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Welding Procedure Specification
4.3 Production Welding Positions Qualified
The production welding positions qualified by a WPS shall conform to the requirements of Table
4.1.
4.4 Type of Qualification Tests
The type and number of qualification tests required to qualify a WPS for a given thickness,
diameter, or both, shall
conform to Table 4.2 (CJP), Table 4.3 (PJP) or Table 4.4 (fillet). Details on the individual NDT
and mechanical test
requirements are found in the following subsections:
(1) Visual Inspection (see 4.8.1)
(2) NDT (see 4.8.2)
(3) Face, root and side bend (see 4.8.3.1)
(4) Reduced Section (see 4.8.3.4)
(5) All-Weld-Metal Tension (see 4.8.3.6)
(6) Macroetch (see4.8.4)
C4.4 Type of Qualification Tests
Table 4.2 summarizes the requirements for the number and type of test specimens and the range of
thicknesses qualified.A test plate thickness of 1 in. [25 mm] or over qualifies a WPS for unlimited
thickness. The 1 in. [25 mm] thickness has been shown to generally reflect the influence of weld
metal chemistry, heat input, and preheat temperature on the weld metal and HAZ. The term
direction of rolling was made optional in the 1988 edition, although the mechanical properties of
steel plate may vary significantly with the direction of rolling and may affect the test resultsFor
example, tensile strength and impact toughness are often greater in the longitudinal direction than
in the transverse direction unless cross rolling is used. Similarly,the rolling direction shown in the
sketches often gives better results in the bend tests. For some applications, toughness results are
required and the direction of rolling should be referenced on the test results.
The WPS qualification for pipe includes conditions for large diameter job size pipe. This is
intended for WPS qualification of large diameter pipe by automatic welding processes, such as
SAW, and may be applied to any welding process that can be used on large diameter pipe, but not
on 8 in. [200 mm] Sch. 120 pipe.
4.5 Weld Types for WPS Qualification WPS For the purpose of WPS qualification, weld types
shall be classified as follows:
(1) CJP groove welds for Nontubular Connections
(2) PJP groove welds for Nontubular Connections (see 4.10)
(3) Fillet Welds for Tubular and Nontubular Connections (see 4.11)
(4) CJP groove welds for Tubular Connections (see 4.12)
(5) PJP groove welds for Tubular T-, Y-, and Kconnections and Butt Joints.(see 4.13)
(6) Plug and Slot welds for Tubular and Nontubular Connections (see 4.14)
4.6 Preparation of WPS
The manufacturer or Contractor shall prepare a written WPS that specifies all of the applicable
essential variables referenced in 4.7. The specific values for these WPS variables shall be obtained
1
from the procedure qualification record
(PQR), which shall serve as written confirmation of a successful WPS qualification.
4.7 Essential Variables
C4.7 Essential Variables
This code allows some degree of departure from the variables used to qualify a WPS. However,
departure from variables which affect the mechanical or chemical composition of material
properties, or soundness of the weldment shall not be allowed without requalification. These latter
variables are referred to as essential variables. The base metal essential variables are listed in
4.7.3. The welding process essential variables are listed in 4.7.1. The positions of test welds are
listed in 4.2.4. Changes in these variables beyond the variation allowed by the subject subsections
shall require requalification of the WPS. Similarly, changes beyond those shown in 4.7.2 require
requalification using RT or UT only.
These essential variables are to be specific in the WPS document and followed in welding
fabrication.
4.7.1 SMAW, SAW, GMAW, GTAW, and FCAW.
Changes beyond the limitations of PQR essential variables for the SMAW, SAW, GMAW,
GTAW, and FCAW processes shown in Table 4.5 and Table 4.6, when CVN testing is specified,
shall require requalification of the WPS (see 4.1.1.3).
C4.7.1 SMAW, SAW, GMAW, GTAW, and FCAW.
Travel speed affects heat input, weld cooling rates, and weld metallurgy, which are important
for the HAZ, for fracture toughness control, and for welding quenched and tempered steels. Proper
selection of travel speed is also necessary to avoid incomplete fusion and slag entrapment.
4.7.2 ESW and EGW.
See Table 4.7 for the PQR essential variable changes requiring WPS requalification for the EGW
and ESW processes.
4.7.3 Base-Metal Qualification.
Base metals listed in Table 3.1 that are subject to WPS qualification testing shall qualify other
base metal groups in conformance with Table 4.8. Base metals not listed in Table 3.1 or Annex M
shall be qualified in conformance with Section4, and have the Engineer’s approval.
WPSs with steels listed in Annex M shall also qualify Table 3.1 or Annex M steels in
conformance with Table 4.7. Annex M contains recommendations for matching strength filler
metal and minimum preheat and interpass temperatures for ASTM A 514,A 517, A 709 Grades 100
and 100W, ASTM A 710 Grade A (Class 1 and 3) steels, and ASTM A 871 Grades 60 and 65.
Preheat and interpass temperatures lower than required per Table 3.2 or calculated per Annex XI
shall be qualified by tests approved by the Engineer.
4.8 Methods of Testing and Acceptance Criteria for WPS Qualification
The welded test assemblies conforming to 4.8.2 shall have test specimens prepared by cutting
the test plate, pipe, or tubing as shown in Figures 4.7 through 4.11, whichever is applicable. The
test specimens shall be prepared for testing in conformance with Figures 4.12, 4.13, 4.14 and 4.18,
as applicable.
4.8.1 Visual Inspection.
For acceptable qualification, welds shall meet the following requirements:
(1) The weld shall be free of cracks
2
(2) All craters shall be filled to the full cross section of the weld.
(3) The face of the weld shall be flush with the surface of the base metal, and the weld shall
merge smoothly with the base metal. Undercut shall not exceed 1/32in.[1 mm]. Weld
reinforcement shall not exceed 1/8in.[3 mm].
(4) The root of the weld shall be inspected, and there shall be no evidence of cracks, incomplete
fusion, or inadequate joint penetration. A concave root surface is allowed within the limits shown
below, provided the total weld thickness is equal to or greater than that of the base metal.
(5) The maximum root surface concavity shall be 1/16 in. [2 mm] and the maximum melt-
through shall be 1/8 in. [3 mm].For tubular T-, Y-, and K-connections, melt-through at the root is
considered desirable and shall not be cause for rejection.
4.8.2 NDT.
Before preparing mechanical test specimens, the qualification test plate, pipe, or tubing shall be
nondestructively tested
for soundness as follows:
C4.8.2 NDT.
All WPS qualification test plates or test pipes shall be subjected to RT or UT to demonstrate
soundness before mechanical testing, regardless of the welding process used. Additionally, NDT
reduces the expense and delays that result rom machining and testing welds having discontinuities
prohibited by the code.
4.8.2.1 RT or UT.
Either RT or UT shall be used. The entire length of the weld in test plates, except the discard
lengths at each end, shall be examined in conformance with Section 6, Part E or F. For tubulars,
the full circumference of the completed weld shall be examined in conformance with Section 6,
Part C.
4.8.2.2 RT or UT Acceptance Criteria.
For acceptable qualification, the weld, as revealed by RT or UT, shall conform to the
requirements of Section 6, Part C.
4.8.3 Mechanical Testing.
Mechanical testing shall be as follows:
4.8.3.1 Root, Face, and Side Bend Specimens (see Figure 4.12 for root and face bends, Figure 4.13
for side bends).
Each specimen shall be bent in a bend test jig that meets the requirements shown in Figures
4.15 through 4.17 or is
substantially in conformance with those figures, provided the maximum bend radius is not
exceeded. Any convenient means may be used to move the plunger member with relation to the
die member.
The specimen shall be placed on the die member of the jig with the weld at midspan. Face bend
specimens shall be placed with the face of the weld directed toward the gap. Root bend and fillet
weld soundness specimens shall be placed with the root of the weld directed toward the gap. Side
bend specimens shall be placed with that side showing the greater discontinuity, if any, directed
toward the gap.
The plunger shall force the specimen into the die until the specimen becomes U-shaped. The
weld and HAZs shall be centered and completely within the bent portion of the specimen after
testing. When using the wraparound jig, the specimen shall be firmly clamped on one end so that
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