11/29/2023
ASME SECTION IX SEMINAR
Bureau Veritas Inspection & Insurance Company
MODULE 4
PART QW, ARTICLE II
PROCEDURE QUALIFICATION
For the benefit of business and people
WELDING PROCEDURE
QUALIFICATIONS
Requirements for preparing and qualifying Welding
Procedure Specifications (WPS) are found in Article II.
Welding procedure qualification variables and testing
requirements are discussed
Some very similar variables are also addressed in the
rules for performance qualifications, so be careful not to
confuse the requirements.
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WELDING PROCEDURE
SPECIFICATION
QW-200.1: A Welding Procedure Specification (WPS) is a
qualified written document prepared to provide direction for
making production welds to the welder or welding operator.
The WPS must address the essential, non-essential, and the
supplementary essential variables (when applicable) and their
acceptable ranges to be followed when welding.
Changes may be made in the nonessential variables of a
WPS to suit production requirements without additional
qualification testing when the changes are documented.
PROCEDURE QUALIFICATION
RECORD
QW-200.2: The Procedure Qualification Record (PQR) documents:
the actual values observed for the essential variables, and
supplementary essential variables (when required) used to
prepare a test coupon, and
the results of mechanical testing applied to verify the
mechanical properties of the test weld.
The PQR supports the qualification of the WPS
Changes to the essential and supplementary essential variables
on the PQR are not permitted without additional qualification
testing, except for editorial changes or Code revisions.
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MULTIPLE PQR's
MULTIPLE WPS's
QW-200.2(f): Multiple PQR's may support one WPS, or a
single PQR may support multiple WPS's.
Separate PQR’s for GTAW and SMAW may be used to
support a single WPS qualified for using both processes
in combination.
A PQR qualified for GTAW and SMAW in combination
may be used to write separate WPS’s for using each
process individually.
All supporting PQR(s) must be referenced on each
WPS.
P-NUMBERS
QW-200.3: To reduce the number of welding procedure
qualifications required, P‐Numbers are assigned to base metals
based upon their chemical composition, weldability, and mechanical
properties.
For steel and steel alloys, Group Numbers are assigned to
materials within each P‐Number, grouping materials with similar
toughness properties.
Group numbers are supplementary essential variables.
P-Numbers are discussed further in QW-420.
Note: When welding a material not assigned a P-Number, the WPS
must be specifically qualified. However, materials with a P-Number
assigned may generally be welded using a WPS qualified using any
material with the same P-Number. (with some limitations)
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COMBINATION
PROCEDURES
QW-200.4: More than one qualified WPS having different
essential or nonessential variables may be used in a single
production joint.
Each WPS may include one or a combination of
processes, filler metals, or other variables.
The qualified range of base metal thickness, weld deposit
thickness, and other variables for each WPS, welding
process, or set of variables must be observed.
ORGANIZATIONAL
RESPONSIBILTY
QW-201: The organization shall certify they have:
qualified each WPS,
performed the procedure qualification test, and
documented the qualification with a PQR
except as otherwise provided in QG-106.1 and QG-106.4
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MECHANICAL TEST
REQUIREMENTS
QW-202: The type and number of tests required for procedure
qualifications, and the qualified ranges for base metal and
deposited weld metal thicknesses for groove welds are found in
Table QW-451.1.
Table QW-451.1 requires a minimum of 2 tensile tests and 4
transverse bend tests for groove weld qualifications.
Table QW-451.3 and Table QW-451.4 address the number
of required tests and qualified thickness ranges for fillet weld
qualifications.
Table QW-451.1
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Table QW-451.1 Notes
(1) QW-403.9 further restricts the limits shown in this table when
referenced in QW-250 for the process under consideration. Also, QW-202.2,
QW-202.3, and QW-202.4 provide exemptions that supersede the limits of
this table. Supplementary essential variable requirements may also further
limit thickness ranges in this table.
(2) For combination of welding procedures, see QW-200.4.
(3) For the SMAW, SAW, GMAW, PAW, LLBW, and GTAW welding
processes only; otherwise per Note (1) or 2T, or 2t , whichever is applicable.
(4) see QW-151.1, QW-151.2, and QW-151.3 for details on multiple
specimens when coupon thicknesses are over 1 in. (25 mm).
(5) Four side‐bend tests may be substituted for the required face‐ and
root‐bend tests, when thickness T is 3/8 in. (10 mm) and over.
(6) For test coupons over 6 in. (150 mm) thick, the full thickness of the
test coupon shall be welded.
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Using Table QW-451.1
Coupon T is 0.010", using GTAW only.
Qualified T = ________ Qualified t = ______
Coupon T is 0.25", using SMAW only.
Qualified T = ________ Qualified t = ______
Coupon T is 0.50", using SMAW only.
Qualified T = ________ Qualified t = ______
Coupon T is 0.50", 0.125” GTAW, 0.375” SMAW.
Qualified T = _______ Qualified GTAW t = ____
Qualified SMAW t = ____
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Using Table QW-451.1
Coupon T is 0.010", using GTAW only.
Qualified T = _0.010” to 0.020”_ Qualified t = _0.020”_
Coupon T is 0.25", using SMAW only.
Qualified T = _0.0625” to 0.50”_ Qualified t = _0.50”_
Coupon T is 0.50", using SMAW only.
Qualified T = _0.1875” to 1.0”__ Qualified t = _1.0”_
Coupon T is 0.50", 0.125” GTAW, 0.375” SMAW.
Qualified T = _0.1875” to 1.0”__ Qualified GTAW t = _0.25”_
Qualified SMAW t = _0.75”_
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Using Table QW-451.1
The coupon T is 1.0" and it is made using SMAW with F-3 and F-4
electrodes. In welding the coupon, 1/4" F-3 is deposited and the
remainder is F-4.
Production T =
Production Deposited Weld Metal F-3 t =
Production Deposited Weld Metal F-4 t =
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Using Table QW-451.1
The coupon T is 1.0" and it is made using SMAW with F-3 and F-4
electrodes. In welding the coupon, 0.25" F-3 is deposited and the
remainder is F-4.
Production T = 0.1875” to 2.0”
Production Deposited Weld Metal F-3 t = 0.5”
Production Deposited Weld Metal F-4 t = 1.5”
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Using Table QW-451.1
The coupon T is 1.5" and it is made using GTAW and SMAW. In
welding the coupon, 0.75" GTAW and SMAW are deposited.
Production T =
Production Deposited Weld Metal GTAW t =
Production Deposited Weld Metal SMAW t =
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Using Table QW-451.1
The coupon T is 1.5“, made using 0.75" GTAW and 0.75” SMAW weld
metal deposits.
Production T = 0.1875” to 8”
Production Deposited Weld Metal GTAW t = 8”
Production Deposited Weld Metal SMAW t = 8”
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Using Table QW-451.1
The coupon T is 10" and it is made using FCAW and SAW. In
welding the coupon, 0.5" FCAW is deposited and the
remainder is SAW.
Production T =
Production Deposited Weld Metal FCAW t =
Production Deposited Weld Metal SAW t =
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Using Table QW-451.1
The coupon T is 10" and it is made using FCAW and SAW. In
welding the coupon, 0.5" FCAW is deposited and the
remainder is SAW.
Production T = 0.1875 to 13.3”
Production Deposited Weld Metal FCAW t = 1.0”
Production Deposited Weld Metal SAW t = 13.3”
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EXPANDED THICKNESS
VARIABLES
QW-202: Expanded ranges of qualified base metal thickness are
provided under specific conditions.
QW-202.2(b) allows partial penetration groove welds up to 8”
thick on unlimited base metal if the test coupon T > 1-1/2“.
QW-202.2(c) allows groove weld qualification to qualify for any
size, diameter or thickness of fillet weld, with some exceptions
for P-11 materials. Fillet weld qualifications may only be used
for non-pressure retaining welds.
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EXPANDED THICKNESS
VARIABLES
QW-202.3 allows unlimited base metal thickness weld repairs
if the test coupon T > 1-1/2”, within the deposited weld metal
thickness limits of Table QW-451.1.
QW-202.4 permits dissimilar thickness welds where the
thinner member meets Table QW-451.1 limits and the thicker
member is unlimited for P-No. 8, P-No. 42 thru 49, P-No. 51
and 52, and P-No. 61 and 62 materials if the test coupon T >
1/4”. For other materials the thicker member is unlimited if the
test coupon T > 1-1/2”.
In the 2023 Edition: QW-202.4(b)(1) was revised by removing
the words “in joints of similar P-No.” to clarify that this rule only
applies to the P-Nos. listed.
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WELDING POSITIONS
QW-203: Unless specifically required otherwise by the
welding variables (QW-250), qualification in any position
qualifies the procedure for all positions.
The welding process and electrodes must be suitable for
use in the positions permitted by the WPS.
A welder or welding operator making the weld deposit
in an acceptable WPS qualification test coupon may only
be qualified for the welding position used to weld the test
coupon.
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PLATE OR PIPE
TEST COUPONS
QW-211: The test coupon base metals may consist of
either plate, pipe, or other product forms, and combinations
of the product forms.
WPS qualifications using a plate test coupon also
qualifies for pipe welding and vice versa.
The dimensions of the test coupon shall be sufficient to
provide the required test specimens.
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MISCELLANEOUS WELDING
QUALIFICATIONS
QW-214: Corrosion Resistant Overlay
QW-215: Electron Beam Welding
QW-216: Hard Facing Overlay
QW-217: Clad Metals
In the 2023 Edition: These rules are revised to address
procedure qualification requirements for single sided welding of
clad plates where the clad is on the root and does not contribute
strength in thickness calculations
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MISCELLANEOUS WELDING
QUALIFICATIONS
QW-218: Applied Linings
In the 2023 Edition: In QW-218.2, replaced the rule that uphill
progression qualifies all positions when attaching applied linings, with a
new rule permitting any welding position to qualify all positions when
attaching applied linings (since most applied linings are relatively thin).
QW-219: Flash Welding
QW-220: Hybrid Laser Welding
QW-221: Hybrid Plasma Welding
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ESSENTIAL VARIABLES
QW-251.2: Essential variables are welding conditions that
will affect the mechanical properties of the weld when
changed.
Essential variables must be addressed in both the PQR
and WPS.
If an essential variable changes from the conditions
originally qualified, additional qualification testing must be
performed to support the new conditions.
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SUPPLEMENTARY
ESSENTIAL VARIABLES
QW-251.2: Supplementary essential variables are welding
conditions that will affect the toughness properties of the weld
when changed .
Supplementary essential variables only need to be
addressed when impact testing is required, and if changed
from the conditions originally qualified, additional
qualification testing must be performed to support the new
conditions.
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NON-ESSENTIAL
VARIABLES
QW-251.3: Nonessential Variables are welding conditions
that will not affect the mechanical properties of the weld when
changed.
If a nonessential variable changes, the procedure need
only be revised.
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SPECIAL PROCESS
VARIABLES
QW-251.4: Special process variables are essential
variables that are unique to a welding process when used to
apply corrosion resistant overlay, hard facing overlay, and
spray fusing overlay welding applications.
When these variables are changed, additional
qualification testing must be performed to support the
new conditions.
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WELDING VARIABLES
Table QW-252 through Table QW-267: The variables
applicable to each welding process, and special processes
using those welding processes, are found in these tables.
There is one variable Table for the welding process (i.e.
QW-253 is SMAW) and another variable Table for special
processes associated with that welding process (i.e. QW-
253.1 for SMAW special processes).
The variable Tables contain “briefs”, an abbreviated
description of the variables, helping the user to recall the
detailed variable descriptions found in the referenced
paragraphs of Article IV.
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ACCEPTABLE WELDING
PROCESSES
Table QW-252: Oxyfuel Gas Welding- OFW
Table QW-253: Shielded Metal Arc Welding- SMAW
Table QW-254: Submerged Arc Welding- SAW
Table QW-255: Gas Metal Arc Welding– GMAW and Flux Core Arc
Welding - FCAW
Table QW-256: Gas Tungsten Arc Welding– GTAW
Table QW-257: Plasma Arc Welding- PAW
Table QW-258: Electroslag Welding– ESW
Table QW-259: Electrogas Welding– EGW
… next page
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ACCEPTABLE WELDING
PROCESSES QW-252 to 267
Table QW-260: Electron Beam Welding - EBW
Table QW-261: Stud Welding
Table QW-262: Inertia and Continuous Drive Friction Welding
Table QW-263: Resistance Welding
Table QW-264: Laser Beam Welding - LBW
Table QW-264.2: Low Power Density Laser Beam Welding – LLBW
Table QW-265: Flash Welding
Table QW-266: Diffusion Welding – DFW
Table QW-267: Friction Stir Welding - FSW
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FILLER METAL F-NUMBERS
QW-430: F‐Number groupings of electrodes and welding rods
are based on usability characteristics affecting the welders
ability to make satisfactory welds with a given filler metal.
(QW-431 and Table QW-432)
F- Number groupings reduce the required number of
WPS and performance qualifications, but filler metals may
not be indiscriminately substituted for one another within a
grouping without considering compatibility of the base and
filler metals metallurgical properties, PWHT design and
service requirements, and mechanical properties.
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ALTERNATE FILLER
METAL F-NUMBERS
QW-433: The following tables identify the filler metal or electrode
used during qualification testing as “Qualified With,” and the
electrodes or filler metals the welder is qualified to use as “Qualified
For.” See Table QW-432 for the F-Number assignments.
Continued next slide
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ALTERNATE FILLER
METAL F-NUMBERS
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WELD METAL A-NUMBERS
QW-441: A-Numbers are a method of categorizing the deposited
chemical composition of ferrous weld metals.
A-Numbers and their chemical composition ranges are listed
in Table QW-442.
A-numbers are often determined by the filler metal
manufacturer during their certification
In some cases they must be determined by the qualifying
organization during WPS qualification, depending on the
variables used with the welding process.
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WELD METAL A-NUMBERS
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2023 Edition Revisions
QW-214.2(a): Revised by replacing the phrase "acceptance standards
as" with "requirements“ to be more inclusive of other requirements.
QW-216.2(a) & QW-382.1(c): Added a reference to QW-195.3, a new
subparagraph adding qualification rules for personnel performing
Liquid Penetrant (PT) examinations, similar to Section I and Section
VIII-1 rules.
Tables QW-253, 255, 256, 257, and 259:
Restored QW-409.4 and QW-410.9 as nonessential variables for SMAW,
GMAW/FCAW, GTAW, PAW, and EGW with some editorial revisions.
Added new supplementary essential variable QW-409.30 addressing the
current type and polarity, and QW-410.87 addressing the number of weld
passes per side.
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2023 Edition Revisions
Table QW-255 (GMAW): Deleted the essential variable QW-409.2
(change in transfer mode) and added new nonessential variables,
QW-409.30 & QW-409.32 (both described below).
Table QW-264 (LBW): Deleted essential variable QW-403.1 (change
in base metal) and added new essential variable QW-403.35
describing the requirements for base metal changes in substantially
more detail.
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2023 Edition Revisions
QW-409.30: Added a new supplementary essential variable
addressing the current type and polarity. This does not apply to P-
Nos. 8, 21 through 26, and 41 through 49.
QW-409.32: Added a new nonessential variable: “At least one of the
following transfer modes shall be specified: (a) short-circuiting arc,
(b) globular, (c) spray, (d) pulsed-spray". The transfer mode is not
essential to mechanical properties.
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CONSIDERATIONS FOR
DEVELOPING A WPS
Economics (materials and labor)
Compatibility between the base metal and weld metal
Metallurgical and mechanical properties of the weld
Heat treatment requirements
Service requirements
Welder's ability
Available welding equipment and materials
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STEPS FOR
WRITING A WPS
Determine the production materials and the range of
thicknesses to be welded
Select a welding process and filler metal
Determine the variables that apply (Tables QW-252 to 267)
Select the desired ranges of variables
Write a preliminary WPS
Perform the qualification test
Complete and certify the PQR
Finalize the WPS
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WPS Writing Exercise
Shall we attempt to write
a preliminary WPS together?
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CODE WELDING
DOCUMENTATION & FORMS
The information to be documented for the qualified WPS
and its supporting certified PQR shall recorded as specified
in QW-200.1 and QW-200.2 respectively.
The “suggested” WPS, PQR, and other welding document
forms in Nonmandatory Appendix B are not mandatory,
but the format chosen by the organization shall contain all
of the required information.
The WPS shall be made available to the welder or
welding operator.
QW-200.2(e): The WPS and PQR shall be made available for
review.
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QUALIFIED WPS’s
Any qualified WPS may be used within the ranges of the
qualified variables.
Additional qualification of a WPS is required when the
essential, or supplementary essential variables (if required), are
revised beyond their qualified ranges; or if toughness
requirements are to be added to an existing WPS qualified
without toughness testing.
WPS requalification may be required if its validity is questioned
for any reason.
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QUESTION 1
Define a Welding Procedure Specification.
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ANSWER 1
QW-200.1
A Welding Procedure Specification (WPS) is
a qualified written welding procedure
prepared to provide direction for making
production welds to the welder or welding
operator.
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QUESTION 2
What must be described in the WPS?
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ANSWER 2
QW-200.1(b)
The WPS must list the essential, non-
essential, and the supplementary essential
variables (when applicable) and their
acceptable ranges to be followed when
welding.
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QUESTION 3
What supporting document must be referenced
on the WPS?
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ANSWER 3
The supporting PQR, see QW-200.1
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QUESTION 4
Define the Procedure Qualification Record.
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ANSWER 4
QW-200.2(a)
A Procedure Qualification Record (PQR) is
a record of variables recorded during the
welding of the test coupon.
It is the observed actual values,
And also includes the results of
mechanical testing applied to verify the
mechanical properties of the test weld.
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QUESTION 5
What information must be included on a PQR?
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ANSWER 5
QW-200.2(b)
A Procedure Qualification Record (PQR)
documents the essential and, when required,
the supplementary essential variables of
QW-250 for each welding process used
during the welding of the test coupon.
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QUESTION 6
What changes may be made to a PQR? Give
an example.
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ANSWER 6
QW-200.2(c)
None, except that editorial corrections or
addenda are permitted. Examples are:
correcting an incorrect P-No. or updating
the P-No. because ASME has reassigned
the material.
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QUESTION 7
When following a WPS that includes more
than one process, filler metal, or set of
variables; how do you apply only one
process, filler metal, or set of variables?
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ANSWER 7
QW-200.4(a)(1) and (2)
Specific variables and qualified ranges must be
based on each individual process, filler metal,
or set of variables.
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QUESTION 8
Define P-Numbers and their purpose.
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ANSWER 8
QW-200.3
To reduce the number of welding
procedure qualifications required,
P‐Numbers are assigned to base metals
based upon chemical composition,
weldability, and mechanical properties.
61
QUESTION 9
Define F-Numbers and their purpose.
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ANSWER 9
QW-430
To reduce the number of welding
procedure qualifications required,
P‐Numbers are assigned to base metals
based upon chemical composition,
weldability, and mechanical properties.
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THE END OF MODULE 4
Any questions?
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