PELATIHAN INSPEKTUR BEJANA TEKAN

WELDING

ASME Sect. IX

Rev. 10 – Nov 2019

 DEFINITIONS

WELDING :
A joining process that produces coalescence of
materials by heating them to the welding
temperature, with or without the application of
Purwidiatmo

pressure or by pressure alone, and with or

without the use of filler metal.

(by AWS A3.0 / ASME Sect. IX )

 WELD
WELD METAL
BASE METAL
Purwidiatmo

T wm > T bm
 WELDING CODE

Provide
Rules, requirements, tolerances, etc. to assure
that the production weld will comply with code
requirements.
Purwidiatmo
 ASME CODES

Boiler & P. Vessel Code

CONSTR. / MAIN CODE REFERENCE CODE
•Sect. I •Sect. II
•Sect. III •Sect. V
Purwidiatmo

•Sect. IV •Sect. IX
•Sect. VIII div. 1, 2, 3 Qualification Standard for :
Welding and Brazing Proce -
•Sect. X
dures, Welders, Brazers, and
•Sect. XI Welding, Brazing & Fusing
Operators
•Etc.
 ASME SECTION IX

PART QG - General Requrement

PART QW. - Welding PART QF – Plastic Fusing

• Art. I - General Req. • Art. XXI - General Req.
• Art. II - W. Proc. Qual.
• Art. XII - Proc. Qual.
• Art. III - W. Perfm. Qual.
Purwidiatmo

• Art. IV - W. Data • Art. XXIII - Perf. Qual.

• Art. V - SWPS • Art. XXIV - Data

PART QB - Brazing • Appendix

• Art. XI - General Req. Mandatory, Nonmandatory
• Art. XII - B. Proc. Qual. • Tech. Inquiries to B & PV
• Art. XIII - B. Perf. Qual. Committee
• Art. XIV - B. Data
 ASME SECTION IX - Article I

WELDING GENERAL REQUIREMENTS

QW – 100 SCOPE
Welding General Requirement

• Preparation and qualification of WPS, Welders & Welding

Operators

QW – 101
• Any WPS shall be qualified in accordance with Article II or an
AWS Standard Welding Procedure Specification (SWPS) -
prior to production welding,

QW – 102
• Performance qualification is to determine Welder’s ability to
deposit sound weld metal
 ASME SECTION IX - Article I

QW - 103 Responsibility :
Each organization :
Welding General Requirement

• Welding : Conduct the tests required to qualify Welding

Procedures and the performance of Welders and Welding
Operators
• Records : shall maintain a record of the results obtained in
welding procedure, welder and welding operator
qualification.

QW - 110 Weld orientation :

See QW - 461.1 for groove weld and QW - 461.2 for fillet weld
 ASME SECTION IX - Article I

QW - 120 Test positions for Groove welds :

Test coupon may be made in any position of QW-461.3 or 461.4,
Welding General Requirement

with angular deviation of :

− 15 O from the specified Vertical & Horizontal plane
− 5 O from the specified incline plane

QW - 121 Plate positions : IG, 2G, 3G & 4G

QW - 122 Pipe positions : IG, 2G, 5G & 6G

 ASME SECTION IX - Article I
QW - 121 Plate positions - Groove Welds
Welding General Requirement

1G 2G

3G 4G
 ASME SECTION IX - Article I
QW - 122 Pipe positions - Groove Weld
Welding General Requirement

00 + 150
900 + 150

1 G - rotate 2 G - rotate / fix

00 + 150
450 + 50

5 G - fix 6 G - fix
 ASME SECTION IX - Article I

QW - 130 Test positions for Fillet welds :

• Test coupon may be made in any position of QW - 461.5 or
Welding General Requirement

461.6, with angular deviation of :

+ 15 O from the specified Vertical & Horizontal planes

QW - 131 Plate positions : IF, 2F, 3F & 4F

QW - 132 Pipe positions : IF, 2F, 2FR, 4F & 5F

 ASME SECTION IX - Article I
QW - 131 Plate positions - Fillet Weld
Welding General Requirement

1F
2F

3F 4F
 ASME SECTION IX - Article I
QW - 132 Pipe positions - Fillet Weld
Welding General Requirement

1 F - rotate 2F 2 FR - rotate

5F - Fix
4F
 ASME SECTION IX - Article I

QW - 140 Types and purposes of tests & examinations

QW - 141 Mechanical tests

Welding General Requirement

Tension tests
• Determine the ultimate strength of groove-weld joints

Guided bend tests

• Determine the degree of soundness & ductility of groove-weld
joints

Fillet weld tests

• Determine the size, contour & degree of soundness of fillet-welds
Notch-toughness tests
• Determine the notch-toughness of the weldment.
 ASME SECTION IX - Article I

QW - 142 Special examination

• For performance qualification; Radiographic examination may be
Welding General Requirement

substituted for mechanical testing ( subject to limitation of QW-

304) for groove welds to prove the ability of welders to make sound
weld

QW - 144 Visual examination

• Determine the final weld surfaces meet specified quality standards
(QW-194)
 ASME SECTION IX - Article I

QW - 150 Tension tests

QW-151 Specimens : - Removal ( QW-463, fr. 202 )
Welding General Requirement

- Prep. see QW - 462.1(a) ~ (e)

 ASME SECTION IX - Article I

QW-152 Tension Test Procedure

- Specimen shall be ruptured under tensile load
Welding General Requirement

- Tensile Strength = Ultimate load / Cross section

Ts = F/A
QW-153 Acceptance criteria
Tensile strength shall not be less than :
- MSTS of the base metal ( QW-422 )
- MSTS of the weaker base metal
- 95% of MSTS of the base metal, if broke in the base
metal outside of the weld or fusion line
 ASME SECTION IX - Article I

QW - 160 Guided bend tests

Materials with elongation < 3%  use macro etch (2019) ‘19
Welding General Requirement

• QW-161 Specimens : - Thk & bend radius (Fig QW 466 .1 ~ 4)

- Removal ( QW-463, fr. 202 )
- Prep. (QW - 462.2 & 462.3)
- Face bend ( transverse & longitudinal )
- Root bend ( transverse & longitudinal )
- Side bend ( transverse )

• QW-163 Acceptance criteria

- No open defect more than 1/8” (3 mm) in any direction
- Open defect on the corner, shall not be considered, unless
caused : Lack of fusion, slag inclusions or other internal
discontinuity
 ASME SECTION IX - Article I

QW - 160 Guided bend tests

General Requirement

FACE BEND ROOT BEND SIDE BEND

 ASME SECTION IX - Article I

QW - 170 Notch toughness tests

• All requirements shall refer to the section specifying
Welding General Requirement

impact requirements & SA - 370 for procedure

QW - 180 Fillet-weld tests

• Specimens : - Removal ( QW-181.1 - 181.2 & - 462.4 )
- Prep. ( QW-462.4 & - 183 )
• Acc. Criteria see QW-183, for Procedure Qualification,
QW-184, for Welder
 ASME SECTION IX - Article I

QW - 183 Macro-examination - for Procedure

Weld metal & HAZ shall show :
Welding General Requirement

- Complete fusion & free from cracks

- Size of legs shall not differ by more than 1/8” (3 mm)

QW - 184 Macro-examination - for Performance

Weld metal & HAZ shall show :
- Complete fusion & free from cracks
- Linear indication at the root shall not more than 1/32” (0.8 mm)
- Concavity & Convexity shall not more than 1/16” (1.5 mm)
- Size of legs shall not differ by more than 1/8” (3 mm)
 ASME SECTION IX - Article I
QW - 191 Volumetric NDE - for Performance
QW-191.1 Technique : - Sect. V Article 2
Welding General Requirement

QW-191.1 Radiographic Examination:

- Linear Indications : L> 3 W
- Rounded Indications : L ≤ 3 W
Rounded indication charts (for RT)

QW-191.2 Ultrasonic Examination

QW - 194 Visual Examination - for Performance
Acc. Criteria :
Test coupon shall show complete joint penetration &
complete fusion
 ASME SECTION IX - Article I

QW - 195 Liquid Penetrant Examination

QW-195.1 Technique : - Sect. V Article 6
Welding General Requirement

QW-195.2 Acceptance Criteria :

- Relevant Linear Indications
- Relevant Rounded Indications
 ASME SECTION IX - Article II
WELDING PROCEDURE QUALIFICATIONS
QW-200.1
‘19
Welding Procedure Qualifications

Each Organization shall prepare written WPS:

a. Welding Procedure Specification ( WPS )
Is a written qualified welding procedure prepared to provide direction
to the welder or welding operator for making production welds to
code requirements.
b. Contents
Essential, non essential & supplementary essential (if any) and
reference supporting PQR
c. Changes
May be made in the nonessential variables, provided such changes
are documented
May be by amendment to WPS or by use of new WPS
d. Format
Any format as long as all variables are included
 ASME SECTION IX - Article II
QW-200.2
Each Organization shall prepare written PQR
Welding Procedure Qualifications

a. Procedure Qualification Record ( PQR )

Is a record of variables recorded during the welding of the test
coupon , its also contains the test results of the tested specimens.
b. Contents
Actual variables used (of each process) during the welding and shall be
certified by Organization
c. Changes
Changes to the PQR (content - including date) is not permitted except
editorial corrections or addenda
d. Format
Any format as long as all variables, type & number of tests and test
results are included
e. Availability
Shall be available for reference & review by the Authorize Inspector
f. Multiple WPSs with one PQR or Single WPS with multiple PQRs may be
used
 ASME SECTION IX - Article II

QW-200.3 P-Number (see QW / QB - 422)

• To reduced the number of WPS .
Welding Procedure Qualifications

• Assigned based on : Composition, Weld ability & Mechanical

properties.

QW-200.4 Combination of Welding Procedures

More than one Procedures having different processes or variables
may be used in one single production joint.
Limits : - The essential, nonessential & supplementary variables are
applied
- Base metal thickness ‘T’ & deposit weld metal thickness
!!! ‘t’ range shall comply to QW-451
- For root deposit only, may qualify for greater T if the test
coupon is at least 1/2” (13 mm)
 ASME SECTION IX - Article II

QW-201 Organizational Responsibility

• The Organization shall certify that he has qualify each WPS,
Welding Procedure Qualifications

performed the qualification test and documented it with

necessary PQR (see also QG – 106)
 ASME SECTION IX - Article II
QW-202 Type of tests required
QW-202.1 Mechanical Tests
Welding Procedure Qualifications

• Type & number of test specimen : see QW-451

• Removal : see QW-463
• If any test specimen fails, the test coupon is considered failed
QW-202.2 Groove and Fillet Welds ‘19

• The thickness ‘ t ‘ of deposited weld metal in QW-451, shall be

exclusive of weld reinforcement
QW-202.3 Weld repair and buildup.
• Groove weld WPS applicable for weld repairs to groove weld
& fillet weld and for buildup.
• Except for fillet welds, the T & t range shall comply to
QW- 451
 ASME SECTION IX - Article II

QW-202.4 Dissimilar Base Metal Thickness

Groove weld WPS applicable for production welds dissimilar base
Welding Procedure Qualifications

metal thickness
• The range of T & t of the thinner and thicker base metal shall
comply to QW-451 (exceptions for P No. 8, 41~46, 51~52 &
61~62)
• More than one procedure qualification may be required to qualify for
some dissimilar thickness combination

QW-203 Limits of Qualification Position

• Qualification in any position, qualifies the procedure for all
positions, the process & electrode must be suitable for the
positions. - see QW-250 for limitation
• Welder/operator making the WPS qualification, qualified for
the position tested - see QW-301.2
 ASME SECTION IX - Article II

QW-210 Preparation of test coupon

• Base metal : Either plate or pipe, will qualify vice-versa
Welding Procedure Qualifications

• Type & dimension for groove welds : Are not essential -

see QW-250 for limitation

QW-250 Welding variables

• Essential - Requalification is req’d if change made
• Non essential - No requalification req’d
• Supplementary - Essential if notch-toughness is req’d
 ASME SECTION IX - Article III

WELDING PERFORMANCE QUALIFICATIONS

Welding Performance Qualifications

QW-300.1 General ‘19

A Welder / Operator may be qualified By :

- Volumetric NDE of a test coupon or the initial production
welding ( limitation see QW - 304 )
- Bend tests taken from a test coupon
The qualification certificate start from the date welding of test
piece was completed
 ASME SECTION IX - Article III
QW-301.1 Intent of tests
• To determine the ability of welders and w. operators to make
Welding Performance Qualifications

sound welds
QW-301.2 Qualification tests
• Each Organization shall qualify each welder or w. operator
for each welding process will be used in accordance with
qualified WPS
• The welder or w. operator who performs the WPS
qualification is qualified within the limit of QW-304 or QW-
305 for positions specified in QW-303

QW-301.3 Identification of welder or w. operator

• Each qualified welder or operator shall be assigned an
identification no. / letter/ symbol.
 ASME SECTION IX - Article III

QW-301.4 Record of tests

Welding Performance Qualifications

• Test results and the essential variables shall be recorded ,

suggested form see Appendix B

QW-302 Type of test required

QW-302.1 Mechanical tests

• Removal : - QW-463.2 for groove weld
- QW-462.4 for fillet weld
• Type & no. : QW-452
• Acc. Criteria : QW-160 0r QW-180
 ASME SECTION IX - Article III

QW-302.2 Volumetric NDE

• Min. length : 6” (150mm)
Welding Performance Qualifications

• Shall include the entire weld circumference for pipe

• For small dia. Pipe, multiple coupons req’d (need not exceed 4)

QW-302.4 Visual examination

• Acceptance criteria for plate & pipe, see QW - 194
QW-303 Limits of Qualified positions & Diameters
( see QW - 461.9 & QW - 452.3 )
QW - 303.1
• Welder who pass for groove weld, also qualified for fillet
welds in all thicknesses and pipe diameters of any size within
the limit of QW-350
 ASME SECTION IX - Article III
QW-304 Welders
• Welder shall pass the Mechanical & visual examinations
Welding Performance Qualifications

• Alternative : For SMAW, SAW, GTAW, PAW, GMAW

(other than SCM), Volumetric NDE (RT or UT) may be used except for
P-No. 2X, 5X & 6X metals, P-No. 2X & 5X metals with GTAW may
also qualified by Volumetric NDE
• A welder qualified according to one WPS also qualified to weld
according to other WPSs with the same welding process & within the
limit of essential variables

QW-304.1 Examination
• Test coupon : - Visual and Mechanical Exam.
- Volumetric NDE as per QW - 304
• Production test : 6” length of first production weld by Volumetric
NDE . ( see also QW-304.2)
 ASME SECTION IX - Article III
QW-305 Welding Operator
• Operator shall pass the Mechanical & visual examinations
Welding Performance Qualifications

• Alternative : For SMAW, SAW, GTAW, PAW, EGW & GMAW

(other than SCM), Volumetric NDE (RT or UT) may be used except
for P-No. 2X, 5X & 6X metals, P-No. 2X & 5X metals with GTAW
may also qualified by Volumetric NDE
• A n operator qualified according to one WPS also qualified to weld
according to other WPSs with the same welding process & within the
limit of essential variables

QW-305.1 Examination
• Test coupon : - Visual and Mechanical Exam.
- Volumetric NDE as per QW - 305
• Production test : 3’ length of first production weld by Volumetric
NDE . (see also QW-305.2)
 ASME SECTION IX - Article III

QW-306 Combination process

• Welder or Welding Operator qualified in combination
Welding Performance Qualifications

process in single test coupon, also qualified on his processes

individually within the limit of the essential variables.
• A Welder may use one test coupon for several processes
• Two or more welders may use the same test coupon with the
same or different processes
QW-320 Retest & Renewal of Qualification
QW-321.1 Immediate retest using Visual Exam.
• Two consecutive test coupons is required

QW-321.2 Immediate retest using Mechanical test

• Two consecutive test coupons is required
 ASME SECTION IX - Article III

QW-321.3 Immediate retest using Volumetric NDE

• Test coupon :
Welding Performance Qualifications

- Plate : two 6 in length plate coupons

- Pipe : two pipe coupons ( multiple coupons need
not exceed 8 )
• Prod. Test : - Welder : 12 in length
- Operator : 6 ft length

QW - 321.4 Further Training

• A new test coupon required ( one coupon only )
 ASME SECTION IX - Article III

QW-322.1 Expiration of qualification

Welding Performance Qualifications

a. The welder/operator has not welded for 6 months or more

b. Where there is specific reason to question his ability.

QW-322.2 Renewal of Qualification

• Under QW-322.1 (a) : By welding a single test coupon of plate or
pipe, of any material, thickness or diameter, in any position and by
testing of the coupon as per QW-301 and QW-302
• Under QW-322.1 (b) : A new test coupon shall be made
 ASME SECTION IX - Article III

QW - 350 Welding variables for Welders

• see QW - 352 ∼ 357
Welding Performance Qualifications
 ASME SECTION IX - Article IV

WELDING DATA

• List of essential, supplementary essential & non essential

variables
• The information of this article shall not be used unless its
Welding Data

referred by other article

 ASME SECTION IX - Article V

STANDARD WELDING PROCEDURE SPECIFICATION

(SWPS)
QW-500
• Acceptable SWPSs listed in Appendix E
• Not permitted when impact test is required
SWPS

QW-510
• Manufacture shall weld and test 1 (one) groove weld test coupon
• The coupon shall be Visually Inspected (QW-302.4) and Mech.
Tested (QW-302.1) or RT (302.1)
 ASME SECTION IX - Article V
STANDARD WELDING PROCEDURE SPECIFICATION
(SWPS)
QW-520 ( Ess. Var.)
• Welding Process
• P or S Number
• Heat treatment
SWPS

• Gas shield to self shield ->FCAW to FCAW G or v.v.

• Transfer mode
• F - Number
• Add. preheat above ambient temp
• etc.
 ASME SECTION IX - Article V
STANDARD WELDING PROCEDURE SPECIFICATION (SWPS)
QW-540 (production requirements) ‘19

• Welding must be done in strict accordance with the SWPS

• May not deviate from conditions specified
• SWPSs may not be supplemented with PQRs
SWPS

• Only the welding processes shown on an SWPS shall be used

• Shall not be used in the same prod. joint together with WPSs
• Can’t be used until demonstrated (welded, tested and
certified)
• Supporting demonstration ident.no. shall be shown on SWPS
• The certified supporting demonstration record available for
review by AI
 QW-452 PERFORMANCE QUALIFICATION THICKNESS LIMITS AND TEST SPECIMENS
QW-452.1 Groove-Weld Test. The following tables identify the required type and number of tests and the thiclrness
of weld metal qualified.

(19) Table QW-452.l(a)

Test Specimens
Type and Number of Examinations and Test Specimens Required
Face Bend Root Bend
QW-462.3(a) or QW-462.3 (a) or
Visual Side Bend QW-462 .3 (b) QW -462.3 (b)
Thiclmess of Weld Metal, Examination QW-462.2 [Note (1)], [Note (1)],
in. (mm) per QW<l02.4 [Note (1)] [Note (2)] [Note (2)]
l..ess !han %(10) X 1 1
%(10) to less than 1. (19) X 2 [Note (3))
3
/4 (19) and over X 2

GENERAL NOTE: The ''Thickness of Weld Metal" is the total weld metal thickness deposited by all welders and all
processes in the te~t coupon exclusive of the weld reinforcement.
NOTES:
(1) To qualify using positions 5 ' or 6G a total o four bend SJ!ccimcns arc rc uircd To qualij)! using a combina-
tion of 2G and SG in a s ingle test coupon, a total ot\s ix bend specimens are required see QW-302.3. The type
of bend te~t shall be based on weld metal thickness.
(2) Coupons tested by face and root bends shall be li mited to weld deposit made by one welder with one or two
processes or two welders with one process each. Weld deposit by each welder and each process shall be pres-
ent on the convex surface of the appropriate bent specimen.
(3) One face and root bend may be substituted for the two side bends. For a test coupon welded in the SG or 6G
position, two face and two root bends may be substituted for the four si de bends in accordance with Fi b'l.tre
QW-463.2(d). For a te~t coupon welded using a combination of2G and SG positions, three face and three root
bends may be substituted for the s ix side bends in accordance with Figure QW-463.2 (f) or Figure
W-463.2 '
 Table QW-452.l(b)
Thickness of Weld Metal Qualified
Thickness, t, of Weld Met al in Thickness of Weld
the Coupon, in. (mm) Metal Qualified
]Not e (1)] and [Note (2)] [Note (3)]

All 2t
~[11) and over with a
1
Maximum to be
minimum of three layers welded

NOTES:
(1) When more than one welder and/or more than one process
and more than one filler metal F- Number is used to deposit
weld metal in a coupon, the thickness, t , of(.\IDy,elqJJi"]taUin
the coupon deposited by each weldc~ w ith each rocess and
each filler metal E-Number in accordance with the applicable
variables under QW-404\ihal lJ>~..ch;tcl:IJii )lqlVand: usedJ.nd jy j-'
dually in the "Thickness,_t of Weld Metal in the Coupon" col-
umn to determine the •Thickness of Weld Metal Qualified."
(2) Two or more pipe test coupons with di fferent wel d metal
thickness may be used to determine the weld metal thickness
qualified and that thickness may be applied to production
welds to the smallest diameter for which the wel der is quali-
fi ed in accordance with Table QW-452.3.
(3) Thickness oftest coupon of 3~(1,9_m.Jl1Lor 0.\:'~!) shall be
used for qualify ing a combination of~lir,e<;...qunqL~S)dcrsJ
each of whom may use the same or a different wel ding process.