1Section IX

Welding
 This course covers the requirements of ASME Section IX by reviewing basic welding metallurgy.  Upon completion of the course,
participants will be able to:
• Learn how to achieve economical compliance with ASME Section IX requirements
• Gain experience to interpret, understand and comply with ASME Section IX
• Review welding processes /variables and basic welding metallurgy
• Review the recent changes to Section IX

Who should attend:

• Welding engineers, quality assurance personnel, auditors, testing labratory personnel, maintenance personnel and jurisdictional
inspection personnel
• Anyone involved in qualifying welders, brazers and operators; or others involved in writing and qualifying welding and brazing
procedure specifications
• Those responsible for reviewing supplier procedures, auditing or reviewing in house procedures and qualifications
• Professionals who estimate jobs where compliance of ASME Section IX is mandatory

Special features:
• Emphasis is placed on writing and qualifying welding procedures that follow Section IX
• Requirements for welders, brazers and operators are closely examined
• Time is provided to address specific problems and concerns of the class
Historical perspective of welding and code development

Learn the relationship of Section IX to other codes

Review of the welding process and common variables

Various welding techniques: fuel gas, shielded metal arc, gas tungsten arc, gas metal arc, submerged arc, plasma arc, electroslag,
electrogas, electron beam, stud, friction, resistance

P-numbers, S-numbers and non code metals, steel metallurgy; hardenability; preheat and postweld heat treatment

Filler metal specifications including F-numbers; A numbers; SFA specifications; non SFA filler metals. Subtopics addressed:

1 Writing the welding procedure specification

2 Learn how to meet code while addressing customer requirements

3 How to provide direction to the welder and find

4 Sources of information for preparing intelligent and meaningful welding procedure specifications

Selecting, preparing, and welding the test coupon to obtain maximum cost-effectiveness. Subtopics addressed:

1 Recording both necessary and worthwhile data; demonstrating code compliance

2 Benefit from a practical session: writing the welding procedure specification

3 Use of Section IX form; other formats; procedure qualification record forms; revisions to records and procedures and receive a
take-home test

4 Welder and welding operator qualifications

5 Conducting performance tests and maintain the continuity of qualifications

6 Review supplemental variables special considerations for notch toughness

7 Learn how welding influences toughness; measuring and recording heat input data; translating heat input data into useful
directions for a welder

8 Brazing processes and variables including differences between the QW (welding)and QB (brazing) sections
9 Preparation of the brazing procedure specification

10 Qualification of the brazing procedure; types of tests; qualification of brazers and brazing operators

Section IX of the ASME Boiler and Pressure Vessel Code

Overview
The forms listed below form the basis for verifying welding procedures and welder performance:

←   WPS    - welding procedure specification

←   PQR     - procedure qualification record
←   WPQ    - welder performance qualification 

There are three steps in qualifying welders and welding procedure specifications to Section IX of the
ASME Boiler and Pressure Vessel Code (BPVC).  

First, prepare a welding procedure specification (WPS). The WPS must contain the minimum
requirements that are specified by the code. The WPS provides guidance for welding by specifying
ranges for each variable.

Second, a procedure qualification record (PQR) is used to verify the WPS. The WPS is qualified by
welding procedure qualification test coupons. The variables and tests used are recorded on a PQR.

Third, the performance of the welders is verified by welding performance qualification test coupons.
The variables and tests used with the particular variable ranges qualified are recorded on a welders
performance qualification (WPQ) record.

Another way of conceptualizing these requirements is shown below:

Specify:
Variable ranges
WPS
Essential variables
Nonessential variables
Record:
Actual variables
PQR
Essential variables
Tests and results
Record:
Actual variables
WPQ
Specify Ranges Qualified
Tests and results

Outline of Articles in ASME Section IX 

An abbreviated summary of items covered in ASME Section IX is provided below 

Article I - Welding General Requirements QW-100

Article I covers the scope of ASME Section IX, the purpose and use of the WPS, PQR and WPQ, responsibility, test
positions, types and purposes of tests and examinations, test procedures, acceptance criteria, visual examination, and
radiographic examination.

Article II - Welding Procedure Qualifications QW-200

Article II covers the rules for the preparation of WPS and PQR. Each process is listed separately in QW-250 with the
essential, supplementary essential and nonessential variables.

The WPS shall specify a value or range for each essential, nonessential and, when necessary, each supplementary
essential variable listed for each welding process. The PQR shall record the value for each essential and, when
necessary, each supplementary essential variable used.

When a change is made in an essential variable, the WPS must be revised, and requalified with a new PQR, unless the
revision can be supported by an existing PQR.

Similarly, when the code requires notch-toughness, supplementary essential variables become additional essential
variables. When a change is made in a supplementary essential variable, the WPS must be revised, and requalified by a
new PQR, unless the revision can be supported by an existing PQR for notch-toughness applications.

Article III - Welding Performance Qualifications QW-300

Article III covers the preparation of WPQ records. Each welding process is listed separately in QW-350 with the essential
variables for welding performance. The WPQ form must record a value for each essential variable used and must list a
range qualified for each of these essential variables.

Article III covers responsibility, type of tests, records, welder identification, positions, diameters, expiration and renewal of
qualifications. Welders and Welding Operators may be qualified by visual and mechanical tests, or by radiography of a
test coupon, or by radiography of the initial production weld.

Article IV - Welding Data QW-400

Article IV covers welding variables that are used in the preparation and qualification of the WPS, PQR or the WPQ as
applicable. Some of the welding variables are listed below:

←   Joints ,  Base Materials ,   Filler Materials ,   Positions ,  Preheat ,  Postweld Heat Treatment
←   Gas ,   Electrical Characteristics ,  Technique

Article IV also includes assignments of P-Numbers (ASME base materials), S-Numbers (other materials), F-Numbers
(grouping of filler metals) and A-Numbers (weld metal chemical analysis).

Tables for WPS qualification thickness limits and tables for WPQ thickness and diameter limits are also included. There
are tables for welding positions signifying that a welder who qualifies in a particular position is qualified to weld within a
range of positions as appropriate. Furthermore, test coupons, the removal of test specimens, and the test jig dimensions
are identified.

Article V - Standard Welding Procedure Specifications (SWPS) QW-500

Article V covers rules for the adoption, demonstration, and application of the Standard Welding Procedure Specifications,
(SWPSs).

If your company is experiencing these or other welding issues you can retain AMC to improve your weld processing.  Hire
AMC to act as your welding specialist . 

ASME Travel Policy

How do I become a certified welder? 

You need to take a test. This test is a practical exam that explores your ability to make sound welds. For most
codes there is no written test or training requirements.

Can I do the welding at my facility and send the test assembly to you for evaluation? 

Yes, most Codes do allow this.

Which test do I take?

This is the big question. It all depends on what type of work you are doing and which code you are working to.
Each code has its own test that, if passed, will qualify you to do work to that code and only that code.

Can you give me some examples of the various tests? 

Yes, they are as follows:

A. If you are welding structural steel like a car trailer, a machine support or a handrail, then probably AWS D1.1
is the right thing to do. If you test and pass on a 3/8" thick plate, using a single vee groove with backing, in the
vertical position, you’ll be qualified to weld in the flat, horizontal and vertical positions on 1/8" to 3/4" thick
steel members.

B. If you are welding pipe that is being used to contain a fluid or gas, such as a high temperature water line,
then ASME Section IX is probably the way to go. If you test and pass on a 5" Schedule 80 (3/8" thick wall) steel
pipe in the 6G (45 degree incline position), you will be qualified to weld 2.875" OD pipe, 3/4" wall thickness and
less, in all positions.

Is a welder who has passed an ASME Section IX qualification automatically qualified for AWS D1.1?

No, each Code only qualifies for itself. There is no hierarchy. However, sometimes the owner can be persuaded
that one Code is as good or better than the other.

Are all welds created equal? 

No, there is no such thing as the perfect weld. All welds contain discontinuities. Each Code determines the
extent of the discontinuity before it is classified a defect and must be repaired. For example, B31 .1 does not
allow any lack of penetration. While B31 .9 only requires that the lack of penetration does not exceed more than
1.5" in any 6" length of weld and that the incomplete root penetration does not exceed the lesser of 1/32" or
20% of the required thickness.

If the work is being done to B31.1 and the temperature is 300 F at 500 psig,do we have to RT?

No, these conditions require VT only. (See table 136.4 of B31 .1) or read the above Code section, to determine
when RT/UT is required.

What do I do if work is being done to B31. 1, and the service conditions only require VT, and the owner
requests, outside of the contract, that RT be performed?
Inform him that for the service conditions the Code specifies that only VT be performed. This is due to the fact
that the Code has a large enough safety factor built into the design that even if there were discontinuities
contained inside the weld, that VT could not detect, that it would still give acceptable service life.

How good do the welds have to be if the contract states that conformance to B31. 1 is required and the
service conditions would require only VT by Code, but the contract has a provision that the owner may
perform random RT?

A. If the specifications do not specify what the acceptance criteria is to be, then you could make the argument
that the acceptance criteria is the same for RT as it is for VT. That is, only root and face conditions will be
considered and that any discontinuities contained within the weld will be ignored. This scenario does not raise
the cost of producing the welds. It only increases the cost of inspection.

B. If the specifications state the acceptance criteria, then that quality of weld must be present on all welds. This
scenario could radically increase the cost of producing the welds.

Do we have to produce a weld map to meet the requirements of B31? 

No, The B31 Codes only require that examination be performed on 100% of the welds. A weld map certainly
helps to verify that you have performed this function but it is not required.

Is there a difference between examination and inspection? 

Yes, B31 .1 states that there is a difference between the two. Inspection performs a Quality Assurance function
while examination performs a Quality Control function. That is, the examiner is the one who physically
performs the NDE and records the results. An inspector has the right to audit any examination, to inspect the
piping using any appropriate examination method required by the engineering design of the Code, and to
review all certifications and records. The intent of B3.1 is to have the contractor perform the examination and
the owner perform inspection

Do we have to hire an outside testing agency to meet the VT requirements for B31. 1?

No, Paragraph 136.3.1 states that examination denotes the function performed by the manufacturer, fabricator,
erector or a party authorized by the owner. Paragraph 136.3.2 states the requirements for that examiner. The
examiner can be qualified to SNT-TC-1A, CP-189, AWS QC-1 or may be someone that has been qualified in
accordance with a program that is based on the following requirements-

a. instruction in the fundaments of the NDE method;

b. on-the-job training;

c. an eye examination performed at least once each year;

d. pass an oral or written examination

e. shall have performed the NDE method at least once per year.

We have a job where the piping system is clearly within the scope of B3 1.9 and outside the scope of
B31. 1; however, the contract requires B31. 1. Can we perform the work to B31.9? 

No, if the contract requirements exceed the Code requirements you must meet the contract requirements. In
this case the work would have to be performed in accordance with B31 .1. It could benefit both parties to review
the requirements after the contract is signed. If the owner is enlightened to the fact that the higher quality
requirements will not increase service life, a change to the appropriate code could result in savings to the
owner and additional profit to the contractor.