A presentation on

ASME SECTION IX
WELDING, BRAZING, AND FUSING
QUALIFICATIONS

(Qualification standard for welding, brazing and fusing procedures ;

welders, brazers and welding, brazing and fusing operators)
 Parts of ASME section IX
▪ Part QG : General requirements.

▪ Part QW : Welding.
➢ Article I : Welding general requirements.
➢ Article II : Welding procedure qualification.
➢ Article III: Welding performance qualification .
➢ Article IV: Welding data.
➢ Article V: Standard welding procedure specifications.

▪ Part QB: Brazing.

▪ Part QF: Plastic fusing.
 Welding Qualifications

Welding procedure qualification Welder/welding operator performance

qualification.

To check integrity of weld for given To check person’s ability to produce a

purpose/service condition. sound weld joint.

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 Important terms (QG-100)
• Procedure specification(QG-101): A written document providing direction
to the person applying the material joining process.
• Procedure qualification(QG-102): The procedure qualification record (PQR)
documents what occurred during the production of a procedure
qualification test coupon and the results of testing that coupon.
• Performance qualification(QG-103):The purpose of qualifying the person
who will use a joining process is to demonstrate that person’s ability to
produce a sound joint when using a procedure specification.
• Performance qualification records(QG-104): Record documents what
occurred during the production of a test coupon by a person using one or
more joining processes following an organization’s procedure
specification.
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 Important terms (QG-105)
• Essential variables-procedure (QG-105.1): Conditions in which a change,
as described in the specific variables, is considered to affect the
mechanical properties (other than notch toughness) of the joint.
• Essential variables-performance (QG-105.2): Conditions in which a
change, as described in the specific variable list, will affect the ability of
the person to produce a sound joint.
• Supplementary essential variables (QG-105.3):Conditions in which a
change will affect the toughness properties of the joint, heat-affected
zone, or base material.
• Non essential variables (QG-105.4): Conditions in which a change, as
described in the specific variables, is not considered to affect the
mechanical properties of the joint
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 WPS
▪ WPS:A Written qualified welding procedure prepared to provide direction
for making production welds to code requirement

▪ Contents of WPS: Essential, Non Essential , and, when required

Supplementary essential variables for each welding process used in WPS.

▪ Changes to the WPS: May be made in non essential variables to suit

production requirements without re-qualification.

▪ Availability of the WPS:WPS used for code production welding shall be

available for reference & review by AI at fabrication site.
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WPS (Sample)
WPS (Sample)
WPS (Sample)
WPS (Sample)
WPS (Sample)
WPS (Sample)
 PQR
▪ PQR :A record of the welding data used to weld a test coupon, contains test
result of the tested specimen.
▪ Content of the PQR: PQR shall document all essential &,when required,
supplementary essential variables for each process used during welding of test
coupon.
▪ Changes to PQR: Changes to PQR are not permitted except
- Editorial Correction-e.g. Correction in an incorrect P no., F no.
- Addenda to the PQR-e.g. Code changes, assign a new F no. to filler metal
- Additional information can be incorporated in PQR at a later date
provided the information is sustained as having been the part of the original
qualification condition by lab record or similar data.
▪ Availability of PQR:PQR shall be available upon request for review by AI.PQR
need not be available to the welder or welding operator.
PQR (Sample)
PQR (Sample)
PQR (Sample)
PQR (Sample)
 WPS & PQR
▪ Multiple WPSs with One PQR / Multiple PQRS With One WPS

▪ Several WPS may be prepared from the data on a single PQR

▪ Single WPS may cover several essential variable changes as long as a

supporting PQR exist for each essential variable &,when required,
supplementary essential variable.
 WELDING PROCEDURE QUALIFICATION
• Proves the Quality / Properties of Weld Joint Prepared by a set of welding
variables.

- Welding Process
- Base Material
- Welding consumable
- Welding Parameters & Techniques ( Position, Polarity, Preheat, Inter Pass
Temp.)
- PWHT

• Qualification limited to the essential variables of the Specific Process

 HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
1. IMPORTANT CLAUSES
▪ Welding Data - Essential, Non Essential & Supplementary Essential Variables.
– QW-250-General, Table QW-252 to 267-process wise, QW-400- welding data.

▪ Parent Metal Grouping - “P” No / Group No – QW-420 & Table QW/QB-422.

▪ Filler Metal Grouping – “ F” No – QW-431-General ,Table QW-432.

▪ Weld Metal Composition Grouping – “A” No – QW- 440, Table QW-442.

▪ Welding Positions, Groove & Fillet – QW-461

 HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
Important clauses
▪ Test Requirements and Qualified Thickness range – QW-451
- Groove weld: Table QW-451.1 & 451.2
- Fillet weld : Table QW-451.3 & 451.4
- Overlay : Table QW-453

▪ Test Specimen – Location, Dimension

- Tension, Bend, fillet weld test, overlay, seam weld, spot weld – QW-462.
- Location of specimen on test piece – Figure QW 463.1(a-f), Figure 464.1(spot &
seam welding)
- Jigs & fixtures of test : Figure QW-466.1 to QW 466.6
 HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
▪ TEST PROCEDURE AND ACCEPTANCE CRITERIA

- Tensile test : QW-152 - Tube # tube sheet : QW-193

- Guided bend test : QW-160 - Visual examination : QW-194
- Toughness test : QW-170 - LPT: QW-195
- Fillet weld test : QW-180 - Resistance weld : QW-196
- Volumetric NDE : QW-191 - LBW : QW-197
- Stud weld : QW-192 - Flash welding : QW-199
TABLE QW-253 WELDING VARIABLES PROCEDURE SPECIFICATION-
SMAW
TABLE QW-253 WELDING VARIABLES PROCEDURE SPECIFICATION-
SMAW
 QW-403 BASE METALS
WPS shall be qualified using one of the following
QW-403.5
▪ Same B.M. to be used in production welding

▪ B.M. listed in the same P-Number group no in QW-422 as the B.M. to be

used in production welding

▪ When B.M. of different P-Number group number combinations are

qualified using a single test coupon, that coupon qualifies the welding of
those two P-Number Group number to them selves as well as to each
other using the variable qualified.
 QW-403 BASE METALS
QW-403.5
▪ Procedure qualification shall be made for each P‐Number Group Number
combination of base metals, even though procedure qualification tests
have been made for each of the two base metals welded to itself.
▪ Two or more qualification records have the same essential and
supplementary essential variables, except that the base metals are
assigned to different Group Numbers within the same P‐Number, then
the combination of base metals is also qualified.
QW-403.6
▪ Minimum B.M. thickness qualified is : T or 16 mm whichever is less.
▪ When T is 6 mm or less , Minimum thickness qualified is 1/2T
 QW-404 FILLER METALS
QW-404.4
▪ A change from one F-Number in QW-432 to any other F-Number or to
any other filler metal not listed in table QW-432.

QW-404.5
▪ Change from one A-Number to any other A-Number in table QW-442.

▪ Qualification with A-No 1 shall qualify for A-No.2 & vice versa.
 QW-405 POSITION
QW-405.2

▪ A change from any position to the vertical uphill progression

▪ Vertical uphill progression shall qualifies for all position

▪ In uphill progression, a change from stringer bead to weave bead.

 QW-406 PREHEAT
QW-406.1

Decrease of more than 55° C in the preheat temperature qualified.

Minimum temperature of welding shall be specified in WPS.

QW-406.3

Increase of more than 55° C in in the maximum interpass temperature

recorded on the PQR
 QW-407 POST WELD HEAT TREATMENT
QW-407.2

▪ Procedure qualification test shall be subjected to PWHT essentially

equivalent to that encountered in the fabrication of production weld,
including at least 80% of the aggregate times at temperature.

▪ The total PWHT time and temperature may be applied in one heating
cycle
 QW-409 ELECTRICAL CHARACTERISTICS
QW-409.1
▪ Increase in heat input, or an increase in volume of weld metal deposited
per unit length of weld, for each process recorded in PQR.

Heat Input = Voltage X Amperage X 60

(J/in. (j/mm)) Travel Speed (in./min(mm/min.))

▪ Volume of weld metal measured by :

1. Increase in bead size(W X T)
2. Decrease in length of weld bead per unit length of electrode.
TABLE QW-254 WELDING VARIABLES PROCEDURE SPECIFICATION-SAW
TABLE QW-254 WELDING VARIABLES PROCEDURE SPECIFICATION-SAW
TABLE QW-255 WELDING VARIABLES PROCEDURE SPECIFICATION-
GMAW & FCAW
TABLE QW-255 WELDING VARIABLES PROCEDURE SPECIFICATION-
GMAW & FCAW
TABLE QW-255 WELDING VARIABLES PROCEDURE SPECIFICATION-
GMAW & FCAW
TABLE QW-256 WELDING VARIABLES PROCEDURE SPECIFICATION-
GTAW
TABLE QW-256 WELDING VARIABLES PROCEDURE SPECIFICATION-
GTAW
TABLE QW-256 WELDING VARIABLES PROCEDURE SPECIFICATION-
GTAW
 QW-420 BASE METAL GROUPING
▪ P‐Numbers are assigned to base metals for the purpose of reducing
the number of welding and brazing procedure qualifications required.

▪ P‐Numbers are alphanumeric designations

▪ In addition, ferrous base metals have been assigned Group Numbers

creating subsets of P‐Numbers that are used when WPSs are required
to be qualified by toughness testing by other Sections or Codes.

▪ Group no. indicates base metal characteristics, such as composition,

weldability, brazeability, and mechanical properties.
 QW-420 BASE METAL GROUPING
P- No Group No Met. Spec. Grade Met. Quality & Form

1 SA 515 / SA 516 SA 60 CS – Plate

P1 2 515 / SA 516 70 CS – Plate

1 SA 106 A/B CS – Pipe

P1
2 SA 106 C CS - Pipe
1 SA333 6 CS – Pipe
P1
3 SA 333 10 CS - Pipe
1 SA 234 WPB CS Pipe Fitting
P1
2 SA 234 WPC CS Pipe Fitting
P1 1 SA 285 C/B CS Plate
P1 1 SA 179 --- CS Tube
1 SA 105 --- CS Forging
P1
2 SA 181 Cl 70 CS Forging
 QW-420 BASE METAL GROUPING

P- No Group No Met. Spec. Grade Met. Quality & Form

P3 2 SA 302 A Mn – 0.5 Mo – Plate

3 SA 302 B,C,D Mn – 0.5 Mo – Plate
P3 1 SA 335 P1 / P2 C – 0.5 Mo – Pipe

P3 3 SA 533 TP- B, Cl- 1 or 2 C – 0.5 Mo – Plate

P3 1 SA 209 T1, T1a, T1b C – 0.5 Mo – Tube

P3 2 SA 282 F1 C – 0.5 Mo – Forging

 QW-420 BASE METAL GROUPING

P- No Group No Met. Spec. Grade Met. Quality & Form

P4 1 SA 387 12, Cl –1 / 2 1Cr. 0.5 Mo – Plate

3 SA 387 11, Cl –1 / 2 1.25 Cr. 0.5 Mo – Plate
P4 1 SA 335 P12 / P11 1Cr (1.25 Cr) – 0.5 Mo – Pipe

P4 2 SA 423 TP - 1 / 2 1.25 Cr. 0.5 Mo – Tube

P4 1 SA 282 F12, Cl- 1 / 2 1. Cr – 0.5 Mo – Forging

SA 336 F11, Cl –1 / 2 / 3 1.25 Cr – 0.5 Mo – Forging
 QW-420 BASE METAL GROUPING

P- No Group No Met. Spec. Grade Met. Quality & Form

P5A 1 SA 387 22, Cl –1 / 2 2. 25 Cr. 1 Mo – Plate

P5B 1 SA 387 5, Cl - 2 5 Cr. 0.5 Mo - Plates
P5A 1 SA 335 P22 2. 25 Cr. 1 Mo – Pipe
P5A 1 SA 213 TP - 22 2. .25 Cr. 1 Mo – Tube

P5B 1 SA 182 F5 5 Cr – 0.5 Mo – Forging

P5C 1 SA 182 F22V 2. 25 Cr – 1 Mo,V – Forging
P5A 1 SA 336 F22, Cl –1 / 3 2. 25 Cr – 1 Mo – Forging
 QW-420 BASE METAL GROUPING

P- No Group No Met. Spec. Grade Met. Quality & Form

P6 2 SA 240 TP 429 15Cr. – Plate

P6 4 SA 731 S41500 13Cr., 4.5 Ni, Mo - Pipe
P6 1 SA 268 TP410 13Cr. – Tube
P6 3 SA 336 F6 13Gr.– Forging
P7 2 SA182 F430 17Cr. - Forging
P7 2 SA 240 TP 430 17Cr. - Plate
P7 2 SA 268 TP430 17Cr. Tube
P7 2 SA 731 TP439 18Cr., Ti – Pipe
 QW-420 BASE METAL GROUPING
Group
P- No Met. Spec. Grade Met. Quality & Form
No

1 SA 312 TP321 18Cr., 10Ni, Ti - Pipe

P8
1 SA 312 TP347 18Cr., 10Ni, Cb - Pipe
1 SA336 TP316 18Cr., 8 Ni, 2Mo -Forging
P8
1 SA 336 TP310 25Cr., 20 Ni, Forging
1 SA 240 TP304 18Cr, 8Ni - Plates
P8
2 SA 204 TP309S 23Cr. 12Cr. - Plates
1 SA 249 TP317 18Cr, 13Ni, 3Mo –Tube
P8
1 SA 249 TP316L 16Cr, 12Ni, 2Mo - Tube
 QW-420 BASE METAL GROUPING

Group
P- No Met. Spec. Grade Met. Quality & Form
No

P9B 1 SA 333 3 3.5Ni - Pipe

P9A 1 SA334 7 2.5Ni - Tube
P9A 1 SA 350 LF5, Cl. 2 1.5Ni - Forging
P9B 1 SA 350 LF3 3.5Ni. - Forging
P9A 1 SA 203 A 2.5Ni. - Plate
P9B 1 SA 203 E 3.3Ni. - Plate
 QW-420 BASE METAL GROUPING

P- No Group No Met. Spec. Grade Met. Quality & Form

P11A 1 SA 333 8 9Ni - Pipe

P11A 1 SA334 8 9Ni - Tube

P11A 5 SA 508 4N, Cl. 2 3.5Ni –1.75 Cr.-0.5Mo.- V, Forging

P11A 5 SA 508 5, Cl. 2 3.5Ni –1.75 Cr.-0.5Mo.- V, Forging

P11A 4 SA 533 TP B, Cl. 3 Mn, 0.5 Mo, 0.5Ni – Plate

P11A 4 SA 533 TP C, Cl. 3 Mn, 0.5 Mo, 0.75Ni - Plate
QW-420 BASE METAL GROUPING
QW-424 BASE METAL USED FOR PROCEURE QUALIFICATION
QW-424 BASE METAL USED FOR PROCEURE QUALIFICATION
 QW-432 F- NUMBER GROUPING

F‐Number grouping of electrodes and welding rods in Table QW-432 is

based essentially on their usability characteristics, which
fundamentally determine the ability of welders to make satisfactory
welds with a given filler metal. This grouping is made to reduce the
number of welding procedure and performance qualifications, where
this can logically be done.
 QW-432 F- NUMBER GROUPING
F NUMBER METALS
1,2,3,4,5,6 STEEL AND STEEL ALLOYS
21,22,23,25,26 ALUMINIUM AND ALUMUNIUM ALLOYS
31,32,33,34,35,36,37 COPPER AND COPPER ALLOYS
41.42.43.44.45.46 NICKEL AND NICKEL ALLOY
51,52,53,54,55,56 TITANIUM AND TITANIUM ALLOYS
61 ZIRCONIUM AND ZIRCONIUM ALLOY
71,72 HARDFACING ALLOYS
TABLE QW-442 A-NUMBERS
 HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
2. UNDERSTAND ASME SECTION II PART C

▪ Specification for welding rods, electrode, filler metal– SFA No

▪ AWS Classification of Welding Consumable
▪ Limits for Chemical Composition & Mechanical Properties of Consumables
▪ standard identifies various information necessary for communication
between a purchaser and a supplier of welding consumables
 HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
3. PREPARE WELDING PROCEDURE SPECIFICATION-WPS

▪ WPS Provides Direction for A Specific Welding

▪ WPS Shall Include All Essential, Supplementary Essential & Non Essential
Variables

▪ WPS Format Available in ASME Sec. IX.- Form QW-482

▪ Each WPS Shall be Assigned with A Unique Number.

 HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
4. PREPARE TEST COUPON AS PER WPS

▪ Coupon Size: 500 mm X 150 mm X T

▪ All Other Details as per Written WPS

▪ Complete the Welding by Reasonably Skilled Welder

▪ All Welding Variables Shall be Used Within the Limit Specified in WPS.

▪ All Variables Actually Used Shall be Documented as Annexure to PQR

(Procedure Qualification Record)
 HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
5. NDT OF WELD COUPON

▪ X-Ray / Radiograph the Weld Joint ( Not a Code Requirement)

▪ Mark Transverse Tensile & Guided Bends As Per Figure QW-463.1(a-f)

▪ Eliminate Defective Weld Portion If Any, While Marking the Test Specimens

▪ Preserve RT Report & X-Ray Film as Annexure to PQR

HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
6. MECHANICAL TEST-QW-451
HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
7. SAMPLE REMOVAL-FIGURE QW-463

LESS THAN 19 MM THK. 19 MM AND ABOVE THK.

HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
8. SPECIMEN PREPARATION-FIG. QW-462.1

TENSILE SPECIMEN
HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
8. SPECIMEN PREPARATION-FIG.462.2

SIDE BEND SPECIMEN

HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
8. SPECIMEN PREPARATION-FIG. 462.2

SIDE BEND SPECIMEN

HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
8. SPECIMEN PREPARATION-FIG. 462.3
HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
8. SPECIMEN PREPARATION-FIG. 462.3

FACE-ROOT BEND SPECIMEN

 HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
9. ACCEPTANCE CRITERIA – TENSILE TEST-QW-153

▪ Min. specified T.S. of base metal

▪ Min. specified T.S. of weaker of the two, if base metal of different min. T.S.
are used.
▪ Min. specified T.S. of weld metal when applicable when the applicable section
provides for the use of weld metal having lower room temp. strength than
base metal.
▪ If specimen breaks in the B.M. out side of the weld or weld interface , the test
shall be accepted as meeting the requirements, provided the strength is not
more than 5% below the minimum specified T.S. of the base metal
 HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
9. ACCEPTANCE CRITERIA – BEND TEST-QW-163

▪ specimens shall have no open discontinuity in the weld or heat‐affected zone

exceeding 3 mm, measured in any direction on the convex surface of the
specimen after bending.
▪ Open discontinuities occurring on the corners of the specimen during testing
shall not be considered unless there is definite evidence that they result from
lack of fusion, slag inclusions, or other internal discontinuities.
▪ For corrosion‐resistant weld overlay cladding, no open discontinuity exceeding
1.5 mm, measured in any direction, shall be permitted in the cladding, and no
open discontinuity exceeding 3 mm shall Be permitted along the approximate
weld interface.
 HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
10. PQR FOLDER
▪ PQR Format Available in Sec. IX
- Assign Unique Number to Each PQR
- WPS No Shall be Referred in PQR
- Record All Relevant Data in the Format.
- Record All Mechanical Test Results
▪ Attach All Test Reports & Welding Parameters Used as Annexure to PQR
▪ Attach base metal and consumable TC.
▪ Attach heat treatment request and chart
 HOW TO QUALIFY GROOVE BUTT WELD PROCEDURE?
WPS REMAINS QUALIFIED WHEN

▪ A Procedure Qualification Coupon Is Welded As Per WPS

▪ All Mechanical Tests of The Coupon Are Completed

▪ All Test Results Are Within The Acceptable Limit

▪ The Supporting PQR No Is Referred In The WPS

11-04-2022 71