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Mechanical Testing :
The type and number of test specimens required for mechanical testing shall
be in accordance with QW-452 except special position. All mechanical tests
shall meet the requirements prescribed in QW-160 or QW-180, as applicable
Volumetric NDE :
When the welder is qualified by volumetric NDE, the minimum length of
coupon(s) to be examined shall be 6 in. (150 mm) and shall include the
entire weld circumference for pipe(s), but for the small diameter pipes
number of the test coupons need not exceed four consecutively made test
coupons. The examination technique and acceptance criteria shall be in
accordance with QW-191.
Visual Examination :
For plate coupons shall be visually examined as per QW-194 & Pipe coupons
shall be visually examined per QW-194 over the entire circumference, inside
and outside.
Type Of Test Required On Welded Coupon (QW-302)
.
B) Fillet Welds : Welders who pass the required tests for fillet welds in the
test positions shall be qualified for the positions of fillet welds shown in
Table QW461.9.
Welders who pass the tests for fillet welds shall be qualified to make
fillet welds only in the thicknesses of material, sizes of fillet welds, and
diameters of pipe and tube 27/8 in. (73 mm) O.D. and over, as shown in
Table QW-452.5, within the applicable essential variables.
Welders and welding operators who make fillet welds on pipe or tube
less than 27/8 in. (73 mm) O.D. must pass the pipe fillet weld test per
Table QW-452.4 or the required mechanical tests in QW-304 and QW-
305 as applicable.
QW-304.1& 305 Examination
Welds made in test coupons for WPQ may be examined by visual and
mechanical examinations (QW-302.1, QW-302.4) or by volumetric NDE (QW-
302.2) for the process(es). Alternatively, a minimum 6 in. (150 mm) length of
the first production weld(s) made by a welder using the process(es) specified
in QW-304 may be examined by volumetric NDE.
(a) For pipe(s) welded in the 5G, 6G, or special positions, the entire production
weld circumference made by the welder shall be examined.
(b) For small diameter pipe where the required minimum length of weld cannot
be obtained from a single production pipe circumference, additional
consecutive circumferences of the same pipe diameter made by the welder
shall be examined, except that the total number of circumferences need not
exceed four.
(c) The examination technique and acceptance criteria for production welds
shall be in accordance with QW-191.
Failure to Meet Examination Standards: If a production weld is selected for
WPQ & the welder has failed the test. In this event, the entire production
weld made by this welder shall be examined and repaired by a qualified
welder. Alternatively, retests may be made as permitted in QW 320.
Two or more welders who are using the same or a different welding
process, may be qualified in combination in a single test coupon.
Retests A welder who fails the welder qualification may be retested under
the following provisions.
(a) For welders retest shall be to examine two 6 in. (150 mm) plate
coupons; for pipe, to examine two or more pipe coupons of the same
diameter for a total of 12 in. (300 mm) of weld, which shall include the
entire weld circumference for pipe or pipes (for small diameter pipe the
total number of consecutively made test coupons need not exceed eight).
(b) At the option of the organization, the welder who has failed the
production weld alternative test may be retested by examining additional
weld areas equal to twice the required length or number of pipe
circumferences of the same or consecutively made production weld(s)
specified in QW-304.1 & QW 305.1.
If this length of weld passes the test, the welder is qualified and the area
of weld on which he had previously failed the test shall be repaired by him
or another qualified welder.
If this length does not meet the examination standards, the welder has
failed the retest and all of the production welds made by this welder shall
be examined completely and repaired by a qualified welder.
QW-322 Expiration & Renewal of Qualification QW-322.1:
The welder has welded with that process using manual or semiautomatic
welding/ Machine or automatic welding, under the supervision and
control of the qualifying organization(s) that will extend his qualification
for an additional 6 months.
(b) When there is a specific reason to question his ability to make welds that
meet the specification, the qualifications that support the welding he is
doing shall be revoked. All other qualifications not questioned remain in
effect.
QW-322.2 Renewal of Qualification.
(a) Renewal of qualification expired under QW-322.1(a) may be made for any
process by welding a single test coupon of either plate or pipe, of any
material, thickness or diameter, in any position, and by testing of that
coupon as required by QW-301 and QW-302. A successful test renews the
welder previous qualifications for that process for those materials,
thicknesses, diameters, positions, and other variables for which he was
previously qualified. Providing the requirements of QW-304 and QW-305 are
satisfied, renewal of qualification under QW-322.1(a) may be done on
production work.
•The welder will make the test weld in accordance with the WPS
•A welding inspector monitors the welding to ensure that the welder is
working in accordance with the WPS.
Project : The name of the project to be filled for which welder is going to be
qualified.
Client /Job No. : Client name or Job No. need to fill in this box.
Contractor : Name of the Contactor/Company/Organization to be filled here
who is going to qualify their welders for the job.
WPS no./Rev. No./Date : WPS no. With date & Rev. No. If done to be filled in
this box & on the basis of this WPS welder performance will be done.
Date of Testing : Date of WPQ to be filled in this block.
Type : Manual/Semi-Auto/Auto : Method of the welding to be filled here like
if a welder is going to be qualify by Manual welding then Manual & if by Auto
the Auto.
Welder Name: Name of the welder to be qualified will be filled here.
Welder ID No. : Welder ID no. To be filled here later if he cleared the NDE
/MT for Welder qualification
Welder Photo : Passport size photograph to be sticked here.
Actual Values /Parameters during welder qualification to
be filled in the Column of Actual Vales & Range
Qualified will be as per ASME sec. IX clauses.
Now the qualified range for the welder will be as follows : GTAW – With or
without backing and for SMAW – with only.
Base Material : a) Specification & type/grade :- In Table no. QW/QB-422
FERROUS/NONFERROUS P-NUMBERS Material have been arranged by
Specification No’s, Type or grade , UNS no., P. no. Group No., Nominal
Composition & product form for the understanding of the Material perfectly.
E.g : if we are going to qualify welder for pressure parts IBR T-91 Specification
& type/grade will be SA 213 T91 as per code.
b) Spec to P No. To P.No. QW-403 : P.No. (Parent Metal No’s) & Group No’s:
Materials are grouped in certain P No’s. The material which having similar
base metal characteristics, such as composition, weld ability, braze ability &
Mechanical properties are grouped in to one P.No:s. , but the base metal may
be unassigned . E.g :P.No for SA213 T91 is 15E as per QW/QB-422.
If Actual Value was 15E+15 E then qualified range will be as per QW-420.
Thickness(plate)/Diameter(Pipe):
Test piece dia to be mention if we are qualifying welder with pipe
The qualified ranges will be as per QW-452 for dia and thickness limits.
SFA No.,AWS No.,F. No. (Filler Metal No.) QW404 :
In Table QW 432 Grouping of Electrodes and Welding Rods for Qualification Filler
metals / Electrode have designated separately in F No’s, ASME specification, AWS
Specification.
SFA,AWS No. & F.No’s for the Filler wires and the electrodes to be filled in this block as per
QW432.
Details of the Filler type to be mentioned in this block i.e it may be solid/metal or flux cored.
Position QW-405: Test Position in which welder is performing test to be mentioned in this
block & qualified range will be as per QW-461.9.
Inert gas Backing/Purging for GTAW QW-408 : Shielding gases are inert
or semi-insert gases that are commonly used in several welding
processes, most notably gas metal arc welding and Gas tungsten arc
welding (GMAW and GTAW, more popularly known as MIG and TIG,
respectively).
Their purpose is to protect the weld area from oxygen and water vapour.
Depending on the materials being welded, these atmospheric gases can
reduce the quality of the weld or make the welding more difficult.
The shielding gas flow rate should be high enough to maintain adequate
shielding for the arc but not so high that it causes turbulence in the weld
pool. The gas flow rate to be used depends on a number of factors such as
the process, welding position, shielding gas, electrode extension and
operating parameters.
Welding current : Type & Polarity QW-409 Enter the current and polarity
for the electrode, electrode-gas or electrode- flux combination being
used. also Tungsten electrode size with type of electrode will be
mentioned here.
Vertical Progression Vertical/Horizontal QW-410 : Details of the
welding technique to me mentioned here.
Then finally it will be submitted by the contractor to EPC and after the
clearance of EPC will submitted it to TPI / Client Engineer
Things to be remembered:
When two metals of different thickness is welded, Heat treatment for the
higher thickness shall be applied.
When the joint is of 2 different P no: , Heat treatment for higher P no: will
be applied.
Heating Band --> Width = 3times of the base metal thickness from the
centre of the joint on each side.
Insulation --> Width = 6 times of the base metal thickness from the
centre of the joint on each side, Thickness = Minimum 25mm with
insulating material.
Thermo couple shall be placed at a distance of 1.5 times of the base metal
thickness from the centre, it should be welded by Spot welding,
K,S,B,R types thermocouples --> K type ( Chromel - Alumel )
Tolerances --> For Rate of heating & Cooling ±10°C & for Soaking temp. -
-> ± 15°C
Separate ID will be given for each qualified welders which will reflect
welding process, position qualified and other limitations.
The record of WPQ will be retained by welding supervisor for his record
and review of customer representative.
The welding supervisor will maintain separate log for welders who
successfully passed WPQ . The log shall indicate welder’s Identity ,
process, position and other limitations.
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