capacity, quantity, content, extent, value, quality, etc.

particulars, as to actual or required size, quality, performance, terms, etc.

requirements for various types of welding consumables and electrodes.

AWS American Welding Society

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

ASNT American Society for Nondestructive Testing

ANSI American National Standards Institute

and traceability of materials. The documents for metals is sometimes

referred to as an MTR Material Test Report or MTC Material Test

For a material control program to be successful, there must be some

various fabrication steps.

2) Color coding system

the Society of Automotive Engineers (SAE), American Iron and Steel

Institute (AISI), and the Copper Development Association (CDA).

The UNS (Unified Number System), establishes 18 series of primary

prefix, followed by five digits.

the requirements of the specified material specification. ASTM has

developed numerous material specifications. To become familiar with what

type of information is provided as well as how it is presented, a typical

steel specification will be discussed.

tempered alloy steel plate, suitable for welding.

3) General Requirements for delivery

tempered alloy steel plate, suitable for welding.

10) Number of tests

13) Supplemental Requeriments

Section A General Requeriments

Section B Required Tests and Test Methods

Section C Manufacture, Packaging, and Identification

Section D Details of Tests

8. Qualification of Procedures and Welders

is the qualification of welding procedures and welders, or welding

Most codes place the burden of responsibility for qualification on the

The responsibility of the WI is to review both WPS and WPQ to determine

if they are in accordance with the code and job specifications.

8. Qualification of Procedures and Welders

welding procedure, and its performance within the procedure qualification.