Pipeline Systems PLSC0017 Requirements for Welder Qualifications in Accordance with ASME Section IX

Transcription

1 June 2018 Pipeline Systems PLSC0017 Requirements for Welder Qualifications in Accordance with ASME Section IX

2 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All Practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these Practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice. This Practice is subject to revision at any time. Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3925 West Braker Lane (R4500), Austin, Texas PIP Member Companies and Subscribers may copy this Practice for their internal use. Changes or modifications of any kind are not permitted within any PIP Practice without the express written authorization of PIP. Authorized Users may attach addenda or overlays to clearly indicate modifications or exceptions to specific sections of PIP Practices. Authorized Users may provide their clients, suppliers and contractors with copies of the Practice solely for Authorized Users purposes. These purposes include but are not limited to the procurement process (e.g., as attachments to requests for quotation/ purchase orders or requests for proposals/contracts) and preparation and issue of design engineering deliverables for use on a specific project by Authorized User s client. PIP s copyright notices must be clearly indicated and unequivocally incorporated in documents where an Authorized User desires to provide any third party with copies of the Practice. PRINTING HISTORY June 2018 Issued Not printed with State funds

3 June 2018 Pipeline Systems Standards for Welder Qualifications per ASME Section IX Table of Contents 1. Scope References Process Industry Practices Industry Codes and Standards Requirements General Qualification Test Visual Examination of a Qualification Weld Destructive Testing Limits of Welder Qualification Re-Test of a Failed Destructive Qualification Exam Requalification by Non-Destructive Testing Re-Test of a Failed Non-Destructive Qualification Exam Revoking Certifications Certification Re-instatement Records... 8 Process Industry Practices Page 1 of 11

4 1. Scope This Practice provides minimum requirements for qualifying welders in accordance with ASME Section IX Code. Welder qualification tests are given to determine the ability of the welder to make sound welds using qualified weld procedures (WPS). For welder qualification requirements in accordance with API 1104, see PIP PLSC References Applicable parts of the following Practices and industry codes and standards shall be considered an integral part of this Practice. The edition in effect on the date of contract award shall be used, except as otherwise noted. Short titles will be used herein where appropriate. 2.1 Process Industry Practices (PIP) PLSC Requirements for Welder Qualifications in Accordance with API Industry Codes and Standards 3. Requirements The American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section IX: Welding and Brazing Qualifications American Petroleum Institute 3.1 General API Welding of Pipelines and Related Facilities The qualification of welders shall be conducted by and in the presence of an authorized American Welding Society Certified Welding Inspector (CWI) All welders shall initially qualify by destructive testing, unless non-destructive testing (NDT) is authorized for butt welds only as an exception by an authorized CWI Before starting the qualification test, the welder shall be permitted a reasonable amount of time to adjust the welding equipment used in the test The welder shall comply with all essential and non-essential variables of the qualified welding procedure during the test The welder shall demonstrate safe welding practices and wear appropriate personal protection equipment (PPE) during the qualification test. Process Industry Practices Page 2 of 11

5 3.2 Qualification Test A welder who has successfully completed a qualification test in accordance with Sections 3.3 and 3.4 of this Practice shall be permitted to perform production welding within the limits of Section 3.5 for one six-month qualification interval The qualification can be extended an additional six months by non-destructive qualification in accordance with Section A welder qualifying to the requirements of an approved welding procedure shall make test welds in accordance with all requirements specified in the welding procedure The ASME Code Section IX qualification test shall consist of two weld samples joined in accordance with ASME Code Section IX Unless otherwise approved by the owner representative, a welder shall test on pipe as follows: a. Pipe greater than or equal to 6 inches ( mm) OD b. Pipe less than or equal to 2-7/8 inches (73.0 mm) OD For the shielded metal arc welding (SMAW), gas tungsten arc welding (GTAW), gas metal arc welding (GMAW) and flux-cored arc welding (FCAW) processes the welder shall make a butt weld in the fixed position with the axis of the pipe in the 6G position (i.e., 45-degree incline) To qualify to weld pipe less than 2-7/8 inches (73.0 mm) OD, test welds shall be made on pipe less than 2-7/8 inches (73.0 mm) OD without a backing strip or consumable insert. See Section items I and J. Two test welds are required to provide enough material for the removal of the required number of test specimens To qualify to weld pipe 2-7/8 inches (73.0 mm) OD and greater, the test weld shall be made as follows: a. On pipe 6 inches ( mm) OD minimum without a backing strip or consumable insert. b. If qualifying on carbon steel, the pipe shall have a nominal diameter of 6 inches ( mm) minimum and a wall thickness of inch (12.7 mm) minimum Unless a deviation is approved by formal written exception signed by the owner representative, a welder qualifying in part or whole using the SMAW process shall successfully complete the examinations referenced in Sections 3.1 and 3.2 to be considered qualified in accordance with ASME Section IX Code. 3.3 Visual Examination of a Qualification Weld For a qualification test weld to be in accordance with the requirements for visual examination, the weld shall be free of cracks, inadequate penetration, unrepaired burn through, and other defects, and present a neat, workmanlike appearance Undercutting adjacent to the final bead on the outside of the pipe shall be in accordance with the following: Process Industry Practices Page 3 of 11

6 a. Undercutting shall not be greater than 1/32-inch (0.79 mm) in depth or 12.5 percent of the pipe wall thickness, whichever is smaller b. Undercutting in any continuous 12-inch (304.8 mm) length of weld shall not be greater than 2-inches (50.8 mm) If automatic or semiautomatic welding is used, filler wire protruding into the inside of the pipe shall be ground out or shall be cause for rejection and subsequent failure Failure to meet the requirements of this Section shall be adequate cause to eliminate additional testing. 3.4 Destructive Testing All butt welds shall have specimens cut from each test weld The locations from which the specimens are to be removed are predetermined and shown in Figure 1. Specimen sizes, orientations, and test jig configuration are shown in Figures 2, 3, and If the test weld consists of segments of pipe nipples, an approximately equal number of specimens shall be removed from each segment The type and total number of destructive test specimens that are to be submitted for testing shall be in accordance with Table 1. Table 1. Specimens Required for Testing Thickness of Weld Metal Side Face Root Less than inch inches to less than inch (See note) inch larger 2 Note: Two sided specimens may be used instead of the root & face bend specimens An authorized CWI may choose to omit the tensile-strength test. If the test is omitted, the specimens designated for the test shall be subject to the nick break test outlined in ASME Code Section IX The specimens shall be air-cooled to ambient temperature before testing For pipe equal to and less than 1-5/16 inches (33.4 mm) OD, one full pipe section specimen can be substituted for the root bend and nick break specimens. 3.5 Limits of Welder Qualification General A welder qualified on a pipe butt weld is qualified to weld fillet welds with no restrictions on size or thickness for the fillet welds. Process Industry Practices Page 4 of 11

7 A welder qualified on pipe in the 6G position is qualified to weld pipe and plate in all positions A welder qualified on pipe in the 1GR position is qualified to weld plate in the flat position Essential Variable Identification by Welding Process The essential variables for the SMAW process are Section items A, B, E, H, I and J The essential variables for the GMAW and FCAW processes are Section items A, B, D, E, F, H, I and J The essential variables for the GTAW process are Section items A, B, C, D, E, G, H, I, J, K, and L If any of the essential variables, or the welding process, is changed from those already qualified, the welder shall be re-qualified to use the new procedure Essential Variables Specific A change in filler metal from one F Number to another F Number or to a filler metal not listed shall require independent qualification, except as noted below. See ASME Section IX Code for a more comprehensive listing of electrodes. NOTE: For F Numbers 1-4, qualification of a welder for any higher F Number qualifies the welder for any lower F Number WITH BACKING, but not vice versa. EXAMPLE: A. A welder qualified with EXX18 (F No. 4) qualifies the welder to weld with F No. 3, F No. 2 and F No. 1 filler metals. B. A change of direction of welding, other than the cap pass, from upward to downward or vice versa. C. The omission or addition of consumable inserts. D. The omission of inert gas backing. E. For groove welds, the omission of backing. Note: A groove weld made from both sides is considered a weld with backing. A partial penetration groove or fillet weld is considered a weld with backing. F. A change from spray arc, globular arc or pulsating arc to short circuiting arc or vice versa. G. A change from AC to DC or vice versa; and in DC welding, a change from straight polarity to reverse polarity or vice versa. H. A change in base metal from one P or S Number group to another. For the most part, low alloy carbon ASTM steels are P number 1. API 5L line pipe is S number 1. Welder qualification on a P number qualifies the same S number, and vice versa. See the ASME Section IX Code for detailed listing of P and S number groups. I. Pipe Diameter Process Industry Practices Page 5 of 11

8 Test Pipe Diameter Pipe Diameter Qualified to Weld Less than 1 inch OD Size tested on & larger 1 inch OD to 2-7/8 inches OD 1 inch OD & Larger Greater than 2-7/8 inches 2-7/8 inches OD & Larger J. Thickness Deposit Thickness Maximum qualified to deposit per weld Less than inch Twice that deposited in the test weld (If short circuit GMAW, welder is limited to 1.1 x the deposited thickness) inch & over No thickness limit Note: Since this is the deposited weld metal thickness, there is no minimum thickness. There are no limits on the actual pipe/plate thickness. Note: If different welding processes are used for the test weld, it is up to the welding inspector to document the different thicknesses deposited by each welding process. K. The addition or deletion of filler metal. L. A change from solid or metal core filler metal to flux cored, or vice versa. 3.6 Re-Test of a Failed Destructive Qualification Exam A welder who fails a welder certification test shall be classified into one of the following categories: a. New Welder: No prior certification on file, or has failed a previous attempt and is past the 30-day wait period after the failure b. Proven Welder: Currently welding on a contractor s project, or returning to service after expiration of certification with a current record on file or in the contractor s data base. c. Compound Welder: A current certification is on file and, at the request of a contractor representative, the welder is seeking a secondary certification Criteria for Retesting New Welder 1. A new welder who attempts and fails a qualification test shall not be eligible to re-test until the expiration of a 30-day wait period. The 30-day wait shall start the day after the failed attempt. 2. A second failure of a new welder shall result in another 30-day wait period from the date of last failure before the welder is eligible to retest. 3. Three consecutive failures shall result in a one-year wait period before a welder is eligible to retest. Process Industry Practices Page 6 of 11

9 Proven Welder 1. At the option of the authorized CWI, a proven welder who accepts the reason for test failure and acknowledges appropriate remedial action can retest on the next business day following the failed attempt. 2. A proven welder who challenges or disputes the reason for failure or the need for remedial action shall require a 30-day wait period before the welder is eligible to retest. 3. A second failure of a proven welder shall result in an additional 30- day wait period before the welder is eligible to retest. At the option of the authorized CWI, a proven welder may be allowed to repeat this requirement until a successful test is obtained Compound Welder 1. A compound welder shall not have his primary certification revoked upon failure of a secondary certification attempt unless there is a specific reason to question the welder s ability to make welds under the welder s primary certification. 2. At the option of the authorized CWI, a compound welder can make up to three attempts to obtain a secondary certification. 3. Time constraints shall not be placed on the three attempts for a secondary certification. 4. If the compound welder reaches the three failed attempt limit, the welder shall wait a minimum of one year from the date of last failure before retesting for another secondary certification. 3.7 Requalification by Non-Destructive Testing A welder qualified by destructive testing can extend that qualification for one additional six-month period by an acceptable radiographic examination of either a production or test weld made by the welder The NDT examinations shall be completed by the end of the sixth month following destructive testing Failure to document acceptable NDT examinations in the six-month period shall disqualify the welder and require requalification by destructive testing in accordance with Sections 3.4, 3.5, and The X-ray report shall include the welder s name or stencil number and indicate that the results are for a requalification weld in accordance with the acceptance criteria of ASME Section IX Code The results shall be documented on Welder Qualification by Non-Destructive Testing Forms (See sample form attached or PIP QW-RQ-NDE) All completed requalification forms shall be signed by the authorized CWI and submitted to the owner representative X-ray interpretation shall be performed by an ASNT- Level II or higher x-ray technician. Process Industry Practices Page 7 of 11

10 3.7.8 X-rays may be performed in the field or on a test sample at the discretion of authorized CWI. 3.8 Re-Test of a Failed Non-Destructive Qualification Exam A welder who fails to produce an acceptable non-destructive requalification weld shall be required to retest in accordance with Sections 3.4 and Revoking Certifications At any time during production welding, qualifications can be revoked if the welder has a reject ratio higher than considered acceptable The following criteria shall be considered a base line that a welder should not exceed: a. Three percent defective welds of any project total b. Three defective welds in a six-month qualification interval A welder may also have their certification revoked if the welder is unable to meet acceptable production rates, or does not follow safe welding practices The contractor who employs the welder shall be responsible for directing or enforcing this Section and communicating revocations to the CWI Certification Re-instatement A welder whose certification has been revoked shall not be eligible to test for recertification until the expiration of a 30-day wait period from the date of revocation The welder shall be required to complete the destructive examination in accordance with Sections 3.4, 3.5, and Records A record shall be made of the tests given to a welder regardless of outcome The record shall include the details and results of each test, whether pass or fail Document submission can be accomplished by any of the following methods: Welder Qualification Form Butt-Branch (ASME IX form for New Welder Qualification record) Form PIP-QW-RQ-NDE (Form for NDE Requalification of Welder record) The welder test records shall be submitted by the authorized CWI to the owner. Process Industry Practices Page 8 of 11

11 Figure 1. Specimen Removal Figure 2. Root and Face Bend Specimens Process Industry Practices Page 9 of 11

12 Figure 3. Side Bend Specimen Figure 4. Bend Test Jig Process Industry Practices Page 10 of 11

13 Standards for Welder Qualifications per ASME Section IX May 16, 2018 Form PIP QW-RQ-NDE Suggested Format for Welder Performance Requalification by Nondestructive Examination in Accordance with (ASME Section IX) Welder s Name Identification no. Test Description Identification of WPS followed Test Coupon Production Weld Specification and type/grade or UNS Number of base metal(s) Thickness Testing Variables and Qualification Limits Welding Variables Actual Values Range Qualified Welding process(es) Type (i.e. manual, semi-automatic) used Backing (with/without) X Plate X Pipe (enter diameter if pipe or tube) Base metal P-Number to P-Number Filler metal or electrode specification(s) (SFA) (info only) Filler metal or electrode classification(s) (info only) Filler metal F-Number(s) Consumable insert (GTAW or PAW) Filler Metal Product Form (solid/metal or flux cored/powder) (GTAW or PAW) Deposit thickness for each process Process 1 3 layers minimum X Yes X No Process 2 3 layers minimum X Yes X No Position(s) Vertical progression (uphill or downhill) Type of fuel gas (OFW) Inert gas backing (GTAW, PAW, GMAW) Transfer mode (spray/globular or pulse to short circuit-gmaw) GTAW current type/polarity (AC, DCEP, DCEN) Results We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the requirements of Section IX of the ASME Boiler and Pressure Vessel Code. Organization Date Certified by Process Industry Practices Page 11 of 11